APRILIA RALLY 50 - 2000 Manual
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APRILIA RALLY 50 - 2000 Manual

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RALLY 50
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aprilia part# 8201831

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Summary of Contents for APRILIA RALLY 50 - 2000

  • Page 1 RALLY 50 use maintenance book aprilia part# 8201831...
  • Page 2 Authorized Outlets and Official Dealers, who can en- Reprint: september 1995, february 1997, sure you reliable and prompt servicing. january 1998, december 1998, Thank you for choosing aprilia. We wish you a nice february 1999, january 2000, november 2000 ride. Produced and printed by:...
  • Page 3 Carefully observe the instructions preceded by the In this manual the various versions are indicated by following warning signs: the following symbols: Safety norms and regulations to protect catalytic version the driver and other people from severe injuries or grave risks. VERSION: Ñ...

  • Page 4: Table Of Contents

    SAFE DRIVE ..................5 MAINTENANCE ................41 BASIC SAFETY RULES ..............6 REGULAR SERVICE INTERVALS CHART ........42 CLOTHING ..................12 IDENTIFICATION DATA ..............44 ACCESSORIES ................13 AIR CLEANER ................45 LOAD ....................14 CHECKING THE TRANSMISSION OIL LEVEL ......46 CHANGING THE TRANSMISSION OIL ......... 47 ARRANGEMENT OF THE MAIN ELEMENTS .......16 FRONT WHEEL ................

  • Page 5: Safe Drive

    safe drive...
  • Page 6 To drive the vehicle it is necessary to be in possession of all the requirements prescribed by law (driving licence, minimum age, psychophysical ability, insurance, state taxes, vehicle registration, number plate, etc.). Gradually get to know the vehicle by driving it first in areas with low traffic and/or private areas.
  • Page 7 Most road accidents are caused by the driver’s lack of experi- ence. NEVER lend the vehicle to beginners and, in any case, make sure that the driver has all the requirements for driving. Rigorously observe all road signs and national and local road regulations.
  • Page 8 Avoid obstacles that could damage the vehicle or make you lose control. Avoid riding in the slipstream created by preceding vehicles in order to increase your speed. Always drive with both hands on the handlebars and both feet on the footrests, in the correct driving posture. Avoid standing up or stretching your limbs while driving.
  • Page 9 The driver should pay attention and avoid distractions caused by people, things and movements (never smoke, eat, drink, read, etc.) while driving. Use only the vehicle’s specific fuels and lubricants (indicated in the "LUBRICANT CHART"); check all oil, fuel and coolant levels regularly.
  • Page 10 If necessary, have the vehicle inspected by an aprilia Official Dealer, who should carefully check the frame, handlebars, suspensions, safety parts and all the devices that you cannot check by yourself.
  • Page 11 Further, said modifications cause the loss of the insurance cover, since insurance policies expressly prohibit to make ONLY ORIGINALS technical changes aimed at increasing the vehicle perform- ance levels. For the reasons stated above, the failure to comply with the tampering prohibition is punished by law with apposite sanc- tions (including the confiscation of the vehicle), which, accord- ing to the case, can be combined with the sanctions provided...

  • Page 12: Clothing

    Before starting, always wear a correctly fastened crash hel- met. Make sure that it is homologated, in good shape, of the right size and that the visor is clean. Wear protective clothing, preferably in light and/or reflecting colours. In this way you will make yourself more visible to the other drivers, thus notably reducing the risk of being knocked down, and you will be more protected in case of fall.

  • Page 13: Accessories

    Do not install electrical devices and do not modify those al- ready existing to avoid electrical overloads, because the vehi- cle could suddenly stop or there could be a dangerous current shortage in the horn and in the lights. aprilia recommends the use of “aprilia genuine accessories”.

  • Page 14: Load

    Be careful and moderate when loading your luggage. Keep any luggage loaded as close as possible to the centre of the vehicle and distribute the load uniformly on both sides, in order to reduce imbalance to the minimum. Furthermore, make sure that the load is firmly secured to the vehicle, especially during long trips.
  • Page 15 Do not carry any bag if it is not tightly secured to the vehicle. Do not carry bags which protrude too much from the luggage- rack or which cover the lights, horn or indicators. Do not carry animals or children on the glove compartment or on the luggage-rack.
  • Page 16 1) Mixer oil tank plug 2) Ignition switch/steering lock 3) Front brake fluid reservoir 4) Bag hook 5) Battery/tool kit compartment 6) Inspection cover 7) Anti-theft hook Fig. 1 1) Fuel tank plug 2) Saddle lock 3) Transmission oil filling cap 4) Kick starter 5) Centre stand Fig.
  • Page 17 1) Horn push button ( 2) Cold start lever ( 3) Rear brake lever 4) Rear-view mirror 5) Direction indicator switch ( 6) Instruments and indicators • 7) Headlight switch ( • 7a) Headlight switch ( • 7b) Headlight switch ( 8) Front brake lever Fig.
  • Page 18 1) Red mixer oil reserve warning light ( 2) Green left direction indicator warning light ( 3) Total kilometres odometer 4) Speedometer 5) Amber low fuel warning light ( 6) Green right direction indicator warning light 7) Green low beam warning light ( 7a) Green low beam warning light ( 7b) Blue high beam warning light ( Fig.
  • Page 19 Description Function Mixer oil reserve warning light It comes on when the ignition switch is in position " " and the start push button “ “ is pressed, thus checking the proper func- tioning of the bulb. If the light does not come on during the starting, provide for re- placing the bulb.
  • Page 20 The electrical parts work only when the ignition switch is in position “ ”. 1) HORN PUSH BUTTON ( The horn is activated when the push button is pressed. 2) COLD START LEVER ( The starter for the cold start of the engine is oper- Fig.
  • Page 21 The electrical parts work only when the ignition switch is in position “ ”. 1) LIGHT SWITCH ( - •) When the engine is started and the light switch is in position "•", the lights are off; when the switch is in position "b", the dashboard lights, the parking lights and the low beam are on.

  • Page 22: Steering Lock

    The ignition switch is positioned on the right side, near the steering column. 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). Never turn the key to position “...

  • Page 23: Unlocking/Locking The Saddle

    To unlock and lift the saddle: Insert the key in the saddle lock (1). Turn the key clockwise and raise the saddle (2). Before lowering and locking the saddle, make sure that you have not left the key in the crash helmet/glove compartment. To lock the saddle, lower and press it (without exer- ting too much pressure), thus making the lock snap shut.

  • Page 24: Bag Hook

    This compartment is positioned in the lower part of the vehicle, between the footrests. To reach it, proceed as follows: Insert the key (2) in the lock. Rotate the key (2) clockwise, pull it and remove the cover (3). The tool kit (1) includes: n.

  • Page 25: Fuel

    Use only premium grade petrol (4 Stars ), in con- formity with the DIN 51600 standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.). Use only unleaded petrol, in conformity with the The fuel used for internal combustion en- DIN 51607 standard, min. O.N. 95 (N.O.R.M.) and 85 gines is extremely inflammable and in (N.O.M.M.).
  • Page 26 The use of the vehicle without mixer oil causes serious damages to the engine. If you run out of oil in the mixer oil tank or if the mixer oil pipe has been removed, it is nec- essary to contact an Official Dealer, who will provide for bleeding the system.

  • Page 27: Checking The Brake Pad Wear

    Sudden resistance or clearance problems The brakes are the parts that most ensure on the brake lever may be due to prob- your safety and for this reason they must lems in the hydraulic system. always be perfectly working. For any doubt regarding the perfect functioning The brake fluid must be changed once a year by of the braking system and in case you are not Official Dealer.
  • Page 28 Remove the handlebar cover, see p. 57 (REMO- VING THE FRONT HANDLEBAR COVER). Unscrew the two screws (1-Fig. 16). Remove the cover (2-Fig. 16). In order not to spill the brake fluid while topping up, keep the fluid in the reservoir parallel to the reservoir rim.

  • Page 29: Checking The Brake Shoe Wear

    The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working. 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, contact your Official Dealer.

  • Page 30: Tyres

    Do not install tyres with air tube on rims for tube- less tyres and viceversa. This vehicle is provided with tubeless tyres. Make sure that the tyres always have their valve Periodically check the tyre inflation pres- sealing caps on, to prevent them from suddenly sure at room temperature.

  • Page 31: Catalytic Silencer

    To have the catalytic converter function correctly and for long and to reduce possible problems regarding Avoid parking the Rally 50 catalytic versi- the soiling of the thermal unit and of the exhaust, it is on near dry brush wood or in places easi- necessary to avoid covering long distances with the ly accessible to children, as the catalytic engine running at constantly low rpm.
  • Page 32 Do not hesitate to consult your 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 Component Check Page Front disc brake Check the functioning, the fluid level and make sure there are no leaks. 27, 28, 53 Check the wear of the pads. Top up, if necessary. Rear drum brake Check the functioning, the idle stroke and the control lever conditions. 29, 52, 54 If the clearance is not correct, adjust it Accelerator...

  • Page 34: Starting

    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 Position the vehicle on the centre stand.
  • Page 35 Avoid pressing the start push button " " (1- Fig. 21) when the engine is running: this may damage the starter. Do not accelerate and pull the brake levers at the same time until you move off. Warm the engine up before leaving. Once the engine has warmed up, rotate the cold start lever "...
  • 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: Running-In

    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 Release the throttle grip and stop the vehicle by putting on the brakes. Move the ignition switch (Fig. 24) to position " ". 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 NEVER leave the ignition key inserted and always use the steering lock. Park the vehicle in a safe place, possibly in a garage or a protected place. When possible, use an additional anti-theft device. Make sure that all documents are in order and the road tax has been paid.
  • Page 40 The anti-theft hook (1) is positioned on the right side of the vehicle, near the rider’s footboard. To prevent the vehicle from being stolen, it is advisa- ble to secure it with a lock, which can be easily found on the market. Do not use the hook to lift the vehicle or for any purpose other than securing the vehicle once it has been parked.

  • Page 41: Maintenance

    Before beginning any maintenance oper- If you need assistance or technical advice, consult ation or any inspection of the vehicle, your aprilia Official Dealer, who can ensure you stop the engine, extract the key from the prompt and accurate servicing. After any mainte- ignition block, wait until the engine and the ex- nance operation, carry out the "Preliminary checking...
  • Page 42 After Every Every running-in 4000 km 8000 km Component [500 km (2500 mi) (5000 mi) OPERATIONS TO BE CARRIED (312 mi)] or 12 months or 24 months OUT BY THE Official Deal- Battery - Terminal fastening - – er (WHICH CAN BE CARRIED Electrolyte level OUT EVEN BY THE USER).
  • Page 43 OPERATIONS TO BE CARRIED After Every 4000 km Every 8000 km OUT BY THE Official Deal- running-in Component (2500 mi) (5000 mi) [500 km or 12 months or 24 months (312 mi)] Rear shock absorber – – Transmission cables and controls –...
  • Page 44 It is a good rule to write down the frame and engine numbers in the space provided in this manual. 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.

  • Page 45: Air Cleaner

    Do not use petrol or inflammable solvents to wash the air cleaner, in order to avoid fires or explosions. Carefully read p. 41 (MAINTENANCE). Remember: 1 mile = 1.6 km 1 km = 0.625 miles Check the conditions of the air cleaner and clean it monthly or every 4000 km, depending on the condi- tions in which the vehicle is used.
  • Page 46 To check the transmission oil level, carry out the fol- lowing operations every 4000 km or every 12 months: Drive for a few miles until the engine reaches the normal running temperature, then stop it. Position the vehicle on the stand. Put a graduated container with at least 120 cm capacity under the drain plug (1).
  • Page 47 Tighten the drain plug and add 110 cm of oil, see p. 77 (LUBRICANT CHART). Tighten the filling cap (2). Tighten the filling cap and the drain plug In case of oil leaks or malfunctions, con- thoroughly and make sure that there are tact your Official Dealer.

  • Page 48: Front Wheel

    DISASSEMBLY Carefully read p. 41 (MAINTENANCE). While disassembling the wheel, be care- ful not to damage the brake pipe, the disc and the pads. To disassemble the front wheel, proceed as follows: Position the vehicle on the centre stand. Place a support under the vehicle, so that the front wheel has enough space to move and the vehicle cannot fall down.
  • Page 49 Disconnect the odometer control (3-Fig. 30). Insert the pin (2-Fig. 30) from the right side of the vehicle (direction of travel). Never pull the front brake lever after re- Insert the spacer ring between the hub and the left moving the wheel, otherwise the calliper fork rod.
  • Page 50 DISASSEMBLY Carefully read p. 41 (MAINTENANCE). Position the vehicle on the centre stand. Before carrying out the following opera- tions, let the engine and the silencer cool down until they reach room temperature, in order to avoid burns. Unscrew and remove the two screws (1-2-Fig. 32) that fasten the silencer to the engine, taking the two bushings of the upper screw (2-Fig.
  • Page 51 Put on the rear brake to lock the wheel. Unscrew and remove the wheel nut (1-Fig. 33) and the washer. Upon reassembly, change the wheel nut (special type). Wheel nut (1-Fig. 33) driving torque: 110 Nm (11 kgm). Release the rear brake lever. Withdraw the wheel.
  • Page 52 If necessary, contact your Official Dealer. If you want to carry out this operation by your- self, keep to the following instructions: Disassemble the rear wheel, see p. 50 (REAR WHEEL). Unscrew and remove the adjuster (1). Do not dirt the shoes and the friction ma- terial with grease, to avoid compromising the braking efficiency of the vehicle.
  • Page 53 Upon reassembly: Neither strike, nor force the cam pin (6) with hammers or others tools, in order not to damage the two O-rings. Manually insert the cam pin (6), rotating and push- ing it slightly. Make sure that the springs (2) are correct- ly coupled.
  • Page 54 1 mm. Fig. 36 If the minimum allowed limit has been reached, if you notice any irregularity in the operation or if any part is damaged, contact your aprilia Official Dealer, who will provide for changing the brake shoes.
  • Page 55 Repeat the previous operation more than once. Fig. 37 If you find that there is a considerable slack, contact your aprilia Official Dealer to restore the optimal steer- ing conditions. 5@75CAF9 R@7 7F9AF7 8SD5PSE 3VAQ È8sq $É...
  • Page 56 Carefully read p. 41 (MAINTENANCE). Handle the painted components with care and avoid scraping or damaging them. Position the vehicle on the stand. The operations marked with the symbol must be carried out on both sides of the ve- hicle. Unscrew and remove the two screws (1-Fig.
  • Page 57 Extract the battery. Unscrew and remove the screw (3-Fig. 40), taking the washer. Handle with care. During the removal, do not damage the in- spection cover tangs. Remove the inspection cover (4-Fig. 40) from its seat, pulling it in the direction of travel. Carefully read p.
  • Page 58 Remove the inspection cover, see p. 56 (REMOV- ING THE INSPECTION COVER). Connect an electronic revolution counter to the spark plug cable. Start the engine. The minimum speed of the engine (idling) must be about 1800 100 rpm; in this case the engine does not make the rear wheel rotate.
  • Page 59 Carefully read p. 41 (MAINTENANCE). The ideal slack of the accelerator control should be about 2-3 mm. To adjust the slack, proceed as follows: Position the vehicle on the centre stand. Remove the protection element (1). Loosen the nut (2) (by turning it clockwise). Act on the adjuster (3), positioned at the beginning of the accelerator control cable.

  • Page 60: Spark Plug

    To remove and clean the spark plug: Take off the spark plug cap (1). Remove all the dirt from the base of the spark plug, then unscrew it with the spanner you will find in the tool kit and extract it from its seat, taking care that neither dust nor other substances enter the cylin- der.

  • Page 61: Battery

    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. 75 (TECHNICAL DATA), in order not to 1 km = 0.625 miles compromise the life and performance of the en- Check the electrolyte level and the tightening of the...
  • Page 62 The battery gives off explosive gases; keep it away from flames, sparks, cigarettes and any If the vehicle remains unused for a long period, re- other source of heat. move the battery and place it in a cool and dry place. During the recharging or the use, make sure that Recharge it completely, by using a trickle charge.
  • Page 63 To check the electrolyte level, proceed as follows: Make sure that the ignition switch is in position “ ”. Remove the battery/tool kit compartment cover, see p. 24 (BATTERY/ TOOL KIT COMPARTMENT). Remove the tool kit compartment. Disconnect the negative cable (–) and then the pos- itive cable (+) of the battery.
  • Page 64 If an electric component does not work or works ir- regularly, or if the vehicle fails to start, it is necessary to check the fuse (1): Turn the ignition switch to position “ ”, to avoid any accidental short circuit. Remove the battery/tool kit compartment cover, see p.
  • Page 65 To rapidly check the correct direction of the beam, place the vehicle on flat ground, 10 m away from a wall. Turn on the low beam, sit on the vehicle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height) (Fig.
  • Page 66 Carefully read p. 65 (BULBS). Remove the key from the ignition switch. Position the vehicle on the centre stand. The operations marked with the symbol must be carried out on both sides of the vehicle. Remove the footrest mat. Unscrew and remove the two fastening screws of the bag hook (1-Fig.
  • Page 67 Manually move the protection element (1-Fig. 50) of the bulb to be changed. Rotate the check tang positioned at the rear of the bulb socket anticlockwise. Extract the bulb and replace it with a new one of the same kind. PARKING LIGHT BULB (not provided in the versions)
  • Page 68 Carefully read p. 65 (BULBS). To change the bulbs, proceed as follows: Unscrew and remove the screw (1). 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 69 Carefully read p. 65 (BULBS). To change the bulb: Unscrew and remove the screw (1). While removing the indicator lens, pro- ceed carefully in order not to break it. Remove the indicator lens (2). Press the bulb (3) slightly and turn it anticlockwise. Remove the bulb from its seat.
  • Page 70 WARNING LIGHT BULBS Extract the relative bulb socket: Pos. Warning light Colour Left direction indicators green oil reserve Mixer Right direction indicators ( green Low beam green High beam blue Low fuel amber Fig. 53 Extract the bulb and replace it with one of the same type.
  • Page 71 Carefully read p. 65 (BULBS). To change them, proceed as follows: Unscrew and remove the two screws (1). While removing the protection screen, proceed carefully in order not to break the cog. Remove the protection screen (2). Slightly press the bulb and rotate it anticlockwise. Remove the bulb from its seat.

  • Page 72: Transport

    Carefully read p. 25 (FUEL). Before transporting the vehicle, it is nec- Stop the engine and wait until it has cooled down. essary to empty the fuel tank and the car- Empty the fuel tank by means of a manual pump burettor completely, making sure that both are or a similar system.
  • Page 73 To remove dirt and mud from the painted surfaces use a low- pressure water jet, carefully wet the dirty parts, remove mud and filth with a soft car sponge Clean the vehicle frequently if it used in particular ar- impregnated with a lot of water and shampoo (2 ÷ 4% eas or conditions, such as: parts of shampoo in water).
  • Page 74 Place the vehicle in an unheated, not-humid room, away from sunlight, with minimum temperature After a long period of inactivity of the vehicle some variations. precautions are necessary to avoid any problem. Cover the vehicle avoiding the use of plastic or Further, it is important to carry out the necessary re- waterproof materials.
  • Page 75 DIMENSIONS Max. length ............. 1750 mm Max. width............800 mm Max. height (rear-view mirror included) ..1310 mm Seat height............770 mm Distance between centres ......1250 mm Min. ground clearance ........155 mm Weight without driver (ready for starting) ..91 kg ENGINE Type ..............
  • Page 76 SUSPENSIONS Front ............. hydraulically operated telescopic fork Stroke ............75 mm Rear.............. hydraulic mono-shock absorber Stroke ............75 mm BRAKES Front ............. disc brake, Ø190 mm with hydraulic transmission Rear ............. drum brake, Ø110 mm, with mechanic transmission WHEELS Front ............. 3.50 x 10"...
  • Page 77 Transmission oil (recommended): F.C., SAE 75W - 90 or GEAR SYNTH, SAE 75W - 90. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the A.P.I. GL-4 specifications. Mixer oil (recommended): GREEN HIT 2 or CITY 2T.
  • Page 81 1) Generator 31) Front right direction indicator 2) CDI 32) Front left direction indicator 3) Spark plug 33) Front parking light 4) H.T. coil (not provided in 5) Voltage regulator 34) Low beam bulb 6) Battery 34) Low/high beam bulb ( 7) Starter 35) Horn 8) Start relay...
  • Page 82 - Do not dispose of oil, fuel, polluting substances and components in the environment. - Do not keep the engine running if it is not necessary. - Avoid disturbing noises.

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