RALLY 50
use+maintenancebook 
aprilia part# 8201831
© 1995 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: february 1995
Reprint: september 1995, february 1997, january 1998, december 1998,
february 1999, january 2000, november 2000
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%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.
2
Carefully observe the instructions preceded by the following warning signs:
Safety norms and regulations to protect athe driver and other people from severe
injuries or grave risks.
cIndications 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:
2 catalytic version
VERSION: |
|
I Italy |
Ñ Slovenia |
U United Kingdom |
% Israel |
A Austria |
K South Korea |
P Portugal |
M Malaysia |
" Finland |
R Chile |
B Belgium |
` Croatia |
D Germany |
^ Australia |
F France |
- United States of America |
E Spain |
] Brazil |
G Greece |
á South Africa |
O Holland |
Î New Zealand |
C Switzerland |
[ Canada |
ˆ Denmark |
|
J Japan |
|
S 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 |
CATALYTIC SILENCER 2........................................................... |
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 ........................................................................ |
39 |
MAINTENANCE ............................................................................. |
41 |
REGULAR SERVICE INTERVALS CHART ................................... |
42 |
IDENTIFICATION DATA ................................................................. |
44 |
AIR CLEANER ................................................................................ |
45 |
CHECKING THE TRANSMISSION OIL LEVEL ............................. |
46 |
CHANGING THE TRANSMISSION OIL ......................................... |
47 |
FRONT WHEEL .............................................................................. |
48 |
REAR WHEEL ................................................................................ |
50 |
GREASING THE REAR BRAKE CAM PIN .................................... |
52 |
CHECKING THE BRAKE PAD WEAR ........................................... |
53 |
CHECKING THE BRAKE SHOE WEAR ........................................ |
54 |
CHECKING THE STEERING ......................................................... |
55 |
CHECKING THE ENGINE FULCRUM AXIS .................................. |
55 |
REMOVING THE INSPECTION COVER ....................................... |
56 |
REMOVING THE FRONT HANDLEBAR COVER .......................... |
57 |
IDLING ADJUSTMENT ................................................................... |
58 |
ADJUSTING THE ACCELERATOR CONTROL ............................. |
59 |
SPARK PLUG ................................................................................. |
60 |
BATTERY ....................................................................................... |
61 |
LONG INACTIVITY OF THE BATTERY ......................................... |
62 |
CHECKING THE ELECTROLYTE LEVEL ..................................... |
63 |
CHANGING THE FUSE .................................................................. |
64 |
ADJUSTING THE HEADLIGHT BEAM .......................................... |
65 |
BULBS ............................................................................................ |
65 |
CHANGING THE HEADLIGHT BULBS .......................................... |
66 |
CHANGING THE FRONT DIRECTION INDICATOR BULBS ........ |
68 |
CHANGING THE REAR DIRECTION INDICATOR BULBS ........... |
69 |
CHANGING THE DASHBOARD BULBS ........................................ |
70 |
CHANGING THE REAR LIGHT BULBS ......................................... |
71 |
TRANSPORT ................................................................................. |
72 |
DRAINING THE FUEL TANK ......................................................... |
72 |
CLEANING ..................................................................................... |
73 |
LONG PERIODS OF INACTIVITY ................................................. |
74 |
AFTER A PERIOD OF INACTIVITY ............................................... |
74 |
TECHNICAL DATA ........................................................................ |
75 |
LUBRICANT CHART ...................................................................... |
77 |
Importers.................................................................................... |
78-79 |
WIRING DIAGRAM - Rally 50 ........................................................ |
80 |
WIRING DIAGRAM KEY - Rally 50 ................................................ |
81 |
4
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.
8 |
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.
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.
COOLER |
OIL |
9 |
A12 |
345 |
10 |
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.
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
12 |
#,/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).
!##%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.
14 |
Avoid hanging bulky, heavy and/or dangerous objects on the handlebars, mudguards and forks, because the vehicle might respond more slowly in turns and its manoeuvrability could be unavoidably impaired.
Do not place bags that are too bulky on the vehicle sides and do not ride with the crash helmet hanging from its string, because it could hit people or obstacles making you lose control of the vehicle.
Do not carry any bag if it is not tightly secured to the vehicle.
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
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1) Mixer oil tank plug
2) Ignition switch/steering lock
3) Front brake fluid reservoir
4) Bag hook
5) Battery/tool kit compartment
6) Inspection cover
7) Anti-theft hook
Fig. 1
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1) Fuel tank plug
2) Saddle lock
3) Transmission oil filling cap
4) Kick starter
5) Centre stand
Fig. 2
16
!22!.'%-%.4 /& 4(% ).3425-%.43
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1)Horn push button (f)
2)Cold start lever (e)
3) Rear brake lever
4) Rear-view mirror
5) Direction indicator switch (c)
6)Instruments and indicators
7)Headlight switch (b- p- •)
7a) |
Headlight switch (b- •) F- O |
|
7b) |
Headlight switch (a- b- •) C- U- P |
|
8) |
Front brake lever |
Fig. 3 |
9)Throttle grip
10)Start push button (r)
11)Ignition switch/steering lock (n- m- s)
17
).3425-%.43 !.$ ).$)#!4/23
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1) |
Red mixer oil reserve warning light (j) |
2) |
Green left direction indicator warning light (c) |
3) |
Total kilometres odometer |
4) |
Speedometer |
5) |
Amber low fuel warning light (g) |
6) Green right direction indicator warning light |
|
|
(c) |
7) |
Green low beam warning light (b) |
7a) |
Green low beam warning light (b) F- O |
7b) Blue high beam warning light (a) |
|
Fig. 4 |
C- U- P |
8) |
Fuel level indicator (g) |
18
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Description |
|
Function |
|
|
|
|
|
Mixer oil reserve warning light |
(j) |
It comes on when the ignition switch is in position "n" and the |
|
|
|
start push button “r“ is pressed, thus checking the proper func- |
|
|
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tioning of the bulb. |
|
|
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If the light does not come on during the starting, provide for re- |
|
|
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placing the bulb. |
|
|
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If the warning light comes on and does not go out af- |
|
|
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ter the start push button "r" has been released, or if |
|
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ait comes on during normal functioning, this means |
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|
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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. |
|
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Total kilometres odometer |
|
It indicates the total number of kilometres covered. |
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Speedometer |
|
It indicates the driving speed. |
|
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|
|
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Fuel level indicator |
|
It indicates the approximate fuel level in the tank. |
|
|
|
|
|
Low beam warning light |
(b) |
It comes on when the headlight is in low beam position. |
|
|
|
|
|
High beam warning light |
(a) |
It comes on when the headlight in high beam position. |
|
C- U- P |
|
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|
|
|
|
|
Low fuel warning light |
(g) |
It comes on when the quantity of fuel left in the tank is about 1,5 L. |
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|
19
-!). ).$%0%.$%.4 #/.42/,3
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cThe 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.
2) COLD START LEVER (e)
The starter for the cold start of the engine is oper- Fig. 5 ated 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
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cThe electrical parts work only when the ignition switch is in position “n”.
1)LIGHT SWITCH (b - p - •)
When the engine is started and the light switch is in position "•", the lights are off; when the switch is in position "b", the dashboard lights, the parking lights and the low beam are on.
1a) LIGHT SWITCH (b- •) F- O
When the engine is started and the light switch is in position "•", the lights are off; when the switch is in position "b", the dashboard lights, the rear parking light and the low beam are on.
1b) LIGHT SWITCH (a- b- •) C- U- P
When the engine is started and the light switch is in position "•", the lights are off; when the switch is in position "b", the dashboard lights, the low beam and the parking lights are on; when it is in position "a", the dashboard lights, the high beam and the parking lights are on.
Fig. 6
2)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).
21
)'.)4)/. 37)4#( &IG
The ignition switch is positioned on the right side, near the steering column.
cThe 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 |
Function |
Key |
|
removal |
||
|
|
|
|
|
s |
The steering is locked. It is nei- |
It is possible to remove |
|
ther possible to start the en- |
the key. |
|
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gine, nor to switch on the lights. |
|
|
|
Steering lock |
|
|
|
|
|
|
|
m |
Neither the engine, nor the |
It is possible to remove |
|
lights can be switched on. |
the key. |
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|
|
|
n |
The engine and the lights can |
It is not possible to re- |
Fig. 8 |
be switched on. |
move the key. |
|
|
|
|
22
!58),)!29 %15)0-%.4
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To unlock and lift the saddle:
Insert the key in the saddle lock (1).
Turn the key clockwise and raise the saddle (2).
cBefore 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.
aBefore leaving, make sure that the saddle is properly locked.
#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).
aDo not load the crash helmet/glove compartment too much.
Maximum allowed weight: 2.5 kg.
cSpecial hooks for the positioning of a lock have been provided under the saddle.
Fig. 9
Fig. 10
23
Fig. 11
Fig. 12
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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
Do not hang excessively bulky bags or aparcels 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.
Max. allowed weight: 1.5 kg.
24
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The fuel used for internal combustion en- agines is extremely inflammable and in particular conditions it can become ex-
plosive.
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 premium grade petrol (4 Stars U), in conformity with the DIN 51600 standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.).
2 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
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