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APRILIA 6.5 - 1996, Manual, Page: 35 / 64

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APRILIA 6.5 - 1996 Manual Download Page 35

COMPONENT 

AFTER RUNNING-IN

(1000 km OR 4 MONTHS)

EVERY 6000 km

OR 8 MONTHS

EVERY 12000 km

OR 16 MONTHS

Battery - fluid level  

C

C

Spark plug

S

Carburettor

C

P

Gearing chain

every 500 km: C

Timing chain

C

Wheel centering

C

Steering bearings and steering   

C

C

Wheel bearings

C

Air filter

P

every 18000 km: S

Engine oil filter

S

S

Clutch clearance

R

R

Tappet clearance

C

R

Braking systems

C

C

Cooling system

C

C

Light system

C

C

Brake fluid

C

every year: S

Coolant

every 2 years: S

Fork oil

S

Engine oil

S

every 500 km: C / every 6000 km: S

Tyre inflation pressure

R

every month: R

Minimum rpm

R

R

Fuel tap

C

C

Nut, bolt, screw tightening

C

C

Suspensions and attitude

C

C

Brake fluid drain

C

Spoke tension

C

C

Fuel pipes

C

every 4 years: S

C

= check, clean, adjust, lubricate or change if necessary.      

 P

 = clean, 

      S

 = change,

       R 

= adjust

Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas or on uneven ground.

Have the maintenance operations on the 

 indicated components carried out by 

DSULOLD

Official Dealers ONLY.

3(5,2',& 0$,17(1$1&( &+$57

Remember:   1 mi = 1,6 km   1 km = 0,625 mi

35

Summary of Contents for 6.5 - 1996

Page 1: ...Motó 6 5 MOTO 6 5 use and maintenance aprilia part 8102710 ...

Page 2: ...r par tial adaptation with any means are reserved for all Countries The mention to products or services supplied by third parties is made only for information purposes and it isn t binding in any case aprilia s p a takes no responsibility as to the performance or the use of said products First edition January 1996 Reprint Produced and printed by 6WXGLR 7HFQR 3XEOLF Viale del Progresso 37038 Soave ...

Page 3: ... Dealers who can ensure you reliable and prompt servicing Thank you for choosing aprilia We wish you a nice ride Carefully observe the instructions preceded by the following warning signs Safety norms and regulations to protect the driver and other people from severe injuries or grave risks Caution norms and suggestions to avoid damaging the vehicle and or hurting yourself or other people Indicati...

Page 4: ...NTENANCE CHART 35 IDENTIFICATION DATA 36 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP 36 CHANGING THE ENGINE OIL AND THE OIL FILTER 37 FRONT WHEEL 38 REAR WHEEL 39 CHAIN 40 REMOVING THE FUEL TANK 42 AIR FILTER 42 FRONT AND REAR SUSPENSION INSPECTION 43 ADJUSTING THE REAR SUSPENSION 43 CHECKING THE STEERING 44 LOCKING UNLOCKING THE SADDLE 45 REMOVING THE SIDES 45 IDLING ADJUSTMENT 46 TAKING UP THE ...

Page 5: ...safe drive ...

Page 6: ...ivate areas The taking of some medicinal prepara tions alcohol and drugs or psycho tropic substances notably increases the risk of accidents Be sure that you are in good psycho physical conditions fit for driving paying particular attention to physical weariness and drowsiness Most road accidents are ascribable to the driver s lack of experience NEVER lend the vehicle to beginners and in any case ...

Page 7: ...e into consideration the road surface conditions visibility etc Do not hit obstacles which could damage the vehicle or make you loose the con trol Do not drive in the slipstream of the preceding vehicles in order to increase your speed Always drive with both hands on the handlebar and both feet on the footrests in the correct driving posture Absolutely avoid standing up or stretch ing your limbs w...

Page 8: ...dent if it has been hit or has fallen down make sure that the control levers the pipes the wires the braking system and the vital parts haven t been dam aged If necessary have the vehicle controlled by an aprilia Official Dealer asking him to carefully check the frame the handle bar the suspensions the safety parts and the devices whose integrity you are not able to verify Always remember to repor...

Page 9: ...s wear your crash helmet correctly fastened Make sure that it is homologated sound of the right size and that the visor is clean Wear protective clothing preferably in light and or reflecting colours This way you will make yourself more visible to other drivers thus notably re ducing the risk of being knocked down and you will be more protected in case of fall This clothing should be very close fi...

Page 10: ... during an emergency Large fairings and windscreens assem bled on the vehicle can produce aerody namic forces capable of compromising the stability of the vehicle itself while driving Make sure that the equipment is well fastened to the vehicle and is not dan gerous during the drive Do not install electrical devices and do not modify those already existing to avoid electrical overloads because the...

Page 11: ...osite string as they could hit people or obstacles thus caus ing the loss of 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 much from the luggage rack or which cover the lights the horn or the indica tors Do not carry animals or children on the glove compartment or on the luggage rack Do not exceed the maximum load allo...

Page 12: ... LJ 1 Fuel tank plug 2 Coolant expansion tank plug 3 Crash helmet hook 4 Battery 5 Fuses 6 Transmission control lever 7 Footrest 8 Side stand 9 Passenger s footrest 55 1 0 17 2 7 0 1 0 176 Fig 1 12 ...

Page 13: ...compartment 2 Fuel tap 3 Motor oil inlet hole plug stick 4 Front brake fluid tank 5 Passenger s footrest 6 Rear suspension spring loading adjusting nut 7 Footrest 8 Rear brake control lever 9 Rear brake fluid tank Fig 2 13 ...

Page 14: ...ntrol lever 9 Headlight switch 10 Horn push button 11 Turn indicator switch 12 Light switchi 13 Starting push button 14 Throttle grip 15 Front brake lever LJ 1 Coolant temperature indicator 2 Speedometer 3 Total kilometres odometer 4 Trip odometer control knob 5 Trip odometer 6 High beam warning light 7 Neutral indicator warning light 8 Low motor oil pressure warning light 9 Turn indicator warning...

Page 15: ...al Turn indicator warning light It blinks when one of the turn indicators is on Low motor oil pressure warning light It comes on every time the key is turned to the ON position and the engine isn t running checking the proper functioning of the lamp If during this phase the lamp doesn t turn on it must be replaced The warning light must go out when the engine starts running exception made for the ...

Page 16: ... downwards To disconnect the starter it is necessary to rotate the lever completely upwards 3 HIGH BEAM SIGNALLER PUSH BUTTON This push button makes it possible to use the high beam sig naller which is useful to send signals to the forthcoming ve hicles when passing and in case of danger or emergency 4 TURN INDICATOR SWITCH To indicate the turn to the left move the switch to the left to indicate t...

Page 17: ...e switch to the position 2 STARTING PUSH BUTTON When the starting push button is pressed the starter makes the engine run For the starting see p 28 STARTING 3 LIGHT SWITCH When the switch is on the position the headlights are off when the switch is on the position the parking lights are on when the switch is on the position the low beams are on It is possible to turn on the high beams by means of ...

Page 18: ...r possible to start the engine nor to switch on the lights It is possible to remove the key OFF Neither the engine nor the lights can be switched on It is possible to remove the key ON The engine and the lights can be switched on It isn t possible to remove the key 8 5 48 30 17 722 7 LJ To reach the tool kit introduce the igni tion key in the lock of the tool kit glove compartment and turn it anti...

Page 19: ... smoke while refuelling or near fuel vapours in any case avoid any con tact with free flames sparks and any other heat source to prevent the fuel from catching fire or from exploding Further prevent fuel from flowing out of the fuel filler as it could catch fire when getting in contact with the red hot surfaces of the engine In case some fuel has accidentally been spilt make sure that the area has...

Page 20: ...ver are due to troubles in the hydraulic system For any doubt regarding the perfect functioning of the braking sys tem and in case you are not able to carry out the usual checking operation s contact your DSULOLD Official Dealer Make sure that the brake disc and the friction surface are neither oily nor greasy especially after maintenance or checking operations Check that the brake cables are neit...

Page 21: ...le in vertical position Remove the gasket Fill the tank with brake fluid see p 59 LUBRICANT CHART until this co vers the glass 1 completely Put the gasket back Put the little cover 3 back and tighten the screws 2 Check the braking efficiency In case of excessive stroke of the brake lever of excessive elasticity or in case there is air in the circuit contact your DSULOLD Official Dealer since it ma...

Page 22: ... Unscrew the plug 2 In order not to spill the brake fluid when topping up keep the fluid in the tank parallel to the ground Remove the gasket Fill the tank until the fluid reaches the MAX notch Put the gasket back Screw the plug 2 thoroughly Check the braking efficiency In case of excessive stroke of the brake lever of excessive elasticity or in case there is air in the circuit contact your DSULOL...

Page 23: ...Remove the protection element 2 Loosen the lock nut 3 Rotate the adjuster 1 until the idle stroke of the clutch lever end is about 10 mm Tighten the lock nut 3 and check the adjustment again Fig 15 Start the engine and engage the 1st gear make sure that the engine does n t stop doesn t tend to advance or that the clutch doesn t slip during the acceleration phase or while the vehicle is running If ...

Page 24: ...ncy of the cooling system is thus preserved For the cooling solution use distilled water mixed with antifreeze Do not remove the radiator plug when the engine is hot since the coolant is under pressure and its temperature is high If it gets in contact with the skin or with clothes it can cause severe burns and or damages The coolant is noxious DO NOT SWALLOW IT KEEP AWAY FROM CHILDREN CHECKING AND...

Page 25: ... the silencer clean and eliminating the exhaust fumes To have the catalytic converter function correctly and for long and to reduce possible problems regarding the soiling of the thermal unit and of the exhaust it is necessary to avoid covering long dis tances with the engine running at con stantly low rpm It is sufficient to alternate these periods with periods in which the engine runs at relativ...

Page 26: ...both their grip and the control lability of the vehicle Change the tyre when it is worn out or in case of puncture on the tread side if the puncture is larger than 5 mm After repairing a tyre have the wheels balanced Use only tyres in the size suggested by aprilia see p 56 TECHNICAL DATA Make sure that the tyres always have their valve sealing caps to prevent them from suddenly going flat Change r...

Page 27: ...g of the starting lock system 50 Fastening elements If necessary tighten all the fastening elements Gearing chain Check the slack 40 Fuel tank Check the fuel level and top up if necessary Make sure there are no leaks or occlusions in the circuit 42 Coolant The coolant level in the expansion tank must be included between the MIN and MAX notches 24 Lights warning lights horn and electric devices Che...

Page 28: ... avoid losing control of the vehicle If this operation is carried out on uphill or downhill roads be particu larly careful Turn the fuel tap lever to the ON po sition 1 Fig 17 Turn the ignition switch to the ON po sition 1 Fig 18 Fig 17 The engine can be started with the side stand down only if the gears are in neutral in this case if you try to engage the gears the en gine stops With the side sta...

Page 29: ...A few seconds after the engine start the warning light must go out If this does not occur it is necessary to top up the engine oil In this case stop the engine immedi ately and proceed as indicated at page 36 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP Do not use the vehicle with insufficient oil in the tank in order not to damage the engine components Warm the engine up until it runs nor mally w...

Page 30: ... 5785 1 5 9 LJ Before departure read p 5 SAFE DRIVE and p 50 CHECKING THE SIDE STAND SWITCH carefully Adjust the inclination of the rear view mirrors properly If there is no other passenger with you make sure that the rear foot rests are closed Before leaving make sure that the side stand is completely folded If there is a passenger with you in struct him her so that he she doesn t create problems...

Page 31: ...s the fric tion surfaces can become overheated thus reducing the braking efficiency Exploit the engine compression and shift down using both brakes intermit tently Do not drive with the engine off In case of wet ground or scarce wheel grip snow ice mud etc drive slowly avoiding sudden brakings or ma noeuvres that could make you lose grip and fall down Pay the utmost attention to any obstacle or va...

Page 32: ... see table After the first 1000 kilometres carry out the checking operation s indicated in the Periodic main tenance chart see p 37 PERIODIC MAINTENANCE CHART in order to avoid hurting yourself or other people and or damaging the vehicle Between the first 1000 and 2000 km drive more briskly change speed and use the maximum acceleration only for a few seconds in order to ensure bet ter coupling of ...

Page 33: ... on the ground Make sure that the vehicle and espe cially its red hot parts do not represent a danger for persons and children Do not leave the vehicle unattended when the engine is on or the key is in serted into the ignition block Do not seat on the vehicle when the prop stand is down 68 67 216 72 35 9 17 7 7 NEVER leave the ignition key in the block and always use the steering lock Park the veh...

Page 34: ...rts Never bite suck chew or swallow any part of the vehicle for any reason If not expressly indicated other wise for the reassembly of the units repeat the disassembly operations reversing the order Ordinary maintenance operations can be carried out by the user but sometimes a basic knowledge of mechanics and spe cific tools are required If you need assistance or technical ad vice consult your apr...

Page 35: ...ear S Coolant every 2 years S Fork oil S Engine oil S every 500 km C every 6000 km S Tyre inflation pressure R every month R Minimum rpm R R Fuel tap C C Nut bolt screw tightening C C Suspensions and attitude C C Brake fluid drain C Spoke tension C C Fuel pipes C every 4 years S C check clean adjust lubricate or change if necessary P clean S change R adjust Carry out the maintenance operations mor...

Page 36: ...e engine and let it cool down for at least 10 minutes in order to allow the oil to flow back to the oil pan and to cool down Keep the vehicle in vertical position with the two wheels resting on the ground Let the engine idle for at least one minute in order to allow the filling of the oil tank Stop the engine If you don t carry out the above mentioned operations you run the risk of making a wrong ...

Page 37: ...n plug 1 Fig 28 positioned on the bottom of the base a special hole has been made on the exhaust silencer Drain the oil and let it drip into a con tainer for a few minutes Remove the metal residues from the drain plug magnet At this point change the oil filter Unscrew the two screws 1 Fig 29 and remove the cover 2 Fig 29 Remove the oil filter and change it Put a thin layer of engine oil on the O r...

Page 38: ...e speedometer control 3 Fig 30 and the spacing bushing posi tioned on the left side of the wheel When removing the wheel ex tract the brake calliper disc with care REASSEMBLY To reassemble the wheel Position the front wheel between the fork rods carefully introducing the disc in the brake calliper Position the spacing bush left side of the wheel and the speedometer con trol 3 Fig 30 Grease the pin...

Page 39: ...ng the rear wheel for ward see p 40 CHAIN and p 41 ADJUSTMENT Remove the wheel from the rear fork When removing the wheel ex tract the brake calliper disc with care REASSEMBLY To reassemble the wheel proceed as follows Position the wheel between the fork rods carefully introducing the disc in the brake calliper Push the wheel forward and position the gearing chain in its seat Insert the pin 1 Fig ...

Page 40: ... check the slack proceed as follows Stop the engine position the vehicle on the side stand and put the gears into neutral Make sure that the vertical oscillation in an intermediate point between pi nion and crown in the lower branch of the chain is about 20 25 mm Fig 33 Move the vehicle forward in such a way as to be able to check the vertical oscillation of the chain also when the wheel turns the...

Page 41: ...n and make sure that they do not present damaged rollers loose pins dry rusty crushed or seized links ex cessive wear lacking O rings excess ively worn or damaged pinion teeth If the chain rollers are damaged the pins are loose and or the O rings are either damaged or lacking it is necessary to replace the whole chain unit pinion crown and chain Lubricate the chain frequently especially if there a...

Page 42: ...in order to avoid fires or explo sions Read page 34 MAINTENANCE care fully Periodically check the conditions of the air filter and clean it every 6000 km If the vehicle is used on dusty or wet roads the cleaning operations should be carried out more frequently 1 Fig 36 1 1 Fig 37 1 2 3 Fig 38 For the cleaning proceed as follows Remove the saddle see p 45 LOCK ING UNLOCKING THE SADDLE Remove the fi...

Page 43: ...d technician is necessary contact your DSULOLD Official Dealer 867 1 7 5 5 6863 16 21 LJ The rear suspension consists of a spring shock absorber unit fixed to the frame and the rear fork by means of a silent block The shock absorber is provided with nut 1 and lock nut 2 for the adjustment of the spring loading The standard adjustment set by the manufacturer is suitable for a driver weighing about ...

Page 44: ... BULBS Loosen the two screws 1 2 Fig 42 Loosen the nut 1 Fig 43 and act on the adjusting metal ring 2 Fig 43 with the apposite key thus taking up the slack Repeat the check until the problem is over Tighten the nut firmly 1 Fig 43 Tighten the screws 1 2 Fig 42 Move the headlight dashboard unit to its initial position Once this operation has been carried out make sure that the handlebar turns smoot...

Page 45: ... two side tangs in the relevant guide pins then tighten the screw 1 firmly Before moving off make sure that the saddle is correctly lock ed 1 2 Fig 46 5 029 1 7 6 6 LJ Proceed as follows Remove the saddle see LOCKING UNLOCKING THE SADDLE Unscrew and remove the screw 1 Fig 45 Unscrew and remove the two screws 1 2 Fig 46 Remove the left side To remove the right side repeat the operations described a...

Page 46: ... 100 rpm 1 Fig 47 By acting on the throttle grip accel erate and decelerate a few times to verify the correct functioning and to check if the idling speed is constant If necessary contact your DSUL OLD Official Dealer 7 1 83 7 7 5277 5 3 6 6 LJ The idle stroke of the throttle grip must be 2 3 mm measured on the edge of the throttle grip itself Otherwise act on the adjusters 1 placed at the beginni...

Page 47: ... the electrode and on the central porcelain part there are neither carbon deposits nor corrosion marks if necessary clean with a spe cial cleaner for spark plugs with an iron wire and or a metal brush 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 elec trodes or too large deposits...

Page 48: ...sed during the recharging Never invert the connection of the bat tery cables Do not incline the vehicle too much in order to avoid dangerous leaks of the battery fluid KEEP AWAY FROM CHILDREN To check the electrolyte level proceed as follows Remove the saddle see p 45 LOCK ING UNLOCKING THE SADDLE Remove the left side see p 45 RE MOVING THE SIDES Remove the two screws 1 and plastic protection 2 Ex...

Page 49: ...he OFF position to avoid any accidental short circuit Remove the left side see p 45 RE MOVING THE SIDES Extract the fuses one by one 1 and check if the filament is broken Before replacing a fuse try to find out what caused the trouble if possible Then replace the fuse with a new one having the same amperage ARRANGEMENT OF THE FUSES 20A fuse From the battery to key switch regulator 15A fuse From th...

Page 50: ... the side stand will push against the switch 3 which will stop the engine If the engine does not stop con sult your DSULOLD Official Dealer who will overhaul the system 867 1 7 7 0 LJ The headlight beam can be adjusted by acting on the two screws 1 2 Fig 54 positioned on the headlight sides To rapidly check the correct direction of the beam place the vehicle on flat ground ten meters away from a w...

Page 51: ...llows Unscrew and extract the screw 1 Fig 56 Rotate the headlight dashboard unit rightwards 1 Fig 57 Unscrew and extract the three screws 2 Fig 57 Remove the left half 1 Fig 58 and the complete parabolic element 2 Fig 58 Remove the bulb socket 3 Fig 58 rotating it anticlockwise Pull the bulb 4 Fig 58 with care and extract it To change the parking light bulb proceed as follows Carry out the first f...

Page 52: ...four screws 1 2 Fig 59 Disconnect the electric connector Unscrew and remove the three screws 1 Fig 60 Remove the whole light Unscrew and remove the two screws 2 Fig 60 Remove the glass 1 Fig 61 Rotate the bulb 2 Fig 61 anticlock wise and extract it from its seat The introduction of a new bulb can be carried out in one sense only because the two guide pins are misaligned 1 2 Fig 59 2 1 Fig 60 2 1 F...

Page 53: ...rotate it anticlockwise Remove the bulb from its seat When reassembling press the protection glass exerting a slight pressure Fig 62 Fig 63 1 1 7 6 2 5 8 6 LJ Read pages 34 MAINTENANCE and 51 BULBS carefully Proceed as follows Unscrew and extract the screw 2 Fig 54 on the right side of the headlight Rotate the headlight leftwards Remove the rubber bulb socket and if necessary change the bulb 1 bul...

Page 54: ...r and sham poo 2 4 parts of shampoo in water Then rinse with plenty of water and dry with chamois leather To clean the outer parts of the engine use a degreaser brushes and wipers Polish with silicone wax only after having carefully washed the vehicle Do not wash the vehicle under the sun especially during the summer when the body is still warm since if the shampoo dries be fore being rinsed away ...

Page 55: ...linder surfaces Remove the battery see p 48 BAT TERY and charge it Wash and dry the vehicle see p 54 CLEANING Polish the painted surfaces with wax Inflate the tyres see p 26 TYRES Position the vehicle so that both tyres are raised from the ground by means of a suitable support Place the vehicle in an unheated not humid room away from sunlight with minimum temperature variations Cover the vehicle a...

Page 56: ...ad lubrication with dry timing case 1 649 5 cm3 100 mm 82 7 mm 9 0 5 1 electric and with kick starter 1200 100 rpm 0 1 mm oil immersed multiple discs with control on the left side of the handlebar with fluid CAPACITY Fuel reserve included Fuel reserve Engine oil Coolant Seats Vehicle max load driver passenger luggage 16 E 2 5 E 2200 cm3 1 E 2 182 kg GEARS Type mechanic no 5 gears with foot control...

Page 57: ...operated telescopic fork 135 mm hydraulic mono shock absorber 120 mm BRAKES Front Rear disc brake Ø 298 mm with hydraulic trans mission disc brake Ø 220 mm with hydraulic trans mission WHEELS TYRES Type Front Rear Front Inflation pressure Rear Inflation pressure aluminium with spokes 2 15 x 18 3 00 x 17 100 90 56H 1 8 bar Drive with passenger 1 8 bar 130 90 68 H 1 9 bar Drive with passenger 2 2 ba...

Page 58: ... 20 A 12 V 180 W BULBS Dipped high beam Parking light Turn indicators Tail lamp brake 12 V 55 60 W 12 V 5 W 12 V 10 W 12 V 5 21 W WARNING LIGHTS Speedometer Idle indicator High beam Turn indicator Oil level Coolant temp indicator 12 V 4 W 12 V 2W 12 V 2W 12 V 2W 12 V 2W 12 V 2W 58 ...

Page 59: ... against corrosion good resistant to water and oxidation Fork oil recommended IP F A 5W or IP F A 20W fork oil If you need an oil with intermediate characteristics in comparison with the two recommended products these can be mixed as indicated below SAE 10W IP F A 5W 67 of the volume IP F A 20W 33 of the volume SAE 15W IP F A 5W 33 of the volume IP F A 20W 67 of the volume Protection of the batter...

Page 60: ... 5 1 5 0 0RWy 60 ...

Page 61: ...light switch 19 Front stoplight switch 20 Water temperature thermistor 21 Fan thermal contact 22 Starter 23 Starting relay 24 Battery 25 Voltage regulator 26 Generator 27 CDI unit 28 Spark coil 29 Diode 1 30 Left front turn indicator 31 Pick up 32 High low beam light 33 Front parking light 34 Right front turn indicator 35 Horn 36 Headlight 37 Fan 38 Spark plug 39 Fuses 40 Engine oil pressure senso...

Page 62: ... GREGORY WAY SOUTH REDDISH STOCKPORT CHESHIRE SK5 7ST UK TEL 0044 161 4765770 FAX 0044 61 4764545 IDEAL MOTO SPORT PTE LTD 31 HOWARD ROAD 1336 SINGAPORE SGP TEL 065 2820082 FAX 2821012 PSRUWHUV 6 25 25 1 63 5 3 576 21 62 ...

Page 63: ...127 63 ...

Page 64: ...k its customers for the purchase of this vehicle Do not dispose of used oil fuel polluting substances and compo nents in the environment Do not keep the engine running if it isn t necessary Avoid troublesome noises Respect nature ...

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