APRILIA 6.5 - 1996 User manual

Motó 6.5

MOTO'

6

5

use and maintenance

This manual is to be considered an integral part of the vehicle,

which must be delivered complete with it also in case of resale.

aprilia s.p.a. reserves the right to modify its models at any

time, without prejudice to the main characteristics here de-

scribed.

All rights as to electronic storage, reproduction and total or par-

tial adaptation, with any means, are reserved for all Countries.

The mention to products or services supplied by third parties is

made only for information purposes and it isn’t binding in any

case.

aprilia s.p.a. takes no responsibility as to the performance or

the use of said products.

First edition: January 1996

Reprint

Produced and printed by

Viale del Progresso - 37038 Soave (VR) - Italia

Tel. 045 - 76 11 911

Fax 045 - 76 12 241

on behalf of

s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - Italia

Tel. 041 - 58 29 111

Fax 041 - 44 10 54

2

Before starting the engine, carefully read this manual, paying

particular attention to the chapter "SAFE DRIVE".

Your and other people’s safety depends not only on your quick-

ness of reflexes and on your agility, but also on what you know

about the vehicle, on its efficiency and on your knowledge of

the basic information for SAFE DRIVE.

Therefore, get a thorough knowledge of the vehicle, in such a

way as to be able to drive in the traffic safely.

For the controls and repairs not expressly described in this ma-

nual, for the purchase of aprilia original spare parts, acces-

sories and other products, as well as for specific technical

advice, contact only aprilia Authorized Outlets and Official

Dealers, who can ensure you reliable and prompt servicing.

Thank you for choosing aprilia. We wish you a nice ride.

Carefully observe the instructions preceded by the following

warning signs:

Safety norms and regulations to protect the driver

and other people from severe injuries or grave

risks.

Caution norms and suggestions to avoid damaging

the vehicle and/or hurting yourself or other people.

Indications to make the operations easier. Techni-

cal information.

IMPORTANT:

When asking your Dealer for spare parts, specify the spare part

code indicated on the SPARE PARTS IDENTIFICATION

LABEL.

Write down the identification code in the space here below, in

order to remember it also in case of loss or deterioration of the

sticker.

The sticker is placed under the saddle, on the left tube of the

pillar.

aprilia

CODICE RICAMBI spare parts code number

N° ABCDE

IUKSAPSFBD

F E GR NL CH DK N IRL

JSGP

3

SAFE DRIVE............................................................................................5

BASIC SAFETY RULES ....................................................................6

CLOTHING.........................................................................................9

ACCESSORIES ...............................................................................10

LOAD................................................................................................10

ARRANGEMENT OF THE MAIN ELEMENTS......................................12

ARRANGEMENT OF THE INSTRUMENTS..........................................14

INSTRUMENTS AND INDICATORS.....................................................14

INSTRUMENT AND INDICATOR TABLE .......................................15

MAIN INDEPENDENT CONTROLS......................................................16

CONTROLS ON THE LEFT SIDE OF THE HANDLEBAR..............16

CONTROLS ON THE RIGHT SIDE OF THE HANDLEBAR ...........17

IGNITION SWITCH..........................................................................18

STEERING LOCK............................................................................18

AUXILIARY EQUIPMENT......................................................................18

TOOL KIT.........................................................................................18

CRASH HELMET HOOK .................................................................19

MAIN COMPONENTS ...........................................................................19

FUEL................................................................................................19

ENGINE OIL.....................................................................................20

BRAKE FLUID (RECOMMENDATIONS)) .......................................20

FRONT BRAKE................................................................................21

REAR BRAKE..................................................................................22

CLUTCH...........................................................................................23

COOLANT........................................................................................24

CATALYTIC SILENCERS................................................................25

TYRES .............................................................................................26

INSTRUCTIONS FOR USE ...................................................................27

PRELIMINARY CHECKING OPERATIONS TABLE .......................27

STARTING .......................................................................................28

DEPARTURE AND DRIVE ..............................................................30

RUNNING-IN....................................................................................32

STOPPING AND PARKING.............................................................33

SUGGESTIONS TO PREVENT THEFT..........................................33

MAINTENANCE.....................................................................................34

PERIODIC MAINTENANCE CHART...............................................35

IDENTIFICATION DATA..................................................................36

CHECKING THE ENGINE OIL LEVEL AND TOPPING UP............36

CHANGING THE ENGINE OIL AND THE OIL FILTER..................37

FRONT WHEEL...............................................................................38

REAR WHEEL.................................................................................39

CHAIN..............................................................................................40

REMOVING THE FUEL TANK........................................................42

AIR FILTER .....................................................................................42

FRONT AND REAR SUSPENSION INSPECTION.........................43

ADJUSTING THE REAR SUSPENSION ........................................43

CHECKING THE STEERING..........................................................44

LOCKING/UNLOCKING THE SADDLE ..........................................45

REMOVING THE SIDES.................................................................45

IDLING ADJUSTMENT....................................................................46

TAKING UP THE THROTTLE GRIP SLACK ..................................46

CHECKING THE BRAKE PAD WEAR............................................46

SPARK PLUG..................................................................................47

BATTERY ........................................................................................48

LONG PERIOD OF INACTIVITY.....................................................49

CHANGING THE FUSES ................................................................49

CHECKING THE SIDE STAND SWITCH........................................50

ADJUSTING THE HEADLIGHT BEAM...........................................50

BULBS.............................................................................................51

CHANGING THE HEADLIGHT BULBS...........................................51

CHANGING THE REAR LIGHT BULBS..........................................52

CHANGING THE NUMBER PLATE BULB......................................53

CHANGING THE TURN INDICATOR BULBS ................................53

CHANGING THE DASHBOARD BULBS ........................................53

TRANSPORT.........................................................................................54

EMPTYING THE FUEL TANK.........................................................54

CLEANING ............................................................................................54

LONG PERIODS OF INACTIVITY ..................................................55

AFTER A LONG PERIOD OF INACTIVITY ....................................55

TECHNICAL DATA ...............................................................................56

WIRING DIAGRAM..........................................................................59

WIRING DIAGRAM KEY .................................................................60

LUBRICANT CHART.......................................................................61

IMPORTERS ...................................................................................62

4

safe drive

To drive the vehicle it is necessary to

have all the requirements provided for in

law (driving licence, minimum age re-

quired, psychophysical ability, insurance,

state taxes, registration, number plate,

etc.).

Gradually get to know the vehicle, driv-

ing it in areas with low traffic and/or in

private areas.

The taking of some medicinal prepara-

tions, alcohol and drugs or psycho tropic

substances notably increases the risk of

accidents.

Be sure that you are in good psycho-

physical conditions, fit for driving, paying

particular attention to physical weariness

and drowsiness.

Most road accidents are ascribable to

the driver’s lack of experience.

NEVER lend the vehicle to beginners

and, in any case, be sure that the driver

has all the requirements necessary for

driving.

6

Rigorously observe the road signs and

the national and local road regulations.

Avoid any abrupt movement, which can

be dangerous for yourself and for other

people (for example: rearing up, speed

limit excess, etc.), and verify and always

take into consideration the road surface

conditions, visibility etc.

Do not hit obstacles which could damage

the vehicle or make you loose the con-

trol.

Do not drive in the slipstream of the

preceding vehicles in order to increase

your speed.

Always drive with both hands on the

handlebar and both feet on the footrests,

in the correct driving posture.

Absolutely avoid standing up or stretch-

ing your limbs while driving.

STOP150m

STOP

¡

150m

7

The driver should neither be inattentive,

nor be distracted, nor influenced by

people, things, movements (do not

smoke, eat, drink, read, etc.) while driv-

ing.

Use only fuels and lubricants that are

specific for the vehicle and indicated in

the "LUBRICANT CHART"; repeatedly

verify that the oil, fuel and coolant levels

are as prescribed.te.

If the vehicle has been involved in an ac-

cident, if it has been hit or has fallen

down, make sure that the control levers,

the pipes, the wires, the braking system

and the vital parts haven’t been dam-

aged.

If necessary, have the vehicle controlled

by an aprilia Official Dealer, asking him

to carefully check the frame, the handle-

bar, the suspensions, the safety parts

and the devices whose integrity you are

not able to verify.

Always remember to report any malfunc-

tion to the technicians and/or the techni-

cians to help them in their work.

Never use the vehicle if the suffered

damage can endanger your safety.

COOLER

OIL

8

Do not absolutely change the position,

the inclination or the colour of: plate, turn

indicators, lights and horns.

Any modification carried out on the ve-

hicle or the removal of original parts can

impair the performance of the vehicle,

thus reducing its safety level or even

making it illegal.

As far as the equipment of the vehicle is

concerned, always keep to the national

and local laws and regulations.

In particular, avoid increasing the perfor-

mance or changing the original features

of the vehicle by means of technical

modifications.

Absolutely avoid racing with other ve-

hicles.

Avoid off-road driving.

Before moving off, always wear your

crash helmet, correctly fastened. Make

sure that it is homologated, sound, of the

right size and that the visor is clean.

Wear protective clothing, preferably in

light and/or reflecting colours.

This way you will make yourself more

visible to other drivers, thus notably re-

ducing the risk of being knocked down,

and you will be more protected in case of

fall. This clothing should be very close-fit-

ting and fastened at the extremities.

Strings, belts and ties should not be

hanging down; prevent these or other ob-

jects from interfering in the drive by get-

ting entangled with moving parts or

driving mechanisms. Do not keep objects

which can be dangerous in case of fall,

for example pointed objects like keys,

pens, glass vials etc. in your pockets

(the same recommendations are valid for

any passenger, too).

A12

345

ONLY ORIGINALS

9

Do not keep objects which can be dan-

gerous in case of fall, for example

pointed objects like keys, pens, glass

vials etc. in your pockets (the same rec-

ommendations are valid for any pas-

senger, too).

The owner of the vehicle is responsible

for the choice, installation and use of any

accessory.

Avoid installing accessories that cover

horns or lights or that could impair their

function, 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 ac-

cess to the controls, since this can pro-

long reaction times during an emergency.

Large fairings and windscreens assem-

bled on the vehicle can produce aerody-

namic forces capable of compromising

the stability of the vehicle itself while

driving.

Make sure that the equipment is well

fastened to the vehicle and is not dan-

gerous during the drive.

Do not install electrical devices and do

not modify those already existing to

avoid electrical overloads, because the

vehicle could suddenly stop or there

could be a dangerous current shortage

in the horn and in the lights.

Be careful and moderate when loading

your luggage. It is necessary to keep the

luggage as close as possible to the ba-

rycenter of the vehicle and to distribute

the load uniformly on the two sides, in

order to reduce any lack of balance to

the minimum.

Further, make sure that the load is firmly

secured to the vehicle, especially during

long trips.

10

Absolutely do not hang bulky, volu-

minous, heavy and/or dangerous objects

on the handlebar, the mudguards and

the forks, as the vehicle could react

more slowly in turns and its manoeuvra-

bility could be unavoidably impaired.

Do not place too bulky bags on the ve-

hicle sides and do not hang the crash

helmet from the apposite string, as they

could hit people or obstacles, thus caus-

ing the loss of control of the vehicle.

Do not carry any bag if it is not tightly se-

cured to the vehicle.

Do not carry bags which protrude too

much from the luggage-rack or which

cover the lights, the horn or the indica-

tors.

Do not carry animals or children on the

glove-compartment or on the luggage-

rack.

Do not exceed the maximum load allowed

for each side-bag.

When the vehicle is overloaded, its sta-

bility and its manoeuvrability can be com-

promised.

KG!

11

1) Fuel tank plug

2) Coolant expansion tank plug

3) Crash helmet hook

4) Battery

5) Fuses

6) Transmission control lever

7) Footrest

8) Side stand

9) Passenger’s footrest

Fig. 1

12

1) Tool kit/glove compartment

2) Fuel tap

3) Motor oil inlet hole plug/stick

4) Front brake fluid tank

5) Passenger’s footrest

6) Rear suspension spring-loading adjusting

nut

7) Footrest

8) Rear brake control lever

9) Rear brake fluid tank

Fig. 2

13

Fig. 3 Fig. 4

1) Left rear-view mirror

2) High beam signaller push button

3) Cold start lever (

)

4) Ignition switch

5) Instruments and indicators

6) Engine stop switch (

- )

7) Right rear-view mirror

8) Clutch control lever

9) Headlight switch (

- )

10) Horn push button (

)

11) Turn indicator switch (

)

12) Light switchi ( - - •)

13) Starting push button (

)

14) Throttle grip

15) Front brake lever

1) Coolant temperature indicator (

)

2) Speedometer

3) Total kilometres odometer

4) Trip odometer control knob

5) Trip odometer

6) High beam warning light (

)

7) Neutral indicator warning light (

)

8) Low motor oil pressure warning light ( )

9) Turn indicator warning ligh (

)

Remember:

1 mi = 1,6 km

1 km = 0,625 mi

14

DESCRIPTION FUNCTION

Revolution counter It indicates the number of engine revolutions per minute.

Speedometer It indicates the driving speed.

Total kilometres odometer It indicates the total number of kilometres covered.

Trip odometer It indicates the partial number of kilometres covered.

Trip odometer control knob By rotating it clockwise, it is possible to set the trip odometer to zero.

High beam warning light

It comes on when the headlight is in "high beam" position.

Idle indicator warning light

It comes on when the transmission is in neutral.

Turn indicator warning light

It blinks when one of the turn indicators is on.

Low motor oil pressure warning light

It comes on every time the key is turned to the "

ON

" position and the engine isn’t running, checking

the proper functioning of the lamp.

If during this phase the lamp doesn’t turn on, it must be replaced.

The warning light must go out when the engine starts running, exception made for the cases in which

the engine is hot and is nearly idling.

If the warning light turns on during the normal running of the engine, this means that the

oil pressure in the circuit is below the usual operating value. In this case, provide for

immediate topping up.

Coolant temperature indicator

It indicates the coolant temperature.

15

The electrical parts work only when the ignition key

is on the "ON" position.

1) HEADLIGHT SWITCH (

- )

When the light switch, see p. 17 (CONTROLS ON THE

RIGHT SIDE OF THE HANDLEBAR) is on the "

", posi-

tion, if the headlight switch is on the "

" position, the high

beam comes on, while if it is on the "

" position, the low

beam comes on.

2) COLD START LEVER (

)

The starter for the engine cold start is operated by rotating

the cold start lever downwards. To disconnect the starter, it is

necessary to rotate the lever completely upwards.

3) HIGH BEAM SIGNALLER PUSH BUTTON

This push button makes it possible to use the high beam sig-

naller, which is useful to send signals to the forthcoming ve-

hicles when passing and in case of danger or emergency.

4) TURN INDICATOR SWITCH (

)

To indicate the turn to the left, move the switch to the left; to

indicate the turn to the right, move the switch to the right.

To turn off the turn indicator, press the switch.

5) HORN PUSH BUTTON (

)

The horn is operated when the "

" push button is pressed

with the ignition key on the "ON" position.

Fig. 5

16

The electrical parts work only when the ignition key

is on the "ON" position.

1) ENGINE STOP SWITCH (

- )

It mainly serves as a safety or emergency switch.

When the switch is on the "

" position, it is possible to start

the engine; the engine is stopped by moving the switch to the

"

" position.

2) STARTING PUSH BUTTON (

)

When the starting push button is pressed, the starter makes

the engine run. For the starting, see p. 28 (STARTING).

3) LIGHT SWITCH (

- - •)

When the switch is on the " • " position, the headlights are

off; when the switch is on the "

" position, the parking

lights are on; when the switch is on the "

" position, the

low beams are on.

It is possible to turn on the high beams by means of the

headlight switch, see p. 16 (CONTROLS ON THE LEFT

SIDE OF THE HANDLEBAR).

Fig. 6

17

Fig. 7

The ignition switch (1) is positioned on

the steering tube plate.

The key operates the ignition

switch/steering lock and opens

the tool kit/glove compartment,

the fuel tank plug and the crash helmet

hook.

Two keys are supplied together with the

vehicle (one spare key).

To lock the steering, turn the handlebar

leftwards completely with the key on the

"

OFF

" position, press the key, release it

and turn it to the "

LOCK

" position.

Extract the key.

Never turn the key to the "LOCK"

position while driving, in order to

avoid losing control of the ve-

hicle.

POSITION FUNCTION

KEY

REMOVAL

LOCK

Steering lock

The steering is

locked.

It is neither

possible to

start the

engine, nor to

switch on the

lights.

It is possible to

remove the

key.

OFF

Neither the

engine, nor the

lights can be

switched on.

It is possible to

remove the

key.

ON

The engine

and the lights

can be

switched on.

It isn’t possible

to remove the

key.

To reach the tool kit, introduce the igni-

tion key in the lock of the tool kit/glove

compartment and turn it anticlockwise.

The tool kit (1) includes:

no. 1 tool case

no. 1 4 mm hexagon spanner

no. 1 5 mm hexagon spanner

no. 1 6 mm hexagon spanner

no. 1 8 mm hexagon spanner

no. 1 5.5/6.2 mm double-ended spanner

no. 1 8/11 mm double-ended spanner

no. 1 10/13 mm double-ended spanner

no. 1 17 mm non-adjustable spanner

no. 1 22 mm hexagon spanner with handle

no. 1 extension for spanner with handle

no. 1 25 mm spark plug spanner

no. 1 screwdriver for cross-slotted screws

Fig. 8

18

Do not drive with your helmet

hanging from the hook, as this

could compromise your safety

while driving.

Thanks to this hook, you no longer have

to carry the crash helmet with yourself

every time you park the vehicle.

To hang the crash helmet, introduce the

key in the lock (1), rotate it anticlockwise

and pass the special looped wire through

the hook (2).

Close the hook and rotate the key clock-

wise.

Make sure that the hook has been

properly closed.

Fig. 9

During refuelling, avoid pushing

the gun (1) to the buttom of the

tank, in order to prevent fuel

from flowing out of the filler.

Screw the plug up carefully after re-

fuelling.

The fuel used for internal combustion

engines is extremely inflammable and

in particular conditions it can become

explosive.

It is important to carry out the refuelling

and the maintenance operations in a

well-ventilated area, with the engine off.

Do not smoke while refuelling or near

fuel vapours, in any case avoid any con-

tact with free flames, sparks and any

other heat source to prevent the fuel

from catching fire or from exploding.

Further, prevent fuel from flowing out

of the fuel filler, as it could catch fire

when getting in contact with the red-hot

surfaces of the engine.

In case some fuel has accidentally been

spilt, make sure that the area has com-

pletely dried and before starting the ve-

hicle verify that there is no fuel inside

the fuel filler neck.

Avoid any contact of the fuel with the

skin and the inhalation of vapours; do

not swallow fuel or pour it from a recep-

tacle into another by means of a tube.

KEEP AWAY FROM CHILDREN

Fig. 10

Since unleaded petrol expands

under the heat of the sun and

due to the effects of sun radia-

tion, never fill the tank to the brim.

Use only unleaded petrol, in conformity

with the DIN 51607 standard, min. O.N.

95 (N.O.R.M.) and 85 (N.O.M.M.).

The fuel tank capacity is approximately

16

, about 2,5 of which make up the

reserve. To unlock the tank plug, insert

the ignition key in the lock and turn it

clockwise (Fig. 10).

19

It is necessary to change the engine oil

after the first 1000 km and afterwards

every 6000 km, see p. 37 (CHANGING

THE ENGINE OIL AND THE OIL FIL-

TER); to check the oil level, see p. 36

(CHECKING THE ENGINE OIL LEVEL

AND TOPPING UP).

Remember:

1 mi = 1,6 km

1 km = 0,625 mi

Oil can cause severe damages

to the skin if handled every

day and for long. Wash your

hands carefully after using it.

If the vehicle is used in very

dusty areas, the oil should be

changed more frequently.

Do not dispose of oil in the environ-

ment. Put it in a sealed container and

take it to the filling station where you

usually buy it.

aprilia recommends:

see p. 59 (LUBRICANT CHART).

Sudden play variations or elastic

resistance on the brake lever are

due to troubles in the hydraulic

system. For any doubt regarding the

perfect functioning of the braking sys-

tem and in case you are not able to

carry out the usual checking operation-

s, contact your Official Dealer.

Make sure that the brake disc and the

friction surface are neither oily nor

greasy, especially after maintenance or

checking operations.

Check that the brake cables are neither

twisted nor worn out.

Prevent water or dust from accidentally

getting into the circuit.

If the brake fluid gets in contact with

the skin or the eyes, it can cause

serious irritations.

Carefully wash the parts of your body

that get in contact with the liquid.

Consult a doctor or an oculist if the liq-

uid gets in contact with your eyes.

Do not dispose of brake fluid in the en-

vironment.

KEEP AWAY FROM CHILDREN

When using the brake fluid, take

care not to spill it on the plastic

or painted parts, since it can

damage them.

20

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