Aprilia RSV MILLE User Manual Part 3 1999

Page 1

NOTE The coolin g fans (21) funct ion only

when the ignition key (2) is in the “ position.

+” (ON)

aCAUTION

Do not leave the ignition key in the “-” (OFF) position since the cooling fans will not run regardless of the coolant temperature. T his will cause the c oolant temperature to continue to rise.

If, before shutting off the engine, you hear the cooli ng fans fun ctioning, stop the e n-

gine but leave the ignition key to “ position. This will allow the cooling fans to draw air through the radiators, and lower the temperature. Turn the ignition key to

-” (OFF) position only when the cooling

“

fans have stopped. If, while riding, the right side of the multi-

function display shows a temperature of 115 – 120 °C (239 – 248 °F) (19), stop riding the vehicle, stop the engine, turn the ignition

+” (ON) position and wait until the

key to “

+” (ON)

cooling fans have sto pped, then turn the ig nition key to “ the coolant level, see p. 56 (COOLANT).

If the symbol “///” (20) is displayed , stop riding the vehicle and let the engine run at 3,000 rpm for approximately two minutes, thus allowing the coolant to circulate normally in the cooling system. Then move the engine stop switch to position “ check the coolant level, see p. 5 6 (C OO LANT). If the symbol “ after the coolant l evel has been che cked, contact your Local aprilia Dealer.

-” (OFF) positio n and check

m” (OFF) and

///” (20) is still displayed

aWARNING

Do not operate the vehicle if the maxi-

mum temperature [120 °C (248 °F)] is exceeded. Serious engine damage or even seizure may result which can cause an upset and serious injury or even death.

Whenever the ignition key (2) is turned to

+” (ON), the right sid e o f th e m ult ifu nction

“

display wi ll show “HIL” (9B) for about three seconds.

aCAUTION

If the symb ol “HIL” (9B) is displayed during the normal running of the engine, this means that the electronic unit has detected an anomaly. In many cases, the engine keeps running with reduced performance levels; immediately contact your Local APRILIADealer

aWARNING

Avoid opening and clo sing the throttle repeatedly and continuously. Failure to head this warning can cause you to accidentally lose control of your vehicle.

When you have to brake, close the throttle and apply both brakes simultaneously in order to obtain the best brake performance.

By applying only the front brake or only the rear brake, you re duce the braking performance considerably and run the risk of locking up one wheel which can cause an upset and subsequent serious injury or even death.

If you stop on an up hill, us e brakes only to slow the vehicle and to keep it in place. Slipping the clutch to keep the vehicle in one place on an uphill grade will very quickly ruin the clutch and overheat the engine.

Before enteri ng a turn, slow down, using the brakes and the engine, to a constant speed and then accelerate slightly

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through the turn. Av oid braking at the last moment. Thi s can cause you to lose control of your vehicle.

If the brakes are operated continuously on downhill grades, the discs and pads will overheat, reducing the braking efficiency. Use engine compre ssion and downshift to retard your vehicle while going downhill. Use the brakes as little as possible to maintain a safe speed.

Never coast downhill with the e ngine off and/or the clutch disengag ed or the transmission in neutral.

On roads that are wet or covered with snow, ice or mud, ride very slowly, avoiding braking or accelerating or maneuvering quickly. Hold the handlebars firmly.

Failure to heed these warnings can cause an upset with su bsequent serious injury or death.

Pay very close attention to any obstacles or variations of the road surface. Uneven roads, rails, manhole covers, painted traffic stripes, traffic dots all be come slippery when wet. Avoid partic ularly steel pl ates which are som etimes used during r oad maintenanc e. They become more slippery than ice once they are wet by rain. If you must ride on such surfaces, decrease your speed and operate the throttle, brakes and steering very gently.

Always use the turn signals any time you intend to change lanes or change direction, and avoid sudden or abrupt turning.

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Switch off the direction indicators as soon as you have changed direction.

Overtake and pass only with care, especially in rainy weather when a water cloud created by larger vehicles reduces visibility and the slip stream could cause you to lose control of your vehicle.

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The internal parts of the engine and transmission must be properly run-in to ensure their long life and dependable operation.

If possible, while breaking in your vehicle, ride on hilly roads a nd/ or roa ds w it h many curves so that the engine and transmission undergo lots of speed changes. It i s also important that, during the r un-in period, the suspension and brak es be treated gently to allow the mating parts to bed.

Therefore, avoid hard braking, high speeds or very bumpy roads during the break in period.

NOTE Only after the first 937 mi (1500

km) of running-in you can expect the best performance from the vehicle.

During break in, obey the following rules:

◆

Do not open the throttle abruptly or fully at low engine speed. This rule applies even after break in has been completed.

◆

During the first 62 mi (100 km), apply the brakes with caution, avoid sudden and prolonged braking. This ensures correct bedding in of the pads on the discs.

◆

During the first 625 mi (1,000 km), never

exceed 6,000 rpm.

aWARNING

After the vehicle has been operated for 625 mi (1,000 km) perform the “checking operations” shown in column “After running-in” of the REGULAR SERVICE INTERVALS CHART, see p. 74. Rectify any faults found. Failur e to heed this warning could lead to damage to your vehicle or engine s eizure or o ther malfun ction which could cause an upset and lead to serious injury or even death.

◆

Between the first 625 mi (1,000 km) and 937 mi (1,500 km) drive more briskly, changing speed and using maximum acceleration for only a few seconds. Never exceed 7,500 rpm.

◆

After the first 937 mi (1,500 km) if you have followed the above break in schedule, the engine should be fully broken in, and will deliver maxi mum performance. However, never exceed the ma ximum allowed rpm (10,500 rpm).

Engine maximum rpm

for the running-in

Mileage mi (km) Max. rpm

0 – 625 (0 – 1,000) 6,000

625 – 937

(1,000 – 1,500)

over 937 (1,500) 10,500

7,500

Page 3

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aWARNING

If possible, avoid stopping abruptly, slowing down suddenly and braking at the last moment.

Failure to comply wi th these instructions may cause an accident with consequent risk of serious injuries or even death.

◆

Release the throttle grip (1) (Pos. A), gradually put on the brakes and at the same time shift down in or der to decrease the speed, see p. 64 (RIDING).

Once the speed has decrea sed, before stopping the vehicle:

◆

Pull in the clutch lever (2) (Pos. B) in or- der to prevent the engine dying.

When the vehicle has come to rest:

◆

Position the shift lever (3) in neutral (green warning light “

◆

Release the clutch lever (2) (Pos. C).

◆

If you are stopping just briefly and not

q” (4) on).

shutting down the engine, keep one brake applied.

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aWARNING

Park the vehicle only on firm flat ground, otherwise it could fall over.

Do not lean the vehicle agains t walls, d o not lay it on the ground.

Park your vehicle away from children and pedestrians, so that they will not come in contact with hot parts.

Do not leave you r vehicle unat tended with the engine running or with the key in the ignition switch.

Do not sit o n the ve hicle wh en the s ide stand is down.

Do not get too close to the cooling fans (A). Even though they are not moving, they could start automatically and suck clothing, hair, etc. into the fan.

If the vehicle falls over, it will leak gasoline which is extremely flammable. Flames or sparks could cause a fire which could destroy not only your vehicle but also buildings arou nd it and cause injury or even death to people as well.

◆

Stop the vehicle, see p . 69 (STOPPIN G).

◆

Move the engine stop switch (1) to the

m” (OFF) position.

“

aCAUTION

Do not leave the ignition on if you have stopped the engine by moving the engine stop switch to the “ tion as this will discharge the battery. When the vehicle has come to rest after stopping the engine with the engine stop switch, turn the ignition switch (3) to the “

m” (OFF) position.

◆

Rotate the key (2) and move the ignition switch (3) to the “

◆

Position your vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

m” (OFF) posi-

m” (OFF) position.

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NOTE Neve r leave th e key in the igniti on

switch.

◆

Lock the steering, see p. 40 (STEERING LOCK) and extract the key.

When you have to park your vehicle in a dark or badly lighted area (parking lot or street), it is sometimes useful to leave the parking lights on s o that you r vehicle will be easily visible.

To leave the parking lights on: see p. 40 (PARKING LIGHTS).

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aWARNING

Position the vehicle on firm and flat ground.

SIDE STAND

◆

Grab the left handle gri p (4) a nd th e pa ssenger grab strap (5).

◆

Put the side stand (6) down with your right foot. Make sure it i s exte nded completely and all the way forward.

◆

Lean the vehicle to th e left u ntil the stand rests firmly on the ground.

◆

Turn the handlebars completely against the left stop.

aWARNING

Make sure the vehicle is stable when parked. If it falls down, it will certainly be damaged and could injure others as well.

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NEVER leave the key (1) in the ignition switch (2), always use the steering lock “ (LOCK). Try to park your ve hicle in a safe place, if at all possible, in a garage or other pro tected place. Lock your vehicle up using a chain and padlock around the rear wheel. Chain t he rear wheel to the swinging arm.

Make sure that all le gal req uire ments : reg istration, license plates, insurance, etc. are in order.

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Write down your name, address and telephone number and the vehicle identification number in the space below, to facilitate finding the owner in case your vehicle

s”

is recovered after theft.

SURNAME: ...............................................

NAME: ......................................................

ADDRESS: ...............................................

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

TELEPHONE NO.: ...................................

NOTE Ver y often stolen vehicles are

identified thanks to the data written in the use/maintenance manual.

Carefully read p. 2 (FOREWORD) and (INTRODUCTION), p. 3 (SAFETY WARNINGS) and (GENERAL SAFETY RULES), p. 5 (WARN INGS - PRECAUTIONS GENERAL ADVICE).

aWARNING

Risk of fire. Keep fuel and other flammable sub-

stances away from the electrical components.

Before beginning any main tenance operation or any inspection of the vehicle, stop the engine, remove the key (1) from the ignition swi tch (2), wait until the engine and the e xhaust syst em have cooled down and if possible lift the vehicle by means of the pro per equipment, on firm and flat ground.

Before proceeding, make sure that the room in which you are working is properly ventilated.

Page 7

Be careful to avoid hot parts of the engine and exhaust system. They are hot enough to cause serious burns.

Avoid the temptation to hold any part of the vehicle in your mouth . The c oati ngs and platings used are, in some cases, toxic.

aCAUTION

In general, reas sembly is perfor med in the reverse order of the disassembly instructions given here.

For some maintenance operations, especially those in which your hands are likely to come in contact with coolant, or engine oil, or gasoline, or bra ke fl uid, it is advisable to use thin disposable gloves, such as thos e made of latex, rubber or nitrile.

The routine maintenance operations described in this manual can usually be performed by the user. However, in some cases, specific tools a nd technical expertise may be required.

Do not hesitate to contact your Local aprilia Dealer who has all the latest factory information and tools to properly service your vehicle. Remember that many s ervic e opera tions, if done improperly, can be very hazardous. If you have any quest ions abou t your abili ty to carry out the operations described here, contact yo ur Local aprilia Dealer.

In all cases, personally carry out the “pre- liminary checking operations” after any maintenance, see p.61 (PRELIMINARY CHECKING OPERATIONS).

aWARNING

Remember that tightening torq ue of all fasteners on the wheels, brakes, axles, suspension are extremel y important to ensure safety, and must be maintained at the prescribed values.

Check the tightening torques of the fasteners regularly, and always use a torque wrench when installing them.

Failure to adhere to this warning could cause the loosening and subsequent loss of critical f asteners, which could cause a wheel to lock or cause other handling prob lems with consequent overturning, and the risk of serious injury or even death.

aWARNING

Fasteners mu st be neither over tightened or undertightened. If they are overtightened, the threads ma y be dam aged and the fa steners will be destroyed, whereas if they are undertightened, they can vibrate and become lost. Obviously, under these circumstances, a serious accident with resultant serious injury or death could ensue.

aCAUTION

After the first 6 25 mi (1,000 km) and successively every 4,687 mi (7,500 km), the word “SERVICE” (3) appear s on the ri ght display. In this case contact your Local APRILIADealer, who will carry out the operations indicated in the regular service intervals chart, see p. 74 (REGULAR SERVICE INTERVAL S CHA RT). To make the word “SERVICE” disappear, press the “LAP” push button (4) and then the push butto n pressed for about 5 seconds.

(5) and ke ep them

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THESE OPERATIONS MAY BE CARRIED OUT BY YOUR Local APRILIADealer, OR BY THE OWNER OF THE VEHICLE

Component

Tightness of the battery termin al s C C Spark plugs C (*) S Drive chain, tension and lubrication every 625 mi (1,000 km): C Air cleaner CS Fork C Light operation/direction C Light system C C Safety switches C C Clutch fluid C Brake fluid C Coolant every 625 mi (1,000 km): C Engine oil every 312 mi (500 km): C Tires C every 625 mi (1,000 km): C Tire pressure R every month: R Engine idling rpm R R

Engine oil pressure warning light LED “ Front and rear brake pad wear before every trip and every 4,687 mi (7,500 km): C

C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust. Perform these maintenance opera tions at on e-ha lf of he s pec ified interv als , if you r v ehi cle is often used in rainy or very dusty conditions, on unpaved roads, or in any kind of competition.

\”

After running-in

[625 mi (1,000 km)]

Every 4,687 mi

(7,500 km) or 8 months

at every start: C

Every 9,375 mi

(15,000 km) or 16 months

(*) = For competition use, change every 2,343 mi (3,750 km).

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THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED OUT BY Local APRILIADealer.

Component

Accelerator cables (adjustmen t) C Rear suspension linkage bearings C Steering bearings and steering C C Wheel bearings C Engine oil filter S S (*) Engine oil filter (on oil tank) P P Engine oil S S (*) Tappet clearance R R Braking systems C C Cooling system C Clutch fluid C every 2 years: S Brake fluid C every 2 years: S Brake pads if worn: S Coolant every 2 years: S Fork oil After the frist 4,687 mi (7,500 km): S / every 14,000 mi (22,500 km): S Wheels/tires C Nut, bolt, screw tightening C C Suspensio ns and attitude C C Brake fluid bleeding C Fuel pipes C every 4 years: S

C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust. Perform these maintenance operations at one-half of he sp ecifi ed in terva ls, if y our ve hicl e is o ften us ed in rainy or very dusty conditions, on unpaved roads, or in any kind of competition.

After running-in

[625 mi (1,000 km)]

Every 4,687 mi

(7,500 km) or 8 months

Every 9,375 mi

(15,000 km) or 16 months

(*) = For competition use, change every 2,343 mi (3,750 km).

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It is a good idea to write down the frame and engine numbers in th e space provided below. Use the frame number (VIN) to identify your vehicle when ordering sp are parts.

aWARNING

In all states and countries, it is against the law to alter the Vehicle Identification Number (VIN). You ca n incur severe penalties by doing this. Also, this will immediately invalidate your warranty.

FRAME NUMBER

The frame number is stamped on the right side of the fork head.

Frame no.

ENGINE NUMBER

The engine number is stamped on the rear part of the left engine crankcase.

Engine no.

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Carefully read p. 72 (MAINTENANCE).

aWARNING

Do not use gasoline or flammable solvents to wash the air cleaner, in order to avoid fire or explosion.

Inspect the air cleaner to ensure that it has not become clogged every 4,68 7 mi (7,50 0 km) or 8 months of use. Renew the air cleaner every 9,375 mi (15,000 km).

The air cle aner must be inspected mo re frequently, cleaned if necessary, and replaced more fre quently if the vehi cle is used on dusty or wet roads.

More frequent cleaning of the air cleaner is suggested, especially if yo ur bike is used under very dusty conditions.

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pressed air jets, they can cause serious personal injur y if directed towards your body.

◆

Grasp the air cleaner vertic ally and stri ke it repeatedly on a clean har d horizontal surface.

◆

If available, clean the air cleaner with a compressed air jet, directi ng it from the inside of the filter towards the outside.

◆

Clean the outer part of the air cleaner with a cloth.

aCAUTION

The air cleaner must not be use d for more than 9,375 mi (15,000 km) regardless of how many times it has been cleaned in the interval. Under very dusty or dirty conditions, it is advisable to replace the air filter more often.

Before the cleaning operation, it is necessary to remove the air cleaner from the vehicle.

REMOVAL

◆

Lift the fuel tank, see p. 94 (LIFTING THE FUEL TANK).

aCAUTION

Before unscrewing and removing the screws (1), clean the filter cas e cover (2) and the filter case (5) with a clean cloth. Prevent any foreign matter from getting into the inlet tubes. This could cause severe engine damage.

◆

Unscrew and remove the seven screws (1) that fasten the filter case cover (2).

◆

Remove the filte r case cover (2).

◆

Extract the air cleaner (3).

aCAU TION

Plug the opening with a clean cloth to prevent any foreign matter from entering the intake tubes.

CLEANING

aCAUTION

Take great care not to deform the perforated metal outside screen. It is very fragile and can be easily damaged. Never use a screwdriver or other sharp hard tool to remove the air cleaner itself.

aWARNING

During this operation, always wear goggles which provide your eyes with 360° protection. Be very careful using com-

CHANGING

◆

Replace the air cleaner with a new one of the same type.

◆

Make sure that the gasket (4) of the filter case (5) is intact; if it is damaged, replace it.

◆

Every 4,687 mi (7,500 km) remove the plug (6) so that any dirt that may have accumulated inside the filter case can be removed.

aCAUTION

When cleaning the air cleaner, make sure that there are no tears. Otherwise, replace the air cleaner. Make sure that the air cleaner is positioned correctly, in such a way as to prevent non-filtered air from entering. Premature wear of the piston ring s, pistons and cylinders is caused by an improperly installed air cleaner.

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Carefully read p. 46 (LUBRICANTS), p. 72 (M AINTENANCE) and p. 122 (LU BRICANT CHART) .

aWARNING

It is critical to the safe operation of your vehicle that the proper lubricants, mai ntained at the proper levels, are used. Failure to heed this warning can lead to an engine seizure wit h subseq uent accident, serious injury or death.

aWARNING

Remember that the tightening torque of all fasteners on the wheels, brakes, axles, and other components of the suspension system is very important to ensure the safety of the vehicle, and must be kept at the prescribed values. Check the tightening torque of the fasteners regularly, and always use a torque wrench when reinstalling them. Failure to comply with this warning could allow one of these compon ents to be lost which could lock a wheel or cause other handling pro blems with consequent overturning and risk of serious injury or even death.

CHECKING

NOTE Positi on the vehicle on firm a nd

flat ground.

aCAUTION

The engine oil level must be checked with warm engine. If the check is carried out with cold engine, the oil level may temporarily lower below the “MIN” mark.

This is not a problem, provided that the engine oil pressure warning light LED

j” does not come on, see p. 30 (IN-

“

STRUMENTS AND INDICATORS TABLE).

aWAR NING

Exhaust gases co ntain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in closed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

◆

Check the oil when the engine is warm, having been ridden for at least 10 mi (16 km).

NOTE If the engine is cold, warm it up

for riding, preferably on a hilly road, for approximately 10 mi (16 km) before checking the oil.

◆

Stop the engine before checking the oil.

aWARNING

Should your vehicle overturn, it will leak gasoline, which is extrem ely flamm able. Flames or sparks may cause a fire, which could destroy not on ly the vehicle, but also the bu ilding in which it is located, and cause serious injuries or even death.

◆

Keep the vehicle in vertical position, with the two wheels resting on the ground.

NOTE If yo u attemp t to chec k the oil with

the vehicle leaned in either direction from the vertical, your measurement w ill be inaccurate.

NOTE If the engine oil tank is dirty, wipe

it with a clean c loth s o th at y ou can see the “MIN” and “MAX” marks.

◆

Look through the appropriate slot (1) in the left fairing. Check the level of the oil in the sight gauge (2).

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Page 13

MAX = maximum level MIN = minimum level

The difference between “MAX” and “MIN” is about 0.53 US qt (500 cm#).

◆

The level is correct if the oil reaches approx the “MAX” mark.

aWARNING

Never exceed the “MAX” mark, nor leave the oil below the “MIN” mark, in order to avoid serious damage to the engine.

If necessary, top up the engine oil tank:

aWARNING

When warmed up, the engine contains hot oil and the engine oil tank (3) is warm; therefore, while carrying out the operations describe d here below be particularly careful, in order to avoid burns.

aCAU TION

Use thick gloves to prevent burns.

◆

Remove the left fairing, see p. 96 (REMOVING THE SIDE FAIRINGS).

aCAU TION

Before unscrewing and removing the filler cap (4), clean it and the area of the tank around it with a clean cloth. Prevent any foreign matter from falling into the oil tank, this could cause serious engine damage. Do not use any flammable solvents such as alcohol or gasoline when wip ing the oil tank. The oil tank is hot enough to cause igniti on of flammable solvents. Use only a nature fiber cloth, i.e. cotton . Man made fabrics such as polyester, etc. could ignite.

◆

Unscrew and remove the filler cap (4).

aCAUTION

When topping up, never exceed the “MAX” level.

◆

Top up the engine oil tank (3) through the filler neck (5), with high-quality engine oil, see p. 122 (LUBRICANT CHART).

◆

Replace and tighten the filler cap (4).

aWARNING

Tighten the filler cap (4) snugly to insure no oil leak.

◆

Replace the left fairing, see p. 96 (REMOVING THE SIDE FAIRINGS).

aWARNING

Never ride your vehicle with low engine oil, or with contaminated oil, or with unapproved oil. Any of these will greatly accelerate wear of yo ur engine, and cause irreparable damage.

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Carefully read p. 72 (MAINTENANCE) and p. 81 (CHECKING THE SWITCHES).

The side stand (1) must rotate about its pivot smoothly and easily.

Perform the following checks:

◆

The springs (2) must be free from damage, wear, or rust, and must fully and firmly retract the side st and when the weight of the vehicle is lifted off of it.

◆

The side stand (1) must rotate freely about its pivot. If necessary, lubricate the pivot, see p. 122 (LUBRICANT CHART).

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The side stand (1) is equipped with a safety system, operated by safety switch (3).

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This system prevents the motor from being started while the stand is extended unless the transmission is in neutral. It also kills the engine if the stand is extended while the engine is running, unless the transmission is in neutral.

T o check the proper funct ioning of th e safety switch (3):

◆

Sit on the vehicle in the normal ridi ng position.

◆

Retract the side stand (1).

aWAR NING

◆

Start the engine, see p. 62 (STARTING).

◆

Release the throttle grip (4) (Pos. A). With the engine idling, pull in the clutch lever (5) completely.

◆

Engage first gear, pushing the shift lever (6) downwards.

◆

Extend the side stand (1).

NOTE Extending the side stand mu st kil l

the engine and the “side stand down” warning light “ gine continues to run:

◆

\” (7) must come on. If the en-

Check the s afety switch (3) o n the side stand (2), see p. 81 (CHECKING THE SWITCHES). Perform t he necessary cleaning or repairs. Repeat the check.

aWARNING

If the engine does not stop when the side stand is extended, do not ride your vehicle. Contact your Local APRILIA Dealer.

Page 15

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Carefully read p. 72 (MAINTENANCE).

Check the switches after the first 625 mi (1,000 km) and thereafter every 4,687 mi (7,500 km).

The vehicle is equipped with four switches:

– stoplight switch on the rear brake pedal

(1);

– stoplight switch on the front brake lever

(2);

– safety switch on the side stand (3); – clutch lever switch (4).

◆

Make sure that there is no dirt or mud on the switch. The switch pin must move freely and without interference, returning automatically to its unapplied position.

◆

Check the spring (5) ; it must not be dam aged, worn or stretched.

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aCAU TION

The front fork oil change operation should be entrusted to your L ocal APRIL IADealer.

Carefully read p. 72 (MAINTENANCE).

Have the front fork oil chan ged after the 4,687 mi (7,500 km) an d thereafter every 14,000 mi (22,500 km).

Every 4,687 mi (7,500 km), carry out the following checking operations:

◆

Apply the front brake lever and push up and down on the ha ndlebar repeate dly, pushing the fork up and down. The fork must move smoothl y and easily, there must be no trace of oil on the fork tubes.

◆

Check the t orque of all th e fasteners on the front fork and inspect the entire front fork to make sure that it is in good condition without leaks or dam age. Repeat for the rear suspension and swinging arm.

aCAUTION

Do not ride your vehicl e if either suspension is damaged in any way, contact your Local APRILIADealer.

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The front suspension consists of an hydraulic fork connected to the steering column by means of two plates.

For the setting of the vehicle attitude, each rod of the fork is provided with an upper screw (1) f or t he ad j us t me nt of t he hy dr a ulic damping on extension, a lower screw (2) for the adjustment of the hydrauli c damping on compression and an upper nut (3) for the adjustment of the spring preload.

NOTE It is possible to adj us t the atti tud e

of the vehicle, by changing the height of its front part. For this type of adjustment, contact your Local aprilia Dealer.

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Page 17

ADJUSTING THE FRONT FORK

The front fork is adjusted at the factory to suit most riding conditions for most riders. However, it is pos sible to adjust the fork s etting to your preference, and to accommodate the full range of operating conditions that the vehicle is intended to be used for.

aCAUTION

When adjusting the fr ont fork, always start from the most rigid setting. Do not rotate adjusters (1) and (2) beyond their limit position, to avoid damaging the threads.

Use the notches (1) and (2) provided on the adjusters as refere nce ma rks for the adjustment of hydraulic damping on extension and hydraulic damping on compression.

Turn the adjusters (1) and (2) 1/8 turn at a time and turn the a djus ting nut (3) one notch at a time. Then, test the ve hicle on the road, to ensure you have obtained the optimal adjustment.

Make sure that the spring preload and hydraulic damping, both on extension and compression, is the same for both sides. A different shock absorber setting on the left and right side will decrease the stability of the vehicle.

When the spring preload is increased, it is necessary to also increase the hydraulic damping, both on extension and compression, to avoid a jerky unsteady shock action while riding.

Upper screw adjusters (1) (2.25 turns in total)

Function Increase of the hydraulic

Recommended kind of road

Notes Rider and passenger Solo rider Standard adjustment From the completely clockwise position, 1.5 turns counter-

Lower screw adjusters (2) (2 turns in total)

Function Increase of the hydraulic

Recommended kind of road

Notes Rider and passenger Solo rider Standard adjustment From the completely clockwise position, 1.5 turns counter-

Upper adjusting nuts (3) (8 notches in total)

Function Spring preload increase Spring preload decrease Attitude The vehicle is more rigid The vehicle is less rigid Recommended kind

of road Notes Rider and passenger Solo rider Standard adjustment Turn the adjustin g nut 5 notch es cou nte rcl oc kwis e from the

By rotating them clockwise (H)

damping on extension Smooth or normal roads Roads with uneven surface

clockwise

By rotating them clockw ise (H)

damping on compression Smooth or normal roads Roads with uneven surface

clockwise

By rotating them clockwise (screwing)

Smooth or normal roads Roads with uneven surface

fully clockwise setting

By rotating them counterclockwise (S)

Decrease of the hydraulic damping on extension

By rotating them counterclockwise (S)

Decrease of the hydraulic damping on compression

By rotating them counterclockwise (unscrewing)

use and maintenance RSV mille

Page 18

2%!23530%.3)/.

The rear suspension consists of a hydraulic shock absorber - spring unit, which is mounted to the frame with a uniball, and to the swinging arm by means of a system of levers.

The ride height of the rear of the vehicle can be set using the spring preload adjusting ring nut (3) and locking ri ng nut, (4). The rear suspension can be tuned by adjusting the extensi on damping with a spring adjuster (1), the damping on compression can be adjusted by a knob (2).

ADJUSTING THE REAR SHOCK ABSORBER

The rear shock absorber is set at the factory to satisfy most ridin g conditi ons, at either low or high speed, and with e ithe r a li ght or full load. However, it is pos sible to tu ne the suspension to y our prefe rence by u sing the above mentioned adjustments.

aCAU TION

When adjusting the rear shock absorber, always start from the stiffest position. This is the fully clockwise position of the extension damper adjusti ng screw (1) and the compression damper knob (2).

Do not rotate the extension damper adjustment screw (1) beyond its limit , this will damage the screw and destroy your shock absorber.

Always make sure, when adjusting screw (1), that it clicks in to an adjustment notch, and is not at a position intermediate between adjustment notches.

The distance between the top of the adjustment ring and the top of the threads must not exc eed 1.10 ± 0.2 0 in (28 ± 5 mm). Adjusting the nut further down on the shock will compress the spring excessively, and result in an uneven bumpy ride. Also, it will be impossible to adequately adjust the extension damping using screw (1).

◆

Loosen the locking rin g nu t (4) b y m ean s of the appropriate spanner wrench.

◆

Adjust th e adjus ting ri ng nut (3) (see figure).

◆

If necessary, adjust the extension damping screw (1) (see table p. 85).

◆

Once the ride height has been properly adjusted, tighten the lock ring nut (4) completely.

◆

Slightly loosen the lock nut (5).

Rotate the adjuster (6) one tu rn at a time so that the adjusting screw (1) faces out to the left side of the vehicle.

◆

Using the appropriate wrench, turn the adjuster ( 6) (whi ch adjust s the ce nter to center distance of the shock absorber unit) (see table p. 85).

use and maintenance RSV mille

Page 19

NOTE Adjust the spring preload and the

extension damping according to t he vehicle use. When the spring preload is increased, it is also necessary to increase the extension damping in order to avoid a bumpy uneven ride. Especially at hi gher preload setti ngs, it is advisable to use full extension damping (screw (1) fully clockwise) or only a couple of clicks clockwise, to avoid a bumpy uneven ride. If necessa ry, c on tac t y our L oc al aprilia Dealer.

Never remove the plug (7) o r attempt to adjust the valve covered by it. This may cause nitrogen to escape which will destroy the function of the shock absorber and could upset the handling of your vehicle, leading to an ac ciden t with subse quent injury or even death.

Never exceed 2-3 clicks with the extension damping adjustment (1) or 5-6 cli cks with the compression dampi ng a dju stmen t kn ob (2), or one turn with the preload adjusting nut (3) at any given ad justment attempt. Ride the vehicle for more than just a few miles on the road between each adjustment, to determine the adjustments most suitable to your use.

Screw adjuster (1) (27 clicks)

Function Increase of the hydraulic Recommended kind

of road Notes Rider and passenger Solo rider Standard adjustment Turn the screw adjuster 14 clicks counterclockwise from its

Knob adjuster (2) (40 clicks)

Function Increase of the hydraulic Recommended kind

of road Notes Rider and passenger Solo rider Standard adjustment Turn the knob 10 clicks clockwise f rom its completely open,

Adjusting ring nut (3) By screwing it By unscrewing it Function Spring preload increase Spring preload decrease Attitude The vehic le is more rigid The vehicle is less rigid Recommended kind of

road Notes Rider and passenger Solo rider

Adjusting nut (6) By unscrewing it By screwing it Function Increase the cen ter-to-center

Attitude The vehic le is highe r The vehicle is lower Recommended kind

of road Notes Rider and passenger Solo rider

By rotating it clockwise (H) By rotating it

damping on extension Smooth or normal roads Roads with uneven surface

most clockwise position

By rotating it clockwise ( +)

damping on compression Smooth or normal roads Roads with uneven surface

most counterclockwise position

Smooth or normal roads Roads with uneven surface

mount distance

Roads with uneven surface Smooth or normal roads

counterclockwise (S)

Decrease of the hydraulic damping on extension

By rotating it counterclockwise (–)

Decrease of the hydraulic damping on compression

Decrease the center-tocenter mount distance

use and maintenance RSV mille

Page 20

#(%#+).'4(%"2!+%0!$7%!2

Carefully read p. 47 (BRAKES), p. 48 (DISC BRAKES) and p. 72 (MAINTENANCE).

NOTE Your vehicle is equipped with

disc brakes and two separate brake systems. The front brake system is equipped w ith two discs, one on the right and one on the left side of the front wheel. The rear brake system is equipped with a single disc on the right side of the wh eel. The following information may re fer to a single braking system, but is applicable for both braking systems.

Check the brake pa d wear after the first 625 mi (1,000 km), before every trip and thereafter every 4,687 mi (7,500 km). The amount of wear that the brake pads experience depends on how the vehicle is

used, how aggressively it is driven, and the condition of the roads upon which it is operated. Wear will be faster than no rmal when the vehicle is driven aggressively, or on dusty or wet roads.

aWAR NING

Check the wear o f the brake pad s before ever y trip.

CHECKING WEAR OF T HE BRAKE PADS

◆

Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Perform a visual check of the fric tion material thickness. Use a flashlight. See the arrows (1) and (2) above.

If the friction material on one pad of a pair, front (3) or re ar (4) , is w orn to 0.06 in (1.5 mm) or less, replace both pads.

aWARNING

Excessive wear of the friction m aterial would cause the contact of the pad metal support with th e disc, with consequent metallic noise and production of sparks from the caliper; braki ng efficiency and safety will be s eriou sly com promised. This could lead to a crash, with subsequent serious injury or death.

aWARNING

Have the pads changed by your Local APRILIADealer.

use and maintenance RSV mille

Page 21

#(%#+).'4(%34%%2).'

The operations necessary to this check require specific skills and therefore should be carried out by your Local

APRILIADealer.

#(%#+).' 4(%37).').'!2-0)6/4

The operations necessary to this check require specific skills and therefore should be carried out by your Local

APRILIADealer.

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NOTE Have so meon e help you kee p the

vehicle in vertical position with the two wheels on the ground.

aWARNING

Lift the vehicle by grasping the two pins (1) only.

◆

Lift (Pos. A) the rear part of the stand (2), insert it from the back of the vehicle and position it so that the two housings (3) of the support pins (4) hook the two pins (1) provided on the vehicle.

If the housings (3) do not a lign with the two pins (1):

◆

Loosen the two knob (5).

◆

Slide the two support pins (4) so that the two housings (3) of the support pins (4) coincide with the two pins (1).

◆

Tighten the two knobs (5).

◆

Rest one foot on the rear part of the stand (2).

◆

Push (Pos. B) the stand (2) downwards until it reaches the end of its stroke (see figure).

0/3)4)/.).'4(%6%()#,%/. 4(%&2/.43500/2434!.$

◆

Position the vehicle on the appropriate rear support stand SITIONING THE VEHICLE ON THE REAR SUPPORT STAND

◆

Lift (Pos. C) the front part o f the stand (6) and insert the its two ends of the stand (7) in the two holes (8) positioned on the lower ends of the front fork.

◆

Rest one foot on the front part of the stand (6).

◆

Push (Pos. D) the stand (6) downwards until it reaches the end of its stroke (see figure).

use and maintenance RSV mille

&, see beside (PO-

&).

Page 22

&2/.47(%%,

aWARNING

The disassembly and reassembly of the front wheel can be diffic ult for t hose u nfamiliar with vehicle maintenance. You may wish to have your Local APRILIA Dealer car ry out thes e operatio ns.

If you wish to perform these operations yourself, caref ully read p. 72 (MAINTENANCE).

While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.

Before carrying out the following ope rations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

NOTE You must use the ap propriate

front and rear support stands to remove the front wheel.

use and maintenance RSV mille

DISASSEMBLY

◆

Position the vehicle on the appropriate rear support stand (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND

◆

Position the vehicle on the appropriate front support stand & (2), see p. 87 (POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND

& (1), see p. 87

&).

aWAR NING

Make sure that the vehicle is stable. If it falls over, it ma y cause damage to bystanders and other p roperty, as well as being damaged itself.

◆

Have a helper steady the handlebar in the straight ahead position.

◆

Remove the left and right front bra ke caliper (3), see p. 98 (REMOVING THE FRONT BRAKE CALIPERS).

aCAU TION

Never touch the front brake lever after removing the brake calipers from the discs. If you do, the cali per pistons ma y be pushed out of their seats, and brake fluid will be spilled. Shou ld you accidentally do this, take you r vehicle to your Local APRILIADealer who will know how to repair this damage.

◆

Place a support (4) under the front tire, in such a way as to keep the wheel in its position after loosening it.

◆

Hold the axle (5) from rotating with an appropriate Allen wrench .

Wheel nut (6) tightening torque:

57.86 ftlb (80 Nm).

◆

Remove the nut (6) and washer (7).

Screw (8) tightening torque:

15.91 ftlb (22 Nm).

◆

★ Loosen the two axle c lamp screws (8),

using the appropriate Allen wrench.

Page 23

NOTE Observe the arrangement of the

left spacer ring (9) and of the right spacer ring (10), in order to be able to reassemble them correctly.

NOTE To facilitate the extraction of the

axle (5), slightly lift the wheel.

◆

Push the axle (5) partly out of the front fork by tapping the threaded end with a rubber hammer or wooden drift.

◆

Support the front wheel and remove the axle (5) manually by pulling it from the left side of the vehicle.

◆

Remove the wheel by pulling it forward.

NOTE The left spacer ring (9) and the

right spacer ri ng (10) remain locate d in their seats on the wheel; but if they have come out, replace them.

REASSEMBLY

◆

Apply a thin film of lubricating grease, see p. 122 (LUBRICANT CHART), to the front axle (5).

NOTE Perform the two follow opera tions

only if the left spa cer ring (9) and/or t he right spacer ring (10) have come out of their seats on the wheel:

aCAUTION

The left spac er ring (9) and the ri ght spacer ring (10) have d ifferent shapes: do not mix them up and pay extra care to correctly install them.

◆

Install the right spacer ri ng (10) in its s eat on the wheel (right sid e) with the larger diameter towards t he o uts id e of the ve hi-

cle (see figure).

◆

Install th e left spacer ri ng (9) in its se at on the whell (left side of the wheel).

aCAU TION

The arrow (11) on the wheel side indicates the rotation direction. Upon reassembly, ma ke su re th a t th e wh ee l is po sitioned correctly: the arrow must be visible on the left side of the vehicle.

◆

Position the wheel between the fork tubes on the support (4).

aWARNING

The front wheel is heavy and can easily crush your fingers should you get them between any part of the wheel and the front fork. Do not attempt to line up the wheel and the axle clamps with y our fingers. Failure to heed this warning can lead to serious personal injury.

◆

Move the wheel around until the axle hole and the axle clamps are aligned.

◆

From the left side of the vehicle, insert the axle (5) and push in completely.

◆

Install the washer (7) and nut (6). Tighten finger tight.

◆

Hold the axle (5) from rotating using the Allen wrench.

◆

Tighten the nut (6) to its appropriate tightening torque.

Nut (6) tightening torque:

57.86 ftlb (80 Nm).

◆

Replace the left and r igh t fron t bra ke cal iper (3), see p. 98 (REMOVING THE FRONT BRAKE CALIPERS).

◆

Remove the front support stand & (2), see p. 87 (POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND

&).

◆

Remove the rear support stand & (1), see p. 87 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND

◆

Apply the front brake lever, and then push down on the handlebars, compressing the fork springs several times. This will align the fork tubes.

◆

★ Tighten the two axle clamp screw (8).

Screw (8) tightening torque:

15.91 ftlb (22 Nm).

&).

aWAR NING

After servicing the brakes, always check them for function. If th e s troke of the lever or pedal is excessive, or if you detect that the effecti veness of the brakes is reduced i n any w ay, ha ve you r vehicle serviced by your Local APRILIA Dealer. It may be necessar y to have your dealer bleed the system, or there may be some other problem with the brake system.

Never ride your vehicle in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your vehicle. Then, try your vehicle in a parking lot or other safe area with little traffic to ensure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subseque nt serious injury or death.

use and maintenance RSV mille

Page 24

2%!27(%%,

aWARNING

The disassembly and reassembly of the rear wheel can be difficult for those unfamiliar with vehicle maintenance. You may wish to have your Local APRILIA Dealer carry out these operations.

If you wish to per form these oper ations yourself, car efully read p. 72 (MAINTE NANCE).

While disassembling and reassembling the wheel, pay extra care not to damage the brake lines, discs or pads.

Before carrying out the following ope rations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

NOTE You must use the appropriate rear

support stands to remove the rear wheel.

DISASSEMBLY

◆

Position the vehicle on the appropriate

use and maintenance RSV mille

rear support stand & (1), see p. 87 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND

&).

aWAR NING

Make sure that the vehicle is stable. If it falls over, it may cause injury to bystanders and other property, as well as being damaged itself.

◆

Place a support (2) under the tire, in such a way as to keep the wheel in its position after loosening it.

Wheel nut (3) tightening torque:

86.80 ftlb (120 Nm).

◆

Remove the nut (3) and recover the washer (4).

NOTE To facilitate the extraction of the

axle (5), slightly lift the wheel.

◆

Remove the axle (5) from the left side of the vehicl e.

NOTE Observe the arrangement of the

right (6) and left (7) chai n tensioners in or-

der to be able to reassemble them correctly.

◆

Remove the right (6) and left (7) chain tensioners.

aWARNING

Keep your fingers well away from the chain and sprocket. You could easily lose a finger if it becomes pinched between these two parts. Use heavy work gloves while installing th e rear wheel. Never at tempt to line the rear wheel up using your fingers. Failure to heed this warning can result in serious personal injury.

◆

Remove the drive chain (8) from the rear sprocket (9) and lay it down outside of the rear sprocket.

NOTE Place the dr ive chai n (8) ou tsi de

of the rear sprocket (9).

◆

Move the wheel forward and pull the d rive chain (8) away from the rear sprocket (9).

◆

Pull the wheel backwards, removing it from the swing arm from behind, carefully removing the disc from the brake caliper.

Page 25

aCAUTION

Never touch the rear brake pedal after removing the rear wheel . If you do, the caliper pistons may be pushe d out of their seats, and brake fluid will be spilled. Should you accidentally do this, take your vehicle to your Loca l APRILIADealer who will know how to repair this damage.

NOTE The left spacer ring (10) and the

right spacer ring (11) remain locate in their seats on the wheel; but if they have come out of their seats retrieve them.

REASSEMBLY

aCAUTION

While reassembling the rear wheel, be careful not to damage the brake line , the disc and the pads.

NOTE Perform the follow operation only

if the left spacer ring (10) and/or the right spacer ring (11) have come out of their seats on the wheel:

◆

Install the left (10) and right (11) spacer rings in their seats on the wheel with the larger diameter to wards the outside of the vehicle (see figure).

aCAUTION

Before proceeding with the reasse mbly, make sure that the torque plate (12) of the brake caliper (13) is posit ioned corr ectly; the plate slot mu st be in serted in the appropriate stop pin (14) in the inner part of the right side of the swinging arm. Insert the disc in the brake caliper carefully.

◆

Position the wheel centrally in the swinging arm, on the support (2).

aWARNING

Keep your fingers we ll away from the chain and sprocket. You could easily lose a finger if it becomes pinched between these two parts. Use heavy work gloves while installing the rear wheel. Never attempt to line the rear wheel up using your fingers. Failure to heed this warning can result in serious pers onal injury.

◆

Move the wheel as far forward as possible, to ins tall the driv e chain (8) on the rear sprocket (9).

◆

Pull the rear wheel backwards unti l the bearing holes are lined up with the holes in the swinging arm.

◆

Rotate the torque plate (12), complete with brake caliper (13), with the stop pin (14) in proper position until it is appropriately aligned with the holes in the swing arm.

◆

Install the right (6 ) and left (7) c hain t ighteners in their seats on the swing arm.

◆

Apply a thin film of lubricating grease, see p. 122 (LUBRICANT CHART), to the rear axle (5).

NOTE To facilitate the insertion of the

axle (5), slightly lift the wheel.

◆

Install the axle (5) completely through the wheel from the left side.

NOTE Ensure that the ax le (5) is pushe d

all the way home with the head in the appropriate seat on the left chain tightener.

◆

Install the washer (4) and tighten the nut (3) finger tight.

◆

Remove the support (2) from under the rear tire.

◆

Check the chain tension, see p. 92 (DRIVE CHAIN).

◆

Tighten the nut (3).

Wheel nut (3) tightening torque:

86.80 ftlb (120 Nm).

aWAR NING

Never ride your veh i c le in traffic immediately after servicing the brakes. Always apply the brake pedal or lever several times before riding your vehicle . Then, try yo ur v eh i cl e in a park ing lo t or other safe area with little t raff ic to ens ure that the brakes are working properly. Failure to observe this warning can lead to a serious accident with subsequent serious injury or death.

Check the wheel centering. Have the tightening torques, centering

and balancing of the wheel checked by your Local APRILIA Dealer. These are critical safety operations, and failure to observe this warning could lead to an upset with subsequent serious injury or death.

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Page 26

$2)6%#(!).

Carefully read p. 72 (MAINTENANCE).

Every 312 mi (50 0 km) check the conditions, the wear, the play (tension) and the lubrication of the drive chain. The vehicle is equipped with an endle ss chain. There is no master link used.

aWARNING

An excessively loose chain may cause noise or make the c hain rattle, with consequent wear of the shoe and of the chain guide plate.

Do not ride your vehicle with an improperly adjusted chain, see p. 93 (ADJUSTMENT).

To inspect the conditio n of the chain, grasp the chain where it goes around the sprocket and try to pull it away from the sprocket. If you can move it more than one-eighth of a n inch away from the sprocket, the chain is worn out and the chain and both front and rear

use and maintenance RSV mille

sprockets must be replaced. See your Local APRILIADealer.

aCAUTION

Lack of maintenance can cause premature wear of the chain an d damage to the sprockets.

Maintain your chain more often if your vehicle is used on dusty or muddy roads.

aWAR NING

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

aWAR NING

Keep your fingers well clea r of the chain and sprocket, especially if you are turning the rear wheel while working on the vehicle. You can easily be seriously injured if a finger is caught between the chain and sprocket. Use work-gloves to carrying out these operations.

CHECKING THE PLAY

To check the play:

◆

Stop the engine.

◆

Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND)

◆

Shift to neutral.

◆

Check the chain play. It should be 0.98 in (25 mm) at mid-bottom span as

shown above.

◆

Move the vehicle forward or backward, or support the rear wheel in the air and turn the wheel to several positions, to check the chain slack at several locations. If the slack is markedly different with the wheel in different positions, the chain and sprockets must be replaced.

aWARNING

Do not ever operate your vehicle with a damaged chain. This could cause wheel seizure which could lead to an upset with subsequent serious injury or death. Lubricate your chain frequently

Page 27

to minimize the possibility of this kind of damage, see p. 93 (CLEANING AND LUBRICATION).

If the play is the same at several locati ons, but is more or less than 0.98 in (25 mm), adju st it, see below (ADJUSTMENT).

ADJUSTMENT

NOTE To adjust the chain it is neces-

sary to use the a ppropriate rear su pport stand

To adjust the chain tension:

◆

Position the vehicle on the appropriate rear support stand &, see p. 87 ( POS ITIONING THE VEHICLE ON THE REAR SUPPORT STAND

Wheel nut (1) tightening torque:

86.80 ftlb (120 Nm).

◆

Loosen the nut (1) to several turns.

&).

NOTE In order to make wheel centering

in the swingi n g a rm ea s ie r, th ere ar e r ef er ence marks (2) and (3) on the swing arm. See illustration above.

◆

Loosen the two lock nuts (4).

◆

Adjust the tension adjusters (5) to obtain the appropriate chain play, ensuring that the edge of tension adjuster is in the same position with regard to the reference marks (2) and (3) on each side of your vehicle.

◆

Tighten the two lock nuts (4).

◆

Tighten the nut (1).

Wheel nut (1) tightening torque:

86.80 ftlb (120 Nm).

◆

Check the chain play again, see p. 92 (CHECKING THE PLAY).

CHECKING THE WEAR OF THE CHAIN AND SPROCKETS

In addition to the check, see p. 92 (CHECKING THE PLAY), inspect the chain an d sprockets to make sure that there are no:

– damaged rollers; – loose pins; – dry, rusty, crushed or seized links; – excessive wear; – missing O rings; – sprocket or teeth excessively worn or

damaged. You may check the wear of the chain and sprocket by grasping the chain where it con-

tacts the rear sproc ket, and pull ing it away from the sprocket as far as you can. If you are able to pul l the chai n far enough away from the sprocket so that you can see light between the side plates of the chain and the sprocket teeth, the chain and sprocket are worn out and should be replaced.

NOTE Always replace both sprockets

and the chain wh en any of these co mponents are replaced.

aCAU TION

If chain rollers are d amaged, the pins and/or the O rings are loose or missing, both sprockets as well as the chain must be replaced.

aCAU TION

Lubricate the chain frequently, especially if it displays any rust or if it is dry to the touch. If, after lubricating the chain, it still has li nks which ca nnot be tu rned easily, the chain must be replaced.

◆

Check the wear of U- sha pe d c hai n gu id e (6).

◆

Finally, check the wear of the rear fork protection shoe.

CLEANING AND LUBRICATION

aCAUTION

The drive chain is provided with O ri ngs among the links, in order to keep the grease inside them. Carry out chain adjustment, lubrication, cleaning and replacement with great care. Remember to keep your fingers clear of the chain and sprocket.

Never wash the chain with water jets, steam jets, high-pressure water jets and highly inflammable solvents.

◆

Wash the chain with a non-flammable solvent. If your chain rusts quickly, lubri-

cate it more often. Lubricate the chain every 312 mi (500 km) or whenever it appears dry. After washing the chain and letting it dry, lubricate it exclusively with spray grease for chains provided with sealing rings, see p. 122 (LUBRICANT CHART).

aCAUTION

Make sure that the chain lubric ant you use is appropriate for “O” ring chains. There are some lub ricants available which contain subst ances which will destroy the “O” rings in your chain. If you have any question , contact yo ur Local APRILIADealer.

NOTE Do not use the vehicle immedi-

ately after lubricat ing the ch ain , gi ve the lubricant a chance to dry, otherwise the chain will spray the lubricant all over you and your vehicle.

use and maintenance RSV mille

Page 28

2%-/6).'4(%2)$%23!$$,%

◆

Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

★

Partially lift the rear side edge of the

rider saddle.

◆

★

Unscrew and remove the screw (1)

and take the bushing.

Screw (1) driving torque:

8.68 ftlb (12 Nm).

◆

Lift and remove the saddle (2).

NOTE Upon reassembly, insert the front

tang of the saddle in the appropriate seat.

aCAUTION

Do not leave you r vehicle unat tended without ensuring that the saddle (2) is properly positioned and l ocked. Should you forget and ride away with the saddle loose, you could be injured.

,)&4).'4(%&5%,4!.+

Carefully read p. 44 (FUEL) and p. 72 (MAINTENANCE).

aWAR NING

Risk of fire. Wait until the engine and the exh aus t silencer have completely cooled down. Fuel vapours are noxio us for your health. Make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Do not smoke and do not use naked flames.

DISPOSE OF UNWANTED FUEL PRO PERLY.

aCAUTION

Never drain the fuel tank, either partially or completely. This may cause damage to the inner components of the fuel tank, or to other parts of the fuel system.

Always ensure that the fuel filler cap is correctly closed.

◆

Remove the passenger saddle (or passenger saddle cover o), see p. 41 (UNLOCKING / LOCKING THE PASSENGER SADDLE).

◆

Remove the rider saddle, see beside (REMOVING THE RIDER SADDLE).

◆

Rotate the handlebars to the straight ahead position.

◆

Unscrew and remove the tw o screws (3) that fasten the front part of the fuel tank (4).

◆

Remove the fuel tank support rod (7) from its seats (5-6).

◆

Lift the front part of the fuel tank (4). Prop it into position using the rod (7) as shown in the figure.

use and maintenance RSV mille

Page 29

2%-/6).'4(%&2/.40!24 /&4(%&!)2).'

Carefully read p. 72 (MAINTENANCE).

◆

Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Turn the ignition switch (1) to “m“ (OFF) position.

◆

Unscrew and remove the two lower screws (2).

◆

★

Unscrew and remove the side screw

(3).

aCAUTION

The rear-view mirrors remain attached to the front part of the fairing, but they will not be not attached firmly. Do not use the mirrors to handle the fairing, as you will damage both mirrors and fairing.

◆

★

Unscrew and remove the two upper

screws (4).

★ NOTE T he position of the plate (5 )

and how it fits with the seat (6) on the support frame on the front part of the fairing for reassembly.

aCAU TION

Handle the plastic and painted components with care and avoid scraping or damaging them. Be very careful not to damage the electrical cables.

◆

Move the front part of the fairing (7) slightly forward.

◆

Lift the r ubber boot (8).

◆

Disconnect the electric connector (9) of

the headlight.

aWAR NING

Upon reassembly, make sure that the electric connector (9) is correctly coupled.

◆

Remove the front part of the fairing (7)

completely, together with the headlight

and the rear-view mirrors.

aCAUTION

Upon reassembly, tighten the screws only moderately. Be careful not to over tighten the screws, this will damage the surrounding plas tic and painted components.

use and maintenance RSV mille

Page 30

2%-/6).'4(%3)$%#/6%23

Carefully read p. 72 (MAINTENANCE).

aWARNING

Before carrying out the following ope rations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Unscrew and remove the two screw s (1).

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them.

◆

Remove the side cover (2).

NOTE Upon reassembly, make sure that

the rear coupling is positioned correctly. Repeat these operation s to remove the

other side cover.

use and maintenance RSV mille

aCAUTION

Upon reassembly, tighten the screws only moderately. Be careful not to over tighten the screws, this will damage the surrounding plas tic and painted components.

2%-/6).' 4(%2%!26)%7-)22/23

Carefully read p. 72 (MAINTENANCE).

◆

Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Unscrew and remove the nut (3), remove the washer (4), the spring (5) and the half sphere (6).

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them.

◆

Remove the rear-view mirror (7).

◆

If it has fallen from its seat, retrieve the cup (8).

NOTE Repeat th ese operations to re -

move the other rear-view mirror.

aWAR NING

After reassembly, correct ly adjust the rear-view mirrors and tighten the nuts in such a way that the mirrors are secure. Failure to heed this wa rning can prev ent you from seeing danger approaching from behind and lead to a serious accident.

2%-/6).'4(%3)$%&!)2).'3

Carefully read p. 72 (MAINTENANCE).

aWARNING

Before carrying out the following ope rations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Rotate the six quick turn screws (9) by giving them 1/4 turn counterclockwise.

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them.

◆

Remove the side fairing (10).

NOTE Re peat these oper ations to r e-

move the other side fairing.

Page 31

2%-/6).'4(%,/7%2&!)2).'

Carefully read p. 72 (MAINTENANCE).

NOTE To remove the lower fairing, it is

necessary to use the appropriate rear support stand

◆

Position the vehicle on the appropriate rear support stand, see p. 87 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND

◆

Remove the two side fairin gs, see p. 96 (REMOVING THE SIDE FAIRIN GS) .

&).

aWAR NING

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Unscrew and remove the two front screws (11).

◆

★

Unscrew and remove the rear screw

(12).

◆

Unscrew and remove the two screws (13) of the rear right profile (14) (inside the exhaust silencer).

aCAUTION

Handle the plastic and painted components with care and avoid scraping or damaging them.

◆

Extend the side stand.

◆

Withdraw the two lines (15) and (16) from the hole provided on the fairing.

◆

Remove the entire lower fairing (17) by lowering it and with small movements try to find the best position to withdraw it from the side stand.

NOTE Upon reassembly, introduce the

two lines (15) and (16) in the hole provided in the fairing.

◆

Take the rear right profile (14).

NOTE Upon reassembly, the upper part

of the profile (14) must be fitted between the lower fairing (17) and the su pport pla te.

aCAUTION

Upon reassembly, tighten the screws only moderately. Be careful not to over tighten the screws, this will damage the surrounding plas tic and painted components.

use and maintenance RSV mille

Page 32

◆

Remove the brake caliper (2) from the disc, leaving it attached to its line (3).

aCAU TION

Never touch the front brake lever after removing the brake caliper from the disc. If you do, the calipe rs pistons may be pushed out of their seats, and brake fluid will be spilled. Shou ld you accidentally do this, take you r vehicle to your Local APRILIADealer who will know how to repair this damage.

2%-/6).' 4(%&2/.4"2!+%#!,)0%23

aWARNING

The disassembly and reassembly of the front brake caliper s can be diffic ult for those unfamiliar with vehicle maintenance. You may wish to have your Local APRILIADealer carry out these operations.

If you wish to perform these operations yourself, caref ully read p. 72 (MAINTENANCE).

The front brake system is equipp ed with two discs, one on the left and one on the right side of the front wheel.

The following in formation may r efer to only one brake caliper but is applicable to both.

While disassembling and reassembling the front brake calipers, pay extra care not to damage the brake lines, discs or pads.

use and maintenance RSV mille

NOTE You must use the appropriate

front support stand to remove the front brake calipers.

DISASSEMBLY

◆

Position the vehicle on the appropriate front support stand &, see p. 87 (POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND

&).

aWAR NING

Make sure that the vehicle is stable. If it falls over, it ma y cause damage to bystanders and other p roperty, as well as being damaged itself.

◆

Have a helper steady the handlebar in the straight ahead position.

Brake caliper screw (1) tightening torque: 36.16 ftlb (50 Nm).

◆

Remove the two screws (1) that fasten the front brake caliper (2).

REASSEMBLY

aWARNING

Keep your fingers clear, do not allow them to become crushed between the wheel, the caliper or the fork. Do not attempt to align the holes in the caliper using your fingers. Failure to obey this warning can cause serious injury.

◆

Insert the brake caliper (2) on the disc and position it so that its fastening holes and the holes on the su pport a re a ligned .

aWARNING

When reassembling the bra ke caliper, replace the caliper screws (1) with two new screws of the same t ype.

◆

Tighten the two screws (1) to the appropriate torque.

Brake caliper screw (1) tightening torque: 36.16 ftlb (50 Nm).

Page 33

aWAR NING

After servicing the brakes, always check them for function. If th e s troke of the lever or pedal is excessive, or if you detect that the effecti veness of the brakes is reduced in any w ay, ha ve you r vehicle serviced by your Local APRILIA Dealer. It may be necessar y to have your dealer bleed the system, or there may be some other problem with the brake system.

)$,).'!$*534-%.4

Carefully read p. 72 (MAINTENANCE).

If the idle becomes irregular, too fast, or too slow, it must be adjusted.

To adjust the idle:

aWARNING

Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in c losed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

◆

Ride for a few miles until the engine reaches normal running temperature, see p. 15 (Coolant temperature indicator

h”).

“

◆

Pull in the clutch lever (1) c ompletely an d put the shift lever (2) in neutral so that the green “

q” light (3) is on.

◆

Keep the vehicle in vertical position, with

both wheels resting on the ground.

◆

Observe the tachometer. The engine must idle 1,250 ± 100 rpm, CO

1% [+ 1% – 0.5% (total range from 0.5% to 2%)].

If it does not:

◆

Insert a flat-tip screwdriver in the appro-

priate hole (4) provided on the right side

cover (5) and adjust the screw (6).

Rotate the screw cloc kwise to increase

engine rpm.

Rotate the screw counterclockwise to

decrease the engine rpm.

◆

Accelerate and decelerate the engine a

few times to make sure, when the throt tle

returns to idle, that the engine idle speed

is still correct.

NOTE If necessary, contact your Local

aprilia Dealer.

use and maintenance RSV mille

Page 34

!$*534).' 4(%4(2/44,%#/.42/,

Carefully read p. 72 (MAINTENANCE).

This vehicle is equipped with two throttle cables.

The following information may refer to just one throttle cable but should be observed with regard to both throttle cabl es.

aWARNING

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

If the throttle sticks, kill the engine with the engine stop switch located on the right handlebar. Do not attempt to restart the engine until the throttle has been repaired and works perfectly. Failure to obey this warning can lead to a runaway with se riously injuries or even death.

If any fastener in the throttle system becomes loose, likewise you w ill lose control of your vehicle.

Either si tuation c an lead to an upset or collision with subsequent serious injury or 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 th e gr ip aw ay from y ou. I t i s es sen tial, 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.

aWARNING

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 vehicl e if the throttl e does not automatically fully return to the id le position when the throttle grip is released. Contact your Local APRILIADeal- er for repairs. Failure to heed this warning can lead to a serious accident and subsequent injury or even death.

The play of the throttle cable must be between 0.08 – 0.12 in (2 – 3 mm), measured at the edge of the grip, see the illustration above.

use and maintenance RSV mille

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Page 35

To adjust the cable:

◆

Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Pull back the rubber boot (1).

◆

Loosen the lock nut (2).

◆

Rotate the adjuste r (3) i n such a way as to restore the prescribed value.

◆

After the adjustment, tighten the lock nut (2) and check the play again.

◆

Replace the rubber boot (1).

◆

Repeat the adjustment for the second cable.

aWARNING

Exhaust gases contain carbon monoxide, which is extremely poisonous if inhaled. Do not start the engine in c losed or badly-ventilated rooms. Failure to observe this warning may cause loss of consciousness or even lead to death by asphyxia.

aWARNING

After you have adjusted the thro ttle, rotate the handlebars full left and full right with the engine idling. Check to ensure that the idle sound is not affe cted by this . Also check that the throttle smoothly and fully closes whe n re le as ed .

!$*534).'4(%#/,$34!24 #(/+%#/.42/,

The operations necessary to adjust the cold start control “ ic skills and therefore should be carried out by your Loca l APRILIADealer.

e

e” (4) require specif-

use and maintenance RSV mille

101

Page 36

30!2+0,5'

Carefully read p. 72 (MAINTENANCE).

NOTE Your vehicle is equipped with two

spark plugs per cylinder (A) (B). The following information refer to the two spark plugs of one cylinder only, but are valid for bo th.

aCAU TION

You must clean and/or ch ange, one by one, all four spark plugs.

Clean the spark plugs every 4,687 mi (7,500 km); change them every 9,375 mi (15,000 km). If you use your vehic le for competition, change the spark plugs every 2,343 mi (3,750 km).

Periodically remove th e spark plugs and clean them carefully, removing carbon deposits; change them if necessary.

The frequency with which this operation must be carried out will vary with the use of

use and maintenance RSV mille

102

the vehicle. Howe ver, sp ark pl ugs m ust be cleaned and changed no less often than described above.

TO REACH THE SPARK PLUG

◆

Lift the fuel tank, see p. 94 (LIFTING THE FUEL TANK).

aWARNING

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

TO REMOVE THE SPARK PLUG

◆

Remove the spark plug cap (1).

aWARNING

During this operation, always wear goggles which provide your eyes with 360°

protection. Be very careful using compressed air jets, they can cause serious personal injury if directed towards your body.

◆

Using compressed air, blow all the dirt away from the base of the spark plug.

NOTE Using the special wrenches from

the tool kit, see p. 42 (GLOV E/TOOL KIT COMPARTMENT).

◆

Place the special spark plug socket wrench (2) completely o ver the spark plug (3).

◆

Insert the 11 – 13 mm open end wrench (4) in the hexagonal seat of the special spark plug socket wrench (2).

aCAU TION

Make sure that no dirt falls into the cylinder through the spark plug hole.

◆

Unscrew the spark plug and extract it from its seat.

Page 37

TO CHECK AND CLEAN THE SPARK PLUG

◆

Inspect the spark plug, and insure that there are no carbon deposits nor corrosion marks on either electrode or the ceramic nose that surrounds the center electrode. If necessary, clean the spark plug with a proprietary spark plug cleaner, and a stainless steel brush.

◆

Using compressed air, carefully blow out the spark plu g after you have cleane d it. Inspect for cracks on the in sulating material, electrode corrosion or erosion, or deposits that you cannot remove. If the spark plug shows any of these defects, it m ust be replaced.

◆

Check the spark plug gap with a thickness gauge.

◆

The gap must be 0.024 – 0.028 in (0.6 –

0.7 mm); if necessary adjust it, carefully

bending the ground (outside) electrode.

TO INSTALL THE SPARK PLUG

◆

Make sure the gasket is in good condition. With the gaske t on, screw th e spark plug into the head by hand.

◆

Tighten the spark plug with the special spark plug socket wrenc h, appro ximat ely one-half turn after it first snugly contacts the cylinder head.

Spark plug tightening torque:

14.47 ftlb (20 Nm).

aCAU TION

The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged. Use the recommended type of spark plug only, see p. 118 (TECHNICAL DATA), in order not to compromise the life and performance of the engine.

aCAUTION

Do not invert the sp ark plug caps (1) position.

◆

Position the spark plug cap (1) properly,

so that it does not come off due t o the vi-

brations of the engine.

NOTE Repeat th ese operations to re -

move, check and clean the other (second) spark plug of the same cylinder and the other two spark plugs of the second cylinder.

◆

Replace the fuel tank, see p. 94 (LIFT-

ING THE FUEL TANK).

use and maintenance RSV mille

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Page 38

#(!.').'&53%3

Carefully read p. 72 (MAINTENANCE).

aCAU TION

Do not repair faulty fuses. Use only recommended fuses. Using fuses of an improper capacity can cause damage to the electrical system or an electrical fire, which could result in total destruction of your vehicle as well as injury to you.

NOTE If a fuse blows frequently, there

probably is a short circuit or an overload in the electrical system. If this occurs, take the vehicle to your Local aprilia Dealer.

If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses.

Your vehicle is equipped with two group of fuses:

– the 15A secondary fuses group (1)

placed on the right side of the fairing, see p. 104 (15A SECONDARY FUSES CIRCUIT);

– the 30A main fu se s grou p (2 ) pla ced un -

der the rider saddle, see p.105 (30A MAIN FUSES CIRCUIT).

NOTE Check the fuses in the order:

– first the fuses of the 15A secondary fuses

group (1);

– second the fuses of the 30A main fuses

group (2).

To check the fuses of the s econdary fuses group (1):

◆

Turn the ignition switch (3) in the “-” (OFF) position.

NOTE Working from the right side of the

fairing:

◆

Loosen the screw (4).

◆

Move the safety clip (5).

◆

Open the cove r of t he bo x (6) co nta i ni ng the secondary fuses group (1).

15A SECONDARY FUSES CIRCUIT

A) From voltage regulator to:

high beam relay, low beam relay.

B) From voltage regulator to:

coils, engine stop relay, fuel pump.

C) From ignition switch to:

electric fans, clock.

D) From ignition switch to:

parking lights, rear stoplights, horn, dashboard lights, direction indicators.

E) From ignition switch to:

electronic unit, fuel pump relay, engine stop relay.

NOTE Three fuses are spare fuse s.

use and maintenance RSV mille

104

Page 39

To check the the fuses of the main fuses group (2):

◆

Turn the ignition switch (3) in the “m” (OFF) position.

◆

Remove the rider saddle, see p. 94 (REMOVING THE RIDER SADDLE).

◆

The fuse carrier (7) contains the main fuses group (2).

30A MAIN FUSES CIRCUIT

F) From battery to: ignition. G) From battery to: ignition.

NOTE One fuse is a spare fuse.

aCAU TION

Extract the fuses one by one, in such a way as to avoid positioning them incorrectly during reassembly.

NOTE If you remove one of the 30A fus-

es, this will set the digital clock and the red line setting to zero. To reset these functions, see p. 32 (MU LTIFUNCTION COMPUTER).

◆

Remove, one by one, the fuse and inspect the filament (8). If it is open, the fuse must be replaced.

◆

Replace the bl own fuse with the ap propriate spare fuse or with a new fuse having the same amperage rating.

aWARNING

If you replace the fuse and it blows again immediately, there is a serious problem with the electrical system of your vehicle. Do not attempt to continue using your vehicle. Take it to your Local APRILIADealer for repair and service.

NOTE If you use th e sp are fus e, rep la ce

it as soon as convenient.

use and maintenance RSV mille

105

Page 40

"!44%29

Carefully read p. 72 (MAINTENANCE).

Your vehicle is equipped with a sealed maintenance free battery. Except for the tightness of the terminals, and required recharging, this battery does not require any other maintenance.

Check the tightness of the terminals afte r the first 625 mi (1,000 km) and successively every 4,687 mi (7,500 km) or 8 months.

aWARNING

Batteries, when charged, give off hydrogen gas, which is highly explosive. Therefore, do not smoke while working on or around the battery, and keep naked flames or sparks away from the battery. Keep gasoline and ot her fl ammabl e substances well away from the battery, since a battery spark could easily ignite th em and cause a devastating fire.

Battery electrol yte is toxic and caustic and can severely burn your eyes or skin. Always wear tight fitting goggles and protecti ve clothi ng when ha ndling battery electrolyte. It is particularly important for you to protect yo ur eyes since even a minuscule amount of battery acid could destroy your vision.

Should you accidentally get even the smallest amount of battery electrolyte on your skin or eyes, immediately flush with large quantities of clear cool water and immediately seek professional

use and maintenance RSV mille

106

medical attention. If someone should accidentall y swallow

battery el ectr olyte, drink a lar ge quan tity of milk or cool clear water and continue with milk of magnesia or vegetable oil. Seek professional medical assistance immediately.

Since the battery gives off explosive hydrogen gas, especially when it is being charged, when you are charging a battery, make sure that the room is properly ventilated. Do not inhale the gases released du ring chargi ng. Do not permit any open flames, sparks or cigarettes or any other source of heat anywhere near the battery while it is charging.

Do not tip the vehicle too much, or tip the battery too much, to avoid electrolyte leaking out. Should you accide ntally spill battery electrolyte on any part of your vehicle, immediately wash it off with lots of cool clear water. Spills may be neutralized with a mixture of baking soda and water, as well. This is particularly important, as the battery electrolyte will severely corrode metallic parts and destroy the finish of plastic and painted parts.

aCAUTION

Never inver t the battery cab les. Observe the proper polarity of the battery. Incorrectly attaching the battery to your vehicle will irreparably des tr oy the el ectrical system of your vehicle.

Connect and disconnect the battery only with the ignition switch (1) in the

m” (OFF) position.

“

First connect the positive cable red (+), then the negative (–).

Disconnect the n egative cable (–) first, then the positive red (+).

If your battery needs to be charged, use a constant voltage, or “taper” charger, with a current rating no greater than 1/10th the capacity of the battery (i.e., for a 50 amp hour battery, the max imum charging cur rent should be 5 amps) . Use of a more powerful charger can not only damage the battery irreparably, but could cause it to overheat and explode.

Page 41

"!44%2934/2!'%

aCAUTION

If this vehicle is not used for more than twenty days, remove the 30A fuses (2), see p. 104 (CHANGING FUSES). This will prevent the discharge of the battery caused by the slight current co nsumption of the multifunction computer.

NOTE The removal of the 30A fuses will

cause the digital clock and the red line setting to go to zero. To reset these functions, see p. 32 (MULTIFUNCTION COMPUTER).

Carefully read p. 106 (BATTERY).

If your vehicle remains unused for mor e than a couple of weeks, it will be necessary to “trickle charge” the ba ttery, to pr event battery damage, see p. 108 (RECHARGING THE BATTERY).

◆

Remove the battery, see p. 107 (REMOVING THE BATTERY ), an d pu t it in a cool, dry place.

◆

The best way to prevent battery det erioration is to constantly leave a “trickle” charger with a capacity of about 1/10th amp attached. These chargers are very economically available from your Local aprilia Dealer, and will ensure that your battery always remains in tip top condition.

◆

If this cannot be done , charg e the b attery for about 30 minutes using a battery charger with a current capacity of no greater than 1/10th the capacity of the battery, see p. 108 (RECHARGING THE BATTERY).

It is important to check the charge periodically (about once a month), during the winter or when the vehicle remains unused, in order to prevent the deterioration of the battery.

◆

Recharge it completely with a normal charge, see p. 108 (RECHARGING THE BATTERY).

◆

While we recommend removing the battery from t he v eh i cl e, i f yo u mu st l eav e it in your vehicle, disconnect bo th battery cables.

#(%#+).'!.$#,%!.).' 4(%4%2-).!,3

Carefully read p. 106 (BATTERY).

◆

Make sure that the ignition switch (1) is

m” (OFF) position.

in “

◆

Remove the rider saddle, see p. 94 (REMOVING THE RIDER SADDLE).

◆

Remove the red protection rubber (3).

◆

Make sure that the cable terminals (4) (5) and the battery terminals (6) (7) are:

– in good conditions (and not corroded or

covered with deposits);

– covered with neutral grease or Vaseline. If it is necessary to clean the battery termi-

nals:

◆

Remove the battery, see p. 107 (REMOVING THE BATTERY).

◆

Brush with a wire brush to eliminate any sign of corrosion.

◆

Install the battery, see p. 108 (INSTALLING THE BATTERY).

2%-/6).'4(%"!44%29

Carefully read p. 106 (BATTERY).

NOTE The r emoval of the b attery will

cause the digital clock and the red line setting to go to zero. To reset these function s, see p. 32 (MULTIFUNCTION COMPUTER).

◆

Make sure that the ignition switch (1) is

in “m” (OFF) position.

◆

Remove the rider saddle, see p. 94 (RE-

MOVING THE RIDER SADDLE).

◆

Unscrew and remove the screw (8).

◆

Remove the battery braket (9) that locks

the battery.

◆

Remove the red protection rubber (3).

◆

Disconnect first the negative (–) cable

terminal (5) and then the positive red (+)

cable terminal (4).

◆

Remove the battery (10) from its com-

partment and put it on a flat surface, in a

cool and dry place.

use and maintenance RSV mille

107

Page 42

aCAUTION

Once it has been removed, store the battery in a safe place and keep it away from children. Even a completely sealed, maintenance free battery can present a danger of injury.

◆

Replace th e battery braket (9).

◆

Screw the screw (8).

◆

Replace the r ide r sa ddle, see p . 94 (REMOVING THE RIDER SADDLE).

#(%#+).' 4(%%,%#42/,94%,%6%,

Carefully read p. 106 (BATTERY).

Your vehicle is equipped with a sealed maintenance free battery that does not require the check of the level battery.

2%#(!2').'4(%"!44%29

Carefully read p. 106 (BATTERY).

aWARNING

This battery is completely sealed. Do not attempt to remove the caps. There is never any need to add water to this battery. Attempting to remove the caps will destroy the battery and could lead to injury throug h the spillage of caustic electrolyte. Recharge the battery according to the table below.

◆

Remove the battery, see p.107 (REMOVING THE BATTERY).

aWAR NING

The battery gives off nox ious and ex plosive gases; keep it away from flames, sparks, cigarettes and any other source of heat.

During recharging or use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging.

◆

Connect the battery charger to the battery.

◆

Charge the battery using a battery charger with a current capacity of no greater than 1/10th the capacity of the battery, see p. 118 (TECHNICAL DATA).

◆

Charge at voltage at amperage and time stated below.

Recharge

Voltage

(amp)

Time

(hours)

Normal 1.2 8 – 10 Quick 12 0.5

aWAR NING

Wait for 5 or 10 minutes after you have finished charging the battery before reinstalling it, the battery continues to pro-duce gas for a short period of time after the charger is removed.

).34!,,).'4(%"!44%29

Carefully read p. 106 (BATTERY).

◆

Check the ch a r ge o f t h e ba t t ery , se e b eside (RECHARGING THE BATTERY).

◆

Make sure that the ignition switch (1) is in the “m” (OFF) position.

◆

Remove the rider saddle, see p. 94 (REMOVING THE RIDER SADDLE).

◆

Unscrew and remove the screw (8).

◆

Remove the battery braket (9).

◆

Put the battery (10) in its container.

◆

Connect, in order, the positive red (+) cable terminal (4) and negative (–) cable terminal (5).

◆

Cover the terminals of the cables and of the battery with neutral grease or Vaseline.

◆

Replace the red protection rubber (3).

◆

Replace th e battery braket (9).

◆

Screw and tighten the screw (8).

◆

Replace the r ide r sa ddle, see p . 94 (REMOVING THE RIDER SADDLE).

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!$*534).'4(%(%!$,)'(4 "%!-6%24)#!,,9

aWAR NING

Do not use the vehicle if the lights are not functioning properly. Do not use the vehicle if the hea dlight is adjusted incorrectly. This could temporarily blind oncoming cars, and also reduce the rider’s ability to see any obstacle along the road while riding at night. It is always ad visable to red uce speed when riding during the night, in such a way as to have the time necessary to avoid any obstacle and to adapt to the poorer visibility that inevitably results from darkness. Failure to observe this warning can cause you to collide with another object, with consequent risk of serious injury or even death.

NOTE The procedure described here is

in compliance with the Italian standard that establishes the maximum height of the headlight beam. For vehicles used in other countries, you must conform with the local regulations.

To quickly check the correct adjustment of the beam, place the vehicle on flat ground,

32.81 ft (10 m) away from a wall. Turn on the low beam, sit on the vehicle

and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height).

To adjust the headlight beam:

◆

Working from the left underside of the

front part of the fairing, adjust the screw

(1) with a short Philips screwdriver.

Turn the screw clockwise to adjust the

beam higher.

Turn the screw countercloc kwise to ad-

just the beam lower.

◆

Make sure that the vertical adjustement

of the headlight beam is correct.

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!$*534).'4(%(%!$,)'(4 "%!-(/2):/.4!,,9

NOTE The terms “right” and “left” are re-

ferred to the rid er seated on th e vehicle in the normal riding position.

It is possible to adjust the horizontal position both to the right and to the left.

To adjust the horizontal headlight beam your vehicle is equipped with:

– one screw (1) to left side of the dash-

board;

– one screw (2) to right side of the dash -

board.

NOTE Adjust one or the other screw, or

if it is necessary them both.

◆

Working from the rearside of the front part of the fairing, adjust the screw (or the screws) with a Philips screwdriver.

With the screw (1) to left side of the dashboard:

– turn the scr ew cloc kwise to adjust the

beam to the right;

– turn the screw counterclock wi se to a d-

just the beam to the left.

With the screw (2) to right side of the dashboard:

– turn the sc rew clockwise to ad just the

beam to the left;

– turn the scr ew counterclockwise to ad-

just the beam to the right.

◆

Make sure that the hori zo nta l a dju stm en t of the headlight beam is correct.

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"5,"3

Carefully read p. 72 (MAINTENANCE).

aWARNING

Risk of fire. Keep fuel and o ther flammable sub-

stances away from the electrical components.

aCAU TION

Before changing a bulb, turn th e ignition switch (1) to the “ and wait a few m inutes so that t he bulb cools down. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fing erprints on the bu lb, since these may cause its overheating and consequent breakage. If you touch the bulb with your bare fingers, remove any fingerprints w ith alc ohol in order to avoid any damage.

TAKE CARE TO AVOID DAMAGING THE ELECTRIC CABLES.

NOTE Befor e changing a bulb, ch eck

the fuses, see p. 104 (CHAN GING FUSES).

m” (OFF) position

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#(!.').' 4(%(%!$,)'(4"5,"3

Carefully read p. 111 (BULBS).

◆

Place the vehicle on the center stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

NOTE Before changing a bulb, check the

fuses, see p. 104 (CHANGING FUSES). The headlight contains:

– two high beam bu l bs (1 ) (o ne u ppe r righ t

position, one upper left posit ion );

– one parking light bulb (2) (central upper

position);

– one low beam bulb (3) (ce ntr al lo wer po-

sition).

To change the bulbs: PARKING LIGHT BULB (CENTRAL UP-

PER POSITION)

NOTE The removal of the front part of

the fairing is necessar y when the parking light bulb and the high beam bu lbs mus t be changed.

aCAUTION

While removing a bulb socket, do not pull on the wires.

Working from the central upper position of the rear part of the fairing.

◆

Grasp the b ulb sock et (4), pull it an d remove it from its seat.

◆

Remove the parking light b ulb (2) and replace it with an identical bulb.

◆

Insert the bulb socket (4) in its seat.

HIGH BEAM BULB (ONE UPPER RIGHT POSITION, ONE UPPER LEFT POSITION)

NOTE Remove the bulb sockets one by

one in such a way as t o avoid replacing them incorrectly during reassembly.

If the bulb sockets mus t all be r emoved a t the same time, take great care to reassemble them in the proper position.

NOTE It is necessary to remove the

front part of the fairing when the par king bulb and the high beam bulbs are changed.

◆

Working from the left side (or right side) of the rear part of the fairing, pull back the rubber boot (5) with your fingers.

◆

Grasp the electric terminal (6) pull it and disconnect it from the bulb (1).

◆

Release the clip (7) positioned at the rear of the bulb socket (8).

◆

Remove the bulb (1) from the seat.

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NOTE Be sure to maintain the same ori-

entation as the old bulb when you install the new bulb. Do not try to force the bulb, it will go easily if it is properly oriented.

◆

Insert the new bulb into its socket (8), ensuring that the tabs ar e correctly positioned.

◆

Replace the clip (7).

◆

Connect the bulb electric terminal (6).

◆

Replace the rubber boot (5).

LOW BEAM BULB (CENTRAL LOWER POSITION)

◆

Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Working from the central underside of the front part of the fairing, pull back the rubber boot (9) with your fingers.

aCAUTION

To extract the bulb electric connector, do not pull its electric wires.

◆

Grasp the bulb electric connector (10), pull it and disconnect it from the bulb (3).

◆

Rotate the bulb socket (11) counterclockwise and extract it from the reflector.

◆

Remove the bulb (3) from the seat.

NOTE Be sure to maintain the same ori-

entation as the old bulb when you install the new bulb. Do not force the bulb, it will go easily if it is properly oriented.

◆

Correctly install the new bulb (3) into the bulb socket (11).

◆

Position the bulb socket (11) in the reflector and rotate it clockwise.

◆

Connect the bulb electric connector (10).

◆

Replace the rubber boot (9).

#(!.').'4(%&2/.4!.$2%!2 $)2%#4)/.).$)#!4/2"5,"3

Carefully read p. 111 (BULBS).

NOTE Before changing a bulb, check

the fuses, see p. 104 (CHANGING FUSES).

◆

Place the vehicle on the stand, see p. 71

(POSITIONING THE VEHICLE ON THE

STAND).

◆

Unscrew and remove the screw (12).

NOTE While removing the lens, use ex-

tra care to be sure that you do not break the key.

◆

Remove the lens (13).

NOTE Upon reassembly, position the

lens correctly in its seat.

aCAUTION

Tighten the screw (12) moderately and with care to avoid damaging the lens.

◆

Push the bulb (14) in s lig htl y a nd rot ate it

counterclockwise.

◆

Extract the bulb from its seat.

NOTE Insert the bulb in the bulb socket,

carefully aligning the two bulb pins with their guides in the socket.

◆

Correctly install a new bulb of the same

type.

NOTE If the bulb socket (15) has fallen

out of its seat, repla ce it c orre ctl y, ens uri ng that the slot in the reflector aligns with the screw hole in the body of the turn signal lamp.

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#(!.').' 4(%2%!2,)'(4"5,"

Carefully read p. 111 (BULBS).

aWARNING

Do not ride your vehicle if the tail light and the stoplight are not working properly. The stoplight is particularly imp ortant to preve nt other vehicles from rearending yo u. Obviously, fail ure to comply with these instructions could lead to a serious accident with subsequent injuries or even death.

NOTE Befor e changing a bulb , check

the fuses, see p. 104 (CHAN GING FUSES), also check the operation of the stoplight switches, see p. 81 (CHECKING THE SWITCHES).

The rear light comprises two units. Each unit contains:

– one parking li ght / stopli ght / licen se plate

bulb (1).

To change the bulb:

◆

Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).

◆

Unscrew and remove the two screws (2).

◆

Remove the lens (3).

NOTE Upon reassembly, make sure

that the lens seats properly.

aCAUTION

Upon reassembly, do not overtighten the two screws (2). Overtightening will crack the lens.

◆

To remove the bulb (1), push the bulb slightly forward and rotate it counterclockwise.

◆

Pull it from its seat.

◆

Correctly install a new bulb of the same type.

NOTE Ensure that the orientation of

your replacement bul b is identical to that o f the original bulb. Do not try to for ce the bulb, it will fit easily if it is pro perly oriented .

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42!.30/24

aCAUTION

Never drain the fuel tank, eith er partia lly or completely. This may cause damage to the inner components of the fuel tank, or to other parts of the fuel system.

Always ensure that the fuel filler cap is correctly closed.

aWAR NING

Never attempt to tow your vehic le with another vehicle.

aWAR NING

While your vehicle is being transpo rted, it must be kept in a vertical position, firmly tied down, an d with the wheels blocked. Transport your vehicle in neutral gear only.

Failure to heed this warning could cause serious damage to the transmission due to vibration of the transport truck.

$2!).).'4(%&5%,4!.+

aCAUTION

Never drain the fuel tank, e ither part ially or completely. This may cause damage to the inner components of the fuel tank, or to other parts of the fuel system.

Always ensure that the fuel filler cap is correctly closed.

#,%!.).'

Clean your vehicle regularly. Your vehicle will look better and work better if you keep it clean. You will find you will need to clean it more frequen tly if it is used in th e following conditions:

– Polluted areas (cities and industrial areas). – Areas characterized by a high percent-

age of salinity and humidity (sea areas,

hot and humid climates). – Particu lar conditions (use of salt and

anti-ice chemical products on the roads

during the winter).

◆

Do not allow contaminants such as in-

dustrial dust, tar spots, dead insects, bird

droppings, etc. to remain on the painted

portions of your vehicle. They will very

quickly etch into and damage the paint.

◆

Do not park your vehicle under trees,

since some trees ooze resins that contain

chemicals which can damage the paint.

aWARNING

After your vehicle has been was hed, the brake functioning w ill be temporarily impaired because of the wetness of the discs and pads. Do not ride in traffic until after you have dried the brakes by repeated braking from slow speed.

Always after washing your vehicle, carry out the preliminary checking operation, see p. 61 (PRELIMINARY CHECKING OPERATIONS ).

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To remove dirt and mud from the painted surfaces, use a low pressure water hose . Carefully wet the dirty parts and re move mud and dirt with a soft car spong e. You may use proprietary car shampoos (2-4% parts of shampoo in clear water), to make this easier.

Carefully flush so that no dirt or girt remains on the paintwor k, and dry with a clean chamois or clean terry towel.

To clean the engine and other non-painted parts, use a mild solve nt and a bristle brush, along with plenty of rags.

aCAU TION

Polish with silicone wax only after having carefully wa shed your vehicl e. Do not wash the vehicle in direct sunlight, especially during the su mme r , w he n th e paintwork is still warm, since if the shampoo dries before bei ng rinsed away, it can damage the paint.

Do not use solvents or water hotter than 40°C to clean the plastic components of the vehicle.

Never use a high pre ssure washer, a steam cleaner, or an air augmented water jet to clean your vehicle, especially the wheel hubs, handleb ar controls, brake reservoirs and cylinders, instruments, electrical compon ents or exhaust silencer.

Such cleaning machinery will force water into critical portions of your vehicle, which could damage your vehicle through corrosion or short circuiting.

Do not use alcohol or other solvents to clean the rubber or plastic parts, or the seat, use only cl ear water with a mild soap.

aWAR NING

Do not apply any prote ctive coating to the seat, such coatings tend to make the seat too slippery.

After washing the vehicle, always:

◆

Lift the fuel tank, see p. 94 (LIFTING THE FUEL TANK).

◆

Remove the plug (1) to ensure that any water or other contaminant th at may have accumulated inside the air cleaner case is drained.

,/.'0%2)/$3/&).!#4)6)49

aCAU TION

NOTE The removal of the 30A fuses will

cause the digital cloc k and the red line setting to go to zero. To reset these functions , see p. 32 (MULTIFUNCTION COMPUTER).

If the vehicle is to be stored for a relatively long period of time, such as over the win ter, some simple pr ecautions will make putting the vehicle back into service much easier.

It is much less difficult to prepare the vehicle for storage properly than it is to restore the vehicle to proper working condition af -

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aWARNING

Before carrying out the following operations, let the engine and the exhaust silencer cool down until they reach room temperature, in order to avoid burns.

◆

Place a plastic bag over the outlet pipe of

the muffler, and tape or tie it tight.

◆

Cover the vehicle with an old sheet or a

light canvas, do not us e a sheet of plastic

or other waterproof material. This will

cause condensation which will result in

corrosion.

ter a storage peri od if you have forgott en or neglected to do this preparation.

To prepare the vehicle for storage:

◆

Remove the battery, see p. 107 (REMOVING THE BATTERY) and storage it, see p. 107 (BATTERY STORAGE).

◆

Wash and dry the vehicle, see p. 115 (CLEANING).

◆

Polish the painted surfaces with wax, see p. 115 (CLEANING).

◆

Inflate the tires, see p. 58 (TIRES).

◆

Do not drain the fuel tank. However, if available, you may wish to add a proprietary fuel storage additive, available from your Local aprilia Dealer or auto- mobile supply st ores . Fo ll ow the in stru ctions on the container of the additive.

NOTE Do not add more than the recom-

mended amount of additive.

aCAUTION

Some fuel additives may damage some components of your fuel system. Check with your Local APRILIADealer.

NOTE You must use the ap propriate

front and rear support stands to store your vehicle so that both tires are raised from the ground.

◆

Position the vehicle on the appropriate rear support stand TIONING THE VEHICLE ON THE REAR SUPPORT STAND

◆

Position the vehicle on the appropriate front support stand TIONING THE VEHICLE ON THE FRONT SUPPORT STAND

◆

Place the vehicle in a cool, dry room, away from direct sunlight, with minimum temperature variation s.

&, see p. 87 (POSI-

&).

&, see p. 87 (POSI-

&).

PUTTING THE VEHICLE BACK INTO SERVICE

◆

Uncover and clean the vehicle, see

p. 115 (CLEANING).

◆

Check the charge of the battery, see

p. 108 (RECH ARGING THE BATTERY)

and install it, see p. 108 (INSTALLING

THE BATTERY).

◆

Carry out the preliminary checking oper-

ations, see p. 61 (PRELIMINARY

CHECKING OPERATIONS).

aWAR NING

Test ride the veh icle at mod erat e s peed in a low traffic area before you ride in heavy traffic.

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4%#(.)#!,$!4!

DIMENSIONS Max. length .................................................. 81.89 in (2,080 mm)

Max. length

(rear mudguard extension included)............... 84.25 in (2,140 mm)

Max. width.................................................... 28.35 in (720 mm)

Max. height

(front part of the fairing included)................. 46.06 in (1,170 mm)

Seat height................................................... 32.28 in (820 mm)

Wheelbase................................................... 55.71 in (1,415 mm)

Min. ground clearance................................. 5.12 in (130 mm)

Curb weight ................................................. 486.78 lb (220.80 kg)

ENGINE Type............................................................. 60° longitudinal V-type, two-cylinder, 4-stroke, with 4 valves per cyl-

Number of cylinders..................................... 2

Total displacement............ ...... ..... ................ 60.88 cu in (997.60 cm#)

Bore / stroke................................................. 3.82 in / 2.66 in (97.00 mm / 67.50 mm)

Compression ratio........................................ 11.4 ± 0.5 : 1

Starting......................................................... electric

Engine idling rpm......................................... 1,250 ± 100 rpm CO 1%

Valve clearance (with engine cold) ............. 0.004 in (0.1 mm) [intake] - 0.006 in (0.15 mm) [exhaust]

Clutch...................................................... ..... multidisc in oil bath, with hydraulic con trol on t he left side of the han-

Lubrication system....................................... dry pan with separate oil tank and cooling radiator

Air cleaner.................................................... with dry filter cartridge

Cooling......................................................... liquid-cooled

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inder, DOHC

[+ 1% – 0.5% (total range from 0.5% to 2%)]

dlebar and PPC device

Page 53

CAPACITY Fuel (reserve included)................................. 5.28 US gal (20 L )

Fuel reserve ................................................. 1.19 ± 0.26 US gal (4.5 ± 1 L )

Engine oil..................................................... oil change 3.91 US qt (3,700 cm#) –

oil and oil filter change 4.12 US qt (3,900 cm#)

Fork oil (for each fork leg) ........................... 17.58 ± 0.08 in (520 ± 2.5 cm#)

Coolant......................................................... 0.66 US gal (2.5

L )

(50% water + 50% antifreeze with ethylene glycol)

Seats............................................................ 2

Vehicle max. load

(driver+passenger+luggage)........................ 396.47 lb (180 kg)

Gross weight limit (GVWR) (*)...................... 883.25 lb (400.63 kg)

Permissible wheel loads (GAWR) (*)

– front........................................................... 334.80 lb (151.86 kg)

– rear............................................................ 548.45 lb (248.77 kg)

(*) These two weights: Gross Vehicle Weight Rating (GVWR) and Gross Axle Weight Rating (GAWR); are stamped on the certification

plate positioned on the front part of the frame, see p. 7 (VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER)).

TRANSMISSION Type.............................................................. mechanical, 6 gears with foot control on the left side of the engine

GEAR RATIOS Ratio Primary Secondary

31/60 = 1 : 1.935 14/35 = 1 : 2.500

16/28 = 1 : 1.750 19/26 = 1 : 1.368 22/24 = 1 : 1.090 23/22 = 1 : 0.956 27/23 = 1 : 0.851

Final ratio Total ratio

16 / 42 = 1 : 2.625 12.698

8.889

6.949

5.537

4.856

4.323

DRIVE CHAIN Type.............................................................. endless (with no master link) with sealed links

Model............................................................ 525

FUEL SUPPLY SYSTEM

Type.............................................................. electronic injection

Choke........................................................... Ø 2.01 in (Ø 51 mm)

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FUEL SUPPLY Fuel.............................................................. unleaded petrol minimum octane rating (R+M) / 2 method 90

FRAME Type ................................................... ..... ..... two-beam, with cas t and stampe d sheet elements

Rake............................................................. 25°

Trail.............................................................. 3.82 in (97 mm)

SUSPENSIONS Front............................................................. u ps ide -do wn tel esc opi c a dju sta bl e fo rk w ith hyd ra ulic operation,

Stroke........................................................... 5.00 in (127 mm)

Rear............................................................. Aluminum a lloy rear swi ngi ng a rm, l ever syst em, and h ydropneu-

Wheel stroke................................................ 5.31 in (135 mm)

BRAKES Front............................................................. with double floati ng disc brak e - Ø 12.60 in (Ø 32 0 mm) - caliper s

Rear............................................................. disc brake - Ø 8.66 in (Ø 220 mm) - caliper with double pin

WHEEL RIMS Type ............................................................. light alloy

Front............................................................. 17” x MT 3.50

Rear............................................................. 17” x MT 6.00

FRONT TIRE Ty pe ............................................................. Pirelli; Metzeler; Michelin

Size.............................................................. 120 / 70 - ZR 17”

- alternative.................................................. 120 / 65 - ZR 17”

Inflation pressure for solo rider .................... 31.90 psi [(220 kPa) (2.20 bar )]

Inflation pressure for rider and passenger... 34.80 psi [(240 kPa) (2.40 bar )] Inflation pressure for rider,

passenger and luggage ............................... 34.80 psi [(240 kPa) (2.40 bar )]

REAR TIRE Type............................................................. Pirelli; Metzeler; Michelin

Size.............................................................. 180 / 55 - ZR17”

- alternative.................................................. 190 / 50 - ZR17”

Inflation pressure for solo rider .................... 36.25 psi [(250 kPa) (2.50 bar)]

Inflation pressure for rider and passenger... 39.15 psi [(270 kPa) (2.7 bar)]

fork leg Ø 1.69 in (Ø 43 mm)

matic 4-way adjustable mono-shock absorber

with four pins

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Inflation pressure for rider,

passenger and luggage................................ 39.15 psi [(270 kPa) (2.70 bar )]

IGNITION Ignition timing............................................... 21.8° ± 2° at 2,800 rpm

SP ARK PLUGS Number per cylinder..................................... 2

Standard....................................................... NGK R DCPR9E

– alternative.................................................. NGK R DCPR8E

Spark plug gap............................................. 0.024 – 0.028 in (0.6 – 0.7 mm)

Resistance.................................................... 5 kΩ

ELECTRIC Battery.......................................................... 12 V - 12 Ah

SYSTEM

BULBS

WARNING LIGHTS Neutral.......................................................... 12 V - 3 W

Main fuses (# 2 fuses) .................................. 30 A

Secondary fuses (# 5 fuses)......................... 15 A

Generator .................................................... 12 V - 350 W

Low beam (halogen)..................................... 12 V - 35 W H3

High beam (halogen).................................... 12 V - 35 + 35 W H3

Front parking light......................................... 12 V - 5 W

Direction indicators....................................... 12 V - 10 W

Rear parking light / stoplight /

license plate light.......................................... 12 V - 5 / 21 W

Tachometer................................................... 12 V - 2 W

Left multifunction display.............................. 12 V - 2 W

Right multifunction display............................ 12 V - 2 W

Direction indicators....................................... 12 V - 3 W

Fuel reserve ................................................. 12 V - 3 W

High beam.................................................... 12 V - 3 W

Side stand down........................................... 12 V - 3 W

Engine oil pressure ...................................... LED

Red line ....................... ...... .......................... LED

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,5"2)#!.4#(!24

Engine oil (recommended): As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications.

Fork oil (recommended): If you need an oil with intermediate characteristics in comparison with the two recommended products, these can be mixed as indicated below:

SAE 10W 0 F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume. SAE 15W 0 F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume.

EXTRA RAID, SAE 15W – 50.

F.A. 5W or 0 F.A. 20W fork oil.

Bearings and other lubrication points (recommended):

As an alternative to the rec ommende d produc t, use hi gh-qua lit y grease for ro lling b earings , workin g tempe rature ran ge -30°C.... +140°C,

dripping point 150 °C... 230°C, high protection against corrosion, good resistance to water and oxidation.

Protection of the battery poles: neutral grease or vaseline. Spray grease for chains (recommended): Brake fluid (recommended): 0 F.F., DOT 5 (DOT 4 compatible).

CHAIN SPRAY.

AUTOGREASE MP.

aWARNING

Use new brake fluid only. Clutch fluid (recommended):

F.F., DOT 5 (DOT 4 compatible).

aWARNING

Use new clutch fluid only. Engine coolant (recommended):

ECOBLU - 40°C.

aWARNING

Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.

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./4%

!3+&/2'%.5).%30!2%0!243/.,9

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Page 58

)MPORTERS

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Page 59

)MPORTERS

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7)2).'$)!'2!-236MILLE

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7)2).'$)!'2!-+%9236MILLE

1) Electronic unit

2) Cam position sensor

3) Throttle valve position sensor

4) Suction pressure sensor

5) Coolant thermistor

6) Air thermistor

7) Fall sensor

8) Diode module

9) Clutch contro l lever switch

10) Neutral switch

11) Arrangement for the installation of the anti-theft device

12) Right dimmer switch

13) Left dimmer switch

14) Engine stop relay

15) Fuel pump relay

16) Start relay

17) Starter

18) Battery

19) Main fuses (30A) (ignition)

20) Generator

21) Pick up

22) Voltage regulator

23) Rear cylinder coil

24) Rear cylinder coil

25) Front cylinder coil

26) Front cylinder coil

27) Spark plugs

28) –

29) Secondary fuses (15A)

A - High beam, low beam B - ISC, coils, fuel pump C - Electric fans, clock D - Parking lights, stoplights, horn,

dashboard lights, direction indicators

E - Electronic unit, fuel pump relay, en-

gine stop relay

30) Ignition switch

31) Low beam relay

32) High beam relay

33) Cooling fan relay

34) Front parking light bulb

35) High beam bulbs

36) Low beam bulb

37) Front right direction indicator

38) Front l eft directi on indicator

39) Thermal switch

40) Cooling fans

41) Rear li ght

42) Dashboard

43) Rear left direction indicator

44) Front cylinder injector

45) Rear cylinder injector

46) Front stoplight switch

47) Rear stoplight switch

48) Rear right direction indicator

49) Horn

50) Multi ple connectors

51) Blinking

52) Fuel pump

53) Low fuel sensor

54) Engine oil pressure switch

55) Coolant temperature thermistor

56) Speed sensor

57) Low fuel warning light

58) Side stand down warning light

59) Neutral warning light

60) Direction indicator warning light

61) Engine oil pressure warning light LED

62) High beam warning light

63) Dashboard bulbs

64) Tachometer

65) Multifunction display (right side)

66) Multifunction display (left side)

67) L ight diode / LAP

68) TEST connectors

69) Headlight

70) Side stand switch

71) Red line warning light LED

72) Rear parking light/stoplight bulbs X) Dashboard connector (20-way)

Y) Electronic un it connector (26-way) Z) Electronic unit connector ( 16-way)

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Ar Orange M Brown Az Li ght blu e N Black B Blue R Red Bi White V Green G Yellow Vi Violet Gr Grey Ro Pink

use and maintenance RSV mille

127

Page 62

aprilia s.p.a. wishes to thank its customers for the purchase of this vehicle. – Do not dispose of oil, fuel, polluting substances and components in the envi-

ronment.

– Do not keep the engine running if it isn’t necessary. – Avoid dist urbing noises. – Respect nature.

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Aprilia RSV MILLE User Manual Part 3 1999

Specifications and Main Features

Frequently Asked Questions

User Manual