APRILIA RSV MILLE - PART 3 1999 Manual Download

Page: 43 / 52

use and maintenance RSV mille Sport Production

TRANSMISSION

Type .......................................................................

mechanical, 6 gears with foot control on the left side of the engine

GEAR RATIOS

Ratio

Primary

Secondary

31/60 = 1 : 1.935

14/35 = 1 : 2.500

16/28 = 1 : 1.750

19/26 = 1 : 1.368

22/24 = 1 : 1.090

23/22 = 1 : 0.956

27/23 = 1 : 0.851

Final ratio

Total ratio

17 / 42 = 1 : 2.470

11,948
8,368
6,543
5,216
4,573
4,073

DRIVE CHAIN

Type .......................................................................

endless (with no connection link) with sealed links

Model .....................................................................

525

FUEL SUPPLY
SYSTEM

Type .......................................................................

electronic injection (Multipoint)

Choke.....................................................................

Ø 51 mm

FUEL SUPPLY

Fuel ........................................................................

premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

FRAME

Type .......................................................................

double two-beam frame with light alloy cast elements and extruded elements

Steering inclination angle.......................................

24.2 °

Fore stroke.............................................................

95 mm

SUSPENSIONS

Front.......................................................................

upside-down telescopic adjustable fork with hydraulic operation, rod Ø 43 mm

Stroke.....................................................................

125 mm

Rear .......................................................................

light-alloy, oscillating rear fork with extruded arms and hydropneumatic adju-
stable mono-shock absorber

Wheel stroke ..........................................................

130 mm

BRAKES

Front.......................................................................

with double floating disc - Ø 320 mm, calipers with four pins with differenti-
ated diameter

Rear .......................................................................

disc brake - Ø 220 mm, caliper with double pin

WHEEL RIMS

Type .......................................................................

in light alloy with withdrawable pin

Front.......................................................................

3.50 x 17”

Rear .......................................................................

6.00 x 17”

FRONT TYRE

Type .......................................................................

120 / 70 ZR - 17

; 120 / 65 2R -17

Model .....................................................................

PIRELLI DRAGON EVO MTR21 CORSA

– Alternative ...........................................................

PIRELLI MTR 01A

Inflation pressure solo rider....................................

230 kPa (2,3 bar)

Ing-02.fm Page 93 Thursday, December 16, 1999 5:21 PM

Summary of Contents for RSV MILLE - PART 3 1999

Page 1: ... der In case any maintenance operation has to be carried out it is advisable to use latex gloves Routine maintenance operations can usu ally be carried out by the user but some times the use of specific tools and specific technical skills may be required In case periodic maintenance operations assistance or technical advice are needed contact an aprilia Official Dealer who will ensure you prompt a...

Page 2: ...k P every 7000 km 4375 mi P Light operation direction C Fork C Light system C C Safety switches C C Clutch fluid C Brake fluid C Coolant C Engine oil S every 3500 km 2187 mi S Tyres C every 1000 km 625 mi C Tyre pressure R every month R Engine idling rpm R R Engine oil pressure warning light LED at every start C Drive chain tension and lubrication every 1000 km 625 mi C Brake pad wear before every...

Page 3: ...Braking systems C C Cooling system C Clutch fluid every 2 years S Brake fluid every 2 years S Coolant every 2 years S Fork oil every 10000 km 6250 mi S Brake pads if worn S Nut bolt screw tightening C C Suspensions and attitude C C Fuel pipes C every 4 years S C check and clean adjust lubricate or change if necessary P clean S change R adjust Carry out the maintenance operations more frequently if...

Page 4: ... identification numbers if you do not want to incur severe penal and administrative sanctions In par ticular the alteration of the frame number results in the immediate invalidity of the guarantee FRAME NUMBER The frame number is stamped on the right side of the steering column Frame no ENGINE NUMBER The engine number is stamped on the rear part of the engine near the pinion Engine no Ing 02 fm Pa...

Page 5: ...or 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 pro vided on the left 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 MAX mark aCAU...

Page 6: ...ns described here below be particularly careful in order to avoid burns Remove the lower fairing see p 67 RE MOVING THE LOWER FAIRING Position a container 1 with more than 4200 cm capacity in correspondence with the drain plug 2 positioned on the tank Unscrew and remove the drain plug 2 positioned on the tank Unscrew and remove the filling cap 3 Drain the oil and let it drop for a few min utes ins...

Page 7: ...oil changes NOTE Prepare a pipe clamp 11 to re place the original one special type Loosen the clamp 12 and disconnect the pipe 13 Unscrew and remove the engine oil filter 10 positioned on the tank and clean it with a jet of compressed air Check the seal of the engine oil filter 10 positioned on the tank screw and tighten it Engine oil filter 10 driving torque 30 Nm 3 0 kgm Connect the pipe 13 and ...

Page 8: ...PORT STAND Insert the two ends of the stand 5 in the two holes 6 positioned on the lower ends of the front fork Rest one foot on the front part of the stand 5 Push the stand 5 downwards until it reaches the end of its stroke 2 2 Check the air cleaner every 7500 4687 mi km or 8 months change it every 15000 km 9375 mi or more frequently if the vehi cle is used on dusty or wet roads It is possible to...

Page 9: ...ce on a clean sur face If necessary clean the air cleaner 3 with a compressed air jet directing it from the inside towards the outside of the filter Clean the outer part of the air cleaner 3 with a cloth CHANGING aCAUTION Do not use filters that have already been used Replace the air cleaner 3 with a new one of the same type Every 7500 km 4687 mi remove the plug 4 Empty its content into a containe...

Page 10: ...le is stable Have someone keep the handlebar steady in running position so that the steering is locked Brake caliper screw 1 driving torque 50 Nm 5 kgm Unscrew and remove the two screws 1 that fasten the front brake caliper 2 Withdraw the brake caliper 2 from the disc leaving it attached to the pipe 3 aCAUTION Never pull the front brake lever after re moving the calipers otherwise the pis tons may...

Page 11: ...el nut 4 driving torque 80 Nm 8 kgm aCAUTION Proceed with care in order not to dam age the brake pads Insert the brake caliper 2 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 1 with two new screws of the same type Screw and tighten the two screws 1 that fasten the b...

Page 12: ... the appropriate rear support stand see p 58 POSI TIONING THE VEHICLE ON THE REAR SUPPORT STAND Wheel nut 1 driving torque 120 Nm 12 kgm Loosen and remove the nut 1 taking the washer Put a support 2 under the tyre in such a way as to keep the wheel in its position after loosening it Withdraw the wheel pin 3 from the left side Make the wheel advance and release the drive chain 4 from the crown gear...

Page 13: ...to align the holes Move the wheel backwards until its cen tral hole and the holes on the rear fork are aligned Rotate the support plate 8 complete with brake caliper 9 and with fulcrum on the stop pin 10 until it is aligned with the holes Introduce the wheel pin 3 completely from the left side aCAUTION Make sure that the wheel pin 3 is in serted completely with the head in the appropriate seat on ...

Page 14: ...intermediate point between pinion and crown in the lower part of the chain is about 25 mm Move the vehicle forwards or turn the wheel in order to be able to check the vertical oscillation of the chain even when the wheel turns the slack must be constant in all the rotation phases of the wheel aCAUTION If in some positions the slack is higher than in others this means that there are crushed or seiz...

Page 15: ...his is not possible contact an APRILIA Official Dealer who will provide for changing the chain Finally check the wear of the rear fork protection shoe CLEANING AND LUBRICATION 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 ...

Page 16: ...ine and the exhaust si lencer have completely cooled down Fuel vapours are noxious for your health Before proceeding 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 Remove the rider saddle see beside REMOVING THE RIDER SADDLE Unscrew and remove the two screws 4 th...

Page 17: ...r support stand see p 58 POSITIO NING THE VEHICLE ON THE REAR SUPPORT STAND Remove the two side fairings see beside 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 Taking the lower fairing support 6 insi de the exhaust silencer Let the side stand down Withdraw the two pipes 7 8 from the hole provided on th...

Page 18: ... the other side cover 2 6 4 2 2 6 7 22 23 Position the vehicle on the side stand on firm and level ground 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 and 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 remo v...

Page 19: ...ear 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 positio ned on the support Move the front part of the fairing 4 sli ghtly 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 ...

Page 20: ...the greatest care lif ting it with slight movements Raise and remove the air cleaner case 4 aCAUTION Plug the openings with a clean cloth to prevent any foreign matters from get ting into the suction ducts aCAUTION Upon reassembly The two conveyors 5 must be posi tioned correctly and adhere perfectly to the spongy material 6 around the front air intake holes Before tightening the screws 3 make sur...

Page 21: ...level ground Carry out a visual check between the disc and the pads proceeding from below on the front part for the front brake calipers 1 from below on the rear part for the rear brake caliper 2 aCAUTION The excessive wear of the friction mate rial would cause the contact of the pad metal support with the disc with conse quent metallic noise and production of sparks from the caliper braking effi ...

Page 22: ...ary contact your APRILIA Official Dealer 2 4 3530 3 The front suspension consists of an hy draulic fork connected to the steering col umn by means of two plates For the setting of the vehicle attitude each rod of the fork is provided with an upper screw 1 for the adjustment of the hydrau lic braking with extended shock absorber a lower screw 2 for the adjustment of the hydraulic braking with compr...

Page 23: ... Decrease of the hydraulic braking with compressed shock absorber Increase of the hydraulic braking with compressed shock absorber Standard adjustment about 11 clicks From the end of stroke complete clockwise rotation give 7 18 anticlockwise clicks Recommended kind of road Normal or uneven roads Smooth surfaces or racetracks Lower screw adjusters 2 By rotating them anticlockwise By rotating them c...

Page 24: ...o adjust the setting according to the intended use of the vehicle 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 adju sters 1 2 beyond the end of stroke in both directions in order to avoid any damage Slightly unscrew the locking ring nut 4 by means of the appropri...

Page 25: ... of the hydraulic braking with extended shock absorber Standard adjustment about 9 clicks From the end of stroke complete clockwise rotation give 7 18 anticlockwise clicks Recommended kind of road Normal or uneven roads Smooth surfaces or racetracks Knob adjuster 2 By rotating it anticlockwise By rotating it clockwise Function Decrease of the hydraulic braking with compressed shock absorber Increa...

Page 26: ... always start from the most rigid setting complete clockwise rotation of the knob Act on the knob 2 to adjust the hydrau lic braking see table DESCRIPTION USE Knop adjuster 2 By rotating it anticlockwise By rotating it clockwise Function Decrease of the hydraulic braking Increase of the hydraulic braking Recommended kind of road Normal or uneven roads Smooth surfaces or racetracks Standard adjustm...

Page 27: ...nctions correctly and to check if the idling speed is constant NOTE If necessary contact your aprilia Official Dealer 534 4 2 4 2 42 Carefully read p 51 MAINTENANCE The idle stroke of the throttle grip must be 2 3 mm measured on the edge of the grip itself If this is not the case proceed as follows Position the vehicle on the side stand on firm and level ground Withdraw the protection element 3 Lo...

Page 28: ...nner on the spark plug Insert the 13 mm fork spanner pro vided in the tool kit in the hexagonal seat of the spark plug spanner Unscrew the spark plug and extract it from its seat taking care to prevent dust or other substances from getting inside the cylinder Extract the spark plug from the socket spanner Make sure that there are neither carbon deposits nor corrosion marks on the elec trode and on...

Page 29: ...p 70 REMOVING THE AIR CLEANER CASE Put back the fuel tank see p 66 LIFT ING THE FUEL TANK 4 37 4 3 Carefully read p 51 MAINTENANCE The vehicle is provided with four switches 2 Stoplight switch on the rear brake con trol lever 3 Stoplight switch on the front brake con trol lever 4 Safety switch on the side stand 5 Switch on the clutch control lever Make sure that there are no dirt or mud deposits o...

Page 30: ... 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 follows Seat on the vehicle in driving position Fold the side stand 1 Start the engine see p 43 STARTING With released throttle grip 4 Pos A and engine idling pull the clutch lever 5 completely Engage the first gear pushing the shift ing lever 6 downwards Lower...

Page 31: ...cks and the recharge when required 4 4 2 3 Carefully read beside BATTERY Make sure that the ignition switch is in position m Remove the rider saddle see p 66 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 grease or Vase line If neces...

Page 32: ...ards 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 Seize 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 th...

Page 33: ...the battery continues to produce gas for a short lapse of time 34 4 44 29 Carefully read p 81 BATTERY Make sure that the ignition switch is in position m Remove the rider saddle see p 66 RE MOVING THE RIDER SADDLE NOTE The battery 1 must be positio ned in its compartment with the terminals facing the rear part of the vehicle Put the battery 1 in its compartment Put back the bracket 2 that locks th...

Page 34: ...e vehicle dis connect the cables from the terminals 4 53 3 Carefully read p 51 MAINTENANCE aCAUTION Do not repair faulty fuses Never use fuses different from the rec ommended ones The use of unsuitable fuses may cause damages to the electric system or in case of short circuit even a fire NOTE If a fuse blows frequently there probably is a short circuit or an overload in the electric system In this...

Page 35: ...15A SECONDARY FUSES A From voltage regulator to high beam relay low beam relay B From voltage regulator to coils engine stop relay fuel pump C From ignition 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 ARRA...

Page 36: ...w 1 by means of a short cross tip screwdriver By SCREWING IT clockwise you set the beam upwards By UNSCREWING IT anticlockwise you set the beam downwards 5 3 Carefully read p 51 MAINTENANCE aWARNING Risk of fire Keep fuel and other flammable sub stances away from the electrical com ponents aCAUTION Before changing a bulb move the igni tion switch to position m and wait a few minutes so that the bu...

Page 37: ...ract the bulb socket do not pull the electric wires Grasp the parking light bulb socket 4 pull it and remove it from its seat Withdraw the bulb 1 and replace it with one of the same type HIGH BEAM BULBS Remove the front part of the fairing see p 69 REMOVING THE FRONT PART OF THE FAIRING Move the protection element 5 of the bulb to be changed with your hands Withdraw the electric terminal 6 Release...

Page 38: ...firm and level ground Unscrew and remove the screw 12 NOTE While removing the protection screen proceed carefully in order not to break the cog Remove the protection screen 13 aWARNING Upon reassembly correctly position the protection screen in its seat Tighten the screw 12 moderately and carefully to avoid damaging the protec tion screen Press the bulb 14 slightly and rotate it anticlockwise Extr...

Page 39: ...protection screen in its seat Tighten the screw 1 carefully without exerting too much pressure in order 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 42 30...

Page 40: ...Then rinse with plenty of water and dry with chamois leather To clean the outer parts of the engine use a degreaser brushes and wipers After washing the vehicle always Lift the fuel tank see p 66 LIFTING THE FUEL TANK Remove the cap 1 Empty its content into a container and deliver it to a salvage centre aCAUTION To clean the lights use a sponge soaked with water and a neutral detergent rub bing th...

Page 41: ... BATTERY and p 84 LONG INACTIVITY OF THE BATTERY Wash and dry the vehicle see p 90 CLEANING Polish the painted surfaces with wax Inflate the tyres see p 38 TYRES By means of a suitable support position the vehicle so that both tyres are raised from the ground Place the vehicle in an unheated not hu mid room away from sunlight with mini mum temperature variations Position and tie a plastic bag on t...

Page 42: ...995 6 cm Bore stroke 100 mm 63 4 mm Compression ratio 11 4 0 5 1 Starting electric Engine idling rpm 1250 100 rpm Clutch multidisc in oil bath with hydraulic control on the left side of the handlebar and PPC device Lubrication system dry pan with separate oil tank and cooling radiator Air cleaner with dry filter cartridge Cooling liquid cooled CAPACITY Fuel reserve included 20 L Fuel reserve 4 5 1...

Page 43: ...ype double two beam frame with light alloy cast elements and extruded elements Steering inclination angle 24 2 Fore stroke 95 mm SUSPENSIONS Front upside down telescopic adjustable fork with hydraulic operation rod Ø 43 mm Stroke 125 mm Rear light alloy oscillating rear fork with extruded arms and hydropneumatic adju stable mono shock absorber Wheel stroke 130 mm BRAKES Front with double floating ...

Page 44: ...ator with permanent magnet 12 V 400 W BULBS Low beam halogen 12 V 55 W High beam halogen 12 V 60 W Front parking light 12 V 5 W Direction indicators 12 V 10 W Rear parking light number plate light stoplight 12 V 5 21 W Revolution counter 12 V 2 W Left multifunction display 12 V 2 W Right multifunction display 12 V 2 W WARNING LIGHTS Neutral 12 V 3 W Direction indicators 12 V 3 W Fuel reserve 12 V ...

Page 45: ...perature range 30 C 140 C dripping point 150 C 230 C high protection against corrosion good resistance to water and oxidation Protection of the battery poles neutral grease or vaseline Spray grease for chains recommended 0CHAIN SPRAY or CHAIN LUBE Brake fluid recommended 0F F DOT 5 DOT 4 compatible or BRAKE 5 1 DOT 5 compatibile DOT 4 aWARNING Use new brake fluid only Clutch fluid recommended 0IP ...

Page 46: ...96 4 3 2 5 30 2 0 243 9 use and maintenance RSV mille Sport Production Ing 02 fm Page 96 Thursday December 16 1999 5 21 PM ...

Page 47: ...97 4 3 2 5 30 2 0 243 9 use and maintenance RSV mille Sport Production Ing 02 fm Page 97 Thursday December 16 1999 5 21 PM ...

Page 48: ...98 use and maintenance RSV mille Sport Production MPORTERS Ing 02 fm Page 98 Thursday December 16 1999 5 21 PM ...

Page 49: ...99 use and maintenance RSV mille Sport Production MPORTERS Ing 02 fm Page 99 Thursday December 16 1999 5 21 PM ...

Page 50: ...100 use and maintenance RSV mille Sport Production 7 2 2 236 MILLE 3PORT 0RODUCTION Ing 02 fm Page 100 Thursday December 16 1999 5 21 PM ...

Page 51: ...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 52: ...ank its customers for the purchase of this vehicle Do not dispose of oil fuel polluting substances and components in the envi ronment Do not keep the engine running if it isn t necessary Avoid disturbing noises Respect nature Ing 02 fm Page 102 Thursday December 16 1999 5 21 PM ...

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