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
&/2%7/2$
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/$5#4)/.
This manual is divided into sections, chap-
ters and paragraphs, b subject. The proce-
dures described are laid out in single opera-
tion, and each operation is indicated b a ◆.
The numbered parts shown in the figures are
identified in the text with the number in paren-
theses or with the s mbol representing them.
Example:
section
-!).).$%0%.$%.4#/.42/,3
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 -
3!&%497!2.).'3
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.
'%.%2!,3!&%4925,%3
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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.
'!3/,).%
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.
(/4#/-0/.%.43
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 -
53%$%.').%/),
aWARNING
Use latex gloves for the maintenance op-
erations that require contact with used
oil. Used engine oil may cause skin can-
cer if repeatedly left in contact with the
skin for prolonged periods. Although
this is unlikely unless you handle used
oil on a daily basis, it is advisable to
thoroughly wash your hands with soap
and water after handling used oil.
KEEP OIL AWAY FROM CHILDREN.
"2!+%&,5)$
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.
#//,!.4
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.
"!44%29(9$2/'%.'!3
!.$%,%#42/,94%
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 -
7!2.).'302%#!54)/.3
'%.%2!,!$6)#%
Before starting the engine, carefull read
this manual and in particular the chapters
“WARNINGS - PRECAUTIONS - GENER-
AL ADVICE” and “SAFE DRIVE” see p. 17.
Your safet and that of those around ou
depends not onl on our skill as a rider,
but also our knowledge about our vehi-
cle and about riding safel . Therefore it is
essential that ou not operate our vehicle
on public streets or highwa s until ou
have received instructions from a qualified
safet organization such as the Motorc cle
Safet Foundation, and are properl
trained and licensed.
2%0/24).'/&$%&%#43
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.
2/!$2%'5,!4)/.3
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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.
./)3%%-)33)/.7!22!.49
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]
).&/2-!4)/./.4(%./)3%
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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 -
6%()#,%)$%.4)&)#!4)/.
.5-"%26).
&2!-%.5-"%2
Ever vehicle produced b aprilia re-
ceives a vehicle identification number
(V.I.N.) stamped:
– on the central tube of the frame (A), to
be able read it see p. 60 (FRAME NUM-
BER);
and also:
– on the identification plate (B) which is lo-
cated on the central tube of the frame.
).&/2-!4)/.#/.4!).%$
).4(%6%()#,%
)$%.4)&)#!4)/..5-"%2
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 -
0/3)4)/./&4(%7!2.).'!$(%3)6%,!"%,3

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

11
use and maintenance Rally 50 -
APR L ASPA%-)33)/.#/.42/,
3934%-7!22!.4934!4%-%.4
YOUR WARRANTY RIGHTS
AND OBLIGATIONS
The California Air Resources Board and
aprilia s.p.a. (hereinafter aprilia) are
pleased to explain the emission control
s stem warrant on our 1999 and later
vehicle. In California new motor vehicles
must be designed, built and equipped to
meet the State’s stringent anti-smog stan-
dards. aprilia must warrant the emission
control s stem on our vehicle for the peri-
ods of time listed below provided there has
been no abuse, neglect or improper main-
tenance of our vehicle.
Your emission control s stem ma include
parts such as the carburetor or fuel-injec-
tion s stem, the ignition s stem, catal tic
converter and engine computer. Also in-
cluded ma be hoses, belts, connectors
and other emission-related assemblies.
Where a warrantable condition exists,
aprilia will repair our vehicle at no cost to
ou, including diagnosis, parts and labor.
-!.5&!#452%237!22!.49
#/6%2!'%
Class I vehicles (50-169 cm#): for a period
of use of five (5) ears or 12,000 kilometers
(7,456 miles), whichever first occurs.
Class II vehicles (170 to 279 cm#): for a pe-
riod of use of five (5) ears or 18,000 kilo-
meters (11,185 miles), whichever first oc-
curs.
Class III vehicles (280 cm# and larger): for
a period of use of five (5) ears or 30,000
kilometers (18,641 miles), whichever first
occurs.
If an emission-related part on our vehicle
is defective, the part will be repaired or re-
placed b aprilia. This is our emission
control s stem DEFECTS WARRANTY.
/7.%237!22!.49
2%30/.3)"),)4)%3
– As the vehicle owner, ou are responsi-
ble for the performance of the required
maintenance listed in our owner's man-
ual. aprilia recommends that ou retain
all receipts covering maintenance on
our vehicle, but aprilia cannot den
warrant solel for the lack of receipts or
for our failure to ensure the perfor-
mance of all scheduled maintenance.
– You are responsible for presenting our
vehicles to an aprilia dealer as soon as
a problem exists. The warrant repairs
should be completed in a reasonable
amount of time, not to exceed 30 da s.
– As the vehicle owner, ou should be
aware that aprilia ma den our war-
rant coverage if our vehicle or a part
has failed due to abuse, neglect, improp-
er maintenance or unapproved modifica-
tions.
If ou have an questions regarding our
warrant rights and resposibilities, ou
should contact aprilia s.p.a., Via G. Ga-
lilei, 1, 30033 Noale (VE) Ital tel. +39 -
041 58 29 111, fax +39 - 041 44 10 54, or
the California Air Resources Board at P.O.
Box 8001, 9528 Telstar Avenue, El Monte,
CA 91734-8001.

12 use and maintenance Rally 50 -
APR L ASPA,)-)4%$7!22!.49
/.%-)33)/.#/.42/,3934%-
aprilia s.p.a., Via G. Galilei, 1, 30033
Noale (VE) Ital (hereinafter aprilia) war-
rants that each new 1999 and later aprilia
motorc cle, that includes as standard
equipment a headlight, taillight and stop-
light, and is street legal:
A. is designed, built and equipped so as to
conform at the time of initial retail pur-
chase with all applicable regulations of
the United States Environmental Pro-
tection Agenc , and the California Air
Resources Board; and
B. is free from defects in material and
workmanship which cause such motor-
c cle to fail to conform with applicable
regulations of the United States Envi-
ronmental Protection Agenc of the Cal-
ifornia Air Resources Board for a period
of use, depending on the engine dis-
placement, of 12,000 kilometers (7,456
miles), if the motorc cle’s engine dis-
placement is less than 170 cubic centi-
meters: of 18,000 kilometers (11,185
miles), if the motorc cle’s engine dis-
placement is equal to or greater than
170 cubic centimeters but less than 280
cubic centimeters; or of 30,000 kilome-
ters (18,641 miles), if the motorc cle’s
engine displacement is 280 cubic centi-
meters or greater; or 5 (five) ears from
the date of initial retail deliver , which-
ever first occurs.
I. COVERAGE. Warrant defects shall be
remedied during customar business
hours at an authorized aprilia motor-
c cle dealer located within the United
States of America in compliance with
the Clean Air Act and applicable regula-
tions of the United States Environmen-
tal Protection Agenc and the California
Air Resources Board. An part or parts
replaced under this warrant shall be-
come the propert of aprilia.
In the State of California onl , emission
related warranted parts are specificall
defined b the state’s Emission Warran-
t Parts List. These warranted parts are:
carburetor and internal parts; intake
manifold; fuel tank; fuel injection s s-
tem; spark advance mechanism; crank-
case breather; air cutoff valves; fuel
tank cap for evaporative emission con-
trolled motorc cles; oil filter cap; pres-
sure control valve; fuel/vapor separator;
canister; igniters; breaker governors; ig-
nition coils; ignition wires; ignition
points; condensers, and spark plugs if
failure occurs prior to the first scheduled
replacement; and hoses, clamps, fit-
tings and tubing used directl in these
parts. Since emission related parts ma
var from model to model, certain mod-
els ma not contain all of these parts
and certain models ma contain func-
tionall equivalent parts.
In the State of California onl , Emission
Control S stem emergenc repairs, as
provided for in the California Adminis-
trative Code, ma be performed b oth-
er than an authorized aprilia dealer. An
emergenc situation occurs when an
authorized aprilia dealer is not reason-
abl available, a part is not available
within 30 da s, or a repair is not com-
plete within 30 da s. An replacement
part can be used in an emergenc re-
pair. aprilia will reimburse the owner for
the expenses, including diagnosis, not
to exceed aprilia’s suggested retail
price for all warranted parts replaced
and labor charges based on aprilia’s
recommended time allowance for the
warrant repair and the geographicall
appropriate hourl labor rate. The own-
er ma be required to keep receipts and
failed parts in order to receive compen-
sation.

13
use and maintenance Rally 50 -
II. LIMITATIONS. This Emission Control
S stem warrant shall not cover an of the
following:
A. Repair or replacement required as a re-
sult of
(1) accident,
(2) misuse,
(3) repairs improperl performed or re-
placements improperl installed,
(4) use of replacement parts or acces-
sories not conforming to aprilia
specifications which adversel affect
performance and/or
(5)use in competitive racing or related
events.
B. Inspections, replacement of parts and
other services and adjustments re-
quired for required maintenance.
C. An motorc cle on which the odometer
mileage has been changed so that actu-
al mileage cannot be readil deter-
mined.
III. LIMITED LIABILITY
A. The liabilit of aprilia under this Emis-
sion Control S stem Warrant is limited
solel to the remect ing of defects in
material of workmanship b an autho-
rized aprilia motorc cle dealer at its
place of business during customar
business hours. This warrant does not
cover inconvenience or loss of use of
the motorc cle or transportation of the
motorc cle to or from the aprilia dealer.
aprilia SHALL NOT BE LIABLE FOR
ANY OTHER EXPENSES, LOSS OR
DAMAGE, WHETHER DIRECT, INCI-
DENTAL, CONSEQUENTIAL OR EX-
EMPLARY ARISING IN CONNECTION
WITH THE SALE OR USE OF OR IN-
ABILITY TO USE THE aprilia MOTOR-
CYCLE FOR ANY PURPOSE. SOME
STATES DO NOT ALLOW THE EX-
CLUSION OR LIMITATION OF ANY IN-
CIDENTAL OR CONSEQUENTIAL
DAMAGES, SO THE ABOVE LIMITA-
TIONS MAY NOT APPLY TO YOU.
B. NO EXPRESS EMISSION CONTROL
SYSTEM WARRANTY IS GIVEN BY
aprilia EXCEPT AS SPECIFICALLY
SET FORTH HEREIN. ANY EMISSION
CONTROL SYSTEM WARRANTY, IM-
PLIED BY LAW, INCLUDING ANY
WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR
PURPOSE, IS LIMITED TO THE EX-
PRESS EMISSION CONTROL SYS-
TEM WARRANTY TERMS STATED IN
THIS WARRANTY, THE FOREGOING
STATEMENTS OF WARRANTY ARE
EXCLUSIVE AND IN LIEU OF ALL
OTHER REMEDIES. SOME STATES
DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY
LASTS SO THE ABOVE LIMITATIONS
MAY NOT APPLY TO YOU.
C. No dealer is authorized to modif this
aprilia Limited Emission Control S s-
tem Warrant .

14 use and maintenance Rally 50 -
IV. LEGAL RIGHTS. THIS WARRANTY
GIVES YOU SPECIFIC LEGAL RIGHTS,
AND YOU MAY ALSO HAVE OTHER
RIGHTS WHICH VARY FROM STATE TO
STATE.
V. THIS WARRANTY IS IN ADDITION TO
THE APR L A LIMITED MOTORCYCLE
WARRANTY.
VI. ADDITIONAL INFORMATION. An re-
placement part that is equivalent in perfor-
mance and durabilit ma be used in the
performance of an maintenance or re-
pairs. However, aprilia is not liable for
these parts. The owner is responsible for
the perfomance of all required maintenace.
Such maintenance ma be performed at a
service establishment or b an individual.
The warrant period begins on the date the
motorc cle is delivered to an ultimate pur-
chaser.

15
use and maintenance Rally 50 -
'%.%2!,).3425#4)/.3
The operations preceded b this
s mbol must be repeated also on
the opposite side of the vehicle.
If not expressl indicated otherwise, for the
reassembl of the units repeat the disas-
sembl operations in reverse order.
The terms “right” and “left” are referred to
the rider seated on the vehicle in the nor-
mal riding position.
NOTE Soon after purchasing the vehi-
cle, write down the identification data pro-
vided in the SPARE PARTS IDENTIFICA-
TION LABEL in the table below. This label
is positioned on the right beam of the
frame; to be able to read it, remove the in-
spection cover, see p. 72 (REMOVING
THE INSPECTION COVER).
These data indicate:
– YEAR = ear of manufacture (Y, 1, 2, …);
– I.M. = modification code (A, B, C, …);
– COUNTRY CODE = countr of homolo-
gation (I, UK, A, …).
and are to be supplied to the Local aprilia
Dealer as reference data for the purchase
of spare parts or specific accessories of
the model ou have acquired.
In this manual the various versions are in-
dicated b the following s mbols:
★
moptional
tdrum brake version
VERSION:
I Italy S Singapore
U United Kingdom sSlovenia
a Austria i Israel
p Portugal ¬ South Korea
F Finland M Malaysia
B Belgium c Chile
d Germany HCroatia
f France AAustralia
E Spain uUnited States
of America
G Greece ÄBrazil
O Holland RSouth Africa
Y Switzerland nNew Zealand
D Denmark CCanada
J Japan

16 use and maintenance Rally 50 -
4!",%/&#/.4%.43
FOREWORD ............................................................. 2
INTRODUCTION ....................................................... 2
SAFETY WARNINGS ................................................ 3
GENERAL SAFETY RULES ..................................... 3
CARBON MONOXIDE .......................................... 3
GASOLINE ............................................................ 3
HOT COMPONENTS ............................................ 3
USED ENGINE OIL ............................................... 4
BRAKE FLUID ....................................................... 4
COOLANT ............................................................. 4
BATTERY HYDROGEN GAS
AND ELECTROLYTE ............................................ 4
WARNINGS - PRECAUTIONS -
GENERAL ADVICE ................................................... 5
REPORTING OF DEFECTS
THAT AFFECT SAFETY ....................................... 5
ROAD REGULATIONS
AND USE OF THE VEHICLE ................................ 5
NOISE EMISSION WARRANTY ........................... 5
INFORMATION ON THE NOISE AND EXHAUST
GAS EMISSION CONTROL SYSTEM .................. 5
TAMPERING WARNING ....................................... 6
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
(FRAME NUMBER) ............................................... 7
INFORMATION CONTAINED IN THE
VEHICLE IDENTIFICATION NUMBER ................. 7
POSITION OF THE
WARNING ADHESIVE LABELS ........................... 8
aprilia s.p.a.EMISSION CONTROL
SYSTEM WARRANTY STATEMENT ................. 11
MANUFACTURER’S
WARRANTY COVERAGE .................................. 11
OWNER’S WARRANTY RESPONSIBILITIES .... 11
aprilia s.p.a. LIMITED WARRANTY ON EMISSION
CONTROL SYSTEM ........................................... 12
GENERAL INSTRUCTIONS ................................... 15
TABLE OF CONTENTS ...................................... 16
BASIC SAFETY RULES ...................................... 18
CLOTHING .......................................................... 23
ACCESSORIES .................................................. 24
LOAD ................................................................... 24
ARRANGEMENT OF THE MAIN ELEMENTS ....... 26
ARRANGEMENT OF THE
INSTRUMENTS/CONTROLS .................................. 28
INSTRUMENTS AND INDICATORS ....................... 28
INSTRUMENTS AND INDICATORS TABLE ...... 29
CONTROLS ............................................................. 30
CONTROLS AT THE LEFT HAND GRIP ............ 30
CONTROLS AT THE RIGHT HAND GRIP .......... 31
IGNITION SWITCH ............................................. 32
STEERING LOCK ............................................... 32
AUXILIARY EQUIPMENT ....................................... 33
UNLOCKING / LOCKING THE SADDLE ............ 33
CRASH HELMET / GLOVE COMPARTMENT .... 33
ANTI-THEFT HOOK ............................................ 33
BATTERY / TOOL KIT COMPARTMENT ........... 34
BAG HOOK ......................................................... 34
REAR MUDGUARD EXTENSION ....................... 34
MAIN COMPONENTS ............................................. 35
FUEL ................................................................... 35
LUBRICANTS ...................................................... 36
BRAKES .............................................................. 37
DISC BRAKES .................................................... 38
REAR DRUM BRAKE 3 ................................... 38
FRONT AND REAR BRAKE ............................... 40
TIRES .................................................................. 42
AUTOMATIC LIGHTS ON ................................... 43
EXHAUST SILENCER ......................................... 43
INSTRUCTIONS FOR USE ..................................... 44
PRELIMINARY CHECKING OPERATIONS ........ 45
STARTING .......................................................... 46
RIDING ................................................................ 48
RUNNING-IN ....................................................... 50
STOPPING .......................................................... 50
PARKING ............................................................ 51
PLACING THE VEHICLE ON THE STAND ........ 51
SUGGESTIONS TO PREVENT THEFT .............. 52
MAINTENANCE ...................................................... 53
REGULAR SERVICE INTERVALS CHART ........ 54
MAINTENANCE RECORD .................................. 56
IDENTIFICATION DATA ..................................... 60
AIR CLEANER ..................................................... 61
FRONT WHEEL .................................................. 62
REAR WHEEL ..................................................... 64
REMOVING THE REAR BRAKE CALIPER ........ 65
CHECKING THE BRAKE PAD WEAR ................ 66
CHECKING THE SHOE WEAR 3 ................... 67
CHECKING THE STEERING .............................. 68
CHECKING THE SWINGING ARM PIVOT ........ 68
CHECKING THE STAND ................................... 69
CHECKING THE SWITCHES ............................. 70
REMOVING THE REAR-VIEW MIRRORS ......... 70
REMOVING THE EXHAUST SILENCER ........... 71
REMOVING THE FRONT
HANDLEBAR COVER ........................................ 72
REMOVING THE INSPECTION COVER ........... 72
REMOVING THE FRONT INNER SHIELD ........ 73
IDLING ADJUSTMENT ....................................... 74
ADJUSTING THE THROTTLE CONTROL ......... 75
SPARK PLUG ..................................................... 76
BATTERY ........................................................... 77
BATTERY STORAGE ......................................... 78
CHECKING AND CLEANING THE TERMINALS 78
REMOVING THE BATTERY .............................. 78
CHECKING THE ELECTROLYTE LEVEL ......... 79
RECHARGING THE BATTERY .......................... 79
INSTALLING THE BATTERY ............................. 79
CHANGING FUSES ........................................... 80
ADJUSTING
THE HEADLIGHT BEAM VERTICALLY ............. 81
ADJUSTING
THE HEADLIGHT BEAM HORIZONTALLY ....... 82
BULBS ................................................................ 83
CHANGING THE HEADLIGHT BULBS .............. 84
CHANGING THE FRONT AND REAR
DIRECTION INDICATOR BULBS ...................... 84
CHANGING THE DASHBOARD BULBS ............ 85
CHANGING THE REAR LIGHT BULB ............... 86
CHANGING THE LICENSE PLATE BULB ......... 86
TRANSPORT .......................................................... 87
DRAINING THE FUEL TANK ............................. 87
CLEANING ............................................................. 89
LONG PERIODS OF INACTIVITY ...................... 90
TECHNICAL DATA ................................................ 91
LUBRICANT CHART .......................................... 95
Importers ........................................................ 96-97
WIRING DIAGRAM - Rall 50 - ..................... 98
WIRING DIAGRAM KEY - Rall 50 - ............. 99

safe drive

18 use and maintenance Rally 50 -
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The instructions given below cover normal
operation of our vehicle and must be
carefull observed. B following these
rules ou will enhance our own safet and
the safet of those around ou. You will
also maximize the life and utilit of our ve-
hicle.
Two wheeled vehicles obviousl do not
provide some of the protection provided b
automobiles, therefore it is essential that
ou wear appropriate protective clothing.
Especiall , never operate our vehicle
without wearing our helmet, gloves, e e
protection, a heav jacket, sturd footwear,
and sturd full length pants.
However, do not assume that even the
best clothing and helmet will protect ou in
the event of an upset or a crash with anoth-
er vehicle. At best, this gear provides
some protection from scrapes and scratch-
es, but ver little, if an , impact protection.
Be sure that ou meet all the requirements
prescribed b local law, including driver’s li-
cense, minimum age, training, insurance,
taxes, vehicle registration, license plate,
etc.
When ou first receive our vehicle, prac-
tice b riding in areas where there is little
traffic. Do not attempt to ride in heav traf-
fic until ou are thoroughl experienced
and riding our vehicle has become sec-
ond nature to ou.
Most states prohibit the operation of this
size vehicle on freewa s or expresswa s,
be sure that it is legal to use our vehicle
before ou take an particular road.
A new vehicle must be carefull broken in,
see p. 50 (RUNNING-IN).
Before starting the engine, make sure that
the brakes, clutch, transmission and throt-
tle controls function properl and that the
fuel and oil suppl is adequate.
The exhaust s stem, brakes, and some
other parts of the vehicle become ver hot
during operation. Do not touch an of
these parts.
Some medicines or drugs, illegal or pre-
scription, and alcohol significantl increase
the risk of accidents. Do not ride while ou
are under the influence of alcohol or drugs,
be the illicit or prescription. Make sure
ou are in good ph sical condition and not
ill before riding our vehicle. Do not ride
our vehicle when ou are particularl tired
or fatigued. Alcohol, drugs and fatigue are
leading causes of vehicle accidents.
Man accidents are caused b the rider’s
inexperience and lack of training. Do not
ride our vehicle until ou have received
training from a recognized training organi-
zation such as the Motorc cle Safet
Foundation. Remember that riding a vehi-
cle, though eas and fun, is quite different
from driving a car. Do not assume that ou
can operate our vehicle safel just be-
cause ou are a competent automobile
driver.
Never lend our vehicle to others unless
ou are sure that the are competent and
properl licensed vehicle operators.

19
use and maintenance Rally 50 -
Observe all rules of the road. Particularl
pa attention to all warning, regulator and
informational signs.
Avoid showing off (i.e., popping wheelies).
Especiall observe speed limits, remember
that road conditions change with the
weather and wet and ic pavements are
particularl dangerous for vehicles, espe-
ciall if ou are riding too fast. Remember
that automobile drivers have a hard time
seeing vehicles, so alwa s give the auto-
mobile the right of wa , even if it is legall
ours.
Before changing lane, look over our
shoulder to make sure that the wa is
clear. Do not rel exclusivel on the rear-
view mirror: ou ma miscalculate the dis-
tance and speed of a vehicle, or ou ma
even not see it at all.
Avoid obstacles that could damage the ve-
hicle or make ou lose control.
Do not tailgate, do not attempt to increase
our gas mileage b following in the slip
stream of cars or trucks in front of ou.
In case of accident motorc cles, scooters
and mopeds do not provide the same de-
gree of protection ensured b automobiles.
The legs, in particular, are exposed the risk
of being injured. However, the additional
installation of leg guards ma actuall in-
crease the risk of injuries and their serious-
ness in case of accident.
Do not install leg guards available on the
market of spare parts and accessories.
Non-compliance with these instructions
ma result in serious injuries or even
death.
Alwa s ride with both hands on the han-
dlebars and feet on the footrests.
Never shift gear without using the clutch, if
the vehicle is so equipped. Do not operate
the shift lever or the other controls sudden-
l or abruptl . Such misuse can damage
the internal components of the vehicle and
consequentl cause seizure, loss of con-
trol, accidents and serious injuries or even
death.
Remain in the seat when ou are riding.
Do not stand up or attempt to stretch while
ou are riding our vehicle. If ou need to
rest, pull over to the side of the road when
it can be safel done.

20 use and maintenance Rally 50 -
It is ver important to our safet that ou
give full attention to the riding task. Watch
what ou are doing, do not allow ourself to
be distracted b other cars, people or
things on the roadside, etc. Never smoke,
eat, drink, read, etc. while riding our vehi-
cle. If ou must consult a map, pull over
when it can be done safel .
Use onl the vehicle’s specific fuels and lu-
bricants indicated in the “LUBRICANT
CHART”; check the oil, fuel and coolant
levels regularl .
If ou and our vehicle are involved in an
accident, insure that there has been no
damage to the control levers, tubes, wires,
braking s stem and other vital parts. If
our vehicle is involved in an accident, take
it immediatel to our Local aprilia Dealer
who has the equipment and knowledge to
check for accidental damage which ma
compromise our safet .
Your aprilia dealer is read and able to
help ou with an safet problems that ou
might have, but of course it is necessar
for ou to report an malfunctions to our
mechanic in order for him to help ou.
Do not use our vehicle if it is damaged. A
damaged vehicle ma become unstable or
present other problems which can increase
the risk of accident, and therefore of seri-
ous injur or even death.
COOLER
OIL