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. 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: esvseÀe Via G. Galilei, 1 - 30033 Noale (VE) - Italy Ph. 041 - 58 29 111 Fax 041 - 44 10 54 Illustrated and printed by: QhsyÀRigxyÀHfvsg Viale del Progresso - 37038 Soave (VR) - Italy Ph. 045 - 76 11 911 Fax 045 - 76 12 241 2 use and maintenance Classic 125 &/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. For the controls and repairs not expressly described in this manual, for the purchase of aprilia Genuine Spare Parts, accessories 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 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° I UK A CODICE RICAMBI spare parts code number Carefully observe the instructions preceded by the following warning signs: a c 2 I U A P " B D F E G O 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 following symbols: catalytic version Italy version United Kingdom version Austria version Portugal version Finland version Belgium version Germany version France version Spain version Greece version Holland version I.M. P A SF J B B C D D F E E C J S V % K M R Q Switzerland version Denmark version Japan version Singapore version Poland version Israel version South Korea version Malaysia version Chile version Bermuda version GR NL CH DK MAL RCH BM SGP PL IL ROK use and maintenance Classic 125 3 4!",% /& #/.4%.43 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 ................................................................... 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 2 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 4 use and maintenance Classic 125 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. 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. 6 use and maintenance Classic 125 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. use and maintenance Classic 125 7 OIL COOLER 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 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. 8 use and maintenance Classic 125 ONLY ORIGINALS A12 345 Never change the pos ...