Embed Size (px)
Citation preview
1
First edition: november 1997
Reprint:
Produced and printed by:editing division
Soave (VERONA) - ItalyTel. +39 - 045 76 11 911Fax +39 - 045 76 12 241E-mail: [email protected]
On behalf of:aprilia s.p.a.via G. Galilei, 1 - 30033 Noale (VE) - ItalyTel. +39 - 041 58 29 111Fax +39 - 041 44 10 54www.aprilia.comThis manual contains all the main information and the in-
structions required for normal use and maintenance ofyour vehicle.For controls and check-ups that cannot be carried outeasily with the standard equipment supplied, we adviseyou to consult our Dealers who can assure you of quickand careful servicing.To keep your aprilia vehicle always in perfect operatingconditions, we advise you to insist on Original Sparesand to have repairs carried out only by aprilia Author-ized Outlets and Official Dealers. When ordering spare parts from the Dealer, alwaysquote the spares code which is stamped on a stickerplaced under the saddle.It is a good idea to make a note of the identification codein the space provided in this manual, so that you will al-ways have a record of it even if the identification stickercomes off.
All information is purely indicative and may be subject tovariation without notice.
aprilia CODICE RICAMBI spare parts code number
N° I.M. A B C D E
I UK A P SF B D F E
GR NL CH DK J SGP PL IL ROK
MAL RCH BM USA
aprilia part# 8202099
2
Carefully observe the instructions preceded by the fol-lowing warning signs:
Safety norms and regulations to protect thedriver and other people from severe injuriesor grave risks.
Indications to make the operations easier.Technical information.
In this manual the various versions are indicated by thefollowing symbols:
#/.4%.43
page
Catalitic silencer � .....................................................2Technical data .............................................................3Identification data ........................................................5Controls arangement .....................................................6Instructions for use .....................................................9Maintenance instructions .........................................15Periodic maintenance chart .....................................26Lubricant chart ..........................................................27Wiring diagram ..........................................................28
#!4!,94)#�3),%.#%2��
Avoid parking the vehicle catalytic versionnear dry brush wood or in places easily ac-cessible to children, as the catalytic silencer
becomes extremely hot during use; be very carefuland avoid any kind of contact before it has com-pletely cooled down.
The catalytic Amico 50 is fitted with a silencer with metalcatalytic converter of the "platinum-rhodium bivalent"type. This device provides for the oxidation of the CO(carbon monoxide) and of the HC (unburned hydrocar-bons) contained in the exhaust gases, changing theminto carbon dioxide and steam, respectively.Due to the catalytic reaction, the high temperaturereached by the exhaust gases makes for the burning ofthe oil particles, thus keeping the silencer clean andeliminating the exhaust fumes.
� catalytic version
� Italy version � Switzerland version
� United Kingdom version � Denmark version
� Austria version � Japan version
� Portugal version Singapore version
Finland version � Poland version
� Belgium version Israel version
� Germany version � South Korea version
� France version � Malaysia version
� Spain version � Chile version
� Greece version � Bermuda version
� Holland version � United States of America version
��
�
3
To have the catalytic converter function correctly and forlong and to reduce possible problems regarding the soil-ing of the thermal unit and of the exhaust, it is necessaryto avoid covering long distances with the engine runningat constantly low rpm.It is sufficient to alternate these periods with periods inwhich the engine runs at relatively high rpm, even if onlyfor a few seconds, but rather frequently.What has been stated above assumes particular impor-tance for the cold starting of the engine: in this case, inorder to reach a rpm regime sufficient to enable the"priming" of the catalytic reaction, just make sure that thetemperature of the thermal unit has reached at least50°C, which generally occurs a few seconds after start-ing the engine.
Do not use leaded petrol, since it causes thedestruction of the catalytic converter.
4%#(.)#!,�$!4!
-/4/2
Model ................................................................... apriliaType ..................................... 2-stroke single-cylinder
with lamellar inletCylinder .............................................................cast ironBore / stroke ...................................... 40 mm e 39,2 mmCompression ratio ................................................... 13:1Displacement ...................................................... 49 cm³Starting ................................................................electricGearbox ..........................................automatic converter
with belt driveTransmission oil capacity................................... 110 cm³
42!.3-)33)/.
Primary ............................................................... “V'' beltSecondary ............................................... reduction gearVariator .................................................................... 3YJ
)'.)4)/.
Typ ..................................................................electronicSpark advance .........................14° at 5000 rpm 1,4 mm
before T.D.C.Spark plug ................................................ NGK BR7 HS
#!2"52%44/2
Model ............... Dell’Orto PHBN 12 (TEI KEI TK12Y12)
�
4
&5%,�3500,9
Fuel .................... premium grade petrol (4 Stars �)according to the DIN 51 600
standard, min. O.N. 98 (N.O.R.M.)and 88 (N.O.M.M.)
Fuel � ........................... unleaded petrol accordingto the DIN 51 607 standard,
min. O.N. 95 (N.O.R.M.)and 85 (N.O.M.M.)
Fuel tank capacity ................................................... 7,5 �of wich 2 � reserve
Mixer oil tank capacity ............................................. 1,3 �
&2!-%
Type ...................... split single beam tubular steel frame
3530%.3)/.3
Front .......................................... fork with articulated rodRear ...............................hydraulic monoshock absorber
"2!+%3
Front ....................................................... disc Ø 155 mmwith hydraulic control
Rear .......................................shoe brake Ø 110x25 mmwith mechanical control
492%3
– Front ........................................................ 100/90×10”Inflation pressure ............................170 kPa (1,7 bar)
– Rear ......................................................... 100/90×10”Inflation pressure ............................190 kPa (1,9 bar)with passenger.................................210 kPa (2,1 bar)
2)-3�
Front ................................................ 2,50×10” light alloyRear ................................................. 2,50×10” light alloy
%,%#42)#�3934%-
Front lights .......................................................12V 15WFront lights �............................................12V 35/35WFront parking light(not provided in the � versions) .....................12V 3 WRear light/stop light ......................................12V 5/21 WTurn indicators .................................................12V 10WDash board light ................. 5×12V 2W (warning lights);
3×12V 1,2W - 1×12V 2WLight for tool case/helmet case .......................12V 1,2WBattery ..............................................................12V 4AhFuse......................................................................... 7,5A
$)-%.3)/.3
Length ..............................................................1780 mmWidth ............................................ 690 mm (handle bar)Height ................ 1060 mm (handle bar); 760 mm (seat)Centre to centre distance ................................1240 mmWeight without fuel and oil .....................................71 kg
5
)$%.4)&)#!4)/.�$!4!
It is a good rule to write down the frame and engine num-bers in the space provided in this manual.
Do not alter the identification numbers if youdo not want to incur severe penal and ad-
ministrative sanctions.
FRAME NUMBER (Fig. 1)The frame number is stamped on the frame. To be ableto read it, it is necessary to raise the saddle (1).
Frame no.
ENGINE NUMBER (Fig. 2)The engine number is stamped on the lower support ofthe rear shock absorber.
Engine no.
�
6
#/.42/,3�!22!.'%-%.4
&IG���
1 - Start push button (�)2 - Lights switch (� - � - •)
2a - Lights switch (� - •)�2b - Lights switch (� - � - •) �
3 - Ignition block/steering lock switch (� - � - �)4 - Turn indicators switch (�)5 - Horn push button ( )6 - Cold start lever (!)7 - Thraottle grip8 - Front brake lever9 - Rear brake lever
&IG���
1 - Speedometer / Odometer2 - Fuel level indicator (")3 - Fuel reserve warning light (")4 - Mixer oil reserve warning light (#)5 - Turn indicators warning light (�)6 - Low beam warning light (�)
6a - High beam warning light (�)�7 - Digital clock
8/9 - Clock adjustment and functions selection pushbuttons
Remember: 1 mile = 1.6 km1 km = 0.625 miles�
7
3%44).'�4(%�#,/#+��� � � &IG���
Display:� Normal display: hours and minutes.� Date display: press (9) once to display the month and
date.� Seconds display: press (9) twice to display the sec-
onds.
Setting� Press (8) once, the date and time will be displayed al-
ternately.� Month: press (8) again and the month will appear on
the right (the rest disappears), press (9) to obtain thedesired month.
� Date: press (8) again and the date will appear on theright. Press (9) to obtain the desired date.
� Hours: press (8) again and the hour will appear on theleft with the letter “A” or “P” (“A” = a.m., “P” = p.m.).Press (9) to obtain the desired hour.
� Minutes: press (8) again and the minutes will appearon the right of the display. Press (9) to obtain the desired minutes
� The clock is now set. Press (8) again to return to normal operation.
#(!.').'�4(%�#,/#+�#%,,� Remove the front grille and headlamp unit, see pag.
25).� Remove the clock support from the rear of dashboard,
acting on the snapcouplings.� Extract the clock and change the cell.
8
&IG���
1 - Fuel tank plug2 - Mixer oil tank plug 3 - Tool case/helmet case
&IG���
1 - Central stand2 - Starter pedal3 - Case4 - Case lock5 - Seat lock6 - Carrier/handle
,/#+3
The key provided starts the engine, operates the steer-ing lock (3-Fig. 3), the luggage case lock (4-Fig. 6) andthe saddle lock (5-Fig. 6).
To operate the steering lock, turn the han-dlebars to the left, press the key, pull it up
and turn it to “�” position, then extract the key.�
9
).3425#4)/.3�&/2�53%
34!24).'
Exhaust gases contain carbon monoxide,which is extremely noxious if inhaled. Avoid starting the vehicle in closed or badly-
ventilated rooms. The non-observance of this warning may cause lossof consciousness or even lead to death by asphyxia. Do not get on the vehicle for the starting.
Electric starting� Position the vehicle on the stand.� Lock at least one wheel, by pulling a brake lever (Fig.
7). If this operation is not carried out, the start relay re-ceives no current and therefore the engine does notstart.
� Turn the ignition switch (Fig. 8) to position "�".
�
10
� Press the start push button “�” (1-Fig. 9) without accel-erating, then release it as soon as the engine starts.
Avoid pressing the start push button "�"(3) when the engine is running: this maydamage the starter.
When the start push button "�" is pressed, the 2stroke oil reserve warning light "#" comes on. With the engine in running condition, when the startpush button "�" is released, the 2 stroke oil reservewarning light "#" must go out; if this does not oc-cur, top up the 2 stroke oil tank.
� If the starting is carried out with cold engine, rotate thecold start lever "!" (1-Fig. 10) downwards.
� Do not accelerate and pull the brake levers at thesame time until you move off.
� Warm the engine up before leaving.� Once the engine has warmed up, rotate the cold start
lever "!" (1-Fig. 10) upwards.
�
11
+)#+�34!24
For the kick start, proceed as follows:� Position the vehicle on the centre stand.� Move to the left side of the vehicle.� To avoid losing control of the vehicle during the start-
ing, lock both wheels by putting on the brake levers(Fig. 7).
� Turn the ignition switch (Fig. 8) to position "�".
Do not push down the kick starter with theengine on.
� Push down the kick starter with your right foot, releas-ing it immediately.If necessary, repeat the operation until the enginestarts.
34!24).'�!&4%2�!�,/.'�0%2)/$�/&�).!#4)6)49
After a long period of inactivity, proceed as follows:� Move the ignition switch (Fig. 8) to position "�".� Make the starter run for about 10 seconds, in order to
ensure the filling up of the float chamber.
To start the engine:� Rotate the cold start lever "!" (1-Fig. 10) downwards.� Slightly open the throttle, then carry out the electric
starting procedure (or KICK START).�
12
$%0!2452%�!.$�$2)6%
Release the throttle grip (Pos. A - Fig. 11), put on therear brake, then move the vehicle down the stand.Get on the vehicle, keeping at least one foot on theground in order not to lose balance.
Properly adjust the inclination of the rear-view mirrors.
To leave, release the brake lever and accelerate by gen-tly rotating the throttle grip (Pos. B - Fig. 11); the vehiclewill start moving.
Avoid opening and closing the throttle griprepeatedly and continuously, so that you donot accidentally lose control of the vehicle.
If you have to brake, close the throttle and put onboth brakes in order to obtain uniform deceleration,properly exerting pressure on the braking parts.
By putting on the front brake only or the rear brakeonly, you reduce the braking force considerably,thus running the risk of locking one wheel and con-sequently losing grip.
Before beginning to turn, slow down or brake driv-ing at moderate and constant speed or acceleratingslightly; avoid braking at the last moment: it wouldbe very easy to skid.
�
�
13
If the brakes are operated continuously ondownhill stretches, the friction surfaces canoverheat, thus reducing the braking efficien-
cy. Never drive with the engine off!
In case of wet ground or scarce wheel grip (snow,ice, mud, etc.), drive slowly, avoiding sudden brak-ings or manoeuvres that could make you lose gripand fall down.
Pay the utmost attention to any obstacle or variationof the ground.
Uneven roads, rails, manhole covers, indicationspainted on the road surface, building site metalplates become rather slippery by rain. For this rea-son all these obstacles have to be carefully avoided,driving smoothly and bending the vehicle as little aspossible.
Always use the turn indicators timely when you in-tend to change lane or direction, avoiding sharp anddangerous movements.
25..).' ).
After the first 500 kilometres, carry out thechecking operations indicated in the column"After running-in" of the PERIODIC MAINTE-
NANCE CHART, see p. 26, in order to avoid hurtingyourself or other people and/or damaging the vehi-cle.
The running-in of the engine is primary to ensure its cor-rect functioning and its correct functioning. If possible, drive on hilly roads and/or roads with manybends, so that the engine, the suspensions and thebrakes undergo a more effective running-in.
For the first 500 km, keep to the following indications:
0-300 kmDo not keep the throttle grip open more than one half forlong stretches.
300-500 kmDo not keep the throttle grip open more than three-fourths for long stretches.
Remember: 1 mile = 1.6 km1 km = 0.625 miles
��
�
14
34/00).'�!.$�0!2+).'��&IG����� Release the throttle grip and stop the vehicle by
putting on the brakes.� Move the ignition switch to position "�".
It is not necessary to close the fuel tap whenthe engine is off, since it is equipped with an
automatic closing system.
0/3)4)/.).'�4(%�6%()#,%�/.�4(%�34!.$��&IG����
Park the vehicle on firm and flat ground, toprevent it from falling down.Neither lean the vehicle against walls, nor
lay it on the ground.Make sure that the vehicle and especially its red-hotparts do not represent a danger for persons andchildren.Do not leave the vehicle unattended when the en-gine is on or the key is inserted into the ignitionswitch.Do not sit on the vehicle when the stand is down.
Seize the vehicle using the rear grab rail and at thesame time push the stand lever downwards (see figure).
Make sure that the vehicle is resting firmly.
�
�
15
-!).4%.!.#%� ).3425#4)/.3
&2/.4�"2!+%��&IG����
This vehicle is provided with front hydraulic disc brake.When the disc pads wear out, the level of the fluid de-creases to automatically compensate for their wear.Periodically check the brake fluid level in the tank andthe wear of the pads, see p. 18 (CHECKING THE PADWEAR).
2%!2�$25-�"2!+%
The brakes are the parts that most ensureyour safety and for this reason they must al-ways be perfectly working.
ADJUSTING THE BRAKE� Measure the distance covered by the lever (9-Fig. 3)
before the brake starts it braking action. The idle stroke at the end of the brake lever must beabout 5 ÷ 10 mm.
� Adjust the clearance by acting on the adjuster(1-Fig. 15).
� Put on the brake (9-Fig. 3) repeatedly and make surethat the wheel turns freely after the brake has been re-leased.
� Check the braking efficiency.
For any doubt regarding the perfect func-tioning of the braking system and in caseyou are not able to carry out the usual
checking operations, contact your APRILIA OfficialDealer.
�
�
16
$)3-!.4,).'�4(%�&2/.4�7(%%,�&IG����� Remove the two plastic elements (1) protecting the
stem.� Unscrew the two screws (2) and remove the brake
caliper.� Unscrew the nut (3).
Coppia di serraggio: 50 Nm (5 kgm).� Slide the pin nut (5).� Remove the wheel.
Upon reassembly position the odometer ca-ble (4) correctly.
!$*534).'�4(%�!##%,%2!4)/.�'2)0�&IG����
Adjust the play on the accelerator via the appropriatetightener on the carburettor.
To access the carburattor:� Remove the screw (1).� Pull the tool-helmet, compartment after disconnecting
the compart- ment lighting cable.
�
17
2%-/6).'�4(%�2%!2�7(%%,��&IG����
Before carrying out the following opera-tions, let the engine and the silencer cooldown until they reach room temperature, in
order to avoid burns.
� Position the vehicle on the centre stand.� Unscrew and remove the two screws (1) and (2).� Slacken the two screws that hold the exhaust silencer
to the cylinder (access through the battery compart-ment)
� Remove the silencer (4).
Upon reassembly, change the exhaust man-ifold-silencer seal.
� Put on the rear brake (9 - Fig. 3) to lock the wheel.� Unscrew and remove the wheel nut (3) and the wash-
er.
Upon reassembly, change the wheel nut(special type).
Wheel nut driving torque: 110 Nm (11 kgm).
� Withdraw the wheel.
�
�
�
18
#(%#+).'�4(%�3(/%�7%!2��&IG����
Check the wear of the rear brake shoes after the first500 km and successively every 4000 km.
Remember: 1 mile = 1.6 km1 km = 0.625 miles
To check the wear of the rear brake shoes, proceed asfollows:� Remove the rear wheel, see p. 17 (REMOVING THE
REAR WHEEL).� To check the thickness of the friction material, which
must never be less than 1 mm (Fig. 19).
If the minimum allowed limit has beenreached, if you notice any irregularity in theoperation or if any part is damaged, contact
your APRILIA Official Dealer, who will provide forchanging the brake shoes.
#(%#+).'�4(%�"2!+%�0!$�7%!2
Check the brake pad wear after the first 500 km and suc-cessively every 2000 km.
Remember: 1 mile = 1.6 km1 km = 0.625 miles
The wear of the brake pads depends on the use, on thekind of drive and on the road. The wear will be greaterwhen the vehicle is driven on dirty or wet roads.
To carry out a rapid checking of the wear of the frontpads, proceed as follows:� Position the vehicle on the centre stand.� Remove the brake caliper cover.� Carry out a visual checking of the friction material
thickness by looking between the brake caliper andthe pads.
If the thickness of the friction material (even of one padonly) has reduced to about 1 mm, replace both pads.
Have the pads changed by your APRILIA Offi-cial Dealer.
�
�
�
�
19
'2%!3).'�4(%�2%!2�"2!+%�#!-�0).�&IG����
Grease the rear brake cam pin every 4000km. If the vehicle is used on dusty roads,
this operation must be carried out more frequently.
Remember: 1 mile = 1.6 km1 km = 0.625 miles
� Disassemble the rear wheel, see p. 17 (REMOVINGTHE REAR WHEEL (Fig. 18)).
� Unscrew and remove the adjuster (1-Fig. 15).
Do not dirt the shoes and the friction materi-al with grease, to avoid compromising thebraking efficiency of the vehicle.
This operation may be difficult because thesprings resist considerably to the removalof the shoes. Be careful not to crush or
bruise your hands and fingers.
� Grasp the inner edge of the two friction elements (1)at its centre and, pulling toward yourself, shake thetwo shoes, thus releasing them.
� Loosen the nut (2) and remove the pin lever (3).� Withdraw the cam pin (4).
Moderately grease only the central part ofthe pin.Avoid dirting the cam or the areas around
the pin seat with grease.
� Grease the central part of the pin by using grease forkinematic motions, see p. 27 (LUBRICANT CHART).
Upon reassembly:
Neither strike, nor force the cam pin (4) withhammers or others tools, in order not todamage the two O-rings.
� Manually insert the cam pin (4), rotating and pushing itslightly.
Make sure that the springs are correctlycoupled.
�
�
�
�
�
�
�
20
2%-/6).'�!.$�#,%!.).'�4(%�!)2�&),4%2
Remember: 1 mile = 1.6 km1 km = 0.625 miles
Check the conditions of the air cleaner and clean itmonthly or every 4000 km, depending on the conditionsin which the vehicle is used.If the vehicle is used on dusty or wet roads, the cleaningoperations and any replacement should be carried outmore frequently.� Position the vehicle on the stand.� To remove the left side panel of the vehicle.� Unscrew the four screws.� Remove the filter case cover and extract the filtering
element.� To clean the filtering element use clean, non-inflam-
mable solvents or solvents with high volatility point,then let it dry thoroughly.
� Apply a filter oil or a thick oil (SAE 80W-90) on thewhole surface of the filtering element, then squeeze itto eliminate the oil in excess.
The filter must be well impregnated, thoughnot dripping.
30!2+�0,5'��&IG����
Periodically remove the spark plug and clean it carefully,removing carbon deposits; change it if necessary.
To remove and clean the spark plug:� Remove the engine compartment cover.� Take off the spark plug cap.� Remove all the dirt from the base of the spark plug,
then unscrew it with the spanner you will find in thetool kit and extract it from its seat, taking care that nei-ther dust nor other substances enter the cylinder.
� Make sure that there are neither carbon deposits, norcorrosion marks on the electrode and on the centralporcelain part; if necessary, clean them with the spe-cial cleaners for spark plugs, with an iron wire and/ ora metal brush.
� Energetically blow some air, in order to prevent the re-moved residues from getting into the engine.If the spark plug has crackings on the insulating mate-rial, corroded electrodes or excessive deposits, itmust be changed.
�
�
21
� Check the spark plug gap with a thickness gauge.The gap must be 0,5 ÷ 0,6 mm; if necessary adjust it,carefully bending the earth electrode.
� Make sure that the washer is in good conditions. � With the washer on, screw the spark plug by hand in
order not to damage the thread.� Tighten the spark plug by means of the spanner you
will find in the tool kit, giving it half a turn to compressthe washer.
� Position the spark plug cap.� Put back the engine compartment cover.
The spark plug must be well tightened,otherwise the engine may overheat andbe seriously damaged.
Change the spark plug every 8000 km.
Use the recommended type of spark plug only,see p. 3 (TECHNICAL DATA), in order not tocompromise the life and performance of theengine.
�
22
"!44%29��&IG����
Remember: 1 mile = 1.6 km1 km = 0.625 miles
Check the electrolyte level and the tightening of the ter-minals after the first 500 km and successively every4000 km or 8 months.
The electrolyte in the battery is toxic andcaustic and if it gets in contact with the skinit can cause burns, since it contains sulphu-
ric acid.Wear protection clothes, a face mask and/or gogglesduring maintenance operations.
In case of contact with the skin, rinse with plenty ofwater.In case of contact with the eyes, rinse with plenty ofwater for 15 minutes, then consult an oculist withoutdelay.
If the electrolyte is accidentally swallowed, drink alot of water or milk, then continue drinking milk ofmagnesia or vegetable oil and consult a doctor with-out delay.
The battery gives off explosive gases; keep it awayfrom flames, sparks, cigarettes and any othersource of heat.
During the recharging or the use, make sure that theroom is properly ventilated and avoid inhaling thegases released during the recharging.
�
�
23
Never invert the connection of the batterycables.Do not incline the vehicle too much, in order
to avoid dangerous leaks of the battery fluid.
KEEP AWAY FROM CHILDREN
Connect and disconnect the battery with theignition switch in position “�”.Connect first the positive cable (+) and then
the negative cable (–).Disconnect following the reverse order.
To check the battery (1), remove the engine compart-ment cover.Make sure that the fluid level is included between thetwo "MIN" and "MAX" notches stamped on the batteryside.If necessary, top up by adding distilled water.To recharge, disconnect the cables, extract the batteryfrom its container and remove the element plugs. A recharge with an amperage equal to 1/10th of the bat-tery capacity is recommended.After the recharging operation, check the electrolyte lev-el again and if necessary top up with distilled water.Tighten the element plugs.
Always connect the battery breather pipe, toprevent the sulphuric acid vapours fromcorroding the electric system, painted parts,
rubber elements or gaskets when they exit thebreather pipe itself.
,/.'�).!#4)6)49�/&�4(%�"!44%29
If the vehicle remains unused for a long period, removethe battery and place it in a cool and dry place. Recharge it completely, by using a trickle charge.If the battery remains on the vehicle, disconnect the ca-bles from the terminals.It is important to check the charge periodically (aboutonce a month), during the winter or when the vehicle re-mains unused, in order to prevent the deterioration of thebattery.
�
�
�
24
#(!.').'�4(%�&53%��&IG����
Do not repair faulty fuses.Never use fuses different from the recom-mended ones.
The use of unsuitable fuses may cause damages tothe electric system or, in case of short circuit, even afire.
If an electric component fails to work, the fuse must bechecked (2).In this case it must be changed with another with thesame amp value.If the fuse cuts out again there is probably a short circuitin the electric system and it is advisable to consult anaprilia Official dealer.
!$*534).'�4(%�(%!$,!-0�"%!-�&IG����
The headlamp beam may be adjusted by turning thescrew provided with a screwdriver (1).
�
25
#(!.').'�4(%�"5,"3�).�4(%�(%!$ ,!-0�!.$�&2/.4�$)2%#4)/.).$)#!4/23��&IG���� ��
By slackening the two screws (2-3-Fig. 23) the two sidecovers of the direction indicators may be removed andthe headlamp reflector unit released.Access is thus obtained to the two bulbs of the directionindicators.The front grille and headlamp unit must be dismantled soas to change the headlamp bulbs.Access to the bulbs may be gained from behind the re-flectors.To remove them unscrew the 2 central screws (4-Fig.24) the 2 screws at the side (1-2-Fig. 24), the screw atthe front (4-Fig. 23) and release the 8 clips (3-Fig. 24).
Proceed with care.Do not damage the tangs and/or their seats.Handle the painted components with care
and avoid scraping or damaging them.
Upon reassembly, correctly position thebase (5) of the rear mirror.
#(!.').'�4(%�"5,"3�).�4(%�2%!2,!-0!.$�2%!2�$)2%#4)/.�).$)#!4/23�&IG����
Unscrew the two screws (1). In this way the 3 transparent covers (2-3) are removedand the bulbs are accessible.
�
�
26
0%2)/$)#�-!).4%.!.#%�#(!24
Cheking operations After running in 500 km Every 4000 km Every 8000 km Notes
Clean and check spark plug � �
Clean air filter �
Check and adjust idling � �
Check fuel pipes �
Check drive oil level change �change every
12000 km or 2 yearsCheck the mixer oil check every 500 km
Check op. mix pump and air bleeding � �
Check op. brakes and shoe wear � �
Greasing the rear brake cam pin �
Checking the brake pad wear � every 2000 km
Brake liquid periodically check change every year
Check driving belt wear �
Check wheel bearings �
Check adjustment of steering bearings � �
Check battery electrolyte level � �
Check tyre wear � �
Check tyre pressure every month
Check wheel alignment �
Check tightness of nuts and bolts � �
Check rear shock absorber �
Checking moving parts on front suspension �
Cleaning scale from exhaust terminal �
If the conditions of use are particularly severe, more frequent maintenance is advised.
27
,5"2)#!.4�#(!24
Transmission oil (recommended): $ F.C., SAE 75W - 90.As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with orsuperior to the A.P.I. GL4 specifications.
Mixer oil (recommended): $ GREEN HIT.Use high-quality oils with characteristics in compliance with or superior to the ISO-L-ETC++, A.P.I. TC++ specifications.
Fork oil (recommended): $ F.A. 5W or $ F.A. 20W fork oil.If you need an oil with intermediate characteristics in comparison with the two recommended products, these can bemixed 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.
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 to water and oxidation resistance.
Protection of the battery poles: neutral grease or vaseline.
Spray grease for chains (recommended): $ CHAIN SPRAY.
Brake fluid (recommended): $ F.F., DOT 5 (DOT 4 compatible).
Use new brake fluid only.
Engine coolant (recommended): $ ECOBLU -40°C.
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.
�
�
28
7)2).'�$)!'2!-� �!-)#/���
29
7)2).'�$)!'2!-�+%9� �!-)#/���
1) Generator 2) CDI 3) Spark plug 4) H.T. coil 5) Voltage regulator 6) Battery 7) Starter 8) Start relay 9) Front stoplight switch10) Rear stoplight switch11) Mixer oil reserve switch13) Fuel level sensor14) Right rear turn indicator15) Rear light16) Left rear turn indicator17) Dip switch18) Turn indicator switch19) Ignition switch20) Control diode21) Crash helmet compartment light22) Blinking23) Dashboard24) Turn indicator warning light25) Mixer oil reserve warning light26) Dashboard light27) Fuel level indicator28) Low fuel warning light29) Low beam warning light
30) Crash helmet compartment light switch31) Front right turn indicator32) Front left turn indicator33) Front parking light
(not provided in the � version)34) Low beam35) Horn36) Pick up37) Fuse38) Multiple connectors39) START push button40) Horn push button42) Low/High beam
#!",%�#/,/523
Ar OrangeAz Light blueB BlueBl WhiteG YellowGr GrayM BrownN BlackR RedV GreenVi Violet
30
APRILIA MOTO U.K. LTD.DUNRAGIT STRANRAERWIGTOWNSHIRE DG9 8PNSCOTLAND (UK)TEL. (1581) 400660FAX (1581) 400661
IDEAL MOTOR SPORT PTE LTD.18, HOWARD ROAD1336 SINGAPORE (SGP)TEL. 2820082FAX 2821012
AVIRAM & GOLDMAN IMPORT & MARKETING CO. LTD.21, TUSHIA STREET61572 TEL-AVIVP.O. BOX 57266ISRAEL (IL)TEL. (3) 5623951FAX (3) 5623950
)MPORTERS
������������� ��� ��������
31
./4%
32
aprilia s.p.a. wishes to thank its customers for the purchase of this vehicle.
- Do not dispose of oil, fuel or polluting substances and components in the environment.
- Do not keep the engine running if it isn’t necessary.
- Avoid troublesome noises.
- Respect nature.
