APRILIA RST MILLE FUTURA - PART 2 2000 Manual Download Page 3

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use and maintenance RSV mille - RSV mille R

OPERATIONS TO BE CARRIED OUT BY
THE

APRILIA

Official Dealer.

Key

= check and clean, adjust, lubricate or

change, if necessary;

= clean;

= change;

= adjust.

NOTE

Perform the maintenance opera-

tions with doubled frequency if the vehicle
is used in rainy or dusty areas, on uneven
surfaces or on racetracks.

(*) = In case of use on race tracks, check

every 3750 km (2343 mi).

(**) = With “R” fork

(

), change

every 10000 km (6250 mi).

(***) = Only in case of:

– intense use on racetracks;
– participation in competitions.

Component

After running-

in [1000 km

(625 mi)]

Every 7500 km
(4687 mi) or 12

months

Every 15000

km (9375 mi)

or 24 months

Rear shock absorber

Transmission cables and controls

Rear suspension linkage bearings

Steering bearings and steering clearance

Wheel bearings

Brake discs

General running of the vehicle

Adjusting the valve clearance

Braking systems

Cooling system

Throttle body pin greasing

Clutch fluid

every 2 years:

Brake fluid

Coolant

Fork oil (**)

after the first 7500 km (4687 mi) and successively

every 22500 km (14000 mi):

Fork oil seals

after the first 30000 km (18750 mi) and

successively every 22500 km (14000 mi):

Brake pads

if worn:

Wheel/Tyres

Nut, bolt, screw tightening

Cylinder synchronization

Suspensions and attitude

Final transmission (chain, crown and pinion)

Fuel pipes

every 4 years:

Clutch wear (*)

Pistons (***)

every 5000 km (3125 mi):

RSVmille-R-UK.book Page 61 Friday, November 17, 2000 3:13 PM

Summary of Contents for RST MILLE FUTURA - PART 2 2000

Page 1: ... are needed contact an aprilia Official Dealer who will ensure you prompt and accurate servicing Ask your aprilia Official Dealer to test the vehicle on the road after a repair or period ic maintenance operation In any case personally carry out the Pre liminary checking operations after any maintenance operation see p 49 PRE LIMINARY CHECKING OPERATIONS NOTE This vehicle is set so that any anomaly...

Page 2: ...y 3750 km 2343 mi Check every two weeks or accord ing to the intervals indicated Component 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 Air cleaner Engine oil filter Engine oil filter on oil tank Fork Light operation direction Light system Safety switches Clutch fluid Brake fluid Coolant Engine oil Tyres Tyre pressure Engine id...

Page 3: ...5000 km 9375 mi or 24 months Rear shock absorber Transmission cables and controls Rear suspension linkage bearings Steering bearings and steering clearance Wheel bearings Brake discs General running of the vehicle Adjusting the valve clearance Braking systems Cooling system Throttle body pin greasing Clutch fluid every 2 years Brake fluid Coolant Fork oil after the first 7500 km 4687 mi and succes...

Page 4: ...umn Frame no ENGINE NUMBER The engine number is stamped on the rear part of the engine near the pinion Engineno 4 6 4 00 50 Carefully read p 43 ENGINE OIL and p 59 MAINTENANCE NOTE Perform the maintenance opera tions with doubled frequency if the vehicle is used in rainy or dusty areas on uneven surfaces or on racetracks Periodically check the engine oil level change the oil after the first 1000 k...

Page 5: ...ra ting temperature Stop the engine see p 57 STOPPING Keep the vehicle in vertical position with the two wheels resting on the ground Check the oil level on the transparent pipe 3 through the apposite slots 1 2 on the left part of the fairing MAX maximum level MIN minimum level The difference between MAX and MIN amounts to approximately 500 cm The level is correct when the oil almost reaches the M...

Page 6: ...CAUTION When warmed up the engine contains hot oil therefore while carrying out the operations described here below be particularly careful in order to avoid burns Remove the lower fairing see p 77 RE MOVING THE LOWER FAIRING Position a container 1 with more than 4000 cm capacity in correspondence with the drain plug 2 positioned on the tank Unscrew and remove the drain plug 2 positioned on the ta...

Page 7: ...il filter 9 on the tank after the first 1000 km 625 mi and suc cessively every 15000 km 9375 mi or every two engine oil changes NOTE Prepare a screwdriver type pipe clamp 10 to replace the original one spe cial type Loosen the clamp 11 and disconnect the pipe 12 Unscrew and remove the engine oil filter 9 positioned on the tank and clean it with a jet of compressed air Check the seal of the engine ...

Page 8: ...he seven screws 2 that fasten the filter case cover 3 Remove the filter case cover 3 Extract the air cleaner 4 Check the conditions of the gasket 5 and change it if it is damaged aCAUTION Plug the opening with a clean cloth in order to prevent any foreign matter to get ito the suction ducts Upon reassembly before positioning the filter case cover 3 make sure that you have not left the cloth or oth...

Page 9: ...0 positioning it so that the width corresponds to the distance between the two pins 7 on the rear fork Tighten the knob 9 At the same time introduce the two fork shaped seats 10 of the stand 11 un der the two pins 7 provided on the vehi cle Rest one foot on the rear part of the stand 11 Push the stand 11 downwards until it reaches the end of its stroke aCAUTION Make sure that the vehicle is stable...

Page 10: ...tion so that the steering is locked Wheel nut 2 driving torque 80 Nm 8 kgm Loosen and remove the wheel nut 2 taking the washer 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 corre...

Page 11: ... 5 left side and tighten them as much as necessary to lock the rotation of the wheel pin 7 Tighten the wheel nut 2 completely Wheel nut 2 driving torque 80 Nm 8 kgm Tighten the two wheel pin clamp screws 4 right side Wheel pin clamp screw driving torque 22 Nm 2 2 kgm Loosen the two wheel pin clamp screws 5 left side Put back the front brake calipers see p 70 FRONT BRAKE CALIPERS With pulled front ...

Page 12: ...er screws 1 aCAUTION Never pull the brake lever after remov ing the caliper otherwise the pistons may go out of their seats thus causing the outflow of the brake fluid In this case consult your APRILIA Official Dealer who will carry out the proper maintenance operation Withdraw the brake caliper 2 from the disc leaving it attached to the pipe 3 Work on the second brake caliper Repeat the operation...

Page 13: ...maged NOTE To remove the rear wheel it is necessary to use the appropriate rear sup port stand m DISASSEMBLY Position the vehicle on the appropriate rear support stand 1 see p 67 POSI TIONING THE VEHICLE ON THE REAR SUPPORT STAND m Put a support 2 under the tyre in such a way as to keep the wheel in its position after loosening it Wheel nut 3 driving torque 120 Nm 12 kgm Loosen and remove the whee...

Page 14: ...val of the final drive unit isn t necessary if the wheel is in the normal running position vertical or in horizontal position with the rear sprocket facing up wards and in both cases secured against overturning NOTE Do not unscrew the five nuts 16 The whole final drive unit must be with drawn from the flexible coupling holder Working B with both hands on the outer diameter of the sprocket 9 withdr...

Page 15: ...ral hole and the holes on the rear fork are aligned Rotate the support plate 12 complete with brake caliper 13 and with fulcrum on the stop pin 17 until it is aligned with the holes Introduce the wheel pin 5 completely from the left side NOTE Make sure that the wheel pin 5 is completely inserted with the head in the relevant seat on the left chain tightener 7 Position the washer and tighten the wh...

Page 16: ...5 mm Move the vehicle forwards or turn the wheel in order to be able to check the vertical oscillation of the chain even when the wheel turns the slack must be con stant in all the rotation phases of the wheel aCAUTION If in some positions the slack is higher than in others this means that there are crushed or seized links in this case contact an APRILIA Official Dealer To prevent the risk of seiz...

Page 17: ...n Check the wear of the chain plastic guide 6 Finally check the wear of the rear fork protection shoe 7 CLEANING AND LUBRICATION aCAUTION The drive chain is provided with O rings among the links in order to keep the grease inside them Carry out the adjustment lubrication cleaning and change of the chain with great care Never wash the chain with water jets steam jets high pressure water jets and hi...

Page 18: ...ding make sure that the room in which you are working is prop erly ventilated Do not inhale fuel vapours Do not smoke and do not use naked flames DO NOT DISPOSE OF FUEL IN THE EN VIRONMENT ú Remove the passenger seat or the glove tool kit compartment cover m see p 29 UNLOCKING LOCKING THE PASSENGER SEAT W Remove the glove tool kit compart ment cover see p 30 UNLOCK ING LOCKING THE GLOVE TOOL KIT C...

Page 19: ... see p 67 POSI TIONING THE VEHICLE ON THE REAR SUPPORT STAND m Remove the two side fairings see p 77 REMOVING THE SIDE FAIRINGS Unscrew and remove the two front screws 3 Unscrew and remove the rear screw 4 Unscrew and remove the two screws 5 of the rear right profile 6 inside the ex haust silencer aCAUTION Handle the plastic and painted compo nents with care to avoid scraping or damaging them Let ...

Page 20: ...cle on the stand see p 58 POSITIONING THE VEHICLE ON THE STAND Unscrew and remove the nut 3 take the washer 4 the spring 5 and the half sphere 6 aCAUTION Handle the plastic and painted compo nents with care to avoid scraping or damaging them Remove the rear view mirror 7 If it has gone out of its seat take the cup 8 NOTE Repeat these operations to re move the other rear view mirror aCAUTION After ...

Page 21: ...ncide with those provided on the front part of the fairing The whole unit must be correctly posi tioned on the support Move the front part of the fairing 4 slightly forward Raise the protection element 5 Disconnect the electric connector 6 of the headlight aCAUTION Upon reassembly make sure that the electric connector 6 is correctly cou pled aCAUTION Handle the plastic and painted compo nents with...

Page 22: ...orbidden to disconnect or remove the safety switch 4 separately from the stand The disconnection or removal of the safety switch 4 alone makes it possi ble to start the vehicle and leave with the stand down which may result in a fall and in serious injuries to the rider and other people and damage to the ve hicle itself For the removal proceed as follows Remove the left side cover see p 78 REMOVIN...

Page 23: ...n Unscrew and remove the screws 11 and take the washers 12 Remove the stand 1 complete with springs 2 support 3 safety switch 4 NOTE Store the following components together complete stand screws 11 and washers 12 in order to be able to install them correctly when the vehicle must be used on roads Put back the lower fairing and the two side fairings see p 77 REMOVING THE LOWER FAIRING 12 11 12 11 9...

Page 24: ...ing of all the compo nents and the functionality of the front and rear suspension joints aCAUTION If you notice irregularities in the opera tion or if the help of a qualified techni cian is necessary contact your APRILIA Official Dealer 2 4 3530 3 Have the fork oil seals changed by a aprilia Official Dealer after the first 30000 km 1875 mi and successively every 22500 km 14000 mi The front suspens...

Page 25: ...ad and hydraulic braking for both rods a different setting of the rods decreases the stability of the vehicle while riding When the spring preload is increased it is necessary to increase also the hy draulic braking in order to avoid sud den jerks while riding For the adjustment of the fork W see p 83 FORK W w W m see p 84 R FORK w W m FORK W The standard setting of the front fork is such as to sa...

Page 26: ...road until obtaining the optimal adjustment clockwise anticlockwise Have this type of adjustment carried out exclusively by an aprilia Official Dealer Front suspension Standard adjust ment Adjustment for racetrack use Possible adjustments Hydraulic adjustment with extended shock absorber screw 1 from completely closed unscrew 12 clicks from completely closed unscrew 8 10 clicks from completely clo...

Page 27: ...the adjustment always start from the most rigid setting complete anti clockwise rotation of the knob Act on the knob 3 to adjust the hydrau lic braking see table anticlockwise clockwise aCAUTION Test the vehicle repeatedly on the road until obtaining the optimal adjustment Adjustable steering damper w W m Standard adjust ment Adjustment for racetrack use Possible adjustments Adjustment from comple...

Page 28: ... 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 adjust ers 1 2 beyond the end of stroke in both directions in order to avoid any damage Unscr...

Page 29: ...UTION w W m In order to avoid compro mising the operation of the shock ab sorber neither loosen the screw 8 nor work on the underlying membrane since this may cause an emission of ni trogen risk of accident clockwise anticlockwise Rear suspension Standard ad justment Adjustment for racetrack use Possible adjustments Shock absorber distance be tween centers A 321 1 5 mm from 321 to 323 mm from 319 ...

Page 30: ...d left are provided with four brake pads The rear brake caliper is provided with two brake pads Carry out a visual check between the disc and the pads proceeding from above on the rear part for the front brake calipers 1 from below on the rear part for the rear brake caliper 2 aWARNING The excessive wear of the friction mate rial would cause the contact of the pad metal support with the disc with ...

Page 31: ...stant NOTE If necessary contact your aprilia Official Dealer 534 4 2 4 2 42 Carefully read p 59 MAINTENANCE NOTE Perform the maintenance opera tions with doubled frequency if the vehicle is used in rainy or dusty areas on uneven surfaces or on racetracks Have the accelerator control cables checked by an aprilia Official Dealer after the first 1000 km 625 mi and successively every 7500 km 4687 mi T...

Page 32: ...re in order to avoid burns Lift the fuel tank see p 76 LIFTING THE FUEL TANK NOTE The vehicle is equipped with two spark plugs per cylinder A and B The following operations refer to the two spark plugs of one cylinder but are valid for both cylinders aCAUTION Carry out all the operations indicated on the first spark plug and then repeat them on the second spark plug of the same cylinder For the re...

Page 33: ...109 TECHNICAL DA TA in order not to compromise the life and performance of the engine To check the spark plug gap use a wire thickness gauge 7 to avoid damaging the platinum covering Check the spark plug gap with a wire thickness gauge 7 aCAUTION Do not try to recover the spark plug gap in any way The gap must be 0 6 0 7 mm other wise it is necessary to change the spark plug Make sure that the was...

Page 34: ...lfway to make sure that the springs provide for lifting it completely The side stand must rotate freely if nec essary grease the joint see p 113 LU BRICANT CHART The side stand 1 is provided with a safety switch 3 that has the function to prevent or interrupt the operation of the engine with the gears on and the side stand 1 down To check the proper functioning of the safety switch 3 proceed as fo...

Page 35: ...sary excepting occasional checks and the recharge when required 4 4 2 3 Carefully read p 93 BATTERY Make sure that the ignition switch is in position 1 Remove the rider saddle see p 76 RE MOVING THE RIDER SADDLE Remove the red protection element 1 Make sure that the cable terminals 2 and the battery terminals 3 are in good conditions and not corroded or covered with deposits covered with neutral g...

Page 36: ...ewards Remove the red protection element 3 Unscrew and remove the screw 4 on the positive terminal Move the positive cable 5 sidewards Unscrew and remove the screw 6 Remove the bracket 7 that locks the battery Grasp the battery 8 firmly and remove it from its compartment by lifting it aWARNING Once it has been removed the battery must be stored in a safe place and kept away from children Position ...

Page 37: ...arger for the desired type of re charge see table Connect the battery with a battery charg er aWARNING During the recharging or the use make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging Switch on the battery charger aWARNING Reassemble the battery only 5 10 min utes after disconnecting the recharge apparatus since the battery continues to pr...

Page 38: ...ten the screw 3 aWARNING Upon reassembly connect first the pos itive cable and then the negative ca ble Connect the positive terminal by means of the screw 4 Connect the negative terminal by means of the screw 5 Cover the terminals of the cables and of the battery with neutral grease or vase line Put back the red protection element 6 Put back the rider saddle see p 76 RE MOVING THE RIDER SADDLE aC...

Page 39: ...ortant to check the charge periodi cally about once a month during the win ter or when the vehicle remains unused in order to prevent the deterioration of the battery Recharge it completely with a normal charge see p 95 RECHARGING THE BATTERY If the battery remains on the vehicle dis connect the cables from the terminals 4 37 4 3 Carefully read p 59 MAINTENANCE The vehicle is provided with four sw...

Page 40: ...d as follows Turn the ignition switch to position 1 to avoid any accidental short circuit Loosen the screw 1 Move the safety clip 2 Open the cover of the box 3 containing the secondary fuses Extract the fuses one by one and check if the filament 4 is broken Before replacing a fuse try to find out the cause of the trouble if possible Replace the damaged fuse with a new one having the same amperage ...

Page 41: ...ion switch to electric fans clock D From ignition switch to parking lights rear stoplights horn dashboard lights direction indicators E From ignition switch to electronic unit fuel pump relay engine stop relay NOTE Three fuses are spare fuses ARRANGEMENT OF THE 30A MAIN FUSES F From battery to ignition G From battery to ignition NOTE One fuse is a spare fuse RSVmille R UK book Page 99 Friday Novem...

Page 42: ...ed on the wall is slightly under the horizontal line of the headlight about 9 10th of the total height To adjust the headlight beam Position the vehicle on the stand see p 58 POSITIONING THE VEHICLE ON THE STAND Working on the rear left side of the front part of the fairing adjust the appropriate screw 1 by means of a short cross tip screwdriver By SCREWING IT clockwise you set the beam upwards By...

Page 43: ...ing a clean and dry cloth Do not leave fingerprints on the bulb since these may cause its overheating and consequent breakage If you touch the bulb with bare hands remove any fingerprint with alcohol in order to avoid any damage DO NOT FORCE THE ELECTRIC CA BLES NOTE Before changing a bulb check the fuses see p 98 CHANGING THE FUSES 4 3 2 5 3 If you need assistance or technical advice consult your...

Page 44: ...a way as to avoid positioning them wrongly upon reassembly If it is necessary to remove all the connec tors at the same time mark them and make sure that you position them correctly upon reassembly Remove the front part of the fairing see p 79 REMOVING THE FRONT PART OF THE FAIRING Move the protection element 4 of the bulb to be changed with your hands aCAUTION To extract the bulb electric connect...

Page 45: ...tors at the same time mark them and make sure that you position them correctly upon reassembly Remove the front part of the fairing see p 79 REMOVING THE FRONT PART OF THE FAIRING Move the protection element 9 with your hands aCAUTION To extract the bulb electric connector do not pull its wires Grasp the bulb electric connector 10 pull it and disconnect it from the bulb Release the two ends of the...

Page 46: ...osition the protection screen in its seat Tighten the screw 1 moderately and carefully to avoid damaging the protection screen Press the bulb 3 slightly and rotate it anticlockwise Extract the bulb 3 from its seat aCAUTION Insert the bulb in the bulb socket mak ing the two bulb pins coincide with the relevant guides on the socket Correctly install a new bulb of the same type aCAUTION If the bulb s...

Page 47: ...CLE ON THE STAND Unscrew and remove the two screws 2 Remove the protection screen 3 NOTE Upon reassembly correctly posi tion the protection screen in its seat Tighten the screw 2 carefully without ex erting too much pressure in order to avoid damaging the protection screen Press the bulb 1 slightly and rotate it anticlockwise Extract the bulb 1 from its seat aCAUTION Insert the bulb in the bulb so...

Page 48: ...nditions use of salt and anti ice chemical products on the roads during the winter Avoid leaving deposits of industrial and polluting powders tar spots dead in sects bird droppings etc on the body Avoid parking the vehicle under trees since in some seasons residues resins fruits or leaves fall down which contain substances that may damage the paint aWARNING After the vehicle has been washed its br...

Page 49: ...washed the vehicle Do not use polishing pastes on matt paints Do not wash the vehicle under the sun especially during the summer when the body is still warm since if the shampoo dries before being rinsed away it can damage the paint Do not use liquids at a temperature ex ceeding 40 C to clean the plastic com ponents of the vehicle aCAUTION Do not direct high pressure water or air jets or steam jet...

Page 50: ...he vehicle in an unheated not hu mid room away from sunlight with mini mum temperature variations Position and tie a plastic bag on the final pipe of the exhaust silencer in order to prevent moisture from getting into it NOTE Position the vehicle on the front m and rear m support stands so that both tyre are raised from the ground Position the vehicle on the appropriate front support stand see p 6...

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