Aprilia RSV MILLE TUONO 2003, RSV MILLE R TUONO 2003 User Manual

8104702

First edition: april 2003

Reprint:

Produced and printed by:

DECA s.r.l.

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

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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 “+” (LOCK)

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.

”.

+”.

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

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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.

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

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TAMPERING WARNING

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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).

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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 5

2 2

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WARNING ADHESIVE LABELS CHART 5

Ref. Description

NOT PROVIDED FOR 49 STATES.

FOR STATE OF CALIFORNIA ONLY.

Ref. Description

to be continued

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Ref. Description

FOR STATE OF CALIFORNIA ONLY.

14a

to be continued

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

Ref. Description

FOR STATE OF CALIFORNIA ONLY.

15a

Muffler stamping.

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

POSITION OF THE WARNING ADHESIVE LABELS T

2 2

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WARNING ADHESIVE LABELS CHART T

Ref. Description

NOT PROVIDED FOR 49 STATES.

FOR STATE OF CALIFORNIA ONLY.

Ref. Description

to be continued

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Ref. Description

FOR STATE OF CALIFORNIA ONLY.

15a

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to be continued

Ref. Description

FOR STATE OF CALIFORNIA ONLY.

16a

Muffler stamping.

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CALIFORNIA EVAPORATIVE

EMISSION SYSTEM 5

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)

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

NOTE In case of malfunction of the fuel system, contact your local aprilia Dealer.

CALIFORNIA EVAPORATIVE

EMISSION SYSTEM T

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 7,456 miles (12,000 kilometers), whichever occurs first.

Class II motorcycles (170 - 279 cu. cm): for a period of use of five (5) years or 11,185 miles (18,000 kilometers), whichever occurs first.

Class III motorcycles (280 cu. cm and larger): for a period of use of five (5) years or 18,641 miles (30,000 kilometers), 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 7,456 miles (12,000 kilometers), if the motorcycle's engine displacement is less than 170 cubic centimeters; of 11,185 miles (18,000 kilometers), if the motorcycle's engine displacement is equal to or greater than 170 cubic centimeters but less than 280 cubic centimeters; or of 18,641 miles (30,000 kilometers), 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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

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.

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

(e.i. \) refer exclusively to the model

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 106 (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

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 7- RSV mille R TUONO

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

WARNING ADHESIVE LABELS CHART 5................... 9

POSITION OF THE WARNING ADHESIVE LABELS T. 12

WARNING ADHESIVE LABELS CHART T................. 13

CALIFORNIA EVAPORATIVE EMISSION SYSTEM 5... 16 CALIFORNIA EVAPORATIVE EMISSION SYSTEM T... 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

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

5 8

STEERING LOCK............................................................... 48

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 J................. 52

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

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 AND 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

J.................................................................................... 96

POSITIONING THE VEHICLE ON THE REAR SERVICE

STAND J....................................................................... 96

POSITIONING THE VEHICLE ON THE FRONT SERVICE

STAND J....................................................................... 96

J...................................................... 52

FRONT WHEEL.................................................................. 97

FRONT BRAKE CALIPERS 5..................................... 99

FRONT BRAKE CALIPERS T................................... 100

REAR WHEEL .................................................................. 101

DRIVE CHAIN................................................................... 104

REMOVING THE RIDER SEAT........................................ 106

LIFTING THE FUEL TANK ............................................... 106

REMOVING THE SIDE FAIRINGS................................... 107

REMOVING THE LOWER FAIRING ................................ 107

REMOVING THE SIDE BODY PANELS .......................... 107

REMOVING THE REAR-VIEW MIRRORS....................... 108

REMOVING THE FRONT FAIRING ................................. 109

REMOVING THE SIDE STAND........................................ 110

INSPECTING THE FRONT AND REAR SUSPENSIONS 112

FRONT SUSPENSION..................................................... 112

REAR SUSPENSION ....................................................... 116

CHECKING THE BRAKE PAD WEAR ............................. 118

ADJUSTING THE COLD START CONTROL (

IDLING ADJUSTMENT..................................................... 119

ADJUSTING THE THROTTLE CONTROL....................... 119

SPARK PLUGS ................................................................ 120

CHECKING THE SIDE STAND........................................ 122

BATTERY ......................................................................... 123

CHECKING AND CLEANING THE TERMINALS............. 123

REMOVING THE BATTERY............................................. 124

CHECKING THE ELECTROLYTE LEVEL........................ 125

RECHARGING THE BATTERY........................................ 125

INSTALLING THE BATTERY........................................... 126

LONG INACTIVITY OF THE BATTERY........................... 127

CHECKING THE SWITCHES........................................... 127

CHANGING THE FUSES ................................................. 128

ADJUSTING THE VERTICAL HEADLIGHT BEAM.......... 130

BULBS .............................................................................. 131

CHANGING THE DASHBOARD BULBS.......................... 131

CHANGING THE HEADLIGHT

BULBS .............................................................................. 132

CHANGING THE FRONT AND REAR DIRECTION

INDICATOR BULBS ......................................................... 134

CHANGING THE TAIL LIGHT BULB................................ 135

TRANSPORT .......................................................... 136

DRAINING THE FUEL TANK ........................................... 136

CLEANING ........................... .................................. 137

LONG PERIODS OF INACTIVITY.................................... 138

TECHNICAL DATA ................................................. 140

TIRES ............................................................................... 142

LUBRICANT CHART ........................................................ 144

AUTHORISED DEALERS AND SERVICE CENTRES..... 145

IMPORTERS .................................................................... 146

IMPORTERS .................................................................... 147

IMPORTERS .................................................................... 148

WIRING DIAGRAM RSV MILLE - RSV MILLE R TUONO -. 150 WIRING DIAGRAM KEY RSV MILLE - RSV MILLE R

TUONO -........................................................................... 151

) ........... 119

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.

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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.

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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 even death.

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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 Official Dealer for repairs. Failure to heed this warning can 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.

Do not attempt to modify the position, angle or color of your license plate. Do not

A12

345

ONLY ORIGINALS

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 7- 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.

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.

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

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

use and maintenance RSV mille TUONO 7- RSV mille R TUONO

+ 124 hidden pages

Aprilia RSV MILLE TUONO 2003, RSV MILLE R TUONO 2003 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual