APRILIA RALLY 50 - 2002 User manual

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© 2002 aprilia SpA - Noale (VE)
This manual is to be considered an integral part of
the vehicle, hich must be delivered complete ith it
also in case of resale.
aprilia s.p.a. reserves the right to modify its models
at any time, ithout prejudice to the main character-
istics here described.
All rights as to electronic storage, reproduction and
total or partial adaptation, ith any means, are re-
served 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 per-
formance or the use of said products.
First edition: december 2002
Reprint:
Produced and printed by:
editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [e-mail]
.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
.aprilia.com
&/2%7/2$
Before starting the engine, carefully read this manu-
al, paying particular attention to the chapter "RIDING
SAFELY". Your and other people’s safety depends
not only on your quickness of reflexes and on your
agility, but also on hat you kno about the vehicle,
on its efficiency and on your kno ledge of the basic
information for RIDING SAFELY.
Therefore, get a thorough kno ledge of the vehicle,
in such a ay as to be able to drive in the traffic safe-
ly.
For the controls and repairs not expressly described
in this manual, for the purchase of aprilia Genuine
Spare Parts, accessories and other products, as ell
as for specific technical advice, contact only aprilia
Authorized Outlets and Official Dealers, ho can en-
sure you reliable and prompt servicing.
Thank you for choosing aprilia. We ish you a nice
ride.

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Carefully observe the instructions preceded by the
follo ing arning signs:
Safety norms and regulations to protect
the driver and other people from severe
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 vehicle.
IM ORTANT:
When asking your Dealer for spare parts, specify
the spare parts code indicated on the SPARE
PARTS IDENTIFICATION LABEL.
Write do n the identification code in the space
here belo , in order to remember it also in case of
loss or deterioration of the label.
The label is positioned under the saddle.
In this manual the various versions are indicated by
the follo ing symbols:
a
c
★
VERSION:
I Italy ÑSlovenia
U United Kingdom % Israel
A Austria K South Korea
P ortugal M Malaysia
" Finland R Chile
B Belgium `Croatia
D Germany ^Australia
F France -United States of America
E Spain ]Brazil
G Greece áSouth Africa
O Holland ÎNew Zealand
C Switzerland [Canada
 Denmark
J Japan
S Singapore

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SAFE DRIVE .....................................................................................5
BASIC SAFETY RULES ................................................................ 6
CLOTHING ................................................................................... 12
ACCESSORIES ........................................................................... 13
LOAD ........................................................................................... 14
ARRANGEMENT OF THE MAIN ELEMENTS .............................. 16
ARRANGEMENT OF THE INSTRUMENTS .................................. 17
INSTRUMENTS AND INDICATORS ............................................. 18
INSTRUMENT AND INDICATOR TABLE .................................... 19
MAIN INDE ENDENT CONTROLS .............................................. 20
CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR .......... 20
CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ........ 21
IGNITION SWITCH ...................................................................... 22
STEERING LOCK ........................................................................ 22
AUXILIARY EQUI MENT .............................................................. 23
UNLOCKING/LOCKING THE SADDLE ....................................... 23
CRASH HELMET / GLOVE COMPARTMENT ............................ 23
BATTERY / TOOL KIT COMPARTMENT .................................... 24
BAG HOOK .................................................................................. 24
MAIN COM ONENTS .................................................................... 25
FUEL ............................................................................................ 25
MIXER OIL TANK ........................................................................ 26
BRAKE FLUID (recommendations) .............................................. 27
FRONT BRAKE ............................................................................ 27
TOPPING UP ............................................................................... 28
REAR BRAKE .............................................................................. 29
TYRES ......................................................................................... 30
AUTOMATIC LIGHT SWITCHING VERSION .............................. 31
CATALYTIC SILENCER .............................................................. 31
INSTRUCTIONS FOR USE ............................................................ 32
PRELIMINARY CHECKING OPERATIONS ................................ 33
STARTING ................................................................................... 34
DEPARTURE AND DRIVE .......................................................... 36
RUNNING-IN ................................................................................ 37
STOPPING AND PARKING ......................................................... 38
POSITIONING THE VEHICLE
ON THE STAND .......................................................................... 38
SUGGESTIONS TO PREVENT THEFT ...................................... 39
ANTI-THEFT HOOK ..................................................................... 40
MAINTENANCE ............................................................................. 41
REGULAR SERVICE
INTERVALS CHART ................................................................... 42
IDENTIFICATION DATA ............................................................. 44
AIR CLEANER ............................................................................ 46
CHECKING THE TRANSMISSION OIL LEVEL .......................... 48
CHANGING THE TRANSMISSION OIL ...................................... 49
FRONT WHEEL .......................................................................... 50
EXHAUST SILENCER ................................................................ 52
REAR WHEEL ............................................................................ 54
GREASING THE REAR BRAKE CAM PIN ................................. 55
CHECKING THE BRAKE PAD WEAR ........................................ 57
CHECKING THE BRAKE SHOE WEAR ..................................... 58
CHECKING THE STEERING ...................................................... 59
CHECKING THE ENGINE FULCRUM AXIS ............................... 59
REMOVING THE INSPECTION COVER .................................... 60
REMOVING THE FRONT HANDLEBAR COVER ...................... 61
IDLING ADJUSTMENT ............................................................... 62
ADJUSTING THE ACCELERATOR CONTROL ......................... 63
SPARK PLUG ............................................................................. 64
BATTERY .................................................................................... 65
LONG INACTIVITY OF THE BATTERY ...................................... 66
CHECKING THE ELECTROLYTE LEVEL .................................. 67
CHANGING THE FUSE .............................................................. 68
ADJUSTING THE HEADLIGHT BEAM ....................................... 69
BULBS ........................................................................................ 69
CHANGING THE HEADLIGHT BULBS ...................................... 70
CHANGING THE FRONT DIRECTION INDICATOR BULBS ..... 72
CHANGING THE REAR DIRECTION INDICATOR BULBS ....... 73
CHANGING THE DASHBOARD BULBS .................................... 74
CHANGING THE REAR LIGHT BULBS ..................................... 75
TRANS ORT ................................................................................ 76
DRAINING THE FUEL TANK ...................................................... 76
CLEANING .................................................................................... 77
LONG PERIODS OF INACTIVITY .............................................. 78
AFTER A PERIOD OF INACTIVITY ............................................ 78
TECHNICAL DATA ....................................................................... 79
LUBRICANT CHART ................................................................... 81
Importers ................................................................................ 82-83
WIRING DIAGRAM - Rally 50 ..................................................... 84
WIRING DIAGRAM KEY - Rally 50 ............................................. 85

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safe drive

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To drive the vehicle it is necessary to be in possession of all
the requirements prescribed by la (driving licence, minimum
age, psychophysical ability, insurance, state taxes, vehicle
registration, number plate, etc.).
Gradually get to kno the vehicle by driving it first in areas ith
lo traffic and/or private areas.
The use of medicins, alcohol and drugs or psychotropic sub-
stances notably increases the risk of accidents.
Be sure that you are in good psychophysical conditions and fit
for driving and pay particular attention to physical eariness
and dro siness.

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STO 150 m
STO
¡
150 m
Most road accidents are caused by the driver’s lack of experi-
ence.
NEVER lend the vehicle to beginners and, in any case, make
sure that the driver has all the requirements for driving.
Rigorously observe all road signs and national and local road
regulations.
Avoid abrupt movements that can be dangerous for yourself
and other people (for example: rearing up on the back heel,
speeding, etc.), and give due consideration to the road sur-
face, visibility and other driving conditions.

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Avoid obstacles that could damage the vehicle or make you
lose control.
Avoid riding in the slipstream created by preceding vehicles in
order to increase your speed.
Al ays drive ith both hands on the handlebars and both feet
on the footrests, in the correct driving posture.
Avoid standing up or stretching your limbs hile driving.

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The driver should pay attention and avoid distractions caused
by people, things and movements (never smoke, eat, drink,
read, etc.) hile driving.
Use only the vehicle’s specific fuels and lubricants (indicated
in the "LUBRICANT CHART"); check all oil, fuel and coolant
levels regularly.
COOLER
OIL

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If the vehicle has been involved in an accident, make sure that
no damage has occurred to the control levers, pipes, ires,
braking system and vital parts.
If necessary, have the vehicle inspected by an aprilia Official
Dealer, ho should carefully check the frame, handlebars,
suspensions, safety parts and all the devices that you cannot
check by yourself.
Al ays remember to report any malfunction to the technicians
to help them in their ork.
Never use the vehicle hen the amount of damage it has suf-
fered endangers your safety.
Never change the position, inclination or colour of: number
plate, direction indicators, lights and horns.
Any modification of the engine or of other members hich is
aimed at increasing the speed or the po er of the vehicle is
prohibited by the la ; in fact, any modification resulting in an
increase of the maximum speed or of the engine displacement
ould change the scooter into a motorcycle, hich implies the
follo ing obligations for the o ner:
– ne homologation;
– ne registration;
– appropriate driving license.
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