APRILIA RALLY 50 Page 16 Manual Download

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use and maintenance

Rally 50

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FOREWORD

............................................................. 2

INTRODUCTION

....................................................... 2

SAFETY WARNINGS

................................................ 3

GENERAL SAFETY RULES

..................................... 3

CARBON MONOXIDE  .......................................... 3
GASOLINE  ............................................................ 3
HOT COMPONENTS  ............................................ 3
USED ENGINE OIL  ............................................... 4
BRAKE FLUID  ....................................................... 4
COOLANT  ............................................................. 4
BATTERY HYDROGEN GAS
AND ELECTROLYTE  ............................................ 4

WARNINGS - PRECAUTIONS -
GENERAL ADVICE

................................................... 5

REPORTING OF DEFECTS
THAT AFFECT SAFETY  ....................................... 5
ROAD REGULATIONS
AND USE OF THE VEHICLE  ................................ 5
NOISE EMISSION WARRANTY  ........................... 5
INFORMATION ON THE NOISE AND EXHAUST
GAS EMISSION CONTROL SYSTEM  .................. 5
TAMPERING WARNING ....................................... 6
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
(FRAME NUMBER)  ............................................... 7
INFORMATION CONTAINED IN THE
VEHICLE IDENTIFICATION NUMBER  ................. 7
POSITION OF THE
WARNING ADHESIVE LABELS  ........................... 8

aprilia s.p.a.

EMISSION CONTROL

SYSTEM WARRANTY STATEMENT  ................. 11
MANUFACTURER’S
WARRANTY COVERAGE  .................................. 11
OWNER’S WARRANTY RESPONSIBILITIES  .... 11

aprilia s.p.a.

LIMITED WARRANTY ON EMISSION

CONTROL SYSTEM ........................................... 12

GENERAL INSTRUCTIONS

................................... 15

TABLE OF CONTENTS  ...................................... 16
BASIC SAFETY RULES ...................................... 18
CLOTHING  .......................................................... 23
ACCESSORIES  .................................................. 24
LOAD ................................................................... 24

ARRANGEMENT OF THE MAIN ELEMENTS

....... 26

ARRANGEMENT OF THE

INSTRUMENTS/CONTROLS

.................................. 28

INSTRUMENTS AND INDICATORS

....................... 28

INSTRUMENTS AND INDICATORS TABLE ...... 29

CONTROLS

............................................................. 30

CONTROLS AT THE LEFT HAND GRIP  ............ 30
CONTROLS AT THE RIGHT HAND GRIP .......... 31
IGNITION SWITCH  ............................................. 32
STEERING LOCK  ............................................... 32

AUXILIARY EQUIPMENT

....................................... 33

UNLOCKING / LOCKING THE SADDLE  ............ 33
CRASH HELMET / GLOVE COMPARTMENT  .... 33
ANTI-THEFT HOOK  ............................................ 33
BATTERY / TOOL KIT COMPARTMENT  ........... 34
BAG HOOK  ......................................................... 34
REAR MUDGUARD EXTENSION ....................... 34

MAIN COMPONENTS

............................................. 35

FUEL  ................................................................... 35
LUBRICANTS  ...................................................... 36
BRAKES  .............................................................. 37
DISC BRAKES  .................................................... 38
REAR DRUM BRAKE

................................... 38

FRONT AND REAR BRAKE  ............................... 40
TIRES  .................................................................. 42
AUTOMATIC LIGHTS ON  ................................... 43
EXHAUST SILENCER ......................................... 43

INSTRUCTIONS FOR USE

..................................... 44

MAINTENANCE

...................................................... 53

REGULAR SERVICE INTERVALS CHART  ........ 54
MAINTENANCE RECORD  .................................. 56
IDENTIFICATION DATA  ..................................... 60
AIR CLEANER ..................................................... 61
FRONT WHEEL  .................................................. 62
REAR WHEEL  ..................................................... 64
REMOVING THE REAR BRAKE CALIPER  ........ 65
CHECKING THE BRAKE PAD WEAR  ................ 66
CHECKING THE SHOE WEAR

................... 67

CHECKING THE STEERING .............................. 68

TRANSPORT

.......................................................... 87

DRAINING THE FUEL TANK ............................. 87

CLEANING

............................................................. 89

LONG PERIODS OF INACTIVITY ...................... 90

TECHNICAL DATA

................................................ 91

LUBRICANT CHART .......................................... 95
Importers ........................................................ 96-97
WIRING DIAGRAM - Rally 50

..................... 98

WIRING DIAGRAM KEY - Rally 50

............. 99

Summary of Contents for RALLY 50

Page 1: ......

Page 2: ...ual to purchase aprilia genuine spare parts accessories and oth er products and for help with specific prob lems please contact your Local aprilia Dealer or service center These profes sionals will be able to promptly and accu rately help Thank you for choosing aprilia Have a great ride This manual is copyright in all countries and reproduction of any part or the whole by any means in print or ele...

Page 3: ... aWARNING The exhaust fumes contain carbon mon oxide a poisonous gas that can cause loss of consciousness and even death 3 Keep gasoline away from children Gaso line is also poisonous Never attempt to si phon gasoline using your mouth Never al low gasoline to contact your skin If you should accidentally spill gasoline on your self change your clothes immediately and wash the area upon which the ga...

Page 4: ...te and burn without a visible flame The coolant ethylene glycol can cause skin irritation and is poisonous if swal lowed Coolant and coolant water mixtures are sweet to the taste and brightly colored therefore are highly attractive to pets and children Take extra precautions to keep new and used coolant out of reach of children and animals KEEP AWAY FROM CHILDREN Risk of burn Do not remove the rad...

Page 5: ...tain other information about motor vehicle safety from the Hotline 2 2 5 4 3 53 4 6 Rules of the road vary from country to coun try It is essential that you understand in ad vance the rules of the road of the country in which your vehicle will be used aWARNING This vehicle has been designed and pro duced for use on even and paved roads or surfaces only Do not use the vehicle on un paved surfaces i...

Page 6: ...fles header pipes or any other com ponent which conducts exhaust gases b Removal or puncturing of any part of the intake system c Lack of proper maintenance d Replacing any moving part of the vehi cle or parts of the exhaust or intake system with parts other than those specified by the manufacturer aCAUTION This product should be checked for re pair or replacement if the vehicle noise has increase...

Page 7: ...ee p 60 FRAME NUM BER and also on the identification plate B which is lo cated on the central tube of the frame 2 4 4 4 6 4 4 5 2 DIGIT MEANING 1 Manufacturer s identification alphanu meric code 2 Vehicle type 3 Model 4 Country for which the vehicle is intend ed 5 Check digit number 6 Model year 7 Assembling factory designation N NOALE VE S SCORZÉ VE 0 NOT SPECIFIED 8 Sequential serial number ...

Page 8: ...8 use and maintenance Rally 50 0 3 4 4 7 2 3 6 3 ...

Page 9: ...9 use and maintenance Rally 50 Ref Description 1 2 3 4 5 6 7 Muffler stamping 8 Ref Description ...

Page 10: ...10 use and maintenance Rally 50 9 10 11 Ref Description 12 13 14 Ref Description ...

Page 11: ... 11 185 miles whichever first oc curs Class III vehicles 280 cm and larger for a period of use of five 5 years or 30 000 kilometers 18 641 miles whichever first occurs If an emission related part on your vehicle is defective the part will be repaired or re placed by aprilia This is your emission control system DEFECTS WARRANTY 7 2 3 7 22 49 2 30 3 4 3 As the vehicle owner you are responsi ble for ...

Page 12: ...fornia Air Resources Board Any part or parts replaced under this warranty shall be come the property of aprilia In the State of California only emission related warranted parts are specifically defined by the state s Emission Warran ty Parts List These warranted parts are carburetor and internal parts intake manifold fuel tank fuel injection sys tem spark advance mechanism crank case breather air ...

Page 13: ...rranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the aprilia dealer aprilia SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES LOSS OR DAMAGE WHETHER DIRECT INCI DENTAL CONSEQUENTIAL OR EX EMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR IN ABILITY TO USE THE aprilia MOTOR CYCLE FOR ANY PURPOSE SOME STATES DO NOT ALLOW THE EX CLUSI...

Page 14: ...IONAL INFORMATION Any re placement part that is equivalent in perfor mance and durability may be used in the performance of any maintenance or re pairs However aprilia is not liable for these parts The owner is responsible for the perfomance of all required maintenace Such maintenance may be performed at a service establishment or by any individual The warranty period begins on the date the motorc...

Page 15: ... to read it remove the in spection cover see p 72 REMOVING THE INSPECTION COVER These data indicate YEAR year of manufacture Y 1 2 I M modification code A B C COUNTRY CODE country of homolo gation I UK A and are to be supplied to the Local aprilia Dealer as reference data for the purchase of spare parts or specific accessories of the model you have acquired In this manual the various versions are ...

Page 16: ...L 35 LUBRICANTS 36 BRAKES 37 DISC BRAKES 38 REAR DRUM BRAKE 3 38 FRONT AND REAR BRAKE 40 TIRES 42 AUTOMATIC LIGHTS ON 43 EXHAUST SILENCER 43 INSTRUCTIONS FOR USE 44 PRELIMINARY CHECKING OPERATIONS 45 STARTING 46 RIDING 48 RUNNING IN 50 STOPPING 50 PARKING 51 PLACING THE VEHICLE ON THE STAND 51 SUGGESTIONS TO PREVENT THEFT 52 MAINTENANCE 53 REGULAR SERVICE INTERVALS CHART 54 MAINTENANCE RECORD 56 I...

Page 17: ...safe drive ...

Page 18: ...st states prohibit the operation of this size vehicle on freeways or expressways be sure that it is legal to use your vehicle before you take any particular road A new vehicle must be carefully broken in see p 50 RUNNING IN Before starting the engine make sure that the brakes clutch transmission and throt tle controls function properly and that the fuel and oil supply is adequate The exhaust syste...

Page 19: ...tream of cars or trucks in front of you In case of accident motorcycles scooters and mopeds do not provide the same de gree of protection ensured by automobiles The legs in particular are exposed the risk of being injured However the additional installation of leg guards may actually in crease the risk of injuries and their serious ness in case of accident Do not install leg guards available on th...

Page 20: ... in an accident insure that there has been no damage to the control levers tubes wires braking system and other vital parts If your vehicle is involved in an accident take it immediately to your Local aprilia Dealer who has the equipment and knowledge to check for accidental damage which may compromise your safety Your aprilia dealer is ready and able to help you with any safety problems that you ...

Page 21: ...e hicle as well as its performance and ser viceability Any modification which affects performance or safety voids your warranty completely For the reasons stated above the failure to comply with the tampering prohibition is punished 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 cra...

Page 22: ...ly reduced Under these conditions all handling of the vehi cle must be done gradually and smoothly Sudden acceleration braking or turning may make you lose control of your vehicle When traction is reduced accelerate and slow using your vehicle s engine braking insofar as possible Avoid rapid harsh application of the brakes Gradually open and close the throttle to avoid spinning or skidding the rea...

Page 23: ...lective vest or clothing with reflective sections sewn into the jacket pants and gloves Be particular aware of approaching automobiles and trucks that might be trying to turn left in front of you Many vehicle accidents are caused by an opposing automobile driver making a left turn without warning in front of the vehicle Inevitably the driver will look right at you and yet swear that they did not s...

Page 24: ...le hamper the operation of the controls and reduce the distance from the ground and the angle of inclination in turns Avoid using accessories that hamper ac cess to the controls since this can prolong reaction times during an emergency Big fairings and windshields installed on the vehicle may produce aerodynamic forc es that will affect the stability of the vehicle during use especially at high sp...

Page 25: ...d espe cially on acceleration Therefore you should avoid hard acceleration and hard braking Many accidents are caused by in experienced riders carrying passengers Remember that allowance must be made for the extra weight of the passenger for all driving maneuvers Avoid abrupt and excessive acceleration Always slow down in time and calculate longer stopping and manoeuvring distanc es Non compliance...

Page 26: ...26 use and maintenance Rally 50 22 4 4 43 9 1 Horn 2 Fuel tank 3 Fuel filler cap 4 Saddle lock 5 Kick starter 6 Air cleaner 7 Fuse carrier 8 Battery 9 Center stand ...

Page 27: ...ance Rally 50 9 1 2 stroke oil tank cap 2 2 stroke oil tank 3 Ignition switch steering lock 4 Bag hook 5 Battery tool kit compartment cover 6 Inspection cover 7 Anti theft hook for the aprilia Body Guard armored cable m ...

Page 28: ...ror 7 Front brake lever 8 Throttle grip 9 Electrical controls on the right side of the handlebar 10 Ignition switch steering lock n m s 3425 43 4 23 11 Red 2 stroke oil reserve warning light j 12 Green left direction indicator warning light c 13 Total miles odometer 14 Speedometer 15 Fuel level indicator g 16 Green right direction indicator warning light c 17 Blue high beam warning light a 18 Ambe...

Page 29: ...r is depressed If the light does not illuminate when the starter button is depressed this indicates that the warning system bulb is burned out and must be replaced before riding The light goes out after the engine starts as long as there is sufficient 2 stroke oil in the 2 stroke oil tank If the warning light comes on and does not go out after the starter button r has been released or if it comes ...

Page 30: ...the left move the switch to the left to indicate the turn to the right move the switch to the right To turn off the direction indicator press the switch 3 DIMMER SWITCH b a When the lever is in the position indicated by the b the parking lights dashboard light and low beam are on When the lever is moved to the a the high beam is illumi nated the dashboard and parking lights remain on 4 COLD START ...

Page 31: ...ON position it is possible to start the engine The engine can be stopped by moving the switch 1 to the m OFF position aCAUTION Do not leave the ignition on if you have stopped the engine by moving the engine stop switch to the m OFF position as this will discharge the battery When the vehicle has come to rest after stopping the engine with the engine stop switch turn the ignition switch A to the m...

Page 32: ...us injury or even death OPERATION To lock the steering Place the vehicle on the stand Turn the handlebar completely leftwards Turn the key 2 to position m OFF and press it Release the key 2 NOTE Turn the key 2 and steer the handlebar at the same time Rotate the key 2 counterclockwise left wards steer the handlebar slowly until the key 2 reaches position s LOCK Extract the key 2 Position Function K...

Page 33: ...e The com partment is positioned under the saddle aWARNING Do not ride the vehicle without wear your crash helmet Many accidents are fatal because of in juries to the head To reach it Raise the saddle 2 see beside UN LOCKING LOCKING THE SADDLE NOTE Position the helmet with the open ing facing downwards as indicated in the figure aWARNING Do not overload the crash helmet glove compartment Maximum a...

Page 34: ...on one end type PH size 2 and 4 mm wrench on the other end n 1 screwdriver handle n 1 8 10 mm socket spanner aWARNING Do not hang excessively bulky bags or parcels to the hook as this may serious ly compromise the manoeuvrability of the vehicle or the movement of your feet The bag hook 4 is positioned on the front part of the inner shield Max allowed weight 3 31 lb 1 5 kg 2 2 5 5 2 84 3 The rear m...

Page 35: ...d other re productive problems If gasoline should be accidentally spilt on the skin or clothes immediately wash it off with soap and water and change clothes Should you accidentally spill gasoline in your eyes flush with a large quantity of water and immediately contact a health professional Should you acci dentally get gasoline into your mouth do not induce vomiting Drink a large quantity of milk...

Page 36: ...will seize This can cause an upset with consequent risk of serious injury or even death It certainly will de stroy your engine Top up the 2 stroke oil tank every 300 mi 500 km The vehicle is provided with a separate mixer that ensures the mixing of petrol and oil for the engine lubrication see p 95 LU BRICANT CHART When the oil level in the 2 stroke oil tank is so low that the reserve is being use...

Page 37: ...r Water on the brakes from washing your vehicle or splashed up from wet roads or crossing puddles or ditches can wet the brakes sufficiently to greatly reduce their effectiveness Failure to heed these warnings may lead to a serious accident with consequent risk of seri ous injury or even death NOTE This vehicle is equipped with front and rear disc brakes with separate hydraulic systems The followi...

Page 38: ...nt brake lever under the upper handle bar cover The rear brake fluid reservoir is located on the left end of the handlebar near the rear brake lever under the upper handlebar cover Check the levels of the brake fluid in the reservoirs see also FRONT AND REAR BRAKE Also check the wear of the pads see p 66 CHECKING THE BRAKE PAD WEAR every 300 mi 500 km aWARNING Never use your vehicle if any portion...

Page 39: ...ey 5 and move the ignition switch 6 to position m OFF Place the vehicle on the center stand aWARNING When the engine is hot be careful not to burn yourself while carrying out the following operations Working from the left rear side of the ve hicle manually rotate the wheel and en sure that it turns freely If necessary Loosen the adjuster 1 making sure that the wheel turns freely aCAUTION After ser...

Page 40: ...ark stamped on the glass gauge 2 If the fluid does not reach the MIN mark aCAUTION When the disc pads wear out the level of the fluid decreases progressively to compensate for their wear Check the front brake pad wear p 66 CHECKING THE BRAKE PAD WEAR and the front disc wear If the pads and or the disc do not need replacing Top up the reservoir see below TOP PING UP TOPPING UP Carefully read p 37 B...

Page 41: ...o not add any additives or other sub stances to the brake fluid aWARNING Use only DOT 5 or 4 fluid taken from a clean sealed container Never reuse used brake fluid NOTE In order to reach the MAX level top up until covering the glass 2 complete ly but leave a space of 0 20 0 23 in 5 6 mm from the brake fluid reservoir rim Top up the reservoir with brake fluid un til the fluid reaches the MAX level ...

Page 42: ...ning can lead to an accident with subsequent serious in jury or even death Some types of tires homologated for this vehicle are provided with wear indicators There are several kinds of wear indica tors For more information on how to check the wear contact your Dealer Visually check if the tires are worn and in this case have them changed If a tire should go flat while you are riding the vehicle do...

Page 43: ...e is started For this reason there is no light switch on your vehicle The lights can be switched off only by stopping the engine Before starting the vehicle make sure that the dimmer switch 2 is in the low beam b position 8 534 3 2 aWARNING Tampering with the exhaust system is prohibited It is against the law for you to alter the exhaust system in a manner that increases the noise carefully read p...

Page 44: ...ect or discover some irregular ities It does not take long to carry out a check up and this operation ensures you much more safety Failure to perform the checks described above may cause accidents or make the vehicle overturn with consequent seri ous injuries or even death aWARNING If the throttle sticks open it may cause a collision with another vehicle or an upset If the throttle sticks kill the...

Page 45: ... Wheel tires Check the tire surface the inflation pressure wear and tear and any damage 42 Brake levers Make sure they work smoothly and are properly lubricated 37 38 39 40 Steering Make sure that the fork head rotates through its entire range without fouling of any kind Make sure that the fork stops touch the frame at full left and full right fork lock 68 Center stand Make sure that it works smoo...

Page 46: ... p 47 STARTING AFTER A LONG PERIOD OF INACTIVITY NOTE To avoid discharging the battery and possibly damaging the starter do not keep the starter button depressed for more than 5 or 10 seconds If the engine does not start in this time wait for 10 seconds and try again aCAUTION Do not depress the starter button r 4 when the engine is running This will damage the starter and other important engine co...

Page 47: ...olding the throttle 6 in a completely open position Pos A STARTING AT VERY COLD AMBIENT TEMPERATURES When the ambient temperature is very cold less than 0 C it may be difficult to start the engine on the first try If this occurs Rotate the cold start lever e 7 down wards Depress the starter button r 4 at the same time open the throttle 6 slightly If the engine starts Release the throttle grip 6 Af...

Page 48: ...an accident with consequent risk of serious injury or even death To ride away Allow the throttle to return to idle 1 Pos A apply the rear brake 2 then remove the vehicle from the stand Get on the vehicle keeping at least one foot on the ground in order not to lose balance Before riding away be sure that the rear view mirrors are correctly adjusted aCAUTION When the vehicle is new to you practice l...

Page 49: ...ated continuously on downhill grades the discs and pads will overheat reducing the braking effi ciency Use engine compression and downshift to retard your vehicle while going downhill Use the brakes as little as possible to maintain a safe speed Never coast downhill with the engine off aWARNING On roads that are wet or covered with snow ice or mud ride very slowly avoiding braking or accelerating ...

Page 50: ...hanges It is also important that during the run in peri od the suspension and brakes be treated gently to allow the mating parts to bed Therefore avoid hard braking high speeds or very bumpy roads during the break in period 0 62 mi 0 100 km Apply the brakes gently avoiding sudden or prolonged braking 0 187 mi 0 300 km Open the throttle no more than one half way for extended periods 187 312 mi 300 ...

Page 51: ... engine stop switch 1 to the m OFF position aCAUTION Do not leave the ignition on if you have stopped the engine by moving the en gine stop switch to the m OFF posi tion as this will discharge the battery When the vehicle has come to rest after stopping the engine with the engine stop switch turn the ignition switch 3 to the m OFF position Rotate the key 2 and move the ignition switch 3 to the m O...

Page 52: ... arm If possible use the appropriate aprilia Body Guard armored cable or an ad ditional anti theft device Make sure that all legal requirements reg istration license plates insurance etc are in order Write down your name address and tele phone number and the vehicle identifica tion number in the space below to facili tate finding the owner in case your vehicle is recovered after theft SURNAME NAME...

Page 53: ...d in this manual can usually be per formed by the user However in some cases specific tools and technical exper tise may be required Do not hesitate to contact your Local aprilia Dealer who has all the latest factory infor mation and tools to properly service your vehicle Remember that many service operations if done improperly can be very hazardous If you have any questions about your ability to ...

Page 54: ...ed roads Component After running in 300 mi 500 km Every 2 500 mi 4 000 km or 12 months Every 5 000 mi 8 000 km or 24 months Battery tightness of the battery terminals electrolyte level Spark plug Air cleaner Accelerate operations Brake locking operation Light operation direction Light system Safety switches Stop light switches Brake fluid 2 stroke oil level every 300 mi 500 km 2 stroke oil reserve...

Page 55: ...very 3 750 mi 6 000 km Steering bearings and steering slack Wheel bearings Brake discs Piston rings every 7 500 mi 12 000 km Mixer accelerator operation General operation of the vehicle Braking systems Rear brake cam pin greasing t Brake fluid every 2 years Fork oil and oil seal every 7 500 mi 12 000 km or 4 years Transmission oil every 7 500 mi 12 000 km or 2 years Rear pulley pins every 7 500 mi...

Page 56: ...receipts for parts you purchase Owner Name Owner Address Owner Telephone Number Vehicle Identification Number V I N frame number see p 60 IDENTIFICA TION DATA Engine Number see p 60 IDENTIFICA TION DATA Local APRILIA Dealer Name Local APRILIA Dealer Address Local APRILIA Dealer Telephone Number Warranty Activation Date from Retail Purchase Warranty Activation Form Date Odometer reading Maintenance...

Page 57: ...57 use and maintenance Rally 50 Date Odometer reading Maintenance Performed Dealer Stamp Follow ã Follow ã ...

Page 58: ...58 use and maintenance Rally 50 Date Odometer reading Maintenance Performed Dealer Stamp Follow ã Follow ã ...

Page 59: ...59 use and maintenance Rally 50 Date Odometer reading Maintenance Performed Dealer Stamp Follow ã ...

Page 60: ...cle Identification Number V I N You can incur severe penalties by doing this Also this will immediately invalidate your warranty FRAME NUMBER The frame number is stamped on the cen tral tube of the frame To be able to read it it is necessary to remove the cover 1 NOTE The cover 1 can be inserted in one direction only The part provided with the tang 2 is the lower part Frame no ENGINE NUMBER The en...

Page 61: ...hicle REMOVAL Remove the inspection cover p 72 RE MOVING THE INSPECTION COVER Unscrew and remove the screw 1 tak ing the washer and the breather pipe ring 2 Unscrew and remove the screw 3 with the relevant washer Loosen the screw 4 of the air manifold clamp Grasp the air manifold complete with the clamp and pull it away thus removing the whole air cleaner casing CLEANING THE AIR FILTER Unscrew the...

Page 62: ...e wheel in its position after loosening it aWARNING Make sure that the vehicle is stable It may cause damage to bystanders and other property as well as being dam aged itself Have a helper steady the handlebar in the straight ahead position Brake caliper screw 3 tightening torque 19 53 ftlb 27 Nm Remove the two screws 3 that fasten the front brake caliper 4 Remove the brake caliper 4 from the disc...

Page 63: ... fastening holes and the holes on the support are aligned NOTE When reassembling the brake caliper replace the caliper screws 3 with two new screws of the same type Tighten the two screws 3 to the appro priate torque Brake caliper screw 3 tightening torque 19 53 ftlb 27 Nm Remove the support 2 from under the tire Remove the support 1 from under the vehicle Retract the center stand Apply the front ...

Page 64: ...a new wheel nut Do not reassemble your vehicle using the old wheel nut This wheel nut is of a special type Wheel nut tightening torque 79 56 ftlb 110 Nm Remove the plastic band 4 and the cardboard 3 Release the rear brake lever 2 3 Withdraw the whell Remove the rear brake caliper 6 see p 65 REMOVING THE REAR BRAKE CALIPER Withdraw the wheel aWARNING After servicing the brakes always check them for...

Page 65: ...al APRILIA Dealer aCAUTION Upon disassembly be careful not to damage the brake lines disc and pads Place the vehicle on the center stand aWARNING Before carring out the following opera tions let the engine and the exhaust si lencer cool down until they reach room temperature in order to avoid burns Unscrew and remove the two screws 1 Brake caliper screw tightening torque 1 19 53 ftlb 27 Nm aWARNIN...

Page 66: ...vehicle on the center stand Only for the front brake caliper re move the brake caliper cover 1 NOTE To check the rear brake pad wear remove the rear brake caliper 2 see p 65 REMOVING THE REAR BRAKE CALIPER Perform a visual check of the friction ma terial thickness Use a flash light If the friction material on one pad of a pair front or rear is worn to 0 06 in 1 5 mm or less replace both pads aWARN...

Page 67: ...rake lever 1 completely and keep it pulled Check the position of the rear brake shoe wear indicator 2 aCAUTION If the rear brake shoe wear indicator 2 is positioned on or beyond the lower reference tooth 4 contact a Local APRILIA Dealer who will provide for re placing the rear brake shoes Position Wear condition Indicator between the two reference teeth 3 and 4 Rear brake shoes within the wear lim...

Page 68: ... an incorrect slack Repeat the previous operation more than once Fore and aft slack should be no consid erable If slack at the axle is consider able arrange to have your vehicle re paired by your Local aprilia Dealer 4 37 2 0 6 4 Carefully read p 53 MAINTENANCE Periodically check the slack existing be tween the engine pin bushings To carry out this operation proceed as fol lows Place the vehicle o...

Page 69: ...oid burns aWARNING Be careful not to let the bike fall over when you lift the bike up to perform this check The stand 1 must rotate about its pivot smoothly and easily Perform the following checks The springs 2 must be free from dam age wear or rust and must fully and firmly retract the side stand when the weight of the vehicle is lifted off of it The stand 1 must rotate freely about its pivot If ...

Page 70: ...ve freely and without interference returning automatically to its unapplied position 2 6 4 2 2 6 7 22 23 Carefully read p 53 MAINTENANCE The following information refers to one rear view mirror only but is valid for both Place the vehicle on the center stand NOTE Group the components of the left and right rear view mirrors separately Pull back the rubber boot 3 with your fingers aCAUTION Hold the ...

Page 71: ...ng opera tions let the engine and the exhaust si lencer cool down until they reach room temperature in order to avoid burns Unscrew and remove the screws 1 and 2 Screw 1 and 2 tightening torque 7 23 ftlb 10 Nm Unscrew and remove the two screws 3 and 4 that fasten the exhaust silencer to the engine Screw 3 and 4 tightening torque 18 08 ftlb 25 Nm Remove the exhaust silencer NOTE Upon reassembly rep...

Page 72: ...ately by raising the edge of the front handlebar cover and releasing the tang Repeat the operation described above for the other tangs Remove the front handlebar cover 3 2 6 4 30 4 6 2 Carefully read p 53 MAINTENANCE Place the vehicle on the center stand Unscrew and remove the two screws 4 Remove the cover 5 Unscrew and remove the screw 6 Remove the battery tool kit compartment cover see p 34 BATT...

Page 73: ...ey from the ignition switch Place the vehicle on the center stand Raise the front part of the foot board mat Unscrew and remove the two fastening screws of the bag hook 1 Remove the bag hook 1 Unscrew and remove the screw A with the relevant washer placed in the bag hook seat Unscrew and remove the screw 2 Unscrew and remove the four screws 3 aCAUTION Proceed with care Do not damage the tangs and ...

Page 74: ...ttery breather tube Connect the battery breather tube 1 Connect in order first the positive cable red and then the negative Connect an electronic revolution counter to the spark plug cable Start the engine The idle speed must be adjusted at 1 800 rpm 100 rpm This is sufficiently fast to keep the engine running smoothly but suf ficiently slow to prevent the transmission from engaging and rotating t...

Page 75: ...the vehicle on the center stand Pull back the rubber boot 1 Loosen the lock nut 2 Rotate the adjuster 3 in such a way as to restore the prescribed value After the adjustment tighten the lock nut 2 and check the play again Replace the rubber boot 1 aWARNING Exhaust gases contain carbon monox ide which is extremely poisonous if in haled Do not start the engine in closed or bad ly ventilated rooms Fa...

Page 76: ... clean the spark plug with a proprietary spark plug clean er and a stainless steel brush Using compressed air carefully blow out the spark plug after you have cleaned it Inspect for cracks on the insulating mate rial electrode corrosion or erosion or deposits that you cannot remove If the spark plug shows any of these de fects it must be replaced Check the spark plug gap with a thick ness gauge Th...

Page 77: ...room is proper ly ventilated Do not inhale the gases released during charging Do not per mit any open flames sparks or ciga rettes or any other source of heat any where near the battery while it is charging Do not tip the vehicle too much or tip the battery too much to avoid electro lyte leaking out Should you accidental ly spill battery electrolyte on any part of your vehicle immediately wash it ...

Page 78: ...itions and not corroded or covered with deposits covered with neutral grease or Vaseline If it is necessary to clean the battery terminals Make sure that the ignition switch 4 is in m OFF position Disconnect first the negative and then the positive cable red Brush with a wire brush to eliminate any sign of corrosion Reconnect first the positive cable red and then the negative cable Cover the termi...

Page 79: ...oom is properly ventilated and avoid inhaling the gases released during the recharging Check the electrolyte level see beside CHECKING THE ELECTROLYTE LEV EL Connect the battery charger to the battery Charge the battery using a battery charg er with a current capacity of no greater than 1 10th the capacity of the battery see p 91 TECHNICAL DATA After the recharging operation check the electrolyte ...

Page 80: ...e fuse Turn the ignition switch 2 in the m OFF position Remove the battery tool kit compartment cover see p 34 BATTERY TOOL KIT COMPARTMENT Remove the tool kit compartment 3 Remove the fuse 1 and inspect the fila ment 4 If it is open the fuse must be replaced Replace the blown fuse with the spare fuse 5 or with a new fuse having the same amperage rating aWARNING If you replace the fuse and it blow...

Page 81: ...you to collide with another object with consequent risk of serious injury or even death NOTE The procedure described here is in compliance with the Italian standard that establishes the maximum height of the headlight beam For vehicles used in other countries you must conform with the local regulations To rapidly check the correct direction of the beam place the vehicle on flat ground 32 81 ft 10 ...

Page 82: ...E FRONT INNER SHIELD Unscrew and remove the screw 1 Unscrew and remove the screws 2 aCAUTION Handle with care Take care not to damage the electric wires Loosen the headlight 3 There are four groups of shims for four dif ferent degrees of adjustment Each shim is marked with the type identifi cation code for example UPPER PIV and with the group number for example 3 see table below Adjustment degree ...

Page 83: ...our screws Make sure that the horizontal adjustment of the headlight beam is correct Replace the front inner shield see p 73 REMOVING THE FRONT INNER SHIELD Make sure that the vertical adjustment of the headlight beam is correct see p 81 ADJUSTING THE HEADLIGHT BEAM VERTICALLY 5 3 Carefully read p 53 MAINTENANCE aWARNING Risk of fire Keep fuel and other flammable sub stances away from the electric...

Page 84: ...ly read p 83 BULBS NOTE Before changing a bulb check the fuse see p 80 CHANGING FUSES Place the vehicle on the center stand Unscrew and remove the screw 2 NOTE While removing the lens use ex tra care to be sure that you do not break the key Remove the lens 3 NOTE Upon reassembly position the lens correctly in its seat aCAUTION Tighten the screw 2 moderately and with care to avoid damaging the lens...

Page 85: ...ly during the reassembly Extract the relative bulb socket Extract the bulb and replace it with one of the same type DASHBOARD LIGHTING BULBS NOTE Extract the bulb sockets one by one in such a way as to avoid positioning them incorrectly during the reassembly Extract the bulb socket of the dashboard part in which there has been a light de crease Extract the bulb and replace it with one of the same ...

Page 86: ...ight contains one bulb only for stop light parking light license plate light To change the bulb Place the vehicle on the center stand Unscrew and remove the two screws 1 NOTE While removing the lens use ex tra care to be sure that you do not break the key Remove the lens 2 NOTE Upon reassembly position the lens correctly in its seat aCAUTION Tighten the two screws 1 moderately and with care to avo...

Page 87: ...ar the vehicle while you are draining the fuel DISPOSE OF UNWANTED FUEL PROP ERLY Place the vehicle on the center stand Stop the engine and wait until it has cooled down Rotate the ignition key to the 2 ON position Observe the fuel lever indicator on the dashboard and verify the fuel level quantity present in the fuel tank see p 91 TECHNICAL DATA Rotate the ignition key to the 1 OFF position and e...

Page 88: ...ptacle Open the carburetor outlet by loosening the drain screw 2 positioned under the float chamber When all the fuel has flowed out of the car buretor Tighten the drain screw 2 completely aWARNING Tighten the drain screw 2 with care to avoid fuel leakages from the carburetor during the refuelling aCAUTION Do not dispose of fuel in the environ ment Put the drained fuel contained in the re ceptacle...

Page 89: ...olish with silicone wax only after hav ing carefully washed your vehicle Do not use polishing pastes on matt paints Do not wash the vehicle in direct sun light especially during the summer when the paintwork is still warm since if the shampoo dries before being rinsed away it can damage the paint Do not use solvents or water hotter than 40 C to clean the plastic components of the vehicle Never use...

Page 90: ...ING THE STAND Remove the battery see p 78 REMOV ING THE BATTERY and p 78 BAT TERY STORAGE Wash and dry the vehicle see p 89 CLEANING Polish the painted surfaces with wax Inflate the tires see p 42 TIRES By means of a suitable support position the vehicle so that both tires are raised from the ground Place the vehicle in an unheated not hu mid room away from sunlight with mini mum temperature varia...

Page 91: ... 250 mm Min ground clearance 6 10 in 155 mm Curb weight 200 62 lb 91 kg ENGINE Type 2 stroke with controlled ignition Number of cylinders 1 Total displacement 3 01 cu in 49 26 cm Bore stroke 1 57 in 1 54 in 40 mm 39 2 mm Compression ratio 12 5 0 5 1 Starting electric kick starter Engine idling rpm 1800 100 rpm Clutch automatic centrifugal dry clutch Change gear automatic stepless variator Cooling ...

Page 92: ...00 lb 185 kg These two weights Gross Vehicle Weight Rating GVWR and Gross Axle Vehicle Weight Rating GAWR are stamped on the cer tification plate positioned on the front part of the frame see p 7 VEHICLE IDENTIFICATION NUMBER V I N FRAME NUM BER TRANSMISSION Speed change gear automatic and stepless Primary V belt Ratios minimum for stepless change 2 6 maximum for stepless change 0 88 Secondary wit...

Page 93: ...r 3 50 x 10 FRONT TIRE Type Pirelli Metzeler Michelin Eurosawatech Cheng Shin Size 120 90 10 54J inflation pressure for solo rider 18 85 psi 130 kPa 1 3 bar inflation pressure for rider and passenger 27 55 psi 190 kPa 1 9 bar inflation pressure for rider passenger and luggage 27 55 psi 190kPa 1 9 bar REAR TIRE Type Pirelli Metzeler Michelin Eurosawatech Cheng Shin Size 130 90 10 59J inflation pres...

Page 94: ...C SYSTEM Battery 12 V 4 Ah Fuse 7 5 A Generator with permanent magnet 12 V 85 W BULBS Low high beam 12 V 35 35 W Front parking light 12 V 3 W Direction indicators 12 V 10 W Stop light parking light license plate light 12 V 21 5 W Dashboard 12 V 1 2 W WARNING LIGHTS High beam 12 V 2 W Direction indicators 12 V 2 W 2 stroke oil reserves 12 V 2 W Low fuel 12 V 2 W ...

Page 95: ...n comparison with the v F A 5W and v F A 20W or Ø FORK 5W and Ø FORK 20W these can be mixed as indicated below SAE 10W v F A 5W 67 of the volume v F A 20W 33 of the volume or Ø FORK 5W 67 of the volume Ø FORK 20W 33 of the volume SAE 15W v F A 5W 33 of the volume v F A 20W 67 of the volume or Ø FORK 5W 33 of the volume Ø FORK 20W 67 of the volume Bearings and other lubrication points recommended v...

Page 96: ...96 use and maintenance Rally 50 MPORTERS ...

Page 97: ...97 use and maintenance Rally 50 MPORTERS ...

Page 98: ...98 use and maintenance Rally 50 7 2 2 2ALLY ...

Page 99: ...0 Control diode 21 Buzzer m 22 Blinking 23 Dashboard 24 Left direction indicator warning light 25 2 stroke oil reserve warning light 26 Dashboard light 27 Fuel level instrument 28 Low fuel warning light 29 High beam warning light 30 Right direction indicator warning light 31 Front right direction indicator 32 Front left direction indicator 33 Front parking light bulb 34 Low high beam bulb 35 Horn ...

Page 100: ...100 4 3 2 5 30 2 0 243 9 use and maintenance Rally 50 ...

Page 101: ...101 4 3 2 5 30 2 0 243 9 use and maintenance Rally 50 ...

Page 102: ...102 4 3 2 5 30 2 0 243 9 use and maintenance Rally 50 ...

Page 103: ...103 4 3 2 5 30 2 0 243 9 use and maintenance Rally 50 ...

Page 104: ...s p a wishes to thank its customers for the purchase of this vehicle Do not dispose of oil fuel polluting substances and components in the envi ronment Do not keep the engine running if it isn t necessary Avoid disturbing noises Respect nature ...

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