Usa - 1999

use and maintenance
part# 8202164
RS 50
1999 aprilia s.p.a. - Noale (VE)
NOTE This manual is an important and

integral part of your motorcycle. Keep it with your motorcycle at all times, even if your motorcycle is resold. aprilia has prepared this manual to supply you, the user, with correct and current information. However, since aprilia constantly improves the design of its motorcycles, there may be slight discrepancies between your motorcycle and the material given in this manual. If you have any questions about your motorcycle, contact your Local aprilia Dealer, as he will have the very latest technical information available from the factory. For tests and repairs not expressly described in this manual, to purchase aprilia genuine spare parts, accessories, and other products, and for help with specific problems, please contact your Local aprilia Dealer or service center. These professionals will be able to promptly and accurately help. Thank you for choosing aprilia. Have a great ride! This manual is copyright in all countries, and reproduction of any part or the whole by any means in print or electronic is strictly prohibited.

This manual is divided into sections, chapters and paragraphs, by subject. The procedures described are laid out in single operation, and each operation is indicated by a . The numbered parts shown in the figures are identified in the text with the number in parentheses or with the symbol representing them. Example:
section

First edition: april 1999 Reprint:
chapter

safety warning
Produced and printed by: editing division Soave (VERONA) - Italy Tel. +39 - 045 76 11 911 Fax +39 - 045 76 12 241 E-mail: customer@stp.it www.stp.it On behalf of: aprilia s.p.a. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39 - 041 58 29 111 Fax +39 - 041 44 10 54 www.aprilia.com
Never turn the key to position while the motorcycle is being operated. If you do so, you will lose control of the motorcycle, and a crash will ensue. OPERATION To lock the steering:
WARNING
paragraph operation

Turn the handlebar completely to the left or to the right. Turn the key (2) to position . Press the key and rotate it to position . Remove the key.
position (2) symbol
use and maintenance RS 50

The following precautionary warnings are used throughout this manual in order to convey the following messages: warning. When you find this symbol on the in Safety careful tomotorcycle or riskthe manual, be the potential of personal injury. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other people's safety and for the motorcycle!

If it is necessary to let the engine run in order to carry out some work, make sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces. If it is necessary to work indoors, use an exhaust evacuation system.
Indicates a potential hazard which may result in serious injury or even death.
WARNING CAUTION
The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and even death.
WARNING

Keep gasoline away from children. Gasoline is also poisonous. Never attempt to siphon gasoline using your mouth. Never allow gasoline to-contact your skin. If you should accidentally spill gasoline on yourself, change your clothes immediately and wash the area upon which the gasoline was splashed thoroughly with hot water and soap. Should you accidentally swallow gasoline, do not induce vomiting. Drink large quantities of clear water or milk and immediately seek professional medical assistance. Should you accidentally get gasoline get your eyes, flush with large quantities of cool, clear water and immediately seek professional medical assistance.
Gasoline is extremely flammable and becomes explosive under certain conditions. KEEP GASOLINE AWAY FROM CHILDREN.
WARNING
Indicates a potential hazard which may result in personal injury or damage to the motorcycle or other property.

NOTE The word NOTE in this manual

precedes important information or instructions.
The engine and all parts of the exhaust system, as well as the braking system, become very hot and remain hot for some time after the motorcycle and the engine are stopped. Before handling any component of your motorcycle after riding, insure that it has cooled sufficiently to be safe to handle.
WARNING
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Use latex gloves for the maintenance operations that require contact with used oil. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is advisable to thoroughly wash your hands with soap and water after handling used oil. KEEP OIL AWAY FROM CHILDREN.
WARNING
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In certain conditions, the ethylene glycol contained in the engine coolant is flammable: its flame is invisible, but you can be burned anyway.
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Brake fluid is extremely poisonous. Do not ever allow brake fluid to be ingested or swallowed. Should brake fluid accidentally be swallowed, drink large quantities of milk or clear water and immediately seek professional medical assistance. Brake fluid is highly destructive of skin and eye tissue. Should you accidentally spill brake fluid on yourself, remove the contaminated clothing, wash your body with soap and warm water immediately and immediately seek professional medical assistance. Should you accidentally splash brake fluid into your eyes, flush with a large quantity of cool, clear water and immediately seek professional medical assistance. KEEP BRAKE FLUID AWAY FROM CHILDREN. 4
CAUTION
Avoid spilling the engine coolant on the exhaust system or on the engine components. They may be hot enough to cause the coolant to ignite and burn without a visible flame. The coolant (ethylene glycol) can cause skin irritation and is poisonous if swallowed. Coolant and coolant/water mixtures are sweet to the taste and brightly colored, therefore are highly attractive to pets and children. Take extra precautions to keep new and used coolant out of reach of children and animals. KEEP AWAY FROM CHILDREN. Risk of burn. Do not remove the radiator cap when the engine is hot. Wait until the engine has completely cooled down. The coolant is under pressure and may cause burns.
WARNING
The battery gives off noxious and explosive gases; keep cigarettes, flames and sparks away from the battery. Provide adequate ventilation when operating or recharging the battery. During the recharging or the use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging. The battery contains sulphuric acid (electrolyte). Contact with the skin or eyes may cause serious burns. Always wear protective clothing, rubber gloves, and tight fitting goggles or a face shield when working around the battery, especially when filling the battery with either water or electrolyte. In case of contact with the skin, flush immediately with plenty of water. In case of contact with the eyes, flush with plenty of water for at least 15 minutes. Immediately consult a health professional. The electrolyte is poisonous. If the electrolyte is accidentally swallowed, drink large quantities of water or milk and then milk of magnesia or vegetable oil. Immediately consult a health professional. KEEP AWAY FROM CHILDREN.
WARNING
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Before starting the engine, carefully read this manual and in particular the chapters WARNINGS - PRECAUTIONS - GENERAL ADVICE and SAFE DRIVE see p. 17. Your safety and that of those around you depends not only on your skill as a rider, but also your knowledge about your motorcycle and about riding safely. Therefore it is essential that you not operate your motorcycle on public streets or highways until you have received instructions from a qualified safety organization such as the Motorcycle Safety Foundation, and are properly trained and licensed.
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You can also obtain other information about motor motorcycle safety from the Hotline. However, the NHTSA cannot be involved in individual problems between you, your dealer or aprilia s.p.a.. To contact the NHTSA, either call the Auto Safety Hotline toll-free number 1-800424-9393 (or 366-0123 in the Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. Further information about motor motorcycle safety can also be obtained from the Hotline.
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Warranty claims should be directed to: aprilia USA Inc.

110 Londonderry Court, Suite 130 Woodstock, GA 30188 USA Tel 770 592 2261 Fax 770 592 4878
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If you believe that your motorcycle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying aprilia. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of motorcycles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer, or aprilia. To contact NHTSA, you may either call the Auto Safety Hotline toll free at 1-800-424-9393 (or 366-0123 in the Washington, D.C. area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590.
Rules of the road vary from country to country. It is essential that you understand in advance the rules of the road of the country in which your motorcycle will be used.
This motorcycle has been designed and produced for use on even and paved roads or surfaces only. Do not use the motorcycle on unpaved surfaces, in order to avoid overturning or other accidents.
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WARNING
ORIGIN OF THE EMISSIONS The combustion process produces carbon monoxide and hydrocarbons. The control of hydrocarbons is very important, because under certain conditions they react to exposure to sunlight and produce photochemical smog. Carbon monoxide does not react in the same way, but it is toxic and poisonous. aprilia utilizes lean carburettor settings and other systems to reduce the production of carbon monoxide and hydrocarbons. EXHAUST EMISSION CONTROL SYSTEM The Exhaust Emission Control System requires lean carburettor settings and no adjustments should be made, except idle speed adjustments by means of the appropriate screw.
aprilia s.p.a. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.
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Tampering with the noise control system is prohibited. Federal law prohibits the following acts or causing thereof: a) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new motorcycle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use, or b) The use of the motorcycle after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: a) Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases. b) Removal or puncturing of any part of the intake system. c) Lack of proper maintenance. d) Replacing any moving part of the motorcycle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
This product should be checked for repair or replacement if the motorcycle no i se h as i nc rea se d si gn i fi ca ntl y through use. Otherwise, the owner may become subject to penalties under state and local ordinances. PROBLEMS THAT MAY AFFECT THE MOTORCYCLE EMISSIONS If any of the following symptoms are observed, immediately have your motorcycle inspected and repaired by your Local aprilia Dealer. Symptoms: Difficult starting or stalling after starting. Irregular idle. Misfiring or backfiring during acceleration. After-burning (backfiring). Poor engine performance, degraded handling, or poor fuel economy.
CAUTION
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Every motorcycle produced by aprilia receives a vehicle identification number (V.I.N.) stamped on the steering head of the frame (A), as shown above, and also on the identification plate (B) which is located on the front portion of the main frame. DIGIT MEANING 1) Manufacturers identification alphanumeric code. 2) Motorcycle type. 3) Model. 4) Country for which the motorcycle is intended. 5) Production year. 6) Assembling factory designation (N = NOALE-VE- , S = SCORZ -VE- , 0 = NOT SPECIFIED). 7) Sequential serial number.
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Ref.
Description
Ref.
Description
Exhaust pipe stamping.
7
WARNING!
Do not use any tire other than those recommended and approved by Aprilia. Maintain proper tire inflation. So not use any tire with less than 1/8" (3mm) tread remainig. Do not repair any tire, nor use a repaired tire. Do not ride your motorcycle overloaded or with an unbalanced load. Failure to follow these warnings can lead to an accident and serious injuries or death. Always ensure that the chain is correctly adjusted. See owner's manual.
CHAIN TENSION WITH NO LOAD
Tires pressure
bar (psi)
Front tire
Tires size
25 35mm
Front tire Rear tire
1.9 1.7 (24.65) (27.55) 1.8 2.1 (26.1) (30.45) 2.1 1.8 (26.1) (30.45)
Pirelli Metzeler Dunlop
90/80 - 17" 46S 90/80 - 17" 46P
Rear tire
Pirelli Metzeler Dunlop
Muffler stamping.
110/80 - 17" 57S 110/80 - 17" 57P
Ref.
Description
Ref.
Description
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13
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WARNING!
COOLANT
14
USE ONL FLUID FOR SEALED CIRCUITS. Y USE ONL ANTIFREEZEAND ANTICORROSIVE Y WITHOUT NITRITE, ENSURING PROTECTION AT -35C AT LEAST.
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YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and aprilia s.p.a. (hereinafter aprilia) are pleased to explain the emission control system warranty on your 1999 and later motorcycle. In California new motor motorc yc l es m us t be d e si g ne d, b ui l t a nd equipped to meet the State's stringent antismog standards. aprilia must warrant the emission control system on your motorcycle for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your motorcycle. Your emission control system may include parts such as the carburetor or fuel-injection system, the ignition system, catalytic converter and engine computer. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, aprilia will repair your motorcycle at no cost to you, including diagnosis, parts and labor.
Class I motorcycles (50-169 cm): for a period of use of five (5) years or 12,000 kilometers (7,456 miles), whichever first occurs. Class II motorcycles (170 to 279 cm): for a period of use of five (5) years or 18,000 kilometers (11,185 miles), whichever first occurs. Class III motorcycles (280 cm and larger): for a period of use of five (5) years or 30,000 kilometers (18,641 miles), whichever first occurs. If an emission-related part on your motorcycle is defective, the part will be repaired or replaced by aprilia. This is your emission control system DEFECTS WARRANTY.
As the motorcycle owner, you are responsible for the performance of the required maintenance listed in your owner's manual. aprilia recommends that you retain all receipts covering maintenance on your motorcycle, but aprilia cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. You are responsible for presenting your motorcycles to an aprilia dealer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. As the motorcycle owner, you should be aware that aprilia may deny your warranty coverage if your motorcycle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. If you have any questions regarding your warranty rights and resposibilities, you should contact aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy tel. +39 041 58 29 111, fax +39 - 041 44 10 54, or the California Air Resources Board at P.O. Box 8001, 9528 Telstar Avenue, El Monte, CA 91734-8001.
11
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aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy (hereinafter aprilia) warrants that each new 1999 and later aprilia motorcycle, that includes as standard equipment a headlight, taillight and stoplight, and is street legal: A. is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and B. is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency of the California Air Resources Board for a period of use, depending on the engine displacement, of 12,000 kilometers (7,456 miles), if the motorcycle's engine displacement is less than 170 cubic centimeters: of 18,000 kilometers (11,185 miles), if the motorcycle's engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 30,000 kilometers (18,641 miles), if the motorcycle's engine displacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initial retail delivery, whichever first occurs.
I. COVERAGE. Warranty defects shall be remedied during customary business hours at any authorized aprilia motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Any part or parts replaced under this warranty shall become the property of aprilia. In the State of California only, emission related warranted parts are specifically defined by the state's Emission Warranty Parts List. These warranted parts are: carburetor and internal parts; intake manifold; fuel tank; fuel injection system; spark advance mechanism; crankcase breather; air cutoff valves; fuel tank cap for evaporative emission controlled motorcycles; oil filter cap; pressure control valve; fuel/vapor separator; canister; igniters; breaker governors; ignition coils; ignition wires; ignition points; condensers, and spark plugs if failure occurs prior to the first scheduled replacement; and hoses, clamps, fittings and tubing used directly in these parts. Since emission related parts may vary from model to model, certain models may not contain all of these parts and certain models may contain functionally equivalent parts.
In the State of California only, Emission Control System emergency repairs, as provided for in the California Administrative Code, may be performed by other than an authorized aprilia dealer. An emergency situation occurs when an authorized aprilia dealer is not reasonably available, a part is not available within 30 days, or a repair is not complete within 30 days. Any replacement part can be used in an emergency repair. aprilia will reimburse the owner for the expenses, including diagnosis, not to exceed aprilia's suggested retail price for all warranted parts replaced and labor charges based on aprilia's recommended time allowance for the warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.
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II. LIMITATIONS. This Emission Control System warranty shall not cover any of the following: A. Repair or replacement required as a result of (1) accident, (2) misuse, (3) repairs improperly performed or replacements improperly installed, (4) use of replacement parts or accessories not conforming to aprilia specifications which adversely affect performance and/or (5)use in competitive racing or related events. B. Inspections, replacement of parts and other services and adjustments required for required maintenance. C. Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined.
III. LIMITED LIABILITY A. The liability of aprilia under this Emission Control System Warranty is limited solely to the remectying of defects in material of workmanship by an authorized aprilia motorcycle dealer at its place of business during customary business hours. This warranty does not cover inconvenience or loss of use of the motorcycle or transportation of the motorcycle to or from the aprilia dealer. aprilia SHALL NOT BE LIABLE FOR ANY OTHER EXPENSES, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY ARISING IN CONNECTION WITH THE SALE OR USE OF OR INABILITY TO USE THE aprilia MOTORCYCLE FOR ANY PURPOSE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU.
B. NO EXPRESS EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY aprilia EXCEPT AS SPECIFICALLY SET FORTH HEREIN. ANY EMISSION CONTROL SYSTEM WARRANTY, IMPLIED BY LAW , INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY, THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES. SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU. C. No dealer is authorized to modify this aprilia Limited Emission Control System Warranty.
13
IV. LEGAL RIGHTS. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE. V. THIS WARRANTY IS IN ADDITION TO THE DSU LOLD LIMITED MOTORCYCLE WARRANTY. VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in the performance of any maintenance or repairs. However, aprilia is not liable for these parts. The owner is responsible for the perfomance of all required maintenace. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins on the date the motorcycle is delivered to an ultimate purchaser.
14
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NOTE
The operations preceded by this symbol must be repeated also on the opposite side of the motorcycle. If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order. The terms right and left are referred to the rider seated on the motorcycle in the normal riding position.
When asking your Dealer for spare parts, specify the spare parts code indicated on the SPARE PARTS IDENTIFICATION LABEL. Write down the identification code in the space here below, in order to remember it also in case of loss or deterioration of the label. The label is positioned under the rider saddle, see pag. 68 (REMOVING THE RIDER SADDLE).
In this manual the various versions are indicated by the following symbols:
VERSION: Italy United Kingdom Austria Portugal Finland Belgium Germany France Spain Greece Holland Switzerland Denmark Japan Singapore
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Poland Israel South Korea Malaysia Chile Bermuda United States of America Australia Brazil South Africa New Zealand Canada Croatia Slovenia
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FOREWORD ......................................................... 2 INTRODUCTION ................................................... 2 SAFETY WARNINGS ........................................... 3 GENERAL SAFETY RULES................................. 3 CARBON MONOXIDE ........................................ 3 GASOLINE ......................................................... 3 HOT COMPONENTS.......................................... 3 USED ENGINE OIL ............................................ 4 BRAKE FLUID .................................................... 4 COOLANT........................................................... 4 BATTERY HYDROGEN GAS AND ELECTROLYTE ......................................... 4 WARNINGS - PRECAUTIONS GENERAL ADVICE .............................................. 5 REPORTING OF DEFECTS THAT AFFECT SAFETY..................................... 5 ROAD REGULATIONS AND USE OF THE MOTORCYCLE ................... 5 NOISE EMISSION WARRANTY......................... 5 INFORMATION ON THE NOISE AND EXHAUST GAS EMISSION CONTROL SYSTEM........................................... 5 TAMPERING WARNING .................................... 6 VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER) ................................ 7 INFORMATION CONTAINED IN THE MOTORCYCLE IDENTIFICATION NUMBER............................... 7 POSITION OF THE WARNING ADHESIVE LABELS........... 8 aprilia s.p.a. EMISSION CONTROL SYSTEM WARRANTY STATEMENT............... 11 MANUFACTURER'S WARRANTY COVERAGE ................................ 11 OWNER'S WARRANTY RESPONSIBILITIES . 11 aprilia s.p.a. LIMITED WARRANTY ON EMISSION CONTROL SYSTEM................ 12 GENERAL INSTRUCTIONS ............................... 15 TABLE OF CONTENTS.................................... 16 SAFE DRIVE ....................................................... 17 BASIC SAFETY RULES ................................... 18 CLOTHING ....................................................... 23 ACCESSORIES ................................................ 24 LOAD ................................................................ 24 ARRANGEMENT OF THE MAIN ELEMENTS ... 26
16
ARRANGEMENT OF THE INSTRUMENTS/CONTROLS................28 INSTRUMENTS AND INDICATORS ...................28 INSTRUMENTS AND INDICATORS TABLE ....29 CONTROLS .........................................................30 CONTROLS AT THE LEFT HAND GRIP ..........30 CONTROLS AT THE RIGHT HAND GRIP .......31 CARBURETOR CONTROLS ............................31 IGNITION SWITCH ...........................................32 STEERING LOCK .............................................32 AUXILIARY EQUIPMENT ...................................33 GLOVE/TOOL KIT COMPARTMENT ...............33 SPECIAL TOOLS ........................................34 MAIN COMPONENTS .........................................35 FUEL .................................................................35 LUBRICANTS....................................................36 BRAKES ............................................................37 DISC BRAKES ..................................................38 FRONT BRAKE .................................................38 REAR BRAKE ...................................................39 ADJUSTING THE SHIFT LEVER......................40 ADJUSTING THE REAR BRAKE......................40 ADJUSTING THE CLUTCH ..............................41 COOLANT .........................................................42 TIRES................................................................44 AUTOMATIC LIGHTS ON .................................45 EXHAUST SILENCER ......................................45 INSTRUCTIONS FOR USE .................................46 PRELIMINARY CHECKING OPERATIONS .....47 STARTING ........................................................48 RIDING..............................................................50 RUNNING-IN .....................................................53 STOPPING........................................................53 PARKING ..........................................................53 SUGGESTIONS TO PREVENT THEFT ...........54 MAINTENANCE...................................................55 REGULAR SERVICE INTERVALS CHART ......56 IDENTIFICATION DATA ...................................58 POSITIONING THE MOTORCYCLE ..........58 ON THE FRONT SUPPORT STAND POSITIONING THE MOTORCYCLE ............59 ON THE REAR SUPPORT STAND CHECKING THE TRANSMISSION OIL LEVEL AND TOPPING UP.........................60 FRONT WHEEL ................................................62 REAR WHEEL...................................................64
DRIVE CHAIN................................................... 66 REMOVING THE RIDER SADDLE................... 68 REMOVING THE SIDE FAIRINGS ................... 68 REMOVING THE FUEL TANK ......................... 69 AIR CLEANER .................................................. 70 REMOVING THE FRONT PART OF THE FAIRING ............................................. 70 INSPECTING THE FRONT AND REAR SUSPENSIONS ............................ 71 CHECKING THE BRAKE PAD WEAR ............. 72 IDLING ADJUSTMENT..................................... 73 ADJUSTING THE THROTTLE CONTROL....... 74 CHECKING THE SIDE STAND ........................ 74 CHECKING THE FUNCTIONING OF THE SAFETY SWITCH ON THE SIDE STAND...................................... 75 CHECKING THE SWITCHES........................... 75 SPARK PLUG ................................................... 76 BATTERY ......................................................... 77 BATTERY STORAGE....................................... 78 CHECKING AND CLEANING THE TERMINALS ............................................. 78 REMOVING THE BATTERY............................. 78 CHECKING THE ELECTROLYTE LEVEL........ 79 RECHARGING THE BATTERY........................ 79 INSTALLING THE BATTERY ........................... 79 CHANGING FUSES.......................................... 80 ADJUSTING THE HEADLIGHT BEAM VERTICALLY ........... 81 ADJUSTING THE HEADLIGHT BEAM HORIZONTALLY ..... 82 BULBS .............................................................. 83 CHANGING THE HEADLIGHT BULBS ............ 84 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS..................... 85 CHANGING THE REAR LIGHT BULB ............. 86 TRANSPORT ...................................................... 87 DRAINING THE FUEL TANK ........................... 87 CLEANING .......................................................... 88 LONG PERIODS OF INACTIVITY.................... 89 TECHNICAL DATA ............................................. 90 LUBRICANT CHART ........................................ 93 Importers......................................................94-95 ....................... 96 WIRING DIAGRAM - RS 50 ............... 97 WIRING DIAGRAM KEY - RS 50
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The instructions given below cover normal operation of your motorcycle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your motorcycle. Motorcycles obviously do not provide some of the protection provided by automobiles, therefore it is essential that you wear appropriate protective clothing. Especially, never operate your motorcycle without wearing your helmet, gloves, eye protection, a heavy jacket, sturdy footwear, and sturdy full length pants. However, do not assume that even the best clothing and helmet will protect you in the event of an upset or a crash with another motorcycle. At best, this gear provides some protection from scrapes and scratches, but very little, if any, impact protection. Be sure that you meet all the requirements prescribed by local law, including drivers license, minimum age, training, insurance, taxes, motorcycle registration, license plate, etc. When you first receive your motorcycle, practice by riding in areas where there is little traffic. Do not attempt to ride in heavy traffic until you are thoroughly experienced and riding your motorcycle has become second nature to you. Most states prohibit the operation of this size motorcycle on freeways or express18
ways, be sure that it is legal to use your motorcycle before you take any particular road. A new motorcycle must be carefully broken in, see p. 53 (RUNNING-IN). Before starting the engine, make sure that the brakes, clutch, transmission and throttle controls function properly and that the fuel and oil supply is adequate. The exhaust system, brakes, and some other parts of the motorcycle become very hot during operation. Do not touch any of these parts. Some medicines or drugs, illegal or prescription, and alcohol significantly increase the risk of accidents. Do not ride while you are under the influence of alcohol or drugs, be they illicit or prescription. Make sure you are in good physical condition and not ill before riding your motorcycle. Do not
ride your motorcycle when you are particularly tired or fatigued. Alcohol, drugs and fatigue are leading causes of motorcycle accidents. Many accidents are caused by the riders inexperience and lack of training. Do not ride your motorcycle until you have received training from a recognized training organization such as the Motorcycle Safety Foundation. Remember that riding a motorcycle, though easy and fun, is quite different from driving a car. Do not assume that you can operate your motorcycle safely just because you are a competent automobile driver. Never lend your motorcycle to others unless you are sure that they are competent and properly licensed motorcycle operators.
Observe all rules of the road. Particularly pay attention to all warning, regulatory and informational signs. Avoid showing off (i.e., popping wheelies). Especially observe speed limits, remember that road conditions change with the weather and wet and icy pavements are particularly dangerous for motorcycles, especially if you are riding too fast. Remember that automobile drivers have a hard time seeing motorcycles, so always give the automobile the right of way, even if it is legally yours. Before changing lane, look over your shoulder to make sure that the way is clear. Do not rely exclusively on the rearview mirror: you may miscalculate the distance and speed of a motorcycle, or you may even not see it at all.
Avoid obstacles that could damage the motorcycle or make you lose control. Do not tailgate, do not attempt to increase your gas mileage by following in the slip stream of cars or trucks in front of you. In case of accident motorcycles, scooters and mopeds do not provide the same degree of protection ensured by automobiles. The legs, in particular, are exposed the risk of being injured. However, the additional installation of leg guards may actually increase the risk of injuries and their seriousness in case of accident. Do not install leg guards available on the market of spare parts and accessories. Non-compliance with these instructions may result in serious injuries or even death.
Always ride with both hands on the handlebars and feet on the footrests. Never shift gear without using the clutch, if the motorcycle is so equipped. Do not operate the shift lever or the other controls suddenly or abruptly. Such misuse can damage the internal components of the motorcycle and consequently cause seizure, loss of control, accidents and serious injuries or even death. Remain in the seat when you are riding. Do not stand up or attempt to stretch while you are riding your motorcycle. If you need to rest, pull over to the side of the road when it can be safely done.
19
OIL
COOLER
It is very important to your safety that you give full attention to the riding task. Watch what you are doing, do not allow yourself to be distracted by other cars, people or things on the roadside, etc. Never smoke, eat, drink, read, etc. while riding your motorcycle. If you must consult a map, pull over when it can be done safely.
Use only the motorcycles specific fuels and lubricants indicated in the LUBRICANT CHART; check the oil, fuel and coolant levels regularly.
If you and your motorcycle are involved in an accident, insure that there has been no damage to the control levers, tubes, wires, braking system and other vital parts. If your motorcycle is involved in an accident, take it immediately to your Local aprilia Dealer who has the equipment and knowledge to check for accidental damage which may compromise your safety. Your aprilia dealer is ready and able to help you with any safety problems that you might have, but of course it is necessary for you to report any malfunctions to your mechanic in order for him to help you. Do not use your motorcycle if it is damaged. A damaged motorcycle may become unstable or present other problems which can increase the risk of accident, and therefore of serious injury or even death.
20
ONLY ORIGINALS
A12 345
Do not attempt to modify the position, angle or color of your license plate. Do not cover it with even a clear plastic covering. Do not modify any of the safety equipment of your motorcycle, especially such safety related items as directional indicators, rear view mirrors, lights or horns. Any modification to your motorcycle will invalidate the warranty. Do not modify your engine in an attempt to increase the horsepower. This can result in irreparable damage to the engine, as well as degradation of the performance and handling of the motorcycle which could lead to an upset, and serious injury or even death.
Have your motorcycle repaired only with original parts, and use only original aprilia or aprilia approved accessories. The use of aftermarket accessories and parts can seriously compromise the safety of your motorcycle as well as its performance and serviceability. Any modification which affects performance or safety voids your warranty completely. For the reasons stated above, the failure to comply with the tampering prohibition is punished by law with apposite sanctions (including the confiscation of the motorcycle), which, according to the case, can be combined with the sanctions provided for not using the crash helmet and/or the number plate, for the violation of fiscal obligations (ownership tax) and with penal sanctions provided for using the motorcycle without driving license.
This motorcycle was not designed to be equipped with a sidecar or to be used to tow trailers or other motorcycles. aprilia does not manufacture sidecars or trailers and therefore cannot predict the effects of such accessories on the manoeuvrability or stability of the motorcycle: it can only warn that such effects may be negative and that any damage to the motorcycle components caused by the use of such accessories will not be covered by the warranty.
21
Never race other motorcycles with your motorcycle. Brake with both the front and rear brakes. The use of one brake only for sudden braking may cause the motorcycle to skid or make the rider lose control of the motorcycle itself. When riding down a steep hill, use the engine as a brake by selecting the same gear, or a lower gear, than you would use to climb the hill. Use front and rear brakes sparingly.
Always ride at the appropriate speed and avoid unnecessary hard acceleration. This not only is safer, but also reduces fuel consumption and increases the life of the motorcycle. If you must ride your motorcycle in rainy weather, or on loose surfaces, remember that traction is greatly reduced. Under these conditions, all handling of the motorcycle must be done gradually and smoothly. Sudden acceleration, braking or turning may make you lose control of your motorcycle. When traction is reduced, accelerate and slow using your motorcycles engine braking insofar as possible. Avoid rapid, harsh application of the brakes.
Gradually open and close the throttle, to avoid spinning or skidding the rear wheel. On rough road surfaces, slow down and ride with particular care. Try to avoid wide open throttle accelerations, unless they are necessary for such things as passing. Dont allow your engine to lug, that is, run at too low an rpm. Shift down to a lower gear. Also, dont over-rev the engine. Observe the redline on the tachometer. Remember that excessively aggressive cornering can cause your motorcycles tires to lose sideways traction, which can result in an upset and serious injury or even death.
22
Always observe posted and statutory speed limits, but do not assume that you can ride as fast as the speed limit under all road conditions. Slowing down a little can greatly increase your safety under all road conditions. Do not ride your motorcycle off road. Do not tamper with the muffler system or the emissions control system of your motorcycle. This is not only bad for the environment, it can subject you to serious penalties.
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Before riding your motorcycle, ensure that your riding gear is in good condition. To be effective, your helmet must fit properly, and the visor or other eye protection must be clean. B oth research and experi ence h ave shown that drivers of other motorcycles often do not see motorcycles or riders. In order to make yourself more conspicuous to these drivers, wear bright reflective clothing, such as a reflective vest, or clothing with reflective sections sewn into the jacket, pants and gloves. Be particular aware of approaching automobiles and trucks that might be trying to turn left in front of you. Many motorcycle accidents are caused by an opposing automobile driver making a left turn without warning in front of the motorcycle.
Inevitably, the driver will look right at you, and yet swear that they did not see you before they turned directly into your path. Ride alert! Wear protective clothing, preferably in light and/or reflecting colours. In this way you will make yourself more visible to the other drivers, thus notably reducing the risk of being knocked down, and you will be more protected in case of fall. Always wear your crash helmet. Many accidents are fatal because of injuries to the head. This clothing should be very tight-fitting and fastened at the wrists and ankles. Strings, belts and ties should not be hanging loose; prevent these and other objects from interfering with driving by getting entangled with moving parts or driving mechanisms.
23
Do not carry sharp objects in your pockets that could be dangerous in case of an upset, for example, pens or mechanical pencils, etc. Also, make sure that your passengers follow this recommendation.
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The owner of the motorcycle is responsible for the choice, installation and use of any accessory. The installation of inappropriate accessories or the overloading of the motorcycle may result in the instability of the motorcycle itself and cause accidents with consequent risk of serious injuries or even death. Windshields could be particularly dangerous, as they can break and injure or cut the rider in case of accident. In case of doubts with regard to any accessory you would like to install or 24
any load you would like to carry, previously consult your Local aprilia Dealer. Avoid installing accessories that cover horns or lights or that could impair their functions, limit the suspension stroke and the steering angle, hamper the operation of the controls and reduce the distance from the ground and the angle of inclination in turns. Avoid using accessories that hamper access to the controls, since this can prolong reaction times during an emergency. Big fairings and windshields installed on the motorcycle may produce aerodynamic forces that will affect the stability of the motorcycle during use, especially at high speeds.
Make sure that anything you carry on your motorcycle is securely attached, and cannot come lose and jam the wheels, forks, etc. Do not install any electrical accessories, and do not modify the electrical system of your motorcycle. Anything that could cause an electrical overload or other fault could cause the motorcycle to suddenly stop, the lights to dim or quit, or the horn and other safety accessories not to work. Use only aprilia genuine accessories.
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Do not overload your motorcycle. Attach luggage or packages as close as possible to the center of your motorcycle and distribute the load from side to side as evenly as possible, to keep imbalance to a minimum. Remember that loads tend to loosen with riding, so frequently check the security of your load.
KG!
Do not hang anything from your motorcycle handlebars, fenders, or forks, because this will upset the handling of your motorcycle, and could prevent you from avoiding an accident. Failure to heed this warning can lead to an upset with subsequent serious injury or even death. Do not ride with your crash helmet hung from the strap because it could easily foul the wheels, fenders, or forks, causing an upset and subsequent serious injury or even death. Carry a passenger only if your motorcycle is equipped with passenger footpegs, handgrips for the passenger to hold on to, and a passenger seat. When carrying a passenger, remember that your motorcycles handling is degraded, that the brakes are less efficient, and the center of gravity is higher and further to the rear.
This makes it more likely that the front wheel will come up off the ground, especially on acceleration. Therefore, you should avoid hard acceleration and hard braking. Many accidents are caused by inexperienced riders carrying passengers. Remember that allowance must be made for the extra weight of the passenger for all driving maneuvers. Avoid abrupt and excessive acceleration. Always slow down in time and calculate longer stopping and manoeuvring distances. Non-compliance with these instructions may lead to the overturning of the motorcycle or to other accidents with consequent serious injuries or even death.
Never carry l oosely packaged items, make sure that everything that you carry on your motorcycle is carefully secured. Do not carry packages which protrude from the luggage rack or which cover any of the signal lights, the headlight, or the horn. Never carry animals or children on the glove compartment or on the luggage rack. Never exceed the labeled maximum load for each saddlebag. Overloading your motorcycle seriously reduces its stability and maneuverability and can lead to an upset with subsequent serious injury or death.
25
$55$1*(0(17 2)
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Left rear-view mirror Radiator cap Radiator Fuel filler cap Spark plug Fuel valve Battery
8) Fuse carrier 9) Passenger left footrest (snapping, closed/open) (in the countries where required) 10) Drive chain 11) Side stand (with automatic return)
12) Rider left footrest (with spring, always open) 13) Shift lever 14) Left fairing 15) Horn
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1) 2) 3) 4) 5) 6) 7)
Glove/tool kit compartment 2 stroke oil tank 2 stroke oil tank cap Rider saddle Saddle lock Air cleaner Ignition switch/steering lock
8) 9) 10) 11) 12) 13) 14)
Right rear-view mirror Front brake reservoir Dashboard Cold start lever Rear brake reservoir Rear brake master cylinder Rear brake pedal
15) Rider right footrest (with spring, always open) 16) Passenger right footrest (snapping, closed/open) (in the countries where required)
27
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Ignition switch/steering lock ( - ) Direction indicator switch ( ) Horn push button ( ) Dimmer switch ( ) High beam signalling push button ( ) Clutch lever Instruments and indicators Front brake lever Throttle grip Start push button ( ) Engine stop switch ( - )
( +
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1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)
Revolution counter Coolant temperature indicator ( ) Green right direction indicator warning light ( ) Green neutral indicator warning light ( ) Red 2 stroke oil reserve warning light ( ) Blue high beam warning light ( ) Green low beam warning light ( ) Green left direction indicator warning light ( ) Trip odometer Odometer reset Total miles odometer Speedometer
* )
28
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Description Right directional indicator Left directional indicator High beam indicator Low beam indicator Tachometer (rpm)
* ()) () ()
Function
( ) Blinks when the right direction indicator is on. Blinks when the left direction indicator is on. Comes on when the headlight is in high beam position or when the high beam signalling is operated. It comes on when the headlight is in low beam position. Indicates the number of revolutions of the engine per minute.
Coolant temperature indicator
It indicates the approximate temperature of the coolant in the engine. When the pointer starts moving beyond the min level, the temperature is sufficient for driving the motorcycle. The normal running temperature range is indicated by the central area of the scale. ( ) If the pointer reaches the red area, stop the engine and check the coolant level, see p. 42 (COOLANT). Do not operate the motorcycle if the maximum temperature is WARNING exceeded. Serious engine damage or even seizure may result which can cause an upset and serious injury or even death.
2 stroke oil reserve warning light
It comes on when the quantity of 2 stroke oil left in the tank is equal to 0.09 US gal (0.35 - ). If the warning light comes on, this indicates that the 2 stroke oil CAUTION reserve is being used. Immediately top up the 2 stroke oil tank, ) see p. 36 (2 STROKE OIL TANK). Failure to heed this warning can lead to engine seizure, upset, and serious injury or even death.
Neutral indicator warning light Trip odometer Odometer Speedometer
( ) Comes on when the gear is in neutral. Indicates the number of miles covered in a trip. To reset to zero, press the odometer control button. Indicates the total number of miles that the motorcycle has traveled since new. Indicates road speed.
29
&21752/6
&21752/6 $7 7+( /()7 +$1' *5,3
NOTE The electrical components function only when the ignition switch (A) is in the (ON) position. The lights are illuminated only when the engine is running.
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; to indicate 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 lever is in the position indicated by the , the parking lights, dashboard light and low beam are on. When the lever is moved to the , the high beam is illuminated, the dashboard and parking lights remain on.

) 4) HIGH BEAM SIGNALING PUSH BUTTON ( Depress the button momentarily to flash the high beam for signaling when passing, etc. and in the event you need someones attention in an emergency.
30
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NOTE The electrical components function only when the ignition switch (A) is in the (ON) position. The lights are illuminated only when the engine is running. 1) ENGINE STOP SWITCH (
Do not use the engine stop switch to stop the engine while the motorcycle is moving. With the switch (1) in the (ON) position it is possible to start the engine. The engine can be stopped by moving the switch (1) to the (OFF) position.
WARNING

- )
Do not leave the ignition on if you have stopped the engine by moving the engine stop switch to the (OFF) position as this will discharge the battery. When the motorcycle has come to rest after stopping the engine with the engine stop switch, turn the ignition switch (A) to the (OFF) position.
CAUTION

When the engine is warmed up, before you ride away, while holding at least one brake, engage neutral (the green neutral light (4) will illuminate). Allow the engine to warm up thoroughly.
2) STARTER SWITCH ( ) When the starter switch is depressed, the starter is engaged and the engine will start. For starting, see p. 48 (STARTING).
&$5%85(725 &21752/6
COLD START LEVER The cold start lever (3) is located on the right side of the carburetor. It can be reached from above through the opening between the fairing and the frame. To operate the cold start lever, push the lever downward.
Do not attempt to disengage the cold start lever by hand. It automatically returns to its initial proper position when the throttle grip is twisted. Do not ride away with the cold start lever pushed downward. For the first few moments, do not accelerate hard. Allow the engine to thoroughly warm up before you demand full performance.
x
CAUTION
Rotating the throttle grip (5) completely counterclockwise (open), quickly, and releasing it immediately, will disengage the cold start lever. You will hear a metallic snap which signals that the cold start lever has returned to its disengaged position.
31
Position
Function The steering is locked. It is neither possible to start the engine, nor to switch on the lights. Neither the engine, nor the lights can be switched on. The engine and the lights can be switched on.
Key removal It is possible to remove the key.
(LOCK) Steering lock
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The ignition switch (1) is located on the upper plate of the steering head. NOTE The key operates the ignition switch/steering lock, the saddle lock and the fuel tank lock. Two keys are supplied together with the motorcycle (one spare key).
Never attempt to place the ignition switch in the locked (LOCK) position while the motorcycle is moving. This will cause loss of control of the motorcycle with possible subsequent accident, serious injury or even death. OPERATION To lock the steering: x Turn the handlebar as far as it will go to the left or to the right. x Turn the key (2) to position (OFF). x Press the key and rotate it to position (LOCK). x Extract the key.
WARNING
+
(OFF)

(ON)
It is possible to remove the key. It is not possible to remove the key.
32
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The glove/tool kit compartment is positioned under the rider saddle; to reach it: x Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE).
The tool kit (1) includes: 0.12 in (3 mm), 0.16 in (4 mm), 0.20 in (5 mm) allen spanners; 0.39 0.43 in (10 11 mm) double fork spanner; 0.83 0.87 in (21 22 mm) spark plug socket spanner; double-ended, cross-/cut headedscrewdriver; bent pin for socket spanner; tool case. Max. allowed weight: 3.31 lb (1.5 kg).
33
Tool
Operations
Page
Support pins Positioning of the motorcycle on the (1) for the rear support rear stand. stand. Rear support Rear wheel disassembly. stand (2). Drive chain adjustment. Front support stand (3). Front wheel disassembly.
58
64 66 62
63(&,$/ 722/6
For some specific maintenance operations it is necessary to use the appropriate special tool as shown at the right. These tools may be ordered from your Local aprilia Dealer.
34
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Gasoline is extremely flammable and in some conditions can become explosive. Therefore, it is necessary to refuel and carry out maintenance operations involving the fuel system in a well-ventilated area with the engine off. Do not refuel or do any maintenance on the fuel system with the engine running. Do not smoke while refueling or near fuel vapors. Never allow any portion of the fuel system to come in contact with naked flames, sparks or other heat sources. Be careful to avoid spilling fuel when you are refueling. Spilled fuel could ignite when it contacts hot engine or exhaust system surfaces. If you accidentally spill some fuel, make sure that it is wiped up or completely evaporated before starting the motorcycle. Since gasoline expands in the fuel tank when the motorcycle is sitting in the open sun, never fill the tank completely to the brim. Leave at least one inch of expansion space. Avoid any contact of the fuel with your skin, and avoid inhalation of fuel vapors. Do not ever attempt to siphon fuel from one container to another using your mouth as suction for a siphon hose.
WARNING
Gasoline is poisonous and carcinogenic and contains chemical substances that cause birth defects and other reproductive problems. If gasoline should be accidentally spilt on the skin or clothes, immediately wash it off with soap and water and change clothes. Should you accidentally spill gasoline in your eyes, flush with a large quantity of water and immediately contact a health professional. Should you accidentally get gasoline into your mouth, do not induce vomiting. Drink a large quantity of milk or clear water and immediately contact a health professional. Never try to siphon gasoline by sucking it with your mouth. Use a manual pump or a similar system. If your motorcycle overturns, it will leak gasoline which is extremely flammable. Flames or sparks may ignite this which will not only destroy the motorcycle but also could do serious property damage to surrounding property and cause serious injuries or even death. ALWAYS KEEP GASOLINE AWAY FROM CHILDREN. DISPOSE OF UNWANTED GASOLINE PROPERLY, DO NOT DUMP IT INTO STORM SEWERS OR INTO A SINK OR TOILET.
WARNING
Use only unleaded petrol minimum octane rating (R+M)/2 method 90. FUEL TANK CAPACITY (reserve included): 3.43 US gal (13 ).
TANK RESERVE: 0.69 US gal (2.6 - ) (mechanical reserve). To refuel, proceed as follows: x Insert the key (1) in the tank filler cap lock. x Turn the key counterclockwise, pull and remove the filler cap (2).
After refueling the tank, replace the filler cap.
WARNING
35
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Proper motorcycle lubrication is critical to safe operation. Failure to maintain proper lubricant levels or to use the proper type of clean, new lubricant, can lead to an engine or transmission seizure with subsequent accident, serious injury or death. Use latex gloves for the maintenance operations that require contact with used oil. Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle used oil on a daily basis, it is advisable to thoroughly wash your hands with soap and water after handling used oil. KEEP OIL AWAY FROM CHILDREN. DISPOSE OF OIL PROPERLY. Be very careful when putting oil in your motorcycle not to spill oil. Clean up any oil spilled immediately because oil can damage the finish of your motorcycle. Also, oil on the tires creates an extremely slippery and therefore dangerous situation. In case of oil leakage do not ride your motorcycle. Before using the motorcycle, have it repaired by your Local DSULOLD Delear. 36
WARNING
2 STROKE OIL TANK
When the 2 stroke oil warning light (1) comes on, this means that the 2 stroke oil reserve is being used. Immediately top up the 2 stroke oil tank. See instructions for topping up, below.
CAUTION
WARNING
If the 2 stroke oil supply is exhausted, the engine will seize. This can cause an upset with consequent risk of serious injury or even death. It certainly will destroy your engine. Top up the 2 stroke oil tank every 300 mi (500 km). The motorcycle is provided with a separate mixer that ensures the mixing of petrol and oil for the engine lubrication, see p. 93 (LUBRICANT CHART). When the oil level in the 2 stroke oil tank is so low that the reserve is being used, the (1) 2 stroke oil reserve warning light located on the dashboard, will illuminate, see p. 28 (INSTRUMENTS AND INDICATORS).
WARNING
CAUTION CAUTION
?
Delear, who can bleed the system. This operation must be carried out before further running, since running the engine with air in the 2 stroke oil system will result in serious damage to the engine, an engine seizure, a possible accident, with subsequent serious injury or death.
DSULOLD
Do not run your engine, even for a moment, without adequate 2 stroke oil in the 2 stroke oil tank. This will cause serious damage to the engine. If you should run out of 2 stroke oil, or if the 2 stroke oil line has been removed, take your motorcycle to your Local
WARNING
To fill the 2 stroke oil tank: x Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). x Remove the filler cap (2). x Using a funnel, fill the tank to the appropriate level with 2 stroke oil. TANK CAPACITY: 1.69 US qt (1.6 - ). TANK RESERVE: 0.37 US qt (0.35 - ).
x
Replace the filler cap (2), ensuring that it is properly seated. x Replace the rider saddle.
TRANSMISSION OIL Check the transmission oil level every 2,500 mi (4,000 km), see p. 60 (CHECKING THE TRANSMISSION OIL LEVEL AND TOPPING UP).
Have your Local DSULOLD Delear change the transmission oil after the first 300 mi (500 km), and thereafter every 5,000 mi (8,000 km). NOTE Use high-quality 75W-90 oil, see p. 93 (LUBRICANT CHART).
CAUTION
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Do not ride your motorcycle with worn or malfunctioning brakes! The brakes are the most important safety system of your motorcycle, and using the bike with brakes that are anything less than perfect is very likely to lead to a collision or upset, with consequent risk of serious injury or death. Check the brake pad wear, as shown on p. 72 (CHECKING THE BRAKE PAD WEAR). Have your brakes serviced by your Local DSULOLD Delear.
WARNING
Wet conditions seriously degrade the performance of your brakes. When the road is wet from rain, you should plan to use double the normal stopping distances since both the brakes themselves and the traction of the tires on the road are reduced by the presence of water. Water on the brakes from washing your motorcycle, or splashed up from wet roads, or crossing puddles or ditches, can wet the brakes sufficiently to greatly reduce their effectiveness. Failure to heed these warnings may lead to a serious accident with consequent risk of serious injury or even death.
WARNING
Sudden resistance or clearance problems on the brake lever may be due to troubles in the hydraulic system. For any doubt regarding the perfect functioning of the braking system and in case you are not able to carry out the usual checking operations, contact your Local DSULOLD Delear.
WARNING
Pay special attention to the brake disc and friction material, making sure that they are neither dirty nor oily, especially after maintenance operations or inspections. Make sure that the brake pipe is neither twisted nor worn out. KEEP AWAY FROM CHILDREN. DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.
WARNING
NOTE
This motorcycle is equipped with front and rear disc brakes with separate hydraulic systems. The following information may refer to just one braking system but should be observed with regard to both brakes.
The brakes are extremely important for your safety. Do not use the motorcycle if the brakes do not work perfectly. Always check the brake efficiency before leaving.
WARNING
37
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As mentioned above, the brakes are the most important safety system on your motorcycle. For your safety, they must be in perfect repair, so they should be checked every time you ride your motorcycle. Oil or other fluid on a disc will contaminate the brake pads. Dirty pads must be discarded and replaced, a dirty or oily disc must be cleaned with a high quality degreaser. Arrange with your Local DSULOLD Delear to flush the systems and change all of the brake fluid once every two years.
WARNING
Check the levels of the brake fluid in the reservoirs, see below (FRONT BRAKE), p. 39 (REAR BRAKE), and the wear of the pads, see p. 72 (CHECKING THE BRAKE PAD WEAR), every 300 mi (500 km). Never use your motorcycle if any portion of either brake system is leaking.
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WARNING
CHECKING THE SYSTEM
NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor.
x x
NOTE This motorcycle is provided with front and rear disc brakes with separate hydraulic systems. When the pads wear out the brake fluid level in the reservoir decreases to automatically compensate for their wear. The front brake fluid reservoir is located on the right end of the handlebar near the front brake lever. The rear brake fluid reservoir is under the upper part of the fairing on the right side of the motorcycle.
Place the motorcycle on the stand. Rotate the handlebars fully counterclockwise so that the top surface of the brake fluid in the front brake reservoir is parallel to the top edge of the reservoir (1). x Ensure that the fluid level is up to the top of the glass gauge (2). If not, top off.
Use only DOT 5 or 4 fluid taken from a clean, sealed container. Never reuse used brake fluid.
WARNING CAUTION
After servicing the brakes, always check them for function. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your motorcycle serviced by your Local DSULOLD Delear. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system. Never ride your motorcycle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your motorcycle. Then, try your motorcycle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death.
CAUTION
38
When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear. x Check the brake pad wear, p. 72 (CHECKING THE BRAKE PAD WEAR) and the disc wear.
If it is not, remove the reservoir filler cap (4). Bring the level up to the MAX mark and replace the filler cap. x Wipe up any fluid that you may have spilled.
Use only DOT 5 or 4 fluid taken from a clean, sealed container. Never reuse used brake fluid.
WARNING CAUTION CAUTION
5($5 %5$.(
When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear.
x
CHECKING THE SYSTEM
NOTE Carry out these checks only on a firm, flat surface such as a concrete garage floor.
The side stand retracts automatically when the motorcycle is picked up from its leaned over position on the stand. Be careful not to let the bike fall over when you lift the bike up to perform this check.
x
Check the brake pad wear, p. 72 (CHECKING THE BRAKE PAD WEAR) and the disc wear.
WARNING
Maintain the motorcycle in a vertical position so that the surface of the fluid in the rear brake reservoir (3) is parallel to the top edge of the reservoir. x Make sure that the fluid level is above the MIN mark.
After servi ci ng the brakes, al ways check them for function. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your motorcycle serviced by your Local DSULOLD Delear. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system.
Never ride your motorcycle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your motorcycle. Then, try your motorcycle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death.
39
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The shift lever (1) may be adjusted by adjusting the length of the rod (2) as follows: x Loosen the nuts (3, 4). x Rotate the rod (2) to adjust the shift lever position. x Tighten the nuts (3, 4). Regularly lubricate the shift lever axle through the slots.
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The brake pedal (5) is adjusted to fit most riders during manufacture. If you wish to adjust the brake pedal: x Loosen the lock nut (6). x Unscrew the brake adjusting bolt (7) completely.
Loosen the lock nut (8) on the master cylinder push rod (9) and run it as far towards the master cylinder as far as it will go on the threads of the push rod. x Screw the push rod (9) completely into the clevis, then unscrew it three to four turns. x Adjust the brake adjuster bolt (7) until the brake pedal (10) is positioned as you like it. x Screw down and tighten the lock nut (6) on the brake adjuster bolt (7). x Screw the master cylinder push rod (9) out of the clevis until it just contacts the master cylinder piston. x Then, screw the push rod into the clevis to obtain a minimum clearance of 0.02 0.04 in (0.5 1 mm) between the master cylinder push rod and the master cylinder piston. x Lock the push rod in position with the lock nut (8).
Be sure there is the specified clearance between the master cylinder push rod and the master cylinder piston. If this caution is not observed, the brake will remain slightly applied, with subsequent brake overheating and wear of pads and discs. Clearance between the push rod and the piston 0.02 0.04 in (0.5 1 mm). After making any brake adjustment apply the brakes repeatedly. Try the brakes in a parking lot or other area where there is little traffic. After you have completed the adjustment, lift the wheel free of the ground and ensure that it rotates freely when the brake is released.
CAUTION
WARNING
40
A limited range of adjustment of the clutch can be accomplished using the adjuster (10) located at the left handlebar: x Pull back the rubber boot (11). x Loosen the lock nut (12). x Rotate the adjuster (10) until the free play at the end of the clutch lever is between 0.39 0.59 in (10 15 mm) (see figure). x Tighten the lock nut (12) to lock the adjuster in place. x Recheck the free play. x Reposition the rubber boot (11).
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Adjust the clutch if the clutch drags or slips during operation.
If it is not possible to properly adjust the clutch this way, see your Local DSULOLD Delear.
WARNING
NOTE
Inspect the clutch cable to make sure that it is not damaged. The inner cable must have no broken strands, and the outer cable must not be kinked or bent. Periodically lubricate the clutch cable with a suitable lubricant, see p. 93 (LUBRICANT CHART). This will protect it from excessive wear and corrosion.
41
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Do not use the motorcycle if the coolant is below the minimum prescribed level. Check the coolant level every 1,250 mi (2,000 km) and after long trips; have the coolant changed by your Local aprilia Dealer every 2 years.
CAUTION
DISPOSE OF THE COOLANT PROPERLY. BE S URE TO K EE P T HE DR AINE D COOLANT AWAY FROM CHILDREN AND PETS. IT IS SWEET TASTING, AS WELL AS EXTREMELY POISONOUS, AND IS VERY ATTRACTIVE TO CHILDREN AND PETS. Use extra caution not to spill the coolant on any hot parts of the engine. It is flammable, and can emit invisible, noxious fumes. Always wear rubber or latex gloves when servicing the cooling system. Have the coolant changed by your Local DSULOLD Delear. The coolant is made up of 50% water and 50% antifreeze. This mixture is ideal for most running temperatures and ensures good protection against corrosion. It is advisable to keep the same mixture also in the hot season, since in this way losses due to evaporation are reduced and it is not necessary to top up very frequently. The mineral salt deposits left in the radiator by evaporated water are thus reduced and the efficiency of the cooling system remains unchanged. If the outdoor temperature is below 0C, check the cooling circuit frequently and if necessary increase the antifreeze concentration (up to maximum 60%).
WARNING
Coolant is poisonous! Do not ingest c o ol an t u n d er an y ci rc u m st an c e . Should you get coolant in your mouth, rinse with cool water and immediately seek medical attention. Coolant is also very dangerous to your skin and eyes. Should you accidentally get coolant on your clothing or skin, change clothes immediately. Wash coolant from your skin with hot water and soap. Should you get coolant in your eyes, flush with plenty of cool water and seek professional medical help at once. Should someone swallow coolant accidentally, induce vomiting, rinse mouth with water, and immediately seek professional medical attention.
WARNING
For the cooling solution use distilled water, in order not to damage the engine.
CAUTION
Risk of burns. Do not remove the filling plug (1) when the engine is hot, since the coolant is under pressure and its temperature is high. If it gets in contact with the skin or with clothes it may cause severe burns and/or damage. CHECKING AND TOPPING UP
WARNING
42
Risk of burns. Check the coolant level and top up the expansion tank with cold engine.
WARNING
Stop the engine and wait until it has cooled down.
NOTE Position the motorcycle on firm and flat ground.

The side stand retracts automatically when the motorcycle is picked up from its leaned over position on the side stand. Be careful not to let the bike fall over when you lift the bike up to perform this check.
x
WARNING
NOTE The cap is equi pped with a breather tube (2). Do not disconnect the breather tube (2). x Unscrew and remove the filler cap (1).
Coolant is poisonous! Do not ingest c o ol an t u n d er an y ci rc um st an c e . Should you get coolant in your mouth, rinse with cool water and immediately seek medical attention. Coolant is also very dangerous to your skin and eyes. Should you accidentally get coolant on your clothing or skin, change clothes immediately. Wash coolant from your skin with hot water and soap. Should you get coolant in your eyes, flush with plenty of cool water and seek professional medical help at once. Should someone swallow coolant accidentally, induce vomiting, rinse mouth with water, and immediately seek professional medical attention.
Do not use your fingers or any other object to check if there is enough coolant.
x
WARNING
WARNING
Keep the motorcycle in a vertical position, with the two wheels resting on the ground. x Loosen the filler cap (1) (by giving it two counterclockwise turns), without removing it. x Wait a few seconds in order to release any residual pressure that may be present in the circuit.
The coolant filler neck has a smaller diameter ring (3) that indicates the proper coolant level. Visually check the coolant level against this ring. Otherwise: x Top up with coolant, see p. 93 (LUBRICANT CHART) until the coolant level reaches the ring (3). Do not exceed this level, otherwise the coolant will flow out while the engine is running. x Replace the filler cap (1).
Have it repaired by your Local Delear.
CAUTION
DSULOLD
43
If the tire is underinflated (pressure is too low), the tire may slip on the rim with consequent loss of control. Again, road holding and handling characteristics will be degraded, and brake performance will be reduced. When the tire is worn to a point where any tread is less than 0.12 in (3 mm) deep, the tire is worn out, and must be replaced. Also, if a tire suffers a puncture that is larger than 0.20 in (5 mm) in its longest dimension, the tire must not be repaired, but should be replaced.
7,5(6
If a tyre goes flat while you are using the motorcycle, do not attempt to go on and avoid braking and steering abruptly. Slowly move to the roadside and stop, using the engine compression to brake. Non-compliance with these instructions may cause accidents with consequent risk of injuries or even death. If the tyres are old, even if not completely worn out, they may become hard and may not ensure good road holding. In this case, have the tyres changed. Have the tyre changed when it is worn out or in case of puncture on the tread side, if the puncture is larger than 0.20 in (5 mm). After repairing a tyre, have the wheels balanced. Use only tyres in the size suggested by DSULOLD, see p. 90 (TECHNICAL DATA). Do not install tyres with air tube on rims for tubeless tyres and viceversa. Make sure that the tyres always have their valve sealing caps on, to prevent them from suddenly going flat. Repair, maintenance, changing and balancing of tires are very important to your safety, and should only be performed by qualified mechanics using the appropriate tools. For this reason, we suggest that you have your tires serviced by your Local DSULOLD Delear.
This motorcycle is equipped with tubeless tires.
Check the tire inflation at room temperature at least once a week, see p. 90 (TECHNICAL DATA). Pressure measurement must always be carried out when the tires are cold, as when the tires are warmed up, pressure will increase, and if they are checked at this time erroneous readings will be seen. If the tire is inflated to too high a pressure, an uncomfortably harsh ride will result, and riding comfort will be compromised. Also, road holding, especially during turns and in wet conditions, will likewise be compromised.
WARNING
After a tire is repaired, balance the wheels. Use only tires that are listed, see p. 90 (TECHNICAL DATA). Insure that all tires are equipped with properly installed valve caps.
Do not use the motorcycle if the tyre wear indicators signal that a change is necessary. Some types of tyres homologated for this motorcycle are provided with wear indicators. There are several kinds of wear indicators. For more information on how to check the wear, contact your Dealer. Visually check if the tyres are worn and in this case have them changed.
WARNING
44
(;+$867 6,/(1&(5
Tampering with the exhaust system is prohibited. It is against the law for you to alter the exhaust system in a manner that increases the noise, carefully read p. 5 (WARNINGS - PRECAUTIONS GENERAL ADVICE). Periodically inspect the entire exhaust system, including the exhaust pipe and silencer, to make sure that no holes have rusted through. Using a wire or small pick, make sure that the drain hole in the bottom of the muffler is open. If the noise of your motorcycle has increased significantly, replace the defective exhaust system components. See your Local aprilia Dealer. Tampering with the exhaust system not only makes your motorcycle loud, it will reduce its performance and shorten its life.
WARNING
New tires are often covered with a slippery mold release compound. Scrub the tires in by riding slowly and making numerous turns for the first few miles. Do not use any kind of tire dressing or other liquid on your tires. Especially do not permit any petroleum products, such as oil, gasoline or brake fluid to come in contact with the tires. If you do, wipe it immediately, then scrub the tire with soap and water and a stiff brush. Do not use a tire that is worn out. Minimum tread depth is measured as shown above. The mi nimum tread depth (2) for both the front and the rear tires is 0.12 in (3 mm).
WARNING
$8720$7,& /,*+76 21
Your motorcycle is equipped with lights that come on automatically as soon as the engine is started. For this reason, there is no light switch on your motorcycle. The lights can be switched off only by stopping the engine. Before starting the motorcycle, make sure that the dimmer switch (3) is in the low beam position.
45
,16758&7, 216 )25 86(
Before you ride away, always do a pre ride check to make sure that all systems are working properly and safe, see p. 47 (PRELIMINARY CHECKING OPERATIONS). Failure to follow this warning can lead to engine seizure, handling instabilities or other problems which can result in an upset and subsequent serious injury or even death.
WARNING
Do not hesitate to consult your Local DSULOLD Delear in case there is something you do not understand about the functioning of some controls or in case you suspect or discover some irregularities. It does not take long to carry out a check-up and this operation ensures you much more safety.
Failure to perform the checks described above may cause accidents or make the motorcycle overturn, with consequent serious injuries or even death.
If the accelerator sticks, it may cause collisions with other motorcycles or other accidents. If any fastener is loose, the rider may lose control of the motorcycle and risk and accident. Both situations may cause serious injuries or even death.
WARNING
46
35(/,0,1$5< &+(&.,1* 23(5$7,216
Component Front and rear disc brakes
Check Check brake operation, lever and pedal play, fluid levels. Check the pads for excessive wear, check the discs for condition. If the discs are unduly scored or show signs of heat discoloration, do not ride the motorcycle. Check both the tire brake systems for evidence of leaks. If there are leaks, do not ride the motorcycle. Make sure that it works smoothly and that it is possible to open and close it completely, in all steering positions. If necessary, adjust and/or lubricate it. Check and/or top up if necessary. Check the tyre surface, the inflation pressure, wear and tear and any damage. Make sure they work smoothly and are properly lubricated. Make sure that the fork head rotates through its entire range without fouling of any kind. Make sure that the fork stops touch the frame at full left and full right fork lock. Check the play of the clutch lever. Ensure that the clutch operates without jerking or slipping. Make sure that it works smoothly and that the spring tension brings it back to its normal position. If necessary, lubricate joints and hinges. Make sure that the safety switch on the side stand operates correctly. Check that all fasteners are tight and properly torqued. Check the slack. Check the fuel level and top up if necessary. Make sure that there are no fuel leaks. Make sure that the filler cap is properly tightened.
Page 36, 37 38, 72 73 36, 60 44 40 41
Throttle 2 stroke oil/ transmission oil Wheel/tyres Brake lever and pedal Steering Clutch Side stand
74, 75
Component nuts, bolts and other fasteners Drive chain Fuel tank
66, 67 35, 69, 87 42, 43 31 77 86
Coolant Engine stop switch (
-
With the engine cold, check the coolant level. Make sure that it is at the prescribed level. ) Make sure that it functions correctly. Check the proper functioning of all the lights and the horn. Do not ride if any of these are not functioning properly.
Lights, warning lights and electrical devices
47
67$57,1*
Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Avoid starting the engine in closed or badly-ventilated rooms. The non-observance of this warning may cause loss of consciousness or even lead to death by asphyxia. When the side stand is extended the engine will not start unless the transmission is in neutral. Note also that if you attempt to shift into gear with the side stand down, the engine will stop. With the side stand retracted, the engine may be started with the gear selector in neutral without pulling in the clutch lever. The engine may be started while the transmission is in gear only if the clutch lever is pulled in.
WARNING
When the motorcycle is lifted to the vertical position when it has been sitting on the side stand, the side stand retracts automatically as it is spring loaded. Be careful not to drop the motorcycle when you first sit on it.
x x x x x x x x
WARNING
If the engine is cold, depress the cold start lever (6).
NOTE
To avoid discharging the battery, and possibly damaging the starter, do not keep the starter button depressed for more than 5 or 10 seconds. If the engine does not start in this time, wait for 10 seconds and try again.
NOTE
48
Retract the side stand. Sit astride the motorcycle. Move the fuel valve lever (1) to the ON position. Rotate the ignition key (2) to the (ON) position. Hold the motorcycle in place by applying at least one brake. Put the shift lever (3) in neutral so that the green light is on. Move the engine stop switch (4) to the (ON) position. Make sure the dimmer switch (5) is in the low beam position.
Do not depress the starter button (7) when the engine is running. This will damage the starter and other important engine components.
x
CAUTION

Press the starter button (7) to start the engine. Leave the throttle in the idle position. Release the button as soon as the engine catches.
Never ride off briskly with a cold engine. Allow the engine to warm up by riding slowly for the first few miles. Starting a warm engine: x Before attempting to start the motor, ensure that the cold start lever is not engaged, see p. 31 (COLD START LEVER).
CAUTION
2
STARTING WITH VERY COLD AMBIENT TEMPERATURES When the ambient temperature is very cold (less than 0C) it may be difficult to start the engine on the first try. If this occurs: x Depress the cold start lever (6). x Depress the starter button (7) for about 10 seconds, at the same time, open the throttle (9) slightly.
If the 2 stroke oil warning light (8) is illuminated, this means that the 2 stroke oil reserve is being used. Top up th e 2 strok e o il tank, see p. 36 (2 STROKE OIL TANK).
CAUTION
If you run your engine without 2 stroke oil, it will seize. This can cause an upset with consequent risk of serious injury or even death.
WARNING
STARTING WITH A FLOODED ENGINE If for some reason the engine fails to start after several attempts, it is possible that the engine may be flooded. That is, there may be too much gasoline in the inlet manifold and the carburetor. To purge the flooding: x Depress the starter button (7) for a few seconds (letting the engine spin over) while holding the throttle (9) in a completely open position (Pos. A).
If the engine starts: Release the throttle grip (9). After letting the engine run for a few seconds, disengage the cold start lever (6), see p. 31 (COLD START LEVER). x If idle is uneven, open the throttle (9) slightly.
x x
If the engine does not start: Wait for a few seconds and repeat the above starting procedure. STARTING AFTER A LONG PERIOD OF INACTIVITY After a long period of inactivity, run the starter for about 10 seconds with the throttle in the closed position to fill the float chamber. To start the engine, open the throttle slightly and carry out the starting procedure.
49
5,',1*
Do not place anything inside the front part of the fairing between the handlebar and the dashboard. Any object placed in this area could jam the forks, and also could restrict visibility of the dashboard.
WARNING
NOTE Before riding away, carefully read

the safe drive chapter, see p. 17 (SAFE DRIVE). If the engine should die while you are riding because of fuel exhaustion, move the fuel valve lever (1) to the reserve position RES. Top off the top as soon as possible. FUEL RESERVE: 0.69 US gal (2.6 - ) (mechanical reserve).
x
Before riding away, be sure that the rear view mirrors are correctly adjusted.
IIf you are riding solo, without a passenger, make sure the passenger foot rests are folded up. Never take your hands off the hand grips nor your feet off the foot rests while you are riding. If you carry a passenger, i nstruct him/her not to move around unduly, and to keep his/her body aligned with yours during turns. Failure to do this could upset the stability of the motorcycle. Failure to follow these warnings may cause an accident with consequent risk of serious injury or even death. 50
WARNING
When the motorcycle is new to you, practice looking in the rear view mirrors. Reflecting surfaces are convex, therefore objects seem to be farther away than they actually are. The mirrors provide a wide angle view, and only experience will allow you to correctly determine how far behind you following motorcycles are.
x
CAUTION
Engage first gear by pressing downwards on the shift lever (4). x Release the brakes.
Do not release the clutch too abruptly, or the motorcycle will rear in the air (do a wheely) or jerk forwards. Never accelerate abruptly or excessively when releasing the clutch lever in order to prevent the clutch fro m slipp in g an d overheating (slow release) or the front wheel from lifting (wheely) (quick release). Failure to observe these instructions can lead to a serious accident with subsequent injury or even death.
WARNING
Ride at reduced speed for the first few miles in order to warm the engine up. x With the throttle grip (2) in the idle position (Pos. A), and the engine idling, pull in the clutch lever (3) completely.
If the 2 stroke oil warning light (5) comes on, this means that the 2 stroke oil is being used. In this case, top up the 2 s troke oil tan k, see p. 36 (2 STROKE OIL TANK). Shifting from higher to lower gears, that is, downshifting, is accomplished as follows: x Rotate the throttle grip (2) clockwise (Pos. A), slow the bike with the brakes, pull in the clutch lever (3), depress the shift lever (4) with your toe, release the clutch.
CAUTION
Slowly but steadily release the clutch lever (3) and, at the same time, open the throttle by rotating the throttle grip (2) slightly counterclockwise (Pos. B). This will start the motorcycle moving. x Increase the speed by gradually rotating the throttle grip (2) (Pos. B). Do not exceed the recommended rpm, see p. 53 (RUNNING-IN).
To engage second gear:
Shift gears fairly quickly but without great force. Develop a feel for shifting with your left toe. Never lug the engine, that is, running it at too low an rpm which can damage the motorcycles engine, and causes rough and juddering acceleration.
x
CAUTION
Shift gears one by one. Simultaneously downshifting more than one gear may cause the engine to exceed its maximum rated rpm (red line). This can seriously damage the engine. Before and during downshift, rotate the throttle clockwise to decelerate in order to avoid overspeeding the engine. Downshifting should be carried out in the following situations: x When riding downhill or when braking, in order to increase the braking action by using the compression of the engine. x When riding uphill if the engine lugs down (rpm decreases).
CAUTION
Rotate the throttle grip (2) clockwise (Pos. A), pull in the clutch lever (3) and lift the shift lever (4) straight up. Release the clutch lever (3) gently, and rotate the throttle counterclockwise to accelerate. x Repeat the last two operations to shift from second, to third, to fourth, to fifth, to sixth.
51
Avoid opening and closing the throttle repeatedly and continuously. Failure to head this warning can cause you to accidentally lose control of your motorcycle. When you have to brake, close the throttle and apply both brakes simultaneously in order to obtain the best brake performance. By applying only the front brake or only the rear brake, you reduce the braking performance considerably and run the risk of locking up one wheel which can cause an upset and subsequent serious injury or even death. If you stop on an uphill, use brakes only to slow the motorcycle and to keep it in place. Slipping the clutch to keep the motorcycle in one place on an uphill grade will very quickly ruin the clutch and overheat the engine.
WARNING
Before entering a turn, slow down, using the brakes and the engine, to a constant speed and then accelerate slightly through the turn. Avoid braking at the last moment. This can cause you to lose control of your motorcycle. If the brakes are operated continuously on downhill grades, the discs and pads will overheat, reducing the braking efficiency. Use engine compression and downshift to retard your motorcycle while going downhill. Use the brakes as little as possible to maintain a safe speed. Never coast downhill with the engine off and/or the clutch disengaged or the transmission in neutral. On roads that are wet or covered with snow, ice or mud, ride very slowly, avoiding braking or accelerating or maneuvering quickly. Hold the handlebars firmly. Failure to heed these warnings can cause an upset with subsequent serious injury or death.
WARNING
Pay very close attention to any obstacles or variations of the road surface. Uneven roads, rails, manhole covers, painted traffic stripes, traffic dots all become slippery when wet. Avoid particularly steel plates which are sometimes used during road maintenance. They become more slippery than ice once they are wet by rain. If you must ride on such surfaces, decrease your speed and operate the throttle, brakes and steering very gently. Always use the turn signals any time you intend to change lanes or change direction, and avoid sudden or abrupt turning. Switch off the direction indicators as soon as you have changed direction. Overtake and pass only with care, especially in rainy weather when a water cloud created by larger motorcycles reduces visibility and the slip stream could cause you to lose control of your motorcycle.
WARNING
52
5811,1*,1
After the motorcycle has been operated for 300 mi (500 km), perform the checking operation shown in the column After running-in of the REGULAR SERVICE INTERVALS CHART, see p. 56. Failure to heed this warning can lead to damage to your motorcycle, engine seizure or other malfunction which could cause an upset and lead to serious injury or even death. The internal parts of the engine and transmission must be properly run-in to ensure their long life and dependable operation. If possible, while breaking in your motorcycle, ride on hilly roads and/or roads with many curves so that the engine and transmission undergo lots of speed changes. It is also important that, during the run-in period, the suspension and brakes be treated gently to allow the mating parts to bed. T herefore, a voi d h ard bra kin g, hi gh speeds or very bumpy roads during the break in period. 0-62 mi (0-100 km) Apply the brakes gently, avoiding sudden or prolonged braking. 0-187 mi (0-300 km) Open the throttle no more than one-half way for extended periods. 187-312 mi (300-500 km) Open the throttle no more than three-quarters for extended periods.
67233,1*
WARNING
When the motorcycle has come to rest: x Position the shift lever (3) in neutral (green warning light on). x Release the clutch lever (2) (Pos. C). x If you are stopping just briefly and not shutting down the engine, keep one brake applied.
3$5.,1*
Park the motorcycle only on firm flat ground, otherwise it could fall over.
WARNING
If possible, avoid stopping abruptly, slowing down suddenly and braking at the last moment. Non-compliance with these instructions may cause accidents with consequent risk of serious injuries or even death. Release the throttle grip (1) (Pos. A), gradually put on the brakes and at the same time shift down in order to decrease the speed, see p. 50 (RIDING). Once the speed has decreased, before stopping the motorcycle: x Pull in the clutch lever (2) (Pos. B) in order to prevent the engine dying.
x
WARNING
Do not lean the motorcycle against walls, do not lay it on the ground. Park your motorcycle away from children and pedestrians, so that they will not come in contact with hot parts. Do not leave your motorcycle unattended with the engine running or with the key in the ignition switch. Do not sit on the motorcycle when the side stand is down. If the motorcycle falls over, it will leak gasoline which is extremely flammable. Flames or sparks could cause a fire which could destroy not only your motorcycle but also buildings around it and cause injury or even death to people as well.
x
Stop the motorcycle, see beside (STOPPING).
53
68**(67,216 72 35(9(17 7+()7
Move the engine stop switch (1) to the (OFF) position.
Do not leave the ignition on if you have stopped the engine by moving the engine stop switch to the (OFF) position as this will discharge the battery. When the motorcycle has come to rest after stopping the engine with the engine stop swi tch, turn the ignition switch (3) to the (OFF) position. x Rotate the key (2) and move the ignition switch (3) to the (OFF) position. x Move the fuel valve lever (4) to the OFF position. x Position your motorcycle on the stand, see the illustration at the top of the next column. NOTE Never leave the key in the ignition switch. x Lock the steering, see p. 32 (STEERING LOCK) and extract the key.
CAUTION

POSITIONING THE MOTORCYCLE ON THE STAND x Grab the left handle grip (5) and the passenger grab strap (6). Danger of fall or overturning. When the motorcycle is stood upright from the parking position, the stand automatically retracts.
x
WARNING
NEVER leave the key in the ignition, always use the steering lock. Try to park your motorcycle in a safe place, if at all possible, in a garage or other protected place. Lock your motorcycle up using a chain and padlock around the rear wheel. Chain the rear wheel to the swinging arm. Make sure that all legal requirements: registration, license plates, insurance, etc. are in order. Write down your name, address and telephone number and the motorcycle identification number in the space below, to facilitate findi ng the owner i n case your motorcycle is recovered after theft. SURNAME: ............................................... NAME: ....................................................... ADDRESS: ................................................ ................................................................... TELEPHONE NO.: ....................................
Put the side stand down with your right foot. Make sure it is extended completely and all the way forward (7). x Lean the motorcycle to the left until the stand rests firmly on the ground. x Turn the handlebars completely against the left stop. Make sure the motorcycle is stable when parked. If it falls down, it will certainly be damaged and could injure others as well.
WARNING
NOTE Very often stolen motorcycles are

identified thanks to the data written in the use/maintenance manual.
54
0$, 17(1$1&(
Avoid the temptation to hold any part of the motorcycle in your mouth. The coatings and platings used are, in some cases, toxic.
Risk of fire. Keep fuel and other flammable substances away from the electrical components. Before beginning any maintenance operation or any inspection of the motorcycle, stop the engine, remove the key (1) from the ignition lock (2), wait until the engine and the exhaust system have cooled down and if possible lift the motorcycle by means of the proper equipment, on firm and flat ground. Before proceeding, make sure that the room in which you are working is properly ventilated. Be careful to avoid hot parts of the engine and exhaust system. They are hot enough to cause serious burns.
WARNING
In general, reassembly is performed in the reverse order of the disassembly instructions given here. For some maintenance operations, especially those in which your hands are likely to come in contact with coolant, or engine oil, or gasoline, or brake fluid, it is advisable to use thin disposable gloves, such as those made of latex, rubber or nitrile. The routine maintenance operations described in this manual can usually be performed by the user. However, in some cases, specific tools and technical expertise may be required. Do not hesitate to contact your Local aprilia Dealer who has all the latest factory information and tools to properly service your motorcycle. Remember that many service operations, if done improperly, can be very hazardous. If you have any questions about your ability to carry out the operations described here, see your Local aprilia Dealer. In all cases, personally carry out the preliminary checking operations after any maintenance, see p. 47 (PRELIMINARY CHECKING OPERATIONS).
CAUTION
Remember that tightening torque of all fasteners on the wheels, brakes, axles, suspension are extremely important to ensure safety, and must be maintained at the prescribed values. Check the tightening torques of the fasteners regularly, and always use a torque wrench when installing them. Failure to adhere to this warning could cause the loosening and subsequent loss of critical fasteners, which could cause a wheel to lock or cause other handling problems with consequent overturning, and the risk of serious injury or even death.
WARNING
Fasteners must be neither overtightened or undertightened. If they are overtightened, the threads may be damaged and the fasteners will be destroyed, whereas if they are undertightened, they can vibrate and become lost. Obviously, under these circumstances, a serious accident with resultant serious injury or death could ensue.
WARNING
55
5(*8/$5 6(59,&( ,17(59$/6 &+$57
THESE OPERATIONS MAY BE CARRIED OUT BY YOUR Local DSULOLD Delear, OR BY THE OWNER OF THE MOTORCYCLE Component Battery/electrolyte level Spark plug Drive chain, tension and lubrication Air cleaner Fork Clutch clearance Light system Brake fluid 2 stroke oil level Coolant Transmission oil Tyre pressure Engine idling rpm Suspension Front and rear brake pad wear R C C S R C R C C every 312 mi (500 km): C every 1,250 mi (2,000 km): C C every month: R C C C S C After running-in [312 mi (500 km)] or 4 months C C Every 2,500 mi (4,000 km) or 8 months C C every 312 mi (500 km): C P C S Every 5,000 mi (8,000 km) or 16 months
C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust. Perform these maintenance operations at one-half of he specified intervals, if your motorcycle is often used in rainy or very dusty conditions, or on unpaved roads.
56
THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED OUT BY Local DSULOLD Delear. Component Carburettor Accelerator cable (adjustment) Steering bearings and steering Wheel bearings 2 stroke oil filter Braking systems Cooling system Brake fluid Coolant Fork oil Wheels / tyres Nut, bolt, screw tightening 2 stroke oil reserve warning light Fuel pipes 2 stroke oil lines Pistons and rings C C C C C C every year: S every 2 years: S after the first 5,000 mi (8,000 km): S / every 12,500 mi (20,000 km): S C C C C C every 4 years: S every 4 years: S C C C C C P After running-in [312 mi (500 km)] or 4 months Every 2,500 mi (4,000 km) or 8 months Every 5,000 mi (8,000 km) or 16 months P
C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust. Perform these maintenance operations at one-half of he specified intervals, if your motorcycle is often used in rainy or very dusty conditions, or on unpaved roads.
57
,'(17,),&$7,21 '$7$
ENGINE NUMBER The engine number is stamped on the upper part of the crankcase on the left side near the front sprocket. To gain access to the engine number: x Remove the left fairing, see p. 68 (REMOVING THE SIDE FAIRINGS). x Remove the two screws (1). x Remove the sprocket cover (2). Engine no.
326,7,21,1*
It is a good idea to write down the frame and engine numbers in the space provided below. Use the frame number (VIN) to identify your motorcycle when ordering spare parts.
7+( 02725&<&/( 21 7+( )5217 6833257 67$1'
In all states and countries, it is against the law to alter the Vehicle Identification Number (VIN). You can incur severe penalties by doing this. Also, this will immediately invalidate your warranty. FRAME NUMBER The frame number is stamped on the right side of the fork head. Frame no.
WARNING
Position the motorcycle on the appropriate rear support stand , see p. 59 (POSITIONING THE MOTORCYCLE ON THE REAR SUPPORT STAND ). x Insert the two ends of the stand (3) in the two holes (4) positioned on the lower ends of the front fork. x Rest one foot on the front part of the stand (5). x Push the stand (5) downwards until it reaches the end of its stroke (see figure).
58
326,7,21,1*
7+( 02725&<&/( 21 7+( 5($5 6833257 67$1'
x x
Loosen the knob (1). Remove the front fork support (2) from the stand. x Insert the support pin (3). x Repeat the previous operations on the opposite side of the stand.
Slide the support pins (3) towards the motorcycle, so that the bosses on the pins touch the swing arm (see figure above). x Tighten the two knobs (1).
NOTE Have someone help you keep the

motorcycle in vertical position with the two wheels on the ground.
x
Lift the motorcycle by grasping the two sides of the swing arm only.
x
WARNING
Rest one foot on the rear part of the stand (4). x Push the stand (4) downwards until it reaches the end of its stroke (see figure).
Insert the stand from the back of the motorcycle and position it so that the two support pins (3) can be located as follows: the right support between the brake caliper and brake line coupling on the swing arm (Pos. A); the left support between the sprocket and chain (Pos. B).
59
x x
Unscrew and remove the screw (1). Remove the gasket (2).
NOTE If you attempt to check the oil with

the motorcycle leaned in either direction from the vertical, your measurement will be inaccurate.
x
The side stand retracts automatically when the motorcycle is picked up from its leaned over position on the side stand. Be careful not to let the bike fall over when you lift the bike up to perform this check. In case of overturning, the motorcycle will leak gasoline, which is extremely flammable. Flames or sparks may cause a fire, which could destroy not only the motorcycle, but also the building in which it is located, and cause serious injuries or even death.
x
WARNING
x x
Visually check to ensure that the oil level is at or above the lower edge of the threaded hole (3).
Check the oil level as described above. Repeat this operation until the oil level is at or slightly above the edge of the threaded hole (3). x Follow the screw installation instructions above.
If it is: x Inspect the gasket (2). Replace if damaged. x Install and tighten the screw (1).
x
Tighten the filler screw snugly to insure no oil leak. Occasionally check that the oil pan cover gasket is not leaking. Never ride the motorcycle with low transmission oil or with contaminated or unapproved lubricants. This will greatly accelerate the wear of moving parts and cause irreparable failure.
WARNING
If it is not: Top the oil up per the following paragraph.
Keep the motorcycle in vertical position, wi th the t wo wheel s resti ng on t he ground.
TOPPING UP If it is necessary to top up the transmission: x Unscrew and remove the filler cap (4). x Pour a small quantity of oil and wait about one minute to allow the oil to flow into the transmissionpan.
61
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The disassembly and reassembly of the front wheel can be difficult for those unfamiliar with motorcycle maintenance. You may wish to have your Local DSULO LD Delear carry out these operations. If you wish to perform these operations yourself, carefully read p. 55 (MAINTENANCE). While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.
WARNING
DISASSEMBLY Position the motorcycle on the appropriate rear support stand , see p. 59 (POSITIONING THE MOTORCYCLE ON THE REAR SUPPORT STAND ). x Position the motorcycle on the appropriate front support stand , see p. 58 (POSITIONING THE MOTORCYCLE ON THE FRONT SUPPORT STAND ).
x
Remove the brake caliper (2) from the disc, leaving it attached to its line (3).
Make sure that the motorcycle is stable. It may cause damage to bystanders and other property, as well as being damaged itself.
x
WARNING
Never touch the front brake lever after removing the brake caliper from the disc. If you do, the caliper pistons may be pushed out of their seats, and brake fluid will be spilled. Should you accidentally do this, take your motorcycle to your Local DSULOLD Delear who will know how to repair this damage.
x
CAUTION
NOTE
You must use the appropriate front and rear support stands to remove the front wheel.
Have a helper steady the handlebar in the straight ahead position.
Place a support (4) under the tire, in such a way as to keep the wheel in its position after loosening it. x Hold the axle (5) from rotating with an appropriate Allen wrench. Wheel nut (6) tightening torque: 57.86 ftlb (80 Nm).
x
Brake cali per screw (1) ti ghtening torque: 15.91 ftlb (22 Nm).
x
62
Remove the two screws (1) that fasten the front brake caliper (2).
Remove the nut (6) and washer (7).
Loosen the axle clamp screw (8), using the appropriate Allen wrench. x Push the axle (5) partly out of the front fork by tapping the threaded end with a rubber hammer or wooden drift.
NOTE
Observe the arrangement of the speedometer drive (10) and of the spacer ring (9), in order to be able to reassemble them correctly. Support the front wheel and remove the axle manually. Remove the spacer ring (9). Remove the wheel by pulling it forward. Disconnect the speedometer drive (10). Remove the washers (11). Remove the speedometer drive cover (12).
Danger of injury. Keep your fingers clear. Do not attempt to line up the wheel and the axle clamps with your fingers.
x x x x x x
WARNING
x x x
x x x x x x
Move the wheel around until the axle hole and the axle clamps are aligned. Push in the axle (5) completely. Install the washer (7) and nut (6). Tighten finger tight. Ensure that the cover (12) is correctly installed on the fork. Hold the axle (5) from rotating using the Allen wrench. Tighten the nut (6) to its appropriate tightening torque.
Remove the front support stand . Remove the rear support stand . Apply the front brake lever, and then push down on the handlebars, compressing the fork springs several times. This will align the fork tubes. x Tighten the axle clamp screw (8). Screw (8) tightening torque: 5.79 ftlb (8 Nm).
REASSEMBLY Carefully read p. 55 (MAINTENANCE).

x
Nut (6) tightening torque: 57.86 ftlb (80 Nm).
x x
x x x
Apply a thin film of lubricating grease to the front axle (5), see p. 93 (LUBRICANT CHART). Install washer (11) on the speedometer drive (10) (boss side (13)). Position the boss (13) of the speedometer drive (10) in the appropriate seat on the wheel hub. Locate the cover (12) over the speedometer drive (10). Position the spacer ring (9) in its seat on the wheel. Position the wheel between the fork rods on the support (4).
While reassembling the wheel, be careful not to damage the brake line, the disc and the pads.
x
CAUTION
After servicing the brakes, always check them for function. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your motorcycle serviced by your Local DSULOLD Delear. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system. Never ride your motorcycle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your motorcycle. Then, try your motorcycle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death.
WARNING
Insert the brake caliper (2) on the disc and position it so that its fastening holes and the holes on the support are aligned.
NOTE When reassembling the brake caliper, replace the caliper screws (1) with two new screws of the same type.
x
Tighten the two screws (1) to the appropriate torque. Brake cali per screw (1) ti ghtening torque: 15.91 ftlb (22 Nm).
63
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The disassembly and reassembly of the rear wheel can be difficult for those unfamiliar with motorcycle maintenance. You may wish to have your Local DSULOLD Delear carry out these operations. If you wish to perform these operations yourself, carefully read p. 55 (MAINTENANCE). While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.
WARNING
TIONING THE MOTORCYCLE ON THE REAR SUPPORT STAND ).
Make sure that the motorcycle is stable. If it falls over, it may cause injury to bystanders and other property, as well as being damaged itself.
x
WARNING
Remove the right (4) and left (5) chain tensioners. x Move the chain off the sprocket and lay it down outside the sprocket.
NOTE Lower the drive chain (6) outside the crown gear (7).
x
Hold the axle (1) from rotating with the appropriate Allen wrench.
Wheel nut (2) tightening torque: 57.86 ftlb (80 Nm).

x x
Make the wheel advance and release the drive chain (6) from the crown gear (7). x Remove the wheel from the swing arm from behind, carefully removing the disc from the brake caliper.
NOTE
You must use the appropriate front and rear support stands to remove the rear wheel.
Remove the nut (2) and washer. Place a support (3) under the tire, in such a way as to keep the wheel in its position after loosening it. x Remove the axle (1) from the right side.
DISASSEMBLY x Position the motorcycle on the appropriate rear support stand, see p. 59 (POSI64
NOTE
Observe the arrangement of the right (4) and left (5) chain tensioners in order to be able to reassemble them correctly.
Never touch the rear brake pedal after removing the wheel. If you do, the caliper pistons may be pushed out of their seats, and brake fluid will be spilled. Should you accidentally do this, take your motorcycle to your Local DSULOLD Delear who will know how to repair this damage.
CAUTION
the brake caliper (11) is positioned correctly; the plate slot must be inserted in the appropriate stop pin (12) in the inner part of the right side of the swinging arm. Insert the disc in the brake caliper carefully. x Position the wheel centrally in the swinging arm. Danger of injury. Keep your fingers well away from the chain and sprocket. You could easily lose a finger if it becomes pinched between these two parts. x Move the wheel forward as far as possible in order to install the chain on the sprocket. Danger of injury. Do not attempt to align the rear wheel and the swinging arm using your fingers. x Pull the rear wheel backwards until the bearing holes are lined up with the holes in the swinging arm. x Rotate the torque plate (10), complete with brake caliper (11), with the stop pin (12) in proper position until it is appropriately aligned with the holes in the swing arm. x Install the right (4) and left (5) chain tighteners in their seats on the swing arm. x Lightly grease the outside of the axle (1). x Install the axle (1) completely through the wheel from the left side. NOTE Ensure that the axle (1) is pushed all the way home with the head in the appropriate seat on the left chain tightener.
Install the washer and tighten the nut (2) finger tight. x Check the chain tension, see p. 66 (DRIVE CHAIN). x Tighten the nut (2). Wheel nut (2) tightening torque: 57.86 ftlb (80 Nm). After servicing the brakes, always check them for function. If the stroke of the lever or pedal is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your motorcycle serviced by your Local DSULOLD Delear. It may be necessary to have your dealer bleed the system, or there may be some other problem with the brake system. Never ride your motorcycle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your motorcycle. Then, try your motorcycle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death. Check the wheel centering. Have the tightening torques, centering and balancing of the wheel checked by your Local DSULOLD Delear. These are critical safety operations, and failure to observe this warning could lead to an upset with subsequent serious injury or death.
WARNING WARNING
WARNING
NOTE Observe the arrangement of the spacer rings (8) and (9) in order to be able to reassemble them correctly. x Remove the left spacer ring (8). x Remove the right spacer ring (9).
REASSEMBLY x Apply a thin film of grease to the outer seals of the rear wheel hub.
The spacer rings have different diameters: do not mix them up and take care to position them correctly.
x
CAUTION
Insert the left (8) and right (9) spacer rings in their seals on the wheel hub. x Install the spacer ring (13) in its correct position, if it has fallen out of the torque plate seat (10). Before proceeding with the reassembly, make sure that the torque plate (10) of
CAUTION
65
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Carefully read p. 55 (MAINTENANCE). This motorcycle is equipped with a chain and master link. When the master link is installed, the clip (1) must be installed with the closed end in the direction of travel as shown above.
than one-eighth of an inch away from the sprocket, the chain is worn out and the c hai n an d bo th front and rear sprockets must be replaced. See your Local DSULOLD Delear.
An excessively loose chain can come off the sprocket which can result in a serious accident and serious damage to the motorcycle from the upset and subsequent serious injury or even death. Do not ride your motorcycle with an improperly adjusted chain, see p. 67 (ADJUSTMENT). To inspect the condition of the chain, grasp the chain where it goes around the sprocket and try to pull it away from the sprocket. If you can move it more 66
WARNING
Lack of maintenance can cause premature wear of the chain and damage to the sprockets. Maintain your chain more often if your motorcycle is used on dusty or muddy roads. CHECKING THE PLAY To check the play: x Stop the engine. x Position the motorcycle on the stand. x Shift to neutral. x Check the chain play. It should be 0.98 1.38 in (25 35 mm) at mid-bottom span as shown above.
CAUTION
Move the motorcycle forward or backward, or support the rear wheel in the air and turn the wheel to several positions, to check the chain slack at several locations. If the slack is markedly different with the wheel in different positions, the chain and sprockets must be replaced.
Do not ever operate your motorcycle with a damaged chain. This could cause wheel seizure which could lead to an upset with subsequent serious injury or death. Lubricate your chain frequently to minimize the possibility of this kind of damage, see p. 67 (CLEANING AND LUBRICATION). If the play is the same at several locations, but is more or less than 0.98 1.38 in (25 35 mm), adjust it, see p. 67 (ADJUSTMENT).
WARNING
x x
Loosen the two lock nuts (5). Adjust the tension adjusters (6) to obtain the appropriate chain play, ensuring that the edge of tension adjuster is in the same position with regard to the reference marks (3-4) on each side of your motorcycle. x Tighten the two lock nuts (5). x Tighten the nut (2). Wheel nut (2) tightening torque: 72.33 ftlb (100 Nm).
x
Lubricate the chain frequently, especially if it displays any rust or if it is dry to the touch. If, after lubricating the chain, it still has links which cannot be turned easily, the chain must be replaced.
x
CAUTION
Finally, check the wear of the rear fork protection shoe.
ADJUSTMENT
Check the chain play again, see p. 66 (CHECKING THE PLAY).
NOTE To adjust the chain it is necessary to use the appropriate rear support stand .
To adjust the chain tension: x Position the motorcycle on the appropriate rear support stand , see p. 59 (POSITIONING THE MOTORCYCLE ON THE REAR SUPPORT STAND ). x Loosen the nut (2) to several turns.
NOTE In order to make wheel centering in the swinging arm easier, there are reference marks (3-4) on the swing arm. See illustration above.
CHECKING THE WEAR OF THE CHAIN AND SPROCKETS I n a d di t i o n t o t he c h ec k, se e p. 6 6 (CHECKING THE PLAY), inspect the chain and sprockets to make sure that there are no: x Damaged rollers. x Loose pins. x Dry, rusty, crushed or seized links. x Excessive wear. x Sprocket or teeth excessively worn or damaged.
Keep your fingers well clear of the chain and sprocket, especially if you are turning the rear wheel while working on the motorcycle. You can easily be seriously injured if a finger is caught between the chain and sprocket. CLEANING AND LUBRICATION
WARNING
Carry out the adjustment, lubrication, cleaning and change of the chain with great care. Lubricate the chain every 300 mi (500 km) or whenever it appears dry. Use a proprietary chain lubricant or SAE 80W-90 oil. Never wash your motorcycle, and especially never wash the chain, with high pressure water, coin operated car laundry wand, steam cleaner, or inflammable solvent.
CAUTION
If chain rollers are damaged and pins are loose, both sprockets as well as the chain must be replaced.
CAUTION
67
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Carefully read p. 55 (MAINTENANCE).

x x x x x
Position the motorcycle on the stand. Insert the key (1) in the lock (2). Rotate the key (1) clockwise. Raise and remove the saddle (3). Remove the flap (4).
Upon reassembly: x Position the flap (4) correctly. x Insert the rear tangs (5) of the saddle in the appropriate seats (see figure). x Lower the saddle and insert the two pins (6) in the relevant seats. x Turn the key (1) anticlockwise, locking the saddle.
Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.
x x x x x x
WARNING
Handle the plastic and painted components with care and avoid scraping or damaging them. Be careful not to damage the electric cables.
x
CAUTION
Before riding, make sure that the saddle (3) is properly positioned and locked: risk of serious injuries or even death.
WARNING
?
Position the motorcycle on the stand. Unscrew and remove the four screws (7). Unscrew and remove the two lower screws (8). For the left fairing: unscrew and remove the two rear screws (9). For the right fairing: unscrew and remove the rear screw (10). Unscrew and remove the four screws (11).
Disconnect the two electric terminals (12) of the direction indicator. x Remove the side fairing (13).
68
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Carefully read p. 35 (FUEL) and p. 55 (MAINTENANCE).
Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapors are poisonous. Make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Do not smoke and do not use naked flames. DISPOSE OF UNWANTED FUEL PROPERLY.
x
WARNING
Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). x Remove the screw (2) and bushing. x Drain the fuel tank completely, see p. 87 (DRAINING THE FUEL TANK). x Position an absorbent cloth (3) on the front support of the seat (4).
Upon reassembly, be sure that the fuel line (6) and clamp (7) are properly installed.
x
CAUTION
Handle with care. While removing the fuel tank (5), DO NOT force the fuel line (6).
x
CAUTION
Remove the fuel line (6) from the fuel valve (8).
Danger! Some fuel may spill.

x
WARNING
Grasp the front part of the fuel tank (5) and lift it slightly. x Using a pair of pliers, release the clamp (7).
Plug the free end of the fuel line (6) and attach it to the motorcycle with a wire or tape in the vertical position. x Grasp the front part of the fuel tank (5), lift it, rotate it and put it on the absorbent cloth (3) positioned on the front support of the seat.
Move the fuel valve lever (1) to the OFF position.
69
REMOVAL Remove the fuel tank, see p. 69 (REMOVING THE FUEL TANK). x Unscrew and remove the screw (1). x Unscrew and remove the six screws (2). x Remove the filter case cover (3). x Remove the filter element (4). x Remove the grid (5).
x
Plug the opening with a clean cloth to prevent any foreign matter from entering the air tubes.
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CAUTION
Do not use gasoline or flammable solvents to wash the air cleaner, in order to avoid fire or explosion. Check the condition of the air cleaner and clean it monthly or every 2,500 mi (4,000 km) depending on the conditions in which the motorcycle is used. If the motorcycle is used on dusty or wet roads, the cleaning operations and any replacement should be carried out more frequently. Before the cleaning operation, it is necessary to remove the air cleaner from the motorcycle.
WARNING
CLEANING x To clean the filter element (4), rinse it in non-flammable solvent, then allow it to dry thoroughly. x Sparingly apply filter oil, or heavy engine oil (SAE 80W-90), then squeeze the filter to eliminate any excess oil.
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x
Position the motorcycle on the stand.
NOTE The filter must be completely wet with oil, but not dripping.
The rear-view mirrors remain attached to the front part of the fairing, but they will not be not attached firmly. Do not use the mirrors to handle the fairing, as you will damage both mirrors and fairing.
x
CAUTION
5 Remove the screws (6).
5 NOTE The position of the plate (7) and how it fits with the seat (8) on the support frame on the front part of the fairing for reassembly.
x x
5 Remove the three screws (9). 5 Remove the screw (10).
70
Position a protection cloth on the front mudguard.
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Handle the plastic and painted components with care and avoid scraping or damaging them. Be very careful not to damage the electrical cables.
x
CAUTION
The front fork oil change operation should be entrusted to your Local DSULO LD Delear. Carefully read p. 55 (MAINTENANCE).
CAUTION
Partially remove the front part of the fairing (11) and put it on the protection cloth positioned on the mudguard. x Disconnect the main light connector. x Remove the front part of the fairing completely.
Have the front fork oil changed after the first 5,000 mi (8,000 km) and successively every 12,500 mi (20,000 km). Every 5,000 mi (8,000 km), carry out the following checking operations: x Apply the front brake lever and push up and down on the handlebar repeatedly, pushing the fork up and down. The fork must move smoothly and easily, there must be no trace of oil on the fork tubes. x Check the torque of all the fasteners on the front fork and inspect the entire front fork to make sure that it is in good condition without leaks or damage. Repeat for the rear suspension and swinging arm.
Do not ride your motorcycle if either suspension is damaged in any way, see your Local DSULOLD Delear.
CAUTION
71
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Carefully read p. 37 (BRAKES), p. 38 (DISC BRAKES) and p. 55 (MAINTENANCE). The following information refers to a single braking system, but is valid for both. Check the brake pad wear after the first 300 mi (500 km) and then every 2,500 mi (4,000 km). The amount of wear that the brake pads experience depends on how the motorcycle is used, how aggressively it is driven, and the condition of the roads upon which it is operated. Wear will be faster than normal when the motorcycle is driven aggressively, or on dusty or wet roads.
Check the wear of the brake pads before every trip. CH ECK IN G W EA R O F TH E B RAK E PADS x Position the motorcycle on the stand. x Perform a visual check of the friction material thickness. Use a flash light. See the arrows (1) and (2) above. If the friction material on one pad of a pair, front (3) or rear (4), is worn to 0.06 in (1.5 mm) or less, replace both pads.
WARNING
Excessive wear of the friction material would cause the contact of the pad metal support with the disc, with consequent metallic noise and production of sparks from the caliper; braking efficiency and safety will be seriously compromised. This could lead to a crash, with subsequent serious i njury or death.
WARNING
Have the pads changed by your Local DSULOLD Delear.
WARNING
72
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Carefully read p. 55 (MAINTENANCE). If the idle becomes irregular, too fast, or too slow, it must be adjusted. To adjust the idle:
Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in closed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.
WARNING
Ride for a few miles until the engine reaches normal running temperature, see p. 15 (Coolant temperature indicator ). x Put the shift lever (1) in neutral so that the green light is on. x Observe the tachometer. The engine must idle between 1,100 100 rpm.
If it does not: Position the motorcycle on the stand. Remove the rubber plug (2) (right fairing). x Insert a flat-tip screwdriver in the hole and adjust the screw (3) on the carburetor. By SCREWING IT clockwise, you increase the engine rpm. By UNSCREWING IT counterclockwise, you decrease the engine rpm. x Twist the throttle grip, accelerating and decelerating a few times to make sure that it functions correctly and to check if the idling speed is constant.
x x
NOTE
If necessary, contact your Local aprilia Dealer.
73
The play of the throttle cable must be between 0.08 0.12 in (2 3 mm), measured at the edge of the grip, see the illustration above. To adjust the cable: x Position the motorcycle on the stand. x Pull back the rubber boot (1). x Loosen the lock nut (2). x Rotate the adjuster (3) in such a way as to restore the prescribed value. x After the adjustment, tighten the lock nut (2) and check the play again. x Replace the rubber boot (1).
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If the throttle sticks open, you will lose control of your motorcycle and a serious accident could result. If any fastener in the throttle system becomes loose, likewise you will lose control of your motorcycle. Either situation can lead to an upset or collision with subsequent serious injury or death.
WARNING
Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in closed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.
WARNING
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Carefully read p. 55 (MAINTENANCE) and p. 75 (CHECKING THE SWITCHES).
After you have adjusted the throttle, rotate the handlebars full left and full right with the engine idling. Check to ensure that the idle sound is not affected by thi s. A lso check that the th ro ttl e smoothly and fully closes when released.
WARNING
The side stand retracts automatically when the motorcycle is picked up from its leaned over position on the side stand. Be careful not to let the bike fall over when you lift the bike up to perform this check. The side stand (4) must rotate about its pivot smoothly and easily. Perform the following checks: x The springs (5) must be free from damage, wear, or rust, and must fully and firmly retract the side stand when the weight of the motorcycle is lifted off of it. x The side stand (4) must rotate freely about its pivot. If necessary, lubricate the pivot, see p. 93 (LUBRICANT CHART).
WARNING
74
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NOTE Extending the side stand must kill

the engine. If the engine continues to run:
x
The side stand (4) is equipped with a safety system, operated by safety switch (6). This system prevents the motor from being started while the stand is extended unless the transmission is in neutral. It also kills the engine if the stand is extended while the engine is running, unless the transmission is in neutral. To check the proper functioning of the safety switch (6): x Sit on the motorcycle in the normal riding position. x Retract the side stand (4). x Start the engine, see p. 48 (STARTING). x Release the throttle grip (7) (Pos. A). With the engine idling, pull in the clutch lever (8) completely. x Engage first gear, pushing the shift lever (9) downwards. x Extend the side stand (4).
Check the safety switch on the side stand (6), see below (CHECKING THE SWITCHES). Perform the necessary cleaning or repairs. x Repeat the check.
If the engine does not stop when the side stand is extended, do not ride your motorcycle. Contact your Local DSULOLD Delear. stoplight switch on the front brake lever (11); safety switch on the side stand (6). x Make sure that there is no dirt or mud on the switch. The switch pin must move freely and without interference, returning automatically to its unapplied position. x Check the spring (12); it must not be damaged, worn or stretched.
WARNING
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Carefully read p. 55 (MAINTENANCE). The motorcycle is equipped with three switches: stoplight switch on the rear brake pedal (10);
75
x x
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To remove and clean the spark plug:
Carefully read p. 55 (MAINTENANCE). Clean the spark plug after the first 312 mi (500 km) and successively every 2,500 mi (4,000 km); change it every 5, 000 mi (8,000 km). Periodically remove the spark plug and clean it carefully, removing carbon deposits; change it if necessary. To reach the spark plug: x Remove the fuel tank, see p. 69 (REMOVING THE FUEL TANK).
Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.
x x
WARNING
Using compressed air, carefully blow out the spark plug after you have cleaned it. Inspect for cracks on the insulating material, electrode corrosion or erosion, or deposits that you cannot remove. If the spark plug shows any of these defects, it must be replaced. Check the spark plug gap with a thickness gauge. The gap must be 0.024 0.028 in (0.6 0.7 mm); if necessary adjust it, carefully bending the ground (outside) electrode. Make sure the gasket is in good condition. With the gasket on, screw the spark plug into the head by hand. Tighten the spark plug with the spark plug wrench, approximately one-half turn after it first snugly contacts the cylinder head.
Spark plug tightening torque: 14.47 ftlb (20 Nm).
Remove the spark plug cap (1). Using compressed air, blow all the dirt away from the base of the spark plug. Using the special spark plug wrench from the tool kit, unscrew the spark plug. Make sure that no dirt falls into the cylinder through the spark plug hole. x Inspect the spark plug, and insure that there are no carbon deposits nor corrosion marks on either electrode or the ceramic nose that surrounds the center electrode. If necessary, clean the spark plug with a proprietary spark plug cleaner, and a stainless steel brush.
The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged. Use the recommended type of spark plug only, see p. 90 (TECHNICAL DATA), in order not to compromise the life and performance of the engine.
x
CAUTION
Position the spark plug cap properly, so that it does not come off due to the vibrations of the engine. x Replace the fuel tank.
76
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Carefully read p. 55 (MAINTENANCE). Check the electrolyte level and the tightness of the terminals after the first 300 mi (500 km) and successively every 2,500 mi (4,000 km) or 8 months.
If someone should accidentally swallow battery electrolyte, drink a large quantity of milk or cool clear water and continue with milk of magnesia or vegetable oil. Seek professional medical assistance immediately. Since the battery gives off explosive hydrogen gas, especially when it is being charged, when you are charging a battery, make sure that the room is properly ventilated. Do not inhale the gases released during charging. Do not permit any open flames, sparks or cigarettes or any other source of heat anyw her e n ear the batte ry w hile it is charging. Do not tip the motorcycle too much, or tip the battery too much, to avoid electrolyte leaking out. Should you accidentally spill battery electrolyte on any part of your motorcycle, immediately wash it off with lots of cool clear water. Spills may be neutralized with a mixture of baking soda and water, as well. This is particularly important, as the battery electrolyte will severely corrode metallic parts and destroy the finish of plastic and painted parts.
Batteries, when charged, give off hydrogen gas, which is highly explosive. Therefore, do not smoke while working on or around the battery, and keep naked flames or sparks away from the battery. Keep gasoline and other flammable substances well away from the battery, since a battery spark could easily ignite them and cause a devastating fire. Battery electrolyte is toxic and caustic and can severely burn your eyes or skin. Always wear tight fitting goggles and protective clothing when handling battery electrolyte. It is particularly important for you to protect your eyes since even a minuscule amount of battery acid could destroy your vision. Should you accidentally get even the smallest amount of battery electrolyte on your skin or eyes, immediately flush with large quantities of clear cool water and immediately seek professional medical attention.
WARNING
Never switch the battery cables. Observe the proper polarity of the battery. Incorrectly attaching the battery to your motorcycle will irreparably destroy the electrical system of your motorcycle.
CAUTION
Connect and disconnect the battery only with the ignition switch (1) in the (OFF) position. First connect the positive cable (+), then the negative (). Disconnect the negative cable () first, then the positive (+). If your battery needs to be charged, use a constant voltage, or taper charger, with a current rating no greater than 1/10th the capacity of the battery (i.e., for a 50 amp hour battery, the maximum charging current should be 5 amps). Use of a more powerful charger can not only damage the battery irreparably, but could cause it to overhead and explode. If your battery is equipped with an overflow tube, always ensure that it is properly installed, and properly routed. Failure to adhere to this instruction can cause corrosive fumes from the battery to cause serious damage to your motorcycle.
77
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If your motorcycle remains unused for more than a couple of weeks, it will be necessary to trickle charge the battery, to prevent battery damage, see p. 79 (RECHARGING THE BATTERY). x Remove the battery, see beside (REMOVING THE BATTERY), and put it in a cool, dry place. x The best way to prevent battery deterioration is to constantly leave a trickle charger with a capacity of about 1/10th amp, attached. These chargers are very economically available from your Local aprilia Dealer, and will ensure that your battery always remains in tip top condition. x If this cannot be done, charge the battery for about 30 minutes using a battery charger with a current capacity of no greater than 1/10th the capacity of the battery, see p. 79 (RECHARGING THE BATTERY). 78
While we recommend removing the battery from the motorcycle, if you must leave it in your motorcycle, disconnect both battery cables.
Brush with a wire brush to eliminate any sign of corrosion. x Reconnect first the positive (+) and then the negative cable (). x Cover the terminals of the cables and of the battery with neutral grease or Vaseline.
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Carefully read p. 77 (BATTERY).

x
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Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). x Make sure that the cable terminals (1) and the battery terminals (2) are: in good conditions (and not corroded or covered with deposits); covered with neutral grease or Vaseline. If it is necessary to clean the battery terminals: x Make sure that the ignition switch (7) is in (OFF) position. x Disconnect first the negative () and then the positive cable (+).

x x x x
x x
Make sure that the ignition switch (7) is in (OFF) position. Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). Release the rubber band (3) from the couplings (4) and (5) and take it. Disconnect first the negative () and then the positive cable (+). Remove the battery breather pipe (6). Remove the battery from its compartment and put it on a flat surface, in a cool and dry place.
Once it has been removed, the battery must be stored in a safe place and kept away from children: risk of serious injuries or even death.
WARNING
The battery gives off noxious and explosive gases; keep it away from flames, sparks, cigarettes and any other source of heat. During the recharging or the use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging.
x
WARNING
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Carefully read p. 77 (BATTERY). To check the electrolyte level, proceed as follows: x Remove the battery, see p. 78 (REMOVING THE BATTERY). x Make sure that the fluid level falls between the MIN and MAX notches stamped on the side of the battery. If it does not: x Remove the battery plugs.
x x
Top up with distilled water only. Do not exceed the MAX mark, since the electrolyte level increases during the recharge.
x
CAUTION
Check the electrolyte level, see beside (CHECKING THE ELECTROLYTE LEVEL). Connect the battery charger to the battery. Charge the battery using a battery charger with a current capacity of no greater than 1/10th the capacity of the battery, see p. 90 (TECHNICAL DATA). After the recharging operation, check the electrolyte level again and if necessary top up with distilled water. Replace the battery plugs.
Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). x Put the battery in its container. x Connect the battery breather tube (6).
Reconnect the battery breather tube (6), see p. 77 (BATTERY).

x
CAUTION
Top up by adding distilled water.
Do not replace the battery plugs until 10 minutes after disconnecting the charger, since the battery continues to produce gas after the charger is removed.
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CAUTION
Connect, in order, the positive (+) and negative () cable. x Cover the terminals of the cables and of the battery with neutral grease or Vaseline.
NOTE First insert the lower coupling (5) and then the upper coupling (4).
x
5(&+$5*,1* 7+( %$77(5<

x
Remove the battery, see p. 78 (REMOVING THE BATTERY). x Remove the battery plugs.

x
Make sure that the ignition switch (7) is in the (OFF) position.
Replace the rubber band (3) in the couplings (5) and (4), taking care to position it correctly. x Replace the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE).
79
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Do not repair faulty fuses. Use only recommended fuses. Using fuses of an improper capacity can cause damage to the electrical system or an electrical fire, which could result in total destruction of your motorcycle as well as injury to you. If a fuse blows frequently, there probably is a short circuit or an overload in the electrical system. If this occurs, take the motorcycle to your Local aprilia Dealer. If an electric component does not work or works irregularly, or if the motorcycle fails to start, it is necessary to check the fuse (1).
CAUTION
To check the fuse: Turn the ignition switch (2) in the (OFF) position. x Remove the rider saddle, see p. 68 (REMOVING THE RIDER SADDLE). x Remove the fuse (1) and inspect the filament (3). If it is open, the fuse must be replaced. x Replace the blown fuse with the spare fuse (4), or with a new fuse having the same amperage rating.
x
NOTE If you use the spare fuse (4), replace it as soon as convenient.
FUSE CIRCUIT A 7.5 amp fuse protects all of the electrical loads except the lighting circuit, which is fed with alternating current directly from the alternator.
NOTE
If you replace the fuse and it blows again immediately, there is a serious problem with the electrical system of your motorcycle. Do not attempt to continue using your motorcycle. Take it to your Local DSULOLD Delear for repair and service.
WARNING
80
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Do not use the motorcycle if the lights are not functioning properly. Do not use the motorcycle if the headlight is adjusted incorrectly. This could temporarily blind oncoming cars, and also reduce the riders ability to see any obstacle along the road while riding at night. It is always advisable to reduce speed when riding during the night, in such a way as to have the time necessary to avoid any obstacle and to adapt to the poorer visibility that inevitably results from darkness. Failure to observe this warning can cause you to collide with another object, with consequent risk of serious injury or even death.
WARNING
NOTE The procedure described here is in compliance with the Italian standard that establishes the maximum height of the headlight beam. For motorcycles used in other countries, you must conform with the local regulations.
To rapidly check the correct direction of the beam, place the motorcycle on flat ground, 32.81 ft (10 m) away from a wall. Turn on the low beam, sit on the motorcycle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height).
To adjust the headlight beam: x Working from the left rear side of the front part of the fairing, adjust the screw (1) with a short Philips screwdriver. By SCREWING IT clockwise, you set the beam higher. By UNSCREWING IT counterclockwise, you set the beam lower.
81
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NOTE The terms right and left are referred to the rider seated on the motorcycle in the normal riding position.
It is possible to adjust the horizontal position both to the right and to the left. The adjustment is carried out using shims and adjusting screws which are supplied as a kit. They will be found in the glove box/tool kit compartment.
To adjust the beam: Remove the front part of the fairing, see p. 70 (REMOVING THE FRONT PART OF THE FAIRING). x Unscrew and remove the screw (1). x Unscrew and remove the screws (2).
x
Handle with care. Take care not to damage the electric wires.
x
CAUTION
There are four groups of shims, for four different degrees of adjustment. Each shim is marked with the type identification code (for example: UPPER) and with the group number (for example: 3) (see table below).
Adjustment degree Gruop 1 2 3 4
Loosen the headlight (3).
Shim UPPER UPPER UPPER UPPER 1 2 3 4 Screw 4,2 x 20 4,2 x 20 4,2 x 20 4,2 x 20 Shim LOWER LOWER LOWER LOWER 1 2 3 4
Screw 4,2 x 20 4,2 x 25 4,2 x 25 4,2 x 30
82
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Risk of fire.
WARNING CAUTION

Keep fuel and other flammable substances away from the electrical components.
Depending on the beam adjustment to be carried out, select: the group necessary for the adjustment; the direction (to the right or to the left).
x x x
NOTE Use shims and screws of the same group.

x
x x
Insert the shims in the headlight screw seats as indicated in figures A and B: rightwards (figure A); leftwards (figure B). x Position the headlight (3) in its seat. x Tighten the lower left screw (1).
Screw the two screws (specific for each shim) (see table). Tighten the three screws. Replace the front part of the fairing, see p. 70 (REMOVING THE FRONT PART OF THE FAIRING). Make sure that the horizontal adjustment of the headlight beam is correct. Make sure that the vertical adjustment of the headlight beam is correct, see p. 81 (ADJUSTING THE HEADLIGHT BEAM VERTICALLY).
Before changing a bulb, turn the ignition switch (4) to the (OFF) position and wait a few minutes so that the bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage. If you touch the bulb with bare hands, remove any fingerprint with alcohol, in order to avoid any damage. TAKE CARE TO AVOID DAMAGING THE ELECTRIC CABLES.
NOTE
Replace the screws (2) with the specific screws corresponding to each shim. Take the screws (2) and keep them in the kit.
NOTE Before changing a bulb, check the fuses, see p. 80 (CHANGING FUSES).
83
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Carefully read p. 83 (BULBS).

x
Position the motorcycle on the stand.
NOTE
Before changing a bulb, check the fuse, see p. 80 (CHANGING FUSES). The headlight contains: one high beam bulb (1) (right side); one parking light bulb (2) (lower side); one low beam bulb (3) (left side).
The high and low beam bulbs are identical. If the low beam is burned out and no spare bulb is available, it is possible to substitute the high beam bulb for the low beam bulb. This should only be done to make it possible to ride a short distance at night to a shop where a new bulb can be obtained or home. To change the bulbs: PARKING LIGHT BULB
HIGH BEAM BULB
NOTE Remove the bulb sockets one by one in such a way as to avoid replacing them incorrectly during reassembly.
If the bulb sockets must all be removed at the same time, take great care to reassemble them in the proper position. x Working from the rear right side of the front part of the fairing, pull back the rubber boot (6) with your fingers. x Rotate the bulb socket (7) counterclockwise and remove it. x Push the bulb (8) toward the back of the socket lightly, and rotate it counterclockwise. x Remove the bulb from the seat.
While removing a bulb socket, do not pull on the wires.

x
CAUTION
Working from the rear side of the front part of the fairing, grasp the bulb socket (4), pull it and remove it from its seat. x Remove the parking light bulb (5) and replace it with an identical bulb.
NOTE
Be sure to maintain the same orientation as the old bulb when you install the new bulb. Do not force the bulb, it will go easily if it is properly oriented.
84
LOW BEAM BULB Remove the bulb sockets one by one in such a way as to avoid replacing them incorrectly during reassembly. If the bulb sockets must all be removed at the same time, take great care to reassemble them in the proper position. x Working from the rear left side of the front part of the fairing, pull back the rubber boot (9) with your fingers. x Rotate the bulb socket (10) counterclockwise and remove it. x Push the bulb (11) toward the back of the socket lightly, and rotate it counterclockwise. x Remove the bulb from the seat.
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NOTE
Tighten the screw (12) moderately and with care to avoid damaging the lens.
x
CAUTION
NOTE
x x
Before changing a bulb, check the fuse, see p. 80 (CHANGING FUSES). Position the motorcycle on the stand. Unscrew and remove the screw (12).
Push the bulb (14) in slightly and rotate it counterclockwise. x Extract the bulb from its seat.
NOTE
x
While removing the lens, use extra care to be sure that you do not break the key. Remove the lens (13).
NOTE Insert the bulb in the bulb socket, carefully aligning the two bulb pins with their guides in the socket.
x
Correctly install a new bulb of the same type.
NOTE
Upon reassembly, position the lens correctly in its seat.
NOTE Be sure to maintain the same orientation as the old bulb when you install the new bulb. Do not try to force the bulb, it will go easily if it is properly oriented.
NOTE If the bulb socket (15) has fallen out of its seat, replace it correctly, ensuring that the slot in the reflector aligns with the screw hole in the body of the turn signal lamp.
85
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x x x
Position the motorcycle on the stand. Unscrew and remove the two screws (1). Remove the lens (2).
Do not ride your motorcycle if the tail light and the stoplight are not working properly. The stoplight is particularly important to prevent other motorcycles from rearending you. Obviously, failure to comply with these instructions could lead to a serious accident with subsequent injuries or even death.
WARNING
NOTE Upon reassembly, make sure that the lens seats properly.
Upon reassembly, do not overtighten the two screws (1). Overtightening will crack the lens.
x
NOTE Ensure that the orientation of your replacement bulb is identical to that of the original bulb. Do not try to force the bulb, it will fit easily if it is properly oriented.
CAUTION
NOTE Before changing a bulb, check the fuse, see p. 80 (CHANGING FUSES), also check the operation of the stoplight switches, see p. 75 (CHECKING THE SWITCHES).
To remove the bulb (3), push the bulb slightly forward and rotate it counterclockwise. x Pull it from its seat.
86
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Carefully read p. 35 (FUEL).
Before transporting your motorcycle, you must empty the fuel tank and drain the carburetor completely, ensuring that both are completely dry. While your motorcycle is being transported, it must be kept in a vertical position, firmly tied down, and with the wheels blocked. Transport your motorcycle in neutral gear only. Failure to heed thi s warning could cause serious damage to the transmission due to vibration of the transport truck.
WARNING
Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Do not smoke or allow open flames near the motorcycle while you are draining the fuel. DISPOSE OF UNWANTED FUEL PROPERLY.
x x
WARNING
After draining the tank, replace the filler cap. To drai n the carburettor com pl etely, proceed as follows: x Position the fuel tap lever (1) on RES. x Start the motorcycle, see p. 48 (STARTING). x Run the engine, at a high idle, until it dies, indicating that the carburetor is completely empty of fuel. Do not hesitate to contact your Local DSULOLD Delear for help.
WARNING
Never attempt to tow your motorcycle with another motorcycle.

WARNING
Position the motorcycle on the stand. Stop the engine and wait until it has cooled down. x Prepare a container with capacity exceeding the fuel quantity present in the tank and put it on the ground on the left side of the motorcycle. x Remove the filler cap. x Empty the fuel tank by means of a manual pump or a similar system.
87
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After your motorcycle has been washed, the brake functioning will be temporarily impaired because of the wetness of the discs and pads. Do not ride in traffic until after you have dried the brakes by repeated braking from slow speed. Always after washing your motorcycle, carry out the preliminary checking operation, see p. 47 (PRELIMINARY CHECKING OPERATIONS). Clean your motorcycle regularly. Your motorcycle will look better and work better if you keep it clean. You will find you will need to clean it more frequently if it is used in the following conditions: Polluted areas (cities and industrial areas). Areas characterized by a high percentage of salinity and humidity (sea areas, hot and humid climates). Particular conditions (use of salt and anti-ice chemical products on the roads during the winter). x Do not allow contaminants such as industrial dust, tar spots, dead insects, bird droppings, etc. to remain on the painted portions of your motorcycle. They will very quickly etch into and damage the paint. x Do not park your motorcycle under trees, since some trees ooze resins that contain chemicals which can damage the paint. 88
WARNING
Polish with silicone wax only after having carefully washed your motorcycle. Do not wash the motorcycle in direct sunlight, especially during the summer, when the paintwork is still warm, since if the shampoo dries before being rinsed away, it can damage the paint. Do not use solvents or water hotter than 40C to clean the plastic components of the motorcycle. Never use a high pressure washer, a steam cleaner, or an air augmented water jet to clean your motorcycle, especially the wheel hubs, handlebar controls, brake reservoirs and cylinders, instruments, electrical components or exhaust silencer. Such cleaning machinery will force water into critical portions of your motorcycle, which could damage your motorcycle through corrosion or short circuiting. Do not use alcohol or other solvents to clean the rubber or plastic parts, or the seat, use only clear water with a mild soap.
CAUTION
To remove dirt and mud from the painted surfaces, use a low pressure water hose. Carefully wet the dirty parts and remove mud and dirt with a soft car sponge. You may use proprietary car shampoos (2-4% parts of shampoo in clear water), to make this easier. Carefully flush so that no dirt or girt remains on the paintwork, and dry with a clean chamois or clean terry towel. To clean the engine and other non-painted parts, use a mild solvent and a bristle brush, along with plenty of rags.
Do not apply any protective coating to the seat, such coatings tend to make the seat too slippery.
WARNING
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If the motorcycle is to be stored for a relatively long period of time, such as over the winter, some simple precautions will make putting the motorcycle back into service much easier. It is much less difficult to prepare the motorcycle for storage properly than it is to restore the motorcycle to proper working condition after a storage period if you have forgotten or neglected to do this preparation. To prepare the motorcycle for storage: x Empty the fuel tank and carburetor, see p. 87 (DRAINING THE FUEL TANK). x Remove the spark plug, see p. 74 (CHECKING THE SIDE STAND). x Pour a teaspoon [0.17 0.34 US fl oz (510 cm 3)] of 2 stroke engine oil into the cylinder.
x x x x
NOTE
x
Cover the spark plug hole with a clean cloth in order to protect the rest of the bike from sprayed oil.
Turn the ignition switch (1) to the (ON) position and push the engine start button (2) for a few seconds to distribute the oil evenly on the surfaces of the cylinder. x Remove the cloth. x Replace the spark plug. x Remove the battery, see p. 78 (REMOVING THE BATTERY) and p. 78 (BATTERY STORAGE).
x x
Wash and dry the motorcycle, see p. 88 (CLEANING). Polish the painted surfaces with wax. Inflate the tyres, see p. 44 (TIRES). By means of a suitable support, position the motorcycle so that both tyres are raised from the ground. Place the motorcycle in an unheated, not-humid room, away from sunlight, with minimum temperature variations. Place a plastic bag over the outlet pipe of the muffler, and tape or tie it tight. Cover the motorcycle with an old sheet or a light canvas, do not use a sheet of plastic or other waterproof material. This will cause condensation which will result in corrosion.
PUTTING THE MOTORCYCLE BACK INTO SERVICE x Uncover and clean the motorcycle, see p. 88 (CLEANING). x Check the charge of the battery, see p. 79 (RECHARGING THE BATTERY) and install it, see p. 79 (INSTALLING THE BATTERY). x Refill the fuel tank, see p. 35 (FUEL). x Carry out the preliminary checking opera ti o n s , s ee p . 47 (P R E L IM IN A R Y CHECKING OPERATIONS).
Test ride the motorcycle at moderate speed in a low traffic area before you ride in heavy traffic.
WARNING
89
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DIMENSIONS
Max. length .................................................. Max. width.................................................... Max. height (front part of the fairing included)................. Seat height................................................... Wheelbase................................................... Min. ground clearance ................................. Curb weight ................................................. Type ............................................................. Number of cylinders ..................................... Total displacement ....................................... Bore / stroke................................................. Compression ratio ........................................ Starting ........................................................ Engine idling rpm ......................................... Clutch........................................................... Cooling.........................................................
75.59 in (1,920 mm) 26.57 in (675 mm) 45.47 in (1,155 mm) 31.89 in (810 mm) 50.39 in (1,280 mm) 6.69 in (170 mm) 253.53 lb (115 kg) one-cylinder, 2-stroke with laminar suction. Separate lubrication with variable strength automatic mixer (1.0 - 3.0 %). 1 3.03 cu in (49.75 cm) 1.59 in / 1.54 in (40.3 mm / 39.0 mm) 12.0 0.5 : 1 electric 1,100 100 rpm multidisc in oil bath, with manual control on the left side of the handlebar. liquid-cooled 3.43 US gal (13 - ) 0.69 US gal (2.6 - ) (mechanical reserve) 27.73 US fl oz (820 cm) 0.24 US gal (0.9 - ) (50% water + 50% antifreeze with ethylene glycol) 1.69 US qt (1.6 - ) 0.37 US qt (0.35 - ) 14.54 US fl oz (430 cm) (for each fork leg) 2 396.83 lb (180 kg)
ENGINE
CAPACITY
Fuel (reserve included) ................................ Fuel reserve ................................................. Transmission oil............................................ Coolant......................................................... 2 stroke oil (reserve included)...................... 2 stroke oil reserve....................................... Front fork oil ................................................ Seats............................................................ Motorcycle max. load (driver+passenger+luggage)........................
90
Gross weight limit (GVWR) (*)...................... Permissible wheel loads (GAVWR) (*) front ........................................................... rear ............................................................
655 lb (297 kg) 220 lb (99.8 kg) 435 lb (197.3 kg)
(*) These two weights: Gross Vehicle Weight Rating (GVWR) and Gross Axle Vehicle Weight Rating (GAVWR); are stamped on the certification plate positioned on the front part of the frame, see p. 7 (VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER)). TRANSMISSION GEAR RATIOS Type ..............................................................
Ratio 1st 2nd 3rd 4th 5th 6th Primary 20/71 = 1 : 3.550 Secondary 12 / 36 = 1: 3.000 16 / 33 = 1: 2.062 19 / 29 = 1: 1.526 22 / 27 = 1: 1.227 24 / 25 = 1: 1.042 25 / 24 = 1: 0.960
mechanical, 6 gears with foot control on the left side of the engine
Final ratio 12 / 47 = 1 : 3.916 Total ratio 1 : 41.712 1 : 28.677 1 : 21.222 1 : 17.064 1 : 14.483 1 : 13.348
CARBURETTOR FUEL SUPPLY FRAME
Number......................................................... Model............................................................ Fuel .............................................................. Type .............................................................. Rake ............................................................. Trail ...............................................................
1 DELL ORTO SHA 14/12 unleaded petrol minimum octane rating (R+M) / 2 method 90 perimeter aluminum backbone 24 4.02 in (102 mm)
SUSPENSIONS
Front ............................................................. hydraulically operated telescopic fork Wheel stroke................................................. 4.33 in (110 mm) Rear.............................................................. hydraulic adjustable mono-shock absorber Wheel stroke................................................. 4.72 in (120 mm) Front ............................................................. disc brake - 11.02 in ( 280 mm) - with hydraulic actuation Rear.............................................................. disc brake - 8.66 in ( 220 mm) - with hydraulic actuation Type .............................................................. Front ............................................................. Rear.............................................................. light alloy 2.50 x 17 3.00 x 17
BRAKES WHEEL RIMS
91
TIRES
FRONT......................................................... inflation pressure for solo rider.................. inflation pressure for rider and passenger REAR ........................................................... inflation pressure for solo rider.................. inflation pressure for rider and passenger
90/80 17 46S; 90/80 17 46P 24.65 psi [(170 kPa) (1.7 bar)] 26.10 1.45 psi [(180 10 kPa) (1.8 0.1 bar )] 110/80 17 57S; 110/80 17 57P 27.55 psi [(190 kPa) (1.9 bar)] 30.45 1.45 psi [(210 10 kPa) (2.1 0.1 bar)] CDI 20 1 before T.D.C. NGK R BR9ES CHAMPION RN1C 0.024 0.028 in (0.6 0.7 mm) 12 V - 4 Ah 7.5 A 12 V - 105 W 12 12 12 12 12 12 12 12 12 12 12 12 12 12 V - 35 W V - 35 W V-5W V - 10 W V - 5 / 21 W V-5W V - 3.4 W V - 1.2 W V - 1.7 W V - 1.7 W V - 1.7 W V - 1.7 W V - 1.7 W V - 1.7 W
IGNITION SPARK PLUG
Type ............................................................. Spark advance ............................................. Standard ...................................................... Alternative .................................................... Spark plug gap............................................. Battery ......................................................... Fuses ........................................................... Generator .................................................... Low beam .................................................... High beam.................................................... Parking light ................................................. Direction indicators ...................................... Rear parking light/ number plate light/stoplight ....................................... Tachometer.................................................. Speedometer ............................................... Coolant temperature indicator......................
ELECTRIC SYSTEM BULBS
WARNING LIGHTS Neutral ......................................................... Right direction indicators.............................. High beam.................................................... 2 stroke oil reserve ...................................... Left direction indicators ................................ Low beam ....................................................
92
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Gearbox oil (recommended): F.C., SAE 75W - 90 As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the A.P.I. GL-4 specifications. 2 stroke oil (recommended): PRO GPX 2. As an alternative to the recommended oil, use high-quality oils with characteristics in compliance with or superior to the ISO-L-ETC++, A.P.I. TC++ specifications. Fork oil (recommended): F.A. 5W or F.A. 20W fork oil. If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed as indicated below: SAE 10W SAE 15W
< <
<
Bearings and other lubrication points (recommended): AUTOGREASE MP. As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30C.... +140C, dripping point 150C... 230C, high protection against corrosion, good resistance to water and oxidation. Protection of the battery poles: neutral grease or vaseline. Spray grease for chains (recommended): Brake fluid (recommended):
< <
F.A. 5W 67% of the volume, + F.A. 5W 33% of the volume, +
< < < <
F.A. 20W 33% of the volume. F.A. 20W 67% of the volume.
<
Use new brake fluid only.
WARNING WARNING
<
CHAIN SPRAY.
F.F., DOT 5 (DOT 4 compatible).
Engine coolant (recommended):
<
ECOBLU - 40C.
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35C at least.
93
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1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29)
Generator Ignition coil Voltage regulator Rectifier Battery Start relay Rear stoplight switch 2 stroke oil reserve sensor Coolant temperature thermistor Neutral switch sensor Low beam bulb Rear left direction indicator Rear light Rear right direction indicator Ignition switch Right dimmer switch Left dimmer switch Complete dashboard Coolant temperature indicator Dashboard bulbs Left direction indicator warning light High beam warning light Low beam warning light 2 stroke oil reserve warning light Neutral warning light Right direction indicator warning light Front right direction indicator High beam bulb Front parking light
30) 31) 32) 33) 34) 35) 36) 37) 38)
Front left direction indicator Horn Blinking Multiple connectors Starter Spark plug Front stoplight switch Headlight Side stand switch
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Ar Az B Bl G Gr M N R V Vi Ro
Orange Light blue Blue White Yellow Grey Brown Black Red Green Violet Pink
97
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aprilia s.p.a. wishes to thank its customers for the purchase of this motorcycle. Do not dispose of oil, fuel, polluting substances and components in the environment. Do not keep the engine running if it isnt necessary. Avoid disturbing noises. Respect nature.
RS 50

Usa - 1999

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use and maintenance

 part# 8202164

1999 aprilia s.p.a. - Noale (VE)

 NOTE This manual is an important and

First edition: april 1999 Reprint:

position (2) symbol

use and maintenance RS 50

NOTE The word NOTE in this manual

use and maintenance RS 50

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Warranty claims should be directed to: aprilia USA Inc.

use and maintenance RS 50

use and maintenance RS 50

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326,7,21 2) 7+( :$51,1* $'+(6,9( /$%(/6

use and maintenance RS 50

Exhaust pipe stamping.

CHAIN TENSION WITH NO LOAD

Front tire Rear tire

Pirelli Metzeler Dunlop

90/80 - 17" 46S 90/80 - 17" 46P

110/80 - 17" 57S 110/80 - 17" 57P

use and maintenance RS 50

use and maintenance RS 50

DSULOLD VSD (0,66,21 &21752/ 6<67(0 :$55$17< 67$7(0(17

use and maintenance RS 50

DSULOLD VSD /,0,7(' :$55$17< 21 (0,66,21 &21752/ 6<67(0

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

%$6,& 6$)(7< 58/(6

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

use and maintenance RS 50

8) 9) 10) 11) 12) 13) 14)

use and maintenance RS 50

$55$1*(0(17 2) 7+( ,167580(176&21752/6

, 16758 0(176 $1' , 1',&$7256

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12)

use and maintenance RS 50

,167580(176 $1' ,1',&$7256 7$%/(

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Coolant temperature indicator

2 stroke oil reserve warning light

Neutral indicator warning light Trip odometer Odometer Speedometer

use and maintenance RS 50

&21752/6 $7 7+( /()7 +$1' *5,3

use and maintenance RS 50

&21752/6 $7 7+( 5,*+7 +$1' *5,3

Key removal It is possible to remove the key.

(LOCK) Steering lock

It is possible to remove the key. It is not possible to remove the key.

use and maintenance RS 50

$8;, /,$5< (48, 30(17

*/29(722/ .,7 &203$570(17

use and maintenance RS 50

part# 8202164

NOTE This manual is an important and

%$77(5< +<'52(1 $6 $1' (/(&752/<7(

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DSULOLD VSD (0,66,21 &21752/ 6<67(0 :$55$17< 67$7(0(17

DSULOLD VSD /,0,7(' :$55$17< 21 (0,66,21 &21752/ 6<67(0

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