APRILIA RSV MILLE - REGULAR SERVICE Bedienungsanleitung

56 use and maintenance RSV mille - RSV mille R

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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 3750 km (2343 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 S (*)

Engine oil filter (on oil tank) P 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 S (*)

Tyres C every 1000 km (625 mi): C

Tyre pressure R every 15 days: C

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.

Perform the maintenance operations with doubled frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces

or on racetracks.

ING-02.FM Page 56 Thursday, December 16, 1999 2:23 PM

use and maintenance RSV mille - RSV mille R

OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer

(**) = With “R” fork w( W&), change every 10000 km (6250 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

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

Throttle body pin greasing C C

Clutch fluid every 2 years: S

Brake fluid every 2 years: S

Coolant every 2 years: S

Fork oil (**) After the frist 7500 km (4687 mi): S / every 22500 km (14000 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.

Perform the maintenance operations with doubled frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces

or on racetracks.

ING-02.FM Page 57 Thursday, December 16, 1999 2:23 PM

58 use and maintenance RSV mille - RSV mille R

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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 58 Thursday, December 16, 1999 2:23 PM

use and maintenance RSV mille - RSV mille R

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Carefully read p. 43 (ENGINE OIL) and

p. 55 (MAINTENANCE).

Periodically check the engine oil level,

change the oil after the first 1000 km (625

mi) and successively every 7500 km (4687

mi), see p. 60 (CHANGING THE ENGINE

OIL AND THE OIL FILTER).

In case of use on racetracks, change every

3750 km (2343 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. 18 (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:

◆Remove the left fairing, see p. 71 (RE-

MOVING THE SIDE FAIRINGS).

◆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. 103 (LUBRICANT CHART).

◆Top up the tank and restore the correct

level, see p. 103 (LUBRICANT CHART).

ING-02.FM Page 59 Thursday, December 16, 1999 2:23 PM

60 use and maintenance RSV mille - RSV mille R

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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. 43 (ENGINE OIL) and

p. 55 (MAINTENANCE) carefully.

Periodically check the engine oil level, see

p. 59 (CHECKING THE ENGINE OIL LEV-

EL AND TOPPING UP) change the oil after

the first 1000 km (625 mi) and successively

every 7500 km (4687 mi).

aCAUTION

In case of use on racetracks, change

every 3750 km (2343 mi).

If the vehicle is used in dusty areas,

change the oil more frequently.

TO 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. 71 (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 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 60 Thursday, December 16, 1999 2:23 PM

use and maintenance RSV mille - RSV mille R

◆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 7500 km (4687 mi) (or every time

you change the oil).

◆Unscrew the two screws (5) and remove

the cover (6).

◆Remove the engine oil filter (7).

aCAUTION

Do not use filters that have already

been used.

◆Spread an oil film on the sealing ring (8)

of the new engine oil filter.

◆Fit the new engine oil filter.

◆Put back the cover (6), screw and tighten

the two screws (5).

CLEANING THE ENGINE OIL FILTER

ON THE TANK

Clean the engine oil 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 pipe clamp (10) to re-

place the original one (special 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 oil filter (9)

positioned on the tank; screw and tighten

it.

Engine oil filter (9) driving torque:

30 Nm (3.0 kgm).

◆Connect the pipe (12) and tighten the

new clamp (10).

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. 103 (LUBRICANT CHART).

◆Pour about 3500 cm#of engine oil

through the filling opening (13), see

p. 103 (LUBRICANT CHART).

◆Tighten the filling cap (3).

◆Start the engine, see p. 47 (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. 59 (CHECKING THE EN-

GINE OIL LEVEL AND TOPPING UP).

ING-02.FM Page 61 Thursday, December 16, 1999 2:23 PM

62 use and maintenance RSV mille - RSV mille R

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◆Position the vehicle on the side stand on

firm and level ground.

◆★Position the pin (1) on the appropriate

seat on the rear fork.

◆★Screw and tighten the screw (2) in the

appropriate threaded hole in the rear

fork.

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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 (3).

◆★Move the fork support (4), positioning it

so that the width corresponds to the dis-

tance between the two pins (1) on the

rear fork.

◆★Tighten 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.

◆Rest one foot on the rear part of the

stand (5).

◆Push the stand (5) 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 (6) in the

two holes (7) positioned on the lower

ends of the front fork.

◆Rest one foot on the front part of the

stand (6).

◆Push the stand (6) downwards until it

reaches the end of its stroke.

ING-02.FM Page 62 Thursday, December 16, 1999 2:23 PM

use and maintenance RSV mille - RSV mille R

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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 clean the air cleaner partially

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 re-

moved. Do not clean the filtering ele-

ment with petrol or solvents, since they

may cause a fire in the fuel supply sys-

tem, with serious danger for the per-

sons in the vicinity and for the vehicle.

REMOVAL

◆Lift the fuel tank, see p. 70 (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 opening with a clean cloth, in

order to prevent any foreign matter to

get ito 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 63 Thursday, December 16, 1999 2:23 PM

64 use and maintenance RSV mille - RSV mille R

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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. 55 (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. 62 (POSI-

TIONING THE VEHICLE ON THE REAR

SUPPORT STAND &).

◆Position the vehicle on the appropriate

front support stand, see p. 62 (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.

ING-02.FM Page 64 Thursday, December 16, 1999 2:23 PM

use and maintenance RSV mille - RSV mille R

REASSEMBLY

Carefully read p. 55 (MAINTENANCE).

aCAUTION

While reassembling the wheel, be care-

ful not to damage the brake pipes, discs

and pads.

The arrow on the wheel side indicates

the rotation direction.

Upon reassembly, make sure that the

wheel is positioned correctly: the arrow

must be visible on the left side of the ve-

hicle.

◆Spread a film of lubricating grease on the

whole length of the wheel pin (7), see

p. 103 (LUBRICANT CHART).

◆Position the wheel between the fork rods

on the support (6).

aWARNING

Danger of injury. Do not introduce your

fingers to align the holes.

◆Move the wheel until its central hole and

the holes on the fork are aligned.

◆Introduce the wheel pin (7) completely.

◆Position the washer and tighten the nut

(4) manually.

◆Lock the rotation of the wheel pin (7).

◆Tighten the nut (4) completely.

Wheel 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 brake caliper.

Brake caliper screw (1) driving torque:

50 Nm (5 kgm)

◆With pulled front brake lever, press the

handlebar repeatedly, thrusting the fork

downwards. In this way the fork rods will

settle properly.

◆★Tighten the two screws (5) of the

wheel pin clamp.

Wheel pin clamp screw (5) driving

torque: 22 Nm (2,2 kgm)

◆Make sure that the following components

are not dirty:

–tyre;

–wheel;

–brake discs.

aWARNING

After reassembly, pull the front brake le-

ver repeatedly and check the correct

functioning of the braking system.

Check the wheel centering.

Have the driving torques, centering and

balancing of the wheel checked by your

APRILIA Official Dealer, in order to avoid

accidents that may be harmful for you

and/or other people.

ING-02.FM Page 65 Thursday, December 16, 1999 2:23 PM

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