Aprilia RST Mille Futura Service Manual

RST mille

INTRODUCTION

GENERAL INFORMATION

PERIODIC MAINTENANCE AND ADJUSTMENTS

ENGINE

FUEL SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

CHASSIS

REPAIR INFORMATION

INDEX

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INTRODUCTION

CONTENTS

0.1 RELEASE 00/2001-11 UPDATE ....... 0-3-00

0.1.1 MANUAL UPDATES.............................. 0-3-00

0.1.2 LIST OF MANUAL PAGES AND UPDATE

0.2 REFERENCE GUIDE ........................ 0-6-00

0.3 FOREWORD ..................................... 0-7-00

0.4 REFERENCE MANUALS .................. 0-7-00

0.4.1 ENGINE WORKSHOP MANUALS........ 0-7-00

0.4.2 PARTS CATALOGUES ......................... 0-7-00

0.4.3 SPECIAL TOOLS CATALOGUES ........ 0-7-00

0.4.4 OWNER'S MANUALS ........................... 0-7-00

0.5 SAFETY INFORMATION .................. 0-8-00

0.5.1 GENERAL PRECAUTIONS AND

0.5.2 BEFORE DISASSEMBLING ANY

0.5.3 DISASSEMBLING THE COMPONENTS .. 0-8-

0.5.4 REASSEMBLING THE COMPONENTS 0-8-00

0.6 SAFETY INFORMATION .................. 0-9-00

0.6.1 CONVENTIONS USED IN THE MANUAL 0-9-00

RST mille

INTRODUCTION

NUMBERS ............................................. 0-3-00

INFORMATION ...................................... 0-8-00

COMPONENTS...................................... 0-8-00

0.7 ABBREVIATIONS/SYMBOLS/

CONVENTIONS.............................. 0-10-00

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RST mille

INTRODUCTION

0.1 RELEASE 00/2001-11 UPDATE

Issue date of original release (Release 00) and subsequent releases:

Original release (Release 00)..................November 2001

0.1.1 MANUAL UPDATES

Always keep manual updated to the latest release you have received.

Add the latest release pages to the manual and destroy all superseded pages (even if they belong to the release before last).

CAUTION

Failure to keep the manual up-to-date or to eliminate superseded pages will make the manual more difficult to consult and creates a risk of improper servicing.

This manual is made up of 10 sections for a total of 376 pages (listed below).

NOTE Please see 0.2 (REFERENCE GUIDE) for

details of standard page nomenclature and page numbering.

0.1.2 LIST OF MANUAL PAGES AND UPDATE NUMBERS

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CONTINUED ➤

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INTRODUCTION

CONTINUED ➤

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CONTINUED ➤

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INTRODUCTION

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INTRODUCTION

0.2 REFERENCE GUIDE

RST mille

1.9 PLACING THE MOTORCYCLE ON THE SERVICE STAND

1.9.1 PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND

Place the motorcycle on the centre stand. Slide both pins (1) of the front wheel stand into the holes (2) at front fork bottom end of the same time. Put one foot on the front end of the stand (3). Press down on stand (3) until it rests fully on the ground.

PLACING THE MOTORCYCLE ON THE

1.9.2 CENTRE STAND

Read paragraph 0.2.1 (GENERAL PRECAUTIONS AND INFORMATION) carefully.

Part no. 8140176 (complete stand).

Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Place the motorcycle on the front wheel stand , see

1.9.1 (PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND).

Hold the nut (1) steady on the inside. Release and remove the rear upper right-hand engine mounting bolt (2).

Torque wrench setting for nut (1) / bolt (2):50 Nm (5,0 kgm).

NOTE

The bolt (2) on the left-hand side is longer

Collect the nut (1). Slide the upper right-hand mounting boss (3) into the upper hole on the right-hand side. Fit the stud bolt (4) into the upper hole on the left-hand

side and screw it fully into the mounting boss (3). Screw the upper left-hand mounting boss (5) fully onto stud bolt (4) and tighten.

Hold the nut (6) on the inside steady. Release and remove the rear lower engine mounting bolt (7).

INFORMAZIONI G

ENERALI

- 17 -

Release 00/2001 - 07

1) Motorcycle model (or engine type)

2) Section title

3) Release progressive number (“00” identifies the original release)

4) Year and month of issue of relevant release

5) Section number

6) Page number (pages are numbered sequentially, numbering begins anew in each section)

- 6 - 00 Release 00/2001 - 11

7) Page update number (progressive number)

8) Subsection number (progressive number)

9) Paragraph number (progressive number)

10) Description of operation (always preceded by the lozenge symbol)

11) Description of operation: the star means that the operation must be repeated on the opposite side of the motorcycle

RST mille

INTRODUCTION

0.3 FOREWORD

- This manual provides the information required for normal servicing.

- The information and illustrations contained in this manual are updated through subsequent releases, see

0.1 (RELEASE 00/2001-11 UPDATE).

- This manual is intended for use by aprilia Dealers and their qualified mechanics. Certain information has been omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. The persons who will use this manual must be fully conversant with the basics of mechanics and with the basic procedures of motorcycle repair. Repairing or inspecting a motorcycle when one does not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to ride. For the same reason, certain basic precautions have been omitted in the descriptions of repair and inspection procedures. Take special care to avoid damage to motorcycle components or injury to persons. aprilia s.p.a.'s mission is to constantly enhance the riding pleasure of final users through the on-going improvement of its products as well as of the relevant technical literature. All aprilia Points of Sale and Subsidiaries worldwide are kept updated on major engineering changes and modifications to repair procedures. Such changes and modifications are then reflected in the next release of the relevant manual. When in doubt about an inspection or repair procedure, please contact the aprilia Consumer Service (A.C.S.) Department, who will be glad to provide full information on the procedure in question as well as on any updates or engineering changes affecting the motorcycle under consideration.

aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Any reference to products or services provided by outside suppliers is for information only and by no means binding, and implies no warranties or responsibilities as to the performance or use of any such products and/or services.

Please read 0.4 (REFERENCE MANUALS) for more detailed information.

Original release: November 2001

Produced and printed by:

DECA s.n.c.

via Risorgimento, 23/1 - 48022 Lugo (RA) - Italia Tel. +39 - 0545 35235 Fax +39 - 0545 32844 E-mail: deca@decagroup.it www.decaweb.it

for:

aprilia Consumer Service s.p.a.

via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italia Tel. +39 - 041 57 86 101 Fax +39 - 041 57 86 100 www.aprilia.com

0.4 REFERENCE MANUALS

0.4.1 ENGINE WORKSHOP MANUALS

aprilia part# (description)

8140582 (1051-1)

8140584 (1053-1)

8140585 (1054-1)

8140583 (1052-1)

8140586 (1055-1)

8140587 (1056-1)

USA

0.4.2 PARTS CATALOGUES

aprilia part# (description)

390W

...............

390Y ................

3901.................

RSV01

I UK

0.4.3 SPECIAL TOOLS CATALOGUES

aprilia part# (description)

8202278

I F D E UK

0.4.4 OWNER'S MANUALS

aprilia part# (description)

Model years 1998 -1999

8102623

8102857

8102858

8102859

8104128

8104099

I F D

P E UK

NL DK SF

GR J UK

AUS

USA

Model years 2000

8104089

8104142

8104143

8104141

8104164

8104171

8104152

8104269

8104267

8104268

I F D

P E UK

NL DK SF

GR J UK

AUS

USA

RSV01

I F D

P E UK

NL DK SF

GR J UK

8104270

8104264

AUS

USA

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INTRODUCTION

RST mille

0.5 SAFETY INFORMATION

The following conventions are used to identify safety information throughout the manual.

This symbol identifies safety-related information.

Whenever you see this symbol in the manual or attached to the motorcycle, use utmost care to avoid the risk of injury. Disregarding the instructions identified by this symbol may put your safety, as well as that of other persons or of the motorcycle at risk!

CAUTION

Disregarding these indications may lead to severe injury or death.

WARNING

Disregarding these indications may lead to minor injury or motorcycle damage.

NOTE The term "NOTE" in this manual precedes

important information or instructions.

0.5.1 GENERAL PRECAUTIONS AND INFORMATION

Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.

CAUTION

Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to the touch to avoid scalds or burns.

CAUTION

Never put any mechanical parts or other vehicle components in your mouth when you have both hands busy. None of the motorcycle components is edible. Some components are harmful to the human body or toxic.

Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the manual, proceed sensibly to avoid disturbing any parts unless strictly necessary. Never attempt to polish matte-finished surfaces with lapping compounds.

Never use fuel instead of solvent to clean the motorcycle.

Do not clean any rubber or plastic parts or the seat with alcohol, petrol or solvents. Clean with water and neutral detergent.

Always disconnect the battery negative (–) lead before soldering any electrical components.

When two or more persons service the same motorcycle together, special care must be taken to avoid personal injury.

Read 1.2 (WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS) carefully.

0.5.2 BEFORE DISASSEMBLING ANY COMPONENTS

- Clean off all dirt, mud, and dust and clear any foreign

objects from the vehicle before disassembling any components.

- Use the model-specific special tools where specified.

0.5.3 DISASSEMBLING THE COMPONENTS

- Never use pliers or similar tools to slacken and/or

tighten nuts and bolts. Always use a suitable spanner.

- Mark all connections (hoses, wiring, etc.) with their

positions before disconnecting them. Identify each connection using a distinctive symbol or convention.

- Mark each part clearly to avoid confusion when

refitting.

- Thoroughly clean and wash any components you have

removed using a detergent with low flash point.

- Mated parts should always be refitted together. These

parts will have seated themselves against one another in service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.

- Certain components are matched-pair parts and

should always be replaced as a set.

- Keep the motorcycle and its components well away

from heat sources.

0.5.4 REASSEMBLING THE COMPONENTS

WARNING

Never reuse a circlip or snap ring. These parts must always be renewed once they have been disturbed.

When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitment to the shaft. Make a rule to check that a newly –fitted circlip or snap ring has located fully into its groove.

Never clean a bearing with compressed air.

NOTE All bearings must rotate freely with no hardness

or noise. Replace any bearings that do not meet these requirements.

- Use ORIGINAL aprilia SPARE PARTS only.

- Use the specified lubricants and consumables.

- Where possible, lubricate a part before assembly.

- When tightening nuts and bolts, start with the largest or

innermost nut/bolt and observe a cross pattern. Tighten evenly in subsequent steps until achieving the specified torque.

- Replace any self-locking nuts, gaskets, seals, circlips

or snap rings, O-rings, split pins, bolts and screws which have a damaged thread.

- Clean all joint surfaces, oil seal edges and gaskets

before assembly.

- Apply a light coat of lithium grease along the edges of

oil seals. Fit oil seals and bearings with the brand or serial number facing outwards (in view).

- Lubricate the bearings abundantly before assembly.

- Make a rule to check that all components you have

fitted are correctly in place.

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INTRODUCTION

- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then operate the motorcycle in a private estate area or in a safe area away from traffic

0.6 SAFETY INFORMATION

0.6.1 CONVENTIONS USED IN THE MANUAL

- This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the summary of sections on page 0-1.

- Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure.

- The terms “left” and “right” are referred to the motorcycle when viewed from the riding position.

- Motorcycle operation and basic maintenance are covered in the “OWNER'S MANUAL”.

 Any operations preceded by the star symbol must

be repeated on the opposite side of the motorcycle.

In this manual any variants are identified with these symbols:

Frame # ZD4DW......(STARTING FROM MODEL YEAR

2001).

ASD

AUTOMATIC SWITCH-ON DEVICE

OPT

Option

Catalysed version

✿

VERSION:

I GR Mal

Italy Greece Malaysia

United

Kingdom

A CH HR

Austria Switzerland Croatia

P DK AUS

Portugal Denmark Australia

SF J

Finland Japan

NL RCH

Netherlands Chile

USA

America

B SGP BR

Belgium Singapore Brazil

D SLO

Germany Slovenia

RSA

Africa

F IL

France Israel

South

Spain

ROK

Korea

CDN

United States of

Republic of South

New

Zealand

Canada

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0.7 ABBREVIATIONS/SYMBOLS/ CONVENTIONS

# = Number < = is less than > = is more than

= is less than or equal to

= is more than or equal to

~ = approximately

∞ = infinite

°C = degrees Celsius (centigrade) °F = degrees Fahrenheit

± = plus or minus

A = Ampere AC =Alternated Current Ah =Ampere per hour API = American Petroleum Institute AV/DC = Anti-Vibration Double Countershaft bar = pressure measurement (1 bar =100 kPa) BDC = Bottom Dead Centre CO = carbon oxide CPU = Central Processing Unit cu cm = cubic centimetres DC = Direct Current DIN = German industrial standards

(Deutsche Industrie Norm)

DOHC = Double Overhead Camshaft ECU = Electronic Control Unit HC = unburnt hydrocarbons HT = High Tension ID = inner diameter ISC = Idle Speed Control ISO = International Standardization Organization kg = kilograms kgm = kilograms per metre (1 kgm =10 Nm) km = kilometres km/h = kilometres per hour kPa = kiloPascal (1 kPa =0.01 bar) KS = clutch side (from the German "Kupplung

seite")

kW = kiloWatt

Ω = kiloOhm

l = litres

LAP = racetrack lap LED = Light Emitting Diode m/s = metres per second max = maximum mbar = millibar (1 mbar =0.1 kPa) mi = miles MIN = minimum MPH = miles per hour MS = flywheel side (from the German

"Magnetoseite")

Ω = megaOhm

N.A. = Not Available N.O.M.M. = Motor Octane Number N.O.R.M. = Research Octane Number Nm = Newton per metre (1 Nm =0.1 kgm) Ø = Diameter OD = outer diameter

Ω = ohm

PPC = Pneumatic Power Clutch rpm = revolutions per minute SAE = Society of Automotive Engineers T.B.E.I. = crowned-head Allen screw

T.C.E.I. = cheese-headed Allen screw T.E. =hexagonal head T.P. =flat head screw TDC = Top Dead Centre TEST = diagnostic check TSI = Twin Spark Ignition UPSIDEDOWN = inverted fork V = Volt W = Watt

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NOTES

INTRODUCTION

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INTRODUCTION

NOTES

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GENERAL INFORMATION

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GENERAL INFORMATION

CONTENTS

1.1 LOCATION OF SERIAL NUMBERS .. 1-3-00

1.1.1 FRAME NUMBER .................................. 1-3-00

1.1.2 ENGINE NUMBER................................. 1-3-00

1.2 WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER

COMPONENT PARTS ...................... 1-3-00

1.2.1 FUEL ...................................................... 1-3-00

1.2.2 ENGINE OIL........................................... 1-4-00

1.2.3 BRAKE FLUID....................................... 1-4-00

1.2.4 COOLANT.............................................. 1-5-00

1.2.5 CLUTCH FLUID ..................................... 1-5-00

1.2.6 CARBON OXIDE ................................... 1-6-00

1.2.7 HOT COMPONENT PARTS .................. 1-6-00

1.3 RUNNING-IN RECOMMENDATIONS 1-6-00

1.4 SPARE PARTS ................................. 1-7-00

1.5 SPECIFICATIONS ............................ 1-7-00

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1.6 LUBRICANT CHART ...................... 1-10-00

1.7 CONSUMABLES ............................ 1-11-00

1.7.1 PRODUCT FEATURES ....................... 1-11-00

1.7.2 PRODUCT APPLICATIONS ............... 1-12-00

1.8 SPECIAL TOOLS............................ 1-15-00

1.8.1 SUNDRY TOOLS ............................... 1-15-00

1.8.2 ENGINE TOOLS .................................. 1-16-00

1.9 PLACING THE MOTORCYCLE ON THE

SERVICE STANDS ......................... 1-17-00

1.9.1 PLACING THE MOTORCYCLE ON THE

FRONT WHEEL STAND ..................... 1-17-00

1.9.2 PLACING THE MOTORCYCLE ON THE

CENTRE STAND ................................ 1-18-00

1.10 HOW TO APPLY THE DECALS ...... 1-19-00

1.11 TORQUE FIGURES ........................ 1-21-00

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1.1 LOCATION OF SERIAL NUMBERS

These numbers are necessary for vehicle registration.

NOTE Altering the identification numbers of vehicle or

engine is a legal offence punishable by heavy fines and penalties. In addition, altering the frame number (VIN) results in immediate warranty invalidation.

1.1.1 FRAME NUMBER

The frame number (Vehicle Identification Number) is etched on the right-hand side of the headstock.

1.1.2 ENGINE NUMBER

The engine number is etched at the rear end of engine, in the area near the sprocket.

GENERAL INFORMATION

1.2 WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS

1.2.1 FUEL

CAUTION

The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refuelling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refuelling or in the proximity of sources of fuel vapours. Avoid contact with bare flames, sources of sparks or any other source which may ignite the fuel or lead to explosion. Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In the event of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel expands from heat and when left under direct sunlight. Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refuelling. Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between different containers using a hose.

DO NOT RELEASE FUEL INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

Use only premium-grade unleaded fuel with a minimum octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.).

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GENERAL INFORMATION

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1.2.2 ENGINE OIL

CAUTION

Prolonged or repeated contact with engine oil may cause severe skin damage. Wash your hands thoroughly after handling engine oil. Do not release into the environment. Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves during servicing.

Change engine oil after the first 1000 km (625 mi) and every 7500 km (4687mi) (*), see 2.13 (ENGINE OIL AND FILTER CHANGE) afterwards.

(*) = On motorcycles used in competition trials, oil should be changed every 3750 km (2343 mi).

(Recommended) engine oil, see 1.6 (LUBRICANT CHART)Front fork fluid

CAUTION

Prolonged or repeated contact with front fork fluid may cause severe skin damage. Wash your hands thoroughly after handling front fork fluid. Dispose of front fork fluid through the nearest waste oil reclamation firm or through the supplier. Wear latex gloves during servicing. Front suspension response can be modified to a certain extent by changing damping settings and/or selecting a particular grade of oil. Standard oil grade is SAE 20 W. Different oil grades can be selected to obtain a particular suspension response. (Choose SAE 5W for a softer suspension, 20W for a stiffer suspension). The two grades can also be mixed in varying solutions to obtain the desired response.

F.A. or Fork have special properties, which enable them to retain virtually the same viscosity regardless of temperature to give constant damping response.

(Recommended) front fork oil, see 1.6 (LUBRICANT CHART).

1.2.3 BRAKE FLUID

NOTEThis vehicle is fitted with front and rear disc

brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems.

CAUTION

Brake fluid is an irritant. Avoid contact with eyes or skin. In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental contact with eyes, contact an eye specialist or seek medical advice.

DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will damage. Check brake fluid level every 7,500 km (4687 mi), see 2.16 (CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL). See also 2.17 (CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL). Change brake fluid every two years, see 2.21 (CHANGING THE FRONT BRAKE FLUID) and 2.22 (CHANGING THE REAR BRAKE FLUID).

(Recommended) brake fluid, see 1.6 (LUBRICANT CHART).

CAUTION

Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up level, as this will damage the braking system. Do not use brake fluid from containers which have been kept open or in storage for long periods. Any sudden changes in play or hardness in the brake levers are warning signs of problems with the hydraulic circuits. Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This is particularly important after servicing or inspections. Make sure the brake lines are not twisted or worn. Prevent accidental ingress of water or dust into the circuit. Wear latex gloves when servicing the hydraulic circuit.

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GENERAL INFORMATION

1.2.4 COOLANT

CAUTION

Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.

DO NOT RELEASE INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

CAUTION

Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear latex gloves when servicing. Do not ride when coolant is below the minimum level.

Check coolant level before each ride and every 15000 km (9375 mi), see 2.14 (CHECKING AND TOPPING UP COOLANT LEVEL) as part of routine maintenance. Change coolant every two years, see 2.15 (COOLANT CHANGE). Coolant mixture is a 50% solution of water and antifreeze. This is the ideal solution for most operating temperatures and provides good corrosion protection. This solution is also suited to the warm season, as it is less prone to evaporative loss and will reduce the need for top-ups. In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the efficiency of the cooling system. When temperature drops below zero degrees centigrade, check the cooling system frequently and add more antifreeze (up to 60% maximum) to the solution. Use distilled water in the coolant mixture. Tap water will damage the engine.

(Recommended) engine anti-freeze, see 1.6 (LUBRICANT CHART).

Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing point:

1.2.5 CLUTCH FLUID

NOTE This vehicle is fitted with a hydraulically

operated clutch.

CAUTION

Clutch fluid is an irritant. Avoid contact with eyes or skin. In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental contact with eyes, contact an eye specialist or seek medical advice.

DO NOT RELEASE CLUTCH FLUID INTO THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

When handling clutch fluid, take care not to spill it onto plastic or paint-finished parts or they will damage. Check clutch fluid level every 7,500 km (4687 mi), see 2.18 (CHECKING AND TOPPING UP CLUTCH FLUID LEVEL). Change clutch fluid every two years, see 2.23 (CHANGING THE CLUTCH FLUID).

(Recommended) clutch fluid, see 1.6 (LUBRICANT CHART).

WARNING

Do not use any clutch fluids other than the specified type. Never mix different types of fluids to top up level, as this will damage the clutch system. Do not use clutch fluid from containers which have been open or kept in storage for long periods. Any sudden changes in play or hardness in the clutch lever are warning signs of problems with the hydraulic circuit. Make sure the clutch hose is not twisted or worn. Avoid accidental ingress of water or dust into the circuit. Wear latex gloves when servicing the hydraulic circuit.

Freezing point °C Coolant

% of volume

-20° 35

-30° 45

-40° 55

NOTE The different brands of anti-freeze available on

the market have varying specifications. Always read product label to determine the degree of protection afforded.

WARNING

Use only nitrite-free anti-freeze and corrosion inhibitors with a freezing point of –35°C as a minimum.

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GENERAL INFORMATION

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1.2.6 CARBON OXIDE

When an operation must be performed with the engine running, position the motorcycle out of doors or in a wellventilated area. Never operate the engine in an enclosed place. Use an exhaust emission extraction plant when working indoors.

CAUTION

Exhaust emissions contain carbon oxide, which is a poisonous gas and may lead to loss of conscience or even death. Operate the engine out of doors or, if working indoors, use an exhaust emission extraction plant.

1.2.7 HOT COMPONENT PARTS

CAUTION

The engine and exhaust component parts become hot when the engine is running and will stay hot for some time after the engine has been stopped. Wear heat gloves before handling these components or allow for the engine and exhaust system to cool down before proceeding.

1.3 RUNNING-IN RECOMMENDATIONS

Proper engine running-in is essential to preserving engine life and performance over time. Twisty roads and gradients are ideal to break in engine, suspension and brakes effectively. Varying speed frequently is also recommended. This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when less stressed. While it is important to put a certain amount of stress to engine components during the running-in period, it is equally important to spare the engine at this stage in vehicle's life.

WARNING

Top acceleration performance is only obtained after covering the first 1500 km (937 mi).

Observe the following instructions:

 Avoid harsh accelerations and do not flip the throttle

open abruptly when the engine is running at low speed, both during and after the running-in period.

 Apply the brakes gently and avoid hard, prolonged

braking until covering the first 100 km (62 mi).

 This will allow the brake pad lining to wear in properly

rubbing on the brake discs.

 Never exceed 6000 rpm (see chart) during the first

1000 km (625 mi).

WARNING

After covering the first 1000 km (625 mi), perform the checks listed in the “post running-in” column of the PERIODIC MAINTENANCE CHART (see 2.1.1). Failure to perform these checks may lead to personal injury to yourself or third persons, or vehicle damage.

 After the first 1000 km (625 mi) and until covering the

first 1500 km (937 mi), a somewhat brisker riding style is acceptable. Vary your speed and use peak acceleration for just a few instants, to allow the different components to become properly seated against one another.

 Never exceed 7500-rpm engine speed (see table).  After 1500 km (937 mi), the engine will be ready for a

more demanding use. However, never exceed the maximum engine speed allowed (10500 rpm).

Recommended maximum engine speed

Distance covered in

Km(mi)

0-1000 (0-625) 6000

1000-1500 (625-937) 7500

over 1500 (937) 10500

rpm

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1.4 SPARE PARTS

Use original aprilia spare parts only to replace original components. Original aprilia spare parts are high-quality components designed and built expressly for aprilia motorcycles.

WARNING

Using any parts OTHER THAN original aprilia parts may lead to loss of performance and damage.

1.5 SPECIFICATIONS

DIMENSIONS

Overall length 2170 mm

Overall width 740 mm

Overall height (front fairing) 1240 mm

Seat height 820 mm

Wheelbase 1435 mm

Minimum ground clearance 135 mm

Weight in running order (including fuel, coolants and 235 kg

ENGINE

Type

4-stroke longitudinal 60° V twin-cylinder engine fitted with 4 valves per cylinder and 2 overhead camshafts

GENERAL INFORMATION

Number of cylinders 2

Total displacement 997.6 2cm³

Max rated crankshaft power 86,5 kW (118 HP) at 9250 rpm

Max rated crankshaft power 77 kW (104 HP) at 9250 rpm

Max torque 96.5 Nm (9.78 kgm) at 7250 rpm

Max torque 90 Nm (9.17 kgm) at 7000 rpm

Bore/stroke 97 mm / 67.5 mm

Compression ratio 11.8 ± 0.5: 1

Average piston speed 22,5 m/s at 10000 rpm

Camshaft during intake stroke 262°, valve lift = 10.6 mm

Camshaft during exhaust stroke 259°, valve lift = 10.6 mm

Timing advance (with 1-mm valve clearance)

Valve clearance, intake 0.12-0.17 mm

Valve clearance, exhaust 0.23-0.28 mm

# Idling rpm 1250 ± 100 rpm

# Top speed rpm 10500 ± 100 rpm

Ignition computer ignition management

Starter electric starter

Spark advance:

Starter motor 12 V / 0.9 kW

Transmission ratio of starter motor i= 49/9 * 30/11 * 64/30 = 31.677

intake valve opens

intake valve closes exhaust valve opens exhaust valve closes

20° before TDC 59°after BDC 64° before TDC 15° after BDC

5° before TDC upon starting, advance is further increased to suit specific consumption.

Clutch

hydraulically operated wet multi-plate clutch with control lever on left-hand handlebar and PPC device

- # 9 friction plates, 3.5 mm thick

- # 9 clutch plates, 1.5 mm thick

CONTINUED ➤

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GENERAL INFORMATION

ENGINE

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Transmission

Lubrication system

Lubrication pressure

Air cleaner with dry filter cartridge

Cooling system liquid cooling

Transmission ratio of coolant pump i wp = 28/27 * 28/28 = 1.037

Coolant pump delivery rate (when thermal expansion valve is open)

Thermal expansion valve starts to open at 65 ± 2 °C (149 ± 5 °F)

Dry engine weight ~ 67 kg

CAPACITIES

Fuel (including reserve) 20.5 l

Fuel reserve 4 ± 1 l

Engine oil oil change 3700 cu cm oil and filter change 3900 cu cm

Front fork oil (each leg) 553 ± 2,5 cu cm

Coolant 2.5 l (50% water + 50% ethylene glycol anti-freeze)

Seat twin-seat 2

Max carrying load (rider + pillion rider + luggage) 182 kg

Mechanical 6-speed transmission with foot control on left-hand side of engine

Dry-sump lubrication system with remote oil tank, # 2 trochoidal pumps and cooler

min 500 kPa (5 bar) 80 °C (176 °F) max. and 6000 rpm

90 l/min at 9000 rpm

DRIVE

Gear 1st 2nd

DRIVE RATIOS

# Sprocket 16 teeth

Chain drive Endless O-ring chain, type 525, size 5/8" x 5/16"

FUEL SYSTEM

Type Electronic fuel injection

Venturi Ø 51 mm

INDUCTION

Type Indirect (MULTIPOINT) injection

Fuel

FRAME

Type

Rake 25.7°

Trail 97 mm

SUSPENSION

Front

3rd 4th 5th 6th

Primary drive ratio 31/60 = 1: 1.935

Secondary drive ratio 14/35 = 1: 2.500 16/28 = 1: 1.750 19/26 = 1: 1.368 22/24 = 1: 1.091 23/22 = 1: 1.957 27/23 = 1: 0.852

Premium-grade unleaded petrol, minimum octane rating 95 (N.O.R.M.) and 85 (N.O.M.M.)

Dual-beam design made from light alloy cast members and extruded members

Adjustable telescopic UPSIDE-DOWN hydraulic fork with Ø 43-mm legs

Final drive ratio 16/43 = 1: 2.687

Total drive ratio

13.000

9.102

7.117

5.674

4.975

4.431

Travel 120 mm

CONTINUED ➤

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GENERAL INFORMATION

Rear

Wheel travel 120 mm

BRAKES

Front

Rear Disc brake - Ø 255 mm, dual-piston caliper - Ø 28

WHEELS

Type Light-alloy wheel rim

Front 3.50 x 17"

Rear 5.50 x 17"

TYRES

Wheel Brand Type Size Recommended

Front (standard) METZELER ME Z4 B 120/70ZR17”

Rear (standard) METZELER ME Z4 180/55ZR17”

Light-alloy single-sided swinging arm and adjustable oil/ air-sprung mono-shock absorber

Twin-disc brake with Ø 300-mm floating discs, fourpiston calipers with Ø 30-mm/ Ø 34-mm diameter

Pressure in kPa (bar)



solo riding



250 (2.5)

290 (2.8)

Front (standard) MICHELIN PILOT SPORT 120/70ZR17” ❖ 250 (2.5)

Rear (standard) MICHELIN PILOT SPORT 180/55ZR17” ❖ 290 (2.8)

Front (option) METZELER ME Z3 120/70ZR17” ❖ 250 (2.5)

Rear (option) METZELER ME Z3 180/55ZR17” ❖ 290 (2.8)

Front (option) PIRELLI MTR21A 120/70ZR17”

Rear (option) PIRELLI MTR22 180/55ZR17”



250 (2.5)

280 (2.8)

 = Road use ; ❖ = Competition

SPARK PLUGS

Standard NGK R DCPR9E

Electrode gap 0.6 -0.7 mm

Resistance 5KΩ

ELECTRIC SYSTEM

Battery rating 12 V - 12 Amps

Main fuses 30A

Auxiliary fuses 15A

Generator (permanent-wound magnet type) rating 12 V - 400 W

Starter motor rating 12 V / 0.9 kW

CONTINUED ➤

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GENERAL INFORMATION

BULBS

Low beam (halogen lamp) 12 V - 55 / 55 W H4

High beam (halogen lamp) 12 V - 60 W H3

Front parking light 12 V - 5 W

Direction indicators 12 V - 10 W

Rear parking light / plate / stop light 12 V - 5/21 W

Rev. counter light LED

Right-hand multi-purpose display light LED

Left-hand multi-purpose display light LED

WARNING LIGHTS

Neutral light LED

Direction indicators LED

Low fuel LED

High beam LED

Stand light LED

Engine oil pressure LED

Red line LED

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1.6 LUBRICANT CHART

(Recommended) engine oil: EXTRA RAID 4, SAE

15W - 50 or TEC 4T SAE 15W - 50. As an

alternative to recommended oils, top brand oils meeting

or exceeding CCMC G-4, A.P.I. SG. specifications can be

used.

(Recommended) fork oil: front fork oil F. A . 5 W or

F.A. 20W.

As an alternative, use FORK 5W or FORK

20W. When you wish to obtain an intermediate response

between those offered by F.A. 5W and F.A. 20W

oils or FORK 5W and FORK 20W oils,

you may mix the different products as follows:

SAE 10W = F.A. 5W 67% of volume, + F.A. 20W

33% of volume, or

FORK 5W 67% of volume, + FORK

20W 33% of volume.

SAE 15W = F.A. 5W 33% of volume, + F.A. 20W

67% of volume, or

FORK 5W 33% of volume, + FORK

20W 67% of volume.

Bearings and other lubrication points

(recommended):

AUTOGREASE MP or GREASE 30.

As an alternative to recommended grease, use top brand

rolling bearing grease that will resist a temperature range

of -30°C…+140°C, with dropping point 150°C…230°C,

high corrosion protection, good resistance to water and

oxidisation.

Battery lead protection: use neutral grease or vaseline.

(Recommended) aerosol chain lubricant: CHAIN

SPRAY or CHAIN LUBE.

CAUTION

Use new brake fluid only.

(Recommended) brake fluid: F.F., DOT 5 (DOT 4

compatible) or BRAKE 5.1, DOT 5 (DOT 4

compatible).

CAUTION

Use new clutch fluid only.

(Recommended) clutch fluid: F.F., DOT 5 (DOT 4

compatible) or BRAKE 5.1, DOT 5 (DOT 4

compatible).

CAUTION

Use only nitrite-free anti-freeze and corrosion inhibitors with a freezing point of -35°C as a minimum.

(Recommended) engine coolant: ECO-BLU -

40°C or COOL.

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1.7 CONSUMABLES

Use only the products specified below for motorcycle maintenance. These products have demonstrated suitability for all usage conditions specified by the manufacturer after long-.time testing.

NOTE The products for which a part number is given

are available at request, see 1.7.2 (PRODUCT APPLICATIONS).

1.7.1 PRODUCT FEATURES

Product Usage and features

Blue LOCTITE

243

GENERAL INFORMATION

Threadlocking adhesive for nuts and bolts up to M36, provides medium-strength fit. Suitable for use on less than perfectly degreased parts. Cure time varies with temperature and substrate up to one hour maximum. Withstands temperatures in the – 55 to 150 °C range (– 99 to 302 °F).

Green LOCTITE

Orange LOCTITE

LOCTITE

8150

Anti Seize 15378

648

574

High-strength retaining compound for bolts. Cure time varies with temperature and substrate up to twelve hours maximum. Withstands temperatures in the – 55 to 175 °C range (– 99 to 347 °F). Mated parts must be heated up to 250 °C (482 °F) before they can be disassembled.

Solvent-free sealant. Eliminates the need for gaskets in joints exposed to high friction and where a specified gap needs to be maintained between parts. Liquid sealant, cures within a few hours after assembly when in contact with metal to form a gasket whose surface structure matches mating surfaces. Resists temperatures from – 55 to 200 °C ( – 99 to 392 °F), inhibits corrosion of sealed surfaces.

High-temperature assembly paste.

Lubricant and corrosion inhibitor, resists high temperatures. When sprayed on both parts, provides long-term maintenancefree operation of contact surfaces. Inhibits corrosion.

MOLYKOTE

G-n

SILASTIC 732 RTV

Lubricating compound for use on heavy-duty stressed parts, for base lubrication and on fits under pressure to avoid corrosion and sticking. Apply on both contact surfaces.

Sealant, prevents ingress of water into flywheel casing.

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GENERAL INFORMATION

1.7.2 PRODUCT APPLICATIONS

Product Part number Applications

Engine oil (*) 8116050

LOCTITE

243 (**)

648 (**)

0897651

0899788

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- Swinging arm rivets, instrument panel/front fairing mount, seat subframe and frame (on assembly).

- Frame-to-engine and frame-to-swinging arm adjusting bushes (on assembly).

- Cable guide screws to frame (on assembly).

- Headstock bearings.

- Headstock top bush.

- Roller bearings of timing idler gear.

- Thrust washer of lower balancing shaft.

- Clutch disengagement shaft.

- Valve stems and buckets.

- Valve guide seals.

- Casing location of camshafts.

- Timing chain tensioner.

- Compound starter gear and idler gear pins.

- Freewheeling clutch-to-gear contact surfaces.

- Inner contact surface of freewheeling clutch.

- Steering retaining bush.

- Rear brake caliper detent.

- Front sprocket.

- Rear brake pedal spindle.

- Cooling fans to support.

- Fuel return line fitting.

- Fuel filler cap.

- Throttle cable pulley nut.

- Throttle cable bracket screws.

- Throttle valve spindle nut.

- Throttle position sensor screws.

- Coolant pump central screw.

- Cylinder connecting bracket screws.

- Engine casing bearing screws.

- Cylinder stud bolts.

- Crankshaft position sensor screws.

- Index lever and plate screws.

- Crankshaft nut.

- Timing gear screws.

- Nut securing counterweight to upper balancing shaft.

- Lower screw of timing idler gear bearing mount.

- Coolant pump idler gear shaft.

- Engine oil pump plug.

- Clutch gear metal plate screws.

- Freewheeling clutch to magnet wheel (on assembly).

- Freewheeling clutch screws.

- Clutch housing nut.

- Screw securing counterweight to lower balancing shaft.

- Flywheel rotor inner cone.

- Flywheel retaining screw.

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Product Part number Applications

G-n (**)

574

0899784

0297434

0297433

Orange LOCTITE (**)

LOCTITE

Anti Seize

15378 (**)

MOLYKOTE

SILASTIC 732 RTV (**) 0297386

Bimol Grease 481 8116053

LUBERING Grease ST 8116038

AP-LUBE temporary lubricant

DID CHAIN LUBE Grease

GENERAL INFORMATION

- Coolant thermal switch.

- Coolant thermistors.

- Contact screw of neutral switch.

- Outer surface of engine oil pump motor.

- Cylinder footprint on crankcase.

- Transmission primary and secondary shaft.

- Crankcase locations of transmission primary and secondary shafts.

- Crankshaft and balancing shaft.

- Crankcase location and spline of transmission primary shaft.

- Crankcase locations of main bearing sleeves.

- Main bearing sleeves.

- Crankcase bearing locations.

- Coolant pump shaft.

- Valve guide seats in cylinder head.

- Valve guide edges.

- Crankcase locations of crankshaft and balancing shaft bearing sleeves.

- Crankcase locations of crankshaft and balancing shaft.

- Bores accommodating piston pins.

- Camshaft cams.

- Starter motor mount.

- Cable bracket on flywheel cover.

- Camshaft sensor cable.

- Front and rear wheel seals (on assembly).

- Swinging arm shaft bearings (on assembly).

- Clutch master cylinder actuating rod (on assembly).

- Rear wheel shaft thread.

- Steering head bearings.

- Rear brake master cylinder actuating rod (on assembly).

- Rear brake pedal spindle.

- Thrust washer of timing idler gear.

- Upper balancing shaft seal.

- Starter motor gear.

- Choke control (on assembly).

- Handlebar counterweight rubber (on assembly).

- Throttle cable adjuster rubbers (on assembly).

- Gearshift lever rubber (on assembly).

- Lower retaining pins of radiators to rubber mounts (on assembly).

- Breather hose to radiator and three-way manifold (on assembly).

- Coolant hose couplings to radiators (on assembly).

- Water and fuel drain hoses to fuel flange (on assembly).

- Throttle body torsion springs (on assembly).

- Drive chain.

“Biosolvent” frame detergent

Cyanoacrilic paste “ACRILON 28”

MOTUL MOTOWASH Degreaser

8116031 - For washing the engine oil tank.

8116945 - Airbox gasket (on assembly).

- - For cleaning frame and swinging arm.

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GENERAL INFORMATION

Product Part number Applications

Anti-seize compound ANTI-SEIZE MOTAGEPASTE AS 1800

Alcohol -

8116043 - Plugs of exhaust take-up points.

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- For cleaning left-hand handlebar before fitting twistgrip.

- Radiator breather hoses into T union.

- Ignition coil mount rubber (on assembly).

- Side body panel rubbers (on assembly).

- For cleaning bottom part of engine.

- Starter relay rubber (on assembly).

- Cush drive to rear wheel sprocket (on assembly).

- Engine oil cooler rubbers (on assembly).

- Hose coupling to coolant filler cap (on assembly).

- For cleaning engine oil tank before decal application.

- Instrument panel/front fairing rubbers (on assembly).

- Rear brake pedal rubber (on assembly).

- Hoses to fuel filter (inside fuel tank) (on assembly).

- Coupling connecting coolant radiators (on assembly).

- Fuel lines to fuel tank (on assembly).

- For cleaning fuel tank before decal application.

(*) = see 1.6 (LUBRICANT CHART). (**) =see 1.7.1 (PRODUCT FEATURES).

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1.8 SPECIAL TOOLS

Special tools have been developed to ensure proper disassembly, re-assembly and adjustment without the risk of damaging any components. Using inadequate tools and/or improvised procedures may lead to irreparable damage. Model-specific special tools for this vehicle are listed below. If needed, order the brandspecific special tools (see Special Tools Catalogue).

WARNING

Always read the instructions supplied with the special tools before use.

GENERAL INFORMATION

1.8.1 SUNDRY TOOLS

Ref. Tool designation and application Part number

Full frame kit including:

2 Tool for chain removal/fitment 8140192

3 Centre stand 8140176

4 Axone 2000 8140595

5 Front wheel stand 8140195

6 Exhaust emission tester 8140196

7 Emission tester tube kit 8140202

8 Tool board 8140199

9 Bearing extractor kit 10 - 30 mm Ø 8140180

– split sleeve for fork seal fitment – socket for steering adjustment – socket for swinging arm spindle – engine mount adjustment

8140203

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GENERAL INFORMATION

1.8.2 ENGINE TOOLS

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Ref. Tool designation and application Part number

1 Full engine tool kit 8140175

2 Drift to fit transmission secondary shaft seal 0277680 3 Drift to fit seal into secondary balancing shaft location 0277660 4 Drift to fit seal into coolant pump shaft location 0277670 5 Drift to fit sliding ring into coolant pump shaft location 0877257 6 Valve guide extractor 0277510 7 Drift for valve guide seal fitment 0277695 8 Drift for valve guide fitment 0277210

9 Drift to fit transmission shaft and clutch shaft seals 8140155 10 Drift to fit main balancing shaft bearing sleeves 0277729 11 Crankshaft bearing sleeve extractor 0277720

12-14 Drifts to fit crankshaft bearing sleeves 0277725

13 Drift to fit clutch cover – crankshaft bearing sleeves 0277727 15 Spark plug tool 8140177 16 Flywheel cover puller 0277252 17 Hexagon nut for flywheel removal 0277780 18 Threaded rod to hold crankshaft in TDC position 0240880 19 Transmission secondary shaft guide sleeve 0277308 20 Vacuum gauge 8140256 21 Fuel/oil pressure gauge 8140181 22 Rotor bolt extractor 8140182 23 Clutch anti-rotation tool 0277881

24 Extractors for clutch cover bearing sleeves

25 Tool to compress valve springs 0276479 26 Tool for valve removal/fitment 8140179 27 Adhesive template for tool board 8157143 28 Engine lifting eyebolt 8140183 29 Primary drive nut extractor 8140184 30 Clutch plate extractors 8140185 31 Engine stand 8140188 32 Engine stand pedestal 8140187 33 Tool to compress piston rings 8140186

8140156 + 8140157 +

0276377

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1.9 PLACING THE MOTORCYCLE ON THE SERVICE STANDS

1.9.1 PLACING THE MOTORCYCLE ON THE FRONT

WHEEL STAND

 Place the motorcycle on the centre stand.  Slide both pins (1) of the front wheel stand (3) into the

holes (2) at front fork bottom end at the same time.

 Put one foot on the front end of the stand (3).  Press down on stand (3) until it rests fully on the

ground.

GENERAL INFORMATION

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GENERAL INFORMATION

1.9.2 PLACING THE MOTORCYCLE ON THE CENTRE STAND

Read 0.5.1 (GENERAL PRECAUTIONS AND INFORMATION) carefully.

Part no. 8140176 (complete stand).

 Remove the lower fairing, see 7.1.33 (REMOVING

THE LOWER FAIRING).

 Place the motorcycle on the front wheel stand ,

see 1.9.1 (PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND).

Hold the nut (1) steady on the inside. Release and remove the rear upper right-hand

engine mounting bolt (2).

Torque wrench setting for nut (1) / bolt (2):

50 Nm (5.0 kgm).

NOTE The bolt (2) on the left-hand side is longer.

Collect the nut (1).  Slide the upper right-hand mounting boss (3) into the

upper hole on the right-hand side.

 Fit the stud bolt (4) into the upper hole on the left-hand

side and screw it fully into the mounting boss (3).

 Screw the upper left-hand mounting boss (5) fully onto

stud bolt (4) and tighten.

Hold the nut (6) on the inside steady. Release and remove the rear lower engine mounting

bolt (7).

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Torque wrench setting for nut (6) / bolt (7):

50 Nm (5.0 kgm).

NOTE The bolt (7) on the right-hand side is longer.

 Slide the lower right-hand mounting boss (8) into the

lower hole on the right-hand side.

 Fit the stud bolt (9) into the lower hole on the left-hand

side and screw it fully into the mounting boss (8).

 Screw the lower left-hand mounting boss (10) fully onto

stud bolt (9) and tighten.

 Fit the bracket (11) onto the mounting bosses (3-8).

The longer portion of the bracket base must be facing forward.

 Snug the two washers (12 - 13) and nuts (14 - 15)

finger-tight.

 Tighten both nuts (14 - 15).  Fit the bracket (16) onto the mounting bosses (5-10)

with the longer portion of the base facing forward.

 Snug the two washers (17 - 18) and nuts (19 - 20)

finger-tight.

 Tighten both nuts (19 - 20).  Remove the wheel stands.

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