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APRILIA Classic 125, Manual

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APRILIA Classic 125 Manual Download Page 2

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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 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 SPA

Via G. Galilei, 1 - 30033 Noale (VE) - Italy
Ph. 041 - 58 29 111
Fax 041 - 44 10 54

Illustrated and printed by:

3TUDIO 4ECNO 0UBLIC

Viale del Progresso - 37038 Soave (VR) - Italy
Ph. 045 - 76 11 911
Fax 045 - 76 12 241

Summary of Contents for Classic 125

Page 1: ...Classic 125 use and maintenance ...

Page 2: ...production 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...

Page 3: ...are 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 ...

Page 4: ...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 ID...

Page 5: ...safe drive ...

Page 6: ... 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 vehic...

Page 7: ...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 standi...

Page 8: ...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 t...

Page 9: ...racteristics 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 be...

Page 10: ... 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 su...

Page 11: ...he 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 maximu...

Page 12: ...nance Classic 125 22 4 4 43 9 IG 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 ...

Page 13: ...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 ...

Page 14: ...irror 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 3425 43 4 23 9 IG 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 ...

Page 15: ...ion 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 ...

Page 16: ...ft 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 i...

Page 17: ...ROLS 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...

Page 18: ... it Release the key and turn it to position s Extract the key 58 29 15 0 4 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 Functio...

Page 19: ...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 start...

Page 20: ...ing 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...

Page 21: ... 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 pa rallel to the MIN mark on the glass Make sure that the fluid is included betwe en the MIN and MAX marks If the fluid does not reach the MIN mark provide for topping up Proceed as follows Unscrew the...

Page 22: ... the correct functioning of the stop light 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 the correct functioning of the braking system or if you cannot carry out the normal checking operations do not hesitate to conta...

Page 23: ...G 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 fixe...

Page 24: ...age indicated in the fol lowing table to the water 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 remi ans unchanged For the cooling solution use distil...

Page 25: ...en 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 TECH NICAL 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 Ch...

Page 26: ... particles thus keeping the silencer clean and elimi nating the exhaust fumes To have the catalytic converter function correctly and for long and to reduce possi ble problems regarding the soiling of the thermal unit and of the exhaust it is neces sary to avoid covering long distances with the engine running at constantly low rpm It is sufficient to alternate these periods with periods in which th...

Page 27: ...rks smoothly and that it is possible to open and close it completely in all steering positions If necessary adjust and or lubricate it 45 Mixer oil transmission oil Check and or top up if necessary 20 36 Wheel tyres Check the tyre surface the inflation pressure wear and tear and any damage 25 Brake levers Make sure that they work smoothly If necessary lubricate the articulations 21 22 Clutch The i...

Page 28: ...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 en gine pull the cold start lever e 3 Fig 23 When the start push button r is pressed the mixer oil reserve warning light j comes on With the engine in running condition when the start push button r is re leased the mixer oil reserve warning light j...

Page 29: ... manouvres Before leaving make sure that the stands are completely folded To start the engine proceed as follows Make sure that the engine is warm With released throttle grip and the en gine idling pull the clutch lever and en gage the first gear by pressing the shift ing pedal Fig 25 Slowly release the clutch lever and at the same time increase the engine rotation speed by turning the throttle gr...

Page 30: ...ads 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 1 km 0 625 miles 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 pro longed brakings This ensures a corr...

Page 31: ...ean the vehicle against walls nor lay it on the ground Make sure that the vehicle and especial ly 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 in serted into the ignition switch Do not sit on the vehicle when the stand is down 35 34 3 4 02 6 4 4 4 NEVER leave the ignition key inserted and always use the...

Page 32: ...IMINARY CHECKING OPER ATIONS Remember 1 miles 1 6 km 1 km 0 625 miles a a c 2 5 2 3 26 4 26 3 24 Component After running in 1000 km Every 4000 km or 8 months Every 8000 km or 16 months Piston coupling and segment clearance C Battery electrolyte level C every 1000 km C Spark plug P S Carburettor C P Wheel centering C C Steering bearings and steering C C Wheel bearings C Air cleaner P S Clutch clear...

Page 33: ... Do not alter the identification numbers if you do not want to in cur severe penal and administrative sanctions ENGINE NUMBER Fig 28 The engine number is stamped on the up per side of the engine near the carburet tor Engine no FRAME NUMBER Fig 29 The frame number is stamped on the right side of the steering column Frame no c Fig 28 Fig 29 ...

Page 34: ...y cause the unti mely 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 di fficult conditions or on dusty and or muddy roads CHECKING THE SLACK To check the chain slack proceed as follo ws Stop the engine position the vehicle on the side stand and the shifting lever in neutral Make sure that the vertical os...

Page 35: ... 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 The crushed or seized links must be lu bricated and made work again If this is not possible contact an APRI...

Page 36: ... ations 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 The oil level must neither exceed the first half of the glass nor be lower than one fourth of the glass itself In the first case the excess oil would flow out through the dra...

Page 37: ... contains very hot oil therefore while carrying out the opera tions described here below be particu larly 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 min utes 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 scre...

Page 38: ...ial Dealer who will carry out the proper maintenance operation REASSEMBLY Carefully read page 32 MAINTENANCE While reassembling the wheel be careful not to damage the brake pipe the disc and the pads For the reassembly of the front wheel pro ceed as follows 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 t...

Page 39: ...pro ceed 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 with out 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 neces...

Page 40: ...uard 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 your finger to slow down the coming out...

Page 41: ... on the whole surface of the filtering element then squeeze it to eliminate the oil in excess The filter must be well impreg nated though not dripping 30 4 4 2 4 2 2 3530 3 3 Have the front suspension oil changed by an APRILIA Official Dealer who will ensure you prompt and accurate servicing Carefully read p 32 MAINTENANCE Remember 1 miles 1 6 km 1 km 0 625 miles Change the front suspension oil ev...

Page 42: ...ock absorber in the desired position see table 2 Fig 39 TABLE 1 ADJUSTING THE REAR SUSPENSION SPRING PRELOAD TABLE 2 REAR SUSPENSION SHOCK ABSORBER POSITION Set both shock absorbers on the same position 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 ...

Page 43: ...reduced to about 1 mm replace both pads Have the pads changed by your APRILIA Official Dealer 4 3 7 2 IG 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 RE AR WHEEL Extract the brake block cover which con tains the two shoes 1 At this point it is possible to check the thi ckness of the friction material...

Page 44: ...il the inconvenience has been eliminated Tighten the screw 1 Fig 43 thorough ly Tighten the two screws 3 Fig 43 At the end of this operation make sure that the handlebars rotate smoothly to avoid any damage to the balls and not to reduce the manoeuvrability of the vehicle 534 4 2 4 2 42 IG The accelerator control must have a slack to ensure the closing of the throttle valve and of the lubrication ...

Page 45: ...APRILIA Official Dealer 4 8 2 IG Carefully read p 32 MAINTENANCE 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 carry out the bleeding Proceed as follows Top up the mixer oil tank see p 20 MIX ER OIL TANK Remove the mixer oil tank plug see p 12 ARRANGEMENT OF THE MAIN EL EMENTS Remove the oil pan guard left side see p 22 REMOVING THE OIL P...

Page 46: ...the in sulating material corroded electrodes or excessive deposits it must be changed Check the spark plug gap with a thick ness gauge The gap must be 0 6 0 7 mm if neces sary 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...

Page 47: ... 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 wa ter Never exceed the MAX mark since the level increases during the recharge For the recharge disconnect the cables remove the battery from its container re move the element plugs and put the bat tery in a cool and d...

Page 48: ... 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...

Page 49: ...lean 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 fre quently Carefully read page 32 MAINTENANCE DO NOT FORCE THE ELECTRIC CABLES 4 4 5 3 IG Carefully read p 32 MAINTENANCE and p 49 BULBS To change the bulbs proceed as fo...

Page 50: ...he fuel tank see p 40 RE MOVING 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 4 2 2 4 5 IG 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 anti clockwise Ext...

Page 51: ... and remove the screw 1 While removing the indicator lens proceed carefully in order not to break it Remove the indicator lens 2 Press the bulb slightly and turn it anti clockwise Remove the bulb from its seat Correctly install a new bulb of the same type If the bulb socket has gone out of its seat insert it again correct ly making the opening of the bulb sock et itself coincide with the seat of t...

Page 52: ... trees since in some seasons residues res ins 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 because of the presence of water on the grip surfaces Calculate long braking distances to avoid accidents Brake repeatedly to re store normal conditions To remove dirt and mud from the paint...

Page 53: ... back the spark plug Remove the battery see p 46 BAT TERY 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 hu mid room away from sunlight with mini mum temperature variations Cover the vehicle avoiding...

Page 54: ... controlled ignition Number of cylinders 1 Total displacement 124 8 cm 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 cm Mixer oil reserve included 2 L Mixer oil reserve 0 5 L Coolant 0 7 L...

Page 55: ...nd 11 kW version Primary Secondary with chain Total engine wheel ratio in sixth gear 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 CARBURETTOR Model Dell Orto PHBH 28 RD Choke tube Ø 28 mm For the D F C and 11 kW version Model Dell Orto PHBL 24 Choke tube Ø 24 mm FUEL SUPPLY Fuel normal version premium grade petrol 4 Stars U according to the DIN 51600 standard min...

Page 56: ...60 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 90 90 19 52H 90 90 19 52S Rear alternative 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 pas...

Page 57: ...manent magnet 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...

Page 58: ...mmended products these can be mixed as indicated below SAE 10W 0F A 5W 67 of the volume 0F A 20W 33 of the volume SAE 15W 0F A 5W 33 of the volume 0F A 20W 67 of the volume Bearings and other lubrication points recommended 0AUTOGREASE MP 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 pro...

Page 59: ...TOWNSHIRE 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 9 ...

Page 60: ...60 use and maintenance Classic 125 7 2 2 LASSIC ...

Page 61: ...tch 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 ...

Page 62: ...62 use and maintenance Classic 125 7 2 2 LASSIC K7 VERSION ...

Page 63: ... 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...

Page 64: ... 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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