Aprilia RS50 Users Manual - English 2004

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2 use and maintenance RS 50

2004 aprilia s.p.a. - Noale (VE)

First edition: january 2004

Reprint:

Producido e impreso por:DECA s.r.l.Via Risorgimento, 23/1 - Lugo (RA) - ItaliaTel. +39 - 0545 35235Fax +39 - 0545 32844E-mail: [email protected]

por cuenta de:aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - ItalyTel. +39 - (0)41 58 29 111Fax +39 - (0)41 44 10 54www.aprilia.com

SAFETY WARNINGS

The following precautionary warnings areused throughout this manual in order toconvey the following messages:

Safety warning. When you find thissymbol on the vehicle or in the

manual, be careful to the potential riskof personal injury. Non-compliance withthe indications given in the messagespreceded by this symbol may result in

grave risks for your and other people'ssafety and for the vehicle!

WARNINGIndicates a potential hazard which mayresult in serious injury or even death.

CAUTIONIndicates a potential hazard which mayresult in minor personal injury or dam-age to the vehicle.

NOTEThe word NOTEin this manualprecedes important information or instruc-tions.

INFORMATION

The operations preceded by thissymbol must be repeated on the

opposite side of the vehicle.

If not expressly indicated otherwise, for thereassembly of the units repeat the disas-sembly operations in reverse order.

The terms rightand leftare referred tothe rider seated on the vehicle in the nor-mal riding position.

Any mention to the use of the vehicle withpassenger is to be intended as referredonly to the countries where this is allowed.

WARNINGS - PRECAUTIONS -

GENERAL ADVICE

Before starting the engine, carefully readthis manual and in particular the chaptersWARNINGS - PRECAUTIONS - GENER-AL ADVICEand SAFE DRIVE.

Your and other peoples safety depends

not only on your quickness of reflexes andon your agility, but also on what you knowabout the vehicle, on its efficiency and onyour knowledge of the basic information forRIDING SAFELY. Therefore, get a thor-ough knowledge of the vehicle, in such away as to be able to drive in the traffic safe-ly.


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3use and maintenance RS 50

NOTEThis manual must be consideredas an integral part of the vehicle and mustalways accompany it, even in case of re-sale.

apriliahas carried out this manual with themaximum attention, in order to supply theuser with correct and updated information.However, since apriliaconstantly im-proves the design of its products, theremay be slight discrepancies between thecharacteristics of your vehicle and thosedescribed in this manual.

For any clarification concerning the infor-mation contained in this manual, do nothesitate to contact your aprilia OfficialDealer.

For control and repair operations not ex-pressly described in this publication, for thepurchase of apriliagenuine spare parts,

accessories and other products, as well asfor specific advice, contact exclusivelyapriliaOfficial Dealers and Service Cent-ers, which guarantee prompt and accurateassistance.

Thank you for choosing aprilia. We wishyou a nice ride.

All rights as to electronic storage, repro-duction and total or partial adaptation, withany means, are reserved for all Countries.

NOTE In some countries the antipollu-tion and noise regulations in force requireperiodical inspections.

The user of the vehicle in these countriesmust:

contact an apriliaOfficial Dealer to havethe non-homologated components re-placed with others homologated for use in

the country in question; carry out the required periodical inspec-

tions.

NOTE Soon after purchasing the vehi-cle, write down the identification data indi-cated on the SPARE PARTS IDENTIFICA-TION LABEL in the table here below. The

label is positioned under the rider saddle;to read it, it is necessary to remove the rid-er saddle, see p. 52 (REMOVING THERIDER SADDLE).

These data indicate:

YEAR = year of manufacture (Y, 1, 2, ...); I.M. = modification code (A, B, C, ...); COUNTRY CODES = homologation

country (I, UK, A, ...).

and are to be supplied to the apriliaOffi-

cial Dealer as reference data for the pur-chase of spare parts or specific accesso-ries of the model you have acquired.

In this manual the various versions are in-dicated by the following symbols:

optional

catalytic version

VERSION:

Italy Singapore

United Kingdom Slovenia

Austria Israel

Portugal South Korea

Finland Malaysia

Belgium Chile

Germany Croatia

France Australia

Spain

United States

of America

Greece Brazil

Holland South Africa

Switzerland New Zealand

Denmark Canada

Japan


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safe drive


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BASIC SAFETY RULES

To drive the vehicle it is necessary to be inpossession of all the requirements pre-

scribed by law (driving licence, minimumage, psychophysical ability, insurance,state taxes, vehicle registration, numberplate, etc.).

Gradually get to know the vehicle by driv-ing it first in areas with low traffic and/or pri-vate areas.

The use of medicins, alcohol and drugs orpsychotropic substances notably increasesthe risk of accidents.Be sure that you are in good psychophysi-

cal conditions and fit for driving and payparticular attention to physical wearinessand drowsiness.

Most road accidents are caused by thedrivers lack of experience.

NEVER lend the vehicle to beginners and,

in any case, make sure that the driver hasall the requirements for driving.


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Rigorously observe all road signs and na-tional and local road regulations.Avoid abrupt movements that can be dan-gerous for yourself and other people (for

example: rearing up on the back wheel,speeding, etc.), and give due considerationto the road surface, visibility and other driv-ing conditions.

Avoid obstacles that could damage the ve-hicle or make you lose control.

Avoid riding in the slipstream created by

preceding vehicles in order to increaseyour speed.

WARNINGAlways drive with both hands on thehandlebars and both feet on the foot-rests (or on the riders footboards), in

the correct driving posture.Avoid standing up or stretching yourlimbs while driving.


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COOLEROIL

The driver should pay attention and avoiddistractions caused by people, things andmovements (never smoke, eat, drink, read,etc.) while driving.

Use only the vehicles specific fuels and lu-bricants indicated in the LUBRICANTCHART; check the oil, fuel and coolantlevels regularly.

If the vehicle has been involved in an acci-dent, make sure that no damage has oc-curred to the control levers, pipes, wires,braking system and vital parts.

If necessary, have the vehicle inspected byan apriliaOfficial Dealer, who should care-fully check the frame, handlebars, suspen-sions, safety parts and all the devices thatyou cannot check by yourself.

Always remember to report any malfunc-tion to the technicians to help them in their

work.

Never use the vehicle when the amount ofdamage it has suffered endangers yoursafety.


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ONLY ORIGINALS

Never change the position, inclination orcolour of: number plate, direction indica-tors, lights and horns.

Any modification of the vehicle will resultin the invalidity of the guarantee.

Any modification of the engine or of othermembers which is aimed at increasing thespeed or the power of the vehicle is prohib-ited by the law; in fact, any modification re-sulting in an increase of the maximumspeed or of the engine displacement wouldchange the scooter into a motorcycle,which implies the following obligations forthe owner: new homologation; new registration; appropriate driving license.

Further, said modifications cause the lossof the insurance cover, since insurancepolicies expressly prohibit to make techni-cal changes aimed at increasing the vehi-

cle performance levels.

For the reasons stated above, the failure tocomply with the tampering prohibition ispunished by law with apposite sanctions(including the confiscation of the vehicle),which, according to the case, can be com-bined with the sanctions provided for not

using the crash helmet and/or the numberplate, for the violation of fiscal obligations(ownership tax) and with penal sanctionsprovided for using the vehicle without driv-ing license.

Never race with other vehicles.

Avoid off-road driving.

CLOTHING

Before starting, always wear a correctlyfastened crash helmet. Make sure that it is

homologated, in good shape, of the rightsize and that the visor is clean.

Wear protective clothing, preferably in lightand/or reflecting colours. In this way youwill make yourself more visible to the otherdrivers, thus notably reducing the risk ofbeing knocked down, and you will be more

protected in case of fall.This clothing should be very tight-fittingand fastened at the wrists and ankles.Strings, belts and ties should not be hang-ing loose; prevent these and other objectsfrom interfering with driving by getting en-tangled with moving parts or driving mech-

anisms.

A12345


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Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in yourpockets (the same recommendations also

apply to passengers).

ACCESSORIES

The owner of the vehicle is responsible forthe choice, installation and use of any ac-

cessory.Avoid installing accessories that coverhorns or lights or that could impair theirfunctions, limit the suspension stroke andthe steering angle, hamper the operation ofthe controls and reduce the distance fromthe ground and the angle of inclination inturns.Avoid using accessories that hamper ac-cess to the controls, since this can prolongreaction times during an emergency.Large fairings and windscreens assembledon the vehicle can produce aerodynamicforces capable of compromising the stabili-ty of the vehicle while driving.

Make sure that the equipment is well fas-tened to the vehicle and not dangerousduring driving. Do not install electrical de-vices and do not modify those already ex-

isting to avoid electrical overloads, be-cause the vehicle could suddenly stop orthere could be a dangerous current short-age in the horn and in the lights. apriliarecommends the use of genuine accesso-ries (apriliagenuine accessories).

LOAD

Be careful and moderate when loadingyour luggage. Keep any luggage loaded asclose as possible to the centre of the vehi-cle and distribute the load uniformly onboth sides, in order to reduce imbalance tothe minimum. Furthermore, make sure thatthe load is firmly secured to the vehicle, es-pecially during long trips.


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KG!

Avoid hanging bulky, heavy and/or danger-ous objects on the handlebars, mudguardsand forks, because the vehicle might re-spond more slowly in turns and its ma-

noeuvrability could be unavoidably im-paired.

Do not place bags that are too bulky on thevehicle sides and do not ride with the crashhelmet hanging from its string, because itcould hit people or obstacles making youlose control of the vehicle.

Do not carry any bag if it is not tightly se-cured to the vehicle.

Do not carry bags which protrude too muchfrom the luggage rack or which cover thelights, horn or indicators.

Do not carry animals or children on theglove compartment or on the luggage rack.

Do not exceed the maximum load allowedfor each side-bag.

When the vehicle is overloaded, its stabilityand its manoeuvrability can be compro-mised.


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ARRANGEMENT OF THE MAIN ELEMENTS

KEY

1) Left rear-view mirror2) Radiator cap3) Radiator4) Fuel tank plug5) Spark plug

6) Fuel tap7) Battery

8) Fuse carrier9) Passenger left footrest

(snapping, closed/open)(in the countries where required)

10) Drive chain

11) Side stand (with automatic return)

12) Rider left footrest(with spring, always open)

13) Shifting lever14) Left fairing15) Horn


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KEY

1) Glove/tool kit compartment2) 2 stroke oil tank3) 2 stroke oil tank plug4) Rider saddle5) Saddle lock

6) Air cleaner7) Ignition switch/steering lock

8) Right rear-view mirror9) Front brake fluid tank

10) Dashboard11) Cold start lever12) Rear brake fluid tank

13) Rear brake pump14) Rear brake control lever

15) Rider right footrest(with spring, always open)

16) Passenger right footrest(snapping, closed/open)(in the countries where required)


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ARRANGEMENT OF THE INSTRUMENTS/CONTROLS

KEY

1) Ignition switch/steering lock (-- )2) Direction indicator switch ( )3) Horn push button ( )4) Dimmer switch (- )5) High beam signalling push button ( )

6) Clutch lever7) Instruments and indicators8) Front brake lever9) Throttle grip

10) Start push button ()11) Engine stop switch (-)

(in the countries where required)12) Cold start lever ()

INSTRUMENTS AND INDICATORS

KEY

1) Revolution counter2) Coolant temperature indicator ()3) Green right direction indicator warning light ( )4) Green neutral indicator warning light ()5) Red 2 stroke oil reserve warning light ( )

6) Blue high beam warning light (

)7) Green low beam warning light ()8) Green left direction indicator warning light ( )9) Partial kilometres odometer

10) Odometer trip control11) Total kilometres odometer12) Speedometer12) Speedometer - only km/h scale


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INSTRUMENTS AND INDICATORS TABLE

Description Function

Right direction indicator warning light () Blinks when the right direction indicator is on.

Left direction indicator warning light () Blinks when the left direction indicator is on.

High beam warning light () Comes on when the headlight is in high beamposition or when the high beam signalling is operated.

Low beam warning light () It comes on when the headlight is in low beam position.

Revolution counter (rpm) Indicates the number of revolutions of the engine per minute.

Coolant temperature indicator ()

It indicates the approximate temperature of the coolant in the engine.When the pointer starts moving beyond the minlevel, the temperature is sufficient for driving thevehicle.The normal running temperature range is indicated by the central area of the scale.If the pointer reaches the red area, stop the engine and check the coolant level, see p. 28 (COOLANT).

If the maximum allowed temperature is exceeded (red area max of thescale), the engine may be seriously damaged.

2 stroke oil reservewarning light ()

It comes on when the quantity of 2 stroke oil left in the tank is equal to 0.35 l.

If the warning light comes on, this means that the 2 stroke oil reserve isbeing used; in this case, provide for topping up, see p. 25 (2 STROKEOIL TANK).

Neutral indicator warning light () Comes on when the gear is in neutral.

Partial kilometres odometer It indicates the partial number of kilometres covered. To set it to zero, use the odometer trip control.

Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.

Total kilometres odometer It indicates the total number of kilometres covered.

Speedometer It indicates the driving speed.

CAUTION

CAUTION


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MAIN INDEPENDENT CONTROLS

NOTEThe electrical parts work only when the ignition switchis in position .

The lighting system works only when the engine is running.

CONTROLS ON THE LEFT PARTOF THE HANDLEBAR

1) HORN PUSH BUTTON ( )The horn is activated when the push button is pressed.

2) DIRECTION INDICATOR SWITCH ( )

To indicate the turn to the left, move the switch to the left; toindicate the turn to the right, move the switch to the right.To turn off the direction indicator, press the switch.

3) DIMMER SWITCH (- )When it is in position the parking lights, the dashboardlight and the low beam are always on.

When it is in position

, the high beam comes on.

NOTEThe lights can be switched off only by stopping theengine.

4) HIGH BEAM SIGNALLING PUSH BUTTON ()It makes it possible to use the high beam for signalling toforthcoming vehicles while overtaking and in case of periland/or emergency.

5) COLD START LEVER ()The starter for the cold start of the engine is operated by rotat-ing the lever "" downwards. To disconnect the starter, movethe lever "" to its initial position.


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CONTROLS ON THE RIGHT PARTOF THE HANDLEBAR

1) ENGINE STOP SWITCH (-)(in the countries where required)

CAUTIONDo not operate the engine stop switch - in runningconditions.

This is a safety or emergency switch. With the switch in posi-tion , it is possible to start the engine; the engine can bestopped by moving the switch to position .

CAUTIONWith stopped engine and ignition switch in position ,the battery may discharge.When the vehicle has come to rest, after stopping the en-gine, move the ignition switch to position .

2) START PUSH BUTTON ()

When the start push button is pressed, the starter makesthe engine run. For the starting, see p. 32 (STARTING).


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IGNITION SWITCH

The ignition switch (1) is positioned on theupper plate of the steering column.

NOTE The key operates the ignition

switch/steering lock, the saddle lock andthe fuel tank lock.Two keys are supplied together with thevehicle (one spare key).

STEERING LOCK

WARNINGNever turn the key to position inrunning conditions, in order to avoidlosing control of the vehicle.

OPERATION

To lock the steering:

Turn the handlebar completely leftwards(or rightwards).

Turn the key to position . Press the key and rotate it to position . Extract the key.

Position FunctionKey

removal

Steering

lock

The steer-ing is

locked.It is neitherpossible tostart theengine, norto switch onthe lights.

It is possi-ble to

remove thekey.

Neither theengine, northe lightscan beswitched on.

It is possi-ble toremove thekey.

The engine

and thelights can beswitched on.

It is not pos-

sible toremove thekey.


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AUXILIARY EQUIPMENT

GLOVE/TOOL KIT COMPARTMENT

The glove/tool kit compartment is posi-tioned under the rider saddle; to reach it:

Remove the rider saddle, see p. 52 (RE-MOVING THE RIDER SADDLE).

The tool kit (1) includes: 3 mm, 4 mm, , 5 mm allen spanners 10-11 mm double fork spanner 21-22 mm spark plug socket spanner Double-ended, cross-/cut headedscrew-

driver Bent pin for socket spanner Tool case

Max. allowed weight: 1.5 kg

REAR MUDGUARD EXTENSION(in the countries where required)

The extension of the rear mudguard (2) is

extremely useful when the road surface iswet, in fact it reduces the reach of the wa-ter spray caused by the rear wheel.

NOTE The rear mudguard extension (2)is supplied as standard component in thecountries where this is required for the ho-mologation.


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SPECIAL TOOLS

To perform some specific operations, it isadvisable to use the following specialtools (to be requested to an apriliaOfficialDealer):

Tool Operations Page

Support pins(1) for the rearsupport stand.

Positioning of the vehicleon the rear stand.

43

Rear support

stand (2)

Rear wheel disassembly.

Drive chain adjustment.

47

50

Front supportstand (3)

Front wheel disassembly.46


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MAIN COMPONENTS

FUEL

WARNINGThe fuel used for internal combustionengines is extremely inflammable andin particular conditions it can becomeexplosive. It is important to carry outthe refuelling and the maintenance op-erations in a well-ventilated area, withthe engine off. Do not smoke while refu-

elling or near fuel vapours, in any caseavoid any contact with naked flames,sparks and any other heat source toprevent the fuel from catching fire orfrom exploding. Further, prevent fuelfrom flowing out of the fuel filler, as itcould catch fire when getting in contactwith the red-hot surfaces of the engine.In case some fuel has accidentally beenspilt, make sure that the area has com-pletely dried and before starting the ve-hicle verify that there is no fuel insidethe fuel filler neck.Since petrol expands under the heat ofthe sun and due to the effects of sun ra-

diation, never fill the tank to the brim.Screw the plug up carefully after refuel-ling. Avoid any contact of the fuel withthe skin and the inhalation of vapours;do not swallow fuel or pour it from a re-ceptacle into another by means of atube.

DO NOT DISPOSE OF FUEL IN THE EN-VIRONMENT.

KEEP AWAY FROM CHILDREN.

Use only leaded or unleaded premiumgrade petrol (4 Stars ), min. O.N. 95

(N.O.R.M.) and 85 (N.O.M.M.).Use only unleaded petrol, inconformity with the DIN 51607 standard,min . O .N. 95 (N.O.R.M. ) and 85(N.O.M.M.).

FUEL TANK CAPACITY(reserve included): 13 l

TANK RESERVE: 2.6 l (mechanical re-serve)

To refuel, proceed as follows: Insert the key (1) in the tank plug lock

(2). Turn the key anticlockwise, pull and

open the fuel flap.

TRANSMISSION OIL

Check the transmission oil level every4000 km (2500 mi), see p. 44 (CHECK-ING THE TRANSMISSION OIL LEVELAND TOPPING UP).

Change the transmission oil after the first500 km (312 mi) and successively every8000 km (5000 mi), see p. 45 (CHANG-ING THE TRANSMISSION OIL).

NOTE Use high-quality 75W-90 oil, seep. 75 (LUBRICANT CHART).

CAUTIONThe oil can cause serious damage tothe skin if handled every day and forlong periods.Wash your hands carefully after usingthe oil.

Do not dispose of the oil in the environ-ment.Put it in a sealed container and take it tothe filling station where you usually buyit or to an oil salvage center.

In case any maintenance operation hasto be carried out, it is advisable to uselatex gloves.

DISC BRAKES


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BRAKE FLUID-recommendations

NOTE This vehicle is provided with frontand rear disc brakes, with separate hy-draulic circuits.

The following information refers to a singlebraking system, but is valid for both.

WARNINGSudden resistance or clearance prob-lems on the brake lever may be due totroubles in the hydraulic system.For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour apriliaOfficial Dealer.

WARNINGMake sure that the brake discs are nei-ther oily nor greasy, especially aftermaintenance or checking operations.Check that the brake cables are neithertwisted nor worn out.Prevent water or dust from accidentallygetting into the circuit.

In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.

If the brake fluid gets in contact with theskin or the eyes, it can cause serious ir-ritations.Carefully wash the parts of your bodythat get in contact with the liquid.Consult a doctor or an oculist if the liq-

uid gets in contact with your eyes.

Do not dispose of the brake fluid in theenvironment.


CAUTIONWhen using the brake fluid, take carenot to spill it on the plastic or paintedparts, since it can damage them.

DISC BRAKES

WARNINGThe brakes are the parts that most en-sure your safety and for this reason

they must always be perfectly working;check them before every trip.

The brake fluid must be changed once ayear by an apriliaOfficial Dealer.

Use brake fluid of the type specified in

the lubricant chart, see p. 75 (LUBRI-CANT CHART).

This vehicle is provided with front and rearhydraulic disc brakes.When the disc pads wear out, the level ofthe fluid decreases to automatically com-pensate for their wear.

The front brake fluid tank is positioned onthe right part of the handlebar, near thefront brake lever coupling.

The rear brake fluid tank is positioned un-der the upper part of the fairing, on the

right side of the vehicle.

Periodically check the brake fluid level inthe tanks, see p. 23 (FRONT BRAKE),p. 24 (REAR BRAKE)and the wear of thepads, see p. 56 (CHECKING THE BRAKEPAD WEAR).

TOPPING UP D t h th MAX l l ith


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FRONT BRAKE

CHECKING

NOTE Position the vehicle on firm andflat ground.

Position the vehicle on the stand. Rotate the handlebar leftwards, so that

the fluid contained in the reservoir is par-allel to the reservoir edge (1).

Make sure that the brake fluid containedin the tank covers the glass gauge (2)

completely. If not, provide for topping up.

TOPPING UP

CAUTIONThe brake fluid may flow out of the res-ervoir. Do not operate the brake lever if

the screws (3) are loose or, most impor-tant, if the brake fluid tank cover hasbeen removed.

Unscrew the two screws (3). Remove the cover (4).

NOTE In order not to spill the brake fluidwhile topping up, keep the fluid in the reser-voir parallel to the reservoir rim.

WARNINGAvoid any prolonged exposure of thebrake fluid to the air.The brake fluid is hygroscopic and

when in contact with the air it absorbsits humidity.Leave the brake fluid tank open ONLYfor the time necessary for topping up.

Remove the gasket (5).

CAUTIONWhen topping up, never exceed the

MAX level.It is advisable to top up until reachingthe MAX level only with new pads.

When the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear.

Do not reach the MAX level with wornout pads, since this will cause a fluidoutflow when the pads are changed.

NOTE In order to reach the MAXlevel,

top up until covering the glass (2) com-pletely, with the brake fluid reservoir rimparallel to the ground.

Fill the tank with brake fluid, see p. 75(LUBRICANT CHART), until it covers theglass completely.

Put back the gasket (5) in its seat cor-rectly.

Put back the cover (4). Screw and tighten the two screws (3).

CAUTIONCheck the braking efficiency. If neces-sary, contact your apriliaOfficial Deal-

er.

In case of excessive stroke of the brakelever, of excessive elasticity or in casethere is air in the circuit, contact yourapriliaOfficial Dealer, since it may benecessary to bleed the system.

TOPPING UP Remove the gasket (3)


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REAR BRAKE

CHECKING


WARNINGDanger of fall or overturning.When the vehicle is straightened fromthe parking position to the driving posi-tion, the stand goes automatically up.

Keep the vehicle in vertical position, sothat the fluid contained in the tank (1) isparallel to the plug (2).

Make sure that the fluid level exceedsthe MINmark.

If the fluid does not reach the MINmark, provide for topping up.

TOPPING UP

CAUTIONThe brake fluid may flow out of the tank.Do not operate the rear brake lever if the

brake fluid tank plug is loose or hasbeen removed.

Unscrew and remove the plug (2).

WARNINGAvoid any prolonged exposure of the

brake fluid to the air.The brake fluid is hygroscopic andwhen in contact with the air it absorbsits humidity.Leave the brake fluid tank open ONLYfor the time necessary for topping up.

NOTE In order not to spill the brake fluidwhile topping up, keep the fluid in the tankparallel to the tank rim (in horizontal posi-tion).

Remove the gasket (3). By means of a syringe, top up the brake

fluid tank (1), see p. 75 (LUBRICANTCHART)until reaching the correct levelbetween the MINand MAXmarks.

CAUTIONIt is advisable to top up until reachingthe MAX level only with new pads.When the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear.Do not reach the MAX level with wornout pads, since this will cause a fluidoutflow when the pads are changed.

To reassemble the components, followthe reverse order.

WARNINGCheck the braking efficiency. If neces-sary, contact your apriliaOfficial Deal-er.

In case of excessive stroke of the brakelever, of excessive elasticity or in casethere is air in the circuit, contact your

apriliaOfficial Dealer, since it may benecessary to bleed the system.

2 STROKE OIL TANK


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2 STROKE OIL TANK

Top up the 2 stroke oil tank every 500 km(312 mi).

The vehicle is provided with a separatemixer that ensures the mixing of petroland oil for the engine lubrication, see p. 75(LUBRICANT CHART).

The 2 stroke oil reserve is indicated by thecoming on of the 2 stroke oil reserve warn-ing light positioned on the dashboard,see p. 14 (INSTRUMENTS AND INDICA-TORS).

CAUTIONThe use of the vehicle without 2 strokeoil causes serious damages to the en-gine.

If you run out of oil in the 2 stroke oil

tank or if the mixer oil pipe has been re-moved, contact an apriliaOfficial Deal-er, who will provide for bleeding thesystem.

This operation is indispensable, sincethe running of the engine with air in the

mixer oil system may result in seriousdamage to the engine.

To introduce the 2 stroke oil in the tank,proceed as follows: Remove the rider saddle, see p. 52 (RE-

MOVING THE RIDER SADDLE). Remove the plug (1).

TANK CAPACITY: 1.6 l

TANK RESERVE: 0.35 l

CAUTIONCarefully wash your hands after han-dling the oil.Do not dispose of the 2 stroke oil in the

environment.


ADJUSTING THE SHIFTING LEVER

It is possible to adjust the position of theshifting lever by means of the rod (2), pro-ceeding as follows:

Loosen the nuts (3, 4).

Rotate the rod and adjust the shifting le-ver height. Tighten the nuts (3, 4).

The gearshift lever pin is kept greasedthanks to the appropriate slot.


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ADJUSTING THE REAR BRAKE

The brake pedal is positioned ergonomical-ly during the assembly of the vehicle.If necessary, it is possible to adjust theheight of the brake pedal:

Loosen the lock nut (1). Unscrew the brake adjuster (2) completely. Screw the lock nut (3) completely on the

pump control rod (4). Screw the pump control rod (4) complete-

ly, then unscrew it by giving 3-4 turns. Screw the brake adjuster (2) until the

brake pedal (5) reaches the desiredheight.

Lock the brake adjuster (2) by means ofthe lock nut (1).

Unscrew the pump control rod (4) andbring it in contact with the pump piston.

Screw the rod in order to ensure a mini-mum clearance of 0.51 mm between

the pump control rod (4) and the pumppiston.

CAUTIONMake sure that there is a certain clear-ance between the brake adjuster andthe point of contact, to prevent thebrake from remaining operated and theconsequent untimely wear of the brak-

ing elements.

Clearance between brake adjuster andpoint of contact: 0.5 1 mm.

Lock the pump control rod by means ofthe lock nut (3).

WARNINGCheck the braking efficiency.If necessary, contact an apriliaOfficialDealer.

After the adjustment, make sure that the

wheel rotates freely with releasedbrake.

Minor adjustments can be carried out by


27/88


ADJUSTING THE CLUTCH

Adjust the clutch and if the engine stops ortends to advance when the clutch lever ispulled and the gears are engaged, or if theclutch slips causing a delay in the acceler-ation in comparison with the engine speed.

Minor adjustments can be carried out bymeans of the adjuster (1):

Withdraw the protection element (2). Loosen the nut (3) (by screwing it). Rotate the adjuster (1), until the idle

stroke at the end of the clutch lever isabout 1015 mm (see figure).

Tighten the nut (3) (by unscrewing it) andlock the adjuster (1).

Check the idle stroke at the end of theclutch lever.

Put back the protection element (2).

WARNINGIf it is not possible to obtain a correctadjustment or if the clutch does notfunction properly, contact your apriliaOfficial Dealer.

NOTE Make sure that the clutch cable isintact: the inner cable and outer sheat mustnot be worn or flattened at any point.

Periodically lubricate the clutch cablewith a suitable lubricant, see p. 75 (LU-BRICANT CHART),in order to avoid its

untimely wear and corrosion.


28/88

TYRES Change the tyre when it is worn out or


29/88


Otherwise:

Top up with coolant, see p. 75 (LUBRI-CANT CHART)until the coolant level ap-proximately reaches the diameter reduc-tion point (3). Do not exceed this level,otherwise the coolant will flow out while

the engine is running. Put back the filling plug (1).

CAUTIONIn case of excessive consumption ofcoolant and in case the tank remainsempty, make sure that there are no

leaks in the circuit.Have it repaired by an apriliaOfficialDealer.

This vehicle is provided with tubeless tyres.

WARNINGPeriodically check the tyre inflation

pressure at room temperature, see p. 72(TECHNICAL DATA).

If the tyres are hot, the measurement isnot correct.Carry out the measurement especiallybefore and after long rides.

If the inflation pressure is too high, theground unevenness cannot be damp-ened and is therefore transmitted to thehandlebar, thus compromising the driv-ing comfort and reducing the road hold-ing during turns.

If, on the contrary, the inflation pressureis too low, the tyre sides are undergreater stress and the tyre itself mayslip on the rim or it may become loose,with consequent loss of control of thevehicle.

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 thetyres, since tyres in bad conditions canimpair both the grip and the controlla-bility of the vehicle.

g yin case of puncture on the tread side, ifthe puncture is larger than 5 mm.After repairing a tyre, have the wheelsbalanced. Use only tyres in the size

suggested by aprilia, see p. 72 (TECHNI-CAL DATA).

Make sure that the tyres always havetheir valve sealing caps on, to preventthem from suddenly going flat.

Change, repair, maintenance and bal-ancing operations are very important

and should be carried out by qualifiedtechnicians with appropriate tools.

For this reason, it is advisable to havethe above mentioned operations carriedout by an apriliaOfficial Dealer or by aqualified tyre repairer.

If the tyres are new, they may still becovered with a slippery film: drive care-fully for the first miles. Do not oil thetyres with unsuitable fluids.If the tyres are old, even if not complete-ly worn out, they may become hard andmay not ensure good road holding.In this case, replace them.

MINIMUM TREAD DEPTH LIMIT

front: ............................................... 2 mmrear: ................................................ 2 mm

CATALYTIC SILENCER EXHAUST SILENCER


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WARNINGAvoid parking the vehicle catalytic ver-sion near dry brush wood or in places

easily accessible to children, as the cat-alytic silencer becomes extremely hotduring use; be very careful and avoidany kind of contact before it has com-pletely cooled down.

The catalytic vehicle is fitted with a silenc-er with metal catalytic converter of theplatinum-rhodium bivalenttype.

This device provides for the oxidation ofthe CO (carbon monoxide) and of the HC(unburned hydrocarbons) contained in theexhaust gases, changing them into carbondioxide and steam, respectively.

CAUTIONDo not use leaded petrol, since it caus-es the destruction of the catalytic con-verter.

WARNINGTampering with noise control systemprohibited.

Owners are warned that the law may pro-hibit:

The removal or rendering inoperative byany person other than for purposes ofmaintenance, repair or replacement, ofany device or element of design incorpo-

rated into any new vehicle for the pur-pose of noise control prior to its sale ordelivery to the ultimate purchaser orwhile it is in use; and

The use of the vehicle after such deviceor element of design has been removedor rendered inoperative by any person.

Check the exhaust silencer and the silenc-er pipes, making sure that there are nei-ther signs of rust, nor holes and that theexhaust system can work effectively.

If the noise produced by the exhaust sys-tem increases, immediately contact yourapriliaOfficial Dealer.

INSTRUCTIONS FOR USE PRELIMINARY CHECKING OPERATIONS


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WARNINGBefore departure, always carry out a

preliminary checking of the vehicle tomake sure that it functions correctlyand safely, see the following table (PRE-LIMINARY CHECKING OPERATIONS).The non-performance of these checkingoperations can cause severe personalinjuries or damages to the vehicle.

Do not hesitate to consult your apriliaOfficial Dealer in case there is some-thing you do not understand about thefunctioning of some controls or in caseyou suspect or discover some irregular-ities.It does not take long to carry out a

check-up and this operation ensuresyou much more safety.

Component Check Page

Front and rear discbrakes

Check the functioning, the idle stroke of the controllevers, the fluid level and make sure there are no leaks.Check the wear of the pads. If necessary, top up the

brake fluid tank.

22, 2324, 56

Accelerator Make sure that it works smoothly and that it is possibleto open and close it completely, in all steering posi-tions. If necessary, adjust and/or lubricate it.

57

2 stroke oil/transmission oil

Check and/or top up if necessary. 25, 44, 45

Wheel/tyres Check the tyre surface, the inflation pressure, wear

and tear and any damage.29

Brake levers Make sure that they work smoothly. If necessary, lubri-cate the articulations and adjust the stroke.

26

Steering Make sure that the steering rotates smoothly, withoutany clearance or slackening.

Clutch The idle stroke at the end of the clutch lever must beabout 1015 mm; the clutch must operate without jerk-ing and/or slipping.

27

Side stand Make sure that it works smoothly and that the springtension brings it back to its normal position.If necessary, lubricate joints and hinges.

64

Fastening elements Make sure that the fastening elements are not loose.If necessary, adjust or tighten them.

Drive chain Check the slack. 50, 51

Fuel tank Check the fuel level and top up, if necessary. Makesure there are no leaks or air bubbles in the circuit.

21, 53, 69

Coolant With cold engine, visually check if the coolant reachesthe prescribed level.

28, 29

Lights, warning lights,horn and electric

devices

Check the proper functioning of the acoustic and visualdevices.

Change the bulbs or intervene in case of failure.

5968


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STARTING

WARNINGExhaust gases contain carbon monox-ide, which is extremely noxious if in-haled.

Avoid starting the engine in closed orbadly-ventilated rooms.The non-observance of this warningmay cause loss of consciousness oreven lead to death by asphyxia.


Get on the vehicle. Move the fuel tap lever (1) to position

ON.

Rotate the key (2) and move the ignitionswitch to position .

Lock at least one wheel, by pulling abrake lever.

Position the shifting lever in neutral(green warning light on).

Move the engine stop switch (3) to posi-tion , (in the countries where re-quired).

Make sure that the dimmer switch (5) isin position .

If the vehicle is started with cold engine,rotate the cold start lever(6) downwards.

NOTETo avoid excessive consumptionof the battery, do not keep the start pushbutton pressed for more than fifteenseconds. If the engine does not start in thislapse of time, wait ten seconds and pressthe start push button again.

Press the start push button (7) with-out accelerating and release it as soon

as the engine starts.

CAUTIONIf the 2 stroke oil warning light comes on, this means that the 2 strokeoil reserve is being used; in this case,

provide for topping up, see p. 25 (2STROKE OIL TANK).

CAUTIONAvoid pressing the start push button (7) when the engine is running,since you may damage the starter.

STARTING WITH FLOODED ENGINE If the engine starts.


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Keep at least one brake lever pulled anddo not accelerate until you start.

CAUTIONNever leave abruptly with cold engine.To reduce the emission of polluting

substances and the consumption of fu-el, warm the engine up by proceeding atlow speed for the first miles.

With warm engine:

Rotate the cold start lever (6) up-wards after the engine has warmed up.

If the starting is not carried out properly or ifthere is too much fuel in the intake ductsand in the carburettor, the engine may getflooded.

To clean a flooded engine:

Press the start push button (7) for afew seconds (letting the engine spinover) with completely (8) open throttle(Pos. A).

STARTING WITH COLD ENGINEWhen the room temperature is low (about0C), it may be difficult to start the engineat the first attempt.

In this case: Rotate the cold start lever (6) down-

wards.

Press the start button

(7) for at least

ten seconds and at the same time rotatethe throttle grip slightly (8).

Release the throttle grip (8). Rotate the cold start lever (6) up-

wards.If the idling is unstable, twist the throttle

grip (8) slightly and frequently.

If the engine does not start.

Wait for a few seconds and then repeat thestarting procedure.

STARTING AFTER A LONG PERIOD

OF INACTIVITYAfter a long period of inactivity, make thestarter run for about ten seconds withoutaccelerating, in order to ensure the fillingof the float chamber.

To start the engine, slightly open the throt-tle and carry out the starting procedure.

DEPARTURE AND DRIVE


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WARNINGDo not position any object inside thefront part of the fairing (between the

handlebar and the dashboard), in ordernot to hinder the rotation of the handle-bar and visibility toward the dashboard.

NOTE Before departure, carefully readthe safe drivechapter, see p. 5 (SAFEDRIVE).If you run out of the standardfuel quantitywhile riding, move the fuel tap lever (1) toposition RES, in order to use the fuel re-serve.FUEL RESERVE: 2.6 l (mechanical re-serve).

WARNINGAny mention to the use of the vehicle

with passenger is to be intended as re-ferred only to the countries where thisis allowed.If you drive without passenger, makesure that the passenger footrests arefolded.While riding, keep your hands on thegrips and your feet on the footrests.

NEVER RIDE IN ANY POSITION OTHERTHAN THOSE INDICATED.

If you drive with a passenger, instructhim/her so that he/she does not createproblems during manouvres.

To leave: Adjust the inclination of the rear-view

mirrors correctly.

WARNINGWith the vehicle at rest, try to get ac-quainted with the use of the rear-viewmirrors. The reflecting surface is con-vex, therefore the objects seem to be

farther away than they actually are.These mirrors offer a wide-angle viewand only experience will allow you toevaluate the distance of the followingvehicles correctly.

Ride at reduced speed for the first miles,in order to warm the engine up.

With released throttle grip (2) (Pos. A)and engine idling, pull the clutch lever (3)completely.

Engage the first gear, by pressing theshifting lever (4) downwards.

Release the brake lever (pulled on the

starting).

WARNINGOn departure, the abrupt release of theclutch lever may cause the engine tostall or the vehicle to jerk forwards.

Never accelerate abruptly or excessive-ly when releasing the clutch lever, in or-der to prevent the clutch from slip-ping (slow release) or the front wheelfrom raising rearing up (quick re-lease).

The downshifting should be carried out inthe following situations:


35/88


Slowly release the clutch lever (3) and atthe same time accelerate by rotating thethrottle grip moderately (2) (Pos. B).The vehicle will start moving.

Increase the speed by gradually rotatingthe throttle grip (2) (Pos. B), without ex-

ceeding the recommended rpm, seep. 37 (RUNNING-IN).

To engage the second gear:

CAUTIONProceed quickly.Never ride the vehicle at too low rpm.

Release the throttle grip (2) (Pos. A),pull the clutch lever (3) and lift the shift-ing lever (4). Release the clutch lever (3)and accelerate.

Repeat the last two operations and shiftup.

CAUTIONIf the 2 stroke oil warning light comes on, this means that the 2 strokeoil reserve is being used; in this case,provide for topping up, see p. 25 (2STROKE OIL TANK).

the following situations:

When riding downhill or when braking, inorder to increase the braking action byusing the compression of the engine.

When riding uphill, if the gear engaged isnot suitable to the speed (high gear,moderate speed) and the engine rpm de-creases.

CAUTIONShift the gears one by one; the simulta-

neous downshifting of more than onegear may make you exceed the maxi-mum rpm (red line).Before and during the downshifting, re-lease the throttle grip and decelerate, inorder to avoid the red line.

To shift down, proceed as follows:

Release the throttle grip (2) (Pos. A). If necessary, pull the brake levers mod-

erately and decrease the speed of thevehicle.

Pull the clutch lever (3) and lower theshifting lever (4) to shift down.

If the brake levers are pulled, release

them. Release the clutch lever and accelerate

moderately.

WARNING WARNING WARNING


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Avoid opening and closing the throttlegrip repeatedly and continuously, sothat you do not accidentally lose controlof the vehicle.

If you have to brake, close the throttleand put on both brakes in order to ob-tain uniform deceleration, properly ex-erting pressure on the braking parts.

By putting on the front brake only or therear brake only, you reduce the braking

force considerably, thus running therisk of locking one wheel and conse-quently losing grip.

If you stop uphill, decelerate completelyand use the brakes only to keep the ve-hicle steady.The use of the engine to keep the vehi-cle steady may cause the overheating ofthe clutch.

Before beginning to turn, slow down orbrake driving at moderate and constantspeed or accelerating slightly; avoidbraking at the last moment: it would be

very easy to skid.

If the brakes are operated continuouslyon downhill stretches, the friction sur-faces may overheat, thus reducing thebraking efficiency.Exploit the engine compression and

shift down by putting on both brakes in-termittently.Never drive downhill with the engineoff!

In case of wet ground or scarce wheelgrip (snow, ice, mud, etc.), drive slowly,avoiding sudden brakings or manoeu-vres that could make you lose grip andfall down.

Pay the utmost attention to any obsta-cle or variation of the ground. Unevenroads, rails, manhole covers, indica-tions painted on the road surface, build-

ing site metal plates become rather slip-pery by rain. For this reason all theseobstacles have to be carefully avoided,driving smoothly and bending the vehi-cle as little as possible.

Always use the turn indicators in time

when you intend to change lane or di-rection, avoiding sharp and dangerousmovements.Switch off the direction indicators assoon as you have changed direction.

Be extremely careful when you overtakeother vehicles or are overtaken.

In case of rain, the water cloud createdby big vehicles reduces visibility; theair shift may make you lose control ofthe vehicle.

RUNNING-IN STOPPING


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WARNINGAfter the first 500 km (312 mi), carry outthe checking operations indicated in the

columnAfter running-in

of the REGU-LAR SERVICE INTERVALS CHART, see

p. 40, in order to avoid hurting yourselfor other people and/or damaging the ve-hicle.

The running-in of the engine is primary toensure its correct functioning and its correct

functioning. If possible, drive on hilly roadsand/or roads with many bends, so that theengine, the suspensions and the brakesundergo a more effective running-in.

For the first 500 km (312 mi), keep to thefollowing indications:

0-100 km (0-62 mi)During the first 100 km (62 mi) put on thebrakes with caution, avoiding sharp andprolonged brakings.This ensures a correct bedding-in of thepads on the brake disc.

0-300 km (0-187 mi)Do not keep the throttle grip open morethan one half for long stretches.

300-500 km (187-312 mi)Do not keep the throttle grip open morethan three-fourths for long stretches.

WARNINGIf possible, avoid stopping abruptly,slowing down suddenly and braking at

the last moment.

Release the throttle grip (1) (Pos. A),gradually put on the brakes and at thesame time shift down in order to de-crease the speed, see p. 34 (DEPAR-TURE AND DRIVE).

Once the speed has decreased, beforestopping the vehicle: Pull the clutch lever (2) in order to pre-

vent the stopping of the engine.

When the vehicle has come to rest: Position the shifting lever in neutral

(green warning light on).

Release the clutch lever. In case of a brief stop, keep at least onebrake on.

PARKING

WARNINGPark the vehicle on firm and flat ground,to prevent it from falling down.

Neither lean the vehicle against walls,nor lay it on the ground.

Make sure that the vehicle and especial-ly its red-hot parts do not represent adanger for persons and children.

Do not leave the vehicle unattendedwhen the engine is on or the key is in-serted into the ignition switch.

Do not sit on the vehicle when the standis down.

SUGGESTIONSTO PREVENT THEFT


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Stop the vehicle, see p. 37 (STOPPING). Move the engine stop switch (1) to posi-

tion , (in the countries where re-quired).

Rotate the key (2) and move the ignitionswitch (3) to position .

Move the fuel tap lever (4) to positionOFF. Position the vehicle on the stand, see

beside (POSITIONING THE VEHICLEON THE STAND).

NOTE Never leave the key in the ignitionswitch.

Lock the steering, see p. 18 (STEERINGLOCK)and extract the key.

POSITIONING THE VEHICLEON THE STAND

Seize the left grip (5) and the passengergrab strap (6).


Press the side stand with your right footand extend it completely (7).

Incline the vehicle until the stand restson the ground.

Steer the handlebar completely left-wards.

WARNINGMake sure that the vehicle is stable.

CAUTIONDo not use any brake lock devices.

Failure to heed this warning can seri-ously damage the braking system andlead to an accident thus provoking seri-ous injuries or death.

NEVER leave the ignition key inserted andalways use the steering lock. Park the ve-hicle in a safe place, possibly in a garage

or a protected place. When possible, usean additional anti-theft device. Make surethat all documents are in order and theroad tax has been paid. Write down yourpersonal data and telephone number inthis page, to facilitate the identification ofthe owner in case of finding after theft.

SURNAME: ...............................................

NAME: .......................................................

ADDRESS: ................................................

...................................................................

TELEPHONE NO.: ....................................

NOTE Very often stolen vehicles areidentified thanks to the data written in theuse/maintenance manual.

MAINTENANCE


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WARNINGRisk of fire.Keep fuel and other flammable sub-stances away from the electrical com-ponents.

Before beginning any service opera-

tions or inspection of the vehicle,switch off the engine and remove thekey, wait until the engine and the ex-haust system have cooled down and, ifpossible, lift the vehicles with the prop-er equipment onto firm and flat ground.

Before proceeding, make sure that the

room in which you are working is prop-erly ventilated.

Keep away from the red-hot parts of theengine and of the exhaust system, in or-der to avoid burns.

WARNINGDo not hold any mechanical piece orother parts of the vehicle with yourmouth: the components are not edibleand some of them are noxious or eventoxic.

CAUTIONIf not expressly indicated otherwise, forthe reassembly of the units repeat thedisassembly operations in reverse or-der.

In case any maintenance operation

should be required, it is advisable touse latex gloves.

Routine maintenance operations can usu-ally be carried out by the user, but some-times specific tools and specific technicalskills may be required.In case periodic maintenance operations,assistance or technical advice are needed,contact an apriliaOfficial Dealer, who will

ensure you prompt and accurate servicing.

Ask your apriliaOfficial Dealer to test thevehicle on the road after a repair or period-ic maintenance operation.In any case, personally carry out the Pre-liminary checking operationsafter anymaintenance operation, see p. 31 (PRE-LIMINARY CHECKING OPERATIONS).

Routine maintenance operations can usu-ally be carried out by the user, but some-times specific tools and specific technicalskills may be required.

REGULAR SERVICE INTERVALSCHART Component

After running-in[500 km (312 mi)]

Every 4000 km(2500 mi) or

Every 8000 km(5000 mi) or


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OPERATIONS TO BE CARRIED OUT BYTHE apriliaOfficial Dealer (WHICHCAN BE CARRIED OUT EVEN BY THE

USER).

Key

"= check and clean, adjust, lubricate orchange, if necessary;

#= clean;

$= change;

%= adjust.

NOTE Carry out the maintenance oper-ations more frequently if you use the vehi-cle in rainy and dusty areas or on unevenground.

p[500 km (312 mi)]

( )12 months

( )24 months

Battery - Terminal fastening -Electrolyte level

" "

Spark plug # every 1000 km (625 mi): #/every 3000 km (1875 mi): $

Air cleaner " #

Clutch clearance % %

Light system " "

Brake fluid "

Coolant every 2000 km (1250 mi): "Mixer oil level every 500 km (312 mi): "

Transmission oil $ " $

Headlight beam direction -operation

"

Engine idling rpm % "

Wheels/tyres and inflationpressure

every month: "

Drive chain tension and lubrication every 500 km: "

Front and rear brake pad wear " every 2000 km (1250 mi): "

OPERATIONS TO BE CARRIED OUT BYTHE apriliaOfficial Dealer. Component

After running-in[500 km (312 mi)]

Every 4000 km(2500 mi) or12 th

Every 8000 km(5000 mi) or24 th


41/88


Key

"= check and clean, adjust, lubricate or

change, if necessary;#= clean;

$= change;

%= adjust.

NOTE Carry out the maintenance oper-ations more frequently if you use the vehi-

cle in rainy and dusty areas or on unevenground.

[500 km (312 mi)]12 months 24 months

Rear shock absorber "

Carburettor #

Idle mixture (CO rate) " Transmission cables and controls " "

Wheel centering "

Steering tube bearings andsteering slack

" "

Wheel bearings "

Brake discs " "

Mixer oil filter #

General running of the vehicle " "

Braking systems " "

Cooling system " "

Brake fluid every year: $

Coolant every 2 years: $

Exhaust silencer/exhaust terminal #

Fork oil and oil seal every 12000 km (7500 mi): $

Piston and piston ringsafter the first 8000 km (5000 mi): "/

every 16000 km (10000 mi): $

Wheels/tyres and inflationpressure

" "

Nut, bolt, screw tightening " " Mixer oil reserve warning light LED " "

Final transmission (chain, crown,pinion)

"

Fuel pipe " every 4 years: $

Mixer oil pipes " every 4 years: $

Clutch wear "


42/88


IDENTIFICATION DATA

It is a good rule to write down the frameand engine numbers in the space providedin this manual.

The frame number can be used for thepurchase of spare parts.

NOTE Do not alter the identificationnumbers if you do not want to incur severepenal and administrative sanctions. In par-ticular, the alteration of the frame numberresults in the immediate invalidity of theguarantee.

FRAME NUMBER

The frame number is stamped on the rightside of the steering column.

Frame no.

ENGINE NUMBER(in the countries where required)

The engine number is stamped on the up-per part of the crankcase, on the left side,near the chain pinion.

To reach it, proceed as follows:

Remove the left fairing, see p. 52 (RE-MOVING THE SIDE FAIRINGS).

Unscrew and remove the two screws (1). Remove the pinion cover (2).

Engine no.

POSITIONING THE VEHICLE ONTHE FRONT SUPPORT STAND

Position the vehicle on the appropriaterear support stand, see p. 43(POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND).

Insert the two ends of the stand (3) in thetwo holes (4) positioned on the lowerends of the front fork.

Rest one foot on the front part of thestand (5).

Push the stand (5) downwards until itreaches the end of its stroke (see figure).


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POSITIONING THE VEHICLE ONTHE REAR SUPPORT STAND

Loosen the knob (1). Withdraw the fork support (2) and extract

it from the stand seat. Insert the support pin (3).

Repeat the previous operations on theopposite side of the stand.

WARNINGRaise the vehicle by means of the tworear fork arms only.

Insert the stand from the back of the ve-hicle and position it so that the two sup-port pins (3) can be housed as follows: the right support between brake caliper

and brake pipe coupling on the rear fork(Pos. A);

the left support between gearwheel and

chain (Pos. B).

Withdraw the support pins (3) and makethem hit against the rear fork.

Tighten the two knobs (1).

NOTE Have someone help you keep thevehicle in vertical position with the twowheels on the ground.

Rest one foot on the rear part of thestand (4).

Push the stand (4) downwards until itreaches the end of its stroke (see figure).

CHECKING

NOTE Position the vehicle on firm and

TOPPING UP

If it were necessary to top up, proceed asf ll


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CHECKING THE TRANSMISSIONOIL LEVEL AND TOPPING UP

Carefully read p. 21 (TRANSMISSIONOIL)and p. 39 (MAINTENANCE).

Check the transmission oil level every4000 km (2500 mi), change it after the first500 km (312 mi) and successively every8000 km (5000 mi), see p. 45 (CHANGINGTHE TRANSMISSION OIL).

flat ground.

Stop the engine and let it cool down forat least ten minutes, in order to allow the

oil to flow back to the oil pan and to cooldown.

Remove the right fairing, see p. 52 (RE-MOVING THE SIDE FAIRINGS).

Unscrew and remove the screw (1). Take the sealing washer (2).


Keep the vehicle in vertical position, with

the two wheels resting on the ground.NOTE The non-performance of the op-erations described above may result in awrong measurement of the level.

Visually check if the oil reaches the loweredge of the threaded hole (3).

If so, proceed as follows: Check and if necessary change the seal-ing washer (2).

Tighten the screw (1).

Otherwise: Provide for topping up.

follows:

Unscrew and remove the filling cap (4). Pour a small quantity of oil and wait

about one minute, to allow the oil to flowuniformly inside the pan.

Visually check if the oil reaches the loweredge of the threaded hole (3).

If this is not the case, top up again withsmall quantities of oil and repeat thecheck through the threaded hole (3), until

reaching the prescribed level. At the end of the operation, screw andtighten the filling cap (4).

WARNINGTighten the filling cap thoroughly andmake sure that there are no oil leaks.

Periodically check that there are noleaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficientlubrication or with contaminated or un-suitable lubricants, since this would ac-

celerate the wear of the moving partsand may also cause irreparable failures.

WARNINGWhen warmed up, the engine contains

Screw and tighten the drain plug (2).

Drain plug (2) driving torque:27 Nm (2 7 kgm)


45/88


CHANGINGTHE TRANSMISSION OIL

Carefully read p. 21 (TRANSMISSIONOIL)and p. 39 (MAINTENANCE).

Check the transmission oil level every

4000 km (2500 mi), change it after the first500 km (312 mi) and successively every8000 km (5000 mi).

CHANGING

Start the engine, see p. 32 (STARTING)and let it idle for a few minutes, in order

to facilitate the outflow of the oil duringthe draining phase.


Stop the engine and let it cool down forat least ten minutes, in order to allow the

oil to flow back to the oil pan and to cooldown.

p, ghot oil; therefore, while carrying out theoperations described here below beparticularly careful, in order to avoid

burns.

Remove the right fairing, see p. 52 (RE-MOVING THE SIDE FAIRINGS).

Remove the exhaust silencer, see p. 54(REMOVING THE EXHAUST SILENC-ER).


Keep the vehicle in vertical position, withthe two wheels resting on the ground.

Put a container (1) with at least 900 cm>capacity in correspondence with thedrain plug (2).

Unscrew and remove the drain plug (2). Unscrew and remove the filling plug (3). Drain the oil and let it drip into the con-

tainer (1) for a few minutes. Remove the metal residues from the

drain plug (2) magnet. Check and if necessary replace the seal-

ing washer of the drain plug (2).

27 Nm (2.7 kgm).

Pour about 820 cm> of transmission oilthrough the filling opening (4), see p. 75

(LUBRICANT CHART). Tighten the filling plug (3).

Start the engine, see p. 32 (STARTING)and let it idle for about one minute, in or-der to ensure the filling up of the trans-mission oil circuit.

Check the oil level and top up if necessary,see p. 44 (CHECKING THE TRANSMIS-SION OIL LEVEL AND TOPPING UP).

WARNINGTighten the filling plug and the drainplug thoroughly and make sure thatthere are no oil leaks.

Periodically check that there are noleaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficientlubrication or with contaminated or un-

suitable lubricants, since this would ac-celerate the wear of the moving partsand may also cause irreparable failures.


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FRONT WHEEL

WARNINGThe disassembly and reassembly of thefront wheel may be difficult for unskilledoperators. If necessary, contact an

apriliaOfficial Dealer.If you want to perform these operationspersonally, keep to the following in-structions.

Carefully read p. 39 (MAINTENANCE).

While disassembling and reassembling

the wheel, be careful not to damage thebrake pipes, the discs and the pads.

NOTE To remove the front wheel it isnecessary to use the appropriate front andrear support stands.

DISASSEMBLY

Position the vehicle on the appropriaterear support stand, see p. 43 (POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND).

Position the vehicle on the appropriate

front support stand, see p. 42 (POSI-TIONING THE VEHICLE ON THEFRONT SUPPORT STAND).

WARNINGMake sure that the vehicle is stable.

Have someone keep the handlebarsteady in running position, so that thesteering is locked.

Brake caliper screw (1) driving torque:22 Nm (2.2 kgm).

Unscrew and remove the two screws (1)that fasten the front brake caliper (2).

Withdraw the brake caliper (2) from thedisc, leaving it attached to the pipe (3).

CAUTIONNever pull the front brake lever after re-moving the brake caliper, otherwise thecaliper pistons may go out of theirseats, thus causing the outflow of thebrake fluid. In this case consult yourapriliaOfficial Dealer, who will carryout the proper maintenance operation.

Put a support (4) under the tyre, in sucha way as to keep the wheel in its positionafter loosening it.

Lock the wheel pin (5) by means of aspanner.

Unscrew and remove the nut (6), takingthe washer (7).

Wheel nut driving torque (6): 80 Nm (8 kgm).

Loosen the screw (8) of the wheel pin

clamp.

Push the wheel pin (5), by carefully act-ing on the threaded end and using a rub-ber hammer if necessary.

Position the wheel between the fork rodson the support (4).

Remove the front support stand. Remove the rear support stand. With pulled front brake lever, press the


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y

NOTE Check the arrangement of thespeedometer drive (10) and of the spacer

ring (9), in order to be able to reassemblethem correctly.

Support the front wheel and extract thewheel pin manually.

Take the spacer ring (9). Remove the wheel by withdrawing it from

the front.

Disconnect the odometer control (10). Take the washer (11). Take the odometer control cover (12).

REASSEMBLY


Spread a film of lubricating grease on thewhole length of the wheel pin (5), seep. 75 (LUBRICANT CHART).

Join the washer (11) to the odometercontrol (10) (tang side (13)).

Position the tang (13) of the odometercontrol (10) in the appropriate seat onthe wheel hub.

Correctly insert the cover (12) on theodometer control (10).

Position the spacer ring (9) in its seat onthe wheel.

WARNINGDanger of injury.Do not introduce your fingers to alignthe holes.

Move the wheel until its central hole andthe holes on the fork are aligned.

Introduce the wheel pin (5) completely. Position the washer (7) and tighten the

nut (6) manually.

Make sure that the cover (12) is correctlycoupled to the fork. Lock the wheel pin (5) rotation. Tighten the nut (6) thoroughly.

Nut (6) driving torque: 80 Nm (8 kgm).

CAUTIONWhile reassembling the wheel, be care-ful not to damage the brake pipe, thedisc and the pads.

Insert the brake caliper (2) on the discand position it so that its fastening holesand the holes on the support are aligned.

NOTE Upon reassembly of the brakecaliper, replace the caliper fasteningscrews (1) with two new screws of thesame type.

Screw and tighten the two screws (1)that fasten the brake caliper.

Brake caliper screw (1) driving torque:

22 Nm (2.2 kgm)

p , phandlebar repeatedly, thrusting the forkdownwards. In this way the fork rods willsettle properly.

Tighten the screw (8) of the wheel pinclamp.

Screw (8) driving torque: 8 Nm (0.8 kgm)

WARNINGAfter reassembly, pull the front brake le-

ver repeatedly and check the correctfunctioning of the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by your

apriliaOfficial Dealer, in order to avoidaccidents that may be harmful for youand/or other people.


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REAR WHEEL

WARNINGThe disassembly and reassembly of therear wheel may be difficult for unskilledoperators. If necessary, contact an

apriliaOfficial Dealer.

If you want to perform these operationspersonally, keep to the following in-structions.


Before carrying out the following opera-tions, let the engine and the exhaust si-lencer cool down until they reach roomtemperature, in order to avoid burns.

CAUTIONWhile disassembling and reassemblingthe wheel, be careful not to damage thebrake pipe, the disc and the pads.

NOTE To remove the rear wheel it isnecessary to use the appropriate rear sup-port stand.

DISASSEMBLY

Position the vehicle on the appropriaterear support stand, see p. 43 (POSI-TIONING THE VEHICLE ON THE REAR

SUPPORT STAND). Lock the wheel pin (1) rotation.

Wheel nut (2) driving torque:80 Nm (8 kgm).

Loosen and remove the nut (2), takingthe washer.

Put a support (3) under the tyre, in sucha way as to keep the wheel in its positionafter loosening it.

Withdraw the wheel pin (1) from the rightside.

NOTE Check the arrangement of theright (4) and left (5) chain tighteners, in or-der to be able to reassemble them correctly.

Take the right (4) and left (5) chain tight-eners.

NOTE Lower the drive chain (6) outsidethe crown gear (7).

Make the wheel advance and release thedrive chain (6) from the crown gear (7).

Withdraw the wheel from the rear forkfrom behind, carefully withdrawing thedisc from the brake caliper.

CAUTIONThe spacer rings have different diame-ters: do not invert them and take care to

Rotate the support plate (10), completewith brake caliper (11) and with fulcrumon the stop pin (12), until it is aligned with


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CAUTIONNever push the rear brake lever after re-moving the wheel, otherwise the caliperpistons may go out of their seats, thuscausing the outflow of the brake fluid. Inthis case consult your apriliaOfficial

Dealer, who will carry out the propermaintenance operation.

NOTE Check the arrangement of thespacer rings (8) and (9), in order to be ableto reassemble them correctly.

Take the left spacer ring (8). Take the right spacer ring (9).

REASSEMBLY

Moderately grease the outer seats of thewheel hub.

ters: do not invert them and take care toposition them correctly.

Insert the left (8) and right (9) spacerrings in their seats on the wheel hub.

Reinsert the spacer ring (13) correctly, if ithas gone out of the brake plate seat (10).

CAUTIONBefore proceeding with the reassembly,make sure that support plate (10) of the

brake caliper (11) is positioned correct-ly; the plate slot must be inserted in theappropriate stop pin (12) in the innerpart of the rear fork right leg. Insert thedisc in the brake caliper carefully.

Position the wheel between the rear forkrods on the support (3).

WARNINGDo not introduce your fingers betweenthe chain and the crown gear.

Make the wheel advance and positionthe drive chain (6) on the crown gear (7).

WARNINGDanger of injury.Do not introduce your fingers to alignthe holes.

Move the wheel backwards, until its cen-tral hole and the holes on the rear fork

are aligned.

the holes. Correctly insert the right (4) and left (5)

chain tighteners in their seats on the fork. Uniformly apply a moderate quantity of

grease on the wheel pin (1). Introduce the wheel pin (1) completely

on the left side.

NOTE Make sure that the wheel pin (1)is completely inserted, with the head in therelevant seat on the left chain tightener (5).

Position the washer and tighten the nut(2) manually.

Check the chain tension, see p. 50(DRIVE CHAIN).

Tighten the nut (2).

Wheel nut (2) driving torque:

80 Nm (8 kgm).

WARNINGAfter reassembly, push the rear brakelever repeatedly and check the correctfunctioning of the braking system.

Check the wheel centering.Have the driving torques, centering andbalancing of the wheel checked by yourapriliaOfficial Dealer, in order to avoidaccidents that may be harmful for youand/or other people.


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DRIVE CHAIN


The vehicle is equipped with a chain withring link joint.

In case of disassembly and reassembly of

the chain, make sure that the clip (1) of thering link joint has its open side opposite thetravelling direction (see figure).

WARNINGAn excessive slackening of the chaincan cause it to come off of the sprock-

ets, which often results in accidents orserious damage to the vehicle.Periodically check the slack and adjustit if necessary, see p. 51 (ADJUST-MENT).To change the chain, contact an apriliaOfficial Dealer, who will ensure youprompt and accurate servicing.

CAUTIONIncorrect maintenance may cause theuntimely wear of the chain and/or dam-ages to the pinion and/or the crown.Carry out the maintenance operationsmore frequently if you use the vehicle in

difficult conditions or on dusty and/ormuddy roads.

CHECKING THE SLACK

To check the slack, proceed as follows: Stop the engine. Position the vehicle on the stand.

Position the shifting lever in neutral. Make sure that the vertical oscillation, inan intermediate point between pinionand crown in the lower part of the chain,is about 25 mm.

Move the vehicle forwards, or turn thewheel, in order to be able to check thevertical oscillation of the chain evenwhen the wheel turns; the slack must beconstant in all the rotation phases of thewheel.

CAUTIONIf in some positions the slack is higherthan in others, this means that there arecrushed or seized links; in this case,contact an apriliaOfficial Dealer. Toprevent the risk of seizures, lubricate thechain frequently, see p. 51 (CLEANING

AND LUBRICATION).

If the slack is uniform, but higher or lowerthan 25 mm, adjust it, see p. 51 (AD-JUSTMENT).

Loosen the two lock nuts (5). Act on the adjusters (6) and adjust the

chain slack, making sure that the refer-k (3 4) tl iti d

CAUTIONLubricate the chain frequently, espe-cially if there are dry or rusty parts The


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ADJUSTMENT

NOTE To adjust the chain it is neces-sary to use the appropriate rear supportstand.

If after the check it is necessary to adjustthe chain tension, proceed as follows:

Position the vehicle on the appropriaterear support stand, see p. 43(POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND).

Loosen the nut (2) completely.

NOTE For the wheel centering fixed ref-erence marks (3-4) are provided, whichcan be seen inside the chain tightenerseats on the rear fork arms, before thewheel pin.

ence marks (3-4) are correctly positionedon both sides of the vehicle.

Tighten the two lock nuts (5). Tighten the nut (2).

Wheel nut driving torque:100 Nm (10 kgm).

Check the chain slack, see p. 50(CHECKING THE SLACK).

CHECKING THE WEAR OF CHAIN,PINION AND CROWN

Further, check the chain and sprocketsand make sure that they do not present:

Damaged rollers.

Loose pins. Dry, rusty, crushed or seized links. Excessive wear. Sprocket or teeth excessively worn or

damaged.

CAUTIONIf the chain rollers are damaged and/orthe pins are loose, it is necessary tochange the whole chain unit (bothsprockets and chain).

cially if there are dry or rusty parts. Thecrushed or seized links must be lubri-cated and made work again.

If this is not possible, contact an apriliaOfficial Dealer, who will provide forchanging the chain.

Finally, check the wear of the rear forkprotection shoe.

CLEANING AND LUBRICATION

CAUTIONCarry out the adjustment, lubrication,cleaning and change of the chain withgreat care.

Lubricate the chain every 4000 km (2500mi) or whenever necessary.

Lubricate the chain with spray grease forchains or with SAE 80W-90 oil.

Never wash the chain with water jets,steam jets, high-pressure water jets and

highly inflammable solvents.


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REMOVING THE RIDER SADDLE


Position the vehicle on the stand. Insert the key (1) in the lock (2). Rotate the key (1) clockwise. Raise and remove the saddle (3). Remove the flap (4).

Upon reassembly: Position the flap (4) correctly. Insert the rear tangs (5) of the saddle in

the appropriate seats (see figure). Lower the saddle and insert the two pins

(6) in the relevant seats. Turn the key (1) anticlockwise, lockingthe saddle.

WARNINGBefore leaving, make sure that the sad-dle (3) is properly positioned and

locked.

REMOVING THE SIDE FAIRINGS


WARNINGBefore carrying out the following opera-tions, let the engine and the exhaust si-

lencer cool down until they reach roomtemperature, in order to avoid burns.

Position the vehicle on the stand. Unscrew and remove the four screws

(7). Unscrew and remove the two lower

screws (8). For the left fairing: unscrew and re-

move the two rear screws (9). For the right fairing: unscrew and re-

move the rear screw (10). Unscrew and remove the four screws

(11).

CAUTIONHandle the plastic and painted compo-nents with care and avoid scraping ordamaging them.Do not force the electric cables.

Disconnect the two electric terminals(12) of the direction indicator.

Remove the side fairing (13).


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LIFTING THE FUEL TANK

Carefully read p. 21 (FUEL)and p. 39(MAINTENANCE).

WARNINGRisk of fire.

Wait until the engine and the exhaust si-lencer have completely cooled down.Fuel vapours are noxious for yourhealth.Before proceeding, make sure that theroom in which you are working is prop-erly ventilated.

Do not inhale fuel vapours.Do not smoke and do not use nakedflames.

DO NOT DISPOSE OF FUEL IN THE EN-VIRONMENT.

Move the fuel tap lever (1) to positionOFF.

Remove the rider saddle, see p. 52 (RE-MOVING THE RIDER SADDLE).

Unscrew and remove the screw (2) andtake the bushing.

Drain the fuel tank completely, see p. 69(DRAINING THE FUEL TANK).

Position a spongy cloth (3) on the frontsupport of the rider saddle (4).

CAUTIONHandle with care.While lifting the fuel tank (5), DO NOTforce the fuel pipe (6).

Grasp the front part of the fuel tank (5)and lift it partially.

Withdraw the clamp (7) by means of aspanner.

CAUTIONUpon reassembly, reintroduce the fuelpipe (6) completely and position theclamp (7) correctly.

Withdraw the fuel pipe (6) from the fuel

tap (8).

WARNINGDanger! The fuel may flow out.

Plug the free end of the fuel pipe (6) andfix it to the vehicle in vertical position.

Grasp the front part of the fuel tank (5),lift it, rotate it and put it on the spongycloth (3) positioned on the front supportof the rider saddle.

REMOVAL

Lift the fuel tank, see p. 53 (LIFTINGTHE FUEL TANK).

U d th (1)


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AIR CLEANER

WARNINGDo not use petrol or inflammable sol-vents to wash the air cleaner, in order toavoid fires or explosions.


Check the conditions of the air cleaner andclean it monthly or every 4000 km, depend-ing on the conditions in which the vehicle isused.

If the vehicle is used on dusty or wet roads,

the cleaning operations and any replace-ment should be carried out more frequent-ly.

Before the cleaning operation, it is neces-sary to remove the air cleaner from the ve-hicle.

Unscrew and remove the screw (1). Unscrew and remove the six screws (2). Remove the filter case cover (3). Remove the filtering element (4). Remove the grid (5).

CAUTIONPlug the opening with a clean cloth, toprevent any foreign matters from enter-ing the suction pipes.

CLEANING

Clean the filtering element (4) with clean,non-inflammable solvents or solventswith high volatility point, then let it drythoroughly.

Apply a filter oil or a thick oil (SAE 80W-90) on the whole surface of the filteringelement, then squeeze it to eliminate theoil in excess.

NOTE The filtering element (4) must bewell impregnated, though not dripping.

REMOVINGTHE EXHAUST SILENCER


WARNINGBefore carrying out the following opera-tions, let the engine and the exhaust si-lencer cool down until they reach roomtemperature, in order to avoid burns. Remove the right fairing, see p. 52 (RE-

MOVING THE SIDE FAIRINGS). Remove the two springs (6).

Release the clip (11) and disconnect thesecondary air pipe (12). Unscrew and remove the screw (7) and

take the washer. Unscrew and remove the screw (8) and

take the washer. Take the support (9). Support the exhaust silencer and with-

draw it from the exhaust manifold (10).

11

12


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Upon reassembly:

Apply a layer of heat-resistant gasketmaterial on the area where the exhaustsilencer is coupled to the exhaust mani-fold.

INSPECTING THE FRONTAND REAR SUSPENSIONS

CAUTIONHave the front fork oil changed by anapriliaOfficial Dealer, who will ensure

Aprilia RS50 Users Manual - English 2004

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