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APRILIA 1115-2, Workshop Manual

The Aprilia 1115-2 Workshop Manual is a comprehensive guide that provides all the necessary information for users to efficiently maintain and repair their Aprilia 1115-2 model. This essential manual is available as a free download from manualshive.com, ensuring easy access to detailed instructions, diagrams, and troubleshooting tips.

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ELECTRIC SYSTEM

RSV mille

6

- 39

Follow 

ã

◆

Turn the reservoirs (2) upside down and place them so
that the sealed parts are over the openings of the bat-
tery cells.

◆

Press on the reservoirs (2) so that the seals break and
the acid is allowed to pour into the battery cells.

NOTE

Make  sure  the  reservoirs  (2)  are  positioned

above the battery as vertically as possible to enable the
liquid to flow out.

◆

Leave the reservoirs (2) in place on the battery for ap-
prox.  twenty  minutes,  checking  the  liquid  flows  out
properly.

a

CAUTION

Do not remove the reservoirs (2) from the battery un-
til all the liquid has poured out.

◆

Should any liquid still be left in the reservoirs (2) once
the twenty minutes are up, tap your fingers on the top of
the reservoirs to help the remaining liquid out.

◆

Lift the reservoirs (2) with care, disengaging them from
the battery.

◆

Place the row of stoppers (3) over the battery cell open-
ings.

◆

Press down firmly until the tops of the stoppers (3) are
flush with the top of the battery.

a

CAUTION

The row of stoppers (3) must NEVER be removed.

◆

Connect the battery to a battery charger.

◆

Subject the battery to a normal charge cycle see 2.4.2
(RECHARGING THE BATTERY).

◆

Refit the battery on the vehicle on being returned to the
customer.

6.11.2 BATTERY MAINTENANCE

◆

If  the  vehicle  remains  unused  for  more  than  fifteen
days, the battery must be recharged to prevent sulpha-
tion, recharge the battery using a normal charge, see
2.4.2 (RECHARGING THE BATTERY).

◆

Smear a film of neutral grease or vaseline on the termi-
nals.

6.11.3 CHECKING THE BATTERY

Should any anomalies be encountered, first check the re-
charging circuit, making sure that it is working correctly,
see 6.3 (CHECKING THE RECHARGING SYSTEM).
In addition, make sure that:

◆

There are no signs of damage (external case cracked)
and no electrolyte leak.

◆

The terminals are securely fastened to the clamps.

◆

Proceed  with the  normal charge for at  least 10 hours,
see 2.4.2 (RECHARGING THE BATTERY).

a

CAUTION

After recharging,  check the  no-load  voltage;  if it is
lower than 12 V, it is absolutely necessary to change
the battery.

6.11.4 RETURN UNDER GUARANTEE BATTERY

The guarantee is not valid if the battery features:

◆

Damage (dented box, bent poles, etc.).

◆

Widespread sulphation (incorrect activation and/or use
of the battery).

Release 00/2002-10

- 00

Summary of Contents for 1115-2

Page 1: ......

Page 2: ...GENERAL INFORMATION 1 SERVICE AND SETTING UP 2 ENGINE 3 FUEL SUPPLY SYSTEM 4 COOLING SYSTEM 5 ELECTRIC SYSTEM 6 CHASSIS 7 REPAIR INFORMATION 8 ANALYTICAL INDEX Release 00 2002 10 00 236 mille U WORKSHOP manual aprilia part 8140688 ...

Page 3: ...ANUALS 0 6 00 0 4 2 SPARE PARTS CATALOGUES 0 6 00 0 4 3 SPECIAL TOOL MANUALS 0 6 00 0 4 4 USE AND MAINTENANCE MANUALS 0 6 00 3 49 7 2 3 0 7 00 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS 0 7 00 0 5 2 BEFORE THE DISASSEMBLY OF THE COMPONENTS 0 7 00 0 5 3 DISASSEMBLING THE COMPONENTS 0 7 00 0 5 4 REASSEMBLING THE COMPONENTS 0 7 00 7 4 53 9 52 3 26 2 0 2 5 0 8 00 0 6 1 ADVICE FOR CONSULTATION 0 8 00 2...

Page 4: ...00 00 2 41 00 00 2 42 00 00 2 43 00 00 2 44 00 00 2 45 00 00 2 46 00 00 2 47 00 00 2 48 00 00 2 49 00 00 2 50 00 00 2 51 00 00 2 52 00 00 2 53 00 00 2 54 00 00 2 55 00 00 2 56 00 00 2 57 00 00 2 58 00 00 2 59 00 00 2 60 00 00 2 61 00 00 2 62 00 00 2 63 00 00 2 64 00 00 2 65 00 00 2 66 00 00 3 1 00 00 3 2 00 00 3 3 00 00 3 4 00 00 3 5 00 00 3 6 00 00 3 7 00 00 3 8 00 00 3 9 00 00 3 10 00 00 3 11 00...

Page 5: ...0 7 53 00 00 7 54 00 00 7 55 00 00 7 56 00 00 7 57 00 00 7 58 00 00 7 59 00 00 7 60 00 00 7 61 00 00 7 62 00 00 7 63 00 00 7 64 00 00 7 65 00 00 7 66 00 00 7 67 00 00 7 68 00 00 7 69 00 00 7 70 00 00 7 71 00 00 7 72 00 00 7 73 00 00 7 74 00 00 7 75 00 00 7 76 00 00 7 77 00 00 7 78 00 00 7 79 00 00 7 80 00 00 7 81 00 00 7 82 00 00 7 83 00 00 7 84 00 00 7 85 00 00 7 86 00 00 7 87 00 00 7 88 00 00 7 ...

Page 6: ...he Release 5 Section number 6 Section page consecutive number 7 Updated page consecutive number 8 Chapter title numbered consecutively 9 Paragraph title numbered consecutively 10 Description of the operation always preceded by a rhombus 11 Description of the operation the star means that the operation must be repeated on the other side of the vehicle Release 00 2002 10 00 ...

Page 7: ...l After Sales Dpt which can give you the information re quired and also inform you about any updates and technical modifications made to the vehicle aprilia s p a reserves the right to modify its models at any time without prejudice to the main characteristics here described All rights as to electronic storage reproduction and total or partial adaptation with any means are reserved for all Countri...

Page 8: ...gether make sure that each is working in safe conditions Carefully read 1 2 INSTRUCTIONS FOR USE OF FU EL LUBRICANTS COOLANT AND OTHER COMPO NENTS 0 5 2 BEFORE THE DISASSEMBLY OF THE COMPONENTS Remove any dirt mud dust and foreign matters from the vehicle before disassembling the components Use when necessary the special tools designed for this vehicle 0 5 3 DISASSEMBLING THE COMPONENTS Do not loo...

Page 9: ...der The terms right and left are referred to the rider seated on the vehicle in the normal riding position For normal maintenance operations and for the use of the vehicle consult the USE AND MAINTENANCE manual The operations preceded by this symbol must be repeated on the opposite side of the vehi cle In this manual the various versions are indicated by the following symbols ò frame ZD4RP and in ...

Page 10: ...tion Organization kg kilograms kgm kilograms per metre 1 kgm 10 Nm km kilometres km h kilometres an hour kΩ kilo ohms kPa kiloPascal 1 kPa 0 01 bar KS clutch side Kupplungseite kW kilowatt L litres LAP lap race course LED Light Emitting Diode LEFT SIDE left side m s metres an second MAX maximum mbar millibar 1mbar 0 1 kPa mi mile MIN minimum MPH miles per hour MS flywheel side Magnetoseite MΩ mega...

Page 11: ...NOTES T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y INTRODUCTION 0 10 RSV mille Release 00 2002 10 00 ...

Page 12: ...RSV mille 1 1 GENERAL INFORMATION 1 Release 00 2002 10 00 ...

Page 13: ... 1 14 00 1 7 2 FRAME TOOLS 1 15 00 1 7 3 FORK TOOLS 1 15 00 1 7 4 ENGINE TOOLS 1 16 00 1 7 5 MISCELLANEOUS TOOLS 1 18 00 1 7 6 TOOLS USED FOR OTHER aprilia VEHICLES 1 20 00 0 3 4 4 6 4 3500 24 34 1 21 00 1 8 1 ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND m 1 21 00 1 8 2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m 1 21 00 1 8 3 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND m 1 21 00 ...

Page 14: ...ot want to incur severe penal and administrative sanctions In particular the alteration of the frame number results in the immediate invalidity of the guarantee 1 1 1 FRAME NUMBER The frame number is stamped on the right side of the steering column 1 1 2 ENGINE NUMBER The engine number is stamped on the rear part of the en gine near the pinion Release 00 2002 10 00 ...

Page 15: ... M M 1 2 2 ENGINE OIL aWARNING Engine oil may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use Do not dispose of the oil in the environment Deliver it to or have it collected by the nearest oil sal vage center or by the supplier In case any maintenance operation has to be carried out it is advisable to use latex gloves For the maintenance i...

Page 16: ...ant gets in con tact with your skin or eyes rinse with plenty of water and consult a doctor If it is swallowed induce vomit rinse mouth and throat with plenty of water and consult a doctor with out delay DO NOT DISPOSE OF THE FLUID IN THE ENVIRON MENT KEEP AWAY FROM CHILDREN Be careful not to spill the coolant on the red hot parts of the engine it may catch fire and send out invisible flames In ca...

Page 17: ...ic resist ance in the clutch levers may be due to trouble in the hydraulic circuits Check that the clutch hoses are not twisted or worn Prevent water or dust from accidentally getting into the circuit In case maintenance operations are to be performed on the hydraulic circuit it is advisable to use latex gloves 1 2 7 CARBON MONOXIDE If it is necessary to let the engine run in order to carry out so...

Page 18: ...disc During the first 1000 km 625 mi never exceed 6000 rpm see table aCAUTION After the first 1000 km 625 mi perform the checking operations indicated in the after running in col umn see 2 1 1 REGULAR SERVICE INTERVALS CHART in order to avoid injuring yourself or others a o damaging the vehicle Between the first 1000 km 625 mi and 1500 km 937 mi drive more briskly change speed and use the max imum...

Page 19: ...ke 259 valve lifting 10 6 mm Valve advance with valve clearance 1mm opening during intake stroke closing during intake stroke opening during exhaust stroke closing during exhaust stroke 20 before TDC 59 after BDC 64 before TDC 15 after BDC ò Valve advance with valve clearance 1mm opening during intake stroke closing during intake stroke opening during exhaust stroke closing during exhaust stroke 2...

Page 20: ...rk oil per rod 520 2 5 cm Coolant 2 5 L 50 water 50 antifreeze with ethylene glycol Seats 2 Vehicle max load driver passenger luggage 182 kg ò Vehicle max load driver passenger luggage 180 kg DRIVE GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 1a 31 60 1 1 935 14 35 1 2 500 17 42 1 2 470 11 948 2a 16 28 1 1 750 8 368 3a 19 26 1 1 368 6 543 4a 22 24 1 1 090 5 216 5a 23 22 1 0 956 4 57...

Page 21: ...SPARK PLUGS Standard NGK R DCPR9E Spark plug gap 0 6 0 7 mm Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V 12 Ah Main fuses 30 A Secondary fuses 15 A Generator with permanent magnet 12 V 400 W Starter 12 V 0 9 kW BULBS Low beam halogen 12 V 55 55 W H4 ò Low beam halogen 12 V 55 W H7U High beam halogen 12 V 60 W H3 ò High beam halogen 12 V 55 W H7U Front parking light 12 V 5 W Direction indicators 12...

Page 22: ...2 5 280 2 8 200 2 0 Front METZELER RENNSPORT 120 70 ZR 17 X X W w 230 2 3 250 2 5 210 2 1 Rear METZELER RENNSPORT 180 55 ZR 17 X X W w 250 2 5 280 2 8 200 2 0 Front MICHELIN PILOT SPORT E 120 70 ZR 17 TL X W 230 2 3 250 2 5 Rear MICHELIN PILOT SPORT E 190 50 ZR 17 TL X W 250 2 5 280 2 8 Front MICHELIN SPORTCUP 120 70 ZR 17 X X w 230 2 3 250 2 5 210 2 1 Rear MICHELIN SPORTCUP 180 55 ZR 17 X X w 250...

Page 23: ...0W 67 of the volume or FORK 5W 33 of the volume FORK 20W 67 of the volume Bearings and other lubrication points recommended 0Bimol Grease 481 0AUTOGREASE MP or GREASE 30 As an alternative to the recommended product use high quality grease for rolling bearings working temperature range 30 C 140 C dripping point 150 C 230 C high protection against corrosion good resistance to water and oxidation Pro...

Page 24: ...he volume FORK 20W 67 of the volume R w W fork oil OHLINS 10W Bearings and other lubrication points recommended 0Bimol Grease 481 0AUTOGREASE MP or GREASE 30 As an alternative to the recommended product use high quality grease for rolling bearings working temperature range 30 C 140 C dripping point 150 C 230 C high protection against corrosion good resistance to water and oxidation Protection of t...

Page 25: ...l tools designed especially for this specific vehicle If necessary request the multi purpose special tools see 0 4 3 SPECIAL TOOL MANUALS aCAUTION Before using the special tools consult any docu ments attached 1 7 1 SUPPORT STANDS xxxxxxx N A available only with the aprilia kit part 8140176 complete support stand kit Pos APRILIA part tool description and function A 8140176 complete support stand k...

Page 26: ...l Pos APRILIA part tool description and function A 8140151 complete tool kit for fork including 1 8140145 Ø 41 mm sealing ring fitting tool 2 8140146 weight to be applied to the tool aprilia part 8140145 Ø 41 mm sealing ring fitting tool e aprilia part 8140189 oil seal fitting tool Ø 43 hole Kit accessory aprilia part 8140151 complete tool kit for fork including 3 8140147 spacer holding tool 4 814...

Page 27: ...GENERAL INFORMATION 1 16 RSV mille 1 7 4 ENGINE TOOLS Release 00 2002 10 00 ...

Page 28: ...on pad for lower balance shaft clutch cover bushes 14 8140177 plug socket spanner 15 0277252 flywheel magneto cover removal tool 16 0277730 flywheel removal hexagonal bolt 17 0240880 threaded bolt to lock the drive shaft at the TDC 18 0277308 gearshift secondary shaft guide bush 19 8140178 pin installation and removal pad 20 8140181 fuel oil pressure gauge compression 21 8140182 rotor bolt bush 22...

Page 29: ...GENERAL INFORMATION 1 18 RSV mille 1 7 5 MISCELLANEOUS TOOLS Release 00 2002 10 00 ...

Page 30: ... 8140426 panel hooks 10 8140432 pushing extractor 11 8140187 engine support stand 12 8124838 battery charger M F 13 0897651 LOCTITE 243 blue 10 cm 14 0899788 LOCTITE 648 green 5 g 15 0899784 LOCTITE 574 orange 16 0297434 LOCTITE 767 Anti Seize 15378 17 0297433 MOLYKOTE G N 50 g 18 0897330 multi purpose grease bp lz 19 0297386 SILASTIC 732 RTV 100 g 20 8116067 LOCTITE 8150 21 8202222 panel adhesive...

Page 31: ...t shaft 8116050 engine oil 8116053 grease v Bimol Grease 481 8116038 grease LUBERING ST xxxxxxx N A AP LUBE temporary lubricant xxxxxxx N A grease DID CHAIN LUBE 8116031 Fluid Biosolvent frame detergent 8116945 ACRILON 28 cyanoacrylic glue xxxxxxx N A MOTUL MOTOWASH degreaser 8116043 ANTI SEIZE MOTAGEPASTE AS 1800 antiscuff paste xxxxxxx N A alcohol 0898011 fluorescent green LOCTITE 275 xxxxxxx N ...

Page 32: ...ten the knob 3 At the same time introduce the two fork shaped seats 4 of the stand 5 under the two pins 1 provided on the vehicle aCAUTION Grasping the stand in another way than indicated in the figure may cause your fingers to be crushed be tween the stand and the ground Grasp the terminal central part of the stand 5 with your hands Pos A Push the stand 5 downwards until it reaches the end of its...

Page 33: ...in 5 all the way onto the stud bolt 4 and tighten Hold the nut on the inside 6 still Driving torque of the engine frame lower fastening screw 50 Nm 5 0 kgm Unscrew and remove the engine lower rear fastening screw 7 NOTE The screw 7 on the right hand side is longer Insert the lower right support pin 8 in the lower hole on the right hand side Insert the stud bolt 9 in the lower hole on the left hand...

Page 34: ... the range 55 to 175 C 99 to 347 F In order to release the part glued it may be necessary to heat the coupled parts to a temperature of 250 C 482 F aprilia part 0899784 LOCTITE 574 orange Solvent free seal in paste to be used instead of seals where there is a high friction factor and where a precise distance is required between the two components Applied in its liquid state it hardens after assemb...

Page 35: ...r brake caliper lock pin Fastening of pinion Fastening of rear brake lever pin Fastening of cooling electrofan on support Fastening of fuel return pipe connection Fastening of fuel filler cap Throttle cable pullet fastening nut Throttle cable support bracket fastening screws Throttle valve pin fastening nut Throttle valve potentiometer fastening screws On coolant pump centre fastening screw On cyl...

Page 36: ...aprilia part 0297434 LOCTITE 767 Anti Seize 15378 On gearshift primary and secondary shaft On gearshift primary and secondary shaft housings On driving shaft and countershaft On the gearshift primary shaft housing and toothing aprilia part 0297433 MOLYKOTE G N 50 g On main bush housings On main bushes On engine casing bearing housings On coolant pump shaft On valve guide slots on the head On valve...

Page 37: ...filter casing aprilia part xxxxxxx N A MOTUL MOTOWASH degreaser Cleaning of frame and fork aprilia part xxxxxxx N A alcohol Cleaning of left handlebar prior to assembly of grip Insertion of radiator breather pipes on T union Assembly of HV coil support rubber element Assembly of side fairing rubber elements Cleaning of lower part of engine Assembly of start relay rubber element Assembly of flexibl...

Page 38: ...eces sary for the correct reassembly NOTE Have the appropriate special tool m to hand aprilia part 0277295 hose clamp installation pliers aCAUTION Upon installation replace the hose clamp that has been removed with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with...

Page 39: ... tighten the screws or bolts by proceeding as described below Manually screw all the fastening elements Applying half the prescribed driving torque tighten the elements that are diametrically opposite each other A and B C and D Repeat the previous operation by applying the pre scribed driving torque NOTE In this way the pressure exerted by the fasten ing elements will be uniformly distributed on t...

Page 40: ...ever mount fastening 1 M6 10 1 0 1 M8 25 2 5 Rear brake pump mount fastening 2 M8 25 2 5 Pinion fastening 1 M10 50 5 0 L Clutch control cylinder fastening 3 M6 10 1 0 Pinion case fastening 3 M6 10 1 0 Fastening of fuel delivery pipe to throttle body 1 M12x1 5 22 2 2 Coolant drain screw 1 M6 10 1 0 Coolant thermistors 2 M14 30 3 0 L Gearshift lever fastening screw 1 M6 10 1 0 O REAR FORK Descriptio...

Page 41: ...Description Q ty Screw nut Nm kgm Notes Fastening of shock absorber collar on dashboard front fairing mount 1 M6 10 1 0 Tube end lock nut 1 M8 12 1 2 Safety dowel on shock absorber collar 1 M5 5 0 5 Fastening of shock absorber tube on lower plate 1 M6 10 1 0 REAR SUSPENSION Shock absorber Description Q ty Screw nut Nm kgm Notes Fastening of shock absorber to frame 1 M10 50 5 0 Linkage Description ...

Page 42: ... 0 2 L Radiator coolant drain plugs 1 1 M6 10 1 0 L Fastening of expansion tank to coils mount 2 M6 10 1 0 Fastening of expansion tank cap 1 M28x3 man Fastening of coolant filler neck 1 M6 10 1 0 Fastening of hose clamps 3 0 3 BRAKING SYSTEMS Front system Description Q ty Screw nut Nm kgm Notes Fastening of right and left brake caliper 2 2 M10x1 25 50 5 0 Fastening of brake fluid tank 1 M6 7 0 7 F...

Page 43: ... ty Screw nut Nm kgm Notes Fastening of filler to tank 3 M5 5 0 5 Fastening of fuel pump flange on tank 8 M6 6 0 6 Fastening of tank front on frame 2 M6 12 1 2 Fastening of tank rear on mount 1 M6 12 1 2 ENGINE OIL TANK AND RADIATOR Description Q ty Screw nut Nm kgm Notes Tank upper fastening screw 1 M6 10 1 0 Tank fastening nut 2 M6 10 1 0 Oil filter 1 M20x1 5 30 3 0 Oil drain plug 1 M8 15 1 5 Oi...

Page 44: ...f riders s footrest supports 4 M8 25 2 5 Fastening of lower fairing support bracket 2 M6 12 1 2 Fastening of riders s footrest protection 4 M5 6 0 6 Fastening of saddle support 4 M10 50 5 0 O Fastening of coil mounts 4 M6 12 1 2 Fastening of dashboard front part of the fairing to frame 2 M6 12 1 2 Fastening of front lower cover 3 M6 7 0 7 RIGHT LEFT HANDLEBARS AND CONTROLS Description Q ty Screw n...

Page 45: ...essure regulator fastening screw 2 M6 3 5 0 35 Throttle cable support bracket fastening screw 3 M5 3 0 3 Throttle cable pullet fastening nut 1 M8 3 0 3 Throttle valve control lever fastening nut 1 M8 3 0 3 Throttle valve potentiometer fastening screw 2 M4 1 6 0 16 Intake flange fastening screw 2 2 M8 19 1 9 Release 00 2002 10 00 Follow ã ...

Page 46: ...letely NOTE It is advisable to use a sprayer 2 When using a sponge dab the surface with the sponge without pressing hard so as to avoid damaging the adhe sive Wet the surface of the adhesive with soapy water Apply the transfer 3 on the surface to be decorated and move it into the right position NOTE Always move the spatula in constant strokes from the centre of the transfer out Using the spatula 1...

Page 47: ...n tape 5 from the surface of the transfer In order to assure good adhesion move the spatula over the transfer again concentrating in particular on the edges and corners NOTE With the wet method the final level of the trans fer is reached approx 48 hours after application Once the application tape has been removed make sure there are no air bubbles anywhere on the surface In the event air bubbles a...

Page 48: ...GENERAL INFORMATION NOTES 1 37 T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y RSV mille Release 00 2002 10 00 ...

Page 49: ...GENERAL INFORMATION NOTES 1 38 T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y RSV mille Release 00 2002 10 00 ...

Page 50: ...RSV mille 2 1 1 SERVICE AND SETTING UP 2 Release 00 2002 10 00 ...

Page 51: ... OPERATIONS 2 36 00 2 20 2 CHECKS TO BE CARRIED OUT AFTER BLEEDING THE BRAKING SYSTEMS 2 37 00 4 54 3934 3 2 38 00 2 21 1 BLEEDING OPERATIONS 2 38 00 2 21 2 CHECKS TO BE CARRIED OUT AFTER BLEEDING THE CLUTCH CONTROL SYSTEM 2 39 00 4 2 4 2 5 2 40 00 4 2 2 2 5 2 41 00 4 54 5 2 42 00 534 4 2 2 2 42 6 2 4 2 6 2 2 42 00 534 4 2 2 2 42 6 2 2 2 43 00 4 2 0 7 2 2 44 00 34 2 2 46 00 2 28 1 CHECKING THE BEA...

Page 52: ...xhaust system in order to avoid burns If not expressly indicated otherwise for the reassem bly of the units repeat the disassembly operations in reverse order 0 2 3 26 0 aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle aCAUTION After the first 1000 km 625 mi and successively eve ...

Page 53: ...2343 mi b Check every two weeks or according to the inter vals indicated TABMAN M2 U UK Components After run ning in 1000 km 625 mi Every 7500 km 4687 mi or 12 months Every 15000 km 9375 mi or 24 months Spark plugs a Stand Air cleaner Engine oil filter b Engine oil filter on oil tank Fork Light operation direction Light system Safety switches Clutch fluid Brake fluid Coolant Engine oil b a Tyres T...

Page 54: ...adjustment Carburation CO adjustment Transmission cables and controls Rear suspension linkage bearings Steering bearings and steering clearance Rear fork bearings and rear fork slack Wheel bearings Brake discs General running of the vehicle Braking systems Clutch control system Cooling system Clutch fluid every 2 years Brake fluid Coolant Fork oil a after the first 7500 km 4687 mi and successively...

Page 55: ...of the vehicle NOTE Before lubricating completely clean all parts re moving rust grease dirt and dust The exposed parts subject to rust are to be lubricated with motor oil or grease see 1 6 LUBRICANT CHART The points to be lubricated are indicated in the LU BRICATION CHART 2 2 1 LUBRICATION CHART 00 Release 00 2002 10 Follow ã ...

Page 56: ...ider left footrest pin 5 Passenger left footrest pin 6 Passenger seat lock 7 Drive chain 8 Rear suspension leverage 9 Side stand pin 10 Passenger right footrest pin 11 Throttle grip 12 Accelerator cables 13 Front wheel pin and bearings 14 Rear fork pin 15 Rider right footrest pin 16 Rear wheel pin and bearings Grease Oil Release 00 2002 10 00 ...

Page 57: ...ler who will carry out the operations indicated in the regular service intervals chart see 2 1 1 REGULAR SERV ICE INTERVALS CHART To make the writing SERV ICE disappear press the LAP push button 6 and then the push button r and keep them pressed for about five seconds With the ignition key 1 in position 2 the standard set tings on the dashboard are the following Right display Clock 7 coolant tempe...

Page 58: ... V max 15 the maximum speed 14 and the distance trip 1 10 are displayed Resetting the maximum speed 14 with the odometer set on the V max function press the push button r for about 2 seconds NOTE The measurement of the maximum speed is rel evant to the distance covered from the last setting to zero of the maximum speed itself The distance trip 1 10 shown on the display indicates the number of kilo...

Page 59: ... has reached the maximum value it starts again from the beginning Press the push button j until the desired rpm value has been set If the push button j is released and then pressed again within 3 seconds intermittently the pointer 4 moves increasing the value by 100 rpm at each click when it has reached the maximum value it starts again from the beginning NOTE It is not possible to set the red lin...

Page 60: ...e temperature is over 130 C 266 F the writ ing 8 appears on the right display aCAUTION If the writing is displayed with a temperature below 130 C 266 F there may be a failure of the electric circuit In this case contact an APRILIA Offi cial Dealer Thermometer range on the display 35 130 C 95 266 F The digital clock 7 appears in the lower part of the right display To set or modify hour and minutes ...

Page 61: ...for the third time the minute segments 22 start blinking in the lower part of the right display digital clock To modify the minute setting press the LAP push but ton 6 on the left part of the handlebar To confirm the minute setting press the push button g 2 3 10 SETTING C OR F When the push button g is pressed for the fourth time the segments of the coolant temperature in C or F 8 start blinking i...

Page 62: ...ay the first time stored 25 press the push but ton k To be able to see the stored times in sequence press the LAP push button 6 The writings etc 26 are displayed To start timing again press the push button k NOTE It is possible to store max forty times after which the LAP push button 6 is not effective any long er To set the memory to zero press the push button l and the LAP push button 6 at the s...

Page 63: ...hen the neg ative cable Disconnect following the reverse order NOTE Check battery voltage with a portable tester If voltage is less than 12V the battery must be recharged If the voltage drops below 8V the electronic unit is not working and is preventing engine operation 2 4 1 CHECKING AND CLEANING THE TERMINALS Carefully read 2 4 BATTERY Battery terminal tightening for the maintenance intervals se...

Page 64: ...n order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer The removal of the 30 A fuses requires the setting to zero of the following functions digital clock and red line setting To reset these functions see 2 3 MULTIFUNCTION COMPUTER If the vehicle remains unused for more than fifteen days it is necessary to recharge the battery in order...

Page 65: ...t see 6 13 ADJUSTING THE VERTICAL HEADLIGHT BEAM and 6 14 ADJUSTING THE HORIZONTAL HEADLIGHT BEAM u Make sure all connectors are inserted properly Make sure all switches are correctly fastened and in proper working order see 6 6 4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH 6 16 CHECKING THE SWITCHES Make sure the air sensor and speedometer sensor are correctly fastened and in proper working ord...

Page 66: ...one cable touch those of another Remove the red protection element 1 NOTE Always connect the positive poles first fol lowing the order indicated below aWARNING The jump leads must not be placed near any moving parts on either vehicle Connect one end of jump lead to the positive pole of the battery on the vehicle providing assistance A and the other end on the positive pole of the battery on the ve...

Page 67: ...k plug caps at the same time Remove the cap 1 of the spark plug 2 Remove any trace of dirt from the spark plug base Introduce the special spanner provided in the tool kit on the spark plug Insert the 13 mm fork spanner provided in the tool kit in the hexagonal seat of the spark plug spanner Unscrew the spark plug and extract it from its seat tak ing care to prevent dust or other substances from ge...

Page 68: ...k plug gap in any way The gap must be 0 6 0 7 mm otherwise it is necessary to change the spark plug Make sure that the washer 8 is in good conditions For the installation With the washer on 8 screw the spark plug by hand in order not to damage the thread Tighten the spark plug by means of the spanner you will find in the tool kit giving it half a turn to compress the washer Spark plug driving torq...

Page 69: ...1 FUEL Fuel pipes for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART aWARNING Risk of fire Wait until the engine and exhaust silencer have com pletely cooled down Fuel vapours are noxious for your health Before proceeding make sure that the room in which you are working is properly ventilated Do not inhale fuel vapours Do not smoke and do not use naked flames Do not dispose of...

Page 70: ...mp Release the hose clamp 9 Disconnect the pipe 10 Place the free end of the pipe 10 inside the container prepared beforehand Insert the male quick release coupling 6 of the pipe 10 all the way into the quick release receptacle 7 The petrol starts draining out immediately Open the tank cap Wait until all the petrol has drained out of the tank Once all the petrol has drained out Connect the pipe 10...

Page 71: ...matter to get ito PARTIAL CLEANING aCAUTION Do not press or strike the metal net of the air cleaner 4 Do not use screwdrivers or alike Seize the air cleaner 4 vertically and strike it more than once on a clean surface If necessary clean the air cleaner 4 with a com pressed air jet directing it from the inside towards the outside of the filter aCAUTION When cleaning the filtering element make sure ...

Page 72: ...ol adjustment 2 11 3 AD JUSTING THE ACCELERATOR CONTROL 2 11 2 IDLING ADJUSTMENT up to frame ZD4MEE009YS000292 as of frame ZD4MEE009YS000293 Engine idling rpm for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART To carry out this operation proceed as follows Ride for a few miles until reaching the normal running temperature Position the gear lever in neutral green warning light ...

Page 73: ...nd check the idle stroke again Put back the protection element 6 aCAUTION After the adjustment make sure that the rotation of the handlebar does not modify the engine idling rpm and that the throttle grip returns smoothly and auto matically to its original position after being released 34 24 The cold start cable must be adjusted so that the hand le ver 9 has 2 3 mm of freeplay If not proceed as fo...

Page 74: ...ry 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 ap proximately 500 cm The level is correct when the oil almost reaches the MAX ...

Page 75: ...ith the drain plug 2 posi tioned 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 drip into the container 1 for a few minutes Check and if necessary replace the sealing washer of the drain plug 2 positioned 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...

Page 76: ...ensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp 9 or with other types of clamp Release the hose clamp 10 Disconnect the pipe 12 Unscrew and remove the engine oil filter 11 posi tioned on the tank and clean it with a jet of compressed air Check the engine oil filter gasket 11 on...

Page 77: ...ht fairing If not proceed as follows Unscrew and remove the expansion tank filling cap 2 aWARNING The coolant is noxious do not swallow it if the cool ant gets in contact with the skin or the eyes it can cause serious irritations Do not use your fingers or any other object to check if there is enough coolant aCAUTION Do not put additives or other subtances into the fluid If you use a funnel or oth...

Page 78: ...y hot To facilitate the fluid outflow remove the circuit filling cap 3 and successively the cap 4 positioned on the expansion tank Once all the coolant has drained out move the contain er 2 under the right hand radiator Unscrew and remove the drain plug 5 retrieving the aluminium washer Once all the coolant has drained out move the contain er under the left hand radiator Unscrew and remove the dra...

Page 79: ...ely below the filler neck 7 Refit the circuit filler cap 3 Top up the coolant in the expansion tank see 2 15 CHECKING AND TOPPING UP COOLANT Start the engine and let it run for a few minutes then al low it to cool and check the level of coolant in the ex pansion tank again If necessary top up see 2 15 CHECKING AND TOP PING UP COOLANT Total quantity 2 5 L including the expansion tank NOTE The bleed...

Page 80: ...d wear see 2 27 CHECKING THE BRAKE PAD WEAR and the disc wear If the pads and or the disc do not need replacing provide for topping up TOPPING UP aCAUTION The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 1 are loose or most important if the brake fluid tank cover has been removed Unscrew the two screws 1 of the brake reservoir 2 by means of a short cross ...

Page 81: ... and flat ground Keep the vehicle in vertical position so that the fluid contained in the tank 1 is parallel to the plug 2 Make sure that the brake fluid contained in the reser voir exceeds the MIN mark by checking through the appropriate slot on the right fairing MIN minimum level MAX maximum level If the fluid does not reach at least the MIN mark aCAUTION When the disc pads wear out the level of...

Page 82: ...rallel to the tank rim in horizontal position Remove the gasket 4 aCAUTION Do not put additives or other subtances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean Fill the tank 1 with brake fluid see 1 6 LUBRICANT CHART until reaching the correct level between the MIN and MAX marks aCAUTION It is advisable to top up until reaching the MAX lev el on...

Page 83: ...k the brake pad wear see 2 27 CHECKING THE BRAKE PAD WEAR and the disc wear If the pads and or the disc do not need replacing provide for topping up Make sure that the fluid level exceeds the MIN mark MIN minimum level MAX maximum level If the fluid does not reach the MIN mark provide for topping up TOPPING UP aCAUTION The fluid may flow out Do not operate the clutch control lever if the reservoir...

Page 84: ...y wash the parts of your body that get in con tact with the liquid Consult a doctor or an oculist if the liquid gets in contact with your eyes DO NOT DISPOSE OF THE FLUID IN THE ENVIRON MENT KEEP AWAY FROM CHILDREN aCAUTION Handle brake fluid with care it may chemically alter painted surfaces and the parts in plastic rubber etc In case any maintenance operation has to be carried out it is advisabl...

Page 85: ...rations it is necessary to top up the brake fluid reservoir more than once Top up the brake fluid tank see 2 17 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID or 2 18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID aWARNING Always wear goggles or a protective screen for the eyes when the brake lever or the brake pads is op erated part of the brake fluid may be sprayed out of the brake fluid reservoir ...

Page 86: ...r brake The resistance is due to the air es cape from the braking system If there are other bleeder valves Repeat the bleed ing operations on the other bleeder valves present in the system If no air bubbles can be noticed in the brake fluid If the resistance met when pulling the brake lever 12 for the front brake or the brake pump rod for the rear brake is correct this means that the system does n...

Page 87: ...and flat ground NOTE Do not close the clutch fluid reservoir after top ping up since for the bleeding operations it is necessary to top up the clutch fluid reservoir more than once Top up the clutch fluid tank see 2 17 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID aWARNING Always wear goggles or a protective screen for the eyes when the clutch lever or the clutch control cyl inder is operated part...

Page 88: ...u id Remove the transparent pipe 3 Tighten the bleeder 2 to prescribed driving torque Clutch fluid bleeder valve driving torque 15 Nm 1 5 kgm Position the protection cap 1 on the bleeder valve 2 DO NOT DISPOSE OF THE FLUID IN THE ENVIRON MENT Empty the container 4 into a suitable receptacle for the collection of used clutch fluid Carefully read 2 21 2 CHECKS TO BE CARRIED OUT AFTER BLEEDING THE CL...

Page 89: ... turn NOTE Make sure that there is always fluid in the tank during the operation otherwise once finished the sys tem will need bleeding see 2 20 BLEEDING THE BRAK ING SYSTEMS Keep an eye on the tank 2 as the fluid flows out and tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 17 CHECKING AND TOP PING UP THE FRONT BRAKE FLUID Loosen the bleeder 1 again approx half a turn Wat...

Page 90: ...urn NOTE Make sure that there is always fluid in the tank during the operation otherwise once finished the sys tem will need bleeding see 2 20 BLEEDING THE BRAK ING SYSTEMS Keep an eye on the tank 2 as the fluid flows out and tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 18 CHECKING AND TOP PING UP THE REAR BRAKE FLUID Loosen the bleeder 1 again approx half a turn Watch ...

Page 91: ...e fluid flows out and tighten the bleeder 1 before it empties entirely Top up the tank 2 see 2 19 CHECKING AND TOP PING UP THE CLUTCH FLUID Loosen the bleeder 1 again approx half a turn Watch as the liquid flows out through the tube and as soon as the colour of the fluid starts to change from dark to light tighten the bleeder 1 again and remove the tube Bleeder 1 driving torque 15 Nm 1 5 kgm Refit...

Page 92: ...ING Tighten the lock nut 1 Unscrew the pump control rod 2 to ensure a minimum clearance of 0 5 1 mm between the rod and the pump piston aCAUTION Make sure that there is a certain idle stroke in the movement of the lever to prevent the brake from re maining applied and the consequent untimely wear of the braking elements Lever 3 idle stroke 4 mm measured at the lever end Lock the pump control rod b...

Page 93: ...g the pads of one front caliper only may af fect the stability and safety of the vehicle with seri ous risks for persons property and the vehicle itself To carry out a rapid checking of the wear of the pads proceed as follows Position the vehicle on the stand NOTE Both front brake calipers right and left are equipped with two ò four brake pads The rear brake caliper is provided with two brake pads...

Page 94: ...sc would thus be negatively affected If the thickness of the friction material even of one front 3 or rear pad 4 only has reduced to about 1 5 mm or even if only one of the wear indicators is not visible any longer for the front brake calipers right and left have all pads of both calipers changed see 7 5 1 CHANG ING THE FRONT BRAKE PADS models up to 2001 for the rear brake caliper have both rear b...

Page 95: ...ING 2 28 2 ADJUSTING THE BEARING SLACK STEERING Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Partially remove the fork upper plate see 7 1 19 RE MOVING THE FORK UPPER PLATE NOTE The safety washer 1 has four tabs two bent upwards and two bent downwards To release the coun ter ring 2 it is necessary to straighten the two tabs that are bent upwards To straighten the tabs use a small flat...

Page 96: ...opposite tabs of the safety washer 1 downwards Counter ring 2 driving torque contact 1 4 turn Lock the adjusting metal ring 3 and tighten the coun ter ring 2 the grooved sections of the two rings must coincide Bend the two tabs of the safety washer 1 upwards in serting them in the grooves of the counter ring 2 Refit the fork upper plate 3 see 7 1 19 REMOVING THE FORK UPPER PLATE aCAUTION Once the ...

Page 97: ... the forecarriage Fork fork oil fork oil seals for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART For the check proceed as follows With pulled front brake lever press the handlebar re peatedly thrusting the fork downwards The stroke must be gentle and there must be no trace of oil on the rods If the fork tends to bottom out carry out a adjusting see 2 29 2 ADJUSTING THE FRONT ...

Page 98: ...the vehicle while riding When the spring preload is increased it is necessary to increase also the hydraulic braking in order to avoid sudden jerks while riding ADJUSTMENT TABLE ò clockwise anticlockwise Front suspension Standard adjustment Adjustment for racetrack use Hydraulic adjustment with ex tended shock absorber screw 1 from completely closed open giving 1 5 turns from completely closed ope...

Page 99: ...ons require the assistance of another opera tor Fix the operating procedure before starting work The removal must be carried out with the greatest care Grip the forecarriage firmly and lift it slightly in the direc tion in which the sliders 4 are inserted on the two fas tening plates 3 6 Place one or more of the shims between the tyre and the support 1 depending on the desired variation Release th...

Page 100: ...TING THE REAR FORK Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Position the vehicle on the special centre stand see 1 8 4 POSITIONING THE VEHICLE ON THE CEN TRE SUPPORT STAND m Loosen the nut 1 completely NOTE Have the appropriate special tool m to hand aprilia part 8140203 complete tool kit for frame in cluding Use the special setscrew spanner to loosen the lock ring 2 completely Wo...

Page 101: ...ng conditions at low and high speed either with reduced load and full load However it is possible to adjust the setting according to how the vehicle is going to be used aCAUTION For the adjustment always start from the most rigid setting screw adjuster 1 and knob adjuster 2 com pletely rotated clockwise Do not rotate the screw adjuster 1 beyond its limit position to avoid damaging the thread Make ...

Page 102: ...ecting the operation of the shock absorb er neither remove the plug 7 nor adjust the under lying valve since this may cause nitrogen to flow out with consequent risk of accidents clockwise anticlockwise Rear suspension Standard adjustment Adjustment for race track use Possible adjustments Shock absorber distance between centers A 322 1 mm 322 1 mm from 320 to 327 mm Spring length preloaded B 130 m...

Page 103: ...hock absorber is adjust ed in such a way as to be suitable for racetrack riding However it is possible to adjust the setting according to how the vehicle is going to be used aCAUTION To calculate the number of clicks of the adjusters 1 2 always start from the most rigid setting complete clockwise rotation of the adjuster Do not force the rotation of the adjusters 1 2 be yond the end of stroke in b...

Page 104: ...en to loosen or remove the screw 7 since this may cause the outflow of ni trogen with the consequent risk of serious accidents clockwise anticlockwise Rear suspension Standard adjustment Adjustment for racetrack use Shock absorber distance between centers A 321 1 5 mm from 321 to 323 mm Spring length preloaded B 147 mm 145 mm Adjustment with extended shock absorber metal ring 1 from completely clo...

Page 105: ... slowly check if the rear sus pension is adjusted correctly see 2 31 2 ADJUSTING THE REAR SHOCK ABSORBER If after the adjustment the defect persists this means that the shock absorber bumps through and must therefore be reloaded 2 4 7 Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Wheel bearings for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART For the check procee...

Page 106: ...s the wheel spins check the relevant components see 7 2 2 CHECKING THE FRONT WHEEL COMPONENTS If after various spins the wheel continues to stop in the same place the wheel needs balancing 8 534 543 Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Nut bolt screw tightening for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART For the tightening aWARNING Let the engine co...

Page 107: ... ets and chain see 7 3 2 REMOVING THE FINAL DRIVE UNIT 2 36 1 CHECKING THE DRIVE CHAIN SLACK To check the slack proceed as follows Position the vehicle on the appropriate rear support stand see 1 8 2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m Position the gear lever in neutral Make sure that the vertical oscillation in an intermedi ate point between pinion and crown in the lower part of t...

Page 108: ...Check the chain slack see 2 36 1 CHECKING THE DRIVE CHAIN SLACK 2 36 4 DRIVE CHAIN TENSION AND LUBRICATION Drive chain tension and lubrication drive final trans mission chain crown pinion for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART Never wash the chain with water jets steam jets high pressure water jets and highly inflammable solvents Wash the chain with naphtha or kero...

Page 109: ...E CLUTCH CONTROL CYLINDER Unscrew and remove the three screws 1 Screws 1 driving torque 12 Nm 1 2 kgm NOTE Release the cable of the side stand switch from the clip Remove the pinion protection case 2 Remove the guide plate 3 Make sure the guide plate 3 is not worn or damaged if so replace with a new one 2 36 6 INSPECTING THE DRIVING CHAIN SHOE Position the vehicle on the stand Make sure the shoe 4...

Page 110: ...5 mm Some types of tyres homologated for this vehicle are provided with wear indicators There are several kinds of wear indicators For more information on how to check the wear con tact your Dealer Do not install tyres with air tube on rims for tubeless tyres and viceversa Make sure that the inflation valves 1 always have their sealing caps on to prevent the tyres from sud denly going flat Change ...

Page 111: ...ess and the tyre itself may slip on the rim or it may become loose with consequent loss of control of the vehicle In case of sudden braking the tyres could even come off the rims Further the vehicle could skid while turning aCAUTION After repairing a tyre have the wheels balanced If the tyres are new they may still be covered with a slippery film drive carefully for the first miles Do not oil the ...

Page 112: ...ted into the receptacle 4 For further information see section 4 FUEL SUPPLY SYSTEM 2 54 0 0 3 Carefully read 1 2 4 BRAKE FLUID and 1 2 6 CLUTCH FLUID Brakes and clutch pipes for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART If you should encounter signs of wear cracking etc replace the pipes 3934 0 0 3 Carefully read 1 2 5 COOLANT Cooling system pipes for the maintenance inte...

Page 113: ... it completely Move the stand to let it up and release it halfway to make sure that the springs provide for lifting it com pletely The side stand must rotate freely if necessary grease the joint see 1 6 LUBRICANT CHART aWARNING If the side stand has wrong rotation and inclination angles when the vehicle is parked the stability of the vehicle may be affected with the consequent risk of overturning ...

Page 114: ...ar brake disc rear brake caliper rear brake pipe fittings brake aCAUTION The fastening elements must be torqued to specifica tion and LOCTITE applied where indicated see 1 10 3 DRIVING TORQUES 6 6 3 Adjusting the valve clearance for the maintenance intervals see 2 1 1 REGULAR SERVICE INTERVALS CHART To adjust the valves refer to the engine service and re pair manual see 0 4 1 ENGINE SERVICE AND RE...

Page 115: ...NOTES SERVICE AND SETTING UP 2 66 RSV mille T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y Release 00 2002 10 00 ...

Page 116: ...3 1 RSV mille 1 3 ENGINE 3 Release 00 2002 10 00 ...

Page 117: ...9 GENERAL INDICATIONS ON MAINTENANCE AND REPAIR WORK 3 3 00 0 243 7 3 33 7 4 54 2 6 4 2 4 2 3 4 00 3 2 1 REMOVING THE EXHAUST PIPES 3 6 00 3 2 2 REMOVING THE GEAR LEVER 3 7 00 3 2 3 REMOVING THE CLUTCH CONTROL CYLINDER 3 8 00 2 6 4 7 2 4 2 3 10 00 3 3 1 POSITIONING THE ENGINE ON THE ENGINE SUPPORT STAND 3 19 00 3 33 4 3 19 00 2 44 4 7 4 2 3 20 00 3 35 3 15 4 4 2 33 9 3 21 00 3 6 1 BLEEDING THE ENG...

Page 118: ...AIR WORK aWARNING During the assembly phase bear in mind the engines weight approx 65 kg and centre of gravity support accordingly Take care around any potentially hazardous points where you might be squashed or cut aCAUTION The maintenance of engines and systems calls for specific experience and the use of special tools Any maintenance and repair work must be performed by suitably trained technic...

Page 119: ...essary to remove the component in question TOP SIDE Front cylinder tappet cover 1 see 0 4 1 ENGINE SERVICE AND REPAIR MANUALS Tappet cover 2 head cylinder and rear piston see 0 4 1 ENGINE SERVICE AND REPAIR MANUALS Front 3 and rear 4 cylinder intake flange Camshaft position sensor and camshafts see 0 4 1 ENGINE SERVICE AND REPAIR MANUALS Front and rear cylinder timing chain tightener see 0 4 1 ENG...

Page 120: ... THE CLUTCH CONTROL CYLINDER Flywheel cover 13 and ignition system see 0 4 1 ENGINE SERVICE AND REPAIR MANUALS Engine oil tank 14 see 7 1 51 REMOVING THE EN GINE OIL TANK Drive pinion 15 see 7 1 53 REMOVING THE DRIVE PINION å ü Driving shaft position sensor 22 see 0 4 1 ENGINE SERVICE AND REPAIR MANUALS RIGHT SIDE Front cylinder coolant thermistor 16 see 5 5 RE MOVING THE COOLANT THERMISTORS Front...

Page 121: ...d remove the three nuts 4 fastening the flange of the exhaust pipe 5 to the front cylinder Nuts 4 driving torque 25 Nm 2 5 kgm Loosen and remove the three nuts 6 fastening the flange of the exhaust pipe 7 to the rear cylinder Nuts 6 driving torque 25 Nm 2 5 kgm aCAUTION When slipping the exhaust pipes 5 7 off the rele vant cylinders take care not to damage the thread of the fastening stud bolts Mo...

Page 122: ...ON Check and where necessary replace the gaskets 8 9 with two new ones of the same type Plug the engines exhaust pipe openings so as to pre vent any foreign bodies entering 3 2 2 REMOVING THE GEAR LEVER Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS aCAUTION Before removing the gearshift lever mark its posi tion in order to be able to reassemble it correctly Position the vehicle on the ...

Page 123: ... screw 2 Clutch control cylinder screw 2 driving torque 20 Nm 2 0 Kgm Unscrew and remove the clutch control cylinder screw 2 complete with bleeder valve 1 and take the two sealing washers 3 aCAUTION Upon reassembly replace the two sealing washers with two new washers of the same type Put a nylon bag on the connection 4 and fix it to the clutch fluid pipe with adhesive tape Follow the procedure of ...

Page 124: ...advisable to secure the pin by locking it with a plastic clamp 10 except when it is necessary to bleed the clutch control system Where necessary remove the flange 11 Upon reassembly aCAUTION Correctly position the flange 11 Do not overturn it upon assembly NOTE When screwing the clutch control cylinder screws 6 take care to fit the flange 10 and the clutch control cylinder 6 in their seat Manually...

Page 125: ...ace before hand Dry weight of the engine 65 kg Turn the ignition switch to position 1 Position the vehicle on the appropriate rear support stand see 1 8 2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m Disconnect the negative cable and positive cable from the battery in that order aCAUTION When refitting first connect the positive cable and then the negative one Remove the fuel tank see 7 1 6...

Page 126: ...taking ex treme care as it remains connected to the electric ca ble by means of the brake light switch 12 Remove the rear brake pump 13 see 7 6 4 REMOV ING THE REAR BRAKE PUMP aCAUTION Move the rear brake pump 13 and secure it in place taking extreme care as it remains connected to the brake fluid pipes The brake fluid tank 14 must be held vertically to prevent the fluid spilling out Remove the cl...

Page 127: ...lean the outside of the engine thoroughly Remove the exhaust pipes see 3 2 1 REMOVING THE EXHAUST PIPES Disconnect the electric connector 20 from the elec trofan Disconnect the electric cables from the horn aCAUTION When refitting make sure the electric connectors are plugged in properly aCAUTION Mark the coupling and pipes so as to prevent them being swapped over by mistake during refitting Remov...

Page 128: ...allation pliers aCAUTION Upon installation replace the hose clamp that has been removed with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp or with other types of clamp Release the hose clamp 26 Remove the complete thermal expansion valve 28 see 5...

Page 129: ...special tool m to hand aprilia part 8140183 engine lifting eye hook 32 a hoist 33 and lifting straps 34 Fasten the special engine lifting hook 32 on and se cure it in place with the screws 30 aWARNING The hoist 33 and the bands 34 for the lifting opera tion must be suitable for safely bearing the weight of the engine The engine weight approx 65 kg Hook the bands 34 onto the hoist 33 and the hook 3...

Page 130: ...ENGINE 3 15 RSV mille Follow ã NOTE The elements fastening the engine to the frame must be removed in the order given RIGHT SIDE A B C D LEFT SIDE E F G H Follow ã Release 00 2002 10 00 ...

Page 131: ...ut 39 still loosen the screw 40 Nut 39 and screw 40 driving torque 50 Nm 5 0 kgm Unscrew and remove the two screws 43 and recover the relevant washers 44 Screws 43 driving torque 50 Nm 5 0 kgm Recover the two spacers 45 Unscrew and remove the two screws 46 and recover the washers 47 Screws 46 driving torque 50 Nm 5 0 kgm Follow ã Release 00 2002 10 00 ...

Page 132: ... screw the adjusting bushes 38 42 on by hand all the way until they touch the en gine before torquing them to specification Holding the inside nut 35 still loosen and remove the screw 36 Holding the inside nut 39 still loosen and remove the screw 40 Holding the inside nut 51 still loosen and remove the screw 52 Nut 51 and screw 52 driving torque 50 Nm 5 0 kgm Holding the inside nut 48 still loosen...

Page 133: ...ds 34 from the hoist Slide the bands 34 out from the frame Move the engine from under the frame Hook the bands 34 back up to the engine NOTE If the engine is to be worked on set it on the rel evant stand 54 see 3 3 1 POSITIONING THE ENGINE ON THE ENGINE SUPPORT STAND aCAUTION If no work is to be performed on the engine leave it rested on the floor and attached to the bands 34 and hoist for extra s...

Page 134: ...ay cause the en gine to fall down with consequent damage to per sons property and the engine itself Screw and tighten the three screws 3 Assemble the engine support stand 2 with the engine support 1 and insert the safety pin 4 in the appropri ate seat Clear and clean the area on which the stand engine as sembly will be positioned Using the hoist move the stand engine assembly to the desired area L...

Page 135: ...ING AND TOP PING UP COOLANT Top up the motor oil see 2 13 CHECKING THE EN GINE OIL LEVEL AND TOPPING UP If the engine has been overhauled bleed the engine oil circuit see 3 6 1 BLEEDING THE ENGINE OIL CIR CUIT and check the engine oil pressure 3 6 2 CHECKING THE ENGINE OIL PRESSURE Check the driving chain is taught and where neces sary adjust see 2 36 1 CHECKING THE DRIVE CHAIN SLACK and 2 36 3 AD...

Page 136: ...gine and let it idle for approx 10 minutes Check the oil level again and where necessary top up 3 6 2 CHECKING THE ENGINE OIL PRESSURE NOTE Have the appropriate special tool m to hand aprilia part 8140181 fuel oil pressure gauge com pression 4 Connect the oil pressure gauge 4 in place of the en gine oil pressure sensor 3 Engine oil pressure min 50 kPa 0 5 bar NOTE Check the oil pressure at a tempe...

Page 137: ...ENGINE 3 22 RSV mille NOTES T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y Release 00 2002 10 00 ...

Page 138: ...4 1 RSV mille 1 2 3 FUEL SUPPLY SYSTEM 4 Release 00 2002 10 00 ...

Page 139: ...8 DRIVING SHAFT POSITION SENSOR 4 13 00 4 7 9 INTAKE PRESSURE SENSOR 4 13 00 4 7 10 INTAKE PRESSURE SENSOR 4 13 00 4 7 11 THROTTLE VALVE POTENTIOMETER 4 13 00 4 7 12 COOLANT THERMISTORS 4 13 00 4 7 13 AIR THERMISTOR 4 13 00 4 7 14 IGNITION COILS 4 13 00 4 2 44 9 4 14 00 4 8 1 REMOVING THE INJECTORS 4 14 00 4 8 2 REMOVING THE THROTTLE BODY 4 14 00 4 8 3 DISASSEMBLING THE THROTTLE BODY 4 16 00 4 8 4...

Page 140: ...ake sure that the room in which you are working is properly ventilated Do not inhale fuel vapours Avoid any contact of the fuel with the skin Do not smoke and do not use naked flames Do not dispose of fuel in the environment Key NOTE ò The pipes 4 and 5 are not connected to the flange but directly to the fuel tank while the two cou plings on the flange are plugged 1 Fuel tank 2 Filler cap 3 Fuel s...

Page 141: ...very 7500 km 4687 mi or 8 months replace every 4 years aWARNING Check the delivery pipe 8 return pipe 9 and rele vant connections extremely carefully the operating pressure of the delivery pipe 8 is approx 450 kPa 4 5 bar Any fuel pipes featuring cracks or cuts must be replaced without exception Fuel leaking from the flange 10 might be due to a dam aged O ring 11 consequently Remove the whole fuel...

Page 142: ...clamp installation pliers aCAUTION Upon installation replace the hose clamp that has been removed with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp or with other types of clamp Lift the pump unit 2 just enough to be able to get at the hose clamp...

Page 143: ...e the whole fuel supply pump unit see 4 3 RE MOVING THE WHOLE FUEL SUPPLY PUMP UNIT NOTE Have the appropriate special tool m to hand aprilia part 0277295 hose clamp installation pliers aCAUTION Upon installation replace the hose clamp that has been removed with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unus...

Page 144: ... Release the hose clamp 1 Pull the fuel pipe 3 off the pump 2 Disconnect the electric connector 4 aCAUTION When reassembling make sure the electric connec tor 4 is plugged in properly Unscrew and remove the screws 5 aCAUTION When performing the operations below take care not to entangle the electric cables Bend the fuel filter 6 over sideways Pos A and keep it held down Lift the pump mount 7 just ...

Page 145: ...the message flashes on the dis play The safety devices inside the engine control unit stop ignition and the injection of the fuel when the speed exceeds the permissible peak rpm which is 10500 rpm or if the vehicle falls over When the vehicle is set on the side stand and a gear is engaged ignition is stopped preventing the vehicle from starting aCAUTION Any modifications or variations made to the ...

Page 146: ...st camshaft sprocket This signal makes it possible to detect the current en gine stroke Intake pressure sensor 13 Location in the intake manifold The pressure measured in the induction pipe is con verted into a voltage signal Moreover the injection time also depends on the induc tion pipe pressure especially when the throttle valve opening angle is limited during idling Throttle valve potentiomete...

Page 147: ... temperature Atmospheric pressure sensor Location inside the engine control unit 5 The intake pressure measured by the sensor is con verted into a voltage signal and is required by the en gine control unit to correct the injection time Air thermistor Location in the intake pipe of the left hand air convey or The resistance measured by the thermistor is convert ed into a voltage signal and is requi...

Page 148: ...regulator 9 Injectors 10 Throttle valve potentiometer 11 Camshaft position sensor 12 Coolant temperature thermistors 13 To multifunction display right hand side 14 Driving shaft position sensor and generator 15 Driving shaft position sensor and generator connector 16 HV ignition coil cylinder 1 front 17 HV ignition coil cylinder 2 rear 18 Spark plug cylinder 1 front 19 Spark plug cylinder 2 rear R...

Page 149: ... control lever switch STA Starter motor relay E 02 Earth IG 12 Front cylinder ignition coil IG 11 Front cylinder ignition coil 4 7 4 ENGINE CONTROL UNIT CONNECTORS For further information see 6 17 CONNECTIONS TO THE ENGINE CONTROL UNIT 16 pin connector 2 Terminal label ling Connections N Driving shaft position sensor G Camshaft position sensor VCC Intake pressure sensor and throttle valve potentio...

Page 150: ...ve component 4 7 7 CAMSHAFT POSITION SENSOR Fault code 11 See 6 4 6 CHECKING THE CAMSHAFT POSITION SENSOR 4 7 8 DRIVING SHAFT POSITION SENSOR Fault code 12 See 6 4 5 CHECKING THE PICK UP 4 7 9 INTAKE PRESSURE SENSOR Fault code 13 See 6 4 11 CHECKING THE INTAKE PRESSURE SEN SOR 4 7 10 INTAKE PRESSURE SENSOR Fault code 14 Check for pressure loss in the connection pipes 1 2 3 and make sure the flow i...

Page 151: ... replaced 4 8 1 REMOVING THE INJECTORS See 4 8 2 REMOVING THE THROTTLE BODY See 6 4 12 CHECKING THE INJECTORS for the checking procedure 4 8 2 REMOVING THE THROTTLE BODY Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Partially remove the fuel tank see 7 1 5 PARTIAL RE MOVAL OF THE FUEL TANK Remove the air filter casing see 7 1 7 REMOVING THE AIR CLEANER CASE Disconnect the electric conn...

Page 152: ...en reassembling make sure the cold start control cable adjuster is properly fastened to the respective coupling and check and where necessary restore the correct freeplay see 2 12 COLD START CABLE Loosen the two clamps 17 18 aCAUTION When removing the throttle body 11 be careful to make sure it remains connected to the fuel tank 20 by means of the fuel pipe 19 Grip the throttle body 11 firmly and ...

Page 153: ...ree T E M5x12 screws 3 Slip the whole support bracket 4 securing the throttle cables with the two bushes 5 and the torsion spring 6 off the throttle body Unscrew and remove the two M6x16 screws 7 and re move the fuel pressure regulator 8 complete with O ring Unscrew and remove the three M6x25 screws 9 and remove the left injector support 10 together with the relevant gasket 11 injector 12 and seal...

Page 154: ...ing ring 18 may be kept in serted in the slot on the throttle body Unscrew and remove the M8x1 nut 19 and remove the spring washer 20 the pulley 21 the two bushes 22 and torsion spring 23 Slide the fulcrum pin 24 together with the lock washer 25 out of the hole on the throttle cable support brack et and remove the two shaft sealing rings 26 with the torsion spring 27 and cold start lever 28 Releas...

Page 155: ... and pipes of the throttle body 1 using compressed air aCAUTION Once the intake pressure sensor 9 its installed not utilice the compressed air for the pipes cleaning danger for damages Check the pipes of the intake pressure sensor 2 watching out for any clogging Check the throttle valves unit and the cable fastening mechanism 3 watching out for any signs of mechani cal damage NOTE In the event the...

Page 156: ...tening them with the new M6x25 9 10 screws respectively Screws 9 10 driving torque 9 Nm 0 9 kgm If the synchronizing screws 11 and respective O rings 12 have been replaced screw on the screws 11 fair ly tight until they touch the stop and then unscrew them a single turn Presetting of synchronizing screws 11 1 turn aCAUTION The precise adjustment of the screws 11 must be performed using a vacuum ga...

Page 157: ...spring 20 are hooked onto the throttle cable support bracket and pulley 21 NOTE Spray a temporary lubricant on the spring 20 see 1 9 2 USE OF CONSUMABLES Fit the spring washer 22 NOTE Apply LOCTITE 243 on the thread of the nut 23 Screw the M8x1 nut 23 and tighten it Nut 23 driving torque 3 Nm 0 3 kgm NOTE Apply LOCTITE 243 on the thread of the screws 25 Fasten the anchoring bracket of the accelera...

Page 158: ...ilter casing see 7 1 7 REMOVING THE AIR CLEANER CASE Unscrew and remove the M8x1 nut 1 and remove the spring washer Slide out the control lever 2 and retrieve the two bush es 3 and torsion spring 4 Remove the control lever 2 from the tie rod of the ball joint 5 ASSEMBLY aCAUTION For the vehicles with the following engine numbers the throttle valve control lever 2 must be replaced with the new grey...

Page 159: ...dy and throttle valve con trol lever 2 Fit the spring washer NOTE Apply LOCTITE 243 on the thread of the nut 1 Screw the M8x1 nut 1 and tighten it Driving torque 1 3 Nm 0 3 kgm NOTE Once assembly is complete make sure the le vers rotate freely The throttle valve control lever 2 must be returned to its original position by the torsion spring Check for end play on the throttle valve control shaft se...

Page 160: ...s closed Use the thickness gauge 1 to measure the minimum play between the lever 2 and the contact surface 3 on the throttle body in a number of points End play min 0 1 mm aCAUTION If the minimum value measured is lower than 0 1 mm the throttle body must be replaced see 0 4 2 SPARE PARTS CATALOGUES With throttle valves open Repeat the above procedure End play min 0 15 mm aCAUTION If the minimum va...

Page 161: ...the adjusting screw 1 until it touches the stop onto the throttle valve control lever 5 and turn it an other 1 2 3 4 turn before tightening the M5x0 5 nut 2 Idling setting 1 2 3 4 turn SETTING THE COLD START DEVICE aCAUTION When the whole throttle cable support bracket must be replaced it is necessary to adjust the cold start control screw 6 again after setting the screw 1 of the throttle valve en...

Page 162: ...e adjusting screw 5 With the throttle valves in the closed position place the potentiometer in its housing 3 NOTE Apply LOCTITE 243 on the thread of the screws 2 Screw the screws 2 on by hand so that they hold the potentiometer 3 in place but do not prevent it from ro tating Connect the four way connector coloured black 1 Connect the two TEST terminals 6 with each other Turn the ignition switch to...

Page 163: ...E To obtain the synchronization of the cylinders adjust the above mentioned values repeatedly always following the given order NOTE The adjustment of one of the three values may cause the incorrect modification of the other two values therefore after any adjustment it is advisable to check all the three values The CO value takes priority over the vacuum value Check the engine number see 1 1 2 ENGI...

Page 164: ...n it so that the connector 10 is on the right hand side of the vehicle Fit the two screws 8 back in place with their respec tive washers and tighten them Torque settings of screws 8 19 Nm 1 9 kgm aCAUTION The throttle body 6 must be fitted perfectly on the intake flanges The clamps 4 5 must be properly tightened Fit the throttle body 6 again complete with air filter casing 7 to the two intake flan...

Page 165: ...the two front and rear exhaust pipe plugs 17 18 NOTE Upon reassembly apply aprilia part 8116043 ANTI SEIZE MOTAGEPASTE AS 1800 antiscuff paste on the threaded of the plugs 17 18 Connect the exhaust gas analysis probes 16 by pro ceeding as follows connect the two rigid pipes to the appropriate exhaust pipe outlets A and B connect the other pipe to the exhaust gas tester 15 Start the engine Check th...

Page 166: ...ront the screw 20 of the throttle body for cylinder 2 rear PROCEDURE FOR THE VEHICLES WHOSE FRAME BEARS THE ZD4RP CODE For the CO values in the cylinders adjust the screw 21 of the central unit for cylinder 1 front the screw 22 of the central unit for cylinder 2 rear For the vacuum values in the cylinders adjust the screw 21 of the central unit for cylinder 1 front the screw 22 of the central unit...

Page 167: ...NOTES FUEL SUPPLY SYSTEM 4 30 RSV mille T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y Release 00 2002 10 00 ...

Page 168: ...RSV mille 5 1 1 2 3 4 COOLING SYSTEM 5 Release 00 2002 10 00 ...

Page 169: ...IN THE RANGE 65 C 149 F TO 80 C 176 F 5 5 00 5 1 3 PATH WITH COOLANT TEMPERATURE OVER 80 C 176 F 5 6 00 2 6 4 2 4 23 5 7 00 2 6 4 42 3 5 8 00 2 6 4 4 4 2 37 4 5 9 00 2 6 4 4 4 2 34 23 5 9 00 2 6 4 4 2 80 3 6 6 5 10 00 5 6 1 CHECKING THE THERMAL EXPANSION VALVE 5 10 00 2 6 4 2 5 11 00 2 6 4 4 2 7 9 5 12 00 2 6 4 80 3 4 5 13 00 4 05 0 5 13 00 00 Release 00 2002 10 ...

Page 170: ...he coolant see 1 2 5 COOLANT Key 1 Front cylinder thermistor 2 Rear cylinder thermistor 3 Breather pipe 4 Coolant compensation pipes 5 Filler hose 6 Filler neck 7 Engine hose right side thermal expansion valve 8 Rear cylinder hose three way manifold 9 Front cylinder hose three way manifold 10 Thermal switch 11 Three way manifold 12 Three way manifold hose left radiator 13 Radiator link hose 14 Lef...

Page 171: ...BELOW 65 C 149 F From pump 1 A coolant inlet in engine 2 B temper ature taken by thermistors 3 4 and displayed on dash board right display C Coolant outlet from engine right side 5 D to thermal expansion valve 6 completely closed E and to pump 1 00 Release 00 2002 10 ...

Page 172: ...3 4 and displayed on dash board right display C Coolant outlet from the following at the same time engine right side 5 D to thermal expansion valve 6 partially open engine left side 7 8 E to three way manifold 9 F to left radiator 10 G to right radiator 11 H to thermal expansion valve 6 partially open From thermal expansion valve partially open I to pump 1 Release 00 2002 10 00 ...

Page 173: ...ld 9 E to left ra diator 10 F to right radiator 11 G to thermal expan sion valve 6 completely open H to pump 1 Temperature taken by the thermal switch 12 if the temperature exceeds 100 C 212 F it enables the operation of the electric fans 13 if the temperature lowers below 85 C 185 F it disa bles the operation of the electric fans 13 aCAUTION When the ignition switch is set to 1 the electrofans sw...

Page 174: ...se clamp with a screw clamp or with other types of clamp Release the hose clamp 7 Pull the pipe 8 off the radiator 4 Unscrew and remove the screw 9 retrieving the bush and the rubber element 10 if necessary NOTE If the rubber element 10 is damaged replace it aCAUTION Proceed with care Do not damage the radiator fins Tilt the radiator 4 slightly forwards and at the same time lift it sliding the two...

Page 175: ...crew and remove the two screws 2 Screws 2 driving torque 6 Nm 0 6 kgm Retrieve the two nuts 3 Tilt the whole electrofan 4 slightly forwards at the same time moving it outwards pulling the internal an chorage pin out of its slot on the radiator 5 Remove the electrofan 4 NOTE If the rubber element 6 is damaged replace it If necessary proceed as follows Unscrew and remove the three screws 7 and retri...

Page 176: ...HE THERMAL SWITCH OPERATION for further details on the thermal switch aCAUTION Plug the hole on the three way manifold so as to pre vent any foreign bodies from falling in 2 6 4 4 4 2 34 23 Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS and 1 2 5 COOLANT NOTE The following procedure refers to a single ther mistor though it is applicable to both Lift the fuel tank see 2 8 LIFTING THE FUE...

Page 177: ...on valve 3 and pull it free of the two couplings 6 7 one small step at a time aCAUTION Plug the coupling openings in such a way as to pre vent any foreign matters from getting in 5 6 1 CHECKING THE THERMAL EXPANSION VALVE Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS and 1 2 5 COOLANT Remove the thermal expansion valve see 5 6 RE MOVING THE THERMAL EXPANSION VALVE Check the heat sensit...

Page 178: ...HANG ING THE COOLANT NOTE Have the appropriate special tool m to hand aprilia part 0277295 hose clamp installation pliers aCAUTION Upon installation replace the hose clamp that has been removed with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp o...

Page 179: ...oved with a new one having the same di mensions see 0 4 2 SPARE PARTS CATALOGUES Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp or with other types of clamp Release the hose clamp 4 Release the hose clamp 5 Release the hose clamp 6 Pull the three pipes 7 8 9 off the manifold 10 Clamp driving torque 11 3 Nm 0 3 kgm Lo...

Page 180: ...ng screw 4 keeping the rear brake fluid tank 5 in place Move the rear brake fluid tank 5 and secure it in place with adhesive tape Unscrew and remove the two fastening screws 6 7 and retrieve the two bushes Remove the expansion tank 8 keeping it the right way up If the inner and outer foam edging is damaged replace it aWARNING The coolant is noxious Put the expansion tank 8 in a safe place KEEP AW...

Page 181: ...NOTES COOLING SYSTEM 5 14 RSV mille T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y Release 00 2002 10 00 ...

Page 182: ...RSV mille 6 1 1 2 3 4 5 ELECTRIC SYSTEM 6 Release 00 2002 10 00 ...

Page 183: ...IC 6 23 00 6 6 3 CHECKING THE STARTING RELAY 6 23 00 6 6 4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH 6 24 00 6 6 5 CHECKING THE DIODE MODULE 6 24 00 37 4 3 6 25 00 6 7 1 SWITCH SET ON RIGHT HANDLEBAR 6 25 00 6 7 2 SWITCH SET ON LEFT HANDLEBAR 6 26 00 6 7 3 SINGLE SWITCHES 6 27 00 4 3934 6 28 00 6 8 1 WIRING DIAGRAM 6 28 00 6 8 2 CHECKING THE LIGHTS RELAY 6 29 00 6 8 3 CHECKING THE LIGHTS LAP D...

Page 184: ...ings if provided aCAUTION Do not pull the cables to disconnect the two connec tors Grasp the two connectors and disconnect them by pull ing in opposite directions If dirt rust dampness etc can be noticed carefully clean the inside of the connector by means of a pressu rized air jet Make sure that the cables are correctly crimped to the terminals positioned inside the connectors NOTE The two connec...

Page 185: ...6 4 ELECTRIC SYSTEM RSV mille 42 0 43 9 54 00 Release 00 2002 10 ...

Page 186: ...er coil 2 25 Front cylinder coil 1 26 Front cylinder coil 2 27 Spark plugs 29 Secondary fuses 15 A 30 Ignition switch 31 Low beam relay 32 High beam relay 33 Cooling fan relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left direction indicat...

Page 187: ...TAGE REGULATOR Wiring diagram key NOTE See 6 2 ELECTRIC COMPONENTS LAYOUT for the positioning of the components 18 Battery 19 Main fuse 30A 20 Generator 22 Voltage regulator 30 Ignition switch 2 1 Standard charging voltage 13 15 V d c at 4000 rpm 6 3 2 CHECKING THE ALTERNATOR LOADLESS OPERATION Remove the rear fairing see 7 1 36 REMOVING THE REAR FAIRING REAR END Disconnect the three way connector...

Page 188: ...THE REAR FAIRING REAR END Disconnect the three way connector 1 coloured brown Disconnect the six way connector 2 coloured white aCAUTION When reassembling make sure the electric connec tors 1 2 are plugged in properly Using a pocket tester scale x 1MΩ measure the re sistance between the cables indicated in the table be low from the regulator side internal female terminals NOTE The green V and whit...

Page 189: ...e valve potentiometer 4 Intake pressure sensor 5 Coolant thermistor 6 Air thermistor 7 Fall sensor 9 Clutch control lever switch 10 Neutral gear switch 15 Fuel pump relay 18 Battery 21 Driving shaft position sensor 23 Rear cylinder coil 1 24 Rear cylinder coil 2 25 Front cylinder coil 1 26 Front cylinder coil 2 30 Ignition switch 44 Front cylinder injector 45 Rear cylinder injector 52 Fuel pump 68...

Page 190: ...t side panel see 7 1 3 REMOVING THE SIDE COVERS Connect the two TEST terminals 1 with each other Turn the ignition switch to position 2 Start the engine or attempt to start it The message DIAG comes up on the left display along with a number corresponding to the reference code relat ing to the fault see table the fault detected may be caused by breaks in the cables and or connections not made prop...

Page 191: ...ngine shut off Connector sensor cable and sensor Yes Coolant thermistor 21 Yes cold starting difficult Air thermistor 22 Yes Yes there is no altimetric compensa tion Atmospheric pressure sensor ECU inside 23 Sensor faulty Cannot be checked replace the ECU Ignition coil 1 of front cylinder 33 Ignition coil faulty or wiring not connected Engine running Connector ignition cable Yes power loss Yes pow...

Page 192: ...CHECKING THE INTAKE PRESSURE SENSOR 6 4 10 CHECKING THE THROTTLE VALVE PO TENTIOMETER 6 4 8 CHECKING THE COOLANT THERMISTOR OPERATION If the engine does not start and the diagnostics fail to de tect any fault check in the given order whether the fuel pump is working properly see 6 5 2 CHECK ING THE FUEL PUMP the injectors are working properly see 6 4 12 CHECK ING THE INJECTORS the connector for th...

Page 193: ...ct operation of the coil by replacing it with another one in perfect condition Repeat the procedure for the other coils NOTE Sometimes the coils when they are cold do not give the values indicated above but they start functioning correctly when the vehicle reaches its normal running temperature If the vehicle functions correctly when cold but succes sively when it reaches the normal running temper...

Page 194: ...er saddle see 7 1 1 REMOVING THE RIDER SADDLE Check whether the sensor 2 is fitted correctly with the arrow inscribed on the rubber element pointing up Disconnect the two way connector 3 coloured white grey and take the measurements on the sensor side terminals aCAUTION Upon reassembly make sure that the electric con nector 3 is correctly coupled Using a pocket tester scale x 100 kΩ measure the re...

Page 195: ...thermistor 1 in a container 3 holding coolant Immerse a thermometer 4 with a 0 150 C 32 302 F range in the same container Place the container on a burner 5 and slowly warm up the liquid Check the temperature indicated on the thermometer 4 and the thermistor 1 value indicated by the tester Make sure that the value varies according to the temper ature as indicated If values do not vary or if they de...

Page 196: ...erse the thermistor in a container 4 holding water Immerse a thermometer 5 with a 0 150 C 32 302 F range in the same container Place the container on a burner 6 and slowly warm up the liquid Check the temperature indicated on the thermometer 5 and the thermistor value indicated by the tester Make sure that the value varies according to the temper ature as indicated If values do not vary or if they...

Page 197: ...ely open the resistance should vary as follows standard value with throttle valves closed 0 34 5 69 kΩ with throttle valves open 2 87 8 41 kΩ aCAUTION The two M4x12 screws 3 fastening the throttle valve potentiometer are painted and can only be removed in the event the actual sensor is replaced NOTE In order to make it easier to unscrew the screws 3 secured using LOCTITE 243 heat them first with a...

Page 198: ...ly voltage be tween the external terminals of the connector 1 measure A Standard value 4 5 5 5 V Turn the ignition switch to position 1 Using a pocket tester scale kΩ measure the resist ance between the terminals of the sensor 2 NOTE Measurements B C and D must be taken individually not at the same time Measurements B C and D must produce the follow ing values Standard values measurement B 12 kΩ 1...

Page 199: ...icable to both Disconnect the two way connector 1 coloured grey and take the measurements on the injector side termi nals Using a pocket tester scale 100 Ω measure the re sistance between the terminals of the injector Standard value 11 17 Ω to 20 C 68 F If the resistance is infinite or lower than the pre scribed level the injector 2 must be changed Repeat the procedure for the other injector Relea...

Page 200: ...f the components Wiring diagram key 11 Arrangement for the installation of the anti theft device 12 Engine stop switch 14 Engine stop relay 15 Fuel pump relay 29 Secondary fuses 15 A 52 Fuel pump A To the battery ignition switch B To the HV coil C To the injectors electronic unit D To the electronic unit Release 00 2002 10 00 ...

Page 201: ...two gaskets 4 and 5 and tighten the perforated screw 5 applying the pre scribed torque in order to ensure perfect seal This is essential since the injection pressure is approx 450 kPa 4 5 bar and any fuel leakage would prove ex tremely dangerous in fact the leaking fuel might end up on high temperature parts of the engine NOTE Have the appropriate special tools m to hand aprilia part 8140197 perfo...

Page 202: ... con nector 1 is correctly coupled Power the two internal male terminals 1 2 at 12 V Using a tester acting as ohmmeter check for breaks between the other two terminals 3 5 Correct value with relay powered 0 Ω Correct value with relay not powered Ω If the resulting values do not correspond to those in dicated change the relay 2 6 5 4 CHECKING THE ENGINE SHUTOFF RELAY The procedure is exactly the sa...

Page 203: ...ng diagram key 8 Diode module 9 Clutch control lever switch 10 Neutral gear switch 12 Start push button 16 Start relay 17 Starter 18 Battery 29 Secondary fuses 15 A 58 Side stand down warning light 59 Neutral warning light 70 Stand switch A To the battery ignition switch B To the secondary fuses 15 A C To the electronic unit Release 00 2002 10 00 ...

Page 204: ...bber protections 3 4 Disconnect the cables 5 6 from the relevant termi nals on the relay 2 From the relay side power the two internal terminals of connector 1 at 12V Using a tester acting as ohmmeter check the for breaks between the two screw contacts on the relay 2 Correct value with relay powered 0 Ω Correct value with relay not powered Ω If the resulting values do not correspond to those in dic...

Page 205: ...ever down wards Lower the side stand 1 thus operating the safety switch 2 At this point the engine must stop the side stand down warning light Æ must come on Should this fail to happen replace the switch 3 6 6 5 CHECKING THE DIODE MODULE Remove the passenger seat see 7 1 2 UNLOCKING LOCKING THE PASSENGER SEAT Disconnect the five way connector 4 coloured white from the module 5 aCAUTION Upon reasse...

Page 206: ...ity of the switches refer ring to the specific diagram below Should any anomalies be encountered change the corre sponding switch set 6 7 1 SWITCH SET ON RIGHT HANDLEBAR 1 Engine stop switch 2 Start push button Pos Cables Ar Gr V R G R V R 2 RUN OFF Release 00 2002 10 00 ...

Page 207: ...h button 2 Direction indicator switch 3 Dimmer switch 4 High beam signaller push button LAP push button multifunction 5 Light switch not provided for e e Pos Cables Gr V G N Bi Bi B R Az B N 7 LAP 8 7 5 4 Pos Cables Gr V G N Bi Bi B R Az B N 7 LAP 8 7 5 4 Release 00 2002 10 00 ...

Page 208: ...tch 3 Rear brake stoplight switch 4 Neutral gear switch 5 Stand switch 6 Clutch lever switch Pos Cables R V Gr V Bi R 2 1 Pos Cables R V Gr V Bi R 2 1 Pos Cables Gr M Operating Pos Cables G G Operating Pos Cables Screw Neutral Stand Cables M V N Down Up Pos Cables Gr M Operating Release 00 2002 10 00 ...

Page 209: ... Left dimmer switch 29 Secondary fuses 15 A 31 Low beam relay 32 High beam relay 34 Front parking light bulb 35 High beam bulbs 36 Low beam bulb 41 Rear light 63 Dashboard bulbs 67 Dimmer switch diode LAP multifunction 69 Headlight 72 Rear parking light stoplight bulbs A To the battery ignition switch B To the right display chronometer Release 00 2002 10 00 ...

Page 210: ...KING THE LIGHTS LAP DIODE multifunction To check operation of diode Disconnect the three way connector 3 coloured white under the rubber protection cap to the left of the handlebar aCAUTION Upon reassembly make sure that the electric con nector 3 is correctly coupled Using a tester in diode test mode check the values between the two male terminals in the diode as illus trated in the figure Correct...

Page 211: ...RING DIAGRAM NOTE See 6 2 ELECTRIC COMPONENTS LAYOUT for the positioning of the components Wiring diagram key 29 Secondary fuses 15 A 33 Electric fan relay 39 Thermal switch 40 Cooling fans A To the battery ignition switch Release 00 2002 10 00 ...

Page 212: ...l switch 4 and connect them together Turn the ignition switch to position aCAUTION Upon reassembly make sure that the electric termi nals 2 3 are properly connected If the electrofan does not work Turn the ignition switch to position 1 Make sure the connector 5 is correctly inserted Rotate the fan manually making sure the blades do not touch the mount Check the recharging system see 6 3 CHECKING T...

Page 213: ...nt Immerse a thermometer 4 with a 0 150 C 32 302 F range in the same container Place the container on a burner 5 and slowly warm up the liquid Check that the temperature reading on the thermome ter 4 and the value indicated by the tester 2 corre spond to the data in the table If the values depart excessively from those indicated in the table change the thermal switch 1 6 9 4 CHECKING THE ELECTROFA...

Page 214: ...ndary fuses D 15 A 53 Low fuel sensor 54 Engine oil pressure switch 55 Coolant temperature thermistor 56 Speed sensor 57 Low fuel warning light 61 Engine oil pressure warning light LED 64 Revolution counter 65 Multifunction display right side coolant temperature 66 Multifunction display left side A To the ignition switch B To the electronic unit Release 00 2002 10 00 ...

Page 215: ...system side With the ignition switch 2 set to 2 the low fuel warning light should come on after a second If the light does not come on as expected make sure the sensor 3 is working properly Fill the tank with petrol With the sensor 3 fully submersed by petrol the light remains unlit Drain the fuel tank completely see 4 2 DRAINING THE FUEL TANK With the sensor 3 fully submersed by petrol the light ...

Page 216: ...gine see 6 4 8 CHECKING THE COOLANT THERMISTOR OPERA TION 6 10 4 ENGINE OIL PRESSURE SENSOR Remove the lower fairing see 7 1 34 REMOVING THE LOWER FAIRING Slip off the rubber protection 3 Disconnect the electric terminal 4 from the sensor 5 and earth it aCAUTION When reassembling make sure the electric terminal 4 is connected properly With the ignition switch set to 2 the red low engine oil pressu...

Page 217: ... sensor connector 1 use a tester to measure the voltage between the grey white Gr Bi and blue orange B Ar cables Correct value 6 V c c Test 3rd Position the vehicle on the appropriate rear support stand see 1 8 2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m Position the gear lever in neutral Perform test 2nd Spin the rear wheel by hand until one of the five screws 4 is in line with the sens...

Page 218: ...ack the rider saddle see 7 1 1 REMOVING THE RIDER SADDLE Remove the upper protection element 3 NOTE Without disconnecting the dashboard connector 1 and the 26 way connector 2 of the electronic unit Working on the dashboard connector 1 and on the 26 way connector 2 of the electronic unit measure the continuity of the grey violet Gr Vi cable measure B with an ohmmeter tester If the result is positiv...

Page 219: ...k large amounts of water or milk then continue drinking milk of magnesia or vegetable oil and promptly call a doc tor The battery gives off explosive gases keep it away from flames sparks cigarettes and any other source of heat During the recharging or the use make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging KEEP AWAY FROM CHILDREN The batt...

Page 220: ...oved Connect the battery to a battery charger Subject the battery to a normal charge cycle see 2 4 2 RECHARGING THE BATTERY Refit the battery on the vehicle on being returned to the customer 6 11 2 BATTERY MAINTENANCE If the vehicle remains unused for more than fifteen days the battery must be recharged to prevent sulpha tion recharge the battery using a normal charge see 2 4 2 RECHARGING THE BATT...

Page 221: ...FUSES 6 12 1 CHANGING THE HEADLIGHT BULBS Position the vehicle on the stand NOTE Before changing a bulb check the fuses see 6 15 CHANGING THE FUSES The headlight contains two high beam bulbs 1 side one parking light bulb 2 upper one low beam bulb 3 lower ò The high beam and the low beam bulbs are equal to each other NOTE The removal of the front part of the fairing is nec essary when the parking l...

Page 222: ... that you position them correctly upon reassembly Remove the front part of the fairing see 7 1 22 RE MOVING THE FRONT PART OF THE FAIRING Move the protection element 5 of the bulb to be changed with your hands aCAUTION To extract the bulb electric connector do not pull its wires Grasp the bulb electric connector 9 pull it and discon nect it from the bulb Release the two ends of the check spring 7 ...

Page 223: ...ectors at the same time mark them and make sure that you position them correctly upon reassembly Remove the front part of the fairing see 7 1 22 RE MOVING THE FRONT PART OF THE FAIRING Move the protection element 10 with your hands aCAUTION To extract the bulb electric connector do not pull its wires Grasp the bulb electric connector 11 pull it and dis connect it from the bulb Release the two ends...

Page 224: ...et 4 goes out of its seat insert it correctly making the bulb socket opening coincide with the screw seat 6 12 3 CHANGING THE REAR LIGHT BULB NOTE The rear light houses two parking light stoplight bulbs 5 The following operations refer to a single bulb but are valid for both Position the vehicle on the stand NOTE Before changing a bulb check the fuses see 6 15 CHANGING THE FUSES and the efficiency...

Page 225: ...N If the defect persists even after the bulb light has been changed check the relevant sensor switch see 6 6 4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH 6 10 2 LOW FUEL WARNING LIGHT 6 10 4 ENGINE OIL PRESSURE SENSOR NOTE The two LEDs 11 and 12 cannot be removed Pos Description 3 Bulbs for right hand display lighting 4 Bulbs for left hand display lighting 5 Bulbs for rev counter lighting Pos W...

Page 226: ...ss tip screwdriver By SCREWING IT clockwise you set the beam up wards By UNSCREWING IT anticlockwise you set the beam downwards After the adjustment aWARNING Make sure that the vertical adjustment of the head light beam is correct 534 4 2 4 4 u NOTE To check the direction of the headlight beam specific procedures must be adopted in accordance with the regulations in force in the country where the ...

Page 227: ...e fuse try to find out the cause of the trouble if possible Replace the damaged fuse with a new one having the same amperage NOTE If you use one of the spare fuses put a new fuse in the proper seat Put back the rider saddle see 7 1 1 REMOVING THE RIDER SADDLE Carry out the operations previously described for the secondary fuses also for the main fuses NOTE The removal of the 30 A fuses requires th...

Page 228: ...witch on the front brake control lever 2 Safety switch on the side stand 3 Switch on the clutch control lever 4 Make sure that there are no dirt or mud deposits on the switch the pin must be able to move without interfer ences returning automatically to its initial position Make sure that the cables are connected correctly Check the spring 5 it must not be damaged worn or weakened Release 00 2002 ...

Page 229: ...the components For further information see 4 7 4 ENGINE CONTROL UNIT CONNECTORS NOTE The initials y and z appearing in the diagram next to the relevant numbers mark the respective termi nals on both connectors y Electronic unit connector 26 way z Electronic unit connector 16 way Follow ã Release 00 2002 10 00 ...

Page 230: ...itch y 20 M V y 21 M Vi 10 Neutral gear switch M 11 Start relay y 22 G R 15 Fuel pump relay y 16 Ar G 21 Driving shaft position sensor z 9 150 300 Ω Bi G z 1 B G Earth y 2 10 11 23 B V z 7 16 23 Rear cylinder coil y 1 4 5 Ω V Gr y 12 Az G 24 Rear cylinder coil y 1 4 5 Ω V Gr y 13 Ro G 25 Front cylinder coil y 1 4 5 Ω V Gr y 25 Ro G 26 Front cylinder coil y 1 4 5 Ω V Gr y 26 Ar Bi 44 Front cylinder...

Page 231: ...6 50 ELECTRIC SYSTEM RSV mille 7 2 2 236 MILLE Release 00 2002 10 00 ...

Page 232: ... beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left direction indicator 44 Front cylinder injector 45 Rear cylinder injector 46 Front stoplight switch 47 Rear stoplight switch 48 Rear right direction indicator 49 Horn 50 Multiple connectors 51 Blinking 52 Fuel pump 53 Low fuel se...

Page 233: ...6 52 ELECTRIC SYSTEM RSV mille 7 2 2 236 MILLE e Release 00 2002 10 00 ...

Page 234: ...h beam bulbs 36 Low beam bulb 37 Front right direction indicator 38 Front left direction indicator 39 Thermal switch 40 Cooling fans 41 Rear light 42 Dashboard 43 Rear left direction indicator 44 Front cylinder injector 45 Rear cylinder injector 46 Front stoplight switch 47 Rear stoplight switch 48 Rear right direction indicator 49 Horn 50 Multiple connectors 51 Blinking 52 Fuel pump 53 Low fuel s...

Page 235: ...ELECTRIC SYSTEM 6 54 RSV mille NOTES T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y Release 00 2002 10 00 ...

Page 236: ...RSV mille 7 1 1 2 3 4 5 6 CHASSIS 7 Release 00 2002 10 00 ...

Page 237: ... 7 2 7 FRONT TYRE 7 48 00 7 2 8 FRONT BRAKE DISCS 7 48 00 7 2 9 DISASSEMBLING THE FRONT WHEEL BEARINGS 7 49 00 7 2 10 ASSEMBLING THE FRONT WHEEL BEARINGS 7 50 00 7 2 11 INSTALLING THE FRONT WHEEL 7 51 00 2 2 7 7 52 00 7 3 1 REMOVING THE REAR WHEEL 7 53 00 7 3 2 REMOVING THE FINAL DRIVE UNIT 7 54 00 7 3 3 CHECKING THE REAR WHEEL COMPONENTS 7 55 00 7 3 4 REAR WHEEL BEARINGS 7 55 00 7 3 5 REAR WHEEL ...

Page 238: ...n left handlebar 12 Left handgrip 13 Left fairing upper panel 14 Fuel tank 15 Left side cover 16 Rear mudguard 17 Passenger left footrest 18 Passenger seat 19 Rear light 20 Saddle support lower moulded cover 21 Rear fork 22 Drive chain 23 Sprocket 24 Rider left footrest 25 Side stand 26 Shock absorber 27 Left fairing 28 Engine oil tank 29 Front fairing lower lockup 30 Radiator spoiler 31 Front bra...

Page 239: ...panel 45 Air filter casing 46 Right handgrip throttle grip 47 Controls on the right part of the handlebar 48 Right rear view mirror 49 Dashboard s upper protection moulding 50 Right air conveyor 51 Right air conveyor cover 52 Front mudguard 53 Right front brake disc 54 Right front brake caliper 55 Engine oil radiator 56 Lower fairing 57 Right fairing 58 Rear brake control lever 59 Rider right foot...

Page 240: ...ise lift and withdraw the seat 6 from behind NOTE Before lowering and locking the seat 6 make sure that you have not left the key in the glove tool kit compartment To lock the seat 6 proceed as follows Introduce its front part under the passenger grab strap 7 Position the seat and press it making the lock snap NOTE Upon request it is possible to supply the glove tool kit compartment cover m to be ...

Page 241: ...ious for your health Before proceeding make sure that the room in which you are working is properly ventilated Do not inhale fuel vapours Do not smoke and do not use naked flames Do not dispose of fuel in the environment FIRE AND OR EXPLOSION HAZARD Position the vehicle on the stand Unscrew and remove the three screws 3 Screws 3 driving torque 5 Nm 0 5 kgm NOTE The other three screws can be left o...

Page 242: ...retrieve the two bushing and should the rubber elements prove damaged replace them Screws 4 driving torque 12 Nm 1 2 kgm aCAUTION Place a cloth under the male quick release coupling 6 to catch any fuel spills Disconnect the male quick release coupling 6 from the receptacle 7 by pressing the relevant button 8 aCAUTION When reassembling make sure the male quick re lease coupling 6 is fitted into the...

Page 243: ...he system to depres surize Unscrew and remove the perforated screw 1 and take the two gaskets 2 Perforated screw 1 driving torque 22 Nm 2 2 kgm aWARNING Upon reassembly change the two gaskets 2 and tighten the perforated screw 1 applying the pre scribed torque in order to ensure perfect seal This is essential since the injection pressure is approx 450 kPa 4 5 bar and any fuel leakage would prove e...

Page 244: ... proceed with the greatest care lifting it with slight move ments Raise and remove the air cleaner case 4 aCAUTION Plug the openings with a clean cloth to prevent any foreign matters from getting into the suction ducts Upon reassembly Make sure that the O ring is correctly positioned on the throttle body The two conveyors 5 must be positioned correct ly and adhere perfectly to the spongy material ...

Page 245: ...battery NOTE If the inner foam edging appears damaged re place it Grasp the battery 8 firmly and remove it from its com partment by lifting it aCAUTION Upon reassembly connect first the positive cable and then the negative cable aWARNING Once it has been removed the battery must be stored in a safe place and kept away from children Position the battery on a flat surface in a cool and dry place 7 1...

Page 246: ...ivibration weight 1 Slide out the pin 3 Slide off the O ring 4 Slide off the end piece 5 End piece 5 driving torque 35 Nm 3 5 kgm Slide out the pin 6 an recover the rubber bush 7 7 1 11 REMOVING THE COLD START CONTROL Remove the grip from the left handlebar see 7 1 12 REMOVING THE GRIPS Remove the electric controls see 7 1 14 REMOVING THE ELECTRIC CONTROLS ON THE LEFT HANDLE BAR Unscrew and remove...

Page 247: ...hen supplied as a spare part the accelerator control grip 2 comes with the accelerator control pipe 3 and therefore it must be removed together with the latter For the removal see 7 1 15 REMOVING THE THROTTLE GRIP ONLY FOR THE LEFT HANDLEBAR GRIP 1 Remove the antivibration weight unit from the left part of the handlebar see 7 1 10 REMOVING THE ANTIV IBRATION WEIGHT Insert the nozzle of a compresse...

Page 248: ...er Unscrew and remove the tank support screw 5 Driving torque of the tank support screw 5 10 Nm 1 0 kgm NOTE Before removing the U bolt 6 mark its position on the handlebar so it can be refitted in the right place Unscrew and remove the two U bolt screws 7 U bolt screws driving torque 7 8 Nm 0 8 kgm Remove the U bolt 6 NOTE When refitting the U bolt 6 must be positioned with the arrow inscribed on...

Page 249: ...h to position 1 Unscrew and remove the two screws 12 fastening the two halves of the casing 13 14 at the bottom Split the two halves of the casing 13 14 apart aCAUTION When reassembling first set the lower half of the casing 13 in place making sure the special locating dowel enters the relevant hole on the handlebar Free the cabling from the three clamps 15 16 17 NOTE Prepare the same number of cl...

Page 250: ...ned to the corre sponding couplings check and if necessary restore the correct slack see 2 11 3 ADJUSTING THE AC CELERATOR CONTROL Move the half casing of the throttle control 5 and dis connect the two throttle cables Slide off the throttle grip 6 7 1 16 REMOVING THE FRONT BRAKE LEVER Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Position the vehicle on the stand Turn the ignition swit...

Page 251: ...eservoir 15 PARTIAL REMOVAL Unscrew and remove the tank support screw 11 Driving torque of the tank support screw 11 10 Nm 1 0 kgm NOTE Before removing the U bolt 12 mark its posi tion on the handlebar so it can be refitted in the right place Unscrew and remove the two U bolt screws 13 U bolt screws driving torque 13 3 Nm 0 3 kgm Remove the U bolt 12 NOTE When refitting the U bolt 12 must be posi ...

Page 252: ...n element 1 has been refitted in the right position Free the cabling from the three clamps 3 4 5 NOTE Prepare the same number of clamps which will be required for reassembly Unscrew and remove the two screws 6 7 fastening the two halves of the casing 8 9 at the bottom NOTE When reassembling the shorter of the two screws 6 must be positioned at the front Split the two halves of the casing 8 9 apart...

Page 253: ...mbly Lift the protection element 3 Disconnect the electric connector 4 aCAUTION When reassembling make sure the connector is plugged in properly Unscrew and remove the screw 5 and take the bush ing NOTE When reassembling position the cable guide 6 correctly Use a chisel to cut into the head of the special screw 7 and turn it until it loosens Unscrew the screw 7 by hand and remove it NOTE When reas...

Page 254: ... withdrawal of the fork upper plate For this reason it is necessary to release them from the respective fastenings to the handlebar Screw 7 driving torque 10 Nm 1 0 kgm Unscrew and remove the screw 7 fastening the clutch fluid tank Screw 6 driving torque 10 Nm 1 0 kgm Unscrew and remove the screw 6 fastening the front brakefluid tank 5 NOTE Loosen ONLY the screw 8 that fastens the up per plate 3 D...

Page 255: ...the cold start control see 7 1 11 REMOV ING THE COLD START CONTROL Right handlebar Remove the front brake lever see 7 1 16 REMOVING THE FRONT BRAKE LEVER Remove the throttle grip see 7 1 15 REMOVING THE THROTTLE GRIP Remove the electric controls on the right handlebar see 7 1 17 REMOVING THE ELECTRIC CONTROLS ON THE RIGHT HANDLEBAR The following information refers to one of the two halves of the h...

Page 256: ...reassembly tighten the screw 8 applying the prescribed torque since it is fixed on plastic Unscrew and remove the two upper screws 9 Screws 9 driving torque 5 Nm 0 5 kgm NOTE Upon reassembly rotate the rear view mirror support so that the fastening holes coincide with those provided on the front part of the fairing The whole unit must be correctly positioned on the sup port Move the front part of ...

Page 257: ...part of the fairing see 7 1 22 RE MOVING THE FRONT PART OF THE FAIRING Unscrew and remove the two fastening screws 3 Screws 3 driving torque 2 Nm 0 2 kgm Remove the protection moulding 4 sliding it out from the back 7 1 25 REMOVING THE DASHBOARD Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Remove the front part of the fairing see 7 1 22 RE MOVING THE FRONT PART OF THE FAIRING Slip off...

Page 258: ...m Move the relay box 6 over to the side Open the collar 7 and release the clutch fluid pipe and the cold start cable aCAUTION When reassembling refit the pipe and cable inside the collar 7 Release the wiring from the two special clamps 8 Release the wiring from the clamps 9 and 10 NOTE Prepare the same number of clamps which will be required for reassembly Unscrew and remove the two nuts 11 Nuts 1...

Page 259: ...screw and remove the screw 3 Screw 3 driving torque 1 Nm 0 1 kgm Unscrew and remove the screw 4 Screw 4 driving torque 2 Nm 0 2 kgm aCAUTION Handle the plastic and painted components with care to avoid scraping or damaging them Lift and remove the panel 5 NOTE Where necessary repeat the procedure to re move the other panel 7 1 30 REMOVING THE FRONT DIRECTION INDICATORS Carefully read 0 5 1 PRECAUT...

Page 260: ...ic cables and the electric con nector 3 Partially remove the air conveyor cover see 2 Disconnect the front indicator electric connector 3 aCAUTION When reassembling make sure the electric connec tor 3 is plugged in properly and that the cable is re fitted in the appropriate seat Remove the air conveyor cover 2 complete with front direction indicator 4 Where necessary remove the front indicator 4 s...

Page 261: ...ON Upon reassembly tighten the screw 3 applying the prescribed torque since it is fixed on plastic Unscrew and remove the lower fastening screw 4 Screw 4 driving torque 4 Nm 0 4 kgm Unscrew and remove the front fastening screw 5 Screw 5 driving torque 5 Nm 0 5 kgm Unscrew and remove the two rear fastening screws 6 Screws 6 driving torque 5 Nm 0 5 kgm Partially remove the air conveyor case 7 Open t...

Page 262: ...driving torque 5 Nm 0 5 kgm aCAUTION Handle the plastic and painted components with care to avoid scraping or damaging them Let the side stand down Withdraw the two pipes 5 6 from the hole provided on the fairing Remove the entire lower fairing 7 by lowering it and with small movements try to find the best position to withdraw it from the side stand NOTE Upon reassembly introduce the two pipes 5 6...

Page 263: ... 0 4 kgm Unscrew and remove the two screws 2 fastening the front of the lower fairing 3 Screws 2 driving torque 5 Nm 0 5 kgm Remove the the lower fairing see 7 1 34 REMOVING THE LOWER FAIRING Unscrew and remove the lower fastening screw 4 Screw 4 driving torque 4 Nm 0 4 kgm aCAUTION Handle the plastic and painted components with care to avoid scraping or damaging them Move the radiator spoiler 5 f...

Page 264: ... screws 2 Screws 2 driving torque 5 Nm 0 5 kgm Unscrew and remove the two lower fastening screws 3 Screws 3 driving torque 3 Nm 0 3 kgm aCAUTION Handle the plastic and painted components with care to avoid scraping or damaging them Remove the end of the rear part of the fairing 4 com plete with rear light 5 7 1 37 REMOVING THE REAR LIGHT Remove the rear fairing rear end 4 see 7 1 36 RE MOVING THE ...

Page 265: ... FAIRING REAR END Unscrew and remove the passenger grab strap fas tening screw 1 Screw 1 driving torque 10 Nm 1 0 kgm Retrieve the grab strap 2 Unscrew and remove the two front fastening screws 3 Screws 3 driving torque 2 Nm 0 2 kgm Unscrew and remove the two lower fastening screws 4 Screws 4 driving torque 2 Nm 0 2 kgm aCAUTION Handle the plastic and painted components with care to avoid scraping...

Page 266: ...EMOVING THE REAR DIRECTION INDICATORS Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Remove the passenger seat see 7 1 2 UNLOCKING LOCKING THE PASSENGER SEAT Turn the ignition switch to position 1 Disconnect the electric connector 7 aCAUTION Upon reassembly make sure that the electric con nector 7 is correctly coupled Loosen and remove the nut 8 Nut 8 driving torque 2 Nm 0 2 kgm Unscrew...

Page 267: ...ector 1 is correctly coupled Unscrew and remove the three screws 2 securing the electronic unit casing 3 to the saddle support lower moulded cover and retrieve the three washers Lift out the electronic unit casing 3 help the two elec tric connectors 4 5 out through the special slot NOTE Should the three rubber parts in the lower part of the casing 3 prove damaged replace them Slide the fuel tank o...

Page 268: ...ew 17 out from underneath Unscrew and remove the lower fastening screw 18 and retrieve the bush 19 for securing luggage Screw 18 driving torque 5 Nm 0 5 kgm Lower the rear part and lift the front of the saddle sup port lower moulded cover 20 Remove the saddle support lower moulded cover 20 complete with direction indicators and number plate holder sliding it off the back NOTE Where necessary remov...

Page 269: ...crews 3 Screws 3 driving torque 5 Nm 0 5 kgm Remove the rear mudguard 4 7 1 44 REMOVING THE PASSENGER FOOTREST SUPPORTS Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Position the vehicle on the stand Only for right hand side passenger footrest support re move the exhaust silencer see 7 1 49 REMOVING THE EXHAUST SILENCER Unscrew and remove the two screws 5 Screws 5 driving torque 25 Nm ...

Page 270: ...IONS Position the vehicle on the stand aWARNING Wait until the engine and the exhaust silencer have completely cooled down Unscrew and remove the screw 7 supporting the low er fairing Screw 7 driving torque 5 Nm 0 5 kgm Unscrew and remove the two screws 8 Screws 8 driving torque 25 Nm 2 5 kgm Remove the whole rider s footrest support 9 NOTE Where necessary repeat the procedure to re move the other...

Page 271: ...sable to remove it in order to gain more room for manoeuvre see 7 1 34 REMOVING THE LOW ER FAIRING Move the retaining ring 5 Turn the fork pin 6 downwards Slide out the fork pin 6 Disengage the spring 7 from the lever 8 Pin 9 driving torque 15 Nm 1 5 kgm Unscrew and remove the pin 9 and retrieve the O ring 10 the lever 8 the washer 11 the O ring 12 NOTE When reassembling apply LOCTITE 243 on the t...

Page 272: ...Loosen and remove the self locking nut 3 and retrieve the washer 4 Nut 3 driving torque 25 Nm 2 5 kgm Unscrew and remove the screw 5 and retrieve the bush 6 and washer 7 If the rubber elements 8 are damaged change them and retrieve the inner spacer 9 Rotate the exhaust silencer 2 slightly both ways in or der to dislodge any deposits preventing it from being removed Slide out the exhaust silencer 2...

Page 273: ...f For the removal proceed as follows Remove the left side cover see 7 1 3 REMOVING THE SIDE COVERS Remove the lower fairing see 7 1 34 REMOVING THE LOWER FAIRING Lift the fuel tank see 2 8 LIFTING THE FUEL TANK NOTE Prepare a clamp 7 to be used for the reassem bly aCAUTION Do not force cables pipes connectors and wires Cut the clamp 8 and release the cable 9 Disconnect the electric connector 10 fr...

Page 274: ... Release the hose clamp 3 Pull off th couplings 4 5 Unscrew and remove the upper fastening screw 6 Screw 6 driving torque 10 Nm 1 0 kgm NOTE If the rubber element proves damaged replace it Loosen and remove the two nuts 7 8 Nuts 7 8 driving torque 10 Nm 1 0 kgm NOTE If the two silent blocks prove damaged replace them Remove the whole tank 9 Unscrew and remove the engine oil filter 10 posi tioned o...

Page 275: ...fastening screws 6 7 8 Screws 6 7 8 driving torque 12 Nm 1 2 kgm NOTE If the rubber elements are damaged change them Remove the radiator 9 7 1 53 REMOVING THE DRIVE PINION Remove the guide plate see 2 36 5 INSPECTING THE DRIVING CHAIN GUIDE PLATE NOTE In order to stop the pinion 13 from turning and enable the screw 10 to be unscrewed put the vehicle in first gear Unscrew and remove the screw 10 an...

Page 276: ...n be very dangerous for the rider and the vehicle after the reassembly of the clutch control cylinder and or after the normal op erating conditions of the clutch system have been re stored it is absolutely necessary to bleed the hydrau lic circuit see 2 21 BLEEDING THE CLUTCH SYSTEMS Position the vehicle on the side stand Remove the plastic protection cap Insert a small rubber pipe on the bleeder ...

Page 277: ...HE EXHAUST SILENCER Disconnect the two electric connectors 1 2 aCAUTION When reassembling make sure the electric connec tors 1 2 are plugged in properly Unscrew and remove the two screws 3 Screws 3 driving torque 50 Nm 5 0 kgm Remove the saddle support 4 sliding it off the back To remove the components attached to the saddle support 4 Unscrew and remove the two screws 5 and remove the voltage regu...

Page 278: ...ITH THE FRONT WHEEL Remove the dashboard mount see 7 1 26 REMOV ING THE DASHBOARD FRONT FAIRING MOUNT Remove the side fairing upper panels see 7 1 29 RE MOVING THE SIDE FAIRING UPPER PANELS Remove the air conveyor cases see 7 1 33 REMOV ING THE AIR CONVEYOR Remove the saddle support complete with footrest see 7 1 56 REMOVING THE SADDLE SUPPORT Remove the rear axle complete with rear wheel see 7 9 ...

Page 279: ...ist 13 must be suitable for bearing the weight of the frame 1 The frame weighs 9 9 kg Lift the frame 1 just enough to remove the special centre support stand m Remove the centre stand 14 see 1 8 4 POSITION ING THE VEHICLE ON THE CENTRE SUPPORT STAND m Once the frame has been completely reinstalled proceed as follows Make sure that all the components are correctly fas tened Make sure that cables an...

Page 280: ...V mille 2 4 7 Key 1 Wheel pin 2 Left spacer up to frame ZDMEE009YS000292 3 Seal 4 Bearing 5 Inner spacer 6 Complete wheel 7 Snap ring 8 Right spacer 9 Washer 10 Nut GREASE see 1 6 LUBRICANT CHART Release 00 2002 10 00 ...

Page 281: ...ocked Wheel nut 2 driving torque 80 Nm 8 kgm Loosen and remove the wheel nut 2 taking the wash er 3 Wheel pin clamp screw driving torque 22 Nm 2 2 kgm Partially unscrew the two wheel pin clamp screws 4 right side Partially unscrew the two wheel pin clamp screws 5 left side NOTE Check the position of the spacer ring 6 right side in order to be able to reinstall it correctly NOTE To facilitate the e...

Page 282: ...mpliance with the check parameters Change both wheel bearings see 7 2 10 ASSEM BLING THE FRONT WHEEL BEARINGS aWARNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check pa...

Page 283: ...ge the pin wheel 1 Maximum eccentricity 0 25 mm 7 2 6 FRONT WHEEL RIM Using a comparator make sure that the radial A and axial B eccentricity of the rim 2 do not exceed the limit value Excessive eccentricity is usually caused by worn or damaged bearings If after changing the bearings the value does not fall within the indicated limit change the rim 2 Maximum radial and axial eccentricity 2 mm 7 2 ...

Page 284: ... spacer 4 are provided with slots A to allow the passage of the extractor teeth NOTE Have the appropriate special tool m to hand aprilia part 8140180 bearing extractors Use a special extractor to extract the right bearing 5 Retrieve the inner spacer 4 Work from the left hand side of the wheel up to frame ZD4MEE009YS000292 Remove the spacer B Remove the seal 2 NOTE Have the appropriate special tool...

Page 285: ...he left hand side of the wheel Insert the spacer 4 NOTE Have the appropriate special tool m to hand aprilia part 8140180 bearing extractors Use a special pad to insert the left bearing 6 NOTE The complete insertion of the left bearing 6 will bring the following components into contact right bearing 5 spacer 4 left bearing 6 aCAUTION After the contact with the right bearing 5 do not push further in...

Page 286: ...ide NOTE Make sure that the wheel pin 1 is completely inserted Position the washer 5 and tighten the wheel nut 6 manually NOTE In this phase for the temporary tightening of the two wheel pin clamp screws 7 left side the driving torque value need not be respected Screw the two wheel pin clamp screws 7 left side and tighten them as much as necessary to lock the ro tation of the wheel pin 1 Tighten t...

Page 287: ... 2 7 Key 1 Nut 2 Washer 3 Side spacers 4 Left chain tightener shoe 5 Bearings 6 Central spacer 7 Complete wheel 8 Snap ring 9 Seal 10 Right chain tightener shoe 11 Wheel pin GREASE see 1 6 LUBRICANT CHART Release 00 2002 10 00 ...

Page 288: ...l from the rear fork from behind carefully withdrawing the disc from the brake caliper aCAUTION Do not operate the rear brake lever after removing the wheel since the pins may go out of their seats and cause brake fluid leakages aCAUTION The left 10 and right spacer rings 11 remain posi tioned in the respective seats on the wheel if they should come off reposition them correctly NOTE The support p...

Page 289: ...ithdrawn from the flexible coupling holder Working B with both hands on the outer diameter of the sprocket 3 withdraw the final drive unit parallely to the wheel axis REASSEMBLY NOTE Introduce the final drive unit parallely to the wheel axis inserting the flexible couplings 5 in the cor responding seats on the flexible coupling holder 2 Working C with both hands on the outer diameter of the sprock...

Page 290: ...mpliance with the check parameters Change both wheel bearings see 7 3 14 ASSEM BLING THE REAR WHEEL BEARINGS aWARNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check par...

Page 291: ...ange the pin wheel 1 Maximum eccentricity 0 25 mm 7 3 7 REAR WHEEL RIM Using a comparator make sure that the radial A and axial B eccentricity of the rim 2 do not exceed the limit value Excessive eccentricity is usually caused by worn or damaged bearings If after changing the bearings the value does not fall within the indicated limit change the rim 2 Maximum radial and axial eccentricity 2 mm 7 3...

Page 292: ...th final drive unit bearings see 7 3 16 AS SEMBLING THE FINAL DRIVE UNIT BEARINGS aWARNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check parameters Change both final d...

Page 293: ...ck is excessive Change all the flexible coupling rubber elements 1 see 7 3 17 REMOVING THE FLEXIBLE COU PLINGS aWARNING Always replace the flexible couplings with ones of the same type 7 3 12 SPROCKET Check the conditions of the sprocket teeth 3 If there are signs of excessive wear Change the crown gea see 7 3 18 REMOVING THE CROWN GEAR the drive pinion see 7 1 53 REMOV ING THE DRIVE PINION and th...

Page 294: ...side of the wheel The ends of the spacer 4 are provided with slots A to allow the passage of the extractor teeth NOTE Have the appropriate special tool m to hand aprilia part 8140180 bearing extractors Use a special extractor to extract the right bearing 5 Retrieve the inner spacer 4 Work from the left hand side of the wheel NOTE Have the appropriate special tool m to hand aprilia part 8140180 bea...

Page 295: ... Work from the left hand side of the wheel Insert the spacer 4 NOTE Have the appropriate special tool m to hand aprilia part 8140180 bearing extractors Use a special pad to insert the left bearing 6 NOTE The complete insertion of the left bearing 6 will bring the following components into contact right bearing 5 spacer 4 left bearing 6 aCAUTION After the contact with the right bearing 5 do not pus...

Page 296: ...seal 2 Remove the snap ring 3 NOTE The elastic ring 3 is provided only on the left side of the final drive unit NOTE Have the appropriate special tool m to hand aprilia part 8140180 bearing extractors Use a special extractor to extract the left bearing 4 Retrieve the inner spacer 5 Use a special extractor to extract the right bearing 6 Take the right spacer ring 7 Thoroughly clean the inside of th...

Page 297: ...n tact with the wheel hub shoulder is complete Y Insert the inner spacer 5 Use a special pad to insert the left bearing 4 NOTE The complete insertion of the left bearing 4 will bring the following components into contact right bearing 6 inner spacer 5 left bearing 4 Insert the elastic ring 3 NOTE The elastic ring 3 is provided only on the left side of the final drive unit Install a new seal 2 Inse...

Page 298: ...ully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Remove the final drive unit see 7 3 2 REMOVING THE FINAL DRIVE UNIT NOTE The flexible couplings remain installed on the flexible coupling holder Extract all the flexible coupling rubber elements Release 00 2002 10 00 ...

Page 299: ...g nuts 3 manually aCAUTION It is forbidden to install the final drive unit 6 on the wheel to tighten the self locking nuts aCAUTION To protect the crown gear install guards in wood or aluminium on the vice jaws Lock only the crown gear in the vice be careful not to lock any other com ponent of the final drive unit Lock the crown gear in the vice NOTE To avoid any deformation and or incorrect cou p...

Page 300: ...t the previous operation by applying the pre scribed driving torque Flexible coupling holder screws driving torque 1 50 Nm 5 0 kgm NOTE In this way the pressure exerted by the fasten ing elements will be uniformly distributed on the joint sur face 7 3 20 CHANGING THE WHEEL RIM Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS In case of replacement of the wheel rim it is necessary to insta...

Page 301: ...the rear fork rods on the support 7 Make the wheel advance and position the drive chain 8 on the crown gear 9 aCAUTION Danger of injury Do not introduce your fingers to align the holes Move the wheel backwards until its central hole and the holes on the rear fork are aligned Rotate the support plate 1 complete with brake cali per 2 and with fulcrum on the stop pin 3 until it is aligned with the ho...

Page 302: ...e of the listed defects are present change the rim Deformation or cracking Marks lines or defects For further information see 7 2 2 CHECKING THE FRONT WHEEL COMPONENTS TYRE Thoroughly check the tyre after removing it If one or more of the listed defects are present do not repair the tyre but change it Hole or crack exceeding 5 mm in diameter or length Mark or cracking on the side Tread depth less ...

Page 303: ...nflation of the tyre aWARNING The tyre it may explode causing serious injuries Never sit on the tyre while inflating it Slightly inflate the tyre do not over inflate NOTE Check the line of the rim on the tyre side It must be equidistant from the edge of the rim along its en tire circumference If the distance between the line of the tyre and the rim varies along the circumference this means that th...

Page 304: ...eder 8 Brake caliper right and left 9 Brake pads 10 Brake disc right and left The front brake fluid tank is positioned on the right part of the handlebar near the front brake lever coupling aWARNING Do not use the vehicle if the braking system leaks flu id For further details see 1 2 4 BRAKE FLUID 2 17 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID 2 20 BLEEDING THE BRAKING SYSTEMS 2 27 CHECKING TH...

Page 305: ...e stop pins 1 can be pulled out Pull out the two flexible stop pins 1 Pull out the two pins 2 Retrieve the spring 3 NOTE Using pliers clamp one pad and then the other shaking them slightly crosswise so as to eliminate any pressure exerted by the caliper pins making it easier to extract the pads Extract the two pads 4 aCAUTION Do not pull the brake lever once the pads have been removed as the calip...

Page 306: ...e pad and then the other shaking them slightly crosswise so as to eliminate any pressure exerted by the caliper pins making it easier to extract the pads Extract the two pads 3 aCAUTION Do not pull the brake lever once the pads have been removed as the caliper pins are liable to come out of their slot resulting in the spillage of brake fluid Insert two new pads positioning them correctly aCAUTION ...

Page 307: ...BRAKE DISCS Brake disc max wobbling 0 3 mm 7 5 4 REMOVING THE FRONT BRAKE DISCS Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Remove the front wheel see 7 2 1 REMOVING THE FRONT WHEEL NOTE The following procedure refers to a single disc though it is applicable to both To unscrew the screws 1 it is advisable to use a per cussion screwdriver thanks to which it will be possible to detach ...

Page 308: ...tc Use latex gloves Driving torque of the brake caliper connection screw 1 20 Nm 2 0 kgm Unscrew and remove the brake caliper connection screw 1 and take the two sealing washers 2 aCAUTION Upon reassembly replace the two sealing washers with two new washers of the same type Put a nylon bag on the coupling 3 and fix it to the brake pipe with adhesive tape Follow the procedure of PARTIAL REMOVAL PAR...

Page 309: ...ign the holes aCAUTION Proceed with care in order not to damage the brake pads Insert the brake caliper 5 on the disc and position it so that its fastening holes and the holes on the support are aligned aWARNING Upon reassembly of the brake caliper replace the caliper fastening screws 4 with two new screws of the same type Screw and tighten the two screws 4 that fasten the brake caliper Front brak...

Page 310: ...ble disc right and left side The rear braking system is with single disc right side For the front braking system the operations described should be carried out on both brake calipers Position the vehicle on the side stand Remove the plastic protection cap Insert a small rubber pipe on the bleeder valve 1 Introduce the free end of the small rubber pipe into a clean container for the collection of t...

Page 311: ...from pump to caliper 8 Rear brake light switch 9 Brake pedal 10 Brake pump The rear brake reservoir is positioned under the right fair ing to reach it remove the right fairing see 7 1 28 RE MOVING THE SIDE FAIRINGS For further details see 1 2 4 BRAKE FLUID 2 18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID 2 20 BLEEDING THE BRAKING SYSTEMS 2 26 ADJUSTING THE REAR BRAKE CONTROL LEVER CLEARANCE 2 27 ...

Page 312: ...em so that the holes are lined up with those in the caliper aCAUTION Always change both pads and make sure that they are correctly positioned inside the caliper Refit the safety spring 3 Keeping the safety spring 3 pressed in the middle in sert the pin 2 so that it passes over it Refit the stop ring 1 Check the brake fluid level see 2 18 CHECKING AND TOPPING UP THE REAR BRAKE FLUID 7 6 2 CHECKING ...

Page 313: ...driver thanks to which it will be possi ble to detach the screws from the LOCTITE 243 Unscrew and remove the five brake disc screws 1 aCAUTION When reassembling apply LOCTITE 243 on the thread of the brake disc screws 1 NOTE When reassembling screw all the screws on manually and tighten them in a crisscross pattern in the following order A B C D E Brake disc screws 1 driving torque 30 Nm 3 0 kgm R...

Page 314: ...assembly replace the two sealing washers with two new washers of the same type Put a nylon bag on the coupling 3 and fix it to the brake pipe with adhesive tape Loosen and move the pipe clamp 4 Slide the pipe 5 from its fitting on the pump Put a nylon bag on the pipe 5 and fix it to the pipe with adhesive tape Follow the procedure of PARTIAL REMOVAL NOTE When reassembling top up the brake fluid se...

Page 315: ...he vehicle on the side stand For the partial removal perform ONLY the operations in dicated in paragraph PARTIAL REMOVAL excluding the COMPLETE REMOVAL COMPLETE REMOVAL Drain the rear braking system see 7 5 7 DRAINING THE BRAKING SYSTEMS aCAUTION Handle brake fluid with care it may chemically alter painted surfaces and the parts in plastic rubber etc Use latex gloves Driving torque of the brake ca...

Page 316: ...y Do not introduce your fingers to align the holes aCAUTION Proceed with care in order not to damage the brake pads Insert the brake caliper on the disc and position it so that its fastening holes and the holes on the support are aligned aWARNING Upon reassembly of the brake caliper replace the screws 4 with two new screws of the same type Screw and tighten the two screws 4 of the brake cali per 5...

Page 317: ...ate 4 Lock ring 5 Lock washer 6 Adjuster ring 7 Protective cover 8 Antidust gasket 9 Bearings 10 Lower plate 11 Steering damper GREASE see 1 6 LUBRICANT CHART For further details see 2 28 STEERING 2 29 INSPECTING THE FRONT AND REAR SUS PENSION Release 00 2002 10 00 ...

Page 318: ...d remove the screw 4 Recover the bracket 5 Screw 6 driving torque 10 Nm 1 0 kgm Unscrew and remove the screw 6 fastening the steer ing shock absorber tube 7 and take the bush 8 Remove the fork upper plate see 7 1 19 REMOVING THE FORK UPPER PLATE NOTE The safety washer 9 is provided with four tabs two bent upwards and two bent downwards To release the counter ring 10 it is necessary to straighten t...

Page 319: ...ver 12 Remove the upper antidust gasket 13 Remove the lower antidust gasket 14 aCAUTION Wash all the components with a clean detergent REASSEMBLY NOTE When reassembling the vehicle and the fore carriage must be positioned as for disassembly and the disassembly procedure then followed in reverse order Smear a film of grease over the entire length of the pin 15 see 1 6 LUBRICANT CHART NOTE Before ti...

Page 320: ...RNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check parameters Change both steering tube bearings see 7 7 5 RE MOVING THE STEERING BEARINGS aWARNING Always change both...

Page 321: ... strike the balls and or the inner race Make sure the bearings are perfectly in contact Wash all the components with a clean detergent 7 7 6 REMOVING THE STEERING SHOCK ABSORBER Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Remove the front part of the fairing see 7 1 22 RE MOVING THE FRONT PART OF THE FAIRING Unscrew and remove the screw 3 Screw 3 driving torque 10 Nm 1 0 kgm Unscrew ...

Page 322: ... upper plug 5 Washer 6 Slide bush 7 Piston assembly 8 Centring bush 9 Spring press tube 10 Spring 11 Spring rest washer 12 Lower collar 13 Slider 14 Slide bush 15 Guide bush 16 Stop ring 17 Gasket 18 Retainer ring 19 Antidust gasket 20 Wheel holder tube 21 Copper washer 22 Centre screw Release 00 2002 10 00 ...

Page 323: ...eck the correspondence of the special notches made on the fork sliders on the fork upper plate and take note of the number of notches in order to be able to reinstall the sliders in the same position A aCAUTION The upper plate must be lined up with the same refer ence notch on both fork sliders Remove the front wheel see 7 2 1 REMOVING THE FRONT WHEEL Remove the front mudguard see 7 1 27 REMOVING ...

Page 324: ...erformed very carefully Rotate the upper screw adjuster 1 completely anti clockwise in order to reduce the hydraulic braking with extended unit Remove the stop ring 2 Unscrew and remove the adjusting element 3 Withdraw the spring preload pushing element 4 Position the wheel holder tube slider unit on a vice interposing the two half shells of the special tool C aCAUTION The wheel holder tube slider...

Page 325: ...he slider upper plug 5 by means of a fork spanner insert ed in the appropriate seat Rest both hands on the tool A Push downwards and at the same time withdraw the tool B Remove the tool A Remove the washer 8 Remove the sliding ring 10 NOTE Before removing them completely keep the spring pressing tube 6 and the spring 11 out of the fork tube for a few seconds so that part of the oil drops inside th...

Page 326: ...y push the pumping element 9 in the slider eight ten times At the end of this operation the tube will slide inside the slider freely If it does not come out during the oil draining process slide off the following components in the order given spring rest washer 13 lower collar 14 Remove the antidust gasket 15 from the slider by al ternately levering on more points with a cut tipped screwdriver Fol...

Page 327: ...he withdrawing action Withdraw the whole wheel holder tube 21 from the slider 22 aCAUTION When withdrawing the slide bushing 17 be careful not to damage it especially its sliding surface With a cut tipped screwdriver to enlarge moderately and withdraw the slide bushing 17 from the tube 21 Withdraw and remove the following components from the tube 21 in the given order guide bushing 20 ring 19 gask...

Page 328: ...oft material aluminium Unscrew and remove the centre screw 23 and take the copper washer 24 Withdraw the complete pumping element 9 from the tube 21 aCAUTION The pumping element 9 must not be removed Take the centering bushing 25 aCAUTION Wash all the components with a clean detergent Release 00 2002 10 00 ...

Page 329: ...angerous SLIDER Make sure that there are neither damages nor cracks Otherwise change it SPRING Check the integrity of the spring 11 making sure that its length does not exceed the limit value If the length does not correspond to the limit value change the spring 11 Minimum length of the spring when not compressed 284 mm Check the condition of the following components slide bushing 17 guide bushing...

Page 330: ... aprilia part 8140151 complete tool kit for fork includ ing A B C D Before reinstalling the gaskets and the bushes spread a film of fork oil on them see 1 6 LUBRICANT CHART Position the wheel holder tube 21 on a vice with the open part facing upwards interposing clamps made of soft material aluminium NOTE Apply some grease inside the centering bushing 25 see 1 6 LUBRICANT CHART Insert the centerin...

Page 331: ... side with the writings towards the stop ring 16 gasket 18 ring 19 guide bushing 20 Move the five components mentioned above complete ly towards the wheel holder Remove the adhesive tape from the end of the wheel holder tube 21 Lock the guide bushing 20 in its position by means of some adhesive tape Put back the slide bushing 17 on the wheel holder tube 21 Follow ã Release 00 2002 10 00 ...

Page 332: ...holder tube 21 before the antidust gasket 15 Grasping the tool D push the antidust gasket 15 in the appropriate seat on the slider 22 and make sure that it is correctly positioned Grasp the tube 21 and move it slowly and alter nately more than once aCAUTION The tube 21 must slide inside the slider 22 smoothly without finding any obstacle if this does not happen it means that the guide bushing 20 t...

Page 333: ... components in the tube 21 in the given order lower collar 14 spring rest washer 13 spring 11 spring pressing tube 6 complete with spring press ing element sliding ring 10 washer 8 Unscrew and remove the threaded pin A1 from the tool A Position the fixed part of the tool A on the spring pressing tube 6 so that the tooth fits in the hole Position the threaded pin A1 in the hole on the fixed part of...

Page 334: ...torque 5 35 Nm 3 5 kgm Rest both hands on the tool A Push downwards and at the same time withdraw the tool B Remove the tool A Position the wheel holder tube slider unit on a vice interposing the two half shells of the special tool C Screw and tighten the slider upper plug 5 on the slider Slider upper plug 5 slider driving torque 35 Nm 3 5 kgm Insert the spring preload pushing element 4 Screw the ...

Page 335: ... the number counted upon disassembly aCAUTION The upper plate must be lined up with the same refer ence notch on both fork sliders Tighten the two screws 6 that fix the lower plate 3 to the slider 1 Screws 6 driving torque 25 Nm 2 5 kgm Tighten the screw 7 that fixes the handlebar 8 to the slider 1 Screw 7 driving torque 25 Nm 2 5 kgm Tighten the screw 9 that fixes the upper plate 4 to the slider ...

Page 336: ...and m 3 is indispensa ble to support the rear fork when the rear wheel has been removed Put a shim under the support base of the rear support stand m 3 in order to place it in operating position hooked to the two pins on the rear fork Unscrew and remove the screws 4 securing the pro filed guard 5 and retrieve the two washers 6 Take and carefully rest on the ground beside the vehi cle the support p...

Page 337: ... the fork pin 15 anticlockwise which will cause the ad juster bush 16 to rotate with it causing it to loosen completely aCAUTION PROCEED WITH THE MAXIMUM CARE The removal must be carried out with the greatest care Support the fork from the front to prevent it acciden tally dropping aWARNING Position a wooden support under the front part of the rear fork to prevent it from lowering and hold it in i...

Page 338: ... CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check parameters Change both rear fork bearings see 7 9 6 DISAS SEMBLING THE REAR FORK GASKETS aWARNING Always change both bearings Always replace the bearings with bearings of the same type 7 9 4 REAR FORK GASKET...

Page 339: ...and roller bearing 6 aCAUTION The bearings must be checked and if necessary changed every time they are disassembled Remove the inner spacer 7 and retrieve the two O rings 8 Remove the inner spacer 9 Remove the seals 10 Use a special extractor to extract the two roller bear ings 11 aCAUTION The bearings must be checked and if necessary changed every time they are disassembled Thoroughly clean the ...

Page 340: ...ar sup port stand 4 NOTE Put a shim 5 under the support base of the rear support stand 4 in order to place it in operating po sition hooked to the two pins on the rear fork Support the fork from the front Adjust its position so that the holes are aligned at the same time pushing the pin 6 all the way in NOTE Make sure that the hex head of the pin 6 is cor rectly inserted in the hexagonal slot on t...

Page 341: ...it the guide plate 15 Refit the pinion protection case 16 Screw and tighten the three screws 17 Screws 17 driving torque 10 Nm 1 0 kgm aCAUTION From this point on reassemble the fork following the removal procedure in the reverse order starting from NOTE X see 7 9 1 REMOVING THE REAR FORK Go ahead with the adjustment of the driving chain ten sion see 2 36 3 ADJUSTING THE DRIVING CHAIN Release 00 2...

Page 342: ...from the opposite side Working from the right hand side of the vehicle loosen and remove the nut 3 Nut 3 driving torque 50 Nm 5 0 kgm Pull the screw 4 out from the opposite side aCAUTION The shock absorber contains pressurized nitrogen In order to avoid the risk of an explosion keep it away from flames and or sources of heat In the event the shock absorber is to be replaced dis charge the nitrogen...

Page 343: ...osite side Working from the right hand side of the vehicle loosen and remove the nut 3 Nut 3 driving torque 50 Nm 5 0 kgm Pull the screw 4 out from the opposite side aCAUTION The shock absorber contains pressurized nitrogen In order to avoid the risk of an explosion keep it away from flames and or sources of heat In the event the shock absorber is to be replaced dis charge the nitrogen by pressing...

Page 344: ...RICANT CHART SEALS Make sure the seals are intact should they prove dam aged or feature signs of excessive wear change them SHOCK ABSORBER Make sure that there are no oil leaks from the shock ab sorber and that its travel is smooth and gradual If this is not the case change the shock absorber aWARNING The shock absorber contains pressurized nitrogen In order to avoid the risk of an explosion keep ...

Page 345: ...remely careful to refit the components correctly making sure that the joints move smoothly Once reassembly is complete check the assembly see 2 32 3 CHECKING THE REAR SUSPENSION LINKAGE 7 10 5 DISASSEMBLING THE SUSPENSION LINKAGE Carefully read 0 5 1 PRECAUTIONS AND GENERAL INFORMATIONS Loosen and remove the nut 8 Nut 8 driving torque 50 Nm 5 0 kgm Slide out the screw 9 Remove the two double conne...

Page 346: ...t type connecting links aCAUTION Only rivet type connecting link chains should be fit ted on this vehicle Release 00 2002 10 00 Key 1 Main body 2 Fixed hexagonal seat for 27 mm spanner 3 Hex head screw for 19 mm spanner 4 Locating dowel 5 Rivet tool 6 A and B reference marks 7 Positioning holes for joining pins 8 Pin exit hole 9 Pusher 10 Breaking side 11 Joining side 12 Support plate 13 Joining p...

Page 347: ...n to be pushed out Insert the pusher 2 on the main body 3 with the part featuring the greatest diameter first Fit the main body 3 on the rivet tool 1 Move the main body 3 so that the locating dowel 4 is in line with mark A on the rivet tool 1 Turn the screw 5 by hand until the pusher 2 touches the pin to be pushed out NOTE Make sure the pusher 2 is perfectly in line with the pin to be pushed out U...

Page 348: ...the pusher 2 touches the support plate 6 Use a 27 mm spanner inserted on the fixed hexagonal seat of the central body 3 to hold the body still Use a 19 mm spanner to turn the screw 5 as far as it will go 7 11 4 RIVETTING THE PINS With the tool already in place on the chain Loosen the screw 5 Remove the main body 3 from the rivet tool 1 Remove the support plate 6 Refit the main body 3 on the rivet ...

Page 349: ...CHASSIS RSV mille NOTES T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y 7 114 Release 00 2002 10 00 ...

Page 350: ...1 2 3 4 5 6 7 RSV mille 8 1 1 2 3 4 5 6 7 REPAIR INFORMATION 8 Release 00 2002 10 00 ...

Page 351: ... 00 8 2 10 COLD START CABLE 8 16 00 8 2 11 ELECTRIC CABLES 8 17 00 4 42 3934 8 22 00 8 3 1 SPARK PLUGS no spark 8 22 00 8 3 2 BATTERY RECHARGING PROBLEMS 8 22 00 8 3 3 IGNITION AND OR STARTING PROBLEMS 8 22 00 8 3 4 AUXILIARY SYSTEM PROBLEMS 8 22 00 4 4 30 4 3 8 23 00 8 4 1 ENGINE 8 23 00 8 4 2 THROTTLE BODY COMPONENTS 8 23 00 8 4 3 SUPPLY SYSTEM 8 23 00 8 4 4 ELECTRIC SYSTEM 8 23 00 8 4 5 FRONT B...

Page 352: ...tarter motor toothing broken Replace Spark plugs dirty Replace Spark plugs wet Clean or replace Spark plugs loose Tighten Spark plugs are not to spec Replace Cold start cable not working Check Fuel filters dirty or fuel supply pipes clogged Clean or replace Fuel pump relay or wiring faulty Replace Fuel pressure regulator faulty Replace Injectors faulty Replace Valve clearance incorrect Adjust The ...

Page 353: ...e Thermal expansion valve faulty locked in closed position Replace Coolant pump or coolant pump control drive faulty Replace Insufficient engine oil in the system Top up with motor oil Oil pump or oil pump control faulty or oil circuit clogged Replace or clean Motor oil not to spec Use motor oil conforming to spec Intake couplings or intake system leaking Replace Injectors faulty Replace Head gask...

Page 354: ...en the engine is started Freewheel gear gear or housing worn or faulty Replace Double gear or intermediate gear of the starter motor worn Replace Starter motor toothing broken Replace The clutch slips Clutch discs worn or distorted Replace Clutch springs exhausted Replace Support plate worn or distorted Replace Motor oil not to spec Use motor oil conforming to spec Clutch control hydraulic system ...

Page 355: ...correct Check Unsuitable fuel Use the prescribed fuel Air cleaner dirty Clean Spark plugs gets dirty too quickly Motor oil level incorrect Check Piston segments worn Replace Piston or cylinder worn Replace Spark plugs electrodes overheated or burnts The engine overheats Adjust Spark plug loose Tighten Alternator does not charge Connection terminals interrupted in short circuit or loose Repair chan...

Page 356: ...eplace Brake pads worn Change pads Contact surfaces of pads soiled by oil grease or brake fluid Change pads Brake discs worn Change disc Air in hydraulic circuit Bleed the circuit Brake discs dirty with oil grease or brake fluid Clean Foreign matter in brake fluid Change brake fluid Brake pump return hole clogged Disassemble and clean brake pump Brakes squeak Pad contact surfaces hardened Restore ...

Page 357: ...hausted Replace Fork too rigid Adjustments incorrect Adjust Fork oil too viscous Replace Too much oil in fork Remove excess oil Noisy fork Fork oil insufficient Top up Suspension coupling screws and nuts loose Tighten Rear wheel oscillates Wheel rim deformed Replace Wheel bearings worn Replace Tyre defective or unsuitable type Replace Fork bearings worn Replace Suspension screws and nuts loose Rep...

Page 358: ...RSV mille 8 9 25 34 7 2 3 0 0 3 8 2 1 FRONT BRAKE PIPES 8 2 2 REAR BRAKE PIPES Release 00 2002 10 00 ...

Page 359: ...8 10 RSV mille 8 2 3 FUEL SYSTEM PIPES Release 00 2002 10 00 ...

Page 360: ...RSV mille 8 11 8 2 4 CLUTCH CONTROL PIPE 8 2 5 PPC DEVICE PRESSURE PIPES Release 00 2002 10 00 ...

Page 361: ...8 12 RSV mille 8 2 6 COOLING SYSTEM PIPES Follow ã Release 00 2002 10 00 ...

Page 362: ...RSV mille 8 13 Follow ã Release 00 2002 10 00 ...

Page 363: ...8 14 RSV mille 8 2 7 ENGINE OIL PIPES Release 00 2002 10 00 ...

Page 364: ...RSV mille 8 15 8 2 8 BREATHER AND IMPURITY DRAINAGE PIPES Release 00 2002 10 00 ...

Page 365: ...8 16 RSV mille 8 2 9 ACCELERATOR CONTROL CABLES 8 2 10 COLD START CABLE Release 00 2002 10 00 ...

Page 366: ...tor 9 Clutch control lever switch connector 10 Left dip switch connector 11 Lights diode LAP 12 Headlight connector 13 Horn 14 Left electrofan connector 15 Thermal switch 16 Right electrofan connector 17 Electric fan relay 18 High beam relay 19 Dipped beam relay 20 Engine oil pressure sensor 21 Side stand switch connector 22 Coolant temperature thermistor 23 Generator pick up connector 24 Rear cyl...

Page 367: ...n fuses 6 Start relay 7 Electronic unit 8 Diode module 9 Fuel pump relay 10 Engine stop relay 11 Rear light connector 12 Arrangement for the installation of the anti theft de vice 13 Rear right indicator connector 14 Rear left indicator connector Follow ã Follow ã Release 00 2002 10 00 ...

Page 368: ...e 7 Air thermistor 8 Starter 9 Stoplight switch on the rear brake control lever 10 Coolant temperature thermistor 11 Neutral gearbox switch 12 Front cylinder 1 coil connector 13 Front cylinder 2 coil connector 14 Camshaft position sensor connector 15 Left injector connector 16 Throttle valve potentiometer 17 Voltage regulator Follow ã Follow ã Release 00 2002 10 00 ...

Page 369: ...8 20 RSV mille Follow ã Follow ã Release 00 2002 10 00 ...

Page 370: ...RSV mille 8 21 Follow ã Release 00 2002 10 00 ...

Page 371: ...HAFT POSITION SEN SOR 6 4 7 CHECKING THE FALL SENSOR 6 4 8 CHECKING THE COOLANT THERMISTOR OP ERATION 6 4 9 CHECKING THE AIR THERMISTOR OPERA TION 6 4 10 CHECKING THE THROTTLE VALVE POTENTI OMETER 6 4 11 CHECKING THE INTAKE PRESSURE SEN SOR 6 4 12 CHECKING THE INJECTORS 6 5 2 CHECKING THE FUEL PUMP 6 5 3 CHECKING THE FUEL PUMP RELAY 6 5 4 CHECKING THE ENGINE SHUTOFF RELAY 6 6 2 STARTING SAFETY OPE...

Page 372: ...eter standard 16 mm ò Pump diameter 15 mm 8 4 6 REAR BRAKING SYSTEM Disc material steel Disc thickness 5 mm minimum 4 5 mm Disc diameter 220 mm Number of caliper pins 2 facing each other Diameter of caliper pins 32 mm Diameter rubber pipes standard FERIT FERODO ID 450 Pad friction material alternative TOSHIBA TT H38GF FERIT FERODO ID 450 452 459 ò Pad friction material alternative TOSHIBA TT H38 T...

Page 373: ...NOTES 8 24 T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y RSV mille Release 00 2002 10 00 ...

Page 374: ... 1 RSV mille 0 1 2 3 4 5 6 7 8 ANALYTICAL INDEX Release 00 2002 10 00 ...

Page 375: ...PIPE FASTENING 8 2 8 9 00 CABLE AND PIPE LAYOUT 8 2 8 9 00 CABLE AND PIPE LAYOUT 8 2 8 9 00 CABLE COLOURS 6 1 1 6 3 00 CABLES AND PIPES RUN FASTENING WIRING 8 2 8 9 00 CAMSHAFT POSITION SENSOR 6 4 6 6 13 00 CENTER SUPPORT STAND POSITIONING THE VEHICLE 1 8 4 1 22 00 CHAIN PINION AND SPROCKET CHECKING THE WEAR 2 36 2 2 59 00 CLUTCH 2 44 2 65 00 CLUTCH REMOVING THE CONTROL CYLINDER 3 2 3 3 8 00 CLUTC...

Page 376: ...BAR REMOVAL 7 1 17 7 17 00 ELECTRIC FAN RELAY 6 9 4 6 32 00 ELECTRICAL CONNECTORS 6 1 2 6 3 00 ELECTRICAL SYSTEM CHECK 8 3 8 22 00 ELECTRONIC SYSTEM FAULTS 6 4 3 6 11 00 ELECTRONIC UNIT 4 7 4 4 12 00 ELECTRONIC UNIT CONNECTIONS 6 17 6 48 00 ELECTRONIC UNIT REMOVAL 7 1 9 7 10 00 END OF THE REAR PART OF THE FAIRING REMOVAL 7 1 36 7 29 00 ENGINE CHECKS TO BE CARRIED OUT AFTER THE REASSEMBLY 3 6 3 21 ...

Page 377: ...CHANGING 2 22 2 40 00 FRONT BRAKE FLUID CHECKING AND TOPPING UP 2 17 2 31 00 FRONT BRAKE LEVER REMOVAL 7 1 16 7 15 00 FRONT BRAKE PADS models up to 2001 CHANGE 7 5 1 7 70 00 FRONT BRAKE PADS RSV01 CHANGE 7 5 2 7 71 00 FRONT BRAKE PUMP REMOVAL 7 5 5 7 72 00 FRONT DIRECTION INDICATORS REMOVAL 7 1 30 7 24 00 FRONT FORK 7 8 7 87 00 FRONT MUDGUARD REMOVAL 7 1 27 7 23 00 FRONT PART OF THE FAIRING REMOVA...

Page 378: ...IALS 0 7 0 9 00 INJECTION SYSTEM DIAGRAM 4 7 3 4 11 00 INJECTORS 6 4 12 6 18 00 INJECTORS REMOVAL 4 8 1 4 14 00 INSTRUCTIONS FOR USE OF FUEL LUBRICANTS COOLANT AND OTHER COMPONENTS 1 2 1 4 00 INTAKE PRESSURE 6 4 11 6 17 00 INTAKE PRESSURE SENSOR 6 4 11 6 17 00 2EF 0AGE JUMP STARTING 2 6 2 17 00 2EF 0AGE 2EF 0AGE LIGHT BEAM VERTICAL ADJUSTMENT 6 13 6 45 00 LIGHT BEAM USA HORIZONTAL ADJUSTMENT 6 14 ...

Page 379: ...1 40 7 31 00 REAR FAIRING REMOVING THE REAR FAIRING REAR END 7 1 36 7 29 00 REAR FORK 2 30 2 51 00 REAR FORK 7 9 7 101 00 REAR LIGHT 6 12 3 6 43 00 REAR LIGHT REMOVAL 7 1 37 7 29 00 REAR MUDGUARD REMOVAL 7 1 43 7 34 00 REAR PART OF THE FAIRING REMOVAL 7 1 38 7 30 00 REAR SHOCK ABSORBER ADJUSTMENT 2 31 2 2 52 00 REAR SUPPORT STAND ASSEMBLING PINS 1 8 1 1 21 00 REAR SUPPORT STAND POSITIONING THE VEH...

Page 380: ... 2 28 1 2 46 00 STEERING LOCK REMOVING THE SWITCH 7 1 18 7 18 00 STEERING SHOCK ABSORBER REMOVAL 7 7 6 7 86 00 SUPPORT STANDS 1 7 1 1 14 00 SWITCHES 6 7 6 25 00 SWITCHES CHECK 6 16 6 47 00 SYMBOLS 0 7 0 9 00 4 2EF 0AGE TECHNICAL DATA 1 5 1 8 00 TECHNICAL DATA AND SPECIFICATIONS 8 4 8 23 00 TECHNICAL INFORMATION ON THE ENGINE 3 1 3 3 00 TECHNICAL SPECIFICATIONS 1 5 1 8 00 TECHNICAL SPECIFICATIONS 8...

Page 381: ... 8 RSV mille 7 2EF 0AGE WHOLE FINAL DRIVE UNIT REMOVAL 7 3 2 7 54 00 WIRING DIAGRAM RSV mille 6 18 6 50 00 WIRING DIAGRAM RSV mille ASD 6 19 6 52 00 8 2EF 0AGE 9 2EF 0AGE 2EF 0AGE Release 00 2002 10 00 ...

Page 382: ...T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y NOTES 9 RSV mille Release 00 2002 10 00 ...

Page 383: ...T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y NOTES 10 RSV mille Release 00 2002 10 00 ...

Page 384: ...T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y NOTES 11 RSV mille Release 00 2002 10 00 ...

Page 385: ...T H I S P A G E H A S B E E N I N T E N T I O N A L L Y L E F T E M P T Y NOTES 12 RSV mille Release 00 2002 10 00 ...

Page 386: ......

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