Page 1
use and maintenance
aprilia
part# 8102785
Classic 125
Page 2
© 1997 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 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
use and maintenance Classic 125
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Page 3
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
ries and other products, as well as for specific technical advice,
contact only
can ensure you reliable and prompt servicing.
Thank you for choosing
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
N˚
IUKAPSFB D F E
aprilia
CODICE RICAMBI spare parts code number
I.M.
aprilia
Genuine Spare Parts, accesso-
Authorized Outlets and Official Dealers, who
aprilia
. We wish you a nice ride.
ABCDE
Carefully observe the instructions preceded by the following
warning signs:
Safety norms and regulations to protect the driver
and other people from severe injuries or grave risks.
a
Indications to make the operations easier. Technical
c
information.
In this manual the various versions are indicated by the following symbols:
catalytic version
2
Italy version
I
United Kingdom version
U
Austria version
A
Portugal version
P
Finland version
"
Belgium version
B
Germany version
D
France version
F
Spain version
E
Greece version
G
Holland version
O
Switzerland version
C
Denmark version
£
Japan version
J
Singapore version
S
Poland version
V
Israel version
%
South Korea version
K
Malaysia version
M
Chile version
R
Bermuda version
Q
GR NL CH DK J SGP PL IL ROK
MALRCH BM
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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
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
2
...................................................................26
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
Page 6
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.
use and maintenance Classic 125
6
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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OIL
COOLER
The driver should pay attention and avoid
distractions caused by people, things and
movements (never smoke, eat, drink, read,
etc.) while driving.
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8
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
ONLY ORIGINALS
Never change the position, inclination or
colour of: number plate, direction indicators, lights and horns.
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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Page 10
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).
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10
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.
Page 11
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
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12
Fig. 1
KEY Fig. 1
1) Mixer oil tank plug
2) Air cleaner
3) Saddle lock
4) Rear suspension spring preload adjusting ring
5) Passenger's footrest
6) Fuses
7) Battery
8) Side stand
9) Footrest
10) Shifting lever
Page 13
KEY Fig. 2
1) Fuel cock
2) Fillercap
3) Front brake fluid tank
4) Ignition switch/steering lock
5) Mixer oil tank
6) Rear brake control lever
Fig. 2
7) Footrest
8) Took kit/glove compartment
9) Passenger's footrest
10) Rear suspension spring preload adjusting ring
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ARRANGEMENT OF THE INSTRUMENTS
Fig. 3 Fig. 4
KEY Fig. 3
1) Left rear-view mirror
2) Clutch lever
3) High beam signalling push button (
4) Cold start lever (
5) Ignition switch/steering lock (
6) Throttle grip
7) Front brake lever
8) Right rear-view mirror
9) Engine stop switch (
10) Light switch (
11) Start push button (
12) Instruments and indicators
13) Horn push button (
14) Direction indicator switch (
15) Dimmer switch (
e)
n - m)
o - p -
r)
f)
b - a)
)
•
c)
a)
n - m - s)
INSTRUMENTS AND INDICATORS
KEY Fig. 4
1) Speedometer
2) Total kilometres odometer
3) Coolant overheating warning light (h)
4) Red mixer oil reserve warning light (
5) Green neutral indicator warning light (
6) Blue high beam warning light (
7) Green direction indicator warning light (
j)
a)
q)
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
warning light
Mixer oil reserve
warning light
In this case, stop the engine and check the coolant level, see p. 24 (COOLANT).
h
a
It comes on when the ignition switch is in position "n" and the start push button “r“ is pressed, thus checking the proper functioning of the bulb.
If the light does not come on during the starting, provide for replacing the bulb.
j
a
see p. 20 (MIXER OIL TANK).
If the maximum allowed temperature is exceeded (the warning light comes on),
the engine may be seriously damaged.
If the warning light comes on and does not go out after the start push button
"
r" has been released, or if it comes on during normal functioning, this means
that the mixer oil reserve is being used; in this case, top up the mixer oil tank,
Neutral indicator warning light
High beam warning light
Direction indicator
warning light
q It comes on when the gear is in neutral.
It comes on when the headlight is in "high beam" position or when the high beam signalling is
a
operated.
It blinks when the direction indicators are on.
c
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MAIN INDEPENDENT CONTROLS
c
CONTROLS ON THE LEFT SIDE
OF THE HANDLEBAR (Fig. 5)
The electrical parts work only when the ignition
switch is in position "
n".
Fig. 5
1) DIMMER SWITCH (
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 "
comes on.
2) DIRECTION INDICATOR SWITCH (
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 (
The horn is activated when the push button is pressed.
4) COLD START LEVER (
The starter for the cold start of the engine is operated by rotating the lever "
To disconnect the starter, move the lever "
sition.
5) HIGH BEAM SIGNALLING PUSH BUTTON (
It makes it possible to use the high beam for signalling to
forthcoming vehicles while overtaking and in case of peril
and/or emergency.
b - a)
b", the low beam
c)
f)
e)
e" downwards.
e" to its initial po-
a)
16
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Page 17
CONTROLS ON THE RIGHT SIDE
OF THE HANDLEBAR (Fig. 6)
The electrical parts work only when the ignition
c
switch is in position "
n".
1) HEADLIGHT SWITCH (
When the light switch is in position "•", the lights are off; when
the switch is in position "
the switch is in position "
on. The high/low beam can be operated by means of the dimmer switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF
THE HANDLEBAR).
2) START PUSH BUTTON (
When the start push button "
the engine run. For the starting, see p. 28 (STARTING).
3) ENGINE STOP SWITCH (
a
This is a safety or emergency switch.
With the switch in position "
gine; the engine can be stopped by moving the switch to position "
a
the engine, move the ignition switch to position "
Do not operate the engine stop switch “
running conditions.
m".
With stopped engine and ignition switch in position "
n", the battery may discharge.
When the vehicle has come to rest, after stopping
o - p -
)
•
p", the parking lights are on; when
o", the low beam or the high beam is
r)
r" is pressed, the starter makes
n - m)
n - m” in
n", it is possible to start the en-
m".
Fig. 6
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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).
The key (1) operates the ignition
c
lock and the fuel tank lock.
Two keys are supplied together with the
vehicle (one spare key).
switch/steering lock, the saddle
STEERING LOCK (Fig. 7)
Never turn the key to position
"
a
vehicle.
OPERATION
To lock the steering:
◆
◆
◆
◆
s" in running conditions, in or-
der to avoid losing control of the
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
The steering is
locked.
s
Steering
lock
m
n
It is neither
possible to
start the
engine, nor to
switch on the
lights.
Neither the
engine, nor the
lights can be
switched on.
The engine
and the lights
can be
switched on.
Key
removal
It is possible
to remove
the key.
It is possible
to remove
the key.
It is not possible to
remove the
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
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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.
Before leaving, make sure that
you have not left the key in the
crash helmet/glove compart-
a
ment 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
The fuel used for internal combustion engines is extremely in-
a
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.
flammable and in particular con-
Fig. 10
KEEP AWAY FROM CHILDREN
Use only premium grade petrol
(4 Stars
51600 standard, min. O.N. 98 (N.O.R.M.)
and 88 (N.O.M.M.).
FUEL TANK CAPACITY
(reserve included): 10
TANK RESERVE: 2 l
To unlock the tank plug, insert the ignition
key in the lock and turn it clockwise.
), in conformity with the DIN
U
l
2
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
Remember:
c
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).
Used transmission oil can seriously damage the skin if handled
a
every day and for long periods.
If the vehicle is used on dusty
roads, change the oil more fre-
a
quently.
Do not dispose of the oil in the
environment. Put it in a sealed
a
station where you usually buy it.
container and take it to the filling
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 “
positioned on the dashboard, see p. 14
and 15 (INSTRUMENTS AND INDICATORS).
If you run out of oil in the mixer
oil tank, or if the mixer oil pipe
a
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
TANK RESERVE: 0.5 l
KEEP AWAY FROM CHILDREN.
has been removed, it is neces-
Wash your hands carefully after
using the oil. Do not dispose of
a
the oil in the environment.
j“
l
Fig. 11
BRAKE FLUID (recommendations)
Sudden resistance or clearance
problems on the brake lever may
a
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.
be due to troubles in the hydrau-
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20
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Check that the brake cable is neither
twisted nor worn out.
Prevent water or dust from accidentally
getting into the circuit.
If the brake fluid gets in contact with the
skin or the eyes, it can cause serious irritations.
Carefully wash the parts of your body
that get in contact with the liquid.
Consult a doctor or an oculist if the liquid gets in contact with your eyes.
Do not dispose of the brake fluid in the
environment.
KEEP AWAY FROM CHILDREN
When using the brake fluid, take
care not to spill it on the plastic
a
damage them.
FRONT BRAKE (Fig. 12)
perfectly working.
The brake fluid must be changed once a
year by an aprilia Official Dealer.
or painted parts, since it can
The brakes are the parts that
most ensure your safety and for
a
this reason they must always be
Fig. 12
This vehicle is provided with front hydraulic
disc brake.
When the disc pads wear out, the level of
the fluid decreases to automatically compensate for their wear.
Periodically check the brake fluid level in
the tank (1) and the pad wear, see p. 43
(CHECKING THE PAD WEAR).
To check the level, incline the vehicle, so
that the fluid contained in the tank (1) is parallel to the "MIN" mark on the glass.
Make sure that the fluid is included between the "MIN" and "MAX" marks.
If the fluid does not reach the "MIN" mark,
provide for topping up.
Proceed as follows:
◆
Unscrew the two screws (2).
◆
Remove the cover (3).
In order not to spill the brake flu-
c
id in the tank parallel to the tank rim (in
horizontal position).
◆
◆
◆
◆
◆
In case of excessive stroke of the brake
lever, of excessive elasticity or in case
there is air in the circuit, contact your
aprilia Official Dealer, since it may be
necessary to bleed the system.
In any case, the bleeding must be carried out after the first 1000 km.
id while topping up, keep the flu-
Remove the gasket.
Top up the brake fluid tank, see p. 58
(LUBRICANT CHART), until reaching
the "MAX" mark.
Put back the gasket in its seat.
Put back the cover (3).
Screw the two screws (2).
Check the braking efficiency. If
necessary, contact your aprilia
a
Official Dealer.
Remember:
c
1 miles = 1.6 km
1 km = 0.625 miles
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21
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Fig. 13
Fig. 14
Fig. 15
REAR BRAKE
The brakes are the parts that
most ensure your safety and for
a
perfectly working.
ADJUSTING THE REAR BRAKE
◆
◆
◆
22
this reason they must always be
Loosen the adjuster (1 - Fig. 13) completely.
Adjust the brake lever (1 - Fig. 14) at the
desired height (in resting position), by
means of the end-of-stroke adjuster (2 Fig. 14).
Take up the idle stroke of the brake lever
by means of the adjuster (1 - Fig. 13).
The idle stroke at the end of the brale lever pedal must be about 5 ÷ 10 mm.
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If the adjuster can be screwed
c
shoes are worn, see p. 43 (CHECKING
THE SHOE WEAR).
◆
◆
braking system, or if you cannot carry
out the normal checking operations, do
not hesitate to contact an aprilia Official Dealer.
completely, this means that the
Check the correct functioning of the
stoplight.
If necessary, adjust the position of the
stoplight switch by means of the apposite nuts (3 - Fig. 14).
Repeatedly put on the brake and make
sure that the wheel rotates freely.
Check the braking efficiency.
If you have any doubt regarding
a
the correct functioning of the
REMOVING THE OIL PAN GUARD
(LEFT SIDE) (Fig. 15)
To reach the left side of the engine it is
necessary to remove the oil pan guard (1),
proceeding as follows:
◆
Unscrew the nut (2) on the shifting lever
and release the rod (3), resting it on the
ground.
◆
Unscrew and remove the three screws
(4) and remove the oil pan guard.
For the reassembly, carry out the previous
operations in the reverse order.
Page 23
Fig. 16 Fig. 17 Fig. 18
ADJUSTING THE CLUTCH
Adjust the clutch lever stroke if, with pulled
brake lever and first gear engaged, the engine stops or tends to advance, or if the
clutch slips causing a delay in the acceleration in comparison with the engine rpm.
Minor adjustments can be carried out by
means of the control lever adjuster (1 - Fig.
16):
◆
Loosen the lock nut (2 - Fig. 16).
◆
Screw or unscrew the control lever adjuster (1 - Fig. 16), until the idle stroke at
the end of the clutch lever is about 10
mm (see Fig. 16). Tighten the lock nut
and check the idle stroke.
If the control lever adjuster is completely
screwed or unscrwed, or if it is not possible
to obtain the correct idle stroke, proceed as
follows:
◆
Loosen the lock nut (2 - Fig. 16) and
screw the control lever adjuster completely (1 - Fig. 16).
◆
Remove the oil pan guard, see p. 22
(REMOVING THE OIL PAN GUARD).
◆
Unscrew the plug (1 - Fig. 17) by means
of a screwdriver or a coin.
◆
Loosen the inner nut (1 - Fig. 18) with the
apposite spanner provided in the tool kit.
◆
Screw the adjusting screw (2 - Fig. 18)
with a screwdriver until taking up the
slack completely.
◆
Unscrew the above mentioned screw
giving it about half a turn, corresponding
to 3 ÷ 4 mm of lever stroke (3 - Fig. 18).
◆
Holding the adjusting screw in fixed position with a screwdriver, tighten the nut
using the apposite spanner again.
◆
Retighten the plug (1 - Fig. 17).
◆
Put back the oil pan guard.
◆
Start the engine and engage the first
gear, making sure that the engine does
not stop or does not tend to advance, or
that the clutch does not slip during the
acceleration phase or while you are driv-
ing.
If it is not possible to obtain a
correct adjustment, or if the
a
ly, contact an aprilia Official Dealer.
tened parts and the sheath must not be
worn out in any point.
clutch does not function proper-
Make sure that the clutch cable
c
is intact: it must not present flat-
use and maintenance Classic 125
23
Page 24
COOLANT
To change the coolant, or in
case of leaks in the circuit, con-
a
tact an aprilia Official Dealer.
Do not use the vehilce if the
coolant is below the minimum
a
prescribed level.
Remember: 1 miles = 1.6 km
c
1 km = 0.625 miles
Fig. 19
ADJUSTING THE SHIFTING LEVER
(Fig. 19)
It is possible to adjust the position of the
shifting lever by means of the rod (1), proceeding as follows:
◆
Loosen the nuts (2) and (3).
◆
Rotate the rod and adjust the shifting lever height.
◆
Tighten the nuts (2) and (3).
The shifting lever pin is kept
greased thanks to the apposite
a
rings.
In case of disassembly, lubricate it and
avoid damaging the sealing rings.
24
recess and to the two sealing
use and maintenance Classic 125
Check the coolant level every 2000 km and
after long rides; change the coolant every 2
years. According to the desired freezing
temperature of the cooling solution, add
the coolant percentage indicated in the following table to the water:
Freezing point
C˚
-20˚ 35
-30˚ 45
-40˚ 55
It is advisable to keep the same mixture
also in the hot season, since in this way
losses due to evaporation are reduced and
it is not necessary to top up very frequently.
The mineral salt deposits left in the radiator
by evaporated water are thus reduced and
the efficiency of the cooling system remians unchanged.
For the cooling solution use distilled water
mixed with antifreeze.
Coolant
% vol.
Fig. 20
Do not remove the expansion
tank cap when the engine is hot,
a
sure and its temperature is high.
If it gets in contact with the skin or with
clothes, it may cause severe burns
and/or damage.
The coolant is noxious:
DO NOT SWALLOW IT.
KEEP AWAY FROM CHILDREN.
CHECKING AND TOPPING UP (Fig. 20)
Proceed as follows:
◆
◆
◆
◆
◆
since the coolant is under pres-
Let the engine cool down for a few minutes.
Keep the vehicle in vertical position.
Remove the radiator plug (1).
Make sure that the coolant covers the radiator plates completely.
Top up, if necessary.
Page 25
If, on the contrary, the inflation pressure
is too low, the tyre sides are under
greater stress and the tyre itself may
slip on the rim or it may become loose,
with consequent loss of control of the
vehicle. In case of sudden braking the
tyres could even get out of the rims.
Further, the vehicle could skid while
turning.
For this reason, it is advisable to have
the above mentioned operations carried
out by an aprilia Official Dealer or by a
qualified tyre repairer.
If the tyres are new, they may still be
covered with a slippery film: drive carefully for the first miles. Do not oil the
tyres with unsuitable fluids.
TYRES
This vehicle is provided with tyres with inner tube.
Periodically check the tyre inflation pressure at room tempera-
a
If the tyres are hot, the measurement is
not correct.
Carry out the measurement especially
before and after long rides.
If the inflation pressure is too high, the
ground unevenness cannot be dampened and is therefore transmitted to the
handlebar, thus compromising the driving comfort and reducing the road holding during turns.
ture.
Check the surface and the wear of the
tyres, since tyres in bad conditions can
impair both the grip and the controllability of the vehicle.
Change the tyre when it is worn out or
in case of puncture on the tread side, if
the puncture is larger than 5 mm.
After repairing a tyre, have the wheels
balanced. Use only tyres in the size
suggested by aprilia, see p. 54 (TECHNICAL DATA).
Do not install tyres with air tube on rims
for tubeless tyres and viceversa.
Make sure that the tyres always have
their valve sealing caps on, to prevent
them from suddenly going flat.
Change, repair, maintenance and balancing operations are very important
and should be carried out by qualified
technicians with appropriate tools.
If the tyres are old, even if not completely worn out, they may become hard and
may not ensure good road holding.
In this case, replace them.
INFLATION PRESSURE
SOLO RIDER
front ................................180 kPa (1.8 bar)
rear.................................200 kPa (2.0 bar)
RIDER AND PASSENGER
front ................................190 kPa (1.9 bar)
rear.................................220 kPa (2.2 bar)
MINIMUM TREAD DEPTH LIMIT
front: ............................................. 1.5 mm
rear: .............................................. 1.5 mm
use and maintenance Classic 125
25
Page 26
CATALYTIC SILENCER
Avoid parking the vehicle cata-
a
ble to children, as the catalytic silencer
becomes extremely hot during use; be
very careful and avoid any kind of contact before it has completely cooled
down.
lytic version near dry brush
wood or in places easily accessi-
2
The catalytic Classic 125 is fitted with a silencer with metal catalytic converter of the
"platinum-rhodium bivalent" type.
This device provides for the oxidation of
the CO (carbon monoxide) and of the HC
(unburned hydrocarbons) contained in the
exhaust gases, changing them into carbon
dioxide and steam, respectively.
Due to the catalytic reaction, the high temperature reached by the exhaust gases
makes for the burning of the oil particles,
thus keeping the silencer clean and eliminating the exhaust fumes.
To have the catalytic converter function
correctly and for long and to reduce possible problems regarding the soiling of the
thermal unit and of the exhaust, it is necessary to avoid covering long distances with
the engine running at constantly low rpm.
It is sufficient to alternate these periods
with periods in which the engine runs at relatively high rpm, even if only for a few seconds, but rather frequently.
What has been stated above assumes particular importance for the cold starting of
the engine: in this case, in order to reach a
rpm regime sufficient to enable the "priming" of the catalytic reaction, just make
sure that the temperature of the thermal
unit has reached at least 50˚C, which generally occurs a few seconds after starting
the engine.
Do not use leaded petrol, since it
a
causes the destruction of the
catalytic converter.
use and maintenance Classic 125
26
Page 27
INSTRUCTIONS FOR USE
PRELIMINARY CHECKING OPERATIONS
Before departure, always carry
out a preliminary checking of the
a
vehicle, to make sure that it
functions correctly and safely, see the
following table PRELIMINARY CHECKING OPERATIONS.
The non-performance of these checking
operations can cause severe personal
injuries or damages to the vehicle.
Do not hesitate to consult your
aprilia Official Dealer in case
a
there is something you do not
understand about the functioning of
some controls or in case you suspect or
discover some irregularities.
It does not take long to carry out a
check-up and this operation ensures
you much more safety.
Component Check Page
Front disc brake
Rear drum brake
Accelerator
Mixer oil/transmission
oil
Wheel/tyres
Brake levers
Clutch
Side stand
Fastening elements
Gearing chain Check the slack. Lubricate, if necessary.
Fuel tank
Coolant
Lights, warning lights,
horn and electric
devices
Check the functioning, the fluid level and make sure there are
no leaks. Check the wear of the pads. Top up, if necessary.
Check the functioning, the idle stroke and the control lever
conditions. If the clearance is not correct, adjust it.
Make sure that it works smoothly and that it is possible to
open and close it completely, in all steering positions.
If necessary, adjust and/or lubricate it.
Check and/or top up, if necessary.
Check the tyre surface, the inflation pressure, wear and tear
and any damage.
Make sure that they work smoothly.
If necessary, lubricate the articulations.
The idle stroke at the end of the clutch lever must be about 10
mm; the clutch must operate without jerking and/or slipping.
Make sure that they work smoothly and that the spring ten-
sion brings it back to its normal position.
If necessary, lubricate joints and hinges.
Make sure that the fastening elements are not loose.
If necessary, adjust or tighten them.
Check the fuel level and top up, if necessary.
Make sure there are no leaks or occlusions in the circuit.
The coolant must cover the radiator plates completely.
Top up, if necessary.
Check the proper functioning of all the devices.
Change the bulbs or intervene in case of failure.
20-21-43
22
45
20-36
25
21-22
23
–
–
–
24
46 ÷ 51
use and maintenance Classic 125
27
Page 28
Fig. 21
Fig. 22
Fig. 23
STARTING
Exhaust gases contain carbon
monoxide, which is extremely
a
ing the engine in closed or badly-ventilated rooms.
The non-observance of this warning
may cause loss of consciousness or
even lead to death by asphyxia.
◆
◆
◆
28
noxious if inhaled. Avoid start-
Before starting the engine, let the side
stand up and lock at least one wheel, to
avoid losing control of the vehicle.
If this operation is carried out on a slope,
be particularly careful.
Rotate the fuel cock lever (1 - Fig. 21) to
position "ON".
Move the ignition switch to position “n“
(Fig. 22).
use and maintenance Classic 125
◆
Put the shifting lever into neutral (green
warning light “
◆
Move the engine stop switch to position
“
n“ (1 - Fig. 23).
◆
Press the start push button “r“ (2 - Fig.
23) without accelerating, then release it
as soon as the engine starts.
If the starting takes place with cold engine, pull the cold start lever “
23).
When the start push button "
a
With the engine in running condition,
when the start push button "
leased, the mixer oil reserve warning
light "
occur, top up the mixer oil tank, see
p. 20 (MIXER OIL TANK).
pressed, the mixer oil reserve
warning light "
j" must go out; if this does not
q“ on) (1 - Fig. 22).
e“ (3 - Fig.
r" is
j" comes on.
r" is re-
◆
Warm the engine up until it turns normally with the cold start lever "
forwards.
Do not start abruptly if the en-
a
"
Starting with flooded engine
If the starting is not carried out properly or
if there is too much fuel in the intake ducts
and in the carburettor, the engine may get
flooded.
gine is cold.
Do not use the cold start lever
e" if the engine is hot.
e" completely
Page 29
Fig. 24 Fig. 25
To clean a flooded engine:
◆
Carry out the first six operations described for the starting, see p. 28
(STARTING).
◆
Push the cold start lever "e" (3 - Fig. 23)
completely forwards.
◆
Press the start push button "r" (2 - Fig.
23) for a few seconds (letting the engine
spin over) with completely open throttle
(Fig. 24).
If the engine starts
Release the start push button "
throttle grip.
If the idling is unstable, twist the throttle
grip slightly and frequently.
r" and the
If the engine does not start
Wait for ten seconds and carry out the
starting procedure, see p. 28 (STARTING).
DEPARTURE AND DRIVE
Before departure, carefully read
c
see p. 5 (RIDING SAFELY).
Properly adjust the inclination of the
rear-view mirrors. If you drive without
passenger, make sure that the rear foot
rests are closed.
If you drive with a passenger, instruct
him/her so that he/she does not create
problems during manouvres.
Before leaving, make sure that the
stands are completely folded.
the "RIDING SAFELY" chapter,
To start the engine, proceed as follows:
◆
Make sure that the engine is warm.
◆
With released throttle grip and the engine idling, pull the clutch lever and engage the first gear by pressing the shifting pedal (Fig. 25).
◆
Slowly release the clutch lever and at the
same time increase the engine rotation
speed, by turning the throttle grip gradually.
◆
When the vehicle has reached a certain
speed, release the throttle grip, pull the
clutch lever and engage the second
gear, lifting the shifting pedal (Fig. 25).
To shift up, repeat the operations described above.
Avoid opening and closing the
throttle grip repeatedly and con-
a
cidentally lose control of the vehicle.
If you have to brake, close the throttle
and put on both brakes in order to obtain uniform deceleration, properly exerting pressure on the braking parts.
By putting on the front brake only or the
rear brake only, you reduce the braking
force considerably, thus running the
risk of locking one wheel and consequently losing grip.
tinuously, so that you do not ac-
use and maintenance Classic 125
29
Page 30
Before beginning to turn, slow down or
brake driving at moderate and constant
speed or accelerating slightly; avoid
braking at the last moment: it would be
very easy to skid.
If the brakes are operated continuously
on downhill stretches, the friction surfaces may overheat, thus reducing the
braking efficiency.
Exploit the engine compression and
shift down by putting on both brakes intermittently.
Never drive downhill with the engine
off!
In case of wet ground or scarce wheel
grip (snow, ice, mud, etc.), drive slowly,
avoiding sudden brakings or manoeuvres that could make you lose grip and
fall down.
Pay the utmost attention to any obstacle or variation of the ground.
Uneven roads, rails, manhole covers,
indications painted on the road surface,
building site metal plates become rather
slippery by rain.
For this reason all these obstacles have
to be carefully avoided, driving smoothly and bending the vehicle as little as
possible.
Always use the turn indicators timely
when you intend to change lane or direction, avoiding sharp and dangerous
movements.
RUNNING-IN
The running-in of the engine is important to
ensure its correct functioning.
If possible, drive on hilly roads and/or
roads with many bends, so that the engine,
the suspensions and the brakes undergo a
more effective running-in.
Remember: 1 miles = 1.6 km
c
Keep to the following indications:
◆
Do not open the throttle completely if the
speed is low, both during and after the
running-in.
◆
During the first 100 km put on the brakes
with caution, avoiding sharp and prolonged brakings. This ensures a correct
bedding-in of the pads on the brake disc
and of the shoes on the drum.
◆
During the first 500 km, never exceed
5000 rpm (see table).
◆
Between the first 500 and 1000 km, never exceed 6000 rpm (see table).
After the first 1000 km, carry out
the checking operations indicat-
a
in" of the REGULAR SERVICE INTERVALS CHART, see p. 32, in order to
avoid hurting yourself or other people
and/or damaging the vehicle.
ed in the column "After running-
1 km = 0.625 miles
◆
Between the first 1000 and 2000 km
drive more briskly, change speed and
use the maximum acceleration only for a
few seconds, in order to ensure better
coupling of the components that are subject to wear; never exceed 7000 rpm
(see table).
◆
After the first 2000 km you can expect
better performance from the engine,
however, without exceeding the max rpm
(7500 rpm - see table).
If at the end of the running-in the
c
distances yet, follow the indications for
running-in for the first 4000 km.
vehicle has not covered long
Running-in max. speeds
km/h
km
Mileage
Gear 1ª 21 25 29 31
2ª 30 36 42 45
3ª 44 52 61 66
4ª 47 56 66 70
5ª 56 68 79 84
6ª 65 78 90 97
rpm 5000 6000 7000 7500
0-500
5001000
1000-
2000
over
2000
use and maintenance Classic 125
30
Page 31
Fig. 26 Fig. 27
STOPPING AND PARKING
To stop the vehicle, proceed as follows:
◆
Release the throttle grip, gradually put
on the brakes and at the same time shift
down in order to decrease the speed.
◆
Pull the clutch lever before the vehicle
has completely stopped, to prevent the
stopping of the engine.
To park the vehicle:
◆
Put the shifting lever in neutral (green
warning light "
◆
Move the ignition switch to position "m".
◆
Position the vehicle on the side stand.
q" on, 1 - Fig. 26).
◆
Turn the fuel cock lever to position "OFF"
(Fig. 27).
◆
Rotate the handlebars completely leftwards.
◆
Lock the steering, see p. 18 (STEERING
LOCK) and extract the key.
Park the vehicle on firm and flat
ground, to prevent it from falling
a
Neither lean the vehicle against walls,
nor lay it on the ground.
Make sure that the vehicle and especially its red-hot parts do not represent a
danger for persons and children.
Do not leave the vehicle unattended
when the engine is on or the key is inserted into the ignition switch.
Do not sit on the vehicle when the stand
is down.
down.
SUGGESTIONS
TO PREVENT THEFT
NEVER leave the ignition key inserted and
always use the steering lock.
Park the vehicle in a safe place, possibly in
a garage or a protected place.
When possible, use an additional anti-theft
device.
Make sure that all documents are in order
and the road tax has been paid.
Write down your personal data and telephone number in this page, to facilitate the
identification of the owner in case of finding
after theft.
SURNAME: ...............................................
NAME: ......................................................
ADDRESS: ...............................................
...................................................................
TELEPHONE NO.: ...................................
Very often stolen vehicles are
c
ten in the use/maintenance manual.
identified thanks to the data writ-
use and maintenance Classic 125
31
Page 32
MAINTENANCE
REGULAR SERVICE INTERVALS CHART
Before beginning any maintenance operation or any inspection of the vehicle, stop the en-
a
gine, extract the key from the ignition
block, wait until the engine and the exhaust system have cooled down and if
possible lift the vehicle by means of the
proper equipment, on firm and flat
ground. Keep away from the red-hot
parts of the engine and of the exhaust
system, in order to avoid burns.
The vehicle is made up of not edible
parts. Never bite, suck, chew or swallow
any part of the vehicle for any reason.
If not expressly indicated otherwise, for the reassembly of the
units repeat the disassembly op-
a
erations in reverse order.
Ordinary maintenance operations can usually be carried out by the user, but sometimes a basic knowledge of mechanics and
specific tools are required. If you need assistance or technical advice, consult your
aprilia Official Dealer, who can ensure you
prompt and accurate servicing.
After any maintenance operation, carry out
the "Preliminary checking operations", see
p. 27 (PRELIMINARY CHECKING OPERATIONS).
Remember:
c
1 miles = 1.6 km
1 km = 0.625 miles
Component
Piston coupling and segment clearance
Battery - electrolyte level
Spark plug
Carburettor
Wheel centering
Steering bearings and steering
Wheel bearings
Air cleaner
Clutch clearance
Braking systems
Cooling system
Light system
Coolant
Brake fluid
Mixer oil level
Fork oil
Transmission oil
Mixer oil pump and air bleeding
Tyre pressure
Engine idling rpm
Fuel cock
Nut, bolt, screw tightening
Suspensions and attitude
Brake fluid bleeding
Spoke tension
Chain tension and lubrication
Fuel pipes
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 by aprilia Official Dealers
ONLY .
After running-in
(1000 km)
C every 1000 km: C
C P
C C
CC
RR
C C
C C
every 2000 km: C / every 2 years: S
every year: S / every 4000 km: C
SC
CR
RR
C C
C C
C C
C
C C
Every 4000 km
or 8 months
C
PS
C
PS
every 1000 km: C
every 500 km: C
every 12000 km: S
every month: R
every 500 km: C
C every 4 month: S
Every 8000 km
or 16 months
every 12000 km: S
use and maintenance Classic 125
32
Page 33
Fig. 28 Fig. 29
IDENTIFICATION DATA
It is a good rule to write down the frame
and engine numbers in the space provided
in this manual.
Do not alter the identification
c
cur severe penal and administrative
sanctions.
numbers if you do not want to in-
ENGINE NUMBER (Fig. 28)
The engine number is stamped on the upper side of the engine, near the carburettor.
Engine no.
FRAME NUMBER (Fig. 29)
The frame number is stamped on the right
side of the steering column.
Frame no.
use and maintenance Classic 125
33
Page 34
CHAIN (Fig. 30)
Carefully read p. 32 (MAINTENANCE).
The vehicle is equipped with a single-unit
chain, in which the main joint is not used.
An excessive slackening of the
chain can cause it to come off of
the sprockets, which often re-
a
sults in accidents or serious damage to
the vehicle.
Periodically check the slack and adjust
it if necessary, see p. 35 (ADJUSTMENT).
To change the chain, contact an aprilia
Official Dealer, who will ensure you
prompt and accurate servicing.
Fig. 30
The vehicle is provided with a chain that
has the main joint and can therefore be
opened.
In case of disassembly and reassembly of
the chain, make sure that the clip of the joining link is installed with the open part facing the direction opposite to the travel direction.
Incorrect maintenance may cause the untimely wear of the chain and/or damage to
the pinion and/or the crown.
Carry out the maintenance operations
more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy
roads.
CHECKING THE SLACK
To check the chain slack, proceed as follows:
◆
Stop the engine, position the vehicle on
the side stand and the shifting lever in
neutral.
◆
Make sure that the vertical oscillation, in
an intermediate point between pinion
and crown in the lower part of the chain,
is about 20 mm.
◆
Move the vehicle forwards, in order to be
able to check the vertical oscillation of
the chain even when the wheel turns; the
slack must be constant in all the rotation
phases of the wheel.
If in some positions the slack is higher than
in others, this means that there are crushed or seized links.
To prevent the risk of seizures, lubricate
the chain frequently, see p. 35 (LUBRICATION AND CLEANING).
If the slack is uniform, but higher than 20
mm, adjust it, see p. 35 (ADJUSTMENT).
use and maintenance Classic 125
34
Page 35
Fig. 31
ADJUSTMENT (Fig. 31)
If after the check it is necessary to adjust
the chain tension, proceed as follows:
◆
Loosen the nut (1) that fastens the rear
wheel pin.
◆
Loosen the nut (2) of the antirotation pin.
◆
Adjust the slack by means of the left (3)
and (4) adjusters, making sure that the
reference numbers visible inside the
slots (5) are the same on both sides.
◆
Once the operation has been completed,
tighten the rear wheel pin fastening nut.
Nut driving torque: 100 Nm (10 kgm).
◆
Tighten the nut (2) of the antirotation pin.
◆
Check the chain slack, see p. 34
(CHECKING THE SLACK).
CHECKING THE WEAR OF CHAIN,
PINION AND CROWN
Check the chain and the sprockets and
make sure that they do not present:
◆
Damaged rollers.
◆
Loose pins.
◆
Dry, rusty, crushed or seized links.
◆
Incorrect adjustment.
◆
Excessive wear.
◆
Lacking O rings.
◆
Sprocket or teeth excessively worn or
damaged.
If the chain rollers are damaged, the pins
are loose and/or the O rings are damaged
or lacking, it is necessary to change the
chain.
Lubricate the chain frequently,
especially if there are dry or
rusty parts.
a
The crushed or seized links must be lubricated and made work again.
If this is not possible, contact an
aprilia Official Dealer, who will provide
for changing the chain.
LUBRICATION AND CLEANING
The gearing chain is provided
with O rings among the links, in
order to keep the grease inside
a
them. Carry out the adjustment, lubrication, cleaning and change of the chain
with great care.
Remember: 1 miles = 1.6 km
c
Lubricate the chain every 500 km or whenever necessary.
Lubricate the chain with spray grease for
chains only, see p. 58 (LUBRICANT
CHART).
Never wash the chain with water
jets, steam jets, high-pressure
water jets and highly inflamma-
a
ble solvents.
1 km = 0.625 miles
use and maintenance Classic 125
35
Page 36
CHECKING THE TRANSMISSION
OIL LEVEL (Fig. 32)
Carefully read p. 20 (TRANSMISSION
OIL), p. 32 (MAINTENANCE) and p. 32
(REGULAR SERVICE INTERVALS
CHART).
Check the transmission oil level every
4000 km, unless the oil change is prescribed at different intervals, see p. 37
(CHANGING THE TRANSMISSION OIL).
Fig. 32
For the check, proceed as follows:
◆
Stop the engine and let it cool down for
at least ten minutes, in order to allow the
oil to drain into the oil pan and to cool
down.
◆
Keep the vehicle in vertical position, on a
flat surface, with the wheels resting on
the ground.
◆
Let the engine spin over for about one
minute, to ensure the filling of the oil
tank.
◆
Stop the engine.
The failure to carry out the oper-
c
to an incorrect oil level measurement.
◆
◆
lower than one fourth of the glass itself.
In the first case the excess oil would
flow out through the drain opening; in
the second case the engine may be seriously damaged.
TOPPING UP (Fig. 32)
If it is necessary to top up the oil tank, proceed as follows:
◆
◆
◆
◆
◆
ations described above may lead
Remove the oil pan guard on the left
side, see p. 22 (REMOVING THE OIL
PAN GUARD).
Make sure that the oil level is included in
the second fourth of the glass (1).
The oil level must neither exceed
c
the first half of the glass, nor be
Remove the plug (2).
Pour a small quantity of oil and wait
about one minute, so that the oil sets on
the base.
Make sure that the oil level reaches at
least half the glass (1).
Otherwise, top up with small quantities of
oil and check through the glass (1), until
reaching the prescribed level.
At the end of this operation, screw the
plug (2).
use and maintenance Classic 125
36
Page 37
CHANGING THE TRANSMISSION
OIL (Fig. 33)
Carefully read p. 20 (TRANSMISSION
OIL) and p. 32 (MAINTENANCE).
Change the transmission oil after the first
1000 km and successively every 12000
km, see p. 32 (REGULAR SERVICE INTERVALS CHART).
Fig. 33
To change the oil, proceed as follows:
◆
Warm the engine for a few minutes, in
order to facilitate the outflow of the oil
during the successive draining phase.
◆
Keep the vehicle in vertical position, on a
flat surface, with the wheels resting on
the ground.
When warmed up, the engine
contains very hot oil; therefore,
a
while carrying out the operations
described here below be particularly
careful, in order to avoid burns .
◆
Remove the oil filling cap (1).
◆
Remove the drain screw (2).
◆
Drain the oil and let it drip for a few minutes in a large container, taking care that
it does not overflow.
◆
Remove the metal residues stuck to the
drain screw magnet.
◆
Check the sealing washer of the drain
screw and retighten it.
◆
Pour about 600 cmC of transmission oil
through the filling opening, see p. 58
(LUBRICANT CHART).
◆
Screw the oil filling cap (1).
◆
Start the engine and let it spin over for
about three minutes.
◆
Stop the engine and check the oil level
again, with the vehicle in vertical position
on flat ground.
use and maintenance Classic 125
37
Page 38
Fig. 34
FRONT WHEEL (Fig. 34)
DISASSEMBLY
Carefully read page 32 (MAINTENANCE).
While disassembling the wheel,
a
pads.
For the disassembly of the front wheel,
proceed as follows:
◆
be careful not to damage the
brake pipe, the disc and the
Lift the front part of the vehicle, placing a
suitable support under the engine, so
that the front wheel can rotate freely and
the vehicle cannot fall down.
◆
Loosen the two screws (1) of the rear
fork clamp.
◆
Loosen the wheel pin (2).
◆
Support the front wheel and withdraw the
wheel pin.
◆
Remove the speedometer control (3)
and take the bush.
Never pull the front brake lever
a
may go out of their seats, thus causing
the outflow of the brake fluid.
In this case consult your aprilia Official
Dealer, who will carry out the proper
maintenance operation.
REASSEMBLY
Carefully read page 32 (MAINTENANCE).
a
For the reassembly of the front wheel, proceed as follows:
◆
◆
after removing the brake caliper,
otherwise the caliper pistons
While reassembling the wheel, be
careful not to damage the brake
pipe, the disc and the pads.
Position the wheel between the fork
rods.
Position the odometer control (3) and the
bush correctly.
◆
Insert the wheel pin (2) from the left side
of the vehicle.
◆
Tighten the wheel pin.
Pin driving torque: 80 Nm (8 kgm).
◆
With pulled front brake lever, press the
handlebars repeatedly, thrusting the fork
downwards. In this way the fork rods will
settle properly.
◆
Tighten the two screws (1) of the fork
clamp.
After reassembly, pull the front
a
the braking system.
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
aprilia Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
brake lever repeatedly and
check the correct functioning of
use and maintenance Classic 125
38
Page 39
Fig. 35
REAR WHEEL (Fig. 35)
DISASSEMBLY
Carefully read page 32 (MAINTENANCE).
For the disassembly of the rear wheel, proceed as follows:
◆
Lift the rear part of the vehicle, placing a
suitable support under the engine, so
that the rear wheel can rotate freely and
the vehicle cannot fall down.
◆
Unscrew and remove the brake adjuster
(1) and release the brake cable (2) from
the pin (3) and from the retainer (4).
◆
Unscrew and remove the nut (5) and release the rod (6) from the antirotation
pin.
◆
Unscrew and remove the nut (7) and
take the washer (8).
◆
Withdraw the wheel pin from the chain
side.
◆
Release the gearing chain from the
crown, pushing the rear hweel forwards.
◆
Withdraw the wheel from the rear fork.
REASSEMBLY
Carefully read p. 32 (MAINTENANCE).
For the reassembly of the rear wheel, proceed as follows:
◆
Position the wheel between the rear fork
rods.
◆
Push the wheel forwards and position
the gearing chain in its seat.
◆
Correctly position the hole of the rod (6)
in correspondence with the antirotation
pin and manually screw the nut (5), without tightening it.
◆
Insert the wheel pin.
◆
Insert the washer (8).
◆
Screw the nut (7) until the wheel pin sets
in its seat.
◆
Check the chain tension and if necessary adjust it, see p. 34 (CHAIN).
◆
Tighten the nut (7).
Nut driving torque: 100 Nm (10 kgm).
◆
Tighten the nut (5).
◆
Insert the brake cable (2) in the retainer
(4) and in the pin (3).
◆
Screw the brake adjuster (1).
◆
Check the rear brake adjustment, see p.
22 (ADJUSTING THE REAR BRAKE).
After reassembly, pull the rear
brake lever repeatedly and
a
check the correct functioning of
the braking system.
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
aprilia Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
use and maintenance Classic 125
39
Page 40
Fig. 36 Fig. 37
REMOVING THE FUEL TANK
Carefully read p. 19 (FUEL) and p. 32
(MAINTENANCE).
Before starting any operation,
a
The petrol may flow out and catch fire if
it gets in contact with the red-hot parts
of the engine and of the exhaust system.
40
wait until the vehicle has cooled
down.
use and maintenance Classic 125
For the disassembly, proceed as follows:
◆
Disconnect the odometer cable from the
wheel.
◆
Unscrew the two screws that fasten the
mudguard to the fork left rod.
◆
Withdraw the cable from the housings on
the mudguard and on the radiator, thus
releasing it.
◆
Move the fuel cock lever to position
"OFF" (1 - Fig. 36).
◆
Disconnect the fuel pipe (2 - Fig. 36)
from the cock.
◆
Raise the saddle, see p. 19 (CRASH
HELMET / GLOVE COMPARTMENT)
and act on the spring pin by means of a
screwdriver (Fig. 36).
◆
Raise the right side of the saddle, near
the cogging, release and remove it.
When releasing the saddle, use
c
coming out of pin and spring (see Fig.
36).
◆
◆
◆
your finger to slow down the
Unscrew and remove the screw (3 - Fig.
36) with the relevant washer.
Slowly raise the tank (Fig. 37) and dis-
connet the warning light connector (1 Fig. 37) and the dashboard light cable
connector (2 - Fig. 37).
Remove the tank, withdrawing the odometer cable.
Page 41
AIR CLEANER (Fig. 38)
Do not use petrol or inflammable
a
sions.
Carefully read p. 32 (MAINTENANCE)
and p. 32 (REGULAR SERVICE INTERVALS CHART).
Check the conditions of the air cleaner
every 4000 km and change it every 8000
km.
If the vehicle is used on dusty or wet roads,
the cleaning operations must be carried
out more frequently.
solvents to wash the filtering element, to avoid fires or explo-
Fig. 38
To clean the air cleaner, proceed as follows:
◆
Remove the air cleaner casing cover (1),
by unscrewing the two screws (2).
◆
Acting on the tooth (3), lift the cover (4)
and withdraw it completely.
◆
Withdraw the filtering element (5).
◆
Wash the filtering element with clean,
non-inflammable solevents or solvents
with high volatility point, then let it dry
thoroughly.
◆
Apply a filter oil or a thick oil (SAE 80W-
90) on the whole surface of the filtering
element, then squeeze it to eliminate the
oil in excess.
The filter must be well impreg-
c
nated, though not dripping.
INSPECTING THE FRONT
AND REAR SUSPENSIONS
Have the front suspension oil
changed by an aprilia Official
Dealer, who will ensure you
a
prompt and accurate servicing.
Carefully read p. 32 (MAINTENANCE).
Remember:
c
1 miles = 1.6 km
1 km = 0.625 miles
Change the front suspension oil every
12000 km.
Further, carry out the following checking
operations:
◆
With pulled front brake lever, press the
handlebar repeatedly, thrusting the fork
downwards.
The stroke must be gentle and there
must be no trace of oil on the rods.
◆
Raise the rear wheel from the ground by
means of a suitable support stand, then
check the rear fork bearings.
◆
Check the fastening of all the components and the functionality of the front
and rear suspension joints.
If you notice irregularities in the
operation or if the help of a qualified technician is necessary,
a
contact your aprilia Official Dealer.
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41
Page 42
TABLE 1 - ADJUSTING THE REAR SUSPENSION SPRING PRELOAD
Adjusting metal ring By screwing it By unscrewing it
Function Spring preload increase Spring preload decrease
Fig. 39
ADJUSTING THE REAR
SUSPENSION (Fig. 39)
The rear suspension consists of a pair of
spring-shock absorber units, fixed to the
rear fork by means of silent-blocks.
The shock absorbers are provided with a
metal ring with five positions, for the adjustment of the spring preload.
The standard adjustment, set by the manufacturer, is suitable for a driver weighing
about 70 kg.
If your weight and needs are different, act
on the metal ring (1) with the apposite
spanner, thus setting the ideal travelling
conditions (see table 1).
It is also possible to adjust the attitude of
the vehicle, by moving the shock absorber
in the desired position (see table 2).
Attitude
Recommended
kind of road
Notes Rider and passenger Solo rider
TABLE 2 - REAR SUSPENSION SHOCK ABSORBER POSITION
Rear shock
absorber position
Function
Attitude
Recommended
kind of road
Set both shock absorbers on the same position.
The attitude of the vehicle
is more rigid
Smooth or normal roads
A B C
The suspension is
softer
The vehicle is
lower
Normal roads Normal roads
Intermediate
position
The vehicle is in
intermediate
position
The attitude of the vehicle
is less rigid
Roads with uneven
surface
a
The suspension is
harder
The vehicle is
higher
Roads with uneven
surface
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42
Page 43
Fig. 40
CHECKING
THE BRAKE PAD WEAR (Fig. 40)
Carefully read page 20 (BRAKE FLUID
(recommendations)), page 21 (DISC
BRAKES), page 32 (MAINTENANCE).
c
Check the brake pad wear after the first
500 km and successively every 2000 km.
The wear of the brake pads depends on
the use, on the kind of drive and on the
road. The wear will be greater when the vehicle is driven on dirty or wet roads.
To verify the front pad wear, it is sufficient
to carry out a quick visual checking between brake caliper and pads, looking
downwards.
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Fig. 41
If the thickness of the friction material
(even of one pad only) has reduced to
about 1 mm, replace both pads.
c
Have the pads changed by your
aprilia Official Dealer.
CHECKING THE SHOE WEAR
(Fig. 41)
Carefully read p. 32 (MAINTENANCE)
and p. 22 (REAR BRAKE).
To check the wear of the rear brake shoes,
proceed as follows:
◆
Remove the rear wheel, see p. 39 (REAR WHEEL).
◆
Extract the brake block cover, which
contains the two shoes (1).
◆
At this point it is possible to check the thickness of the friction material, which
must never be less than 1 mm. If the minimum thickness allowed has been reached, if you notice any anomaly in the
operation or if any part is damaged, contact an aprilia Authorized Dealer, who
will provide for changing the shoes.
◆
After checking the shoes or, if necessary, having them changed, reinstall the
brake block cover on the wheel and perform the reassembly operations, see p.
39 (REAR WHEEL).
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43
Page 44
Fig. 42 Fig. 43
Fig. 44
CHECKING THE STEERING
Carefully read p. 32 (MAINTENANCE).
To check the steering, it is necessary to:
◆
Raise the front wheel, using a support or
a suitable stand.
◆
Shake the fork in the travelling direction
(Fig. 42).
If you notice any slack:
◆
Loosen the two screws (3 - Fig. 43).
◆
Loosen the screw (1 - Fig. 43).
◆
Adjust the metal ring (2 - Fig. 43) by
means of the apposite spanner, taking
up the slack with small rotations.
use and maintenance Classic 125
44
c
would be damaged.
◆
◆
◆
a
damage to the balls and not to reduce
the manoeuvrability of the vehicle.
Do not tighten the adjusting ring
excessively, since the balls
Check the steering repeatedly, until the
inconvenience has been eliminated.
Tighten the screw (1 - Fig. 43) thoroughly.
Tighten the two screws (3 - Fig. 43).
At the end of this operation,
make sure that the handlebars
rotate smoothly, to avoid any
ADJUSTING THE ACCELERATOR
CONTROL (Fig. 44)
The accelerator control must have a slack
to ensure the closing of the throttle valve
and of the lubrication pump.
To get this slack, act on the apposite adjuster (1) positioned at the beginning of the
accelerator control cable, after withdrawing
the protection element (2).
Carry out these operations only
a
brication pump are correctly adjusted.
after making sure that the cables
of the carburettors and of the lu-
Page 45
The engine idling speed (in neutral) must
be about 1300 ± 150 rpm.
◆
Twist the throttle grip, accelerating and
decelerating a few times to make sure
that it functions correctly and to check if
the idling speed is constant.
Fig. 45
IDLING ADJUSTMENT (Fig. 45)
Carefully read p. 32 (MAINTENANCE).
Adjust the idling every time it is irregular.
To carry out this operation, proceed as fol-
lows:
◆
Ride for a few miles, until reaching the
normal running temperature.
◆
Position the vehicle on the side stand.
◆
Connect an electronic revolution counter
to the spark plug cable.
◆
Adjust the screw (1) of the carburettor,
positioned under the tank on the left side
of the vehicle; by turning it clockwise,
you increase the engine rpm, while by
turning it anticlockwise, you decrease
the engine rpm.
a
BLEEDING THE MIXER OIL
(Fig. 46)
Carefully read p. 32 (MAINTENANCE).
a
sary to carry out the bleeding.
Proceed as follows:
◆
◆
◆
If necessary, contact your
aprilia Official Dealer.
If you run out of oil in the mixer
oil tank or if the mixer oil pipe
has been removed, it is neces-
Top up the mixer oil tank, see p. 20 (MIXER OIL TANK).
Remove the mixer oil tank plug, see p.
12 (ARRANGEMENT OF THE MAIN ELEMENTS).
Remove the oil pan guard - left side -,
see p. 22 (REMOVING THE OIL PAN
GUARD).
Fig. 46
◆
Unscrew and remove the three screws
(1) of the pump cover (2).
◆
Remove the cross-slotted screw (3) positioned on the mixer pump and wait until
the oil flows out of the hole.
◆
When no more air bubbles can be seen
in the oil that flows out of the hole, tighten the screw (3).
It is important to wait until no
a
engine with air inside the mixer oil system may result in serious damage to the
engine itself.
◆
◆
◆
more air bubbles are present in
the oil, since the running of the
Put back the cover (2) and tighten the
three screws (1).
Put back the oil pan guard.
Screw the mixer oil tank plug.
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45
Page 46
Fig. 47
SPARK PLUG (Fig. 47)
c
Carefully read page 32 (MAINTENANCE).
Change the spark plug every 8000 km.
Periodically remove the spark plug and
clean it carefully, removing carbon deposits. Change it if necessary.
To reach the spark plug:
◆
◆
◆
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Unscrew the tool kit compartment cover,
see p. 18 (TOOL KIT).
Unscrew the two fastening screws.
Remove the tool kit compartment.
To remove and clean the spark plug:
◆
Take off the spark plug cap.
◆
Remove all the dirt from the base of the
spark plug, then unscrew it with the
spanner you will find in the tool kit and
extract it from its seat, taking care that
neither dust nor other substances enter
the cylinder.
◆
Make sure that there are neither carbon
deposits, nor corrosion marks on the
electrode and on the central porcelain
part; if necessary, clean them with the
special cleaners for spark plugs, with an
iron wire and/or a metal brush.
◆
Energetically blow some air, in order to
prevent the removed residues from getting into the engine.
If the spark plug has crackings on the insulating material, corroded electrodes or
excessive deposits, it must be changed.
◆
Check the spark plug gap with a thickness gauge.
The gap must be 0.6 ÷ 0.7 mm; if necessary adjust it, carefully bending the earth
electrode.
◆
Make sure that the washer is in good
conditions.
With the washer on, screw the spark
plug by hand in order not to damage the
thread.
◆
Tighten the spark plug by means of the
spanner you will find in the tool kit, giving
it half a turn to compress the washer.
The spark plug must be well
tightened, otherwise the engine
may overheat and be seriously
a
damaged.
Use the recommended type of spark
plug only, see p. 54 (TECHNICAL DATA), in order not to compromise the life
and performance of the engine.
◆
Put back the spark plug cap.
◆
Put back the tool kit compartment, tightening the two screws thoroughly.
◆
Put back the tool kit compartment cover.
BATTERY
Carefully read page 32 (MAINTENANCE).
Remember:
c
1 miles = 1.6 km
1 km = 0.625 miles
Check the electrolyte level and the tightening of the terminals every 1000 km.
The electrolyte in the battery is
toxic and caustic and if it gets in
contact with the skin it can
a
cause burns, since it contains sulphuric
acid.
Wear protection clothes, a face mask
and/or goggles during maintenance operations.
use and maintenance Classic 125
46
Page 47
In case of contact with the skin, rinse
with plenty of water.
In case of contact with the eyes, rinse
with plenty of water for fifteen minutes,
then consult an oculist without delay.
If the electrolyte is accidentally swallowed, drink a lot of water or milk, then
continue drinking milk of magnesia or
vegetable oil and consult a doctor without delay.
remove the battery from its container, remove the element plugs and put the battery in a cool and dry place.
A recharge with an amperage equal to
1/10th of the battery capacity is recommended.
After the recharging operation, check the
electrolyte level again and if necessary top
up with distilled water. Then tighten the element plugs and put back the battery in its
container.
The battery gives off explosive gases;
keep it away from flames, sparks, cigarettes and any other source of heat.
During the recharging or the use, make
sure that the room is properly ventilated
and avoid inhaling the gases released
during the recharging.
KEEP AWAY FROM CHILDREN
Never invert the connection of the bat-
tery cables.
Do not incline the vehicle too much, in
order to avoid dangerous leaks of the
battery fluid.
Connect and disconnect the battery
with the ignition switch in position "
Connect first the positive cable (+) and
then the negative cable (–).
Disconnect following the reverse order.
m".
Fig. 48
CHECKING THE ELECTROLYTE
LEVEL (Fig. 48)
Carefully read page 46 (BATTERY).
To check the electrolyte level, proceed as
follows:
◆
Remove the four screws (1) that fasten
the protection shell.
◆
Remove the shell (2).
◆
Make sure that the fluid level is included
between the two “MIN” and “MAX”
marks stamped on the battery side.
If necessary, top up by adding distilled water. Never exceed the “MAX” mark, since
the level increases during the recharge.
For the recharge, disconnect the cables,
Always connect the battery
breather pipe, to prevent the sulphuric acid vapours from cor-
a
roding the electric system, painted
parts, rubber elements or gaskets when
they exit the breather pipe itself.
LONG INACTIVITY
OF THE BATTERY
If the vehicle remains unused for a long period, remove the battery and place it in a
cool and dry place. Recharge it completely,
by using a trickle charge.
If the battery remains on the vehicle, disconnect the cables from the terminals.
It is important to check the charge periodically (about once a month), during the winter or when the vehicle remains unused, in
order to prevent the deterioration of the
battery.
use and maintenance Classic 125
47
Page 48
Fig. 49
ARRANGEMENT OF THE FUSES
20 A fuse
From battery to:
ignition switch, voltage regulator.
15A fuse
From ignition switch to:
all light loads.
7.5 A fuse
From ignition switch to:
ignition.
CHANGING THE FUSES (Fig. 49)
Carefully read page 32 (MAINTENANCE).
Do not repair faulty fuses.
Never use fuses different from
the recommended ones.
a
The use of unsuitable fuses may cause
damages to the electric system or, in
case of short circuit, even a fire.
If a fuse blows frequently, there
c
overload in the electric system. In this
case it is advisable to consult an
aprilia Official Dealer.
48
probably is a short circuit or an
use and maintenance Classic 125
If an electric component does not work or
works irregularly, or if the vehicle fails to
start, it is necessary to check the fuses:
◆
Turn the ignition switch to position “m”,
to avoid any accidental short circuit.
◆
Pull the left side, by grasping it on its two
upper ends, and remove it.
◆
Extract the fuses one by one and check if
the filament is broken.
◆
Before replacing a fuse, try to find out the
cause of the trouble, if possible.
◆
Then replace the damaged fuse with a
new one having the same amperage.
◆
Put back the side.
Page 49
H
Fig. 50
ADJUSTING
THE HEADLIGHT BEAM
To rapidly check the correct direction of the
beam, place the vehicle on flat ground, 10
m away from a wall.
Turn on the low beam, sit on the vehicle
and make sure that the beam projected on
the wall is slightly under the horizontal line
of the headlight (about 9/10th of the total
height, see Fig. 50).
To adjust the headlight beam, proceed as
follows:
◆
Loosen the screw (1 - Fig. 51).
◆
Turn the headlight and adjust the beam.
◆
Tighten the screw (1 - Fig. 51).
Fig. 51
BULBS
Before changing a bulb, turn the
ignition switch to position "
Change the bulb wearing clean
a
gloves or using a clean and dry cloth.
Do not leave fingerprints on the bulb,
since these may cause its overheating
and consequent breakage.
If you touch the bulb with bare hands,
remove any fingerprint with alcohol, in
order to prevent it from blowing frequently.
Carefully read page 32 (MAINTENANCE).
DO NOT FORCE THE ELECTRIC
CABLES
m".
Fig. 52
CHANGING
THE HEADLIGHT BULBS (Fig. 52)
Carefully read p. 32 (MAINTENANCE)
and p. 49 (BULBS).
To change the bulbs, proceed as follows:
◆
Unscrew and remove the screw (1 Fig. 51).
◆
Remove the headlight and unscrew the
two screws (1 - Fig. 52).
◆
Grasp the lower part of the parabolic element, which will rotate until it is released.
The low beam/high beam bulb socket
(larger) must be rotated anticlockwise; the
parking light bulb socket (smaller) must be
withdrawn.
Extract the bulb socket and replace the
damaged bulb.
use and maintenance Classic 125
49
Page 50
Fig. 53 Fig. 54 Fig. 55
CHANGING THE DASHBOARD
BULBS
Carefully read p. 32 (MAINTENANCE)
and p. 49 (BULBS).
Proceed as follows:
CHANGING THE WARNING LIGHT
BULBS
◆
Unscrew and remove the five screws (1 Fig. 53) around the fillercap and the front
screw (2 - Fig. 53).
◆
Raise the warning light unit (1 - Fig. 54).
◆
Withdraw the bulb socket and replace
the damaged bulb.
use and maintenance Classic 125
50
SPEEDOMETER/ODOMETER BULBS
◆
Remove the fuel tank, see p. 40 (REMOVING THE FUEL TANK).
◆
Unscrew the nut (2 - Fig. 54) that locks
the odometer, supporting the latter so
that it does not fall down.
◆
Extract the odometer and replace the
damaged bulb/bulbs (Fig. 53).
CHANGING THE REAR LIGHT
BULB (Fig. 55)
Carefully read p. 32 (MAINTENANCE)
and p. 49 (BULBS).
Proceed as follows:
◆
Unscrew and remove the two screws (1).
◆
Remove the glass (2).
◆
Slightly press the bulb and rotate it anticlockwise.
◆
Extract the bulb from its seat.
The new bulb can be inserted in
c
one sense only, since the two
guide pins are misaligned.
◆
Correctly install a new bulb.
Page 51
Fig. 56 Fig. 57
Fig. 58
CHANGING
THE NUMBER PLATE BULB
Carefully read p. 32 (MAINTENANCE)
and p. 49 (BULBS).
To change the bulb, proceed as follows:
◆
Unscrew and remove the screw (1-Fig.
56).
◆
Remove the light unit (2-Fig. 57).
◆
Extract the bulb socket (3-Fig. 57).
◆
Withdraw the number plate bulb and replace it with a new one of the same type.
CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS
(Fig. 58)
Carefully read p. 32 (MAINTENANCE)
and p. 49 (BULBS).
To change the bulb:
◆
Unscrew and remove the screw (1).
c
not to break it.
◆
◆
◆
◆
While removing the indicator
lens, proceed carefully in order
Remove the indicator lens (2).
Press the bulb slightly and turn it anticlockwise.
Remove the bulb from its seat.
Correctly install a new bulb of the same
type.
c
ly, making the opening of the bulb socket itself coincide with the seat of the
screw.
c
seat.
Tighten the screw (1) carefully, without
exerting too much pressure, in order to
avoid damaging the indicator lens.
If the bulb socket has gone out
of its seat, insert it again correct-
Upon reassembly, correctly position the indicator lens in its
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TRANSPORT
c
tank and the carburettor completely,
making sure that both are completely
dry. During transport, the vehicle must
be held upright, in its normal use position, to avoid any oil and battery fluid
leakage.
DRAINING THE FUEL TANK
Carefully read page 19 (FUEL).
◆
◆
◆
◆
When all the fuel has flowed out, turn the
drain screw until the breather shuts.
Before transporting the vehicle,
it is necessary to empty the fuel
Stop the engine.
Empty the fuel tank by means of a manual pump or a similar system.
Put the free end of the fuel draining pipe
into a receptacle.
Open the carburettor breather acting on
the drain screw.
CLEANING
Clean the vehicle frequently if it
a
◆
◆
◆
◆
◆
a
because of the presence of water on the
grip surfaces.
Calculate long braking distances to
avoid accidents. Brake repeatedly to restore normal conditions.
used in particular areas or con-
ditions, such as:
Polluted areas (cities and industrial
areas).
Areas characterized by an high percentage of salinity and humidity (sea
areas, hot and humid climates).
Particular conditions (use of salt and
anti-ice chemical products on the
roads during the winter).
Avoid leaving deposits of industrial
and polluting powders, tar spots,
dead insects, bird droppings, etc. on
the body.
Avoid parking the vehicle under trees,
since in some seasons residues, resins, fruits or leaves fall down, which
contain substances that may damage
the paint.
After the vehicle has been
washed, its braking functions
could be temporarily impaired
c
pressure water jet; carefully wet the
dirty parts, remove mud and filth with a
soft car sponge impregnated with a lot
of water and shampoo (2÷4% parts of
shampoo in water).
Then rinse with plenty of water and dry
with chamois leather.
To clean the outer parts of the engine
use a degreaser, brushes and wipers.
Polish with silicone wax only after having carefully washed the vehicle.
c
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 and
on the left side of the handlebars, brake
pump, instruments and indicators, silencer exhaust, glove compartment, ignition switch/steering lock.
Never use solvents to clean the rubber
and plastic parts.
To remove dirt and mud from the
painted surfaces use a low-
Do not wash the vehicle under
the sun, especially during the
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52
Page 53
LONG PERIODS OF INACTIVITY
After a long period of inactivity of the vehicle some precautions are necessary to
avoid any problem.
Further, it is important to carry out the necessary repairs and a general check up before the period of inactivity, since you could
forget to carry them out later.
Proceed as follows:
◆
Empty the fuel tank and the carburettor,
see p. 52 (DRAINING THE FUEL
TANK).
Put back the tank plug.
◆
Extract the spark plug and pour a teaspoon (5-10 cmC) of two-stroke engine oil
into the cylinder.
Move the ignition switch to position “
press the start push button “
r” for a few
n”,
seconds, to distribute the oil evenly on
the cylinder surfaces.
Put back the spark plug.
◆
Remove the battery, see p. 46 (BATTERY).
◆
Wash and dry the vehicle, see p. 52
(CLEANING).
◆
Polish the painted surfaces with wax.
◆
Inflate the tyres, see p. 25 (TYRES).
◆
By means of a suitable support, position
the vehicle so that both tyres are raised
from the ground.
◆
Place the vehicle in an unheated, not-humid room, away from sunlight, with minimum temperature variations.
◆
Cover the vehicle avoiding the use of
plastic or waterproof materials.
AFTER A PERIOD OF INACTIVITY
◆
Uncover and clean the vehicle, see p. 52
(CLEANING).
◆
Check the electrolyte level in the battery
and install it, see p. 46 (BATTERY).
◆
Make sure that the fuel drain screw is
thoroughly screwed (breather pipe closing index), see p. 52 (DRAINING THE
FUEL TANK).
◆
Refuel, see p. 19 (FUEL).
◆
Carry out the preliminary checking operations, see p. 27 (PRELIMINARY
CHECKING OPERATIONS).
Have a test ride at moderate
a
speed in a low-traffic area.
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53
Page 54
TECHNICAL DATA
DIMENSIONS Max. length...................................................... 2300 mm
Max. width........................................................ 780 mm
Max. height (handlebars included)................... 1120 mm
Seat height ...................................................... 830 mm
Distance between centres............................... 1550 mm
Min. ground clearance ..................................... 180 mm
Weight without driver (ready for starting)......... 148 kg
ENGINE Type ................................................................. ROTAX 122 - 2 stroke with controlled ignition
Number of cylinders......................................... 1
Total displacement........................................... 124.8 cmC
Bore / stroke.................................................... 54 mm / 54.5 mm
Compression ratio ........................................... 12.5 ± 0.5:1
Starting............................................................ electric
Clutch .............................................................. multidisc in oil bath, with manual lever control on the left side of the
handlebar.
Cooling ............................................................ liquid-cooled
CAPACITY Fuel (reserve included).................................... 10 l
Fuel reserve..................................................... 2 l
Transmission oil ............................................... 600 cmC
Mixer oil (reserve included).............................. 2 l
Mixer oil reserve.............................................. 0.5 l
Coolant............................................................ 0.7 l
Fork oil (for each tube)..................................... 420 cmC
Seats ............................................................... n˚ 2
Vehicle max. load
(driver + passenger + luggage) ....................... 172 kg
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GEAR Type.................................................................
Gear ratios: 1ª.................................................
2ª..................................................
3ª..................................................
4ª..................................................
5ª..................................................
6ª..................................................
mechanical, 6 gears with foot control on the left side of the engine.
Z = 10 / 30 = 1 : 3.000
Z = 14 / 29 = 1 : 2.071
Z = 17 / 27 = 1 : 1.588
Z = 19 / 25 = 1 : 1.315
Z = 21 / 23 = 1 : 1.095
Z = 22 / 21 = 1 : 0.954
TRANSMISSION Primary ............................................................
CARBURETTOR
FUEL SUPPLY
Secondary (with chain) ....................................
Total engine/wheel ratio (in sixth gear) ...........
For the “
Primary ............................................................
Secondary (with chain) ...................................
Total engine/wheel ratio (in sixth gear) ...........
Model ..............................................................
Choke tube......................................................
For the “
Model ..............................................................
Choke tube......................................................
Fuel:
– normal version ............................................. premium grade petrol (4 Stars
– catalytic version
D - F - C and 11 kW” version
D - F - C and 11 kW” version
...................................... unleaded petrol according to the DIN 51607 standard, min. O.N. 95
2
Z = 19 / 63 = 1 : 3.315
Z = 14 / 40 = 1 : 2.857
1 : 9.043
Z = 19 / 63 = 1 : 3.315
Z = 15 / 40 = 1 : 2.666
1 : 9.035
Dell’Orto PHBH 28 RD
Ø 28 mm
Dell’Orto PHBL 24
Ø 24 mm
) according to the DIN 51600
standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.)
(N.O.R.M.) and 85 (N.O.M.M.)
U
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55
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FRAME
Type .................................................................
Steering inclination angle ................................
Fore stroke.......................................................
Open double cradle
33˚
98 mm
SUSPENSIONS Front................................................................ Hydraulically operated telescopic fork
120 mm
n˚2 Hydraulic shock absorbers
70 mm
BRAKES
Stroke..............................................................
Rear.................................................................
Stroke..............................................................
Front................................................................ disc brake - Ø 260 mm - with hydraulic transmission
Rear................................................................. drum brake, Ø 160 mm, with mechanic transmission
WHEELS RIMS................................................................ with stainless steel Ø 4 mm spokes
Front................................................................ 1.85 x 19"
Rear................................................................. 2.50 x 16"
TYRES............................................................. with inner tube
Front................................................................
– alternative .................................................
Rear.................................................................
– alternative .................................................
90/90 - 19" - 52H
90/90 - 19" - 52S
130/90 - 16" - 67H
130/90 - 16" - 67S
STANDARD INFLATION PRESSURE
Front................................................................ 180 kPa (1.8 bar)
Rear................................................................. 200 kPa (2.0 bar)
INFLATION PRESSURE WITH PASSENGER (where drive with passenger is allowed)
Front................................................................ 190 kPa (1.9 bar)
Rear................................................................. 220 kPa (2.2 bar)
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Page 57
IGNITION Type................................................................. NIPPONDENSO - CDI
Spark advance................................................ 14˚ ± 2˚ to 1500 rpm before T.D.C.
Standard spark plug........................................
Spark plug gap................................................
Engine idle rpm...............................................
NGK BR10 EG
0.6 ÷ 0.7 mm
1300 ± 150 rpm
ELECTRIC
SYSTEM
Battery.............................................................
Fuse................................................................
Generator (with permanent magnet)...............
12 V - 9 Ah
7.5 / 15 / 20 A
12 V - 185 W
Low/high beam bulb ....................................... 12 V - 35 / 35 W
Front parking light bulb ................................... 12 V - 5 W
Direction indicator bulbs.................................. 12 V - 10 W
Speedometer bulb........................................... 12 V - 2 W
Total kilometres odometer bulb ....................... 12 V - 2 W
Rear parking light / stoplight bulb.................... 12 V - 5 / 21 W
Number plate bulb........................................... 12 V - 5 W
Neutral indicator warning light......................... 12 V - 2 W
High beam warning light ................................. 12 V - 2 W
Direction indicator warning light...................... 12 V - 2 W
Mixer oil reserve warning light......................... 12 V - 2 W
Coolant overheating warning light................... 12 V - 2 W
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57
Page 58
LUBRICANT CHART
Gearbox oil (recommended):
As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the
A.P.I. GL-4 specifications.
F.C., SAE 75W - 90
0
2 stroke oil (recommended):
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):
If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed as indicated
below:
SAE 10W
SAE 15W
Bearings and other lubrication points (recommended):
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):
Brake fluid (recommended):
F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume.
0
F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume.
0
Use new brake fluid only.
MAX 2T COMPETITION
0
F.A. 5W or 0 F.A. 20W fork oil.
0
CHAIN SPRAY.
0
F.F., DOT 5 (DOT 4 compatible).
0
AUTOGREASE MP.
0
a
Engine coolant (recommended)
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.
: 0 ECOBLU - 40°C.
1
a
use and maintenance Classic 125
58
Page 59
Importers
APRILIA MOTO U.K. LTD
DUNRAGIT
STRANRAER
WIGTOWNSHIRE DG9 8PN
SCOTLAND (UK)
TEL. (01581) 400660
FAX (01581) 400661
IDEAL MOTOR SPORT PTE LTD
18, HOWARD ROAD
1336 SINGAPORE (SGP)
TEL. 2820082
FAX 2821012
AVIRAM & GOLDMAN IMPORT & MARKETING CO. LTD
21, TUSHIA STREET
61572 TEL-AVIV
P.O. BOX 57266
ISRAEL (IL)
TEL. (3) 5623951
FAX (3) 5623950
ASK FOR GENUINE SPARE PARTS ONLY
use and maintenance Classic 125
59
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WIRING DIAGRAM - Classic 125
use and maintenance Classic 125
60
Page 61
WIRING DIAGRAM KEY - Classic 125
1)Generator
2)Ignition coil
3)Starter
4)Voltage regulator
5)Fuses
6)Battery
7)Start relay
8)Front stoplight switch
9)Rear stoplight switch
10)Coolant temperature thermal switch
11)Mixer oil reserve sensor
12)Neutral position sensor
14)Left rear direction indicator
15)Rear light
16)Right rear direction indicator
17)Blinking
18)Key switch
19)Right dimmer switch
20)Left dimmer switch
21)Warning light unit
22)Odometer
23)Dashboard bulb
25)Solenoid
26)Neutral warning light
27)Mixer oil reserve warning light
28)High beam warning light
29)Direction indicator warning light
30)Horn
31)Right front direction indicator
32)Low/high beam bulb
33)Front parking light bulb
34)Left front direction indicator
35)Electronic rave unit
36)Multiple connectors
37)Spark plug
39)Complete headlight
42)CDI
43)Number plate light
44)Pick up
CABLE COLOURS
ArOrange
AzLight blue
B Blue
BlWhite
G Yellow
GrGrey
M Brown
N Black
R Red
V Green
ViViolet
use and maintenance Classic 125
61
Page 62
WIRING DIAGRAM - Classic 125 - 11 kW version
use and maintenance Classic 125
62
Page 63
WIRING DIAGRAM KEY - Classic 125 - 11 kW version
1)Generator
2)Ignition coil
3)Starter
4)Voltage regulator
5)Fuses
6)Battery
7)Start relay
8)Front stoplight switch
9)Rear stoplight switch
10)Coolant temperature thermal switch
11)Mixer oil reserve sensor
12)Neutral position sensor
14)Left rear direction indicator
15)Rear light
16)Right rear direction indicator
17)Blinking
18)Key switch
19)Right dimmer switch
20)Left dimmer switch
21)Warning light unit
22)Odometer
23)Dashboard bulb
26)Neutral warning light
27)Mixer oil reserve warning light
28)High beam warning light
29)Direction indicator warning light
30)Horn
31)Right front direction indicator
32)Low/high beam bulb
33)Front parking light bulb
34)Left front direction indicator
36)Multiple connectors
37)Spark plug
39)Complete headlight
42)CDI
43)Number plate light
44)Pick up
CABLE COLOURS
ArOrange
AzLight blue
B Blue
BlWhite
G Yellow
GrGrey
M Brown
N Black
R Red
V Green
ViViolet
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63
Page 64
use and maintenance Classic 125
64
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.
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