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APRILIA RALLY 50 Use And Maintenance Book
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APRILIA RALLY 50 Use And Maintenance Book

APRILIA RALLY 50 Use And Maintenance Book

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Summary of Contents for APRILIA RALLY 50

  • Page 1 WWW.PlanDeGraissage.ORG...
  • Page 2 &/2%7/2$ aprilia SpA aprilia s.p.a. aprilia aprilia s.p.a aprilia aprilia aprilia s.p.a. WWW.PlanDeGraissage.ORG...
  • Page 3 Safety norms and regulations to protect VERSION: the driver and other people from severe Ñ Italy Slovenia injuries or grave risks. Israel United Kingdom Indications to make the operations easier. Technical information. South Korea Austria The operations preceded by this symbol Portugal Malaysia must be repeated on the opposite side of...
  • Page 4 4!",% /& #/.4%.43 SAFE DRIVE ARRANGEMENT OF THE MAIN ELEMENTS ARRANGEMENT OF THE INSTRUMENTS INSTRUMENTS AND INDICATORS MAIN INDEPENDENT CONTROLS AUXILIARY EQUIPMENT MAIN COMPONENTS INSTRUCTIONS FOR USE TRANSPORT CLEANING TECHNICAL DATA MAINTENANCE WWW.PlanDeGraissage.ORG...
  • Page 5 safe drive WWW.PlanDeGraissage.ORG...
  • Page 6 "!3)# 3!&%49 25,%3 WWW.PlanDeGraissage.ORG...
  • Page 7 STOP 150 m 150 m STOP WWW.PlanDeGraissage.ORG...
  • Page 8 WWW.PlanDeGraissage.ORG...
  • Page 9 COOLER WWW.PlanDeGraissage.ORG...
  • Page 10 WWW.PlanDeGraissage.ORG...
  • Page 11 ONLY ORIGINALS WWW.PlanDeGraissage.ORG...
  • Page 12 #,/4().' WWW.PlanDeGraissage.ORG...
  • Page 13 !##%33/2)%3 aprilia aprilia WWW.PlanDeGraissage.ORG...
  • Page 14 ,/!$ WWW.PlanDeGraissage.ORG...
  • Page 15 WWW.PlanDeGraissage.ORG...
  • Page 16 !22!.'%-%.4 /& 4(% -!). %,%-%.43 C7W 8sq  Fig. 1 C7W 8sq  Fig. 2 WWW.PlanDeGraissage.ORG...
  • Page 17 !22!.'%-%.4 /& 4(% ).3425-%.43 C7W 8sq  n m s Fig. 3 WWW.PlanDeGraissage.ORG...
  • Page 18 ).3425-%.43 !.$ ).$)#!4/23 C7W È8sq É Fig. 4 WWW.PlanDeGraissage.ORG...
  • Page 19 ).3425-%.4 !.$ ).$)#!4/2 4!",% Description Function Mixer oil reserve warning light If the warning light comes on and does not go out af- ter the start push button " " has been released, or if it comes on during normal functioning, this means that the mixer oil reserve is being used;...

  • Page 20: Direction Indicator Switch

    -!). ).$%0%.$%.4 #/.42/,3 #/.42/,3 /. 4(% ,%&4 3)$% /& 4(% (!.$,%"!2 &IG  The electrical parts work only when the ignition switch is in position “ ”. 1) HORN PUSH BUTTON ( 2) COLD START LEVER ( Fig. 5 3) DIRECTION INDICATOR SWITCH ( WWW.PlanDeGraissage.ORG...

  • Page 21: Start Push Button

    #/.42/,3 /. 4(% 2)'(4 3)$% /& 4(% (!.$,%"!2 &IG  The electrical parts work only when the ignition switch is in position “ ”. 1) START PUSH BUTTON ( Fig. 6 WWW.PlanDeGraissage.ORG...

  • Page 22: Operation

    )'.)4)/. 37)4#( &IG  The key (1-Fig. 8) operates the ignition switch/steering lock, the battery/tool kit compartment and the saddle lock. Two keys are supplied together with the vehicle (one spare key). 34%%2).' ,/#+ &IG  Never turn the key to position “ ”...
  • Page 23 !58),)!29 %15)0-%.4 5.,/#+).',/#+).' 4(% 3!$$,% &IG  ◆ ◆ Before lowering and locking the saddle, make sure that you have not left the key in the crash helmet/glove compartment. ◆ Before leaving, make sure that the saddle is Fig. 9 properly locked.
  • Page 24 "!44%29  4//, +)4 #/-0!24-%.4 &IG  ◆ ◆ Fig. 11 Maximum allowed weight: 1.5 kg. "!' (//+ &IG  Do not hang excessively bulky bags or parcels to the hook, as this may seriously compromise the manoeuvrability of the vehicle or the movement of your feet.
  • Page 25 -!). #/-0/.%.43 &5%, &IG  The fuel used for internal combustion en- gines is extremely inflammable and in particular conditions it can become ex- plosive. ◆ It is important to carry out the refuelling and the maintenance operations in a well-ventilated area, ◆...
  • Page 26 If you run out of oil in the mixer oil tank or if the mixer oil pipe has been removed, it is nec- APRILIA essary to contact an Official Dealer, who will provide for bleeding the system.
  • Page 27 For any doubt regarding the perfect functioning The brake fluid must be changed once a year by APRILIA of the braking system and in case you are not Official Dealer. able to carry out the usual checking operations,...
  • Page 28 Fig. 15 ◆ ◆ ◆ ◆ Check the braking efficiency. If neces- APRILIA sary, contact your Official Dealer. In case of excessive movement of the brake lever, of excessive elasticity or in case APRILIA there is air in the circuit, contact your ficial Dealer, since it may be necessary to bleed the system.

  • Page 29: Adjusting The Brake

    For any doubt regarding the perfect functioning of the braking system and in case you are not able to carry out the usual checking operations, APRILIA contact your Official Dealer. ADJUSTING THE BRAKE ◆...
  • Page 30 For this reason, it is advisable to have the above APRILIA mising the driving comfort and reducing the road mentioned operations carried out by an Official Dealer or by a qualified tyre repairer.
  • Page 31 !54/-!4)# ,)'(4 37)4#().' 6%23)/. #!4!,94)# 3),%.#%2 Avoid parking the Rally 50 catalytic ver- sion near dry brush wood or in places easily accessible to children, as the cata- lytic silencer becomes extremely hot during use; be very careful and avoid any kind of contact be- fore it has completely cooled down.
  • Page 32 APRILIA Do not hesitate to consult your ).3425#4)/.3 &/2 53% Official Dealer in case there is something you do not understand about the func- Before departure, always carry out a pre- tioning of some controls or in case you suspect liminary checking of the vehicle, to make or discover some irregularities.
  • Page 33 02%,)-).!29 #(%#+).' /0%2!4)/.3 Component Check Page ÷ WWW.PlanDeGraissage.ORG...

  • Page 34: Electric Starting

    34!24).' Exhaust gases contain carbon monoxide, which is extremely noxious if inhaled. Avoid starting the vehicle in closed or badly-ventilated rooms. The non-observance of this warning may cause loss of consciousness or even lead to death by asphyxia. Do not get on the vehicle for the starting. ELECTRIC STARTING ◆...

  • Page 35: Kick Start

    Avoid pressing the start push button " " (1- Fig. 21) when the engine is running: this may damage the starter. ◆ ◆ ◆ KICK START ◆ ◆ ◆ ◆ Fig. 21 Do not push down the kick starter with the engine on.
  • Page 36 Avoid opening and closing the throttle grip repeatedly and continuously, so that you do not accidentally lose control of the vehicle. If you have to brake, close the throttle and put on both brakes in order to obtain uniform decelera- tion, properly exerting pressure on the braking parts.
  • Page 37 25..).' ). Pay the utmost attention to any obstacle Remember: 1 mile = 1.6 km or variation of the ground. 1 km = 0.625 miles Uneven roads, rails, manhole covers, indications After the first 500 kilometres, carry out the painted on the road surface, building site metal checking operations indicated in the col- plates become rather slippery by rain.
  • Page 38 34/00).' !.$ 0!2+).' ◆ ◆ It is not necessary to close the fuel tap w h e n t h e e n g i n e i s o f f , s i n c e i t i s equipped with an automatic closing system.
  • Page 39 35''%34)/.3 4/ 02%6%.4 4(%&4 Very often stolen vehicles are identified t h a n k s t o t h e d a t a w r i t t e n o n t h e use/maintenance manual. WWW.PlanDeGraissage.ORG...
  • Page 40 !.4) 4(%&4 (//+ &IG ! Do not use the hook to lift the vehicle or for any purpose other than securing the vehicle once it has been parked. Fig. 25A WWW.PlanDeGraissage.ORG...
  • Page 41 -!).4%.!.#% Before beginning any maintenance oper- ation or any inspection of the vehicle, aprilia stop the engine, extract the key from the ignition block, wait until the engine and the ex- haust system have cooled down and if possible lift the vehicle by means of the proper equipment, on firm and flat ground.
  • Page 42 4000 km 8000 km Component [500 km (2500 mi) (5000 mi) OPERATIONS TO BE CARRIED APRILIA (312 mi)] or 12 months or 24 months OUT BY THE Official Deal- er (WHICH CAN BE CARRIED OUT EVEN BY THE USER).
  • Page 43 OPERATIONS TO BE CARRIED $IWHU APRILIA (YHU\  NP (YHU\  NP UXQQLQJLQ OUT BY THE Official Deal- &RPSRQHQW  PL  PL > NP RU  PRQWKV RU  PRQWKV  PL @ ¥ ¥ ¥ ¥ ¥ ¥ ¥...
  • Page 44 )$%.4)&)#!4)/. $!4! Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the altera- tion of the frame number results in the immediate invalidity of the guarantee. ENGINE NUMBER (Fig. 26) Fig.
  • Page 45 FRAME NUMBER (Fig. 27) Fig. 27 WWW.PlanDeGraissage.ORG...
  • Page 46 REMOVAL Fig. 28 Have the appropriate special tool APRILIA be requested to Official Dealer): – clamp installation pliers (1). Upon installation, replace the hose clamp that has been removed with a new one...

  • Page 47: Cleaning The Air Filter

    ◆ ◆ ◆ ◆ ◆ Handle the plastic and painted compo- nents with care to avoid scraping or dam- aging them. ◆ ◆ ◆ Fig. 28B Upon reassembly, position the pipe (10) correctly. ◆ ◆ ◆ ◆ ◆ ◆ The filter must be well impregnated, though not dripping.
  • Page 48 Tighten the filling cap and the drain plug thoroughly and make sure that there are In case of oil leaks or malfunctions, con- no oil leaks. APRILIA tact your Official Dealer. Periodically check that there are no leaks in cor- DO NOT DISPOSE OF THE TRANSMISSION OIL respondence with the oil pan cover seal.
  • Page 49 ◆ 4(% 42!.3-)33)/. /), &IG  ◆ Tighten the filling cap and the drain plug In case of oil leaks or malfunctions, con- APRILIA thoroughly and make sure that there are tact your Official Dealer. no oil leaks. DO NOT DISPOSE OF THE TRANSMISSION OIL Periodically check that there are no leaks in cor- IN THE ENVIRONMENT.
  • Page 50 &2/.4 7(%%, DISASSEMBLY Carefully read p. 41 (MAINTENANCE). While disassembling the wheel, be care- ful not to damage the brake pipe, the disc and the pads. ◆ Place a support under the vehicle, so that the front wheel has enough space to move and the vehicle cannot fall down.
  • Page 51 ◆ causing the outflow of the brake fluid. APRILIA In this case consult your Official Dealer, who will carry out the proper maintenance opera- Wheel pin nut driving torque: tion.
  • Page 52 Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, to be re- quested to an aprilia Official Dealer. Do not attempt to reinstall the removed hose Fig. 32 clamp, since it is unusable.
  • Page 53 Handle the plastic and painted compo- nents with care to avoid scraping or dam- aging them. ◆ ◆ ◆ DO NOT adjust the nuts (10) of the flange (11), but follow the procedure described below ◆ Screws (12-13-Fig. 32) driving torque: 12 Nm (1,2 kgm).
  • Page 54 Upon reassembly, change the wheel nut (special type). Wheel nut (1-Fig. 33C) driving torque: 110 Nm (11 kgm). Fig. 33C APRILIA Genuine Spare Parts only. After reassembly, pull the rear brake lever repeatedly and check the correct func- tioning of the braking system.
  • Page 55 The greasing of the rear brake cam pin can be difficult or complicated for an un- skilled operator. Fig. 34 APRILIA If necessary, contact your Official Dealer. If you want to carry out this operation by your- self, keep to the following instructions: ◆...
  • Page 56 ◆ ◆ ◆ Moderately grease only the central part of the pin. Avoid dirting the cam or the areas around the pin seat with grease. ◆ Neither strike, nor force the cam pin (6) with hammers or others tools, in order not to damage the two O-rings.
  • Page 57 Carefully read p. 27 (BRAKE FLUID (recommen- dations)), p. 27 (FRONT BRAKE), p. 41 (MAINTE- NANCE). Remember: 1 mile = 1.6 km 1 km = 0.625 miles Fig. 35 ◆ ◆ ◆ APRILIA Have the pads changed by your Official Dealer. WWW.PlanDeGraissage.ORG...
  • Page 58 #(%#+).' 4(% "2!+% 3(/% 7%!2 &IG  Carefully read p. 29 (REAR BRAKE) and p. 41 (MAINTENANCE). ◆ ◆ Fig. 36 aprilia WWW.PlanDeGraissage.ORG...
  • Page 59 Do not shake the fork excesively, otherwise you may take in consideration the movement of the stand, thus observing an incorrect slack. Repeat the previous operation more than once. Fig. 37 ◆ aprilia 5@75CAF9 R@7 7F9AF7 8SD5PSE 3VAQ È8sq $É p. 41 (MAINTENANCE) Carefully read ◆...
  • Page 60 2%-/6).' 4(% ).30%#4)/. #/6%2 Carefully read p. 41 (MAINTENANCE). Handle the painted components with care and avoid scraping or damaging them. ◆ The operations marked with the symbol must be carried out on both sides of the ve- hicle. ◆ ◆...
  • Page 61 ◆ ◆ Handle with care. During the removal, do not damage the in- spection cover tangs. ◆ 2%-/6).' 4(% &2/.4 (!.$,%"!2 #/6%2 !BB  Carefully read p. 41 (MAINTENANCE). Fig. 41 Handle the painted components with care and avoid scraping or damaging them. Handle with care.
  • Page 62 Carefully read p. 41 (MAINTENANCE). Remember: 1 mile = 1.6 km ◆ 1 km = 0.625 miles Do not act on the air adjusting screw, to avoid variations of the carburation set- ting. ◆ APRILIA If necessary, contact your Official Dealer. ◆ WWW.PlanDeGraissage.ORG...
  • Page 63 !$*534).' 4(% !##%,%2!4/2 #/.42/, &IG  Carefully read p. 41 (MAINTENANCE). ◆ ◆ ◆ ◆ Fig. 43 ◆ WWW.PlanDeGraissage.ORG...
  • Page 64 ◆ ◆ ◆ ◆ Fig. 44 30!2+ 0,5' &IG  Carefully read p. 41 (MAINTENANCE). ◆ Remember: 1 mile = 1.6 km ÷ 1 km = 0.625 miles ◆ ◆ ◆ WWW.PlanDeGraissage.ORG...
  • Page 65 "!44%29 The spark plug must be well tightened, otherwise the engine may overheat and Carefully read p. 41 (MAINTENANCE). be seriously damaged. Use the recommended type of spark plug only, Remember: 1 mile = 1.6 km see p. 79 (TECHNICAL DATA), in order not to 1 km = 0.625 miles compromise the life and performance of the en- gine.
  • Page 66 ,/.' ).!#4)6)49 /& 4(% "!44%29 The battery gives off explosive gases; keep it away from flames, sparks, cigarettes and any other source of heat. During the recharging or the use, make sure that the room is properly ventilated and avoid inhal- ing the gases released during the recharging.

  • Page 67: Recharging The Battery

    #(%#+).' 4(% %,%#42/,94% ,%6%, &IG  ◆ “ ” ◆ ◆ ◆ Upon reassembly, connect first the positive cable (+) and then the negative cable (-). Fig. 45 ◆ ◆ ◆ ◆ "MIN" "MAX" ◆ ◆ ◆ ◆ ◆ Never exceed the "MAX" notch, since the electrolyte level increases during the re- charge.
  • Page 68 If a fuse blows frequently, there probably is a short circuit or an overload in the electric system. APRILIA In this case it is advisable to consult an Official Dealer. Carefully read p. 41 (MAINTENANCE). WWW.PlanDeGraissage.ORG...
  • Page 69 !$*534).' 4(% (%!$,)'(4 "%!- ◆ Fig. 47 "5,"3 Before changing a bulb, turn the ignition switch to position “ ”. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage.
  • Page 70 #(!.').' 4(% (%!$,)'(4 "5,"3 Carefully read p. 69 (BULBS). Remove the key from the ignition switch. ◆ The operations marked with the symbol must be carried out on both sides of the vehicle. ◆ ◆ Fig. 49 ◆ ◆ ◆ ◆...
  • Page 71 ◆ ◆ ◆ Fig. 50 WWW.PlanDeGraissage.ORG...
  • Page 72 #(!.').' 4(% &2/.4 $)2%#4)/. ).$)#!4/2 "5,"3 &IG  Carefully read p. 69 (BULBS). ◆ Upon reassembly, tighten the screw (1) carefully, in order not to damage the pro- tection screen. While removing the protection screen (2), proceed carefully in order not to break it. ◆...
  • Page 73 #(!.').' 4(% 2%!2 $)2%#4)/. ).$)#!4/2 "5,"3 &IG  Carefully read p. 69 (BULBS). ◆ While removing the indicator lens, pro- ceed carefully in order not to break it. ◆ ◆ ◆ ◆ Fig. 52 If the bulb socket (4) has gone out of its seat, insert it again correctly, making the opening of the bulb socket itself coincide with the seat of the screw.
  • Page 74 WARNING LIGHT BULBS ◆ Pos. Warning light Colour ◆ Fig. 53 DASHBOARD LIGHTING BULBS #(!.').' 4(% $!3("/!2$ "5,"3 ◆ &IG  Carefully read p. 69 (BULBS). Pos. Lit part ◆ ◆ ◆ ◆ WWW.PlanDeGraissage.ORG...
  • Page 75 #(!.').' 4(% 2%!2 ,)'(4 "5,"3 &IG  Carefully read p. 69 (BULBS). ◆ While removing the protection screen, proceed carefully in order not to break the cog. ◆ ◆ ◆ Fig. 54 Insert the bulb in the socket, making the two bulb pins coincide with the relevant guides on the socket.
  • Page 76 $2!).).' 4(% &5%, 4!.+ &IG  42!.30/24 Carefully read p. 25 (FUEL). Before transporting the vehicle, it is nec- ◆ essary to empty the fuel tank and the car- ◆ burettor completely, making sure that both are completely dry. During transport, the vehicle must be held upright, in its normal use position, to avoid any oil and battery fluid leakage.
  • Page 77 #,%!.).' ◆ ◆ ◆ Polish with silicone wax only after having carefully washed the vehicle. ◆ Do not use polishing pastes on matt paints. Do not wash the vehicle under the sun, especially during the summer, when the body is ◆...
  • Page 78 ,/.' 0%2)/$3 /& ).!#4)6)49 ◆ ◆ !&4%2 ! 0%2)/$ /& ).!#4)6)49 ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ Have a test ride at moderate speed in a ◆ low-traffic area. WWW.PlanDeGraissage.ORG...
  • Page 79 4%#(.)#!, $!4! ± WWW.PlanDeGraissage.ORG...
  • Page 80 ÷ ± WWW.PlanDeGraissage.ORG...
  • Page 81 ,5"2)#!.4 #(!24 Transmission oil (recommended): Mixer oil (recommended): Fork oil (recommended): Bearings and other lubrication points (recommended): Protection of the battery poles: WARNING Use new brake fluid only. Brake fluid (recommended): WARNING Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least. Engine coolant (recommended): WWW.PlanDeGraissage.ORG...
  • Page 82 )MPORTERS WWW.PlanDeGraissage.ORG...
  • Page 83 )MPORTERS WWW.PlanDeGraissage.ORG...
  • Page 84 7)2).' $)!'2!- 2ALLY  WWW.PlanDeGraissage.ORG...
  • Page 85 7)2).' $)!'2!- +%9 2ALLY  #!",% #/,/523 WWW.PlanDeGraissage.ORG...
  • Page 86 ./4% !3+ &/2 '%.5).% 30!2% 0!243 /.,9 WWW.PlanDeGraissage.ORG...
  • Page 87 ./4% !3+ &/2 '%.5).% 30!2% 0!243 /.,9 WWW.PlanDeGraissage.ORG...
  • Page 88 WWW.PlanDeGraissage.ORG...