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APRILIA RSV Mille 1000 1999, Technical Training Course, Page: 22 / 90

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APRILIA RSV Mille 1000 1999 Technical Training Course Download Page 22

Aprilia Consumer Service Spa
Technical Service and Training
Release 4  july 99

This material is didactic and
may be changed following the technical
 development of the product

1.4 FAULTS TABLE

FAULT CODE

COMPONENT INVOLVED

CAUSE

NOTES

11

CAMSHAFT SENSOR

Sensor not connected, faulty
wiring, sensor broken

START ENGINE

(t>4 sec)

12

CRANKSHAFT SENSOR

Sensor not connected, faulty
wiring, sensor broken

START ENGINE

(t>4 sec)

13

INTAKE PRESSURE SENSOR

Sensor not connected, faulty
wiring, sensor broken

ENGINE RUNNING OR
ENGINE STOPPED

14

INTAKE/ATMOSPHERIC PRESSURE
SENSOR

Increased differences
between sensor signals

ENGINE RUNNING OR
ENGINE STOPPED

15

THROTTLE SENSOR

Sensor not connected, faulty
wiring, sensor broken

ENGINE RUNNING OR
ENGINE STOPPED

21

COOLANT TEMPERATURE SENSOR

Sensor not connected, faulty
wiring, sensor broken

ENGINE RUNNING OR
ENGINE STOPPED

22

AIR TEMPERATURE SENSOR

Sensor not connected, faulty
wiring, sensor broken

ENGINE RUNNING OR
ENGINE STOPPED

23

ATMOSPHERIC PRESSURE SENSOR

Sensor – inside control unit
– defective

ENGINE RUNNING OR
ENGINE STOPPED

33

COIL 1 CYLINDER1

Coil not connected, faulty wiring,
sensor broken

ENGINE RUNNING

34

COIL 2 CYLINDER 1

Coil not connected, faulty wiring,
sensor broken

ENGINE RUNNING

35

COIL 1 CYLINDER 2

Coil not connected, faulty wiring,
sensor broken

ENGINE RUNNING

36

COIL 2 CYLINDER 2

Coil not connected, faulty wiring,
sensor broken

ENGINE RUNNING

41

TIP OVER SENSOR

NOT CONNECTED

DEFECTIVE

ENGINE RUNNING OR
ENGINE STOPPED

NO START

CONDITIONS AT START

-

Tip over conditions

-

Safety logic not
satisfied

-

Two defective coils
on same cylinder

See table

WHAT TO DO WHEN A FAULT CODE APPEARS:

1.

  CHECK COMPONENT WITH TESTER

2.

  CHECK CONTACTS (SENSOR/WIRING– WIRING/CONTROL UNIT)

3.

  CHECK WIRING

Summary of Contents for RSV Mille 1000 1999

Page 1: ...onsumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product RSV 1000 Technical Training Course...

Page 2: ...ent linked with highpowered bikes For Aprilia the sense of wonder means breaking away from set patterns having the courage to face new challenges in this case shaking off a paradoxically conservatile...

Page 3: ...e was to create a motorcycle with extremely compact dimensions one that could cleave the air in an optimumn fashion and protect the rider against the impact of the wind and high speeds The flow inside...

Page 4: ...r it is equally true that the dimensione of the engine are penalized by the size of the angle between the cilinders The decision to use a 60 V formation two cylinder engine responds perfectly to the n...

Page 5: ...the rear axle In high powered two cylinder engines this phenomenon is accentuated by the high engine braking effect this can cause the so called bouncing or the tendency of the rear wheel to block and...

Page 6: ...n the basis of the data received control operation of both the injection system and the ignition system The injectors are fed by a pump which produces a constant pressure of 330 Kpa The throttle bodie...

Page 7: ...es as the reply to four very precise requests light weight aerodynamic line respect for the environment and for approval standards The choice of the 2 in 1 exhaust proved to be the most appropriate si...

Page 8: ...technical development of the product As regards respect for the environment the engine of the RSV Mille complies with the parameters of the future European standards EURO 1 which comes into force in 1...

Page 9: ...he frame giving it the most in terms of planning and knowledge of structures choice of materials weight distribution and dynamic behaviour Particular care was taken with the torsional stiffness with a...

Page 10: ...of this rnotorcycle is the analog and digital dashboard It is to all effects a real computer on board able to supply the rider w th all the information ho needs at any time A sophisticated exclusive d...

Page 11: ...eel disks with diameter of 320 mm At the rear the bike is fitted with 220 mm disk and caliper with double opposed piston d 30 mm In terms of product quality the RSV Mille has achieved an even higher i...

Page 12: ...wer together with a lower specific consumption and reducing the unburt elements in the exhaust gases These advantages are got thank to a more exact air fuel ratio metering and a good spark advance con...

Page 13: ...he throttle opening angle and engine temperature signals At the start the control unit receives the engine revolutions and phase signals which allow the injection and ignition control To make the star...

Page 14: ...injection time To determine the injection time there are a number of different sensors which increase or reduce the injection volume on the basis of the atmospheric pressure atmospheric temperature e...

Page 15: ...he compensation devices illustrated later on The switch from D J to alpha n occurs gradually See down figure As shown in the above figure the D J map is almost 100 active in low load running condition...

Page 16: ...elta Alpha compensation boosts the engine fuel supply during rapid acceleration cuts off the fuel during deceleration Positioned inside the control unit box Reads the Patm The control unit normally re...

Page 17: ...nd the position of the camshaft The control unit also detects the starting phase injecting the fuel into the cylinders asynchronously Crankshaft sensor Camshaft position sensor Reads the position of t...

Page 18: ...e product Injection stop control Rpm limiter Software control The control unit stops the injection if the rpm are excessive Deceleration The injector function is disabled during deceleration with the...

Page 19: ...0 rpm the control unit de energizes the coil signal to prevent a possible kick back in the pistons when turning the bike off Tip over sensor If the bike tips over the tip over sensor stops the injecto...

Page 20: ...tic errors in the injection components To check the crankshaft and camshaft sensors make a starting attempt lasting 4 sec If EFI DOES NOT appear this means there is no connection between the display a...

Page 21: ...tandard values SEE CO SETTING 3 If there are any faults the fault codes will appear in sequence The sequence will keep repeating until you exit the Dealer Mode AFTER REPAIRING THE FAULT SWITCH THE BIK...

Page 22: ...SENSOR Sensor not connected faulty wiring sensor broken ENGINE RUNNING OR ENGINE STOPPED 22 AIR TEMPERATURE SENSOR Sensor not connected faulty wiring sensor broken ENGINE RUNNING OR ENGINE STOPPED 23...

Page 23: ...OTING WHAT TO DO IF THE ENGINE DOESN T START AND NO FAULT IS SHOWN ON THE SELF DIAGNOSTICS SYSTEM Check the fuel pump Check the injectors Check that the anti theft system connector is connected Check...

Page 24: ...TY RUN POSSIBILITY CAMSHAFT SENSOR NOT POSSIBLE POSSIBLE CRANKSHAFT SENSOR NOT POSSIBLE NOT POSSIBLE MANIFOLD PRESSURE SENSOR OR PRESSURE SENSOR SIGNAL POSSIBLE POSSIBLE THROTTLE POSITION SENSOR POSSI...

Page 25: ...speed press key B for about 1 second a 1st partial reset instantaneous speed on display press key R for about 3 seconds 1st partial 0 b maximum speed reset maxS and 1st partial on display press key R...

Page 26: ...AP go back to b Stop watch Press and hold LAP and then within 0 7 seconds press key D to start the stop watch b 1 Press LAP stop watch starts the LAP key is not enabled for 10 sec b 2 Starting from ti...

Page 27: ...and the rpm The devices described below affect the timing in the stopping or starting of the ignition system Crankshaft sensor The engine pick up coil produces a signal when it meets the projecting pa...

Page 28: ...ting as shown in the separate figure The ignition phase starts in this way asynchronous synchronous phase 1 The control unit reads coolant temperature throttle angle engine rpm Patm Battery voltage Th...

Page 29: ...signal for each cycle INT COMPRESS IGNITION EXPANSION EXHAUST corresponding to an angle of 720 The camshaft sensor sends 12 signals for each rotation of the crankshaft i e one signal every 60 The firs...

Page 30: ...s set by the clipped signal of the pick up The CPU gives consensus to the ignition only These are fixed spark timing and fixed dwell timing conditions At medium rpm levels the spark dwell timing is fi...

Page 31: ...chnical development of the product SECTION 3 DESCRIPTION OF ELECTRONIC INJECTION SYSTEM The RSV1000 electronic injection system is made up of the following components 1 Electronic control unit 2 Senso...

Page 32: ...cal system by two fast connectors As well as being fed with power and receiving signals from the sensors through these connectors the control unit also controls the injectors and l t ignition coils an...

Page 33: ...erial is didactic and may be changed following the technical development of the product In addition the following systems components are inside the control unit coils injectors control power circuit A...

Page 34: ...rilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product ECU ELECTRONIC WIRING DIAGRA...

Page 35: ...y plug in connectors that plug into the ECU printed circuit The connectors connect the control unit to the sensors and actuators injectors coils via the wiring Also most of the connected components ca...

Page 36: ...ervice and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product SECTION 4 POSITIONING OF SENSORS AND INJECTORS The position of eac...

Page 37: ...nce and allows the ECU to recognise the exact sequence of each single cylinder resetting the internal count to zero during the asynchronous ignition phase The ohmic resistance of the sensor measured a...

Page 38: ...resistive sensor The sensor sends a voltage signal proportional to the opening angle of the throttle valve to the control unit The sensor is positioned in the throttle assembly as shown in the figure...

Page 39: ...s positioned inside the magneto flywheel Sends a voltage pulse to the control unit for every 60 of rotation and is of fundamental importance together with the camshaft pulse in allowing the ECU to set...

Page 40: ...angle is greater than 44 degrees it activates the switch terminals A monitoring resistor is connected in parallel to the switch for the control unit to check the connection to the component This new...

Page 41: ...rs although only one of them is connected to the ECU the other is connected to the control panel SW ECU DIAGNOSIS EXISTENT OHMIC DIAGNOSIS AVERAGE VALUE 20C 2700 OHMS DELTA CAN BE 300 OHM MEASURED BET...

Page 42: ...the air cleaner box and provides a linear voltage in the range of 1 to 4 2 Volts to the control unit It must be supplied with a continuous voltage of 5 Volts provided by the control unit The operating...

Page 43: ...g the technical development of the product INJECTORS Each cylinder has an injector The location in the throttle assembly is shown in the figure The injector used is made up of the following components...

Page 44: ...Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product OTHER RELEVANT ELECTRICAL COMPONENTS STARTER MOTOR The character...

Page 45: ...development of the product DIODE MODULE The figure shows the electrical wiring in the module The continuity of the diodes can be checked with a tester or with a 4 5 12 Volt battery with an arbitrary...

Page 46: ...ning Release 4 july 99 This material is didactic and may be changed following the technical development of the product VOLTAGE REGULATOR The voltage regulator is situated at the rear of the bike on th...

Page 47: ...UUM SWITCH ISC 29 SECONDARY FUSES 30 KEY SWITCH 31 DIPPED BEAM RELAY 32 MAIN BEAM RELAY 33 FANS RELAY 34 FRONT SIDE LIGHT 35 MAIN BEAM LIGHT 36 DIPPED BEAM LIGHT 37 FRONT RH DIRECTION INDICATOR 38 FRO...

Page 48: ...the intake pressure The excess pressure is vented by the regulator and the excess fuel goes back to the tank through the return hose The regulator is controlled by the inlet manifold average pressure...

Page 49: ...erial is didactic and may be changed following the technical development of the product The regulator shown in the figure has the following components a vacuum operated diaphragm and spring and a stee...

Page 50: ...Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product POSITIONING OF ELECTRICAL COMPONENTS ON BIKE VOLTAGE RE...

Page 51: ...and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product COIL DIODE UNIT POWER RELAY DIAG CONNECTOR THROTTLE SENSOR ABS PRESS SEN...

Page 52: ...OLTAGE TEST Check the electrolyte level Check the battery voltage Start the engine and take it up to 4000 rpm Switch the light switch to dipped beam test the DC voltage between the battery terminals w...

Page 53: ...from its housing and tilt it sideways at an angle greater than 45 to simulate a fall The standard reading must be 0 1 Ohms CHECK 5 THERMISTOR CHECK Check the sensor resistance using the tester in the...

Page 54: ...e engine off turn the ignition key to ON When positioned in the throttle body enable the control unit diagnostics function If there are no errors i e sensors all OK one of three possible numbers will...

Page 55: ...CHECK The readings below taken one by one must give a value of 15 kOhms Ohmmeter between 1 3 Ohmmeter between1 2 CHECK 8 DIODE MODULE CHECK Disconnect the connector from the diode module and apply th...

Page 56: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 57: ...fuel tank Disconnect the pump assembly 3 way connector Feed the green and blue wires coming from the side of the pump assembly with 12 Vdc Ensure that the pump works by giving a buzz and checking that...

Page 58: ...WIRING DIAGRAM PASSING LAP CLAXON LIGHTS LIGHTS P LIGHTS H H Lo H HI TURN R TURN L DISPLAY CRONOMETRO A D 36 34 35 35 72 72 63 31 32 29 67 LEGENDA 29 SECONDARY FUSES 31 MAIN BEAM LIGHTS RELAY 32 DIPPE...

Page 59: ...THROTTLE SENSOR INTAKE PRESSURE SENSOR TERMISTOR H20 AIR TERMISTOR HT COIL 23 HT COIL 24 HT COIL 25 HT COIL 26 PICK UP 2 3 4 5 6 7 28 21 ECU FRONT INIETTOR REAR INIETTOR SENSORE CADUTA DIODES UNIT SP...

Page 60: ...KE PRESSURE SENSOR 4 15 3 5 L R R 10 15 KOHM SEE COMP CHECK BLUE RED BROWN WHITE PINK H20 THERMISTOR 5 15 6 L R 1 9 2 9 KOHM BLUE RED RED BLACK AIR THERMISTOR 6 15 13 L R IDEM BLUE RED RED GREEN TIP O...

Page 61: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 62: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 63: ...MP THERMISTOR 56 SPEED SENSOR 57 FUEL WARNING LIGHT 61 OIL PRESSURE WARNING LIGHT 64 REV COUNTER 65 MULTIFUNCTION DISPLAY 66 SPEEDOMETER CHECK H20 TEMPERATURE INDICATOR DISCONNECT THE THERMISTOR CONNE...

Page 64: ...be more than 6 Volts dc 3 Starting from test 2 turn the wheel so that a screw comes on to the sensor at that moment the voltage should go to zero for about 2 sec and then back to 6 Volts If test 1 do...

Page 65: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 66: ...to the four sections 2 internal and 2 external that form the side fairings with a special polished finish Given the high rigidity of the frame there is no longer any need for the classical cradle arou...

Page 67: ...dactic and may be changed following the technical development of the product NOTE FOR THE REMOVAL AND REFITTING OF THE ENGINE AND SWINGARM ON THE FRAME SPECIAL WRENCHES MUST BE USED FOR UNSCREWING THE...

Page 68: ...ers an excellent MODULARITA through a 4 position adjusting lever The braking pads are studied for informing the rider when the thickness of the braking element is lower than 1 mm FRONT BRAKE DISK Stee...

Page 69: ...ticlockwise Turn it clockwise for having a hardener setting The total setting positions are 40 C Rebound in order to have a softer setting turn the setting screw anticlockwise Turn it clockwise for ha...

Page 70: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 71: ...ic and may be changed following the technical development of the product FRONT FORK SPECIFICATION BEARING PIPE DIAMETER 43 mm STROKE 127 mm REBOUND ADJ COMPRESSION EFFECT MAX 2 TURN SPRING PRE LOAD MA...

Page 72: ...valve Line 3 links line 2 to the airbox when the throttle valve opens to an angle greater than 10 12 degrees During deceleration the system configuration is as shown in the figure The negative pressur...

Page 73: ...ice Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product SECTION 10 TIMING SETTING OF RSV MILLE ENGINE R...

Page 74: ...ERT FIXING SCREW AFTER REACHING THE TDC OF THE REQUESTED CYLINDER 1 3 DETAIL OF THE FIXING POINTS ON THE CRANKSHAFT ATTENTION THE TIMING SETTING OF EACH CYLINDER MUST BE DONE AFTER POSITIONING THE FIX...

Page 75: ...ment of the product 2 TIMING SETTING OF THE REAR CYLINDER 2 3 2 1 ALIGNEMENT OF THE INTERMEDIATE GEAR USING THE PRINTED REFERENCES ON CRANKCASE 2 2 ALIGNEMENT OF THE CAMSHAFT GEARS WITH THE PRINTED RE...

Page 76: ...hanged following the technical development of the product TIMING SETTING OF THE FRONT CYLINDER 1 3 1 ALIGNEMENT OF CRANKSHAFT AND PRIMARY BALANCESHAFT WITH PAINTED REFERENCES 3 2 ALIGNEMENT OF INTERME...

Page 77: ...sumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product SECTION 11 GENERAL DATA RSV MILLE TEC...

Page 78: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 1 TECHNICAL DATA...

Page 79: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

Page 80: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 2 LUBRICANT CHART...

Page 81: ...lia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 3 PRELIMINARY CHECKING OPERATI...

Page 82: ...prilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 4 SERVICE MAINTENANCE CHART...

Page 83: ...0 3 L572 Securing cooling fan support 2 2 M6 6 0 6 Securing cooling fan motor to the support 3 3 M4 2 0 2 L243 Cooling liquid exhaust screws 1 1 M6 10 1 L572 Securing of espansion chamber to the ignit...

Page 84: ...p support 2 SWP 2 9X12 1 5 0 15 Securing of pump wiring to the flange 2 M6 10 1 Fuel tank Description Qnty Screw nut Nm Kgm ref Securing of the fuel filler cap 3 M5 5 0 5 Securing of the fuel pump fla...

Page 85: ...ght support to rear fairing 2 2 M5 h 5 l 3 0 5 0 3 Securing of rear fairing passenger belt 2 M6 12 1 2 Securing of frame cover 4 M5 2 0 2 Securing of internal fairing and side fairing 8 SWP 2 9 1 0 1...

Page 86: ...hing clutch side Hex socket screw 2 M8X25 25 2 5 Bushing Flywheel side Cilinder head screw 1 M8X20 25 2 5 Bushing Flywheel side Cilinder head screw 1 M6X20 11 1 1 L243 ENGINE SHAFT COUNTERSHAFT GEARBO...

Page 87: ...1 1 1 Cilinder head Sparkplug 4 18 1 8 Intake flange Cilinder head screw 4 M8X25 19 1 9 Distribuition chain tension adjuster Locking screw 2 M16X1 5 30 3 Cilinder head Temperature sensor 1 20 2 Cilind...

Page 88: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 6 WIRING DIAGRAM...

Page 89: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product 6 1 WIRING DIAGRAM KEY...

Page 90: ...Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

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