User manual APRILIA PEGASO 650

FOREWORD ­ This manual supplies the main information for normal servicing procedures. ­ The information and illustrations contained in this manual are updated to the moment of its publication. ­ This publication is meant for professional mechanics, therefore many notions have been intentionally omitted, as they were regarded as superfluous. For any further information, contact aprilia s.p.a. SERVICE DEPARTMENT. ­ For any further information see the ENGINE SERVICE MANUAL, No 933 (D-UK) / No 934 (I-E-F), the ENGINE SPARE PARTS CATALOGUE and the "CHASSIS PARTS" SPARE PARTS CATALOGUE, No 261V aprilia s.p.a. reserves the right to modify its models at any time, without prejudice to the main characteristics here described. All rights as to electronic storage, reproduction and total or partial 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 is not binding in any case. aprilia s.p.a. takes no responsibility as to the performance or the use of said products. TABLE OF CONTENTS GENERAL INFORMATION 1 2 3 4 5 6 7 8 SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM HOW TO USE YOUR SERVICE AND REPAIR MANUAL x ELECTRICAL SYSTEM c x ADVICE FOR CONSULTATION ­ If not expressly described otherwise, the reassembly of the groups is to be carried out repeating the disassembly phases in the reverse order. ­ For each single operation on the engine, consult the specific manual. ­ For ordinary maintenance, consult the "USE AND MAINTENANCE" manual. Remember: 1 mile = 1.6 km 1 km = 0.625 miles CHASSIS PARTS REPAIR INFORMATION SYMBOLS Carefully observe the instructions preceded by the following warning signs: Safety norms and regulations to protect the pilot, the mechanic and other people from severe injuries or grave risks. Indications to make the operations easier. Technical information. The operations preceded by this symbol must be repeated on the opposite side of the vehicle. First edition: march 1997 Reprint: Produced and printed by: Studio Tecno Public Viale del Progresso - 37038 Soave (VR) - Italy Ph. 045 - 76 11 911 Fax 045 - 76 12 241 On behalf of: aprilia s.p.a. Via G. Galilei, 1 - 30033 Noale (VE) - Italy Ph. 041 - 58 29 111 Fax 041 - 44 10 54 a c 5 In this manual the various versions are indicated by the following symbols: & optional 2 catalytic version U United Kingdom version A Austria version C Switzerland version 0 -3 NOTE / NOTES / ANMERKUNGEN 0 -4 INFORMAZIONI GENERALI INFORMACIONES GENERALES GENERAL INFORMATION 1 2 3 4 5 6 7 8 1 -1 INFORMACIONES GENERALES GENERAL INFORMATION INFORMACIONES GENERALES 1 GENERAL INFORMATION 1 INDICE 1.1 POSICIÓN DE LOS NÚMEROS DE SERIE ............ Pag. 1-5 1.1.1 NÚMERO DE BASTIDOR..................... Pag. 1-5 1.1.2 NÚMERO DE MOTOR .......................... Pag. 1-5 1.2 ADVERTENCIAS PARA EL COMBUSTIBLE, LUBRICANTES Y LÍQUIDO REFRIGERANTE ............... Pag. 1-5 1.2.1 COMBUSTIBLE .................................... Pag. 1-5 1.2.2 ACEITE DEL MOTOR........................... Pag. 1-5 1.2.3 ACEITE PARA HORQUILLA................ Pag. 1-8 1.2.4 LÍQUIDO DE FRENOS ......................... Pag. 1-8 1.2.5 LÍQUIDO REFRIGERANTE .................. Pag. 1-8 1.3 NORMAS PARA EL RODAJE ............... Pag. 1-9 1.4 PRECAUCIONES E INFORMACIONES GENERALES ..... Pag. 1-9 1.5 PIEZAS DE REPUESTO ...................... Pag. 1-12 1.6 FICHA TECNICA ................................... Pag. 1-12 1.7 TABLA DE LOS LUBRICANTES ....... Pag. 1-15 1.8 EQUIPOS ESPECIALES ...................... Pag. 1-16 TABLE OF CONTENTS 1.1 POSITION OF SERIAL NUMBERS ..... Pag. 1-5 1.1.1 FRAME NUMBER ................................. Pag. 1-5 1.1.2 ENGINE NUMBER ............................... Pag. 1-5 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS AND COOLANT ........... Pag. 1-5 1.2.1 FUEL ..................................................... Pag. 1-5 1.2.2 ENGINE OIL.......................................... Pag. 1-5 1.2.3 FORK OIL ........................................... Pag. 1-10 1.2.4 BRAKE FLUID .................................... Pag. 1-10 1.2.5 COOLANT........................................... Pag. 1-10 1.3 RUNNING-IN RULES ........................... Pag. 1-11 1.4 PRECAUTIONS AND GENERAL INFORMATION ..................................... Pag. 1-11 1.5 SPARE PARTS ...................................... Pag. 1-12 1.6 TECHNICAL SPECIFICATIONS ................................ Pag. 1-12 1.7 LUBRICANT CHART............................ Pag. 1-15 1.8 SPECIAL TOOLS .................................. Pag. 1-16 1 2 3 4 5 6 7 8 1 -3 INFORMACIONES GENERALES 1.1 POSICIÓN DE LOS NÚMEROS DE SERIE Estos números son necesarios para matricular el vehículo. La alteración de los números de identificación puede provocar graves sanciones penales y administrativas y la invalidez de la garantía. 1.1.1 NÚMERO DE BASTIDOR El número del bastidor está impreso en el tubo de la dirección, en la parte derecha del vehículo. 1.1.2 NÚMERO DE MOTOR El número del motor está impreso en la parte trasera superior. GENERAL INFORMATION 1.1 POSITION OF SERIAL NUMBERS These numbers are necessary in order to register the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions and to cause the immediate invalidation of the guarantee. 1.1.1 FRAME NUMBER The frame number is printed on the vehicle right side of the steering tube. 1.1.2 ENGINE NUMBER The engine number is printed high up on the rear part of the vehicle. 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS AND COOLANT 1.2.1 FUEL The fuel used for internal combustion engines is extremely inflammable and in certain conditions can become explosive. It is advisable to perform the operations of refuelling and maintenance in a well-ventilated area with the engine switched off. Do not smoke while refuelling or when near fuel vapours and, in any case, avoid contact with naked flames, sparks and any other source of heat that might cause the fuel to catch fire or to explode. Avoid escape of fuel from the fuel filler as it could ignite on contact with the red-hot surfaces of the engine. In case fuel has accidentally been spilt, make sure that the area is completely dry before starting the vehicle. Never fill the tank to the brim as fuel expands under the heat of the sun and reacts to the effects of sun radiation . Close the cap securely after refuelling. Avoid contact of the fuel with the skin and inhalation of the fumes; do not swallow fuel or pour it from one container into another by means of a tube. Do not dispose of fuel in the environment. KEEP FUEL AWAY FROM CHILDREN. Normal version: premium grade petrol (4 Stars U) according to the DIN 51 600 standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.). Catalytic version 2: unleaded petrol according to the DIN 51 607 standard, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.). 1.2.2 ENGINE OIL Engine oil may cause serious damage to the skin if handled daily and for long periods. It is advisable to wash your hands thoroughly after using. Do not dispose of oil in the environment. Deliver it to or have it collected by the nearest used oil recovery firm or by the supplier. Check engine oil level every 500 km; see 2.12 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP). Change engine oil after the first 1000 km and successively every 6000 km; see 2.13 (CHANGING ENGINE OIL AND OIL FILTER). Recommended engine oil: IP SUPERBIKE 4, SAE 5W - 40. As an alternative to the recommended oil, high quality oils with performance conforming or superior to CCMC G-4, A.P.I.SG. specifications may be used. c c 1.2 ADVERTENCIAS PARA EL COMBUSTIBLE, LUBRICANTES Y LÍQUIDO REFRIGERANTE 1.2.1 COMBUSTIBLE El combustible para la propulsión de los motores de explosión, es muy inflamable y puede volverse explosivo en determinadas condiciones. Es oportuno reponer gasolina y realizar las operaciones de mantenimiento en una zona ventilada y con el motor apagado. No fume durante la provisión de gasolina y cerca de los vapores del combustible; evite el contacto con llamas, chispas y cualquier otra fuente que pueda causar el encendido o la explosión. Además, evite que el combustible salga de la boca de llenado, ya que éste podría incendiarse si toca las superficies candentes del motor. En caso que se vierta accidentalmente combustible, antes de arrancar el vehículo, controle que la zona esté completamente seca. El combustible se dilata con el calor y bajo la acción de los rayos solares. Por lo tanto, nunca llene el depósito hasta el tope. Cierre cuidadosamente la tapa al finalizar las operaciones de reposición. Evite el contacto del combustible con la piel, la inhalación de los vapores, la ingestión y el trasiego de un recipiente a otro por medio de un tubo. No esparsa el combustible en el medio ambiente. MANTÉNGASE LEJOS DEL ALCANCE DE LOS NIÑOS. Versión normal: Gasolina super (4 Stars U) DIN 51 600, mínimo octano 98 (N.O.R.M.) y 88 (N.O.M.M.). Versión catalítica 2: Gasolina super sin plomo según DIN 51 607, mínimo octano 95 (N.O.R.M) y 85 (N.O.M.M.). 1.2.2 ACEITE DEL MOTOR El aceite del motor puede causar graves daños a la piel si es manipulado por mucho tiempo y diariamente. Se aconseja lavarse las manos tras haberlo manipulado. No esparza el aceite en el medio ambiente. Entréguelo o hágalo retirar por la empresa de recuperación de aceites usados más cercana o por el proveedor. Controle cada 500 km el nivel del aceite del motor; véase 2.12 (CONTROL DEL NIVEL DEL ACEITE DEL MOTOR Y RELLENO). Cambie el aceite del motor tras los primeros 1000 km y sucesivamente cada 6000 km; véase 2.13 (CAMBIO DEL ACEITE MOTOR Y DEL FILTRO DEL ACEITE DEL MOTOR). Aceite del motor (aconsejado): IP SUPERBIKE 4, SAE 5W - 40. Como alternativa a el aceite aconsejado, pueden utilizarse aceites de marca con características conformes o superiores a las normas CCMC G-4, A.P.I. SG. a a a a 1 -5 GENERAL INFORMATION 1.2.3 FORK OIL Fork oil may cause serious damage to the skin if handled daily and for long periods. It is advisable to wash your hands thoroughly after using. Do not dispose of oil in the environment. Deliver it to or have it collected by the nearest used oil recovery firm or by the supplier. Recommended fork oil: IP F.A. 5W or IP F.A. 20W fork oil. If an intermediate performance is desired (between those of IP F.A. 5W and IP F.A. 20W) the products can be mixed as follows: 67% of volume SAE 10W IP F.A. 5W + 33% of volume IP F.A. 20W 33% of volume SAE 15W IP F.A. 5W + 67% of volume IP F.A. 20W 1.2.5 COOLANT The coolant can be harmful if swallowed or if it touches the skin or eyes. If it comes in contact with the skin or eyes, rinse thoroughly with large quantities of water. If the coolant is swallowed, induce vomiting and immediately consult a doctor. a a a a Do not remove the radiator cap when the engine is hot as the coolant is under pressure and at a very high temperature. KEEP COOLANT AWAY FROM CHILDREN. Do not use vehicle if the coolant level is below the minimum prescribed. Check coolant level every 1000 km and after long runs, see 2.14 (CHECKING AND TOPPING UP COOLANT); change it every 12000 km or every 2 years (whichever occurs first), see 2.15 (CHANGING THE COOLANT). The coolant is composed of 50% water and 50% antifreeze. This mixture is ideal for most running temperatures and ensures good protection against corrosion. 1.2.4 BRAKE FLUID This vehicle is provided with front and rear disc brakes, with separate hydraulic circuits. The following information refers to a single braking system, but is valid for both. Brake fluid may cause irritation if it comes into contact with the skin or eyes. Carefully wash the part of the body that has come into contact with the fluid. Consult an oculist or a physician if the fluid comes into contact with your eyes. Do not dispose of brake fluid in the environment. KEEP BRAKE FLUID AWAY FROM CHILDREN c a a a It is advisable to keep the same mixture in the hot season as well, since in this way losses due to evaporation are reduced and it is not necessary to top up so frequently. The mineral salt deposits left in the radiator by evaporated water are thus lessened and the efficiency of the cooling system remains unaltered. If the outdoor temperature is below 0°, check th cooling circuit frequently and inf necessary increase the antifreeze concentration (up to maximum 60%). Use distilled water for the cooling solution so as not to damage the engine. Recommended coolant: IP ECOBLU - 40° On the basis of the desired freezing temperature of the coolant mixture, add to the water the percentage of coolant indicated in the following table: Freezing point °C -20° -30° Coolant of the volume % 35 45 55 Use the brake fluid; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. Recommended brake fluid: IP F.F. DOT 5 (DOT 4 compatible) To avoid serious damage to the braking system, do not use fluids other than the recommended ones nor mix different fluids for topping up. Do not use brake fluid taken from old or already opened containers. Do not use brake fluid left from previous repairs if they were done some time ago. Sudden variations in clearance or an elastic resistance in the brake levers may be due to trouble in the hydraulic circuits. Make sure that the brake discs and the friction pads are completely free of grease or oil, especially after maintenance or checking operations. Check that the brake cables are not twisted or worn. Make sure that neither water nor dust accidentally enter the circuit. In case maintenance operations are to be performed on the hydraulic circuit, it is advisable to use latex gloves. The characteristics of the various antifreeze liquids are different. Be sure to read the label on the product to learn the degree of protection it guarantees. c -40° a Use only antifreeze and anticorrosive without nitrite in order to ensure protection at at least -35°C. 1 - 10 GENERAL INFORMATION 1.3 RUNNING-IN RULES The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads or roads with many curves where the engine, the suspensions and the brakes are submitted to a more efficacious running-in. 1.4 PRECAUTIONS AND GENERAL INFORMATION Follow with care these recommendations when repairing, disassembling and reassembling the vehicle. The use of naked flames is forbidden for any type of operation. Before commencing any service or inspection operation on the vehicle, switch off the engine and remove the key, wait until the engine and the exhaust system have cooled down and, if possible, raise the vehicle with the suitable equipment onto firm flat ground. In order to avoid burns, be careful not to touch any parts of engine or exhaust system which have not cooled down completely. The vehicle is constructed of inedible parts. Do not bite, suck, chew or swallow any part of the vehicle for any reason whatever. If not expressly described, the reassembly of the units is carried out by reversing the order of operations. Do not run the engine in closed or badly ventilated places. Handle fuel with the greatest caution. Never use fuel as a solvent for cleaning the vehicle. Disconnect the negative cable (­) from the battery when electric welding. When two or more persons are working together, make sure that each is working in safe conditions. ­ Use only original aprilia SPARE PARTS. ­ Use the recommended lubricants. ­ Use, when necessary, the special tools designed for this vehicle. ­ Always use the centre stand, if the vehicle is provided with it. ­ In order to carry out certain interventions we recommend using a stand to hold the vehicle in a vertical position. ­ When tightening screws and nuts, begin with those having greater diameters or with inner ones, proceeding diagonally. Tighten screws or nuts in successive passages before applying driving torque. ­ Clean and wash carefully any disassembled parts with low inflammability detergents. ­ Whenever possible, lubricate the parts before reassembly. ­ Make sure that each component has been reassembled correctly. ­ Always replace gaskets, grommets, circlips, O-rings and split pins with new ones. ­ Before disconnecting the joints (pipes, cables, etc.), mark the positions on all of them and mark them with different distinguishing signs. Each piece must be marked clearly, in order not to have problems during installation. The bearings must rotate freely, without halting a/o noise otherwise they must be replaced. Never re-use a circlip. When a circlip is disassembled from a shaft it must be replaced with a new one. When assembling a new circlip be careful not to stretch its ends more than strictly necessary to put it on the shaft. After installing a circlip, make sure that it is completely and firmly inserted in its seat. a x x x Only after the first 1500 km of running-in is it possible to obtain the best performance. a Keep in mind these important indications: Do not open the throttle completely if the speed is low, both during and after the running-in. During the first 100 km put on the brakes with caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake disc. Do not open the throttle at low speeds, both during and after running-in. Brake cautiously during the first 100 km, avoiding abrupt and prolonged braking to ensure a correct adaptation of the brake disc pads. Do not exceed 4000 rpm during the first 500 km (see table). Do not exceed 5000 rpm between the first 500 and 1000 km (see table). x x x After the first 1000 km perform the checking operations indicated in the "after running-in" column, see 2.1.1 (PERIODIC SERVICE CHART FOR THE COMPONENTS) in order to avoid injuring yourself or others a/o damaging the vehicle. x a x Between the first 1000 and 2000 km increase and vary your speed, using the maximum acceleration only briefly to ensure better coupling of the components subject to wear. NEVER exceed 5500 rpm (see table). After the first 2000 km you may expect better performance from the engine without, however, exceeding a maximum 6250 rpm. Engine maximum rpm for the running-in Mileage km 0 - 500 500 - 1000 1000 - 2000 over 2000 Max. rpm 4000 5000 5500 6250 a 1 - 11 INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION 1.5 PARTI DI RICAMBIO In caso di sostituzione, utiizzare solo Ricambi Originali aprilia. I Ricambi Originali aprilia sono di alta qualità, progettati e costruiti espressamente per i veicoli aprilia. L'impiego di ricambi NON originali aprilia può causare problemi di prestazioni e danneggiamenti. 1.6 CARATTERISTICHE TECNICHE DIMENSIONI / DIMENSIONES / DIMENSIONS 1.5 PIEZAS DE REPUESTO En caso de substitución, utilice sólo Repuestos Originales aprilia. Los Repuestos Originales aprilia son de alta calidad, proyectados y fabricados expresamente para vehículos aprilia. Utilizar repuestos NO originales aprilia, puede causar daños y problemas de rendimientos. 1.6 FICHA TECNICA 2218 mm 880 mm 1265 mm 840 mm 1480 mm 200 mm 200 kg 1.5 SPARE PARTS For any replacement, use aprilia Genuine Spare Parts only. aprilia Genuine Spare Parts are high-quality parts, expressly designed and manufactured for aprilia vehicles. Failure to use aprilia Genuine Spare Parts may result in incorrect performance and damages. 1.6 TECHNICAL SPECIFICATIONS a a a Lunghezza max / Longitud máx. / Max. length Larghezza max / Anchura máx. / Max. width Altezza max (agli strumenti) / Altura máx. (hasta los instrumentos) / Max. height (height of instruments) Altezza alla sella / Altura hasta el sillín / Saddle height Interasse / Distancia entre los ejes / Distance between centres Altezza libera minima dal suolo / Altura libre mínima del suelo / Min. ground clearance Peso a vuoto (in ordine di marcia) / Peso en vacío (en orden de marcha) / Weight without driver (ready for starting) MOTORE / MOTOR / ENGINE Tipo / Tipo / Type ROTAX 655 - monocilindrico 4 tempi con 5 valvole, lubrificazione a carter secco, due alberi a camme in testa / ROTAX 655 - monocilíndrico de 4 tiempos con 5 válvulas, lubricación con cárter seco, dos árboles de leva en la culata / ROTAX 655- single-cylinder, 4-stroke with 5 valves, dry-sump lubrication 1 651,88 cmC 100 mm / 83 mm 9 ± 0,5 : 1 elettrico / eléctrico / electric giri/min / rpm / rpm Multidisco in bagno d'olio con comando sul lato sinistro del manubrio / Multidisco en baño de aceite con mando en el lado izquierdo del manillar / Multiple disc in oil bath with control lever on left side of handlebar Meccanico a 5 rapporti con comando a pedale sul lato sinistro del motore / Disques multiples en bain d'huile avec commande sur le côté gauche du guidon / Mechanical gearshift, 5 gears with foot lever on left side of engine a liquido / por líquido / liquid-cooled Numero cilindri / Número cilindros / Number of cylinders Cilindrata / Cilindrada / Displacement Alesaggio e corsa / Diámetro y carrera / Bore and stroke Rapporto di compressione / Relación de compresión / Compression ratio Avviamento / Arranque / Starting Frizione / Embrague / Clutch N° giri del motore al minimo / N° revoluciones del motor al mínimo / Idling engine 1400 ± 100 Cambio / Cambio / Change gear Raffreddamento / Refrigeración / Cooling CAPACITÀ / CAPACIDAD / CAPACITY Carburante (inclusa riserva) / Combustible (reserva incluida) / Fuel (reserve included) 22 l 4l 2200 cmC (2150 cmC cambio olio - 2200 cmC cambio olio e filtro) 2200 cmC (2150 cmC cambio aceite - 2200 cmC cambio aceite y filtro) 2200 cmC (2150 cmC oil change - 2200 cmC oil and filter change) 430 cmC 1,4 l 2 182 kg Riserva carburante / Reserva combustible / Fuel reserve Olio motore / Aceite motor / Engine oil Olio forcella (stelo destro e stelo sinistro) / Aceite horquilla (barra derecha y barra izquierda) / Fork oil (right fork tube and left fork tube) Liquido refrigerante / Líquido refrigerante / Coolant Posti / Asientos / Seats MAX CARICO VEICOLO / MÁX. CARGA VEHÍCULO / VEHICLE MAX. LOAD (pilota + passeggero + bagaglio) / (piloto + pasajero + equipaje) / (driver + passenger + luggage) 1 - 12 INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION TRASMISSIONE RAPPORTI DI STRASMISSIONE / Rapporto 1ª 2ª 3ª 4ª 5ª Primaria 37/72 = 1 : 1,946 Secondaria 12/33 = 1 : 2,750 16/28 = 1 : 1,750 16/21 = 1 : 1,312 22/33 = 1 : 1,045 24/21 = 1 : 0,875 Rapporto finale 16/47 = 1 : 2,937 Rapporto totale 15,720 10,003 7,502 5,976 5,001 TRANSMISION RELACIONES Relación del cambio 1ª 2ª 3ª 4ª 5ª Gear 1ª 2ª 3ª 4ª 5ª Transmisión primaria 37/72 = 1 : 1,946 Transmisión secundaria 12/33 = 1 : 2,750 16/28 = 1 : 1,750 16/21 = 1 : 1,312 22/33 = 1 : 1,045 24/21 = 1 : 0,875 Secondary transmission 12/33 = 1 : 2,750 16/28 = 1 : 1,750 16/21 = 1 : 1,312 22/33 = 1 : 1,045 24/21 = 1 : 0,875 Mikuni BST 33 Ø 31,5mm Relación final 16/47 = 1 : 2,937 Relación total 15,720 10,003 7,502 5,976 5,001 Total gear ratio 15,720 10,003 7,502 5,976 5,001 TRANSMISSION GEAR RATIOS Primary transmission 37/72 = 1 : 1,946 Final gear ratio 16/47 = 1 : 2,937 CARBURATORI / CARBURADORES / CARBURETTORS Modello / Modelo / Model Diffusore / Difusor / Choke tube ALIMENTAZIONE / ALIMENTACION / FUEL SUPPLY Tipo / Tipo / Type Carburante / Combustible / Fuel ­ versione normale / versión normal / normal version a caduta / por gravedad / gravity feed benzina super (4 Stars U) DIN 51 600, minimo ottanico 98 (N.O.R.M.) e 88 (N.O.M.M.) / gasolina super (4 Stars U) DIN 51 600, mínimo octanos 98 (N.O.R.M.) y 88 (N.O.M.M.) / premium grade petrol (4 Stars U) DIN 51 600, O.N. 98 (N.O.R.M.) and 88 benzina super senza piombo DIN 51 607, minimo ottanico 95 (N.O.R.M.) e 85 (N.O.M.M.) / gasolina super sin plomo según DIN 51 607, mínimo octanos 95 (N.O.R.M.) y 85 (N.O.M.M.) / premium grade unleaded petrol DIN 51 607 min, O.N. 95 (N.O.R.M.) and 85 A struttura composita in acciaio e lega leggera con culla e reggisella smontabili / Con estructura compuesta de acero y aleación ligera con cuna y vástago del sillín desmontables / Composite structure made of steel and light alloy, with removable cradle and saddle pillar. 28° 109 mm forcella telescopica a funzionamento idraulico / horquilla telescópica con funcionamiento hidráulico / hydraulically operated telescopic fork 180 mm monoammortizzatore idraulico / amortiguador hidráulico / hydraulic shock absorber 49 mm a disco Ø 300 mm con trasmissione idraulica / de disco Ø 300 mm con transmisión hidráulica / disc brake, 300 mm with hydraulic transmission a disco Ø 220 mm con trasmissione idraulica / de disco Ø 220 mm con transmisión hidráulica / disc brake, 220 mm with hydraulic transmission in alluminio a raggi tangenti / de aluminio de radios tangentes / Aluminium tangent spoke wheels ­ versione catalittica / versión catalítica / catalytic version 2 TELAIO / BASTIDOR / FRAME Tipo / Tipo / Type Angolo inclinazione sterzo / Ángulo inclinación dirección / Steering inclination angle Avancorsa / Lanzamiento / Fore stroke SOSPENSIONI / SUSPENSIONES / SUSPENSIONS Anteriore / Delantera / Front Escursione / Carrera / Stroke Posteriore / Trasera / Rear Escursione / Carrera / Stroke FRENI / FRENOS / BRAKES Anteriore / Delantero / Front Posteriore / Trasero / Rear RUOTE / RUEDAS / WHEELS Tipo / Tipo / Type CERCHI / LLANTAS / RIMS Anteriore / Delantera / Front 2,15 19" Posteriore / Trasera / Rear 3,00 17" PNEUMATICI / NEUMATICOS / TYRES Anteriore / Delantera / Front 100/90 - 19 57H Posteriore / Trasera / Rear 130/80 - R17 65H PRESSIONE DI GONFIAGGIO STANDARD / PRESION DE HINCHADO ESTANDARD / STANDARD INFLATION PRESSURE Anteriore / Delantera / Front 180 kPa (1,8 bar) Posteriore / Trasera / Rear 190 kPa (1,9 bar) PRES. DI GONFIAGGIO CON PASSEGGERO / PRESION DE HINCHADO CON PASAJERO / INFLATION PRES. WITH PASSENGER Anteriore / Delantera / Front 180 kPa (1,8 bar) Posteriore / Trasera / Rear 220 kPa (2,2 bar) 1 - 13 INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION ACCENSIONE / ENCENDIDO / IGNITION Tipo / Tipo / Type Candela standard / Bujía estándard / Standard spark plug Distanza elettrodi candela / Distancia electrodos bujía / Spark plug gap C.D.I. (a scarica capacitiva) / NIPPONDENSO C.D.I. (por descarga capacitativa) / NIPPONDENSO C.D.I. (capacitive discharge) / NIPPONDENSO NGK DR 8 EA - NGK DR 8 ES 0,6 ÷ 0,7 mm IMPIANTO ELETTRICO / INSTALACION ELECTRICA / ELECTRIC SYSTEM Batteria / Batería / Battery 12 V - 12 Ah Fusibili / Fusibles / Fuses 20 - 15 - 7,5 A Generatore (a magnete permanente) / Generador (de magneto permanente) / 12 V - 280 W Generator (with permanent magnet) LAMPADINE / BOMBILLAS / BULBS Luce anabbagliante-abbagliante / Luz de cruce/luz larga / Low/high beam Luce abbagliante / Luz larga / High beam Luce posizione / Luz de posición / Parking light Indicatori di direzione / Indicadores de dirección / Direction indicators Luce di posizione posteriore-stop / Luz de posición trasera-freno / Rear parking and stop light Luce targa / Luz placa de matriícula / Plate light Tachimetro / Taquímetro / Speedometer Contagiri / Contador de revoluciones / Revolution counter Indicatore temperatura liquido refrigerante / Indicador de la temperatura del líquido refrigerante / Coolant temperature indicator SPIE / LUCES INDICADORAS / WARNING LIGHTS Indicatori di direzione / Indicadores de dirección / Direction indicators Riserva carburante / Reserva combustible / Low fuel Pressione olio motore / Presión del aceite motor / Engine oil pressure Cambio in folle / Cambio en punto muerto / Gear in neutral Luce abbagliante / Luz larga / High beam Luce anabbagliante / Luz de cruce/ Low beam 12 V - 55 / 60 W 12 V - 3 W 12 V - 5 W 12 V - 10 W 12 V - 5/21 W 12 V 3 W 12 V - 3 W 12 V - 2 W 12 V - 1,2 W 12 V - 3 W 12 V - 3 W 12 V - 2 W 12 V - 3 W 12 V - 2 W 12 V - 3 W 1.7 TABELLA LUBRIFICANTI SUPERBIKE 4, SAE 5W - 40. Olio motore (consigliato): In alternativa agli olî consigliati, si possono utilizzare olî di marca con prestazioni conformi o superiori alle specifiche CCMC G-4, A.P.I. SG. Olio forcella (consigliato): olio per forcelle F.A. 5W oppure F.A. 20W. Qualora si intendesse disporre di un comportamento intermedio tra quelli offerti da sono miscelare i prodotti come sotto indicato: SAE 10W F.A. 5W 67% del volume, + F.A. 20W 33% del volume SAE 15W F.A. 5W 33% del volume, + F.A. 20W 67% del volume 0 0 0 0 0 0 0 0 F.A. 5W e da 0 F.A. 20W, si pos- Cuscinetti e altri punti di lubrificazione (consigliato): AUTOGREASE MP. In alternativa al prodotto consigliato, utilizzare grasso di marca per cuscinetti volventi, campo di temperatura utile -30°C...+140°C, punto di gocciolamento 150 °C...230 °C, elevata protezione anticorrosiva, buona resistenza all'acqua e all'ossidazione. Protezione poli batteria: Grasso neutro oppure vaselina. Grasso spray per catene (consigliato): Liquido freni (consigliato): 0 0 F.F., DOT 5 (Compatibile DOT 4) 0 ECOBLU - 40 °C. 0 CHAIN SPRAY. a a Impiegare solo liquido freni nuovo. Liquido refrigerante motore (consigliato): Impiegare solo antigelo e anticorrosivo senza nitrito, che assicuri una protezione almeno ai -35 °C. 1 - 14 INFORMACIONES GENERALES 1.7 TABLA DE LOS LUBRICANTES GENERAL INFORMATION SUPERBIKE 4, SAE 5W - 40. Aceite motor (aconsejado): En sustitución al aceite aconsejado pueden utilizarse aceites de marca con prestaciones conformes o superiores a las especificaciones CCMC G-4, A.P.I. SG. F.A. 5W o F.A. 20W. Aceite horquilla (aconsejado): aceite para horquillas En caso de que se quiera conseguir un comportamiento intermedia entre las ofrecidas por 20W, pueden mezclarse los productos según lo indicado a continuación: F.A. 5W 67% del volumen, + F.A. 20W 33% del volumen. SAE 10W F.A. 5W 33% del volumen, + F.A. 20W 67% del volumen. SAE 15W 0 0 0 0 0 0 0 0 F.A. 5W y por 0 F.A. AUTOGREASE MP. Cojinetes y otros puntos de lubricación (aconsejado): En sustitución al producto aconsejado, utilice grasa de marca para cojinetes rodantes, campo de temperatura útil -30°C...+140°C, punto de goteo 150°C...230°C, elevada protección antioxidante, buena resistencia al agua y a la oxidación. Protección polos batería: Grasa neutra o vaselina. Grasa spray para cadenas (aconsejada): Líquido frenos (aconsejado): 0 Líquido refrigerante del motor (aconsejado): a a 0 F.F., DOT 5 (Compatible DOT 4). 0 ECOBLU -40°C. 0 CHAIN SPRAY. Utilice sólo líquido frenos nuevo. Utilice sólo anticongelante y antioxidante sin nitrito que garantice una protección por lo menos a los -35°C. 1.7 LUBRICANT CHART SUPERBIKE 4, SAE 5W-40. Engine oil (recommended): As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications. F.A. 5W or F.A. 20 W. Fork oil (recommended): fork oil If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed as indicated below: F.A. 5W 67% of the volume, + F.A. 20W 33% of the volume. SAE 10W F.A. 5W 33% of the volume, + F.A. 20W 67% of the volume. SAE 15W 0 0 0 0 0 0 0 Bearings and other lubrication points (recommended): AUTOGREASE MP. As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30°C...+140°C, dripping point 150°C...230°C, high protection against corrosion, good resistance to water and oxidation. Protection of the battery poles: neutral grease or Vaseline. Spray grease for chains (recommended): Brake fluid (recommended): 0 Engine coolant (recommended): a a 0 F.F., DOT 5 (compatible with DOT 4). 0 ECOBLU -40°C. 0 CHAIN SPRAY. Use new brake fluid only. Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least. SUPERBIKE 4, SAE 5W-40. Engine oil (recommended): As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications. F.A. 5W or F.A. 20 W. Fork oil (recommended): 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 F.A. 5W 67% of the volume, + F.A. 20W 33% of the volume. SAE 15W F.A. 5W 33% of the volume, + F.A. 20W 67% of the volume. 0 0 0 0 0 0 0 1 - 15 INFORMAZIONI GENERALI 1.8 ATTREZZI SPECIALI ­ Tondino (1) per sfilamento perno forcellone (permette lo sfilamento parziale del perno durante la rimozione del motore dal telaio). ­ Chiave a tubo (2) per ghiera di bloccaggio perno forcellone. ­ Cacciavite (3) a 90° per regolazione vite aria su carburatori. 1.8 EQUIPOS ESPECIALES x x x Redondo de hierro (1) para extraer el eje basculante (permite extraer parcialmente el eje durante el desmontaje del motor del bastidor). Llave tubular (2) para tuerca de bloqueo eje basculante. Destornillador (3) a 90° para ajustar el tornillo aire sobre los carburadores. 1.8 SPECIAL TOOLS x x x Rod iron (1) for the withdrawing of the rear fork pin (it makes it possible to withdraw the pin partially during the removal of the engine from the frame). Socket spanner (2) for the rear fork pin locking ring. 90° screwdriver (3) for the adjustment of the air screw on the carburettors. NOTE / NOTES / ANMERKUNGEN 1 - 16 1 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO PERIODIC SERVICE AND SETTING UP OPERATIONS 2 3 4 5 6 7 8 2 -1 OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO PERIODIC SERVICE AND SETTING UP OPERATIONS OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO ÍNDICE 2 PERIODIC SERVICE AND SETTING UP OPERATIONS TABLE OF CONTENTS 2 2.1 PLAN PARA EL MANTENIMIENTO PERIÓDICO ......................................................Pag. 2-4 2.1.1 FICHA DE MANTENIMIENTO PERIÓDICO ....Pag. 2-5 2.2 PUNTOS POR LUBRICAR.........................Pag. 2-6 2.3 BATERÍA ...........................................................Pag. 2-9 2.3.1 CONTROL DEL NIVEL DEL ELECTROLITO .Pag. 2-9 2.3.2 RECARGA BATERIA ....................................Pag. 2-11 2.3.3 LARGA INACTIVIDAD ..................................Pag. 2-11 2.1 PERIODIC SERVICE PLAN ...................... Pag. 2-4 2.1.1 PERIODIC SERVICE CHART FOR THE COMPONENTS .............................. Pag. 2-5 2.2 POINTS TO LUBRICATE .......................... Pag. 2-6 2.3 BATTERY ......................................................... Pag. 2-9 2.3.1 CHECKING THE ELECTROLYTE LEVEL ..... Pag. 2-9 2.3.2 RECHARGING THE BATTERY .................... Pag. 2-11 2.3.3 LONG INACTIVITY OF THE BATTERY ....... Pag. 2-11 2.4 EXHAUST MANIFOLD NUTS................ Pag. 2-11 2.5 AIR CLEANER.............................................. Pag. 2-13 2.6 SPARK PLUG ............................................... Pag. 2-15 2.7 CARBURETTORS ....................................... Pag. 2-17 2.8 FUEL TUBING.............................................. Pag. 2-17 2.9 ACCELERATOR CABLE .......................... Pag. 2-17 2.9.1 ADJUSTING THE ACCELERATOR CONTROL ................ Pag. 2-17 2.9.2 ADJUSTMENT OF IDLING RPM .................. Pag. 2-17 2.10 COLD START CABLE............................. Pag. 2-19 2.11 CLUTCH CABLE....................................... Pag. 2-19 2 2.4 TUERCAS DE LOS TUBOS DE ESCAPE ..................................................Pag. 2-11 2.5 FILTRO DEL AIRE ......................................Pag. 2-13 2.6 BUJÍA ...............................................................Pag. 2-15 2.7 CARBURADORES .......................................Pag. 2-17 2.8 TUBERÍAS DEL COMBUSTIBLE .........Pag. 2-17 2.9 CABLE DEL ACELERADOR ....................Pag. 2-17 2.9.1 AJUSTE MANDO ACCELERADOR ..............Pag. 2-17 2.9.2 AJUSTE DEL RÉGIMEN DEL RALENTÍ ......Pag. 2-17 2.10 CABLE DEL ARRANQUE EN FRÍO ..Pag. 2-19 2.11 CABLE DEL EMBRAGUE ......................Pag. 2-19 2.12 CONTROL DEL NIVEL DEL ACEITE DEL MOTOR Y RELLENO.....................Pag. 2-21 2.13 CAMBIO DEL ACEITE MOTOR Y DEL FILTRO DEL ACEITE DEL MOTOR ..Pag. 2-23 2.13.1 PURGA DEL AIRE DE LA BOMBA DE ALIMENTACIÓN DEL ACEITE ..............Pag. 2-25 2.12 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP................................... Pag. 2-21 2.13 CHANGING ENGINE OIL AND OIL FILTER...................................... Pag. 2-23 2.13.1 AIR BLEEDING FROM OIL DELIVERY PUMP ...................... Pag. 2-25 2.14 CONTROL Y RELLENO DEL LÍQUIDO REFRIGERANTE ...........Pag. 2-27 2.15 SUBSTITUCIÓN DEL LÍQUIDO REFRIGERANTE .......................................Pag. 2-29 2.16 CADENA DE TRANSMISIÓN...............Pag. 2-31 2.16.1 2.16.2 2.16.3 2.16.4 CONTROL DEL JUEGO ..............................Pag. 2-31 CONTROL DEL DESGASTE .......................Pag. 2-33 AJUSTE .......................................................Pag. 2-33 LIMPIEZA Y LUBRICACIÓN .......................Pag. 2-33 2.14 CHECKING AND TOPPING UP COOLANT ........... Pag. 2-27 2.15 CHANGING THE COOLANT ............... Pag. 2-29 2.16 DRIVING CHAIN ...................................... Pag. 2-31 2.16.1 2.16.2 2.16.3 2.16.4 CLEARANCE CONTROL ........................... Pag. 2-31 CHECKING WEAR...................................... Pag. 2-33 ADJUSTMENT ............................................ Pag. 2-33 CLEANING AND LUBRICATION ............... Pag. 2-33 2.17 CONTROL Y RELLENO LIQUIDO FRENO DELANTERO ..............................Pag. 2-35 2.18 CONTROL Y RELLENO LIQUIDO FRENO TRASERO ...............Pag. 2-37 2.19 PURGA DEL AIRE DEL SISTEMA DE FRENADO .............Pag. 2-39 2.20 AJUSTE DEL PEDAL DEL FRENO TRASERO ..........................Pag. 2-41 2.21 AJUSTE DE LA PALANCA DEL FRENO DELANTERO ..................Pag. 2-41 2.22 COMPROBACION DESGASTE PASTILLAS ........................Pag. 2-41 2.23 NEUMÁTICOS ............................................Pag. 2-43 2.23.1 CONDICIONES DE LA BANDA DE RODAMIENTO .......................................Pag. 2-43 2.23.2 PRESIÓN DE INFLADO ..............................Pag. 2-43 2.24 DIRECCIÓN .................................................Pag. 2-45 2.24.1 CONTROL JUEGO COJINETES .................Pag. 2-45 2.24.2 AJUSTE JUEGO COJINETES ....................Pag. 2-45 2.25 HORQUILLA DELANTERA ...................Pag. 2-47 2.26 HORQUILLA TRASERA .........................Pag. 2-47 2.26.1 AJUSTE BASCULANTE .............................Pag. 2-47 2.27 SUSPENSIÓN TRASERA ......................Pag. 2-49 2.27.1 AJUSTE SUSPENSION TRASERA ............Pag. 2-49 2.27.2 AJUSTE SUSPENSION TRASERA CON REGULACION HIDRAULICA ....................................Pag. 2-51 DE PRECARGA 2.27.3 CONTROL PALANCAS SUSPENSION TRASERA ............................Pag. 2-51 2.28 RUEDA DELANTERA ..............................Pag. 2-53 2.29 RUEDA TRASERA ....................................Pag. 2-53 2.17 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID................ Pag. 2-35 2.18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID................... Pag. 2-37 2.19 BLEEDING THE BRAKING SYSTEM ...................... Pag. 2-39 2.20 REAR BRAKE PEDAL ADJUSTMENT .......................................... Pag. 2-41 2.21 FRONT BRAKE LEVER ADJUSTMENT .......................................... Pag. 2-41 2.22 CHECKING THE BRAKE PAD WEAR ...................... Pag. 2-41 2.23 TYRES........................................................... Pag. 2-43 2.23.1 CONDITION OF TREAD ............................. Pag. 2-43 2.23.2 INFLATION PRESSURE ............................. Pag. 2-43 2.24 STEERING................................................... Pag. 2-45 2.24.1 CHECKING THE BEARING SLACKS ........ Pag. 2-45 2.24.2 ADJUSTING THE BEARING SLACKS ...... Pag. 2-45 2.25 FRONT FORK ............................................ Pag. 2-47 2.26 REAR FORK ............................................... Pag. 2-47 2.26.1 ADJUSTING THE REAR FORK ................. Pag. 2-47 2.27 REAR SUSPENSION .............................. Pag. 2-49 2.27.1 ADJUSTING THE REAR SUSPENSION .... Pag. 2-49 2.27.2 ADJUSTING THE REAR SUSPENSIONWITH PRELOAD HYDRAULIC ADJUSTMENT 2-51 2.27.3 CHECKING THE REAR SUSPENSION LINKAGE ........ Pag. 2-51 2.28 FRONT WHEEL......................................... Pag. 2-53 2.29 REAR WHEEL ............................................ Pag. 2-53 & &...............Pag. 2.30 APRIETE DE LOS TORNILLOS Y TUERCAS ................................................Pag. 2-54 2.30 TIGHTENING SCREWS AND NUTS .................................................. Pag. 2-54 2 -3 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS Questa sezione descrive le procedure d'intervento per la manutenzione periodica dei principali componenti del veicolo. Prima di iniziare qualsiasi intervento di manutenzione o ispezione al veicolo, arrestare il motore e togliere la chiave, attendere che motore e impianto di scarico si siano raffreddati, sollevare possibilmente il veicolo con apposita attrezzatura, su di un terreno solido e in piano. Porre particolare attenzione alle parti ancora calde del motore e dell'impianto di scarico, in modo tale da evitare ustioni. Il veicolo e' costruito con parti non commestibili. Non mordere, succhiare, masticare o ingerire nessuna parte dello stesso per nessun motivo. Se non espressamente descritto, il rimontaggio dei gruppi segue in senso inverso le operazioni di smontaggio. Esta sección describe los procedimientos de mantenimiento periódico de los principales componentes del vehículo. Antes de comenzar con cualquier tipo de mantenimiento o inspección del vehículo, apague el motor y quite la llave, espere a que el motor y el sistema de escape se hayan enfriado y levante el vehículo con un equipo adecuado, sobre una superficie sólida y plana. Para evitar quemaduras, tenga cuidado con las piezas del motor y del sistema de escape que aún estén caliente. El vehículo está fabricado con piezas no comestibles. No muerda, chupe, mastique ni trague ninguna pieza del mismo por ningún motivo. Si no está expresamente indicado, la reinstalación de los grupos sigue el orden contrario a las operaciones de desmontaje. This section describes the procedures for periodic service on the principal components of the vehicle. Before beginning any service operations or inspection of the vehicle, switch off the engine and remove the key, wait until the engine and the exhaust system have cooled down and, if possible, lift the vehicles with the proper equipment onto firm and flat ground. In order to avoid burns, be careful not to touch any parts of the engine or exhaust system which have not cooled down completely. The vehicle is constructed of nonedible parts. Do not bite, suck, chew or low any part of the vehicle for any reason whatever. If not expressly described otherwise, reassembly of the units is carried out repeating the disassembly operations in the reverse order. a a a c c c c Remember: 1 mile = 1.6 km 1 km = 0.625 miles 2.1 PIANO PER LA MANUTENZIONE PERIODICA Per mantenere ottimali le condizioni di funzionamento del veicolo, aprilia raccomanda di rispettare gli intervalli previsti per gli interventi di manutenzione periodica dei vari componenti. 2.1 PLAN PARA EL MANTENIMIENTO PERIÓDICO Para que las condiciones de funcionamiento del vehículo se mantengan óptimas, aprilia aconseja respetar los intervalos previstos para las intervenciones de mantenimiento periódico de los diferentes componentes. 2.1 PERIODIC SERVICE PLAN aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle. 2 -4 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS 2.1.1 SCHEDA DI MANUTENZIONE PERIODICA 2.1.1 FICHA DE MANTENIMIENTO PERIÓDICO Fine rodaggio (1000 km ou 4 mesi) Fin rodaje (1000 km o 4 meses) After running-in (1000 km or 4 months) 2.1.1 PERIODIC SERVICE CHART FOR THE COMPONENTS Ogni 6000 km o 8 mesi Cada 6000 km o 8 meses Every 6000 km or 8 months Ogni 12000 km o 16 mesi Cada 12000 km o 16 meses Every 12000 km or 16 months COMPONENTI COMPONENTES SERVICE Batteria - livello liquido / Batería - nivel líquido / Battery - liquid level Candela / Bujía / Spark plug Carburatori / Carburadores / Carburettors Catena di trasmissione / Cadena de transmisión / Driving chain Catena di distribuzione / Cadena de distribución / Timing chain Cuscinetti biellismi sospensione / Cojinetes palancas suspensión / Suspension linkage bearings Centratura ruote / Centrado de las ruedas / Wheel truing Cuscinetti di sterzo e sterzo / Cojinetes de dirección y dirección / Steering bearings and steering Cuscinetti ruote / Cojinetes de las ruedas / Wheel bearings Filtro aria / Filtro del aire / Air cleaner Filtro olio motore (sul telaio) / Filtro del aceite del motor (sul bastidor) / Engine oil filter (on the frame) Filtro olio motore / Filtro del aceite del motor / Engine oil filter Gioco frizione / Juego del embrague / Clutch clearance Gioco punterie / Juego de los empujaválvulas / Tappet clearance Impianti frenanti / Sistema de frenado / Braking system Impianto di raffreddamento / Sistema de refrigeración / Cooling system Impianto luci / Instalación de las luces / Lighting system Liquido freni / Líquido de frenos / Brake fluid Liquido refrigerante / Líquido refrigerante / Coolant Olio forcella / Aceite de la horquilla / Fork oil Olio motore / Aceite del motor / Engine oil Pressione dei pneumatici / Presión de los neumáticos / Tyre pressure Regime minimo di giri motore / Régimen de ralentí / Engine idling rpm Rubinetto carburante / Grifo del combustible / Fuel cock Serraggio bulloneria / Apriete del conjunto de pernos / Tightening bolts and nuts Sospensioni ed assetto / Suspensiones y posición / Suspensions and position Spurgo liquido freni / Purga del líquido de frenos / Brake fluid bleeding Tensione raggi / Tensión de los radios / Spoke tension Tubi carburante / Tubos del combustible / Fuel pipes C C C C P ogni / cada / every 500 km: C S C ogni / cada / every 30000 km: C C C C C C S S R C C C C C ogni / cada / every 1000 km: C S S S R R C C C ogni anno / cada año / every year: S ogni 2 anni / cada 2 años / every 2 year: S S S R R C C C C C C C ogni 4 anni / cada 4 años / every 4 year: S ogni / cada / every 500 km: C / 6000 km: S ogni mese / cada meses / every month: R R C C C C = controllare e pulire, regolare, lubrificare o sostituire se necessario / controle y limpie, ajuste, lubrique o substituya si es necesario / check and clean, adjust, lubricate or change, if necessary. P = pulire / Limpie / clean S = sostituire / substituya / change R = regolare / ajuste / adjust Eseguire le operazioni di manutenzione più frequentemente se il veicolo viene utilizzato in zone piovose, polverose o su percorsi accidentati / Si el vehículo se utiliza en zonas lluviosas, polvorientas o en carreteras accidentadas, realice las operaciones de mantenimiento más frecuentemente / Carry out service operations more frequently if the vehicle is used in rainy, dusty areas or on uneven roads. 2 -5 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS 2.2 PUNTI DA LUBRIFICARE Una lubrificazione corretta è importante per un funzionamento scorrevole e una lunga durata del veicolo. Prima della lubrificazione, ripulire completamente ogni parte da eventuale ruggine e rimuovere tutto il grasso, la sporcizia e la polvere. Le parti esposte che sono soggette alla ruggine, devono essere lubrificate con olio motore o grasso, vedi 1.7 (TABELLA LUBRIFICANTI). Nella "SCHEDA DI LUBRIFICAZIONE" sono riportati i punti da lubrificare. LEGENDA SCHEDA DI LUBRIFICAZIONE 1) Perno e cuscinetti ruota anteriore 2) Cuscinetti sterzo 3) Perno leva frizione/cavo frizione 4) Cavo leva per l'avviamento a freddo 5) Perno e cuscinetti ruota posteriore 6) Perno poggiapiedi passeggero 7) Perno cavalletto laterale 8) Comando acceleratore 9) Cavi acceleratore 10) Rinvio tachimetro/contachilometri 11) Perno forcellone posteriore 12) Viti di fulcro cavalletto centrale & (n° 2 ingrassatori) 13) Leverismi sospensione posteriore 14) Catena di trasmissione 2.2 PUNTOS POR LUBRICAR Una lubricación correcta es importante para que las piezas no se agarroten y garantizar una larga duración del vehículo. Antes de lubricar, limpie el herrumbre de cada pieza y quite toda la grasa, la suciedad y el polvo. Las piezas expuestas, que están sujetas al herrumbre, deben lubricarse con aceite motor o grasa, véase 1.7 (TABLA DE LOS LUBRICANTES). En la "FICHA DE LUBRICACIÓN" están indicados los puntos por lubricar. 2.2 POINTS TO LUBRICATE Correct lubrication is important for a good performance and long life of the vehicle. Before lubricating, completely clean all parts, removing rust, grease, dirt and dust. The exposed parts subject to rust are to be lubricated with engine oil or grease. See 1.7 (LUBRICANT CHART). The points to be lubricated are indicated in the "LUBRICATION CHART" c c c PIE DE LA ILUSTRACIÓN DE LA FICHA DE LUBRICACIÓN 1) Eje y cojinetes de la rueda delantera 2) Cojinetes de la dirección 3) Perno de la palanca del embrague/cable embrague 4) Cable de la palanca para el arranque en frío 5) Eje y cojinetes de la rueda trasera 6) Perno reposapiés del pasajero 7) Perno del soporte lateral 8) Mando del acelerador 9) Cables del acelerador 10) Transmisión taquímetro/cuentakilómetros 11) Eje del basculante 12) Tornillos de fulcro caballete central & (n° 2 engrasadores) 13) Mecanismos de palanca suspensión trasera 14) Cadena de transmisión LUBRICATRION CHART KEY 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Front wheel pin and bearings Steering bearings Clutch lever pin /clutch cable Lever cable for cold starting Rear wheel pin and bearings Passenger footrest pin Side stand pin Accelerator control handgrip Accelerator cables Speedometer/total kilometres odemeter transmission Rear fork pin Centre stand fulcrum screws & (n. 2 lubricators) Rear suspension leverage Driving chain 2 -6 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS SCHEDA DI LUBRIFICAZIONE s = Grasso v = Olio FICHA DE LUBRICACIÓN s = Grasa v = Aceite LUBRICATION CHART s = Grease v = Oil 2 3 4 1 7 12 6 5 8 9 14 13 12 11 10 2 -7 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO 2.3 BATTERIA Leggere attentamente 1.4 (PRECAUZIONI E INFORMAZIONI GENERALI). Dopo i primi 1000 km (o 4 mesi) e successivamente ogni 6000 km (o 8 mesi) controllare il livello dell'elettrolita e il serraggio dei morsetti. L'elettrolita della batteria è tossico, caustico, e a contatto con l'epidermide può causare ustioni, in quanto contiene acido solforico. Indossare abiti protettivi, una maschera per il viso e/o occhiali nel caso di manutenzione. Se del liquido elettrolitico venisse a contatto con la pelle, lavare con abbondante acqua corrente. Se venisse a contatto con gli occhi, lavare con acqua abbondante per quindici minuti, quindi rivolgersi tempestivamente a un oculista. Se venisse ingerito accidentalmente, bere grosse quantità di acqua o latte, continuare con latte di magnesia od olio vegetale, quindi rivolgersi prontamente a un medico. La batteria emana gas esplosivi (specialmente durante la fase di attivazione e/o ricarica), è opportuno tenere lontane fiamme, scintille, sigarette e qualsiasi altra fonte di calore. Durante la ricarica o l'uso, provvedere a un'adeguata ventilazione del locale, evitare l'inalazione dei gas emessi durante la ricarica della stessa. Non invertire mai il collegamento dei cavi della batteria. Porre attenzione a non inclinare troppo il veicolo onde evitare pericolose fuoriuscite del liquido della batteria. a a a a Il liquido della batteria è corrosivo. Non versarlo o spargerlo, in particolare sulle parti in plastica. TENERE LONTANO DALLA PORTATA DEI BAMBINI. Collegare e scollegare la batteria con l'interruttore di accensione in posizione "m". Collegare prima il prima il cavo positivo (+) e poi quello negativo (­). Scollegare seguendo l'ordine inverso. 2.3.1 CONTROLLO LIVELLO ELETTROLITA Per il controllo del livello dell'elettrolita è necessario: x Rimuovere la fiancatina sinistra, vedi 7.1.4 (RIMOZIONE FIANCATINE LATERALI DESTRA E SINISTRA). x Svitare e togliere la vite (1). x Rimuovere il coperchio batteria (2). x Controllare che il livello del liquido sia compreso fra le due tacche "MIN" e "MAX", stampigliate sul lato della batteria. x Diversamente: Togliere i tappi degli elementi. a x Non superare il riferimento "MAX", in quanto il livello aumenta durante la ricarica. Controllare con un tester portatile la tensione della batteria. Se la tensione è inferiore a 12V, la batteria deve essere ricaricata. c Ripristinare il livello del liquido solo aggiungendo acqua distillata. 2 -8 OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO 2.3 BATERÍA Lea con mucha atención 1.4 (PRECAUCIONES E INFORMACIONES GENERALES). Controle tras los primeros 1000 km (o 4 meses) y sucesivamente cada 6000 km (o 8 meses) el nivel del electrólito y el apretamiento de los bornes. El electrolito de la batería es tóxico, cáustico y si toca la piel puede causar quemaduras ya que contiene ácido sulfúrico. En el caso de mantenimiento, colóquese ropa de protección, una máscara para la cara y/o gafas. Si el líquido electrolítico tocara la piel, lávese abundantemente con agua corriente. Si entra en contacto con los ojos, lave abundamente con agua por quince minutos y luego diríjase inmediatamente a un oculista. Si se traga accidentalmente, beba mucha agua o leche, siga con leche de magnesia o aceite vegetal, luego diríjase inmediatamente a un médico. La batería emana gases explosivos (especialmente durante la fase de activación y/o recarga), es conveniente mantener alejadas llamas, chispas, cigarrillos y cualquier otra fuente de calor. Durante la recarga o el uso, ventile adecuadamente el local, evite inhalar los gases que emite durante la recarga de la misma. Nunca invierta las conexiones de los cables de la batería. Tenga cuidado en no inclinar demasiado el vehículo para evitar que el riesgo de que el líquido salga de la batería. PERIODIC SERVICE AND SETTING UP OPERATIONS 2.3 BATTERY Carefully read 1.4 (PRECAUTIONS AND GENERAL INFORMATION). Check the electrolyte level and the tightening of the terminals after the first 1000 km (or 4 months) and then every 6000 km (or 8 months). The electrolyte in the battery is toxic and caustic and may cause burns on contact with the skin as it contains sulphuric acid. Wear protective clothing, a face mask and/or goggles during service operations. If electrolyte liquid comes in contact with the skin, wash with large quantities of running water. In case of contact with the eyes, wash with large quantities of water for fifteen minutes and consult an oculist without delay. If the liquid is accidentally swallowed, drink large amounts of water or milk, then continue drinking milk of magnesia or vegetable oil and promptly call a doctor. The battery gives off explosive gases, particularly during the phase of starting and/or recharging; keep it away from flames, sparks, cigarettes and any other source of heat. During recharging or using, make sure the room is properly ventilated and avoid inhaling the gases released during recharging. Never invert the connection of the battery cables. a a a a a a El líquido de la batería es corrosivo. No lo vierta o desparrame, en particular, sobre las piezas de plástico. a a The battery fluid which is very corrosive. Do not pour or spill it, especially on the plastic parts. MANTÉNGASE ALEJADO DEL ALCANCE DE LOS NIÑOS. Conecte y desconecte la batería con el interruptor de encendido en posición "m". Conecte antes el cable positivo (+) y luego el negativo (­). Desconecte siguiendo el orden contrario. 2.3.1 CONTROL DEL NIVEL DEL ELECTROLITO Para controlar el nivel del electrolito es necesario: x Quitar el panel izquierdo, véase 7.1.4 (DESMONTAJE PANELES LATERALES DERECHO E IZQUIERDO). x Destornillar y quitar el tornillo (1). x Quitar la tapa batería (2). x Controlar que el nivel del líquido esté comprendido entre las dos muescas "MIN" y "MAX" , impresas sobre el lado de la batería. Eventualmente: x Quite los tapones de los elementos. KEEP AWAY FROM CHILDREN. Connect and disconnect the battery with the ignition switch in position "m". Connect first the positive cable (+) and then the negative cable (­). Disconnect following the reverse order. 2.3.1 CHECKING THE ELECTROLYTE LEVEL To check the electrolyte level: x Remove the left side, see 7.1.4 (REMOVING THE RIGHT AND LEFT SIDES). x Unscrew and remove the screw (1). x Remove the battery cover (2). x Make sure that the fluid level is included between the two "MIN" and "MAX" notches stamped on the battery side. Otherwise: x Remove the element plugs. a x No supere la referencia "MAX" , ya que el nivel aumenta durante la recarga. a x Never exceed the "MAX" notch, since the level increases during the recharge. Controle con un tester portátil, la tensión de la batería. Si la tensión es inferior a 12V, hay que recargar la batería. c Restaure el nivel del líquido añadiendo sólo agua destilada. Check battery voltage with a portable tester. If voltage is less than 12V, the battery must be recharged. c Top up by adding distilled water only. 2 -9 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO 2.3.2 RICARICA Effettuare il controllo livello elettrolita, ripristinandolo se necessario, quindi: x x Assicurarsi che l'interruttore di accensione sia in posizione "m". Scollegare nell'ordine il cavo negativo (­) e quello positivo (+). Nel rimontaggio collegare prima il cavo positivo (+) e poi quello negativo (­). a x Sfilare il tubetto sfiato batteria. Nel rimontaggio collegare sempre il tubetto sfiato batteria, per evitare che i vapori di acido solforico, uscendo dallo sfiato, possano corrodere l'impianto elettrico, le parti verniciate, i particolari in gomma o le guarnizioni. x x x x x a Rimuovere la batteria dall'alloggiamento e sistemarla in un luogo fresco e asciutto. Togliere i tappi degli elementi. Collegare la batteria a un carica batterie. È consigliata una ricarica utilizzando un amperaggio di 1/10 della capacità della batteria stessa. A ricarica avvenuta, ricontrollare il livello dell'elettrolita ed eventualmente rabboccare con acqua distillata. 2.3.3 LUNGA INATTIVITÀ Nel caso il veicolo rimanga inattivo per un lungo periodo, rimuovere la batteria e ricaricarla completamente, usando una ricarica lenta. Sistemare la batteria in un luogo fresco e asciutto e se rimane sul veicolo, scollegare i cavi dai terminali. Nei periodi invernali o quando il veicolo rimane fermo, è importante controllare la carica (circa una volta al mese) per evitarne il degrado. Per la manutenzione della batteria fare riferimento al capitolo 6.11.2 (MANUTENZIONE). 2.4 DADI COLLETTORI DI SCARICO Leggere attentamente 1.4 (PRECAUZIONI E INFORMAZIONI GENERALI). Serrare dopo i primi 1000 km (o 4 mesi) e successivamente ogni 6000 km (o 8 mesi). a x x Lasciare raffreddare il motore sino al raggiungimento della temperatura ambiente. Rimuovere la carenatura anteriore, vedi 7.1.14 (RIMOZIONE CARENATURA ANTERIORE). 5 Serrare i dadi del collettore di scarico (vedi figura) alla coppia prescritta. Coppia di serraggio dadi: 25 Nm (2,5 kgm) 2 - 10 OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO 2.3.2 RECARGA BATERIA Controle y si acaso restaure el nivel del electrolito, luego: x Controle que el interruptor de encendido esté en posición "m". x Desconecte según el orden el cable negativo (­) y el positivo (+). PERIODIC SERVICE AND SETTING UP OPERATIONS 2.3.2 RECHARGING THE BATTERY Check the electrolyte level, if necessary top up, then: x Make sure that the ignition switch is in position "m". x Disconnect, in order, the negative (­) and positive (+) cable. a x Durante la instalación conecte antes el cable positivo (+) y luego el negativo (­). a x Upon reassembly, connect first the positive cable (+) and then the negative cable (­). Extraiga el tubo respiradero batería. Remove the battery breather pipe. Durante la instalación, conecte siempre el tubo respiradero de la batería para evitar que los vapores del ácido sulfúrico, al salir del respiradero, puedan corroer la instalación eléctrica, las partes barnizadas, las piezas de goma o las juntas. x x x x x a Upon reassembly, always connect the battery breather pipe, to prevent the sulphuric acid vapours from corroding the electric system, painted parts, rubber elements or gaskets when they exit the breather pipe itself. x x x x x a Saque la batería de su alojamiento y colóquela en un lugar fresco y seco. Quite los tapones de los elementos. Conecte la batería a un carga-baterías. Se aconseja una recarga utilizando un amperaje de 1/10 de la capacidad de la misma batería. Tras haber realizado la recarga, vuelva a controlar el nivel del electrolito y de resultar necesario rellene con agua destilada. Extract the battery from its container and put it in a cool and dry place. Remove the element plugs. Connect the battery with a battery charger. A recharge with an amperage equal to 1/10th of the battery capacity is recommended. After the recharging operation, check the electrolyte level again and if necessary top up with distilled water. 2.3.3 LARGA INACTIVIDAD Si el vehículo queda inactivo por un largo período, quite la batería y recárguela completamente, utilizando una recarga lenta. Guarde la batería en un lugar fresco y seco y si queda montada en el vehículo, desconecte los cables de los bornes. Durante el invierno o cuando el vehículo queda parado, es importante controlar la carga (una vez al mes aproximadamente) para evitar que se degrade. Para el mantenimiento de la batería refiérase al capítulo 6.11.2 (MANTENIMIENTO). 2.4 TUERCAS DE LOS TUBOS DE ESCAPE Lea con mucha atención 1.4 (PRECAUCIONES E INFORMACIONES GENERALES). Apriete tras los primeros 1000 km (ó 4 meses) y sucesivamente, cada 6000 km (o 8 meses). 2.3.3 LONG INACTIVITY OF THE BATTERY If the vehicle remains unused for long periods, remove the battery and recharge it completely, using a trickle charge. Keep the battery in a cool, dry place. If the battery remains on the vehicle, disconnect the cables from the terminals. During the winter months or whenever the vehicle is not in use, it is important to check the charge (about once a month) in order to prevent deterioration of the battery. For maintenance of the battery refer to chapter 6.11.2 (MAINTENANCE). 2.4 EXHAUST MANIFOLD NUTS Read 1.4 carefully (PRECAUTIONS AND GENERAL INFORMATION). Tighten nuts after the first 1000 km (or 4 months) and then after every 6000 km (or 8 months). a x x Deje enfriar el motor hasta que el mismo alcance la temperatura ambiente. a x x Allow the engine to cool down until it reaches room temperature. Desmonte el carenado delantero, véase 7.1.14 (DESMONTAJE CARENADO DELANTERO). 5 Apriete las tuercas del tubo de escape (véase figura) con el par indicado. Remove the front fairing, see 7.1.14 (REMOVING THE FRONT FAIRING). 5 Tighten the exhaust manifold nuts (see figure) to the prescribed torque. Par de apriete tuercas: 25 Nm (2,5 kgm) Driving torque: 25 Nm (2.5 kgm) 2 - 11 OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO 2.5 FILTRO ARIA Leggere attentamente 1.4 (PRECAUZIONI E INFORMAZIONI GENERALI). Pulire ogni 6000 km. Sostituire ogni 12000 km. La pulizia parziale del filtro aria non esclude o posticipa la sostituzione del filtro stesso. Non avviare il motore con il filtro aria rimosso. Non utilizzare benzina o solventi per la pulizia dell'elemento filtrante; potrebbero causare un incendio al sistema di alimentazione, con grave pericolo per le persone e il veicolo. a RIMOZIONE x x x Rimuovere la sella, vedi 7.1.3 (RIMOZIONE SELLA). Ruotare in senso orario il convogliatore aria (1) sollevarlo e rimuoverlo. Estrarre il filtro aria (2). Pulizia parziale a x x x Non premere o battere sulla rete metallica del filtro aria. Non agire con cacciaviti o altro sul filtro stesso. Afferrare il filtro aria verticalmente e batterlo più volte sopra un piano pulito. All'occorrenza, pulire il filtro aria con un getto d'aria compressa (dirigendolo dall'interno verso l'esterno del filtro). Pulire esternamente il filtro aria con un panno. Sostituzione x x x Sostituire il filtro aria con uno nuovo dello stesso tipo. Controllare l'integrità della guarnizione (3); se danneggiata sostituirla. Ogni 6000 km, rimuovere il tappino (4) e lasciar fuoriuscire eventuali impurità depositate all'interno della cassa filtro. Durante le operazioni di pulizia dell'elemento filtrante, verificare che non vi siano lacerazioni. In caso contrario sostituire l'elemento fil- trante. Assicurarsi che l'elemento filtrante sia correttamente posizionato, in modo da non far passare aria non filtrata. Non dimenticare che l'usura precoce dei segmenti del pistone e del cilindro è spesso causata dall'elemento filtrante difettoso o mal posizionato. Se si utilizza il veicolo in zone polverose, pulire l'elemento filtrante più frequentemente. L'utilizzo del veicolo senza l'elemento filtrante o con l'elemento danneggiato aumenta in modo considerevole l'usura del motore. Assicurarsi che l'elemento filtrante sia sempre in perfette condizioni. La durata del motore dipende in gran parte da questo componente. a 2 - 12 OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE PUESTA A PUNTO 2.5 FILTRO DEL AIRE Lea con mucha atención 1.4 (PRECAUCIONES E INFORMACIONES GENERALES). Limpie cada 6000 km. Substituya cada 12000 km. La limpieza parcial del filtro no excluye ni aplaza la sustitución del filtro mismo. No ponga en marcha el motor si se ha desmontado el filtro de aire. No utilice gasolina o disolventes para limpiar el elemento filtrante; esto podría causar un incendio en el sistema de alimentación con grave peligro para las personas y para el vehículo. PERIODIC SERVICE AND SETTING UP OPERATIONS 2.5 AIR CLEANER Read 1.4 carefully (PRECAUTIONS AND GENERAL INFORMATION). Clean every 6000 km. Replace every 12000 km. The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself. Do not start the engine if the air cleaner has been removed. Do not use petrol or solvents to clean the filtering element; they may cause a fire in the fuel system, with serious risks for people and for the vehicle itself. a a REMOVAL DESMONTAJE x x x x x x Desmonte el sillín, véase 7.1.3 (DESMONTAJE SILLIN). Gire en sentido horario el encuazador de aire (1), levántela y extráigala. Extraiga el filtro del aire (2). Remove the saddle, see 7.1.3 (REMOVING THE SADDLE). Rotate the air conveyor (1) clockwise, raise and remove it. Extract the air cleaner (2).