APRILIA RALLY 50 - 1999 User manual

use and maintenance
Rally 50
aprilia part# 8201997

2use and maintenance Rally 50
© 1996 aprilia s.p.a. - Noale ( E)
This manual is to be considered an integral part of the vehicle,
which must be delivered complete with it also in case of resale.
aprilia s.p.a. reserves the right to modify its models at any time,
without prejudice to the main characteristics here described.
All rights as to electronic storage, reproduction and total or par-
tial adaptation, with any means, are reserved for all Countries.
The mention to products or services supplied by third parties is
made only for information purposes and is not binding in any
case.
aprilia s.p.a takes no responsibility as to the performance or the
use of said products.
First edition: october 1996
Reprint: july 1997, november 1997, february 1999
Produced and printed by:
Studio Tecno Public
iale del Progresso - 37038 Soave ( R) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
www.stp.it
E-mail: [e-mail]
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale ( E) - Italy
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com

3
use and maintenance Rally 50
&/2%7/2$
Before starting the engine, carefully read this manual, paying
particular attention to the chapter "RIDING SAFELY".
Your and other people’s safety depends not only on your quick-
ness of reflexes and on your agility, but also on what you know
about the vehicle, on its efficiency and on your knowledge of the
basic information for RIDING SAFELY.
Therefore, get a thorough knowledge of the vehicle, in such a
way as to be able to drive in the traffic safely.
For the controls and repairs not expressly described in this man-
ual, for the purchase of aprilia Genuine Spare Parts, accesso-
ries and other products, as well as for specific technical advice,
contact only aprilia Authorized Outlets and Official Dealers, who
can ensure you reliable and prompt servicing.
Thank you for choosing aprilia. We wish you a nice ride.
IMPORTANT:
When asking your Dealer for spare parts, specify the spare parts
code indicated on the SPARE PARTS IDENTIFICATION LA-
BEL. Write down the identification code in the space here below,
in order to remember it also in case of loss or deterioration of the
label.
The label is positioned under the inspection cover, stuck to the
frame and to read it it is necessary to remove the inspection cov-
er, see p. 46 (REMO ING THE INSPECTION CO ER).
Carefully observe the instructions preceded by the following
warning signs:
Safety norms and regulations to protect the dri er
and other people from se ere injuries or gra e risks.
Indications to make the operations easier. Technical
information.
The operations preceded by this symbol must be re-
peated on the opposite side of the ehicle.
In this manual the various versions are indicated by the following
symbols:
1liquid-cooled ersion
2catalytic ersion
3drum brake ersion
VERSION:
I Italy O Holland QBermuda
U United
Kingdom C Switzerland -United States of America
A Austria  Denmark ^Australia
P Portugal J Japan ÍBrazil
" Finland S Singapore °South Africa
B Belgium V Poland ÎNew Zealand
D Germany % Israel [Canada
F France K South Korea `Croatia
E Spain M Malaysia ÑSlo enia
G Greece Chile
a
c
★

4use and maintenance Rally 50
).$)#%'%.%2!,%
RIDING SAFELY ............................................................................. 5
BASIC SAFETY RULES ............................................................ 6
CLOTHING ................................................................................ 9
ACCESSORIES ....................................................................... 10
LOAD ....................................................................................... 10
ARRANGEMENT OF THE MAIN ELEMENTS.............................. 12
ARRANGEMENT OF THE INSTRUMENTS ................................. 14
INSTRUMENTS AND INDICATORS............................................. 14
INSTRUMENT AND INDICATOR TABLE................................ 15
MAIN INDEPENDENT CONTROLS.............................................. 16
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR ...... 16
CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR.... 17
IGNITION SWITCH..................................................................18
STEERING LOCK.................................................................... 18
AUXILIARY EQUIPMENT ............................................................. 19
UNLOCKING/LOCKING THE SADDLE................................... 19
CRASH HELMET / GLO E COMPARTMENT ........................ 19
ANTI-THEFT HOOK ................................................................ 19
BATTERY / TOOL KIT COMPARTMENT................................ 20
BAG HOOK.............................................................................. 20
MAIN COMPONENTS ................................................................... 21
FUEL........................................................................................ 21
MIXER OIL TANK .................................................................... 22
BRAKE FLUID (RECOMMENDATIONS)................................. 22
DISC BRAKES......................................................................... 23
REAR DRUM BRAKE 3...................................................... 24
TYRES ..................................................................................... 25
COOLANT 1........................................................................ 26
CATALYTIC SILENCER 2.................................................. 28
INSTRUCTIONS FOR USE ........................................................... 29
PRELIMINARY CHECKING OPERATIONS ............................ 29
STARTING............................................................................... 30
DEPARTURE AND DRI E ...................................................... 32
RUNNING-IN ........................................................................... 33
STOPPING AND PARKING.....................................................33
POSITIONING THE EHICLE ON THE STAND ..................... 33
SUGGESTIONS TO PRE ENT THEFT.................................. 34
MAINTENANCE ............................................................................ 35
REGULAR SER ICE INTER ALS CHART ............................ 35
IDENTIFICATION DATA.......................................................... 36
AIR CLEANER ......................................................................... 37
CHECKING THE TRANSMISSION OIL LE ELONE............... 38
CHANGING THE TRANSMISSION OIL .................................. 39
FRONT WHEEL....................................................................... 40
REAR WHEEL ......................................................................... 42
GREASING THE REAR BRAKE CAM PIN.............................. 43
CHECKING THE BRAKE PAD WEAR .................................... 44
CHECKING THE BRAKE SHOE WEAR 3.......................... 44
CHECKING THE STEERING .................................................. 45
CHECKING THE ENGINE FULCRUM AXIS ........................... 45
REMO ING THE INSPECTION CO ER ................................ 46
IDLING ADJUSTMENT............................................................ 47
ADJUSTING THE ACCELERATOR CONTROL...................... 47
SPARK PLUG .......................................................................... 48
BATTERY ................................................................................ 49
CHECKING THE ELECTROLYTE LE EL............................... 50
LONG INACTI ITY OF THE BATTERY .................................. 50
CHANGING THE FUSE........................................................... 51
ADJUSTING THE HEADLIGHT BEAM.................................... 52
BULBS ..................................................................................... 53
CHANGING THE HEADLIGHT BULBS ................................... 53
CHANGING THE DASHBOARD BULBS................................. 54
CHANGING THE REAR LIGHT BULB .................................... 55
CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS............................................ 55
TRANSPORT................................................................................. 56
DRAINING THE FUEL TANK .................................................. 56
CLEANING .................................................................................... 57
LONG PERIODS OF INACTI ITY........................................... 58
AFTER A LONG PERIOD OF INACTI ITY ............................. 58
TECHNICAL DATA ....................................................................... 59
LUBRICANT CHART ............................................................... 62
IMPORTERS............................................................................ 63
WIRING DIAGRAM (air-cooled version) .................................. 64
WIRING DIAGRAM KEY.......................................................... 65
WIRING DIAGRAM (liquid-cooled version 1)...................... 66
WIRING DIAGRAM KEY
(liquid-cooled version 1) ...................................................... 67

safe drive

6use and maintenance Rally 50
"!3)#3!&%4925,%3
To drive the vehicle it is necessary to be in
possession of all the requirements pre-
scribed by law (driving licence, minimum
age, psychophysical ability, insurance,
state taxes, vehicle registration, number
plate, etc.).
Gradually get to know the vehicle by driv-
ing it first in areas with low traffic and/or pri-
vate areas.
The use of medicins, alcohol and drugs or
psychotropic substances notably increases
the risk of accidents.
Be sure that you are in good psychophysi-
cal conditions and fit for driving and pay
particular attention to physical weariness
and drowsiness.
Most road accidents are caused by the
driver’s lack of experience.
NE ER lend the vehicle to beginners and,
in any case, make sure that the driver has
all the requirements for driving.

7
use and maintenance Rally 50
Rigorously observe all road signs and na-
tional and local road regulations.
Avoid abrupt movements that can be dan-
gerous for yourself and other people (for
example: rearing up on the back wheel,
speeding, etc.), and give due consideration
to the road surface, visibility and other driv-
ing conditions.
Avoid obstacles that could damage the ve-
hicle or make you lose control.
Avoid riding in the slipstream created by
preceding vehicles in order to increase
your speed.
Always drive with both hands on the han-
dlebars and both feet on the footrests, in
the correct driving posture.
Avoid standing up or stretching your limbs
while driving.

8use and maintenance Rally 50
The driver should pay attention and avoid
distractions caused by people, things and
movements (never smoke, eat, drink, read,
etc.) while driving.
Use only the vehicle’s specific fuels and lu-
bricants (indicated in the "LUBRICANT
CHART"); check all oil, fuel and coolant
levels regularly.
If the vehicle has been involved in an acci-
dent, make sure that no damage has oc-
curred to the control levers, pipes, wires,
braking system and vital parts.
If necessary, have the vehicle inspected by
an aprilia Official Dealer, who should care-
fully check the frame, handlebars, suspen-
sions, safety parts and all the devices that
you cannot check by yourself.
Always remember to report any malfunc-
tion to the technicians to help them in their
work.
Never use the vehicle when the amount of
damage it has suffered endangers your
safety.
COOLER
OIL

9
use and maintenance Rally 50
Never change the position, inclination or
colour of: number plate, direction indica-
tors, lights and horns.
Any modification of the vehicle will result
in the invalidity of the guarantee.
Any modification of the engine or of other
members which is aimed at increasing the
speed or the power of the vehicle is prohib-
ited by the law; in fact, any modification re-
sulting in an increase of the maximum
speed or of the engine displacement would
change the scooter into a motorcycle,
which implies the following obligations for
the owner:
– new homologation;
– new registration;
– appropriate driving license.
Further, said modifications cause the loss
of the insurance cover, since insurance
policies expressly prohibit to make techni-
cal changes aimed at increasing the vehi-
cle performance levels.
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 vehicle),
which, according to the case, can be com-
bined 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 vehicle without driv-
ing license.
Never race with other vehicles.
Avoid off-road driving.
#,/4().'
Before starting, always wear a correctly
fastened crash helmet. Make sure that it is
homologated, in good shape, of the right
size and that the visor is clean.
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. 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 mov-
ing parts or driving mechanisms.
A12
345
ONLY ORIGINALS

10 use and maintenance Rally 50
Do not keep objects that can be dangerous
in case of fall, for example pointed objects
like keys, pens, glass vials etc. in your
pockets (the same recommendations also
apply to passengers).
!##%33/2)%3
The owner of the vehicle is responsible for
the choice, installation and use of any ac-
cessory.
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 ac-
cess to the controls, since this can prolong
reaction times during an emergency. Large
fairings and windscreens assembled on
the vehicle can produce aerodynamic forc-
es capable of compromising the stability of
the vehicle while driving.
Make sure that the equipment is well fas-
tened to the vehicle and not dangerous
during driving.
Do not install electrical devices and do not
modify those already existing to avoid elec-
trical overloads, because the vehicle could
suddenly stop or there could be a danger-
ous current shortage in the horn and in the
lights. aprilia recommends the use of
“aprilia genuine accessories”.
,/!$
Be careful and moderate when loading
your luggage. Keep any luggage loaded as
close as possible to the centre of the vehi-
cle and distribute the load uniformly on
both sides, in order to reduce imbalance to
the minimum. Furthermore, make sure that
the load is firmly secured to the vehicle, es-
pecially during long trips.

11
use and maintenance Rally 50
Avoid hanging bulky, heavy and/or danger-
ous objects on the handlebars, mudguards
and forks, because the vehicle might re-
spond more slowly in turns and its ma-
noeuvrability could be unavoidably im-
paired.
Do not place bags that are too bulky on the
vehicle sides and do not ride with the crash
helmet hanging from its string, because it
could hit people or obstacles making you
lose control of the vehicle.
Do not carry any bag if it is not tightly se-
cured to the vehicle.
Do not carry bags which protrude too much
from the luggage-rack or which cover the
lights, horn or indicators.
Do not carry animals or children on the
glove compartment or on the luggage-rack.
Do not exceed the maximum load allowed
for each side-bag.
When the vehicle is overloaded, its stability
and its manoeuvrability can be compro-
mised.
KG!

12 use and maintenance Rally 50
!22!.'%-%.4/&4(%-!).%,%-%.43
+%9
1) Coolant expansion tank plug 1
2) Bag hook
3) Battery/tool kit compartment
4) Fuel tank
5) Fuel tank plug
6) Saddle lock
7) Transmission oil filling cap
8) Transmission oil drain plug
9) Kick starter

13
use and maintenance Rally 50
+%9
1) Mixer oil tank plug
2) Mixer oil tank
3) Ignition switch/steering lock
4) Inspection cover
5) Fuse carrier
6) Horn
7) Battery
8) Central stand

14 use and maintenance Rally 50
!22!.'%-%.4/&4(%).3425-%.43
+%9
1) Cold start lever (e)
2) Horn push button (f)
3) Direction indicator switch (c)
4) Rear brake lever
5) Left rear-view mirror
6) Instruments and indicators
7) Right rear-view mirror
8) Front brake lever
9) Throttle grip
10) Headlight switch (b - •)
11) Start push button (r)
12) Ignition switch/steering lock (n - m - s)
).3425-%.43!.$).$)#!4/23
+%9
1) Fuel level indicator (g)
2) Speedometer
3) Total kilometres odometer
4) Coolant temperature indicator (h) 1
5) Green direction indicator warning light (c)
6) Red mixer oil reserve warning light (j)
7) Green low beam warning light(b)
8) Amber low fuel warning light (g)

15
use and maintenance Rally 50
).3425-%.4!.$).$)#!4/24!",%
Description Function
Direction indicator warning light (c)It blinks when the direction indicators are on.
Mixer oil reser e warning light (j)
It comes on when the ignition switch is in position "n" and the start push button
“r“ is pressed, thus checking the proper functioning of the bulb.
If the light does not come on during the starting, provide for replacing the bulb.
If the warning light comes on and does not go off after releasing
the start push button "r", or if it comes on during normal function-
ing, this means that the mixer oil reser e is being used; in this
case, pro ide for topping up the mixer oil tank, see p. 22 (MIXER OIL
TANK).
Total kilometres odometer It indicates the total number of kilometres covered.
Speedometer It indicates the driving speed.
Low beam warning light (b)It comes on when the headlight is in position "low beam".
Low fuel warning light (g)It comes on when the quantity of fuel left in the tank is about 1.5 L.
Fuel le el indicator (g)It indicates the approximate fuel level in the tank.
Coolant temperature indicator 1(h)
It indicates the approximate temperature of the coolant in the engine.
When the pointer starts moving beyond the "min" level, the temperature is suffi-
cient for driving the vehicle.
The normal running temperature range is indicated by the white area of the
scale.
If the pointer reaches the red area, stop the engine and check the coolant level,
see p. 26 (COOLANT).
If the maximum allowed temperature is exceeded (red area "max"
of the scale), the engine may be seriously damaged.
a
a

16 use and maintenance Rally 50
-!).).$%0%.$%.4#/.42/,3
#/.42/,3/.4(%,%&43)$%/&4(%(!.$,%"!2
The electrical parts work only when the ignition
switch is in position “n”.
1) HORN PUSH BUTTON (f)
The horn is activated when the push button is pressed.
2) COLD START LEVER (e)
When the lever is rotated clockwise (outwards), the starter for
the cold start of the engine is activated.
To disconnect the starter, rotate the lever completely anti-
clockwise (inwards).
3) DIRECTION INDICATOR SWITCH (c)
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.
c

17
use and maintenance Rally 50
#/.42/,3/.4(%2)'(43)$%
/&4(%(!.$,%"!2
The electrical parts work only when the ignition
switch is in position "n".
1) LIGHT SWITCH (b - •)
When the light switch is in position “•”, the lights are off; when
the switch is in position “b”, the rear parking light and the low
beam are on.
2) START PUSH BUTTON (r)
When the start push button is pressed and one of the brake
levers (front or rear) is activated at the same time, the starter
makes the engine run.
For the starting procedure, see p. 30 (STARTING).
c

18 use and maintenance Rally 50
)'.)4)/.37)4#(
The ignition switch is positioned on the
right side, near the steering column.
The key (1) operates the ignition
switch/steering lock, the bat-
tery/tool kit compartment and the sad-
dle lock.
Two keys are supplied together with the
ehicle (one spare key).
34%%2).',/#+
Ne er turn the key to position “s” in
running conditions, in order to a oid
losing control of the ehicle.
OPERATION
To lock the steering:
◆Turn the handlebar completely leftwards.
◆Turn the key (1) to position “m” and
press it.
◆Release the key and turn it to position
“s”.
◆Extract the key.
c
Position Function Key
remo al
s
Steering
lock
The steering
is locked.
It is neither
possible to
start the en-
gine, nor to
switch on the
lights.
It is possible
to remove
the key.
m
Neither the
engine, nor
the lights can
be switched
on.
It is possible
to remove
the key.
n
The engine
and the lights
can be
switched on.
It is not pos-
sible to re-
move the
key.

19
use and maintenance Rally 50
!58),)!29%15)0-%.4
5.,/#+).',/#+).'
4(%3!$$,%
To unlock and lift the saddle:
◆Insert the key in the saddle lock (1).
◆Turn the key clockwise and raise the
saddle (2).
Before lowering and locking the
saddle, make sure that you ha e
not left the key in the crash hel-
met/glo e compartment.
◆To lock the saddle, lower and press it
(without exerting too much pressure),
thus making the lock snap shut.
Before lea ing, make sure that
the saddle is properly locked.
#2!3((%,-%4',/6%
#/-0!24-%.4
Thanks to the crash helmet/glove compart-
ment, you no longer have to carry the
crash helmet or other objects with you eve-
ry time you park the vehicle.
The compartment is positioned under the
saddle.
To reach it:
◆Raise the saddle (2), see (UNLOCK-
ING/LOCKING THE SADDLE).
Do not load the crash hel-
met/glo e compartment too
much.
Maximum allowed weight: 2.5 kg.
Special hooks for the position-
ing of a lock ha e been pro ided
under the saddle.
!.4)4(%&4(//+
The anti-theft hook (3) is positioned on the
right side of the vehicle, near the rider’s
footboard.
To prevent the vehicle from being stolen, it
is advisable to secure it with the aprilia
“Body-Guard” armored cable & (4), avail-
able at any aprilia Official Dealer.
Do not use the hook to lift the e-
hicle or for any purpose other
than securing the ehicle once it
has been parked.
c
a
a
c
a

20 use and maintenance Rally 50
"!44%294//,+)4
#/-0!24-%.4
This compartment is positioned in the low-
er part of the vehicle, between the foot-
rests.
To reach it, proceed as follows:
◆Insert the key (1) in the lock.
◆Rotate the key (1) clockwise, pull it and
remove the cover (2).
The tool kit (3) includes:
no. 1 tool case
no. 1 25 mm spark plug spanner
no. 1 tube for spark plug spanner
no. 1 8/10 mm socket spanner
no. 1 4 mm cross-/cut-headed screwdriver
no. 1 screwdriver handle
Before locking the co er (2),
make sure that you ha e not left
the key in the battery/tool kit
compartment.
To lock the cover (2), lower it and rotate the
key anticlockwise.
Maximum allowed weight: 1.5 kg.
"!'(//+
Do not hang excessi ely bulky
bags or parcels to the hook, as
this may seriously compromise
the manoeu rability of the ehicle or the
mo ement of your feet.
The bag hook (4) is positioned on the front
part of the inner shield.
Max. allowed weight: 1.5 kg.
aa