Aprilia RSV Mille 2002 Service Manual

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Page 2

RSV mille

INTRODUCTION

GENERAL INFORMATION

SERVICE AND SETTING UP

ENGINE

FUEL SUPPLY SYSTEM

COOLING SYSTEM

ELECTRIC SYSTEM

CHASSIS

REPAIR INFORMATION

ANALYTICAL INDEX

236mille U 

WORKSHOP manual

aprilia part# 8140688

Release 00/2002-10

0 -1

- 00

Page 3

INTRODUCTION

RSV mille

INTRODUCTION

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 ...................................................... 0-3-00

0.1.1 INFORMATION ON THE

UPDATING OF THE MANUAL ............... 0-3

0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3-00

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2%&%2%.#%-!.5!,3 ......................... 0-6-00

0.4.1 ENGINE SERVICE AND

REPAIR MANUALS ................................ 0-6

0.4.2 SPARE PARTS CATALOGUES ............ 0-6-00

0.4.3 SPECIAL TOOL MANUALS .................. 0-6-00

0.4.4 USE AND MAINTENANCE MANUALS . 0-6-00

3!&%497!2.).'3 ............................... 0-7-00

0.5.1 PRECAUTIONS AND GENERAL

INFORMATIONS .................................... 0-7

0.5.2 BEFORE THE DISASSEMBLY OF THE

COMPONENTS ...................................... 0-7

0.5.3 DISASSEMBLING THE COMPONENTS 0-7-0 0

0.5.4 REASSEMBLING THE COMPONENTS 0-7-00

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0.6.1 ADVICE FOR CONSULTATION ............ 0-8-00

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Release 00/2002-10

Page 4

RSV mille

INTRODUCTION

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Date of the first edition (Release 00) and of the following Releases:

First edition (Release 00) ............................october 2002

0.1.1 INFORMATION ON THE UPDATING OF THE MANUAL

The manual must be updated every time a new “Release” is received.

Insert the pages of the last Release in the manual and eliminate the corresponding obsolete pages (even if belonging to a previous Release).

aWARNING

The failure to update the manual and to eliminate the obsolete pages makes it more difficult to consult the manual and may lead to the performance of incorrect operations on the vehicle, with serious consequences for the safety of the vehicle and of persons and property.

The manual consists of # 10 sections, for a total amount of # 384 pages, as listed below.

NOTE For the nomenclature of the standard page of

the manual (and specifically for the definition of the page number) see 0.2 (HOW TO CONSULT THE MANUAL).

0.1.2 UPDATED MANUAL GENERAL LIST

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INTRODUCTION

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RSV mille

0 -4

- 00

Release 00/2002-10

Page 6

RSV mille

 (/74/#/.35,44(%-!.5!,

INTRODUCTION

1) Vehicle (or engine) model

2) Section

3) Release consecutive number (“00” indicates the first

edition)

4) Year and month of publication of the Release

5) Section number

6) Section page consecutive number

Release 00/2002-10

7) Updated page consecutive number

8) Chapter title (numbered consecutively)

9) Paragraph title (numbered consecutively)

10) Description of the operation (always preceded by a rhombus)

11) Description of the operation: the star means that the operation must be repeated on the other side of the vehicle

0 -5

- 00

Page 7

INTRODUCTION

RSV mille

 &/2%7/2$

– This manual supplies the main information for normal

servicing procedures.

– In the future, the information and illustrations that make

up this manual will be updated by means of “Releases”, see 0.1 (UPDATE OF RELEASE 00/2002-10).

– This publication is intended for the aprilia Dealers and

their qualified engineers; many notions were voluntarily omitted, because they were considered superfluous. Since it is not possible to include complete mechanical information in this publication, the persons using this manual must have a basic mechanical training and a basic knowledge of the procedures regarding motor vehicles repair systems. Without this knowledge, the repair or servicing of the vehicle may be ineffective or even dangerous. The manual does not describe all the procedures for the repair and servicing of the vehicle in detail, therefore it is important to be particularly careful, in order to avoid any damage to components and persons. In order to grant its customers more and more satisfaction in the use of the vehicle, aprilia s.p.a. will keep improving its products and the relevant documentation. The main technical modifications and the modifications in the vehicle repair procedures are communicated to all aprilia Outlets and Branches the world over. These modifications will be described in the successive editions of this manual. In case of need or doubts regarding the repair and inspection procedures, contact the Technical AfterSales Dpt., which can give you the information required and also inform you about any updates and technical modifications made to the vehicle.

aprilia s.p.a. reserves the right to modify its models at any time, without prejudice to the main characteristics here described. All rights as to electronic storage, reproduction and total or partial adaptation, with any means, are reserved for all Countries. The mention to products or services supplied by third parties is made only for information purposes and it isn’t binding in any case. aprilia takes no responsibility as to the performance or use of said products.

For further information, see 0.4 (REFERENCE MANUALS).

First edition: october 2002

Prodotto e stampato da:

editing division Soave (VERONA) - Italia tel. +39 045.7611911 fax +39 045.7612241 E-mail: customer@stp.it www.stp.it

 2%&%2%.#%-!.5!,3

0.4.1 ENGINE SERVICE AND REPAIR MANUALS

APRILIA part# (countries)

8140582 (1051-1) I 8140584 (1053-1) f 8140585 (1054-1) d 8140583 (1052-1) E 8140586 (1055-1) U 8140587 (1056-1) u

0.4.2 SPARE PARTS CATALOGUES

APRILIA part# (countries)

390W IU 390Y IU 3901 IU

0.4.3 SPECIAL TOOL MANUALS

APRILIA part# (countries)

8202278 IfdEU

0.4.4 USE AND MAINTENANCE MANUALS

APRILIA part# (countries)

models 1998 - 1999

8102623 Ifd 8102857 pEU 8102858 ODF 8102859 GJU 8104128 A 8104099 u

models 2000

8104089 Ifd

8104142 pEU 8104143 ODF 8104141 GJU 8104164 A 8104171 u

8104152 Ifd 8104269 pEU 8104267 ODF 8104268 GJU 8104270 A 8104264 u

per conto di:

aprilia s.p.a. Technical After-Sales Department - Technical Documentation Department

via G. Galilei, 1 - 30033 Noale (VE) - Italia tel.+39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com

0 -6

- 00

Release 00/2002-10

Page 8

RSV mille

INTRODUCTION

 3!&%497!2.).'3

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

Safety warning. When you find this symbol on

the vehicle or in the manual, be careful to the potential risk of personal injury. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other people’s safety and for the vehicle!

aWARNING

Indicates a potential hazard which may result in serious injury or even death.

aCAUTION

Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.

NOTE The word “NOTE” in this manual precedes im-

portant information or instructions.

0.5.1 PRECAUTIONS AND GENERAL INFORMA-

TIONS

Follow with care these recommendations when repairing, disassembling and reassembling the vehicle.

aWARNING

The use of naked flames is forbidden for any type of operation. Before beginning any maintenance operation or any inspection of the vehicle, stop the engine, extract the key from the ignition block, wait until the engine and the exhaust system have cooled down and if possible lift the vehicle by means of the proper equipment, on firm and flat ground. Keep away from the red-hot parts of the engine and of the exhaust system, in order to avoid burns.

aWARNING

Do not hold any mechanical piece or other parts of the vehicle with your mouth: the components are not edible and some of them are noxious or even toxic.

If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order. Any reference to operations from other chapters must be interpreted logically in order to avoid components being removed unnecessarily. Do not use polishing pastes on matt paints.

Never use fuel as a solvent for cleaning the vehicle.

Do not use alcohol, petrol or solvents to clean the rubber and plastic parts and the saddle: use only water and mild soap.

Disconnect the negative cable (–) from the battery when electric welding.

When two or more persons are working together, make sure that each is working in safe conditions.

Carefully read 1.2 (INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENTS).

0.5.2 BEFORE THE DISASSEMBLY OF THE COMPONENTS

– Remove any dirt, mud, dust and foreign matters from

the vehicle before disassembling the components.

– Use, when necessary, the special tools designed for

this vehicle.

0.5.3 DISASSEMBLING THE COMPONENTS

– Do not loosen and/or tighten the screws and nuts using

pliers or other tools: instead, always use the proper spanner.

– Before disconnecting the joints (pipes, cables, etc.),

mark the positions on all of them and mark them with different distinguishing signs. Each piece must be marked clearly, in order not to have problems during installation.

– Clean and wash carefully any disassembled parts with

low inflammability detergents.

– Keep the parts that are used in pairs together, since

they have adapted to each other following the normal

wear. Some components must be used together or replaced completely.

– Keep away from heat sources.

0.5.4 REASSEMBLING THE COMPONENTS

aCAUTION

Never use a seeger ring twice. When a seeger ring is removed, it must be replaced with a new one. When assembling a new seeger ring be careful not to stretch its ends more than strictly necessary to put it on the shaft. After installing a seeger ring, make sure that it is completely and firmly inserted in its seat.

Do not use compressed air to clean the bearings.

NOTE The bearings must rotate freely, without halting

a/o noise otherwise they must be replaced.

– Use only original aprilia SPARE PARTS. – Use the recommended lubricants. – Whenever possible, lubricate the parts before reas-

sembly.

– When tightening screws and nuts, begin with those

having greater diameters or with inner ones, proceeding diagonally. Tighten screws or nuts in successive passages before applying driving torque.

– Always replace lock nuts, seals, sealing rings, snap

rings, O-rings, split pins and screws, whenever the thread appears damaged, with new ones.

– Before the assembly, clean all the connection surfaces,

the oil seal edges and the gaskets. Apply a thin layer of lithium-based grease on the oil seal edges. Put back the oil seals and the bearings with the mark or serial number facing towards the outside (visible side).

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Page 9

INTRODUCTION

★

– When installing the bearings, lubricate them abundant-

ly.

– Make sure that each component has been reassem-

bled correctly.

– After a repair or periodic maintenance operation, carry

out the preliminary checks and test the vehicle in a private area or, in any case, in a low-traffic area.

RSV mille

(/74/53%9/523%26)#%!.$2%0!)2

-!.5!,

0.6.1 ADVICE FOR CONSULTATION

– This manual is divided into section and chapters, each

one of which corresponds to a category of main components. To consult them, see the sections’ index, see page 0-1.

– If not expressly indicated otherwise, for the reassembly

of the units repeat the disassembly operations in reverse order.

– The terms “right” and “left” are referred to the rider

seated on the vehicle in the normal riding position.

– For normal maintenance operations and for the use of

the vehicle, consult the “USE AND MAINTENANCE” manual.

The operations preceded by this symbol must be repeated on the opposite side of the vehicle.

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

frame # ZD4RP............(and in any case from model 2001)

automatic light switching version (Automatic Switch-on

Device)

optional

catalytic version

VERSION:

Italy

United King-

dom

Austria

Portugal

Finland

Belgium

Germany

France

Spain

Greece

Holland

Switzerland

Denmark

Japan

Singapore

Slovenia

Israel

South Korea

Malaysia

Chile

Croatia

Australia

United States

of America

Brazil

South Africa

New Zealand

Canada

0 -8

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RSV mille

!""2%6)!4)/.339-"/,3).)4)!,3

# = number < = is less than > = is greater than

≤ = is equal to or less than ≥ = is equal to or greater than

~ = approximately

∞ = infinity

°C = degrees Celsius (centigrade) °F = degrees Fahrenheit ± = plus or minus a.c. = alternating current A = ampère Ah = ampere per hour API = American Petroleum Institute HV = high voltage AV/DC = AntiVibration Double Countershaft bar = unit of pressure (1 bar = 100 kPa) d.c. = direct current cm# = cubic centimetres CO = carbon monoxide CPU = Central Processing Unit DIN = German industrial normative (Deutsche

Industrie Norm)

DOHC = Double Overhead Camshaft ECU = Engine Control Unit rpm = revolutions per minute HC = unburnt hydrocarbons ISC = idle speed control ISO = International Standardization Organization kg = kilograms kgm = kilograms per metre (1 kgm = 10 Nm) km = kilometres km/h = kilometres an hour kΩ = kilo-ohms kPa = kiloPascal (1 kPa = 0.01 bar) KS = clutch side (Kupplungseite) kW = kilowatt

L = litres

LAP = lap (race course) LED = Light Emitting Diode LEFT

SIDE = left side m/s = metres an second MAX = maximum mbar = millibar (1mbar = 0.1 kPa) mi = mile MIN = minimum MPH = miles per hour MS = flywheel side (Magnetoseite) MΩ = megaohm N.A. = not available (Not Available) N.O.M.M. = “Motor” method octane number N.O.R.M. = “Research” method octane number Nm = newton per meter (1 Nm = 0.1 kgm)

Ω = ohm

INTRODUCTION

PICK-UP = pick-up BDC = bottom dead centre TDC = top dead centre PPC = Pneumatic Power Clutch RIGHT

SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostics test T.B.E.I. = convex socket head T.C.E.I. = hexagonal socket head T.E. = hex-head T.P. = flat head TSI = Twin Spark Ignition UPSIDE-

DOWN = upside-down rods V = volt W = watt Ø = diameter

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Page 11

INTRODUCTION

NOTES

RSV mille

0 -10

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Page 12

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GENERAL INFORMATION

Release 00/2002-10

1 -1

- 00

Page 13

GENERAL INFORMATION

4!",%/&#/.4%.43

0/3)4)/./&4(%3%2)!,

.5-"%23 .................................................. 1-3-00

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

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

).3425#4)/.3&/253%/&

&5%,,5"2)#!.43#//,!.4!.$

/4(%2#/-0/.%.43 .......................... 1-4

1.2.1 FUEL ........................................................ 1-4-00

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

1.2.3 FORK OIL ................................................ 1-4-00

1.2.4 BRAKE FLUID ......................................... 1-5-00

1.2.5 COOLANT ............................................... 1-5-00

1.2.6 CLUTCH FLUID ....................................... 1-6-00

1.2.7 CARBON MONOXIDE ............................. 1-6-00

1.2.8 HOT COMPONENTS ............................... 1-6-00

25..).').25,%3 ............................... 1-7-00

30!2%0!243 .......................................... 1-7-00

4%#(.)#!,30%#)&)#!4)/.3 ............ 1-8-00

,5"2)#!.4#(!24 .............................. 1-12-00

1.6.1 LUBRICANT CHART (for models

up to 2001) ............................................ 1-12

1.6.2 LUBRICANT CHART ò ..................... 1-13-00

30%#)!,4//,3m .............................. 1-14-00

1.7.1 SUPPORT STANDS .............................. 1-14-00

1.7.2 FRAME TOOLS ..................................... 1-15-00

1.7.3 FORK TOOLS ....................................... 1-15-00

1.7.4 ENGINE TOOLS .................................... 1-16-00

1.7.5 MISCELLANEOUS TOOLS ................... 1-18-00

1.7.6 TOOLS USED FOR OTHER

aprilia VEHICLES ................................. 1-20

0/3)4)/.).'4(%6%()#,%/.

4(%3500/2434!.$ ......................... 1-21

1.8.1 ASSEMBLING THE PINS FOR THE

REAR SUPPORT STAND m ............... 1-21

1.8.2 POSITIONING THE VEHICLE ON

THE REAR SUPPORT STAND m ...... 1-21

1.8.3 POSITIONING THE VEHICLE ON THE

FRONT SUPPORT STAND m ............ 1-21

1.8.4 POSITIONING THE VEHICLE ON THE

CENTRE SUPPORT STAND m .......... 1-22

#/.35-!",%3 ..................................... 1-23-00

1.9.1 PRODUCT PROPERTIES ..................... 1-23-00

1.9.2 USE OF CONSUMABLES ..................... 1-25-00

&!34%.).'%,%-%.43 .................... 1-28-00

1.10.1 JOINTS WITH HOSE CLAMPS

AND SCREW CLAMPS ....................... 1-28

1.10.2 GENERAL SPECIFICATIONS OF

THE DRIVING TORQUES ................... 1-29

1.10.3 DRIVING TORQUES ........................... 1-30-00

-00

RSV mille

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42!.3&%23 ........................................... 1-36-00

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RSV mille

 0/3)4)/./&4(%3%2)!,.5-"%23

These numbers are necessary for the registration of the vehicle.

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 invalidity of the guarantee.

1.1.1 FRAME NUMBER

The frame number is stamped on the right side of the steering column.

1.1.2 ENGINE NUMBER

The engine number is stamped on the rear part of the engine, near the pinion.

GENERAL INFORMATION

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Page 15

GENERAL INFORMATION

RSV mille

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,5"2)#!.43#//,!.4!.$/4(%2 #/-0/.%.43

1.2.1 FUEL

aWARNING

The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive. It is important to carry out the refuelling and the maintenance operations in a well-ventilated area, with the engine off. Do not smoke while refuelling or near fuel vapours, in any case avoid any contact with naked flames, sparks and any other heat source to prevent the fuel from catching fire or from exploding.

Further, prevent fuel from flowing out of the fuel filler, as it could catch fire when getting in contact with the red-hot surfaces of the engine. In case some fuel has accidentally been spilt, make sure that the area has completely dried and before starting the vehicle verify that there is no fuel inside the fuel filler neck. Since petrol expands under the heat of the sun and due to the effects of sun radiation. Never fill the tank to the brim. Screw the plug up carefully after refuelling.

Avoid any contact of the fuel with the skin and the inhalation of vapours; do not swallow fuel or pour it from a receptacle into another by means of a tube.

DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

Use only premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

1.2.2 ENGINE OIL

aWARNING

Engine oil may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of the oil in the environment. Deliver it to or have it collected by the nearest oil salvage center or by the supplier.

In case any maintenance operation has to be carried out, it is advisable to use latex gloves.

For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the lubricant types, see 1.6 (LUBRICANT CHART).

1.2.3 FORK OIL

aWARNING

Fork oil may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. Do not dispose of the oil in the environment. Deliver it to or have it collected by the nearest oil salvage center or by the supplier.

In case any maintenance operation has to be carried out, it is advisable to use latex gloves.

By changing the damper settings and/or the viscosity of the oil contained in them, the suspension response may be altered partially.

Standard oil viscosity: SAE 20 W.

The viscosity ratings which can be chosen based on the type of fork stiffness desired (SAE 5W soft, 20W stiff).

The two products can be used in different percentages until the desired response is obtained.

v F.A. is that your viscosity alters little with changes in temperature and their damping response therefore remains constant.

For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the lubricant types, see 1.6 (LUBRICANT CHART).

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GENERAL INFORMATION

1.2.4 BRAKE FLUID

NOTE This vehicle is provided with front and rear disc

brakes, with separate hydraulic circuits. The following information refers to a single braking system, but is valid for both.

aWARNING

If the brake fluid gets in contact with the skin or the eyes, it can cause serious irritations. Carefully wash the parts of your body that get in contact with the liquid. Consult a doctor or an oculist if the liquid gets in contact with your eyes.

DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

When using the brake fluid, take care not to spill it on the plastic or painted parts, since it can damage them.

For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the lubricant types, see 1.6 (LUBRICANT CHART).

aCAUTION

To avoid serious damage to the braking system, do not use fluids other than the recommended ones nor mix different fluids for topping up. Do not use brake fluid taken from old or already opened containers. Sudden variations in clearance or an elastic resistance in the brake levers may be due to trouble in the hydraulic circuits. Make sure that the brake discs and the friction pads are completely free of grease or oil, especially after maintenance or checking operations. Check that the brake cables are neither twisted nor worn out. Prevent water or dust from accidentally getting into the circuit.

In case maintenance operations are to be performed on the hydraulic circuit, it is advisable to use latex gloves.

1.2.5 COOLANT

aWARNING

The coolant is noxious: do not swallow it; if the coolant gets in contact with the skin or the eyes, it can cause serious irritations. If the coolant gets in contact with your skin or eyes, rinse with plenty of water and consult a doctor. If it is swallowed, induce vomit, rinse mouth and throat with plenty of water and consult a doctor without delay.

DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

Be careful not to spill the coolant on the red-hot parts of the engine: it may catch fire and send out invisible flames.

In case any maintenance operation should be required, it is advisable to use latex gloves.

Do not use the vehicle if the coolant is below the minimum prescribed level.

For the maintenance intervals, see 2.1.1 (REGULAR

SERVICE INTERVALS CHART).

The coolant is composed of 50% water and 50% antifreeze. This mixture is ideal for most running temperatures and ensures good protection against corrosion.

It is advisable to keep the same mixture in the hot season as well, since in this way losses due to evaporation are reduced and it is not necessary to top up so frequently. The mineral salt deposits left in the radiator by evaporated water are thus lessened and the efficiency of the cooling system remains unaltered.

If the outdoor temperature is below 0°, check th cooling circuit frequently and inf necessary increase the antifreeze concentration (up to maximum 60%).

For the cooling solution use distilled water, in order not to damage the engine.

For the lubricant types, see 1.6 (LUBRICANT CHART).

On the basis of the desired freezing temperature of the coolant mixture, add to the water the percentage of coolant indicated in the following table:

Release 00/2002-10

Freezing point °C Coolant of the volume

-20 35

-30 45

-40 55

NOTE The characteristics of the various antifreeze liq-

uids are different. Be sure to read the label on the product to learn the degree of protection it guarantees.

aCAUTION

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

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Page 17

GENERAL INFORMATION

RSV mille

1.2.6 CLUTCH FLUID

NOTE This vehicle is provided with hydraulic clutch

control.

aWARNING

If the clutch fluid gets in contact with the skin or the eyes, it can cause serious irritations. Carefully wash the parts of your body that get in contact with the liquid. Consult a doctor or an oculist if the liquid gets in contact with your eyes.

DO NOT DISPOSE OF THE FLUID IN THE ENVIRONMENT.

KEEP AWAY FROM CHILDREN.

When using the clutch fluid, take care not to spill it on the plastic and painted parts, since it damages them.

For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the lubricant types, see 1.6 (LUBRICANT CHART).

aCAUTION

To avoid serious damage to the system, do not use fluids other than the recommended ones nor mix different fluids for topping up. Do not use clutch fluid taken from old or already opened containers.

Sudden variations in clearance or an elastic resistance in the clutch levers may be due to trouble in the hydraulic circuits. Check that the clutch hoses are not twisted or worn. Prevent water or dust from accidentally getting into the circuit.

In case maintenance operations are to be performed on the hydraulic circuit, it is advisable to use latex gloves.

1.2.7 CARBON MONOXIDE

If it is necessary to let the engine run in order to carry out some work, make sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces. If it is necessary to work indoors, use an exhaust evacuation system.

aWARNING

The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and even death.

Run the engine in an open area or, if it is necessary to work indoors, use an exhaust evacuation system.

1.2.8 HOT COMPONENTS

aWARNING

The engine and the components of the exhaust system become very hot and remain hot for some time after the engine has been stopped.

Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.

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RSV mille

GENERAL INFORMATION

 25..).').25,%3

The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes undergo a more effective running-in.

During running-in, change speed. In this way the components are first “loaded” and then “relieved” and the engine parts can thus cool down. Even if it is important to stress the engine components during running-in, take care not to exceed.

aCAUTION

Only after the first 1500 km (937 mi) of running-in is it possible to obtain the best performance.

Keep to the following indications:

◆ Do not open the throttle completely if the speed is low,

both during and after the running-in.

◆ During the first 100 km (62 mi) put on the brakes with

caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake disc.

◆ During the first 1000 km (625 mi) never exceed 6000

rpm. (see table).

aCAUTION

After the first 1000 km (625 mi) perform the checking operations indicated in the “after running-in” column, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) in order to avoid injuring yourself or others a/o damaging the vehicle.

 30!2%0!243

For any replacement, use aprilia Genuine Spare Parts only, see 0.4.2 (SPARE PARTS CATALOGUES). aprilia Genuine Spare Parts are high-quality parts, expressly designed and manufactured for aprilia vehicles.

aCAUTION

Failure to use APRILIA Genuine Spare Parts may result in incorrect performance and damages.

◆ Between the first 1000 km (625 mi) and 1500 km (937

mi) drive more briskly, change speed and use the maximum acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 7500 rpm (see table).

◆ After the first 1500 km (937 mi) you can expect better

performance from the engine, however, without exceeding the maximum allowed (10500 rpm).

Engine maximum rpm recommended

Mileage km (mi) rpm

0 – 1000 (0 – 625) 6000

1000 – 1500 (625 – 937) 7500

over 1500 (937) 10500

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GENERAL INFORMATION

 4%#(.)#!,30%#)&)#!4)/.3

DIMENSIONS

Max. length 2080 mm ò Max. length 2070 mm

Max. length (with number plate-holder extension)

Max. width 720 mm ò Max. width 725 mm

Max. height (front part of the fairing included) 1170 mm

Seat height 820 mm

Distance between centres 1415 mm

Min. ground clearance 130 mm

Weight ready for starting (fuel and fluid included) 221 kg

ENGINE

Model V990

Type 60° longitudinal V-type, two-cylinder, 4-stroke, with 4

Number of cylinders 2

Total displacement 997.62 cm#

Max. rated power (to driving shaft) 86.5 kW at 9250 rpm ò Max. rated power (to driving shaft) 92 kW at 9250 rpm

Bore/stroke 97 mm/67.5 mm

Compression ratio 11.8 ± 0.4 : 1

Average piston speed 22.5 m/s at 10000 rpm

Camshaft during intake stroke 259°, valve lifting= 10.6 mm ò Camshaft during intake stroke 262°, valve lifting= 11.4 mm

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

Valve advance (with valve clearance 1mm) opening during intake stroke

stroke

stroke ò Valve advance (with valve clearance 1mm) opening during

intake stroke

stroke

Valve clearance during intake stroke 0.12 – 0.17 mm

Valve clearance during exhaust stroke 0.23 – 0.28 mm

Diameter of the inlet valve plate 36.0 mm

Diameter of the exhaust valve plate 31.0 mm

# Engine revolutions at minimum rpm 1250 ± 100 rpm

# Engine revolutions at peak rpm 10250 ± 100 rpm

Ignition electronically controlled

Starting electric

Spark advance Variable according to speed and load

Starter motor gear ratio i= 49/9 * 30/11 * 64/30 = 31.677

Clutch multidisc in oil bath, with hydraulic control on the left

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- 00

closing during intake

opening during exhaust

closing during exhaust

closing during intake

opening during exhaust

closing during exhaust

2140 mm

valves per cylinder, DOHC.

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

25° before TDC 58° after BDC 64° before TDC 15° after BDC

side of the handlebar and PPC device

- # 9 lined discs; thick 3.5 mm

- # 9 internal discs; thick 1.5 mm

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Page 20

RSV mille

GENERAL INFORMATION

ENGINE

Transmission Mechanical, 6 gears with foot control on the left side of

the engine

Lubrication system dry pan with separate oil tank, # 2 trochoidal pumps

and cooling radiator

Lubrication pressure min 500 kPa (5 bar)

at max 80 °C (176 °F) and 6000 rpm

Air cleaner with dry filter cartridge

Cooling liquid-cooled

Coolant pump gear ratio i

= 28/27 * 28/28 = 1.037

Coolant pump delivery (with thermal expansion valve open) 90 L /min and 9000 rpm

Thermal expansion valve opening start temperature 75 ± 2 °C (149 ± 5 °F)

Engine dry weight ~ 65 kg

CAPACITY

Fuel (reserve included) 20 L ò Fuel (reserve included) 18 L

Fuel reserve 4.5 ± 1 L

Engine oil oil change 3700 cm#

oil and oil filter change 3900 cm#

Fork oil (per rod) 520 ± 2.5 cm#

Coolant 2.5 L(50% water + 50% antifreeze with ethylene glycol)

Seats 2

Vehicle max. load (driver + passenger + luggage) 182 kg ò Vehicle max. load (driver + passenger + luggage) 180 kg

DRIVE

GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio

31/60 = 1: 1.935 14/35 = 1: 2.500 17/42 = 1: 2.470 11.948

16/28 = 1: 1.750 8.368 19/26 = 1: 1.368 6.543 22/24 = 1: 1.090 5.216 23/22 = 1: 0.956 4.573

27/23 = 1: 0.851 4.073 # sprocket teeth 17 Drive chain Endless type (with no connection link) with sealed links,

model 525, dimensions 5/8" x 5/16"

FUEL SUPPLY SYSTEM

Type electronic injection Choke Ø 51 mm

FUEL SUPPLY

Type indirect injection (MULTIPOINT) Fuel premium grade unleaded petrol, min. O.N. 95

(N.O.R.M.) and 85 (N.O.M.M.).

FRAME

Type two-beam frame with light alloy cast elements and

extruded elements Steering inclination angle 25° Fore stroke 97 mm ò Fore stroke 99 mm (with front tyre 120/70)

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GENERAL INFORMATION

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SUSPENSIONS

Front UPSIDE-DOWN telescopic adjustable fork with hydrau-

lic operation, rod Ø 43 mm Stroke 127 mm Rear oscillating rear fork in light alloy with differentiated pro-

file arms and hydropneumatic adjustable mono-shock

absorber Wheel stroke 135 mm

BRAKES

Front with double floating disc – Ø 320 mm, calipers with four

pins Rear disc brake – Ø 220 mm, caliper with double pin

WHEEL RIMS

Type in light alloy with withdrawable pin Front 3.50 x 17" Rear 6.00 x 17"

SPARK PLUGS

Standard NGK R DCPR9E Spark plug gap 0.6 – 0.7 mm Resistance 5 kΩ

ELECTRIC SYSTEM

Battery 12 V – 12 Ah Main fuses 30 A Secondary fuses 15 A Generator (with permanent magnet) 12 V – 400 W Starter 12 V/0.9 kW

BULBS

Low beam (halogen) 12 V – 55/55 W H4 ò Low beam (halogen)

12 V – 55 W H7U

High beam (halogen) 12 V – 60 W H3 ò High beam (halogen)

12 V – 55 W H7U

Front parking light 12 V – 5 W Direction indicators 12 V – 10 W Rear parking lights/Number plate light/Stoplight 12 V – 5/21 W Revolution counter 12 V – 2 W Right multifunction display 12 V – 2 W

WARNING LIGHTS

Neutral 12 V – 3 W Direction indicators 12 V – 3 W Fuel reserve 12 V – 3 W High beam 12 V – 2 W Stand down 12 V – 3 W Engine oil pressure LED Red line LED

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TYRES ✱ = series w. ✱ ✱ = series W.

GENERAL INFORMATION

Recom-

mended

Wheel Make Model Type Size

Road Track

Front PIRELLI DRAGON EVO MTR21 CORSA 120/70-ZR 17" X – W

Rear PIRELLI DRAGON EVO MTR22 CORSA 180/55-ZR 17" X – W

Rear PIRELLI DRAGON EVO MTR22 CORSA 190/50-ZR 17" X – W

✱

Front

✱

Rear

✱ ✱

Front

Rear METZELER SPORTTEC M1 180/55-ZR 17" X X

✱ ✱

Rear

Front METZELER RENNSPORT – 120/70-ZR 17" X X

Rear METZELER RENNSPORT – 180/55-ZR 17" X X

PIRELLI

METZELER SPORTTEC M1 120/70-ZR 17" X X

METZELER SPORTTEC M1 190/50-ZR 17" X X

DRAGON

SUPERCORSA

DRAGON

SUPERCORSA

– 120/70-ZR 17" X X

– 180/55-ZR 17" X X

Alter-

native

Solo rider

(2.3)

(2.5)

Ww230

(2.3)

Ww250

(2.5)

Ww230

(2.3)

Ww250

(2.5)

Ww250

(2.5)

Ww230

(2.3)

Ww250

(2.5)

Pressure kPa (bar)

Normal use

230

250

Rider

and

pas-

senger

250

(2.5)

280

(2.8)

280

(2.8)

250

(2.5)

280

(2.8)

250

(2.5)

280

(2.8)

280

(2.8)

250

(2.5)

280

(2.8)

Track

(2.1)

(2.0)

(2.1)

(2.0)

(2.1)

(2.0)

–

210

200

210

200

210

200

✱ ✱

Front

✱ ✱

Rear

Front MICHELIN SPORTCUP – 120/70-ZR 17" X X w

Rear MICHELIN SPORTCUP – 180/55-ZR 17" X X w

Front MICHELIN PILOT RACE H 120/70-ZR 17" – X w ––

Rear MICHELIN PILOT RACE H 180/55-ZR 17" – X w ––

Front

Rear

✱ ✱

Front

✱ ✱

Rear

Rear DUNLOP SPORTMAX D 207 RR 180/55-ZR 17" X X W

MICHELIN PILOT SPORT E

BRIDGE-

STONE

BRIDGE-

STONE

BRIDGE-

STONE

DUNLOP SPORTMAX D 207 F RR 120/70-ZR 17" X X

DUNLOP SPORTMAX D 207 RR 190/50-ZR 17" X – W

BT 010 – 120/70-ZR 17" X – W

BT 010 – 180/55-ZR 17" X – W

BT 010 – 190/50-ZR 17" X – W

120/70-ZR 17"

190/50-ZR 17"

X – W

Ww230

230

(2.3)

250

(2.5)

230

(2.3)

250

(2.5)

230

(2.3)

250

(2.5)

250

(2.5)

(2.3)

250

(2.5)

250

(2.5)

250

(2.5)

280

(2.8)

250

(2.5)

280

(2.8)

250

(2.5)

280

(2.8)

280

(2.8)

250

(2.5)

280

(2.8)

280

(2.8)

–

210

(2.1)

190

(1.9)

210

(2.1)

190

(1.9)

–

210

(2.1)

–

190

(1.9)

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GENERAL INFORMATION

 ,5"2)#!.4#(!24

1.6.1 LUBRICANT CHART (for models up to 2001)

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

FORK 20W, these can be mixed as indicated below:

SAE 10W =

SAE 15W =

Bearings and other lubrication points (recommended): As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -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):

F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume or

F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume or

EXTRA RAID 4, SAE 15W - 50 or TEC 4T SAE 15W - 50.

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

an alternative FORK 5W or FORK 20W fork oil.

F.A. 5W and 0 F.A. 20 W or FORK 5W and

FORK 5W 67% of the volume + FORK 20W 33% of the volume.

FORK 5W 33% of the volume + FORK 20W 67% of the volume.

Bimol Grease 481, 0 AUTOGREASE MP or GREASE 30.

CHAIN SPRAY or CHAIN LUBE.

WARNING

Use new brake fluid only.

F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (DOT 4 compatible).

RSV mille

Clutch fluid (recommended):

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

Engine coolant (recommended):

WARNING

Use new clutch fluid only.

F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (DOT 4 compatible).

WARNING

ECOBLU -40 °C or COOL.

OILL-UK

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1.6.2 LUBRICANT CHART ò

Engine oil (recommended): 0 EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15 W - 50.

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.

W Fork oil (recommended):

If you need an oil with intermediate characteristics in comparison with the

FORK 20W, these can be mixed as indicated below:

SAE 10W =

SAE 15W =

“R”

w ( W & ) fork oil: OHLINS 10W.

Bearings and other lubrication points (recommended):

As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -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):

F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume or

FORK 5W 67% of the volume + FORK 20W 33% of the volume.

F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume or

FORK 5W 33% of the volume + FORK 20W 67% of the volume.

F.A. 5W or 0 F.A. 20W; as an alternative FORK 5W or FORK 20W.

F.A. 5W and 0 F.A. 20W or FORK 5W and

0 Bimol Grease 481,

CHAIN SPRAY or CHAIN LUBE.

AUTOGREASE MP or GREASE 30.

GENERAL INFORMATION

Brake fluid (recommended):

Clutch fluid (recommended):

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

Engine coolant (recommended):

aWARNING

Use new brake fluid only.

F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (compatible DOT 4).

aWARNING

Use new clutch fluid only.

F.F., DOT 5 (compatible with DOT 4) or BRAKE 5.1, DOT 5 (compatible DOT 4).

aWARNING

ECOBLU –40°C or COOL.

OILN-ING

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GENERAL INFORMATION

RSV mille

 30%#)!,4//,3

In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods. Below is a list of the special tools designed especially for this specific vehicle. If necessary, request the multi-purpose special tools, see

0.4.3 (SPECIAL TOOL MANUALS).

aCAUTION

Before using the special tools, consult any documents attached.

1.7.1 SUPPORT STANDS

Pos. APRILIA part# (tool description and function)

A 8140176 (complete support stand kit)

1 8146486 (front support stand)

2 xxxxxxx N.A. [centre stand]

3 8705021 (rear support stand)

xxxxxxx N.A. = available only with the aprilia kit part#

8140176 (complete support stand kit)

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1.7.2 FRAME TOOLS

Pos. APRILIA part# (tool description and function)

A 8140203 (complete tool kit for frame including)

1 8140189 [oil seal fitting tool - Ø 43 hole. Kit accessory aprilia part# 8140151 (complete tool kit for fork includ-

ing)]

2 8140190 (steering tightening tool)

3 8140191 (rear fork pin and engine support tightening tool)

GENERAL INFORMATION

1.7.3 FORK TOOLS

Pos. APRILIA part# (tool description and function)

A 8140151 (complete tool kit for fork including)

1 8140145 (Ø 41 mm sealing ring fitting tool)

2 8140146 [weight to be applied to the tool: aprilia part# 8140145 (Ø 41 mm sealing ring fitting tool)] e aprilia

3 8140147 (spacer holding tool)

4 8140148 (spacer/pumping element separating plate)

5 8140149 (protection element for disassembly operations)

6 8140150 (drilled rod for pumping element bleeding)

part# 8140189 [oil seal fitting tool - Ø 43 hole. Kit accessory aprilia part# 8140151 (complete tool kit for fork including)]

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GENERAL INFORMATION

1.7.4 ENGINE TOOLS

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Pos. APRILIA part# (tool description and function)

A 8140175 (complete tool kit for engine including)

1 0277680 (gearshift secondary shaft oil seal assembly pad)

2 0277660 (upper countershaft oil seal assembly pad)

3 0277670 (coolant pump shaft housing oil seal assembly pad)

4 0877257 (assembly pad for water pump shaft seat sliding ring)

5 0277510 (valve guide disassembly pad)

6 0277210 (valve guide assembly)

7 0277695 (valve guide oil seal assembly pad)

8 8140155 (gearshift shaft oil seal - clutch shaft oil seal assembly pad)

9 0277725 (driving shaft bush inserter pad)

10 0277720 (driving shaft sleeve puller** pad)

11 0277537 (lower countershaft bush inserter pad)

12 0277727 (driving shaft - clutch cover bush inserter pad)

13 0277729 (insertion pad for lower balance shaft clutch cover bushes)

14 8140177 (plug socket spanner)

15 0277252 (flywheel magneto cover removal tool)

16 0277730 (flywheel removal hexagonal bolt)

17 0240880 (threaded bolt to lock the drive shaft at the TDC)

18 0277308 (gearshift secondary shaft guide bush)

19 8140178 (pin installation and removal pad)

20 8140181 (fuel-oil pressure gauge-compression)

21 8140182 (rotor bolt bush)

22 0277881 (clutch blocking tool)

23 8140156 + 8140157 + 0276377 (clutch cover sleeve puller)

24 0276479 (valve spring compression tool)

25 8140179 (valves disassembly and reassembly bow)

26 8157143 (adhesive for tool holder panel RSVmille)

27 8140183 (engine lifting eye hook)

28 8140184 (primary transmission nut disassembly bush)

29 8140185 (clutch disc** extraction hook lever)

30 8140188 (engine support)

31 8140186 (piston ring compression tool)

32 8140197 (perforated bolt for fuel pressure test fuel)

33 8140205 (camshaft template)

34 8140426 (panel hooks)

GENERAL INFORMATION

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GENERAL INFORMATION

1.7.5 MISCELLANEOUS TOOLS

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Pos. APRILIA part# (tool description and function)

1 8140196 [Plurigas (Italian)]

1 8140578 [Plurigas (English)]

2 8140192 (chain installation kit)

3 8140180 (bearing extractors)

4 8140202 (exhaust gas analysis probes)

5 8140267 (intake flange for vacuometer)

6 8140256 (vacuometer)

7 8140424 (OHLINS fork spanner)

8 8140199 (tool panel)

9 8140426 (panel hooks)

10 8140432 (pushing extractor)

11 8140187 (engine support stand)

12 8124838 (battery charger M.F.)

0897651 [LOCTITE

0899788 [LOCTITE

0899784 (LOCTITE

0297434 (LOCTITE

0297433 [MOLYKOTE

243 blue (10 cm³)]

648 green (5 g)]

574 orange)

767 Anti-Seize 15378)

G-N (50 g)]

18 0897330 (multi-purpose grease bp lz)

19 0297386 [SILASTIC 732 RTV (100 g)]

8116067 (LOCTITE

8150)

21 8202222 (panel adhesive sheet)

22 8140074 (lower countershaft bush inserter pad)

23 8140204 (rear stand supports)

24 0277295 (hose clamp installation pliers)

GENERAL INFORMATION

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GENERAL INFORMATION

1.7.6 TOOLS USED FOR OTHER APRILIA6%()#,%3

Pos. APRILIA part# (tool description and function)

1 0877650 (handle for pads)

2 0277265 (extractor for balance shaft, gearbox input and output shaft)

– 8116050 (engine oil) – 8116053 (grease v Bimol Grease 481)

– 8116038 (grease LUBERING ST)

– xxxxxxx N.A. (AP-LUBE temporary lubricant)

– xxxxxxx N.A. (grease DID CHAIN LUBE)

– 8116031 (Fluid “Biosolvent” frame detergent)

– 8116945 (“ACRILON 28” cyanoacrylic glue)

– xxxxxxx N.A. (MOTUL MOTOWASH degreaser)

– 8116043 (ANTI-SEIZE MOTAGEPASTE AS 1800 antiscuff paste)

– xxxxxxx N.A. (alcohol)

–

0898011 (fluorescent green LOCTITE

–

xxxxxxx N.A. (LOCTITE

572)

275)

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xxxxxxx N.A. = not available

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 0/3)4)/.).'4(%6%()#,%/.4(%

3500/2434!.$

1.8.1 ASSEMBLING THE PINS FOR THE REAR

SUPPORT STAND m

NOTE Have the appropriate special tool m to hand:

– aprilia part# xxxxxxx N.A. [centre stand].

◆ Position the vehicle on the side stand on firm and level

ground.

~Position the pin (1) on the appropriate seat on the

rear fork.

~Screw and tighten the screw (2) in the appropriate

threaded hole in the rear fork.

1.8.2 POSITIONING THE VEHICLE ON THE REAR

SUPPORT STAND m

NOTE Have the appropriate special tool m to hand:

– aprilia part# xxxxxxx N.A. [centre stand].

◆ Fit the relevant pins, see 1.8.1 (ASSEMBLING THE

PINS FOR THE REAR SUPPORT STAND m).

NOTE Have someone help you keep the vehicle in ver-

tical position with the two wheels on the ground.

~Loosen the knob (3). ~Move the fork support (4), positioning it so that the

width corresponds to the distance between the two pins (1) on the rear fork.

~Tighten the knob (3).

◆ At the same time introduce the two fork-shaped seats

(4) of the stand (5) under the two pins (1) provided on the vehicle.

GENERAL INFORMATION

aCAUTION

Grasping the stand in another way than indicated in the figure may cause your fingers to be crushed between the stand and the ground.

◆ Grasp the terminal central part of the stand (5) with

your hands (Pos.A).

◆ Push the stand (5) downwards until it reaches the end

of its stroke.

1.8.3 POSITIONING THE VEHICLE ON THE FRONT

SUPPORT STAND m

NOTE Have the appropriate special tool m to hand:

– aprilia part# 8146486 (front support stand).

◆ Position the vehicle on the appropriate rear support

stand, see 1.8.2 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m).

◆ Insert the two ends of the stand (6) in the two holes (7)

positioned on the lower ends of the front fork.

aCAUTION

Grasping the stand in another way than indicated in the figure may cause your fingers to be crushed between the stand and the ground.

◆ Grasp the terminal central part of the stand (6) with

your hands (Pos.A).

◆ Push the stand (6) downwards until it reaches the end

of its stroke.

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GENERAL INFORMATION

1.8.4 POSITIONING THE VEHICLE ON THE CENTRE

SUPPORT STAND m

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

NOTE Have the appropriate special tool m to hand:

– aprilia part# 8146486 (front support stand).

◆ Set the vehicle on the relevant front support stand, see

1.8.3 (POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND m).

~Hold the nut on the inside (1) still.

Driving torque of the engine-frame rear fastening screw: 50 Nm (5.0 kgm).

~Unscrew and remove the engine upper rear fastening

screw (2).

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

~Retrieve the nut (1).

◆ Insert the upper right support pin (3) in the upper hole

on the right-hand side.

◆ Insert the stud bolt (4) in the upper hole on the left-hand

side and screw it all the way onto the pin (3).

◆ Screw the upper left support pin (5) all the way onto the

stud bolt (4) and tighten.

~Hold the nut on the inside (6) still.

Driving torque of the engine-frame lower fastening screw: 50 Nm (5.0 kgm).

~Unscrew and remove the engine lower rear fastening

screw (7).

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

◆ Insert the lower right support pin (8) in the lower hole on

the right-hand side.

◆ Insert the stud bolt (9) in the lower hole on the left-hand

side and screw it all the way onto the pin (8).

◆ Screw the lower left support pin (10) all the way onto

the stud bolt (9) and tighten.

◆ Place the support bracket (11) with the longer side of

the base facing forwards, on the two support pins (3 -

8).

◆ Insert the two washers (12) (13) and two nuts (14) (15),

screwing them on by hand.

◆ Tighten the two nuts (14) (15).

◆ Place the support bracket (16) with the longer side of

the base facing forwards, on the two support pins (5) (10).

◆ Insert the two washers (17) (18) and two nuts (19) (20),

screwing them on by hand.

◆ Tighten the two nuts (19) (20).

◆ Remove the front and rear support stands.

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 #/.35-!",%3

Only use the products given below for any maintenance work. The materials mentioned have been tested for many years and are suitable for all the application conditions indicated by the manufacturer.

NOTE The consumables, which are coded, are availa-

ble on application, see 1.9.2 (USE OF CONSUMABLES).

1.9.1 PRODUCT PROPERTIES

APRILIA part# (product) Use and properties

GENERAL INFORMATION

aprilia part# 0897651 [LOCTITE®

243 blue (10 cm³)]

aprilia part# 0898011 (fluorescent green LOCTITE

aprilia part# 0899788 [LOCTITE 648 green (5 g)]

aprilia part# 0899784 (LOCTITE 574 orange)

275) (**)

Adhesive in paste for screws and nuts up to M36 and for couplings with medium hold. It can be used on parts which have not been completely degreased.

The hardening time depends on the temperature and the material (maximum one hour). Resistance to temperatures in the range – 55 to 150 °C (– 99 to 302 °F).

It prevents the loosening of the threaded components and the fluid leakages due to vibrations.

It must be used on clean, degreased and non-oxidized components.

Apply a quantity sufficient to cover all the threaded part.

Paste for strong fastening of screws. The hardening time depends on the temperature and the

material (maximum twelve hours). Resistance to temperatures in the range -55 to 175 °C ( – 99 to

347 °F). In order to release the part glued, it may be necessary to heat

the coupled parts to a temperature of 250 °C (482 °F).

Solvent-free seal in paste, to be used instead of seals where there is a high friction factor and where a precise distance is required between the two components. Applied in its liquid state, it hardens after assembly on contact with the metal within a few hours. A seal is created whose surface structure adapts to the surfaces to be sealed.

Resistance to temperatures in the range – 55 to 200 °C (– 99 to 392 °F); where applied, it seals the surfaces against corrosion.

aprilia part# 8116067 (LOCTITE®

8150)

aprilia part# 0297434 (LOCTITE 767 Anti-Seize 15378)

aprilia part# 0297433 [MOLYKOTE G-N (50 g)]

aprilia part# 0297386 [SILASTIC 732 RTV (100 g)]

Release 00/2002-10

Paste to be used on components subjected to high temperature.

Lubricant and anticorodal resistant to high temperatures. It must be sprayed on both components and makes sure the

sliding surfaces remain maintenance free for a long time. It prevents corrosion.

Lubricating paste to be used on support points subjected to heavy loads, for standard lubrication and on couplings under pressure, in order to prevent corrosion which would prevent subsequent disassembly.

To apply on the two surfaces.

It is used as a sealant, preventing water from getting inside the flywheel cover.

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GENERAL INFORMATION

1.9.2 USE OF CONSUMABLES

RSV mille

For use descriptions that have been involuntarily omitted in this list and for any further information on the use of expendable materials, see 0.4.2 (SPARE PARTS CATALOGUES).

(*) = see 1.6 (LUBRICANT CHART).

(**) = see 1.9.1 (PRODUCT PROPERTIES).

xxxxxxx N.A. = not available

APRILIA part# (product) Description of use

aprilia part# 8116050 (engine oil) (*) – Assembly of rivets on fork, dashboard/front fairing mount, saddle

support and frame.

– Assembly of frame/engine and frame/fork adjusting bushes. – Assembly of fairlead screws on frame. – Insertion of steering head bearings. – Steering head upper bush. – On timing intermediate gear roller bearings. – On lower countershaft thrust washer. – Clutch disengaging shaft. – On valve stems and valve lifter buckets. – On valve guide oil seals. – On camshaft housings. – On the timing chain tightener. – On double starter gear and idler gear pins. – On the freewheel gear/freewheel contact surface. – On the freewheel inner contact surface. – On the piston segment seats.

aprilia part# 0897651 [LOCTITE cm³)] (**)

243 blue (10

– Fastening of steering shock absorber bush. – Fastening of rear brake caliper lock pin. – Fastening of pinion. – Fastening of rear brake lever pin. – Fastening of cooling electrofan on support. – Fastening of fuel return pipe connection. – Fastening of fuel filler cap. – Throttle cable pullet fastening nut. – Throttle cable support bracket fastening screws. – Throttle valve pin fastening nut. – Throttle valve potentiometer fastening screws. – On coolant pump centre fastening screw. – On cylinder joining bracket fastening screws. – On engine half-casing bearing lock screws. – On the cylinder fastening stud bolts (engine crankcase half side). – On driving shaft position sensor fastening screws. – On the camshaft position sensor fastening screws. – On index lever and plate fastening screws. – On driving shaft fastening nut. – On timing gear fastening screws. – On upper countershaft counterweight fastening nut. – On intermediate timing gear bearing support lower fastening

screw. – On the thread of the coolant duct plug on the rear cylinder. – On the thread of the engine oil pressure sensor. – On the thread of the stator fastening screws.

aprilia part# 0898011 (fluorescent green LOC-

275) (**)

TITE

aprilia part# xxxxxxx N.A. (LOCTITE® 572)

– On the thread of the cylinder coolant inlet and outlet pipes.

– Fastening of coolant thermal switch. – Fastening of the coolant draining screws positioned on the

radiators.

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APRILIA part# (product) Description of use

aprilia part# 0899788 [LOCTITE® 648 green (5

g)] (**)

– On coolant pump idler gear pin. – On engine oil pump plug. – On the fastening screws of the clutch gear spring-holding plate. – Freewheel assembly on flywheel magneto. – On the freewheel/rotor flange fastening screws. – On clutch housing fastening nut. – On lower countershaft counterweight fastening screw. – On the freewheel housing fastening screws. – On flywheel rotor inner cone. – On flywheel fastening screw. – On the contact surface between the freewheel housing and the

flywheel magneto.

– On the thread of the stud bolts that fasten the exhaust pipes to the

cylinders (cylinder side).

aprilia part# 8116043 (ANTI-SEIZE MOTAGE-

– Assembly of plugs for checking CO on exhaust pipes.

PASTE AS 1800 antiscuff paste)

aprilia part# 0899784 (LOCTITE (**)

574 orange)

– Fastening of coolant thermistors. – On neutral gear switch contact screw. – On the contact surface of the engine oil pump central body with

the external body and with the crankcase. – On the cylinder’s base where it rests on the engine casing. – On the thread of the 90° oil union on the rear cylinder.

aprilia part# 0297434 (LOCTITE

15378) (**)

767 Anti-Seize

– On gearshift primary and secondary shaft. – On gearshift primary and secondary shaft housings. – On driving shaft and countershaft. – On the gearshift primary shaft housing and toothing.

aprilia part# 0297433 [MOLYKOTE

G-N (50 g)]

– On main bush housings. – On main bushes. – On engine casing bearing housings. – On coolant pump shaft. – On valve guide slots on the head. – On valve guide edges. – On the contact area with the cams of the valve caps. – On driving shaft and countershaft bush housings. – On driving shaft and countershaft housings. – On connecting rod/piston pin slots. – On camshaft cams. – On starter motor fastening housing.

aprilia part# 0297386 [SILASTIC 732 RTV (100 g)] (**)

– On cable bracket on flywheel cover. – On camshaft sensor cable. – On the camshaft sensor cable guide.

aprilia part# 8116053 (grease v Bimol Grease

481)

– Assembly of front and rear wheel seals. – Assembly of fork pin bearings. – Assembly of clutch pump control rod. – On rear wheel pin thread. – On steering head bearings. – Assembly of rear brake pump control rod. – On rear brake lever pin. – On intermediate timing gear thrust washer. – Upper countershaft oil seal. – Starter motor gear.

aprilia part# 8116038 (grease LUBERING ST) – Assembly of cold-start control.

GENERAL INFORMATION

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GENERAL INFORMATION

APRILIA part# (product) Description of use

aprilia part# xxxxxxx N.A. (AP-LUBE temporary

lubricant)

aprilia part# xxxxxxx N.A. (grease DID CHAIN LUBE)

aprilia part# 8116031 (Fluid “Biosolvent” frame detergent)

aprilia part# 8116945 (“ACRILON 28” cyanoacrylic glue)

aprilia part# xxxxxxx N.A. (MOTUL MOTOWASH degreaser)

aprilia part# xxxxxxx N.A. (alcohol) – Cleaning of left handlebar prior to assembly of grip.

– Assembly of handlebar counterweights rubber element. – Assembly of throttle cable adjuster rubber elements. – Assembly of rubber element on gearshift lever. – Insertion of radiator lower pins on supporting rubber elements. – Assembly of breather pipe on radiator and three-way manifold. – Assembly of coolant couplings on radiators. – Assembly of water and fuel drainage pipes on fuel pump flange. – Assembly of throttle body torsion springs.

– Lubrication of driving chain.

– Washing of engine oil tank.

– Assembly gasket air filter casing.

– Cleaning of frame and fork.

– Insertion of radiator breather pipes on “T” union. – Assembly of HV coil support rubber element. – Assembly of side fairing rubber elements. – Cleaning of lower part of engine. – Assembly of start relay rubber element. – Assembly of flexible couplings on rear wheel sprocket. – Assembly of rubber elements on engine oil radiator. – Assembly of coupling on coolant filler. – Cleaning of engine oil tank prior to application of transfers. – Assembly of dashboard/front fairing mount rubber elements. – Assembly of rubber element on rear brake lever. – Assembly of pipes on fuel filter (inside tank). – Assembly of coolant radiator union coupling. – Assembly of fuel pipes on tank. – Cleaning of fuel tank prior to application of transfers.

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 &!34%.).'%,%-%.43

1.10.1 JOINTS WITH HOSE CLAMPS AND SCREW CLAMPS

Carefully read 1.2 (INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENTS).

aCAUTION

Remove ONLY the clamps indicated in the maintenance procedures.

This text is not to be intended as an authorization to arbitrarily remove the clamps present on the vehicle.

aWARNING

Before removing a clamp, make sure that the removal does not involve any fluid leakage; if so, provide for preventing such leakages and protect the components positioned near the joint.

HOSE CLAMPS

For the removal it is sufficient to use simple pliers, while for the installation it is necessary to use a special tool (see below). Before removing a clamp, prepare the material necessary for the correct reassembly.

GENERAL INFORMATION

NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp or with other types of clamp.

aCAUTION

Proceed with care, in order not to damage the joint components.

◆ Work with the pliers on the head of the hose clamp,

forcing until you release it.

SCREW CLAMPS

For the removal and installation it is sufficient to use a simple screwdriver.

aCAUTION

Check the conditions of the screw clamp and if necessary replace it with a new one of the same type and dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

When fastening the clamp, make sure that the joint is sufficiently stable.

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GENERAL INFORMATION

1.10.2 GENERAL SPECIFICATIONS OF THE DRIVING TORQUES

The following table indicates the standard driving torques for screws and bolts with metric ISO thread.

RSV mille

Screw or

bolt thread

M6 10 6 0.6

M8 12 15 1.5

M10 14 30 3.0

M12 17 55 5.5

M14 19 85 8.5

M16 22 130 13.0

For specific joints or couplings of the vehicle, see 1.10.3 (DRIVING TORQUES).

If not specified otherwise, the indicated driving torques are valid for clean and dry threads, at room temperature.

Spanner

Driving torque

Nm kgm

NOTE In order to avoid any deformation and/or imper-

fect coupling, tighten the screws or bolts by proceeding as described below:

◆ Manually screw all the fastening elements.

◆ Applying half the prescribed driving torque, tighten the

elements that are diametrically opposite each other: (A) and (B); (C) and (D).

◆ Repeat the previous operation by applying the pre-

scribed driving torque.

NOTE In this way the pressure exerted by the fasten-

ing elements will be uniformly distributed on the joint surface.

For the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

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GENERAL INFORMATION

1.10.3 DRIVING TORQUES

Steel/aluminium fastening screws with similar coefficient of elasticity

Screw or bolt

thread

Driving torque

Nm kgm

M430.3 M560.6 M6 10 1.0

M8 25 2.5 M10 50 5.0 M12 86 8.6

NOTE For the engine component driving torques, refer

to the engine service and repair manual, see 0.4.1 (ENGINE SERVICE AND REPAIR MANUALS).

KEY

L243 = fasten with LOCTITE L572 = fasten with LOCTITE L574 = fasten with LOCTITE® 574 man. = fasten by hand O = oil with motor oil STD = tighten by applying the STANDARD driving torques W=aprilia part# 8116043 (ANTI-SEIZE

MOTAGEPASTE AS 1800 antiscuff paste)

® ®

243 572

aCAUTION

The fastening elements featured in the table must be torqued to specification using a torque spanner and LOCTITE The elements marked ( for safety.

Description Q.ty Screw/nut Nm kgm Notes

● Front connection 2+2 M10 50 5.0 –

● Left-side upper and lower rear connection 2 M10 50 5.0 –

● Adjusting bush right-side upper and lower rear connection 2 M20x1.5 12 1.2 O

● Lock ring right-side upper and lower rear connection 2 M20x1.5 50 5.0 –

● Screw right-side upper and lower rear connection 2 M10 50 5.0 –

Description Q.ty Screw/nut Nm kgm Notes

Engine oil inlet flange 2 M6 10 1.0 – Engine oil outlet flange. 2 M6 10 1.0 – Engine oil drain plug 1 M8 10 1.0 –

Rear brake lever mount fastening

Rear brake pump mount fastening 2 M8 25 2.5 –

● Pinion fastening 1 M10 50 5.0 L

Clutch control cylinder fastening 3 M6 10 1.0 – Pinion case fastening 3 M6 10 1.0 – Fastening of fuel delivery pipe to throttle body 1 M12x1.5 22 2.2 Coolant drain screw 1 M6 10 1.0 – Coolant thermistors 2 M14 30 3.0 L Gearshift lever fastening screw 1 M6 10 1.0 O

applied, where indicated.

●) are particularly important

ENGINE

Fastening of engine to frame

Elements fastened to the engine

1M6101.0 1M8252.5–

–

REAR FORK

Description Q.ty Screw/nut Nm kgm Notes

● Fork pin metal ring 1 M30x1.5 60 6.0 –

● Rear fork pin adjusting bush 1 M30x1.5 12 1.2 O

● Fork pin nut 1 M20x1.5 90 9.0 –

● Caliper mount locking pin 1 M12 50 5.0 L

Chain tightener screw and nut 1+1 M8 man. O Brake pipe grommet fastening 2 M5 4 0.4

– Chain case fastening 2 M5 4 0.4 – Chain tightener shoe fastening 2 M5 3 0.3 – Rear mudguard fastening 2+2 M5 3 0.3

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GENERAL INFORMATION

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SIDE STAND

Description Q.ty Screw/nut Nm kgm Notes

Fastening of stand plate to frame 2 M10 40 4.0 O Stand fastening pin 1 M10x1.25 10 1.0

– Switch fastening screw 1 M6 10 1.0 L Lock nut 1 M10x1.25 30 3.0 –

FRONT SUSPENSION

Front fork

Description Q.ty Screw/nut Nm kgm Notes

● Fastening of upper plate on fork tubes 1+1 M8 25 2.5 –

● Fastening of lower plate on fork tubes 2+2 M8 25 2.5 –

Steering head metal ring 1 M35x1 20 2.0 – Steering head lock ring

1 M35x1 man. + 1 /4 turn – Steering shock absorber bush 2 M8 22 2.2 – Upper plate fastening plug 1 M29x1 100 10.0 O Lower plate travel-end bush fastening screw

1+1 M8 22 2.2 – Centre screw 1+1 M10x1.5 35 3.5 – Slider upper plug/pumping element 1+1 – 35 3.5 – Slider upper plug

● Fork/wheel pin clamp cover 2+2 M8 22 2.2 –

1+1 – 35 3.5 –

Steering damper

Description Q.ty Screw/nut Nm kgm Notes

Fastening of shock absorber collar on dashboard/front fairing

1M6101.0

–

mount Tube end lock nut 1 M8 12 1.2 – Safety dowel on shock absorber collar 1 M5 5 0.5

–

Fastening of shock absorber tube on lower plate 1 M6 10 1.0 –

REAR SUSPENSION

Shock absorber

Description Q.ty Screw/nut Nm kgm Notes

● Fastening of shock absorber to frame 1 M10 50 5.0 –

Linkage

Description Q.ty Screw/nut Nm kgm Notes

● Fastening of single connecting rod to frame 1 M10 50 5.0 –

● Fastening of single/double connecting rod to frame 1 M10 50 5.0 –

● Fastening of double connecting rod fork 1 M10 50 5.0 –

● Fastening of double connecting rod / shock absorber 1 M10 50 5.0 –

ELECTRIC SYSTEM

Description Q.ty Screw/nut Nm kgm Notes

Fastening of battery clamping bracket 1 M6 3 0.3 Fastening of horn mount 1 M8x1.25 25 2.5 Fastening of speed sensor on rear brake caliper mount 1 M6 12 1.2 Fastening of rear indicators 2 M6 2-3 0.2-0.3 Fastening of electronic unit protection case 3 SWP3.9 STD STD

– – – – –

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GENERAL INFORMATION

ELECTRIC SYSTEM

Description Q.ty Screw/nut Nm kgm Notes

Fastening of voltage regulator 2 M6 12 1.2 Fastening of front indicators 2 M6 2-3 0.2-0.3 Fastening of coil to mount 8 M5 5 0.5 Fastening of rear light to rear fairing end 2 SWP3.9 STD STD

Fastening of headlight to front fairing

3SWP3.9STDSTD

1M6 40.4 Fastening of relay box to dashboard/front fairing mount 2 M6 3 0.3 Fastening of cables to relay 2 M6 4 0.4 Fastening of fuse box to dashboard/front fairing mount 2 M6 3 0.3 Fastening of earth to frame 1 M6 10 1.0 Fastening of relay cable to starter 1 M6 5 5.0

– – – – – – – – – – –

FRONT WHEEL

Description Q.ty Screw/nut Nm kgm Notes

● Wheel pin nut 1 M25x1.5 80 8.0 –

REAR WHEEL

Description Q.ty Screw/nut Nm kgm Notes

Fastening of sprocket on sprocket holder 5 M10 50 5.0 – Wheel pin nut 1 M25x1.5 120 12.0 –

COOLING SYSTEM

Description Q.ty Screw/nut Nm kgm Notes

Thermal switch on 3-way manifold 1 M14x1.5 30 3.0 L Fastening of electrofan mount 2+2 M6 6 0.6

– Fastening of electrofan motor to mount 3+3 M4 2 0.2 L Radiator coolant drain plugs 1+1 M6 10 1.0 L Fastening of expansion tank to coils mount 2 M6 10 1.0 Fastening of expansion tank cap 1 M28x3 man. Fastening of coolant filler neck 1 M6 10 1.0

–

– Fastening of hose clamps – – 3 0.3 –

BRAKING SYSTEMS

Front system

Description Q.ty Screw/nut Nm kgm Notes

● Fastening of right and left brake caliper 2+2 M10x1.25 50 5.0 –

Fastening of brake fluid tank Fastening of brake fluid tank bracket

● Brake disc fastening 6+6 M8 30 3.0 L

● Fastening of the front brake pipe 1+1+1 M10x1.25 20 2.0 –

1 M6 7 0.7 – 1 M6 10 1.0 –

Fastening of locking bracket of front brake three-way connection 1 M5 3 0.3 –

● Brake fluid bleeder 3 M10x1 15 1.5 –

Rear system

Description Q.ty Screw/nut Nm kgm Notes

● Brake caliper fastening 2 M8 25 2.5 –

Brake lever pin 1 M8 15 1.5 L Fastening of brake fluid tank 1 M5 1 0.1 – Brake pump fastening 2 M6 12 1.2 Brake rod lock nut 1 M6 man.

● Brake disc fastening 5 M8 30 3.0 L

● Brake pipe fastening 1+1 M10x1 20 2.0 –

● Brake fluid bleeder 1 M10x1 15 1.5 –

Brake lever support front fastening Brake lever support rear fastening

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GENERAL INFORMATION

RSV mille

CLUTCH CONTROL

Description Q.ty Screw/nut Nm kgm Notes

Fastening of clutch fluid pipe 1 M10x1 20 2.0

– Fastening of fluid tank bracket 1 M6 10 1.0 – Fastening of clutch fluid tank on mount 1 M5 3 0.3 – Clutch fluid bleeder 1 M10x1 15 1.5

–

EXHAUST SYSTEM

Description Q.ty Screw/nut Nm kgm Notes

Fastening of exhaust pipes to engine 3+3 M8 25 2.5

Exhaust silencer fastening 1 M8 25 2.5

–

Exhaust pipe CO plug 1+1 G1/8” 25 2.5 W

FUEL TANK

Fuel pump flange

Description Q.ty Screw/nut Nm kgm Notes

Fuel return fitting 1 M6 6 0.6 L

Fastening of pump mount to flange 3 M5 4 0.4

Fastening of electric terminals on flange 2 M5 5 0.5

–

Closing of fuel return 1 M6 10 1.0 L

● Fastening of fuel delivery pipe on flange 1 M12x1.5 22 2.2 –

Petrol level sensor on pump mount 2 SWP 2.9 1 0.1

Fastening of fuel pump cables on flange 2 M6 10 1.0

–

Fuel tank

Description Q.ty Screw/nut Nm kgm Notes

Fastening of filler to tank 3 M5 5 0.5 –

Fastening of fuel pump flange on tank 8 M6 6 0.6

Fastening of tank front on frame 2 M6 12 1.2

Fastening of tank rear on mount 1 M6 12 1.2

–

ENGINE OIL TANK AND RADIATOR

Description Q.ty Screw/nut Nm kgm Notes

Tank upper fastening screw 1 M6 10 1.0 –

Tank fastening nut 2 M6 10 1.0

Oil filter 1 M20x1.5 30 3.0

Oil drain plug 1 M8 15 1.5

Oil level pipe fittings 2 M10x1 20 2.0

Radiator fastening screw 3 M6 12 1.2

–

FRAME/FAIRINGS

Description Q.ty Screw/nut Nm kgm Notes

Radiator spoiler fastening 3 M6 4 0.4

Fastening of number plate holder to rear mudguard extension 2 M5 2 0.2

–

Fastening of reflector holder to number plate holder 2 M5 6 0.6 –

Front mudguard fastening 4 M5 5 0.5 O

Rearview mirror fastening nut 1+1 M6 8 0.8

–

Fastening of rearview mirror mounts and front fairing to mount 4 M5 5 0.5 –

Lower fastening of front fairing to conveyors 2 M5 4 0.4 –

Lower fastening of front fairing (on upper part) 2 M5 4 0.4 –

Fastening of conveyors to frame and mount 14 SWP 3.9 STD STD

–

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RSV mille

GENERAL INFORMATION

FRAME/FAIRINGS

Description Q.ty Screw/nut Nm kgm Notes

Fastening of conveyor covers 6 M6 5 0.5

Fastening of side fairing upper panel 2+2 M5

front 1

rear 2

0.1

0.2

–

Fastening of dashboards upper protection moulding 4 M6 2 0.2 –

Fastening of lower fairing to frame 4 M6 5 0.5 –

Fastening of silencer protection to lower fairing 2 M6 5 0.5 –

Fastening of sides 4 M6 5 0.5

–

Fastening of saddle support bush and lower moulded cover 2 M6 5 0.5 –

Fastening of saddle support lower moulded cover 4 M6 4 0.4 –

Fastening of rear fairing to saddle support lower moulded cover 6 M6 2 0.2

Fastening of rear fairing end to rear fairing 2+2 M5

upper 5 low-

er 3

0.5

0.3

–

Fastening of rear fairing/passenger grab strap 2 M6 10 1.0 –

Fastening of internal fairing and side fairing 8 SWP 2.9 STD STD

–

Fastening of dashboard to mount 3 M6 5 0.5 –

Fastening of riders’s saddle 2 M6 12 1.2 –

Fastening of riders’s saddle front mount 4 M6 12 1.2

–

Fastening of passenger seat lock 2 M6 10 1.0 –

Fastening of passenger seat lock key-operated control 2 M6 12 1.2 –

Fastening of passenger footrest supports 4 M8 25 2.5

–

Fastening of riders’s footrest supports 4 M8 25 2.5 –

Fastening of lower fairing support bracket 2 M6 12 1.2 –

Fastening of riders’s footrest protection 4 M5 6 0.6

–

Fastening of saddle support 4 M10 50 5.0 O

Fastening of coil mounts 4 M6 12 1.2 –

Fastening of dashboard/front part of the fairing to frame 2 M6 12 1.2

–

Fastening of front lower cover 3 M6 7 0.7 –

RIGHT/LEFT HANDLEBARS AND CONTROLS

Description Q.ty Screw/nut Nm kgm Notes

Fastening of anti-vibration weights 1+1 M6 10 1.0 –

Anti-vibration weights metal ring 1+1 M18x1 35 3.5 –

● Fastening of right/left handlebars to the fork 1+1 M8 25 2.5 –

Handlebars lock screw 1+1 M6 10 1.0

–

Fastening of left dimmer switch 1 M5x1 2 0.2 –

Fastening of right dimmer switch 1 M4 2 0.2 –

● Fastening of the front brake control lever 2 M6 8 0.8 –

● Fastening of clutch lever 2 M6 8 0.8 –

AIR FILTER CASING

Description Q.ty Screw/nut Nm kgm Notes

Fastening of air filter casing cover 7 M5 2 0.2 –

Fastening of air filter casing to throttle body 6 M6 7 0.7 O

Fastening of intake conveyors 4 SWP3.9 STD STD –

Fastening of air sensor support plate 1 SWP3.9 STD STD

–

Reduction diaphragm 1 SWP3.9 1 0.1 –

Suction coupling clamp 1 – 2 0.2 –

Filter case front support 2 M6 8 0.8 –

Release 00/2002-10

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GENERAL INFORMATION

THROTTLE BODY

Description Q.ty Screw/nut Nm kgm Notes

Injector support fastening screw 3+2 M6 9 0.9 –

Pressure regulator fastening screw 2 M6 3.5 0.35 –

Throttle cable support bracket fastening screw 3 M5 3 0.3 –

Throttle cable pullet fastening nut 1 M8 3 0.3

Throttle valve control lever fastening nut 1 M8 3 0.3 –

Throttle valve potentiometer fastening screw 2 M4 1.6 0.16 –

Intake flange fastening screw 2+2 M8 19 1.9

RSV mille

–

1 -34

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Page 46

RSV mille

 ).3425#4)/.3&/2!00,9).'

42!.3&%23

When removing parts of the frame:

aCAUTION

Handle the plastic and painted components with care to avoid scraping or damaging them. Proceed with care. Do not damage the tangs and/or their seats.

When applying the transfers, follow the instructions given below carefully.

It is advisable to use the following tools:

– relatively stiff spatula (1);

NOTE Generally, soft, squeegee-type spatulas do not

remove enough water from under the transfer.

– sponge or sprayer (2) with water.

NOTE Add detergent to the water (1-3%) and shake

until you get soap bubbles.

Apply as follows:

◆ Place the transfer (3) upside down on a work surface.

◆ Keeping the transfer spread out on the work surface,

remove the protective backing (4) completely.

NOTE It is advisable to use a sprayer (2).

When using a sponge, dab the surface with the sponge, without pressing hard so as to avoid damaging the adhesive.

◆ Wet the surface of the adhesive with soapy water.

◆ Apply the transfer (3) on the surface to be decorated

and move it into the right position.

NOTE Always move the spatula in constant strokes

from the centre of the transfer out.

◆ Using the spatula (1), press down reasonably hard and

move the spatula across the surface of the transfer until the excess soap and water has been removed from underneath.

NOTE Do not lift the corners and/or sides of the trans-

fer.

◆ Use an absorbent cloth and, working from the centre

out, dry the transfer.

◆ Move the spatula over the transfer again with firm, even

strokes, pressing down as hard as possible. Move the spatula in strokes from the centre out, taking special care with the corners and sides to make sure the whole surface sticks evenly.

GENERAL INFORMATION

Release 00/2002-10

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Page 47

GENERAL INFORMATION

NOTE Where the transfer features application tape

(5)✱, the tape must be removed 20-30 minutes after the application of the transfer.

✱

The application tape is used to facilitate the application of trademarks and letters, arranging them in the correct place on the surface to be decorated, and to give the self-adhesive more body during application.

◆ Remove the application tape (5) from the surface of the

transfer.

◆ In order to assure good adhesion, move the spatula

over the transfer again, concentrating in particular on the edges and corners.

NOTE With the wet method, the final level of the trans-

fer is reached approx. 48 hours after application.

◆ Once the application tape has been removed, make

sure there are no air bubbles anywhere on the surface.

In the event air bubbles are encountered:

◆ Use a pin or paper cutter (6) to make a hole in the edge

(7) of the air bubble.

◆ Using the spatula (1), work from the edge opposite the

hole and push the bubble so the air escapes.

RSV mille

1 -36

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Page 48

RSV mille

NOTES

GENERAL INFORMATION

Release 00/2002-10

1 -37

- 00

Page 49

GENERAL INFORMATION

NOTES

RSV mille

1 -38

- 00

Release 00/2002-10

Page 50

RSV mille

SERVICE AND SETTING UP

Release 00/2002-10

2 -1

- 00

Page 51

SERVICE AND SETTING UP

4!",%/&#/.4%.43

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2.1.1 REGULAR SERVICE INTERVALS CHART ..... 2-4-00

0/).432%15)2).',5"2)#!4)/.

2.2.1 LUBRICATION CHART .................................... 2-6-00

-5,4)&5.#4)/.#/-054%2

2.3.1 SEGMENT OPERATION CHECK ..................... 2-8-00

2.3.2 SWITCHING FROM km TO mi (from km/h to MPH) AND

VICEVERSA (LEFT DISPLAY) ......................... 2-9

2.3.3 SETTING THE INSTANTANEOUS, MAXIMUM AND AVERAGE SPEED

(LEFT DISPLAY) ............................................... 2-9

2.3.4 SETTING THE RED LINE THRESHOLD

(WITH ENGINE OFF ONLY) ........................... 2-10-00

2.3.5 MULTIFUNCTION (RIGHT DISPLAY) ............ 2-11-00

2.3.6 STANDARD SETTING: COOLANT

TEMPERATURE AND DIGITAL CLOCK ........ 2-11-00

2.3.7 BATTERY VOLTAGE - VBATT ...................... 2-11-00

2.3.8 SETTING THE HOUR ..................................... 2-12-00

2.3.9 SETTING THE MINUTES ................................ 2-12-00

2.3.10 SETTING °C OR °F ....................................... 2-12-00

2.3.11 CHRONOMETER (RIGHT DISPLAY) ........... 2-13-00

2.3.12 DIAGNOSTICS .............................................. 2-13-00

"!44%29

2.4.1 CHECKING AND CLEANING THE

TERMINALS .................................................... 2-14

2.4.2 RECHARGING THE BATTERY ...................... 2-15-00

2.4.3 LONG INACTIVITY OF THE BATTERY ......... 2-15-00

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2.11.1 CHECKING THE OPERATION OF THE

ACCELERATOR CONTROL ......................... 2-23

2.11.2 IDLING ADJUSTMENT ................................. 2-23-00

2.11.3 ADJUSTING THE ACCELERATOR

CONTROL ....................................................... 2-24

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2.20.1 BLEEDING OPERATIONS ........................... 2-36-00

2.20.2 CHECKS TO BE CARRIED OUT

AFTER BLEEDING THE BRAKING

SYSTEMS ...................................................... 2-37

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2.21.1 BLEEDING OPERATIONS ........................... 2-38-00

2.21.2 CHECKS TO BE CARRIED OUT

AFTER BLEEDING THE CLUTCH

CONTROL SYSTEM ...................................... 2-39

....................................................... 2-14-00

......................................... 2-17-00

.............................................. 2-18-00

............................................. 2-22-00

.......................................... 2-23-00

..................................................... 2-28-00

.......................... 2-3-00

........ 2-6-00

.................. 2-8-00

-00

......................... 2-16-00

......................... 2-20-00

..................... 2-20-00

-00

................................ 2-24-00

....................... 2-25-00

............................... 2-26-00

.................... 2-29-00

..................... 2-31-00

....................... 2-32-00

................................. 2-34-00

.. 2-35-00

-00

.... 2-38-00

-00

RSV mille

#(!.').'4(%&2/.4"2!+%

............................................................ 2-40-00

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2.28.1 CHECKING THE BEARING SLACK

2.28.2 ADJUSTING THE BEARING SLACK

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2%!23530%.3)/.

2.29.1 FRONT SUSPENSION .................................. 2-48-00

2.29.2 ADJUSTING THE FRONT FORK ................. 2-49-00

2.29.3 ADJUSTING THE HEIGHT OF THE

2%!2&/2+

2.30.1 ADJUSTING THE REAR FORK ................... 2-51-00

).30%#4).'4(%2%!23530%.3)/.

MODELSUPTO

2.31.1 REAR SUSPENSION .................................... 2-52-00

2.31.2 ADJUSTING THE REAR SHOCK

).30%#4).'4(%2%!2

3530%.3)/.

2.32.1 REAR SUSPENSION .................................... 2-54-00

2.32.2 ADJUSTING THE REAR SHOCK

2.32.3 CHECKING THE REAR SUSPENSION

&2/.47(%%, 2%!27(%%, %8(!534-!.)&/,$.543 $2)6%#(!).

2.36.1 CHECKING THE DRIVE CHAIN SLACK ..... 2-58-00

2.36.2 CHECKING THE DRIVING CHAIN,

2.36.3 ADJUSTING THE DRIVING CHAIN ............. 2-59-00

2.36.4 DRIVE CHAIN TENSION AND

2.36.5 INSPECTING THE DRIVING CHAIN

2.36.6 INSPECTING THE DRIVING CHAIN

492%3

2.37.1 CONDITION OF TREAD ............................... 2-61-00

2.37.2 INFLATION PRESSURE ............................... 2-62-00

&5%,0)0%3 "2!+%!.$#,54#(0)0%3 #//,).'3934%-0)0%3 #(%#+).'4(%3)$%34!.$ .54"/,43#2%74)'(4%.).' 6!,6%3 #,54#( 0)34/.3

........................................................... 2-42-00

................................................... 2-46-00

STEERING ..................................................... 2-46

.................................. 2-48-00

FORECARRIAGE .......................................... 2-50

ABSORBER ................................................... 2-52

ABSORBER ................................................... 2-54

LINKAGE ....................................................... 2-56-00

PINION AND SPROCKET WEAR ................. 2-59

LUBRICATION .............................................. 2-59

GUIDE PLATE ............................................... 2-60-00

SHOE ............................................................. 2-60

................................................. 2-51-00

................................. 2-52-00

...................................... 2-54-00

........................................... 2-56-00

.............................................. 2-57-00

............................................. 2-58-00

........................................................... 2-61-00

................................................. 2-63-00

........................................................ 2-65-00

....................................................... 2-65-00

...................................................... 2-65-00

.................. 2-57-00

................. 2-63-00

....................... 2-63-00

............... 2-64-00

2-41-00

.......... 2-42-00

............. 2-43-00

... 2-44-00

-00

....... 2-65-00

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This section describes the procedures for periodic service on the principal components of the vehicle.

aWARNING

Before beginning any maintenance operation or any inspection of the vehicle, stop the engine, extract the key from the ignition block, wait until the engine and the exhaust system have cooled down and if possible lift the vehicle by means of the proper equipment, on firm and flat ground.

Keep away from the red-hot parts of the engine and of the exhaust system, in order to avoid burns.

If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order.

 0%2)/$)#3%26)#%0,!.

aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle.

SERVICE AND SETTING UP

aCAUTION

After the first 1000 km (625 mi) and successively every 7500 km (4687 mi), the writing “SERVICE” (1) appears on the right display.

In this case, carry out the operations prescribed in the periodic service plan. If the bike is being used for competition, perform the operations more frequently, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

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SERVICE AND SETTING UP

2.1.1 REGULAR SERVICE INTERVALS CHART

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 nec-

essary;

 = clean;  = change;  = adjust.

NOTE Perform the maintenance operations with dou-

bled frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces or on racetracks.

(*a) = In case of use on racetracks, change every 3750

km (2343 mi).

(*b) = Check every two weeks or according to the inter-

vals indicated.

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Components

Spark plugs (*a) – 

Stand  –

Air cleaner – 

Engine oil filter (*b)  –

Engine oil filter (on oil tank)  – 

Fork  – 

Light operation/direction –  –

Light system

Safety switches

Clutch fluid –  –

Brake fluid –  –

Coolant – – 

Engine oil (*b)  (*a) –

Tyres  –

Tyre pressure (*c)  –

Engine idling rpm  –

Battery terminal tightening  –

Engine oil pressure warning light LED at every start:

Drive chain tension and lubrication every 1000 km (625 mi):

Brake pad wear 

After run-

ning-in [1000

km (625 mi)]

 –

TABMAN-M2-U-UK

Every 7500

km (4687 mi)

or 12 months

before every trip and every

2000 km (1250 mi):

Every 15000

km (9375 mi)

or 24 months

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OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer.

KEY

 = check and clean, adjust, lubricate or change, if nec-

essary;

 = clean;  = change;  = adjust.

NOTE Perform the maintenance operations with dou-

bled frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces or on racetracks.

(*a) = With “R” fork w (W m), change every 10000

km (6250 mi).

(*b) = Only in case of:

(*c) = In case of use on race tracks, check every 3750 km

– intense use on racetracks; – participation in competitions.

(2343 mi).

SERVICE AND SETTING UP

Components

Rear shock absorber – – Accelerator cables (adjustment) Carburation, CO adjustment Transmission cables and controls Rear suspension linkage bearings – – Steering bearings and steering clearance Rear fork bearings and rear fork slack Wheel bearings – Brake discs General running of the vehicle Braking systems Clutch control system Cooling system – Clutch fluid Brake fluid Coolant

Fork oil (*a)

Fork oil seals

Brake pads if worn:

Pistons (*b) every 5000 km (3125 mi):

Adjusting the valve clearance Wheel/Tyres Nut, bolt, screw tightening – Cylinder synchronization Suspensions and attitude Clutch fluid bleeding Brakes fluid bleeding Final transmission (chain, crown and pinion) –

Fuel pipes –

Brakes and clutch pipes –

Cooling system pipes – Clutch wear (*c) –

TABMAN-M2-C-UK

After running-

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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SERVICE AND SETTING UP

 0/).432%15)2).',5"2)#!4)/.

Correct lubrication is important for good performance and the long life of the vehicle.

NOTE Before lubricating, completely clean all parts, re-

moving rust, grease, dirt and dust. The exposed parts subject to rust are to be lubricated with motor oil or grease, see 1.6 (LUBRICANT CHART).

The points to be lubricated are indicated in the “LUBRICATION CHART”.

2.2.1 LUBRICATION CHART

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LUBRICATION CHART KEY

1) Steering bearings

2) Clutch lever pin

3) Lever cable for cold starting

4) Rider left footrest pin

5) Passenger left footrest pin

6) Passenger seat lock

7) Drive chain

8) Rear suspension leverage

9) Side stand pin

10) Passenger right footrest pin

11) Throttle grip

12) Accelerator cables

13) Front wheel pin and bearings

14) Rear fork pin

15) Rider right footrest pin

16) Rear wheel pin and bearings

■ = Grease ▲ = Oil

SERVICE AND SETTING UP

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SERVICE AND SETTING UP

 -5,4)&5.#4)/.#/-054%2

KEY

A) Left multifunction digital display (speedometer -

odometer). B) Multifunction computer programming push buttons. C) Right multifunction digital display (coolant tempera-

ture - clock - battery voltage - chronometer - diagnos-

tic). When the ignition key (1) is rotated to position “2”, the fol-

lowing warning lights come on on the dashboard: – red line warning light LED “max” (2);

– red engine oil pressure warning light LED “.” (3),

which remains on until the engine starts.

The pointer (4) of the revolution counter shifts to the maximum value (rpm) set by the user. After about three seconds the red line warning light LED “max” (2) goes off; the pointer (4) of the revolution counter returns to its initial position. The writing “ multifunction display for three seconds.

In this way the component operation is tested.

(),” (5) appears on the right side of the

aCAUTION

After the first 1000 km (625 mi) and successively every 7500 km (4687 mi), the writing “SERVICE” (5a) appears on the right display.

In this case contact an APRILIA Official Dealer, who will carry out the operations indicated in the regular service intervals chart, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). To make the writing “SERVICE” disappear, press the “LAP” push button (6) and then the push button r and keep them pressed for about five seconds.

With the ignition key (1) in position “2” the standard settings on the dashboard are the following:

Right display: Clock (7), coolant temperature in °C (8). Left display: Instantaneous speed in km/h (9), trip 1 (trip

odometer) (10), total kilometres/miles odometer (11). Upon installation of the battery or of the 30A main fuses:

– the revolution counter pointer (4) makes twelve clock-

wise clicks, thus checking the operation of the revolution counter itself;

– the instantaneous, maximum and average speed func-

tion is set in “km/h”;

– the coolant temperature is set in °C; – the digital clock is set to zero; – the red line is set at 6000 rpm, indicated by the coming

on of the red line warning light LED “max ” (red) (2).

NOTE If necessary, carry out the appropriate adjust-

ments.

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2.3.1 SEGMENT OPERATION CHECK

◆ Press the push buttons l and k at the same time.

◆ Rotate the ignition key (1) from position “1” to position

“2”.

All the segments (13) (13a) will remain on until the push buttons l and k are released.

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2.3.2 SWITCHING FROM km TO mi (from km/h to MPH) AND VICEVERSA (LEFT DISPLAY)

◆ Press the push button l until, after about five seconds,

all the writings (12) on the left display start blinking.

◆ Release the push button l.

◆ Press the push button k to change the unit of meas-

urement from “km” to “mi” (from “km/h” to “MPH”) or viceversa.

◆ To confirm the setting, press the push button l for

about five seconds.

2.3.3 SETTING THE INSTANTANEOUS, MAXIMUM AND AVERAGE SPEED (LEFT DISPLAY)

NOTE Two seconds after the vehicle has started mov-

ing, the instantaneous speed is automatically shown on the display, even if a different function is set.

When the ignition key is rotated to position “2”, the instantaneous speed (9) and the partial number of kilometres/miles covered “trip 1” (10) appear on the left display.

Resetting “trip 1” (10): with the odometer set on the instantaneous speed function, press the push button r for about two seconds.

◆ To display the maximum speed (14) and the distance

“trip 1” (10), press the push button k for about one second. The writing “V max” (15), the maximum speed (14) and the distance “trip 1” (10) are displayed.

Resetting the maximum speed (14): with the odometer set on the “V max” function, press the push button r for about 2 seconds.

NOTE The measurement of the maximum speed is rel-

evant to the distance covered from the last setting to zero of the maximum speed itself. The distance “trip 1” (10) shown on the display indicates the number of kilometres/ miles covered from the last setting to zero, to the distance “trip 1”.

◆ To display the average speed (16) and the distance

“trip 2” (17), press the push button k again for about 1 second.

The writing “AVS” (18), the average speed (16) and the distance “trip 2” (17) are displayed.

Resetting the average speed (16) and the distance “trip 2” (17): with the odometer set on the “AVS” function, press the push button r for about 1 second.

NOTE The measurement of the average speed is rele-

vant to the distance “trip 2” (odometer).

The distance “trip 2” (17) shown on the display indicates the number of kilometres/miles covered from the last setting to zero.

If more than 1000 km (625 mi) are covered without setting “trip 2” to zero, the value of the average speed will be wrong.

To display the instantaneous speed (13) and the distance “trip 1” (10), press the push button k again.

SERVICE AND SETTING UP

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SERVICE AND SETTING UP

2.3.4 SETTING THE RED LINE THRESHOLD (WITH ENGINE OFF ONLY)

When the maximum rpm set is exceeded, the red line warning light LED “max” (2) positioned on the dashboard starts blinking.

If the push button j is pressed for less than one second, the pointer of the revolution counter (4) shifts to the red line value set for three seconds, after which it returns to its initial position.

For the adjustment, proceed as follows:

◆ Press the push button j, release it and press it j

again within 3 seconds. The pointer (4) moves increasing the value by 1000 rpm at each click, as long as j is kept pressed; when it has reached the maximum value, it starts again from the beginning.

◆ Press the push button j until the desired rpm value

has been set.

◆ If the push button j is released and then pressed

again within 3 seconds, intermittently, the pointer (4) moves increasing the value by 100 rpm at each click; when it has reached the maximum value, it starts again from the beginning.

NOTE It is not possible to set the red line at values low-

er than 2000 rpm or higher than 12000 rpm.

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aCAUTION

Never exceed the recommended rpm, see table.

◆ To confirm, release the push button j. After three sec-

onds, the red line threshold setting is stored.

NOTE The setting is confirmed by the coming on of the

red line warning light LED “max” (2).

Engine maximum rpm recommended

Mileage km (mi) rpm

0 – 1000 (0 – 625) 6000

1000 – 1500 (625 – 937) 7500

over 1500 (937) 10500

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2.3.5 MULTIFUNCTION (RIGHT DISPLAY)

The right display (multifunction) includes the coolant temperature in °C (°F) (8) and the digital clock (7) as standard settings.

NOTE When the engine is cold, the writing “9”

blinks. By pressing the push button g, the following functions

can be obtained in sequence:

Standard setting: Temperature in °C

and digital clock

Battery voltage (V BATT)

Setting the hour

Setting the minutes

SERVICE AND SETTING UP

Setting °C or °F

2.3.6 STANDARD SETTING: COOLANT TEMPERATURE AND DIGITAL CLOCK

The coolant temperature value (8) is shown in the upper part of the right display. It is possible to switch from °C to °F and viceversa, see 2.3.10 (SETTING °C OR °F). – When the temperature is below 35 °C (95 °F), the writ-

ing “9” (8) blinks on the right display.

– When the temperature is over 115 °C (239 °F), the value

(8) blinks on the right display, even if a function different from the standard setting has been set.

– When the temperature is over 130 °C (266 °F), the writ-

///” (8) appears on the right display.

ing “

aCAUTION

If the writing “///” is displayed with a temperature below 130 °C (266 °F), there may be a failure of the electric circuit. In this case, contact an APRILIA Official Dealer.

Thermometer range on the display: 35–130°C (95–266 °F).

The digital clock (7) appears in the lower part of the right display. To set or modify hour and minutes, see 2.3.8 (SETTING THE HOUR) and (SETTING THE MINUTES).

2.3.7 BATTERY VOLTAGE - VBATT

◆ If the push button g is pressed once, the battery volt-

age expressed in volt (19) appears in the lower part of the right display, while the coolant temperature (8) is displayed in the upper part. The writing “V BATT” (20) is displayed. The recharge circuit functions correctly if at 4000 rpm the battery voltage with low beam on is included between 13 and 15 V.

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SERVICE AND SETTING UP

2.3.8 SETTING THE HOUR

◆ When the push button g is pressed for the second

time, the hour segments (21) start blinking in the lower part of the right display (digital clock).

◆ To modify the hour setting, press the “LAP” push button

(6) on the left part of the handlebar.

◆ To confirm the hour setting, press the push button g.

2.3.9 SETTING THE MINUTES

◆ When the push button g is pressed for the third time,

the minute segments (22) start blinking in the lower part of the right display (digital clock).

◆ To modify the minute setting, press the “LAP” push but-

ton (6) on the left part of the handlebar.

◆ To confirm the minute setting, press the push button g.

2.3.10 SETTING °C OR °F

◆ When the push button g is pressed for the fourth time,

the segments of the coolant temperature in °C or °F (8) start blinking in the upper part of the display.

◆ To modify from °C to °F setting, or vice versa, press the

“LAP” push button (6) on the left part of the handlebar.

◆ To confirm the setting, press the push button g.

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2.3.11 CHRONOMETER (RIGHT DISPLAY)

The chronometer makes it possible to measure the time per lap with the vehicle on a racetrack and to store the data, in such a way as to be able to consult them successively.

When the “CHRONOMETER” function has been selected, it is not possible to recall the following functions:

– maximum speed “V max”; – average speed “AVS”; – distance “trip 2”.

◆ To operate the chronometer, press the “LAP” push but-

ton (6) and, within seven seconds, the push button g.

◆ To start timing, press the “LAP” push button (6) and re-

lease it immediately.

◆ To store the time acquired, press the “LAP” push button

(6).

The “LAP” push button (6) is not enabled for 10 seconds and the last time stored (23) is shown on the display.

After which, the chronometer with the current timing (24) is displayed, starting from ten seconds.

◆ To display the first time stored (25), press the push but-

ton k.

◆ To be able to see the stored times in sequence, press

the “LAP” push button (6). The writings /, /, /,

/, etc. (26) are displayed.

◆ To start timing again, press the push button k.

NOTE It is possible to store max. forty times, after

which the “LAP” push button (6) is not effective any longer.

◆ To set the memory to zero, press the push button l

and the “LAP” push button (6) at the same time for two seconds.

◆ To leave the chronometer function, press the “LAP”

push button (6) and the push button g.

The coolant temperature (8) and the digital clock (7) appear on the right display (multifunction).

NOTE When the engine is cold, the writing “9”

blinks.

SERVICE AND SETTING UP

2.3.12 DIAGNOSTICS

Whenever the ignition switch is turned to position “2”, the writing “(),” is displayed for about three seconds.

aCAUTION

If the writing “HIL” is displayed during the normal operation of the engine, this means that the electronic unit has detected an anomaly.

In many cases, the engine keeps running with reduced performance levels, see 6.4 (IGNITION SYSTEM).

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SERVICE AND SETTING UP

 "!44%29

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

There are two kinds of commercially available batteries:

– batteries requiring maintenance featuring cell plugs; – maintenance-free batteries with no cell plugs as they

do not call for the electrolyte level to be checked and topped up.

NOTE This vehicle is provided with a maintenance-free

battery and no operation is necessary, excepting occasional checks and the recharge when required.

When changing batteries, replace with a battery of the same type. For further information, see 6.11 (BATTERY).

aCAUTION

Never invert the connection of the battery cables. Connect and disconnect the battery with the ignition switch in position “1”, otherwise some components may be damaged. Connect first the positive cable (+) and then the negative cable (–). Disconnect following the reverse order.

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NOTE Check battery voltage with a portable tester.

If voltage is less than 12V, the battery must be recharged. If the voltage drops below 8V, the electronic unit is not working and is preventing engine operation.

2.4.1 CHECKING AND CLEANING THE TERMINALS

Carefully read 2.4 (BATTERY).

Battery terminal tightening:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

◆ Make sure that the ignition switch is in position “1”.

◆ Put back the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).

◆ Remove the red protection element (1).

◆ Make sure that the cable terminals (2) and the battery

terminals (3) are:

– in good conditions (and not corroded or covered

with deposits);

– covered with neutral grease or vaseline.

If necessary, proceed as follows:

◆ Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY).

◆ Brush the cable terminals (2) and the battery terminals

(3) with a wire brush, in order to eliminate any trace of corrosion.

◆ Install the battery.

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2.4.2 RECHARGING THE BATTERY

Carefully read 2.4 (BATTERY).

NOTE If the start relay emits a vibration-type noise

when the start pushbutton is pressed “+”, it is a sure sign that the battery is almost completely flat.

NOTE Do not remove the battery plugs: without plugs

the battery may be damaged.

◆ Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY).

◆ Prepare an appropriate battery charger.

◆ Set the charger for the desired type of recharge (see ta-

ble).

◆ Connect the battery to a battery charger.

aWARNING

During the recharging, make sure that the room is properly ventilated.

◆ Switch on the battery charger.

SERVICE AND SETTING UP

Type of

recharge

Normal 12 1.2 8 - 10 Quick 12 12 0.5

2.4.3 LONG INACTIVITY OF THE BATTERY

Carefully read 2.4 (BATTERY).

Volt (V) Ampère (A)

Time

(hours)

aCAUTION

If the vehicle remains unused for more than twenty days, disconnect the 30A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer.

The removal of the 30 A fuses requires the setting to zero of the following functions: digital clock and red line setting.

To reset these functions, see 2.3 (MULTIFUNCTION COMPUTER).

If the vehicle remains unused for more than fifteen days, it is necessary to recharge the battery, in order to prevent its sulphation, see 2.4.2 (RECHARGING THE BATTERY):

◆ Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY) and put it in a cool and dry place.

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 2.4.2

(RECHARGING THE BATTERY).

If the battery remains on the vehicle, disconnect the cables from the terminals.

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SERVICE AND SETTING UP

 %,%#42)##/-0/.%.43

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

Light operation/direction, light system, safety switches:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the check, proceed as follows:

◆ Position the vehicle on the stand.

◆ Check all the lighting devices are working.

◆ Check the direction of the headlight beam is correct,

see 6.13 (ADJUSTING THE VERTICAL HEADLIGHT BEAM) and 6.14 (ADJUSTING THE HORIZONTAL HEADLIGHT BEAM u).

◆ Make sure all connectors are inserted properly.

◆ Make sure all switches are correctly fastened and in

proper working order, see:

– 6.6.4 (CHECKING THE SIDE STAND AND THE

SAFETY SWITCH).

– 6.16 (CHECKING THE SWITCHES).

◆ Make sure the air sensor and speedometer sensor are

correctly fastened and in proper working order.

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aCAUTION

The sensitive area on the sensors must be kept clean at all times. Any mud, dirt etc. on them is liable to alter the measurements and the subsequent data transfer.

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 *5-034!24).'

Carefully read 2.4 (BATTERY).

aWARNING

The vehicle should only be jump-started when the vehicles battery is partially/completely flat and recharging is not possible.

Do not attempt to start the vehicle by pushing or towing it.

The vehicle providing assistance must have a battery (the recharge source) with exactly the same rated voltage (data to be found on the battery) as the battery of the vehicle to be started, see 1.5 (TECHNICAL SPECIFICATIONS).

Follow the procedure below to the letter so as to avoid the danger of the battery exploding and possibly injuring people and/or property (this is liable to compromise the electric components of both vehicles).

◆ Prepare the auxiliary vehicle, in such a way as to have

access to the battery of the same.

◆ Make sure that the ignition switch is in position “1”.

◆ Put back the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).

NOTE Leave the battery cables of both vehicles con-

nected.

SERVICE AND SETTING UP

aCAUTION

Take care never to let the clamps of one cable touch those of another.

◆ Remove the red protection element (1).

NOTE Always connect the positive poles (+) first, fol-

lowing the order indicated below.

aWARNING

The jump leads must not be placed near any moving parts on either vehicle.

◆ Connect one end of jump lead to the positive pole (+) of

the battery on the vehicle providing assistance (A); and the other end on the positive pole (+) of the battery on the vehicle to be started (B).

◆ Connect one end of the other jump lead to the negative

pole (–) of the battery on the vehicle providing assistance (A); and earth the other end on the frame (far from the battery) of the vehicle to be started (B).

DO NOT CONNECT TO THE NEGATIVE POLE (–).

◆ Start the engine of the auxiliary vehicle.

NOTE During the starting phase, the engine of the aux-

iliary vehicle must keep running.

◆ Proceed to the starting of the broken-down vehicle.

NOTE Attempt to start the vehicle for no more than ten

seconds at a time, where necessary, repeating the attempt at intervals of approx. one minute.

NOTE Once started, keep both engines running for ap-

prox. two minutes.

◆ Stop both engines.

◆ Disconnect the negative booster cable (-) from both

batteries.

◆ Disconnect the positive booster cable (+) from both bat-

teries.

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SERVICE AND SETTING UP

 30!2+0,5'3

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

Spark plugs:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

aCAUTION

Check, clean or change all the spark plugs, one by one. Even if only one spark plug needs changing, always replace all of them.

NOTE The vehicle is equipped with two spark plugs

per cylinder (A) and (B). The following operations refer to one spark plug only, but are valid for both.

To reach the spark plugs:

aCAUTION

Let the engine cool down until it reaches room temperature.

Never disconnect the spark plug cap with the engine running, since you may get an electric shock from the ignition system.

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

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For the removal, proceed as follows:

aCAUTION

Do not invert the position of the two spark plug caps. Do not remove the two spark plug caps at the same time.

◆ Remove the cap (1) of the spark plug (2).

◆ Remove any trace of dirt from the spark plug base.

◆ Introduce the special spanner provided in the tool kit on

the spark plug.

◆ Insert the 13 mm fork spanner provided in the tool kit in

the hexagonal seat of the spark plug spanner.

◆ Unscrew the spark plug and extract it from its seat, tak-

ing care to prevent dust or other substances from getting inside the cylinder.

For the check and cleaning:

aCAUTION

This vehicle is fitted with spark plugs featuring platinum-type electrodes. To clean the spark plugs, do not use wire brushes and/or abrasive products, but only a pressurized air jet.

– centre electrode (3); – insulating (4); – side electrode (5).

◆ Make sure that there are neither carbon deposits, nor

corrosion marks on the electrodes and on the insulating material; if necessary, clean them with a pressurized air jet.

If the spark plug has crackings on the insulating material, corroded electrodes, excessive deposits or the tip (6) of the central electrode (3) is rounded, it must be changed.

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aCAUTION

When changing the spark plug, check the thread pitch and length. If the threaded part is too short, the carbon deposits will accumulate on the thread seat, and therefore the engine may be damaged during the installation of the right spark plug.

Use the recommended type of spark plugs only, see

1.5 (TECHNICAL SPECIFICATIONS), in order not to

compromise the life and performance of the engine.

aCAUTION

To check the spark plug gap, use a wire thickness gauge (7) to avoid damaging the platinum covering.

◆ Check the spark plug gap with a wire thickness gauge

(7).

aCAUTION

Do not try to recover the spark plug gap in any way.

The gap must be 0.6 – 0.7 mm, otherwise it is necessary to change the spark plug.

◆ Make sure that the washer (8) is in good conditions.

SERVICE AND SETTING UP

For the installation:

◆ With the washer on (8), screw the spark plug by hand in

order not to damage the thread.

◆ Tighten the spark plug by means of the spanner you

will find in the tool kit, giving it half a turn to compress the washer.

Spark plug driving torque: 20 Nm (2 kgm).

aCAUTION

The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged.

◆ Position the spark plug cap (1) properly, so that it does

not come off due to the vibrations of the engine.

NOTE Repeat the operations described on the second

spark plug of the same cylinder and successively on both spark plugs of the other cylinder.

Put back the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

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 ,)&4).'4(%&5%,4!.+

Carefully read 1.2.1 (FUEL).

aWARNING

Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down.

◆ Remove the passenger seat, see 7.1.2 (UNLOCKING/

LOCKING THE PASSENGER SEAT).

◆ Put back the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).

◆ Unscrew and remove the two screws (1) that fasten the

front part of the fuel tank (2).

◆ Remove the fuel tank support rod (5) from the relevant

anchorage seats (3) (4).

NOTE The rubber-covered end of the rod (5) must be

introduced in the central hole of the steering pin.

◆ Lift the front part of the fuel tank (2) and introduce the

rod (5) as indicated in the figure.

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 $2!).).'4(%&5%,4!.+

Carefully read 1.2.1 (FUEL).

Fuel pipes:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

aWARNING

Risk of fire. Wait until the engine and exhaust silencer have completely cooled down.

Fuel vapours are noxious for your health. Before proceeding, 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.

Do not dispose of fuel in the environment.

◆ Stop the engine and wait until it has cooled down.

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

◆ Prepare a container with capacity exceeding the fuel

quantity present in the tank and put it on the ground on the left side of the vehicle.

NOTE Place a cloth under the male quick-release cou-

pling (1) to catch any fuel spills.

◆ Disconnect the male quick-release coupling (6) from

the receptacle (7) by pressing the relevant button.

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NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp (8) or with other types of clamp.

◆ Release the hose clamp (9).

◆ Disconnect the pipe (10).

◆ Place the free end of the pipe (10) inside the container

prepared beforehand.

◆ Insert the male quick-release coupling (6) of the pipe

(10) all the way into the quick-release receptacle (7). The petrol starts draining out immediately.

◆ Open the tank cap.

◆ Wait until all the petrol has drained out of the tank.

Once all the petrol has drained out:

◆ Connect the pipe (10) and install a new hose clamp.

◆ Insert the male quick-release coupling (6) into the re-

ceptacle (7).

NOTE Make sure the male quick coupling (6) has been

correctly inserted into the receptacle (7).

◆ Put back the fuel tank.

◆ Close the tank cap again.

SERVICE AND SETTING UP

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 !)2#,%!.%2

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

Air cleaner:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

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.

◆ On each maintenance operation, remove the small plug

(1), drain the contents into a container and then deliver it to a salvage center.

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REMOVAL

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

◆ Unscrew and remove the seven 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 with a clean cloth, in order to prevent any foreign matter to get ito.

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 com-

pressed 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 element.

◆ Clean the outer part of the air cleaner (4) with a clean

cloth.

CHANGING

◆ Replace the air cleaner (4) with a new one of the same

type.

aCAUTION

Do not use filters that have already been used. Make sure that the filtering element is positioned cor-

rectly, in such a way as to prevent non-filtered air from entering.

aCAUTION

Remember that the untimely wear of the piston segments and the cylinder may be caused by a faulty or uncorrectly positioned filtering element.

If the vehicle is used in dusty areas, clean the filtering element more frequently.

Using the vehicle without the filtering element, or with the element damaged, considerably increases wear and tear on the engine. Make sure the filtering element is always in perfect condition. The life of the engine depends, for the most part, on this component.

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 !##%,%2!4/2

SERVICE AND SETTING UP

2.11.1 CHECKING THE OPERATION OF THE

Transmission cables and controls:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

For the check, proceed as follows:

ACCELERATOR CONTROL

aWARNING

The use of the vehicle with damaged, excessively bent or twisted accelerator cable may hinder the regular operation of the accelerator and make you lose control of the vehicle while riding.

Make sure that the rotation of the handlebar does not modify the engine idle speed and that the throttle grip returns smoothly and automatically to its original position after being released.

If necessary, proceed as follows:

NOTE For the lubrication of the components use the

specific lubricant available on the market.

◆ Check the correct position and the lubrication of the fol-

lowing components:

– sheath; – throttle grip adjuster (1); – throttle body adjuster (2); – throttle body pin (3); – cable couplings (ends); – accelerator control.

◆ Check the idle speed, 2.11.2 (IDLING ADJUSTMENT).

◆ Check the accelerator control adjustment, 2.11.3 (AD-

JUSTING THE ACCELERATOR CONTROL).

2.11.2 IDLING ADJUSTMENT

(*) = up to frame # ZD4MEE009YS000292

(**) = as of frame # ZD4MEE009YS000293

Engine idling rpm:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

To carry out this operation, proceed as follows:

◆ Ride for a few miles until reaching the normal running

temperature.

◆ Position the gear lever in neutral (green warning light

“/” on).

◆ Check the engine idling rpm on the revolution counter.

The engine idling speed must be about 1250 ± 100 rpm.

If necessary, proceed as follows:

◆ Position the vehicle on the stand.

◆ (*) Introduce a small cut-headed screwdriver in the ap-

propriate hole provided on the right side cover and turn the adjusting knob (4).

– When the screw is turned clockwise, the rpm increas-

es.

– When the screw is turned anticlockwise, the rpm de-

creases.

◆ (**) ò Turn the adjusting knob (5) provided on the

right side of the vehicle. – When the knob is turned clockwise, the rpm increases; – When the knob is turned anticlockwise, the rpm de-

creases.

◆ Twist the throttle grip, accelerating and decelerating a

few times to make sure that it functions correctly and to

check if the idling speed is constant.

For further information, see section 4 (FUEL SUPPLY SYSTEM).

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◆ Unscrew and remove the two M6x25 screws (14) and

the right injector support (15), together with the relevant gasket (16), injector (17) and sealing ring (18).

NOTE The injector’s sealing ring (18) may be kept in-

serted in the slot on the throttle body.

◆ Unscrew and remove the M8x1 nut (19) and remove

the spring washer (20), the pulley (21), the two bushes (22) and torsion spring (23).

◆ Slide the fulcrum pin (24), together with the lock washer

(25), out of the hole on the throttle cable support bracket and remove the two shaft sealing rings (26) with the torsion spring (27) and cold-start lever (28).

FUEL SUPPLY SYSTEM

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4.8.4 INSPECTING THE THROTTLE BODY

TESTING THE INJECTOR

aWARNING

The fuel is explosive and highly inflammable. Keep fuel away from ignition sparks, heat and flames.

NOTE The injectors can be controlled electrically.

◆ Check the following components:

– wiring and connections; – injector or injection signal of the engine control unit,

see 6.4 (IGNITION SYSTEM).

Checking injector resistance:

See 6.4.12 (CHECKING THE INJECTORS).

THROTTLE BODY

aCAUTION

Use neutral detergents only. For cleaning, use a product for removing sealing, a degreasing product or a detergent for cleaning when cold.

◆ Clean all the openings and pipes of the throttle body (1)

using compressed air.

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aCAUTION

Once the intake pressure sensor (9) its installed, not utilice the compressed air for the pipes cleaning; danger for damages.

◆ Check the pipes of the intake pressure sensor (2),

watching out for any clogging.

◆ Check the throttle valves unit and the cable fastening

mechanism (3), watching out for any signs of mechanical damage.

NOTE In the event the synchronization screws (4) or

O-rings (5) are replaced, synchronize the cylinders, see

4.8.10 (CYLINDER SYNCHRONIZATION).

◆ Unscrew the two cylinder synchronization screws (4)

only in case of air escapes.

◆ When replacing the tie rod of the ball joint (6), disen-

gage the tie rod from the throttle valve control lever (7) and throttle cable pulley (8).

◆ Once a new ball joint tie rod (6) has been fitted, make

sure it moves freely.

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4.8.5 REFITTING THE THROTTLE BODY

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

aCAUTION

After disassembling the throttle body, replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are supplied with the repair kit.

◆ Fit the new O-rings (1) and seals (2) on both injector.

◆ Insert the injector (3) in the left injector support (4) and

in the right injector support (5).

◆ Fit the left injector support gasket (6), right injector sup-

port gasket (7) and the two seals (8) on the throttle body.

◆ Install the complete left injector support (4) and right in-

jector support (5) in the throttle body, fastening them with the new M6x25 (9) (10) screws respectively.

Screws (9) (10) driving torque: 9 Nm (0.9 kgm).

◆ If the synchronizing screws (11) and respective O-rings

(12) have been replaced, screw on the screws (11) fairly tight until they touch the stop and then unscrew them a single turn.

Presetting of synchronizing screws (11): 1 turn.

FUEL SUPPLY SYSTEM

aCAUTION

The precise adjustment of the screws (11) must be performed using a vacuum gauge, see 4.8.10 (CYLINDER SYNCHRONIZATION).

◆ Fasten the fuel pressure regulator (13) using the two

M6x16 screws (14).

Screws (14) driving torque: 3.5 Nm (0.35 kgm).

NOTE Smear a film of grease over the surfaces of the

fulcrum pin (18), see 1.6 (LUBRICANT CHART).

◆ Insert the cold-start lever (15), torsion spring (16) and

shaft sealing ring (17) on the fulcrum pin (18).

◆ Insert the complete fulcrum pin (18) in the throttle cable

support bracket.

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FUEL SUPPLY SYSTEM

NOTE Make sure the torsion spring is hooked to the

cold-start lever (15) and cable support bracket.

◆ Spray chain grease onto the spring (16), see 1.6 (LU-

BRICANT CHART).

◆ Insert the shaft sealing ring (17) on the fulcrum pin (18).

◆ Fit the two bushes (19) and torsion spring (20).

◆ Fit the pulley (21) on the throttle cable support bracket.

aCAUTION

Make sure that the ends of the torsion spring (20) are hooked onto the throttle cable support bracket and pulley (21).

NOTE Spray a temporary lubricant on the spring (20),

see 1.9.2 (USE OF CONSUMABLES).

◆ Fit the spring washer (22).

NOTE Apply

(23).

◆ Screw the M8x1 nut (23) and tighten it.

Nut (23) driving torque: 3 Nm (0.3 kgm).

NOTE Apply

screws (25).

◆ Fasten the anchoring bracket of the accelerator cables

(24) with the three hex-head screws M5x12 (25).

LOCTITE

243 on the thread of the nut

243 on the thread of the

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Screws (25) driving torque: 3 Nm (0.3 kgm).

◆ Fit the throttle valve control lever (26), see 4.8.6 (RE-

PLACING THE THROTTLE VALVE CONTROL LEVER).

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4.8.6 REPLACING THE THROTTLE VALVE CONTROL LEVER

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

DISASSEMBLY

◆ Partially remove the fuel tank, see 7.1.5 (PARTIAL RE-

MOVAL OF THE FUEL TANK).

◆ Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

◆ Unscrew and remove the M8x1 nut (1) and remove the

spring washer.

◆ Slide out the control lever (2) and retrieve the two bush-

es (3) and torsion spring (4).

◆ Remove the control lever (2) from the tie rod of the ball

joint (5).

ASSEMBLY

aCAUTION

For the vehicles with the following engine numbers, the throttle valve control lever (2) must be replaced with the new grey-coloured lever.

FUEL SUPPLY SYSTEM

     

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           

  

                                                             

–

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◆ Fit the two bushes (3) and torsion spring (4) on the

throttle body.

◆ Fit the throttle valve control lever (2) on the throttle

valve spindle.

NOTE Spray a temporary lubricant on the spring (4),

see 1.9.2 (USE OF CONSUMABLES).

aCAUTION

Make sure the ends of the torsion spring (4) are hooked onto the throttle body and throttle valve control lever (2).

◆ Fit the spring washer.

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NOTE Apply

(1).

◆ Screw the M8x1 nut (1) and tighten it.

Driving torque (1): 3 Nm (0.3 kgm).

LOCTITE

243 on the thread of the nut

NOTE Once assembly is complete, make sure the le-

vers rotate freely.

The throttle valve control lever (2) must be returned to its original position by the torsion spring.

Check for end play on the throttle valve control shaft, see

4.8.7 (CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY) and adjust as necessary, see 4.8.8 (ADJUSTING THE THROTTLE BODY).

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4.8.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY

◆ Partially remove the fuel tank, see 7.1.5 (PARTIAL RE-

MOVAL OF THE FUEL TANK).

◆ Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

NOTE Have an appropriate thickness gauge (1) to

hand with a 0.05 mm scale.

With throttle valves closed:

◆ Use the thickness gauge (1) to measure the minimum

play between the lever (2) and the contact surface (3) on the throttle body in a number of points.

End play: min. 0.1 mm.

aCAUTION

If the minimum value measured is lower than 0.1 mm, the throttle body must be replaced, see 0.4.2 (SPARE PARTS CATALOGUES).

With throttle valves open:

◆ Repeat the above procedure.

FUEL SUPPLY SYSTEM

End play: min. 0.15 mm.

aCAUTION

If the minimum value measured is lower than 0.15 mm, the throttle body must be replaced, see 0.4.2 (SPARE PARTS CATALOGUES).

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4.8.8 ADJUSTING THE THROTTLE BODY

◆ Partially remove the fuel tank, see 7.1.5 (PARTIAL RE-

MOVAL OF THE FUEL TANK).

◆ Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

SETTING IDLING

aCAUTION

The screw (1) of the throttle valve end of stroke is painted and cannot be adjusted.

Only when the whole throttle cable support bracket is replaced can the adjusting screw (1) be turned again.

◆ Loosen the M5x0.5 nut (2).

◆ Unscrew the adjusting screw (1) of the throttle valve

end of stroke, until the throttle valves (3) adhere to the throttle body (4).

◆ Screw the adjusting screw (1) until it touches the stop

onto the throttle valve control lever (5), and turn it another 1/2 – 3/4 turn before tightening the M5x0.5 nut (2).

Idling setting: 1/2 – 3/4 turn.

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SETTING THE COLD-START DEVICE

aCAUTION

When the whole throttle cable support bracket must be replaced, it is necessary to adjust the cold start control screw (6) again, after setting the screw (1) of the throttle valve end of stroke.

NOTE Have an appropriate thickness gauge.

◆ Loosen the M5x0.5 nut (7).

◆ Pull back the cold-start lever (8) until it touches the

screw (6).

◆ Adjust the screw (6) so that the clearance between the

idling adjusting screw (1) and the throttle valve control lever (5) is in the range 1.6 to 1.8 mm.

Adjustment: 1.6 – 1.8 mm.

◆ Secure the screw (6) by tightening the M5x0.5 nut (7).

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4.8.9 CHANGING AND ADJUSTING THE THROTTLE VALVE POTENTIOMETER

With the engine switched off:

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

◆ Disconnect the four-way connector (coloured black)

(1).

aCAUTION

The two screws M4x12 (2) that fasten the throttle valve potentiometer are painted and can be removed or loosened only in case of change or adjustment of the potentiometer itself.

FUEL SUPPLY SYSTEM

NOTE In order to make it easier to unscrew the screws

(2) secured using LOCTITE hot air blower.

◆ Unscrew and remove the screws (2).

◆ Remove the potentiometer (3).

243, heat them first with a

aCAUTION

Any adjustment of the position sensor must be performed with the valves closed, meaning the throttle valve control lever (4) must touch the adjusting screw (5).

◆ With the throttle valves in the closed position, place the

potentiometer in its housing (3).

NOTE Apply LOCTITE

screws (2).

◆ Screw the screws (2) on by hand so that they hold the

potentiometer (3) in place but do not prevent it from rotating.

◆ Connect the four-way connector (coloured black) (1).

◆ Connect the two “TEST” terminals (6) with each other.

◆ Turn the ignition switch to position “2”.

◆ Turn the potentiometer (3) until the display reads “”.

◆ Tighten the two screws (2), holding the potentiometer

(3).

Driving torque of the throttle valve potentiometer screws (2): 1.6 Nm (0.16 kgm).

243 on the thread of the

NOTE Verify the presence of the writing “ ” on the

display (7) and if the value displayed is different repeat the adjustment.

◆ Turn the ignition switch to position “1”.

◆ Disconnect the two “TEST” terminals (6).

◆ Put back the fuel tank, see 2.8 (LIFTING THE FUEL

TANK).

For further information, see 6.4.10 (CHECKING THE THROTTLE VALVE POTENTIOMETER).

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4.8.10 CYLINDER SYNCHRONIZATION

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.1 (FUEL).

Carburation, CO adjustment:Carburation, CO adjustment:

for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

INTRODUCTION The synchronization of the cylinders depends on the

compliance with the following conditions: a) Engine idling speed: – 1250 ± 50 rpm ;

b) CO values in the cylinders: (*1) – non-catalytic version (excluding u) from 0.8% to

1.3% ;

– catalytic version (excluding u) from 1.5% to 2.0%; – catalytic version u from 1.5% to 2.0%;

c) Vacuum values in the cylinders: (*2) – 300 ± 30 mbar.

(*1) A difference is accepted for the CO values: of cylin-

der “1” (front) and of cylinder “2” (rear).

(*2) A difference is accepted for the vacuum values: of

cylinder “1” (front) and of cylinder “2” (rear).

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NOTE To obtain the synchronization of the cylinders,

adjust the above mentioned values repeatedly, always following the given order.

NOTE The adjustment of one of the three values may

cause the incorrect modification of the other two values, therefore after any adjustment it is advisable to check all the three values.

The CO value takes priority over the vacuum value.

◆ Check the engine number, see 1.1.2 (ENGINE

NUMBER), and choose the suitable procedure according to the result of this check.

NOTE From engine # 686065.. To allow the check of

the cylinder vacuum values, the throttle body is equipped with the special coupling (1) and therefore it is not necessary to replace the intake flange with the vacuometer socket (2)

NOTE From engine # 686065. DO NOT carry out the

operations marked with the symbol “

✖”.

NOTE Have the appropriate special tool m to hand:

– aprilia part# 8140267 (intake flange for vacuometer)

(2);

– aprilia part# 8140256 (vacuometer) (3).

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

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◆✖ Loosen the two clamps (4) (5).

aCAUTION

✖ Take extreme care when removing the throttle body

(6) as it remains connected to cables and pipes.

◆✖ Grip the throttle body firmly (6), complete with air filter

casing (7), and shift it slightly one way and the other, lifting and sliding it off the intake flanges.

◆✖ Move the throttle body off to the left-hand side of the

vehicle.

◆✖ Unscrew and remove the two screws (8) fastening the

intake flange (9) to the front cylinder and recover the washers.

◆✖ Remove the intake flange (9) of cylinder “1” (front).

◆✖ Fit the vacuometer intake flange (2) in place, and po-

sition it so that the connector (10) is on the right-hand side of the vehicle.

◆✖ Fit the two screws (8) back in place with their respec-

tive washers and tighten them.

Torque settings of screws (8): 19 Nm (1.9 kgm).

aCAUTION

✖ The throttle body (6) must be fitted perfectly on the

intake flanges; The clamps (4) (5) must be properly tightened.

◆✖ Fit the throttle body (6) again, complete with air filter

casing (7), to the two intake flanges.

◆✖ Tighten the two clamps (4) (5).

◆ Slide the pipe (11) off the vacuum connector.

◆ Hang the vacuometer (3) on the handlebars.

◆ Insert the free end of the vacuometer pipe (12) into the

connector (13).

◆✖ Insert the free end of the vacuometer pipe (14) into

the connector (10) of the intake flange (2).

◆ From engine # 686065. Insert the free end of the vac-

uometer pipe (14) into the connector (1) of the throttle body.

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aCAUTION

The cylinder syncronization must be carried out with the engine warmed up:

– coolant temperature 75 – 95 °C (167 – 203 °F); – room temperature 20 – 30 °C (68 – 86 °F).

NOTE Have the appropriate special tools m to hand:

– aprilia part# 8140196 [Plurigas (Italian)] (15) or aprilia

part# 8140578 [Plurigas (English)] (15);

– aprilia part# 8140202 (exhaust gas analysis probes)

(16).

aWARNING

Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours.

Avoid any contact of the fuel with the skin. Do not smoke and do not use naked flames. Do not dispose of fuel in the environment.

Plugs (17) (18) driving torque: 25 Nm (2.5 kgm).

◆ Loosen and remove the two front and rear exhaust pipe

plugs (17) (18).

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NOTE Upon reassembly, apply aprilia part# 8116043

(ANTI-SEIZE MOTAGEPASTE AS 1800 antiscuff paste) on the threaded of the plugs (17) (18).

◆ Connect the exhaust gas analysis probes (16) by pro-

ceeding as follows:

– connect the two rigid pipes to the appropriate exhaust

pipe outlets A) and (B);

– connect the other pipe to the exhaust gas tester (15).

◆ Start the engine.

◆ Check the following on the revolution counter:

– engine idling speed. For the value, see INTRODUC-

TION, point a).

◆ Check the following on the analyzer:

– the CO values in the cylinders. For the values, see IN-

TRODUCTION, point b).

– the vacuum values in the cylinders. For the values, see

INTRODUCTION - point c).

If the adjustment is necessary:

NOTE Proceed with the adjustment of the value that is

not within the prescribed range, following the instructions given in the INTRODUCTION.

◆ For the engine idling speed, see 2.11.2 (IDLING AD-

JUSTMENT).

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◆ Check the first five digits of the frame number and

choose the suitable procedure according to the result of this check.

PROCEDURE FOR THE VEHICLES WHOSE FRAME BEARS THE ZD4ME CODE

◆ For the CO values in the cylinders, adjust:

– the screw (19) for cylinder “1” (front); – the screw (20) for cylinder “2” (rear);

◆ For the vacuum values in the cylinders, adjust:

– the screw (19) (of the throttle body) for cylinder “1”

(front);

– the screw (20) (of the throttle body) for cylinder “2”

(rear);

PROCEDURE FOR THE VEHICLES WHOSE FRAME BEARS THE ZD4RP CODE

◆ For the CO values in the cylinders, adjust:

– the screw (21) (of the central unit) for cylinder “1”

(front);

– the screw (22) (of the central unit) for cylinder “2”

(rear).

◆ For the vacuum values in the cylinders, adjust:

– the screw (21) (of the central unit) for cylinder “1”

(front);

– the screw (22) (of the central unit) for cylinder “22”

(rear).

FUEL SUPPLY SYSTEM

At the end of the cylinder synchronization check or adjustment:

◆✖ Remove the vacuometer socket (2) and put back the

intake flange (9).

aCAUTION

✖ It is vital that the vacuometer intake flange (2) be re-

placed with the original intake flange (9).

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NOTES

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COOLING SYSTEM

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4!",%/&#/.4%.43

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$%3#2)04)/. ........................................... 5-3

5.1.1 PATH WITH COOLANT TEMPERATURE BELOW 65 °C

(149 °F) .................................................... 5-4

5.1.2 PATH WITH COOLANT TEMPERATURE IN THE RANGE 65 °C (149 °F) TO 80

°C (176 °F) ............................................... 5-5

5.1.3 PATH WITH COOLANT TEMPERATURE OVER 80 °C

(176 °F) .................................................... 5-6

2%-/6).'4(%2!$)!4/23 .............. 5-7-00

2%-/6).'4(%#//,).'

%,%#42/&!.3 ......................................... 5-8

2%-/6).'4(%#//,!.4

4(%2-!,37)4#( ................................. 5-9

2%-/6).'4(%#//,!.4

4(%2-)34/23 ......................................... 5-9

2%-/6).'4(%4(%2-!,

%80!.3)/.6!,6% .............................. 5-10

5.6.1 CHECKING THE THERMAL

EXPANSION VALVE ............................. 5-10

2%-/6).'4(%&),,%2.%#+ ......... 5-11-00

2%-/6).'4(%4(2%%7!9

-!.)&/,$ ............................................... 5-12

2%-/6).'4(%%80!.3)/.

4!.+ ......................................................... 5-13

#//,!.405-0 .................................. 5-13-00

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 $%3#2)04)/.

The centrifugal pump (positioned inside the engine and driven by the latter) draws coolant and distributes it to the galleries in the cylinders and in the heads in order to cool the internal parts of the engine. The path of the coolant on leaving the engine varies depending on the temperature of the actual coolant, and is illustrated below. The coolant volume increase (caused by the temperature increase) is compensated for in the expansion tank.

COOLING SYSTEM

To check and top up the coolant, refer to the “LOW” and “FULL” reference marks, see 2.15 (CHECKING AND TOPPING UP COOLANT).

For any information regarding the coolant, see 1.2.5 (COOLANT).

Key

1) Front cylinder thermistor

2) Rear cylinder thermistor

3) Breather pipe

4) Coolant compensation pipes

5) Filler hose

6) Filler neck

7) Engine hose (right side) - thermal expansion valve

8) Rear cylinder hose - three-way manifold

9) Front cylinder hose - three-way manifold

10) Thermal switch

11) Three-way manifold

12) Three-way manifold hose - left radiator

13) Radiator link hose

14) Left radiator electrofan

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15) Left radiator (vertical flow)

16) Right radiator (vertical flow)

17) Right radiator electrofan

18) Thermal expansion valve hose - pump

19) Right radiator hose - thermal expansion valve

20) Three-way thermal expansion valve (type with heatsensitive wax)

21) Centrifugal pump

22) Expansion tank

————> = Direction of flow with thermal expansion

- – – – – –> = Direction of flow with thermal expansion

valve open

valve shut

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COOLING SYSTEM

5.1.1 PATH WITH COOLANT TEMPERATURE BELOW 65 °C (149 °F)

From pump (1) "A" coolant inlet in engine (2) "B" temperature taken by thermistors (3) (4) and displayed on dashboard right display. "C" Coolant outlet from engine (right side) (5) "D" to thermal expansion valve (6) (completely closed) "E" and to pump (1).

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5.1.2 PATH WITH COOLANT TEMPERATURE IN THE RANGE 65 °C (149 °F) TO 80 °C (176 °F)

From pump (1) "A" coolant inlet in engine (2) "B" temperature taken by thermistors (3) (4) and displayed on dashboard right display. "C" Coolant outlet from the following at the same time:

– engine (right side) (5) "D" to thermal expansion valve

(6) (partially open);

– engine (left side) (7)(8) "E" to three-way manifold (9)

"F" to left radiator (10) "G" to right radiator (11) "H" to thermal expansion valve (6) (partially open).

From thermal expansion valve (partially open) "I" to pump (1).

COOLING SYSTEM

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COOLING SYSTEM

5.1.3 PATH WITH COOLANT TEMPERATURE OVER 80 °C (176 °F)

From pump (1) "A" coolant inlet in engine (2) "B" temperature taken by thermistors (3) (4) and displayed on dashboard right display. "C" Coolant outlet from engine (left side) (7) (8) "D" to three-way manifold (9)(*) "E" to left radiator (10) "F" to right radiator (11) "G" to thermal expansion valve (6) (completely open) "H" to pump (1). (*) Temperature taken by the thermal switch (12):

– if the temperature exceeds 100°C (212 °F), it enables

the operation of the electric fans (13);

– if the temperature lowers below 85°C (185 °F), it disa-

bles the operation of the electric fans (13).

aCAUTION

When the ignition switch is set to “1” the electrofans switch off regardless of the coolant temperature.

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Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

NOTE The following procedure refers to a single radia-

tor, though it is applicable to both.

◆ Turn the ignition switch to position “1”.

◆ Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

◆ Disconnect the electric connector (1).

aCAUTION

Upon reassembly, make sure that the electric connector (1) is correctly coupled.

◆ Remove the radiator spoiler, see 7.1.35 (REMOVING

THE RADIATOR SPOILER).

◆ Loosen and move the clamp (2).

◆ Pull the coupling (3) off the radiator (4).

◆ Loosen and move the clamp (5).

◆ Pull the coupling (6) off the radiator (4).

NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp or with other types of clamp.

◆ Release the hose clamp (7).

◆ Pull the pipe (8) off the radiator (4).

◆ Unscrew and remove the screw (9), retrieving the bush

and the rubber element (10) if necessary.

NOTE If the rubber element (10) is damaged, replace it.

COOLING SYSTEM

aCAUTION

Proceed with care. Do not damage the radiator fins.

◆ Tilt the radiator (4) slightly forwards and at the same

time lift it, sliding the two lower anchorage pins (12) (13) from their slot on the radiator mount (11).

◆ Remove the radiator (4) complete with the electrofan

(14).

aCAUTION

Plug the coupling openings, in such a way as to prevent any foreign matters from getting in.

NOTE If the rubber elements (15) are damaged, re-

place them.

If necessary, proceed as follows:

◆ Remove the cooling electrofan, see 5.3 (REMOVING

THE COOLING ELECTROFANS).

aCAUTION

Foreign bodies, filth, etc. sticking to the radiator fins must be removed by means of a jet of compressed air. Any bent fins are to be straightened using a small flat-tip screwdriver. If the couplings (3) (6) feature cuts and/or cracks, they must be replaced. Before reassembly, thoroughly wash the inside of the radiator with clean water only.

NOTE Where necessary, remove the other radiator.

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Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

NOTE The following procedure refers to a single elec-

trofan, though it is applicable to both.

◆ Turn the ignition switch to position “1”.

◆ Remove the relevant side fairing, see 7.1.28 (REMOV-

ING THE SIDE FAIRINGS).

◆ Disconnect the electric connector (1).

aCAUTION

Upon reassembly, make sure that the electric connector (1) is correctly coupled.

◆ Unscrew and remove the two screws (2).

Screws (2) driving torque: 6 Nm (0.6 kgm).

◆ Retrieve the two nuts (3).

◆ Tilt the whole electrofan (4) slightly forwards, at the

same time moving it outwards, pulling the internal anchorage pin out of its slot on the radiator (5).

◆ Remove the electrofan (4).

NOTE If the rubber element (6) is damaged, replace it.

If necessary, proceed as follows:

◆ Unscrew and remove the three screws (7) and retrieve

the washers.

Screws (7) driving torque: 2 Nm (0.2 kgm).

◆ Slide out the grating (8) protecting the electrofan motor

(9).

NOTE Where necessary, remove the other electrofan.

See 6.9 (COOLING ELECTROFAN) for further details.

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37)4#(

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Turn the ignition switch to position “1”.

◆ Remove the left fairing, see 7.1.28 (REMOVING THE

SIDE FAIRINGS).

◆ Disconnect the electric connectors (1) (2) from the ther-

mal switch (3).

aCAUTION

When reassembling, make sure the electric connectors (1–2) are plugged in properly.

◆ Prepare a new thermal switch and apply LOCTITE

572 on its thread.

◆ Unscrew and remove the thermal switch (3) and re-

trieve the gasket.

◆ Insert the gasket on the new thermal switch.

◆ Screw the thermal switch (3) on by hand before tighten-

ing it.

Thermal switch (3) driving torque: 30 Nm (3.0 kgm).

◆ If any coolant spilled during removal, once the opera-

tion is complete, top up the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT).

NOTE See 6.9.3 (CHECKING THE THERMAL

SWITCH OPERATION) for further details on the thermal switch.

COOLING SYSTEM

aCAUTION

Plug the hole on the three-way manifold so as to prevent any foreign bodies from falling in.

 2%-/6).'4(%#//,!.44(%2-)34/23

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

NOTE The following procedure refers to a single ther-

mistor, though it is applicable to both.

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

◆ Disconnect the electric connector (4).

aCAUTION

Upon reassembly, make sure that the electric connector (4) is correctly coupled.

◆ Prepare a new thermistor and apply LOCTITE

its thread.

◆ Unscrew and remove the thermistor (5).

◆ Screw the thermistor (5) on by hand before tightening

it.

Thermistor (5) driving torque: 30 Nm (3.0 kgm).

◆ If any coolant spilled during removal, once the opera-

tion is complete, top up the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT).

NOTE Where necessary, remove the other thermistor.

See 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION) for further details on the thermistors.

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6!,6%

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp or with other types of clamp.

◆ Release the hose clamp (1).

◆ Pull the pipe (2) off the thermal expansion valve (3).

Clamps driving torque (4) (5): 7 Nm (0.7 kgm).

◆ Loosen the clamps (4) (5).

◆ Grip the thermal expansion valve (3) and pull it free of

the two couplings (6) (7) one small step at a time.

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aCAUTION

Plug the coupling openings, in such a way as to prevent any foreign matters from getting in.

5.6.1 CHECKING THE THERMAL EXPANSION VALVE

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Remove the thermal expansion valve, see 5.6 (RE-

MOVING THE THERMAL EXPANSION VALVE).

◆ Check the heat-sensitive wax for signs of cracking or

excessive wear: in this case, replace the whole valve (3).

Check the valve (3) is working properly as follows:

◆ Tie a piece of string around the valve (3).

◆ Place a container (8) holding coolant on a burner (9).

◆ Immerse the valve (3) in the container.

NOTE The valve (3) must be fully submersed without

allowing it to touch the walls or bottom of the container (8).

◆ Secure the string so that the valve (3) remains in place.

◆ Heat the coolant, using a thermometer (10) with a 0 –

150 °C (32 – 302 °F) range to check the rise in temperature.

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◆ Take note of the temperature reading when the valve

(3) starts to open.

Valve (3) opening temperature: 65 ±2 °C (149 ± 3.6 °F).

◆ Continue heating the coolant.

◆ When the temperature of the coolant reaches 80 °C

(176 °F), the valve (3) should have opened by at least 7 mm (39 mm measured from the edge).

Valve (3) opening: ≥ 7 mm at 80 °C (176 °F).

NOTE If the valve does not meet both conditions (initial

opening temperature and maximum opening), it must be replaced.

 2%-/6).'4(%&),,%2.%#+

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

COOLING SYSTEM

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp or with other types of clamp.

◆ Release the hose clamp (1).

◆ Release the hose clamp (2).

◆ Pull the pipe (3) off the neck (4).

◆ Pull the coupling (5) off the neck (4).

aCAUTION

Plug the coupling openings, in such a way as to prevent any foreign matters from getting in.

◆ Move the pipe clamp (6).

◆ Pull the pipe (7) off the neck (4).

◆ Unscrew and remove the screw (8) and take the bush-

ing.

◆ Remove the filler neck (4).

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Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Turn the ignition switch to position “1”.

◆ Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

◆ Remove the engine oil tank, see 7.1.51 (REMOVING

THE ENGINE OIL TANK).

◆ Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

◆ Disconnect the electric connectors (1) (2) from the ther-

mal switch (3).

aCAUTION

When reassembling, make sure the electric connectors (1) (2) are plugged in properly.

NOTE Have the appropriate special tool m to hand:

– aprilia part# 0277295 (hose clamp installation pliers).

aCAUTION

Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0.4.2 (SPARE PARTS CATALOGUES).

Do not attempt to reinstall the removed hose clamp, since it is unusable.

Do not replace the removed hose clamp with a screw clamp or with other types of clamp.

◆ Release the hose clamp (4).

◆ Release the hose clamp (5).

◆ Release the hose clamp (6).

◆ Pull the three pipes (7) (8) (9) off the manifold (10).

Clamp driving torque (11): 3 Nm (0.3 kgm).

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◆ Loosen the pipe clamp (11) and move it downwards.

◆ Grip the manifold (10) and slide it up off the coupling

(12) one small step at a time.

aCAUTION

Plug the coupling openings, in such a way as to prevent any foreign matters from getting in.

If necessary, proceed as follows:

◆ Unscrew and remove the thermal switch (3) and re-

trieve the gasket.

NOTE When reassembling, apply LOCTITE

the thread of the thermal switch.

Thermal switch (3) driving torque: 30 Nm (3.0 kgm).

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Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

◆ Remove the right fairing, see 7.1.28 (REMOVING THE

SIDE FAIRINGS).

◆ Move the pipe clamp (1).

◆ Pull the pipe (2) off the filler neck (3).

◆ Bend the pipe (2) back on itself and secure it in place

on the top of the expansion tank with adhesive tape.

◆ Unscrew and remove the fastening screw (4), keeping

the rear brake fluid tank (5) in place.

◆ Move the rear brake fluid tank (5) and secure it in place

with adhesive tape.

◆ Unscrew and remove the two fastening screws (6–7)

and retrieve the two bushes.

◆ Remove the expansion tank (8), keeping it the right

way up.

◆ If the inner and outer foam edging is damaged, replace

it.

aWARNING

The coolant is noxious. Put the expansion tank (8) in a safe place.

KEEP AWAY FROM CHILDREN.

COOLING SYSTEM

 #//,!.405-0

For further information on the coolant pump, refer to the engine service and repair manual, see 0.4.1 (ENGINE SERVICE AND REPAIR MANUALS).

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Aprilia RSV Mille 2002 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual