Aprilia CLASSIC 125 User Manual 1997
use and maintenance
aprilia
part# 8102785
Classic 125
© 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
2
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
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.
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The use of medicins, alcohol and drugs or
psychotropic substances notably increases
the risk of accidents.
Be sure that you are in good psychophysical conditions and fit for driving and pay
particular attention to physical weariness
and drowsiness.
Most road accidents are caused by the
driver’s lack of experience.
NEVER lend the vehicle to beginners and,
in any case, make sure that the driver has
all the requirements for driving.
Rigorously observe all road signs and national and local road regulations.
Avoid abrupt movements that can be dangerous for yourself and other people (for
example: rearing up on the back wheel,
speeding, etc.), and give due consideration
to the road surface, visibility and other driving conditions.
Avoid obstacles that could damage the vehicle or make you lose control.
Avoid riding in the slipstream created by
preceding vehicles in order to increase
your speed.
Always drive with both hands on the handlebars and both feet on the footrests (or
on the rider’s footboards), in the correct
driving posture.
Avoid standing up or stretching your limbs
while driving.
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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.
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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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.
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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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
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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15
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
use and maintenance Classic 125
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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17
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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19
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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