Ing-02.fm Page 52 Friday, December 17, 1999 11:16 AM 2%'5,!2 3%26)#% ).
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Ing-02.fm Page 54 Friday, December 17, 1999 11:16 AM )$%.4)&)#!4)/. $!4! It is a good rule to write down the frame and engine numbers in the space provided in this manual. The frame number can be used for the purchase of spare parts. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the guarantee.
Ing-02.fm Page 55 Friday, December 17, 1999 11:16 AM #(%#+).' 4(% %.').% /), ,%6 %, !.$ 4/00).' 50 Carefully read p. 39 (ENGINE OIL) and p. 51 (MAINTENANCE). Periodically check the engine oil level, change the oil after the first 1000 km (625 mi) and successively every 7500 km (4687 mi), see p. 56 (CHANGING THE ENGINE OIL AND THE OIL FILTER). In case of use on racetracks, change every 3750 km (2343 mi). TO CARRY OUT THE CHECKING: a CAUTION The engine oil level must be checked with warm engine.
Ing-02.fm Page 56 Friday, December 17, 1999 11:16 AM #(!.').' 4(% %.').% /), !.$ 4(% /), &),4%2 a CAUTION The engine oil and the oil filter change operations may be difficult for unskilled operators. If necessary, contact an APRILIA Official Dealer. If you want to carry them out personally, follow the instructions given below. Carefully read p. 39 (ENGINE OIL) and p. 51 (MAINTENANCE) carefully. Periodically check the engine oil level, see p.
Ing-02.fm Page 57 Friday, December 17, 1999 11:16 AM ◆ Screw and tighten the drain plug (4). Driving torque of the drain plug (4) positioned on the engine: 12 Nm (1,2 kgm). CHANGING THE ENGINE OIL FILTER Change the engine oil filter after the first 1000 km (625 mi) and successively every 7500 km (4687 mi) (or every time you change the oil). ◆ ◆ Unscrew the two screws (5) and remove the cover (6). Remove the engine oil filter (7). a CAUTION Do not use filters that have already been used.
Ing-02.fm Page 58 Friday, December 17, 1999 11:16 AM !33%-",).' 4(% 0).3 &/2 4(% 2%!2 3500/24 34!.$ & 0/3)4)/.).' 4(% 6%()#,% /. 4(% 2%!2 3500/24 34!.$ & 0/3)4)/.).' 4(% 6%()#,% /. 4(% &2/.4 3500/24 34!.$ & ◆ NOTE Have someone help you keep the ◆ ◆ ◆ Position the vehicle on the side stand on firm and level ground. ★ Position the pin (1) on the appropriate seat on the rear fork. ★ Screw and tighten the screw (2) in the appropriate threaded hole in the rear fork.
Ing-02.fm Page 59 Friday, December 17, 1999 11:16 AM !)2 #,%!.%2 Check the air cleaner every 7500 (4687 mi)km or 8 months, change it every 15000 km (9375 mi) or more frequently if the vehicle is used on dusty or wet roads. It is possible to clean the air cleaner partially after using the vehicle on this kind of roads. a CAUTION The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself. Do not start the engine if the air cleaner has been removed.
Ing-02.fm Page 60 Friday, December 17, 1999 11:16 AM &2/.4 7(%%, a CAUTION The disassembly and reassembly of the front wheel may be difficult for unskilled operators. If necessary, contact an APRILIA Official Dealer. If you want to perform these operations personally, keep to the following instructions. Carefully read p. 51 (MAINTENANCE). While disassembling and reassembling the wheel, be careful not to damage the brake pipes, the discs and the pads.
Ing-02.fm Page 61 Friday, December 17, 1999 11:16 AM aWARNING Upon reassembly of the brake caliper, replace the caliper fastening screws (1) with two new screws of the same type. ◆ REASSEMBLY Carefully read p. 51 (MAINTENANCE). a CAUTION While reassembling the wheel, be careful not to damage the brake pipes, discs and pads. The arrow on the wheel side indicates the rotation direction.
Ing-02.fm Page 62 Friday, December 17, 1999 11:16 AM 2%!2 7(%%, a CAUTION The disassembly and reassembly of the rear wheel may be difficult for unskilled operators. If necessary, contact an APRILIA Official Dealer. If you want to perform these operations personally, keep to the following instructions. Carefully read p. 51 (MAINTENANCE). Before carrying out the following operations, let the engine and the silencer cool down until they reach room temperature, in order to avoid burns.
Ing-02.fm Page 63 Friday, December 17, 1999 11:16 AM REASSEMBLY ◆ a CAUTION Before proceeding with the reassembly, make sure that support plate (8) of the brake caliper (9) is positioned correctly; the plate slot must be inserted in the appropriate stop pin (10) in the inner part of the rear fork right rod. Insert the disc in the brake caliper carefully. ◆ ◆ ◆ Spread a film of lubricating grease on the whole length of the wheel pin (3), see p. 90 (LUBRICANT CHART).
Ing-02.fm Page 64 Friday, December 17, 1999 11:16 AM a CAUTION Carry out the maintenance operations more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy roads. $2)6% #(!). Carefully read p. 51 (MAINTENANCE). The vehicle is equipped with an endless chain, in which a ring link joint is not used. a CAUTION An excessive slackening of the chain may cause noise or make the chain rattle, with consequent wear of the shoe and of the chain guide plate.
Ing-02.fm Page 65 Friday, December 17, 1999 11:16 AM CHECKING THE WEAR OF CHAIN, PINION AND CROWN Further, check the chain and sprockets and make sure that they do not present: – damaged rollers; – loose pins; – dry, rusty, crushed or seized links; – excessive wear; – lacking O rings; – sprocket or teeth excessively worn or damaged. a CAUTION ◆ ◆ Loosen the two lock nuts (4).
Ing-02.fm Page 66 Friday, December 17, 1999 11:16 AM 2%-/6).' 4(% 2)$%2 3!$$,% ,)&4).' 4(% &5%, 4!.+ ◆ Carefully read p. 30 (FUEL) and p. 51 (MAINTENANCE). Position the vehicle on the side stand on firm and level ground. ◆ ★ Partially raise the rear side edge of the saddle. ◆ ★ Unscrew and remove the screw (1) and take the bushing (2). Screw (1) driving torque: 12 Nm (1.2 kgm). ◆ Raise and remove the saddle (3). NOTE Upon reassembly, insert the front tang of the saddle in the appropriate seat.
Ing-02.fm Page 67 Friday, December 17, 1999 11:16 AM #(%#+).' 4(% "2!+% 0!$ 7%!2 Carefully read p. 31 (BRAKE FLUID recommendations), (DISC BRAKES) and p. 51 (MAINTENANCE). NOTE The following information refer to a single braking system, but are valid for both. Check the brake pad wear every 7500 km (4687 mi) and before every trip. The wear of the disc brake pads depends on the use, on the kind of drive and on the road. a WARNING Check the wear of the brake pads, especially before every trip. .
Ing-02.fm Page 68 Friday, December 17, 1999 11:16 AM ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/.3 Carefully read p. 51 (MAINTENANCE). NOTE Have the front fork oil changed by an aprilia Official Dealer, who will ensure you prompt and accurate servicing. Have the front fork oil changed after the first 7500 km (4687 mi) and successively every 22500 km (14000 mi).
Ing-02.fm Page 69 Friday, December 17, 1999 11:16 AM a CAUTION For the adjustment, always start from the most rigid setting (adjuster completely rotated clockwise). Do not force the rotation of the adjusters (1-2) beyond the end of stroke in both directions, in order to avoid any damage. Use the notches (1-2) provided on the adjusters as reference marks for the adjustment of the hydraulic braking with compressed and extended shock absorber.
Ing-02.fm Page 70 Friday, December 17, 1999 11:16 AM 2%!2 3530%.3)/. The rear suspension consists of a springshock absorber unit, fixed to the frame by means of silent-blocks and to the rear fork by means of lever systems. For the setting of the vehicle attitude, the shock absorber is provided with a screw adjuster (1) for the adjustment of the hydraulic braking with extended shock absorber, a ring nut for the adjustment of the spring preload (2) and a locking ring nut (3).
Ing-02.fm Page 71 Friday, December 17, 1999 11:16 AM a CAUTION Adjust the spring preload and the hydraulic braking with extended shock absorber according to the conditions of use of the vehicle. When the spring preload is increased, it is necessary to increase also the hydraulic braking with extended shock absorber, in order to avoid sudden jerks while riding.
Ing-02.fm Page 72 Friday, December 17, 1999 11:16 AM !$*534).' 4(% !##%,%2!4/2 #/.42/, Carefully read p. 51 (MAINTENANCE). )$,).' !$*534-%.4 Carefully read p. 51 (MAINTENANCE). Adjust the idling every time it is irregular. To carry out this operation, proceed as follows: ◆ Ride for a few miles until reaching the normal running temperature, see p. 17 (Coolant temperature indicator “h”). ◆ Position the gear lever in neutral (green warning light “ q ” on).
Ing-02.fm Page 73 Friday, December 17, 1999 11:16 AM #(%#+).' 4(% 3)$% 34!.$ !.$ 4(% 3!&%49 37)4#( Carefully read p. 51 (MAINTENANCE) and p. 78 (CHECKING THE SWITCHES). The side stand (1) must rotate without hindrances. Carry out the following checks: ◆ The springs (2) must not be damaged, worn, rusty or weakened. ◆ The side stand must rotate freely, if necessary grease the joint, see p. 90 (LUBRICANT CHART).
Ing-02.fm Page 74 Friday, December 17, 1999 11:16 AM 30!2+ 0,5'3 Carefully read p. 51 (MAINTENANCE). Check the spark plugs every 7500 km (4687 mi), change them every 15000 km (9375 mi). In case of use on racetracks, change the spark plugs every 3750 km (2343 mi). Periodically remove the spark plugs and clean them carefully, removing carbon deposits; change them if necessary. To reach the spark plugs: ◆ Lift the fuel tank, see p. 66 (LIFTING THE FUEL TANK).
Ing-02.fm Page 75 Friday, December 17, 1999 11:16 AM NOTE "!44%29 Carefully read p. 51 (MAINTENANCE). a WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. Never invert the connection of the battery cables. Connect and disconnect the battery with the ignition switch in position “m”, otherwise some components may be damaged. Connect first the positive cable (+) and then the negative cable (–). Disconnect following the reverse order.
Ing-02.fm Page 76 Friday, December 17, 1999 11:16 AM 2%-/6).' 4(% "!44%29 a CAUTION To remove the battery it is necessary to set to zero the digital clock and the red line setting. To reset these functions, see p. 18 (MULTIFUNCTION COMPUTER). ◆ ◆ ◆ ◆ ◆ ◆ ◆ ◆ Make sure that the ignition switch is in position “m”. Remove the rider saddle, see p. 66 (REMOVING THE RIDER SADDLE). Unscrew and remove the screw (1) on the negative terminal (–). Move the negative cable (2) sidewards.
Ing-02.fm Page 77 Friday, December 17, 1999 11:16 AM 2%#(!2').' 4(% "!44%29 Carefully read p. 75 (BATTERY). a CAUTION Do not remove the battery plugs: without plugs the battery may be damaged. ◆ ◆ ◆ ◆ Remove the battery, see p. 76 (REMOVING THE BATTERY). Prepare an appropriate battery charger. Set the charger for the desired type of recharge (see table) Connect the battery with a battery charger.
Ing-02.fm Page 78 Friday, December 17, 1999 11:16 AM ,/.' ).!#4)6)49 /& 4(% "!44%29 a CAUTION If the vehicle remains unused for more than twenty days, disconnect the 30A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer. NOTE The removal of the 30A fuses requires the setting to zero of the following functions: digital clock and red line setting. To reset these functions, see p. 18 (MULTIFUNCTION COMPUTER).
Ing-02.fm Page 79 Friday, December 17, 1999 11:16 AM #(!.').' 4(% &53%3 Carefully read p. 51 (MAINTENANCE). a CAUTION Do not repair faulty fuses. Never use fuses different from the recommended ones. The use of unsuitable fuses may cause damages to the electric system or, in case of short circuit, even a fire. NOTE If a fuse blows frequently, there probably is a short circuit or an overload in the electric system. In this case it is advisable to consult an aprilia Official Dealer.
Ing-02.fm Page 80 Friday, December 17, 1999 11:16 AM ARRANGEMENT OF THE 15A SECONDARY FUSES A) From voltage regulator to: high beam relay, low beam relay. B) From voltage regulator to: coils, engine stop relay, fuel pump. C) From ignition switch to: electric fans, clock. D) From ignition switch to: parking lights, rear stoplights, horn, dashboard lights, direction indicators. E) From ignition switch to: electronic unit, fuel pump relay, engine stop relay. NOTE Three fuses are spare fuses.
Ing-02.fm Page 81 Friday, December 17, 1999 11:16 AM "5,"3 Carefully read p. 51 (MAINTENANCE). aWARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. a CAUTION !$*534).' 4(% 6%24)#!, (%!$,)'(4 "%!- NOTE To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used.
Ing-02.fm Page 82 Friday, December 17, 1999 11:16 AM #(!.').' 4(% (%!$,)'(4 "5,"3 Carefully read p. 81 (BULBS). The headlight contains: – two high beam bulbs (1) (side). – one parking light bulb (2) (lower). – one low beam bulb (3) (lower). To change the bulbs, proceed as follows: ◆ Position the vehicle on the side stand, on firm and level ground. ◆ For the left and lower bulbs, turn the handlebar completely leftwards and work on the rear left side of the front part of the fairing.
Ing-02.fm Page 83 Friday, December 17, 1999 11:16 AM LOW BEAM BULB a CAUTION To extract the bulb electric connector, do not pull its electric wires. ◆ ◆ ◆ ◆ Grasp the bulb electric connector (10), pull it and disconnect it from the bulb (3). Move the protection element (11) with your hands. Release the check spring (12) positioned at the rear of the bulb socket (13). Extract the bulb (3) from its seat and replace it with a new one of the same type.
Ing-02.fm Page 84 Friday, December 17, 1999 11:16 AM #(!.').' 4(% 2%!2 ,)'(4 "5," Carefully read p. 81 (BULBS). NOTE The rear light houses two parking light/stoplight bulbs. The following operations refer to a single bulb, but are valid for both. Before changing a bulb, check the efficiency of the stoplight switches, see p. 78 (CHECKING THE SWITCHES). ◆ Remove the passenger seat, see p. 27 (UNLOCKING / LOCKING THE PASSENGER SEAT). a CAUTION To extract the bulb socket, do not pull the electric wires.
Ing-02.fm Page 85 Friday, December 17, 1999 11:16 AM #,%!.).' Clean the vehicle frequently if it used in particular areas or conditions, such as: ◆ Polluted areas (cities and industrial areas). ◆ Areas characterized by an high percentage of salinity and humidity (sea areas, hot and humid climates). ◆ Particular conditions (use of salt and anti-ice chemical products on the roads during the winter). ◆ Avoid leaving deposits of industrial and polluting powders, tar spots, dead insects, bird droppings, etc.
Ing-02.fm Page 86 Friday, December 17, 1999 11:16 AM ,/.' 0%2)/$3 /& ).!#4)6)49 a CAUTION ◆ Place the vehicle in an unheated, not-humid room, away from sunlight, with minimum temperature variations. Position and tie a plastic bag on the final pipe of the exhaust silencer, in order to prevent moisture from getting into it. Cover the vehicle avoiding the use of plastic or waterproof materials.
Ing-02.fm Page 87 Friday, December 17, 1999 11:16 AM 4%#(.)#!, $!4! DIMENSIONS Max. length ............................................................ Max. length (rear mudguard extension included) ...... Max. width.............................................................. Max. height (front part of the fairing included) Seat height............................................................. Distance between centres...................................... Min. ground clearance ........................
Ing-02.fm Page 88 Friday, December 17, 1999 11:16 AM GEAR RATIOS Ratio 1st 2nd 3rd 4th 5th 6th DRIVE CHAIN Type ....................................................................... endless (with no connection link) with sealed links Model ..................................................................... 525 FUEL SUPPLY SYSTEM Type ....................................................................... electronic injection (Multipoint) Choke.......................................................
Ing-02.fm Page 89 Friday, December 17, 1999 11:16 AM REAR TYRE Type ....................................................................... 180 / 55 ZR - 17” Model ..................................................................... PIRELLI MTR 22 - DRAGON EVO E3 75 R 0053585 Alternative .............................................................. BRIDGESTONE PT56R - BATTLAX E4 75 R 0000664 METZELER STEEL MEZ3 E3 75 R 0053918 MICHELIN PILOT SPORT E2 75 R 006566 Inflation pressure solo rider............
Ing-02.fm Page 90 Friday, December 17, 1999 11:16 AM ,5"2)#!.4 #(!24 0 Engine oil (recommended): EXTRA RAID 4, SAE 15W - 50 or TEC 4T SAE 15W - 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications. Fork oil (recommended): 0 0 F.A. 5W or F.A. 20 W fork oil; an alternative FORK 5W or FORK 20W fork oil.
Ing-02.fm Page 91 Friday, December 17, 1999 11:16 AM ./4% !3+ &/2 '%.5).% 30!2% 0!243 /.
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Ing-02.fm Page 96 Friday, December 17, 1999 11:16 AM aprilia s.p.a. wishes to thank its customers for the purchase of this vehicle. – Do not dispose of oil, fuel, polluting substances and components in the environment. – Do not keep the engine running if it isn’t necessary. – Avoid disturbing noises. – Respect nature.
