aprilia - sonic 50 (manual taller)

7/24/2019 Aprilia - Sonic 50 (MANUAL TALLER)

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Sonic 50

use and maintena

aprilia

part# 8202105


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2 use and maintenance Sonic 50

1998 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 par-tial adaptation, with any means, are reserved for all Countries.

The mention to products or services supplied by third parties ismade only for information purposes and is not binding in anycase.

aprilia s.p.a

takes no responsibility as to the performance or theuse of said products.

First edition: january 1998

Reprint: march 1998

Produced and printed by:

Studio Tecno Public

Viale del Progresso - 37038 Soave (VR) - ItalyTel. +39 (0)45 -76 11 911Fax +39 (0)45 -76 12 241

www.stp.itE-mail: [email protected]

On behalf of:

aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - ItalyTel. +39 (0)41 - 58 29 111Fax +39 (0)41 - 44 10 54www.aprilia.com


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3use and maintenance Sonic 50

FOREWORD

Before starting the engine, carefully read this manual, payingparticular attention to the chapter "RIDING SAFELY".Your and other peoples safety depends not only on your quick-ness of reflexes and on your agility, but also on what you knowabout the vehicle, on its efficiency and on your knowledge of thebasic information for RIDING SAFELY.Therefore, get a thorough knowledge of the vehicle, in such away as to be able to drive in the traffic safely.For the controls and repairs not expressly described in this man-ual, for the purchase of aprilia

Genuine Spare Parts, accesso-ries and other products, as well as for specific technical advice,contact only aprilia

Authorized Outlets and Official Dealers, whocan 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 partscode indicated on the SPARE PARTS IDENTIFICATION LA-BEL. Write down the identification code in the space here below,in order to remember it also in case of loss or deterioration of thelabel.The label is positioned on the right beam of the frame; to read it,remove the inspection cover, see p. 50 (REMOVING THE IN-SPECTION COVER).

Carefully observe the instructions preceded by the followingwarning signs:

Safety norms and regulations to protect the driverand other people from severe injuries or grave risks.

Indications to make the operations easier. Technicalinformation.

The operations preceded by this symbol must be re-peated on the opposite side of the vehicle.

In this manual the various versions are indicated by the followingsymbols:

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 AUS

_

automatic light switching version (Automatic Switch-on Device)

&

optional

1 liquid-cooled version

2 catalytic versionI Italy version Denmark version

U United Kingdom version J Japan version

A Austria version S Singapore version

P Portugal version V Poland version

" Finland version % Israel version

B Belgium version K South Korea version

DGermany version

MMalaysia version

F France version R Chile version

E Spain version Q Bermuda version

G Greece version - United States of America version

O Holland version ^ Australia version

C Switzerland version

a


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TABLE OF CONTENTS

SAFE DRIVE

...............................................................5BASIC SAFETY RULES ......................................6CLOTHING ..........................................................9ACCESSORIES .................................................10

LOAD .................................................................10

ARRANGEMENT OF THE MAIN ELEMENTS

........12

ARRANGEMENT OF THE INSTRUMENTS

............14

INSTRUMENTS AND INDICATORS

........................14INSTRUMENT AND INDICATOR TABLE .........15

MAIN INDEPENDENT CONTROLS

.........................16CONTROLS ON THE LEFT SIDE

OF THE HANDLEBAR ......................................16CONTROLS ON THE RIGHT SIDEOF THE HANDLEBAR ......................................17IGNITION SWITCH ...........................................18

STEERING LOCK .............................................18

AUXILIARY EQUIPMENT

........................................19

UNLOCKING/LOCKING THE SADDLE ............19

CRASH HELMET / GLOVE COMPARTMENT .. 19ANTI-THEFT HOOK ..........................................19TOOL KIT ..........................................................20BAG HOOK .......................................................20

GLOVE COMPARTMENT .................................20

MAIN COMPONENTS

..............................................21FUEL .................................................................212 STROKE OIL TANK .......................................22BRAKE FLUID - recommendations ...................22FRONT BRAKE DISC .......................................23

REAR DRUM BRAKE ........................................24TYRES ...............................................................25

COOLANT1

..................................................26AUTOMATICLIGHT SWITCHING VERSION_

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

CATALYTIC SILENCER2

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

INSTRUCTIONS FOR USE

......................................29PRELIMINARY CHECKING OPERATIONS ...... 29STARTING ........................................................30DEPARTURE AND DRIVE ................................32RUNNING-IN .....................................................33

STOPPING ........................................................33PARKING ..........................................................33POSITIONING THE VEHICLEON THE STAND ................................................34

SUGGESTIONS TO PREVENT THEFT ............34

MAINTENANCE

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

REGULAR SERVICE INTERVALS CHART ......35IDENTIFICATION DATA ...................................36AIR CLEANER ...................................................37CHECKINGTHE TRANSMISSION OIL LEVEL ....................38

CHANGINGTHE TRANSMISSION OIL ................................39FRONT WHEEL ................................................40REAR WHEEL ...................................................42

CHECKINGTHE BRAKE PAD WEAR ..................................43CHECKINGTHE SHOE WEAR ............................................44GREASING

THE REAR BRAKE CAM PIN ...........................44CHECKING THE STEERING ............................46CHECKINGTHE ENGINE FULCRUM AXIS .........................46REMOVING

THE EXHAUST SILENCER ..............................47REMOVINGTHE FRONT HANDLEBAR COVER .................48REMOVING

THE REAR HANDLEBAR COVER ....................48REMOVINGTHE FRONT TRANSPARENT SCREEN ...........49

REMOVINGTHE REAR-VIEW MIRROR ..............................49

REMOVINGTHE INSPECTION COVER ...............................50REMOVING THE FRONT COVEROF THE REAR PART OF THE FAIRING ..........50IDLING ADJUSTMENT .....................................51

ADJUSTINGTHE ACCELERATOR CONTROL .....................51

SPARK PLUG ....................................................52BATTERY ..........................................................53LONG INACTIVITY OF THE BATTERY ............53CHECKING AND CLEANING

THE TERMINALS ..............................................54REMOVING THE BATTERY .............................54CHECKINGTHE ELECTROLYTE LEVEL ............................55

RECHARGING THE BATTERY ........................55INSTALLING THE BATTERY ............................55CHANGING THE FUSE ....................................56ADJUSTINGTHE VERTICAL HEADLIGHT BEAM ................57BULBS ...............................................................57

CHANGING THE HEADLIGHT BULBS .............58CHANGING THE HEADLIGHT BULBSC

%

S

K

_

.......................................59CHANGING THE FRONTDIRECTION INDICATOR BULBS .....................60

CHANGING THE DASHBOARD BULBS ..... .....61

CHANGING THE REAR LIGHT BULB ..............62CHANGING THE NUMBER PLATE BULBA

C

%

S

K

_

................................62

TRANSPORT

............................................................63DRAINING THE FUEL TANK ............................63

CLEANING

...............................................................64

LONG PERIODS OF INACTIVITY ....................65AFTER A PERIOD OF INACTIVITY ..................65

TECHNICAL DATA

..................................................66LUBRICANT CHART .........................................70Importers ...........................................................71

WIRING DIAGRAM Sonic 50 ............................72WIRING DIAGRAM KEY Sonic 50 ....................73

WIRING DIAGRAMSonic 50C

%

S

K

_

.........................74WIRING DIAGRAM KEYSonic 50C

%

S

K

_

.........................75
http://-/?-http://-/?-http://-/?-


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safe drive


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BASIC SAFETY RULES

To drive the vehicle it is necessary to be in

possession of all the requirements pre-scribed by law (driving licence, minimumage, psychophysical ability, insurance,state taxes, vehicle registration, numberplate, etc.).

Gradually get to know the vehicle by driv-ing it first in areas with low traffic and/or pri-vate areas.

The use of medicins, alcohol and drugs orpsychotropic substances notably increasesthe risk of accidents.

Be sure that you are in good psychophysi-cal conditions and fit for driving and payparticular attention to physical wearinessand drowsiness.

Most road accidents are caused by thedrivers lack of experience.

NEVER lend the vehicle to beginners and,in any case, make sure that the driver hasall the requirements for driving.


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Rigorously observe all road signs and na-tional and local road regulations.

Avoid abrupt movements that can be dan-gerous for yourself and other people (forexample: rearing up on the back wheel,speeding, etc.), and give due considerationto the road surface, visibility and other driv-ing conditions.

Avoid obstacles that could damage the ve-hicle or make you lose control.

Avoid riding in the slipstream created bypreceding vehicles in order to increaseyour speed.

Always drive with both hands on the han-dlebars and both feet on the footrests, inthe correct driving posture.

Avoid standing up or stretching your limbswhile driving.

STOP150m

STOP

150m


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The driver should pay attention and avoiddistractions caused by people, things andmovements (never smoke, eat, drink, read,etc.) while driving.

Use only the vehicles specific fuels and lu-bricants (indicated in the LUBRICANTCHART); check all oil, fuel and coolantlevels regularly.

If the vehicle has been involved in an acci-dent, make sure that no damage has oc-curred to the control levers, pipes, wires,braking system and vital parts.

If necessary, have the vehicle inspected byan aprilia

Official Dealer, who should care-fully check the frame, handlebars, suspen-sions, safety parts and all the devices thatyou cannot check by yourself.

Always remember to report any malfunc-tion to the technicians to help them in theirwork.

Never use the vehicle when the amount ofdamage it has suffered endangers yoursafety.

COOLER

OIL


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Never change the position, inclination orcolour of: number plate, direction indica-tors, lights and horns.

Any modification of the vehicle will result inthe invalidity of the guarantee.

Any modification of the engine or of othermembers which is aimed at increasing thespeed or the power of the vehicle is prohib-ited by the law; in fact, any modification re-sulting in an increase of the maximumspeed or of the engine displacement wouldchange the scooter into a motorcycle,which implies the following obligations forthe owner: new homologation; new registration; appropriate driving license.

Further, said modifications cause the lossof the insurance cover, since insurancepolicies expressly prohibit to make techni-cal changes aimed at increasing the vehi-cle performance levels.

For the reasons stated above, the failure tocomply with the tampering prohibition ispunished by law with apposite sanctions(including the confiscation of the vehicle),which, according to the case, can be com-bined with the sanctions provided for notusing the crash helmet and/or the numberplate, for the violation of fiscal obligations

(ownership tax) and with penal sanctionsprovided for using the vehicle without driv-ing license.

Never race with other vehicles.

Avoid off-road driving.

CLOTHING

Before starting, always wear a correctly

fastened crash helmet. Make sure that it ishomologated, in good shape, of the rightsize and that the visor is clean.

Wear protective clothing, preferably in lightand/or reflecting colours. In this way youwill make yourself more visible to the otherdrivers, thus notably reducing the risk ofbeing knocked down, and you will be moreprotected in case of fall. This clothingshould be very tight-fitting and fastened at

the wrists and ankles. Strings, belts andties should not be hanging loose; preventthese and other objects from interferingwith driving by getting entangled with mov-ing parts or driving mechanisms.

A12

345

ONLY ORIGINALS


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Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in your

pockets (the same recommendations alsoapply to passengers).

ACCESSORIES

The owner of the vehicle is responsible for

the choice, installation and use of any ac-cessory.

Avoid installing accessories that coverhorns or lights or that could impair theirfunctions, limit the suspension stroke andthe steering angle, hamper the operation ofthe controls and reduce the distance fromthe ground and the angle of inclination inturns. Avoid using accessories that ham-per access to the controls, since this can

prolong reaction times during an emergen-cy. Large fairings and windscreens assem-bled on the vehicle can produce aerody-namic forces capable of compromising thestability of the vehicle while driving. Makesure that the equipment is well fastened tothe vehicle and not dangerous during driv-ing.

Do not install electrical devices and do notmodify those already existing to avoid elec-trical overloads, because the vehicle could

suddenly stop or there could be a danger-ous current shortage in the horn and in thelights. aprilia

recommends the use of

aprilia

genuine accessories.

LOAD

Be careful and moderate when loadingyour luggage. Keep any luggage loaded as

close as possible to the centre of the vehi-cle and distribute the load uniformly onboth sides, in order to reduce imbalance tothe minimum. Furthermore, make sure thatthe load is firmly secured to the vehicle, es-pecially during long trips.


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Avoid hanging bulky, heavy and/or danger-ous objects on the handlebars, mudguardsand forks, because the vehicle might re-

spond more slowly in turns and its ma-noeuvrability could be unavoidably im-paired.

Do not place bags that are too bulky on thevehicle sides, because it could hit peopleor obstacles making you lose control of thevehicle.

Do not carry any bag if it is not tightly se-cured to the vehicle.

Do not carry bags which protrude too muchfrom the luggage-rack or which cover thelights, horn or indicators.

Do not carry animals or children on theglove compartment or on the luggage-rack.

Do not exceed the maximum load allowedfor each side-bag.

When the vehicle is overloaded, its stabilityand its manoeuvrability can be compro-mised.

KG!


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ARRANGEMENT OF THE MAIN ELEMENTS

KEY

1) Bag hook2) Fuel tank3) Fuel tank plug4) Saddle lock5) Transmission oil filling cap6) Kick starter

7) Transmission oil drain plug8) Centre stand9) Air cleaner

10) Side stand&

11) Horn


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KEY

1) 2 stroke oil tank plug2) 2 stroke oil tank3) Glove compartment4) Ignition switch/steering lock5) Brake fluid reservoir (front brake)6) Coolant expansion tank plug1

7) Expansion tank

8) Front cover of the rear part of the fairing9) Inspection cover

10) Battery11) Fuse carrier12) Anti-theft hook (for the aprilia

Body-Guard armored cable&

).


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ARRANGEMENT OF THE INSTRUMENTS

KEY

1) Direction indicator switch (

c

) 2) Horn push button (

f

) 3) Cold start lever (

e

) 4) Rear brake lever 5) Left rear-view mirror (not provided in theU

version) 6) Instruments and indicators 7) Right rear-view mirror (in the countries where required) 8) Front brake lever 9) Throttle grip10) Headlight switch (

b

-

)10a) Headlight switch (

a

-b

-

)C

%

S

K

10b) Headlight dimmer switch (

a

-b

)_

11) Start push button (

r

)12) Ignition switch/steering lock (

n

-m

- s

)

INSTRUMENTS AND INDICATORS

KEY

1) Fuel level indicator (

g

)2) Speedometer3) Total kilometres odometer4) Coolant temperature indicator (

h

)1

5) Green direction indicator warning light (

c

)6) Red 2 stroke oil reserve warning light (

j

)7) Green low beam warning light (

b

)7a) Blue high beam warning light (

a

)C

%

S

K

_

8) Amber low fuel warning light (

g

)


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INSTRUMENT AND INDICATOR TABLE

Description Function

Direction indicator warning light (

c

)

It blinks when the direction indicators are on.

2 stroke oil reserve warning light (

j

)

It comes on when the ignition switch is in position

n

and the start push button

r

is pressed, thus checking the proper functioning of the bulb.If the light does not come on during the starting, provide for replacing the bulb.

If the warning light comes on and does not go out after the startpush button

r

has been released, or if it comes on during nor-mal functioning, this means that the 2 stroke oil reserve is being

used; in this case, top up the 2 stroke oil tank, see p. 22 (2 STROKE OILTANK).

Total kilometres odometer

It indicates the total number of kilometres covered.

Speedometer It indicates the driving speed.

Low beam warning light (b) It comes on when the headlight is in low beam position.

High beam warning lightC%SK_ (a)

It comes on when the headlight in high beam position.

Low fuel warning light (g) It comes on when the quantity of fuel left in the tank is about 1,5 l.

Fuel level indicator (g) It indicates the approximate fuel level in the tank.

Coolant temperature indicator1 (h)

It indicates the approximate temperature of the coolant in the engine.When the pointer starts moving beyond the min level, the temperature is suffi-cient for driving the vehicle.The normal running temperature range is indicated by the central area of thescale.If the pointer reaches the red area, stop the engine and check the coolant level,see p. 26(COOLANT1).

If the maximum allowed temperature is exceeded (red area maxof the scale), the engine may be seriously damaged.

a

a


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MAIN INDEPENDENT CONTROLS

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR

The electrical parts work only when the ignitionswitch is in position

n

.

The lighting system works only when the engine is

running.

1) HORN PUSH BUTTON (

f

)

The horn is activated when the push button is pressed.

2) COLD START LEVER (

e

)

The starter for the cold start of the engine is operated by ro-tating the lever downwards.To disconnect the cold start, bring the lever to its initial posi-tion.

3) DIRECTION INDICATOR SWITCH (

c

)

To indicate the turn to the left, move the switch to the left; toindicate the turn to the right, move the switch to the right.To turn off the direction indicator, press the switch.

c

c


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CONTROLS ON THE RIGHT SIDEOF THE HANDLEBAR

The electrical parts work only when the ignitionswitch is in position

n

.

The lighting system works only when the engine isrunning.

1) LIGHT SWITCH (

b

-

)

When the light switch is in position

, the lights are off; whenthe switch is in position

b

, the rear parking light and the lowbeam are on.

1a) LIGHT SWITCH (

a

-b

- )C%SKWhen the light switch is in position , the lights are off;

when the switch is in position b

the low beam and theparking lights are on; when it is in position a the highbeam and the parking lights are on.

1b) DIMMER SWITCH (a- b )_When the dimmer switch is in position b, the low beamand the parking lights are on; when it is in position a, thehigh beam and the parking lights are on.

The lights can be switched off only by stoppingthe engine.

2) START PUSH BUTTON (r)When the start push button is pressed and one of the brakelevers (front or rear) is activated at the same time, the startermakes the engine run.For the starting procedure, see p. 30 (STARTING).

c

c

c


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IGNITION SWITCH

The ignition switch is positioned on theright side, near the steering column.

The key (1) operates the ignitionswitch/steering lock, glove com-partment and the saddle lock.Two keys are supplied together with thevehicle (one spare key).

STEERING LOCK

Never turn the key to position

s

inrunning conditions, in order to avoidlosing control of the vehicle.

OPERATION

To lock the steering:

Turn the handlebar completely leftwards.

Turn the key (1) to position

m

andpress it.

Release the key.

Turn the key and steer the han-

dlebar at the same time.

Rotate the key (1) anticlockwise (left-wards), steer the handlebar slowly untilthe key (1) reaches position

s

.

Extract the key.

c

c

Position FunctionKey

removal

s

Steering

lock

The steeringis locked.It is neitherpossible tostart the en-

gine, nor toswitch on thelights.

It is possibleto removethe key.

m

Neither theengine, northe lights canbe switchedon.

It is possibleto removethe key.

n

The engine

and the lightscan beswitched on.

It is not pos-

sible to re-move thekey.


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AUXILIARY EQUIPMENT

UNLOCKING/LOCKINGTHE SADDLE

To unlock and lift the saddle:

Insert the key in the saddle lock (1).

Turn the key clockwise and raise thesaddle (2).

Before lowering and locking thesaddle, make sure that you have

not left the key in the crash hel-met/glove compartment.

To lock the saddle, lower and press it

(without exerting too much pressure),thus making the lock snap shut.

Before leaving, make sure thatthe saddle is properly locked.

CRASH HELMET / GLOVECOMPARTMENT

Thanks to the crash helmet/glove compart-ment, you no longer have to carry thecrash helmet or other objects with you eve-ry time you park the vehicle.

The compartment is positioned under thesaddle.

To reach it:

Raise the saddle, see beside (UNLOCK-ING/LOCKING THE SADDLE).

Position the helmet with theopening facing upwards, as

shown in the figure.

Do not load the crash hel -met/glove compartment toomuch.

Maximum allowed weight: 2.5 kg.

ANTI-THEFT HOOK

The anti-theft hook (3) is positioned on the

rear side of the vehicle, near the rear light.To prevent the vehicle from being stolen, itis advisable to secure it with the aprilia


(4), avail-able at any aprilia

Official Dealer.

Do not use the hook to lift the ve-hicle or for any purpose otherthan securing the vehicle once it

has been parked.

c

a

ca

a


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TOOL KIT

The tool kit is hooked to the underside ofthe saddle.

To reach it, proceed as follows:

Lift the saddle (1), see p. 19 (UNLOCK-ING/LOCKING THE SADDLE).

Release the rubber band (2) from thehook.

Take the tool kit (3).

The tool kit (3) includes: n. 1 tool case n. 1 21 mm spark plug socket spanner n. 1 socket spanner rod

n. 1 8/10 mm socket spanner n. 1 double-ended, cross-/cut headed-screwdriver type PH size 2

n. 1 screwdriver handle n. 1 3 mm hexagon spanner n. 1 4 mm hexagon spanner


BAG HOOK

Do not hang excessively bulkybags or parcels to the hook, asthis may seriously compromise

the manoeuvrability of the vehicle orthe movement of your feet.

The bag hook (4) is positioned on the frontpart of the inner shield.

Max. allowed weight: 1.5 kg.

GLOVE COMPARTMENT

It is placed under the handlebar, on the in-ner part of the shield.

To reach it:

Introduce the ignition key (5) in the lock.

Turn the key clockwise, pull it and openthe door (6).

Before locking the door, makesure that you have not left thekey in the glove compartment.

To lock the door (6), raise and press it. It isnot necessary to use the key.


a

a


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MAIN COMPONENTS

FUEL

The fuel used for internal com-bustion engines is extremely in-flammable and in particular con-

ditions it can become explosive.

It is important to carry out the refuellingand the maintenance operations in awell-ventilated area, with the engine off.

Do not smoke while refuelling or nearfuel vapours, in any case avoid any con-tact with naked flames, sparks and anyother heat source to prevent the fuelfrom catching fire or from exploding.

Further, prevent fuel from flowing out ofthe fuel filler, as it could catch fire whengetting in contact with the red-hot sur-faces of the engine.

In case some fuel has accidentally been

spilt, make sure that the area has com-pletely dried and before starting the ve-hicle verify that there is no fuel insidethe fuel filler neck.

Since petrol expands under the heat ofthe sun and due to the effects of sun ra-diation, never fill the tank to the brim.

Screw the plug (1) up carefully after re-fuelling.

Avoid any contact of the fuel with theskin and the inhalation of vapours; donot swallow fuel or pour it from a recep-tacle into another by means of a tube.

KEEP AWAY FROM CHILDREN

Use only premium grade petrol (4 Stars

U

), in conformity with the DIN 51600

standard, min. O.N. 98 (N.O.R.M.) and 88(N.O.M.M.).

2

Use only unleaded petrol, in conformitywith the DIN 51607 standard, min. O.N. 95(N.O.R.M.) and 85 (N.O.M.M.).

FUEL TANK CAPACITY(reserve included): 8 l

TANK RESERVE: 1.5 l

To refuel, proceed as follows:

Lift the saddle, see p. 19 (UNLOCK-ING/LOCKING THE SADDLE).

Unscrew and remove the fuel tank plug(1).

Refuel.

a

Thi i i i di bl i M k h h b k di d h


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2 STROKE OIL TANK

Top up the 2 stroke oil tank every 500 km.

The vehicle is provided with a separatemixer that makes it possible to mix petrol

with oil for the lubrication of the engine, seep. 70 (LUBRICANT CHART).

The reserve is indicated by the coming onof the 2 stroke oil reserve warning light

j

positioned on the dashboard, see p.14and 15 (INSTRUMENTS AND INDICA-TORS).

The use of the vehicle without 2stroke oil causes serious dam-

ages to the engine.

If you run out of oil in the 2 stroke oiltank or if the mixer oil pipe has been re-moved, it is necessary to contact an

aprilia

Official Dealer, who will providefor bleeding the system.

This operation is indispensable, sincethe operation of the engine with air inthe mixer oil system may cause seriousdamages to the engine itself.

To top up the 2 stroke oil tank, proceed asfollows:


Remove the plug (1).2 STROKE OIL TANK CAPACITY: 1.6 l

TANK RESERVE: 0.5 l

Wash your hands carefully afterusing the oil.Do not dispose of the oil in the

environment.

KEEP AWAY FROM CHILDREN.

BRAKE FLUID - recommendations

Sudden resistance or clearanceproblems on the brake lever maybe due to problems in the hy-

draulic system.

For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour aprilia

Official Dealer.

Make sure that the brake disc and thefriction elements are neither oily norgreasy, especially after maintenance orchecking operations.

Check that the brake cable is neithertwisted nor worn out.

Prevent water or dust from accidentallygetting into the circuit.

In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.

If the brake fluid gets in contact with theskin or the eyes, it can cause serious ir-ritations.Carefully wash the parts of your body

that get in contact with the liquid.Consult a doctor or an oculist if the liq-uid gets in contact with your eyes.

Do not dispose of the brake fluid in theenvironment.


When using the brake fluid, takecare not to spill it on the plasticor painted parts, since it irrepa-

rably damages them.

a

a

a

a

U th t (3)


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FRONT BRAKE DISC

The brakes are the parts thatmost ensure your safety and forthis reason they must always be

perfectly working.The brake fluid must be changed once ayear by an aprilia

Official Dealer.

This vehicle is provided with front hydraulicdisc brake.

When the disc pads wear out, the level ofthe fluid decreases to automatically com-pensate for their wear.

The brake fluid reservoir (1) is positioned

near the front brake lever coupling. Period-ically check the brake fluid level in the res-ervoir (1) and the pad wear, see p. 43(CHECKING THE BRAKE PAD WEAR).

CHECKING

To check the brake fluid level, proceed asfollows:

Position the vehicle on the centre stand.

Rotate the handlebar leftwards, so that

the fluid contained in the reservoir is par-allel to the

MIN

mark stamped on theglass (2).

Make sure that the level of the brake fluidcontained in the tank exceeds the

MIN

mark stamped on the glass (2).

If not, provide for topping up.

TOPPING UP

Carefully read p. 22 (BRAKE FLUID -

recommendations).

The brake fluid may flow out ofthe reservoir. Do not operate thebrake lever if the screws (3) are

loose or, most important, if the brakefluid tank cover has been removed.

Unscrew the two screws (3).

Remove the cover (4).

Remove the guide cover (5).

In order not to spill the brake fluidwhile topping up, keep the fluid inthe reservoir parallel to the reser-

voir rim.

Remove the gasket (6).

In order to reach the MAXlevel,top up until covering the glass

(2) completely, with the brake fluid res-ervoir rim parallel to the ground.

The topping up to the MAXlev-el can be carried out only withnew pads.

The fluid level decreases progressivelywith the pad wear.

Do not top up to the MAXlevel withworn pads, since this may cause an out-flow of liquid when the brake pads arechanged.

Fill the tank with brake fluid, see p. 70(LUBRICANT CHART),until it covers theglass completely.

Put back the gasket (6) in its seat cor-rectly.

Put back the guide cover (5) correctly.

Put back the cover (4). Screw and tighten the two screws (3).

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Check the braking efficiency. Ifnecessary, contact your aprilia

Official Dealer.In case of excessive movement of thebrake lever, of excessive elasticity or in

case there is air in the circuit, contactyour aprilia

Official Dealer, since it maybe necessary to bleed the system.

REAR DRUM BRAKE

The brakes are the parts thatmost ensure your safety and forthis reason they must always be

perfectly working.

For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour aprilia

Official Dealer.

ADJUSTING THE BRAKE

Measure the distance covered by the le-ver before the brake starts it braking ac-tion. The idle stroke at the end of thebrake lever must be about 10 mm.

Adjust the clearance by acting on the ad-juster (1).

Put on the brake repeatedly and makesure that the wheel turns freely after thebrake has been released.

Check the braking efficiency.

The fact that the adjuster (1) can betightened completely or the indicator (2)is positioned beyond the reference

tooth (3) indicates that the brake shoesare worn; in this case, see p. 44(CHECKING THE SHOE WEAR).

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If on the contrary the inflation pres- Change reparation maintenance and


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TYRES

This vehicle is provided with tyres withinner tube.

Periodically check the tyre infla-tion pressure at room tempera-ture.

If the tyres are hot, the measurement isnot correct.

Carry out the measurement especiallyafter long rides.

If the inflation pressure is too high, theground unevenness cannot be damp-ened and is therefore transmitted to thehandlebar, thus compromising the driv-ing comfort and reducing the road hold-ing during turns.

If, on the contrary, the inflation pres-sure is too low, the tyre sides are undergreater stress and the tyre itself mayslip on the rim or it may become loose,with consequent loss of control of thevehicle.

In case of sudden braking the tyrescould even get out of the rims. Further,the vehicle could skid while turning.

Check the surface and the wear of thetyres, since tyres in bad conditions canimpair both the grip and the controlla-bility of the vehicle.

Change the tyre when it is worn out orin case of puncture on the tread side, ifthe puncture is larger than 5 mm.

Use only tyres in the size suggested by

aprilia

, see p. 66 (TECHNICAL DATA).

Do not install tyres with air tube on rimsfor tubeless tyres and viceversa.

Make sure that the tyres always havetheir valve sealing caps on, to preventthem from suddenly going flat.

Change, reparation, maintenance andbalancing operations are very importantand should be carried out by qualifiedtechnicians with appropriate tools.

For this reason, it is advisable to havethe above mentioned operations carriedout by an aprilia

Official Dealer or by aqualified tyre repairer.

If the tyres are new, they maystill be covered with a slipperyfilm: drive carefully for the first

miles.

Do not oil the tyres with unsuitable flu-ids.

INFLATION PRESSURE

SOLO RIDERfront: ...............................170 kPa (1.7 bar)rear: ................................190 kPa (1.9 bar)

RIDER AND ONE PASSENGER(in the countries where this is allowed)front: ...............................170 kPa (1.7 bar)rear: ................................210 kPa (2.1 bar)

MINIMUM TREAD DEPTH LIMIT

front: ............................................. 1.5 mmrear: .............................................. 1.5 mm

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The coolant is made up of 50% water and


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COOLANT

1

Do not use the vehicle if thecoolant is below the minimumprescribed level.

Remember: 1 mile = 1.6 km1 km = 0.625 miles

Check the coolant level every 2000 km andafter long rides; change it every 2 years.

Have the coolant changed by an

aprilia

Official Dealer.

The coolant is made up of 50% water and50% antifreeze.

This mixture is ideal for most running tem-peratures and ensures good protectionagainst corrosion.

It is advisable to keep the same mixturealso in the hot season, since in this waylosses due to evaporation are reduced and

it is not necessary to top up very frequent-ly.

The mineral salt deposits left in the radiatorby evaporated water are thus reduced andthe efficiency of the cooling system re-mains unchanged.

If the outdoor temperature is below 0,check the cooling circuit frequently and ifnecessary increase the antifreeze concen-tration (up to maximum 60%).

Do not remove the expansiontank cap when the engine is hot,since the coolant is under pres-

sure and its temperature is high.

If it gets in contact with the skin or withclothes it may cause severe burnsand/or damages.

The coolant is noxious:

DO NOT SWALLOW IT.

KEEP AWAY FROM CHILDREN.

DO NOT DISPOSE OF THE COOLANT INTHE ENVIRONMENT.

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CHECKING AND TOPPING UP1

DO NOT DISPOSE OF THE FLUID INTHE ENVIRONMENT.

Proceed as follows:


Unscrew and remove the filling plug (1).Two reference elements indicating theminimum and maximum level,

MIN

and

MAX

, are provided inside the expan-sion tank.

Looking through the filling hole, makesure that the coolant level is included be-tween the

MIN

and

MAX

elements.

If neither element is covered by the cool-ant, proceed as follows:

Top up until the coolant level reachesapproximately the

MAX

element.Do not exceed this level, otherwise the

coolant will flow out of the tank when theengine is running.

Screw the filling plug (1).

In case of excessive consump-tion of coolant and in case theexpansion tank remains empty,

make sure that there are no leaks in thecircuit.

Have it repaired by an apriliaOfficialDealer.

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Due to the catalytic reaction, the high tem-


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AUTOMATICLIGHT SWITCHING VERSION_

The vehicles provided with the AutomaticSwitch-on Device can be immediately rec-ognized, since the lights come automati-cally on as soon as the engine is started.

For this reason the light switch is replacedby a dimmer switch.

The lights can be switched off only by stop-ping the engine.

For the versions with high beam, proceedas follows:

Before starting the vehicle, make surethat the dimmer switch is in position

b

(front low beam).

CATALYTIC SILENCER2

Avoid parking the vehicle cata-lytic version near dry brushwood or in places easily accessi-

ble to children, as the catalytic silencerbecomes extremely hot during use; bevery careful and avoid any kind of con-tact before it has completely cooleddown.

The catalytic vehicle is fitted with a silencerwith metal catalytic converter of the plati-num-rhodium bivalent type.

This device provides for the oxidation of

the CO (carbon monoxide) and of the HC(unburned hydrocarbons) contained in theexhaust gases, changing them into carbondioxide and steam, respectively.

ue to t e cata yt c eact o , t e g teperature reached by the exhaust gasesmakes for the burning of the oil particles,thus keeping the silencer clean and elimi-nating the exhaust fumes.

To have the catalytic converter functioncorrectly and for long and to reduce possi-ble problems regarding the soiling of the

thermal unit and of the exhaust, it is neces-sary to avoid covering long distances withthe engine running at constantly low rpm.

It is sufficient to alternate these periodswith periods in which the engine runs at rel-atively high rpm, even if only for a few sec-onds, but rather frequently.

What has been stated above assumes par-ticular importance for the cold starting ofthe engine: in this case, in order to reach a

rpm regime sufficient to enable the prim-ing of the catalytic reaction, just makesure that the temperature of the thermalunit has reached at least 50C, which gen-erally occurs a few seconds after startingthe engine.

Do not use leaded petrol, since itcauses the destruction of thecatalytic converter.

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INSTRUCTIONS FOR USE PRELIMINARY CHECKING OPERATIONS


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INSTRUCTIONS FOR USE

Before departure, always carryout a preliminary checking of thevehicle, to make sure that it

functions correctly and safely, see thefollowing table PRELIMINARY CHECK-ING OPERATIONS.

The non-performance of these checkingoperations can cause severe personalinjuries or damages to the vehicle.

Do not hesitate to consult your

aprilia

Official Dealer in casethere is something you do not

understand about the functioning ofsome controls or in case you suspect ordiscover some irregularities.It does not take long to carry out a

check-up and this operation ensuresyou much more safety.

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PRELIMINARY CHECKING OPERATIONS

Component Check Page

Front brake Check the functioning, the fluid level and make surethere are no leaks.Check the wear of the pads. Top up, if necessary.

22, 23, 43

Rear drum brake Check the functioning, the idle stroke and the controllever conditions.

If the clearance is not correct, adjust it.

24, 44, 45

Accelerator Make sure that it works smoothly and that it is possible toopen and close it completely, in all steering positions.If necessary, adjust and/or lubricate it.

51

2 stroke oil Check and/or top up, if necessary. 22

Wheel/tyres Check the tyre surface, the inflation pressure, wear andtear and any damage.

25

Brake levers Make sure that they work smoothly.

If necessary, lubricate the articulations.22, 23, 24

Steering Make sure that the steering rotates smoothly, without anyclearance or slackening.

46

Centre stand, side

stand&Make sure that they work smoothly and that the springtension brings it back to its normal position.If necessary, lubricate joints and hinges.

Fastening elements Make sure that the fastening elements are not loose.If necessary, adjust or tighten them.

Fuel tank Check the fuel level and top up, if necessary.Make sure there are no leaks or occlusions in the circuit.

21

Coolant1 The coolant level in the expansion tank must be includedbetween the MINand MAXmarkings.Top up, if necessary.

26, 27

Lights, warninglights, horn andelectric devices

Check the proper functioning of all the devices.Change the bulbs or intervene in case of failure. 53 62


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STARTING

Exhaust gases contain carbonmonoxide, which is extremelynoxious if inhaled.

Avoid starting the vehicle in closed or

badly-ventilated rooms.The non-observance of this warningmay cause loss of consciousness oreven lead to death by asphyxia.

Do not get on the vehicle for the start-ing.

ELECTRIC STARTING


Make sure that the light switch (1) is inposition

.

_

Make sure that the dimmer switch (2)is in position

b

.

Turn the ignition switch (3) to position

n

.

Lock at least one wheel, by pulling abrake lever (4).If this operation is not carried out, the

start relay receives no current and there-fore the engine does not start.

Press the start push button

r

(5) with-out accelerating, then release it as soonas the engine starts.

When the start push button

r

ispressed, the 2 stroke oil reservewarning light

j

comes on.With the engine in running condition,when the start push button

r

is re-

leased, the 2 stroke oil reserve warninglight

j

must go out; if this does notoccur, top up the 2 stroke oil tank, seep. 22 (2 STROKE OIL TANK).

If the starting is carried out with cold en-gine, rotate the cold start lever

e

(6)downwards.

Avoid pressing the start pushbutton

r

(5) when the engine is

running: this may damage thestarter.

Do not accelerate and pull the brake le-vers at the same time until you move off.

Warm the engine up before leaving.

Once the engine has warmed up, seep. 15 (Coolant temperature indicator

1

), rotate the cold start lever

e

(6)upwards.

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KICK START

For the kick start, proceed as follows:


Move to the left side of the vehicle.

Make sure that the light switch (1) is in

position

.

_

Make sure that the dimmer switch (2)is in position

b

.


n

.

To avoid losing control of the vehicle dur-ing the starting, lock both wheels byputting on the brake levers (4).

Do not push down the kick start-

er with the engine on. Push down the kick starter (7) with your

right foot, releasing it immediately.If necessary, repeat the operation untilthe engine starts.

STARTING AFTER A LONG PERIOD OFINACTIVITY

After a long period of inactivity, proceed asfollows: Make sure that the light switch (1) is in

position._Make sure that the dimmer switch (2)

is in position b. Turn the ignition switch (3) to position

n. Make the starter run for about 10 sec-

onds, in order to ensure the filling up ofthe float chamber.

To start the engine: Rotate the cold start lever e (6) down-

wards. Slightly open the throttle, then carry out

the electric starting procedure (or KICKSTART).

a

Avoid opening and closing theth ttl i t dl d

Pay the utmost attention to anyb t l i ti f tha a


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DEPARTURE AND DRIVE

Release the throttle grip (

pos. A

), put onthe rear brake, then move the vehicle downthe stand.

Get on the vehicle, keeping at least onefoot on the ground in order not to lose bal-ance.

Properly adjust the inclination ofthe rear-view mirrors.

To leave, release the brake lever and ac-celerate by gently rotating the throttle grip(

pos. B

); the vehicle will start moving.

throttle grip repeatedly and con-tinuously, so that you do not ac-

cidentally lose control of the vehicle.

If you have to brake, close the throttleand put on both brakes in order to ob-tain uniform deceleration, properly ex-erting pressure on the braking parts.

By putting on the front brake only or therear brake only, you reduce the brakingforce considerably, thus running therisk of locking one wheel and conse-quently losing grip.

Before beginning to turn, slow down orbrake driving at moderate and constantspeed or accelerating slightly; avoid

braking at the last moment: it would bevery easy to skid.

If the brakes are operated continuouslyon downhill stretches, the friction sur-faces can overheat, thus reducing thebraking efficiency.Never drive with the engine off!

In case of wet ground or scarce wheelgrip (snow, ice, mud, etc.), drive slowly,

avoiding sudden brakings or manoeu-vres that could make you lose grip andfall down.

obstacle or variation of theground.

Uneven roads, rails, manhole covers,indications painted on the road surface,building site metal plates become rath-er slippery by rain. For this reason allthese obstacles have to be carefully

avoided, driving smoothly and bendingthe vehicle as little as possible.

Always use the turn indicators timelywhen you intend to change lane or di-rection, avoiding sharp and dangerousmovements.

If the 2 stroke oil reserve warn-ing light

j

comes on during

the normal functioning of the en-gine, this means that the 2 stroke oil re-serve is being used; in this case, top upthe mixer oil tank, see p. 22 (2 STROKEOIL TANK).

1

If the pointer of the coolanttemperature indicator

h

reach-es the red area, stop the engine

and check the coolant level, see p. 26(COOLANT).

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RUNNING-IN


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After the first 500 kilometres,carry out the checking opera-tions indicated in the column

Af-ter running-in

of the REGULAR SERV-ICE INTERVALS CHART, see p. 35, in

order to avoid hurting yourself or otherpeople and/or damaging the vehicle.

The running-in of the engine is primary toensure its correct functioning and its correctfunctioning. If possible, drive on hilly roadsand/or roads with many bends, so that theengine, the suspensions and the brakesundergo a more effective running-in.

For the first 500 km, keep to the followingindications:

0-300 km

Do not keep the throttle grip open morethan one half for long stretches.

300-500 km

Do not keep the throttle grip open morethan three-fourths for long stretches.

STOPPING

I f possible, avoid stoppingabruptly, slowing down suddenlyand braking at the last moment.

Release the throttle grip (

pos. A

) andgradually put on the brakes to stop thevehicle.

In case of a brief stop, keep at least onebrake on.

PARKING

Park the vehicle on firm and flatground, to prevent it from fallingdown.

Neither lean the vehicle against walls,nor lay it on the ground.

Make sure that the vehicle and especial-ly its red-hot parts do not represent adanger for persons and children.

Do not leave the vehicle unattended

when the engine is on or the key is in-serted into the ignition switch.

Do not sit on the vehicle when the standis down.

Stop the vehicle, see beside (STOP-PING).


m. Position the vehicle on the stand, see

p. 34 (POSITIONING THE VEHICLE ONTHE STAND).

It is not necessary to close thefuel tap when the engine is off,

since it is equipped with an automaticclosing system.

Never leave the key in the igni-tion switch.

Lock the steering, see p. 18 (STEERINGLOCK)and extract the key (2).

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POSITIONING THE VEHICLEON THE STAND

Carefully read p. 33 (PARKING).

CENTRE STAND

Grasp the left handgrip and the left reargrab rail (1).

Push down the stand lever (2).

SIDE STAND&

Grasp the left handgrip and the left reargrab rail (1).

Push down the side stand with your rightfoot, extending it completely (3).

Incline the vehicle until the stand restson the ground (4).

Steer the handlebar completely left-wards.

Make sure that the vehicle is sta-ble.

SUGGESTIONSTO PREVENT THEFT

NEVER leave the ignition key inserted andalways use the steering lock.

Park the vehicle in a safe place, possibly ina garage or a protected place.

If possible, use the appropriate aprilia


, or an ad-ditional anti-theft device.

Make sure that all documents are in orderand the road tax has been paid.

Write down your personal data and tele-phone number in the space provided in thispage, to facilitate the identification of theowner in case of finding after theft.

SURNAME:................................................

NAME:........................................................

ADDRESS:.................................................

...................................................................

TELEPHONE NO.: .....................................

Very often stolen vehicles are

identified thanks to the data writ-ten on the use/maintenance manual.

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MAINTENANCE REGULAR SERVICE INTERVALS CHART


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Before beginning any mainte-nance operation or any inspec-tion of the vehicle, stop the en-

gine, extract the key from the ignitionblock, wait until the engine and the ex-haust system have cooled down and ifpossible lift the vehicle by means of theproper equipment, on firm and flatground. Keep away from the red-hotparts of the engine and of the exhaustsystem, in order to avoid burns.The vehicle is made up of not edibleparts. Never bite, suck, chew or swallowany part of the vehicle for any reason.

If not expressly indicated other-wise, for the reassembly of the

units repeat the disassembly op-erations reversing their order.

Ordinary maintenance operations can usu-ally be carried out by the user, but some-times a basic knowledge of mechanics andspecific tools are required.If you need assistance or technical advice,consult your aprilia

Official Dealer, whocan ensure you prompt and accurate serv-icing. After any maintenance operation,carry out the Preliminary checking opera-tions, see p. 29 (PRELIMINARY CHECK-ING OPERATIONS).


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COMPONENTAfter running-in

(500 km)Every 4000 km

or 8 monthsEvery 8000 kmor 16 months

Rear shock absorber C C

Battery/electrolyte level C C

Spark plug C C S

Carburettor - idling R C

Driving belt C

Steering column bearings C CWheel bearings C

Removal of deposits from the exhaust P

Air cleaner C P

Accelerator operation C C

Brake locking operation C C

Braking systems C C

Rear brake cam pin greasing C

Stop light switch C

Brake fluid every year: S

Coolant 1 every 2000 km: C / every 2 years : S2 stroke oil every 500 km: C

Transmission oil Severy 3000 kmor 6 months: C

every 12000 kmor 2 years: S

Light direction - operation C

Wheels/tyres - inflation pressure every month: R

Nut, bolt, screw tightening C C

Front suspension C C

2 stroke oil reserve warning light C C

Fuel pipe C

Mixer oil pipe C CRear brake shoe wear C C

Front brake pad wear C every 2000 km: C

C= check, clean, adjust, lubricate or change, if necessary;P= clean; S= change; R= adjust. Carry out the maintenance operations more frequently i f youuse the vehicle in rainy and dusty areas or on uneven ground.

Have maintenance operations on the components indicated by carried out by apriliaOfficial Dealers ONLY.


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IDENTIFICATION DATA

It is a good rule to write down the frameand engine numbers in the space providedin this manual.The frame number can be used for the

purchase of spare parts.

Do not alter the identificationnumbers if you do not want to in-

cur severe penal and administrativesanctions. In particular, the alteration ofthe frame number results in the immedi-ate invalidity of the guarantee.

ENGINE NUMBER

The engine number is stamped near thelower support of the rear shock absorber.

Engine no.

FRAME NUMBER

The frame number is stamped on the cen-tral tube of the frame. To be able to read it,it is necessary to remove the cover (1).

Frame no.

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AIR CLEANER

Do not use petrol or inflammablesolvents to wash the air cleaner,in order to avoid fires or explo-sions.

Carefully read p. 35 (MAINTENANCE).


Check the conditions of the air cleaner andclean it monthly or every 4000 km, depend-ing on the conditions in which the vehicle isused.

If the vehicle is used on dusty or wet roads,the cleaning operations and any replace-ment should be carried out more frequent-ly.

To clean the filtering element it is neces-sary to remove the whole filter casing fromthe vehicle.

REMOVAL

Remove the inspection cover, see p. 50(REMOVING THE INSPECTION COV-ER).

Remove the front cover of the rear part

of the fairing, see p. 50 (REMOVINGTHE FRONT COVER OF THE REARPART OF THE FAIRING).

Unscrew and remove the screw (1), tak-ing the washer.

Upon reassembly, position therear brake cable eyelet (2) cor-

rectly.

Unscrew and remove the screw (3) withthe relevant washer.

Loosen the screw (4) of the air manifoldclamp.

Grasp the air manifold in correspond-ence with the clamp and pull it, thus re-moving the whole air cleaner casing.

CLEANING THE AIR FILTER

Unscrew the three screws (5).

Remove the filter case cover (6) and ex-tract the filtering element (7).

To clean the filtering element use clean,

non-inflammable solvents or solventswith high volatility point, then let it drythoroughly.

Apply a filter oil or a thick oil (SAE 80W-90) on the whole surface of the filteringelement, then squeeze it to eliminate theoil in excess.

The filter must be well impreg-nated, though not dripping.

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CHECKINGTHE TRANSMISSION OIL LEVEL

In case of oil leaks or malfunc-tions, contact your aprilia

Offi-

cial Dealer.

DO NOT DISPOSE OF THE TRANSMIS-SION OIL IN THE ENVIRONMENT.



To check the transmission oil level, carryout the following operations every 3000 kmor every 6 months:

Drive for a few miles until the enginereaches the normal running temperature,

see p. 15 (Coolant temperature indicator

1

), then stop it.


Put a graduated container (1) with atleast 110 cm

C

capacity under the drainplug (2).

Unscrew the filling cap (3) and the oildrain plug (2).

Let all the oil flow out of the oil pan.

Measure the quantity and if it is less than100 cm

C

, top up by adding the lacking

quant i ty , see p. 70 (LUBRICANTCHART).

Tighten the drain plug (2).

Provide for filling up, using the oil collect-ed into the graduated container (1).

Tighten the filling cap (3).

Tighten the filling cap and thedrain plug thoroughly and makesure that there are no oil leaks.

Periodically check that there are no

leaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficientlubrication or with contaminated or un-suitable lubricants, since this would ac-celerate the wear of the moving partsand may also cause irreparable failures.

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CHANGINGTHE TRANSMISSION OIL

In case of oil leaks or malfunc-tions, contact your aprilia

Offi-cial Dealer.

DO NOT DISPOSE OF THE TRANSMIS-SION OIL IN THE ENVIRONMENT.Put it in a sealed container and take it tothe filling station where you usually buyit or to an oil salvage center.Carefully read p. 35 (MAINTENANCE).


To ensure the efficiency and long life of thevehicle, it is necessary to change the oil af-ter the first 500 km and successively every12000 km or every 2 years.

Proceed as follows:

Drive for a few miles until the enginereaches the normal running temperature,see p. 15 (Coolant temperature indicator

1

), then stop the engine.


Put a graduated container (1) with atleast 110 cm

C

capacity under the drainplug (2).

Unscrew the filling cap (3) and the oildrain plug (2).

Let all the oil flow out of the oil pan.

Tighten the drain plug and add 100 cm

C

of oil, see p. 70 (LUBRICANT CHART).

Tighten the filling cap (3).

Tighten the filling cap and thedrain plug thoroughly and makesure that there are no oil leaks.

Periodically check that there are noleaks in correspondence with the oilpan cover seal.

Do not use the vehicle with insufficientlubrication or with contaminated or un-suitable lubricants, since this would ac-celerate the wear of the moving partsand may also cause irreparable failures.

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FRONT WHEEL

DISASSEMBLY


While disassembling the wheel,be careful not to damage thebrake pipe, the disc and the

pads.

To disassemble the front wheel, proceedas follows:


Prepare a 200 mm high support,

the base of which must measure200 x 200 mm.

Place the support under the vehicle anda spongy cloth between them, so that thefront wheel can move freely and the ve-hicle cannot fall down.


Unscrew and remove the two screws (1).

Brake caliper screw driving torque (1):27 Nm (2.7 kgm).

Never pull the front brake leverafter removing the brake caliper,otherwise the caliper pistons

may go out of their seats, thus causingthe outflow of the brake fluid.In this case consult your aprilia

OfficialDealer, who will carry out the propermaintenance operation.

Remove the brake caliper (2), by careful-ly withdrawing it from the brake disc.

Unscrew the metal ring (3) and withdrawthe odometer cable (4) from the control(5).

Lock the wheel pin (6) by means of aspanner.

Unscrew and remove the nut (7), takingthe washer (8).

Wheel pin-nut driving torque:50 Nm (5 kgm).

Push the wheel pin (6), by carefully act-ing on the threaded end and using a rub-ber hammer if necessary.

Check the arrangement of thespeedometer drive (5) and of the

spacer ring (9), in order to be able to re-assemble them correctly.

Support the front wheel and extract thewheel pin manually.

Take the spacer ring (9).

Remove the wheel, carefully withdrawingthe disc from the brake caliper.

Disconnect the odometer control (5).

Handle with care.Prevent the gear (10) from com-

ing out of the odometer control (5).

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Reassemble the brake caliper (2), bycarefully inserting it on the brake disc.

S d ti ht th t (1)


41/80


REASSEMBLY


While reassembling the wheel, becareful not to damage the brakepipe, the disc and the pads.

To reassemble the front wheel, proceed asfollows:

If the gear (10) has come out ofthe odometer control (5), clean

and grease it, then reassemble it withthe crown gear (11) coupled with theworm screw (12).

Do not force the odometer control (5)onto the appropriate wheel hub seat(13), in order not to break the two teeth(A) of the gear (10).

Position the odometer control (5) correct-ly in the appropriate seat in the wheelhub (13).

Apply a reasonable quantity ofgrease uniformly on the wheel

pin (6).

Position the wheel between the forkrods.

Insert the seat (14) of the odometer con-trol (5) in correspondence with the anti-rotation pin (15).

Insert the wheel pin (6) from the rightside of the vehicle (travelling direction).

Insert the spacer (9) between the huband the fork left rod.

Insert the washer (8), lock the rotation ofthe wheel pin (6) with a spanner, screwand tighten the nut (7).

Wheel pin nut driving torque:50 Nm (5 kgm).

Screw and tighten the two screws (1).

Brake caliper screw driving torque (1):27 Nm (2.7 kgm).

Remove the support from under the vehi-cle.

After reassembly, pull the frontbrake lever repeatedly andcheck the correct functioning of

the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by your

aprilia

Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.a

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REAR WHEEL

DISASSEMBLY


Remove the exhaust silencer, see p. 47(REMOVING THE EXHAUST SILENCER).

To unscrew the wheel nut (1), itis necessary to lock the rotation

of the wheel.

Pull the rear brake lever (2) completely,then put a small piece of cardboard (3)on the grip and keep the rear brake leverpulled by holding it against the grip bymeans of a plastic band (4).

Unscrew and remove the wheel nut (1)and the washer.

Upon reassembly, change thewheel nut (special type).

Wheel nut driving torque:110 Nm (11 kgm).

Remove the plastic band (4) and takethe piece of cardboard (3).

Release the rear brake lever.

Withdraw the wheel.

Use aprilia

Genuine Spare Partsonly.

After reassembly, pull the rearbrake lever repeatedly andcheck the correct functioning of

the braking system.

Check the wheel centering.

Have the driving torques, centering andbalancing of the wheel checked by your

aprilia

Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.

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CHECKINGTHE BRAKE PAD WEAR

Carefully read p. 22 (BRAKE FLUID -recommendations), p. 23 (FRONTBRAKE DISC), p. 35 (MAINTENANCE).


Check the brake pad wear after the first500 km and successively every 2000 km.

The wear of the brake pads depends onthe use, on the kind of drive and on theroad. The wear will be greater when the ve-hicle is driven on dirty or wet roads.

To carry out a rapid checking of the wear ofthe front pads, proceed as follows:


Remove the brake caliper cover (1).

Carry out a visual checking of the frictionmaterial thickness by looking betweenthe brake caliper and the pads.

If the thickness of the friction material(even of one pad only) has reduced toabout 1 mm, replace both pads.

Have the pads changed by your

aprilia

Official Dealer.

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CHECKING THE SHOE WEAR

Carefully read p. 24 (REAR DRUMBRAKE) and p. 35 (MAINTENANCE).

Check the wear of the rear brake shoes af-ter the first 500 km and successively every4000 km.

To verify the wear of the rear brake shoes,proceed as follows:

Pull the rear brake lever (1) completelyand keep it pulled.

Check the position of the rear brakeshoe wear indicator (2).

If the rear brake shoe wear indi-cator (2) is positioned on or be-yond the lower reference tooth

(4), contact an aprilia Official Dealer,who will provide for replacing the rearbrake shoes.

GREASINGTHE REAR BRAKE CAM PIN



Grease the rear brake cam pinevery 4000 km. If the vehicle is

used on dusty roads, this operationmust be carried out more frequently.

The greasing of the rear brakecam pin can be difficult or com-plicated for an unskilled opera-

tor.If necessary, contact your aprilia

Offi-cial Dealer.If you want to carry out this operationby yourself, keep to the following in-structions:

Disassemble the rear wheel, see p. 42(REAR WHEEL).

Unscrew and remove the adjuster (5).

Do not dirt the shoes and thefriction material with grease, to

avoid compromising the brakingefficiency of the vehicle.

Position Wear condition

Indicator betweenthe two referenceteeth (3) and (4).

Rear brake shoeswithin the wear limit.

Indicator on orbeyond the lowerreference tooth (4).

Rear brake shoesworn.To be replaced.

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Upon reassembly:

Do not hit or force the cam pin

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This operation may be difficultbecause the springs (6) resistconsiderably to the removal of

the shoes. Be careful not to crush orbruise your hands and fingers.

Grasp the inner edge of the two frictionelements (7) at its centre and, pulling to-ward yourself, shake the two shoes, thusreleasing them.

Before removing the pin lever(8), mark it.

Mark the cam pin (9) and the pin lever (8)with an indelible felt-tip (10), as indicated

in the figure (A).

Lock the screw (11) with an hexagonspanner and loosen the nut (12).

Remove the pin lever (8).

Before removing the rear brakeshoe wear indicator (2), mark it.

Mark the cam pin (9) and the rear brakeshoe wear indicator (2) with an indeliblefelt-tip (10), as indicated in the figure (B).

Withdraw and remove the rear brakeshoe wear indicator (2) and the relevantgasket.

Withdraw the cam pin (9).

Moderately grease only the cen-tral part of the pin.Avoid dirting the cam or the are-

as around the pin seat with grease.

Grease the central part of the pin by us-ing grease for kinematic motions, seep. 70 (LUBRICANT CHART).

Do not hit or force the cam pin(9) with any hammer or other ob-ject.

Manually insert the cam pin (9), by rotat-ing and pushing it moderately.

Put back the rear brake shoe wear indi-

cator (2) and the pin lever (8), makingthe reference marks (A) and (B) coincidewith those on the cam pin (9).

The wrong positioning of therear brake shoe wear indicatorresults in the wrong measure-

ment of the rear brake shoe wear, withconsequent risk of compromising yoursafety and that of other people and ofdamaging the vehicle.

Put back the two friction elements (7),coupling the plane ends (12) with thecam pin (9) and the shaped ends (13)with the fulcrum pin (14).

Check the correct coupling ofthe springs (6).

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CHECKING THE STEERING


Every now and then it is advisable to checkthe steering, in order to verify if there areslacks.

To check the steering it is necessary to:


Prepare a 200 mm high support,the base of which must measure

200 x 200 mm.

Place the support under the vehicle anda spongy cloth between them, so that the

front wheel can move freely and the ve-hicle cannot fall down.


Shake the fork in the direction of travel(see figure).

Do not shake the fork excesive-ly, otherwise you may take in

consideration the movement of thestand, thus observing an incorrectslack.Repeat the previous operation morethan once.

If you find that there is a considerableslack, contact your aprilia

Official Dealerto restore the optimal steering condi-tions.

CHECKINGTHE ENGINE FULCRUM AXIS


Periodically check the slack existing be-tween the engine pin bushings.

To carry out this operation, proceed as fol-lows:


Shake the wheel perpendicularly to thedirection of travel (see figure).

If you find any slack, make sure that allthe fastening elements of the fulcrumaxis are well tightened.

If the slack persists, contactyour aprilia

Official Dealer.

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REMOVINGTHE EXHAUST SILENCER



Before performing the opera-tions described below, let theengine and the exhaust silencer

cool down until they have reached roomtemperature, in order to avoid burns.

1

It is not necessary to removethe protection cover (1).

Unscrew and remove the three screws(2).

Remove the protection cover (3).

Unscrew and remove the screw (4) thatfastens the mudguard.

If the additional flange (5) is pro-vided, do not unscrew thescrews (6) and (7), but follow the

procedure described here below.

Unscrew and remove the screws (8) and(9).

Screw (8) and (9) driving torque:12 Nm (1.2 kgm).

Unscrew and remove the two screws(10) and (11) that fasten the exhaust si-lencer to the engine.

Screw (10) and (11) driving torque:25 Nm (2.5 kgm).

Remove the exhaust silencer.

Upon reassembly, replace thegasket positioned between the

exhaust manifold and the silencer witha new one.

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REMOVINGTHE FRONT HANDLEBAR COVER



Support the front part of the fair-ing (1), in order to prevent it from

accidentally falling down.

Unscrew and remove the screw (2).

Proceed with care.Do not damage the tangs and/ortheir seats.

Handle the plastic and painted compo-nents with care and avoid scraping ordamaging them.

Remove the front part of the fairing (1).

Remove the gasket (3).

Unscrew and remove the screws (4).



Remove the front handlebar cover (7).

REMOVING THE REARHANDLEBAR COVER


Remove the front handlebar cover, seebeside (REMOVING THE FRONT HAN-DLEBAR COVER).



Unscrew the metal ring (10) and with-draw the odometer cable from the cou-pling.

Disconnect the two electric terminals(11) and (12).

The rear handlebar cover (13)(complete with switches, instru-ments and indicators) remains

connected to the electric cables andtherefore cannot be completely re-moved.

Proceed with care in order to avoiddamaging the components.

Partially remove the rear handlebar cov-er (13).

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REMOVING THE FRONTTRANSPARENT SCREEN



Rotate the handlebar completely right-wards.


Proceed with care.Do not damage the tangs and/ortheir seats.

Handle the plastic and painted compo-nents with care and avoid scraping ordamaging them.

Rotate the handlebar to the central posi-tion.

Unscrew and remove the three screws(2).

Withdraw the front cover (3) (radiatorgrid (4) ) by pulling it downwards.

Remove the front transparent screen (5),

together with the collar (6), by withdraw-ing it in the travelling direction.

Upon reassembly:

Make sure that the gasket (7) is correctlyinserted in its seat.

REMOVINGTHE REAR-VIEW MIRROR



Lift the protection element (8).

Support the rear-view mirror (9),to prevent it from accidentallyfalling down.

Keep the screw (10) locked and loosenthe nut (11) completely.

Remove the rear-view mirror (9).

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REMOVINGTHE INSPECTION COVER


Handle the painted components

with care and avoid scraping ordamaging them.



Lift the front part of the inspection cover(2) and remove it by withdrawing it in thetravelling direction.

Upon reassembly, correctly in-

sert the two side tangs in theirseats.

REMOVING THE FRONT COVER OFTHE REAR PART OF THE FAIRING


Handle the plastic and painted

components with care and avoidscraping or damaging them.



Unscrew and remove the two upperscrews (3).

Unscrew and remove the side screw(4).

The front cover of the rear part ofthe fairing can be removed (and

put back) only with lowered saddle.

Before lowering and locking thesaddle, make sure that you have

not left the key in the crash-hel-met/glove compartment.

Lower the saddle.

Remove the front cover of the rear partof the fairing (5) by withdrawing it in thetravelling direction.

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The minimum speed of the engine (idling)must be about 1800 100 rpm; in this casethe engine does not make the rear wheel

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IDLING ADJUSTMENT



Adjust the idling after the first 500 km andevery time it is irregular.

To carry out this operation, proceed as fol-lows:

Drive for a few miles until the enginereaches the normal running temperature,see p. 15 (Coolant temperature indicator

1

), then stop the engine.


Remove the inspection cover, see p. 50(REMOVING THE INSPECTION COV-ER).

Connect an electronic revolution counterto the spark plug cable.

Start the engine.

rotate.

If necessary:

Remove the front cover of the rear partof the fairing, see p. 50 (REMOVINGTHE FRONT COVER OF THE REARPART OF THE FAIRING).

Act on the adjusting screw (1) positionedon the carburettor.

By SCREWING IT (clockwise), you in-crease the engine rpm.

By UNSCREWING IT (anticlockwise), youdecrease the engine rpm.

Twist the throttle grip, accelerating anddecelerating a few times to make surethat it functions correctly and to check ifthe idling speed is constant.

Do not act on the air adjustingscrew, to avoid variations of the

carburation setting.

If necessary, contact your apriliaOfficial Dealer.

ADJUSTINGTHE ACCELERATOR CONTROL


The ideal slack of the accelerator control

should be about 2-3 mm.To adjust the slack, proceed as follows: Position the vehicle on the centre stand. Remove the protection element (2). Loosen the nut (3) (by turning it clock-

wise). Act on the adjuster (4), positioned at the

beginning of the accelerator control ca-ble.

After the adjustment: Tighten the nut (3) (by turning it anti-

clockwise), thus locking the adjuster (4)and put back the protection element (2).

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Check the spark plug gap with a thick-ness gauge.The gap must be 0,5 0,6 mm; if neces-sary adjust it carefully bending the earth


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SPARK PLUG



Check the spark plug after the first 500 kmand successively every 4000 km; change itevery 8000 km.

Periodically remove the spark plug andclean it carefully, removing carbon depos-its; change it if necessary.

To reach the spark plug:

Remove the inspection cover, see p. 50(REMOVING THE INSPECTION COV-

ER).

To remove and clean the spark plug:

Take off the spark plug cap (1).

Remove all the dirt from the base of thespark plug, then unscrew it with thespanner you will find in the tool kit andextract it from its seat, taking care that

neither dust nor other substances enterthe cylinder.

Make sure that there are neither carbondeposits, nor corrosion marks on theelectrode and on the central porcelainpart; if necessary, clean them with thespecial cleaners for spark plugs, with aniron wire and/ or a metal brush.

Energetically blow some air, in order toprevent the removed residues from get-

ting into the engine.If the spark plug has crackings on the in-sulating material, corroded electrodes orexcessive deposits, it must be changed.

sary adjust it, carefully bending the earthelectrode.

Make sure that the washer is in goodconditions. With the washer on, screwthe spark plug by hand in order not todamage the thread.

Tighten the spark plug by means of thespanner you will find in the tool kit, givingit half a turn to compress the washer.

The spark plug must be welltightened, otherwise the enginemay overheat and be seriously

damaged.Use the recommended type of sparkplug only, see p. 66 (TECHNICAL DA-TA),in order not to compromise the life

and performance of the engine.

Position the spark plug cap (1).

Put back the inspection cover.

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BATTERY


If the electrolyte is accidentally swal-lowed, drink a lot of water or milk, thencontinue drinking milk of magnesia orvegetable oil and consult a doctor with


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Check the electrolyte level and the tighten-ing of the terminals after the first 500 km

and successively every 4000 km or 8months.

The electrolyte in the battery istoxic and caustic and if it gets incontact with the skin it can

cause burns, since it contains sulphuricacid.Wear protection clothes, a face maskand/or goggles during maintenance op-erations.

In case of contact with the skin, rinsewith plenty of water.

In case of contact with the eyes, rinsewith plenty of water for 15 minutes, thenconsult an oculist without delay.

vegetable oil and consult a doctor with-out delay.

The battery gives off explosive gases;keep it away from flames, sparks, ciga-rettes and any other source of heat.During the recharging or the use, make

sure that the room is properly ventilatedand avoid inhaling the gases releasedduring the recharging.


Never invert the connection ofthe battery cables.

Do not incline the vehicle too much, in

order to avoid dangerous leaks of thebattery fluid.

Connect and disconnect the batterywith the ignition switch in position

m

.Connect first the positive cable (+) andthen the negative cable ().

Disconnect following the reverse order.

The electrolyte is corrosive.

Do not pour or spill it, especially on theplastic parts.

LONG INACTIVITYOF THE BATTERY

If the vehicle remains unused for a long pe-riod:

Remove the battery, see p. 54 (REMO-

VING THE BATTERY) and put it in a cooland dry place.

Recharge it completely, by using a tricklecharge, see p. 55 (RECHARGING THEBATTERY).

If the battery remains on the vehicle, dis-connect the cables from the terminals.

It is important to check the charge periodi-cally (about once a month), during the win-ter or when the vehicle remains unused, in

order to prevent the deterioration of thebattery.

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CHECKING AND CLEANING THETERMINALS

Carefully read p. 53 (BATTERY).

Remove the inspection cover, see p. 50

(REMOVING THE INSPECTION COV-ER).

Make sure that the cable terminals (1)and the battery terminals (2) are: in good conditions (and not corroded

or covered with deposits); covered with special grease or Vase-

line.

If necessary:

Make sure that the ignition switch is inposition

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.

Disconnect first the negative () andthen the positive cable (+).

Brush with a wire brush to eliminate any

sign

aprilia - sonic 50 (manual taller)

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