Aprilia SL MILLE 1999 User Manual
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OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)
Component
After running-in
[1000 km (625 mi)]
Every 7500 km
(4687 mi) or 8 months
Every 15000 km
(9375 mi) or 16 months
Spark plugs C (*) S (*)
Air filter CS
Engine oil filter S S (*)
Engine oil filter (on oil tank) P P
Light operation/direction C
Fork C
Light system C C
Safety switches C C
Clutch fluid C
Brake fluid C
Coolant C
Engine oil S S (*)
Tyres C every 1000 km (625 mi): C
Tyre pressure R every month: R
Engine idling rpm R R
Engine oil pressure warning light LED at every start: C
Drive chain tension and lubrication every 1000 km (625 mi): C
Brake pad wear before every trip and every 7500 km (4687 mi): C
C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust.
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven ground or
on racetracks.
(*) = In case of use on racetracks, change every 3750 km (2343 mi).
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OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer
Component
Rear suspension linkage bearings
After running-in
[1000 km (625 mi)]
Every 7500 km
(4687 mi) or 8 months
Every 15000 km
(9375 mi) or 16 months
C
Steering bearings and steering C C
Wheel bearings C
Tappet clearance R R
Braking systems C C
Cooling system C
Clutch fluid every 2 years: S
Brake fluid every 2 years: S
Coolant every 2 years: S
Fork oil After the frist 7500 km (4687 mi): S / every 22500 km (14000 mi): S
Brake pads if w orn: S
Nut, bolt, screw tightening C C
Suspensions and attitude C C
Fuel pipes C every 4 years: S
C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust.
Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven ground or
on racetracks.
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It is a good rule to w rite down the frame
and engine numbers in the space provided
in this manual.
The frame number ca n be us ed for th e purchase of spare parts.
NOTE Do not alter the identification
numbers if you do not want to incur severe
penal and administrative sanctions. In particular, the alteration of the frame number
results in the immediate inva lidity of the
guarantee.
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FRAME NUMBER
The frame number is stamped on the right
side of the steering column.
Frame no.
ENGINE NUMBER
The engine number is stamped on the rear
part of the engine, near the pinion.
Engine no.
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Carefully read p. 39 (ENGINE OIL) and
p. 51 (MAINTENANCE).
Periodically check the engine oil level,
change the oil after the first 1000 km (625
mi) and successively every 7500 km (4687
mi), see p. 56 (CHANGING THE ENGINE
OIL AND THE OIL FILTER).
In case of use on racetrac ks, cha nge eve ry
3750 km (2343 mi).
TO CARRY OUT THE CHECKING:
aCAU TION
The engine oil level must be checked
with warm engine.
If the check is carried out with cold engine, the oil level may temporarily lower
below the “MIN” mark.
This is not a problem, provided that the
engine oil pressure warning light LED
j” does not come on, see p. 16 (IN-
“
STRUMENTS AND INDICATORS TABLE).
◆
Start the engine, see p.43 (STARTING).
◆
Allow the engine to idle for about 15-20
minutes, or ride the vehicle on a country
road for approximately 15 km (9.5 mi).
◆
Stop the engine.
◆
Keep the vehicle in vertical position, with
the two wheels resting on the ground.
◆
Check the oil level in the transparent
pipe (1) through the appropriate slot provided on the left fairing.
MAX = maximum level
MIN = minimum level.
The difference between “MAX” and “MIN”
amounts to approximately 460 cm#.
◆
The level is correct when the oil almost
reaches the “MAX” mark.
aCAUTION
Never exceed the “MAX” mark, nor
leave the oil below the “MIN” mark, in
order to avoid serious damage to the
engine.
If necessary, top up the engine oil by proceeding as follows:
◆
Position the vehicle on the side stand on
firm and level ground.
◆
Unscrew and remove the filling cap (2).
aCAU TION
Do not put additives or other substances into the oil.
If you use a funnel or other similar
items, make sure that they are perfectly
clean.
NOTE Use high-quality 15W-50 oil, see
p. 90 (LUBRICANT CHART).
◆
Top up the tank an d restore the corr ect
level, see p. 90 (LUBRICANT CHART).
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aCAUTION
The engine oil and the oil filter change
operations may be difficult for unskilled
operators.
If necessary, contact an APRILIA Official
Dealer.
If you want to carry them out personally, follow the instructions given below.
Carefully read p. 39 (ENGINE OIL) and
p. 51 (MAINTENANCE) carefully.
Periodically check the engine oil level, see
p. 55 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP) change the oi l after
the first 1000 km (625 mi) a nd success ively
every 7500 km (4687 mi).
aCAUTION
In case of use on racetracks, change
every 3750 km (2343 mi).
If the vehicle is used in dusty areas,
change the oil more frequently.
CHANGING THE ENGINE OIL:
NOTE The oil flows out completely and
without problems when it is warm and
therefore more fluid: to achieve this condition, the engine sho uld run for approximately twenty minutes.
aCAU TION
When warmed up, the engine contains
hot oil; therefore, while carrying out the
operations describe d here below be
particularly careful, in order to avoid
burns.
◆
Position the vehicle on the side stand on
firm and level ground.
◆
Position a container (1) with more than
4000 cm# capacity in correspondence
with the drain plug (2) positioned on the
tank.
◆
Unscrew and remove the drain plug (2)
positioned on the tank.
◆
Unscrew and remove the filling cap (3).
◆
Drain the oil and let it drop for a few minutes inside the container (1).
◆
Check and if neces sar y replace the sealing washer of t he drain plug (2) p ositioned on the tank.
◆
Screw and tighten the drain plug (2) on
the tank.
Drain plug (2) driving torque:
15 Nm (1.5 kgm).
◆
Move the container (1) an d pos ition i t under the engine base, in correspondence
with the drain plug positioned on the engine (4).
◆
Unscrew and remo ve the dra in plug p ositioned on the engine (4).
◆
Drain the oil an d l et it d rip inside the con tainer (1) for a few minutes.
aCAUTION
Do not dispose of the oil in the environment. Put it in a sealed containe r and
take it to the filling sta tion where you
usually buy it or to an oil salvage center.
◆
Remove the metal residues from the
drain plug (4) magnet.
use and maintenance SL mille
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◆
Screw and tighten the drain plug (4).
Driving torque of the drain plug (4) positioned on the engine: 12 Nm (1,2 kgm).
CHANGING THE ENGINE OIL FILTER
Change the engine oil filter after the
first 1000 km (625 mi) and successively
every 7500 km (4687 mi) (or every time
you change the oil).
◆
Unscrew the two screws (5) and remove
the cover (6).
◆
Remove the engine oil filter (7).
aCAU TION
Do not use filters that have already
been used.
◆
Spread an oil film on the sealing ring (8)
of the new engine oil filter.
◆
Fit the new engine oil filter.
◆
Put back the cover (6) , screw and tig hten
the two screws (5).
CLEANING THE ENGINE OIL FILTER
ON THE TANK
Clean the engine oil filter (9) on th e tan k
after the first 1000 km (625 mi) and successively every 15000 km (9375 mi) (or
every two engine oil changes).
NOTE Prepare a pipe clamp (10) to re -
place the original one (special type).
◆
Loosen the clamp (11) and disconnect
the pipe (12).
◆
Unscrew and remove the engine oil filter
(9) positioned on the tank and clean it
with a jet of compressed air.
◆
Check the se al of the engine oil f ilter (9)
positioned on the ta nk; s crew an d tig hten
it.
Engine oil filter (9) driving torque:
30 Nm (3.0 kgm).
◆
Connect the pipe (12) and tighten the
new clamp (10).
aCAU TION
Do not put additives or other substances into the oil.
If you use a funnel or other similar
items, make sure that they are perfectly
clean.
NOTE Use high-quality 15W-50 oil, see
p. 90 (LUBRICANT CHART).
◆
Pour about 3500 cm# of engine oil
through the filling openin g (13), see p. 90
(LUBRICANT CHART).
◆
Tighten the filling cap (3).
◆
Start the engine, see p. 43 (STARTING)
and let it idle for about one minute, in order to ensure the filling up of the engine
oil circuit.
◆
Check the oil level and top up if necessary, see p. 55 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP).
use and maintenance SL mille
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◆
Position the vehicle on the side stand on
firm and level ground.
◆
★ Position the pin (1) on the appropriate
seat on the rear fork.
◆
★ Screw and tighten the screw (2) in the
appropria te threaded hole i n the rear
fork.
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NOTE Have someone hel p you ke e p the
vehicle in vertical position with the two
wheels on the ground.
◆
★Loosen the knob (3).
◆
★Move the fork support (4), po sitionin g it
so that the width corresponds to the distance between th e two pins (1) on the
rear fork.
◆
★Tighten the knob (3).
◆
Make the two housings on the stand (4)
coincide with the two pins (1) provided
on the vehicle.
◆
Rest one foot on the rear part of the
stand (5).
◆
Push the stand (5) downwards until it
reaches the end of its stroke.
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◆
Position the vehicle on the appropriate
rear support stand, se e beside (POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND
◆
Insert the two ends of the stand (6) in the
two holes (7) positioned on the lower
ends of the front fork.
◆
Rest one foot on the front part of the
stand (6).
◆
Push the stand (6) downwards until it
reaches the end of its stroke.
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Check the air cleaner every 7500 (4687
mi)km or 8 month s, chan ge it ever y 1500 0
km (9375 mi) or more fre quentl y if the vehicle is used on dusty or wet roads.
It is possible to clea n the air cl eaner parti ally after using the vehicle on this kind of
roads.
aCAU TION
The partial cleaning of the filter does
not exclude or postpone the replacement of the filter itself.
Do not start the engine if the air cleaner
has been removed.
Do not clean the filtering element with
petrol or solvents, sin ce they may
cause a fire in the fuel supply system,
with serious danger for the persons in
the vicinity and for the vehicle.
REMOVAL
◆
Lift the fuel tank, see p. 66 (LIFTING
THE FUEL TANK).
◆
Unscrew and remove t he seven screws
(1) that fasten the filter case cover (2).
◆
Remove the filter case cover (2).
◆
Extract the air cleaner (3).
aCAU TION
Plug the opening wit h a clean cloth, i n
order to prevent any foreign matter to
get ito the suction ducts.
PARTIAL CLEANING
aCAUTION
Do not press or strike the metal net of
the air cleaner (3).
Do not use screwdrivers or alike.
◆
Seize the air cleaner (3) vertically and
strike it more than once on a clean surface.
◆
If necessary, clean the air cleaner (3)
with a compressed air jet (directing it
from the inside towards the outside of
the filter).
◆
Clean the outer part of the air cleaner,
(3) with a cloth.
CHANGING
aCAUTION
Do not use filters that have already
been used.
◆
Replace the air cleaner (3) with a new
one of the same type.
◆
Every 7500 km (4687 mi), remove the
plug (4).
◆
Empty its content into a container and
deliver it to a salvage centre.
aCAU TION
When cleaning the filtering element,
make sure that there are no tears.
Otherwise, change the filtering element.
Make sure that the filtering element is
positioned correctly, in such a way as
to prevent non-filtered air from entering.
Remember that the untimely w ear of the
piston segments and the cylinder may
be caused by a faulty or uncorrectly positioned filtering element.
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aCAUTION
The disassembly and reassembly of the
front wheel may be difficu lt for unskille d
operators. If ne cessary, contact an
APRILIA Official Dealer.
If you want to perform these operations
personally, keep to the following in structions.
Carefully read p. 51 (MAINTENANCE).
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipes, the discs and the pads.
NOTE To remove the front wheel it is
necessary to use the appropriate front and
rear support stands
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&.
DISASSEMBLY
◆
Position the vehicle on the appropriate
rear support stand, see p. 58 (POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND
◆
Position the vehicle on the appropriate
front support stand , see p. 58 (POSI TIONING THE VEHICLE ON THE
FRONT SUPPORT STAND
&).
&).
aCAU TION
Make sure that the vehicle is stable.
◆
Have someone keep the handlebar
steady in running position, so that the
steering is locked.
Brake caliper screw (1) driving torque:
50 Nm (5 kgm).
◆
★
Unscrew and remove the two screws
(1) that fasten the front brake caliper (2).
◆
★
Withdraw the brake caliper (2) from
the disc, leaving it attached to the pipe
(3).
aCAUTION
Never pull the front brake lever after removing the calipers, otherwise the pistons may go out of their seats, thus
causing the outflow of the brake fluid. In
this case consult your APRILIA Official
Dealer, who will carr y out the proper
maintenance operation.
Wheel nut (4) driving torque:
80 Nm (8 kgm).
◆
Loosen and remove the nut (4), taking
the washer.
◆
★
Partially unscrew the two screws (5)
from the wheel pin clamp.
◆
Put a support (6) under the tyre, in such
a way as to keep the wheel in its position
after loosening it.
◆
Withdraw the wheel pin (7) from the left
side.
◆
Remove the wheel withdrawing it from
the front and take the left spacer ring (8)
if it has come out of its seat.
REASSEMBLY
Carefully read p. 51 (MAINTENANCE).
aCAU TION
While reassembling the wheel, be careful not to damage the brake pipes, discs
and pads.
The arrow on the wheel side indicates
the rotation direction. Upon reassembly, make sure that the wheel is pos itioned correctly: the arrow m ust b e v isible on the left side of the vehicle.
◆
Spread a film of lubricati ng grease on the
whole leng th of the wheel pi n (7), see
p. 90 (LUBRICANT CHART).
◆
If the left spacer ring (8) has come out of
its seat on the wheel during disassembl y,
correctly position it there.
◆
Position the wheel between the fork rods
on the support (6).
aWARNING
Danger of injury.
Do not introduce your fingers to align
the holes.
◆
Move the wheel until its central hole and
the holes on the fork are aligned.
◆
Introduce the wheel pin (7) completely.
◆
Position the washer and tighten the nut
(4) manually.
◆
Lock the rotation of the wheel pin (7).
◆
Tighten the nut (4) completely.
Wheel nut (4) driving torque:
80 Nm (8 kgm).
aCAUTION
Proceed with care, in order not to damage the brake pads.
◆
★
Insert the brake caliper (2) on the disc
and position it so that its fastening holes
and the holes on the su pport a re a ligned .
aWARNING
Upon reassembly of the brake caliper,
replace th e caliper fasten ing scre ws (1)
with two new screws of the same type.
◆
★
Screw and tighten the two screws (1)
that fasten the brake caliper.
Brake caliper screw (1) driving torque:
50 Nm (5 kgm).
◆
With pulled front brake lever, press the
handlebar repeate dly, thrusting the fork
downwards. In this way the fork rods will
settle properly.
◆
★
Tighten the two screws (5) of the
wheel pin clamp.
Wheel pin clamp sc rew (5) driving
torque: 22 Nm (2,2 kgm).
◆
Make sure that the fol lowing c omponen ts
are not dirty:
– tyre;
– wheel;
– brake discs .
aWARNING
After reassembly, pull the front brake lever repeatedly and check the correct
functioning of the braking system.
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
APRILIA Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
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aCAUTION
The disassembly and reassembly of the
rear wheel may be difficult for unskilled
operators. If ne cessary, contact an
APRILIA Official Dealer.
If you want to perform these operations
personally, keep to the following in structions.
Carefully read p. 51 (MAINTENANCE).
Before carrying out the following ope ra-
tions, let the engine an d the silencer
cool down until they reach room te mperature, in order to avoid burns.
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipe, the disc and the pads.
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NOTE To remove the rear wheel it is
necessary to use the appropriate rear support stand
DISASSEMBLY
◆
Position the vehicle on the appropriate
rear support stand, see p. 58 (POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND
Wheel nut (1) driving torque:
120 Nm (12 kgm).
◆
Loosen and remove the nut (1), taking
the washer.
◆
Put a support (2) under the tyre, in such
a way as to keep th e w h eel in its position
after loosening it.
◆
Withdraw the wheel pin (3) from the left
side.
&.
&).
◆
Make the wheel ad vance an d release the
drive chain (4) from the crown gear (5).
aCAUTION
Check the position of the chain tighteners (6-7), in orde r to be able to reassemble them correc t ly .
◆
Remove the right (6) and left (7) chain
tighteners.
◆
Remove the entire wheel withdrawing it
from behind.
aCAUTION
Do not operate the rear br ak e le ver after
removing the wheel, since the pins may
go out of their seats and cause brake
fluid leakages.
In this case consult your APRILIA Official
Dealer, who will carr y out the proper
maintenance operation.
REASSEMBLY
aCAU TION
Before proceeding with the reassembly,
make sure that suppo rt plate (8) of the
brake caliper (9) is positioned correc tly;
the plate slot must be inserted in the appropriate stop pin (10) in the inner part
of the rear fork right rod.
Insert th e d isc in t he b r ak e cal ip e r ca r e fully.
◆
Spread a film of lubricati ng grease on the
whole leng th of the wheel pi n (3), see
p. 90 (LUBRICANT CHART).
◆
Position the right (6) and left (7) chain
tighteners in their seats on the rear fork
arms.
◆
Position the wheel between the rear fork
rods on the support (2).
◆
Make the wheel advance and position
the drive chain (4) on the c rown g ear (5 ).
aWARNING
Danger of injury.
Do not introduce your fingers to align
the holes.
◆
Move the wheel back ward s, unt il its ce ntral hole and the holes on the rear fork
are aligned.
◆
Rotate the support plate (8), complete
with brake caliper (9) and with ful crum on
the stop pin (10), until it is aligned with
the holes.
◆
Introduce the wheel pin (3) completely
from the left side.
aCAUTION
Make sure that the wheel pin (3) is inserted completely, with the head in the
appropriate seat on the left chain tightener (7).
◆
Position the washer and tighten the nut
(1) manually.
◆
Check the chain tension, see p. 64
(DRIVE CHAIN).
◆
Tighten the nut (1).
Wheel nut (1) driving torque:
120 Nm (12 kgm).
◆
Make sure that the fol lowing c omponen ts
are not dirty:
– tyre;
– wheel;
– brake discs .
aCAU TION
Check the wheel centering.
Have the driving torques, centering and
balancing of the wheel checked by your
APRILIA Official Dealer, in order to avoid
accidents that may be harmful for you
and/or other people.
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$2)6%#(!).
Carefully read p. 51 (MAINTENANCE).
The vehicle is equipped with an endle ss
chain, in which a ring link joint is not used.
aCAUTION
An excessive slackening of the chain
may cause noise or make the chain rattle, with consequent wear of the shoe
and of the chain guide plate.
Periodically check the slack and adjust
it if necessary, see beside (ADJUSTMENT).
To change the chain, contact an APRILIA
Official Dealer, who will ensure you
prompt and accurate servicing.
Incorrect main tenance may cause the
untimely wear of the chain and/or damages to the pinion and/or the crown.
aCAU TION
Carry out the maintenance operations
more frequently if you use the vehicle in
difficult conditions or on dusty and/or
muddy roads.
CHECKING THE SLACK
To check the slack, proceed as follows:
◆
Stop the engine.
◆
Position the vehicle on the side stand on
firm and level ground.
◆
Position the shifting lever in neutral.
◆
Make sure th at th e verti cal os cilla tion, i n
an intermediate point between pinion
and crown in the lower part of the chain,
is about 25 mm.
◆
Move the vehicle forwards, or turn the
wheel, in order to be able to check the
vertical oscillation of the chain even
when the wheel turns; the slack must be
constant in all the rotation phases of the
wheel.
aCAU TION
If in some positions the slack is higher
than in others, this means that there are
crushed or seized links; in this case,
contact an APRILIA Official Dealer. To
prevent the risk of seizures, lubricate the
chain frequently, see p. 65 (C LEANING
AND LUBRICATION).
If the slack is uniform, but higher or lower
than 25 mm, adjust it, see beside (ADJUSTMENT).
ADJUSTMENT
NOTE To adjust the chain it is necessary
to use the appropri ate rear support st and
&.
If after the check it is necessary to adjust
the chain tension, proceed as follows:
◆
Position the vehicle on the appropriate
rear support stand, see p. 58 (POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND
◆
Loosen the nut (1) completely.
NOTE For the wheel centering fixed ref-
erence marks (2-3) are provided, which
can be seen inside the chain tightener
seats on the rear fork arms, before the
wheel pin.
&).
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64
◆
Loosen the two lock nuts (4).
◆
Act on the adjusters (5) and adjust the
chain slack, making sure that t he reference marks (2-3) are correc tly posit ioned
on both sides of the vehicle.
◆
Tighten the two lock nuts (4).
◆
Tighten the nut (1).
Wheel nut driving torque (1):
120 Nm (12 kgm).
◆
Check the chain slack, see p. 64
(CHECKING THE SLACK).
CHECKING THE WEAR OF CHAIN,
PINION AND CROWN
Further, check the chain and sprockets
and make sure that they do not present:
– damaged rollers;
– loose pins;
– dry, rusty, crushed or seiz ed lin ks ;
– excessive wear;
– lacking O rings;
– sprocket or teeth excessively worn or
damaged.
aCAUTION
If the chain rollers are damaged, the
pins are loose and/or the O rings are
damaged or lacking, it is necessary to
change the whole chain unit (both
sprockets and chain).
Lubricate the chain frequently, especially if there are dry or rusty parts.
The crushed or seized links must be lubricated and made work again.
If this is not possible, contact an APRILIA
Official Dealer, who will provide for
changing the chain.
◆
Finally, check the wear of the rear fork
protection shoe.
CLEANING AND LUBRICATION
aCAU TION
The drive chain is provided with O ri ngs
among the links, in order to keep the
grease inside them.
Carry out the adjustment, lubrication,
cleaning and change of the chain with
great care.
Never wash the chain with water jets,
steam jets, high-pressure water jets and
highly inflammable solvents.
◆
Wash the chain with naphtha or kerosene. If it tends to rust quickly, intensify
the maintenance intervals.
Lubricate the chain every 1000 km (625
mi) or whenever necessary.
◆
After washing the chain and letting it dry,
lubricate it with spray grease for chains
provided with sealing rings, see p. 90
(LUBRICANT CHART).
aCAU TION
The lubricants for chains available on
the market can contain substances that
are dangerous for the rubber sealing
rings of the chain.
NOTE Do not use the vehicle soon after
lubricating the chain, since due to the centrifugal force the lubricant would be
sprayed outwards and dir ty the surrounding areas.
use and maintenance SL mille
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