use and maintenance aprilia part# 8201997 Rally 50 © 1996 aprilia s.p.a. - Noale (VE) This manual is to be considered an integral part of the vehicle, which must be delivered complete with it also in case of resale. 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. First edition: october 1996 Reprint: july 1997, november 1997, february 1999 Produced and printed by: Studio Tecno Public Viale del Progresso - 37038 Soave (VR) - Italy Tel. +39 - 045 76 11 911 Fax +39 - 045 76 12 241 www.stp.it E-mail: customer@stp.it On behalf of: aprilia s.p.a. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39 - 041 58 29 111 Fax +39 - 041 44 10 54 www.aprilia.com 2 use and maintenance Rally 50 &/2%7/2$ Before starting the engine, carefully read this manual, paying particular attention to the chapter "RIDING SAFELY". Your and other people's safety depends not only on your quickness of reflexes and on your agility, but also on what you know about the vehicle, on its efficiency and on your knowledge of the basic information for RIDING SAFELY. Therefore, get a thorough knowledge of the vehicle, in such a way as to be able to drive in the traffic safely. For the controls and repairs not expressly described in this manual, for the purchase of aprilia Genuine Spare Parts, accessories and other products, as well as for specific technical advice, contact only aprilia Authorized Outlets and Official Dealers, who can ensure you reliable and prompt servicing. Thank you for choosing aprilia. We wish you a nice ride. IMPORTANT: When asking your Dealer for spare parts, specify the spare parts code indicated on the SPARE PARTS IDENTIFICATION LABEL. Write down the identification code in the space here below, in order to remember it also in case of loss or deterioration of the label. The label is positioned under the inspection cover, stuck to the frame and to read it it is necessary to remove the inspection cover, see p. 46 (REMOVING THE INSPECTION COVER). Carefully observe the instructions preceded by the following warning signs: a c # Safety norms and regulations to protect the driver 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. In this manual the various versions are indicated by the following symbols: 1 liquid-cooled version 2 catalytic version 3 drum brake version VERSION: Italy I U United Kingdom Austria A P Portugal " Finland B Belgium D Germany F France E Spain G Greece O Holland C Switzerland Denmark J Japan S Singapore V Poland % Israel K South Korea M Malaysia R Chile Q Bermuda - United States of America ^ Australia Í Brazil ° South Africa Î New Zealand [ Canada ` Croatia Ñ Slovenia Rally 50 use and maintenance 3 ).$)#% '%.%2!,% RIDING SAFELY ............................................................................. 5 BASIC SAFETY RULES ............................................................ 6 CLOTHING ................................................................................ 9 ACCESSORIES ....................................................................... 10 LOAD ....................................................................................... 10 ARRANGEMENT OF THE MAIN ELEMENTS.............................. 12 ARRANGEMENT OF THE INSTRUMENTS ................................. 14 INSTRUMENTS AND INDICATORS............................................. 14 INSTRUMENT AND INDICATOR TABLE................................ 15 MAIN INDEPENDENT CONTROLS.............................................. 16 CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR ...... 16 CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR.... 17 IGNITION SWITCH.................................................................. 18 STEERING LOCK.................................................................... 18 AUXILIARY EQUIPMENT ............................................................. 19 UNLOCKING/LOCKING THE SADDLE................................... 19 CRASH HELMET / GLOVE COMPARTMENT ........................ 19 ANTI-THEFT HOOK ................................................................ 19 BATTERY / TOOL KIT COMPARTMENT................................ 20 BAG HOOK.............................................................................. 20 MAIN COMPONENTS ................................................................... 21 FUEL........................................................................................ 21 MIXER OIL TANK .................................................................... 22 BRAKE FLUID (RECOMMENDATIONS)................................. 22 DISC BRAKES......................................................................... 23 ...................................................... 24 REAR DRUM BRAKE TYRES ..................................................................................... 25 ........................................................................ 26 COOLANT .................................................. 28 CATALYTIC SILENCER INSTRUCTIONS FOR USE ........................................................... 29 PRELIMINARY CHECKING OPERATIONS ............................ 29 STARTING............................................................................... 30 DEPARTURE AND DRIVE ...................................................... 32 RUNNING-IN ........................................................................... 33 STOPPING AND PARKING..................................................... 33 POSITIONING THE VEHICLE ON THE STAND ..................... 33 SUGGESTIONS TO PREVENT THEFT .................................. 34 MAINTENANCE ............................................................................ 35 REGULAR SERVICE INTERVALS CHART ............................ 35 IDENTIFICATION DATA.......................................................... 36 AIR CLEANER ......................................................................... 37 CHECKING THE TRANSMISSION OIL LEVELONE............... 38 CHANGING THE TRANSMISSION OIL .................................. 39 FRONT WHEEL....................................................................... 40 REAR WHEEL ......................................................................... 42 GREASING THE REAR BRAKE CAM PIN.............................. 43 CHECKING THE BRAKE PAD WEAR .................................... 44 CHECKING THE BRAKE SHOE WEAR .......................... 44 CHECKING THE STEERING .................................................. 45 CHECKING THE ENGINE FULCRUM AXIS ........................... 45 REMOVING THE INSPECTION COVER ................................ 46 IDLING ADJUSTMENT............................................................ 47 ADJUSTING THE ACCELERATOR CONTROL ...................... 47 SPARK PLUG .......................................................................... 48 BATTERY ................................................................................ 49 CHECKING THE ELECTROLYTE LEVEL............................... 50 LONG INACTIVITY OF THE BATTERY .................................. 50 CHANGING THE FUSE........................................................... 51 ADJUSTING THE HEADLIGHT BEAM.................................... 52 BULBS ..................................................................................... 53 CHANGING THE HEADLIGHT BULBS ................................... 53 CHANGING THE DASHBOARD BULBS................................. 54 CHANGING THE REAR LIGHT BULB .................................... 55 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS............................................ 55 TRANSPORT................................................................................. 56 DRAINING THE FUEL TANK .................................................. 56 CLEANING .................................................................................... 57 LONG PERIODS OF INACTIVITY........................................... 58 AFTER A LONG PERIOD OF INACTIVITY ............................. 58 TECHNICAL DATA ....................................................................... 59 LUBRICANT CHART ............................................................... 62 IMPORTERS............................................................................ 63 WIRING DIAGRAM (air-cooled version) .................................. 64 WIRING DIAGRAM KEY.......................................................... 65 WIRING DIAGRAM (liquid-cooled version ) ...................... 66 WIRING DIAGRAM KEY (liquid-cooled version ) ...................................................... 67 3 1 3 2 1 1 4 use and maintenance Rally 50 safe drive "!3)# 3!&%49 25,%3 To drive the vehicle it is necessary to be in possession of all the requirements prescribed by law (driving licence, minimum age, psychophysical ability, insurance, state taxes, vehicle registration, number plate, etc.). Gradually get to know the vehicle by driving it first in areas with low traffic and/or private areas. The use of medicins, alcohol and drugs or psychotropic substances notably increases the risk of accidents. Be sure that you are in good psychophysical conditions and fit for driving and pay particular attention to physical weariness and drowsiness. Most road accidents are caused by the driver's lack of experience. NEVER lend the vehicle to beginners and, in any case, make sure that the driver has all the requirements for driving. 6 use and maintenance Rally 50 Rigorously observe all road signs and national and local road regulations. Avoid abrupt movements that can be dangerous for yourself and other people (for example: rearing up on the back wheel, speeding, etc.), and give due consideration to the road surface, visibility and other driving conditions. Avoid obstacles that could damage the vehicle or make you lose control. Avoid riding in the slipstream created by preceding vehicles in order to increase your speed. Always drive with both hands on the handlebars and both feet on the footrests, in the correct driving posture. Avoid standing up or stretching your limbs while driving. use and maintenance Rally 50 7 OIL COOLER The driver should pay attention and avoid distractions caused by people, things and movements (never smoke, eat, drink, read, etc.) while driving. Use only the vehicle's specific fuels and lubricants (indicated in the "LUBRICANT CHART"); check all oil, fuel and coolant levels regularly. If the vehicle has been involved in an accident, make sure that no damage has occurred to the control levers, pipes, wires, braking system and vital parts. If necessary, have the vehicle inspected by an aprilia Official Dealer, who should carefully check the frame, handlebars, suspensions, safety parts and all the devices that you cannot check by yourself. Always remember to report any malfunction to the technicians to help them in their work. Never use the vehicle when the amount of damage it has suffered endangers your safety. 8 use and maintenance Rally 50 ONLY ORIGINALS A12 345 Never change the position, inclination or colour of: number plate, direction indicators, lights and horns. Any modification of the vehicle will result in the invalidity of the guarantee. Any modification of the engine or of other members which is aimed at increasing the speed or the power of the vehicle is prohibited by the law; in fact, any modification resulting in an increase of the maximum speed or of the engine displacement would change the scooter into a motorcycle, which implies the following obligations for the owner: ­ new homologation; ­ new registration; ­ appropriate driving license. Further, said modifications cause the loss of the insurance cover, since insurance policies expressly prohibit to make technical changes aimed at increasing the vehicle performance levels. 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 combined with the sanctions provided for not using the crash helmet and/or the number plate, for the violation of fiscal obligations (ownership tax) and with penal sanctions provided for using the vehicle without driving license. Never race with other vehicles. Avoid off-road driving. #,/4().' Before starting, always wear a correctly fastened crash helmet. ...