APRILIA Amico 50 1997 User manual

1
First edition: november 1997
Reprint:
Produced and printed by:
editing division
Soave (VERON ) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [e-mail]
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
This manual contains all the main information and the in-
structions required for normal use and maintenance of
your vehicle.
For controls and check-ups that cannot be carried out
easily with the standard equipment supplied, we advise
you to consult our Dealers who can assure you of quick
and careful servicing.
To keep your aprilia vehicle always in perfect operating
conditions, we advise you to insist on Original Spares
and to have repairs carried out only by aprilia uthor-
ized Outlets and Official Dealers.
When ordering spare parts from the Dealer, always
quote the spares code which is stamped on a sticker
placed under the saddle.
It is a good idea to make a note of the identification code
in the space provided in this manual, so that you will al-
ways have a record of it even if the identification sticker
comes off.
ll information is purely indicative and may be subject to
variation without notice.
aprilia CODICE RIC MBI spare parts code number
N° I.M. ABCDE
IUKA PSFB D F E
GR NL CH DK J SGP PL IL ROK
MAL RCH BM USA
aprilia part# 8202099

2
Carefully observe the instructions preceded by the fol-
lowing warning signs:
Saf ty norms and r gulations to prot ct th
driv r and oth r p opl from s v r injuri s
or grav risks.
Indications to mak th op rations asi r.
T chnical information.
In this manual the various versions are indicated by the
following symbols:
#/.4%.43
pag
Catalitic silencer 2.....................................................2
Technical data .............................................................3
Identification data ........................................................5
Controls arangement .....................................................6
Instructions for use .....................................................9
Maintenance instructions .........................................15
Periodic maintenance chart .....................................26
Lubricant chart ..........................................................27
Wiring diagram ..........................................................28
#!4!,94)#3),%.#%2
2
Avoid parking th v hicl catalytic v rsion
n ar dry brush wood or in plac s asily ac-
c ssibl to childr n, as th catalytic sil nc r
b com s xtr m ly hot during us ; b v ry car ful
and avoid any kind of contact b for it has com-
pl t ly cool d down.
The catalytic mico 50 is fitted with a silencer with metal
catalytic converter of the "platinum-rhodium bivalent"
type. This device provides for the oxidation of the CO
(carbon monoxide) and of the HC (unburned hydrocar-
bons) contained in the exhaust gases, changing them
into carbon dioxide and steam, respectively.
Due to the catalytic reaction, the high temperature
reached by the exhaust gases makes for the burning of
the oil particles, thus keeping the silencer clean and
eliminating the exhaust fumes.
2catalytic v rsion
IItaly v rsion CSwitz rland v rsion
UUnit d Kingdom v rsion D nmark v rsion
AAustria v rsion JJapan v rsion
PPortugal v rsion SSingapor v rsion
"Finland v rsion VPoland v rsion
BB lgium v rsion %Isra l v rsion
DG rmany v rsion KSouth Kor a v rsion
FFranc v rsion MMalaysia v rsion
ESpain v rsion RChil v rsion
GGr c v rsion QB rmuda v rsion
OHolland v rsion -Unit d Stat s of Am rica v rsion
a
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3
To have the catalytic converter function correctly and for
long and to reduce possible problems regarding the soil-
ing of the thermal unit and of the exhaust, it is necessary
to avoid covering long distances with the engine running
at constantly low rpm.
It is sufficient to alternate these periods with periods in
which the engine runs at relatively high rpm, even if only
for a few seconds, but rather frequently.
What has been stated above assumes particular impor-
tance for the cold starting of the engine: in this case, in
order to reach a rpm regime sufficient to enable the
"priming" of the catalytic reaction, just make sure that the
temperature of the thermal unit has reached at least
50°C, which generally occurs a few seconds after start-
ing the engine.
Do not us l ad d p trol, sinc it caus s th
d struction of th catalytic conv rt r.
4%#(.)#!,$!4!
-/4/2
Model ................................................................... aprilia
Type .....................................2-stroke single-cylinder
with lamellar inlet
Cylinder .............................................................cast iron
Bore / stroke ...................................... 40 mm e 39,2 mm
Compression ratio ................................................... 13:1
Displacement ...................................................... 49 cm³
Starting ................................................................electric
Gearbox ..........................................automatic converter
with belt drive
Transmission oil capacity................................... 110 cm³
42!.3-)33)/.
Primary ............................................................... “V'' belt
Secondary ............................................... reduction gear
Variator .................................................................... 3YJ
)'.)4)/.
Typ ..................................................................electronic
Spark advance .........................14° at 5000 rpm 1,4 mm
before T.D.C.
Spark plug ................................................ NGK BR7 HS
#!2"52%44/2
Model ............... Dell’Orto PHBN 12 (TEI KEI TK12Y12)
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4
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Fuel .................... premium grade petrol (4 Stars U)
according to the DIN 51 600
standard, min. O.N. 98 (N.O.R.M.)
and 88 (N.O.M.M.)
Fuel 2........................... unleaded petrol according
to the DIN 51 607 standard,
min. O.N. 95 (N.O.R.M.)
and 85 (N.O.M.M.)
Fuel tank capacity ................................................... 7,5 L
of wich 2 L reserve
Mixer oil tank capacity ............................................. 1,3 L
&2!-%
Type ...................... split single beam tubular steel frame
3530%.3)/.3
Front .......................................... fork with articulated rod
Rear ...............................hydraulic monoshock absorber
"2!+%3
Front ....................................................... disc Ø 155 mm
with hydraulic control
Rear .......................................shoe brake Ø 110x25 mm
with mechanical control
492%3
– Front ........................................................ 100/90×10”
Inflation pressure ............................170 kPa (1,7 bar)
– Rear ......................................................... 100/90×10”
Inflation pressure ............................190 kPa (1,9 bar)
with passenger.................................210 kPa (2,1 bar)
2)-3
Front ................................................ 2,50×10” light alloy
Rear ................................................. 2,50×10” light alloy
%,%#42)#3934%-
Front lights .......................................................12V 15W
Front lights C............................................12V 35/35W
Front parking light
(not provided in the O versions).....................12V 3 W
Rear light/stop light ...................................... 12V 5/21 W
Turn indicators .................................................12V 10W
Dash board light ................. 5×12V 2W (warning lights);
3×12V 1,2W - 1×12V 2W
Light for tool case/helmet case .......................12V 1,2W
Battery ..............................................................12V 4 h
Fuse......................................................................... 7,5
$)-%.3)/.3
Length ..............................................................1780 mm
Width ............................................ 690 mm (handle bar)
Height ................ 1060 mm (handle bar); 760 mm (seat)
Centre to centre distance ................................1240 mm
Weight without fuel and oil .....................................71 kg

5
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It is a good rule to write down the frame and engine num-
bers in the space provided in this manual.
Do not alt r th id ntification numb rs if you
do not want to incur s v r p nal and ad-
ministrativ sanctions.
FRAME NUMBER (Fig. 1)
The frame number is stamped on the frame. To be able
to read it, it is necessary to raise the saddle (1).
Frame no.
ENGINE NUMBER (Fig. 2)
The engine number is stamped on the lower support of
the rear shock absorber.
Engine no.
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6
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1 - Start push button (r)
2 - Lights switch (b - p - •)
2a - Lights switch (b - •) O
2b - Lights switch (a - b - •) C
3 - Ignition block/steering lock switch (n - m - s)
4 - Turn indicators switch (c)
5 - Horn push button ( )
6 - Cold start lever (e)
7 - Thraottle grip
8 - Front brake lever
9 - Rear brake lever
&IG
1 - Speedometer / Odometer
2 - Fuel level indicator (g)
3 - Fuel reserve warning light (g)
4 - Mixer oil reserve warning light (j)
5 - Turn indicators warning light (c)
6 - Low beam warning light (b)
6a - High beam warning light (a)C
7 - Digital clock
8/9 - Clock adjustment and functions selection push
buttons
R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
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Display:
◆Normal display: hours and minutes.
◆Date display: press (9) once to display the month and
date.
◆Seconds display: press (9) twice to display the sec-
onds.
S tting
◆Press (8) once, the date and time will be displayed al-
ternately.
◆Month: press (8) again and the month will appear on
the right (the rest disappears), press (9) to obtain the
desired month.
◆Date: press (8) again and the date will appear on the
right. Press (9) to obtain the desired date.
◆Hours: press (8) again and the hour will appear on the
left with the letter “ ” or “P” (“ ” = a.m., “P” = p.m.).
Press (9) to obtain the desired hour.
◆Minutes: press (8) again and the minutes will appear
on the right of the display.
Press (9) to obtain the desired minutes
◆The clock is now set.
Press (8) again to return to normal operation.
#(!.').'4(%#,/#+#%,,
◆Remove the front grille and headlamp unit, see pag.
25).
◆Remove the clock support from the rear of dashboard,
acting on the snapcouplings.
◆Extract the clock and change the cell.

8
&IG
1 - Fuel tank plug
2 - Mixer oil tank plug
3 - Tool case/helmet case
&IG
1 - Central stand
2 - Starter pedal
3 - Case
4 - Case lock
5 - Seat lock
6 - Carrier/handle
,/#+3
The key provided starts the engine, operates the steer-
ing lock (3-Fig. 3), the luggage case lock (4-Fig. 6) and
the saddle lock (5-Fig. 6).
To op rat th st ring lock, turn th han-
dl bars to th l ft, pr ss th k y, pull it up
and turn it to “s” position, th n xtract th k y.
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Exhaust gas s contain carbon monoxid ,
which is xtr m ly noxious if inhal d.
Avoid starting th v hicl in clos d or badly-
v ntilat d rooms.
Th non-obs rvanc of this warning may caus loss
of consciousn ss or v n l ad to d ath by asphyxia.
Do not g t on th v hicl for th starting.
El ctric starting
◆Position the vehicle on the stand.
◆Lock at least one wheel, by pulling a brake lever (Fig.
7). If this operation is not carried out, the start relay re-
ceives no current and therefore the engine does not
start.
◆Turn the ignition switch (Fig. 8) to position "n".
a

10
◆Press the start push button “r” (1-Fig. 9) without accel-
erating, then release it as soon as the engine starts.
Avoid pr ssing th start push button "r"
(3) wh n th ngin is running: this may
damag th start r.
Wh n th start push button "r" is pr ss d, th 2
strok oil r s rv warning light "j" com s on.
With th ngin in running condition, wh n th start
push button "r" is r l as d, th 2 strok oil r s rv
warning light "j" must go out; if this do s not oc-
cur, top up th 2 strok oil tank.
◆If the starting is carried out with cold engine, rotate the
cold start lever "e" (1-Fig. 10) downwards.
◆Do not accelerate and pull the brake levers at the
same time until you move off.
◆Warm the engine up before leaving.
◆Once the engine has warmed up, rotate the cold start
lever "e" (1-Fig. 10) upwards.
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11
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For the kick start, proceed as follows:
◆Position the vehicle on the centre stand.
◆Move to the left side of the vehicle.
◆To avoid losing control of the vehicle during the start-
ing, lock both wheels by putting on the brake levers
(Fig. 7).
◆Turn the ignition switch (Fig. 8) to position "n".
Do not push down th kick start r with th
ngin on.
◆Push down the kick starter with your right foot, releas-
ing it immediately.
If necessary, repeat the operation until the engine
starts.
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fter a long period of inactivity, proceed as follows:
◆Move the ignition switch (Fig. 8) to position "n".
◆Make the starter run for about 10 seconds, in order to
ensure the filling up of the float chamber.
To start the engine:
◆Rotate the cold start lever "e" (1-Fig. 10) downwards.
◆Slightly open the throttle, then carry out the electric
starting procedure (or KICK ST RT).
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12
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Release the throttle grip (Pos. - Fig. 11), put on the
rear brake, then move the vehicle down the stand.
Get on the vehicle, keeping at least one foot on the
ground in order not to lose balance.
Prop rly adjust th inclination of th r ar-
vi w mirrors.
To leave, release the brake lever and accelerate by gen-
tly rotating the throttle grip (Pos. B - Fig. 11); the vehicle
will start moving.
Avoid op ning and closing th throttl grip
r p at dly and continuously, so that you do
not accid ntally los control of th v hicl .
If you hav to brak , clos th throttl and put on
both brak s in ord r to obtain uniform d c l ration,
prop rly x rting pr ssur on th braking parts.
By putting on th front brak only or th r ar brak
only, you r duc th braking forc consid rably,
thus running th risk of locking on wh l and con-
s qu ntly losing grip.
B for b ginning to turn, slow down or brak driv-
ing at mod rat and constant sp d or acc l rating
slightly; avoid braking at th last mom nt: it would
b v ry asy to skid.
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13
If th brak s ar op rat d continuously on
downhill str tch s, th friction surfac s can
ov rh at, thus r ducing th braking ffici n-
cy. N v r driv with th ngin off!
In cas of w t ground or scarc wh l grip (snow,
ic , mud, tc.), driv slowly, avoiding sudd n brak-
ings or mano uvr s that could mak you los grip
and fall down.
Pay th utmost att ntion to any obstacl or variation
of th ground.
Un v n roads, rails, manhol cov rs, indications
paint d on th road surfac , building sit m tal
plat s b com rath r slipp ry by rain. For this r a-
son all th s obstacl s hav to b car fully avoid d,
driving smoothly and b nding th v hicl as littl as
possibl .
Always us th turn indicators tim ly wh n you in-
t nd to chang lan or dir ction, avoiding sharp and
dang rous mov m nts.
25..).').
Aft r th first 500 kilom tr s, carry out th
ch cking op rations indicat d in th column
"Aft r running-in" of th PERIODIC MAINTE-
NANCE CHART, s p. 26, in ord r to avoid hurting
yours lf or oth r p opl and/or damaging th v hi-
cl .
The running-in of the engine is primary to ensure its cor-
rect functioning and its correct functioning.
If possible, drive on hilly roads and/or roads with many
bends, so that the engine, the suspensions and the
brakes undergo a more effective running-in.
For the first 500 km, keep to the following indications:
0-300 km
Do not keep the throttle grip open more than one half for
long stretches.
300-500 km
Do not keep the throttle grip open more than three-
fourths for long stretches.
R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
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14
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◆Release the throttle grip and stop the vehicle by
putting on the brakes.
◆Move the ignition switch to position "m".
It is not n c ssary to clos th fu l tap wh n
th ngin is off, sinc it is quipp d with an
automatic closing syst m.
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Park th v hicl on firm and flat ground, to
pr v nt it from falling down.
N ith r l an th v hicl against walls, nor
lay it on th ground.
Mak sur that th v hicl and sp cially its r d-hot
parts do not r pr s nt a dang r for p rsons and
childr n.
Do not l av th v hicl unatt nd d wh n th n-
gin is on or th k y is ins rt d into th ignition
switch.
Do not sit on th v hicl wh n th stand is down.
Seize the vehicle using the rear grab rail and at the
same time push the stand lever downwards (see figure).
Mak sur that th v hicl is r sting firmly.
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This vehicle is provided with front hydraulic disc brake.
When the disc pads wear out, the level of the fluid de-
creases to automatically compensate for their wear.
Periodically check the brake fluid level in the tank and
the wear of the pads, see p. 18 (CHECKING THE P D
WE R).
2%!2$25-"2!+%
Th brak s ar th parts that most nsur
your saf ty and for this r ason th y must al-
ways b p rf ctly working.
ADJUSTING THE BRAKE
◆Measure the distance covered by the lever (9-Fig. 3)
before the brake starts it braking action.
The idle stroke at the end of the brake lever must be
about 5 ÷ 10 mm.
◆djust the clearance by acting on the adjuster
(1-Fig. 15).
◆Put on the brake (9-Fig. 3) repeatedly and make sure
that the wheel turns freely after the brake has been re-
leased.
◆Check the braking efficiency.
For any doubt r garding th p rf ct func-
tioning of th braking syst m and in cas
you ar not abl to carry out th usual
ch cking op rations, contact your
APRILIA Official
D al r.
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16
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&IG
◆Remove the two plastic elements (1) protecting the
stem.
◆Unscrew the two screws (2) and remove the brake
caliper.
◆Unscrew the nut (3).
Coppia di s rraggio: 50 Nm (5 kgm).
◆Slide the pin nut (5).
◆Remove the wheel.
Upon r ass mbly position th odom t r ca-
bl (4) corr ctly.
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djust the play on the accelerator via the appropriate
tightener on the carburettor.
To access the carburattor:
◆Remove the screw (1).
◆Pull the tool-helmet, compartment after disconnecting
the compart- ment lighting cable.
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17
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B for carrying out th following op ra-
tions, l t th ngin and th sil nc r cool
down until th y r ach room t mp ratur , in
ord r to avoid burns.
◆Position the vehicle on the centre stand.
◆Unscrew and remove the two screws (1) and (2).
◆Slacken the two screws that hold the exhaust silencer
to the cylinder (access through the battery compart-
ment)
◆Remove the silencer (4).
Upon r ass mbly, chang th xhaust man-
ifold-sil nc r s al.
◆Put on the rear brake (9 - Fig. 3) to lock the wheel.
◆Unscrew and remove the wheel nut (3) and the wash-
er.
Upon r ass mbly, chang th wh l nut
(sp cial typ ).
Wh l nut driving torqu : 110 Nm (11 kgm).
◆Withdraw the wheel.
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18
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Check the wear of the rear brake shoes after the first
500 km and successively every 4000 km.
R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
To check the wear of the rear brake shoes, proceed as
follows:
◆Remove the rear wheel, see p. 17 (REMOVING THE
RE R WHEEL).
◆To check the thickness of the friction material, which
must never be less than 1 mm (Fig. 19).
If th minimum allow d limit has b n
r ach d, if you notic any irr gularity in th
op ration or if any part is damag d, contact
your
APRILIA Official D al r, who will provid for
changing th brak sho s.
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Check the brake pad wear after the first 500 km and suc-
cessively every 2000 km.
R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
The wear of the brake pads depends on the use, on the
kind of drive and on the road. The wear will be greater
when the vehicle is driven on dirty or wet roads.
To carry out a rapid checking of the wear of the front
pads, proceed as follows:
◆Position the vehicle on the centre stand.
◆Remove the brake caliper cover.
◆Carry out a visual checking of the friction material
thickness by looking between the brake caliper and
the pads.
If the thickness of the friction material (even of one pad
only) has reduced to about 1 mm, replace both pads.
Hav th pads chang d by your
APRILIA Offi-
cial D al r.
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19
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Gr as th r ar brak cam pin v ry 4000
km. If th v hicl is us d on dusty roads,
this op ration must b carri d out mor fr qu ntly.
R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
◆Disassemble the rear wheel, see p. 17 (REMOVING
THE RE R WHEEL (Fig. 18)).
◆Unscrew and remove the adjuster (1-Fig. 15).
Do not dirt th sho s and th friction mat ri-
al with gr as , to avoid compromising th
braking ffici ncy of th v hicl .
This op ration may b difficult b caus th
springs r sist consid rably to th r moval
of th sho s. B car ful not to crush or
bruis your hands and fing rs.
◆Grasp the inner edge of the two friction elements (1)
at its centre and, pulling toward yourself, shake the
two shoes, thus releasing them.
◆Loosen the nut (2) and remove the pin lever (3).
◆Withdraw the cam pin (4).
Mod rat ly gr as only th c ntral part of
th pin.
Avoid dirting th cam or th ar as around
th pin s at with gr as .
◆Grease the central part of the pin by using grease for
kinematic motions, see p. 27 (LUBRIC NT CH RT).
Upon reassembly:
N ith r strik , nor forc th cam pin (4) with
hamm rs or oth rs tools, in ord r not to
damag th two O-rings.
◆Manually insert the cam pin (4), rotating and pushing it
slightly.
Mak sur that th springs ar corr ctly
coupl d.
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R m mb r: 1 mil = 1.6 km
1 km = 0.625 mil s
Check the conditions of the air cleaner and clean it
monthly or every 4000 km, depending on the conditions
in which the vehicle is used.
If the vehicle is used on dusty or wet roads, the cleaning
operations and any replacement should be carried out
more frequently.
◆Position the vehicle on the stand.
◆To remove the left side panel of the vehicle.
◆Unscrew the four screws.
◆Remove the filter case cover and extract the filtering
element.
◆To clean the filtering element use clean, non-inflam-
mable solvents or solvents with high volatility point,
then let it dry thoroughly.
◆pply a filter oil or a thick oil (S E 80W-90) on the
whole surface of the filtering element, then squeeze it
to eliminate the oil in excess.
Th filt r must b w ll impr gnat d, though
not dripping.
30!2+0,5'&IG
Periodically remove the spark plug and clean it carefully,
removing carbon deposits; change it if necessary.
To remove and clean the spark plug:
◆Remove the engine compartment cover.
◆Take off the spark plug cap.
◆Remove all the dirt from the base of the spark plug,
then unscrew it with the spanner you will find in the
tool kit and extract it from its seat, taking care that nei-
ther dust nor other substances enter the cylinder.
◆Make sure that there are neither carbon deposits, nor
corrosion marks on the electrode and on the central
porcelain part; if necessary, clean them with the spe-
cial cleaners for spark plugs, with an iron wire and/ or
a metal brush.
◆Energetically blow some air, in order to prevent the re-
moved residues from getting into the engine.
If the spark plug has crackings on the insulating mate-
rial, corroded electrodes or excessive deposits, it
must be changed.
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