use and maintenance 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 partial adaptation, with any means, are reserved for all Countries.
&/2%7/2$ 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.
!",% /& #/.4%.43 SAFE DRIVE ..................................................................................................... 5 BASIC SAFETY RULES ............................................................................. 6 CLOTHING ................................................................................................. 9 ACCESSORIES ........................................................................................ 10 LOAD ..............................................................
safe drive
"!3)# 3!&%49 25,%3 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. 6 use and maintenance Classic 125 The use of medicins, alcohol and drugs or psychotropic substances notably increases the risk of accidents.
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.
OIL The driver should pay attention and avoid distractions caused by people, things and movements (never smoke, eat, drink, read, etc.) while driving. 8 use and maintenance Classic 125 COOLER 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.
ONLY ORIGINALS A12 345 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.
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). 10 use and maintenance Classic 125 !##%33/2)%3 The owner of the vehicle is responsible for the choice, installation and use of any accessory.
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.
!22!.'%-%.4 /& 4(% -!). %,%-%.43 Fig.
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!22!.'%-%.4 /& 4(% ).3425-%.43 ).3425-%.43 !.$ ).$)#!4/23 Fig.
).3425-%.43 !.$ ).$)#!4/23 Description Function Speedometer It indicates the driving speed. Total kilometres odometer It indicates the total number of kilometres covered. Coolant overheating warning light It comes on when the coolant reaches or exceeds the limit temperature. In this case, stop the engine and check the coolant level, see p. 24 (COOLANT). h a If the maximum allowed temperature is exceeded (the warning light comes on), the engine may be seriously damaged.
-!). ).$%0%.$%.4 #/.42/,3 #/.42/,3 /. 4(% ,%&4 3)$% /& 4(% (!.$,%"!2 &IG c The electrical parts work only when the ignition switch is in position "n". 1) DIMMER SWITCH (b - a) When the light switch (right side of the handlebar) is in position "o", if the dimmer switch is in position "a", the high beam comes on, while if it is in position "b", the low beam comes on.
#/.42/,3 /. 4(% 2)'(4 3)$% /& 4(% (!.$,%"!2 &IG c 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 dimmer switch, see p. 16 (CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR).
34%%2).' ,/#+ &IG a Never turn the key to position "s" in running conditions, in order to avoid losing control of the vehicle. Fig. 7 )'.)4)/. 37)4#( &IG The ignition switch is positioned on the right side of the vehicle, between the fuel tank and the steering tube (Fig. 7). c 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).
-!). #/-0/.%.43 &5%, a Fig. 9 #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 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.
42!.3-)33)/. /), c 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 TOPPING UP), p. 37 (CHANGING THE TRANSMISSION OIL) and p. 58 (LUBRICANT CHART). a a a Used transmission oil can seriously damage the skin if handled every day and for long periods. If the vehicle is used on dusty roads, change the oil more frequently.
Check that the brake cable is neither twisted nor worn out. Prevent water or dust from accidentally getting into the circuit. 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). 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.
Fig. 13 2%!2 "2!+% a The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working. ADJUSTING THE REAR BRAKE ◆ 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.
Fig. 16 !$*534).' 4(% #,54#( 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.
#//,!.4 a a c To change the coolant, or in case of leaks in the circuit, contact an APRILIA Official Dealer. Do not use the vehilce if the coolant is below the minimum prescribed level. Remember: 1 miles = 1.6 km 1 km = 0.625 miles Fig. 19 !$*534).' 4(% 3()&4).' ,%6%2 &IG 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).
492%3 This vehicle is provided with tyres with inner tube. a Periodically check the tyre inflation pressure at room temperature. 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.
#!4!,94)# 3),%.#%2 2 a Avoid parking the vehicle catalytic version near dry brush wood or in places easily accessible 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. 26 use and maintenance Classic 125 The catalytic Classic 125 is fitted with a silencer with metal catalytic converter of the "platinum-rhodium bivalent" type.
).3425#4)/.3 &/2 53% a Before departure, always carry out a preliminary checking of the 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.
Fig. 21 34!24).' ◆ a Exhaust gases contain carbon monoxide, which is extremely noxious if inhaled. Avoid starting 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. ◆ ◆ ◆ 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.
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).
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.
35''%34)/.3 4/ 02%6%.4 4(%&4 Fig. 26 34/00).' !.$ 0!2+).' 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 "q" on, 1 - Fig. 26). ◆ Move the ignition switch to position "m".
-!).4%.!.#% a Before beginning any maintenance operation or any inspection of the vehicle, stop the engine, 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.
Fig. 28 Fig. 29 )$%.4)&)#!4)/. $!4! ENGINE NUMBER (Fig. 28) FRAME NUMBER (Fig. 29) It is a good rule to write down the frame and engine numbers in the space provided in this manual. The engine number is stamped on the upper side of the engine, near the carburettor. Engine no. The frame number is stamped on the right side of the steering column. c Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. Frame no.
CHECKING THE SLACK Fig. 30 #(!). &IG Carefully read p. 32 (MAINTENANCE). The vehicle is equipped with a single-unit chain, in which the main joint is not used. a An excessive slackening of the chain can cause it to come off of the sprockets, which often results 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. 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).
c The failure to carry out the operations described above may lead to an incorrect oil level measurement. ◆ ◆ 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). c Fig. 32 #(%#+).' 4(% 42!.3-)33)/. /), ,%6%, &IG Carefully read p. 20 (TRANSMISSION OIL), p. 32 (MAINTENANCE) and p. 32 (REGULAR SERVICE INTERVALS CHART).
◆ ◆ ◆ ◆ ◆ ◆ Fig. 33 #(!.').' 4(% 42!.3-)33)/. /), &IG 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). ◆ ◆ 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.
◆ ◆ ◆ ◆ 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. a Fig. 34 &2/.4 7(%%, &IG DISASSEMBLY a While disassembling the wheel, be careful not to damage the brake pipe, the disc and the pads.
◆ ◆ ◆ ◆ 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). Fig. 35 2%!2 7(%%, &IG DISASSEMBLY Carefully read page 32 (MAINTENANCE).
Fig. 36 2%-/6).' 4(% &5%, 4!.+ Carefully read p. 19 (FUEL) and p. 32 (MAINTENANCE). a Before starting any operation, wait until the vehicle has cooled down. 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 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.
).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/.3 a Have the front suspension oil changed by an APRILIA Official Dealer, who will ensure you prompt and accurate servicing. Carefully read p. 32 (MAINTENANCE). c Remember: 1 miles = 1.6 km 1 km = 0.625 miles Fig. 38 !)2 #,%!.%2 &IG a Do not use petrol or inflammable solvents to wash the filtering element, to avoid fires or explo- sions. Carefully read p. 32 (MAINTENANCE) and p. 32 (REGULAR SERVICE INTERVALS CHART).
TABLE 1 - ADJUSTING THE REAR SUSPENSION SPRING PRELOAD Adjusting metal ring By screwing it By unscrewing it Function Spring preload increase Spring preload decrease Attitude The attitude of the vehicle is more rigid The attitude of the vehicle is less rigid Recommended kind of road Smooth or normal roads Roads with uneven surface Notes Rider and passenger Solo rider Fig. 39 !$*534).' 4(% 2%!2 3530%.3)/.
#(%#+).' 4(% 3(/% 7%!2 &IG Carefully read p. 32 (MAINTENANCE) and p. 22 (REAR BRAKE). Fig. 40 #(%#+).' 4(% "2!+% 0!$ 7%!2 &IG Carefully read page 20 (BRAKE FLUID (recommendations)), page 21 (DISC BRAKES), page 32 (MAINTENANCE). c Remember: 1 mile = 1.6 km 1 km = 0.625 miles 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.
Fig. 42 #(%#+).' 4(% 34%%2).' 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. 44 use and maintenance Classic 125 c Fig.
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. a If necessary, contact your APRILIA Official Dealer. Fig. 45 )$,).' !$*534-%.4 &IG Carefully read p. 32 (MAINTENANCE). Fig. 46 ",%%$).' 4(% -)8%2 /), &IG ◆ ◆ Carefully read p. 32 (MAINTENANCE). Adjust the idling every time it is irregular.
To remove and clean the spark plug: Take off the spark plug cap. ◆ Remove all the dirt from the base of the spark plug, then unscrew it with the spanner you will find in the tool kit and extract it from its seat, taking care that neither dust nor other substances enter the cylinder.
In case of contact with the skin, rinse with plenty of water. remove the battery from its container, remove the element plugs and put the battery in a cool and dry place. A recharge with an amperage equal to 1/10th of the battery capacity is recommended. After the recharging operation, check the electrolyte level again and if necessary top up with distilled water. Then tighten the element plugs and put back the battery in its container.
ARRANGEMENT OF THE FUSES 20 A fuse From battery to: ignition switch, voltage regulator. 15A fuse From ignition switch to: all light loads. 7.5 A fuse From ignition switch to: ignition. Fig. 49 #(!.').' 4(% &53%3 &IG Carefully read page 32 (MAINTENANCE). a Do not repair faulty fuses. Never use fuses different from the recommended ones. The use of unsuitable fuses may cause damages to the electric system or, in case of short circuit, even a fire.
H Fig. 50 !$*534).' 4(% (%!$,)'(4 "%!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.
Fig. 53 #(!.').' 4(% $!3("/!2$ "5,"3 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. Fig. 54 SPEEDOMETER/ODOMETER BULBS Remove the fuel tank, see p. 40 (REMOVING THE FUEL TANK). ◆ Unscrew the nut (2 - Fig.
Fig. 56 #(!.').' 4(% .5-"%2 0,!4% "5," 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. Fig. 57 #(!.').' 4(% &2/.4 !.$ 2%!2 $)2%#4)/. ).$)#!4/2 "5,"3 &IG Carefully read p. 32 (MAINTENANCE) and p. 49 (BULBS).
42!.30/24 #,%!.).' c Before transporting the vehicle, it is necessary to empty the fuel 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. $2!).).' 4(% &5%, 4!.+ a ◆ ◆ ◆ ◆ Carefully read page 19 (FUEL). ◆ ◆ ◆ ◆ Stop the engine. Empty the fuel tank by means of a manual pump or a similar system.
◆ ◆ ◆ ◆ ◆ ◆ ,/.' 0%2)/$3 /& ).!#4)6)49 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.
4%#(.)#!, $!4! DIMENSIONS Max. length ...................................................... Max. width ....................................................... Max. height (handlebars included) .................. Seat height ...................................................... Distance between centres ............................... Min. ground clearance ..................................... Weight without driver (ready for starting)......... ENGINE Type.................................................
GEAR Type ................................................................ Gear ratios: 1ª ................................................. 2ª.................................................. 3ª.................................................. 4ª.................................................. 5ª.................................................. 6ª.................................................. TRANSMISSION Primary ............................................................ Z = 19 / 63 = 1 : 3.
FRAME Type................................................................. Open double cradle Steering inclination angle ................................ 33° Fore stroke ...................................................... 98 mm SUSPENSIONS Front ................................................................ Stroke .............................................................. Rear................................................................. Stroke ...............................................
IGNITION Type ................................................................ NIPPONDENSO - CDI Spark advance ................................................ 14° ± 2° to 1500 rpm before T.D.C. Standard spark plug ........................................ NGK BR10 EG Spark plug gap................................................ 0.6 ÷ 0.7 mm Engine idle rpm ............................................... 1300 ± 150 rpm ELECTRIC SYSTEM Battery.............................................................
,5"2)&)#!.4 #(!24 0 Gearbox oil (recommended): F.C., SAE 75W - 90 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. 0 MAX 2T COMPETITION 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. 0 0 F.A. 5W or F.A. 20W fork oil.
)MPORTERS 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 !3+ &/2 '%.5).% 30!2% 0!243 /.
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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 environment. – Do not keep the engine running if it isn’t necessary. – Avoid disturbing noises. – Respect nature.
