Aprilia RSV Mille 2002 Service Manual
RSV mille
INTRODUCTION
GENERAL INFORMATION
SERVICE AND SETTING UP
ENGINE
FUEL SUPPLY SYSTEM
COOLING SYSTEM
0
1
2
3
4
5
ELECTRIC SYSTEM
CHASSIS
REPAIR INFORMATION
ANALYTICAL INDEX
6
7
8
@
236mille U
WORKSHOP manual
aprilia part# 8140688
Release 00/2002-10
0 -1
- 00
INTRODUCTION
RSV mille
0
INTRODUCTION
4!",%/&#/.4%.43
50$!4%/&2%,%!3%
...................................................... 0-3-00
0.1.1 INFORMATION ON THE
UPDATING OF THE MANUAL ............... 0-3
0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3-00
(/74/#/.35,44(%-!.5!, ..... 0-5-00
&/2%7/2$ ............................................... 0-6-00
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!&%497!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
(/74/53%9/523%26)#%
!.$2%0!)2-!.5!, ........................... 0-8
0.6.1 ADVICE FOR CONSULTATION ............ 0-8-00
!""2%6)!4)/.339-"/,3
).)4)!,3 .................................................... 0-9
-00
-00
-00
-00
-00
-00
0 -2
- 00
Release 00/2002-10
RSV mille
INTRODUCTION
50$!4%/&2%,%!3%
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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0 -3
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INTRODUCTION
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RSV mille
0 -4
- 00
Release 00/2002-10
RSV mille
(/74/#/.35,44(%-!.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
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
ò
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
RSV mille
INTRODUCTION
3!&%497!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
a
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).
Follow
ã
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0 -7
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INTRODUCTION
★
Follow
ã
– 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
(/74/53%9/523%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)
ò
automatic light switching version (Automatic Switch-on
e
Device)
optional
m
catalytic version
o
VERSION:
Italy
I
United King-
U
dom
Austria
a
Portugal
p
Finland
F
Belgium
B
Germany
d
France
f
Spain
E
Greece
G
Holland
O
Switzerland
Y
Denmark
D
Japan
J
Singapore
S
Slovenia
s
Israel
i
South Korea
¬
Malaysia
M
Chile
c
Croatia
H
Australia
A
United States
u
of America
Brazil
Ä
South Africa
R
New Zealand
n
Canada
C
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!""2%6)!4)/.339-"/,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
Release 00/2002-10
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INTRODUCTION
NOTES
T
H
I
S
P
A
G
E
H
A
S
B
E
E
N
N
I
T
E
N
T
O
I
N
A
L
L
Y
L
E
F
T
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Y
T
P
M
E
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GENERAL INFORMATION
1
Release 00/2002-10
1 -1
- 00
1
GENERAL INFORMATION
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&/253%/&
&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//,3m .............................. 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(%3500/2434!.$ ......................... 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
-00
-00
-00
-00
-00
-00
-00
-00
-00
RSV mille
).3425#4)/.3&/2!00,9).'
42!.3&%23 ........................................... 1-36-00
1 -2
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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
Release 00/2002-10
1 -3
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GENERAL INFORMATION
RSV mille
).3425#4)/.3&/253%/&&5%,
,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).
1 -4
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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.
1 -5
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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.
1 -6
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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
stroke
ò Valve advance (with valve clearance 1mm) opening during
intake stroke
stroke
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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closing during intake
opening during exhaust
closing during exhaust
closing during intake
opening during exhaust
closing during exhaust
m
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
Release 00/2002-10
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Follow
ã
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Follow
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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
wp
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
a
1
a
2
a
3
a
4
a
5
a
6
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)
Follow
ã
Release 00/2002-10
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GENERAL INFORMATION
Follow
ã
RSV mille
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
1 -10
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Follow
ã
Release 00/2002-10
RSV mille
Follow
ã
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
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)
(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
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)
(2.0)
(2.1)
(2.0)
–
–
–
210
200
210
200
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
Rear
✱ ✱
Front
✱ ✱
Rear
Rear DUNLOP SPORTMAX D 207 RR 180/55-ZR 17" X X W
MICHELIN PILOT SPORT E
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"
TL
190/50-ZR 17"
TL
X – W
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)
Release 00/2002-10
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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):
0
F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume or
0
F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume or
0
EXTRA RAID 4, SAE 15W - 50 or TEC 4T SAE 15W - 50.
0
F.A. 5W or 0 F.A. 20 W fork oil;
an alternative FORK 5W or FORK 20W fork oil.
0
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.
0
Bimol Grease 481, 0 AUTOGREASE MP or GREASE 30.
0
CHAIN SPRAY or CHAIN LUBE.
a
WARNING
Use new brake fluid only.
0
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):
0
a
WARNING
Use new clutch fluid only.
F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (DOT 4 compatible).
a
WARNING
0
ECOBLU -40 °C or COOL.
OILL-UK
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Release 00/2002-10
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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
0
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
0
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.
0
F.A. 5W and 0 F.A. 20W or FORK 5W and
0
0 Bimol Grease 481,
CHAIN SPRAY or CHAIN LUBE.
0
AUTOGREASE MP or GREASE 30.
0
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):
0
0
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.
0
OILN-ING
Release 00/2002-10
1 -13
- 00
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).
m
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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Release 00/2002-10
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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)]
Release 00/2002-10
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- 00
GENERAL INFORMATION
1.7.4 ENGINE TOOLS
RSV mille
1 -16
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Release 00/2002-10
RSV mille
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
Release 00/2002-10
1 -17
- 00
GENERAL INFORMATION
1.7.5 MISCELLANEOUS TOOLS
RSV mille
1 -18
- 00
Release 00/2002-10
RSV mille
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.)
13
14
15
16
17
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)]
20
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
Release 00/2002-10
1 -19
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