Aprilia RSV MILLETUONO User Manual 2002
© 2002 aprilia s.p.a. - Noale (VE)
First edition: august 2002
Reprint:
Produced and printed by:
DECA s.n.c.
Via Risorgimento, 23/1 - Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decaweb.it
www.decaweb.it
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 - 041 58 29 111
Fax +39 - 041 44 10 54
www.aprilia.com
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FOREWORD
NOTE This manual is an important and
integral part of your vehicle. Keep it with
your vehicle at all times, even if your
vehicle is resold.
aprilia has prepared this manual to supply
you, the user, with correct and current
information. However, since aprilia
constantly improves the design of its
vehicles, there may be slight discrepancies
between your vehicle and the material
given in this manual. If you have any
questions about your vehicle, contact your
local aprilia Dealer, as he will have the
very latest technical information available
from the factory.
For tests and repairs not expressly
described in this manual, to purchase
aprilia genuine spare parts, accessories,
and other products, and for help with
specific problems, please contact your
official Dealer aprilia or service center.
These professionals will be able to
promptly and accurately help.
Thank you for choosing aprilia. Have a
great ride!
This manual is copyright in all countries;
partial or complete reproduction of any part
by any means in print or electronic is
strictly prohibited.
INTRODUCTION
This manual is divided into sections, chapters
and paragraphs, by subject. The procedures
described are laid out in single operation, and
each operation is indicated by a ◆.
The numbered parts shown in the figures are
identified in the text with the number in
parentheses or with the symbol representing
them.
Example (the following text is generic and
does not refer to this specific vehicle):
section
chapter
safety
warning
paragraph
operation
position (2)
symbol “
MAIN INDEPENDENT CONTROLS
STEERING LOCK
Never attempt to place the ignition
switch in the locked “
position while the vehicle is moving.
OPERATION
To lock the steering:
Turn the handlebar completely to the
left or to the right.
Turn the key (2) to position “
”
Press the key and turn it to position “
Remove the key.
” (LOCK)
”.
”.
SAFETY WARNINGS
The following precautionary warnings are
used throughout this manual in order to
convey the following messages:
Safety Warning: When you see
this symbol on the vehicle or in
the manual, pay particular attention to
the potential risk of personal injury or
death. Non-compliance with the
instructions given in the warning
messages preceded by this symbol may
result in serious risk for your and other
people’s safety and for the vehicle.
Indicates a potential hazard which may
result in serious injury or even death.
Indicates a potential hazard which may
result in personal injury or damage to
the vehicle or other property.
NOTE The word “NOTE” in this manual
precedes important information or
instructions.
GENERAL SAFETY RULES
CARBON MONOXIDE
If it is necessary to run the engine in order
to carry out maintenance operation, 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.
The exhaust fumes contain carbon
monoxide, a poisonous gas that can
cause loss of consciousness and even
death.
Carbon monoxide is both colorless and
odorless, and cannot be detected by
smell, vision, or any other sense. Avoid
breathing exhaust fumes under any
circumstances.
GASOLINE
Keep gasoline away from children. Gasoline
is also poisonous. Never attempt to siphon
gasoline using your mouth. Never allow
gasoline to contact your skin. If you should
accidentally spill gasoline on yourself, change
your clothes immediately and wash the area
upon which the gasoline was splashed
thoroughly with hot water and soap. Should
you accidentally swallow gasoline, do not
induce vomiting. Drink large quantities of clear
water or milk and immediately seek
professional medical assistance. Should you
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accidentally get gasoline into your eyes, flush
with large quantities of cool, clear water and
immediately seek professional medical
assistance.
Gasoline is extremely flammable and
becomes explosive under certain
conditions.
KEEP GASOLINE AWAY FROM CHILDREN.
HOT COMPONENTS
The engine and all parts of the exhaust
system, as well as the braking system,
become very hot and remain hot for
some time after the vehicle and the
engine are stopped. Before handling
any component of your vehicle after
riding, ensure that it has cooled
sufficiently to be safe to handle.
USED ENGINE OIL
Use latex gloves for the maintenance
operations that require contact with
used oil. Used engine oil may cause
skin cancer if repeatedly left in contact
with the skin for prolonged periods.
Although this is unlikely unless you
handle used oil on a daily basis, it is
advisable to thoroughly wash your
hands with soap and water after
handling used oil.
KEEP OIL AWAY FROM CHILDREN.
3
BRAKE FLUID
Brake fluid is extremely poisonous. Do not
ever allow brake fluid to be ingested or
swallowed. Should brake fluid accidentally
be swallowed, drink large quantities of
milk or clear water and immediately seek
professional medical assistance. Brake
fluid is highly destructive of skin and eye
tissue. Should you accidentally spill clutch
fluid on yourself, remove the
contaminated clothing, wash your body
with soap and warm water immediately
and seek professional medical assistance
with no delay. . Should you accidentally
splash brake fluid into your eyes, flush
with a large quantity of cool, clear water
and immediately seek professional
medical assistance.
KEEP BRAKE FLUID AWAY FROM
CHILDREN.
CLUTCH FLUID
Clutch fluid is extremely poisonous. Do
not ever allow clutch fluid to be ingested
or swallowed. Should clutch fluid
accidentally be swallowed, drink large
quantities of milk or clear water and
immediately seek professional medical
assistance. clutch fluid is highly
destructive of skin and eye tissue. Should
you accidentally spill clutch fluid on
yourself, remove the contaminated
clothing, wash your body with soap and
warm water immediately and immediately
seek professional medical assistance.
Should you accidentally splash clutch
fluid into your eyes, flush with a large
quantity of cool, clear water and
immediately seek professional medical
assistance.
KEEP CLUTCH FLUID AWAY FROM
CHILDREN.
COOLANT
In certain conditions, the ethylene glycol
contained in the engine coolant is
flammable: its flame is invisible, but you
can be burned anyway.
Avoid spilling the engine coolant on the
exhaust system or on the engine
components. They may be hot enough to
cause the coolant to ignite and burn
without a visible flame.
The coolant (ethylene glycol) can cause
skin irritation and is poisonous if
swallowed.
Coolant and coolant/water mixtures are
sweet to the taste and brightly colored,
therefore are highly attractive to pets and
children. Take extra precautions to keep
new and used coolant out of reach of
children and animals.
KEEP COOLANT AWAY FROM
CHILDREN.
Risk of burns.
Do not remove the radiator cap when the
engine is hot. Wait until the engine has
completely cooled down. The coolant is
under pressure and may splash out and
cause burns.
BATTERY HYDROGEN GAS
AND ELECTROLYTE
The battery gives off noxious and
explosive gases; keep cigarettes, flames
and sparks away from the battery.
Provide adequate ventilation when
operating or recharging the battery.
During recharging and use, make sure
that the room is properly ventilated and
avoid inhaling the gases released
during the recharging.
The battery contains sulphuric acid
(electrolyte). Contact with the skin or
eyes may cause serious burns. Always
wear protective clothing, rubber gloves,
and tight fitting goggles or a face shield
when working around the battery,
especially when filling the battery with
either water or electrolyte.
In case of contact with the skin, flush
immediately with plenty of water. In case
of contact with the eyes, flush with plenty
of water for at least 15 minutes.
Immediately consult a health professional.
The electrolyte is poisonous.
If the electrolyte is accidentally
swallowed, drink large quantities of
water or milk and then milk of magnesia
or vegetable oil. Immediately consult a
health professional.
KEEP BATTERIES AND ELECTROLYTE
AWAY FROM CHILDREN.
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WARNINGS - PRECAUTIONS GENERAL ADVICE
Before starting the engine, carefully read this
manual and in particular the chapters
“WARNINGS - PRECAUTIONS - GENERAL
ADVICE” and “SAFE DRIVE” see p. 17.
Your safety and that of those around you
depends not only on your skill as a rider, but
also your knowledge about your vehicle and
about riding safely. Therefore it is essential
that you not operate your vehicle on public
streets or highways until you have received
instructions from a qualified safety
organization such as the Motorcycle Safety
Foundation, and are properly trained and
licensed.
REPORTING OF DEFECTS
THAT AFFECT SAFETY
If you believe that your vehicle has a defect
which could cause a crash or could cause
injury or death, you should immediately
inform the National Highway Traffic Safety
Administration (NHTSA) in addition to
notifying aprilia. If NHTSA receives similar
complaints, it may open an investigation, and
if it finds that a safety defect exists in a group
of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot
become involved in individual problems
between you, your dealer, or aprilia. To
contact NHTSA, you may either call the Auto
Safety Hotline toll free at 1-800-424-9393
(or 366-0123 in the Washington, D.C. area)
or write to: NHTSA, U.S. Department of
Transportation, Washington, D.C. 20590.
You can also obtain other information about
motor vehicle safety from the Hotline.
ROAD REGULATIONS
AND USE OF THE VEHICLE
Rules of the road vary from country to
country. It is essential that you understand
in advance the rules of the road of the
country in which your vehicle will be used.
This vehicle has been designed and
produced for use only on paved roads. It
is not designed to be used on even
smooth graded dirt roads, or trails. It is
not designed for off road competition, or
for cross country riding. Do not use this
vehicle on rough or unimproved
surfaces, or in other off road areas.
Failure to heed this warning could lead
to an upset with subsequent injury and
even death.
NOISE EMISSION WARRANTY
aprilia s.p.a. warrants that this exhaust
system, at the time of sale, meets all
applicable U.S. EPA Federal noise standards.
This warranty extends to the first person who
buys this exhaust system for purposes other
than resale, and to all subsequent buyers.
Warranty claims should be directed to:
aprilia USA Inc.
110 Londonderry Court, Suite 130
Woodstock, GA 30188
USA
Tel770 592 2261
Fax770 592 4878
INFORMATION ON THE NOISE
AND EXHAUST GAS EMISSION
CONTROL SYSTEM
ORIGIN OF THE EMISSIONS
The combustion process produces carbon
monoxide and hydrocarbons. The control
of hydrocarbons is very important, because
under certain conditions they react to
exposure to sunlight and produce
photochemical smog.
Carbon monoxide does not react in the
same way, but it is toxic and poisonous.
aprilia utilizes “lean” carburetor settings
and other systems to reduce the
production of carbon monoxide and
hydrocarbons.
TAMPERING WARNING
Tampering with the noise control system is
prohibited. Federal law prohibits the
following acts or causing thereof:
a) The removal or rendering inoperative by
any person other than for purposes of
maintenance, repair, or replacement, of
any device or element of design
incorporated into any new vehicle for
the purpose of noise control prior to its
sale or delivery to the ultimate
purchaser or while it is in use, or
b) The use of the vehicle after such device
or element of design has been removed
or rendered inoperative by any person.
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Among those acts presumed to constitute
tampering are the acts listed below:
a) Removal of, or puncturing the muffler,
baffles, header pipes or any other
component which conducts exhaust
gases.
b) Removal of or puncturing any part of
the intake system.
c) Lack of proper maintenance.
d) Replacing any moving part of the
vehicle, or parts of the exhaust or intake
system, with parts other than those
specified by the manufacturer.
This product should be checked for
repair or replacement if the vehicle
noise has increased significantly
through use. Otherwise, the owner may
become subject to penalties under state
and local ordinances.
PROBLEMS THAT MAY AFFECT
THE VEHICLE EMISSIONS
If any of the following symptoms are
observed, immediately have your vehicle
inspected and repaired by your aprilia
Official Dealer.
Symptoms:
– Difficult starting or stalling after starting.
– Irregular idle.
– Misfiring or backfiring during acceleration.
– After-burning (backfiring).
– Poor engine performance, degraded
handling, or poor fuel economy.
VEHICLE IDENTIFICATION
NUMBER (V.I.N.)
(FRAME NUMBER)
Every vehicle produced by aprilia receives
a vehicle identification number (V.I.N.)
stamped:
– on the steering head of the frame (A), as
shown above;
and also:
– on the identification plate (B) which is
located on the front portion near the
steering head of the frame.
INFORMATION CONTAINED
IN THE VEHICLE
IDENTIFICATION NUMBER
Description of the vehicle identification
number (V.I.N.), stamped on the steering
head of the frame (A) and on the
identification plate (B).
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DIGIT MEANING
1) Manufacturer’s identification
alphanumeric code.
2) Vehicle type.
3) Model.
4) Country for which the vehicle is
intended.
5) #= Check digit number.
6) Model year.
7) Assembling factory designation
(N = NOALE-VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).
8) Sequential serial number.
FOR STATE OF CALIFORNIA ONLY:
FOR STATE OF CALIFORNIA ONLY:
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POSITION OF THE WARNING ADHESIVE LABELS
2 2
12
C
C
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WARNING ADHESIVE LABELS CHART
Ref. Description
1
NOT PROVIDED FOR 49 STATES.
2
FOR STATE OF CALIFORNIA ONLY.
2a
3
Ref. Description
4
5
6
7
to be continued
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Ref. Description
Ref. Description
10
11
8
12
13
9
14
FOR STATE OF CALIFORNIA ONLY.
14a
to be continued
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Ref. Description
15
FOR STATE OF CALIFORNIA ONLY.
15a
Muffler stamping.
16
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POSITION OF THE WARNING ADHESIVE LABELS
2 2
12
C
C
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WARNING ADHESIVE LABELS CHART
Ref. Description
1
NOT PROVIDED FOR 49 STATES.
2
FOR STATE OF CALIFORNIA ONLY.
2a
Ref. Description
4
5
6
3
7
to be continued
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Ref. Description
Ref. Description
10
11
8
12
13
9
14
15
FOR STATE OF CALIFORNIA ONLY.
15a
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to be continued
Ref. Description
16
FOR STATE OF CALIFORNIA ONLY.
16a
Muffler stamping.
17
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CALIFORNIA EVAPORATIVE
EMISSION SYSTEM
FOR STATE OF CALIFORNIA ONLY.
The system consists of:
1) Fuel tank
2) Fuel pump flange
3) Fuel tank breather line
4) Breather line (to tee)
5) Tee
6) Breather line (to purge valve)
7) Purge valve
8) Breather line (to carbon canister)
9) Carbon canister
10) Drain line (to narrow passage)
11) Restrictor Ø 0.06 in (Ø 1.5 mm)
12) Drain line (to manifold vacuum port)
13) Manifold vacuum port (right front part
of throttle body)
14) Vacuum line (from purge valve)
15) Tee
16) Sensor line
17) Fuel pressure regulator
18) Vacuum line (to ported vacuum port)
19) Ported vacuum port (left rear part of
throttle body)
20) Air box
21) Warm air inlet (from air box)
22) Tee
23) Warm air inlet (to one way valve)
24) One way valve
25) Warm air inlet (from one way valve)
26) Warm air inlet (to carbon canister)
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NOTE In case of malfunction of the fuel system, contact your local aprilia Dealer.
CALIFORNIA EVAPORATIVE
EMISSION SYSTEM
FOR STATE OF CALIFORNIA ONLY.
The system consists of:
1) Fuel tank
2) Fuel pump flange
3) Fuel tank breather line
4) Breather line (to tee)
5) Tee
6) Breather line (to purge valve)
7) Purge valve
8) Breather line (to carbon canister)
9) Carbon canister
10) Drain line (to narrow passage)
11) Restrictor Ø 0.06 in (Ø 1.5 mm)
12) Drain line (to manifold vacuum port)
13) Manifold vacuum port (right front part
of throttle body)
14) Vacuum line (from purge valve)
15) Tee
16) Sensor line
17) Fuel pressure regulator
18) Vacuum line (to ported vacuum port)
19) Ported vacuum port (left rear part of
throttle body)
20) Air box
21) Warm air inlet (from air box)
22) Tee
23) Warm air inlet (to one way valve)
24) One way valve
25) Warm air inlet (from one way valve)
26) Warm air inlet (to carbon canister)
NOTE In case of malfunction of the fuel system, contact your local aprilia Dealer.
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aprilia s.p.a. - EMISSION
CONTROL SYSTEM
WARRANTY STATEMENT
YOUR WARRANTY RIGHTS
AND OBLIGATIONS
The California Air Resources Board and
aprilia s.p.a. (hereinafter “aprilia”) are
pleased to explain the emission control
system warranty on your 1999 and later
motorcycle. In California new motor
vehicles must be designed, built and
equipped to meet the State's stringent antismog standards. aprilia must warrant the
emission control system on your
motorcycle for the periods of time listed
below provided there has been no abuse,
neglect or improper maintenance of your
motorcycle.
Your emission control system may include
parts such as the carburetor or fuel
injection system, the ignition system,
catalytic converter and engine computer.
Also included may be hoses, belts,
connectors and other emission-related
assemblies.
Where a warrantable condition exists,
aprilia will repair your motorcycle at no
cost to you, including diagnosis, parts and
labor.
MANUFACTURER’S EMISSIONS
SYSTEM WARRANTY COVERAGE
Class I motorcycles (50 - 169 cu. cm): for a
period of use of five (5) years or 12,000
kilometers (7,456 miles), whichever occurs
first.
Class II motorcycles (170 - 279 cu. cm): for
a period of use of five (5) years or 18,000
kilometers (11,185 miles), whichever
occurs first.
Class III motorcycles (280 cu. cm and
larger): for a period of use of five (5) years
or 30,000 kilometers (18,641 miles),
whichever occurs first.
If an emission-related part on your
motorcycle is defective, the part will be
repaired or replaced by aprilia. This is your
emission control system DEFECTS
WARRANTY.
OWNER'S WARRANTY
RESPONSIBILITIES
– As the motorcycle owner, you are
responsible for the performance of the
required maintenance listed in your
owner's manual. aprilia recommends that
you retain all receipts covering
maintenance on your motorcycle, but
aprilia cannot deny warranty solely for the
lack of receipts or for your failure to ensure
the performance of all scheduled
maintenance.
– You are responsible for presenting your
motorcycle to an aprilia dealer as soon as
a problem exists. The warranty repairs
should be completed in a reasonable
amount of time, not to exceed 30 days.
– As the motorcycle owner, you should be
aware that aprilia may deny your warranty
coverage if your motorcycle or a part has
failed due to abuse, neglect, improper
maintenance or unapproved modifications.
If you have any questions regarding your
warranty rights and responsibilities, you
should contact aprilia USA, Inc., 10933
Crabapple Road, Suite 100, Roswell, GA
3007, or the California Air Resources
Board at P.O. Box 8001, 9528 Telstar
Avenue, El Monte, CA 91734-8001.
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aprilia s.p.a. - LIMITED
WARRANTY ON EMISSION
CONTROL SYSTEM
aprilia s.p.a., Via G. Galilei, 1, 30033
Noale (VE) Italy (hereinafter “aprilia”)
warrants that each new 1999 and after
aprilia motorcycle, that includes as
standard equipment a headlight, taillight
and stoplight, and is street legal:
A. is designed, built and equipped so as to
conform at the time of initial retail
purchase with all applicable regulations
of the United States Environmental
Protection Agency, and the California
Air Resources Board; and
B. is free from defects in material and
workmanship which cause such
motorcycle to fail to conform with
applicable regulations of the United
States Environmental Protection
Agency or the California Air Resources
Board for a period of use, depending on
the engine displacement, of 12,000
kilometers (7,456 miles), if the
motorcycle's engine displacement is
less than 170 cubic centimeters; of
18,000 kilometers (11,185 miles), if the
motorcycle's engine displacement is
equal to or greater than 170 cubic
centimeters but less than 280 cubic
centimeters; or of 30,000 kilometers
(18,641 miles), if the motorcycle's
engine displacement is 280 cubic
centimeters or greater; or 5 (five) years
from the date of initial retail delivery,
whichever first occurs.
I. COVERAGE. Warranty defects shall be
remedied during customary business
hours at any authorized aprilia
motorcycle dealer located within the
United States of America in compliance
with the Clean Air Act and applicable
regulations of the United States
Environmental Protection Agency and
the California Air Resources Board. Any
part or parts replaced under this
warranty shall become the property of
aprilia.
In the State of California only, emission
related warranted parts are specifically
defined by the state's Emission
Warranty Parts List. These warranted
parts are: carburetor and internal parts;
intake manifold; fuel tank; fuel injection
system; spark advance mechanism;
crankcase breather; air cutoff valves;
fuel tank cap for evaporative emission
controlled vehicles; oil filler cap;
pressure control valve; fuel/vapor
separator; canister; igniters; breaker
governors; ignition coils; ignition wires;
ignition points; condensers, and spark
plugs if failure occurs prior to the first
scheduled replacement; and hoses,
clamps, fittings and tubing used directly
in these parts. Since emission related
parts may vary from model to model,
certain models may not contain all of
these parts and certain models may
contain functionally equivalent parts.
In the State of California only, Emission
Control System emergency repairs, as
provided for in the California
Administrative Code, may be performed
by other than an authorized aprilia
dealer. An emergency situation occurs
when an authorized aprilia dealer is not
reasonably available, a part is not
available within 30 days, or a repair is
not complete within 30 days. Any
replacement part can be used in an
emergency repair. aprilia will reimburse
the owner for the expenses, including
diagnosis, not to exceed aprilia's
suggested retail price for all warranted
parts replaced and labor charges based
on aprilia's recommended time
allowance for the warranty repair and
the geographically appropriate hourly
labor rate. The owner may be required
to keep receipts and failed parts in order
to receive compensation.
II. LIMITATIONS. This Emission Control
System warranty shall not cover any of
the following:
A. Repair or replacement required as a
result of
(1) accident,
(2) misuse,
(3) repairs improperly performed or
replacements improperly installed,
(4) use of replacement parts or
accessories not conforming to aprilia
specifications which adversely affect
performance and/or
(5) use in competitive racing or related
events.
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B. Inspections, replacement of parts and
other services and adjustments
required for required maintenance.
C. Any motorcycle on which the odometer
mileage has been changed so that
actual mileage cannot be readily
determined.
III.LIMITED LIABILITY
A. The liability of aprilia under this
Emission Control System Warranty is
limited solely to the remedying of
defects in material or workmanship by
an authorized aprilia motorcycle dealer
at its place of business during
customary business hours. This
warranty does not cover inconvenience
or loss of use of the motorcycle or
transportation of the motorcycle to or
from the aprilia dealer. aprilia SHALL
NOT BE LIABLE FOR ANY OTHER
EXPENSES, LOSS OR DAMAGE,
WHETHER DIRECT, INCIDENTAL,
CONSEQUENTIAL OR EXEMPLARY
ARISING IN CONNECTION WITH THE
SALE OR USE OF OR INABILITY TO
USE THE aprilia MOTORCYCLE FOR
ANY PURPOSE. SOME STATES DO
NOT ALLOW THE EXCLUSION OR
LIMITATION OF ANY INCIDENTAL OR
CONSEQUENTIAL DAMAGES, SO
THE ABOVE LIMITATIONS MAY NOT
APPLY TO YOU.
B. NO EXPRESS EMISSION CONTROL
SYSTEM WARRANTY IS GIVEN BY
aprilia EXCEPT AS SPECIFICALLY
SET FORTH HEREIN. ANY EMISSION
CONTROL SYSTEM WARRANTY
IMPLIED BY LAW, INCLUDING ANY
WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR
PURPOSE, IS LIMITED TO THE
EXPRESS EMISSION CONTROL
SYSTEM WARRANTY TERMS
STATED IN THIS WARRANTY. THE
FOREGOING STATEMENTS OF
WARRANTY ARE EXCLUSIVE AND IN
LIEU OF ALL OTHER REMEDIES.
SOME STATES DO NOT ALLOW
LIMITATIONS ON HOW LONG AN
IMPLIED WARRANTY LASTS SO THE
ABOVE LIMITATIONS MAY NOT
APPLY TO YOU.
C. No dealer is authorized to modify this
aprilia Limited Emission Control
System Warranty.
IV.LEGAL RIGHTS. THIS WARRANTY
GIVES YOU SPECIFIC LEGAL
RIGHTS, AND YOU MAY ALSO HAVE
OTHER RIGHTS WHICH VARY FROM
STATE TO STATE.
V. THIS WARRANTY IS IN ADDITION TO
THE aprilia LIMITED MOTORCYCLE
WARRANTY.
VI.ADDITIONAL INFORMATION. Any
replacement part that is equivalent in
performance and durability may be
used in the performance of any
maintenance or repairs. However,
aprilia is not liable for these parts. The
owner is responsible for the
performance of all required
maintenance. Such maintenance may
be performed at a service
establishment or by any individual. The
warranty period begins on the date the
motorcycle is delivered to an ultimate
purchases.
aprilia s.p.a.
Via G. Galilei, 1
30033 Noale (VE) Italy
aprilia USA, Inc.
110 Londonderry Ct., Suite 130
Woodstock, GA 30188
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GENERAL INSTRUCTIONS
★
The operations preceded by this
symbol must be repeated also on
the opposite side of the vehicle.
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.
The competition adjustment must be used
in organized racing or circular course
competitive event, under the auspices of a
recognized sanctioning body or by permit
issued by the local governmental authority
having jurisdiction.
It is strictly forbidden to use the
competition adjustment while riding the
vehicle on public streets, roads, or
highways.
Both the and the models are
high performance motorcycles. The
is intended primarily for racing, and is
not intended for use carrying
passengers, luggage or parcels. It is
strictly forbidden to carry anything
other than the rider on the
model.
Any mention in this manual of
passenger, luggage or parcels refers
only to the
model.
Never carry any parcels on the
glove/tool kit compartment cover
; small parcels may be carried only
on the passenger seat, see p. 51
(LUGGAGE RACK FASTENINGS
).
Failure to heed these warnings may lead
to a serious accident with consequent risk
of serious injury or even death.
In the text and/or showns the symbol (e.i.
) preceded by the symbol of the model
) refer exclusively to the model
(e.i.
indicated.
Example:
be intended as optional only to the
in a text and/or shown is to
model.
NOTE Soon after purchasing the
vehicle, write down the identification data
provided in the SPARE PARTS
IDENTIFICATION LABEL in the table
below. This label is positioned on the left
part of the frame; to be able to read it,
remove the rider seat, see 105
(REMOVING THE RIDER SEAT).
These data indicate:
– YEAR = year of manufacture (Y, 1, 2, …);
– M. = modification code (A, B, C, …);
– COUNTRY CODE = country of
homologation (I, UK, A, …).
and are to be supplied to the aprilia
Official Dealer as reference data for the
purchase of spare parts or specific
accessories of the model you have
acquired.
In this manual the various versions are
indicated by the following symbols:
RSV mille model
RSV mille R model
automatic switch-
on device
catalytic version
optional
VERSION:
Italy
United Kingdom
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
use and maintenance RSV mille TUONO - RSV mille R TUONO
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CONTENTS
FOREWORD ................................ ............................... 2
INTRODUCTION ....................................... ................. 2
MAIN INDEPENDENT CONTROLS............................. 2
STEERING LOCK................................................................. 2
SAFETY WARNINGS ................................................. 3
GENERAL SAFETY RULES ........................................ 3
CARBON MONOXIDE.......................................................... 3
GASOLINE ........................................................................... 3
HOT COMPONENTS ........................................................... 3
USED ENGINE OIL .............................................................. 3
BRAKE FLUID ...................................................................... 4
CLUTCH FLUID.................................................................... 4
COOLANT ............................................................................ 4
BATTERY HYDROGEN GAS AND ELECTROLYTE ........... 4
WARNINGS - PRECAUTIONS - GENERAL ADVICE.... 5
REPORTING OF DEFECTS THAT AFFECT SAFETY ........ 5
ROAD REGULATIONS AND USE OF THE VEHICLE......... 5
NOISE EMISSION WARRANTY .......................................... 5
INFORMATION ON THE NOISE AND EXHAUST GAS
EMISSION CONTROL SYSTEM.......................................... 5
TAMPERING WARNING...................................................... 5
VEHICLE IDENTIFICATION NUMBER (V.I.N.)
(FRAME NUMBER) .............................................................. 6
INFORMATION CONTAINED IN THE VEHICLE
IDENTIFICATION NUMBER................................................. 6
POSITION OF THE WARNING ADHESIVE LABELS W...... 8
WARNING ADHESIVE LABELS CHART W......................... 9
POSITION OF THE WARNING ADHESIVE LABELS W.... 12
WARNING ADHESIVE LABELS CHART W....................... 13
CALIFORNIA EVAPORATIVE EMISSION SYSTEM W..... 16
CALIFORNIA EVAPORATIVE EMISSION SYSTEM W..... 17
APRILIA S.P.A. - EMISSION CONTROL SYSTEM
WARRANTY STATEMENT ................................................ 18
APRILIA S.P.A. - LIMITED WARRANTY ON EMISSION
CONTROL SYSTEM .......................................................... 19
GENERAL INSTRUCTIONS .................................... . 21
BASIC SAFETY RULES..................................................... 24
CLOTHING ......................................................................... 29
ACCESSORIES.................................................................. 30
LOAD.................................................................................. 30
LOCATION OF KEY COMPONENTS ........................ 32
LOCATION OF KEY COMPONENTS ........................ 34
ARRANGEMENT OF THE INSTRUMENTS /
CONTROLS................... ........................................... 36
INSTRUMENTS AND INDICATORS ......................... 37
INSTRUMENTS AND INDICATORS TABLE...................... 38
MULTIFUNCTION COMPUTER......................................... 40
MAIN INDEPENDENT CONTROLS....................... .... 46
CONTROLS ON LEFT HANDLEBAR................................. 46
CONTROLS AT THE RIGHT HAND GRIP......................... 47
IGNITION SWITCH............................................................. 48
STEERING LOCK............................................................... 48
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STEERING LOCK............................................................... 49
PARKING LIGHTS.............................................................. 49
UNLOCKING/LOCKING THE PASSENGER SEAT ........... 50
GLOVE/TOOL KIT COMPARTMENT................................. 50
LUGGAGE RACK FASTENINGS....................................... 51
SPECIAL TOOLS
ACCESSORIES.................................................................. 52
NUMBER PLATE-HOLDER EXTENSION
MAIN COMPONENTS.................. ............................. 53
FUEL................................................................................... 53
LUBRICANTS..................................................................... 55
BRAKES ............................................................................. 56
DISC BRAKES.................................................................... 57
FRONT BRAKE .................................................................. 58
REAR BRAKE..................................................................... 59
CLUTCH FLUID - RECOMMENDATIONS ......................... 61
CLUTCH ............................................................................. 62
COOLANT .......................................................................... 63
TIRES ................................................................................. 65
ENGINE OIL ....................................................................... 66
ADJUSTING THE FRONT BRAKE CONTROL LEVER AND
THE CLUTCH CONTROL LEVER...................................... 67
ADJUSTING THE REAR BRAKE CONTROL LEVER
CLEARANCE...................................................................... 67
ADJUSTING THE REAR BRAKE CONTROL LEVER AND
THE GEAR SHIFT LEVER ................................................. 68
AUTOMATIC LIGHT SWITCHING VERSION
EXHAUST SILENCER/EXHAUST TERMINAL................... 68
INSTRUCTIONS FOR USE ....................................... 69
GETTING ON AND OFF THE VEHICLE............................ 69
PRELIMINARY CHECKING OPERATIONS....................... 71
PRELIMINARY CHECKING OPERATIONS....................... 73
STARTING.......................................................................... 74
DEPARTURE AND DRIVE ................................................. 77
RUNNING-IN ...................................................................... 80
STOPPING ......................................................................... 81
PARKING............................................................................ 81
POSITIONING THE VEHICLE ON THE STAND................ 82
SUGGESTIONS TO PREVENT THEFT............................. 82
MAINTENANCE ....................................................... 83
REGULAR SERVICE INTERVALS CHART ....................... 85
KEY..................................................................................... 85
MAINTENANCE RECORD ................................................. 87
IDENTIFICATION DATA..................................................... 91
JOINTS WITH CLICK CLAMPS AN D WITH SCREW CLAMPS
91
CHECKING THE ENGINE OIL LEVEL AND TOPPING UP... 91
CHANGING THE ENGINE OIL AND THE OIL FILTER...... 93
AIR CLEANER.................................................................... 95
ASSEMBLING THE PINS FOR THE REAR SERVICE STAND
.................................................................................... 96
POSITIONING THE VEHICLE ON THE REAR SERVICE
STAND
POSITIONING THE VEHICLE ON THE FRONT SERVICE
...................................................... 52
................. 52
........... 68
....................................................................... 96
....................................................................... 96
STAND
FRONT WHEEL.................................................................. 97
FRONT BRAKE CALIPERS................................................ 99
REAR WHEEL .................................................................. 100
DRIVE CHAIN................................................................... 103
REMOVING THE RIDER SEAT........................................ 105
LIFTING THE FUEL TANK ............................................... 105
REMOVING THE SIDE FAIRINGS................................... 106
REMOVING THE LOWER FAIRING ................................ 106
REMOVING THE SIDE BODY PANELS .......................... 106
REMOVING THE REAR-VIEW MIRRORS....................... 107
REMOVING THE FRONT FAIRING ................................. 108
REMOVING THE SIDE STAND........................................ 109
INSPECTING THE FRONT AND REAR SUSPENSIONS 111
FRONT SUSPENSION..................................................... 111
REAR SUSPENSION ....................................................... 115
CHECKING THE BRAKE PAD WEAR ............................. 117
ADJUSTING THE COLD START CONTROL (
IDLING ADJUSTMENT..................................................... 118
ADJUSTING THE THROTTLE CONTROL....................... 118
SPARK PLUGS ................................................................ 119
CHECKING THE SIDE STAND........................................ 121
BATTERY ......................................................................... 122
CHECKING AND CLEANING THE TERMINALS............. 122
REMOVING THE BATTERY............................................. 123
CHECKING THE ELECTROLYTE LEVEL........................ 124
RECHARGING THE BATTERY........................................ 124
INSTALLING THE BATTERY........................................... 125
LONG INACTIVITY OF THE BATTERY........................... 126
CHECKING THE SWITCHES........................................... 126
CHANGING THE FUSES ................................................. 127
ADJUSTING THE VERTICAL HEADLIGHT BEAM.......... 129
BULBS .............................................................................. 130
CHANGING THE DASHBOARD BULBS.......................... 130
CHANGING THE HEADLIGHT BULBS............................ 131
CHANGING THE FRONT AND REAR DIRECTION
INDICATOR BULBS ......................................................... 133
CHANGING THE TAIL LIGHT BULB................................ 134
TRANSPORT .......................................................... 135
DRAINING THE FUEL TANK ........................................... 135
CLEANING ....................... ...................................... 136
LONG PERIODS OF INACTIVITY.................................... 137
TECHNICAL DATA ................................................. 139
LUBRICANT CHART ........................................................ 143
AUTHORISED DEALERS AND SERVICE CENTRES..... 144
IMPORTERS .................................................................... 146
WIRING DIAGRAM - RSV MILLE TUONO .................. 148
WIRING DIAGRAM KEY - RSV MILLE TUONO .......... 149
WIRING DIAGRAM - RSV MILLE R TUONO ............... 150
WIRING DIAGRAM KEY - RSV MILLE R TUONO ...... 151
) ........... 118
safe drive
BASIC SAFETY RULES
The instructions given below cover normal
operation of your vehicle and must be
carefully observed. By following these rules
you will enhance your own safety and the
safety of those around you. You will also
maximize the life and utility of your vehicle.
Two wheeled vehicles obviously do not
provide some of the protection provided by
automobiles, therefore it is essential that
you wear appropriate protective clothing.
Especially, never operate your vehicle
without wearing your helmet, gloves, eye
protection, a heavy jacket, sturdy footwear,
and sturdy full length pants.
However, do not assume that even the
best clothing and helmet will protect you in
the event of an upset or a crash with
another vehicle. At best, this gear provides
some protection from scrapes and
scratches, but very little, if any, impact
protection.
Be sure that you meet all the requirements
prescribed by local law, including driver’s
license, minimum age, training, insurance,
taxes, vehicle registration, license plate,
etc.
When you first receive your vehicle,
practice by riding in areas where there is
little traffic. Do not attempt to ride in heavy
traffic until you are thoroughly experienced
and riding your vehicle has become
second nature to you.
Although this vehicle is legal for operation
on freeways and expressways, it is
advisable to not ride on these high speed
highways until you are thoroughly familiar
with your vehicle, and have attained a high
degree of skill in its operation.
A new vehicle must be carefully broken in,
see p. 80 (RUNNING-IN).
Before starting the engine, make sure that
the brakes, clutch, transmission and
throttle controls function properly and that
the fuel and oil supply is adequate.
The exhaust system, brakes, and some
other parts of the vehicle become very hot
during operation. Do not touch any of these
parts.
Some medicines or drugs, illegal or under
prescription, and alcohol significantly
increase the risk of accidents. Do not ride
while you are under the influence of
alcohol or drugs, be they illicit or under
prescription. Make sure you are in good
physical condition and not ill before riding
your vehicle. Do not ride your vehicle when
you are particularly tired or fatigued.
Alcohol, drugs and fatigue are leading
causes of vehicle accidents.
Many accidents are caused by the rider’s
inexperience and lack of training. Do not
ride your vehicle until you have received
training from a recognized training
organization such as the Motorcycle Safety
Foundation. Remember that riding a two
wheeled vehicle, though easy and fun, is
quite different from driving a car. Do not
assume that you can operate your vehicle
safely just because you are a competent
automobile driver.
Never lend your vehicle to others unless
you are sure that they are competent and
properly licensed vehicle operators.
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Observe all rules of the road. Particularly
pay attention to all warning, regulatory and
informational signs.
Avoid showing off (i.e., popping wheelies).
Especially observe speed limits, remember
that road conditions change with the
weather and wet and icy pavements are
particularly dangerous for vehicles,
especially if you are riding too fast.
Remember that automobile drivers have a
hard time seeing two wheeled vehicles, so
always give the automobile the right of
way, even if it is legally yours.
Before changing lanes, look over your
shoulder to make sure that the way is
clear. Do not rely exclusively on the rearview mirror: you may miscalculate the
distance and speed of a vehicle, or you
may even not see it at all.
Avoid obstacles that could damage the
vehicle or make you lose control.
Do not tailgate, do not attempt to increase
your gas mileage by following in the slip
stream of cars or trucks in front of you.
In case of accident motorcycles, scooters
and mopeds do not provide the same
degree of protection ensured by
automobiles. The legs, in particular, are
exposed the risk of being injured.
However, the additional installation of leg
guards may actually increase the risk of
injuries and their seriousness in case of
accident.
Do not install leg guards available on the
market of spare parts and accessories.
Non-compliance with these instructions
may result in serious injuries or even
death.
Always ride with both hands on the
handlebars and feet on the footrests.
Never shift gear without using the clutch, if
the vehicle is so equipped. Do not operate
the shift lever or the other controls
suddenly or abruptly. Such misuse can
damage the internal components of the
vehicle and consequently cause seizure,
loss of control, accidents and serious
injuries or even death.
Remain in the seat when you are riding. Do
not stand up or attempt to stretch while you
are riding your vehicle. If you need to rest,
pull over to the side of the road when it can
be safely done.
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25
OIL
COOLER
It is very important to your safety that you
give full attention to the riding task. Watch
what you are doing, do not allow yourself to
be distracted by other cars, people or
things on the roadside, etc. Never smoke,
eat, drink, read, etc. while riding your
vehicle. If you must consult a map, pull
over when it can be done safely.
Use only the vehicle’s specific fuels and
lubricants indicated in the “LUBRICANT
CHART”; check the oil, fuel and coolant levels
regularly.
If the throttle sticks open, it may cause a
collision with another vehicle, or an upset.
If the throttle sticks, kill the engine with the
engine stop switch located on the right
handlebar.
Do not attempt to restart the engine until
the throttle has been repaired and works
perfectly. Failure to obey this warning can
lead to a runaway with seriously injuries or
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26
even death.
Your vehicle is equipped with a double cable
throttle. One cable opens the throttle when
you rotate the throttle grip toward you; the
other closes the throttle when you rotate the
grip away from you. It is essential, when you
release the throttle grip, that it automatically
return to the idle position. This double cable
arrangement enhances safety by providing for
positive closing of the throttle.
In the event of a throttle sticking
emergency, always kill the engine using
the engine stop switch located near the
throttle grip on the right handlebar. Never
use your vehicle if the throttle does not
automatically fully return to the idle
position when the throttle grip is released.
Contact your aprilia
repairs. Failure to heed this warning can
Official Dealer
for
lead to a serious accident and subsequent
injury or even death.
If you and your vehicle are involved in an
accident, insure that there has been no
damage to the control levers, tubes, wires,
braking system and other vital parts. If your
vehicle is involved in an accident, take it
immediately to your aprilia Official Dealer
who has the equipment and knowledge to
check for accidental damage which may
compromise your safety.
Your aprilia dealer is ready and able to
help you with any safety problems that you
might have, but of course it is necessary
for you to report any malfunctions to your
mechanic in order for him to help you.
Do not use your vehicle if it is damaged. A
damaged vehicle may become unstable or
present other problems which can increase
the risk of accident, and therefore of
serious injury or even death.
A12
345
ONLY ORIGINALS
Do not attempt to modify the position,
angle or color of your license plate. Do not
cover it with even a clear plastic covering.
Do not modify any of the safety equipment
of your vehicle, especially such safety
related items as directional indicators, rear
view mirrors, lights or horns.
Any modification to your vehicle will
invalidate the warranty.
Do not modify your engine in an attempt to
increase the horsepower. This can result in
irreparable damage to the engine, as well
as degradation of the performance and
handling of the vehicle which could lead to
an upset, and serious injury or even death.
Have your vehicle repaired only with
original parts, and use only original aprilia
or aprilia approved accessories. The use
of aftermarket accessories and parts can
seriously compromise the safety of your
vehicle as well as its performance and
serviceability. Any modification which
affects performance or safety voids your
warranty completely.
Tampering with the emissions or noise
control systems on your vehicle is against
the law, and can be punished by large
fines.
In some jurisdictions, it can even lead to
the confiscation of your vehicle.
use and maintenance RSV mille TUONO - RSV mille R TUONO
This vehicle was not designed to be
equipped with a sidecar or to be used to
tow trailers or other vehicles.
aprilia does not manufacture sidecars or
trailers and therefore cannot predict the
effects of such accessories on the
manoeuvrability or stability of the vehicle: it
can only warn that such effects may be
negative and that any damage to the
vehicle components caused by the use of
such accessories will not be covered by
the warranty.
27
Never race other vehicles with your
vehicle.
Brake with both the front and rear brakes.
The use of one brake only for sudden
braking may cause the vehicle to skid or
make the rider lose control of the vehicle
itself.
When riding down a steep hill, use the
engine as a brake by selecting the same
gear, or a lower gear, than you would use
to climb the hill. Use front and rear brakes
sparingly.
Always ride at the appropriate speed and
avoid unnecessary hard acceleration. This
not only is safer, but also reduces fuel
consumption and increases the life of the
vehicle.
If you must ride your vehicle in rainy
weather, or on loose surfaces, remember
that traction is greatly reduced. Under
these conditions, all handling of the vehicle
must be done gradually and smoothly.
Sudden acceleration, braking or turning
may make you lose control of your vehicle.
When traction is reduced, accelerate and
slow using your vehicle’s engine braking
insofar as possible. Avoid rapid, harsh
application of the brakes.
Gradually open and close the throttle, to
avoid spinning or skidding the rear wheel.
On rough road surfaces, slow down and
ride with particular care.
Try to avoid wide open throttle
accelerations, unless they are necessary
for such things as passing.
Don’t allow your engine to “lug,” that is, run
at too low an rpm. Shift down to a lower
gear. Also, don’t over-rev the engine.
Observe the redline on the tachometer.
Remember that excessively aggressive
cornering can cause your vehicle’s tires to
lose sideways traction, which can result in
an upset and serious injury or even death.
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Always observe posted and statutory
speed limits, but do not assume that you
can ride as fast as the speed limit under all
road conditions. Slowing down a little can
greatly increase your safety under all road
conditions.
Do not ride your vehicle off road.
Do not tamper with the muffler system or
the emissions control system of your
vehicle. This is not only bad for the
environment, it can subject you to serious
penalties.
CLOTHING
Before riding your vehicle, ensure that your
riding gear is in good condition. To be
effective, your helmet must fit properly, and
the visor or other eye protection must be
clean.
Both research and experience have shown
that drivers of other vehicles often do not
see vehicles or riders. In order to make
yourself more conspicuous to these
drivers, wear bright reflective clothing,
such as a reflective vest, or clothing with
reflective sections sewn into the jacket,
pants and gloves. Be particular aware of
approaching automobiles and trucks that
might be trying to turn left in front of you.
Many vehicle accidents are caused by an
opposing automobile driver making a left
turn without warning in front of the vehicle.
Inevitably, the driver will look right at you,
and yet swear that they did not see you
before they turned directly into your path.
Ride alert!
Wear protective clothing, preferably in light
and/or reflecting colors. In this way you will
make yourself more visible to the other
drivers, thus notably reducing the risk of
being knocked down, and you will be more
protected in case of fall.
Always wear your crash helmet. Many
accidents are fatal because of injuries to
the head.
This clothing should be very tight-fitting
and fastened at the wrists and ankles.
Strings, belts and ties should not be
hanging loose; prevent these and other
objects from interfering with driving by
getting entangled with moving parts or
driving mechanisms.
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Do not carry sharp objects in your pockets
that could be dangerous in case of an
upset, for example, pens or mechanical
pencils, etc. Also, make sure that your
passengers follow this recommendation.
ACCESSORIES
The owner of the vehicle is responsible for
the choice, installation and use of any
accessory.
The installation of inappropriate accessories
or the overloading of the vehicle may result in
the instability of the vehicle itself and cause
accidents with consequent risk of serious
injuries or even death. Windshields could be
particularly dangerous, as they can break
and injure or cut the rider in case of accident.
In case of doubts with regard to any
accessory you would like to install or any
load you would like to carry, previously
consult your aprilia Official Dealer.
Avoid installing accessories that cover
horns or lights or that could impair their
functions, limit the suspension stroke and
the steering angle, hamper the operation of
the controls and reduce the distance from
the ground and the angle of inclination in
turns.
Avoid using accessories that hamper
access to the controls, since this can
prolong reaction times during an
emergency.
Fairings and windshields installed on the
vehicle may produce aerodynamic forces
that will affect the stability of the vehicle
during use, especially at high speeds.
Make sure that anything you carry on your
vehicle is securely attached, and cannot
come lose and jam the wheels, forks, etc.
Do not install any electrical accessories,
and do not modify the electrical system of
your vehicle. Anything that could cause an
electrical overload or other fault could
cause the vehicle to suddenly stop, the
lights to dim or quit, or the horn and other
safety accessories not to work. Use only
aprilia genuine accessories.
LOAD
Do not overload your vehicle. Attach
luggage or packages as close as possible
to the center of your vehicle and distribute
the load from side to side as evenly as
possible, to keep imbalance to a minimum.
Remember that loads tend to loosen with
riding, so frequently check the security of
your load.
Do not hang anything from your vehicle
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