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 con­stantly 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 oth­er 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

chapter

safety
warning

paragraph

operation

position (2)

symbol ≈

MAIN INDEPENDENT CONTROLS

STEERING LOCK

WARNING

Never attempt to place the ignition
switch in the locked “
tion 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.

+” (LOCK) posi-

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SAFETY WARNINGS

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

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

Gasoline is extremely flammable and be­comes explosive under certain condi­tions.

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

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.

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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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-

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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.

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 can­not 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 1-800-424­9393 (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 [phone]
Fax [phone]

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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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 vehi-

cle, or parts of the exhaust or intake

system, with parts other than those

specified by the manufacturer.

PROBLEMS THAT MAY AFFECT
THE VEHICLE EMISSIONS

If any of the following symptoms are ob­served, 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 accelera-

tion.

√ 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 lo-

cated on the front portion near the steer­ing head of the frame.

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.

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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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POSITION OF THE WARNING ADHESIVE LABELS

II

I

I

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WARNING ADHESIVE LABELS CHART

Ref.

1

2

3

Description

Ref.

4 Muffler stamping.

5

Description

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Follow X

R

9

Follow X

Ref.

Description

Ref.

Description

6

8

9

7

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Follow X

R

Follow X

Ref.

10

11

Description

Ref.

13

14

Description

12

15

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Follow X

11

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Follow X

Ref.

16

17

18

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Description

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EVAPORATIVE EMISSION SYSTEM

The system consists of:

1) Fuel tank.

2) Water drain line.

3) Fuel tank breather nipple.

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.

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.

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).

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 emis­sion 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 cm

3

): 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 motor­cycle is defective, the part will be repaired
or replaced by aprilia. This is your emis­sion control system DEFECTS WARRAN­TY.

OWNER'S WARRANTY
RESPONSIBILITIES

√ As the motorcycle owner, you are re-

sponsible for the performance of the re­quired 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 Av­enue, 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 reason­ably 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 re-

sult of
(1) accident,
(2) misuse,
(3) repairs improperly performed or re­placements improperly installed,
(4) use of replacement parts or acces­sories not conforming to aprilia specifi­cations which adversely affect perfor­mance and/or
(5) use in competitive racing or related
events.

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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 Emis-

sion 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 MOTOR­CYCLE 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 Sys-

tem 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 re-

placement 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

with the vehicle, see p. 154 (TECHNICAL
DATA).

NOTE Soon after purchasing the vehi-

cle, write down the identification data pro­vided in the SPARE PARTS IDENTIFICA­TION LABEL in the table below. This label
is positioned on the left part of rider saddle
support; to be able to read it, remove the
rider saddle, see p. 128 (REMOVING THE
RIDER SADDLE).

These data indicate:

√ 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.

In this manual the various versions are in­dicated by the following symbols:

catalytic version

L

optional

J

VERSION:

Italy

+

United Kingdom

4

Austria

>

Portugal

M

Finland

(

Belgium

$

Germany

A

France

C

Spain

'

Greece

)

Holland

/

Switzerland

6

Denmark

&

Japan

,

Singapore

2

Slovenia

P

Israel

F

South Korea

e

Malaysia

-

Chile

@

Croatia

*

Australia

#

United States

R

of America

Brazil

g

South Africa

1

New Zealand

K

Canada

%

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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

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NOTE

ASK FOR GENUINE SPARE PARTS ONLY

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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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OIL

COOLER

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

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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

A12

345

ONLY ORIGINALS

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.

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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.

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.

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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

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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 gen­uine 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.

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.

2) Left rear-view mirror.

3) Clutch fluid reservoir.

4) Ignition switch/steering
lock/parking lights ( -  -
 - ).

5) Engine oil tank cap.

6) Passenger saddle lock.

7) Rider left footrest (spring
equipped,always extend­ed).

8) Rider saddle.

9) Battery.

10) Passenger saddle.

11) Electronic Control Unit
(ECU).

12) Rear fork.

13) Drive chain.

14) Passenger left footrest (re­tractable).

15) Center stand J.

16) Side stand.

17) Shift lever.

18) Engine oil filter.

19) Engine oil tank.

20) Engine oil level.

21) Horn.

22) Left fairing.

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