APRILIA RSV MILLE - PART 3 1999 Bedienungsanleitung

use and maintenance RSV mille Sport Production

-!).4%.!.#%

aWARNING

Risk of fire.

Keep fuel and other flammable sub-

stances away from the electrical com-

ponents.

Before beginning any maintenance op-

eration or any inspection of the vehicle,

stop the engine, extract the key from

the ignition block, wait until the engine

and the exhaust system have cooled

down and if possible lift the vehicle by

means of the proper equipment, on firm

and flat ground.

Before proceeding, make sure that the

room in which you are working is prop-

erly ventilated.

Keep away from the red-hot parts of the

engine and of the exhaust system, in or-

der to avoid burns.

The vehicle is made up of not edible

parts. Never bite, suck, chew or swallow

any part of the vehicle for any reason.

aCAUTION

If not expressly indicated otherwise, for

the reassembly of the units repeat the

disassembly operations in reverse or-

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 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. 42 (PRE-

LIMINARY CHECKING OPERATIONS).

aCAUTION

After the first 1000 km (625 mi) and suc-

cessively every 7500 km (4687 mi), the

writing “SERVICE” (1) appears on the

right display.

In this case, perform the operations pre-

scribed in the regular service intervals

chart; in case of use on racetracks, car-

ry out these operations more frequent-

ly, see p. 52 - 53 (REGULAR SERVICE

INTERVALS CHART).

Ing-02.fm Page 51 Thursday, December 16, 1999 5:21 PM

52 use and maintenance RSV mille Sport Production

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OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER)

(*) = In case of use on racetracks, change every 1000 km (625 mi).

(* *) = In case of use on racetracks, change every 5000 km (3126 mi)

Component After running-in

[1000 km (625 mi)] Every 7500 km

(4687 mi) or 8 months Every 15000 km

(9375 mi) or 16 months

Spark plugs CS(**)

Air filter CS

Engine oil filter S every 3500 km (2187 mi): S (*)

Engine oil filter (on oil tank) 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 trip and every 7500 km (4687 mi): C

C= check and clean, adjust, lubricate or change, if necessary; P= clean; S= change; R= adjust.

Carry out the maintenance operations more frequently if you use the vehicle in rainy and dusty areas, on uneven ground or

on racetracks.

Ing-02.fm Page 52 Thursday, December 16, 1999 5:21 PM

use and maintenance RSV mille Sport Production

OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer

Component After running-in

[1000 km (625 mi)] Every 7500 km

(4687 mi) or 8 months Every 15000 km

(9375 mi) or 16 months

Rear suspension linkage bearings C

Steering bearings and steering C C

Wheel bearings C

Tappet clearance R R

Braking systems C C

Cooling system C

Clutch fluid every 2 years: S

Brake fluid every 2 years: S

Coolant every 2 years: S

Fork oil 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 you use the vehicle in rainy and dusty areas, on uneven ground or

on racetracks.

Ing-02.fm Page 53 Thursday, December 16, 1999 5:21 PM

54 use and maintenance RSV mille Sport Production

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It is a good rule to write down the frame

and engine numbers in the space provided

in this manual.

The frame number can be used for the pur-

chase of spare parts.

NOTE Do not alter the 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 Page 54 Thursday, December 16, 1999 5:21 PM

use and maintenance RSV mille Sport Production

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Carefully read p. 39 (ENGINE OIL) and

p. 51 (MAINTENANCE).

Periodically check the engine oil level,

change the oil after the first 1000 km (625

mi) and successively every 3500 km (2187

mi), see p. 56 (CHANGING THE ENGINE

OIL AND THE OIL FILTER).

In case of use on racetracks, change every

1000 km (625 mi).

TO CARRY OUT THE CHECKING:

aCAUTION

The engine oil level must be checked

with warm engine.

If the check is carried out with cold en-

gine, the oil level may temporarily lower

below the “MIN”mark.

This is not a problem, provided that the

engine oil pressure warning light LED

“j”does not come on, see p. 16 (IN-

STRUMENTS AND INDICATORS TA-

BLE).

◆Start the engine, see p. 43 (STARTING).

◆Allow the engine to idle for about 15-20

minutes, or ride the vehicle on a country

road for approximately 15 km (9.5 mi).

◆Stop the engine.

◆Keep the vehicle in vertical position, with

the two wheels resting on the ground.

◆Check the oil level in the transparent

pipe (1) through the appropriate slot 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.

aCAUTION

Never exceed the “MAX”mark, nor

leave the oil below the “MIN”mark, in

order to avoid serious damage to the

engine.

If necessary, top up the engine oil by pro-

ceeding as follows:

◆Position the vehicle on the side stand on

firm and level ground.

◆Unscrew and remove the filling cap (2).

aCAUTION

Do not put additives or other substanc-

es into the oil.

If you use a funnel or other similar

items, make sure that they are perfectly

clean.

NOTE Use high-quality 15W-50 oil, see

p. 90 (LUBRICANT CHART).

◆Top up the tank and restore the correct

level, see p. 95 (LUBRICANT CHART).

Ing-02.fm Page 55 Thursday, December 16, 1999 5:21 PM

56 use and maintenance RSV mille Sport Production

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aCAUTION

The engine oil and the oil filter change

operations may be difficult for unskilled

operators.

If necessary, contact an APRILIA Official

Dealer.

If you want to carry them out personal-

ly, follow the instructions given below.

Carefully read p. 39 (ENGINE OIL) and

p. 51 (MAINTENANCE) carefully.

Periodically check the engine oil level, see

p. 55 (CHECKING THE ENGINE OIL LEV-

EL AND TOPPING UP) change the oil after

the first 1000 km (625 mi) and successively

every 3500 km (2187 mi).

aCAUTION

In case of use on racetracks, change

every 1000 km (625 mi).

If the vehicle is used in dusty areas,

change the oil more frequently.

CHANGE:

NOTE The oil flows out completely and

without problems when it is warm and

therefore more fluid: to achieve this condi-

tion, the engine should run for approxi-

mately twenty minutes.

aCAUTION

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. 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 inside the container (1).

◆Check and if necessary replace the seal-

ing washer of the drain plug (2) posi-

tioned on the tank.

◆Screw and tighten the drain plug (2) on

the tank.

Drain plug (2) driving torque:

15 Nm (1.5 kgm).

◆Move the container (1) and position it un-

der the engine base, in correspondence

with the drain plug positioned on the en-

gine (4).

◆Unscrew and remove the drain plug posi-

tioned on the engine (4).

◆Drain the oil and let it drip inside the con-

tainer (1) for a few minutes.

aCAUTION

Do not dispose of the oil in the environ-

ment. Put it in a sealed container and

take it to the filling station where you

usually buy it or to an oil salvage cent-

er.

◆Remove the metal residues from the

drain plug (4) magnet.

Ing-02.fm Page 56 Thursday, December 16, 1999 5:21 PM

use and maintenance RSV mille Sport Production

◆Screw and tighten the drain plug (4).

Driving torque of the drain plug (4) posi-

tioned on the engine: 12 Nm (1,2 kgm).

CHANGING THE ENGINE OIL FILTER

Change the engine oil filter after the

first 1000 km (625 mi) and successively

every 3500 km (2187 mi) (or every time

you change the oil).

◆Unscrew and remove the screws (5).

◆Unscrew and remove the screws (6).

◆Remove the cover (7).

◆Remove the engine oil filter (8).

aCAUTION

Do not use filters that have already

been used.

◆Spread an oil film on the sealing ring (9)

of the new engine oil filter.

◆Fit the new engine oil filter.

◆Put back the cover (7).

◆Screw and tighten the screws (5) and

(6).

CLEANING THE ENGINE OIL FILTER

ON THE TANK

Clean the engine oil filter (10) on the

tank after the first 1000 km (625 mi) and

successively every 7000 km (4375 mi)

(or every two engine 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 tighten the

new clamp (11).

aCAUTION

Do not put additives or other substanc-

es into the oil.

If you use a funnel or other similar items,

make sure that they are perfectly clean.

NOTE Use high-quality 15W-50 oil, see

p. 90 (LUBRICANT CHART).

◆Pour about 4200 cm#of engine oil

through the filling opening (14), see p. 90

(LUBRICANT CHART).

◆Tighten the filling cap (3).

◆Start the engine, see p. 43 (STARTING)

and let it idle for about one minute, in or-

der to ensure the filling up of the engine

oil circuit.

◆Check the oil level and top up if neces-

sary, see p. 55 (CHECKING THE EN-

GINE OIL LEVEL AND TOPPING UP).

Ing-02.fm Page 57 Thursday, December 16, 1999 5:21 PM

58 use and maintenance RSV mille Sport Production

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NOTE Have someone help you keep the

vehicle in vertical position with the two

wheels on the ground.

◆★Loosen the knob (1).

◆★Move the fork support (2), positioning it

so that the width corresponds to the dis-

tance between the two pins (3) on the

rear fork.

◆★Tighten the knob (1).

◆Introduce the two fork-shaped seats (2)

of the stand (4) under the two pins (3)

provided on the vehicle.

◆Rest one foot on the rear part of the

stand (4).

◆Push the stand (4) downwards until it

reaches the end of its stroke.

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◆Position the vehicle on the appropriate

rear support stand, see beside (POSI-

TIONING THE VEHICLE ON THE REAR

SUPPORT 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 toclean the air cleaner partial-

ly after using the vehicle on this kind of

roads.

aCAUTION

The partial cleaning of the filter does

not exclude or postpone the replace-

ment of the filter itself.

Do not start the engine if the air cleaner

has been removed.

Do not clean the filtering element with

petrol or solvents, since they may

cause a fire in the fuel supply system,

with serious danger for the persons in

the vicinity and for the vehicle.

Ing-02.fm Page 58 Thursday, December 16, 1999 5:21 PM

use and maintenance RSV mille Sport Production

REMOVAL

◆Lift the fuel tank, see p. 66 (LIFTING

THE FUEL TANK).

◆Unscrew and remove the seven screws

(1) that fasten the filter case cover (2).

◆Remove the filter case cover (2).

◆Extract the air cleaner (3).

aCAUTION

Plug the openings with a clean cloth, to

prevent any foreign matters from get-

ting into the suction ducts.

Upon reassembly, before putting back

the filter case cover (2), make sure that

you have not left the cloth or other ob-

jects inside the case.

PARTIAL CLEANING

aCAUTION

Do not press or strike the metal net of

the air cleaner (3).

Do not use screwdrivers or alike.

◆Seize the air cleaner (3) vertically and

strike it more than once on a clean 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 container and

deliver it to a salvage centre.

aCAUTION

When cleaning the filtering element,

make sure that there are no tears.

Otherwise, change the filtering element.

Make sure that the filtering element is

positioned correctly, in such a way as

to prevent non-filtered air from entering.

Remember that the untimely wear of the

piston segments and the cylinder may

be caused by a faulty or uncorrectly po-

sitioned filtering element.

Ing-02.fm Page 59 Thursday, December 16, 1999 5:21 PM

60 use and maintenance RSV mille Sport Production

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aCAUTION

The disassembly and reassembly of the

front wheel may be difficult for unskilled

operators. If necessary, contact an

APRILIA Official Dealer.

If you want to perform these operations

personally, keep to the following in-

structions.

Carefully read p. 51 (MAINTENANCE).

While disassembling and reassembling

the wheel, be careful not to damage the

brake pipes, the discs and the pads.

NOTE To remove the front wheel it is

necessary to use the appropriate front &

and rear support stands.

DISASSEMBLY

◆Position the vehicle on the appropriate

rear support stand, see p. 58 (POSI-

TIONING THE VEHICLE ON THE REAR

SUPPORT STAND ).

◆Position the vehicle on the appropriate

front support stand, see p. 58 (POSI-

TIONING THE VEHICLE ON THE

FRONT SUPPORT STAND &).

aCAUTION

Make sure that the vehicle is stable.

◆Have someone keep the handlebar

steady in running position, so that the

steering is locked.

Brake caliper screw (1) driving torque:

50 Nm (5 kgm).

◆★Unscrew and remove the two screws

(1) that fasten the front brake caliper (2).

◆★Withdraw the brake caliper (2) from

the disc, leaving it attached to the pipe

(3).

aCAUTION

Never pull the front brake lever after re-

moving the calipers, otherwise the pis-

tons 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.

Wheel nut (4) driving torque:

80 Nm (8 kgm).

◆Loosen and remove the nut (4), taking

the washer.

◆★Partially unscrew the two screws (5)

from the wheel pin clamp.

◆Put a support (6) under the tyre, in such

a way as to keep the wheel in its position

after loosening it.

◆Withdraw the wheel pin (7) from the left

side.

◆Remove the wheel withdrawing it from

the front and take the left spacer ring (8)

if it has come out of its seat.

Ing-02.fm Page 60 Thursday, December 16, 1999 5:21 PM

Andere Handbücher für RSV MILLE - PART 3 1999

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