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use maintenance+ book

PEGASO I.E.650

aprilia part# 8104312

2 use and maintenance Pegaso 650 I.E.

© 2001 aprilia s.p.a. - Noale (VE)

First edition: february 2001

Reprint: january 2002, february 2002, november 2002, may 2003

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.com

The following precautionary warnings areused throughout this manual in order toconvey the following messages:

Safety warning. When you find thissymbol on the vehicle or in the

manual, be careful to the potential riskof personal injury. Non-compliance withthe indications given in the messagespreceded by this symbol may result ingrave risks for your and other people’ssafety and for the vehicle!

WARNINGIndicates a potential hazard which mayresult in serious injury or even death.

CAUTIONIndicates a potential hazard which mayresult in minor personal injury or dam-age to the vehicle.

NOTE The word “NOTE” in this manualprecedes important information or instruc-tions.

The operations preceded by thissymbol must be repeated also on

the opposite side of the vehicle.If not expressly indicated otherwise, for thereassembly of the units repeat the disas-sembly operations in reverse order.The terms “right” and “left” are referred tothe rider seated on the vehicle in the nor-mal riding position.

Before starting the engine, carefully readthis manual and in particular the section“SAFE DRIVE”.Your and other people’s safety dependsnot only on your quickness of reflexes andon your agility, but also on what you knowabout the vehicle, on its efficiency and onyour knowledge of the basic information for“SAFE DRIVE”. Therefore, get a thoroughknowledge of the vehicle, in such a way asto be able to drive in the traffic safely.

NOTE Keep a stock of one bulb per typewith the vehicle (see technical data).

3use and maintenance Pegaso 650 I.E.

NOTE This manual must be consideredas an integral part of the vehicle and mustalways accompany it, even in case of re-sale.

aprilia has carried out this manual with themaximum attention, in order to supply theuser with correct and updated information.However, since aprilia constantly im-proves the design of its products, theremay be slight discrepancies between thecharacteristics of your vehicle and thosedescribed in this manual. For any clarifica-tion concerning the information containedin this manual, do not hesitate to contactyour aprilia Official Dealer.

For control and repair operations not ex-pressly described in this publication, for thepurchase of aprilia genuine spare parts,accessories and other products, as well asfor specific advice, contact exclusivelyaprilia Official Dealers and Service Cent-ers, which guarantee prompt and accurateassistance. Thank you for choosing aprilia. We wishyou a nice ride.All rights as to electronic storage, repro-duction and total or partial adaptation, withany means, are reserved for all Countries.

NOTE In some countries the antipollu-tion and noise regulations in force requireperiodical inspections.

The user of the vehicle in these countriesmust:

– contact an aprilia Official Dealer to havethe non-homologated components re-placed with others homologated for usein the country in question;

– carry out the required periodical inspec-tions.

NOTE Soon after purchasing the vehi-cle, write down the identification data indi-cated on the SPARE PARTS IDENTIFICA-TION LABEL in the table here below. Thislabel is positioned on the left side of thesaddle support; to read it, it is necessary toremove the saddle, see p. 21 (UNLOCK-ING/LOCKING THE SADDLE).

These data indicate:– YEAR = year of manufacture (Y, 1, 2, ...);– I.M. = modification code (A, B, C, ...);– COUNTRY CODES = homologation coun-

try (I, UK, A, ...).

and are to be supplied to the aprilia OfficialDealer as reference data for the purchaseof spare parts or specific accessories ofthe model you have acquired.

In this manual the various versions are in-dicated by the following symbols:

automatic light switching version (Automatic Switch-on Device)

optional

TIBET version

coolant expansion version

catalytic version

VERSION:

Italy Singapore

United King-dom

Slovenia

Austria Israel

Portugal South Korea

Finland Malaysia

Belgium Chile

Germany Croatia

France Australia

Spain United States of America

Greece Brazil

Holland South Africa

Switzerland New Zealand

Denmark Canada

Japan


SAFE DRIVE ............................................................. 5

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

ARRANGEMENT OF THE MAIN ELEMENTS ....... 12ARRANGEMENT OF THE INSTRUMENTS/CONTROLS .................................. 14INSTRUMENTS AND INDICATORS ....................... 15

INSTRUMENTS AND INDICATORS TABLE ..... 16MAIN INDEPENDENT CONTROLS ........................ 18

CONTROLS ON THE LEFT PART OF THE HANDLEBAR ............................................. 18CONTROLS ON THE RIGHT PART OF THE HANDLEBAR ....................................... 19IGNITION SWITCH ............................................ 20STEERING LOCK .............................................. 21

AUXILIARY EQUIPMENT ....................................... 21UNLOCKING/LOCKING THE SADDLE ............. 21GLOVE/TOOL KIT COMPARTMENT ................ 22ANTI-THEFT HOOK .......................................... 22REAR LUGGAGE RACK ................................... 22SPECIAL TOOLS m ........................................ 23ACCESSORIES ................................................. 23SIDE BAGS m (supplied as standard equipment in the countries where required) ....... 24REAR CASE m (supplied as standard equipment in the countries where required) ....... 26

MAIN COMPONENTS ............................................. 27FUEL .................................................................. 27BRAKE FLUID - recommendations .................... 29DISC BRAKES ................................................... 30FRONT BRAKE ................................................. 31REAR BRAKE .................................................... 33COOLANT .......................................................... 34TYRES ............................................................... 36ENGINE OIL ...................................................... 37CLUTCH ............................................................ 38ADJUSTING THE REAR BRAKE CONTROL LEVER CLEARANCE ........................................ 39AUTOMATIC LIGHT SWITCHING VERSION e .................................................... 39

CATALYTIC EXHAUST SILENCERS o ......... 40EXHAUST SILENCERS .................................... 40

INSTRUCTIONS FOR USE .................................... 40GETTING ON AND OFF THE VEHICLE .......... 40PRELIMINARY CHECKING OPERATIONS ..... 42PRELIMINARY CHECKING OPERATIONS ..... 43STARTING ........................................................ 44DEPARTURE AND DRIVE ............................... 47RUNNING-IN ..................................................... 50STOPPING ........................................................ 51PARKING .......................................................... 51POSITIONING THE VEHICLE ON THE STAND .............................................................. 52SUGGESTIONS TO PREVENT THEFT ........... 54

MAINTENANCE ..................................................... 55REGULAR SERVICE INTERVALS CHART ...... 56IDENTIFICATION DATA ................................... 58JOINTS WITH CLICK CLAMPS AND WITH SCREW CLAMPS ................................... 58CHECKING THE ENGINE OIL LEVEL AND TOPPING UP ........................................... 59CHANGING THE ENGINE OIL AND THE OIL FILTER .............................................................. 60AIR CLEANER .................................................. 62FRONT WHEEL ................................................ 64REAR WHEEL .................................................. 66POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m .......................... 69POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND m ........................ 69DRIVE CHAIN ................................................... 70REMOVAL OF THE FUEL TANK ...................... 72REMOVING THE OIL SUMP GUARD .............. 73REMOVING THE RIGHT AND LEFT SIDES .... 73REMOVING THE DRIVE CHAIN GUARDS ........................................................... 74INSTALLING THE SIDE BAG SUPPORTS m (supplied as standard equipment in the countries where required) ................................. 74INSTALLING THE REAR CASE SUPPORTS m (supplied as standard equipment in the countries where required) ................................. 76CHECKING THE STEERING ............................ 77CHECKING THE REAR FORK FULCRUM AXIS .............................................. 77

INSPECTING THE FRONT AND REAR SUSPENSIONS ................................................ 77FRONT SUSPENSION ..................................... 77REAR SUSPENSION ........................................ 78REAR SUSPENSION WITH HYDRAULIC PRELOAD ADJUSTMENT m .......................... 79CHECKING THE BRAKE PAD WEAR .............. 80IDLING ADJUSTMENT ..................................... 81ADJUSTING THE ACCELERATOR CONTROL 82ADJUSTING THE COLD START CONTROL ......................................................... 82REAR-VIEW MIRRORS .................................... 83SPARK PLUG ................................................... 84CHECKING THE STAND .................................. 86BATTERY .......................................................... 87CHECKING THE ELECTROLYTE LEVEL ........ 88CHECKING AND CLEANING THE TERMINALS ...................................................... 88REMOVING THE BATTERY ............................. 89RECHARGING THE BATTERY ........................ 90INSTALLING THE BATTERY ............................ 90LONG INACTIVITY OF THE BATTERY ............ 91CHECKING THE SWITCHES ........................... 91CHANGING THE FUSES .................................. 92ADJUSTING THE VERTICAL HEADLIGHT BEAM ........................................... 93DASHBOARD LIGHTING .................................. 93BULBS ............................................................... 94CHANGING THE HEADLIGHT BULBS ............ 94CHANGING THE FRONT DIRECTION INDICATOR BULBS .......................................... 96CHANGING THE REAR DIRECTION INDICATOR BULBS .......................................... 96CHANGING THE REAR LIGHT BULB ................................................................. 97CHANGING THE NUMBER PLATE BULB ....... 97

TRANSPORT .......................................................... 98CLEANING ............................................................. 98

LONG PERIODS OF INACTIVITY .................. 100TECHNICAL DATA .............................................. 101

LUBRICANT CHART ....................................... 104Importers .................................................. 106-107WIRING DIAGRAM - Pegaso 650 I.E. ............ 108

safe drive


To drive the vehicle it is necessary to be inpossession 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 thedriver’s lack of experience.NEVER lend the vehicle to beginners and,in any case, make sure that the driver hasall the requirements for driving.


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 (oron the rider’s footboards), in the correctdriving posture.Avoid standing up or stretching your limbswhile driving.


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

Use only the vehicle’s specific fuels and lu-bricants indicated in the “LUBRICANTCHART”; check all oil, fuel and coolant lev-els 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.

COOLEROIL


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 vehicle and/or theremoval of original components can com-promise vehicle performance levels andsafety or even make it illegal.We recommend respecting all regulationsand national and local provisions regardingthe equipment of the vehicle.In particular, avoid all modifications that in-crease the vehicle’s performance levels oralter its original characteristics.Never race with other vehicles.

Before starting, always wear a correctlyfastened 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 clothing should be very tight-fittingand fastened at the wrists and ankles;strings, belts and ties should not be hang-ing loose; prevent these and other objectsfrom interfering with driving by getting en-tangled with moving parts or driving mech-anisms.

ONLY ORIGINALS

A12345


Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in yourpockets (the same recommendations alsoapply to passengers).

The owner of the vehicle is responsible forthe 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 hamper ac-cess to the controls, since this can prolongreaction times during an emergency.Big fairings and windshields installed onthe vehicle may produce aerodynamic forc-es that affect the stability of the vehicle, es-pecially when riding at high speed.

Make sure that the equipment is well fas-tened to the vehicle and not dangerousduring driving. Do not install electrical devices and do notmodify those already existing to avoid elec-trical overloads, because the vehicle couldsuddenly stop or there could be a danger-ous current shortage in the horn and in thelights. aprilia recommends the use of genuineaccessories (aprilia genuine accessories).

Be careful and moderate when loadingyour luggage. Keep any luggage loaded asclose as possible to the center of gravity ofthe vehicle and distribute the load uniform-ly on both sides, in order to reduce umbal-ance to the minimum. Furthermore, makesure that the load is firmly secured to thevehicle, especially during long trips.


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 and do not ride with the crashhelmet, because they could hit people orobstacles, 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!


1) Headlight2) Ignition switch/steering lock3) Left rear-view mirror4) Fuel tank filler cap5) Fuel tank6) Coolant expansion tank cap7) Battery8) Electronic unit

9) Fuse carrier10) Passenger grab rail11) Glove/tool kit compartment12) Rear luggage rack13) Rear fork14) Passenger left footrest

(snapping, closed/open)

15) Centre stand (*)16) Side stand17) Rider left footrest18) Shifting lever19) Not provided .

Coolant expansion

19A) . Coolant expan-sion

20) Rear luggage rack (*)21) Left side bag (*)(*) = Prov ided as s tandard

equipment in the countrieswhere required


1) Rear light2) Passenger grab rail3) Saddle lock4) Saddle5) Rear brake fluid tank6) Air cleaner7) Rear shock absorber

8) Engine oil level plug-dipstick9) Front brake fluid tank

10) Right rear-view mirror11) Horn12) Engine oil tank13) Idle speed adjusting knob14) Engine oil filter

15) Rear brake control lever16) Rider right footrest17) Anti-theft hook (for shielded

cable “Body-Guard” aprilia)

18) Rear brake pump19) Passenger right footrest

(snapping, closed/open)

20) Drive chain21) Right side bag (supplied

as standard equipment in the countries where re-quired)


1) Clutch lever2) Instruments and indicators3) Ignition switch/steering lock ( - - !)4) Front brake lever5) Throttle grip6) Engine stop switch ( - )7) Start push button (")

8) Light switch (# - $ - •) (not provided for )9) Direction indicator switch (%)

10) Horn push button (&)11) Dimmer switch (' - ()12) High beam signalling push button (()13) Cold start lever ())


1) Revolution counter2) Speedometer3) Total kilometres odometer4) Coolant temperature indicator (*)5) Partial kilometres odometer6) Odometer trip control7) Red engine oil pressure warning light (+)

8) Blue high beam warning light (() 9) Red diagnostic warning light (,)

10) Amber low fuel warning light (-)11) Green direction indicator warning light (%)12) Green neutral indicator warning light (.)


Description Function

Direction indicator warning light % Blinks when the direction indicators are on.

High beam warning light ( Comes on when the high beam bulbs are on or when the headlight signaller is operated.

Revolution counter rpmIndicates the number of revolutions of the engine per minute.

Never exceed the engine max. speed rate, see p. 50 (RUNNING-IN).

Low fuel warning light -It comes on when the quantity of fuel still available in the fuel tank is less than 5 .In this case, top up as soon as possible, see p. 27 (FUEL).

Engine oil pressure Warning light +

Comes on whenever the ignition switch is in position “” and the engine is not running, thuschecking the functionality of the bulb. If the light does not come on in this phase, contact an aprilia Official Dealer.

If the engine oil pressure warning light “+” remains on after thestart or comes on during the normal operation of the engine, this

means that the engine oil pressure in the circuit is insufficient.In this case, stop the engine immediately and contact an APRILIA Official Dealer.

Neutral indicator warning light . Comes on when the gear is in neutral.

Diagnostic warning light ,

It comes on whenever the ignition switch is positioned on “” and goes out a few seconds afterthe engine start.

Do not carry out any operation on the components of the vehiclewith the ignition switch in position “”.

With the engine stop switch in position “ ”, it comes on whenever the ignition switch ispositioned on “” and remains on, with low light intensity, thus checking the correct op-eration of the injection circuit.If the light does not come on in this phase, contact an aprilia Official Dealer.

If the diagnostic warning light “,” remains on after the enginestart or comes on during the normal operation of the engine, this

means that the electronic unit has detected an anomaly. In many cases the engine keepsrunning with limited functions; contact an APRILIA Official Dealer immediately.

Follow ã

CAUTION

CAUTION

CAUTION

CAUTION


Follow ã

Description Function

Speedometer (km/h) It indicates the driving speed.

Total kilometres odometer It indicates the total number of kilometres covered.

Coolant temperature indicator *

It indicates the approximate temperature of the coolant in the engine.When the pointer starts moving beyond the “40” level, the temperature is sufficient for drivingthe vehicle.The normal operating temperature appears on the graduated area of the scale.

The switching on and off of the cooling fan does not depend on theposition of the ignition switch. To lower the coolant temperature,

the cooling fan works even when the engine is off and it is disconnected automatically.If the maximum allowed temperature is exceeded (red area of thescale), the engine may be seriously damaged.

If the pointer gets near the red area, stop the engine, wait until the cooling fan is disconnectedand check the coolant level, see p. 34 (COOLANT).If the pointer reaches the red area, stop the vehicle and let the engine idle for approximately twominutes, thus permitting the regular circulation of the coolant in the system; then, position theengine stop switch on “ ” and check the coolant level, see p. 34 (COOLANT). If the situation onthe dashboard remains the same after the coolant level has been checked, do not start the ve-hicle and contact an aprilia Official Dealer.

Partial kilometres odometer It indicates the partial number of kilometres covered. To set it to zero, use the odometer trip con-trol.

Odometer trip control Rotate it anticlockwise to set the partial kilometres odometer to zero.

CAUTION

CAUTION


NOTE The electrical parts work only when the ignition switchis in position “”.

1) HORN PUSH BUTTON (&)The horn is activated when the push button is pressed.

2) DIRECTION INDICATOR SWITCH (%)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.

3) DIMMER SWITCH (' - ()When the light switch is in position “#”: if the dimmer switchis in position “(”, the high beam comes on; while if it is in po-sition “'”, the low beam comes on.

3) DIMMER SWITCH (' - () When it is in position “'” the parking lights, the dashboardlight and the low beam are always on.When it is in position “(”, the high beam comes on.

4) HIGH BEAM SIGNALLING PUSH BUTTON (()It makes it possible to use the high beam for signalling toforthcoming vehicles while overtaking and in case of periland/or emergency.The high beam blinking is operated by pressing the push but-ton, independently of the position of the light switch (# - $- •).

NOTE To disconnect the high beam blinking, release the pushbutton.

5) COLD START LEVER ())The starter for the cold start of the engine is operated by ro-tating the lever “)” downwards.To disconnect the starter, move the lever “)” to its initial posi-tion.


NOTE The electrical parts work only when the ignition switchis in position “”.

1) ENGINE STOP SWITCH ( - )

WARNINGDo not operate the engine stop switch “ - ” in runningconditions.

This is a safety or emergency switch. With the switch pressed in position “”, it is possible to startthe engine; when the switch is pressed to position “ ”, theengine stops.

CAUTIONWith stopped engine and ignition switch in position “”, thebattery may discharge.When the vehicle has come to rest, after stopping the en-gine, move the ignition switch to position “ ”.

2) LIGHT SWITCH (# - $ - •) (not provided for )When the light switch is in position “•”, the lights are off; whenthe switch is in position “$”, the parking lights and the dash-board light are on; when the switch is in position “#”, theparking lights, the dashboard light and the low beam are on. The high beam can be operated by means of the dimmerswitch.

3) START PUSH BUTTON (")When the start push button “"” is pressed, the starter makesthe engine run. For the starting, see p. 44 (STARTING).


The ignition switch (1) is positioned on theupper plate of the steering column.

NOTE The key operates the ignitionswitch/steering lock, the fuel tank lock (2)and the saddle lock (3).

Two keys are supplied together with thevehicle (one spare key).

NOTE Do not keep the spare key on thevehicle.

Position Function Key removal

Steering lock

The steer-ing is locked. It is neither pos-sible to start the engine, nor to switch on the lights.

It is possible to remove the key.

Neither the engine, nor the lights can be switched on.

It is possible to remove the key.

The engine and the lights can be switched on.

It is not possi-ble to remove the key.


WARNINGNever turn the key to position “!” 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 “ ”. Press the key (1) and rotate it to position

“!”. Withdraw the key (1).

Position the vehicle on the stand, see p.52 (POSITIONING THE VEHICLE ONTHE STAND).

Insert the key (1) in the saddle lock (2). Turn the key (1) clockwise and raise and

remove the saddle.

NOTE Before lowering and locking thesaddle, make sure that you have not leftthe key in the glove/tool kit compartment.

To lock the saddle: Position the tangs (3) in the seat, lower

and press the saddle, making the locksnap.

WARNINGBefore leaving, make sure that the sad-dle is properly locked.


To reach the glove/tool kit compart-ment, proceed as follows: Remove the rider saddle, see p. 21 (UN-

LOCKING/LOCKING THE SADDLE).

The tool kit (1) includes:– 3, 4, 5, 6, 8 mm bent hexagon spanners

(2);– 5. 5 – 7 mm double fork spanner (3);– 8 – 11 mm double fork spanner (4);– 10 – 13 mm double fork spanner (5);– 19 mm simple fork spanner (6);– 24 mm simple fork spanner (7); – 18 mm socket spanner for spark plug

(8);– socket spanner rod (9);– double-ended, cross-/cut-headed screw-

driver (10);– tool case (11);

Maximum allowed weight: 1.5 kg.

The anti-theft hook (12) is positioned onthe right side of the vehicle, near the riderfootboard.

To prevent the vehicle from being stolen, itis advisable to secure it with the shieldedcable “Body-Guard” aprilia (13), avail-able at the aprilia Official Dealers .

WARNINGDo not use the hook to lift the vehicle orfor other purposes, since it has beendesigned exclusively to secure the vehi-cle once it has been parked.

Maximum weight allowed for the rearluggage rack (14): 9 kg


To perform some specific operations, it isadvisable to use the following special tools(to be requested to an aprilia Official Deal-er):

The vehicle may be equipped with the fol-lowing accessories (to be requested to theaprilia Official Dealer):

– side bags , see p. 24 [SIDE BAGS (supplied as standard equipment inthe countries where required)];

– rear case , see p. 26 [REAR CASE (supplied as standard equipment inthe countries where required)];

– centre stand (supplied as standardequipment in the countries where re-quired).

Tool Operations

Support pins (1) for the rear support stand, see p. 69 (PO-SITIONING THE VEHICLE ON THE REAR SUPPORT STAND m).

Positioning of the vehicle on the rear stand.

Rear support stand (2), see p. 69 (POSITIONING THE VEHI-CLE ON THE REAR SUP-PORT STAND m).

Rear wheel di-sassembly.Drive chain adjustment.

Front support stand (3), see p. 69 (POSITIONING THE VEHI-CLE ON THE FRONT SUP-PORT STAND m).

Front wheel disassembly.

Washer (4) for front support stand, see p. 69 (POSITIO-NING THE VEHICLE ON THE FRONT SUPPORT STAND m).

Front wheel disassembly.

Click clamp (5) installation pli-ers, see p. 58 (CLICK CLAMPS).

Click clamp in-stallation.


!"# $%$&#$'# "(!)"&% !& %*"+,&%'!"-*"'"'"(!'"#.

Thanks to the use of the side bags it is pos-sible to transport clothes or other objectseven in bad weather, so that they are pro-tected and do not constitute a hindrance ora risk for the rider.

NOTE If the side bags are not installedon the vehicle, before using them it is nec-essary to install the appropriate supports,see p. 74 [INSTALLING THE SIDE BAGSUPPORTS (supplied as standardequipment in the countries where re-quired)].

Clean and lubricate the coupling lock onthe bag every 6000 km (3750 mi) or 12months.

NOTE The following information refersto one unit only, but is valid for both.

To open the side bag, proceed as fol-lows: Position the vehicle on the stand, see p.

52 (POSITIONING THE VEHICLE ONTHE STAND).

Introduce the key (1) in the lock. Turn the key (1) anticlockwise. Extract the key (1) and insert it in the oth-

er lock. Turn the key (1) anticlockwise. Lift the two parts of the lock (2). Open the case (3).



WARNINGIf it is necessary to transport more thanone object, distribute the load uniformlyon the side bags.Secure the luggage by means of the ap-propriate elastic belts, in such a way asto avoid dangerous movements of thesame during the trip. It is not advisable to use the vehiclewith only one side bag installed.

Do not load the side bags excessively.

Maximum allowed weight: 5 kg (for eachbag).


To remove the side bag, proceed as fol-lows: Introduce the key (4) in the lock. Turn the key (4) clockwise and at the

same time move the lower part of thebag slightly towards the outside (A).

Grasp the bag firmly with both hands, asindicated in the figure.

Lift the bag (B) slightly and release it (C)from the appropriate coupling seats (5)on the bag support.



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

WARNINGUpon reassembly, make sure that thebag is properly anchored to its support.

Upper part: perfect fitting of the bagcoupling pins in the coupling seats pro-vided on the support;

Lower part: perfect fitting of the supportcoupling pin in the relevant lock provid-ed on the bag; when the lock snaps, thecoupling is correct.


!"# $%$&#$'# "(!)"&% !& %*"+,&%'!"-*"'"'"(!'"#.

Thanks to the use of the rear case, you nolonger have to carry the crash helmet orother bulky objects with you every time youpark the vehicle.

NOTE Write down your personal dataon the appropriate plate positioned on thelock.

Clean and lubricate the coupling lock onthe lower part of the case every 6000 km(3750 mi) or 12 months.

NOTE If the rear case is not installed onthe vehicle, before using it, it is necessaryto install the appropriate supports, see p.76 [INSTALLING THE REAR CASE SUP-PORTS (supplied as standard equip-ment in the countries where required)].

To open the rear case, proceed as fol-lows: Position the vehicle on the stand, see p.


Introduce the key (1) in the lock. Rotate the key (1) clockwise. Remove the handle (2). Lift the lock (3). Release the upper part (4) of the lock (3)

from the case (5). Lift the upper part of the case to open it

(5).

NOTE The case can contain two“CRASH” helmets.



WARNINGDo not load the rear case excessively.

Maximum allowed weight: 5 kg.

To remove the rear case, proceed as fol-lows: Introduce the key (1) in the lock. Rotate the key (1) clockwise. Extract the handle (2) and grasp it firmly

with one hand. Press the appropriate push button (6). Lift the case (7) and withdraw it from the

relevant front couplings.


WARNINGUpon reassembly, make sure that thecase is properly anchored to its sup-port.

Front part: perfect fitting of the supportcoupling elements into the seats pro-vided on the case;

Rear part: perfect fitting of the supportcoupling pin in the relevant lock on thecase; when the lock snaps, the couplingis correct.


WARNINGThe fuel used for internal combustionengines is extremely inflammable andin particular conditions it can becomeexplosive. 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.

WARNINGFurther, 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 beenspilt, 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.

WARNINGScrew the plug up carefully after refuel-ling. Avoid any contact of the fuel withthe skin and the inhalation of vapours;do not swallow fuel or pour it from a re-ceptacle into another by means of atube.

DO NOT DISPOSE OF FUEL IN THE EN-VIRONMENT.

KEEP AWAY FROM CHILDREN.Use only unleaded petrol, in conformitywith the DIN 51 607 standard, min. O.N. 95(N.O.R.M.) and 85 (N.O.M.M.)


To refuel, proceed as follows: Raise the flap (1). Insert the key (2) in the tank plug lock

(3). Turn the key clockwise, pull and open

the fuel flap.

FUEL TANK CAPACITY (reserve included): 21 TANK RESERVE: 5

CAUTIONDo not put additives or other substanc-es into the fuel.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

WARNINGDo not fill the tank completely; the max-imum fuel level must remain below thelower edge of the filler neck (see figure).

CAUTIONDuring the refilling operations, be care-ful to avoid damaging the inner parts ofthe tank with the fuel pump.

Refuel.

After refuelling:

NOTE The cap can be closed only whenthe key (2) is inserted.

With inserted key (2), close the cap bypressing it.

WARNINGMake sure that the cap is properlyclosed. Withdraw the key (2). Close the flap (1).


'"+,))"&#$%!,&

NOTE This vehicle is provided with frontand rear disc brakes, with separate hy-draulic circuits.

The following information refers to a singlebraking system, but is valid for both.

WARNINGSudden resistance or clearance prob-lems on the brake lever may be due totroubles in the hydraulic system.For any doubt regarding the perfectfunctioning of the braking system andin case you are not able to carry out theusual checking operations, contactyour $'! !$ Official Dealer.

WARNINGMake sure that the brake discs are nei-ther oily nor greasy, especially aftermaintenance or checking operations.

Check that the brake cables are 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.

WARNINGCarefully wash the parts of your bodythat get in contact with the liquid. Con-sult a doctor or an oculist if the liquidgets in contact with your eyes.

DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

CAUTIONWhen using the brake fluid, take carenot to spill it on the plastic or paintedparts, since it can damage them.


WARNINGThe brakes are the parts that most en-sure your safety and for this reasonthey must always be perfectly working;check them before every trip.A dirty disc soils the pads, with conse-quent reduction of the braking efficien-cy. Dirty pads must be replaced, while dirtydiscs must be cleaned with a high-qual-ity degreaser.The brake fluid must be changed everytwo years by an $'! !$ Official Dealer.Use brake fluid of the type specified inthe lubricant chart, see p. 104 (LUBRI-CANT CHART).

NOTE This vehicle is provided with discbrakes with two, front and rear braking sys-tems having separate hydraulic circuits.

The front braking system is with single disc(left side).

The rear braking system is with single disc(left side).The following information refers to a singlebraking system, but is valid for both.When the disc pads wear out, the level ofthe fluid decreases to automatically com-pensate for their wear.The front brake fluid tank is positioned onthe right part of the handlebar, near thefront brake lever coupling.

The rear brake reservoir is positioned onthe right side of the vehicle, near the rearbrake control lever.

NOTE Carry out the maintenance oper-ations halving the intervals indicated, if thevehicle is used in rainy or dusty areas or onuneven surfaces.

Have the brake discs checked by an april-ia Official Dealer after the first 1000 km(625mi) and successively every 6000 km(3750 mi).Before departure, check the brake fluid lev-el in the reservoirs, see p. 31 (FRONTBRAKE), p. 33 (REAR BRAKE), and thewear of the pads, see p. 80 (CHECKINGTHE BRAKE PAD WEAR).Have the brake fluid changed every twoyears by an aprilia Official Dealer.

WARNINGDo not use the vehicle if the brakingsystem leaks fluid.


CHECK Keep the vehicle in vertical position and

turn the handlebar, so that the fluid con-tained in the tank is parallel to the brakefluid tank cover.

Make sure that the fluid level exceedsthe “MIN” mark.MIN= minimum level

If the fluid does not reach at least the “MIN”mark:

CAUTIONWhen the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear.

Check the brake pad wear, see p. 80(CHECKING THE BRAKE PAD WEAR)and the disc wear.

If the pads and/or the disc do not need re-placing, provide for topping up.

TOPPING UPCarefully read p. 29 (BRAKE FLUID -recommendations).

CAUTIONThe brake fluid may flow out of the tank.Do not operate the front brake lever ifthe screws (1) and (2) are loose or, mostimportant, if the brake fluid tank coverhas been removed.

CAUTIONPosition a cloth under the brake reser-voir, in case some fluid should bespilled.

Keep the vehicle in vertical position andturn the handlebar, so that the fluid con-tained in the tank is parallel to the brakefluid tank cover.

Unscrew the screw (1), using a short,cross-tip screwdriver.

Unscrew the screw (2).

WARNINGAvoid any prolonged exposure of thebrake fluid to the air.The brake fluid is hygroscopic andwhen in contact with the air it absorbsits humidity. Leave the brake fluid tank open ONLYfor the time necessary for topping up.


Raise and remove the cover (3) togetherwith the screws (1) and (2).

Remove the gasket (4).

CAUTIONIn order not to spill the brake fluid whiletopping up, do not shake the vehicle.Do not put additives or other subtancesinto the fluid.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

NOTE In order to reach the “MAX” level,top up until covering the glass (5) complete-ly, with the brake fluid reservoir rim parallelto the ground.

Top up the reservoir (6) by adding brakefluid, see p. 104 (LUBRICANT CHART),until reaching the correct level.

CAUTIONDo not exceed the “MAX” level whiletopping up.It is advisable to top up until reachingthe “MAX” level only with new pads.Do not reach the “MAX” level with wornout pads, since this will cause a fluidoutflow when the pads are changed.

Put back the gasket (4) in its seat cor-rectly.

Put back the cover (3). Screw and tighten the screw (2). Screw and tighten the screw (1).

WARNINGCheck the braking efficiency.

In case of excessive stroke of the brakelever or reduced efficiency of the brak-ing system, contact an $'! !$ OfficialDealer, since it may be necessary tobleed the system.


CHECK Remove the right side panel, see p. 73

(REMOVING THE RIGHT AND LEFTSIDES).

Keep the vehicle in vertical position. Make sure that the fluid level exceeds

the “MIN” mark.MIN= minimum levelMAX= maximum level

If the fluid does not reach at least the “MIN”mark:

CAUTIONWhen the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear. Check the brake pad wear, see p. 80

(CHECKING THE BRAKE PAD WEAR)and the disc wear.

If the pads and/or the disc do not need re-placing, provide for topping up.

TOPPING UPCarefully read p. 29 (BRAKE FLUID -recommendations).

CAUTIONThe brake fluid may flow out of the tank.Do not pull the rear brake lever if thebrake fluid tank cover has been re-moved.

WARNINGAvoid any prolonged exposure of thebrake fluid to the air.The brake fluid is hygroscopic andwhen in contact with the air it absorbsits humidity. Leave the brake fluid tank open ONLYfor the time necessary for topping up.

Unscrew and remove the plug (1). Remove the gasket (2).

CAUTIONIn order not to spill the brake fluid whiletopping up, keep the fluid in the tankparallel to the tank rim (in horizontal po-sition).Do not put additives or other subtancesinto the fluid.If you use a funnel or other similaritems, make sure that they are perfectlyclean. Fill the tank (3) with brake fluid, see p.

104 (LUBRICANT CHART), until reach-ing the correct level between the “MIN”and “MAX” marks.

CAUTIONIt is advisable to top up until reachingthe “MAX” level only with new pads.Do not reach the “MAX” level with wornout pads, since this will cause a fluidoutflow when the pads are changed.Check the braking efficiency.In case of excessive stroke of the brakelever or reduced efficiency of the brak-ing system, contact an $'! !$ OfficialDealer, since it may be necessary tobleed the system.


CAUTIONDo not use the vehicle if the coolant isbelow the minimum prescribed level“MIN”.


Before departure, check the coolant level,see p. 35 (CHECKING AND TOPPINGUP); have the coolant changed every twoyears: for this operation, contact an apriliaOfficial Dealer.

WARNINGThe coolant is noxious: do not swallowit; if the coolant gets in contact with theskin or the eyes, it can cause serious ir-ritations.

If the fluid gets in contact with your skinor eyes, rinse with plenty of water andconsult a doctor. If it is swallowed, in-duce vomit, rinse mouth and throat withplenty of water and consult a doctorwithout delay.


DO NOT DISPOSE OF THE FLUID INTHE ENVIRONMENT.

WARNINGBe careful not to spill the coolant on thered-hot parts of the engine: it may catchfire and send out invisible flames.

In case any maintenance operationshould be required, it is advisable touse latex gloves.

CAUTIONHave the pads changed by your $'! !$Official Dealer.

The coolant is composed 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 andit 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%).

For the cooling solution use distilled water,in order not to damage the engine.

WARNINGDo not remove the expansion tank plug(1) when the engine is hot, since thecoolant is under pressure and its tem-perature is high.If it gets in contact with the skin or withclothes it may cause severe burnsand/or damage.


CHECKING AND TOPPING UP

WARNINGCheck the coolant level and top up theexpansion tank with cold engine.

Stop the engine and wait until it hascooled down.

Keep the vehicle in vertical position, withthe two wheels resting on the ground.

Not provided . Make sure thatthe level of the fluid contained in the ex-pansion tank (2) is included between the“MAX” and “MIN” marks.

MAX= maximum levelMIN= minimum level

. The level is correct when the oilalmost reaches the “MAX” mark.

If not, proceed as follows:

Unscrew and remove the filling cap (1).

WARNINGThe coolant is noxious: do not swallowit; if the coolant gets in contact with theskin or the eyes, it can cause serious ir-ritations. Do not use your fingers or any other ob-ject to check if there is enough coolant.

CAUTIONDo not put additives or other subtancesinto the fluid.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

Top up the expansion tank by addingcoolant, see p. 104 (LUBRICANTCHART), until this almost reaches the“MAX” level. Do not exceed this level,otherwise the fluid will flow out while theengine is running.

Put back the filling cap (1).

CAUTIONIn case of excessive consumption ofcoolant and in case the tank remainsempty, make sure that there are noleaks in the circuit. Have it repaired byan $'! !$ Official Dealer.


This vehicle is provided with tyres withtube.


WARNINGCheck the inflation pressure at roomtemperature every two weeks.

Check the conditions of the tyres andthe inflation pressure at room tempera-ture every 1000 km (625 mi), see p. 101(TECHNICAL DATA).

WARNINGPeriodically check the tyre inflationpressure at room temperature, see p.101 (TECHNICAL DATA).

If the tyres are hot, the measurement isnot correct.Carry out the measurement especiallybefore and after 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 pressureis too low, the tyre sides (1) 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 come off the rims.

Further, the vehicle could skid whileturning.

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

Some types of tyres homologated forthis vehicle are provided with wear indi-cators.

There are several kinds of wear indica-tors. For more information on how tocheck the wear, contact your Dealer. Visually check if the tyres are worn andin this case have them changed.

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

WARNINGThe tyres must be replaced with othertyres of the type and model recom-mended by the manufacturer, see p. 101(TECHNICAL DATA); the use of tyresdifferent from those prescribed may ad-versely affect the manoeuvrability of thevehicle.Do not install tyres with air tube on rimsfor tubeless tyres and viceversa.Make sure that the inflation valves (2)always have their sealing caps on, toprevent the tyres from suddenly goingflat.

Change, repair, maintenance and bal-ancing operations are very importantand therefore they must be performedby qualified technicians with appropri-ate tools.


WARNINGFor this reason, it is advisable to havethe above mentioned operations carriedout by an $'! !$ Official Dealer or by aqualified tyre repairer.If the tyres are new, they may still becovered with a slippery film: drive care-fully for the first miles. Do not oil thetyres with unsuitable fluids. If the tyresare old, even if not completely worn out,they may become hard and may not en-sure good road holding.In this case, replace them.MINIMUM TREAD DEPTH LIMIT (3):front and rear 2 mm and in any case notless than prescribed by the regulations inforce in the country where the vehicle isused.

WARNINGEngine oil may cause serious damageto the skin if handled daily and for longperiods.

Wash your hands carefully after use.


DO NOT DISPOSE OF THE OIL IN THEENVIRONMENT.

Put it in a sealed container and take it tothe filling station where you usually buyit or to an oil salvage center.


CAUTIONIf the engine oil pressure warning light“+” comes on during the normal oper-ation of the engine, this means that theengine oil pressure in the circuit is in-sufficient.

In this case, check the engine oil level,see p. 59 (CHECKING THE ENGINE OILLEVEL AND TOPPING UP); if the levelisn’t correct, stop the engine immedi-ately and contact an $'! !$ OfficialDealer.

CAUTIONProceed with care.Do not spill the oil!Take care not to smear any component,the area in which you are working andthe surrounding area. Carefully removeany trace of oil.In case of leakages or malfunctions,contact an $'! !$ Official Dealer.

Periodically check the engine oil level, seep. 59 (CHECKING THE ENGINE OIL LEV-EL AND TOPPING UP).For the engine oil change, see p. 56 (REG-ULAR SERVICE INTERVALS CHART)and p. 60 (CHANGING THE ENGINE OILAND THE OIL FILTER).

NOTE Use high-quality 5W – 40 oil, seep. 104 (LUBRICANT CHART).


ADJUSTING THE CLUTCHAdjust the clutch after the first 1000 km(625 mi) and successively every 6000 km(3750 mi) and when the engine stops orthe vehicle (with pulled clutch lever andgears on) tends to move forward, or if theclutch slips, causing a delay in the acceler-ation with respect to the engine rpm.

For the adjustment, proceed as follows: Position the vehicle on the stand, see p.


Withdraw the protection element (1). Loosen the lock nut (2). Rotate the adjuster (3), until the idle

stroke of the clutch lever is about 10mm.

Tighten the lock nut (2) and check theadjustment again.

Start the engine, see p. 44 (STARTING). Pull the clutch control lever completely

and engage the 1st gear.

Make sure that the engine does not stop,that the vehicle does not tend to move for-ward, or that the clutch does not slip duringthe acceleration phase or while the vehicleis running.

WARNINGIf it is not possible to obtain a correctadjustment or if the clutch does notfunction properly, contact your $'! !$Official Dealer.

CAUTIONMake sure that the clutch control cableis intact: the inner cable and outer sheatmust not be worn or flattened at anypoint.


/

The brake control lever is positioned ergo-nomically during the assembly of the vehi-cle. If necessary, it is possible to adjust thebrake control lever clearance:

Loosen the lock nut (1). Screw the brake adjuster (2) completely. Screw the lock nut (3) completely on the

pump control rod (4). Screw the pump control rod (4) com-

pletely, then unscrew it by giving 3 – 4turns.

Screw the brake adjuster (2) until thebrake pedal reaches the desired height.

Lock the brake adjuster (2) by means ofthe lock nut (1).

Unscrew the pump control rod (4) andbring it in contact with the pump piston.

Screw the rod in order to ensure a mini-mum clearance of 0.5 – 1 mm betweenthe pump control rod (4) and the pumppiston.

CAUTIONMake sure that there is a certain idlestroke in the movement of the lever (5),to prevent the brake from remaining ap-plied and the consequent untimely wearof the braking elements.

Lever (5) idle stroke: 4 mm (measured atthe lever end).

Lock the pump control rod (4) by meansof the lock nut (3).

CAUTIONAfter the adjustment, make sure that thewheel rotates freely with releasedbrake.Check the braking efficiency.

If necessary, contact your $'! !$ Offi-cial Dealer.

The vehicles provided with this device canbe immediately recognized, since the lightscome automatically on as soon as the igni-tion switch is turned to position “”.

For this reason, no light switch is provided.The lights can be switched off only by turn-ing the ignition switch to position “ ”.

Before starting the vehicle, make sure thatthe dimmer switch is in position “'” (frontlow beam).


NOTE The following information refersto a single exhaust silencer, but is valid forboth.

WARNINGAvoid parking the vehicle catalytic ver-sion near dry brush wood or in placeseasily accessible to children, as the cat-alytic silencer becomes extremely hotduring use; be very careful and avoidany kind of contact before it has com-pletely cooled down.

The catalytic vehicle is fitted with a silencerwith metal catalytic converter of the “plati-num-rhodium bivalent” type.This device provides for the oxidation ofthe CO (carbon monoxide) and of the HC(unburned hydrocarbons) contained in theexhaust gases, changing them into carbondioxide and steam, respectively.

CAUTIONDo not use leaded petrol, since it caus-es the destruction of the catalytic con-verter.

WARNINGTampering with the noise control sys-tem is prohibited.

Owners are warned that the law may pro-hibit:– the removal or rendering inoperative by

any person, other than for purposes ofmaintenance, repair or replacement, ofany device or element of design incorpo-rated into any new vehicle – for the pur-pose of noise control – prior to its sale ordelivery to the ultimate purchaser orwhile it is in use;

– the use of the vehicle after such deviceor element of design has been removedor rendered inoperative by any person.

Check the exhaust silencer and the silencerpipes, making sure that there are neithersigns of rust, nor holes and that the exhaustsystem works effectively.If the noise produced by the exhaust systemincreases, immediately contact your apriliaOfficial Dealer.

The instructions below must be followedwith the maximum care in order to avoidany injury to persons and damage to prop-erty and to the vehicle, caused by the fall-ing of the rider or the passenger from thevehicle and/or the falling or overturning ofthe vehicle itself.

WARNINGRisk of falling and overturning.Proceed with care.

The operations and movements required toget on and off the vehicle must be per-formed with complete freedom of move-ment and with the hands free from obstruc-tion caused by holding objects, the helmet,gloves or glasses.


The vehicle is provided with two stands:centre stand and side stand.

CAUTIONDo not start the engine with the vehiclepositioned on the centre stand. Engag-ing the gears may make you lose con-trol of the vehicle.Do not get on or let the passenger geton the vehicle if this is positioned onthe centre stand.It is forbidden to position the vehicle onthe centre stand while seated astridethe vehicle in riding position.

Get on and off the vehicle only from the leftside and always with extended side stand.

CAUTIONDo not apply the load of your weight orof the passenger’s weight onto the sidestand.

The stand has been designed to supportthe weight of the vehicle and a minimumload, without the rider and the passenger.

Getting on the vehicle into the riding posi-tion with extended side stand is permittedonly for the purpose of preventing the vehi-cle from falling or overturning and does notenvision the loading of the weight of therider and passenger onto the side stand.

While getting on and off, the weight of thevehicle may cause an unbalance and theconsequent loss of equilibrium, and the ve-hicle may fall or overturn.

NOTE The rider must always be the firstperson to get on the vehicle and the last toget off and it is the rider who controls thebalance and stability of the vehicle whenthe passenger gets on and off.

When getting on and off the vehicle, thepassenger must make careful movements,in order to maintain the balance of the vehi-cle and the rider.

NOTE The rider is responsible for in-structing the passenger how to safely geton and off the vehicle.

The vehicle is equipped with special pas-senger footrests to make it easier to get onand off the vehicle. The passenger must al-ways use the left footrest to get on and offthe vehicle.

Neither get off, nor try to get off the vehicleby jumping or stretching your leg down tothe ground. In both cases this would com-promise the stability and balance of the ve-hicle.

NOTE Bags or objects strapped to therear of the vehicle can represent an obsta-cle while getting on and off.

In any case, perform a controlled move-ment with your right leg, which must avoidstriking and safely pass the rear part of thefairing or the luggage without creating un-balance.


GETTING ON THE VEHICLE Grasp the handlebar correctly and get on

the vehicle without loading your weightonto the side stand.

NOTE If it is impossible for you to placeboth feet on the ground, place the right footon the ground (in case of unbalance, theleft side of the vehicle is prevented fromfalling over by the side stand) and keep theleft foot ready to rest on the ground.

Place both feet on the ground andstraighten the vehicle into riding positionwhile keeping it in balance.

NOTE The rider must not extract or at-tempt to extract the passenger footrestwhile seated astride the vehicle, becausethis might compromise the stability and bal-ance of the vehicle.

Have the passenger extract the two pas-senger footrests.

Instruct the passenger how to safely geton the vehicle.

Kick the side stand completely back us-ing your left foot.

GETTING OFF THE VEHICLE Choose a suitable parking area, see p.

51 (PARKING). Stop the vehicle, see p. 51 (STOPPING).

WARNINGMake sure that the parking surface isfree from obstacles, firm and flat.

With the left shoe heel, extend the sidestand completely by acting on the appro-priate lever.

NOTE If it is impossible for you to placeboth feet on the ground, place the right footon the ground (in case of unbalance, theleft side of the vehicle is prevented fromfalling over by the side stand) and keep theleft foot ready to rest on the ground.

Place both feet on the ground, keepingthe vehicle in balance in riding position.

Instruct the passenger how to safely getoff the vehicle.

CAUTIONRisk of falling and overturning.Make sure that the passenger has gotoff the vehicle.Do not load your weight onto the sidestand.

Incline the vehicle until the stand restson the ground.

Grasp the handlebar correctly and get offthe vehicle.

Rotate the handlebar completely left-wards.

Lift the passenger footrests.

CAUTIONMake sure that the vehicle is stable.

WARNINGBefore departure, always carry out apreliminary checking of the vehicle tomake sure that it functions correctlyand safely, see the following table (PRE-LIMINARY CHECKING OPERATIONS). The non-performance of these checkingoperations can cause severe personalinjuries or damages to the vehicle.Do not hesitate to consult your aprilia Offi-cial Dealer in case there is something youdo 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 ensures you muchmore safety.


Component Check Page

Front and rear disc brakes

Check the functioning, the idle stroke of the control levers, the fluid level and makesure there are no leaks. Check the wear of the pads. If necessary, top up the fluid tank.

29 (BRAKE FLUID - recommendations), 30 (DISC BRAKES), 31 (FRONT BRAKE), 33

(REAR BRAKE), 80 (CHECKING THE BRAKE PAD WEAR)

Accelerator Make sure that it works smoothly and that it is possible to open and close it com-pletely, in all steering positions. If necessary, adjust and/or lubricate it.

82 (ADJUSTING THE ACCELERATOR CONTROL)

Engine oil Check and/or top up if necessary. 37 (ENGINE OIL), 59 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP)

Wheel/tyres Check the tyre surface, the inflation pressure, wear and tear and any damage.Remove any foreign matter that may be stuck in the tread grooves. 36 (TYRES)

Brake levers Make sure that they work smoothly.Lubricate the articulations and adjust the stroke if necessary.

39 (ADJUSTING THE REAR BRAKE CONTROL LEVER CLEARANCE)

Clutch The idle stroke at the end of the clutch lever must be approximately 10 mm; the clutchmust work without jerking and/or slipping. 38 (CLUTCH)

Steering Make sure that the steering rotates smoothly, without any clearance or slackening. –

Side stand and centre stand m (supplied as standard equipment in the countries where required)

Make sure that it operates correctly. Make sure that when the stand is let up or downthere is no friction and that the spring tension brings it back to its normal position. If necessary, lubricate joints and hinges. Make sure that the safety switch operates correctly.

86 (CHECKING THE STAND), 91 (CHECKING THE SWITCHES)

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

Drive chain Check the slack. 70 (DRIVE CHAIN)

Fuel tankCheck the fuel level and top up, if necessary.Check the circuit for leaks. Make sure that the fuel cap is correctly closed.

27 (FUEL)

Coolant The coolant level in the expansion tank must be included between thmax e “MAX”and “MIN” marks.

34 (COOLANT), 35 (CHECKING AND TOPPING UP)

Engine stop switch ( - ) Make sure that it operates correctly. 19 [ENGINE STOP SWITCH (2 - 1)]

Lights, warning lights LED, horn, rear brake light switch end electric devices

Check the proper functioning of the acoustic and visual devices. Change the bulbs orintervene in case of failure.

87 (BATTERY) – 97 (CHANGING THE NUMBER PLATE BULB)


WARNINGDo not position any object inside thefront part of the fairing (between thehandlebar and the dashboard), in ordernot to hinder the rotation of the handle-bar and visibility toward the dashboard.

NOTE Before starting the engine, care-fully read chapter “safe drive”, see p. 5(SAFE DRIVE).

WARNINGExhaust gases contain carbon monox-ide, which is extremely noxious if in-haled. Avoid starting the engine in closed orbadly-ventilated rooms.The non-observance of this warningmay cause loss of consciousness oreven lead to death by asphyxia.

NOTE With the side stand down, the en-gine can be started only if the gears are inneutral; in this case, if you try to engagethe gears, the engine stops.

With the side stand up, it is possible to startthe engine either in neutral gear or with en-gaged gears and pulled in clutch lever.

Get on the vehicle in riding position, seep. 40 (GETTING ON AND OFF THE VE-HICLE).

Make sure that the stand is completelyup.

Not provided for . Make sure thatthe light switch (1) is in position “•”.

Make sure that the dimmer switch (2) isin position “'”.

Move the engine stop switch (3) to posi-tion “”.

Rotate the key (4) and move the ignitionswitch to position “”.

At this point the following lights come onon the dashboard:

– the engine oil pressure warning light“+” (5) (which will remain on until theengine is started);

– the diagnostic warning light “,” (6)(which will remain on for a few secondsafter the engine start).

The fuel pump will pressurize the fuel sup-ply circuit, sending out a hum for aboutthree seconds.

CAUTIONIf the low fuel warning light “-” (7)comes on on the dashboard, provide fortopping up as soon as possible, see p.27 (FUEL).


Operate the front brake lever completely. Pull the clutch lever (8) completely and

shift the gearbox lever (9) into neutral[green warning light “.” (10) on].

NOTE If the room temperature is low(near to or lower than 0°C), see p. 46(STARTING WITH COLD ENGINE).

CAUTIONTo avoid excessive consumption of thebattery, do not keep the start push but-ton “"” pressed for more than fifteenseconds. If the engine does not start in this lapseof time, wait ten seconds and press thestart push button “"” again.

Press the start push button “"” (11) with-out accelerating and release it as soonas the engine starts.

CAUTIONAvoid pressing the start push button“"” (11) when the engine is running,since you may damage the starter.

If the engine oil pressure warning light“+” (5) remains on, or if it comes onduring the normal operation of the en-gine, this means that the oil pressure inthe circuit is insufficient.In this case, stop the engine immediate-ly and contact an $'! !$ Official Dealer.

Keep at least one brake lever pulled anddo not accelerate until you start.

CAUTIONNever leave abruptly with cold engine. To reduce the emission of pollutingsubstances and the consumption of fu-el, warm the engine up by proceeding atlow speed for the first miles.

CAUTIONIf the diagnostic warning light “,” (6)comes on on the dashboard during thenormal operation of the engine, thismeans that the electronic unit has de-tected an anomaly. In many cases the engine keeps run-ning with limited functions; contact an$'! !$ Official Dealer immediately.


STARTING WITH COLD ENGINEWhen the room temperature is low (about0°C), it may be difficult to start the engineat the first attempt.

In this case: Rotate the cold start lever “)” (12) down-

wards.

Insist for at least ten seconds with thestart push button “"” (11) pressed and atthe same time moderately rotate thethrottle grip (13).

If the engine starts. Release the start push button “"” (11)

and the throttle grip (13). Rotate the cold start lever “)” (12) up-

wards. If the idling is unstable, twist the throttle

grip (13) slightly and frequently.

If the engine does not start.Wait a few seconds and repeat the coldSTART PROCEDURE.


WARNINGDo not position any object inside thefront part of the fairing (between the han-dlebar and the dashboard), in order notto hinder the rotation of the handlebarand visibility toward the dashboard.

NOTE Before departure, carefully readthe “safe drive” chapter, see p. 5 (SAFEDRIVE).

CAUTIONIf the low fuel warning light “-” (1) posi-tioned on the dashboard comes onwhile the vehicle is running, this meansthat 5 of fuel are still available in thetank.Provide for topping up as soon as pos-sible, see p. 27 (FUEL).

WARNINGIf you drive without passenger, makesure that the passenger footrests arefolded.While riding, keep your hands on thegrips and your feet on the footrests.

NEVER RIDE IN ANY POSITION OTHERTHAN THOSE INDICATED.

WARNINGIf you drive with a passenger, instructhim/her so that he/she does not createproblems during manouvres.

Before leaving, make sure that thestand is completely up.

To leave: Start the engine, see p. 44 (STARTING). Adjust the inclination of the rear-view

mirrors correctly, see p. 83 (REAR-VIEWMIRRORS).

CAUTIONWith the vehicle at rest, try to get ac-quainted with the use of the rear-viewmirrors. The reflecting surface is con-vex, therefore the objects seem to befarther away than they actually are.These mirrors offer a “wide-angle” viewand only experience will allow you toevaluate the distance of the followingvehicles correctly.

With released throttle grip (2) (Pos.A)and engine idling, pull the clutch lever (3)completely.

Engage the first gear, by pushing thegear lever (4) downwards.

Release the brake lever (pulled on thestarting).


WARNINGOn departure, the abrupt release of theclutch lever may cause the engine tostall or the vehicle to jerk forwards.

Never accelerate abruptly or excessive-ly when releasing the clutch lever, in or-der to prevent the clutch from “slip-ping” (slow release) or the front wheelfrom raising “rearing up” (quick re-lease).

Slowly release the clutch lever (3) and atthe same time accelerate by slightly turn-ing the throttle grip (2) (Pos.B).

The vehicle will start moving. Ride at reduced speed for the first miles,

in order to warm the engine up.

CAUTIONNever exceed the recommended rpm,see p. 50 (RUNNING-IN).

Increase the speed by gradually rotatingthe throttle grip (2) (Pos.B), without ex-ceeding the recommended rpm, see p.50 (RUNNING-IN).

To engage the second gear:

CAUTIONProceed quickly.Never ride the vehicle at too low rpm.

Release the throttle grip (2) (Pos.A), pullthe clutch lever (3) and lift the shifting le-ver (4). Release the clutch lever (3) andaccelerate.

Repeat the last two operations and shiftup.

CAUTIONIf the engine oil pressure warning light“+” (5) comes on during the normaloperation of the engine, this means thatthe engine oil pressure in the circuit isinsufficient.

In this case, stop the engine immediate-ly and contact an $'! !$ Official Dealer.

The downshifting should be carried outin the following situations: When riding downhill or when braking, in

order to increase the braking action byusing the compression of the engine.

When riding uphill, if the gear engaged isnot suitable to the speed (high gear,moderate speed) and the engine rpm de-creases.

CAUTIONShift the gears one by one; the simulta-neous downshifting of more than onegear may make you exceed the maxi-mum rpm (red line).Before and during the downshifting, re-lease the throttle grip and decelerate, inorder to avoid the “red line”.


To shift down, proceed as follows: Release the throttle grip (2) (Pos.A). If necessary, pull the brake levers mod-

erately and decrease the speed of thevehicle.

Pull the clutch lever (3) and lower theshifting lever (4) to shift down.

If the brake levers are pulled, releasethem.

Release the clutch lever and acceleratemoderately.

CAUTIONIf the pointer on the coolant temperatureindicator indicates a temperature over120 °C, stop the vehicle and let the en-gine idle for approximately two minutes,thus permitting the regular circulationof the coolant in the system; at thispoint, position the engine stop switchon “ ” and check the coolant level, seep. 34 (COOLANT).

If the situation on the dashboard re-mains the same after the coolant levelhas been checked, do not start the vehi-cle and contact an $'! !$ Official Deal-er.Do not position the ignition key on “ ”,since the cooling fan would stop inde-pendently of the coolant temperatureand in this case the temperature wouldincrease even further.

If the diagnostic warning light “,”comes on on the dashboard during thenormal operation of the engine, thismeans that the electronic unit has de-tected an anomaly.

In many cases the engine keeps run-ning with limited functions; contact an$'! !$ Official Dealer immediately.

To avoid the overheating of the clutch,keep the engine running with vehicle atrest, engaged gears and pulled clutchlever for the shortest possible time.

WARNINGAvoid opening and closing the throttlegrip repeatedly and continuously, sothat you do not accidentally lose controlof the vehicle. If you have to brake,close the throttle and put on bothbrakes in order to obtain uniform decel-eration, properly exerting pressure onthe braking parts.

By putting on the front brake only or therear brake only, you reduce the brakingforce considerably, thus running the

risk of locking one wheel and conse-quently losing grip.

If you stop uphill, decelerate completelyand use the brakes only to keep the ve-hicle steady.The use of the engine to keep the vehi-cle steady may cause the overheating ofthe clutch.

Before beginning to turn, slow down orbrake driving at moderate and constantspeed or accelerating slightly; avoidbraking at the last moment: it would bevery easy to skid.

If the brakes are operated continuouslyon downhill stretches, the friction sur-faces may overheat, thus reducing thebraking efficiency. Exploit the enginecompression and shift down by puttingon both brakes intermittently. Never drive downhill with the engineoff!

When visibility is insufficient, switch onthe low beam even during the day, in or-der to make your vehicle more visible.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.

WARNINGPay the utmost attention to any obsta-cle or variation of the ground. Uneven roads, rails, manhole covers,indications painted on the road surface,


building site metal plates become ratherslippery by rain. For this reason allthese obstacles have to be carefullyavoided, driving smoothly and leaningthe vehicle as little as possible.

Always use the turn indicators in timewhen you intend to change lane or di-rection, avoiding sharp and dangerousmovements.Switch off the direction indicators assoon as you have changed direction.

Be extremely careful when you overtakeother vehicles or are overtaken. In case of rain, the water cloud createdby big vehicles reduces visibility; theair shift may make you lose control ofthe vehicle.

The running-in of the engine is essential toensure its duration and correct functioning. If possible, drive on hilly roads and/orroads with many bends, so that the engine,the suspensions and the brakes undergo amore effective running-in.During running-in, change speed. In this way the components are first “load-ed” and then “relieved” and the engineparts can thus cool down. Even if it is important to stress the enginecomponents during running-in, take carenot to exceed.

NOTE Only after the first 2000 km (1250mi) of running-in you can expect the bestperformance levels from the vehicle.

Keep to the following indications:

Do not open the throttle completely if thespeed is low, both during and after therunning-in.

During the first 500 km (312 mi) put onthe brakes with caution, avoiding sharpand prolonged brakings. This ensures acorrect bedding-in of the pads on thebrake disc.

During the first 500 km (312 mi) neverexceed 4000 rpm.

When the total number of km covered bythe vehicle is included between 500 km(312 mi) and 1000 km (625 mi), neverexceed 5000 rpm.

WARNINGAfter the first 1000 km (625 mi), have an$'! !$ Official Dealer carry out thechecks indicated in the column “Afterrunning-in” of the regular service inter-vals chart, see p. 56 (REGULAR SERV-ICE INTERVALS CHART), in order toavoid hurting yourself or other peopleand/or damaging the vehicle.

Between the first 1000 (625 mi) and2000 km (1250 mi) drive more briskly,change speed and use the maximum ac-celeration only for a few seconds, in or-der to ensure better coupling of the com-ponents); never exceed 5500 rpm (seetable).

After the first 2000 km (1250 mi) you canexpect better performance from the en-gine, however, without exceeding themaximum allowed (6250 rpm).

Engine maximum rpm recommended

Mileage km (mi) rpm

0 – 500 (0 – 312) 4000

500 – 1000 (312 – 625) 5000

1000 – 2000 (625 – 1250) 5500

over 2000 (1250) 6250


WARNINGIf possible, avoid stopping abruptly,slowing down suddenly and braking atthe last moment.

Release the throttle grip (1) (Pos.A),gradually put on the brakes and at thesame time shift down in order to de-crease the speed, see p. 47 (DEPAR-TURE AND DRIVE).

Once the speed has decreased, beforestopping the vehicle: Pull the clutch lever (2) in order to pre-

vent the stopping of the engine.

When the vehicle has come to rest: Shift the gear lever to neutral (green

warning light “.” on). Release the clutch lever (2). In case of a brief stop, keep at least one

brake on.

It is very important to choose a suitableparking area, respecting the road signs andthe indications given below.

WARNINGPark the vehicle on firm and flat ground,to prevent it from falling down.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 notleave the vehicle unattended when theengine is on or the key is inserted intothe ignition switch.Do not get too near the cooling fan evenif it is not in operation, since it may startand parts of clothes, hair, etc. may getentangled in it.

WARNINGThe fall or excessive inclination of thevehicle may cause the fuel to flow out ofthe tank.

The fuel used for internal combustionengines is extremely inflammable andin particular conditions it can becomeexplosive.

CAUTIONDo not apply the load of your weight orof the passenger’s weight onto the sidestand.

To park the vehicle: Choose a suitable parking area. Stop the vehicle, see p. 51 (STOPPING). Move the engine stop switch (3) to posi-

tion “ ”. Rotate the key (4) and move the ignition

switch (5) to position “ ”.


WARNINGWhen getting on or off the vehicle, keepto the instructions given, see p. 40(GETTING ON AND OFF THE VEHICLE).

Following the indications, wait until thepassenger has got off the vehicle beforedismounting.

Lock the steering, see p. 21 (STEERINGLOCK) and extract the key.

WARNINGMake sure that the vehicle is stable.

SIDE STANDTo place the vehicle on the side standwhile seated astride the vehicle, see p. 40(GETTING ON AND OFF THE VEHICLE).If any manoeuvre (for example, moving thevehicle) required the lifting of the stand, toplace the vehicle on the stand again, pro-ceed as follows:


Choose a suitable parking area, see p.51 (PARKING).

Grasp the left grip (1) and the handle (2).

Press the side stand with your right footand extend it completely (3).

Incline the vehicle until the stand restson the ground.

Steer the handlebar completely left-wards.



CENTRE STAND (suppl ied asstandard equipment in the countrieswhere required)

WARNINGIt is forbidden to position the vehicle onthe centre stand while seated astridethe vehicle in riding position.


Choose a suitable parking area, see p.51 (PARKING).

Grasp the left grip (1) and the handle (2).

CAUTIONThe lowering of the side stand is sug-gested, for safety reasons, in order toprevent the vehicle from falling down oroverturning in case of unbalance.

NOTE Do not let the side stand touchthe ground. Keep the vehicle in vertical po-sition.

Press the side stand with your right footand extend it completely (3).

Push down the lever (4) (Pos.A) of thecentre stand and make it rest on theground.

CAUTIONProceed with care.The positioning of the vehicle on thecentre stand may be difficult, since thevehicle is very heavy. Release the grip(1) and the handle (2) only after posi-tioning the vehicle on the stand.

Load your weight on the lever (4)(Pos.B) of the centre stand and at thesame time move your centre of gravitytowards the rear part of the (Pos.C) vehi-cle.


Let the side stand up.


NEVER leave the ignition key (1) insertedand always use the steering lock “!”.

Park the vehicle in a safe place, possibly ina garage or a protected place.When possible, use an additional anti-theftdevice.Make sure that all documents are in orderand the road tax has been paid.

Write down your personal data and tele-phone number in this page, to facilitate theidentification of the owner in case of findingafter theft.

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

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

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

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

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

NOTE Very often stolen vehicles areidentified thanks to the data written in theuse/maintenance manual.


Carefully read p. 2 (SAFETY WARN-INGS), (TECHNICAL INFORMATION)and (WARNINGS - PRECAUTIONS -GENERAL ADVICE).

WARNINGRisk of fire.Keep fuel and other flammable sub-stances away from the electrical com-ponents.

Before beginning any maintenance op-eration or any inspection of the vehicle,stop the engine, extract the key fromthe ignition block, wait until the engineand the exhaust system have cooleddown and if possible lift the vehicle bymeans of the proper equipment, on firmand flat ground.

WARNINGBefore proceeding, make sure that theroom in which you are working is prop-erly ventilated.

Keep away from the red-hot parts of theengine and of the exhaust system, in or-der to avoid burns.

Do not hold any mechanical piece orother parts of the vehicle with yourmouth: the components are not edibleand some of them are noxious or eventoxic.

CAUTIONIf not expressly indicated otherwise, forthe reassembly of the units repeat thedisassembly operations in reverse or-der.


Routine maintenance operations can usu-ally be carried out by the user, but some-times specific tools and specific technicalskills may be required. In case periodic maintenance operations,assistance or technical advice are needed,contact an aprilia Official Dealer, who willensure you prompt and accurate servicing.

Ask your aprilia Official Dealer to test thevehicle on the road after a repair or period-ic maintenance operation.In any case, personally carry out the “Pre-liminary checking operations” after anymaintenance operation, see p. 43 (PRE-LIMINARY CHECKING OPERATIONS).


OPERATIONS TO BE CARRIED OUT BYTHE $'! !$ Official Dealer (WHICHCAN BE CARRIED OUT EVEN BY THEUSER).

Key = check and clean, adjust, lubricate or

change, if necessary; = clean; = change;

= adjust.


(*) = Check every two weeks or accordingto the intervals indicated.

(**) = (provided as standard equip-ment in the countries where re-quired).

CO = carbon monoxide.

ComponentAfter run-

ning-in [1000 km (625 mi)]

Every 6000 km (3750 mi) or 12 months


Battery – Terminal fastening – Electrolyte level –

Spark plug –

Air cleaner –

Engine oil filter –Engine oil filter (on oil tank) –

Fork –

Light operation/direction – –Light system

–Safety switchesBrake fluid – –Coolant – –

Engine oil (*) –Side bag coupling pins (**) – –Tyres every 1000 km (625 mi): Tyre pressure (*) every 1000 km (625 mi): Engine idling rpm and CO –Securing locks for the side bags and the rear case (**) – –

Diagnostic warning light at every start:Engine oil pressure Warning light at every start:Flexible couplings upon each final transmission change : Drive chain tension and lubrication every 500 km (375 mi):

Brake pad wear before every trip and every

2000 km (1250 mi):Flexible coupling wear and flexible cou-pling unit slack – –


OPERATIONS TO BE CARRIED OUT BYTHE $'! !$ Official Dealer

Key = check and clean, adjust, lubricate or

change, if necessary; = clean; = change;

= adjust.


CO = carbon monoxide.

ComponentAfter running-

in [1000 km (625 mi)]

Every 6000 km (3750 mi)

or 12 months


Rear shock absorber – –

Battery – Terminal fastening – –

Carburation, CO adjustment –

Timing chain – –

Transmission cables and controls –

Wheel centering – –

Rear suspension linkage bearings – –

Steering bearings and steering clearance –

Wheel bearings –

Brake discs –

Fuel pump filter every 15000 km (9375 mi):

General running of the vehicle –

Clutch clearance –

Adjusting the valve clearance –

Braking systems –

Cooling system – –

Brake fluidevery 2 years:

Coolant

Fork oil every 12000 km (7500 mi):

Fork oil seals after the first 30000 km (18750 mi) and successively every 22500 km (14000 mi):

Brake pads if worn:

Wheel/Tyres

–

Nut, bolt, screw tightening –

Suspensions and attitude –

Spoke tension –

Final transmission (chain, crown and pinion) – –

Fuel pipes – every 4 years:

Clutch wear – –


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 pur-chase of spare parts.

NOTE Do not alter the identificationnumbers if you do not want to incur severepenal and administrative sanctions. In par-ticular, the alteration of the frame numberresults in the immediate invalidity of theguarantee.

FRAME NUMBERThe frame number (1) is stamped on theright side of the steering column.Frame no.

ENGINE NUMBERThe engine number (2) is stamped on therear part of the engine, near the pinion.Engine no.

/

CAUTIONRemove ONLY the clamps indicated inthe maintenance procedures.This text is not to be intended as an au-thorization to arbitrarily remove theclamps present on the vehicle.

WARNINGBefore removing a clamp, make surethat the removal does not involve anyfluid leakage; if so, provide for prevent-ing such leakages and protect the com-ponents positioned near the joint.

CLICK CLAMPSFor the removal it is sufficient to use simplepliers, while for the installation it is neces-sary to use a special tool (see below).Before removing a clamp, prepare the ma-terial necessary for the correct reassembly.

NOTE Have the appropriate special tool to hand:– clamp installation pliers, see p. 23 (SPE-

CIAL TOOLS ).

CAUTIONUpon installation, replace the clickclamp that has been removed with anew one having the same dimensions,to be requested to an $'! !$ OfficialDealer.Do not attempt to reinstall the removedclick clamp, since it is unusable.

Do not replace the removed click clampwith a screw clamp or with other typesof clamp.

CAUTIONProceed with care, in order not to dam-age the joint components.

Work with the pliers on the head of theclick clamp, forcing until you release it.

SCREW CLAMPSFor the removal and installation it is suffi-cient to use a simple screwdriver.

CAUTIONCheck the conditions of the clamp andif necessary replace it with a new one ofthe same type and dimensions, to be re-quested to an $'! !$ Official Dealer.When fastening the clamp, make surethat the joint is sufficiently stable.


Carefully read p. 37 (ENGINE OIL) and p.55 (MAINTENANCE).Periodically check the engine oil level,change the oil after the first 1000 km (625mi) and successively every 6000 km (3750mi) or 12 months, see p. 60 (CHANGINGTHE ENGINE OIL AND THE OIL FILTER).

For the check, proceed as follows:

NOTE To warm the engine and have theengine oil reach the operating temperature,do not let the engine idle with the vehicle atrest. According to the correct procedure, itis advisable to carry out the check after atrip of after covering approximately 15 km(10 mi) on a road outside town (this is suffi-cient for the engine oil to reach the operat-ing temperature).

Stop the engine, see p. 51 (STOPPING). Keep the vehicle in vertical position, with

the two wheels resting on the ground. Insert the plug-dipstick (1) completely in

the inlet hole (2), without screwing it. Extract the plug-dipstick (1) again and

read the oil level on the dipstick:MAX = maximum levelMIN = minimum level.The difference between “MAX” and “MIN”amounts to approximately 300 cm. The level is correct when the oil almost

reaches the “MAX” mark.

CAUTIONNever exceed the “MAX” mark, norleave the oil below the “MIN” mark, inorder to avoid serious damage to theengine.

If necessary, top up the engine oil byproceeding as follows:

CAUTIONDo not put additives or other substanc-es into the oil.If you use a funnel or other similaritems, make sure that they are perfectlyclean.


After extracting the plug-dipstick (1), topup the tank through the inlet hole (2) untilreaching the correct level, see p. 104(LUBRICANT CHART).


CAUTIONThe engine oil and the oil filter changeoperations may be difficult for unskilledoperators. If necessary, contact your $'! !$ Offi-cial Dealer. If you want to perform these operationspersonally, keep to the following in-structions.Carefully read p. 37 (ENGINE OIL) and p.55 (MAINTENANCE).

Periodically check the engine oil level, seep. 59 (CHECKING THE ENGINE OIL LEV-EL AND TOPPING UP) change the oil afterthe first 1000 km (625 mi) and successivelyevery 6000 km (3750 mi) or 12 months.

CAUTIONIf the vehicle is used in dusty areas,change the oil more frequently.

WARNINGWhen warmed up, the engine containshot oil; therefore, while carrying out theoperations described here below beparticularly careful, in order to avoidburns.

To change, proceed as follows:

NOTE To warm the engine and have theengine oil reach the operating temperature,do not let the engine idle with the vehicle atrest. According to the correct procedure, itis advisable to carry out the check after atrip of after covering approximately 15 km(10 mi) on a road outside town (this is suffi-cient for the engine oil to reach the operat-ing temperature).

Stop the engine, see p. 51 (STOPPING). Keep the vehicle in vertical position, with

the two wheels resting on the ground. Remove the oil sump guard, see p. 73

(REMOVING THE OIL SUMP GUARD). Position a container (1) with more than

2500 cm capacity in correspondencewith the drain plug (2) positioned on thetank.

Unscrew and remove the drain plug (2)positioned on the tank.

Unscrew and remove the plug-dipstick(3).

Drain the oil and let it drip into the con-tainer (1) for a few minutes.

Check and if necessary replace the seal-ing washer of the drain plug (2) posi-tioned on the tank.

Screw and tighten the drain plug (2) onthe tank.

Drain plug (2) driving torque: 22 Nm (2.2kgm). Move the container (1) and position it un-

der the engine base, in correspondencewith the drain plug positioned on the en-gine (4).

Unscrew and remove the drain plug posi-tioned on the engine (4).

Drain the oil and let it drip into the con-tainer (1) for a few minutes.


CAUTIONDo not dispose of the oil in the environ-ment. Put it in a sealed container andtake it to the filling station where youusually buy it or to an oil salvage cent-er.

Remove the metal residues from thedrain plug (4) magnet.

Screw and tighten the drain plug (4).Driving torque of the drain plug (4) posi-tioned on the engine: 40 Nm (4.0 kgm).

Clean the parts dirty with oil with a cloth.

CHANGING THE ENGINE OIL FILTERChange the engine oil filter after thefirst 1000 km (625 mi) and successivelyevery 6000 km (3750 mi) or 12 months(on each engine oil change). Unscrew the two screws (5) and remove

the cover (6). Remove the engine oil filter (7).

CAUTIONDo not use filters that have alreadybeen used.

Spread an oil film on the sealing ring (8)of the new engine oil filter.

Fit the new engine oil filter. Put back the cover (6), screw and tighten

the two screws (5).

CLEANING THE ENGINE OIL FILTER ONTHE TANKClean the engine oil filter (9) on the tankafter the first 1000 km (625 mi) and suc-cessively every 12000 km (7500 mi) (orevery two engine oil changes). Remove the fuel tank, see p. 72 (RE-

MOVAL OF THE FUEL TANK).

NOTE Have the appropriate special tool to hand:– clamp installation pliers, see p. 23 (SPE-

CIAL TOOLS ).

CAUTIONUpon installation, replace the clickclamp that has been removed with anew one having the same dimensions,to be requested to an $'! !$ OfficialDealer.Do not attempt to reinstall the removedclick clamp, since it is unusable.Do not replace the removed click clampwith a screw clamp (10) or with othertypes of clamp.

Release the click clamp (11). Disconnect the pipe (12).


Pull the engine oil filter (9) and clean itwith a jet of compressed air.

Check the seal of the engine oil filter (9)positioned on the tank; screw and tightenit.

Engine oil filter (9) driving torque: 35Nm (3.5 kgm).

Connect the pipe (12) and install a newclick clamp.

CAUTIONDo not put additives or other substanc-es into the oil.

If you use a funnel or other similaritems, make sure that they are perfectlyclean.


Pour about 1600 cm of engine oilthrough the filling opening (13), see p.104 (LUBRICANT CHART).

Screw the plug-dipstick (3). Put back the fuel tank, see p. 72 (RE-

MOVAL OF THE FUEL TANK). Put back the oil sump guard, see p. 73

(REMOVING THE OIL SUMP GUARD). Start the engine, see p. 44 (STARTING)

and let it idle for about one minute, in or-der to ensure the filling up of the engineoil circuit.

Check the oil level and top up if neces-sary, see p. 59 (CHECKING THE EN-GINE OIL LEVEL AND TOPPING UP).

Check the air cleaner every 6000 km (3750mi) or 12 months, change it every 12000 km(7500 mi) or more frequently if the vehicle isused on dusty or wet roads.It is possible to clean the air cleaner partiallyafter using the vehicle on this kind of roads.

CAUTIONThe partial cleaning of the filter does notexclude or postpone the replacement ofthe filter itself. Do not start the engine ifthe air cleaner has been removed. Do notclean the filtering element with petrol orsolvents, since they may cause a fire inthe fuel supply system, with serious dan-ger for the persons in the vicinity and forthe vehicle.

DO NOT DISPOSE OF POLLUTING SUB-STANCES OR COMPONENTS IN THEENVIRONMENT.


REMOVAL Remove the rider saddle, see p. 21 (UN-

LOCKING/LOCKING THE SADDLE). Rotate the air conveyor (1) clockwise,

then lift and remove it. Check the conditions of the gasket (2)

and change it if it is damaged. Extract the air cleaner (3).

CAUTIONPlug the opening with a clean cloth, inorder to prevent any foreign matter toget ito the suction ducts.

Make sure that the filtering element ispositioned correctly, in such a way asto prevent non-filtered air from entering.

Remember that the untimely wear of thepiston segments and the cylinder maybe caused by a faulty or uncorrectly po-sitioned filtering element.

PARTIAL CLEANING

CAUTIONDo not press or strike the metal net ofthe air cleaner (3).Do not use screwdrivers or alike.

Seize the air cleaner (3) vertically andstrike it more than once on a clean sur-face.

If necessary, clean the air cleaner (3)with a compressed air jet (directing itfrom the inside towards the outside ofthe filter).

CAUTIONWhen cleaning the filtering element,make sure that there are no tears. Otherwise, change the filtering element.

Clean the outer part of the air cleaner (3)with a clean cloth.

CHANGING

CAUTIONDo not use filters that have alreadybeen used.

Replace the air cleaner (3) with a newone of the same type.

Put back the saddle, see p. 21 (UNLOCK-ING/LOCKING THE SADDLE).

Every 6000 km (3750 mi) or 12 months,remove the plug (4). Empty its contentinto a container and deliver it to a salvagecentre.


CAUTIONThe disassembly and reassembly of thefront wheel may be difficult for unskilledoperators. If necessary, contact your $'! !$ Offi-cial Dealer.If you want to perform these operationspersonally, keep to the following in-structions.Carefully read p. 55 (MAINTENANCE).While disassembling and reassemblingthe wheel, be careful not to damage thebrake pipes, the disc and the pads.

WARNINGRiding with damaged rims may be dan-gerous for the rider, other persons andthe vehicle.Check the conditions of the wheel rimand change it if it is damaged.

NOTE Weight without driver (ready forstarting): 200 kg.

DISASSEMBLY Position the vehicle on the appropriate

front support stand, see p. 69 (POSI-TIONING THE VEHICLE ON THEFRONT SUPPORT STAND ).

Put a support (1) under the tyre, in sucha way as to keep the wheel in its positionafter loosening it.

CAUTIONMake sure that the vehicle is stable.

Partially unscrew the two wheel pinclamp screws (2) (right side).

Unscrew the wheel pin (3) completely.

NOTE To facilitate the extraction of thewheel pin, slightly raise the wheel.

Support the front wheel and manuallywithdraw the wheel pin (3).

Take the left spacer ring (4) (left side).

NOTE Upon removal, check the positionof the tachometer/odometer transmissioncable, since this will be useful for the reas-sembly.

Remove the speedometer/odometercontrol (5) from the wheel seat.

NOTE Remove the wheel, withdrawingthe disc from the brake caliper with care.

Remove the wheel by withdrawing it fromthe front.

CAUTIONNever pull the front brake lever after re-moving the wheel, otherwise the caliperpistons may go out of their seats, thuscausing the outflow of the brake fluid. Inthis case consult your $'! !$ OfficialDealer, who will carry out the propermaintenance operation.


REASSEMBLY Spread a film of lubricating grease on the

whole length of the wheel pin (3), greasethe inside of the speedometer/odometercontrol (5), see p. 104 (LUBRICANTCHART).

Position the tang of the speedome-ter/odometer control (5) in the appropri-ate seat of the wheel hub.

Position the odometer control seat cor-rectly, in correspondence with the spe-cial antirotation pin (6).

CAUTIONWhile reassembling the wheel, be care-ful not to damage the brake pipes, discsand pads.

Position the wheel between the fork rodson the support (1).

CAUTIONProceed with care while inserting thedisc in the brake caliper.

WARNINGDanger of injury. Do not introduce yourfingers to align the holes.

Move the wheel until its central hole andthe holes on the fork are aligned.

Position the spacer ring (4) between thewheel hub and the fork left rod.

Introduce the wheel pin (3) completelyfrom the right side and tighten it.

wheel pin driving torque (3): 80 Nm (8kgm).

Remove the support (1) that upon disas-sembly was put under the tyre.

WARNINGDue to the weight and dimensions ofthe vehicle, the following operationmust be performed by two persons.

NOTE Weight without driver (ready forstarting): 200 kg.

Remove the front support stand, see p. 69(POSITIONING THE VEHICLE ON THEFRONT SUPPORT STAND ).

Remove the rear support stand, see p. 69(POSITIONING THE VEHICLE ON THEREAR SUPPORT STAND ).

With pulled front brake lever, press thehandlebar repeatedly, thrusting the forkdownwards. In this way the fork rods willsettle properly.


Tighten the two wheel pin clamp screws(2) (right side).

Wheel pin clamp screw driving torque(2): 12 Nm (1.2 kgm).

Make sure that the following componentsare not dirty:

– tyre;– wheel;– brake discs.

WARNINGAfter reassembly, pull the front brake le-ver repeatedly and check the correctfunctioning of the braking system.Have the driving torques, centering andbalancing of the wheel checked by your$'! !$ Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.


CAUTIONThe disassembly and reassembly of therear wheel may be difficult for unskilledoperators. If necessary, contact your $'! !$ Offi-cial Dealer.

If you want to perform these operationspersonally, keep to the following instruc-tions.

Carefully read p. 55 (MAINTENANCE).

WARNINGBefore carrying out the following opera-tions, let the engine and the silencercool down until they reach room tem-perature, in order to avoid burns.

WARNINGRiding with damaged rims may be dan-gerous for the rider, other persons andthe vehicle.Check the conditions of the wheel rimand change it if it is damaged.

DISASSEMBLY Position the vehicle on the appropriate

rear support stand, see p. 69 (POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND ).

Put a support (1) under the tyre, in sucha way as to keep the wheel in its positionafter loosening it.

Lock the rotation of the wheel pin (2) withthe appropriate key.

Unscrew and remove the nut (3) and re-trieve the washer (4).

Wheel nut (3) driving torque: 100 Nm (10kgm).

NOTE To facilitate the extraction of thewheel pin, slightly raise the wheel.

Withdraw the wheel pin (2) from the leftside and take the washer (5).

NOTE Lower the drive chain (6) outsidethe crown gear (7).

Make the wheel advance and release thedrive chain (6) from the crown gear (7).

Withdraw the wheel from the rear forkfrom behind, carefully withdrawing thedisc from the brake caliper.


CAUTIONDo not operate the rear brake lever afterremoving the wheel, since the pins maygo out of their seats and cause brakefluid leakages. In this case consult your$'! !$ Official Dealer, who will carryout the proper maintenance operation.

NOTE The support plate (8) completewith brake caliper (9) remains positionedon the left side of the rear fork.

Proceed with care. If the final drive unit(10) is installed on the flexible couplingholder (11), do not overturn or rotate therear wheel in horizontal position on the rearsprocket side (A), since the final drive unitwould come off and fall down, with the riskof damaging the rear sprocket (7).

NOTE The removal of the final drive unitisn’t necessary if the wheel is in the normalrunning position (vertical) or in horizontalposition with the rear sprocket facing up-wards and in both cases secured againstoverturning.

NOTE Do not unscrew the six nuts (12).The whole final drive unit must be with-drawn from the flexible coupling holder.

Withdraw the final transmission unit (10),keeping it parallel to the wheel axis.

Remove the four flexible couplings (13)from the flexible coupling holder (11).

NOTE Check the conditions of the fourflexible couplings (13); if they are damagedor excessively worn, change them, see p.56 (REGULAR SERVICE INTERVALSCHART).

REASSEMBLY

NOTE Insert the final transmission unit,parallel to the wheel axis, introducing thedrive pins in the relevant seats, between aflexible coupling and the other.

Position the four flexible couplings (13) inthe relevant seats in the flexible couplingholder (11).

Insert the final drive unit in the flexiblecoupling holder (11).


CAUTIONBefore proceeding with the reassembly,make sure that support plate (8) of thebrake caliper (9) is positioned correctly;the plate slot must be inserted in the ap-propriate stop pin in the inner part ofthe rear fork right rod.Insert the disc in the brake caliper care-fully.

Position the wheel between the rear forkrods on the support (1).

WARNINGDo not introduce your fingers betweenthe chain and the crown gear.

Make the wheel advance and positionthe drive chain (6) on the crown gear (7).

Uniformly apply a moderate quantity ofgrease on the wheel pin (2), see p. 104(LUBRICANT CHART).

WARNINGDanger of injury. Do not introduce your fingers to alignthe holes.

Move the wheel backwards, until its cen-tral hole and the holes on the rear forkare aligned.

Rotate the support plate (8), completewith brake caliper (9) and with fulcrum onthe stop pin, until it is aligned with theholes.

Insert the washer (5) in the wheel pin (2). Introduce the wheel pin (2) completely

from the left side.

NOTE Make sure that the wheel pin (2)is completely inserted.

Position the washer (4) and tighten thewheel nut (3) manually.

Lock the rotation of the wheel pin (2) withthe appropriate key and tighten the nut(3).

Wheel nut driving torque (2–3): 100 Nm(10 kgm).

Make sure that the following componentsare not dirty:

– tyre;– wheel;– brake disc.

CAUTIONAfter reassembly, pull the rear brake le-ver repeatedly and check the correctfunctioning of the braking system.

Have the driving torques, centering andbalancing of the wheel checked by your$'! !$ Official Dealer, in order to avoidaccidents that may be harmful for youand/or other people.


Loosen the knob (1). Withdraw the fork support (2) and extract

it from the stand seat. Insert the support pin (3). Repeat the previous operations on the

opposite side of the stand. Remove the two drive chain guards, see

p. 74 (REMOVING THE DRIVE CHAINGUARDS).

Pull the front brake lever (4) completely,then put a small piece of cardboard (5)on the grip and keep the front brake leverpulled by holding it against the grip bymeans of a plastic band (6).

WARNINGRaise the vehicle by means of the tworear fork arms only.

Insert the stand from the rear side of thevehicle and position it so that the two

support pins (3) rest on the lower part ofthe rear fork rods:

– the right support (Pos.A);– the left support (Pos.B). Withdraw the support pins (3) and make

them hit against the rear fork. Tighten the two knobs (1). Push the stand forward (7) until the sup-

port pin (3) rests, on the right side, againstthe rear fastening plate of the lower chainguard.

NOTE Have someone help you keep thevehicle in vertical position with the twowheels on the ground.

Rest one foot on the rear part of thestand (7).

Push the stand (7) downwards until itreaches the end of its stroke (see figure).

NOTE To position the vehicle on thefront support stand it is necessary to usethe appropriate rear support stand .

Position the vehicle on the appropriaterear support stand , p. 69 (POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND ).

Position the two appropriate washers (8)on the upper ends (9) of the stand.

Insert the two ends of the stand (9) in thetwo holes (10) positioned on the lowerends of the front fork.

Rest one foot on the front part of thestand (11).

Push the stand (11) downwards until itreaches the end of its stroke (see figure).


Carefully read p. 55 (MAINTENANCE).The vehicle is equipped with an endlesschain, in which a ring link joint is not used.

CAUTIONAn excessive slackening of the chainmay cause noise or make the chain rat-tle, with consequent wear of the shoeand of the chain guide plate.Periodically check the slack and adjustit if necessary, see p. 70 (ADJUST-MENT).To change the chain, contact an $'! !$Official Dealer, who will ensure youprompt and accurate servicing.Incorrect maintenance may cause theuntimely wear of the chain and/or dam-ages to the pinion and/or the crown.

CAUTIONCarry out the maintenance operationsmore frequently if you use the vehicle indifficult conditions or on dusty and/ormuddy roads.

CHECKING THE SLACK

To check the slack, proceed as follows: Stop the engine, see p. 51 (STOPPING). Position the vehicle on the appropriate

rear support stand, see p. 69 (POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND ).

Position the shifting lever in neutral. Make sure that the vertical oscillation, in

an intermediate point between pinionand crown in the lower part of the chain,is included between 35–45 mm.

Rotate the wheel manually, in such away as to check the vertical oscillation ofthe chain even in other positions; theslack must be constant in all the wheelrotation phases.

CAUTIONIf in some positions the slack is higherthan in others, this means that there arecrushed or seized links; in this case,contact an $'! !$ Official Dealer. Toprevent the risk of seizures, lubricatethe chain frequently, see p. 71 (CLEAN-ING AND LUBRICATION).

If the clearance is slack is uniform, buthigher than 45 mm or lower than 35 mm,adjust it, see p. 70 (ADJUSTMENT).

ADJUSTMENTIf after the check it is necessary to adjustthe chain tension, slacken the chain to in-crease the slack, tighten the chain to de-crease it.

Position the vehicle on the appropriaterear support stand, see p. 69 (POSI-TIONING THE VEHICLE ON THE REARSUPPORT STAND ).


Loosen the nut (2).


NOTE Numbered reference marks con-nected with the movement of the adjusters(3) (4) are provided for the wheel center-ing.These reference marks can be seen bylooking inside two slots (5) (6) positionedon the rear fork rods, before the wheel pin. Act on the left (3) and right (4) adjusters

and adjust the chain slack, making sure,on both sides of the vehicle, that thesame reference marks can be seenwhen looking inside the slots (5) (6).


Tighten the nut (2).

Wheel nut driving torque (1) (2): 100 Nm(10 kgm).

Check the chain slack, see p. 70(CHECKING THE SLACK).

CHECKING THE DRIVING CHAIN, PIN-ION AND SPROCKET WEARFurther, check the chain and sprocketsand make sure that they do not present:– damaged rollers;– loose pins;– dry, rusty, crushed or seized links;– excessive wear;– lacking O rings;– sprocket or teeth excessively worn or

damaged.

CAUTIONIf the chain rollers are damaged, thepins are loose and/or the O rings aredamaged or lacking, it is necessary tochange the whole chain unit (bothsprockets and chain).

CAUTIONLubricate the chain frequently, espe-cially if there are dry or rusty parts. The crushed or seized links must be lu-bricated and made work again.If this is not possible, contact an $'! !$ Official Dealer, who will provide forchanging the chain.

Finally, check the wear of the rear forkprotection shoe.

CLEANING AND LUBRICATION

CAUTIONThe drive chain is provided with O ringsamong the links, in order to keep thegrease inside them. Carry out the adjustment, lubrication,cleaning and change of the chain withgreat care.

Never wash the chain with water jets,steam jets, high-pressure water jets andhighly inflammable solvents.

Wash the chain with naphtha or kero-sene. If it tends to rust quickly, intensifythe maintenance intervals.

Lubricate the chain every 500 km (312 mi)or whenever necessary. After washing the chain and letting it dry,

lubricate it with spray grease for chainsprovided with sealing rings, see p. 104(LUBRICANT CHART).

CAUTIONThe lubricants for chains available onthe market may contain substances thatare dangerous for the rubber sealingrings of the chain.

NOTE Do not use the vehicle soon afterlubricating the chain, since due to the cen-tr ifugal force the lubricant would besprayed outwards and dirty the surround-ing areas.


Carefully read p. 27 (FUEL) and p. 55(MAINTENANCE).

WARNINGRisk of fire.Wait until the engine and the exhaust si-lencer have completely cooled down.

Fuel vapours are noxious for yourhealth.Before proceeding, make sure that theroom in which you are working is prop-erly ventilated. Do not inhale fuel vapours. Do not smoke and do not use nakedflames.

DO NOT DISPOSE OF FUEL IN THE EN-VIRONMENT.

Turn the ignition switch to position “ ”. Remove the rider saddle, see p. 21 (UN-

LOCKING/LOCKING THE SADDLE). Unscrew and remove the centre screw

(1). Take the washer (2) and the rubber pad

(3)./Unscrew and remove the three screws

(4). Disconnect the electric connector (5)

from the fuel pump.

CAUTIONUpon reassembly, make sure that theelectric connector (5) is correctly cou-pled.

WARNINGPosition a clean cloth under the rapidcouplings (6) and (7), in order to absorbthe small quantity of fuel that will flowout of them after disconnection.

Release and disconnect the rapid cou-plings (6) (7).

WARNINGUpon reassembly, make sure that therapid couplings (6) (7) are inserted cor-rectly.Working from the left-hand side of thevehicle: Move the fairing (8) moderately towards

the outside.

NOTE Mark the two pipes (9) (10) in orderto be able to insert them in the relevant unionupon reassembly. Withdraw the two pipes (9) (10) down-

wards:– pipe (9) = fuel tank overflow;– pipe (10) = water drainage from tank

cap.

WARNINGWhen reassembling, make sure thepipes are plugged in properly (9) (10).



Grasp the tank (11) and, pulling it back-wards, withdraw it from the two front sup-ports.

Raise and remove the tank (11).

WARNINGPosition the tank in a safe place, withthe cap facing upwards; neither over-turn, nor tilt it, since the fillercap is nottight and the fuel would flow out of thetank.


WARNINGWait until the engine and the exhaust si-lencer have completely cooled down.


Unscrew and remove the four screws(1).


Remove the oil sump guard (2).

NOTE If the deadening material insidethe oil sump guard (2) is deteriorated, con-tact an aprilia Official Dealer to have itchanged.

Carefully read 55 (MAINTENANCE).

WARNINGWait until the engine and the exhaust si-lencer have completely cooled down.

Remove the saddle, see p 21 (UNLOCK-ING/LOCKING THE SADDLE).

Unscrew and remove the four screws(3).

Remove the side cover (4).


NOTE If the heat-resistant material in-side the oil sump guard (4) is deteriorated,contact an aprilia Official Dealer to have itchanged.




Unscrew and remove the two screws (1). From the opposite side, unscrew and re-

move the screw (2).


Lift and remove the upper guard (3). Unscrew and remove the two screws (4). Remove the lower protection element

(5).

!"#$%$&#$'#"(!)"&%!&%*"+,&%'!"-*"'"'"(!'"#.

NOTE If also the rear case supportsmust be installed beside the side bag sup-ports, it is necessary to install the formerfirst, see p. 76 [INSTALLING THE REARCASE SUPPORTS (supplied as stand-ard equipment in the countries where re-quired)].


The following parts are supplied togeth-er with the side bag supports:– four screws T.E. M8 x 20 (1) (2) with the

relevant washers (3) (4);– two screws T.C.E.I. M8 x 20 (5);– two screws T.C.E.I. M8 x 30 (6);– two spacers (7);– two front couplings (8);– two rear couplings (9).

3

1

4

5

2

3


NOTE The operations marked with arenot necessary if the rear case supports areinstalled.

/Remove the side panels, see p. 73(REMOVING THE RIGHT AND LEFTSIDES).

0Unscrew and remove the screw (A)./Unscrew and remove the screw (B)

and take the washer.

NOTE Take the screws (A) (B) and thewasher and store them in a safe place, sothat if necessary you can use them again.

/Position the front coupling (8)./Insert the screw (1) with the relevant

washer (3) and screw it manually.0Position the rear coupling (9).0Insert the screw (2) with the relevant

washer (4) and screw it manually./Loosen and remove the nut (10) that

fastens the passenger footboard./Position the bag support (11).

/Put back the nut (10) and screw itmanually.

0Position the spacer ring (7)./Insert the screws (5) (6) and screw

them manually./Tighten the screws (5) (6) and the nut

(10), without applying the torque pre-scribed.

/Tighten the screw (1) and the screw(2), applying the torque prescribed.

Driving torque of screws (1) (2): 25Nm (2.5 kgm).

/Unscrew and remove the screws (5)(6) and the nut (10).

/Remove the bag support (11)./Put back the side cover, see p. 73

(REMOVING THE RIGHT AND LEFTSIDES).

CAUTIONHandle the bag support (11) with care,and avoid damaging the side.

/Put back the bag support (11)./Insert and tighten the screws (5) (6),

applying the torque prescribed.

Driving torque of screws (5) (6): 25Nm (2.5 kgm).

/Put back the nut (10) and tighten it ap-plying the torque prescribed.

Driving torque of nut (10): 50 Nm (5.0kgm).

Install the side bags, see p. 24 [SIDEBAGS (supplied as standard equip-ment in the countries where required)].

Check the wear of the coupling pins every6000 km (3750 mi) or 12 months, and ifnecessary have them changed by an april-ia Official Dealer.


!"#$%$&#$'#"(!)"&%!&%*"+,&%'!"-*"'"'"(!'"#.


The following parts are supplied togeth-er with the rear case supports:– two screws T.C.E.I. M8 x 20 (1);– two screws T.C.E.I. M8 x 30 (2) with the

relevant washers (3);– two screws T.C.E.I. M8 x 55 (4);– two lock nuts (5);– two spacers (6);– two rear couplings (7).

NOTE The operations marked with arenot necessary if the side bag supports areinstalled.

/Remove the side panels, see p. 73(REMOVING THE RIGHT AND LEFTSIDES).

0Unscrew and remove the screw (A)./Unscrew and remove the screw (B)

and take the washer (C).

NOTE Take the screw (A) and position itin a safe place in order to be able to use itagan if necessary; the screw (B) and thewasher (C) will be reused in the followingoperations.

0Position the rear coupling (7).0Insert the screw (B) with the relevant

washer (C) and screw it manually./Position the spacer ring (6)./Position the case side support (8)./Insert the screws (1) (4) and screw

them manually./Position the plate (9) on the two side

supports (8)./Insert one of the screws (2), with the

relevant washer (3)./Working on the lower side, position the

nut (5) and tighten it manually.

0Tighten the screw (B), applying thetorque prescribed.

Screw (B) driving torque: 25 Nm (2.5kgm).

/Tighten the screws (1) (4) and the nut(5), applying the torque prescribed.

Driving torque screws (1) (4) and nut(5): 25 Nm (2.5 kgm).

/Put back the side panels, see p. 73(REMOVING THE RIGHT AND LEFTSIDES).

Install the rear case, see p. 26 [REARCASE (supplied as standard equip-ment in the countries where required)].

Check the wear of the coupling pin every6000 km (3750 mi) or 12 months, and ifnecessary have it changed by an apriliaOfficial Dealer.


CAUTIONThe operations necessary to check thesteering require specific knowledge andexperience, therefore it is advisable tocontact an $'! !$ Official Dealer.

CAUTIONThe operations necessary to check therear fork fulcrum axis require specificknowledge and experience, therefore itis advisable to contact an $'! !$ Offi-cial Dealer.


NOTE Have the front fork oil changed byan aprilia Official Dealer, who will ensureyou prompt and accurate servicing.

Have the front fork oil changed every12000 km (7500 mi).

Carry out the following checks after the first1000 km (625 mi) and successively every12000 km (7500 mi):

With pulled front brake lever, press thehandlebar repeatedly, thrusting the forkdownwards. The stroke must be gentleand there must be no trace of oil on therods.

Check the fastening of all the compo-nents and the functionality of the frontand rear suspension joints.

CAUTIONIf you notice irregularities in the opera-tion or if the help of a qualified technicianis necessary, contact your $'! !$ Offi-cial Dealer.

Have the fork oil seals changed by a apriliaOfficial Dealer after the first 30000 km(18750 mi) and successively every 22500km (14000 mi). The front suspension consists of an hy-draulic fork connected to the steering col-umn by means of two plates.The standard setting of the front fork is ad-justed in such a way as to be suitable formost driving conditions, at high and lowspeed, for the transport of the rider withluggage.

CAUTIONIf necessary, contact an $'! !$ OfficialDealer.


The rear suspension consists of a spring-shock absorber unit, fixed to the frame bymeans of a uni-ball and to the rear fork bymeans of lever systems.

For the setting of the vehicle attitude,the shock absorber is provided:– with a screw adjuster (1) for the adjust-

ment of the hydraulic braking with ex-tended shock absorber;

– an adjusting ring nut (2) and a lockingring nut (3) for the adjustment of thespring preload.

ADJUSTING THE REAR SHOCK ABSORBERCheck and if necessary adjust the rearshock absorber every 12000 km (7500 mi).The standard setting of the rear shock ab-sorber is adjusted so that it is suitable formost driving conditions.The standard adjustment, set by the manu-facturer, is suitable for a rider weighing ap-proximately 70 kg.If your weight and needs are different, forexample in case of ride with passengerand full load, it is advisable to contact anaprilia Official Dealer.

According to the conditions of use of thevehicle, it is possible to adjust the hydraulicbraking with extended shock absorber byadjusting the screw (1); for the adjustment,keep to the following indications:

Uneven or irregular road surface –HARD adjustment: Turn the screw (1) to the right (clock-

wise).

Normal or regular road surface – SOFTadjustment: Turn the screw (1) to the left (anticlock-

wise).

CAUTIONAdjust the spring preload and the hy-draulic braking with extended shock ab-sorber according to the conditions ofuse of the vehicle.

When the spring preload is increased, itis necessary to increase also the hy-draulic braking with extended shock ab-sorber, in order to avoid sudden jerkswhile riding.

If necessary, contact an $'! !$ OfficialDealer.

Test the vehicle repeatedly on the road,until obtaining the optimal adjustment.


REAR SHOCK ABSORBER ADJUSTMENT TABLE

Rear shock absorber

Standard adjustment

(INTERMEDIATE) for normal load (for example, rider and

passenger)

SOFT adjustment for light load (for

example, rider only)

HARD adjustment for heavy load (for

example, rider, passenger and

luggage)

Hydraulic adjustment with extended shock absorber, screw (1)

starting from the SOFT adjustment position, rotate the

knob clockwise, giving it 25 clicks.

turn completely anticlockwise

(SOFT)

turn completely clockwise (HARD)

Spring preload, knob (2)

starting from the soft adjustment position

(anticlockwise), rotate the knob

clockwise, giving it a full turn (9 clicks)

turn completely anticlockwise

turn completely clockwise

/

With this type of suspension it is possibleto adjust the spring preload and the hy-draulic braking with extended shock ab-sorber.

CAUTIONAdjust the spring preload and the hy-draulic braking with extended shock ab-sorber according to the conditions ofuse of the vehicle.

When the spring preload is increased, itis necessary to increase also the hy-draulic braking with extended shock ab-sorber, in order to avoid sudden jerkswhile riding.


Carefully read p. 29 (BRAKE FLUID -recommendat ions ) , p . 30 (D ISCBRAKES) and p. 55 (MAINTENANCE).

NOTE The following information refer toa single braking system, but are valid forboth.

Check the brake pad wear after the first1000 km (625 mi) and successively every2000 km (1250 mi) and before every trip. The wear of the disc brake pads dependson the use, on the kind of drive and on theroad.

WARNINGCheck the wear of the brake pads, espe-cially before every trip.

To carry out a rapid checking of thewear of the pads, proceed as follows: Position the vehicle on the stand, see p.


Carry out a visual check between thedisc and the pads, proceeding:– from below, on the front part, for the

front brake caliper (1);– from above, on the rear part, for the

rear brake calipers (2).

CAUTIONThe excessive wear of the friction mate-rial would cause the contact of the padmetal support with the disc, with conse-quent metallic noise and production ofsparks from the caliper; braking effi-ciency, safety and soundness of thedisc would thus be negatively affected.

If the thickness of the friction material[even of one front (3) or rear pad (4) only]has reduced to about 1.5 mm (or even ifonly one of the wear indicators is not visi-ble any longer):

– for the front brake caliper have bothfront brake caliper pads changed.

– for the rear brake caliper, have bothpads of the caliper changed.

WARNINGHave the pads changed by your $'! !$Official Dealer.


/


NOTE In case of start at low ambienttemperature [near to or lower than 0° C(32° F)], see p. 46 (STARTING WITHCOLD ENGINE). In any case, if the normalrunn ing tempera ture has not beenreached, an anomaly in the engine idlingrpm may be noticed. This is normal, sincethe engine idling rpm return to regular val-ues when the engine reaches the normalrunning temperature.

To check the engine idling rpm cor-rectly, proceed as follows:

Ride for a few miles until reaching thenormal running temperature, see p. 17(Coolant temperature indicator “*”).

Position the gear lever in neutral (greenwarning light “.” on).

Check the engine idling rpm on the revo-lution counter.

The engine idling speed must be about1300 ± 100 rpm.If the engine idling rpm are within thevalues indicated, do not modify them inany way.

CAUTIONIn case of irregular engine idling rpm,contact exclusively an $'! !$ OfficialDealer.

An excessive increase in the engineidling rpm may cause irregularities inthe operation of the engine and damagethe engine itself and other components.

It is advisable to change the settingonly when it is really necessary (if,when the throttle grip is released, theengine stops or keeps running at higherrpm than prescribed) and it is impossi-ble to reach an $'! !$ Official Dealer.

Only when really necessary:

CAUTIONRisk of burns.

Some parts of the vehicle are extremelyhot (for example, the exhaust pipe and,to a lesser extent, the exhaust pipeguard).

Wear safety gloves to protect yourselffrom those parts of the vehicle whosetemperature is too high.

Proceed with care and do not touch theexhaust pipe guard for any reason wha-tsoever.

Release the idling adjusting cable (1)from the cable guide positioned behindthe right stanchion of the frame.

Turn the adjusting knob (2).

– BY SCREWING IT (clockwise), you in-crease the rpm;

– BY UNSCREWING IT (anticlockwise),you decrease the rpm;

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


/


Have the accelerator control cableschecked by an aprilia Official Dealer afterthe first 1000 km (625 mi) and successivelyevery 6000 km (3750 mi).The idle stroke of the throttle grip must be2–3 mm, measured on the edge of the gripitself.

If not, proceed as follows: Position the vehicle on the stand, see p.


Withdraw the protection element (1). Loosen the lock nut (2). Rotate the adjuster (3) in such a way as

to restore the prescribed value.

After the adjustment, tighten the lock nut(2) and check the idle stroke again.

Put back the protection element (1).

CAUTIONAfter the adjustment, make sure that therotation of the handlebar does not mod-ify the engine idling rpm and that thethrottle grip returns smoothly and auto-matically to its original position afterbeing released.

/


Have the accelerator control cableschecked by an aprilia Official Dealer afterthe first 1000 km (625 mi) and successivelyevery 6000 km (3750 mi).The idle stroke of the cold start control (4)must be 2–3 mm, measured on the edge ofthe control itself.

If not, proceed as follows: Position the vehicle on the stand, see p.


Withdraw the protection element (5). Loosen the lock nut (6). Rotate the adjuster (7) in such a way as

to restore the prescribed value.

After the adjustment, tighten the lock nut(6) and check the idle stroke again.

Put back the protection element (5).

CAUTIONAfter the adjustment, make sure that therotation of the handlebar does not mod-ify the engine idling rpm.


WARNINGDo not use the vehicle with the rear-view mirrors turned incorrectly.Before leaving, always make sure thatthe rear-view mirrors are not rotated up-wards and are correctly adjusted.

WARNINGFor the adjustment of the rear-view mir-rors, wear clean gloves or use a cleancloth, in order to avoid dirtying the re-flecting surface and reducing visibility.

REMOVING THE REAR-VIEW MIRRORS Position the vehicle on the stand, see p.


Raise the protection element (1). Loosen and remove the stop nut (2).

CAUTIONUpon reassembly, before tightening thelock nut (2), make sure that the rear-view mirror support rod is directed insuch a way as to be aligned with thehandlebar.

Withdraw the entire rear-view mirror unit(3) upwards and remove it.

Repeat these operations to remove theother rear-view mirror.

ADJUSTMENT OF THE REAR-VIEW MIRRORS

Get on the vehicle in riding position, seep. 40 (GETTING ON AND OFF THE VE-HICLE).

CAUTIONHandle the components with care.

Rotate the rear-view mirror (4) and ad-just the inclination correctly.

Repeat the same operations to adjust theother rear-view mirror. Make sure that there are no dirt or mud

deposits.



Check the spark plug every 6000 km (3750mi), change them every 12000 km (7500mi).

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

To reach the spark plug:

WARNINGBefore carrying out the following opera-tions, let the engine and the silencercool down until they reach room tem-perature, in order to avoid burns.

Remove the fuel tank, see p. 72 (RE-MOVAL OF THE FUEL TANK).

For the removal, proceed as follows: Remove the cap (1) of the spark plug (2). Remove any trace of dirt from the spark

plug base. Introduce the special spanner provided

in the tool kit on the spark plug. Unscrew the spark plug and extract it

from its seat, taking care to prevent dustor other substances from getting insidethe cylinder.

For the check and cleaning:

Key:– centre electrode (3);– insulating (4);– side electrode (5). Make sure that there are neither carbon

deposits, nor corrosion marks on theelectrodes and on the insulating materi-al; if necessary, clean them with a pres-surized air jet.

If the spark plug has crackings on the insu-lating material, corroded electrodes, ex-cessive deposits or the tip (6) of the centralelectrode (3) is rounded, i t must bechanged.


CAUTIONWhen changing the spark plug, checkthe thread pitch and length. If the threaded part is too short, the car-bon deposits will accumulate on thethread seat, and therefore the enginemay be damaged during the installationof the right spark plug. Use the recommended type of sparkplugs only, see p. 101 (TECHNICAL DA-TA), in order not to compromise the lifeand performance of the engine. Check the spark plug gap with a thick-

ness gauge. The spark plug gap must be 0,6 – 0,7mm; if necessary, adjust it, bending thecentre electrode (6) with care.

Make sure that the washer (7) is in goodconditions.

For the installation: With the washer on (7), screw the spark

plug by hand in order not to damage thethread.

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

Spark plug driving torque: 20 Nm (2.0kgm).

CAUTIONThe spark plug must be well tightened,otherwise the engine may overheat andbe seriously damaged.

CAUTIONMake sure that the cap (1) is correctlyconnected to the spark plug (2). Due tothe vibrations of the engine, the incor-rect position would cause the discon-nection of the spark plug cap, with seri-ous damage to the engine.

Correctly insert the cap (1) in the sparkplug (2), until you hear the click.

Put back the fuel tank, see p. 72 (RE-MOVAL OF THE FUEL TANK).


Carefully read p. 55 (MAINTENANCE)and p. 91 (CHECKING THE SWITCHES).

The vehicle is provided with:– side stand (1);– centre stand (2) (supplied as stand-

ard equipment in the countries where re-quired).

The stand has two positions:– normal or lifted;– extended.

It is the rider who must provide for extend-ing and lifting the stand.The stand must rotate without hindrances.The springs (3) provide for keeping thestand in the desired position (extended orlifted).

SIDE STAND Position the vehicle on the centre stand,

see p. 52 (POSITIONING THE VEHICLEON THE STAND).

The springs (3) must not be damaged,worn, rusty or weakened.

Make sure that the stand presents noslack in either position (extended and lift-ed).

Lower the stand, making sure that thesprings provide for extending it com-pletely.

Move the stand to let it up and release ithalfway to make sure that the springsprovide for lifting it completely.

The side stand must rotate freely, if nec-essary grease the joint, see p. 104 (LU-BRICANT CHART).

The side stand (1) is provided with a safetyswitch (4) that has the function to preventor interrupt the operation of the engine withthe gears on and the side stand (1) down.

To check the proper functioning of thesafety switch (4), proceed as follows: Start the engine, see p. 44 (STARTING). With released throttle grip (5) (Pos.A)

and engine idling, pull the clutch lever (6)completely.

Engage the first gear, by pushing thegear lever (7) downwards.

Lower the side stand (1), thus operatingthe safety switch (4).

At this point: – the engine must stop;

CAUTIONIf the engine does not stop, contact an$'! !$ Official Dealer.

CENTRE STAND (supplied as stand-ard equipment in the countries whererequired) Position the vehicle on the side stand,

see p. 52 (POSITIONING THE VEHICLEON THE STAND).

The springs (3) must not be damaged,worn, rusty or weakened.

Make sure that when lifted the standpresents no slacks.

Move the stand and release it, makingsure that the springs lift it completely.

The side stand must rotate freely, if nec-essary grease the joint, see p. 104 (LU-BRICANT CHART).




The electrolyte in the battery is toxicand caustic and may cause burns oncontact with the skin as it contains sul-phuric acid. Wear protection clothes, aface mask and/or goggles during main-tenance operations.

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

In case of contact with the eyes, washwith large quantities of water for fifteenminutes and consult an oculist withoutdelay.

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-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, makesure that the room is properly ventilatedand avoid inhaling the gases releasedduring the recharging.


Do not incline the vehicle too much, inorder to avoid dangerous leaks of thebattery fluid.

CAUTIONNever invert the connection of the bat-tery cables.Connect and disconnect the batterywith the ignition switch in position “ ”,otherwise some components may bedamaged.Connect first the positive cable (+) andthen the negative cable (–).Disconnect following the reverse order.


Carefully read p. 87 (BATTERY).

To check the electrolyte level, proceedas follows: Make sure that the ignition switch is in po-

sition “ ”. Remove the left cover, see p. 73 (RE-

MOVING THE RIGHT AND LEFTSIDES).

Make sure that the fluid level is includedbetween the two “MIN” and “MAX” notch-es stamped on the battery side.

If necessary, proceed as follows: Remove the battery, see p. 89 (REMOV-

ING THE BATTERY). Remove the element plugs.

CAUTIONDo not exceed the “MAX” mark, sincethe electrolyte level increases duringthe recharge. Top up the fluid by adding only distilled

water. Put back the left cover, see p. 73 (RE-



Make sure that the ignition switch is in po-sition “ ”.

Remove the left cover, see p. 73 (RE-MOVING THE RIGHT AND LEFTSIDES).

Remove the red protection element (1). Make sure that the cable terminals (2) and

the battery terminals (3) are:

– in good conditions (and not corroded orcovered with deposits);

– covered with neutral grease or vase-line.

If necessary, proceed as follows: Remove the battery, see p. 89 (REMOV-

ING THE BATTERY). Brush the cable terminals (2) and the

battery terminals (3) with a wire brush, inorder to eliminate any trace of corrosion.

Install the battery, see p. 90 (INSTALL-ING THE BATTERY).

Put back the left cover, see p. 73 (RE-MOVING THE RIGHT AND LEFTSIDES).



Make sure that the ignition switch is inposition “ ”.


Unscrew and remove the screw (1). Remove the battery cover (2). Unscrew and remove the screw (3) on

the negative terminal (–). Move the negative cable (4) sidewards. Remove the red protection element (5). Unscrew and remove the screw (6) on

the positive terminal (+). Move the positive cable (7) sidewards.

CAUTIONDo not force the electric cables.

Withdraw the breather pipe (8). Grasp the battery (9) firmly and remove it

from its compartment, by bending it to-wards the outside and lifting it.

WARNINGOnce it has been removed, the batterymust be stored in a safe place and keptaway from children.

Position the battery on a flat surface, in acool and dry place.

Put back the left cover, see p. 73 (RE-MOVING THE RIGHT AND LEFTSIDES).

WARNINGUpon reassembly, connect first the pos-itive cable (+) and then the negative ca-ble (–).

NOTE For the installation of the battery,see p. 90 (INSTALLING THE BATTERY).



Remove the battery, see p. 89 (REMOV-ING THE BATTERY).

Prepare an appropriate battery charger. Set the charger for the desired type of re-

charge.

NOTE A recharge with an amperageequal to 1/10th of the battery capacity isrecommended.

Connect the battery with a battery charg-er.

WARNINGDuring the recharging or the use, makesure that the room is properly ventilatedand avoid inhaling the gases releasedduring the recharging.

Switch on the battery charger. After the recharging operation, check the

electrolyte level again and if necessarytop up with distilled water.

WARNINGReassemble the battery only 5/10 min-utes after disconnecting the rechargeapparatus, since the battery continuesto produce gas for a short lapse of time.


Make sure that the ignition switch is inposition “ ”.


NOTE The battery (1) must be posi-tioned in its compartment with the termi-nals directed towards the outside part ofthe vehicle.

Put the battery (1) in its compartment.

WARNINGUpon reassembly, connect first the pos-itive cable (+) and then the negative ca-ble (–).

Connect the positive terminal (+) bymeans of the screw (2).

Connect the negative terminal (–) bymeans of the screw (3).

Put back the red protection element (4).

CAUTIONUpon reassembly always connect thebattery breather pipe, to prevent the sul-phuric acid vapours from corroding theelectric system, painted parts, rubberelements or gaskets when they exit thebreather pipe itself.

Put back the breather pipe (5). Put back the battery cover (6). Position and tighten the screw (7). Put back the left cover, see p. 73 (RE-



If the vehicle remains unused for morethan fifteen days, it is necessary to re-charge the battery, in order to prevent itssulphation, see p. 90 (RECHARGING THEBATTERY).

Remove the battery, see p. 89 (REMOV-ING THE BATTERY) and put it in a cooland dry place.

It is important to check the charge periodi-cally (about once a month), during the win-ter or when the vehicle remains unused, inorder to prevent the deterioration of thebattery. Recharge it completely with a trickle

charge, see p 90 (RECHARGING THEBATTERY).

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


The vehicle is provided with fourswitches:

1) Stoplight switch on the rear brake con-trol lever;

2) Stoplight switch on the front brake con-trol lever;

3) Safety switch on the side stand;

4) Switch on the clutch control lever.

Make sure that there are no dirt or muddeposits on the switch; the pin must beable to move without interferences, re-turning automatically to its initial position.

Make sure that the cables are connectedcorrectly.

Check the spring (5): it must not be dam-aged, worn or weakened.



CAUTIONDo not repair faulty fuses.Never use fuses different from the rec-ommended ones.The use of unsuitable fuses may causedamages to the electric system or, incase of short circuit, even a fire.

NOTE If a fuse blows frequently, thereprobably is a short circuit or an overload inthe electric system.

In this case it is advisable to consult anaprilia Official Dealer.If an electric component does not work orworks irregularly, or if the vehicle fails tostart, it is necessary to check the fuses.

For the check, proceed as follows: Turn the ignition switch to position “ ”,

to avoid any accidental short circuit. Remove the rider saddle, see p. 21 (UN-

LOCKING/LOCKING THE SADDLE). Extract the fuses one by one and check if

the filament (1) is broken. Before replacing a fuse, try to find out the

cause of the trouble, if possible. Replace the damaged fuse with a new

one having the same amperage.

NOTE If you use one of the spare fuses,put a new fuse in the proper seat.

ARRANGEMENT OF THE FUSESA) Fuse 20 A (yellow) – From battery

to:ignition switch, voltage regulator, elec-tric cooling fan.

B) Fuse 15 A (light blue) – From igni-tion switch to:all light loads.

C) Fuse 7.5 A (red) – From ignitionswitch to:ignition, starting safety logic.

NOTE Three fuses are spare fuses.


/

NOTE To check the direction of theheadlight beam, specific procedures mustbe adopted, in accordance with the regula-tions in force in the country where the vehi-cle is used.

To rapidly check the correct direction of thebeam, place the vehicle on flat ground, 10m away from a wall. Turn on the low beam, sit on the vehicleand make sure that the beam projected onthe wall is slightly under the horizontal lineof the headlight (about 9/10th of the totalheight).

To adjust the headlight beam: Position the vehicle on the stand, see p.


Working on the lower side of the frontpart of the fairing, act on the appropriatescrew (1) with the spanner (8 mm) pro-vided in the tool kit.BY ROTATING IT CLOCKWISE, you setthe beam upwards.BY ROTATING IT ANTICLOCKWISE,you set the beam downwards.

After the adjustment:

WARNINGMake sure that the vertical adjustmentof the headlight beam is correct.

If you need assistance or technical advice,consult your aprilia Official Dealer, whocan ensure you prompt and accurate serv-icing.




CAUTIONBefore changing a bulb, move the igni-tion switch to position “ ” and wait afew minutes, so that the bulb coolsdown.Change the bulb wearing clean glovesor using a clean and dry cloth.Do not leave fingerprints on the bulb,since these may cause its overheatingand consequent breakage.

If you touch the bulb with bare hands,remove any fingerprint with alcohol, inorder to avoid any damage.

DO NOT FORCE THE ELECTRIC CA-BLES.

NOTE Before changing a bulb, checkthe fuses, see p. 92 (CHANGING THEFUSES).

Carefully read p. 94 (BULBS).

The headlight contains:– one high beam bulb (1) (left side);– one parking light bulb (2) (lower).– one low beam bulb/high beam (3) (right

side).

To change, proceed as follows: Position the vehicle on the stand, see p.


NOTE Proceed on the side of the bulb tobe changed.


HIGH BEAM BULBS Move the protection element (4) with

your hands. Grasp the electric terminal (5), pull it and

disconnect it from the bulb (1). Release the check spring (6) positioned

at the rear of the bulb socket (7). Extract the bulb (1) from its seat and re-

place it with a new one of the same type.

NOTE Insert the bulb in the bulb socket,making the relevant positioning seats coin-cide.

PARKING LIGHT BULB Move the protection element (8) with

your hands.

CAUTIONTo extract the bulb socket, do not pullthe electric wires.

Grasp the parking light bulb socket (9),pull it and remove it from its seat.

Withdraw the bulb (2) and replace it withone of the same type.

LOW BEAM BULB/HIGH BEAM Move the protection element (10) with

your hands.

CAUTIONTo extract the bulb electric connector,do not pull its electric wires.

Grasp the bulb electric connector (11),pull it and disconnect it from the bulb (3).

Rotate the bulb socket (12) anticlockwiseand extract it from its seat.

Press the bulb (3) slightly and rotate itanticlockwise.

Extract the bulb (3) from its seat and re-place it with a new one of the same type.

NOTE Insert the bulb in the bulb socket,making the appropriate tangs (13) coincidewith the relevant seats (14) on the reflec-tor.




Unscrew and remove the two screws (1). Remove the protection screen (2).

CAUTIONUpon reassembly, correctly position theprotection screen in its seat. Tightenthe screw (1) moderately and carefully,to avoid damaging the protectionscreen.


Extract the bulb (3) from its seat.

CAUTIONInsert the bulb in the bulb socket, mak-ing the two bulb pins coincide with therelevant guides on the socket.

Correctly install a new bulb of the sametype.



Unscrew and remove the screw (4).

CAUTIONWhile removing the protection screen,proceed carefully in order not to breakthe cog.

Remove the protection screen (5).

CAUTIONUpon reassembly, correctly position theprotection screen in its seat. Tightenthe screw (4) moderately and carefully,to avoid damaging the protectionscreen.


Extract the bulb (6) from its seat.



CAUTIONIf the bulb socket (7) goes out of itsseat, insert it correctly, making the bulbsocket opening coincide with the screwseat.



NOTE The rear light houses two parkinglight/stoplight bulbs (1).

The following operations refer to a singlebulb, but are valid for both.Before changing a bulb, check the efficien-cy of the stoplight switches, see p. 91(CHECKING THE SWITCHES). Position the vehicle on the stand, see p.


Unscrew and remove the two screws (2). Remove the protection screen (3).

NOTE Upon reassembly, correctly posi-tion the protection screen in its seat.

Tighten the screw (2) carefully, without ex-erting too much pressure, in order to avoiddamaging the protection screen. Press the bulb (1) slightly and rotate it

anticlockwise. Extract the bulb (1) from its seat.




To change, proceed as follows: Position the vehicle on the stand, see p.


Unscrew and remove the screw (4), tak-ing the nut.

Remove the light unit (5).

CAUTIONDo not pull the electric wires to extractthe bulb socket.

Grasp the bulb socket (6), pull it and re-move it from its seat.

Withdraw the bulb (7) and replace it witha new one of the same type.


NOTE During transport, the vehicle mustbe kept in vertical position, it must be firmlyanchored and the 1st gear must be en-gaged, in order to avoid any leak of fuel,oil, coolant.

CAUTIONIn case of failure, do not tow the vehicle,but ask for assistance.

Clean the vehicle frequently if it used inparticular areas or conditions, such as:– Polluted areas (cities and industrial are-

as).– Areas characterized by an high percent-

age of salinity and humidity (sea areas,hot and humid climates).

– Particular conditions (use of salt and anti-ice chemical products on the roads duringthe winter).

– Avoid leaving deposits of industrial andpolluting powders, tar spots, dead in-sects, bird droppings, etc. on the body.

– Avoid parking the vehicle under trees,since in some seasons residues, resins,fruits or leaves fall down, which containsubstances that may damage the paint.

WARNINGAfter the vehicle has been washed, itsbraking functions could be temporarilyimpaired because of the presence ofwater on the grip surfaces.

Calculate long braking distances toavoid accidents.

Brake repeatedly to restore normal con-ditions.

Carry out the preliminary checking op-erations, see p. 43 (PRELIMINARYCHECKING OPERATIONS).


To remove dirt and mud from the paintedsurfaces use a low- pressure water jet,carefully wet the dirty parts, remove mudand filth with a soft car sponge impregnat-ed with a lot of water and shampoo (2 – 4%parts of shampoo in water).Then rinse with plenty of water and dry withchamois leather. To clean the outer parts of the engine usea degreaser, brushes and wipers.

After washing the vehicle, always: Position the vehicle on the stand, see p.


Remove the cap (1). Empty its content into a container and

deliver it to a salvage centre.

CAUTIONTo clean the lights, use a spongesoaked with water and a neutral deter-gent, rubbing the surfaces delicatelyand rinsing frequently with plenty of wa-ter.

Polish with silicone wax only after hav-ing carefully washed the vehicle.

Do not use polishing pastes on mattpaints.

Do not wash the vehicle under the sun,especially during the summer, when thebody is still warm, since if the shampoodries before being rinsed away, it candamage the paint.

Do not use liquids at a temperature ex-ceeding 40°C to clean the plastic com-ponents of the vehicle.

CAUTIONDo not direct high-pressure water or airjets or steam jets on to the followingcomponents: wheel hubs, controls onthe right and left side of the handlebar,bearings, brake pumps, instrumentsand indicators , exhaust p ipes ,glove/tool kit compartment, ignitionswitch/steering lock, radiator wings,fuel cap, lights and electric connec-tions.

Do not use alcohol, petrol or solvents toclean the rubber and plastic parts andthe saddle: use only water and mildsoap.

WARNINGDo not apply protection waxes onto thesaddle, in order not to make it too slip-pery.


After a long period of inactivity of the vehi-cle some precautions are necessary toavoid any problem.

Further, it is important to carry out the nec-essary repairs and a general check up be-fore the period of inactivity, since you couldforget to carry them out later.

Proceed as follows: Remove the battery, see p. 89 (REMOV-

ING THE BATTERY) and p. 91 (LONGINACTIVITY OF THE BATTERY).

Wash and dry the vehicle, see p. 98(CLEANING).

Polish the painted surfaces with wax. Inflate the tyres, see p. 36 (TYRES).

Place the vehicle in an unheated, not-hu-mid room, away from sunlight, with mini-mum temperature variations.

NOTE Position the vehicle on the front and rear support stands, so thatboth tyre are raised from the ground.

Set the vehicle on the relevant front sup-port stand, see 69 (POSITIONING THEVEHICLE ON THE FRONT SUPPORTSTAND ).

Put a plastic bag on each exhaust tail-pipe and bind it around it, in order to pre-vent moisture from getting into the tail-pipe.

Cover the vehicle avoiding the use ofplastic or waterproof materials.

AFTER A PERIOD OF INACTIVITY

NOTE Withdraw the plastic bags fromthe exhaust tailpipes.

Uncover and clean the vehicle, see p. 98(CLEANING).

Check the charge of the battery, see p.90 (RECHARGING THE BATTERY) andinstall it, see p. 90 (INSTALLING THEBATTERY).

Refill the fuel tank, see p. 27 (FUEL). Carry out the preliminary checking oper-

at ions, see p. 43 (PRELIMINARYCHECKING OPERATIONS).

WARNINGHave a test ride at moderate speed in alow-traffic area.


DIMENSIONS Max. length ............................................................ 2214 mmMax. width.............................................................. 910 mmMax. height (front part of the fairing included) ....... 1253 mmSeat height............................................................. 815 mmDistance between centres...................................... 1466 mmMin. ground clearance ........................................... 200 mmWeight ready for starting........................................ 200 kg

ENGINE Model ..................................................................... 655 EFIType ....................................................................... one-cylinder, 4-stroke with 5 valves, 2 camshafts at the head Number of cylinders ............................................... 1Total displacement................................................. 652 cmBore/stroke............................................................. 100 mm/83 mmCompression ratio.................................................. 9 ± 0.5: 1Starting................................................................... electricEngine idling rpm ................................................... 1300 ± 100 rpmClutch..................................................................... multidisc in oil bath, with control on the left side of the handlebarLubrication system................................................. dry pan with separate oil tankAir cleaner.............................................................. with dry filter cartridgeCooling................................................................... liquid-cooled

TRANSMISSION Type ....................................................................... mechanical, 5 gears with foot control on the left side of the engine

CAPACITY Fuel (reserve included) .......................................... 21 Fuel reserve ........................................................... 5 Engine oil ............................................................... oil change 2150 cm – oil and oil filter change 2200 cmFork oil .................................................................. 570 cm(per rod)Coolant................................................................... 1.4 (50% water + 50% antifreeze with ethylene glycol)

. Coolant .................................................... 1,25 (50% water + 50% antifreeze with ethylene glycol)Seats...................................................................... 2Vehicle max. load .................................................. 180 kg (driver + passenger + luggage)


GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio1ª 37/72 = 1 : 1.946 12/33 = 1 : 2.750 16/46 = 1 : 2.875 15.3852ª 16/28 = 1 : 1.750 9.7913ª 16/21 = 1 : 1.312 7.344ª 22/23 = 1 : 1.045 5.8465ª 24/21 = 1 : 0.875 4.895

DRIVE CHAINType ....................................................................... endless (with no connection link) with sealed linksModel ..................................................................... 525

FUEL SUPPLY SYSTEM

Type ....................................................................... electronic injection (Multipoint)Choke..................................................................... Ø 34 mm

FUEL SUPPLY Fuel ........................................................................ Unleaded petrol according to the DIN 51 607 standard, min. O.N. 95(N.O.R.M.) and 85 (N.O.M.M.)

FRAME Type ....................................................................... composite structure in steel and light alloy, with removable cradle and saddlepillar

Steering inclination angle....................................... 28°Fore stroke............................................................. 109 mm

SUSPENSIONS Front....................................................................... upside-down telescopic adjustable fork with hydraulic operation, rod Ø 45mm

Stroke..................................................................... 170 mmRear ....................................................................... oscillating rear fork with differentiated profile arms and hydraulic adjustable

mono-shock absorberWheel stroke .......................................................... 165 mm

BRAKES Front....................................................................... disc brake – Ø 300 mm – with hydraulic transmissionRear ....................................................................... disc brake – Ø 240 mm – with hydraulic transmission

WHEEL RIMS Type ....................................................................... light alloy with spokes Front....................................................................... 2.15 x 19”Rear ....................................................................... 3.00 x 17”

TYRES FRONT.................................................................. 100/90 – 19 57 H– alternative...................................................... 100/90 – R19 57 H; 100/90 – 19 57 S; 100/90 – 19 57 T

– Inflation pressure - solo rider– off-road driving .............................................. 190 kPa (1.9 bar)– asphalted road .............................................. 190 kPa (1.9 bar)

– Inflation pressure rider with passenger– off-road driving .............................................. 190 kPa (1.9 bar)– asphalted road............................................... 190 kPa (1.9 bar)


TYRES REAR .................................................................... 130/80 – R17 65 H– alternative...................................................... 140/70 – 17 66 H; 130/80 – 17 65 S;

130/80 – 17 65 T; 130/80 – 17 65 H– Inflation pressure - solo rider

– off-road driving .............................................. 210 kPa (2.1 bar)– asphalted road............................................... 210 kPa (2.1 bar)

– Inflation pressure rider with passenger– off-road driving .............................................. 210 kPa (2.1 bar)– asphalted road............................................... 230 kPa (2.3 bar)

IGNITION Type ....................................................................... SAGEM - inductive ignition system

SPARK PLUGS Standard ................................................................ NGK R DR8EBSpark plug gap....................................................... 0.6 – 0.7 mmResistance ............................................................. 5 kΩ

ELECTRIC SYSTEMBattery.................................................................... 12 V – 12 AhFuses .................................................................... 7.5 A – 15 A – 20 AGenerator (with permanent magnet) ..................... 12 V – 270 W

BULBS Low beam bulb/high beam .................................... 12 V – 55/60 WHigh beam ............................................................. 12 V – 60 WFront parking light .................................................. 12 V – 3 WDirection indicators ................................................ 12 V – 10 WRear parking lights/Stoplight .................................. 12 V – 5/21 WNumber plate light.................................................. 12 V – 3 WRevolution counter ................................................. 12 V – 2 WSpeedometer ........................................................ 12 V – 2 WCoolant temperature indicator................................ 12 V – 2 W

WARNING LIGHTS Neutral ................................................................... 12 V – 3 WDirection indicators ................................................ 12 V – 3 WFuel reserve ........................................................... 12 V – 3 WHigh beam.............................................................. 12 V – 3 WEngine oil pressure ................................................ 12 V – 3 WDiagnostics ............................................................ 12 V – 3 W


Engine oil (recommended): SUPERBIKE 4, SAE 5W-40 or 4T FORMULA RACING, SAE 5W-40.As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to theCCMC G-4, A.P.I. SG specifications.

Fork oil (recommended): F.A. 5W or F.A. 20 W fork oil;an alternative FORK 5W or FORK 20W fork oil.

If you need an oil with intermediate characteristics in comparison with the F.A. 5W and F.A. 20 W or FORK 5W and FORK 20W, these can be mixed as indicated below:

SAE 10W = F.A. 5W 67% of the volume, + F.A. 20W 33% of the volume or FORK 5W 67% of the volume + FORK 20W 33% of the volume.

SAE 15W = F.A. 5W 33% of the volume, + F.A. 20W 67% of the volume or FORK 5W 33% of the volume + FORK 20W 67% of the volume.

Bearings and other lubrication points (recommended): AUTOGREASE MP or GREASE 30.As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30 °C…+140 °C,dripping point 150 °C…230 °C, high protection against corrosion, good resistance to water and oxidation.

Protection of the battery poles: neutral grease or Vaseline.

Spray grease for chains (recommended): CHAIN SPRAY or CHAIN LUBE.

WARNINGUse new brake fluid only.

Brake fluid (recommended): F.F., DOT 5 (compatible with DOT 4) or BRAKE 5.1, DOT 5 (compatible with DOT 4).

WARNINGUse only antifreeze and anticorrosive without nitrite, ensuring protection at -35 °C at least.

Engine coolant (recommended): ECOBLU -40 °C or COOL.

105

use and maintenance Pegaso 650 I.E.


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1) Side stand switch 2) Multiple connectors 3) Clutch control lever switch 4) Diode 1 5) Diode 2 6) Engine oil pressure switch 7) Neutral gear switch 8) Light relay 9) Low fuel warning light10) High beam warning light11) Direction indicator warning light12) Diagnostic warning light13) Neutral warning light14) Engine oil pressure Warning light15) Dashboard bulbs16) Coolant temperature indicator17) Dashboard resistance 18) Dashboard19) Blinking20) Horn21) Left dimmer switch22) Ignition switch23) Right dimmer switch24) Rear left direction indicator25) Parking light bulb/rear stoplight26) Electronic unit 27) Rear light28) Number plate bulb29) Rear right direction indicator30) Front stoplight switch31) Rear stoplight switch32) Thermal switch cooling electrofan33) Cooling electrofan34) Injection relay

35) Start relay36) Starter37) Battery38) Voltage regulator39) Fuses40) Generator 41) Pick up42) Fuel pump43) Low fuel sensor44) Injector 245) Injector 146) Throttle valve position sensor47) Coolant temperature thermistor48) Air thermistor49) Spark plug50) Coil51) Octane number selection (not

provided as standard equipment)52) Diagnostic connection53) Front right direction indicator54) High beam bulbs55) Low beam bulb/high beam56) Front parking light bulb57) Headlight58) Front left direction indicator59) Fall sensorX) Shielded cables

Ar OrangeAz Light blueB BlueBi WhiteG YellowGr GreyM BrownN BlackR RedRo PinkV GreenVi Violet

110


111



aprilia s.p.a.wishes to thank its customers for the purchase of this vehicle:

– Do not dispose of oil, fuel, polluting substances and components in the envi-ronment.

– Do not keep the engine running if it isn’t necessary.

– Avoid disturbing noises.

– Respect nature.

use maintenance + book -...

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