APRILIA | RALLY 50 - 2002 | Technical information | APRILIA RALLY 50 - 2002 Technical information

© 2002 aprilia SpA - 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: december 2002
Reprint:
Produced and printed by:
editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: customer@stp.it
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
2
&/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.
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.
★
The operations preceded by this symbol
must be repeated on the opposite side of
the vehicle.
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 saddle.
In this manual the various versions are indicated by
the following symbols:
VERSION:
I
U
A
P
"
B
D
F
E
G
O
C
ˆ
J
S
Italy
United Kingdom
Austria
Portugal
Finland
Belgium
Germany
France
Spain
Greece
Holland
Switzerland
Ñ
%
K
M
R
`
^
]
á
Î
[
Slovenia
Israel
South Korea
Malaysia
Chile
Croatia
Australia
United States of America
Brazil
South Africa
New Zealand
Canada
Denmark
Japan
Singapore
3
4!",% /& #/.4%.43
SAFE DRIVE .....................................................................................5
BASIC SAFETY RULES ................................................................ 6
CLOTHING ................................................................................... 12
ACCESSORIES ........................................................................... 13
LOAD ........................................................................................... 14
ARRANGEMENT OF THE MAIN ELEMENTS .............................. 16
ARRANGEMENT OF THE INSTRUMENTS .................................. 17
INSTRUMENTS AND INDICATORS ............................................. 18
INSTRUMENT AND INDICATOR TABLE .................................... 19
MAIN INDEPENDENT CONTROLS .............................................. 20
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR .......... 20
CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ........ 21
IGNITION SWITCH ...................................................................... 22
STEERING LOCK ........................................................................ 22
AUXILIARY EQUIPMENT .............................................................. 23
UNLOCKING/LOCKING THE SADDLE ....................................... 23
CRASH HELMET / GLOVE COMPARTMENT ............................ 23
BATTERY / TOOL KIT COMPARTMENT .................................... 24
BAG HOOK .................................................................................. 24
MAIN COMPONENTS .................................................................... 25
FUEL ............................................................................................ 25
MIXER OIL TANK ........................................................................ 26
BRAKE FLUID (recommendations) .............................................. 27
FRONT BRAKE ............................................................................ 27
TOPPING UP ............................................................................... 28
REAR BRAKE .............................................................................. 29
TYRES ......................................................................................... 30
AUTOMATIC LIGHT SWITCHING VERSION .............................. 31
CATALYTIC SILENCER .............................................................. 31
INSTRUCTIONS FOR USE ............................................................ 32
PRELIMINARY CHECKING OPERATIONS ................................ 33
STARTING ................................................................................... 34
DEPARTURE AND DRIVE .......................................................... 36
RUNNING-IN ................................................................................ 37
STOPPING AND PARKING ......................................................... 38
POSITIONING THE VEHICLE
ON THE STAND .......................................................................... 38
SUGGESTIONS TO PREVENT THEFT ...................................... 39
ANTI-THEFT HOOK ..................................................................... 40
MAINTENANCE ............................................................................. 41
4
REGULAR SERVICE
INTERVALS CHART ................................................................... 42
IDENTIFICATION DATA ............................................................. 44
AIR CLEANER ............................................................................ 46
CHECKING THE TRANSMISSION OIL LEVEL .......................... 48
CHANGING THE TRANSMISSION OIL ...................................... 49
FRONT WHEEL .......................................................................... 50
EXHAUST SILENCER ................................................................ 52
REAR WHEEL ............................................................................ 54
GREASING THE REAR BRAKE CAM PIN ................................. 55
CHECKING THE BRAKE PAD WEAR ........................................ 57
CHECKING THE BRAKE SHOE WEAR ..................................... 58
CHECKING THE STEERING ...................................................... 59
CHECKING THE ENGINE FULCRUM AXIS ............................... 59
REMOVING THE INSPECTION COVER .................................... 60
REMOVING THE FRONT HANDLEBAR COVER ...................... 61
IDLING ADJUSTMENT ............................................................... 62
ADJUSTING THE ACCELERATOR CONTROL ......................... 63
SPARK PLUG ............................................................................. 64
BATTERY .................................................................................... 65
LONG INACTIVITY OF THE BATTERY ...................................... 66
CHECKING THE ELECTROLYTE LEVEL .................................. 67
CHANGING THE FUSE .............................................................. 68
ADJUSTING THE HEADLIGHT BEAM ....................................... 69
BULBS ........................................................................................ 69
CHANGING THE HEADLIGHT BULBS ...................................... 70
CHANGING THE FRONT DIRECTION INDICATOR BULBS ..... 72
CHANGING THE REAR DIRECTION INDICATOR BULBS ....... 73
CHANGING THE DASHBOARD BULBS .................................... 74
CHANGING THE REAR LIGHT BULBS ..................................... 75
TRANSPORT ................................................................................ 76
DRAINING THE FUEL TANK ...................................................... 76
CLEANING .................................................................................... 77
LONG PERIODS OF INACTIVITY .............................................. 78
AFTER A PERIOD OF INACTIVITY ............................................ 78
TECHNICAL DATA ....................................................................... 79
LUBRICANT CHART ................................................................... 81
Importers ................................................................................ 82-83
WIRING DIAGRAM - Rally 50 ..................................................... 84
WIRING DIAGRAM KEY - Rally 50 ............................................. 85
safe drive
5
"!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.
6
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.
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.
¡
STOP 150 m
150 m
STOP
7
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, in the correct driving posture.
Avoid standing up or stretching your limbs while driving.
8
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 all oil, fuel and coolant
levels regularly.
OIL
COOLER
9
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.
A12
345
10
Never change the position, inclination or colour of: number
plate, direction indicators, lights and horns.
Any modification of the engine or of other members which is
aimed at increasing the speed or the power of the vehicle is
prohibited by the law; in fact, any modification resulting in an
increase of the maximum speed or of the engine displacement
would change the scooter into a motorcycle, which implies the
following obligations for the owner:
– new homologation;
– new registration;
– appropriate driving license.
Further, said modifications cause the loss of the insurance
cover, since insurance policies expressly prohibit to make
technical changes aimed at increasing the vehicle performance levels.
For the reasons stated above, the failure to comply with the
tampering prohibition is punished by law with apposite sanctions (including the confiscation of the vehicle), which, according to the case, can be combined with the sanctions provided
for not using the crash helmet and/or the number plate, for the
violation of fiscal obligations (ownership tax) and with penal
sanctions provided for using the vehicle without driving license.
Never race with other vehicles.
Avoid off-road driving.
ONLY ORIGINALS
11
#,/4().'
Before starting, always wear a correctly fastened crash helmet. Make sure that it is homologated, in good shape, of the
right size and that the visor is clean.
Wear protective clothing, preferably in light and/or reflecting
colours. In this way you will make yourself more visible to the
other drivers, thus notably reducing the risk of being knocked
down, and you will be more protected in case of fall.
This clothing should be very tight-fitting and fastened at the
wrists and ankles. Strings, belts and ties should not be hanging loose; prevent these and other objects from interfering with
driving by getting entangled with moving parts or driving
mechanisms.
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).
12
!##%33/2)%3
The owner of the vehicle is responsible for the choice, installation and use of any accessory.
Avoid installing accessories that cover horns or lights or that
could impair their functions, limit the suspension stroke and
the steering angle, hamper the operation of the controls and
reduce the distance from the ground and the angle of inclination in turns.
Avoid using accessories that hamper access to the controls,
since this can prolong reaction times during an emergency.
Large fairings and windscreens assembled on the vehicle can
produce aerodynamic forces capable of compromising the stability of the vehicle while driving.
Make sure that the equipment is well fastened to the vehicle
and not dangerous during driving.
Do not install electrical devices and do not modify those already existing to avoid electrical overloads, because the vehicle could suddenly stop or there could be a dangerous current
shortage in the horn and in the lights. aprilia recommends the
use of “aprilia genuine accessories”.
13
,/!$
Be careful and moderate when loading your luggage.
Keep any luggage loaded as close as possible to the centre of
the vehicle and distribute the load uniformly on both sides, in
order to reduce imbalance to the minimum.
Furthermore, make sure that the load is firmly secured to the
vehicle, especially during long trips.
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.
14
Do not carry any bag if it is not tightly secured to the vehicle.
Do not carry bags which protrude too much from the luggagerack or which cover the lights, horn or indicators.
Do not carry animals or children on the glove compartment or
on the luggage-rack.
Do not exceed the maximum load allowed for each side-bag.
When the vehicle is overloaded, its stability and its manoeuvrability can be compromised.
KG!
15
!22!.'%-%.4
/& 4(% -!). %,%-%.43
+%9 &IG 1)
2)
3)
4)
5)
6)
7)
Mixer oil tank plug
Ignition switch/steering lock
Front brake fluid reservoir
Bag hook
Battery/tool kit compartment
Inspection cover
Anti-theft hook
Fig. 1
+%9 &IG 1)
2)
3)
4)
5)
Fig. 2
16
Fuel tank plug
Saddle lock
Transmission oil filling cap
Kick starter
Centre stand
!22!.'%-%.4
/& 4(% ).3425-%.43
+%9 &IG 1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Horn push button (f)
Cold start lever (e)
Rear brake lever
Rear-view mirror
Direction indicator switch (c)
Instruments and indicators
Front brake lever
Throttle grip
Start push button (r)
Ignition switch/steering lock (n - m - s)
Fig. 3
17
).3425-%.43 !.$ ).$)#!4/23
+%9 &IG 1)
2)
3)
4)
5)
6)
Red mixer oil reserve warning light (j)
Green left direction indicator warning light (c)
Total kilometres odometer
Speedometer
Amber low fuel warning light (g)
Green right direction indicator warning light
( c)
7) Green low beam warning light (b)
8) Fuel level indicator (g)
Fig. 4
18
).3425-%.4 !.$ ).$)#!4/2 4!",%
Description
Mixer oil reserve warning light
Function
( j)
It comes on when the ignition switch is in position "n" and the
start push button “r“ is pressed, thus checking the proper functioning of the bulb.
If the light does not come on during the starting, provide for replacing the bulb.
a
If the warning light comes on and does not go out after the start push button "r" has been released, or if
it comes on during normal functioning, this means
that the mixer oil reserve is being used; in this case, top up
the mixer oil tank, see p. 26 (MIXER OIL TANK).
Direction indicator warning light
(c)
It blinks when the direction indicators are on.
Total kilometres odometer
It indicates the total number of kilometres covered.
Speedometer
It indicates the driving speed.
Fuel level indicator
It indicates the approximate fuel level in the tank.
Low beam warning light
(b)
It comes on whenever the ignition switch is turned to position “n”.
Low fuel warning light
(g)
It comes on when the quantity of fuel left in the tank is about 1,5 L.
19
-!). ).$%0%.$%.4 #/.42/,3
#/.42/,3 /. 4(% ,%&4 3)$%
/& 4(% (!.$,%"!2 &IG c
The electrical parts work only when the
ignition switch is in position “n”.
1) HORN PUSH BUTTON (f)
The horn is activated when the push button is
pressed.
Fig. 5
2) COLD START LEVER (e)
The starter for the cold start of the engine is operated by rotating the lever downwards.
To disconnect the cold start, bring the lever to its
initial position.
3) DIRECTION INDICATOR SWITCH (c)
To indicate the turn to the left, move the switch to
the left; to indicate the turn to the right, move the
switch to the right.
To turn off the direction indicator, press the switch.
20
#/.42/,3 /. 4(% 2)'(4 3)$%
/& 4(% (!.$,%"!2 &IG c
The electrical parts work only when the
ignition switch is in position “n”.
1) START PUSH BUTTON (r)
When the start push button is pressed and one of
the brake levers (front or rear) is activated at the
same time, the starter makes the engine run.
For the starting procedure, see p. 34 (STARTING).
Fig. 6
21
)'.)4)/. 37)4#( &IG The ignition switch is positioned on the right side,
near the steering column.
c
The key (1-Fig. 8) operates the ignition
switch/steering lock, the battery/tool kit
compartment and the saddle lock. Two keys are
supplied together with the vehicle (one spare key).
34%%2).' ,/#+ &IG Never turn the key to position “s” in running conditions, in order to avoid losing control of the vehicle.
Fig. 7
OPERATION
To lock the steering:
◆ Turn the handlebar completely leftwards.
◆ Turn the key (1) to position “m” and press it.
◆ Release the key and turn it to position “s”.
◆ Extract the key.
Position
s
m
n
Key
removal
The steering is locked. It is nei- It is possible to remove
ther possible to start the enthe key.
gine, nor to switch on the lights.
Function
Steering lock
Fig. 8
22
Neither the engine, nor the
lights can be switched on.
It is possible to remove
the key.
The engine and the lights can
be switched on.
It is not possible to remove the key.
!58),)!29 %15)0-%.4
5.,/#+).',/#+).' 4(% 3!$$,% &IG To unlock and lift the saddle:
◆ Insert the key in the saddle lock (1).
◆ Turn the key clockwise and raise the saddle (2).
Before lowering and locking the saddle,
make sure that you have not left the key in
the crash helmet/glove compartment.
◆ To lock the saddle, lower and press it (without exerting too much pressure), thus making the lock snap
shut.
c
a
Before leaving, make sure that the saddle is
properly locked.
Fig. 9
#2!3( (%,-%4 ',/6% #/-0!24-%.4
&IG Thanks to the crash helmet/glove compartment, you no
longer have to carry the crash helmet or other objects
with you every time you park the vehicle. The compartment is positioned under the saddle. To reach it:
◆ Raise the saddle, see (UNLOCKING/LOCKING THE
SADDLE).
a
Do not load the crash helmet/glove compartment too much.
Maximum allowed weight: 2.5 kg.
c
Special hooks for the positioning of a lock
have been provided under the saddle.
Fig. 10
23
"!44%29 4//, +)4 #/-0!24-%.4
&IG Fig. 11
This compartment is positioned in the lower part of the
vehicle, between the footrests.
To reach it, proceed as follows:
◆ Insert the key (2) in the lock.
◆ Rotate the key (2) clockwise, pull it and remove the
cover (3).
The tool kit (1) includes:
n. 1 tool case
n. 1 25 mm spark plug socket spanner
n. 1 socket spanner rod
n. 1 8/10 mm socket spanner
n. 1 double-ended, cross-/cut-headed screwdriver
n. 1 screwdriver handle
To lock the cover (3), lower it and rotate the key anticlockwise.
Maximum allowed weight: 1.5 kg.
"!' (//+ &IG a
Do not hang excessively bulky bags or
parcels to the hook, as this may seriously
compromise the manoeuvrability of the
vehicle or the movement of your feet.
The bag hook (1) is positioned on the front part of the
inner shield.
Fig. 12
24
Max. allowed weight: 1.5 kg.
-!). #/-0/.%.43
&5%, &IG a
The fuel used for internal combustion engines is extremely inflammable and in
particular conditions it can become explosive.
It is important to carry out the refuelling and the
maintenance operations in a well-ventilated area,
with the engine off.
Do not smoke while refuelling or near fuel vapours, in any case avoid any contact 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 surfaces of the engine.
In case some fuel has accidentally been spilt,
make sure that the area has completely dried and
before starting the vehicle verify that there is no
fuel inside the fuel filler neck.
Since petrol expands under the heat of the sun
and due to the effects of sun radiation, never fill
the tank to the brim.
Screw the plug (1) up carefully after refuelling.
Avoid any contact of the fuel with the skin and
the inhalation of vapours; do not swallow fuel or
pour it from a receptacle into another by means
of a tube.
KEEP AWAY FROM CHILDREN
Use only unleaded petrol, in conformity with the DIN
51607 standard, min. O.N. 95 (N.O.R.M.) and 85
(N.O.M.M.).
FUEL TANK CAPACITY (reserve included): 6 L
TANK RESERVE: 1,5 L
To refuel, proceed as follows:
◆ Lift the saddle, see p. 23 (UNLOKKING/LOCKING
THE SADDLE).
◆ Unscrew and remove the fuel tank plug (1).
◆ Refuel.
Fig. 13
25
a
The use of the vehicle without mixer oil
causes serious damages to the engine.
If you run out of oil in the mixer oil tank or
if the mixer oil pipe has been removed, it is necessary to contact an APRILIA Official Dealer, who
will provide for bleeding the system.
This operation is indispensable, since the operation of the engine with air in the mixer oil system
may cause serious damages to the engine itself.
Fig. 14
-)8%2 /), 4!.+ &IG The vehicle is provided with a separate mixer that
makes it possible to mix petrol with oil for the lubrication of the engine, see p. 81 (LUBRICANT CHART).
The reserve is indicated by the coming on of the mixer oil reserve warning light " j" positioned on the
dashboard, see p. 18 and 19 (INSTRUMENTS AND
INDICATORS).
26
To top up the mixer oil tank, proceed as follows:
◆ Lift the saddle, see p. 23 (UNLOKKING/LOCKING
THE SADDLE).
◆ Remove the plug (1).
MIXER OIL TANK CAPACITY: 1.3 L
TANK RESERVE: 0.35 L
a
Wash your hands carefully after using the
oil. Do not dispose of the oil in the environment.
KEEP AWAY FROM CHILDREN.
"2!+% &,5)$ RECOMMENDATIONS
a
Sudden resistance or clearance problems
on the brake lever may be due to problems in the hydraulic system.
For any doubt regarding the perfect functioning
of the braking system and in case you are not
able to carry out the usual checking operations,
contact your APRILIA Official Dealer.
Make sure that the brake disc and the friction elements are neither oily nor greasy, especially after
maintenance or checking operations.
Check that the brake cable is neither twisted nor
worn out.
Prevent water or dust from accidentally getting
into the circuit.
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.
Consult a doctor or an oculist if the liquid gets in
contact with your eyes.
Do not dispose of the brake fluid in the environment.
KEEP AWAY FROM CHILDREN
a
When using the brake fluid, take care not
to spill it on the plastic or painted parts,
since it irreparably damages them.
&2/.4 "2!+%
a
The brakes are the parts that most ensure
your safety and for this reason they must
always be perfectly working.
The brake fluid must be changed once a year by
an APRILIA Official Dealer.
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.
The brake fluid reservoir is positioned under the handlebar cover, near the brake lever coupling.
Periodically check the brake fluid level in the reservoir and the wear of the pads, see p. 57 (CHECKING
THE BRAKE PAD WEAR).
To check the brake fluid level, proceed as follows:
◆ Incline the vehicle, so that the fluid contained in the
tank is parallel to the "MIN" mark stamped on the
glass (1-Fig. 15).
◆ Make sure that the level of the brake fluid contained in the ta nk e xceeds th e "MIN" ma rk
stamped on the glass.
◆ If not, provide for topping up, see p. 28 (TOPPING
UP).
27
4/00).' 50
◆
◆
◆
Remove the handlebar cover, see p. 61 (REMOVING THE FRONT HANDLEBAR COVER).
Unscrew the two screws (1-Fig. 16).
Remove the cover (2-Fig. 16).
a
In order not to spill the brake fluid while
topping up, keep the fluid in the reservoir
parallel to the reservoir rim.
◆
◆
Fig. 15
◆
◆
◆
◆
Remove the gasket.
Fill the tank with brake fluid, see p. 81 (LUBRICANT CHART), until it covers the glass (1-Fig. 15)
completely.
Put back the gasket in its seat.
Put back the cover (2-Fig. 16).
Screw and tighten the two screws (1-Fig. 16).
Put back the handlebar cover.
a
Check the braking efficiency. If necessary, contact your APRILIA Official Dealer.
In case of excessive movement of the
brake lever, of excessive elasticity or in case
there is air in the circuit, contact your APRILIA Official Dealer, since it may be necessary to bleed
the system.
In any case, the bleeding must be carried out after the first 500 km.
Fig. 16
28
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
2%!2 "2!+%
a
The brakes are the parts that most ensure
your safety and for this reason they must
always be perfectly working.
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.
ADJUSTING THE BRAKE
◆
◆
◆
Measure the distance covered by the lever before
the brake starts it braking action.
The idle stroke at the end of the brake lever must
be about 10 mm (Fig. 17).
Adjust the clearance by acting on the adjuster (1Fig. 18).
Put on the brake repeatedly and make sure that
the wheel turns freely after the brake has been released.
Check the braking efficiency.
Fig. 17
c
◆
If the adjuster (1-Fig. 18) can be screwed
up completely, this means that the brake
shoes are worn out.
In this case, see p. 58 (CHECKING THE BRAKE
SHOE WEAR).
Fig. 18
29
492%3
This vehicle is provided with tubeless tyres.
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 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.
If, on the contrary, the inflation pressure is too
low, the tyre sides are under greater stress and
the tyre itself may slip on the rim or it may become loose, with consequent loss of control of
the vehicle.
In case of sudden braking the tyres could even
get out of the rims. Further, the vehicle could
skid while turning.
Check the surface and the wear of the tyres,
since tyres in bad conditions can impair both the
grip and the controllability of the vehicle.
Change the tyre when it is worn out or in case of
puncture on the tread side, if the puncture is larger than 5 mm.
Use only tyres in the size suggested by APRILIA,
see p. 79 (TECHNICAL DATA).
30
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.
Change, reparation, maintenance and balancing
operations are very important and should be carried out by qualified technicians with appropriate
tools.
For this reason, it is advisable to have the above
mentioned operations carried out by an APRILIA
Official Dealer or by a qualified tyre repairer.
a
If the tyres are new, they may still be covered with a slippery film: drive carefully
for the first miles.
Do not oil the tyres with unsuitable fluids.
TYRE PRESSURE
CONDITION
FRONT
REAR
To obtain the best grip and manoeuvrability on dry and wet road surface.
130 kPa
(1,3 bar)
170 kPa
(1,7 bar)
To obtain greater smoothness, with
satisfying grip on dry road surface
and sufficient grip on wet road surface.
190 kPa
(1,9 bar)
210 kPa
(2,1 bar)
!54/-!4)# ,)'(4 37)4#().'
6%23)/.
of the oil particles, thus keeping the silencer clean
and eliminating the exhaust fumes.
This vehicle is equipped with a device that switches
the lights on automatically when the engine is started.
For this reason, no light switch is provided.
The lights can be switched off only by stopping the
engine.
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.
#!4!,94)# 3),%.#%2
a
Avoid parking the Rally 50 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 vehicle 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.
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.
Due to the catalytic reaction, the high temperature
reached by the exhaust gases makes for the burning
31
).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 p. 33 (PRELIMINARY CHECKING OPERATIONS).
The non-performance of these checking operations can cause severe personal injuries or damages to the vehicle.
32
a
Do not hesitate to consult your APRILIA
Official Dealer in case there is something
you do not understand about the functioning of some controls or in case you suspect
or discover some irregularities.
It does not take long to carry out a check-up and
this operation ensures you much more safety.
02%,)-).!29 #(%#+).' /0%2!4)/.3
Component
Check
Page
Front disc brake
Check the functioning, the fluid level and make sure there are no leaks.
Check the wear of the pads. Top up, if necessary.
27, 28, 55
Rear drum brake
Check the functioning, the idle stroke and the control lever conditions.
If the clearance is not correct, adjust it.
29, 54, 56
Accelerator
Make sure that it works smoothly and that it is possible to open and
close it completely, in all steering positions.
If necessary, adjust and/or lubricate it.
61
Mixer oil
Check and/or top up, if necessary.
Wheel/tyres
Check the tyre surface, the inflation pressure, wear and tear and any
damage.
Brake levers
Make sure that they work smoothly.
If necessary, lubricate the articulations.
Stand
Make sure that they work smoothly and that the spring tension brings it
back to its normal position.
If necessary, lubricate joints and hinges.
—
Fastening elements
Make sure that the fastening elements are not loose.
If necessary, adjust or tighten them.
—
Fuel tank
Check the fuel level and top up, if necessary.
Make sure there are no leaks or occlusions in the circuit.
25
Lights, wa rnin g lights, Check the proper functioning of all the devices.
horn and electric devices Change the bulbs or intervene in case of failure.
26, 48, 49
30
27, 28, 29
65 ÷ 75
33
34!24).'
a
Exhaust gases contain carbon monoxide,
which is extremely noxious if inhaled.
Avoid starting the vehicle in closed or
badly-ventilated 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
◆
◆
◆
Fig. 19
◆
Position the vehicle on the centre stand.
Turn the ignition switch (Fig. 19) to position "n".
Lock at least one wheel, by pulling a brake lever
(Fig. 20). If this operation is not carried out, the
start relay receives no current and therefore the
engine does not start.
Press the start push button "r" (1-Fig. 21) without
accelerating, then release it as soon as the engine
starts.
a
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 released, the mixer oil reserve warning light "j"
must go out; if this does not occur, top up the
mixer oil tank, see p. 26 (MIXER OIL TANK).
◆
Fig. 20
34
If the starting is carried out with cold engine, rotate
the cold start lever "e" (1-Fig. 22) downwards.
Avoid pressing the start push button "r" (1Fig. 21) when the engine is running: this may
damage the starter.
◆ 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. 22) upwards.
KICK START
For the kick start, proceed as follows:
◆ Position the vehicle on the centre stand.
◆ Move to the left side of the vehicle.
◆ Turn the ignition switch (Fig. 19) to position "n".
◆ To avoid losing control of the vehicle during the starting, lock both wheels by putting on the brake levers
(Fig. 20).
a
Fig. 21
a
Do not push down the kick starter with the
engine on.
◆ Push down the kick starter with your right foot, releasing it immediately. If necessary, repeat the operation
until the engine starts.
STARTING AFTER A LONG PERIOD OF INACTIVITY
After a long period of inactivity, proceed as follows:
◆ Move the ignition switch (Fig. 19) to position "n".
◆ Make the starter run for about ten seconds, in order to
ensure the filling up of the float chamber.
To start the engine:
◆ Rotate the cold start lever "e" (1-Fig. 22) downwards.
◆ Slightly open the throttle, then carry out the electric
starting procedure (or KICK START).
Fig. 22
35
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.
Fig. 23
$%0!2452% !.$ $2)6%
Release the throttle grip (Fig. 23 - pos. A), 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 (Fig. 23 - pos. B); the
vehicle will start moving.
36
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 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.
a
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.
If the mixer oil reserve warning light "j"
comes on during the normal functioning
of the engine, this means that the mixer
oil reserve is being used; in this case, top up the
mixer oil tank, see p. 26 (MIXER OIL TANK).
a
c
25..).').
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
a
After the first 500 kilometres, carry out the
checking operations indicated in the column "After running-in" of the REGULAR
SERVICE INTERVALS CHART, see p. 42, 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:
0-100 km
During the first 100 km put on the brakes with caution, avoiding sharp and prolonged brakings.
This ensures a correct bedding-in of the pads on the
brake disc.
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.
37
34/00).' !.$ 0!2+).'
◆
Release the throttle grip and stop the vehicle by
putting on the brakes.
Move the ignition switch (Fig. 24) 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.
Fig. 24
Neither lean the vehicle against walls, nor
lay it on the ground.
Make sure that the vehicle and especially its redhot 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 (1) and at
the same time push the stand lever (2) downwards
(see figure).
Make sure that the vehicle is resting firmly.
Fig. 25
38
35''%34)/.3 4/ 02%6%.4 4(%&4
NEVER leave the ignition key inserted and always
use the steering lock.
Park the vehicle in a safe place, possibly in a garage
or a protected place.
When possible, use an additional anti-theft device.
Make sure that all documents are in order and the
road tax has been paid.
Write down your personal data and telephone
number in the space provided in this page, to facilitate the identification of the owner in case of finding
after theft.
SURNAME: ................................................................
NAME:........................................................................
ADDRESS:.................................................................
...................................................................................
c
TELEPHONE NO.:.....................................................
Very often stolen vehicles are identified
thanks to the data written on the
use/maintenance manual.
39
!.4)4(%&4 (//+ &IG !
The anti-theft hook (1) is positioned on the right side
of the vehicle, near the rider’s footboard.
To prevent the vehicle from being stolen, it is advisable to secure it with a lock, which can be easily found
on the market.
a
Do not use the hook to lift the vehicle or
for any purpose other than securing the
vehicle once it has been parked.
Fig. 25A
40
-!).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.
Do not hold any mechanical piece or other parts
of the vehicle with your mouth: the components
are not edible and some of them are noxious or
even toxic.
Ordinary maintenance operations can usually be carried out by the user, but sometimes a basic knowledge of mechanics and specific tools are required.
If you need assistance or technical advice, consult
your aprilia Official Dealer, who can ensure you
prompt and accurate servicing. After any maintenance operation, carry out the "Preliminary checking
operations", see p. 33 (PRELIMINARY CHECKING
OPERATIONS).
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
a
If not expressly indicated otherwise, for
the reassembly of the units repeat the disassembly operations in reverse order.
In case any maintenance operation should be required, it is advisable to use latex gloves.
41
2%'5,!2 3%26)#%
).4%26!,3 #(!24
OPERATIONS TO BE CARRIED
OUT BY THE APRILIA Official Dealer (WHICH CAN BE CARRIED
OUT EVEN BY THE USER).
Key
=
=
=
=
check and clean, adjust, lubricate or change, if necessary;
clean;
change;
adjust.
c
Perform the maintenance
operations with doubled
frequency if the vehicle is used in
rainy or dusty areas, on uneven
surfaces or on racetracks
42
Component
After
running-in
[500 km
(312 mi)]
Every
Every
4000 km
8000 km
(2500 mi)
(5000 mi)
or 12 months or 24 months
Battery - Terminal fastening Electrolyte level
Spark plug
–
–
Carburettor - idle speed
Air cleaner
–
–
Accelerator operation
Brake locking operation
–
–
Light system
Cylinder cooling system
–
every 20.000 km (12500 mi): (outside cleaning)
Stop light switches
Brake fluid
–
–
–
–
2 stroke oil
Light direction - operation
–
every 500 km (312 mi): –
Wheels/tyres and inflation pressure
Rear brake shoe wear Q
every month:
–
Front brake pad wear
every 2000 km (1250 mi): OPERATIONS TO BE CARRIED
OUT BY THE APRILIA Official Dealer.
Key
=
=
=
=
check and clean, adjust, lubricate or change, if necessary;
clean;
change;
adjust.
c
Perform the maintenance
operations with doubled
frequency if the vehicle is used in
rainy or dusty areas, on uneven
surfaces or on racetracks
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43
)$%.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. In particular, the alteration of the frame number results in the immediate
invalidity of the guarantee.
ENGINE NUMBER (Fig. 26)
Fig. 26
The engine number is stamped on the lower support
of the rear shock absorber.
Engine no.
44
FRAME NUMBER (Fig. 27)
The frame number is stamped on the central tube of
the frame. To be able to read it, it is necessary to remove the cover (1).
Frame no.
Fig. 27
45
!)2 #,%!.%2 &IG !"
Carefully read p. 41 (MAINTENANCE).
a
Do not use petrol or inflammable solvents
to wash the air cleaner, in order to avoid
fires or explosions.
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.
Fig. 28
c
a
REMOVAL
m
(to
Have the appropriate special tool
be requested to APRILIA Official Dealer):
– clamp installation pliers (1).
Upon installation, replace the hose clamp
that has been removed with a new one
having the same dimensions, to be requested to an APRILIA Official Dealer.
Do not attempt to reinstall the removed hose
clamp, since it is unusable.
Do not replace the removed hose clamp with a
screw clamp (2) or with other types of clamp.
◆
Fig. 28A
46
◆
Position the vehicle on the stand.
Remove the inspection cover, see p. 60 (REMOVING THE INSPECTION COVER).
◆
◆
◆
◆
◆
Lift the rubber mat (3).
Unscrew and remove the screw (4), taking the washer.
Unscrew and remove the screw (5), taking the
bushing.
Unscrew and remove the screw (6).
Unscrew and remove the two screws (7).
a
Handle the plastic and painted components with care to avoid scraping or damaging them.
◆
◆
Slightly move the rear part (8) of the lower shield.
Release the hose clamp (9).
Disconnect the pipe (10).
c
◆
Fig. 28B
Upon reassembly, position the pipe (10)
correctly.
◆
◆
◆
◆
Unscrew and remove the screw (11), taking the
washer and the breather pipe ring (12).
Unscrew and remove the screw (13) with the relevant washer.
Loosen the screw (14) of the air manifold clamp.
Seize the air manifold in correspondence with the
clamp and pull it, thus removing the whole air
cleaner.
CLEANING THE AIR FILTER
◆ Unscrew the three screws (15).
◆ Remove the filter case cover (16) 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.
47
Fig. 29
#(%#+).'
4(% 42!.3-)33)/. /), ,%6%, &IG a
In case of oil leaks or malfunctions, contact your APRILIA Official Dealer.
DO NOT DISPOSE OF THE TRANSMISSION OIL
IN THE ENVIRONMENT.
c
Carefully read p. 41 (MAINTENANCE).
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
48
To check the transmission oil level, carry out the following operations every 4000 km or every 12
months:
◆ Drive for a few miles until the engine reaches the
normal running temperature, then stop it.
◆ Position the vehicle on the stand.
◆ Put a graduated container with at least 120 cm #
capacity under the drain plug (1).
◆ Unscrew the filling cap (2) and the oil drain plug
(1).
◆ Let all the oil flow out of the oil pan, measure the
quantity and if it is less than 110 cm#, top up by
adding the lacking quantity, see p. 81 (LUBRICANT CHART).
◆ Tighten the drain plug (1).
◆ Provide for filling up, using the oil collected into the
graduated container.
◆ Tighten the filling cap (2).
a
Tighten the filling cap and the drain plug
thoroughly and make sure that there are
no oil leaks.
Periodically check that there are no leaks in correspondence with the oil pan cover seal.
Do not use the vehicle with insufficient lubrication or with contaminated or unsuitable lubricants, since this would accelerate the wear of the
moving parts and may also cause irreparable failures.
#(!.').'
4(% 42!.3-)33)/. /), &IG a
In case of oil leaks or malfunctions, contact your APRILIA Official Dealer.
DO NOT DISPOSE OF THE TRANSMISSION OIL
IN THE ENVIRONMENT.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil
salvage center.
Carefully read p. 41 (MAINTENANCE).
c
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
◆
◆
Tighten the drain plug and add 110 cm# of oil, see
p. 81 (LUBRICANT CHART).
Tighten the filling cap (2).
a
Tighten the filling cap and the drain plug
thoroughly and make sure that there are
no oil leaks.
Periodically check that there are no leaks in correspondence with the oil pan cover seal.
Do not use the vehicle with insufficient lubrication or with contaminated or unsuitable lubricants, since this would accelerate the wear of the
moving parts and may also cause irreparable failures.
To ensure the efficiency and long life of the vehicle, it
is necessary to change the oil after the first 500 km
and successively every 12000 km or every 2 years.
Proceed as follows:
◆ Drive for a few miles until the engine reaches the
normal running temperature, then stop the engine.
◆ Position the vehicle on the stand.
◆ Put a graduated container with at least 120 cm #
capacity under the drain plug (1).
◆ Unscrew the filling cap (2) and the oil drain plug
(1).
◆ Let all the oil flow out of the oil pan.
49
&2/.4 7(%%,
DISASSEMBLY
Carefully read p. 41 (MAINTENANCE).
a
While disassembling the wheel, be careful not to damage the brake pipe, the disc
and the pads.
To disassemble the front wheel, proceed as follows:
◆ Position the vehicle on the centre stand.
a
Place a support under the vehicle, so that
the front wheel has enough space to
move and the vehicle cannot fall down.
Fig. 30
◆
◆
◆
◆
Loosen the screw of the wheel pin clamp (1-Fig.
30).
Lock the wheel pin (2-Fig. 30) by means of an
hexagon spanner.
Remove the nut (1-Fig. 31), taking the washer.
Push the wheel pin (2-Fig. 30), by carefully acting
on the threaded end and using a rubber hammer if
necessary.
c
Check the arrangement of the odometer
control and spacer ring, in order to be
able to reassemble them correctly.
◆
◆
Fig. 31
50
Support the front wheel and extract the wheel pin
manually.
Remove the wheel, carefully withdrawing the disc
from the brake calliper.
◆
Disconnect the odometer control (3-Fig. 30).
a
Never pull the front brake lever after removing the wheel, otherwise the calliper
pistons may go out of their seats, thus
causing the outflow of the brake fluid.
In this case consult your APRILIA Official Dealer,
who will carry out the proper maintenance operation.
◆
Take the washer and the spacer ring.
REASSEMBLY
Carefully read p. 41 (MAINTENANCE).
a
While reassembling the wheel, be careful
not to damage the brake pipe, the disc and
the pads.
To reassemble the front wheel, proceed as follows:
◆ Position the wheel between the fork rods, carefully
inserting the disc in the brake calliper.
◆ Position the odometer control tang (3-Fig. 30) in
the apposite seat in the wheel hub.
◆ Position the odometer control seat in correspondence with the special antirotation pin.
◆ Place the washer between the odometer control
and the right fork rod.
◆
◆
◆
Insert the pin (2-Fig. 30) from the right side of the
vehicle (direction of travel).
Insert the spacer ring between the hub and the left
fork rod.
Insert the washer, lock the rotation of the wheel
pin (2-Fig. 30) by means of an hexagon spanner
and screw and tighten the nut (1-Fig. 31).
Wheel pin nut driving torque:
50 Nm (5 kgm).
◆
◆
With pulled front brake lever, press the handlebar
repeatedly, thrusting the fork downwards.
In this way the fork rods will properly bed in.
Tighten the wheel pin clamp screw (1-Fig. 30).
a
After reassembly, pull the front brake lever repeatedly and check the correct
functioning of the braking system.
Check the wheel centering.
Have the driving torques, centering and balancing of the wheel checked by your APRILIA Official
Dealer, in order to avoid accidents that may be
harmful for you and/or other people.
51
%8(!534 3),%.#%2
&IG ! "
DISASSEMBLY
c
Carefully read p. 41 (MAINTENANCE).
m
(to
Have the appropriate special tool
be requested to APRILIA Official Dealer):
– clamp installation pliers (1).
a
Fig. 32
Upon installation, replace the hose clamp
that has been removed with a new one
having the same dimensions, to be requested to an aprilia Official Dealer.
Do not attempt to reinstall the removed hose
clamp, since it is unusable.
Do not replace the removed hose clamp with a
screw clamp (2) or with other types of clamp.
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.
◆
◆
◆
◆
◆
Fig. 33
52
Position the vehicle on the stand.
Lift the rubber mat (3).
Unscrew and remove the screw (4), taking the washer.
Unscrew and remove the screw (5).
Unscrew and remove the two screws (6).
a
Handle the plastic and painted components with care to avoid scraping or damaging them.
◆
◆
◆
Slightly move the rear part (7) of the lower shield.
Release the hose clamp (8).
Disconnect the pipe (9).
a
DO NOT adjust the nuts (10) of the flange
(11), but follow the procedure described
below
◆
Unscrew and remove the screws (12-13-Fig. 32).
Screws (12-13-Fig. 32) driving torque:
12 Nm (1,2 kgm).
◆
Fig. 33A
Unscrew and remove the two screws (14-15-Fig.
32) that fasten the silencer to the engine, taking
the two bushings of the upper screw (15-Fig. 32).
Screws (14-15-Fig. 32) driving torque:
25 Nm (2,5 kgm).
c
◆
Remove the silencer.
Upon reassembly, change the exhaust
manifold-silencer seal.
Fig. 33B
53
2%!2 7(%%,
DISASSEMBLY
Carefully read p. 41 (MAINTENANCE).
◆
◆
◆
Remove the exhaust silencer, see p. 52 (EXHAUST SILENCER).
Put on the rear brake to lock the wheel.
Unscrew and remove the wheel nut (1-Fig. 33C)
and the washer.
c
c
Upon reassembly, change the wheel nut
(special type).
Fig. 33C
Wheel nut (1-Fig. 33C) driving torque:
110 Nm (11 kgm).
Use
APRILIA Genuine Spare Parts only.
a
After reassembly, pull the rear brake lever
repeatedly and check the correct functioning of the braking system.
Check the wheel centering.
Have the driving torques, centering and balancing of the wheel checked by your APRILIA Official
Dealer, in order to avoid accidents that may be
harmful for you and/or other people.
54
'2%!3).'
4(% 2%!2 "2!+% #!- 0). &IG c
c
Carefully read p. 41 (MAINTENANCE).
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
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.
a
The greasing of the rear brake cam pin
can be difficult or complicated for an unskilled operator.
If necessary, contact your APRILIA Official Dealer.
If you want to carry out this operation by yourself, keep to the following instructions:
◆
◆
Fig. 34
Disassemble the rear wheel, see p. 54 (REAR
WHEEL).
Unscrew and remove the adjuster (1).
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 (2) resist considerably to the
removal of the shoes. Be careful not to
crush or bruise your hands and fingers.
55
◆
◆
◆
Grasp the inner edge of the two friction elements
(3) at its centre and, pulling toward yourself, shake
the two shoes, thus releasing them.
Loosen the nut (4) and remove the pin lever (5).
Withdraw the cam pin (6).
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. 81 (LUBRICANT
CHART).
Upon reassembly:
◆
a
Neither strike, nor force the cam pin (6)
with hammers or others tools, in order
not to damage the two O-rings.
a
Make sure that the springs (2) are correctly coupled.
◆
56
Manually insert the cam pin (6), rotating and pushing it slightly.
#(%#+).' 4(% "2!+% 0!$ 7%!2
&IG Carefully read p. 27 (BRAKE FLUID (recommendations)), p. 27 (FRONT BRAKE), p. 41 (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. The wear will be
greater when the vehicle is driven on dirty or wet
roads.
Fig. 35
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 (1).
◆ 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
Official Dealer.
APRILIA
57
#(%#+).' 4(% "2!+% 3(/% 7%!2
&IG Carefully read p. 29 (REAR BRAKE) and p. 41
(MAINTENANCE).
Fig. 36
58
Check the wear of the rear brake shoes after the first
500 km and successively every 4000 km.
To check the wear of the rear brake shoes, proceed
as follows:
◆ Remov e the rear whee l, se e p. 54 (RE AR
WHEEL).
◆ At this point it is possible to check the thickness of
the friction material, which must never be less
than 1 mm.
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(% 34%%2).' &IG Carefully read p. 41 (MAINTENANCE).
Every now and then it is advisable to check the steering,
in order to verify if there are slacks.
To check the steering it is necessary to:
◆ Position the vehicle on the centre stand.
a
c
◆
Place a support under the vehicle, so that the
front wheel has enough space to move and
the vehicle cannot fall down.
Shake the fork in the direction of travel (see figure).
Do not shake the fork excesively, otherwise you
may take in consideration the movement of the
stand, thus observing an incorrect slack. Repeat the
previous operation more than once.
◆
Fig. 37
If you find that there is a considerable slack, contact
your aprilia Official Dealer to restore the optimal steering conditions.
#(%#+).' 4(% %.').% &5,#25- !8)3
&IG Carefully read p. 41 (MAINTENANCE).
Periodically check the slack existing between the engine
pin bushings.
To carry out this operation, proceed as follows:
◆ Position the vehicle on the centre stand.
◆ Shake the wheel perpendicularly to the direction of
travel (see figure).
◆ If you find any slack, make sure that all the fastening
elements of the fulcrum axis are well tightened.
a
If the slack persists, contact your
ficial Dealer.
APRILIA Of-
Fig. 38
59
2%-/6).' 4(% ).30%#4)/. #/6%2
c
c
Carefully read p. 41 (MAINTENANCE).
Handle the painted components with care
and avoid scraping or damaging them.
◆
Position the vehicle on the stand.
The operations marked with the symbol ★
must be carried out on both sides of the ve-
hicle.
★ Unscrew and remove the two screws (1-Fig.
◆ ★ Remove the cover (2-Fig. 39).
◆ ★ Unscrew and remove the screw (3-Fig. 39).
◆
Fig. 39
39).
c
Handle with care.
During the removal, take care not to damage the two tangs of the battery/tool kit compartment cover (opposite side of the lock).
◆
◆
◆
Remove the battery/tool kit compartment cover.
Remove the tool kit compartment (1-Fig. 40).
Disconnect the battery breather pipe (2-Fig. 40).
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. Handle the battery with
care. Neither overturn the battery, nor spill the
electrolyte.
Fig. 40
60
◆
◆
Extract the battery.
Unscrew and remove the screw (3-Fig. 40), taking
the washer.
c
Handle with care.
During the removal, do not damage the inspection cover tangs.
◆
Remove the inspection cover (4-Fig. 40) from its
seat, pulling it in the direction of travel.
2%-/6).' 4(% &2/.4 (!.$,%"!2
#/6%2 !BB c
c
Carefully read p. 41 (MAINTENANCE).
Handle the painted components with care
and avoid scraping or damaging them.
◆
Position the vehicle on the stand.
The operations marked with the symbol ★
must be carried out on both sides of the
vehicle.
Fig. 41
c
Handle with care. During removal, be
careful and avoid damaging the tangs.
◆
◆ ★
◆
◆
◆
◆
Raise the rubber protection of the rear-view mirror (1).
★ Unscrew the mirror-holder pin (2) and remove it,
together with the rear-view mirror.
★ Take the spacer(3).
Unscrew and remove the two screws (4) on the
dashboard.
Unscrew and remove the front screw (5), under
the front part of the fairing.
◆
◆
Insert a small-tip screwdriver in the joint of the two
handlebar covers (front and rear), in correspondance with one of the side tangs.
Lever moderately, by raising the edge of the front
handlebar cover (6) and releasing the tang.
Repeat the operation for the other tangs (four upper and four lower tangs), acting first on the side
ones and then on the central ones.
Remove the front handlebar cover.
61
Remove the inspection cover, see p. 60 (REMOVING THE INSPECTION COVER).
◆ Connect an electronic revolution counter to the
spark plug cable.
◆ Start the engine.
The minimum speed of the engine (idling) must be
about 1800 ± 100 rpm; in this case the engine does
not make the rear wheel rotate.
If necessary:
◆ Act on the adjusting screw (1) positioned on the
carburettor.
By SCREWING IT (clockwise), you increase the engine rpm.
By UNSCREWING IT (anticlockwise), you decrease
the engine rpm.
◆ Twist the throttle grip, accelerating and decelerating a few times to make sure that it functions correctly and to check if the idling speed is constant.
◆ Close the inspection cover.
◆
Fig. 42
)$,).' !$*534-%.4 &IG c
Carefully read p. 41 (MAINTENANCE).
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Adjust the idling after the first 500 km and every time
it is irregular.
To carry out this operation, proceed as follows:
◆ Drive for a few miles until the engine reaches the
normal running temperature, then stop the engine.
◆ Position the vehicle on the centre stand.
62
c
Do not act on the air adjusting screw, to
avoid variations of the carburation set-
ting.
a
If necessary, contact your
Dealer.
APRILIA Official
!$*534).'
4(% !##%,%2!4/2 #/.42/, &IG Carefully read p. 41 (MAINTENANCE).
The ideal slack of the accelerator control should be
about 2-3 mm.
To adjust the slack, proceed as follows:
◆ Position the vehicle on the centre stand.
◆ Remove the protection element (1).
◆ Loosen the nut (2) (by turning it clockwise).
◆ Act on the adjuster (3), positioned at the beginning
of the accelerator control cable.
After the adjustment:
◆ Tighten the nut (2) (by turning it anticlockwise),
thus locking the adjuster (3) and put back the protection element (1).
Fig. 43
63
Fig. 44
30!2+ 0,5' &IG c
Carefully read p. 41 (MAINTENANCE).
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
Check the spark plug after the first 500 km; change it
every 4000 km.
Periodically remove the spark plug and clean it carefully, removing carbon deposits; change it if necessary.
To reach the spark plug:
◆ Remove the inspection cover, see p. 60 (REMOVING THE INSPECTION COVER).
64
To remove and clean the spark plug:
◆ Take off the spark plug cap (1).
◆ 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.
a
The spark plug must be well tightened,
otherwise the engine may overheat and
be seriously damaged.
Use the recommended type of spark plug only,
see p. 79 (TECHNICAL DATA), in order not to
compromise the life and performance of the engine.
◆
◆
Position the spark plug cap (1).
Put back the inspection cover.
"!44%29
c
Carefully read p. 41 (MAINTENANCE).
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 12 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
sulphuric acid.
Wear protection clothes, a face mask and/or goggles during maintenance operations.
a
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.
65
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.
KEEP AWAY FROM CHILDREN
a
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.
c
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.
The electrolyte is corrosive.
Do not pour or spill it, especially on the plastic
parts.
66
,/.' ).!#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.
#(%#+).' 4(% %,%#42/,94% ,%6%,
&IG To check the electrolyte level, proceed as follows:
◆ Make sure that the ignition switch is in position
“m”.
◆ Remove the battery/tool kit compartment cover, see
p. 24 (BATTERY/ TOOL KIT COMPARTMENT).
◆ Remove the tool kit compartment.
◆ Disconnect the negative cable (–) and then the positive cable (+) of the battery.
c
Upon reassembly, connect first the positive
cable (+) and then the negative cable (-).
Disconnect the breather pipe (1).
Extract the battery and put it on a plane surface.
◆ Make sure that the fluid level is included between
the two "MIN" and "MAX" notches stamped on the
battery side.
Otherwise:
◆ Unscrew and remove the element plugs.
◆
◆
a
Never exceed the "MAX" notch, since the
electrolyte level increases during the recharge.
◆
Top up by adding distilled water.
RECHARGING THE BATTERY
Check the electrolyte leve, top up if necessary, then
proceed as follows:
Fig. 45
◆
◆
◆
◆
◆
Put the battery in a cool and dry place.
Unscrew and remove the element plugs.
Connect the battery with a battery charger.
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.
a
Upon reassembly, 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.
67
Fig. 46
#(!.').' 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.
c
If a fuse blows frequently, there probably
is a short circuit or an overload in the
electric system.
In this case it is advisable to consult an APRILIA
Official Dealer.
Carefully read p. 41 (MAINTENANCE).
68
If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary
to check the fuse (1):
◆ Turn the ignition switch to position “m”, to avoid
any accidental short circuit.
◆ Remove the battery/tool kit compartment cover,
see p. 24 (BATTERY/ TOOL KIT COMPARTMENT).
◆ Extract the fuse and check if the filament is broken.
◆ Before replacing the fuse, try to find out the cause
of the trouble, if possible.
◆ Then replace the damaged fuse with the spare
fuse (2) or with a new one having the same amperage.
c
If you use one of the spare fuse (2), put a
new fuse in the suitable seat.
ARRANGEMENT OF THE FUSE
7.5 A fuse from the battery to:
all the electric loads, excluding the light circuit, which
is fed with alternate current.
!$*534).' 4(% (%!$,)'(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) (Fig. 47).
To adjust the headlight beam:
◆ Act on the suitable screw (1-Fig. 48) by means of
a screwdriver.
By TURNING IT CLOCKWISE, you set the beam upwards.
By TURNING IT ANTICLOCKWISE, you set the
beam downwards.
Fig. 47
"5,"3
a
a
Before changing a bulb, turn the ignition
switch to position “m”.
Change the bulb wearing clean gloves or
using a clean 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
frequently.
Carefully read p. 41 (MAINTENANCE).
DO NOT FORCE THE ELECTRIC CABLES
Fig. 48
69
#(!.').' 4(% (%!$,)'(4 "5,"3
c
c
Carefully read p. 69 (BULBS).
Remove the key from the ignition switch.
◆
Position the vehicle on the centre stand.
The operations marked with the symbol ★
must be carried out on both sides of the
vehicle.
◆ ★
◆
Fig. 49
◆
◆
◆
◆
Remove the footrest mat.
Unscrew and remove the two fastening screws of
the bag hook (1-Fig. 49).
Remove the bag hook (1-Fig. 49).
Unscrew and remove the screw (with the relevant
washer) positioned in the seat of the bag hook.
Unscrew and remove the two screws (2-Fig. 49).
Unscrew and remove the eight screws (3-Fig. 49).
a
Proceed with care.
Do not damage the tangs and/or their
seats.
Handle the painted components with care and
avoid scraping or damaging them.
◆
70
Withdraw and remove the front inner shield, rotating it toward the saddle.
◆
◆
◆
Manually move the protection element (1-Fig. 50)
of the bulb to be changed.
Rotate the check tang positioned at the rear of the
bulb socket anticlockwise.
Extract the bulb and replace it with a new one of
the same kind.
Fig. 50
71
#(!.').' 4(% &2/.4 $)2%#4)/.
).$)#!4/2 "5,"3 &IG Carefully read p. 69 (BULBS).
To change the bulbs, proceed as follows:
◆ Unscrew and remove the screw (1).
a
Upon reassembly, tighten the screw (1)
carefully, in order not to damage the protection screen.
c
While removing the protection screen (2),
proceed carefully in order not to break it.
Fig. 51
◆
◆
◆
Remove the protection screen (2).
Press the bulb (3) slightly and turn it anticlockwise.
Remove the bulb from its seat.
a
Insert the bulb in the socket making the
two bulb pins coincide with the relevant
guides on the socket.
◆
72
Correctly install a bulb of the same type.
#(!.').' 4(% 2%!2 $)2%#4)/.
).$)#!4/2 "5,"3 &IG Carefully read p. 69 (BULBS).
To change the bulb:
◆ Unscrew and remove the screw (1).
c
While removing the indicator lens, proceed carefully in order not to break it.
◆
◆
◆
Remove the indicator lens (2).
Press the bulb (3) slightly and turn it anticlockwise.
Remove the bulb from its seat.
Correctly install a new bulb of the same type.
c
c
◆
If the bulb socket (4) has gone out of its
seat, insert it again correctly, making the
opening of the bulb socket itself coincide with
the seat of the screw.
Fig. 52
Upon reassembly, correctly position the
indicator lens in its seat.
Tighten the screw (1) carefully, without exerting
too much pressure, in order to avoid damaging
the indicator lens.
73
WARNING LIGHT BULBS
◆
Extract the relative bulb socket:
Pos.
1
2
3
4
5
◆
Warning light
Colour
Left direction indicators (c)
green
Mixer oil reserve (j)
Right direction indicators (c)
Low beam (b)
Low fuel (g)
red
green
green
amber
Extract the bulb and replace it with one of the
same type.
Fig. 53
#(!.').' 4(% $!3("/!2$ "5,"3
&IG Carefully read p. 69 (BULBS).
The dashboard contains:
◆ The warning light bulbs.
◆ The dashboard lighting bulbs.
To change the bulbs, proceed as follows:
◆ Remove the handlebar cover, see p. 61 (REMOVING THE FRONT HANDLEBAR COVER), without
disconnecting it from the electric wires and from
the speedometer cable.
74
DASHBOARD LIGHTING BULBS
◆ Extract the bulb socket of the dashboard part in
which there has been a light decrease:
Pos.
◆
Lit part
6
left part
7
centre part
8
right part
Extract the bulb and replace it with one of the
same type.
#(!.').' 4(% 2%!2 ,)'(4 "5,"3
&IG Carefully read p. 69 (BULBS).
To change them, proceed as follows:
◆ Unscrew and remove the two screws (1).
c
While removing the protection screen,
proceed carefully in order not to break the
cog.
◆
◆
Remove the protection screen (2).
Slightly press the bulb and rotate it anticlockwise.
Remove the bulb from its seat.
c
c
◆
Insert the bulb in the socket, making the
two bulb pins coincide with the relevant
guides on the socket.
◆
Fig. 54
Correctly install a new bulb of the same type.
Upon reassembly, correctly position the
protection screen in its seat.
Tighten the screws (1) carefully, without exerting
too much pressure, in order to avoid damaging
the protection screen (2).
75
$2!).).' 4(% &5%, 4!.+ &IG 42!.30/24
c
Carefully read p. 25 (FUEL).
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.
◆
◆
Stop the engine and wait until it has cooled down.
Empty the fuel tank by means of a manual pump
or a similar system.
To empty the carburettor completely, proceed as follows:
◆ Remove the inspection cover, see p. 60 (REMOVING THE INSPECTION COVER).
◆ Remove the filter casing, see p. 46 (AIR CLEANER - REMOVAL).
◆ Put the free end of the pipe (1) into a receptacle.
◆ Open the carburettor breather by loosening the
drain screw (2) positioned under the float chamber.
When all the fuel has flowed out:
◆ Tighten the drain screw (2) until the breather
shuts.
a
Tighten the drain screw (2) carefully, to
avoid fuel leaks from the carburettor
breather pipe during the refuelling.
Fig. 55
76
#,%!.).'
Clean the vehicle frequently if it used in particular areas or conditions, such as:
◆ Polluted areas (cities and industrial areas).
◆ Areas characterized by an high percentage of salinity and humidity (sea areas, hot and humid climates).
◆ Particular conditions (use of salt and anti-ice
chemical products on the roads during the winter).
◆ Avoid leaving deposits of industrial and polluting
powders, tar spots, dead insects, bird droppings,
etc. on the body.
◆ Avoid parking the vehicle under trees, since in
some seasons residues, resins, fruits or leaves
fall down, which contain substances that may
damage the paint.
a
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
restore normal conditions.
Carry out the preliminary checking operations,
see p. 33 (PRELIMINARY CHECKING OPERATIONS).
To remove dirt and mud from the painted surfaces
use a low- pressure water jet, carefully wet the dirty
parts, remove mud and filth with a soft car sponge
impregnated with a lot of water and shampoo (2 ÷ 4%
parts of shampoo in water).
Then rinse with plenty of water and dry with chamois
leather.
To clean the outer parts of the engine use a degreaser, brushes and wipers.
a
Polish with silicone wax only after having
carefully washed the vehicle.
Do not use polishing pastes on matt
paints. Do not wash the vehicle under the sun,
especially during the summer, when the body is
still warm, since if the shampoo dries before being rinsed away, it can damage the paint.
Do not use water (or liquids) at a temperature exceeding 40°C to clean the plastic components of
the vehicle.
Use neither high pressure water/air jets, nor vapour jets on the following parts: wheel hubs, controls on the right and on the left side of the handlebar, bearings, brake pumps, instruments and
indicators, silencer exhaust, glove/tool kit compartment, ignition switch/steering lock.
Do not use alcohol or solvents to clean the rubber and plastic parts and the saddle: use water
and mild soap.
Do not apply protection waxes onto the saddle, in
order not to make it too slippery.
77
,/.' 0%2)/$3 /& ).!#4)6)49
After a long period of inactivity of the vehicle some
precautions are necessary to avoid any problem.
Further, it is important to carry out the necessary repairs and a general check up before the period of inactivity, since you could forget to carry them out later.
Proceed as follows:
◆ Empty the fuel tank and the carburettor, see p. 76
(DRAINING THE FUEL TANK).
Put back the tank plug.
◆ Extract the spark plug and pour a teaspoon (5-10
cm#) of two-stroke engine oil into the cylinder.
Move the ignition switch to position “n”, press the
start push button “r” for a few seconds, to distribute the oil evenly on the cylinder surfaces.
Put back the spark plug.
◆ Remove the battery, see p. 65 (BATTERY).
◆ Wash and dry the vehicle, see p. 77 (CLEANING).
◆ Polish the painted surfaces with wax.
◆ Inflate the tyres, see p. 30 (TYRES).
◆ By means of a suitable support, position the vehicle so that both tyres are raised from the ground.
78
◆
◆
Place the vehicle in an unheated, not-humid room,
away from sunlight, with minimum temperature
variations.
Cover the vehicle avoiding the use of plastic or
waterproof materials.
!&4%2 ! 0%2)/$ /& ).!#4)6)49
◆
◆
◆
◆
◆
Uncover and clean the vehicle, see p. 77 (CLEANING).
Check the electrolyte level in the battery and install it, see p. 65 (BATTERY).
Make sure that the fuel drain screw is thoroughly
screwed (breather pipe closing index), see p. 76
(DRAINING THE FUEL TANK).
Refuel, see p. 25 (FUEL).
Carry out the preliminary checking operations, see
p. 33 (PRELIMINARY CHECKING OPERATIONS).
a
Have a test ride at moderate speed in a
low-traffic area.
4%#(.)#!, $!4!
DIMENSIONS
Max. length ..................................................... 1750 mm
Max. width....................................................... 800 mm
Max. height (rear-view mirror included) .......... 1310 mm
Seat height...................................................... 770 mm
Distance between centres .............................. 1250 mm
Min. ground clearance .................................... 155 mm
Weight without driver (ready for starting) ........
91 kg
ENGINE
Type ................................................................
Number of cylinders ........................................
Total displacement ..........................................
Bore/stroke .....................................................
Compression ratio...........................................
Starting ...........................................................
Clutch..............................................................
Change gear ...................................................
Cooling............................................................
Fuel (reserve included) ...................................
Fuel reserve ....................................................
Transmission oil ..............................................
Mixer oil (reserve included).............................
Mixer oil reserve .............................................
Seats...............................................................
Vehicle max. load (driver + luggage) ..............
(driver+passenger+luggage)...........................
CAPACITY
TRANSMISSION Speed change gear ........................................
Primary ...........................................................
Ratios..............................................................
Secondary.......................................................
MINARELLI, 2-stroke with controlled ignition
1
49.26 cm #
40 mm / 39.2 mm
12.5 ± 0.5:1
electric + kick starter
centrifugal
automatic stepless variator
with forced air
6L
1.5 L
110 cm#
1.3 L
0.35 L
1 (2 in the countries where this is allowed)
105 kg
180 kg (in the countries where this is allowed)
automatic and stepless
V-belt
minimum for stepless change: 2.6 - maximum for stepless change: 0.88
with gears
CARBURETTOR Model .............................................................. DELL’ORTO PHBN 12
Choke tube ..................................................... Ø12 mm
FUEL SUPPLY
Fuel ................................................................ unleaded petrol according to the DIN 51607 standard, min. O.N. 95
(N.O.R.M.) and 85 (N.O.M.M.)
FRAME
Type ..............................................................
one-beam, split in two cradles
79
SUSPENSIONS
Front .............................................................
Stroke ...........................................................
Rear..............................................................
Stroke ...........................................................
hydraulically operated telescopic fork
75 mm
hydraulic mono-shock absorber
75 mm
BRAKES
Front .............................................................
Rear .............................................................
disc brake, Ø190 mm with hydraulic transmission
drum brake, Ø110 mm, with mechanic transmission
WHEELS
Front ............................................................. 3.50 x 10"
Rear.............................................................. 3.50 x 10"
TYRES.......................................................... tubeless
Front ............................................................. 120/90 - 10"
Rear.............................................................. 130/90 - 10"
STANDARD INFLATION PRESSURE
Front ............................................................. 130 kPa (1.3 bar)
Rear.............................................................. 170 kPa (1.7 bar)
INFLATION PRESSURE WITH PASSENGER (where drive with passenger is allowed)
Front ............................................................. 190 kPa (1.9 bar)
Rear.............................................................. 210 kPa (2.1 bar)
IGNITION
Type..............................................................
Spark advance..............................................
Standard spark plug .....................................
Spark plug gap .............................................
Engine idle rpm.............................................
CDI
14° before T.D.C.
NGK BR7 HS
0.5 ÷ 0.6 mm
1800 ± 100 rpm
ELECTRIC
SYSTEM
Battery ..........................................................
Fuse..............................................................
Generator (with permanent magnet) ............
Low beam bulbs ...........................................
Front parking light bulb ................................
Direction indicator bulbs ...............................
Rear parking/stoplight bulbs .........................
Dashboard bulbs ..........................................
Low beam warning light ................................
Direction indicator warning light....................
Mixer oil reserve warning light ......................
Low fuel warning light ...................................
12 V - 4 Ah
7.5 A
12 V - 85 W
12 V - 15 W
12 V - 5 W
12 V - 10 W
12 V - 5/21 W
12 V - 1.2 W
12 V - 1.2 W
12 V - 1.2 W
12 V - 1.2 W
12 V - 1.2 W
80
,5"2)#!.4 #(!24
0
Transmission oil (recommended):
F.C., SAE 75W - 90 or
GEAR SYNTH, 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
GREEN HIT 2 or
CITY 2T.
Mixer 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;
an alternative
FORK 5W or
FORK 20W fork oil.
If you need an oil with intermediate characteristics in comparison with the
F.A. 5W and
F.A. 20W or
FORK 20W, these can be mixed as indicated below:
Fork oil (recommended):
SAE 10W =
0
0
FORK 5W and
0 F.A. 5W 67% of the volume + 0 F.A. 20W 33% of the volume, or
FORK 5W 67% of the volume +
FORK 20W 33% of the volume;
0 F.A. 5W 33% of the volume + 0 F.A. 20W 67% of the volume, or
FORK 5W 33% of the volume +
FORK 20W 67% of the volume.
Bearings and other lubrication points (recommended): 0 AUTOGREASE MP or
GREASE 30.
SAE 15W =
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 protection against corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or vaseline.
aWARNING
Use new brake fluid only.
Brake fluid (recommended):
0 F.F., DOT 5 (DOT 4 compatible) or
BRAKE 5.1, DOT 5 (DOT 4 compatible).
aWARNING
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.
Engine coolant (recommended):
0 ECOBLU - 40°C or
COOL.
81
)MPORTERS
82
)MPORTERS
83
7)2).' $)!'2!- 2ALLY 84
7)2).' $)!'2!- +%9 2ALLY 1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
13)
14)
15)
16)
17)
18)
19)
20)
22)
23)
24)
25)
26)
27)
28)
29)
30)
Generator
CDI
Spark plug
H.T. coil
Voltage regulator
Battery
Starter
Start relay
Front stoplight switch
Rear stoplight switch
Mixer oil reserve switch
Fuel level sensor
Rear right direction indicator
Rear light
Rear left direction indicator
Bridge
Direction indicator switch
Key switch
Control diode
Blinking
Dashboard
Left direction indicator warning light
Mixer oil reserve warning light
Dashboard light
Fuel level instrument
Low fuel warning light
Low beam warning light
Right direction indicator warning light
31)
32)
33)
34)
35)
36)
37)
38)
39)
40)
Front right direction indicator
Front left direction indicator
Front parking light
Low beam bulb
Horn
Pick up
Fuse
Multiple connectors
Start push button
Horn push button
#!",% #/,/523
Ar
Az
B
Bi
G
Gr
M
N
R
V
Vi
Orange
Light blue
Blue
White
Yellow
Grey
Brown
Black
Red
Green
Violet
85
./4%
!3+ &/2 '%.5).% 30!2% 0!243 /.,9
86
./4%
!3+ &/2 '%.5).% 30!2% 0!243 /.,9
87
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 is not necessary.
- Avoid disturbing noises.
- Respect nature.
88
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