APRILIA RALLY 50 - 2003 User manual

2use and maintenance Rally 50 -
© 2003 aprilia s.p.a. - Noale (VE)
First edition: March 2003
Reprint:
Produced and printed b :
editing division
Soave (VERONA) - Ital
Tel. +39 - 045 76 11 911
Fax +39 - 045 76 12 241
E-mail: [e-mail]
www.stp.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Ital
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com
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NOTE This manual is an important and
integral part of our vehicle. Keep it with
our vehicle at all times, even if our vehi-
cle is resold.
aprilia has prepared this manual to suppl
ou, the user, with correct and current in-
formation. However, since aprilia con-
stantl improves the design of its vehicles,
there ma be slight discrepancies between
our vehicle and the material given in this
manual. If ou have an questions about
our vehicle, contact our Local aprilia
Dealer, as he will have the ver latest tech-
nical information available from the factor .
For tests and repairs not expressl de-
scribed in this manual, to purchase aprilia
genuine spare parts, accessories, and oth-
er products, and for help with specific prob-
lems, please contact our Local aprilia
Dealer or service center. These profes-
sionals will be able to promptl and accu-
ratel help.
Thank ou for choosing aprilia. Have a
great ride!
This manual is cop right in all countries,
and reproduction of an part or the whole
b an means in print or electronic is strict-
l prohibited.
).42/$5#4)/.
This manual is divided into sections, chap-
ters and paragraphs, b subject. The proce-
dures described are laid out in single opera-
tion, and each operation is indicated b a ◆.
The numbered parts shown in the figures are
identified in the text with the number in paren-
theses or with the s mbol representing them.
Example:
section
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chapter
34%%2).',/#+
safety
warning
aWARNING
Never turn the key to position “s while
the vehicle is being operated. If you do
so, you will lose control of the vehicle,
and a crash will ensue.
paragraph
OPERATION
operation To lock the steering:
◆Turn the handlebar completel to the left.
position (2) ◆Turn the ke (2) to position “m”
(OFF) and press it.
symbol “s”
◆Release the ke and rotate it to position
“s” (LOCK).
◆Remove the ke .

3
use and maintenance Rally 50 -
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The following precautionar warnings are
used throughout this manual in order to
conve the following messages:
Safety warning. When you find this
symbol on the vehicle or in the
manual, be careful to the potential risk of
personal injury. Non-compliance with
the indications given in the messages
preceded by this symbol may result in
grave risks for your and other people’s
safety and for the vehicle!
aWARNING
Indicates a potential hazard which may
result in serious injury or even death.
aCAUTION
Indicates a potential hazard which may
result in personal injury or damage to
the vehicle or other property.
NOTE The word “NOTE” in this manual
precedes important information or instruc-
tions.
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If it is necessar to let the engine run in or-
der to carr out some work, make sure that
the area in which ou are operating is prop-
erl ventilated. Never run the engine in en-
closed spaces.
If it is necessar to work indoors, use an
exhaust evacuation s stem.
aWARNING
The exhaust fumes contain carbon mon-
oxide, a poisonous gas that can cause
loss of consciousness and even death.
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Keep gasoline awa from children. Gaso-
line is also poisonous. Never attempt to si-
phon gasoline using our mouth. Never al-
low gasoline to contact our skin. If ou
should accidentall spill gasoline on our-
self, change our clothes immediatel and
wash the area upon which the gasoline
was splashed thoroughl with hot water
and soap. Should ou accidentall swal-
low gasoline, do not induce vomiting.
Drink large quantities of clear water or milk
and immediatel seek professional medical
assistance. Should ou accidentall get
gasoline get our e es, flush with large
quantities of cool, clear water and immedi-
atel seek professional medical assis-
tance.
aWARNING
Gasoline is extremely flammable and be-
comes explosive under certain condi-
tions.
KEEP GASOLINE AWAY FROM CHIL-
DREN.
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aWARNING
The engine and all parts of the exhaust
system, as well as the braking system,
become very hot and remain hot for
some time after the vehicle and the en-
gine are stopped. Before handling any
component of your vehicle after riding,
insure that it has cooled sufficiently to
be safe to handle.
a

4use and maintenance Rally 50 -
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aWARNING
Use latex gloves for the maintenance op-
erations that require contact with used
oil. Used engine oil may cause skin can-
cer if repeatedly left in contact with the
skin for prolonged periods. Although
this is unlikely unless you handle used
oil on a daily basis, it is advisable to
thoroughly wash your hands with soap
and water after handling used oil.
KEEP OIL AWAY FROM CHILDREN.
"2!+%&,5)$
aCAUTION
Brake fluid is extremely poisonous. Do
not ever allow brake fluid to be ingested
or swallowed. Should brake fluid acci-
dentally be swallowed, drink large quanti-
ties of milk or clear water and immediate-
ly seek professional medical assistance.
Brake fluid is highly destructive of skin
and eye tissue. Should you accidentally
spill brake fluid on yourself, remove the
contaminated clothing, wash your body
with soap and warm water immediately
and immediately seek professional medi-
cal assistance. Should you accidentally
splash brake fluid into your eyes, flush
with a large quantity of cool, clear water
and immediately seek professional medi-
cal assistance.
KEEP BRAKE FLUID AWAY FROM CHIL-
DREN.
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In certain conditions, the eth lene gl col
contained in the engine coolant is flamma-
ble: its flame is invisible, but ou can be
burned an wa .
aWARNING
Avoid spilling the engine coolant on the
exhaust system or on the engine compo-
nents. They may be hot enough to cause
the coolant to ignite and burn without a
visible flame.
The coolant (ethylene glycol) can cause
skin irritation and is poisonous if swal-
lowed.
Coolant and coolant/water mixtures are
sweet to the taste and brightly colored,
therefore are highly attractive to pets
and children. Take extra precautions to
keep new and used coolant out of reach
of children and animals.
KEEP AWAY FROM CHILDREN.
Risk of burn.
Do not remove the radiator cap when the
engine is hot. Wait until the engine has
completely cooled down. The coolant is
under pressure and may splash out and
cause burns.
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aWARNING
The battery gives off noxious and explo-
sive gases; keep cigarettes, flames and
sparks away from the battery. Provide
adequate ventilation when operating or
recharging the battery.
During the recharging or the use, make
sure that the room is properly ventilated
and avoid inhaling the gases released
during the recharging.
The battery contains sulphuric acid
(electrolyte). Contact with the skin or
eyes may cause serious burns. Always
wear protective clothing, rubber gloves,
and tight fitting goggles or a face shield
when working around the battery, espe-
cially when filling the battery with either
water or electrolyte.
In case of contact with the skin, flush im-
mediately with plenty of water. In case of
contact with the eyes, flush with plenty
of water for at least 15 minutes. Immedi-
ately consult a health professional.
The electrolyte is poisonous.
If the electrolyte is accidentally swal-
lowed, drink large quantities of water or
milk and then milk of magnesia or vege-
table oil. Immediately consult a health
professional.
KEEP AWAY FROM CHILDREN.

5
use and maintenance Rally 50 -
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Before starting the engine, carefull read
this manual and in particular the chapters
“WARNINGS - PRECAUTIONS - GENER-
AL ADVICE” and “SAFE DRIVE” see p. 17.
Your safet and that of those around ou
depends not onl on our skill as a rider,
but also our knowledge about our vehi-
cle and about riding safel . Therefore it is
essential that ou not operate our vehicle
on public streets or highwa s until ou
have received instructions from a qualified
safet organization such as the Motorc cle
Safet Foundation, and are properl
trained and licensed.
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4(!4!&&%#43!&%49
If ou believe that our vehicle has a defect
which could cause a crash or could cause
injur or death, ou should immediatel in-
form the National Highway Traffic Safety
Administration (NHTSA) in addition to no-
tif ing aprilia. If NHTSA receives similar
complaints, it ma open an investigation,
and if it finds that a safet defect exists in a
group of vehicles, it ma order a recall and
remed campaign. However, NHTSA can-
not become involved in individual problems
between ou, our dealer, or aprilia. To
contact NHTSA, ou ma either call the
Auto Safety Hotline toll free at 1-800-424-
9393 (or 366-0123 in the Washington, D.C.
area) or write to: NHTSA, U.S. Depart-
ment of Transportation, Washington, D.C.
20590.
You can also obtain other information about
motor vehicle safet from the Hotline.
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Rules of the road var from countr to coun-
tr . It is essential that ou understand in ad-
vance the rules of the road of the countr in
which our vehicle will be used.
aWARNING
This vehicle has been designed and pro-
duced for use on even and paved roads or
surfaces onl . Do not use the vehicle on un-
paved surfaces, in order to avoid overturn-
ing or other accidents.
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aprilia s.p.a. warrants that this exhaust
s stem, at the time of sale, meets all appli-
cable U.S. EPA Federal noise standards.
This warrant extends to the first person
who bu s this exhaust s stem for purpos-
es other than resale, and to all subse-
quent bu ers.
Warrant claims should be directed to:
aprilia USA Inc.
110 Londonderr Court, Suite 130
Woodstock, GA 30188
USA
Tel [phone]
Fax [phone]
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ORIGIN OF THE EMISSIONS
The combustion process produces carbon
monoxide and h drocarbons. The control
of h drocarbons is ver important, because
under certain conditions the react to ex-
posure to sunlight and produce photo-
chemical smog.
Carbon monoxide does not react in the
same wa , but it is toxic and poisonous.
aprilia utilizes “lean” carburetor settings
and other s stems to reduce the produc-
tion of carbon monoxide and h drocar-
bons.
EXHAUST EMISSION
CONTROL SYSTEM
The Exhaust Emission Control S stem re-
quires “lean” carburetor settings and no
adjustments should be made, except idle
speed adjustments b means of the appro-
priate screw.

6use and maintenance Rally 50 -
4!-0%2).'7!2.).'
Tampering with the noise control s stem is
prohibited. Federal law prohibits the fol-
lowing acts or causing thereof:
a) The removal or rendering inoperative b
an person other than for purposes of
maintenance, repair, or replacement, of
an device or element of design incor-
porated into an new vehicle for the pur-
pose of noise control prior to its sale or
deliver to the ultimate purchaser or
while it is in use, or
b) The use of the vehicle after such device
or element of design has been removed
or rendered inoperative b an person.
Among those acts presumed to constitute
tampering are the acts listed below:
a) Removal of, or puncturing the muffler,
baffles, header pipes or an other com-
ponent which conducts exhaust gases.
b) Removal or puncturing of an part of
the intake s stem.
c) Lack of proper maintenance.
d) Replacing an moving part of the vehi-
cle, or parts of the exhaust or intake
s stem, with parts other than those
specified b the manufacturer.
aCAUTION
This product should be checked for re-
pair or replacement if the vehicle noise
has increased significantly through use.
Otherwise, the owner may become sub-
ject to penalties under state and local or-
dinances.
PROBLEMS THAT MAY AFFECT
THE VEHICLE EMISSIONS
If an of the following s mptoms are ob-
served, immediatel have our vehicle in-
spected and repaired b our Local aprilia
Dealer.
Symptoms:
– Difficult starting or stalling after starting.
– Irregular idle.
– Misfiring or backfiring during accelera-
tion.
– After-burning (backfiring).
– Poor engine performance, degraded
handling, or poor fuel econom .

7
use and maintenance Rally 50 -
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.5-"%26).
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Ever vehicle produced b aprilia re-
ceives a vehicle identification number
(V.I.N.) stamped:
– on the central tube of the frame (A), to
be able read it see p. 60 (FRAME NUM-
BER);
and also:
– on the identification plate (B) which is lo-
cated on the central tube of the frame.
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DIGIT MEANING
1) Manufacturer’s identification alphanu-
meric code.
2) Vehicle t pe.
3) Model.
4) Countr for which the vehicle is intend-
ed.
5) # = Check digit number.
6) Model ear.
7) Assembling factor designation
(N = NOALE-VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).
8) Sequential serial number.

8use and maintenance Rally 50 -
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9
use and maintenance Rally 50 -
Ref. Description
1
2
3
4
5
6
7Muffler stamping.
8
Ref. Description

10 use and maintenance Rally 50 -
9
10
11
Ref. Description
12
13
14
Ref. Description