Aprilia ETV MILLE CAPONORD ABS User Manual 2003

ETV mille Caponord - ETV mille Caponord ABS

use+maintenance book

aprilia part# 8104780

© 2003 aprilia s.p.a. - Noale (VE)

First edition: september 2003 Reprint:

Produced and printed by:

DECA s.r.l.

Via Risorgimento, 23/1 - Lugo (RA) - Italia Tel. +39 - 0545 35235

Fax +39 - 0545 32844 E-mail: [e-mail] www.decaweb.it

On behalf of: aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39 - (0)41 58 29 111

Fax +39 - (0)41 44 10 54 www.aprilia.com

FOREWORD

NOTE This manual is an important and integral part of your vehicle. Keep it with your vehicle at all times, even if your vehicle is resold.

aprilia has prepared this manual to supply

you, the user, with correct and current information. However, since aprilia con-

stantly improves the design of its vehicles, there may be slight discrepancies between your vehicle and the material given in this

manual. If you have any questions about your vehicle, contact your Local aprilia

Dealer, as he will have the very latest technical information available from the factory.

For tests and repairs not expressly described in this manual, to purchase aprilia

genuine spare parts, accessories, and oth-

er products, and for help with specific problems, please contact your Local aprilia

Dealer or service center. These professionals will be able to promptly and accurately help.

Thank you for choosing aprilia. Have a great ride!

This manual is copyright in all countries, and reproduction of any part or the complete by any means in print or electronic is strictly prohibited.

INTRODUCTION

This manual is divided into sections, chapters and paragraphs, by subject. The procedures described are laid out in single operation, and each operation is indicated by a .

The numbered parts shown in the figures are identified in the text with the number in parentheses or with the symbol representing them.

Example (the following text is generic and does not refer to this specific vehicle):

section

MAIN INDEPENDENT CONTROLS

chapter

STEERING LOCK

safety warning

paragraph

operation

position (2)

symbol ≈+∆

WARNING

Never attempt to place the ignition switch in the locked “+” (LOCK) position while the vehicle is moving.

OPERATION

To lock the steering:

Turn the handlebar completely to the left or to the right.

Turn the key (2) to position ≈ ∆.

Press the key and turn it to position ≈+∆.

Remove the key.

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SAFETY WARNINGS

The following precautionary warnings are used throughout this manual in order to convey the following messages:

Safety Warning. When you see this symbol on the vehicle or in the

manual, pay particular attention to the potential risk of personal injury or death. Non-compliance with the instructions given in the warning messages preceded by this symbol may result in grave risk for your and other people’s safety and for the vehicle.

WARNING

Indicates a potential hazard which may result in serious injury or even death.

CAUTION

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 instructions.

GENERAL SAFETY RULES

CARBON MONOXIDE

If it is necessary to run the engine in order to carry out maintenance operation, make

sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces.

If it is necessary to work indoors, use an exhaust evacuation system.

WARNING

The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and even death.

WARNING

Carbon monoxide is both colorless and odorless, and cannot be detected by smell, vision, or any other sense. Avoid breathing exhaust fumes under any circumstances.

GASOLINE

Keep gasoline away from children. Gasoline is also poisonous. Never attempt to siphon gasoline using your mouth. Never allow gasoline to contact your skin. If you should accidentally spill gasoline on yourself, change your clothes immediately and wash the area upon which the gasoline was splashed thoroughly with hot water and soap. Should you accidentally swallow gasoline, do not induce vomiting. Drink large quantities of clear water or milk and immediately seek professional medical assistance. Should you accidentally get gasoline get your eyes, flush with large quantities of cool, clear water and immediately seek professional medical assistance.

WARNING

Gasoline is extremely flammable and becomes explosive under certain conditions.

KEEP GASOLINE AWAY FROM CHILDREN.

HOT COMPONENTS

WARNING

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 engine are stopped. Before handling any component of your vehicle after riding, insure that it has cooled sufficiently to be safe to handle.

USED ENGINE OIL

WARNING

Use latex gloves for the maintenance operations that require contact with used oil. Used engine oil may cause skin cancer 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.

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3

BRAKE FLUID

CAUTION

Brake fluid is extremely poisonous. Do not ever allow brake fluid to be ingested or swallowed. Should brake fluid accidentally be swallowed, drink large quantities of milk or clear water and immediately 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 medical assistance. Should you accidentally splash brake fluid into your eyes, flush with a large quantity of cool, clear water and immediately seek professional medical assistance.

KEEP BRAKE FLUID AWAY FROM CHILDREN.

CLUTCH FLUID

CAUTION

Clutch fluid is extremely poisonous. Do not ever allow clutch fluid to be ingested or swallowed. Should clutch fluid accidentally be swallowed, drink large quantities of milk or clear water and immediately seek professional medical assistance. clutch fluid is highly destructive of skin and eye tissue. Should you accidentally spill clutch 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 clutch fluid into your eyes, flush with a large quantity of cool, clear water and immediately seek professional medical assistance.

KEEP CLUTCH FLUID AWAY FROM CHILDREN.

COOLANT

In certain conditions, the ethylene glycol contained in the engine coolant is flammable: its flame is invisible, but you can be burned anyway.

WARNING

Avoid spilling the engine coolant on the exhaust system or on the engine components. 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 swallowed.

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 COOLANT AWAY FROM CHILDREN.

Risk of burns.

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.

BATTERY HYDROGEN GAS AND ELECTROLYTE

WARNING

The battery gives off noxious and explosive gases; keep cigarettes, flames and sparks away from the battery. Provide adequate ventilation when operating or recharging the battery.

During recharging and 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, especially when filling the battery with either water or electrolyte.

In case of contact with the skin, flush immediately with plenty of water. In case of contact with the eyes, flush with plenty of water for at least 15 minutes. Immediately consult a health professional.

The electrolyte is poisonous.

If the electrolyte is accidentally swallowed, drink large quantities of water or milk and then milk of magnesia or vegetable oil. Immediately consult a health professional.

KEEP BATTERIES AND ELECTROLYTE AWAY FROM CHILDREN.

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WARNINGS - PRECAUTIONS - GENERAL ADVICE

Before starting the engine, carefully read this manual and in particular the chapters ≈WARNINGS - PRECAUTIONS - GENERAL ADVICE∆ and ≈SAFE DRIVE∆ see p. 17.

Your safety and that of those around you depends not only on your skill as a rider, but also your knowledge about your vehicle and about riding safely. Therefore it is essential that you not operate your vehicle on public streets or highways until you have received instructions from a qualified safety organization such as the Motorcycle Safety Foundation, and are properly trained and licensed.

REPORTING OF DEFECTS THAT AFFECT SAFETY

If you believe that your vehicle has a defect which could cause a crash or could cause

injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying aprilia. If NHTSA receives similar

complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA can-

not become involved in individual problems between you, your dealer, or aprilia. To

contact NHTSA, you may 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. Department of Transportation, Washington, D.C. 20590.

You can also obtain other information about motor vehicle safety from the Hotline.

ROAD REGULATIONS

AND USE OF THE VEHICLE

Rules of the road vary from country to country. It is essential that you understand in advance the rules of the road of the country in which your vehicle will be used.

WARNING

This vehicle has been designed and produced for use on paved roads, and for smooth graded dirt roads and trails. It is not designed to be used on even smooth graded dirt roads, or trails. It is not designed for off road competition, or for cross country riding. Do not use this vehicle on rough or unimproved surfaces, or in other off road areas. Failure to heed this warning could lead to an upset with subsequent injury and even death.

WARNING

If the bike is to be used off-road, on public land, it is the owner’s responsibility to install a spark arrester approved by the US Forest Service for this engine displacement or larger.

NOISE EMISSION WARRANTY

aprilia s.p.a. warrants that this exhaust system, at the time of sale, meets all applicable U.S. EPA Federal noise standards. This warranty extends to the first person who buys this exhaust system for purposes other than resale, and to all subsequent buyers.

Warranty claims should be directed to: aprilia USA Inc.

109 Smoke Hill Lane, Suite 190 Woodstock, GA 30188

USA
Tel	001 770 592 2261
Fax	001 770 592 4878

INFORMATION ON THE NOISE AND EXHAUST GAS EMISSION CONTROL SYSTEM

ORIGIN OF THE EMISSIONS

The combustion process produces carbon monoxide and hydrocarbons. The control of hydrocarbons is very important, because under certain conditions they react to exposure to sunlight and produce photochemical smog.

Carbon monoxide does not react in the same way, but it is toxic and poisonous. aprilia utilizes ≈lean∆ carburetor settings and other systems to reduce the production of carbon monoxide and hydrocarbons.

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5

TAMPERING WARNING

Tampering with the noise control system is prohibited. Federal law prohibits the following acts or causing thereof:

a)The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery 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 by any person.

Among those acts presumed to constitute tampering are the acts listed below:

a)Removal of, or puncturing the muffler, baffles, header pipes or any other component which conducts exhaust gases.

b)Removal or puncturing of any part of the intake system.

c)Lack of proper maintenance.

d)Replacing any moving part of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.

CAUTION

This product should be checked for repair or replacement if the vehicle noise has increased significantly through use. Otherwise, the owner may become subject to penalties under state and local ordinances.

PROBLEMS THAT MAY AFFECT THE VEHICLE EMISSIONS

If any of the following symptoms are ob-

served, immediately have your vehicle inspected and repaired by your Local aprilia

Dealer.

Symptoms:

√Difficult starting or stalling after starting.

√Irregular idle.

√Misfiring or backfiring during acceleration.

√After-burning (backfiring).

√Poor engine performance, degraded handling, or poor fuel economy.

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

(FRAME NUMBER)

Every vehicle produced by aprilia receives a vehicle identification number (V.I.N.) stamped:

√ on the steering head of the frame (A), as shown above;

and also:

√ on the identification plate (B) which is located on the front portion near the steering head of the frame.

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INFORMATION CONTAINED IN THE VEHICLE IDENTIFICATION NUMBER

Description of the vehicle identification number (V.I.N.), stamped on the steering head of the frame (A) and on the identification plate (B).

DIGIT MEANING

1)Manufacturer»s identification alphanumeric code.

2)Vehicle type.

3)Model.

4)Country for which the vehicle is intended.

5)#= Check digit number.

6)Model year.

7)Assembling factory designation (N = NOALE-VE- ,

S = SCORZÉ -VE- ,

0 = NOT SPECIFIED).

8)Sequential serial number.

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7

POSITION OF THE WARNING ADHESIVE LABELS

	II
III
III
II
I
I
II
I
I
I
I
I		III
II
	IIII IIIII

III

I

I

IIIIII
I
I
I
I
I
	I
	I
	I
	I
	I
	I
III	II
IIIIIII

8

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WARNING ADHESIVE LABELS CHART
Ref.	Description
1
2
3

Ref. Description

4 Muffler stamping.

5

Follow X

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9

Follow X

Ref. Description

6

7

Ref. Description

8

9

Follow X

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Follow X

Ref. Description

10

11

12

Ref. Description

13

14

15

Follow X

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Follow X																			EVAPORATIVE EMISSION SYSTEM
Ref.						Description
																			The system consists of:
																			1)	Fuel tank.
																			2)	Water drain line.
																			3)	Fuel tank breather nipple.
16																			4)	Breather line (to tee).
																			5)	Roll-over valve.
																			6)	Breather line (to purge valve).
																			7)	Purge valve (to carbon canister).
																			8)	Breather line (to carbon canister).
																			9)	Carbon canister.
																			10)	Drain line (to electric purge valve).
																			11)	Electric purge valve (from carbon canister).
																			12)	Drain line (from electric purge valve).
																			13)	≈T∆ tee.
																			14)	≈T∆ tee.
																			15)	≈X∆ tee.
17																			16)	Drain line (to manifold vacuum port).
																			17)	Manifold vacuum port (on rear part of throttle body).
																			18)	Throttle body.
																			19)	Vacuum line (from purge valve).
																			20)	≈T∆ tee.
																			21)	Vacuum line (to ported vacuum port).
																			22)	Ported vacuum port (front part of throttle body).
																			23)	Air box.
																			24)	Warm air inlet fitting (from air box).
																			25)	≈T∆ tee.
18																			26)	Warm air inlet (from air box).
																			27)	≈Y∆ tee.
																			28)	Warm air inlet (to carbon canister).
																			29)	Warm air inlet (to one way valve).
																			30)	One way valve.
																			31)	Warm air inlet (from one way valve).
																			32)	Water or other contaminant drain line.
																			33)	Front cylinder ≈1∆ synchronization line.
																			34)	Rear cylinder ≈2∆ synchronization line.
																			35)	Plug.
																			36)	To power clutch (from manifold vacuum port).
																			37)	To power clutch (from ported vacuum port).
																			38)	Vacuum line(from ≈T∆ tee).

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NOTE In case of malfunction of the fuel system, contact your Local aprilia Dealer.

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aprilia s.p.a. - EMISSION CONTROL SYSTEM WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and aprilia s.p.a. (hereinafter ≈aprilia∆) are

pleased to explain the emission control system warranty on your 1999 and later motorcycle. In California new motor vehicles must be designed, built and equipped

to meet the State's stringent anti-smog standards. aprilia must warrant the emis-

sion control system on your motorcycle for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your motorcycle.

Your emission control system may include parts such as the carburetor or fuel injection system, the ignition system, catalytic converter and engine computer. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, aprilia will repair your motorcycle at no

cost to you, including diagnosis, parts and labor.

MANUFACTURER’S EMISSIONS SYSTEM WARRANTY COVERAGE

Class I motorcycles (50 √ 169 cm3): for a period of use of five (5) years or 12,000 kilometers (7,456 miles), whichever first occurs.

Class II motorcycles (170 √ 279 cm3): for a period of use of five (5) years or 18,000 kilometers (11,185 miles), whichever first occurs.

Class III motorcycles (280 cm3 and larger): for a period of use of five (5) years or 30,000 kilometers (18,641 miles), whichever first occurs.

If an emission-related part on your motor-

cycle is defective, the part will be repaired or replaced by aprilia. This is your emis-

sion control system DEFECTS WARRANTY.

OWNER'S WARRANTY RESPONSIBILITIES

√ As the motorcycle owner, you are responsible for the performance of the re-

quired maintenance listed in your owner's manual. aprilia recommends that

you retain all receipts covering maintenance on your motorcycle, but aprilia

cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

√ You are responsible for presenting your motorcycle to an aprilia dealer as soon

as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

√ As the motorcycle owner, you should be aware that aprilia may deny your war-

ranty coverage if your motorcycle or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

If you have any questions regarding your

warranty rights and responsibilities, you should contact aprilia USA, Inc., 10933

Crabapple Road, Suite 100, Roswell, GA 3007, or the California Air Resources Board at P.O. Box 8001, 9528 Telstar Av-

enue, El Monte, CA 91734-8001.

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aprilia s.p.a. - LIMITED WARRANTY ON EMISSION CONTROL SYSTEM

aprilia s.p.a., Via G. Galilei, 1, 30033 Noale (VE) Italy (hereinafter ≈aprilia∆) warrants that each new 1999 and after aprilia

motorcycle, that includes as standard equipment a headlight, taillight and stoplight, and is street legal:

A.is designed, built and equipped so as to conform at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board; and

B.is free from defects in material and workmanship which cause such motorcycle to fail to conform with applicable regulations of the United States Environmental Protection Agency or the California Air Resources Board for a period of use, depending on the engine displacement, of 12,000 kilometers (7,456 miles), if the motorcycle's engine displacement is less than 170 cubic centimeters; of 18,000 kilometers (11,185 miles), if the motorcycle's engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 30,000 kilometers (18,641 miles), if the motorcycle's engine displacement is 280 cubic centimeters or greater; or 5 (five) years from the date of initial retail delivery, whichever first occurs.

I.COVERAGE. Warranty defects shall be

remedied during customary business hours at any authorized aprilia motorcycle dealer located within the United States of America in compliance with the Clean Air Act and applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Any part or parts

replaced under this warranty shall become the property of aprilia.

In the State of California only, emission related warranted parts are specifically defined by the state's Emission Warranty Parts List. These warranted parts are: carburetor and internal parts; intake manifold; fuel tank; fuel injection system; spark advance mechanism; crankcase breather; air cutoff valves; fuel tank cap for evaporative emission controlled vehicles; oil filler cap; pressure control valve; fuel/vapor separator; canister; igniters; breaker governors; ignition coils; ignition wires; ignition points; condensers, and spark plugs if failure occurs prior to the first scheduled replacement; and hoses, clamps, fittings and tubing used directly in these parts. Since emission related parts may vary from model to model, certain models may not contain all of these parts and certain models may contain functionally equivalent parts.

In the State of California only, Emission Control System emergency repairs, as provided for in the California Adminis-

trative Code, may be performed by other than an authorized aprilia dealer. An

emergency situation occurs when an authorized aprilia dealer is not reason-

ably available, a part is not available within 30 days, or a repair is not complete within 30 days. Any replacement

part can be used in an emergency repair. 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 warranty repair and the geographically appropriate hourly labor rate. The owner may be required to keep receipts and failed parts in order to receive compensation.

II.LIMITATIONS. This Emission Control System warranty shall not cover any of the following:

A. Repair or replacement required as a result of

(1)accident,

(2)misuse,

(3)repairs improperly performed or replacements improperly installed,

(4)use of replacement parts or accessories not conforming to aprilia specifi-

cations which adversely affect performance and/or

(5) use in competitive racing or related events.

use and maintenance ETV mille Caponord ABS R 15

B.Inspections, replacement of parts and other services and adjustments required for required maintenance.

C.Any motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined.

III. LIMITED LIABILITY

A. The liability of aprilia under this Emission Control System Warranty is limited solely to the remedying of defects in

material or workmanship by an authorized aprilia motorcycle dealer at its

place of business during customary business hours. This warranty does not cover inconvenience or loss of use of

the motorcycle or transportation of the motorcycle to or from the aprilia dealer. aprilia SHALL NOT BE LIABLE FOR

ANY OTHER EXPENSES, LOSS OR DAMAGE, WHETHER DIRECT, INCIDENTAL, CONSEQUENTIAL OR EXEMPLARY ARISING IN CONNECTION

WITH THE SALE OR USE OF OR INABILITY TO USE THE aprilia MOTOR-

CYCLE FOR ANY PURPOSE. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATIONS 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 IMPLIED BY LAW, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM 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 modify this aprilia Limited Emission Control System Warranty.

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 aprilia LIMITED MOTORCYCLE WARRANTY.

VI. ADDITIONAL INFORMATION. Any replacement part that is equivalent in performance and durability may be used in

the performance of any maintenance or repairs. However, aprilia is not liable for

these parts. The owner is responsible for the performance of all required maintenance. Such maintenance may be performed at a service establishment or by any individual. The warranty period begins on the date the motorcycle is delivered to an ultimate purchases.

aprilia s.p.a.

Via G. Galilei, 1 30033 Noale (VE) Italy

aprilia USA, Inc.

109 Smoke Hill Lane, Suite 190 Woodstock, GA 30188

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GENERAL INSTRUCTIONS

The operations preceded by this

symbol must be repeated also on the opposite side of the vehicle.

If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.

The terms ≈right∆ and ≈left∆ are referred to the rider seated on the vehicle in the normal riding position.

	NOTE Keep a stock of one bulb per type	In this manual the various versions are in-
	with the vehicle, see p. 154 (TECHNICAL	dicated by the following symbols:
	DATA).	L catalytic version
	NOTE Soon after purchasing the vehi-
		J optional
	cle, write down the identification data pro-	VERSION:
	vided in the SPARE PARTS IDENTIFICA-
		+ Italy	2 Singapore
	TION LABEL in the table below. This label
	is positioned on the left part of rider saddle	4 United Kingdom	P Slovenia
	support; to be able to read it, remove the	> Austria	F Israel
	rider saddle, see p. 128 (REMOVING THE	M Portugal	e South Korea
	RIDER SADDLE).
		( Finland	- Malaysia
		$ Belgium	@ Chile
		A Germany	* Croatia
		C France	# Australia
		' Spain	R United States
			of America
		) Greece	g Brazil
		/ Holland	1 South Africa
		6 Switzerland	K New Zealand
	These data indicate:	& Denmark	% Canada
		, Japan
	√ YEAR = year of manufacture (Y, 1, 2, º);
	√ I.M. = modification code (A, B, C, º);
	√ COUNTRY CODE = country of homolo-
	gation (I, UK, A, º).

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 you have acquired.

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TABLE OF CONTENTS
FOREWORD ................................................................	2
INTRODUCTION..........................................................	2
STEERING LOCK.................................................	2
SAFETY WARNINGS..................................................	3
GENERAL SAFETY RULES ......................................	3
CARBON MONOXIDE ..........................................	3
GASOLINE............................................................	3
HOT COMPONENTS............................................	3
USED ENGINE OIL ..............................................	3
BRAKE FLUID ......................................................	4
CLUTCH 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) ..............................................	6
INFORMATION CONTAINED
IN THE VEHICLE
IDENTIFICATION NUMBER.................................	7
POSITION OF THE WARNING ADHESIVE
LABELS ................................................................	8
WARNING ADHESIVE LABELS CHART .............	9
EVAPORATIVE EMISSION SYSTEM ................	12
aprilia s.p.a. - EMISSION
CONTROL SYSTEM
WARRANTY STATEMENT.................................	14
aprilia s.p.a. - LIMITED
WARRANTY ON EMISSION
CONTROL SYSTEM...........................................	15
GENERAL INSTRUCTIONS.....................................	17
TABLE OF CONTENTS......................................	18
BASIC SAFETY RULES .....................................	22
CLOTHING .........................................................	27
ACCESSORIES ..................................................	28
LOAD ..................................................................	28

ARRANGEMENT OF THE MAIN ELEMENTS.......	30
ARRANGEMENT OF THE INSTRUMENTS/
CONTROLS................................................................	32
INSTRUMENTS AND INDICATORS.......................	33
INSTRUMENTS AND INDICATORS TABLE .....	34
SETTING PUSH BUTTONS ..............................	38
CONTROLS................................................................	40
CONTROLS AT THE LEFT HAND GRIP...........	40
CONTROLS AT THE RIGHT HAND GRIP ........	40
IGNITION SWITCH ............................................	42
STEERING LOCK ..............................................	43
PARKING LIGHTS .............................................	44
AUXILIARY EQUIPMENT.........................................	44
UNLOCKING/LOCKING
THE PASSENGER SADDLE .............................	44
REMOVING THE GLOVE/TOOL KIT
COMPARTMENT COVER .................................	44
LARGER SURFACE FOR LUGGAGE...............	45
LOCKING/UNLOCKING THE GLOVE/TOOL KIT
COMPARTMENT COVER .................................	45
GLOVE/TOOL KIT COMPARTMENT ................	46
SPECIAL TOOLS J........................................	46
ACCESSORIES .................................................	47
OUTLET .............................................................	47
MAIN COMPONENTS...............................................	48
FUEL ..................................................................	48
LUBRICANTS ....................................................	50
BRAKES.............................................................	51
DISC BRAKES ...................................................	52
FRONT BRAKE..................................................	53
REAR BRAKE ....................................................	56
ABS ....................................................................	58
CLUTCH.............................................................	60
ADJUSTING THE CLUTCH LEVER ..................	64
ADJUSTING
THE FRONT BRAKE LEVER.............................	64
ADJUSTING THE SHIFT LEVER ......................	64
ADJUSTING THE CLEARANCE
OF THE REAR BRAKE PEDAL .........................	65
COOLANT..........................................................	66
TIRES.................................................................	68
WHEEL SPOKES TENSION..............................	69
EXHAUST SILENCER .......................................	70
CATALYTIC CONVERTER L.........................	70
SPARK ARRESTER ..........................................	70
INSTRUCTIONS FOR USE ......................................	71
GETTING ON AND OFF THE VEHICLE ...........	71
PRELIMINARY CHECKING OPERATIONS ......	73

PRELIMINARY CHECKING OPERATIONS
CHART ...............................................................	74
STARTING .........................................................	75
RIDING...............................................................	78
RUNNING-IN......................................................	81
STOPPING.........................................................	82
PARKING ...........................................................	83
PLACING THE VEHICLE
ON THE STAND.................................................	85
SUGGESTIONS
TO PREVENT THEFT........................................	87
MAINTENANCE.........................................................	87
REGULAR SERVICE INTERVALS CHART.......	89
MAINTENANCE RECORD.................................	91
IDENTIFICATION DATA ....................................	95
JOINTS WITH CLICK CLAMPS AND WITH
SCREW-TYPE CLAMPS....................................	95
AIR CLEANER ...................................................	96
CHECKING THE ENGINE OIL LEVEL AND
TOPPING UP .....................................................	99
CHECKING THE STAND .................................	101
CHECKING THE AIR TEMPERATURE
SENSOR ..........................................................	102
CHECKING THE FUNCTIONING
OF THE SAFETY SWITCH
ON THE SIDE STAND .....................................	103
CHECKING THE SWITCHES ..........................	105
INSPECTING THE FRONT
AND REAR SUSPENSIONS............................	106
FRONT SUSPENSION ....................................	107
REAR SUSPENSION.......................................	108
CHECKING THE BRAKE PAD WEAR.............	111
CHECKING THE STEERING...........................	112
CHECKING THE SWINGING ARM PIVOT......	112
PLACING THE VEHICLE ON THE FRONT
SUPPORT STAND J....................................	113
FRONT WHEEL ...............................................	114
REAR WHEEL..................................................	119
DRIVE CHAIN ..................................................	123
REMOVING THE FUEL TANK.........................	128
REMOVING THE SIDE FAIRINGS ..................	130
REMOVING THE OIL PAN GUARD ................	131
REMOVING
THE FRONT BRAKE CALIPERS.....................	132
REMOVING THE RIDER SADDLE ..................	134
REAR-VIEW MIRRORS ...................................	135
ADJUSTING THE THROTTLE CONTROL ......	137
ADJUSTING THE COLD START (CHOKE)
CONTROL........................................................	138

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IDLE ADJUSTMENT ........................................	139
SPARK PLUGS................................................	139
CHANGING FUSES.........................................	142
REMOVING THE FUSE BOX COVER ............	145
BATTERY.........................................................	145
BATTERY STORAGE ......................................	146
CHECKING AND CLEANING
THE TERMINALS ............................................	147
REMOVING THE BATTERY............................	147
CHECKING
THE ELECTROLYTE LEVEL...........................	147
RECHARGING THE BATTERY .......................	148
INSTALLING THE BATTERY ..........................	148
HEADLIGHT BEAM .........................................	150
BULBS .............................................................	154
CHANGING THE DASHBOARD BULBS .........	154
CHANGING
THE HEADLIGHT BULBS................................	155
CHANGING THE FRONT DIRECTION
INDICATOR BULBS.........................................	158
CHANGING
THE REAR LIGHT BULBS...............................	165
CHANGING THE REAR DIRECTION
INDICATOR BULBS.........................................	166
CHANGING
THE LICENSE PLATE BULB...........................	166
TRANSPORT ...........................................................	166
DRAINING THE FUEL TANK...........................	166
CLEANING...............................................................	166
LONG PERIODS OF INACTIVITY ...................	166
TECHNICAL DATA .................................................	166
LUBRICANT CHART .......................................	166
Official Dealers and Service Centers ...............	166
Importers ..........................................................	166
Importers ..........................................................	166
Importers ..........................................................	166
Importers ..........................................................	166
WIRING DIAGRAM ETV mille Caponord
ABS R............................................................	166
WIRING DIAGRAM KEY ETV mille Caponord
ABS R............................................................	166

use and maintenance ETV mille Caponord ABS R 19

NOTE

ASK FOR GENUINE SPARE PARTS ONLY

20 use and maintenance ETV mille Caponord ABS R

safe drive

BASIC SAFETY RULES

The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your vehicle.

Two wheeled vehicles obviously do not provide some of the protection provided by automobiles, therefore it is essential that you wear appropriate protective clothing. Especially, never operate your vehicle without wearing your helmet, gloves, eye protection, a heavy jacket, sturdy footwear, and sturdy full length pants.

However, do not assume that even the best clothing and helmet will protect you in the event of an upset or a crash with another vehicle. At best, this gear provides some protection from scrapes and scratches, but very little, if any, impact protection.

Be sure that you meet all the requirements prescribed by local law, including driver»s license, minimum age, training, insurance, taxes, vehicle registration, license plate, etc.

When you first receive your vehicle, practice by riding in areas where there is little traffic. Do not attempt to ride in heavy traffic until you are thoroughly experienced and riding your vehicle has become second nature to you.

Although this vehicle is legal for operation on freeways and expressways, it is advis-

able to not ride on these high speed highways until you are thoroughly familiar with your vehicle, and have attained a high degree of skill in its operation.

A new vehicle must be carefully broken in, see p. 81 (RUNNING-IN).

Before starting the engine, make sure that the brakes, clutch, transmission and throttle controls function properly and that the fuel and oil supply is adequate.

The exhaust system, brakes, and some other parts of the vehicle become very hot during operation. Do not touch any of these parts.

Some medicines or drugs, illegal or prescription, and alcohol significantly increase the risk of accidents. Do not ride while you are under the influence of alcohol or drugs, be they illicit or prescription. Make sure you are in good physical condition and not ill

before riding your vehicle. Do not ride your vehicle when you are particularly tired or fatigued. Alcohol, drugs and fatigue are leading causes of vehicle accidents.

Many accidents are caused by the rider»s inexperience and lack of training. Do not ride your vehicle until you have received training from a recognized training organization such as the Motorcycle Safety Foundation. Remember that riding a two wheeled vehicle, though easy and fun, is quite different from driving a car. Do not assume that you can operate your vehicle safely just because you are a competent automobile driver.

Never lend your vehicle to others unless you are sure that they are competent and properly licensed vehicle operators.

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Observe all rules of the road. Particularly pay attention to all warning, regulatory and informational signs.

Avoid showing off (i.e., popping wheelies). Especially observe speed limits, remember that road conditions change with the weather and wet and icy pavements are particularly dangerous for vehicles, especially if you are riding too fast. Remember that automobile drivers have a hard time seeing two wheeled vehicles, so always give the automobile the right of way, even if it is legally yours.

Before changing lanes, look over your shoulder to make sure that the way is clear. Do not rely exclusively on the rearview mirror: you may miscalculate the distance and speed of a vehicle, or you may even not see it at all.

Avoid obstacles that could damage the vehicle or make you lose control.

Do not tailgate, do not attempt to increase your gas mileage by following in the slip stream of cars or trucks in front of you.

In case of accident motorcycles, scooters and mopeds do not provide the same degree of protection ensured by automobiles. The legs, in particular, are exposed the risk of being injured. However, the additional installation of leg guards may actually increase the risk of injuries and their seriousness in case of accident.

Do not install leg guards available on the market of spare parts and accessories. Non-compliance with these instructions may result in serious injuries or even death.

Always ride with both hands on the handlebars 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 suddenly or abruptly. Such misuse can damage the internal components of the vehicle and consequently cause seizure, loss of control, accidents and serious injuries or even death.

Remain in the seat when you are riding. Do not stand up or attempt to stretch while you are riding your vehicle. If you need to rest, pull over to the side of the road when it can be safely done.

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COOLER

OIL

It is very important to your safety that you give full attention to the riding task. Watch what you are doing, do not allow yourself to be distracted by other cars, people or things on the roadside, etc. Never smoke, eat, drink, read, etc. while riding your vehicle. If you must consult a map, pull over when it can be done safely.

Use only the vehicle»s specific fuels and lubricants indicated in the ≈LUBRICANT CHART∆; check the oil, fuel and coolant levels regularly.

If the throttle sticks open, it may cause a collision with another vehicle, or an upset.

If the throttle sticks, kill the engine with the engine stop switch located on the right handlebar.

Do not attempt to restart the engine until the throttle has been repaired and works perfectly. Failure to obey this warning can

lead to a runaway with seriously injuries or even death.

Your vehicle is equipped with a double cable throttle. One cable opens the throttle when you rotate the throttle grip toward you; the other closes the throttle when you rotate the grip away from you. It is essential, when you release the throttle grip, that it automatically return to the idle position.

This double cable arrangement enhances safety by providing for positive closing of the throttle.

WARNING

In the event of a throttle sticking emergency, always kill the engine using the engine stop switch located near the throttle grip on the right handlebar. Never use your vehicle if the throttle does not automatically fully return to the idle position when the throttle grip is re-

leased. Contact your Local aprilia Dealer for repairs. Failure to heed this warning can lead to a serious accident and subsequent injury or even death.

If you and your vehicle are involved in an accident, insure that there has been no damage to the control levers, tubes, wires, braking system and other vital parts. If your

vehicle is involved in an accident, take it immediately to your Local aprilia Dealer

who has the equipment and knowledge to check for accidental damage which may compromise your safety.

Your aprilia dealer is ready and able to help you with any safety problems that you might have, but of course it is necessary for you to report any malfunctions to your mechanic in order for him to help you.

Do not use your vehicle if it is damaged. A damaged vehicle may become unstable or

24 use and maintenance ETV mille Caponord ABS R

ONLY ORIGINALS

A12 345

present other problems which can increase the risk of accident, and therefore of serious injury or even death.

Do not attempt to modify the position, angle or color of your license plate. Do not cover it with even a clear plastic covering. Do not modify any of the safety equipment of your vehicle, especially such safety related items as directional indicators, rear view mirrors, lights or horns.

Any modification to your vehicle will invalidate the warranty.

Do not modify your engine in an attempt to increase the horsepower. This can result in irreparable damage to the engine, as well as degradation of the performance and handling of the vehicle which could lead to an upset, and serious injury or even death.

Have your vehicle repaired only with original parts, and use only original aprilia or

aprilia approved accessories. The use of aftermarket accessories and parts can seriously compromise the safety of your vehicle as well as its performance and serviceability. Any modification which affects performance or safety voids your warranty completely.

Tampering with the emissions or noise control systems on your vehicle is against the law, and can be punished by large fines.

In some jurisdictions, it can even lead to the confiscation of your vehicle.

This vehicle was not designed to be equipped with a sidecar or to be used to tow trailers or other vehicles.

aprilia does not manufacture sidecars or trailers and therefore cannot predict the effects of such accessories on the manoeuvrability or stability of the vehicle: it can only warn that such effects may be negative and that any damage to the vehicle components caused by the use of such accessories will not be covered by the warranty.

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Never race other vehicles with your vehicle.

Brake with both the front and rear brakes. The use of one brake only for sudden braking may cause the vehicle to skid or make the rider lose control of the vehicle itself.

When riding down a steep hill, use the engine as a brake by selecting the same gear, or a lower gear, than you would use to climb the hill. Use front and rear brakes sparingly.

Always ride at the appropriate speed and avoid unnecessary hard acceleration. This not only is safer, but also reduces fuel consumption and increases the life of the vehicle.

If you must ride your vehicle in rainy weather, or on loose surfaces, remember that traction is greatly reduced. Under these conditions, all handling of the vehicle must be done gradually and smoothly. Sudden acceleration, braking or turning may make you lose control of your vehicle. When traction is reduced, accelerate and slow using your vehicle»s engine braking insofar as possible. Avoid rapid, harsh application of the brakes.

Gradually open and close the throttle, to avoid spinning or skidding the rear wheel.

On rough road surfaces, slow down and ride with particular care.

Try to avoid wide open throttle accelerations, unless they are necessary for such things as passing.

Don»t allow your engine to ≈lug,∆ that is, run at too low an rpm. Shift down to a lower gear. Also, don»t over-rev the engine. Observe the redline on the tachometer.

Remember that excessively aggressive cornering can cause your vehicle»s tires to lose sideways traction, which can result in an upset and serious injury or even death.

26 use and maintenance ETV mille Caponord ABS R

Always observe posted and statutory speed limits, but do not assume that you can ride as fast as the speed limit under all road conditions. Slowing down a little can greatly increase your safety under all road conditions.

Do not ride your vehicle off road.

Do not tamper with the muffler system or the emissions control system of your vehicle. This is not only bad for the environment, it can subject you to serious penalties.

CLOTHING

Before riding your vehicle, ensure that your riding gear is in good condition. To be effective, your helmet must fit properly, and the visor or other eye protection must be clean.

Both research and experience have shown that drivers of other vehicles often do not see vehicles or riders. In order to make yourself more conspicuous to these drivers, wear bright reflective clothing, such as a reflective vest, or clothing with reflective sections sewn into the jacket, pants and gloves. Be particular aware of approaching automobiles and trucks that might be trying to turn left in front of you. Many vehicle accidents are caused by an opposing automobile driver making a left turn without warning in front of the vehicle.

Inevitably, the driver will look right at you, and yet swear that they did not see you before they turned directly into your path. Ride alert!

Wear protective clothing, preferably in light and/or reflecting colours. In this way you will make yourself more visible to the other drivers, thus notably reducing the risk of being knocked down, and you will be more protected in case of fall.

Always wear your crash helmet. Many accidents are fatal because of injuries to the head.

This clothing should be very tight-fitting and fastened at the wrists and ankles. Strings, belts and ties should not be hanging loose; prevent these and other objects from interfering with driving by getting entangled with moving parts or driving mechanisms.

use and maintenance ETV mille Caponord ABS R 27

Do not carry sharp objects in your pockets that could be dangerous in case of an upset, for example, pens or mechanical pencils, etc. Also, make sure that your passengers follow this recommendation.

ACCESSORIES

The owner of the vehicle is responsible for the choice, installation and use of any accessory.

The installation of inappropriate accessories or the overloading of the vehicle may result in the instability of the vehicle itself and cause accidents with consequent risk of serious injuries or even death. Windshields could be particularly dangerous, as they can break and injure or cut the rider in case of accident. In case of doubts with regard to any accessory you would like to install or

any load you would like to carry, previously consult your Local aprilia Dealer.

Avoid installing accessories that cover horns or lights or that could impair their functions, limit the suspension stroke and the steering angle, hamper the operation of the controls and reduce the distance from the ground and the angle of inclination in turns.

Avoid using accessories that hamper access to the controls, since this can prolong reaction times during an emergency.

Fairings and windshields installed on the vehicle may produce aerodynamic forces that will affect the stability of the vehicle during use, especially at high speeds.

Make sure that anything you carry on your vehicle is securely attached, and cannot come lose and jam the wheels, forks, etc. Do not install any electrical accessories, and do not modify the electrical system of your vehicle. Anything that could cause an electrical overload or other fault could cause the vehicle to suddenly stop, the lights to

dim or quit, or the horn and other safety accessories not to work. Use only aprilia gen-

uine accessories.

LOAD

Do not overload your vehicle. Attach luggage or packages as close as possible to the center of your vehicle and distribute the load from side to side as evenly as possible, to keep imbalance to a minimum. Remember that loads tend to loosen with riding, so frequently check the security of your load.

28 use and maintenance ETV mille Caponord ABS R

KG!

Do not hang anything from your vehicle handlebars, fenders, or forks, because this will upset the handling of your vehicle, and could prevent you from avoiding an accident. Failure to heed this warning can lead to an upset with subsequent serious injury or even death.

Do not ride with your crash helmet hung from the strap because it could easily foul the wheels, fenders, or forks, causing an upset and subsequent serious injury or even death.

Carry a passenger only if your vehicle is equipped with passenger footrests, handgrips for the passenger to hold on to, and a passenger saddle.

When carrying a passenger, remember that your vehicle»s handling is degraded, that the brakes are less efficient, and the center of gravity is higher and further to the rear.

This makes it more likely that the front wheel will come up off the ground, especially on acceleration. Therefore, you should avoid hard acceleration and hard braking. Many accidents are caused by inexperienced riders carrying passengers. Remember that allowance must be made for the extra weight of the passenger for all driving maneuvers.

Avoid abrupt and excessive acceleration. Always slow down in time and calculate longer stopping and manoeuvring distances. Non-compliance with these instructions may lead to the overturning of the vehicle or to other accidents with consequent serious injuries or even death.

Never carry loosely packaged items, make sure that everything that you carry on your vehicle is carefully secured.

Do not carry packages which protrude from the luggage rack or which cover any of the signal lights, the headlight, or the horn.

Never carry animals or children on the glove compartment or on the luggage rack.

Never exceed the labeled maximum load for each saddlebag.

Overloading your vehicle seriously reduces its stability and maneuverability and can lead to an upset with subsequent serious injury or death.

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ARRANGEMENT OF THE MAIN ELEMENTS

KEY
1)	Headlight.		6)	Passenger saddle lock.	11)	Electronic Control Unit		16)	Side stand.
2)	Left rear-view mirror.		7)	Rider left footrest (spring		(ECU).		17)	Shift lever.
3)	Clutch fluid reservoir.			equipped,always extend-	12)	Rear fork.		18)	Engine oil filter.
4)	Ignition switch/steering			ed).	13)	Drive chain.		19)	Engine oil tank.
	lock/parking lights ( - -		8)	Rider saddle.	14)	Passenger left footrest (re-		20)	Engine oil level.
	- ).		9)	Battery.		tractable).		21)	Horn.
5)	Engine oil tank cap.		10)	Passenger saddle.	15)	Center stand J.		22)	Left fairing.

30 use and maintenance ETV mille Caponord ABS R