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APRILIA RS 50 TUONO Use And Maintenance Book

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RS
TUONO
50
use+maintenancebook
aprilia part# 8202413

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Summary of Contents for APRILIA RS 50 TUONO

  • Page 1 TUONO use+maintenancebook aprilia part# 8202413...

  • Page 2: Safety Warnings

    © 2004 aprilia s.p.a. - Noale (VE) SAFETY WARNINGS INFORMATION ★ The following precautionary warnings are The operations preceded by this used throughout this manual in order to symbol must be repeated on the convey the following messages: opposite side of the vehicle.
  • Page 3 √ modification code (A, B, C, ...); with any means, are reserved for all √ homologation country (I, UK, A, ...). Countries. and are to be supplied to the aprilia Official NOTE some countries Dealer as reference data for the purchase of...

  • Page 4: Table Of Contents

    MAIN COMPONENTS ......22 AIR CLEANER............54 Importers..............81 FUEL................ 22 REMOVING WIRING DIAGRAM - RS 50 TUONO ....83 TRANSMISSION OIL ..........22 THE EXHAUST SILENCER......... 54 WIRING DIAGRAM KEY - RS 50 TUONO..84 BRAKE FLUID-recommendations ....... 23 REMOVING THE FRONT FAIRING....
  • Page 5 safe drive...

  • Page 6: Basic Safety Rules

    Gradually get to know the vehicle by driving it first in areas with low traffic and/or private areas. use and maintenance RS 50 Tuono...
  • Page 7 (or on the rider’s footboards), your speed. wheel, speeding, etc.), and give due in the correct driving posture. consideration to the road surface, visibility Avoid standing up or stretching your and other driving conditions. limbs while driving. use and maintenance RS 50 Tuono...
  • Page 8 A l w a y s r e m e m b e r t o r e p o r t a n y malfunction to the technicians to help them in their work. Never use the vehicle when the amount of damage it has suffered endangers your safety. use and maintenance RS 50 Tuono...

  • Page 9: Clothing

    Strings, belts and ties should not be Avoid off-road driving. hanging loose; prevent these and other objects from interfering with driving by getting entangled with moving parts or driving mechanisms. use and maintenance RS 50 Tuono...

  • Page 10: Accessories

    Furthermore, make sure that at high speed. the load is firmly secured to the vehicle, especially during long trips. use and maintenance RS 50 Tuono...
  • Page 11 RS 50 Tuono...

  • Page 12: Arrangement Of The Main Elements

    13) Shifting lever 4) Fuel tank plug (in the countries where required) 14) Left fairing 5) Spark plug 10) Drive chain 15) Horn 6) Fuel tap 11) Side stand (with automatic return) 7) Battery use and maintenance RS 50 Tuono...
  • Page 13 (snapping, closed/open) 5) Saddle lock 13) Rear brake fluid tank (in the countries where required) 6) Air cleaner 14) Rear brake pump 7) Ignition switch/steering lock 15) Rear brake control lever 8) Right rear-view mirror use and maintenance RS 50 Tuono...

  • Page 14: Arrangement Of The Instruments/Controls

    3) Horn push button ( 10) Start push button ( ) 4) Dimmer switch ( 11) Cold start lever ( ) 5) High beam signalling push button ( 6) Clutch lever 7) Instruments and indicators use and maintenance RS 50 Tuono...

  • Page 15: Instruments And Indicators

    11) Total kilometres odometer 5) Red 2 stroke oil reserve warning light ( 12) Speedometer 6) Blue high beam warning light ( 13) Speedometer - only km/h scale 7) Green low beam warning light ( use and maintenance RS 50 Tuono...

  • Page 16: Instruments And Indicators Table

    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. use and maintenance RS 50 Tuono...

  • Page 17: Main Independent Controls

    5) COLD START LEVER ( ) The starter for the cold start of the engine is operated by rotating the lever " " downwards. To disconnect the starter, move the lever " " to its initial position. use and maintenance RS 50 Tuono...

  • Page 18: Of The Handlebar

    CONTROLS ON THE RIGHT PART OF THE HANDLEBAR 1) START PUSH BUTTON ( ) When the start push button ≈ ∆ is pressed, the starter makes the engine run. For the starting, see p. 32 (STARTING). use and maintenance RS 50 Tuono...

  • Page 19: Ignition Switch

    (one spare key). To lock the steering: Turn the handlebar completely leftwards. ◆ Turn the key to position ≈ ∆. ◆ Press the key and rotate it to position ≈ ∆. ◆ Extract the key. ◆ use and maintenance RS 50 Tuono...

  • Page 20: Auxiliary Equipment

    √ D o u b l e - e n d e d , c r o s s - / c u t headedscrewdriver √ Bent pin for socket spanner √ Tool case Max. allowed weight: 1.5 kg use and maintenance RS 50 Tuono...

  • Page 21: Special Tools

    Drive chain adjustment. Front support Front wheel disassembly. stand (3) SPECIAL TOOLS To perform some specific operations, it is advisable to use the following special tools (to be requested to an aprilia Official Dealer). use and maintenance RS 50 Tuono...

  • Page 22: Main Components

    In case any maintenance operation has To refuel, proceed as follows: means of a tube. to be carried out, it is advisable to use Insert the key (1) in the tank plug lock ◆ latex gloves. (2). use and maintenance RS 50 Tuono...

  • Page 23: Brake Fluid-Recommendations

    Official Dealer. the tanks, see p. 24 (FRONT BRAKE), p. 25 (REAR BRAKE) and the wear of the pads, see p. 57 (CHECKING THE BRAKE PAD WEAR). use and maintenance RS 50 Tuono...

  • Page 24: Front Brake

    Remove the gasket (5). ◆ Make sure that the brake fluid contained ◆ aprilia Official Dealer, since it may be in the tank covers the glass gauge (2) CAUTION necessary to bleed the system. completely.

  • Page 25: Rear Brake

    Keep the vehicle in vertical position, so ◆ aprilia Official Dealer, since it may be that the fluid contained in the tank (1) is necessary to bleed the system. parallel to the plug (2).

  • Page 26: Stroke Oil Tank

    Do not dispose of the 2 stroke oil in the the running of the engine with air in the environment. mixer oil system may result in serious damage to the engine. KEEP AWAY FROM CHILDREN. use and maintenance RS 50 Tuono...

  • Page 27: Adjusting The Rear Brake

    0 . 5 ÷ 1 m m between the pump control rod (4) and the pump piston. use and maintenance RS 50 Tuono...

  • Page 28: Adjusting The Clutch

    In case maintenance operations are to be performed, it is advisable to use latex gloves. Have the coolant changed by an aprilia Official Dealer. use and maintenance RS 50 Tuono...
  • Page 29 Have it repaired by an aprilia Official CHECKING AND TOPPING UP Do not use your fingers or any other Dealer. object to check if there is enough coolant.

  • Page 30: Tyres

    CO (carbon monoxide) and of the HC the above mentioned operations carried to the handlebar, thus compromising (unburned hydrocarbons) contained in the out by an aprilia Official Dealer or by a the driving comfort and reducing the exhaust gases, changing them into carbon qualified tyre repairer.

  • Page 31: Instructions For Use

    Wheel/tyres Check the tyre surface, the inflation pressure, wear and tear and any damage. Do not hesitate to consult your aprilia Brake levers Make sure that they work smoothly. If necessary, O f f i c i a l D e a l e r i n c a s e t h e r e i s lubricate the articulations and adjust the stroke.

  • Page 32: Starting

    When the vehicle is straightened from the start push button ≈ ∆ again. the parking position to the driving position, the stand goes automatically Get on the vehicle. ◆ Move the fuel tap lever (1) to position ◆ ≈ON∆. use and maintenance RS 50 Tuono...
  • Page 33 (6). at low speed for the first miles. With warm engine: Rotate the cold start lever ≈ ∆ (3) ◆ upwards after the engine has warmed use and maintenance RS 50 Tuono...

  • Page 34: Departure And Drive

    “rearing up” vehicles correctly. (quick release). NEVER RIDE IN ANY POSITION OTHER THAN THOSE INDICATED. Ride at reduced speed for the first miles, ◆ in order to warm the engine up. use and maintenance RS 50 Tuono...
  • Page 35 Release the clutch lever and accelerate ◆ comes on, this means that the 2 stroke moderately. oil reserve is being used; in this case, provide for topping up, see p. 26 (2 STROKE OIL TANK). use and maintenance RS 50 Tuono...
  • Page 36 In case of rain, the water cloud created grip and fall down. overheating of the clutch. by big vehicles reduces visibility; the air shift may make you lose control of the vehicle. use and maintenance RS 50 Tuono...

  • Page 37: Running-In

    300-500 km (187-312 mi) inserted into the ignition switch. Do not keep the throttle grip open more than three-fourths for long stretches. Do not sit on the vehicle when the stand is down. use and maintenance RS 50 Tuono...

  • Page 38: Suggestions To Prevent Theft

    Incline the vehicle until the stand rests ◆ on the ground. TELEPHONE NO.: ........NOTE Very often stolen vehicles are WARNING identified thanks to the data written in the Make sure that the vehicle is stable. use/maintenance manual. use and maintenance RS 50 Tuono...

  • Page 39: Maintenance

    Ask your aprilia Official Dealer to test the CAUTION key, wait until the engine and the vehicle on the road after a repair or...

  • Page 40: Regular Service Intervals Chart

    Headlight beam direction - operation uneven ground. √ Engine idling rpm every month: Wheels/tyres and inflation pressure every 500 km: Drive chain tension and lubrication every 2000 km (1250 mi): Front and rear brake pad wear use and maintenance RS 50 Tuono...
  • Page 41 Battery terminals tightening √ Mixer oil reserve warning light LED √ √ Final transmission (chain, crown, pinion) √ every 4 years: Fuel pipe √ every 4 years: Mixer oil pipes √ √ Clutch wear use and maintenance RS 50 Tuono...

  • Page 42: Identification Data

    (see figure). of the guarantee. Engine no. FRAME NUMBER The frame number is stamped on the right side of the steering column. Frame no. use and maintenance RS 50 Tuono...

  • Page 43: Positioning The Vehicle On The Rear Support Stand

    (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). use and maintenance RS 50 Tuono...

  • Page 44: Checking The Transmission Oil Level And Topping Up

    If so, proceed as follows: and may also cause irreparable failures. Check and if necessary change the ◆ sealing washer (2). Tighten the screw (1). ◆ Otherwise: Provide for topping up. ◆ use and maintenance RS 50 Tuono...

  • Page 45: Changing The Transmission Oil

    Stop the engine and let it cool down for sealing washer of the drain plug (2). at least ten minutes, in order to allow the oil to flow back to the oil pan and to cool down. use and maintenance RS 50 Tuono...

  • Page 46: Front Wheel

    If you want to perform these operations brake fluid. In this case consult your FRONT SUPPORT STAND personally, keep to th e following aprilia Official Dealer, who will carry out instructions. WARNING the proper maintenance operation. Carefully read p. 39 (MAINTENANCE).
  • Page 47 ◆ Spread a film of lubricating grease on the aprilia Official Dealer, in order to avoid While reassembling the wheel, be whole length of the wheel pin (5), see accidents that may be harmful for you careful not to damage the brake pipe, p.

  • Page 48: Rear Wheel

    ◆ Withdraw the wheel from the rear fork avoid burns. 80 Nm (8 kgm). from behind, carefully withdrawing the ◆ disc from the brake caliper. Loosen and remove the nut (2), taking the washer. use and maintenance RS 50 Tuono...
  • Page 49 Take the right spacer ring (9). ◆ balancing of the wheel checked by your Danger of injury. aprilia Official Dealer, in order to avoid Do not introduce your fingers to align accidents that may be harmful for you REASSEMBLY the holes.

  • Page 50: Drive Chain

    . 5 1 and crown in the lower part of the chain, (ADJUSTMENT). is about 25 mm. To change the chain, contact an aprilia Official Dealer, who will ensure you prompt and accurate servicing. use and maintenance RS 50 Tuono...
  • Page 51 Tighten the two lock nuts (5). ◆ If this is not possible, contact an aprilia Tighten the nut (2). ◆ Official Dealer, who will provide for changing the chain.

  • Page 52: Removing The Rider Saddle

    (3) is properly positioned and scraping or damaging them. locked. use and maintenance RS 50 Tuono...

  • Page 53: Lifting The Fuel Tank

    DO NOT DISPOSE OF FUEL IN THE of the rider saddle. ENVIRONMENT. Move the fuel tap lever (1) to position ◆ ≈OFF∆. Remove the rider saddle, see p. 52 ◆ (REMOVING THE RIDER SADDLE). use and maintenance RS 50 Tuono...

  • Page 54: Air Cleaner

    Be fore the cleaning operation, it is take the washer. necessary to remove the air cleaner from Take the support (9). ◆ the vehicle. Support the exhaust silencer and withdraw ◆ it from the exhaust manifold (10). use and maintenance RS 50 Tuono...

  • Page 55: Removing The Front Fairing

    (2) because it is fixed on plastic. c o m p o n e n t s w i t h c a r e a n d a v o i d scraping or damaging them. use and maintenance RS 50 Tuono...

  • Page 56: Inspecting The Front And Rear Suspensions

    CAUTION If y ou notic e irregularities in the operation or if the help of a qualified technician is necessary, contact your aprilia Official Dealer. use and maintenance RS 50 Tuono...

  • Page 57: Checking The Brake Pad Wear

    1 mm, replace both pads. √ Front pad (3). CAUTION √ Rear pad (4). Check the wear of the brake pads, especially before every trip. WARNING Have the pads changed by your aprilia Official Dealer. use and maintenance RS 50 Tuono...

  • Page 58: Idling Adjustment

    The engine idling speed must be about the idling speed is constant. 1100 ± 100 rpm. NOTE If necessary, contact your aprilia Official Dealer. use and maintenance RS 50 Tuono...

  • Page 59: Spark Plug

    Energetically blow some air, in order to ◆ ◆ prevent the removed residues from getting into the engine. If the spark plug has crackings on the insulating material, corroded electrodes or excessive deposits, it mu st be changed. use and maintenance RS 50 Tuono...

  • Page 60: Battery

    Connect and disconnect the battery cigarettes and any other source of heat. with the ignition switch in position “ ”. Connect first the positive cable (+) and then the negative cable (–). Disconnect following the reverse order. use and maintenance RS 50 Tuono...

  • Page 61: Checking And Cleaning The Terminals

    WARNING Once it has been removed, the battery must be stored in a safe place and kept away from children. use and maintenance RS 50 Tuono...

  • Page 62: Checking The Electrolyte Level

    Remove the element plugs. ◆ continues to produce gas for a short Put back the rider saddle, see p. 52 ◆ lapse of time. (REMOVING THE RIDER SADDLE). use and maintenance RS 50 Tuono...

  • Page 63: Changing The Fuse

    Upon reassembly, first screw the works irregularly, or if the vehicle fails to Official Dealer. three nuts (7) (without tightening them) and start, it is necessary to check the fuse (1). then tighten them. use and maintenance RS 50 Tuono...
  • Page 64 After every cleaning operation, (18), without exceeding the depth (C). remove the reference mark and remove Clean the outlet pipe (19) by means of ◆ any deposit from the cleaning brush. the cleaning brush. use and maintenance RS 50 Tuono...

  • Page 65: Checking The Side Stand

    ◆ The springs (2) must not be damaged, ◆ damaged, worn or weakened. worn, rusty or weakened. The side stand must rotate freely, if ◆ necessary grease the joint, see p. 76 (LUBRICANT CHART). use and maintenance RS 50 Tuono...

  • Page 66: Adjusting The Vertical Headlight Beam

    (about 9/10th of the total height). CAUTION Upon disassembly and reassembly, check the position of inner cover (2) and make sure that it is properly seated on the front fairing. use and maintenance RS 50 Tuono...

  • Page 67: Bulbs

    (4), DO NOT FORCE THE ELECTRIC pull it and remove it from its seat. CABLES. Withdraw the parking light bulb (5) and ◆ replace it with one of the same type. use and maintenance RS 50 Tuono...

  • Page 68: Changing The Front And Rear Direction Indicator Bulbs

    Upon reassembly, correctly coincide. coincide. position the protection screen in its seat. Correctly install a new bulb of the same Correctly install a new bulb of the same ◆ ◆ type. type. use and maintenance RS 50 Tuono...

  • Page 69: Changing The Rear Light Bulb

    Upon reassembly, correctly NOTE position the protection screen in its seat. If the bulb socket (15) goes out of its seat, insert it correctly, making the bulb socket opening coincide with the screw seat. use and maintenance RS 50 Tuono...

  • Page 70: Transport

    If necessary, contact an aprilia Official Empty the fuel tank by means of a ◆ Dealer. manual pump or a similar system. WARNING In case of failure, do not tow the vehicle, but ask for assistance. use and maintenance RS 50 Tuono...

  • Page 71: Cleaning

    WARNING Do not apply protection waxes onto the saddle, in order not to make it too slippery. use and maintenance RS 50 Tuono...

  • Page 72: Long Periods Of Inactivity

    ◆ humid room, away from sunlight, with minimum temperature variations. WARNING Cover the vehicle avoiding the use of Have a test ride at moderate speed in a ◆ plastic or waterproof materials. low-traffic area. use and maintenance RS 50 Tuono...

  • Page 73: Technical Data

    285 cm> (for each rod) Seats ............1 (2 in the countries where this is allowed) Vehicle max. load (driver + luggage) ......... 105 kg (driver+passenger+luggage) ......180 kg (in the countries where this is allowed) use and maintenance RS 50 Tuono...
  • Page 74 - Æ 280 mm - with hydraulic transmission Rear ............. disc brake - Æ 220 mm - with hydraulic transmission WHEEL RIMS Type ............. light alloy Front............. 2.50 x 17∆ Rear ............. 3.00 x 17∆ use and maintenance RS 50 Tuono...
  • Page 75 2 stroke oil reserve ........12 V - 1.7 W Left direction indicators ........ 12 V - 1.7 W Low beam ............. 12 V - 1.7 W (*) (in the countries where this is allowed) use and maintenance RS 50 Tuono...

  • Page 76: Lubricant Chart

    F.F., DOT 4 ( BRAKE 5.1 DOT 4 DOT 5 compatible) or (DOT 5 compatible) WARNING Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least. Engine coolant (recommended): ECOBLU - 40°C or COOL use and maintenance RS 50 Tuono...

  • Page 77: Authorised Dealers And Service Centres

    AUTHORISED DEALERS AND SERVICE CENTRES THE VALUE OF SERVICE Thanks to ongoing technical updates and product-specific technical training, aprilia Authorised Network engineers are familiar with every detail of this motorcycle and have the special equipment required for correct maintenance and repair.

  • Page 78: Importers

    Importers APRILIA via G. Galilei, 1 - 30033 Noale (VE) Italy Tel. +39(0)41 5829111 - Fax +39(0)41 441054 - Servizio Clienti aprilia +39(0)41 5079821 APRILIA WORLD SERVICE UK branch 15 Gregory Way - SK5 7ST Stockport - Cheshire Tel. 0044-161 475 1800 - Fax 0044-161 475 1825 - Email: massimo_granata@aprilia.com...

  • Page 79: Importers

    Tel. 0032-9-2829410 - Fax. 0032-9-2810012 - Email: Kurt_Derynck@rad.be T.M.P. Hammervej 32 - 7900 - Nikobing Mors Tel. 0045-97-722233 - Fax. 0045-97-722143/33 - Email: thomas@aprilia.dk TUONTI NAKKILA OY P.o.B. 18 - 29250 - Nakkila Tel. 00358-2-5352500 - Fax. 00358-2-5372793 - Email: satu.saarinen@aprilia.fi RO GROUP INT.(sede operativa)

  • Page 80: Importers

    Tel. 0027-11-7868486 - Fax. 0027-11-7868482 - Email: motovelo@betech.co.za APRILIA DE MEXICO, SA. de CV. San Jeromino - 64640 - 552 Monterrey N.L. Tel. 0052-818333-4493 - Fax. 0052-818348-9398 - sbertu Email: javier@aprilia.com.mx BIKE KOREA CO. LTD. YeungSoo Bldg. 302 #206-25, Ohjang-Dong, Chung-Ku Seoul Tel.

  • Page 81: Importers

    Ul. Zakliki z Mydlnik 16 30-198 Krakow Tel. 0048-126232680 - Fax 0048-124253366 - Email: lukasz.wicher@ktm.info TOTAL TITANIUM SDN BHD Lot 7B Jalan Bersatu 13/4 - Section 13 46200 Petaling Jaya Selangor Tel. 0060326983500 - Fax 0060326981195 - Email: ajackso@attglobal.net use and maintenance RS 50 Tuono...
  • Page 82 WIRING DIAGRAM - RS 50 Tuono PASSING Bi/N Bi/N Bi/R Bi/R use and maintenance RS 50 Tuono...

  • Page 83: Wiring Diagram - Rs 50 Tuono

    WIRING DIAGRAM KEY - RS 50 Tuono 1) Generator 36) Front stoplight switch 2) Coil 37) Headlight 3) Regulator 38) Direction indicators extension 4) Rectifier 5) Battery CABLE COLOURS 6) Start relay 7) Rear stoplight switch Ar Orange 8) Oil level sensor...
  • Page 84 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RS 50 Tuono...
  • Page 85 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RS 50 Tuono...
  • Page 86 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RS 50 Tuono...
  • Page 87 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RS 50 Tuono...
  • Page 88 √ Do not dispose of oil, fuel, polluting substances and components in the environment. √ Do not keep the engine running if it isn»t necessary. √ Avoid disturbing noises.

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