APRILIA Pegaso 650 Installation and operating manual

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FOREWORD
– This manual supplies the main information for normal
servicing procedures.
– The information and illustrations contained in this man-
ual are updated to the moment of its publication.
– This publication is meant for professional mechanics,
therefore many notions have been intentionally omit-
ted, as they were regarded as superfluous.
For any further information, contact aprilia s.p.a.
SERVICE DEPARTMENT.
– For any further information see the ENGINE SERVICE
MANUAL, No 933 (D-UK) / No 934 (I-E-F), the EN-
GINE SPARE PARTS CATALOGUE and the "CHAS-
SIS PARTS" SPARE PARTS CATALOGUE, No 261V
aprilia s.p.a. reserves the right to modify its models at
any time, without prejudice to the main characteristics
here described.
All rights as to electronic storage, reproduction and total
or partial adaptation, with any means, are reserved for all
Countries.
The mention to products or services supplied by third par-
ties is made only for information purposes and is not
binding in any case.
aprilia s.p.a. takes no responsibility as to the perfor-
mance or the use of said products.
HOW TO USE YOUR SERVICE
AND REPAIR MANUAL
◆
ADVICE FOR CONSULTATION
– If not expressly described otherwise, the reas-
sembly of the groups is to be carried out repeat-
ing the disassembly phases in the reverse or-
der.
– For each single operation on the engine, consult the
specific manual.
– For ordinary maintenance, consult the "USE AND
MAINTENANCE” manual.
Remember: 1 mile = 1.6 km
1 km = 0.625 miles
◆
SYMBOLS
Carefully observe the instructions preceded by the fol-
lowing warning signs:
Safety norms and regulations to protect the
pilot, the mechanic and other people from se-
vere injuries or grave risks.
Indications to make the operations easier.
Technical information.
The operations preceded by this symbol must
be repeated on the opposite side of the vehi-
cle.
In this manual the various versions are indicated by
the following symbols:
&optional
2catalytic version
UUnited Kingdom version
AAustria version
CSwitzerland version
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★First edition: march 1997
Reprint:
Produced and printed by:
Studio Tecno Public
Viale del Progresso - 37038 Soave (VR) - Italy
Ph. 045 - 76 11 911
Fax 045 - 76 12 241
On behalf of:
aprilia s.p.a.
Via G. Galilei, 1 - 30033 Noale (VE) - Italy
Ph. 041 - 58 29 111
Fax 041 - 44 10 54
TABLE OF CONTENTS
GENERAL INFORMATION 1
SERVICE AND SETTING UP 2
ENGINE 3
FUEL SUPPLY SYSTEM 4
COOLING SYSTEM 5
ELECTRICAL SYSTEM 6
CHASSIS PARTS 7
REPAIR INFORMATION 8

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NOTE / NOTES / ANMERKUNGEN

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INFORMAZIONI GENERALI
INFORMACIONES GENERALES
GENERAL INFORMATION

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GENERAL INFORMATIONINFORMACIONES GENERALES
INFORMACIONES GENERALES
1
INDICE
1.1 POSICIÓN
DE LOS NÚMEROS DE SERIE ............Pag. 1-5
1.1.1 NÚMERO DE BASTIDOR .....................Pag. 1-5
1.1.2 NÚMERO DE MOTOR ..........................Pag. 1-5
1.2 ADVERTENCIAS PARA
EL COMBUSTIBLE, LUBRICANTES
Y LÍQUIDO REFRIGERANTE ...............Pag. 1-5
1.2.1 COMBUSTIBLE ....................................Pag. 1-5
1.2.2 ACEITE DEL MOTOR ...........................Pag. 1-5
1.2.3 ACEITE PARA HORQUILLA ................Pag. 1-8
1.2.4 LÍQUIDO DE FRENOS .........................Pag. 1-8
1.2.5 LÍQUIDO REFRIGERANTE ..................Pag. 1-8
1.3 NORMAS PARA EL RODAJE ...............Pag. 1-9
1.4 PRECAUCIONES
E INFORMACIONES GENERALES .....Pag. 1-9
1.5 PIEZAS DE REPUESTO ......................Pag. 1-12
1.6 FICHA TECNICA ...................................Pag. 1-12
1.7 TABLA DE LOS LUBRICANTES .......Pag. 1-15
1.8 EQUIPOS ESPECIALES ......................Pag. 1-16
GENERAL INFORMATION
1
TABLE OF CONTENTS
1.1 POSITION OF SERIAL NUMBERS .....Pag. 1-5
1.1.1 FRAME NUMBER .................................Pag. 1-5
1.1.2 ENGINE NUMBER ...............................Pag. 1-5
1.2 INSTRUCTIONS
FOR USE OF FUEL,
LUBRICANTS AND COOLANT ...........Pag. 1-5
1.2.1 FUEL .....................................................Pag. 1-5
1.2.2 ENGINE OIL ..........................................Pag. 1-5
1.2.3 FORK OIL ...........................................Pag. 1-10
1.2.4 BRAKE FLUID ....................................Pag. 1-10
1.2.5 COOLANT ...........................................Pag. 1-10
1.3 RUNNING-IN RULES ...........................Pag. 1-11
1.4 PRECAUTIONS AND GENERAL
INFORMATION .....................................Pag. 1-11
1.5 SPARE PARTS ......................................Pag. 1-12
1.6 TECHNICAL
SPECIFICATIONS ................................Pag. 1-12
1.7 LUBRICANT CHART ............................Pag. 1-15
1.8 SPECIAL TOOLS ..................................Pag. 1-16

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GENERAL INFORMATIONINFORMACIONES GENERALES
1.1 POSICIÓN DE LOS NÚMEROS DE SERIE
Estos números son necesarios para matricular el vehícu-
lo.
La alteración de los números de identificación
puede provocar graves sanciones penales y
administrativas y la invalidez de la garantía.
1.1.1 NÚMERO DE BASTIDOR
El número del bastidor está impreso en el tubo de la di-
rección, en la parte derecha del vehículo.
1.1.2 NÚMERO DE MOTOR
El número del motor está impreso en la parte trasera su-
perior.
1.2 ADVERTENCIAS PARA EL COMBUSTIBLE,
LUBRICANTES Y LÍQUIDO REFRIGERANTE
1.2.1 COMBUSTIBLE
El combustible para la propulsión de los mo-
tores de explosión, es muy inflamable y puede
volverse explosivo en determinadas condicio-
nes. Es oportuno reponer gasolina y realizar las ope-
raciones de mantenimiento en una zona ventilada y
con el motor apagado. No fume durante la provisión
de gasolina y cerca de los vapores del combustible;
evite el contacto con llamas, chispas y cualquier otra
fuente que pueda causar el encendido o la explosión.
Además, evite que el combustible salga de la boca de
llenado, ya que éste podría incendiarse si toca las su-
perficies candentes del motor. En caso que se vierta
accidentalmente combustible, antes de arrancar el
vehículo, controle que la zona esté completamente
seca. El combustible se dilata con el calor y bajo la
acción de los rayos solares. Por lo tanto, nunca llene
el depósito hasta el tope. Cierre cuidadosamente la
tapa al finalizar las operaciones de reposición.
Evite el contacto del combustible con la piel, la inha-
lación de los vapores, la ingestión y el trasiego de un
recipiente a otro por medio de un tubo.
No esparsa el combustible en el medio ambiente.
MANTÉNGASE LEJOS DEL ALCANCE DE LOS NI-
ÑOS.
Versión normal:
Gasolina super (4 Stars
U
) DIN 51 600, mínimo octano
98 (N.O.R.M.) y 88 (N.O.M.M.).
Versión catalítica
2
:
Gasolina super sin plomo según DIN 51 607, mínimo oc-
tano 95 (N.O.R.M) y 85 (N.O.M.M.).
1.2.2 ACEITE DEL MOTOR
El aceite del motor puede causar graves da-
ños a la piel si es manipulado por mucho
tiempo y diariamente. Se aconseja lavarse las
manos tras haberlo manipulado. No esparza el aceite
en el medio ambiente. Entréguelo o hágalo retirar por
la empresa de recuperación de aceites usados más
cercana o por el proveedor.
Controle cada 500 km el nivel del aceite del motor; véase
2.12 (CONTROL DEL NIVEL DEL ACEITE
DEL MOTOR Y RELLENO). Cambie el aceite del motor
tras los primeros 1000 km y sucesivamente cada 6000
km; véase 2.13 (CAMBIO DEL ACEITE MOTOR Y DEL
FILTRO DEL ACEITE DEL MOTOR).
Aceite del motor (aconsejado):
IP SUPERBIKE 4, SAE 5W - 40.
Como alternativa a el aceite aconsejado, pueden utilizar-
se aceites de marca con características conformes o su-
periores a las normas CCMC G-4, A.P.I. SG.
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1.1 POSITION OF SERIAL NUMBERS
These numbers are necessary in order to register the ve-
hicle. Do not alter the identification numbers if you
do not want to incur severe penal and admin-
istrative sanctions and to cause the immediate invali-
dation of the guarantee.
1.1.1 FRAME NUMBER
The frame number is printed on the vehicle right side of
the steering tube.
1.1.2 ENGINE NUMBER
The engine number is printed high up on the rear part of
the vehicle.
1.2 INSTRUCTIONS FOR USE OF FUEL,
LUBRICANTS AND COOLANT
1.2.1 FUEL
The fuel used for internal combustion engines
is extremely inflammable and in certain con-
ditions can become explosive.
It is advisable to perform the operations of refuelling
and maintenance in a well-ventilated area with the en-
gine switched off. Do not smoke while refuelling or
when near fuel vapours and, in any case, avoid con-
tact with naked flames, sparks and any other source
of heat that might cause the fuel to catch fire or to
explode. Avoid escape of fuel from the fuel filler as it
could ignite on contact with the red-hot surfaces of
the engine. In case fuel has accidentally been spilt,
make sure that the area is completely dry before
starting the vehicle.
Never fill the tank to the brim as fuel expands under
the heat of the sun and reacts to the effects of sun ra-
diation .
Close the cap securely after refuelling.
Avoid contact of the fuel with the skin and inhalation
of the fumes; do not swallow fuel or pour it from one
container into another by means of a tube.
Do not dispose of fuel in the environment.
KEEP FUEL AWAY FROM CHILDREN.
Normal version:
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.).
Catalytic version 2:
unleaded petrol according to the DIN 51 607 standard,
min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).
1.2.2 ENGINE OIL
Engine oil may cause serious damage to the
skin if handled daily and for long periods.
It is advisable to wash your hands thoroughly
after using.
Do not dispose of oil in the environment.
Deliver it to or have it collected by the nearest used
oil recovery firm or by the supplier.
Check engine oil level every 500 km; see 2.12
(CHECKING THE ENGINE OIL LEVEL AND TOPPING
UP).
Change engine oil after the first 1000 km and successive-
ly every 6000 km; see 2.13 (CHANGING ENGINE OIL
AND OIL FILTER).
Recommended engine oil:
IP SUPERBIKE 4, SAE 5W - 40.
As an alternative to the recommended oil, high quality oils
with performance conforming or superior to CCMC G-4,
A.P.I.SG. specifications may be used.
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GENERAL INFORMATION
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1.2.3 FORK OIL
Fork oil may cause serious damage to the
skin if handled daily and for long periods.
It is advisable to wash your hands thoroughly
after using.
Do not dispose of oil in the environment.
Deliver it to or have it collected by the nearest used
oil recovery firm or by the supplier.
Recommended fork oil: IP F.A. 5W or IP F.A. 20W fork
oil.
If an intermediate performance is desired (between those
of IP F.A. 5W and IP F.A. 20W) the products can be mi-
xed as follows:
67% of volume SAE 10W IP F.A. 5W +
33% of volume IP F.A. 20W
33% of volume SAE 15W IP F.A. 5W +
67% of volume IP F.A. 20W
1.2.4 BRAKE FLUID
This vehicle is provided with front and rear
disc brakes, with separate hydraulic circuits.
The following information refers to a single braking
system, but is valid for both.
Brake fluid may cause irritation if it comes
into contact with the skin or eyes.
Carefully wash the part of the body that has
come into contact with the fluid.
Consult an oculist or a physician if the fluid comes
into contact with your eyes.
Do not dispose of brake fluid in the environment.
KEEP BRAKE FLUID AWAY FROM CHILDREN
Use the brake fluid; it may chemically alter
painted surfaces and the parts in plastic, rub-
ber, etc.
Recommended brake fluid:
IP F.F. DOT 5 (DOT 4 compatible)
To avoid serious damage to the braking sy-
stem, do not use fluids other than the recom-
mended ones nor mix different fluids for top-
ping up.
Do not use brake fluid taken from old or already ope-
ned containers. Do not use brake fluid left from pre-
vious repairs if they were done some time ago.
Sudden variations in clearance or an elastic resistan-
ce in the brake levers may be due to trouble in the
hydraulic circuits.
Make sure that the brake discs and the friction pads
are completely free of grease or oil, especially after
maintenance or checking operations.
Check that the brake cables are not twisted or worn.
Make sure that neither water nor dust accidentally
enter the circuit.
In case maintenance operations are to be performed
on the hydraulic circuit, it is advisable to use latex
gloves.
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1.2.5 COOLANT
The coolant can be harmful if swallowed or if
it touches the skin or eyes.
If it comes in contact with the skin or eyes,
rinse thoroughly with large quantities of water.
If the coolant is swallowed, induce vomiting and im-
mediately consult a doctor.
Do not remove the radiator cap when the en-
gine is hot as the coolant is under pressure
and at a very high temperature.
KEEP COOLANT AWAY FROM CHILDREN.
Do not use vehicle if the coolant level is below
the minimum prescribed.
Check coolant level every 1000 km and after long runs,
see 2.14 (CHECKING AND TOPPING UP COOLANT);
change it every 12000 km or every 2 years (whichever
occurs first), see 2.15 (CHANGING THE COOLANT).
The coolant is composed of 50% water and 50% antifree-
ze. This mixture is ideal for most running temperatures
and ensures good protection against corrosion.
It is advisable to keep the same mixture in the hot season
as well, since in this way losses due to evaporation are
reduced and it is not necessary to top up so frequently.
The mineral salt deposits left in the radiator by evapora-
ted water are thus lessened and the efficiency of the coo-
ling system remains unaltered.
If the outdoor temperature is below 0˚, check th cooling
circuit frequently and inf necessary increase the antifree-
ze concentration (up to maximum 60%).
Use distilled water for the cooling solution so as not to da-
mage the engine.
Recommended coolant: IP ECOBLU - 40˚
On the basis of the desired freezing temperature of the
coolant mixture, add to the water the percentage of coo-
lant indicated in the following table:
The characteristics of the various antifreeze
liquids are different. Be sure to read the label
on the product to learn the degree of protection it
guarantees.
Use only antifreeze and anticorrosive without
nitrite in order to ensure protection at at least
-35˚C.
Freezing point
˚C Coolant of the volume %
-20˚ 35
-30˚ 45
-40˚ 55
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GENERAL INFORMATION
1.3 RUNNING-IN RULES
The running-in of the engine is essential to ensure its du-
ration and correct functioning.
If possible, drive on hilly roads or roads with many curves
where the engine, the suspensions and the brakes are
submitted to a more efficacious running-in.
Only after the first 1500 km of running-in is it
possible to obtain the best performance.
Keep in mind these important indications:
◆Do not open the throttle completely if the speed is low,
both during and after the running-in.
◆During the first 100 km put on the brakes with caution,
avoiding sharp and prolonged brakings. This ensures
a correct bedding-in of the pads on the brake disc.
◆Do not open the throttle at low speeds, both during and
after running-in.
◆Brake cautiously during the first 100 km, avoiding ab-
rupt and prolonged braking to ensure a correct adap-
tation of the brake disc pads.
◆Do not exceed 4000 rpm during the first 500 km (see
table).
◆Do not exceed 5000 rpm between the first 500 and
1000 km (see table).
After the first 1000 km perform the checking
operations indicated in the “after running-in”
column, see 2.1.1 (PERIODIC SERVICE
CHART FOR THE COMPONENTS) in order to avoid
injuring yourself or others a/o damaging the vehicle.
◆Between the first 1000 and 2000 km increase and vary
your speed, using the maximum acceleration only
briefly to ensure better coupling of the components
subject to wear.
NEVER exceed 5500 rpm (see table).
◆After the first 2000 km you may expect better perfor-
mance from the engine without, however, exceeding a
maximum 6250 rpm.
Engine maximum rpm
for the running-in
Mileage km Max. rpm
0 - 500 4000
500 - 1000 5000
1000 - 2000 5500
over 2000 6250
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1.4 PRECAUTIONS AND GENERAL
INFORMATION
Follow with care these recommendations when repairing,
disassembling and reassembling the vehicle.
The use of naked flames is forbidden for any
type of operation.
Before commencing any service or inspection
operation on the vehicle, switch off the engine and
remove the key, wait until the engine and the exhaust
system have cooled down and, if possible, raise the
vehicle with the suitable equipment onto firm flat
ground.
In order to avoid burns, be careful not to touch any
parts of engine or exhaust system which have not
cooled down completely.
The vehicle is constructed of inedible parts.
Do not bite, suck, chew or swallow any part of the ve-
hicle for any reason whatever.
If not expressly described, the reassembly of the
units is carried out by reversing the order of opera-
tions. Do not run the engine in closed or badly venti-
lated places.
Handle fuel with the greatest caution.
Never use fuel as a solvent for cleaning the vehicle.
Disconnect the negative cable (–) from the battery
when electric welding.
When two or more persons are working together,
make sure that each is working in safe conditions.
– Use only original aprilia SPARE PARTS.
– Use the recommended lubricants.
– Use, when necessary, the special tools designed for
this vehicle.
– Always use the centre stand, if the vehicle is provided
with it.
– In order to carry out certain interventions we recom-
mend using a stand to hold the vehicle in a vertical po-
sition.
– When tightening screws and nuts, begin with those ha-
ving greater diameters or with inner ones, proceeding
diagonally.
Tighten screws or nuts in successive passages before
applying driving torque.
– Clean and wash carefully any disassembled parts with
low inflammability detergents.
– Whenever possible, lubricate the parts before reas-
sembly.
– Make sure that each component has been reassem-
bled correctly.
– Always replace gaskets, grommets, circlips, O-rings
and split pins with new ones.
– Before disconnecting the joints (pipes, cables, etc.),
mark the positions on all of them and mark them with
different distinguishing signs.
Each piece must be marked clearly, in order not to
have problems during installation.
The bearings must rotate freely, without halting a/o
noise otherwise they must be replaced.
Never re-use a circlip.
When a circlip is disassembled from a shaft it
must be replaced with a new one.
When assembling a new circlip be careful not to
stretch its ends more than strictly necessary to put it
on the shaft.
After installing a circlip, make sure that it is com-
pletely and firmly inserted in its seat.
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INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION
1.5 PARTI DI RICAMBIO
In caso di sostituzione, utiizzare solo
Ricambi Originali aprilia.
I Ricambi Originali aprilia sono di
alta qualità, progettati e costruiti
espressamente per i veicoli aprilia.
L’impiego di ricambi NON
originali aprilia può cau-
sare problemi di prestazio-
ni e danneggiamenti.
1.6 CARATTERISTICHE
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TECNICHE
DIMENSIONI / DIMENSIONES / DIMENSIONS
Lunghezza max / Longitud máx. / Max. length 2218 mm
Larghezza max / Anchura máx. / Max. width 880 mm
Altezza max (agli strumenti) / Altura máx. (hasta los instrumentos) /
Max. height (height of instruments) 1265 mm
Altezza alla sella / Altura hasta el sillín / Saddle height 840 mm
Interasse / Distancia entre los ejes / Distance between centres 1480 mm
Altezza libera minima dal suolo / Altura libre mínima del suelo / Min.ground clearance 200 mm
Peso a vuoto (in ordine di marcia) / Peso en vacío (en orden de marcha) /
Weight without driver (ready for starting) 200 kg
MOTORE / MOTOR / ENGINE
Tipo / Tipo / Type ROTAX 655 - monocilindrico 4 tempi con 5 valvole,
lubrificazione a carter secco, due alberi a camme in
testa /
ROTAX 655 - monocilíndrico de 4 tiempos con 5
válvulas, lubricación con cárter seco, dos árboles
de leva en la culata
/
ROTAX655-single-cylinder, 4-stroke with 5 valves,
dry-sump lubrication
Numero cilindri / Número cilindros / Number of cylinders 1
Cilindrata / Cilindrada / Displacement 651,88 cmC
Alesaggio e corsa / Diámetro y carrera / Bore and stroke 100 mm / 83 mm
Rapporto di compressione / Relación de compresión / Compression ratio 9 ± 0,5 : 1
Avviamento / Arranque / Starting elettrico / eléctrico / electric
N˚ giri del motore al minimo / N˚ revoluciones del motor al mínimo / Idling engine 1400 ± 100 giri/min / rpm / rpm
Frizione / Embrague / Clutch Multidisco in bagno d’olio con comando sul lato sinistro
del manubrio / Multidisco en baño de aceite con mando
en el lado izquierdo del manillar / Multiple disc in oil
bath with control lever on left side of handlebar
Cambio / Cambio / Change gear Meccanico a 5 rapporti con comando a pedale sul lato
sinistro del motore / Disques multiples en bain d'huile
avec commande sur le côté gauche du guidon /
Mechanical gearshift, 5 gears with foot lever on left side
of engine
Raffreddamento / Refrigeración / Cooling a liquido / por líquido / liquid-cooled
CAPACITÀ / CAPACIDAD / CAPACITY
Carburante (inclusa riserva) / Combustible (reserva incluida) /
Fuel (reserve included) 22l
Riserva carburante / Reserva combustible / Fuel reserve 4l
Olio motore / Aceite motor / Engine oil 2200 cmC(2150 cmCcambio olio - 2200 cmCcambio
olio e filtro)
2200 cm C (2150 cm C cambio aceite - 2200 cm C cambio
aceite y filtro)
2200 cmC(2150 cmCoil change - 2200 cmCoil and filter
change)
Olio forcella (stelo destro e stelo sinistro) /
Aceite horquilla ( barra derecha y
barra izquierda ) / Fork oil (right fork tube and left fork tube) 430 cmC
Liquido refrigerante / Líquido refrigerante / Coolant 1,4l
Posti / Asientos / Seats 2
MAX CARICO VEICOLO / MÁX.CARGA VEHÍCULO / VEHICLE MAX. LOAD
(pilota + passeggero + bagaglio) / ( piloto + pasajero + equipaje ) /
(driver + passenger + luggage)182 kg
1.5 SPARE PARTS
For any replacement, use aprilia Ge-
nuine Spare Parts only. aprilia Ge-
nuine Spare Parts are high-quality
parts, expressly designed and manu-
factured for aprilia vehicles.
Failure to use aprilia Gen-
uine Spare Parts may result
in incorrect performance
and damages.
1.6 TECHNICAL
SPECIFICATIONS
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1.5 PIEZAS DE REPUESTO
En caso de substitución, utilice sólo
Repuestos Originales aprilia. Los Re-
puestos Originales aprilia son de alta
calidad, proyectados y fabricados ex-
presamente para vehículos aprilia.
Utilizar repuestos NO origi-
nales aprilia, puede cau-
sar daños y problemas de
rendimientos.
1.6 FICHA
TECNICA
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INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION
TRASMISSIONE
RAPPORTI Rapporto Primaria Secondaria Rapporto finale Rapporto totale
DI STRASMISSIONE / 1ª 37/72 = 1 : 1,946 12/33 = 1 : 2,750 16/47 = 1 : 2,937 15,720
2ª 16/28 = 1 : 1,750 10,003
3ª 16/21 = 1 : 1,312 7,502
4ª 22/33 = 1 : 1,045 5,976
5ª 24/21 = 1 : 0,875 5,001
TRANSMISION
RELACIONES Relación del cambio Transmisión primaria Transmisión secundaria Relación final Relación total
1ª 37/72 = 1 : 1,946 12/33 = 1 : 2,750 16/47 = 1 : 2,937 15,720
2ª 16/28 = 1 : 1,750 10,003
3ª 16/21 = 1 : 1,312 7,502
4ª 22/33 = 1 : 1,045 5,976
5ª 24/21 = 1 : 0,875 5,001
TRANSMISSION
GEAR RATIOS Gear Primary transmission Secondary transmission Final gear ratio Total gear ratio
1ª 37/72 = 1 : 1,946 12/33 = 1 : 2,750 16/47 = 1 : 2,937 15,720
2ª 16/28 = 1 : 1,750 10,003
3ª 16/21 = 1 : 1,312 7,502
4ª 22/33 = 1 : 1,045 5,976
5ª 24/21 = 1 : 0,875 5,001
CARBURATORI / CARBURADORES / CARBURETTORS
Modello / Modelo / Model Mikuni BST 33
Diffusore / Difusor / Choke tube Ø 31,5mm
ALIMENTAZIONE / ALIMENTACION / FUEL SUPPLY
Tipo / Tipo / Type a caduta / por gravedad / gravity feed
Carburante / Combustible / Fuel
– versione normale /
versión normal / normal version benzina super (4 Stars U) DIN 51 600, minimo ottanico 98
(N.O.R.M.) e 88 (N.O.M.M.) / gasolina super (4 Stars U) DIN
51 600 , mínimo octanos 98 (N.O.R.M.) y 88 (N.O.M.M.) /
premium grade petrol (4 Stars U) DIN 51 600, O.N. 98
(N.O.R.M.) and 88
– versione catalittica / versión catalítica / catalytic version 2benzina super senza piombo DIN 51 607, minimo ottanico 95
(N.O.R.M.) e 85 (N.O.M.M.) / gasolina super sin plomo según
DIN 51 607, mínimo octanos 95 (N.O.R.M.) y 85 (N.O.M.M.) /
premium grade unleaded petrol DIN 51 607 min, O.N.95
(N.O.R.M.) and 85
TELAIO / BASTIDOR / FRAME
Tipo / Tipo / Type A struttura composita in acciaio e lega leggera con culla e reg-
gisella smontabili / Con estructura compuesta de acero y
aleación ligera con cuna y vástago del sillín desmontables /
Composite structure made of steel and light alloy, with remov-
able cradle and saddle pillar.
Angolo inclinazione sterzo / Ángulo inclinación dirección /
Steering inclination angle 28˚
Avancorsa / Lanzamiento / Fore stroke 109 mm
SOSPENSIONI / SUSPENSIONES / SUSPENSIONS
Anteriore / Delantera / Front forcella telescopica a funzionamento idraulico /
horquilla telescópica con funcionamiento hidráulico /
hydraulically operated telescopic fork
Escursione / Carrera / Stroke 180 mm
Posteriore / Trasera / Rear monoammortizzatore idraulico /
amortiguador hidráulico /
hydraulic shock absorber
Escursione / Carrera / Stroke 49 mm
FRENI / FRENOS / BRAKES
Anteriore / Delantero / Front a disco Ø 300 mm con trasmissione idraulica /
de disco Ø 300 mm con transmisión hidráulica /
disc brake, 300 mm with hydraulic transmission
Posteriore / Trasero / Rear a disco Ø 220 mm con trasmissione idraulica /
de disco Ø 220 mm con transmisión hidráulica /
disc brake, 220 mm with hydraulic transmission
RUOTE / RUEDAS / WHEELS
Tipo / Tipo / Type in alluminio a raggi tangenti / de aluminio de radios tangentes /
Aluminium tangent spoke wheels
CERCHI / LLANTAS / RIMS
Anteriore / Delantera / Front 2,15 ∞19"
Posteriore / Trasera / Rear 3,00 ∞17"
PNEUMATICI / NEUMATICOS / TYRES
Anteriore / Delantera / Front 100/90 - 19 57H
Posteriore / Trasera / Rear 130/80 - R17 65H
PRESSIONE DI GONFIAGGIO STANDARD / PRESION DE HINCHADO ESTANDARD / STANDARD INFLATION PRESSURE
Anteriore / Delantera / Front 180 kPa (1,8 bar)
Posteriore / Trasera / Rear 190 kPa (1,9 bar)
PRES.DI GONFIAGGIO CON PASSEGGERO / PRESION DE HINCHADO CON PASAJERO / INFLATION PRES.WITH PASSENGER
Anteriore / Delantera / Front 180 kPa (1,8 bar)
Posteriore / Trasera / Rear 220 kPa (2,2 bar)

1- 14
INFORMAZIONI GENERALI / INFORMACIONES GENERALES / GENERAL INFORMATION
ACCENSIONE / ENCENDIDO / IGNITION
Tipo / Tipo / Type C.D.I. (a scarica capacitiva) / NIPPONDENSO
C.D.I. (por descarga capacitativa) / NIPPONDENSO
C.D.I. (capacitive discharge) / NIPPONDENSO
Candela standard / Bujía estándard / Standard spark plug NGK DR 8 EA - NGK DR 8 ES
Distanza elettrodi candela / Distancia electrodos bujía / Spark plug gap 0,6 ÷ 0,7 mm
IMPIANTO ELETTRICO / INSTALACION ELECTRICA / ELECTRIC SYSTEM
Batteria / Batería / Battery 12 V - 12 Ah
Fusibili / Fusibles / Fuses 20 - 15 - 7,5 A
Generatore (a magnete permanente) /
Generador (de magneto permanente) /
Generator (with permanent magnet) 12 V - 280 W
LAMPADINE / BOMBILLAS / BULBS
1.7 TABELLA LUBRIFICANTI
Olio motore (consigliato): 0SUPERBIKE 4, SAE 5W - 40.
In alternativa agli olî consigliati, si possono utilizzare olî di marca con prestazioni conformi o superiori alle specifiche
CCMC G-4, A.P.I. SG.
Olio forcella (consigliato): olio per forcelle 0F.A. 5W oppure 0F.A. 20W.
Qualora si intendesse disporre di un comportamento intermedio tra quelli offerti da 0F.A. 5W e da 0F.A. 20W, si pos-
sono miscelare i prodotti come sotto indicato:
SAE 10W 0F.A. 5W 67% del volume, + 0F.A. 20W 33% del volume
SAE 15W 0F.A. 5W 33% del volume, + 0F.A. 20W 67% del volume
Cuscinetti e altri punti di lubrificazione (consigliato): 0AUTOGREASE MP.
In alternativa al prodotto consigliato, utilizzare grasso di marca per cuscinetti volventi, campo di temperatura utile
-30°C…+140°C, punto di gocciolamento 150 °C…230 °C, elevata protezione anticorrosiva, buona resistenza all’acqua e
all’ossidazione.
Protezione poli batteria: Grasso neutro oppure vaselina.
Grasso spray per catene (consigliato): 0CHAIN SPRAY.
Liquido freni (consigliato): 0F.F., DOT 5 (Compatibile DOT 4)
Impiegare solo liquido freni nuovo.
Liquido refrigerante motore (consigliato): 0ECOBLU - 40 °C.
Impiegare solo antigelo e anticorrosivo senza nitrito, che assicuri una protezione almeno ai -35 °C.
Luce anabbagliante-abbagliante / Luz de cruce/luz larga / Low/high beam 12 V - 55 / 60 W
Luce abbagliante / Luz larga / High beam 12 V - 3 W
Luce posizione / Luz de posición / Parking light 12 V - 5 W
Indicatori di direzione / Indicadores de dirección / Direction indicators 12 V - 10 W
Luce di posizione posteriore-stop / Luz de posición trasera-freno / Rear parking
and stop light 12 V - 5/21 W
Luce targa / Luz placa de matriícula / Plate light 12V 3 W
Tachimetro / Taquímetro / Speedometer 12 V - 3 W
Contagiri / Contador de revoluciones / Revolution counter 12 V - 2 W
Indicatore temperatura liquido refrigerante /
Indicador de la temperatura del
líquido refrigerante / Coolant temperature indicator 12V - 1,2 W
SPIE / LUCES INDICADORAS /WARNING LIGHTS
Indicatori di direzione / Indicadores de dirección / Direction indicators 12 V - 3 W
Riserva carburante / Reserva combustible / Low fuel 12 V - 3 W
Pressione olio motore / Presión del aceite motor /
Engine oil pressure 12 V - 2 W
Cambio in folle / Cambio en punto muerto / Gear in neutral 12 V - 3 W
Luce abbagliante / Luz larga / High beam 12 V - 2 W
Luce anabbagliante / Luz de cruce / Low beam 12 V - 3 W
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1- 15
GENERAL INFORMATIONINFORMACIONES GENERALES
1.7 TABLA DE LOS LUBRICANTES
Aceite motor (aconsejado): 0SUPERBIKE 4, SAE 5W - 40.
En sustitución al aceite aconsejado pueden utilizarse aceites de marca con prestaciones conformes o superiores a las es-
pecificaciones CCMC G-4, A.P.I. SG.
Aceite horquilla (aconsejado): aceite para horquillas 0F.A. 5W o 0F.A. 20W.
En caso de que se quiera conseguir un comportamiento intermedia entre las ofrecidas por 0F.A. 5W y por 0F.A.
20W, pueden mezclarse los productos según lo indicado a continuación:
SAE 10W 0F.A. 5W 67% del volumen, + 0F.A. 20W 33% del volumen.
SAE 15W 0F.A. 5W 33% del volumen, + 0F.A. 20W 67% del volumen.
Cojinetes y otros puntos de lubricación (aconsejado): 0AUTOGREASE MP.
En sustitución al producto aconsejado, utilice grasa de marca para cojinetes rodantes, campo de temperatura útil
-30˚C…+140˚C, punto de goteo 150˚C…230˚C, elevada protección antioxidante, buena resistencia al agua y a la oxida-
ción.
Protección polos batería: Grasa neutra o vaselina.
Grasa spray para cadenas (aconsejada): 0CHAIN SPRAY.
Líquido frenos (aconsejado): 0F.F., DOT 5 (Compatible DOT 4).
Utilice sólo líquido frenos nuevo.
Líquido refrigerante del motor (aconsejado): 0ECOBLU -40˚C.
Utilice sólo anticongelante y antioxidante sin nitrito que garantice una protección por lo menos a los
-35˚C.
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1.7 LUBRICANT CHART
Engine oil (recommended): 0SUPERBIKE 4, SAE 5W-40.
As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or
superior to the CCMC G-4, A.P.I. SG specifications.
Fork oil (recommended): fork oil 0F.A. 5W or 0F.A. 20 W.
If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed
as indicated below:
SAE 10W 0F.A. 5W 67% of the volume, + 0F.A. 20W 33% of the volume.
SAE 15W 0F.A. 5W 33% of the volume, + 0F.A. 20W 67% of the volume.
Bearings and other lubrication points (recommended): 0AUTOGREASE MP.
As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range
-30˚C…+140˚C, dripping point 150˚C…230˚C, high protection against corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or Vaseline.
Spray grease for chains (recommended): 0CHAIN SPRAY.
Brake fluid (recommended): 0F.F., DOT 5 (compatible with DOT 4).
Use new brake fluid only.
Engine coolant (recommended): 0ECOBLU -40˚C.
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35˚C at least.
Engine oil (recommended): 0SUPERBIKE 4, SAE 5W-40.
As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or
superior to the CCMC G-4, A.P.I. SG specifications.
Fork oil (recommended): fork oil 0F.A. 5W or 0F.A. 20 W.
If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed
as indicated below:
SAE 10W 0F.A. 5W 67% of the volume, + 0F.A. 20W 33% of the volume.
SAE 15W 0F.A. 5W 33% of the volume, + 0F.A. 20W 67% of the volume.
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INFORMAZIONI GENERALI
1- 16
1.8 ATTREZZI SPECIALI
– Tondino (1) per sfilamento perno forcellone (permette
lo sfilamento parziale del perno durante la rimozione
del motore dal telaio).
– Chiave a tubo (2) per ghiera di bloccaggio perno forcel-
lone.
– Cacciavite (3) a 90˚ per regolazione vite aria su carbu-
ratori.
1.8 EQUIPOS ESPECIALES
◆Redondo de hierro (1) para extraer el eje basculante
(permite extraer parcialmente el eje durante el des-
montaje del motor del bastidor).
◆Llave tubular (2) para tuerca de bloqueo eje basculan-
te.
◆Destornillador (3) a 90˚ para ajustar el tornillo aire so-
bre los carburadores.
1.8 SPECIAL TOOLS
◆Rod iron (1) for the withdrawing of the rear fork pin (it
makes it possible to withdraw the pin partially during
the removal of the engine from the frame).
◆Socket spanner (2) for the rear fork pin locking ring.
◆90˚ screwdriver (3) for the adjustment of the air screw
on the carburettors.
NOTE / NOTES / ANMERKUNGEN

2 - 1
1
2
3
4
5
6
7
8
OPERAZIONI DI MANUTENZIONE
PERIODICA E DI MESSA A PUNTO
OPERACIONES DE MANTENIMIENTO
PERIÓDICOY DE PUESTA A PUNTO
PERIODIC SERVICE
AND SETTING UP OPERATIONS

2 - 3
OPERACIONES DE MANTENIMIENTO PERIÓDICO Y DE
PUESTA A PUNTO
PERIODIC SERVICE AND SETTING UP OPERATIONS
2
OPERACIONES DE MANTENIMIENTO
PERIÓDICO Y DE PUESTA A PUNTO
2
ÍNDICE
2.1 PLAN PARA EL MANTENIMIENTO
PERIÓDICO
......................................................Pag. 2-4
2.1.1 FICHA DE MANTENIMIENTO PERIÓDICO ....Pag. 2-5
2.2 PUNTOS POR LUBRICAR
.........................Pag. 2-6
2.3 BATERÍA
...........................................................Pag. 2-9
2.3.1 CONTROL DEL NIVEL DEL ELECTROLITO .Pag. 2-9
2.3.2 RECARGA BATERIA ....................................Pag. 2-11
2.3.3 LARGA INACTIVIDAD ..................................Pag. 2-11
2.4 TUERCAS DE LOS TUBOS
DE ESCAPE
..................................................Pag. 2-11
2.5 FILTRO DEL AIRE
......................................Pag. 2-13
2.6 BUJÍA
...............................................................Pag. 2-15
2.7 CARBURADORES
.......................................Pag. 2-17
2.8 TUBERÍAS DEL COMBUSTIBLE
.........Pag. 2-17
2.9 CABLE DEL ACELERADOR
....................Pag. 2-17
2.9.1 AJUSTE MANDO ACCELERADOR ..............Pag. 2-17
2.9.2 AJUSTE DEL RÉGIMEN DEL RALENTÍ ......Pag. 2-17
2.10 CABLE DEL ARRANQUE EN FRÍO
..Pag. 2-19
2.11 CABLE DEL EMBRAGUE
......................Pag. 2-19
2.12 CONTROL DEL NIVEL DEL ACEITE
DEL MOTOR Y RELLENO
.....................Pag. 2-21
2.13 CAMBIO DEL ACEITE MOTOR Y DEL
FILTRO DEL ACEITE DEL MOTOR
..Pag. 2-23
2.13.1 PURGA DEL AIRE DE LA BOMBA
DE ALIMENTACIÓN DEL ACEITE ..............Pag. 2-25
2.14 CONTROL Y RELLENO
DEL LÍQUIDO REFRIGERANTE
...........Pag. 2-27
2.15 SUBSTITUCIÓN DEL LÍQUIDO
REFRIGERANTE
.......................................Pag. 2-29
2.16 CADENA DE TRANSMISIÓN
...............Pag. 2-31
2.16.1 CONTROL DEL JUEGO ..............................Pag. 2-31
2.16.2 CONTROL DEL DESGASTE .......................Pag. 2-33
2.16.3 AJUSTE .......................................................Pag. 2-33
2.16.4 LIMPIEZA Y LUBRICACIÓN .......................Pag. 2-33
2.17 CONTROL Y RELLENO LIQUIDO
FRENO DELANTERO
..............................Pag. 2-35
2.18 CONTROL Y RELLENO
LIQUIDO FRENO TRASERO
...............Pag. 2-37
2.19 PURGA DEL AIRE
DEL SISTEMA DE FRENADO
.............Pag. 2-39
2.20 AJUSTE DEL PEDAL
DEL FRENO TRASERO
..........................Pag. 2-41
2.21 AJUSTE DE LA PALANCA
DEL FRENO DELANTERO ..................Pag. 2-41
2.22 COMPROBACION
DESGASTE PASTILLAS
........................Pag. 2-41
2.23 NEUMÁTICOS
............................................Pag. 2-43
2.23.1 CONDICIONES DE LA BANDA
DE RODAMIENTO .......................................Pag. 2-43
2.23.2 PRESIÓN DE INFLADO ..............................Pag. 2-43
2.24 DIRECCIÓN .................................................Pag. 2-45
2.24.1 CONTROL JUEGO COJINETES .................Pag. 2-45
2.24.2 AJUSTE JUEGO COJINETES ....................Pag. 2-45
2.25 HORQUILLA DELANTERA
...................Pag. 2-47
2.26 HORQUILLA TRASERA .........................Pag. 2-47
2.26.1 AJUSTE BASCULANTE .............................Pag. 2-47
2.27 SUSPENSIÓN TRASERA ......................Pag. 2-49
2.27.1 AJUSTE SUSPENSION TRASERA ............Pag. 2-49
2.27.2 AJUSTE SUSPENSION TRASERA
CON REGULACION HIDRAULICA
DE PRECARGA
&
....................................Pag. 2-51
2.27.3 CONTROL PALANCAS
SUSPENSION TRASERA ............................Pag. 2-51
2.28 RUEDA DELANTERA
..............................Pag. 2-53
2.29 RUEDA TRASERA
....................................Pag. 2-53
2.30 APRIETE DE LOS TORNILLOS
Y TUERCAS
................................................Pag. 2-54
PERIODIC SERVICE
AND SETTING UP OPERATIONS
2
TABLE OF CONTENTS
2.1 PERIODIC SERVICE PLAN
......................Pag. 2-4
2.1.1 PERIODIC SERVICE CHART
FOR THE COMPONENTS ..............................Pag. 2-5
2.2 POINTS TO LUBRICATE
..........................Pag. 2-6
2.3 BATTERY
.........................................................Pag. 2-9
2.3.1 CHECKING THE ELECTROLYTE LEVEL .....Pag. 2-9
2.3.2 RECHARGING THE BATTERY ....................Pag. 2-11
2.3.3 LONG INACTIVITY OF THE BATTERY .......Pag. 2-11
2.4 EXHAUST MANIFOLD NUTS................Pag. 2-11
2.5 AIR CLEANER..............................................Pag. 2-13
2.6 SPARK PLUG ...............................................Pag. 2-15
2.7 CARBURETTORS .......................................Pag. 2-17
2.8 FUEL TUBING..............................................Pag. 2-17
2.9 ACCELERATOR CABLE ..........................Pag. 2-17
2.9.1 ADJUSTING
THE ACCELERATOR CONTROL................Pag. 2-17
2.9.2 ADJUSTMENT OF IDLING RPM..................Pag. 2-17
2.10 COLD START CABLE.............................Pag. 2-19
2.11 CLUTCH CABLE.......................................Pag. 2-19
2.12 CHECKING THE ENGINE OIL LEVEL
AND TOPPING UP...................................Pag. 2-21
2.13 CHANGING ENGINE OIL
AND OIL FILTER......................................Pag. 2-23
2.13.1 AIR BLEEDING
FROM OIL DELIVERY PUMP ......................Pag. 2-25
2.14 CHECKING
AND TOPPING UP COOLANT ...........Pag. 2-27
2.15 CHANGING THE COOLANT ...............Pag. 2-29
2.16 DRIVING CHAIN ......................................Pag. 2-31
2.16.1 CLEARANCE CONTROL ...........................Pag. 2-31
2.16.2 CHECKING WEAR......................................Pag. 2-33
2.16.3 ADJUSTMENT ............................................Pag. 2-33
2.16.4 CLEANING AND LUBRICATION ...............Pag. 2-33
2.17 CHECKING AND TOPPING UP
THE FRONT BRAKE FLUID................Pag. 2-35
2.18 CHECKING AND TOPPING UP
THE REAR BRAKE FLUID...................Pag. 2-37
2.19 BLEEDING
THE BRAKING SYSTEM......................Pag. 2-39
2.20 REAR BRAKE PEDAL
ADJUSTMENT ..........................................Pag. 2-41
2.21 FRONT BRAKE LEVER
ADJUSTMENT ..........................................Pag. 2-41
2.22 CHECKING
THE BRAKE PAD WEAR ......................Pag. 2-41
2.23 TYRES...........................................................Pag. 2-43
2.23.1 CONDITION OF TREAD .............................Pag. 2-43
2.23.2 INFLATION PRESSURE.............................Pag. 2-43
2.24 STEERING...................................................Pag. 2-45
2.24.1 CHECKING THE BEARING SLACKS ........Pag. 2-45
2.24.2 ADJUSTING THE BEARING SLACKS ......Pag. 2-45
2.25 FRONT FORK ............................................Pag. 2-47
2.26 REAR FORK ...............................................Pag. 2-47
2.26.1 ADJUSTING THE REAR FORK .................Pag. 2-47
2.27 REAR SUSPENSION ..............................Pag. 2-49
2.27.1 ADJUSTING THE REAR SUSPENSION ....Pag. 2-49
2.27.2 ADJUSTING
THE REAR SUSPENSIONWITH PRELOAD
HYDRAULIC ADJUSTMENT &...............Pag. 2-51
2.27.3 CHECKING
THE REAR SUSPENSION LINKAGE ........Pag. 2-51
2.28 FRONT WHEEL.........................................Pag. 2-53
2.29 REAR WHEEL ............................................Pag. 2-53
2.30 TIGHTENING SCREWS
AND NUTS ..................................................Pag. 2-54

2- 4
OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO
Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS
Questa sezione descrive le procedu-
re d’intervento per la manutenzione
periodica dei principali componenti
del veicolo.
Prima di iniziare qualsiasi
intervento di manutenzione
o ispezione al veicolo, ar-
restare il motore e togliere la chia-
ve, attendere che motore e impian-
to di scarico si siano raffreddati,
sollevare possibilmente il veicolo
con apposita attrezzatura, su di un
terreno solido e in piano.
Porre particolare attenzione alle
parti ancora calde del motore e
dell’impianto di scarico, in modo
tale da evitare ustioni.
Il veicolo e’ costruito con parti non
commestibili. Non mordere, suc-
chiare, masticare o ingerire nessu-
na parte dello stesso per nessun
motivo.
Se non espressamente de-
scritto, il rimontaggio dei
gruppi segue in senso inverso le
operazioni di smontaggio.
2.1 PIANO PER LA
MANUTENZIONE
PERIODICA
Per mantenere ottimali le condizioni
di funzionamento del veicolo, aprilia
raccomanda di rispettare gli intervalli
previsti per gli interventi di manuten-
zione periodica dei vari componenti.
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Esta sección describe los procedi-
mientos de mantenimiento periódico
de los principales componentes del
vehículo.
Antes de comenzar con
cualquier tipo de manteni-
miento o inspección del ve-
hículo, apague el motor y quite la
llave, espere a que el motor y el
sistema de escape se hayan en-
friado y levante el vehículo con un
equipo adecuado, sobre una su-
perficie sólida y plana.
Para evitar quemaduras, tenga
cuidado con las piezas del motor y
del sistema de escape que aún es-
tén caliente.
El vehículo está fabricado con pie-
zas no comestibles.
No muerda, chupe, mastique ni
trague ninguna pieza del mismo
por ningún motivo.
Si no está expresamente
indicado, la reinstalación
de los grupos sigue el orden con-
trario a las operaciones de des-
montaje.
2.1 PLAN PARA EL
MANTENIMIENTO
PERIÓDICO
Para que las condiciones de funcio-
namiento del vehículo se mantengan
óptimas, aprilia aconseja respetar
los intervalos previstos para las inter-
venciones de mantenimiento periódi-
co de los diferentes componentes.
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This section describes the proce-
dures for periodic service on the prin-
cipal components of the vehicle.
Before beginning any serv-
ice operations or inspec-
tion of the vehicle, switch
off the engine and remove the key,
wait until the engine and the ex-
haust system have cooled down
and, if possible, lift the vehicles
with the proper equipment onto
firm and flat ground.
In order to avoid burns, be careful
not to touch any parts of the en-
gine or exhaust system which
have not cooled down completely.
The vehicle is constructed of non-
edible parts.
Do not bite, suck, chew or low any
part of the vehicle for any reason
whatever.
If not expressly described
otherwise, reassembly of
the units is carried out repeating
the disassembly operations in the
reverse order.
Remember:
1 mile = 1.6 km
1 km = 0.625 miles
2.1 PERIODIC SERVICE PLAN
aprilia recommends respecting the
intervals indicated for the periodic
service on the various components in
order to ensure the best operating
conditions of the vehicle.
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OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO
Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS
2- 5
2.1.1 SCHEDA DI MANUTENZIONE
PERIODICA
COMPONENTI
COMPONENTES
SERVICE
Fine rodaggio
(1000 km ou 4 mesi)
Fin rodaje
(1000 km o 4 meses)
After running-in
(1000 km or 4 months)
Ogni 6000 km
o 8 mesi
Cada 6000 km
o 8 meses
Every 6000 km
or 8 months
Ogni 12000 km
o 16 mesi
Cada 12000 km
o 16 meses
Every 12000 km
or 16 months
Batteria - livello liquido / Batería - nivel líquido /
Battery - liquid level CC
Candela / Bujía / Spark plug CS
Carburatori / Carburadores / Carburettors CP
Catena di trasmissione / Cadena de transmisión /
Driving chain ogni /
cada / every
500 km: C
Catena di distribuzione / Cadena de distribución /
Timing chain C
Cuscinetti biellismi sospensione / Cojinetes palancas
suspensión / Suspension linkage bearings ogni /
cada / every 30000 km: C
Centratura ruote / Centrado de las ruedas /
Wheel truing C
Cuscinetti di sterzo e sterzo / Cojinetes de dirección y
dirección / Steering bearings and steering CC
Cuscinetti ruote / Cojinetes de las ruedas /
Wheel bearings C
Filtro aria / Filtro del aire / Air cleaner CS
Filtro olio motore (sul telaio) / Filtro del aceite del motor
(sul bastidor) / Engine oil filter (on the frame) SS
Filtro olio motore / Filtro del aceite del motor /
Engine oil filter SS
Gioco frizione / Juego del embrague /
Clutch clearance RR
Gioco punterie / Juego de los empujaválvulas /
Tappet clearance CR
Impianti frenanti / Sistema de frenado /
Braking system CC
Impianto di raffreddamento / Sistema de refrigeración /
Cooling system CC
Impianto luci / Instalación de las luces / Lighting system CC
Liquido freni / Líquido de frenos /
Brake fluid Cogni anno /
cada año /
every year: S
Liquido refrigerante / Líquido refrigerante /
Coolant ogni /
cada / every
1000 km: Cogni 2 anni /
cada 2 años /
every 2 year: S
Olio forcella / Aceite de la horquilla /
Fork oil S
Olio motore / Aceite del motor / Engine oil Sogni /
cada / every
500 km: C / 6000 km: S
Pressione dei pneumatici / Presión de los neumáticos /
Tyre pressure Rogni mese / cada meses / every month: R
Regime minimo di giri motore / Régimen de ralentí /
Engine idling rpm RR
Rubinetto carburante / Grifo del combustible /
Fuel cock CC
Serraggio bulloneria / Apriete del conjunto de pernos /
Tightening bolts and nuts CC
Sospensioni ed assetto / Suspensiones y posición /
Suspensions and position CC
Spurgo liquido freni / Purga del líquido de frenos / Brake
fluid bleeding C
Tensione raggi / Tensión de los radios /
Spoke tension CC
Tubi carburante / Tubos del combustible /
Fuel pipes Cogni 4 anni /
cada 4 años /
every 4 year: S
C= controllare e pulire, regolare, lubrificare o sostituire se necessario / controle y limpie, ajuste, lubrique o substituya si es necesario /
check and clean, adjust, lubricate or change, if necessary.
P= pulire / Limpie / clean S = sostituire / substituya / change R = regolare / ajuste / adjust
Eseguire le operazioni di manutenzione più frequentemente se il veicolo viene utilizzato in zone piovose, polverose o su per-
corsi accidentati / Si el vehículo se utiliza en zonas lluviosas, polvorientas o en carreteras accidentadas, realice las operacio-
nes de mantenimiento más frecuentemente / Carry out service operations more frequently if the vehicle is used in rainy, dusty
areas or on uneven roads.
2.1.1 FICHA DE MANTENIMIENTO
PERIÓDICO 2.1.1 PERIODIC SERVICE CHART FORTHE COMPONENTS

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OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO
Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS
2.2 PUNTI DA LUBRIFICARE
Una lubrificazione corretta è impor-
tante per un funzionamento scorre-
vole e una lunga durata del veicolo.
Prima della lubrificazione,
ripulire completamente
ogni parte da eventuale ruggine e
rimuovere tutto il grasso, la spor-
cizia e la polvere.
Le parti esposte che sono sogget-
te alla ruggine, devono essere lu-
brificate con olio motore o grasso,
vedi 1.7 (TABELLA LUBRIFICAN-
TI).
Nella “SCHEDA DI LUBRIFICAZIO-
NE” sono riportati i punti da lubri-
ficare.
LEGENDA SCHEDA
DI LUBRIFICAZIONE
1) Perno e cuscinetti ruota anterio-
re
2) Cuscinetti sterzo
3) Perno leva frizione/cavo frizione
4) Cavo leva per l’avviamento a
freddo
5) Perno e cuscinetti ruota posterio-
re
6) Perno poggiapiedi passeggero
7) Perno cavalletto laterale
8) Comando acceleratore
9) Cavi acceleratore
10) Rinvio tachimetro/contachilometri
11) Perno forcellone posteriore
12) Viti di fulcro cavalletto centrale
&(n˚ 2 ingrassatori)
13) Leverismi sospensione posterio-
re
14) Catena di trasmissione
c
2.2 PUNTOS POR LUBRICAR
Una lubricación correcta es importan-
te para que las piezas no se agarro-
ten y garantizar una larga duración
del vehículo.
Antes de lubricar, limpie el
herrumbre de cada pieza y
quite toda la grasa, la suciedad y
el polvo.
Las piezas expuestas, que están
sujetas al herrumbre, deben lubri-
carse con aceite motor o grasa,
véase 1.7 (TABLA DE LOS LUBRI-
CANTES).
En la “FICHA DE LUBRICACIÓN”
están indicados los puntos por lu-
bricar.
PIE DE LA ILUSTRACIÓN
DE LA FICHA DE LUBRICACIÓN
1) Eje y cojinetes de la rueda delan-
tera
2) Cojinetes de la dirección
3) Perno de la palanca del embra-
gue/cable embrague
4) Cable de la palanca para el
arranque en frío
5) Eje y cojinetes de la rueda trasera
6) Perno reposapiés del pasajero
7) Perno del soporte lateral
8) Mando del acelerador
9) Cables del acelerador
10) Transmisión taquímetro/cuenta-
kilómetros
11) Eje del basculante
12) Tornillos de fulcro caballete cen-
tral &(n˚ 2 engrasadores)
13) Mecanismos de palanca suspen-
sión trasera
14) Cadena de transmisión
c
2.2 POINTS TO LUBRICATE
Correct lubrication is important for a
good performance and long life of the
vehicle.
Before lubricating, com-
pletely clean all parts, re-
moving rust, grease, dirt and dust.
The exposed parts subject to rust
are to be lubricated with engine oil
or grease. See 1.7 (LUBRICANT
CHART).
The points to be lubricated are in-
dicated in the "LUBRICATION
CHART"
LUBRICATRION CHART KEY
1) Front wheel pin and bearings
2) Steering bearings
3) Clutch lever pin /clutch cable
4) Lever cable for cold starting
5) Rear wheel pin and bearings
6) Passenger footrest pin
7) Side stand pin
8) Accelerator control handgrip
9) Accelerator cables
10) Speedometer/total kilometres
odemeter transmission
11) Rear fork pin
12) Centre stand fulcrum screws &
(n. 2 lubricators)
13) Rear suspension leverage
14) Driving chain
c

OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO / OPERACIONES DE MANTENIMIENTO PERIÓDICO
Y DE PUESTA A PUNTO / PERIODIC SERVICE AND SETTING UP OPERATIONS
2- 7
FICHA DE LUBRICACIÓN
■ = Grasa
▲= Aceite
LUBRICATION CHART
■ = Grease
▲= Oil
16
3
4
5
12
7
8
11
14 12
13
2
9
10
SCHEDA DI LUBRIFICAZIONE
■ = Grasso
▲= Olio

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OPERAZIONI DI MANUTENZIONE PERIODICA E DI MESSA A PUNTO
2.3 BATTERIA
Leggere attentamente 1.4 (PRECAUZIONI E INFOR-
MAZIONI GENERALI).
Dopo i primi 1000 km (o 4 mesi) e successivamente ogni
6000 km (o 8 mesi) controllare il livello dell’elettrolita e il
serraggio dei morsetti.
L'elettrolita della batteria è tossico, caustico,
e a contatto con l'epidermide può causare
ustioni, in quanto contiene acido solforico.
Indossare abiti protettivi, una maschera per il viso
e/o occhiali nel caso di manutenzione.
Se del liquido elettrolitico venisse a contatto
con la pelle, lavare con abbondante acqua cor-
rente. Se venisse a contatto con gli occhi, lava-
re con acqua abbondante per quindici minuti, quindi ri-
volgersi tempestivamente a un oculista. Se venisse
ingerito accidentalmente, bere grosse quantità di ac-
qua o latte, continuare con latte di magnesia od olio ve-
getale, quindi rivolgersi prontamente a un medico.
La batteria emana gas esplosivi (specialmente durante
la fase di attivazione e/o ricarica), è opportuno tenere
lontane fiamme, scintille, sigarette e qualsiasi altra fon-
te di calore. Durante la ricarica o l'uso, provvedere a
un'adeguata ventilazione del locale, evitare l'inalazione
dei gas emessi durante la ricarica della stessa.
Non invertire mai il collegamento dei cavi della batte-
ria.
Porre attenzione a non inclinare troppo il veicolo onde
evitare pericolose fuoriuscite del liquido della batteria.
Il liquido della batteria è corrosivo.
Non versarlo o spargerlo, in particolare sulle
parti in plastica.
TENERE LONTANO DALLA PORTATA DEI BAMBINI.
Collegare e scollegare la batteria con l’inter-
ruttore di accensione in posizione “m”.
Collegare prima il prima il cavo positivo (+) e
poi quello negativo (–).
Scollegare seguendo l’ordine inverso.
2.3.1 CONTROLLO LIVELLO ELETTROLITA
Per il controllo del livello dell'elettrolita è necessario:
◆Rimuovere la fiancatina sinistra, vedi 7.1.4 (RIMO-
ZIONE FIANCATINE LATERALI DESTRA E SINI-
STRA).
◆Svitare e togliere la vite (1).
◆Rimuovere il coperchio batteria (2).
◆Controllare che il livello del liquido sia compreso fra le
due tacche “MIN” e “MAX”, stampigliate sul lato della
batteria.
Diversamente:
◆Togliere i tappi degli elementi.
Non superare il riferimento “MAX”, in quanto
il livello aumenta durante la ricarica.
◆Ripristinare il livello del liquido solo aggiungendo ac-
qua distillata.
Controllare con un tester portatile la tensione
della batteria. Se la tensione è inferiore a 12V,
la batteria deve essere ricaricata.
a
a
a
a
a
c