© 2003 aprilia s.p.a. - Noale (VE)
First edition: March 2003
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
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NOTE This manual is an important and integral part of your vehicle. Keep it with your vehicle at all times, even if your vehicle is resold.
aprilia has prepared this manual to supply you, the user, with correct and current information. However, since aprilia constantly improves the design of its vehicles, there may be slight discrepancies between your vehicle and the material given in this manual. If you have any questions about your vehicle, contact your Local aprilia Dealer, as he will have the very latest technical information available from the factory.
For tests and repairs not expressly described in this manual, to purchase aprilia genuine spare parts, accessories, and other products, and for help with specific problems, please contact your Local aprilia Dealer or service center. These professionals will be able to promptly and accurately help.
Thank you for choosing aprilia. Have a great ride!
This manual is copyright in all countries, and reproduction of any part or the whole by any means in print or electronic is strictly prohibited.
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This manual is divided into sections, chapters and paragraphs, by subject. The procedures described are laid out in single operation, and each operation is indicated by a .
The numbered parts shown in the figures are identified in the text with the number in parentheses or with the symbol representing them.
Example:
section
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chapter
34%%2).' ,/#+
safety warning
paragraph
operation
position (2)
symbol “s”
aWARNING
Never turn the key to position “s” while the vehicle is being operated. If you do so, you will lose control of the vehicle, and a crash will ensue.
OPERATION
To lock the steering:
Turn the handlebar completely to the left.
Turn the key (2) to position “m” (OFF) and press it.
Release the key and rotate it to position “s” (LOCK).
Remove the key.
2 |
use and maintenance Rally 50 - |
3!&%49 7!2.).'3
The following precautionary warnings are used throughout this manual in order to convey the following messages:
Safety warning. When you find this asymbol on the vehicle or in the manual, be careful to the potential risk of personal injury. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other people’s safety and for the vehicle!
aWARNING
Indicates a potential hazard which may result in serious injury or even death.
aCAUTION
Indicates a potential hazard which may result in personal injury or damage to the vehicle or other property.
NOTE The word “NOTE” in this manual precedes important information or instructions.
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If it is necessary to let the engine run in order to carry out some work, make sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces.
If it is necessary to work indoors, use an exhaust evacuation system.
aWARNING
The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and even death.
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Keep gasoline away from children. Gasoline is also poisonous. Never attempt to siphon gasoline using your mouth. Never allow gasoline to contact your skin. If you should accidentally spill gasoline on yourself, change your clothes immediately and wash the area upon which the gasoline was splashed thoroughly with hot water and soap. Should you accidentally swallow gasoline, do not induce vomiting. Drink large quantities of clear water or milk and immediately seek professional medical assistance. Should you accidentally get gasoline get your eyes, flush with large quantities of cool, clear water and immediately seek professional medical assistance.
aWARNING
Gasoline is extremely flammable and becomes explosive under certain conditions.
KEEP GASOLINE AWAY FROM CHILDREN.
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aWARNING
The engine and all parts of the exhaust system, as well as the braking system, become very hot and remain hot for some time after the vehicle and the engine are stopped. Before handling any component of your vehicle after riding, insure that it has cooled sufficiently to be safe to handle.
use and maintenance Rally 50 - 3
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aWARNING
Use latex gloves for the maintenance operations that require contact with used oil. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is advisable to thoroughly wash your hands with soap and water after handling used oil.
KEEP OIL AWAY FROM CHILDREN.
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aCAUTION
Brake fluid is extremely poisonous. Do not ever allow brake fluid to be ingested or swallowed. Should brake fluid accidentally be swallowed, drink large quantities of milk or clear water and immediately seek professional medical assistance. Brake fluid is highly destructive of skin and eye tissue. Should you accidentally spill brake fluid on yourself, remove the contaminated clothing, wash your body with soap and warm water immediately and immediately seek professional medical assistance. Should you accidentally splash brake fluid into your eyes, flush with a large quantity of cool, clear water and immediately seek professional medical assistance.
KEEP BRAKE FLUID AWAY FROM CHILDREN.
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In certain conditions, the ethylene glycol contained in the engine coolant is flammable: its flame is invisible, but you can be burned anyway.
aWARNING
Avoid spilling the engine coolant on the exhaust system or on the engine components. They may be hot enough to cause the coolant to ignite and burn without a visible flame.
The coolant (ethylene glycol) can cause skin irritation and is poisonous if swallowed.
Coolant and coolant/water mixtures are sweet to the taste and brightly colored, therefore are highly attractive to pets and children. Take extra precautions to keep new and used coolant out of reach of children and animals.
KEEP AWAY FROM CHILDREN.
Risk of burn.
Do not remove the radiator cap when the engine is hot. Wait until the engine has completely cooled down. The coolant is under pressure and may splash out and cause burns.
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aWARNING
The battery gives off noxious and explosive gases; keep cigarettes, flames and sparks away from the battery. Provide adequate ventilation when operating or recharging the battery.
During the recharging or the use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging.
The battery contains sulphuric acid (electrolyte). Contact with the skin or eyes may cause serious burns. Always wear protective clothing, rubber gloves, and tight fitting goggles or a face shield when working around the battery, especially when filling the battery with either water or electrolyte.
In case of contact with the skin, flush immediately with plenty of water. In case of contact with the eyes, flush with plenty of water for at least 15 minutes. Immediately consult a health professional.
The electrolyte is poisonous.
If the electrolyte is accidentally swallowed, drink large quantities of water or milk and then milk of magnesia or vegetable oil. Immediately consult a health professional.
KEEP AWAY FROM CHILDREN.
4 |
use and maintenance Rally 50 - |
7!2.).'3 02%#!54)/.3
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Before starting the engine, carefully read this manual and in particular the chapters “WARNINGS - PRECAUTIONS - GENERAL ADVICE” and “SAFE DRIVE” see p. 17.
Your safety and that of those around you depends not only on your skill as a rider, but also your knowledge about your vehicle and about riding safely. Therefore it is essential that you not operate your vehicle on public streets or highways until you have received instructions from a qualified safety organization such as the Motorcycle Safety Foundation, and are properly trained and licensed.
2%0/24).' /& $%&%#43 4(!4 !&&%#4 3!&%49
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying aprilia. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or aprilia. To contact NHTSA, you may either call the Auto Safety Hotline toll free at 1-800-424- 9393 (or 366-0123 in the Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590.
You can also obtain other information about motor vehicle safety from the Hotline.
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Rules of the road vary from country to country. It is essential that you understand in advance the rules of the road of the country in which your vehicle will be used.
aWARNING
This vehicle has been designed and produced for use on even and paved roads or surfaces only. Do not use the vehicle on unpaved surfaces, in order to avoid overturning or other accidents.
./)3% %-)33)/. 7!22!.49
aprilia s.p.a. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
Warranty claims should be directed to:
aprilia USA Inc.
110 Londonderry Court, Suite 130 Woodstock, GA 30188
USA
Tel 770 592 2261
Fax 770 592 4878
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ORIGIN OF THE EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. The control of hydrocarbons is very important, because under certain conditions they react to exposure to sunlight and produce photochemical smog.
Carbon monoxide does not react in the same way, but it is toxic and poisonous. aprilia utilizes “lean” carburetor settings and other systems to reduce the production of carbon monoxide and hydrocarbons.
EXHAUST EMISSION
CONTROL SYSTEM
The Exhaust Emission Control System requires “lean” carburetor settings and no adjustments should be made, except idle speed adjustments by means of the appropriate screw.
use and maintenance Rally 50 - 5
4!-0%2).' 7!2.).'
Tampering with the noise control system is prohibited. Federal law prohibits the following acts or causing thereof:
a)The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or
b)The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
a)Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.
b)Removal or puncturing of any part of the intake system.
c)Lack of proper maintenance.
d)Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
aCAUTION
This product should be checked for repair or replacement if the vehicle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.
PROBLEMS THAT MAY AFFECT THE VEHICLE EMISSIONS
If any of the following symptoms are observed, immediately have your vehicle inspected and repaired by your Local aprilia Dealer.
Symptoms:
–Difficult starting or stalling after starting.
–Irregular idle.
–Misfiring or backfiring during acceleration.
–After-burning (backfiring).
–Poor engine performance, degraded handling, or poor fuel economy.
6 |
use and maintenance Rally 50 - |
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Every vehicle produced by aprilia receives a vehicle identification number (V.I.N.) stamped:
– on the central tube of the frame (A), to be able read it see p. 60 (FRAME NUMBER);
and also:
– on the identification plate (B) which is located on the central tube of the frame.
DIGIT MEANING
1)Manufacturer’s identification alphanumeric code.
2)Vehicle type.
3)Model.
4)Country for which the vehicle is intended.
5)# = Check digit number.
6)Model year.
7)Assembling factory designation (N = NOALE-VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).
8)Sequential serial number.
use and maintenance Rally 50 - 7
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Ref. Description
1
2
3
4
Ref. Description
5
6
7Muffler stamping.
8
use and maintenance Rally 50 - 9
Ref. Description
9
10
11
Ref. Description
12
13
14
10 use and maintenance Rally 50 -
APRILIA S P A %-)33)/. #/.42/, 3934%- 7!22!.49 34!4%-%.4
YOUR WARRANTY RIGHTS
AND OBLIGATIONS
The California Air Resources Board and aprilia s.p.a. (hereinafter aprilia) are pleased to explain the emission control system warranty on your 1999 and later vehicle. In California new motor vehicles must be designed, built and equipped to meet the State’s stringent anti-smog standards. aprilia must warrant the emission control system on your vehicle for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your vehicle.
Your emission control system may include parts such as the carburetor or fuel-injec- tion system, the ignition system, catalytic converter and engine computer. Also included may be hoses, belts, connectors and other emission-related assemblies.
Where a warrantable condition exists, aprilia will repair your vehicle at no cost to you, including diagnosis, parts and labor.
-!.5&!#452%2 3 7!22!.49 #/6%2!'%
Class I vehicles (50-169 cm#): for a period of use of five (5) years or 12,000 kilometers (7,456 miles), whichever first occurs.
Class II vehicles (170 to 279 cm#): for a period of use of five (5) years or 18,000 kilometers (11,185 miles), whichever first occurs.
Class III vehicles (280 cm# and larger): for a period of use of five (5) years or 30,000 kilometers (18,641 miles), whichever first occurs.
If an emission-related part on your vehicle is defective, the part will be repaired or replaced by aprilia. This is your emission control system DEFECTS WARRANTY.
/7.%2 3 7!22!.49 2%30/.3)"),)4)%3
–As the vehicle owner, you are responsible for the performance of the required maintenance listed in your owner's manual. aprilia recommends that you retain all receipts covering maintenance on your vehicle, but aprilia cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.
–You are responsible for presenting your vehicles to an aprilia dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.
–As the vehicle owner, you should be aware that aprilia may deny your warranty coverage if your vehicle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.
If you have any questions regarding your warranty rights and resposibilities, you should contact aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy tel. +39 - 041 58 29 111, fax +39 - 041 44 10 54, or the California Air Resources Board at P.O. Box 8001, 9528 Telstar Avenue, El Monte, CA 91734-8001.
use and maintenance Rally 50 - 11
APRILIA S P A ,)-)4%$ 7!22!.49 /. %-)33)/. #/.42/, 3934%-
aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy (hereinafter aprilia) warrants that each new 1999 and later aprilia motorcycle, that includes as standard equipment a headlight, taillight and stoplight, and is street legal:
A.is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and
B.is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency of the California Air Resources Board for a period of use, depending on the engine displacement, of 12,000 kilometers (7,456 miles), if the motorcycle’s engine displacement is less than 170 cubic centimeters: of 18,000 kilometers (11,185 miles), if the motorcycle’s engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 30,000 kilometers (18,641 miles), if the motorcycle’s engine displacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initial retail delivery, whichever first occurs.
I.COVERAGE. Warranty defects shall be remedied during customary business hours at any authorized aprilia motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Any part or parts replaced under this warranty shall become the property of aprilia.
In the State of California only, emission related warranted parts are specifically defined by the state’s Emission Warranty Parts List. These warranted parts are: carburetor and internal parts; intake manifold; fuel tank; fuel injection system; spark advance mechanism; crankcase breather; air cutoff valves; fuel tank cap for evaporative emission controlled motorcycles; oil filter cap; pressure control valve; fuel/vapor separator; canister; igniters; breaker governors; ignition coils; ignition wires; ignition points; condensers, and spark plugs if failure occurs prior to the first scheduled replacement; and hoses, clamps, fittings and tubing used directly in these parts. Since emission related parts may vary from model to model, certain models may not contain all of these parts and certain models may contain functionally equivalent parts.
In the State of California only, Emission Control System emergency repairs, as provided for in the California Administrative Code, may be performed by other than an authorized aprilia dealer. An emergency situation occurs when an authorized aprilia dealer is not reasonably available, a part is not available within 30 days, or a repair is not complete within 30 days. Any replacement part can be used in an emergency repair. aprilia will reimburse the owner for the expenses, including diagnosis, not to exceed aprilia’s suggested retail price for all warranted parts replaced and labor charges based on aprilia’s recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.
12 use and maintenance Rally 50 -
II. LIMITATIONS. This Emission Control System warranty shall not cover any of the following:
A.Repair or replacement required as a result of
(1)accident,
(2)misuse,
(3)repairs improperly performed or replacements improperly installed,
(4)use of replacement parts or accessories not conforming to aprilia
specifications which adversely affect performance and/or
(5)use in competitive racing or related events.
B.Inspections, replacement of parts and other services and adjustments required for required maintenance.
C.Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined.
III. LIMITED LIABILITY
A.The liability of aprilia under this Emission Control System Warranty is limited solely to the remectying of defects in material of workmanship by an authorized aprilia motorcycle dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the aprilia dealer.
aprilia SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE aprilia MOTORCYCLE FOR ANY PURPOSE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
B.NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY aprilia EXCEPT AS SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEM WARRANTY, IMPLIED BY LAW, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY, THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
C.No dealer is authorized to modify this aprilia Limited Emission Control System Warranty.
use and maintenance Rally 50 - 13
IV. LEGAL RIGHTS. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.
V. THIS WARRANTY IS IN ADDITION TO THE APRILIA LIMITED MOTORCYCLE WARRANTY.
VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, aprilia is not liable for these parts. The owner is responsible for the perfomance of all required maintenace. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser.
14 use and maintenance Rally 50 -
'%.%2!, ).3425#4)/.3
The operations preceded by this symbol must be repeated also on
the opposite side of the vehicle.
If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.
The terms “right” and “left” are referred to the rider seated on the vehicle in the normal riding position.
NOTE Soon after purchasing the vehicle, write down the identification data provided in the SPARE PARTS IDENTIFICATION LABEL in the table below. This label is positioned on the right beam of the frame; to be able to read it, remove the inspection cover, see p. 72 (REMOVING THE INSPECTION COVER).
These data indicate:
–YEAR = year of manufacture (Y, 1, 2, …);
–I.M. = modification code (A, B, C, …);
–COUNTRY CODE = country of homologation (I, UK, A, …).
and are to be supplied to the Local aprilia Dealer as reference data for the purchase of spare parts or specific accessories of the model you have acquired.
In this manual the various versions are indicated by the following symbols:
m optional
t drum brake version
VERSION: |
|
I Italy |
S Singapore |
U United Kingdom s Slovenia |
|
a Austria |
i Israel |
p Portugal |
¬ South Korea |
F Finland |
M Malaysia |
B Belgium |
c Chile |
d Germany |
H Croatia |
f France |
A Australia |
E Spain |
United States |
u of America |
|
G Greece |
Ä Brazil |
O Holland |
R South Africa |
Y Switzerland |
n New Zealand |
D Denmark |
C Canada |
J Japan |
|
use and maintenance Rally 50 - 15
4!",% /& #/.4%.43 |
|
FOREWORD ............................................................. |
2 |
INTRODUCTION ....................................................... |
2 |
SAFETY WARNINGS ................................................ |
3 |
GENERAL SAFETY RULES ..................................... |
3 |
CARBON MONOXIDE .......................................... |
3 |
GASOLINE ............................................................ |
3 |
HOT COMPONENTS ............................................ |
3 |
USED ENGINE OIL ............................................... |
4 |
BRAKE FLUID ....................................................... |
4 |
COOLANT ............................................................. |
4 |
BATTERY HYDROGEN GAS |
|
AND ELECTROLYTE ............................................ |
4 |
WARNINGS - PRECAUTIONS - |
|
GENERAL ADVICE ................................................... |
5 |
REPORTING OF DEFECTS |
|
THAT AFFECT SAFETY ....................................... |
5 |
ROAD REGULATIONS |
|
AND USE OF THE VEHICLE ................................ |
5 |
NOISE EMISSION WARRANTY ........................... |
5 |
INFORMATION ON THE NOISE AND EXHAUST |
|
GAS EMISSION CONTROL SYSTEM .................. |
5 |
TAMPERING WARNING ....................................... |
6 |
VEHICLE IDENTIFICATION NUMBER (V.I.N.) |
|
(FRAME NUMBER) ............................................... |
7 |
INFORMATION CONTAINED IN THE |
|
VEHICLE IDENTIFICATION NUMBER ................. |
7 |
POSITION OF THE |
|
WARNING ADHESIVE LABELS ........................... |
8 |
aprilia s.p.a. EMISSION CONTROL |
|
SYSTEM WARRANTY STATEMENT ................. |
11 |
MANUFACTURER’S |
|
WARRANTY COVERAGE .................................. |
11 |
OWNER’S WARRANTY RESPONSIBILITIES .... |
11 |
aprilia s.p.a. LIMITED WARRANTY ON EMISSION |
|
CONTROL SYSTEM ........................................... |
12 |
GENERAL INSTRUCTIONS ................................... |
15 |
TABLE OF CONTENTS ...................................... |
16 |
BASIC SAFETY RULES ...................................... |
18 |
CLOTHING .......................................................... |
23 |
ACCESSORIES .................................................. |
24 |
LOAD ................................................................... |
24 |
ARRANGEMENT OF THE MAIN ELEMENTS ....... |
26 |
ARRANGEMENT OF THE |
|
INSTRUMENTS/CONTROLS .................................. |
28 |
INSTRUMENTS AND INDICATORS ....................... |
28 |
INSTRUMENTS AND INDICATORS TABLE ...... |
29 |
CONTROLS ............................................................. |
30 |
CONTROLS AT THE LEFT HAND GRIP ............ |
30 |
CONTROLS AT THE RIGHT HAND GRIP .......... |
31 |
IGNITION SWITCH ............................................. |
32 |
STEERING LOCK ............................................... |
32 |
AUXILIARY EQUIPMENT ....................................... |
33 |
UNLOCKING / LOCKING THE SADDLE ............ |
33 |
CRASH HELMET / GLOVE COMPARTMENT .... |
33 |
ANTI-THEFT HOOK ............................................ |
33 |
BATTERY / TOOL KIT COMPARTMENT ........... |
34 |
BAG HOOK ......................................................... |
34 |
REAR MUDGUARD EXTENSION ....................... |
34 |
MAIN COMPONENTS ............................................. |
35 |
FUEL ................................................................... |
35 |
LUBRICANTS ...................................................... |
36 |
BRAKES .............................................................. |
37 |
DISC BRAKES .................................................... |
38 |
REAR DRUM BRAKE 3................................... |
38 |
FRONT AND REAR BRAKE ............................... |
40 |
TIRES .................................................................. |
42 |
AUTOMATIC LIGHTS ON ................................... |
43 |
EXHAUST SILENCER ......................................... |
43 |
INSTRUCTIONS FOR USE ..................................... |
44 |
PRELIMINARY CHECKING OPERATIONS ........ |
45 |
STARTING .......................................................... |
46 |
RIDING ................................................................ |
48 |
RUNNING-IN ....................................................... |
50 |
STOPPING .......................................................... |
50 |
PARKING ............................................................ |
51 |
PLACING THE VEHICLE ON THE STAND ........ |
51 |
SUGGESTIONS TO PREVENT THEFT .............. |
52 |
MAINTENANCE ...................................................... |
53 |
REGULAR SERVICE INTERVALS CHART ........ |
54 |
MAINTENANCE RECORD .................................. |
56 |
IDENTIFICATION DATA ..................................... |
60 |
AIR CLEANER ..................................................... |
61 |
FRONT WHEEL .................................................. |
62 |
REAR WHEEL ..................................................... |
64 |
REMOVING THE REAR BRAKE CALIPER ........ |
65 |
CHECKING THE BRAKE PAD WEAR ................ |
66 |
CHECKING THE SHOE WEAR 3 ................... |
67 |
CHECKING THE STEERING .............................. |
68 |
CHECKING THE SWINGING ARM PIVOT |
........ 68 |
CHECKING THE STAND ................................... |
69 |
CHECKING THE SWITCHES ............................. |
70 |
REMOVING THE REAR-VIEW MIRRORS ......... |
70 |
REMOVING THE EXHAUST SILENCER ........... |
71 |
REMOVING THE FRONT |
|
HANDLEBAR COVER ........................................ |
72 |
REMOVING THE INSPECTION COVER ........... |
72 |
REMOVING THE FRONT INNER SHIELD ........ |
73 |
IDLING ADJUSTMENT ....................................... |
74 |
ADJUSTING THE THROTTLE CONTROL ......... |
75 |
SPARK PLUG ..................................................... |
76 |
BATTERY ........................................................... |
77 |
BATTERY STORAGE ......................................... |
78 |
CHECKING AND CLEANING THE TERMINALS 78 |
|
REMOVING THE BATTERY .............................. |
78 |
CHECKING THE ELECTROLYTE LEVEL ......... |
79 |
RECHARGING THE BATTERY .......................... |
79 |
INSTALLING THE BATTERY ............................. |
79 |
CHANGING FUSES ........................................... |
80 |
ADJUSTING |
|
THE HEADLIGHT BEAM VERTICALLY ............. |
81 |
ADJUSTING |
|
THE HEADLIGHT BEAM HORIZONTALLY ....... |
82 |
BULBS ................................................................ |
83 |
CHANGING THE HEADLIGHT BULBS .............. |
84 |
CHANGING THE FRONT AND REAR |
|
DIRECTION INDICATOR BULBS ...................... |
84 |
CHANGING THE DASHBOARD BULBS ............ |
85 |
CHANGING THE REAR LIGHT BULB ............... |
86 |
CHANGING THE LICENSE PLATE BULB ......... |
86 |
TRANSPORT .......................................................... |
87 |
DRAINING THE FUEL TANK ............................. |
87 |
CLEANING ............................................................. |
89 |
LONG PERIODS OF INACTIVITY ...................... |
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TECHNICAL DATA ................................................ |
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LUBRICANT CHART .......................................... |
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Importers ........................................................ |
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WIRING DIAGRAM - Rally 50 - ..................... |
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WIRING DIAGRAM KEY - Rally 50 - ............. |
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16 use and maintenance Rally 50 -
safe drive
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The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your vehicle.
Two wheeled vehicles obviously do not provide some of the protection provided by automobiles, therefore it is essential that you wear appropriate protective clothing. Especially, never operate your vehicle without wearing your helmet, gloves, eye protection, a heavy jacket, sturdy footwear, and sturdy full length pants.
However, do not assume that even the best clothing and helmet will protect you in the event of an upset or a crash with another vehicle. At best, this gear provides some protection from scrapes and scratches, but very little, if any, impact protection.
Be sure that you meet all the requirements prescribed by local law, including driver’s license, minimum age, training, insurance, taxes, vehicle registration, license plate, etc.
When you first receive your vehicle, practice by riding in areas where there is little traffic. Do not attempt to ride in heavy traffic until you are thoroughly experienced and riding your vehicle has become second nature to you.
Most states prohibit the operation of this size vehicle on freeways or expressways,
be sure that it is legal to use your vehicle before you take any particular road.
A new vehicle must be carefully broken in, see p. 50 (RUNNING-IN).
Before starting the engine, make sure that the brakes, clutch, transmission and throttle controls function properly and that the fuel and oil supply is adequate.
The exhaust system, brakes, and some other parts of the vehicle become very hot during operation. Do not touch any of these parts.
Some medicines or drugs, illegal or prescription, and alcohol significantly increase the risk of accidents. Do not ride while you are under the influence of alcohol or drugs, be they illicit or prescription. Make sure you are in good physical condition and not ill before riding your vehicle. Do not ride your vehicle when you are particularly tired
or fatigued. Alcohol, drugs and fatigue are leading causes of vehicle accidents.
Many accidents are caused by the rider’s inexperience and lack of training. Do not ride your vehicle until you have received training from a recognized training organization such as the Motorcycle Safety Foundation. Remember that riding a vehicle, though easy and fun, is quite different from driving a car. Do not assume that you can operate your vehicle safely just because you are a competent automobile driver.
Never lend your vehicle to others unless you are sure that they are competent and properly licensed vehicle operators.
18 use and maintenance Rally 50 -
Observe all rules of the road. Particularly pay attention to all warning, regulatory and informational signs.
Avoid showing off (i.e., popping wheelies). Especially observe speed limits, remember that road conditions change with the weather and wet and icy pavements are particularly dangerous for vehicles, especially if you are riding too fast. Remember that automobile drivers have a hard time seeing vehicles, so always give the automobile the right of way, even if it is legally yours.
Before changing lane, look over your shoulder to make sure that the way is clear. Do not rely exclusively on the rearview mirror: you may miscalculate the distance and speed of a vehicle, or you may even not see it at all.
Avoid obstacles that could damage the vehicle or make you lose control.
Do not tailgate, do not attempt to increase your gas mileage by following in the slip stream of cars or trucks in front of you.
In case of accident motorcycles, scooters and mopeds do not provide the same degree of protection ensured by automobiles. The legs, in particular, are exposed the risk of being injured. However, the additional installation of leg guards may actually increase the risk of injuries and their seriousness in case of accident.
Do not install leg guards available on the market of spare parts and accessories. Non-compliance with these instructions may result in serious injuries or even death.
Always ride with both hands on the handlebars and feet on the footrests.
Never shift gear without using the clutch, if the vehicle is so equipped. Do not operate the shift lever or the other controls suddenly or abruptly. Such misuse can damage the internal components of the vehicle and consequently cause seizure, loss of control, accidents and serious injuries or even death.
Remain in the seat when you are riding. Do not stand up or attempt to stretch while you are riding your vehicle. If you need to rest, pull over to the side of the road when it can be safely done.
use and maintenance Rally 50 - 19
It is very important to your safety that you give full attention to the riding task. Watch what you are doing, do not allow yourself to be distracted by other cars, people or things on the roadside, etc. Never smoke, eat, drink, read, etc. while riding your vehicle. If you must consult a map, pull over when it can be done safely.
COOLER |
OIL |
Use only the vehicle’s specific fuels and lubricants indicated in the “LUBRICANT CHART”; check the oil, fuel and coolant levels regularly.
If you and your vehicle are involved in an accident, insure that there has been no damage to the control levers, tubes, wires, braking system and other vital parts. If your vehicle is involved in an accident, take it immediately to your Local aprilia Dealer who has the equipment and knowledge to check for accidental damage which may compromise your safety.
Your aprilia dealer is ready and able to help you with any safety problems that you might have, but of course it is necessary for you to report any malfunctions to your mechanic in order for him to help you.
Do not use your vehicle if it is damaged. A damaged vehicle may become unstable or present other problems which can increase the risk of accident, and therefore of serious injury or even death.
20 use and maintenance Rally 50 -
ONLY ORIGINALS
A12 345
Do not attempt to modify the position, angle or color of your license plate. Do not cover it with even a clear plastic covering. Do not modify any of the safety equipment of your vehicle, especially such safety related items as directional indicators, rear view mirrors, lights or horns.
Any modification to your vehicle will invalidate the warranty.
Do not modify your engine in an attempt to increase the horsepower. This can result in irreparable damage to the engine, as well as degradation of the performance and handling of the vehicle which could lead to an upset, and serious injury or even death.
Have your vehicle repaired only with original parts, and use only original aprilia or aprilia approved accessories. The use of aftermarket accessories and parts can seriously compromise the safety of your vehicle as well as its performance and serviceability. Any modification which affects performance or safety voids your warranty completely.
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.
This vehicle was not designed to be equipped with a sidecar or to be used to tow trailers or other vehicles.
aprilia does not manufacture sidecars or trailers and therefore cannot predict the effects of such accessories on the manoeuvrability or stability of the vehicle: it can only warn that such effects may be negative and that any damage to the vehicle components caused by the use of such accessories will not be covered by the warranty.
use and maintenance Rally 50 - 21
Never race other vehicles with your vehicle.
Brake with both the front and rear brakes. The use of one brake only for sudden braking may cause the vehicle to skid or make the rider lose control of the vehicle itself.
When riding down a steep hill, use the engine as a brake by selecting the same gear, or a lower gear, than you would use to climb the hill. Use front and rear brakes sparingly.
Always ride at the appropriate speed and avoid unnecessary hard acceleration. This not only is safer, but also reduces fuel consumption and increases the life of the vehicle.
If you must ride your vehicle in rainy weather, or on loose surfaces, remember that traction is greatly reduced. Under these conditions, all handling of the vehicle must be done gradually and smoothly. Sudden acceleration, braking or turning may make you lose control of your vehicle. When traction is reduced, accelerate and slow using your vehicle’s engine braking insofar as possible. Avoid rapid, harsh application of the brakes.
Gradually open and close the throttle, to avoid spinning or skidding the rear wheel.
On rough road surfaces, slow down and ride with particular care.
Try to avoid wide open throttle accelerations, unless they are necessary for such things as passing.
Don’t allow your engine to “lug,” that is, run at too low an rpm. Shift down to a lower gear. Also, don’t over-rev the engine. Observe the redline on the tachometer.
Remember that excessively aggressive cornering can cause your vehicle’s tires to lose sideways traction, which can result in an upset and serious injury or even death.
22 use and maintenance Rally 50 -
Always observe posted and statutory speed limits, but do not assume that you can ride as fast as the speed limit under all road conditions. Slowing down a little can greatly increase your safety under all road conditions.
Do not ride your vehicle off road.
Do not tamper with the muffler system or the emissions control system of your vehicle. This is not only bad for the environment, it can subject you to serious penalties.
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Before riding your vehicle, ensure that your riding gear is in good condition. To be effective, your helmet must fit properly, and the visor or other eye protection must be clean.
Both research and experience have shown that drivers of other vehicles often do not see vehicles or riders. In order to make yourself more conspicuous to these drivers, wear bright reflective clothing, such as a reflective vest, or clothing with reflective sections sewn into the jacket, pants and gloves. Be particular aware of approaching automobiles and trucks that might be trying to turn left in front of you. Many vehicle accidents are caused by an opposing automobile driver making a left turn without warning in front of the vehicle.
Inevitably, the driver will look right at you, and yet swear that they did not see you before they turned directly into your path. Ride alert!
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.
Always wear your crash helmet. Many accidents are fatal because of injuries to the head.
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.
use and maintenance Rally 50 - 23
Do not carry sharp objects in your pockets that could be dangerous in case of an upset, for example, pens or mechanical pencils, etc. Also, make sure that your passengers follow this recommendation.
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The owner of the vehicle is responsible for the choice, installation and use of any accessory.
The installation of inappropriate accessories or the overloading of the vehicle may result in the instability of the vehicle itself and cause accidents with consequent risk of serious injuries or even death. Windshields could be particularly dangerous, as they can break and injure or cut the rider in case of accident. In case of doubts with regard to any accessory you would like to install or
any load you would like to carry, previously consult your Local aprilia Dealer.
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.
Big fairings and windshields installed on the vehicle may produce aerodynamic forces that will affect the stability of the vehicle during use, especially at high speeds.
Make sure that anything you carry on your vehicle is securely attached, and cannot come lose and jam the wheels, forks, etc. Do not install any electrical accessories, and do not modify the electrical system of your vehicle. Anything that could cause an electrical overload or other fault could cause the vehicle to suddenly stop, the lights to dim or quit, or the horn and other safety accessories not to work. Use only aprilia genuine accessories.
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Do not overload your vehicle. Attach luggage or packages as close as possible to the center of your vehicle and distribute the load from side to side as evenly as possible, to keep imbalance to a minimum. Remember that loads tend to loosen with riding, so frequently check the security of your load.
24 use and maintenance Rally 50 -
KG! |
Do not hang anything from your motorcycle handlebars, fenders, or forks, because this will upset the handling of your motorcycle, and could prevent you from avoiding an accident. Failure to heed this warning can lead to an upset with subsequent serious injury or even death.
Do not ride with your crash helmet hung from the strap because it could easily foul the wheels, fenders, or forks, causing an upset and subsequent serious injury or even death.
Carry a passenger only if your vehicle is equipped with passenger footpegs, handgrips for the passenger to hold on to, and a passenger seat.
When carrying a passenger, remember that your vehicle’s handling is degraded, that the brakes are less efficient, and the center of gravity is higher and further to the rear.
This makes it more likely that the front wheel will come up off the ground, especially on acceleration. Therefore, you should avoid hard acceleration and hard braking. Many accidents are caused by inexperienced riders carrying passengers. Remember that allowance must be made for the extra weight of the passenger for all driving maneuvers.
Avoid abrupt and excessive acceleration. Always slow down in time and calculate longer stopping and manoeuvring distances. Non-compliance with these instructions may lead to the overturning of the vehicle or to other accidents with consequent serious injuries or even death.
Never carry loosely packaged items, make sure that everything that you carry on your vehicle is carefully secured.
Do not carry packages which protrude from the luggage rack or which cover any of the signal lights, the headlight, or the horn.
Never carry animals or children on the glove compartment or on the luggage rack.
Never exceed the labeled maximum load for each saddlebag.
Overloading your vehicle seriously reduces its stability and maneuverability and can lead to an upset with subsequent serious injury or death.
use and maintenance Rally 50 - 25
!22!.'%-%.4 /& 4(% -!). %,%-%.43
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Horn. |
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Air cleaner. |
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Fuel tank. |
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Fuse carrier. |
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Fuel filler cap. |
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Battery. |
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Saddle lock. |
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Center stand. |
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Kick starter. |
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26 use and maintenance Rally 50 -
+%9
1)2 stroke oil tank cap.
2)2 stroke oil tank.
3)Ignition switch/steering lock.
4)Bag hook.
5)Battery/tool kit compartment cover.
6)Inspection cover.
7)Anti-theft hook (for the aprilia “BodyGuard” armored cable m).
use and maintenance Rally 50 - 27
!22!.'%-%.4 /& 4(% ).3425-%.43 #/.42/,3 ).3425-%.43 !.$ ).$)#!4/23
+%9
1)Electrical controls on the left side of the handlebar
2)Cold start lever (e)
3)Rear brake lever
4)Left rear-view mirror
5)Instruments and indicators
6)Right rear-view mirror
7)Front brake lever
8)Throttle grip
9)Electrical controls on the right side of the handlebar
10)Ignition switch/steering lock (n - m - s)
11)Red 2 stroke oil reserve warning light (j)
12)Green left direction indicator warning light (c)
13)Total miles odometer
14)Speedometer
15)Fuel level indicator (g)
16)Green right direction indicator warning light (c)
17)Blue high beam warning light (a)
18)Amber low fuel warning light (g)
28 use and maintenance Rally 50 -
).3425-%.43 !.$ ).$)#!4/23 4!",%
Description |
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Function |
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Directional indicator |
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Blinks when the right (or the left) direction indicator is on. |
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High beam indicator |
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Comes on when the headlight is in “high beam” position or when the high beam signalling is |
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operated. |
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Low fuel warning light |
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It comes on when the quantity of fuel left in the tank is about 0.71 US gal (1.5 L ). |
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Fuel level indicator |
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It indicates the approximate fuel level in the tank. |
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It comes on when the ignition switch is turned to the “n” (ON) and the starter button “r“ is |
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depressed. |
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If the light does not illuminate when the starter button is depressed, this indicates that the |
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warning system bulb is burned out, and must be replaced before riding. |
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2 stroke oil reserve |
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The light goes out after the engine starts, as long as there is sufficient 2 stroke oil in the 2 |
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stroke oil tank. |
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warning light |
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If the warning light comes on and does not go out after the |
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aCAUTION |
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starter button “r” has been released, or if it comes on dur- |
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ing normal riding, this indicates that the 2 stroke oil reserve is being used. Immedi- |
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ately top up the 2 stroke oil tank, see p. 36 (2 STROKE OIL TANK). Failure to heed this |
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warning can lead to engine seizure, upset, and serious injury or even death. |
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Odometer |
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Indicates the total number of miles that the vehicle has traveled since new. |
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Speedometer |
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Indicates road speed. |
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use and maintenance Rally 50 - 29
#/.42/,3
#/.42/,3 !4 4(% ,%&4 (!.$ '2)0
NOTE The electrical components function only when the ignition switch (A) is in the “n” (ON) position.
The lights are illuminated only when the engine is running.
1) HORN PUSH BUTTON ( f)
The horn is activated when the push button is pressed.
2) 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.
3) DIMMER SWITCH ( b - a)
When the lever is in the position indicated by the “b”, the parking lights, dashboard light and low beam are on.
When the lever is moved to the “a” , the high beam is illuminated, the dashboard and parking lights remain on.
4) COLD START LEVER (e)
Operate the cold start (choke) by rotating the lever downwards.
To disengage the cold start, return the lever to its initial position.
30 use and maintenance Rally 50 -
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