APRILIA CLASSIC 125 - 03-1997 Owner's manual

Classic 125

use and maintenance

2

use and maintenance Classic 125

This manual is to be considered an integral part of the vehicle,

which must be delivered complete with it also in case of resale.

aprilia s.p.a. reserves the right to modify its models at any time,

without prejudice to the main characteristics here described.

All rights as to electronic storage, reproduction and total or 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:

Via G. Galilei, 1 - 30033 Noale (VE) - Italy

Ph. 041 - 58 29 111

Fax 041 - 44 10 54

Illustrated and printed by:

Viale del Progresso - 37038 Soave (VR) - Italy

Ph. 045 - 76 11 911

Fax 045 - 76 12 241

use and maintenance Classic 125

3

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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 quick-

ness 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 thor-

ough 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 man-

ual, for the purchase of aprilia Genuine Spare Parts, accesso-

ries and other products, as well as for specific technical advice,

contact only aprilia Authorized Outlets and Official Dealers, who

can ensure you reliable and prompt servicing.

Thank you for choosing aprilia. We wish you a nice ride.

IMPORTANT:

When asking your Dealer for spare parts, specify the spare parts

code indicated on the SPARE PARTS IDENTIFICATION LA-

BEL.

Write down the identification code in the space here below, in or-

der to remember it also in case of loss or deterioration of the la-

bel.

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

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.

Indications to make the operations easier. Technical

information.

In this manual the various versions are indicated by the fol-

lowing symbols:

aprilia

CODICE RICAMBI spare parts code number

N°

I.M.

ABCDE

IUKA PSFBD F E

GR NL CH DK J SGP PL IL ROK

MAL RCH BM

2

catalytic version

I

Italy version

U

United Kingdom version

C

Switzerland version

A

Austria version



Denmark version

P

Portugal version

J

Japan version

"

Finland version

S

Singapore version

B

Belgium version

V

Poland version

D

Germany version

%

Israel version

F

France version

K

South Korea version

E

Spain version

M

Malaysia version

G

Greece version

R

Chile version

O

Holland version

Q

Bermuda version

a

c

4

use and maintenance Classic 125

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SAFE DRIVE ..................................................................................................... 5

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

CLOTHING ................................................................................................. 9

ACCESSORIES ........................................................................................ 10

LOAD ........................................................................................................ 10

ARRANGEMENT OF THE MAIN ELEMENTS ............................................... 12

ARRANGEMENT OF THE INSTRUMENTS ................................................... 14

INSTRUMENTS AND INDICATORS .............................................................. 14

INSTRUMENTS AND INDICATORS ........................................................ 15

MAIN INDEPENDENT CONTROLS ............................................................... 16

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR ....................... 16

CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR .................... 17

IGNITION SWITCH................................................................................... 18

STEERING LOCK..................................................................................... 18

AUXILIARY EQUIPMENT ............................................................................... 18

TOOL KIT ................................................................................................. 18

CRASH HELMET/GLOVE COMPARTMENT ........................................... 19

MAIN COMPONENTS..................................................................................... 19

FUEL......................................................................................................... 19

TRANSMISSION OIL................................................................................ 20

MIXER OIL TANK ..................................................................................... 20

BRAKE FLUID (recommendations) .......................................................... 20

FRONT BRAKE ........................................................................................ 21

REAR BRAKE........................................................................................... 22

REMOVING THE OIL PAN GUARD (LEFT SIDE) ................................... 22

ADJUSTING THE CLUTCH...................................................................... 23

ADJUSTING THE SHIFTING LEVER....................................................... 24

COOLANT ................................................................................................ 24

TYRES ...................................................................................................... 25

CATALYTIC SILENCER

2 ................................................................... 26

INSTRUCTIONS FOR USE............................................................................. 27

PRELIMINARY CHECKING OPERATIONS............................................. 27

STARTING................................................................................................ 28

DEPARTURE AND DRIVE ....................................................................... 29

STOPPING AND PARKING ..................................................................... 31

SUGGESTIONS TO PREVENT THEFT.................................................. 31

MAINTENANCE .............................................................................................. 32

REGULAR SERVICE INTERVALS CHART ............................................. 32

IDENTIFICATION DATA........................................................................... 33

CHAIN ....................................................................................................... 34

CHECKING THE TRANSMISSION OIL LEVEL........................................ 36

CHANGING THE TRANSMISSION OIL ................................................... 37

FRONT WHEEL ........................................................................................ 38

REAR WHEEL .......................................................................................... 39

REMOVING THE FUEL TANK.................................................................. 40

AIR CLEANER .......................................................................................... 41

INSPECTING THE FRONT AND REAR SUSPENSIONS ........................ 41

ADJUSTING THE REAR SUSPENSION .................................................. 42

CHECKING THE BRAKE PAD WEAR...................................................... 43

CHECKING THE SHOE WEAR ............................................................... 43

CHECKING THE STEERING.................................................................... 44

ADJUSTING THE ACCELERATOR CONTROL ..................................... 44

IDLING ADJUSTMENT .............................................................................45

BLEEDING THE MIXER OIL .................................................................... 45

SPARK PLUG ........................................................................................... 46

BATTERY.................................................................................................. 46

CHECKING THE ELECTROLYTE LEVEL................................................ 47

LONG INACTIVITY OF THE BATTERY .................................................. 47

CHANGING THE FUSES..........................................................................48

ADJUSTING THE HEADLIGHT BEAM..................................................... 49

BULBS ...................................................................................................... 49

CHANGING THE HEADLIGHT BULBS .................................................... 49

CHANGING THE DASHBOARD BULBS .................................................. 50

CHANGING THE REAR LIGHT BULB...................................................... 50

CHANGING THE NUMBER PLATE BULB ...............................................51

CHANGING THE FRONT AND REAR

DIRECTION INDICATOR BULBS............................................................. 51

TRANSPORT................................................................................................... 52

DRAINING THE FUEL TANK.................................................................... 52

CLEANING ...................................................................................................... 52

LONG PERIODS OF INACTIVITY ............................................................ 53

AFTER A PERIOD OF INACTIVITY ......................................................... 53

TECHNICAL DATA ......................................................................................... 54

LUBRICANT CHART ................................................................................ 58

Importers ................................................................................................... 59

WIRING DIAGRAM - Classic 125 ............................................................. 60

WIRING DIAGRAM KEY - Classic 125 ..................................................... 61

WIRING DIAGRAM - Classic 125 - 11 kW version ................................... 62

WIRING DIAGRAM KEY - Classic 125 - 11 kW version ........................... 63

safe drive

6

use and maintenance Classic 125

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To drive the vehicle it is necessary to be in

possession of all the requirements pre-

scribed by law (driving licence, minimum

age, psychophysical ability, insurance,

state taxes, vehicle registration, number

plate, etc.).

Gradually get to know the vehicle by driv-

ing it first in areas with low traffic and/or pri-

vate areas.

The use of medicins, alcohol and drugs or

psychotropic substances notably increases

the risk of accidents.

Be sure that you are in good psychophysi-

cal 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.

use and maintenance Classic 125

7

Rigorously observe all road signs and na-

tional and local road regulations.

Avoid abrupt movements that can be dan-

gerous for yourself and other people (for

example: rearing up on the back wheel,

speeding, etc.), and give due consideration

to the road surface, visibility and other driv-

ing conditions.

Avoid obstacles that could damage the ve-

hicle or make you lose control.

Avoid riding in the slipstream created by

preceding vehicles in order to increase

your speed.

Always drive with both hands on the han-

dlebars 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.

8

use and maintenance Classic 125

COOLER

OIL

The driver should pay attention and avoid

distractions caused by people, things and

movements (never smoke, eat, drink, read,

etc.) while driving.

Use only the vehicle’s specific fuels and lu-

bricants indicated in the "LUBRICANT

CHART"; check the oil, fuel and coolant

levels regularly.

If the vehicle has been involved in an acci-

dent, make sure that no damage has oc-

curred to the control levers, pipes, wires,

braking system and vital parts.

If necessary, have the vehicle inspected by

an aprilia Official Dealer, who should care-

fully check the frame, handlebars, suspen-

sions, safety parts and all the devices that

you cannot check by yourself.

Always remember to report any malfunc-

tion to the technicians to help them in their

work.

Never use the vehicle when the amount of

damage it has suffered endangers your

safety.

use and maintenance Classic 125

9

ONLY ORIGINALS

Never change the position, inclination or

colour of: number plate, direction indica-

tors, lights and horns.

Any modification of the vehicle and/or the

removal of original components can com-

promise 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 in-

crease the vehicle’s performance levels or

alter its original characteristics.

Never race with other vehicles.

Avoid off-road driving.

#,/4().'

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 hang-

ing loose; prevent these and other objects

from interfering with driving by getting en-

tangled with moving parts or driving mech-

anisms.

A12

345

10

use and maintenance Classic 125

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).

!##%33/2)%3

The owner of the vehicle is responsible for

the choice, installation and use of any ac-

cessory.

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 ac-

cess 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 stabili-

ty of the vehicle while driving.

Make sure that the equipment is well fas-

tened to the vehicle and not dangerous

during driving. Do not install electrical de-

vices and do not modify those already ex-

isting to avoid electrical overloads, be-

cause the vehicle could suddenly stop or

there could be a dangerous current short-

age in the horn and in the lights. aprilia

recommends the use of genuine accesso-

ries (aprilia genuine accessories).

,/!$

Be careful and moderate when loading

your luggage. Keep any luggage loaded as

close as possible to the centre of the vehi-

cle 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, es-

pecially during long trips.

use and maintenance Classic 125

11

KG!

Avoid hanging bulky, heavy and/or danger-

ous objects on the handlebars, mudguards

and forks, because the vehicle might re-

spond more slowly in turns and its ma-

noeuvrability could be unavoidably im-

paired.

Do not place bags that are too bulky on 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 se-

cured 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 compro-

mised.

12

use and maintenance Classic 125

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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

Fig. 1

use and maintenance Classic 125

13

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1) Fuel cock

2) Fillercap

3) Front brake fluid tank

4) Ignition switch/steering lock

5) Mixer oil tank

6) Rear brake control lever

7) Footrest

8) Took kit/glove compartment

9) Passenger’s footrest

10) Rear suspension spring preload adjusting

ring

Fig. 2

14

use and maintenance Classic 125

!22!.'%-%.4/&4(%).3425-%.43

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1) Left rear-view mirror

2) Clutch lever

3) High beam signalling push button (

a)

4) Cold start lever (e)

5) Ignition switch/steering lock (

n - m - s)

6) Throttle grip

7) Front brake lever

8) Right rear-view mirror

9) Engine stop switch (

n - m)

10) Light switch (o - p -

•

)

11) Start push button (

r)

12) Instruments and indicators

13) Horn push button (

f)

14) Direction indicator switch (

c)

15) Dimmer switch (

b - a)

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1) Speedometer

2) Total kilometres odometer

3) Coolant overheating warning light (

h)

4) Red mixer oil reserve warning light (

j)

5) Green neutral indicator warning light (

q)

6) Blue high beam warning light (a)

7) Green direction indicator warning light (

c)

Fig. 3 Fig. 4

use and maintenance Classic 125

15

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Description Function

Speedometer It indicates the driving speed.

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

Coolant overheating

warning light

h

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

In this case, stop the engine and check the coolant level, see p. 24 (COOLANT).

If the maximum allowed temperature is exceeded (the warning light comes on),

the engine may be seriously damaged.

Mixer oil reserve

warning light j

It comes on when the ignition switch is in position "n" and the start push button “r“ is pres-

sed, thus checking the proper functioning of the bulb.

If the light does not come on during the starting, provide for replacing the bulb.

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,

see p. 20 (MIXER OIL TANK).

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

High beam warning light

a

It comes on when the headlight is in "high beam" position or when the high beam signalling is

operated.

Direction indicator

warning light

c

It blinks when the direction indicators are on.

a

16

use and maintenance Classic 125

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The electrical parts work only when the ignition

switch is in position "

n".

1) DIMMER SWITCH (

b - a)

When the light switch (right side of the handlebar) is in posi-

tion "

o", if the dimmer switch is in position "a", the high

beam comes on, while if it is in position "

b", the low beam

comes on.

2) DIRECTION INDICATOR SWITCH (

c)

To indicate the turn to the left, move the switch to the left; to

indicate the turn to the right, move the switch to the right. To

turn off the direction indicator, press the switch on its centre.

3) HORN PUSH BUTTON (

f)

The horn is activated when the push button is pressed.

4) COLD START LEVER (

e)

The starter for the cold start of the engine is operated by rotat-

ing the lever "

e" downwards.

To disconnect the starter, move the lever "

e" to its initial po-

sition.

5) HIGH BEAM SIGNALLING PUSH BUTTON (

a)

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

forthcoming vehicles while overtaking and in case of peril

and/or emergency.

Fig. 5

c

use and maintenance Classic 125

17

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The electrical parts work only when the ignition

switch is in position "

n".

1) HEADLIGHT SWITCH (

o - p -

•

)

When the light switch is in position "

•

", the lights are off; when

the switch is in position "

p", the parking lights are on; when

the switch is in position "

o", the low beam or the high beam is

on. The high/low beam can be operated by means of the dim-

mer switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF

THE HANDLEBAR).

2) START PUSH BUTTON (

r)

When the start push button "

r" is pressed, the starter makes

the engine run. For the starting, see p. 28 (STARTING).

3) ENGINE STOP SWITCH (

n - m)

Do not operate the engine stop switch “

n - m” in

running conditions.

This is a safety or emergency switch.

With the switch in position "

n", it is possible to start the en-

gine; the engine can be stopped by moving the switch to posi-

tion "

m".

With stopped engine and ignition switch in posi-

tion "

n", the battery may discharge.

When the vehicle has come to rest, after stopping

the engine, move the ignition switch to position "

m".

c

a

Fig. 6

18

use and maintenance Classic 125

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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

switch/steering lock, the saddle

lock and the fuel tank lock.

Two keys are supplied together with the

vehicle (one spare key).

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Never turn the key to position

"

s" in running conditions, in or-

der to avoid losing control of the

vehicle.

OPERATION

To lock the steering:

◆

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.

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4//,+)4&IG

To reach the tool kit (right side of the vehi-

cle), 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

Fig. 7

c

Position Function

Key

removal

s

Steering

lock

The steering is

locked.

It is neither

possible to

start the

engine, nor to

switch on the

lights.

It is possible

to remove

the key.

m

Neither the

engine, nor the

lights can be

switched on.

It is possible

to remove

the key.

n

The engine

and the lights

can be

switched on.

It is not pos-

sible to

remove the

key.

a

Fig. 8

use and maintenance Classic 125

19

#2!3((%,-%4',/6%

#/-0!24-%.4&IG

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 complete-

ly; 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-

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.

-!).#/-0/.%.43

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The fuel used for internal com-

bustion engines is extremely in-

flammable and in particular con-

ditions it can become explosive.

It is important to carry out the refuelling

and the maintenance operations in a

well-ventilated area, with the engine off.

Do not smoke while refuelling or near

fuel vapours, in any case avoid any con-

tact 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 sur-

faces of the engine.

In case some fuel has accidentally been

spilt, make sure that the area has com-

pletely dried and before starting the ve-

hicle 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 ra-

diation, never fill the tank to the brim.

Screw the plug (Fig. 10) up carefully af-

ter refuelling.

Avoid any contact of the fuel with the

skin and the inhalation of vapours; do

not swallow fuel or pour it from a recep-

tacle into another by means of a tube.

KEEP AWAY FROM CHILDREN

Use only premium grade petrol

(4 Stars

U

), in conformity with the DIN

51600 standard, min. O.N. 98 (N.O.R.M.)

and 88 (N.O.M.M.).

FUEL TANK CAPACITY

(reserve included): 10

L

TANK RESERVE: 2 L

To unlock the tank plug, insert the ignition

key in the lock and turn it clockwise.

Fig. 9

a

Fig. 10

2

ONLY FOR THE CATALYTIC VERSION

Use only unleaded petrol, in conform-

ity with the DIN 51607 standard, min.

O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

20

use and maintenance Classic 125

42!.3-)33)/./),

Remember:

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 TOP-

PING UP), p. 37 (CHANGING THE

TRANSMISSION OIL) and p. 58 (LUBRI-

CANT CHART).

Used transmission oil can seri-

ously damage the skin if handled

every day and for long periods.

If the vehicle is used on dusty

roads, change the oil more fre-

quently.

Do not dispose of the oil in the

environment. Put it in a sealed

container and take it to the filling

station where you usually buy it.

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The vehicle is provided with a separate

mixer that ensures the mixing of petrol and

oil for the correct lubrication of the engine,

see p. 58 (LUBRICANT CHART).

The reserve is indicated by the coming on

of the mixer oil reserve warning light “

j“

positioned on the dashboard, see p. 14

and 15 (INSTRUMENTS AND INDICA-

TORS).

If you run out of oil in the mixer

oil tank, or if the mixer oil pipe

has been removed, it is neces-

sary to bleed the mixer oil, see p. 45

(BLEEDING THE MIXER OIL).

To introduce the oil in the tank, remove the

plug (1) on the left side of the vehicle, be-

tween the tank and the steering tube.

MIXER OIL TANK CAPACITY: 2

L

TANK RESERVE: 0.5 L

Wash your hands carefully after

using the oil. Do not dispose of

the oil in the environment.

KEEP AWAY FROM CHILDREN.

"2!+%&,5)$RECOMMENDATIONS

Sudden resistance or clearance

problems on the brake lever may

be due to troubles in the hydrau-

lic system.

For any doubt regarding the perfect

functioning of the braking system and

in case you are not able to carry out the

usual checking operations, contact

your APRILIA Official Dealer.

Make sure that the brake disc is neither

oily nor greasy, especially after mainte-

nance or checking operations.

c

a

Fig. 11

a

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