aprilia part# 8202099

aprilia part# 8202099
aprilia part# 8202099
First edition: november 1997
Reprint:
Produced and printed by:
editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [email protected]
www.stp.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com
structions required for normal use and maintenance of
your vehicle.
For controls and check-ups that cannot be carried out
easily with the standard equipment supplied, we advise
you to consult our Dealers who can assure you of quick
and careful servicing.
To keep your aprilia vehicle always in perfect operating
conditions, we advise you to insist on Original Spares
and to have repairs carried out only by aprilia Authorized Outlets and Official Dealers.
When ordering spare parts from the Dealer, always
quote the spares code which is stamped on a sticker
placed under the saddle.
It is a good idea to make a note of the identification code
in the space provided in this manual, so that you will always have a record of it even if the identification sticker
comes off.
aprilia
CODICE RICAMBI spare parts code number
N°
I
UK
A
I.M.
A
B
C
D
E
P
SF
B
D
F
E
GR NL CH DK
J
SGP PL
IL ROK
MAL RCH BM USA
All information is purely indicative and may be subject to
variation without notice.
This manual contains all the main information and the in1
Carefully observe the instructions preceded by the following warning signs:
a
c
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:
2 catalytic version
I Italy version
U United Kingdom version
A Austria version
P Portugal version
" Finland version
B Belgium version
D Germany version
F France version
E Spain version
G Greece version
O Holland version
2
C
ˆ
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
United States of America version
#/.4%.43
page
2
Catalitic silencer
.....................................................2
Technical data .............................................................3
Identification data ........................................................5
Controls arangement .....................................................6
Instructions for use .....................................................9
Maintenance instructions .........................................15
Periodic maintenance chart .....................................26
Lubricant chart ..........................................................27
Wiring diagram ..........................................................28
#!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.
The catalytic Amico 50 is fitted with a silencer with metal
catalytic converter of the "platinum-rhodium bivalent"
type. This device provides for the oxidation of the CO
(carbon monoxide) and of the HC (unburned hydrocarbons) contained in the exhaust gases, changing them
into carbon dioxide and steam, respectively.
Due to the catalytic reaction, the high temperature
reached by the exhaust gases makes for the burning of
the oil particles, thus keeping the silencer clean and
eliminating the exhaust fumes.
To have the catalytic converter function correctly and for
long and to reduce possible problems regarding the soiling of the thermal unit and of the exhaust, it is necessary
to avoid covering long distances with the engine running
at constantly low rpm.
It is sufficient to alternate these periods with periods in
which the engine runs at relatively high rpm, even if only
for a few seconds, but rather frequently.
What has been stated above assumes particular importance for the cold starting of the engine: in this case, in
order to reach a rpm regime sufficient to enable the
"priming" of the catalytic reaction, just make sure that the
temperature of the thermal unit has reached at least
50°C, which generally occurs a few seconds after starting the engine.
a
Do not use leaded petrol, since it causes the
destruction of the catalytic converter.
4%# ( .)# ! , $ !4!
-/4/2
Model ................................................................... aprilia
Type ..................................... 2-stroke single-cylinder
with lamellar inlet
Cylinder .............................................................cast iron
Bore / stroke ...................................... 40 mm e 39,2 mm
Compression ratio ................................................... 13:1
Displacement ...................................................... 49 cm³
Starting ................................................................ electric
Gearbox ..........................................automatic converter
with belt drive
Transmission oil capacity................................... 110 cm³
42!.3-)33)/.
Primary ............................................................... “V'' belt
Secondary ............................................... reduction gear
Variator .................................................................... 3YJ
)'.)4)/.
Typ .................................................................. electronic
Spark advance .........................14° at 5000 rpm 1,4 mm
before T.D.C.
Spark plug ................................................ NGK BR7 HS
#!2"52%44/2
Model ............... Dell’Orto PHBN 12 (TEI KEI TK12Y12)
3
&5%, 3500,9
U
Fuel .................... premium grade petrol (4 Stars
)
according to the DIN 51 600
standard, min. O.N. 98 (N.O.R.M.)
and 88 (N.O.M.M.)
........................... unleaded petrol according
Fuel
to the DIN 51 607 standard,
min. O.N. 95 (N.O.R.M.)
and 85 (N.O.M.M.)
2
Fuel tank capacity ................................................... 7,5 L
of wich 2 L reserve
Mixer oil tank capacity ............................................. 1,3 L
492%3
– Front ........................................................ 100/90×10”
Inflation pressure ............................170 kPa (1,7 bar)
– Rear ......................................................... 100/90×10”
Inflation pressure ............................190 kPa (1,9 bar)
with passenger................................. 210 kPa (2,1 bar)
2)-3
Front ................................................ 2,50×10” light alloy
Rear ................................................. 2,50×10” light alloy
%,%#42)# 3934%-
"2!+%3
Front lights .......................................................12V 15W
Front lights
............................................12V 35/35W
Front parking light
(not provided in the
versions) .....................12V 3 W
Rear light/stop light ...................................... 12V 5/21 W
Turn indicators .................................................12V 10W
Dash board light ................. 5×12V 2W (warning lights);
3×12V 1,2W - 1×12V 2W
Light for tool case/helmet case .......................12V 1,2W
Battery ..............................................................12V 4Ah
Fuse......................................................................... 7,5A
Front ....................................................... disc Ø 155 mm
with hydraulic control
$)-%.3)/.3
&2!-%
Type ...................... split single beam tubular steel frame
3530%.3)/.3
Front .......................................... fork with articulated rod
Rear ...............................hydraulic monoshock absorber
Rear .......................................shoe brake Ø 110x25 mm
with mechanical control
4
C
O
Length ..............................................................1780 mm
Width ............................................ 690 mm (handle bar)
Height ................ 1060 mm (handle bar); 760 mm (seat)
Centre to centre distance ................................1240 mm
Weight without fuel and oil .....................................71 kg
)$ %.4)&)# !4)/ . $! 4!
It is a good rule to write down the frame and engine numbers in the space provided in this manual.
c
Do not alter the identification numbers if you
do not want to incur severe penal and administrative sanctions.
FRAME NUMBER (Fig. 1)
The frame number is stamped on the frame. To be able
to read it, it is necessary to raise the saddle (1).
Frame no.
ENGINE NUMBER (Fig. 2)
The engine number is stamped on the lower support of
the rear shock absorber.
Engine no.
5
# / .42/ ,3 ! 22 ! .' %- %. 4
&IG 1 - Start push button (r)
2 - Lights switch (b - p - •)
2a - Lights switch (b - •)
2b - Lights switch (a - b - •)
3 - Ignition block/steering lock switch (n 4 - Turn indicators switch (c)
5 - Horn push button (f)
6 - Cold start lever (e)
7 - Thraottle grip
8 - Front brake lever
9 - Rear brake lever
O
C
m - s)
&IG 1 - Speedometer / Odometer
2 - Fuel level indicator (g)
3 - Fuel reserve warning light (g)
4 - Mixer oil reserve warning light (j)
5 - Turn indicators warning light (c)
6 - Low beam warning light (b)
6a - High beam warning light (a)
7 - Digital clock
8/9 - Clock adjustment and functions selection push
buttons
C
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
6
3%44).' 4(% #,/#+ &IG Display:
◆ Normal display: hours and minutes.
◆ Date display: press (9) once to display the month and
date.
◆ Seconds display: press (9) twice to display the seconds.
Setting
◆ Press (8) once, the date and time will be displayed alternately.
◆ Month: press (8) again and the month will appear on
the right (the rest disappears), press (9) to obtain the
desired month.
◆ Date: press (8) again and the date will appear on the
right. Press (9) to obtain the desired date.
◆ Hours: press (8) again and the hour will appear on the
left with the letter “A” or “P” (“A” = a.m., “P” = p.m.).
Press (9) to obtain the desired hour.
◆ Minutes: press (8) again and the minutes will appear
on the right of the display.
Press (9) to obtain the desired minutes
◆ The clock is now set.
Press (8) again to return to normal operation.
#(!.').' 4(% #,/#+ #%,,
◆
◆
◆
Remove the front grille and headlamp unit, see pag.
25).
Remove the clock support from the rear of dashboard,
acting on the snapcouplings.
Extract the clock and change the cell.
7
&IG 1 - Fuel tank plug
2 - Mixer oil tank plug
3 - Tool case/helmet case
&IG 1 - Central stand
2 - Starter pedal
3 - Case
4 - Case lock
5 - Seat lock
6 - Carrier/handle
,/#+3
The key provided starts the engine, operates the steering lock (3-Fig. 3), the luggage case lock (4-Fig. 6) and
the saddle lock (5-Fig. 6).
c
To operate the steering lock, turn the handlebars to the left, press the key, pull it up
and turn it to “s” position, then extract the key.
8
). 342 5# 4)/. 3 &/ 2 53%
34!24).'
a
Exhaust gases contain carbon monoxide,
which is extremely noxious if inhaled.
Avoid starting the vehicle in closed or badlyventilated rooms.
The non-observance of this warning may cause loss
of consciousness or even lead to death by asphyxia.
Do not get on the vehicle for the starting.
Electric starting
Position the vehicle on the stand.
◆ Lock at least one wheel, by pulling a brake lever (Fig.
7). If this operation is not carried out, the start relay receives no current and therefore the engine does not
start.
◆ Turn the ignition switch (Fig. 8) to position "n".
◆
9
◆
Press the start push button “r” (1-Fig. 9) without accelerating, then release it as soon as the engine starts.
a
Avoid pressing the start push button "r"
(3) when the engine is running: this may
damage the starter.
When the start push button "r" is pressed, the 2
stroke oil reserve warning light "j" comes on.
With the engine in running condition, when the start
push button "r" is released, the 2 stroke oil reserve
warning light "j" must go out; if this does not occur, top up the 2 stroke oil tank.
◆
◆
◆
◆
10
If the starting is carried out with cold engine, rotate the
cold start lever "e" (1-Fig. 10) downwards.
Do not accelerate and pull the brake levers at the
same time until you move off.
Warm the engine up before leaving.
Once the engine has warmed up, rotate the cold start
lever "e" (1-Fig. 10) upwards.
+)#+ 34!24
34!24).'
For the kick start, proceed as follows:
◆ Position the vehicle on the centre stand.
◆ Move to the left side of the vehicle.
◆ To avoid losing control of the vehicle during the starting, lock both wheels by putting on the brake levers
(Fig. 7).
◆ Turn the ignition switch (Fig. 8) to position "n".
!&4%2 ! ,/.' 0%2)/$ /& ).!#4)6)49
a
Do not push down the kick starter with the
engine on.
◆
After a long period of inactivity, proceed as follows:
◆ Move the ignition switch (Fig. 8) to position " n".
◆ Make the starter run for about 10 seconds, in order to
ensure the filling up of the float chamber.
To start the engine:
Rotate the cold start lever "e" (1-Fig. 10) downwards.
◆ Slightly open the throttle, then carry out the electric
starting procedure (or KICK START).
◆
Push down the kick starter with your right foot, releasing it immediately.
If necessary, repeat the operation until the engine
starts.
11
$%0!2452% !.$ $2)6%
Release the throttle grip (Pos. A - Fig. 11), put on the
rear brake, then move the vehicle down the stand.
Get on the vehicle, keeping at least one foot on the
ground in order not to lose balance.
a
Properly adjust the inclination of the rearview mirrors.
To leave, release the brake lever and accelerate by gently rotating the throttle grip (Pos. B - Fig. 11); the vehicle
will start moving.
a
Avoid opening and closing the throttle grip
repeatedly and continuously, so that you do
not accidentally lose control of the vehicle.
If you have to brake, close the throttle and put on
both brakes in order to obtain uniform deceleration,
properly exerting pressure on the braking parts.
By putting on the front brake only or the rear brake
only, you reduce the braking force considerably,
thus running the risk of locking one wheel and consequently losing grip.
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.
12
a
If the brakes are operated continuously on
downhill stretches, the friction surfaces can
overheat, thus reducing the braking efficiency. Never drive with the engine off!
In case of wet ground or scarce wheel grip (snow,
ice, mud, etc.), drive slowly, avoiding sudden brakings or manoeuvres that could make you lose grip
and fall down.
Pay the utmost attention to any obstacle or variation
of the ground.
Uneven roads, rails, manhole covers, indications
painted on the road surface, building site metal
plates become rather slippery by rain. For this reason all these obstacles have to be carefully avoided,
driving smoothly and bending the vehicle as little as
possible.
Always use the turn indicators timely when you intend to change lane or direction, avoiding sharp and
dangerous movements.
25..).').
a
After the first 500 kilometres, carry out the
checking operations indicated in the column
"After running-in" of the PERIODIC MAINTENANCE CHART, see p. 26, in order to avoid hurting
yourself or other people and/or damaging the vehicle.
The running-in of the engine is primary to ensure its correct functioning and its correct functioning.
If possible, drive on hilly roads and/or roads with many
bends, so that the engine, the suspensions and the
brakes undergo a more effective running-in.
For the first 500 km, keep to the following indications:
0-300 km
Do not keep the throttle grip open more than one half for
long stretches.
300-500 km
Do not keep the throttle grip open more than threefourths for long stretches.
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
13
34/00).' !.$ 0!2+).' &IG ◆
◆
Release the throttle grip and stop the vehicle by
putting on the brakes.
Move the ignition switch to position "m".
c
It is not necessary to close the fuel tap when
the engine is off, since it is equipped with an
automatic closing system.
0/3)4)/.).' 4(% 6%()#,%
/. 4(% 34!.$ &IG a
Park the vehicle on firm and flat ground, to
prevent it from falling down.
Neither lean the vehicle against walls, nor
lay it on the ground.
Make sure that the vehicle and especially 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 inserted into the ignition
switch.
Do not sit on the vehicle when the stand is down.
Seize the vehicle using the rear grab rail and at the
same time push the stand lever downwards (see figure).
Make sure that the vehicle is resting firmly.
14
- !). 4%. ! .# % ). 342 5# 4) /. 3
&2/.4 "2!+% &IG This vehicle is provided with front hydraulic disc brake.
When the disc pads wear out, the level of the fluid decreases to automatically compensate for their wear.
Periodically check the brake fluid level in the tank and
the wear of the pads, see p. 18 (CHECKING THE PAD
WEAR).
2%!2 $25- "2!+%
a
The brakes are the parts that most ensure
your safety and for this reason they must always be perfectly working.
ADJUSTING THE BRAKE
Measure the distance covered by the lever (9-Fig. 3)
before the brake starts it braking action.
The idle stroke at the end of the brake lever must be
about 5 ÷ 10 mm.
◆ Adjust the clearance by acting on the adjuster
(1-Fig. 15).
◆
◆
◆
Put on the brake (9-Fig. 3) repeatedly and make sure
that the wheel turns freely after the brake has been released.
Check the braking efficiency.
a
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.
15
$)3-!.4,).' 4(% &2/.4 7(%%,
&IG ◆
◆
◆
Remove the two plastic elements (1) protecting the
stem.
Unscrew the two screws (2) and remove the brake
caliper.
Unscrew the nut (3).
Coppia di serraggio: 50 Nm (5 kgm).
◆
◆
Slide the pin nut (5).
Remove the wheel.
c
Upon reassembly position the odometer cable (4) correctly.
!$*534).' 4(% !##%,%2!4)/. '2)0
&IG Adjust the play on the accelerator via the appropriate
tightener on the carburettor.
To access the carburattor:
◆ Remove the screw (1).
◆ Pull the tool-helmet, compartment after disconnecting
the compart- ment lighting cable.
16
2%-/6).' 4(% 2%!2 7(%%, &IG a
Before carrying out the following operations, let the engine and the silencer cool
down until they reach room temperature, in
order to avoid burns.
◆
◆
◆
◆
Position the vehicle on the centre stand.
Unscrew and remove the two screws (1) and (2).
Slacken the two screws that hold the exhaust silencer
to the cylinder (access through the battery compartment)
Remove the silencer (4).
c
Upon reassembly, change the exhaust manifold-silencer seal.
◆
◆
Put on the rear brake (9 - Fig. 3) to lock the wheel.
Unscrew and remove the wheel nut (3) and the washer.
c
Upon reassembly, change the wheel nut
(special type).
Wheel nut driving torque: 110 Nm (11 kgm).
◆
Withdraw the wheel.
17
a
If the minimum allowed limit has been
reached, if you notice any irregularity in the
operation or if any part is damaged, contact
your APRILIA Official Dealer, who will provide for
changing the brake shoes.
#(%#+).' 4(% "2!+% 0!$ 7%!2
Check the brake pad wear after the first 500 km and successively every 2000 km.
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
The wear of the brake pads depends on the use, on the
kind of drive and on the road. The wear will be greater
when the vehicle is driven on dirty or wet roads.
#(%#+).' 4(% 3(/% 7%!2 &IG Check the wear of the rear brake shoes after the first
500 km and successively every 4000 km.
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
To check the wear of the rear brake shoes, proceed as
follows:
◆
Remove the rear wheel, see p. 17 (REMOVING THE
REAR WHEEL).
◆
To check the thickness of the friction material, which
must never be less than 1 mm (Fig. 19).
18
To carry out a rapid checking of the wear of the front
pads, proceed as follows:
◆ Position the vehicle on the centre stand.
◆ Remove the brake caliper cover.
◆ Carry out a visual checking of the friction material
thickness by looking between the brake caliper and
the pads.
If the thickness of the friction material (even of one pad
only) has reduced to about 1 mm, replace both pads.
c
Have the pads changed by your APRILIA Official Dealer.
'2%!3).' 4(% 2%!2 "2!+% #!- 0).
c
&IG Grease the rear brake cam pin every 4000
km. If the vehicle is used on dusty roads,
this operation must be carried out more frequently.
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
◆
◆
Disassemble the rear wheel, see p. 17 (REMOVING
THE REAR WHEEL (Fig. 18)).
Unscrew and remove the adjuster (1-Fig. 15).
a
a
Do not dirt the shoes and the friction material with grease, to avoid compromising the
braking efficiency of the vehicle.
This operation may be difficult because the
springs resist considerably to the removal
of the shoes. Be careful not to crush or
bruise your hands and fingers.
◆
◆
◆
Grasp the inner edge of the two friction elements (1)
at its centre and, pulling toward yourself, shake the
two shoes, thus releasing them.
Loosen the nut (2) and remove the pin lever (3).
Withdraw the cam pin (4).
a
Moderately grease only the central part of
the pin.
Avoid dirting the cam or the areas around
the pin seat with grease.
◆
Grease the central part of the pin by using grease for
kinematic motions, see p. 27 (LUBRICANT CHART).
Upon reassembly:
a
Neither strike, nor force the cam pin (4) with
hammers or others tools, in order not to
damage the two O-rings.
◆
Manually insert the cam pin (4), rotating and pushing it
slightly.
a
Make sure that the springs are correctly
coupled.
19
2%-/6).' !.$ #,%!.).'
30!2+ 0,5' &IG 4(% !)2 &),4%2
Periodically remove the spark plug and clean it carefully,
removing carbon deposits; change it if necessary.
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Check the conditions of the air cleaner and clean it
monthly or every 4000 km, depending on the conditions
in which the vehicle is used.
If the vehicle is used on dusty or wet roads, the cleaning
operations and any replacement should be carried out
more frequently.
◆ Position the vehicle on the stand.
◆ To remove the left side panel of the vehicle.
◆ Unscrew the four screws.
◆ Remove the filter case cover and extract the filtering
element.
◆ To clean the filtering element use clean, non-inflammable solvents or solvents with high volatility point,
then let it dry thoroughly.
◆ Apply a filter oil or a thick oil (SAE 80W-90) on the
whole surface of the filtering element, then squeeze it
to eliminate the oil in excess.
c
The filter must be well impregnated, though
not dripping.
20
To remove and clean the spark plug:
◆ Remove the engine compartment cover.
◆ 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.
◆ Make sure that there are neither carbon deposits, nor
corrosion marks on the electrode and on the central
porcelain part; if necessary, clean them with the special cleaners for spark plugs, with an iron wire and/ or
a metal brush.
◆ Energetically blow some air, in order to prevent the removed residues from getting into the engine.
If the spark plug has crackings on the insulating material, corroded electrodes or excessive deposits, it
must be changed.
◆
◆
◆
◆
◆
◆
Check the spark plug gap with a thickness gauge.
The gap must be 0,5 ÷ 0,6 mm; if necessary 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 you
will find in the tool kit, giving it half a turn to compress
the washer.
Position the spark plug cap.
Put back the engine compartment cover.
a
The spark plug must be well tightened,
otherwise the engine may overheat and
be seriously damaged.
Change the spark plug every 8000 km.
Use the recommended type of spark plug only,
see p. 3 (TECHNICAL DATA), in order not to
compromise the life and performance of the
engine.
21
"!44%29 &IG c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Check the electrolyte level and the tightening of the terminals after the first 500 km and successively every
4000 km or 8 months.
a
The electrolyte in the battery is toxic and
caustic and if it gets in contact with the skin
it can cause burns, since it contains sulphu-
ric acid.
Wear protection clothes, a face mask and/or goggles
during maintenance operations.
In case of contact with the skin, rinse with plenty of
water.
In case of contact with the eyes, rinse with plenty of
water for 15 minutes, then consult an oculist without
delay.
If the electrolyte is accidentally swallowed, drink a
lot of water or milk, then continue drinking milk of
magnesia or vegetable oil and consult a doctor without delay.
The battery gives off explosive gases; keep it away
from flames, sparks, cigarettes and any other
source of heat.
During the recharging or the use, make sure that the
room is properly ventilated and avoid inhaling the
gases released during the recharging.
22
a
Never invert the connection of the battery
cables.
Do not incline the vehicle too much, in order
to avoid dangerous leaks of the battery fluid.
KEEP AWAY FROM CHILDREN
a
Connect and disconnect the battery with the
ignition switch in position “m”.
Connect first the positive cable (+) and then
the negative cable (–).
Disconnect following the reverse order.
,/.' ).!#4)6)49 /& 4(% "!44%29
If the vehicle remains unused for a long period, remove
the battery and place it in a cool and dry place.
Recharge it completely, by using a trickle charge.
If the battery remains on the vehicle, disconnect the cables from the terminals.
It is important to check the charge periodically (about
once a month), during the winter or when the vehicle remains unused, in order to prevent the deterioration of the
battery.
To check the battery (1), remove the engine compartment cover.
Make sure that the fluid level is included between the
two "MIN" and "MAX" notches stamped on the battery
side.
If necessary, top up by adding distilled water.
To recharge, disconnect the cables, extract the battery
from its container and remove the element plugs.
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.
Tighten the element plugs.
a
Always connect the battery breather pipe, to
prevent the sulphuric acid vapours from
corroding the electric system, painted parts,
rubber elements or gaskets when they exit the
breather pipe itself.
23
#(!.').' 4(% &53% &IG 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.
If an electric component fails to work, the fuse must be
checked (2).
In this case it must be changed with another with the
same amp value.
If the fuse cuts out again there is probably a short circuit
in the electric system and it is advisable to consult an
aprilia Official dealer.
!$*534).' 4(% (%!$,!-0 "%!&IG The headlamp beam may be adjusted by turning the
screw provided with a screwdriver (1).
24
#(!.').' 4(% "5,"3 ). 4(%
(%!$,!-0 !.$ &2/.4 $)2%#4)/.
).$)#!4/23 &IG By slackening the two screws (2-3-Fig. 23) the two side
covers of the direction indicators may be removed and
the headlamp reflector unit released.
Access is thus obtained to the two bulbs of the direction
indicators.
The front grille and headlamp unit must be dismantled so
as to change the headlamp bulbs.
Access to the bulbs may be gained from behind the reflectors.
To remove them unscrew the 2 central screws (4-Fig.
24) the 2 screws at the side (1-2-Fig. 24), the screw at
the front (4-Fig. 23) and release the 8 clips (3-Fig. 24).
a
c
Proceed with care.
Do not damage the tangs and/or their seats.
Handle the painted components with care
and avoid scraping or damaging them.
Upon reassembly, correctly position the
base (5) of the rear mirror.
#(!.').' 4(% "5,"3 ). 4(% 2%!2,!-0
!.$ 2%!2 $)2%#4)/. ).$)#!4/23
&IG Unscrew the two screws (1).
In this way the 3 transparent covers (2-3) are removed
and the bulbs are accessible.
25
0%2)/$)# -!).4%.!.#% #(!24
Cheking operations
Clean and check spark plug
After running in 500 km Every 4000 km Every 8000 km
★
★
★
★
★
Clean air filter
Check and adjust idling
★
Check fuel pipes
Check drive oil level
change
Check the mixer oil
change every
12000 km or 2 years
★
check every 500 km
Check op. mix pump and air bleeding
★
Check op. brakes and shoe wear
★
★
★
★
Greasing the rear brake cam pin
Checking the brake pad wear
★
Brake liquid
every 2000 km
periodically check
★
Check wheel bearings
Check adjustment of steering bearings
★
★
Check battery electrolyte level
★
★
Check tyre wear
★
★
Check tyre pressure
every month
Check wheel alignment
★
★
★
Check rear shock absorber
★
Checking moving parts on front suspension
★
Cleaning scale from exhaust terminal
★
If the conditions of use are particularly severe, more frequent maintenance is advised.
26
change every year
★
Check driving belt wear
Check tightness of nuts and bolts
Notes
,5"2)#!.4 #(!24
0
Transmission 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. GL4 specifications.
0
Fork oil (recommended): 0 F.A. 5W or 0 F.A. 20W fork oil.
If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be
Mixer oil (recommended):
GREEN HIT.
Use high-quality oils with characteristics in compliance with or superior to the ISO-L-ETC++, A.P.I. TC++ specifications.
mixed as indicated below:
0 F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume.
0 F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume.
Bearings and other lubrication points (recommended): 0 AUTOGREASE MP.
As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range
SAE 10W
SAE 15W
-30°C…+140°C, dripping point 150°C…230°C, high protection against corrosion, good to water and oxidation resistance.
Protection of the battery poles: neutral grease or vaseline.
Spray grease for chains (recommended):
Brake fluid (recommended):
a
0 CHAIN SPRAY.
0 F.F., DOT 5 (DOT 4 compatible).
Use new brake fluid only.
Engine coolant (recommended):
a
0 ECOBLU -40°C.
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.
27
7)2).' $)!'2!- !-)#/ 28
7)2).' $)!'2!- +%9 !-)#/ 1) Generator
2) CDI
3) Spark plug
4) H.T. coil
5) Voltage regulator
6) Battery
7) Starter
8) Start relay
9) Front stoplight switch
10) Rear stoplight switch
11) Mixer oil reserve switch
13) Fuel level sensor
14) Right rear turn indicator
15) Rear light
16) Left rear turn indicator
17) Dip switch
18) Turn indicator switch
19) Ignition switch
20) Control diode
21) Crash helmet compartment light
22) Blinking
23) Dashboard
24) Turn indicator warning light
25) Mixer oil reserve warning light
26) Dashboard light
27) Fuel level indicator
28) Low fuel warning light
29) Low beam warning light
30) Crash helmet compartment light switch
31) Front right turn indicator
32) Front left turn indicator
33) Front parking light
version)
(not provided in the
34) Low beam
35) Horn
36) Pick up
37) Fuse
38) Multiple connectors
39) START push button
40) Horn push button
42) Low/High beam
O
#!",% #/,/523
Ar
Az
B
Bl
G
Gr
M
N
R
V
Vi
Orange
Light blue
Blue
White
Yellow
Gray
Brown
Black
Red
Green
Violet
29
)MPORTERS
APRILIA MOTO U.K. LTD.
DUNRAGIT
STRANRAER
WIGTOWNSHIRE DG9 8PN
SCOTLAND (UK)
TEL. (1581) 400660
FAX (1581) 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
30
./4%
31
aprilia s.p.a. wishes to thank its customers for the purchase of this vehicle.
- Do not dispose of oil, fuel or polluting substances and components in the environment.
- Do not keep the engine running if it isn’t necessary.
- Avoid troublesome noises.
- Respect nature.
32
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