APRILIA RALLY 50 - 2002 User manual

2
© 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.

3
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

4
4!",%/&#/.4%.43
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

5
safe drive

6
"!3)#3!&%4925,%3
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.

7
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.

8
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.

9
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

10
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.
A12
345

11
Further, said modifications cause the loss of the insurance
cover, since insurance policies expressly prohibit to make
technical changes aimed at increasing the vehicle perform-
ance levels.
For the reasons stated above, the failure to comply ith the
tampering prohibition is punished by la ith apposite sanc-
tions (including the confiscation of the vehicle), hich, accord-
ing to the case, can be combined ith the sanctions provided
for not using the crash helmet and/or the number plate, for the
violation of fiscal obligations (o nership tax) and ith penal
sanctions provided for using the vehicle ithout driving li-
cense.
Never race ith other vehicles.
Avoid off-road driving.
ONLY ORIGINALS

12
#,/4().'
Before starting, al ays ear a correctly fastened crash hel-
met. 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 ay you ill make yourself more visible to the
other drivers, thus notably reducing the risk of being knocked
do n, and you ill be more protected in case of fall.
This clothing should be very tight-fitting and fastened at the
rists and ankles. Strings, belts and ties should not be hang-
ing loose; prevent these and other objects from interfering ith
driving by getting entangled ith moving parts or driving
mechanisms.
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 pas-
sengers).

13
!##%33/2)%3
The o ner of the vehicle is responsible for the choice, installa-
tion and use of any accessory.
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 inclina-
tion in turns.
Avoid using accessories that hamper access to the controls,
since this can prolong reaction times during an emergency.
Large fairings and indscreens assembled on the vehicle can
produce aerodynamic forces capable of compromising the sta-
bility of the vehicle hile driving.
Make sure that the equipment is ell fastened to the vehicle
and not dangerous during driving.
Do not install electrical devices and do not modify those al-
ready existing to avoid electrical overloads, because the vehi-
cle could suddenly stop or there could be a dangerous current
shortage in the horn and in the lights. aprilia recommends the
use of “aprilia genuine accessories”.

14
,/!$
Be careful and moderate hen loading your luggage.
Keep any luggage loaded as close as possible to the centre of
the vehicle 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, especially during long trips.
Avoid hanging bulky, heavy and/or dangerous objects on the
handlebars, mudguards and forks, because the vehicle might
respond more slo ly in turns and its manoeuvrability could be
unavoidably impaired.
Do not place bags that are too bulky on the vehicle sides and
do not ride ith the crash helmet hanging from its string, be-
cause it could hit people or obstacles making you lose control
of the vehicle.

15
Do not carry any bag if it is not tightly secured to the vehicle.
Do not carry bags hich protrude too much from the luggage-
rack or hich 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 allo ed for each side-bag.
When the vehicle is overloaded, its stability and its manoeu-
vrability can be compromised.
KG!

16
!22!.'%-%.4
/&4(%-!).%,%-%.43
+%9&IG
1) Mixer oil tank plug
2) Ignition s itch/steering lock
3) Front brake fluid reservoir
4) Bag hook
5) Battery/tool kit compartment
6) Inspection cover
7) Anti-theft hook
+%9&IG
1) Fuel tank plug
2) Saddle lock
3) Transmission oil filling cap
4) Kick starter
5) Centre stand
Fig. 1
Fig. 2

17
!22!.'%-%.4
/&4(%).3425-%.43
+%9&IG
1) Horn push button (f)
2) Cold start lever (e)
3) Rear brake lever
4) Rear-vie mirror
5) Direction indicator s itch (c)
6) Instruments and indicators
7) Front brake lever
8) Throttle grip
9) Start push button (r)
10) Ignition s itch/steering lock (n - - s)Fig. 3

18
).3425-%.43!.$).$)#!4/23
+%9&IG
1) Red mixer oil reserve arning light (j)
2) Green left direction indicator arning light (c)
3) Total kilometres odometer
4) Speedometer
5) Amber lo fuel arning light (g)
6) Green right direction indicator arning light
(c)
7) Green lo beam arning light (b)
8) Fuel level indicator (g)
Fig. 4

19
).3425-%.4!.$).$)#!4/24!",%
Description Function
Mixer oil reserve warning light (j)It comes on hen the ignition s itch is in position "n" and the
start push button “r“ is pressed, thus checking the proper func-
tioning of the bulb.
If the light does not come on during the starting, provide for re-
placing the bulb.
If the warning light comes on and does not go out af-
ter the start push button "r" has been released, or if
it comes on during normal functioning, this means
that the mixer oil reserve is being used; in this case, top up
the mixer oil tank, see p. 26 (MIXER OIL TANK).
Direction indicator warning light (c)It blinks hen the direction indicators are on.
Total kilometres odometer It indicates the total number of kilometres covered.
Speedometer It indicates the driving speed.
Fuel level indicator It indicates the approximate fuel level in the tank.
Low beam warning light (b)It comes on henever the ignition s itch is turned to position “n”.
Low fuel warning light (g)It comes on hen the quantity of fuel left in the tank is about 1,5 L.
a

20
-!).).$%0%.$%.4#/.42/,3
#/.42/,3/.4(%,%&43)$%
/&4(%(!.$,%"!2&IG
The electrical parts work only when the
ignition switch is in position “n”.
1) HORN USH BUTTON (f)
The horn is activated hen the push button is
pressed.
2) COLD START LEVER (e)
The starter for the cold start of the engine is oper-
ated by rotating the lever do n ards.
To disconnect the cold start, bring the lever to its
initial position.
3) DIRECTION INDICATOR SWITCH (c)
To indicate the turn to the left, move the s itch to
the left; to indicate the turn to the right, move the
s itch to the right.
To turn off the direction indicator, press the s itch.
c
Fig. 5