Aprilia RSV MILLE User Manual Part 3 1999
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 APRILIADealer
.
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
use and maintenance RSV mille
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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.
25..).').
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
34/00).'
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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0!2+).'
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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-!).4%.!.#%
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4/02%6%.44(%&4
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.
use and maintenance RSV mille
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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.
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
APRILIADealer, 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
R
use and maintenance RSV mille
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THESE OPERATIONS MAY BE CARRIED OUT BY YOUR Local APRILIADealer, 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).
use and maintenance RSV mille
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-
THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED OUT BY Local APRILIADealer.
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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)$%.4)&)#!4)/.$!4!
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.
use and maintenance RSV mille
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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.
use and maintenance RSV mille
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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).
use and maintenance RSV mille
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-
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).
use and maintenance RSV mille
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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
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.
◆
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.
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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
IADealer.
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 APRILIADealer.
&2/.43530%.3)/.
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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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)
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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).
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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
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