Aprilia RSV MILLE User Manual Part 2 2000
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aWARNING
Risk of fire.
Keep fuel and o ther flammable substances away from the electrical components.
Before beginning any service operations or inspection of the vehicle,
switch off the engine and remove the
key, wait until the engine and the exhaust system have cooled down and, if
possible, lift the vehicles with the proper equipment onto firm and flat ground.
Before proceed ing, make sure that th e
room in which you are working is properly ventilated.
Keep away from the red-hot parts of the
engine and of the exhau st system, in order to avoid burns.
Do not hold any mecha nical piece or
other parts of the vehicle with your
mouth: the co mponents ar e not edible
and some of them are noxious or even
toxic.
aCAUTION
If not expressly indicated otherwise, for
the reassembly of the units repeat the
disassembly operations in reverse order.
In case any maintenance operation
should be required, it is advisable to
use latex gloves.
Routine maintenance operations can usually be carried out by the user, but sometimes specific tools and spec ific technical
skills may be required.
In case periodic ma intenance oper ations,
assistance or technical advice are needed,
contact an aprilia Official Dealer, who will
ensure you prompt and accurate servicing.
Ask your aprilia Official Dealer to test the
vehicle on the road after a repair or periodic maintenance operation.
In any case, personally carry out the “Pre-
liminary checking operations” after any
maintenance operation, see p. 49 (PRELIMINARY CHECKING OPERATIONS).
NOTE This vehicle is set so that any
anomaly can be detected in real time and
stored by th e electronic unit.
Whenever the ignition switch is brought to
position “2”, the writing "HIL" (1) appears
on the right side of the multifunction display
for approximately three seconds.
aCAUTION
If the writing “HIL” ( 1) is displayed
during the norm al operation o f the engine, this means that the electronic unit
has detected an anomaly.
In many cases, the en gine keeps running with redu ced performan ce levels;
immediately contact an APRILIA Offi cial
Dealer.
aCAUTION
After the first 1000 km (625 mi) and successively every 750 0 km (4687 mi), t he
word "SERVICE" (2) appears on the
right display.
In this case contact an APRILIA Official
Dealer, who will carry out the operations
indicated in the regular service inter vals
chart, see p. 60 (REGULAR SERVICE INTERVALS CHART). To make the writing
“SERVICE” disappear, press the “LAP”
push button (3) and then the push button r (4) and keep them pressed for
about five seconds.
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OPERATIONS TO BE CARRIED OUT BY
THE APRILIA Official Dealer (WHICH
CAN BE CARRIED OUT EVEN BY THE
USER).
Key
= check and clean, adjust, lubricate or
change, if necessary;
= clean;
= change;
= adjust.
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
(*) = In case of use on racetracks, c ha nge
every 3750 km (2343 mi).
(**) = Check every two weeks or accord-
ing to the intervals indicated.
Component
After run-
ning-in [1000
km (625 mi)]
Every 7500
km (4687 mi)
or 12 months
Every 15000
km (9375 mi)
or 24 months
Spark plu gs (*)
Air cleaner
Engine oil filter (*)
Engine oil filter (on oil tank)
Fork
Light operation/directi on
Light system
Safety switches
Clutch fluid
Brake fluid
Coolant
Engine oil (*)
Tyres
Tyre pressure (**)
Engine idling rpm
Engine oil pressure warning light LED at every start:
Drive chain tension and lubrication every 1000 km (625 mi):
Brake pad wear
before every trip and every
2000 km (1250 mi):
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OPERATIONS TO BE CARRIED OUT BY
THE APRILIA Official Dealer.
Key
= check and clean, adjust, lubricate or
change, if necessary;
= clean;
= change;
= adjust.
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
(*) = In case of use on race tracks, check
every 3750 km (2343 mi).
(**) = With “R” fork w (W m), change
every 10000 km (6250 mi).
(***) = Only in case of:
– intense use on racetracks;
– participation in competitions.
After running-
Component
Rear shock absorber
Transmission cables and controls
Rear suspension linkage bearings
Steering bearings and steering clearance
Wheel bearings
Brake discs
General running of the vehicle
Adjusting the valve clearance
Braking systems
Cooling system
Throttle body pin greasing
Clutch fluid
Brake fluid
Coolant
Fork oil (**)
Fork oil seals
Brake pads if worn:
Wheel/Tyres
Nut, bolt, screw tightening
Cylinder synchronization
Suspensions and attitude
Final transmission (chain, crown and pinion)
Fuel pipes
Clutch wear (*)
Pistons (***) every 5000 km (3125 mi):
in [1000 km
(625 mi)]
after the first 7500 km (4687 mi) and successively
after the first 30000 km (18750 mi) and
successively every 22500 km (14000 mi):
Every 7500 km
(4687 mi) or 12
months
every 2 years:
every 22500 km (14000 mi):
Every 15000
km (9375 mi)
or 24 months
every 4 years:
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It is a good rule to w rite down the frame
and engine numbers in the space provided
in this manual.
The frame number ca n be us ed for th e purchase of spare parts.
NOTE Do not alter the identification
numbers if you do not want to incur severe
penal and administrative sanctions. In particular, the alteration of the frame number
results in the immediate inva lidity of the
guarantee.
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FRAME NUMBER
The frame number is stamped on the right
side of the steering column.
Frame no.
ENGINE NUMBER
The engine number is stamped on the rear
part of the engine, near the pinion.
Engine no.
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Carefully read p. 43 (ENGINE OIL) and p.
59 (MAINTENANCE).
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
Periodically check the engine oil level,
change the oil after the first 1000 km (625
mi) and successively every 7500 km (4687
mi), see p. 64 (CHANGING THE ENGINE
OIL AND THE OIL FILTER).
aCAUTION
In case of use on racetracks, change
the engine oil every 3750 km (2343 mi).
If the vehicle is used in dusty areas,
change the oil more frequently.
MAX
MIN
DIAG
km/h
X1000
rpm
BORLETTI
VEGLIA
N
max
1
2
3
4
5
6
7
8
9
10
11
12
A
A
MAX
2
4
3
M
A
MI
N
3
X
M
I
N
MAX
For the check, proceed as follows:
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
“.” (A) does not come on, see p. 18
(INSTRUMENTS AND INDICATORS TABLE).
NOTE To warm the engine and have the
engine oil reach th e operatin g temperatu re,
do not let the engine idl e with the v ehicl e at
rest. According to the correct procedure, it
is advisable to carry out the check after a
trip of after covering approximately 15 km
(10 mi) on a road outside to wn (this is sufficient for the engine oil to reach the operating temperature).
1
◆ Stop the engine, see p. 57 (STOPPING).
◆ Keep the vehicle in vertical position, with
the two wheels resting on the ground.
◆ Check the oil level on the transparent
pipe (3) through the a ppo si te slots (1 ) (2 )
on the left part of the fairing.
MAX = maximum level
MIN = minimum level.
The difference between “MAX” and “MIN”
amounts to approximately 500 cm#.
◆ The level is correct when the oil almost
reaches the “MAX” mark.
aCAUTION
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 by
proceeding as follows:
MIN
◆ Remove the left fairing, see p. 77 (RE-
MOVING THE SIDE FAIRINGS).
◆ Unscrew and remove the filling cap (4).
aCAUTION
Do not put additives or other substances into the oil.
If you use a funnel or other similar
items, make sure that they are perfectly
clean.
NOTE Use high-quality 15W – 50 oil,
see p. 113 (LUBRICANT CHART).
◆ Top up the tank and restore the correc t
level, see p. 113 (LUBRICANT CHART).
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aCAUTION
The engine oil and the oil filter change
operations may be difficult for unskilled
operators.
If necessary, contact your APRILIA Official Dealer.
If you want to perform these operations
personally, keep to the follow ing instructions.
Carefully read p. 43 (ENGINE OIL) and p.
59 (MAINTENANCE).
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
Periodically check the engine oil level, see
p. 62 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP) change the oi l after
the first 1000 km (625 mi) a nd success ively
every 7500 km (4687 mi).
aCAUTION
In case of use on racetracks, change
the engine oil every 3750 km (2343 mi).
If the vehicle is used in dusty areas,
change the oil more frequently.
To change, proceed as follows:
NOTE The oil flows out completely and
without problems when it is warm and
therefore more fluid: to achieve this condition, the engine sho uld run for approximately twenty minutes.
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aCAUTION
When warmed up, the engine contains
hot oil; therefore, while carrying out the
operations describe d here below be
particularly careful, in order to avoid
burns.
◆ Remove the lower fairing, see p. 77 (RE-
MOVING THE LOWER FAIRING).
◆ Position a container (1) with more than
4000 cm# capacity in correspondence
with the drain plug (2) positioned on the
tank.
◆ Unscrew and remove the drain plug (2)
positioned on the tank.
◆ Unscrew and remove the filling cap (3).
◆ Drain the oil and let it drip into the con-
tainer (1) for a few minutes.
◆ Check and if nec es sary replace the seal-
ing washer of t he drain plug (2) p ositioned on the tank.
◆ Screw and tighten the drain plug (2) on
the tank.
Drain plug (2) driving torque: 15 Nm
(1.5 kgm).
◆ Move the container (1 ) and p ositi on it un -
der the engine base, in correspondence
with the drain plug positioned on the engine (4).
◆ Unscrew and re move the drain plu g posi-
tioned on the engine (4).
◆ Drain the oil and let it drip into the con-
tainer (1) for a few minutes.
aCAUTION
Do not dispose of oil in the environment. Put it in a sealed containe r and
take it to the filling sta tion where you
usually buy it or to an oil salvage center.
◆ Remove the metal residues from the
drain plug (4) magnet.
◆ Screw and tighten the drain plug (4).
Driving torque of the drain plug (4) positioned on the engine: 12 Nm (1.2 kgm).
CHANGING THE ENGINE OIL FILTER
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
Change the engine oil filter after the
first 1000 km (625 mi) and successively
every 7500 km (4687 mi) (or every time
you change the oil).
◆ Unscrew the two screws (5) and remove
the cover (6).
◆ Remove the engine oil filter (7).
aCAUTION
Do not use filters that have already
been used.
◆ Spread an oil film on the sealing ring (8)
of the new engine oil filter.
◆ Fit the new engine oil filter.
◆ Put back the cove r (6), sc rew and tighte n
the two screws (5).
CLEANING THE ENGINE OIL FILTER ON
THE TANK
NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
Clean the engine oil filter (9) on the tank
after the first 1000 km (625 mi) and successively every 15000 km (9375 mi) (or
every two engine oil changes).
NOTE Prepare a screwdriver-type pipe
clamp (10) to re pl ace t he original one (special type).
◆ Loosen the clamp (11) and disconnect
the pipe ( 12).
◆ Unscrew and remove the engine oil filter
(9) positioned on the tank and clea n it
with a jet of compressed air.
◆ Check the seal of the engine oil filter (9)
positioned on the tank; screw and tighten
it.
Engine oil filter (9) drivin g torque: 30
Nm (3 kgm).
◆ Connect the pipe (12) and tighten the
new clamp (10).
aCAUTION
Do not put additives or other substances into the oil.
If you use a funnel or other similar
items, make sure that they are perfectly
clean.
NOTE Use high-quality 15W – 50 oil,
see p. 113 (LUBRICANT CHART).
◆ Pour about 3500 cm# of engine oil
through the filling opening (13), see p.
113 (LUBRICANT CHART).
◆ Tighten the filling cap (3).
◆ Start the engine, see p. 50 (STARTING)
and let it idle for about one minute, in order to ensure the fi lling up of the engine o il
circuit.
◆ Check the oil level and top up if neces-
sary, see p. 62 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP).
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NOTE Perform the maintenance opera-
tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.
Check the air cleaner every 7500 km (4687
mi) or 12 months, change it every 150 00 km
(9375 mi) or more frequently if the vehic le i s
used on dusty or wet roads.
It is possible to clean the air cleaner partially
after using the vehicle on this kind of roads.
aCAUTION
The partial cleaning of the filter does not
exclude or postpone the replacement of
the filter itself. Do not start the engine if
the air cleaner has been removed. Do
not clean the filtering element with petrol
or solvents, since they may cause a fire
in the fuel supply system, with serious
danger for the persons in the vicinity and
for the vehicle.
DO NOT DISPOSE OF POLLUTING SUBSTANCES OR COMPONENTS IN THE
ENVIRONMENT.
◆ Every 7500 km (4687 mi), remove the
plug (1), empty its conte nt i nto a co nta iner and deliver it to a salvage centre.
REMOVAL
◆ Lift the fuel tank, see p. 76 (LIFTING
THE FUEL TANK)
◆ Unscrew and remove the se ven screws
(2) that fasten the filter case cover (3).
◆ Remove the filter case cover (3).
◆ Extract the air cleaner (4).
◆ Check the conditions of the gasket (5)
and change it if it is damaged.
aCAUTION
Plug the opening wit h a clean cloth, i n
order to prevent any foreign matter to
get ito the suction ducts.
Upon reassembly, before positi oning
the filter case cover (3), make sure that
you have not left the cloth or other objects inside the filter case (6).
Make sure that the filtering element is
positioned correctly, in such a way as
to prevent non-filtered air from entering .
Remember that the untimely wea r of the
piston segments and the cylinder may
be caused by a faulty or uncorrectly positioned filtering element.
PARTIAL CLEANING
aCAUTION
Do not press or strike the metal net of
the air cleaner (4).
Do not use screwdrivers or alike.
◆ Seize the air cleaner (4) vertically and
strike it more than once on a clean surface.
◆ If necessary, clean the air cleaner (4)
with a compressed air jet (directing it
from the inside towards the outside of
the filter).
aCAUTION
When cleaning the filtering element,
make sure that there are no tears.
Otherwise, change the filtering el ement.
◆ Clean the outer part of the air cleaner (4)
with a clean cloth.
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CHANGING
aCAUTION
Do not use filters that have already
been used.
◆ Replace the air cleaner (4) with a new
one of the same type.
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◆ Position the vehicle on the stand, see p.
58 (POSITIONING THE VEHICLE ON
THE STAND).
~Position the pin (7) on the appropriate
seat on the rear fork.
~Screw and tighten the screw (8) in the
appropriate threaded hole in the rear
fork.
m
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◆ Assemble the two pins (7), see p. 67
(ASSEMBLING THE PINS FOR THE
REAR SUPPORT STAND m).
m
NOTE Have someone help you k eep the
vehicle in vertical position with the two
wheels on the ground.
~Loosen the knob (9).
~Move the fork support (10), positioning
it so that the width corr esponds to the
distance between the two pins (7) on the
rear fork.
~Tighten the knob (9).
◆ At the same time introduce the two fork-
shaped seats (10) of the stand (1 1) under the two pins (7) provided on the v ehicle.
◆ Rest one foot on the rear part of the
stand (11).
◆ Push the stand (11) downwards until it
reaches the end of its stroke.
aCAUTION
Make sure that the vehicle is stable.
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◆ Position the vehicle on the appropriate
rear support stand, see p. 67 (ASSEMBLING THE PINS FOR THE REAR
SUPPORT STAND m).
◆ Insert the two ends of the stand (12) in
the two holes (13) positioned on the lower ends of the front fork.
◆ Rest one foot on the front part of the
stand (14).
◆ Push the stand (14) downwards until it
reaches the end of its stroke.
m
aCAUTION
Make sure that the vehicle is stable.
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aCAUTION
The disassembly and reassembly of the
front wheel may be difficu lt for unskille d
operators.
If necessary, contact your APRILIA Official Dealer.
If you want to perform these operations
personally, keep to the following in structions.
Carefully read p. 59 (MAINTENANCE).
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipes, the discs and the pads.
aWARNING
Riding with damaged rims may be dangerous for the rider, other persons and
the vehicle.
Check the conditions of the wheel rim
and change it if it is damaged.
DISASSEMBLY
◆ Remove the front brake calipers, see p.
70 (FRONT BRAKE CALIPERS).
◆ Put a support (1) under the tyre, in such
a way as to keep th e w h eel in its position
after loosening it.
aCAUTION
Make sure that the vehicle is stable.
◆ Have someone keep the handlebar
steady in running position, so that the
steering is locked.
Wheel nut (2) driving torque: 80 Nm (8
kgm).
◆ Loosen and remove the wheel nut (2),
taking the washer (3).
Wheel pin clamp screw driving torque:
22 Nm (2.2 kgm).
◆ Partially unscrew the two wheel pin
clamp screws (4) (right side).
◆ Partially unscrew the two wheel pin
clamp screws (5) (left side).
NOTE Check the position of the spacer
ring (6) (right side ), in order to be able to
reinstall it correctly.
NOTE To facilitate the extraction of the
wheel pin, slightly raise the wheel.
◆ Push the wheel pin (7), b y carefully acting
on the threaded end and using a rubber
hammer if necessary.
◆ Support the front wheel and manually
withdraw the wheel pin (7).
◆ Remove the whee l by wit hdrawing it from
the front.
aCAUTION
The spacer ring (6) remains in its seat
on the wheel; if it comes off, reposition
it correctly (see REASSEMBLY).
REASSEMBLY
◆ Spread a film of lubrica ting grease on the
whole leng th of th e wheel pin (7 ), see p.
113 (LUBRICANT CHART).
aCAUTION
While reassembling the wheel, be careful not to damage the b rake pipes, discs
and pads.
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NOTE Eseguire l’operazione che segue,
solo se il distanziale (6) è fuoriuscito dalla
sede.
◆ Insert the spacer ring (6) with its longer
diameter towards t he o uts id e of the ve hicle.
aCAUTION
The arrow on the wheel side indicates
the rotation direction.
Upon reassembly, make sure that the
wheel is positioned correctly: the arrow
must be visible on the le ft side of the vehicle.
◆ Position the wheel between the fork rods
on the support (1).
aWARNING
Danger of injury. Do not introduce your
fingers to align the holes.
◆ Move the wheel until its central hole and
the holes on the fork are aligned.
◆ Introduce the wheel pin (7) completely
from the left side.
NOTE Make sure that the wheel pin (7)
is completely inserted.
◆ Position the washer (3) and tighten the
wheel nut (2) manually.
NOTE In this phase, for the temporary
tightening of the two wheel pin clamp
screws (5) (left side), the driving to rque value need not be respected.
◆ Screw the two wheel pin clamp screws
(5) (left side) and tighten them as much
as necessary to lock the rotation of the
wheel pin (7).
◆ Tighten the wheel nut (2) completely.
Wheel nut (2) driving torque: 80 Nm (8
kgm).
◆ Tighten the two wheel pin clamp screws
(4) (right side).
Wheel pin clamp screw driving torque:
22 Nm (2.2 kgm).
◆ Loosen the two wheel pin clamp screws
(5) (left side).
◆ Put back the front brake calipers, see p.
70 (FRONT BRAKE CALIPERS).
◆ With pulled front brake lever, press the
handlebar repeatedly, thr usting the fork
downwards. In this way the fork rods will
settle properly.
◆ Position the vehicle on the side stand,
see p. 58 (POSITIONING THE VEHICLE
ON THE STAND).
◆ Tighten the two screws (5) of the wheel
pin clamp (left side).
Wheel pin clamp screw driving torque
(5): 22 Nm (2.2 kgm)
◆ Make sure that the followi ng compo nents
are not dirty:
– tyre;
– wheel;
– brake discs.
aWARNING
After reassembly, pull the front brake lever repeatedly and check the correct
functioning of the braking system.
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
APRILIA Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
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&2/.4"2!+%#!,)0%23
Carefully read p. 59 (MAINTENANCE).
aWARNING
A dirty disc soils the pads, with consequent reduction of the braking efficiency. Dirty pads must be replaced, while
dirty discs must be cleaned with a highquality degreaser.
aCAUTION
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipes, the discs and the pads.
NOTE To remove the front brake cali-
pers, it is necessary to use the appropriate
front m and rear support stands m.
DISASSEMBLY
◆ Position the vehicle on the appropriate
front support stand, see p. 67 (POSITIONING THE VEHICLE ON THE
FRONT SUPPORT STAND m).
aCAUTION
Make sure that the vehicle is stable.
◆ Manually rotate the wheel, so that the
space between two spokes of the rim is
in correspondence with t he brake caliper.
◆ Have someone keep the handlebar
steady in running position, so that the
steering is locked.
Brake caliper screw dri ving torque (1):
50 Nm (5 kgm).
◆✱ Unscrew and remove the two brake
caliper screws (1).
aCAUTION
Never pull the brake lever after removing the caliper, otherwise the pistons
may go out of their seats, thus causing
the outflow of the brake fluid.
In this case consult y our APRILIA Offic ial
Dealer, who will carry out the proper
maintenance operation.
◆✱ Withdraw the brake caliper (2) from
the disc, leaving it attached to the pipe
(3).
Work on the second brake caliper:
◆ Repeat the operations marked with ✱.
REASSEMBLY
aCAUTION
Proceed with care, in order not to damage the brake pads.
◆✖ Insert the brake caliper (2) on the disc
and position it so that its fastening holes
and the holes o n the suppo rt ar e alig ned.
aWARNING
Upon reassembly of the brake caliper,
replace the caliper fastening screws (1)
with two new screws of the same type.
◆✖ Screw and tighten the two screws (1)
that fasten the brake caliper.
Brake caliper screw driving torque:
50 Nm (5 kgm).
Work on the second brake caliper:
◆ Repeat the operations marked with ✖.
◆ Remove the front support stand m, see
p. 67 (POSITIONING THE VEHICLE ON
THE FRONT SUPPORT STAND m).
aCAUTION
After reassembly, pull the brake lever
repeatedly and check the correct functioning of the braking system.
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2%!27(%%,
aCAUTION
The disassembly and reassembly of the
rear wheel may be difficult for unskilled
operators.
If necessary, contact your APRILIA Offi-
cial Dealer.
If you want to per form these operat ions
personally, keep to the following instructions.
Carefully read p. 59 (MAINTENANCE).
Before carrying out the following opera-
tions, let the engine and the silencer
cool down until the y reach room temperature, in order to avoid burns.
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipe, the disc and the pads.
aWARNING
Riding with damaged rims may be dangerous for the rider, other persons and
the vehicle.
Check the conditions of the wheel rim
and change it if it is damaged.
NOTE To remove the rear wheel it is
necessary to use the appropriate rear support stand m.
DISASSEMBLY
◆ Position the vehicle on the appropriate
rear support stand (1), see p. 67 (POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND m).
◆ Put a support (2) under the tyre, in such
a way as to keep the wheel in its position
after loosening it.
Wheel nut (3) driving torque: 120 Nm
(12 kgm).
◆ Loosen and remove the wheel nut (3),
taking the washer (4).
NOTE To facilitate the extraction of the
wheel, slightly raise the wheel.
◆ Withdraw the wheel pin (5) from the left
side.
NOTE Check the arrangement of the
right (6) and left (7) chain tighteners, in order to be able to reassemble them correctly.
◆ Take the right (6) and left (7) chain tight-
eners.
NOTE Lower the drive chain (8) outside
the crown gear (9).
◆ Make the wheel a dvance and releas e the
drive chain (8) from the crown gear (9).
◆ Withdraw the wheel from the rear fork
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71
from behind, carefully withdrawing the
disc from the brake caliper.
aCAUTION
Do not operate the rear br ak e le ver after
removing the wheel, since the pins may
go out of their seats and cause brake
fluid leakages. In this case con sult your
APRILIA Official Dealer, who will carry
out the proper maintenance operation.
aCAUTION
The left (10) and right spacer rings (11)
remain positioned in the respective
seats on the wheel; if they should come
off, reposition them correctly (see REASSEMBLY).
NOTE The support plate (12) of the
brake caliper (13) remains positioned on
the right side of the rear fork.
Proceed with care. If the final drive unit
(14) is installed on the flexible coupling
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72
holder (15), do not overturn or rotate the
rear wheel in horizontal position on the rear
sprocket side (A), since the final drive unit
would come off and fall down, with the risk
of damaging the rear sprocket (9) .
NOTE The removal of the final drive unit
isn’t necessary if the wh ee l is in t he normal
running position (vertical) or in horizontal
position with the rear sprocket facing upwards and in both cases se cured against
overturning.
NOTE Do not unscrew the five nuts (16).
The whole final drive unit must be withdrawn from the flexible coupling holder.
◆ Working (B) with both hands on th e outer
diameter of the sprocket (9), withdraw
the final drive unit parallel y to the wh eel
axis.
REASSEMBLY
If the final drive unit (14) has been re-
moved:
NOTE Introduce the final drive unit, par-
allely to the wheel axis, inserting the flexible coupling rubber elements in the corresponding seats on the flexible coupling
holder (15).
◆ Working (C) with both han ds on the oute r
diameter of the sprocket (9), insert the final drive unit in the flexible coupling
holder (15).
NOTE Perform the operation described
below only if the left (10) and/or the right
spacer ring (11) have come off their seats.
◆ Insert the left (10) and/o r the right sp acer
ring (11) in the respective seats, with the
longer diameter towards the outside of
the vehicle.
C
OK !
NO!
B
OK !
OK !
OK !
NO!
A
A
NO!
aCAUTION
Before proceeding with the reassembly,
make sure that support plate (12) of the
brake caliper (13) is positioned correctly; the plat e sl o t must b e in se r te d i n th e
appropriate stop pin (17) in the inner
part of the rear fork right rod.
Insert th e d isc in t he b r ak e cal ip e r ca r e fully.
◆ Position the wheel between the rear fork
rods on the support (2).
Do not introduce yo ur fingers betw een
the chain and the crown gear.
◆ Make the wheel advance and position
the drive chain (8) on the crown gear (9).
◆ Correctly insert the right (6) and left (7)
chain tighteners in their seats on the
fork.
◆ Uniformly apply a moderate quantity of
aWARNING
OK !
OK !
NO!
C
B
9
grease on the wheel pin (5), see p. 113
(LUBRICANT CHART).
9
aWARNING
Danger of injury.
Do not introduce your fingers to align
the holes.
◆ Move the wheel backward s, unt il its ce n-
tral hole and the holes on the rear fork
are aligned.
◆ Rotate the support plate (12), complete
with brake caliper (13) and with fulcrum
on the stop pin (17 ), until it i s aligned w ith
the holes.
◆ Introduce the wheel pin (5) completely
from the left side.
NOTE Make sure that the wheel pin (5)
is completely inserted, with the head in the
relevant seat on the l eft c hain tightener (7).
◆ Position the washer and tighten the
wheel nut (3) manually.
◆ Check the chain tension, see p. 74
(DRIVE CHAIN).
◆ Tighten the wheel nut (3).
Wheel nut (3) driving torque: 120 Nm
(12 kgm).
◆ Make sure that the followi ng compo nents
are not dirty:
– tyre;
– wheel;
– brake discs.
aCAUTION
After reassembly, pull the rear brake lever repeatedly and check the correct
functioning of the braking system.
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
APRILIA Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
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73
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