APRILIA 1115-2 Instruction manual

0-1
RSV mille
INTRODUCTION 0
GENERAL INFORMATION 1
SERVICE AND SETTING UP 2
ENGINE 3
FUEL SUPPLY SYSTEM 4
COOLING SYSTEM 5
ELECTRIC SYSTEM 6
CHASSIS 7
REPAIR INFORMATION 8
ANALYTICAL INDEX @
Release 00/2002-10 - 00
236mille U 
WORKSHOP manual
a rilia part# 8140688

INTRODUCTION
0
0-2
RSV mille
INTRODUCTION
4!",%/&#/.4%.43
50$!4%/&2%,%!3%
 ...................................................... 0-3-00
0.1.1 INFORMATION ON THE
UPDATING OF THE MANUAL ............... 0-3-00
0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3-00
(/ 4/#/.35,44(%-!.5!, ..... 0-5-00
&/2% /2$ ............................................... 0-6-00
2%&%2%.#%-!.5!,3 ......................... 0-6-00
0.4.1 ENGINE SERVICE AND
REPAIR MANUALS ................................ 0-6-00
0.4.2 SPARE PARTS CATALOGUES ............ 0-6-00
0.4.3 SPECIAL TOOL MANUALS .................. 0-6-00
0.4.4 USE AND MAINTENANCE MANUALS . 0-6-00
3!&%49 !2.).'3 ............................... 0-7-00
0.5.1 PRECAUTIONS AND GENERAL
INFORMATIONS .................................... 0-7-00
0.5.2 BEFORE THE DISASSEMBLY OF THE
COMPONENTS ...................................... 0-7-00
0.5.3 DISASSEMBLING THE COMPONENTS 0-7-00
0.5.4 REASSEMBLING THE COMPONENTS 0-7-00
(/ 4/53%9/523%26)#%
!.$2%0!)2-!.5!, ........................... 0-8-00
0.6.1 ADVICE FOR CONSULTATION ............ 0-8-00
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).)4)!,3 .................................................... 0-9-00
Release 00/2002-10
- 00

INTRODUCTION
0-3
RSV mille
50$!4%/&2%,%!3%
Date of the first edition ( elease 00) and of the following
eleases:
First edition ( elease 00) ............................october 2002
0.1.1 INFORMATION ON THE UPDATING OF THE
MANUAL
The manual must be u dated every time a new “Re-
lease” is received.
The manual consists of # 10 sections, for a total amount
of # 384 pages, as listed below.
NOTE For the nomenclature of the standard page of
the manual (and specifically for the definition of the page
number) see 0.2 (HOW TO CONSULT THE MANUAL).
Insert the ages of the last Release in the manual
and eliminate the corres onding obsolete ages
(even if belonging to a revious Release).
aWARNING
The failure to u date the manual and to eliminate
the obsolete ages makes it more difficult to con-
sult the manual and may lead to the erformance
of incorrect o erations on the vehicle, with serious
consequences for the safety of the vehicle and of
ersons and ro erty.
0.1.2 UPDATED MANUAL GENERAL LIST
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age# Release
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INTRODUCTION
0-4
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INTRODUCTION
0-5
RSV mille
 (/ 4/#/.35,44(%-!.5!,
1) Vehicle (or engine) model
2) Section
3) elease consecutive number (“00” indicates the first
edition)
4) Year and month of publication of the elease
5) Section number
6) Section page consecutive number
7) Updated page consecutive number
8) Chapter title (numbered consecutively)
9) Paragraph title (numbered consecutively)
10) Description of the operation (always preceded by a
rhombus)
11) Description of the operation: the star means that the
operation must be repeated on the other side of the
vehicle
Release 00/2002-10 - 00

INTRODUCTION
0-6
RSV mille
 &/2% /2$
– This manual supplies the main information for normal
servicing procedures.
– In the future, the information and illustrations that make
up this manual will be updated by means of “ eleases”,
see 0.1 (UPDATE OF ELEASE 00/2002-10).
– This publication is intended for the a rilia Dealers and
their qualified engineers; many notions were voluntarily
omitted, because they were considered superfluous.
Since it is not possible to include complete mechanical
information in this publication, the persons using this
manual must have a basic mechanical training and a
basic knowledge of the procedures regarding motor ve-
hicles repair systems.
Without this knowledge, the repair or servicing of the
vehicle may be ineffective or even dangerous.
The manual does not describe all the procedures for
the repair and servicing of the vehicle in detail, there-
fore it is important to be particularly careful, in order to
avoid any damage to components and persons.
In order to grant its customers more and more satisfac-
tion in the use of the vehicle, a rilia s. .a. will keep
improving its products and the relevant documenta-
tion.
The main technical modifications and the modifica-
tions in the vehicle repair procedures are communicat-
ed to all a rilia Outlets and Branches the world over.
These modifications will be described in the succes-
sive editions of this manual.
In case of need or doubts regarding the repair and in-
spection procedures, contact the Technical After-
Sales Dpt., which can give you the information re-
quired and also inform you about any updates and
technical modifications made to the vehicle.
a rilia s. .a. reserves the right to modify its models at any
time, without prejudice to the main characteristics here
described.
All rights as to electronic storage, reproduction and total
or partial adaptation, with any means, are reserved for all
Countries.
The mention to products or services supplied by third par-
ties is made only for information purposes and it isn’t bind-
ing in any case.
a rilia takes no responsibility as to the performance or
use of said products.
For further information, see 0.4 ( EFE ENCE MANU-
ALS).
First edition: october 2002
Prodotto e stampato da:
editing division
Soave (VE ONA) - Italia
tel. [phone]
fax [phone]
E-mail: custome[email protected]
www.stp.it
per conto di:
a rilia s. .a.
Technical After-Sales De artment - Technical Documentation De artment
via G. Galilei, 1 - 30033 Noale (VE) - Italia
tel.[phone]
fax [phone]
www.aprilia.com
www.serviceaprilia.com
 2%&%2%.#%-!.5!,3
0.4.1 ENGINE SERVICE AND REPAIR MANUALS
0.4.2 SPARE PARTS CATALOGUES
0.4.3 SPECIAL TOOL MANUALS
0.4.4 USE AND MAINTENANCE MANUALS
APRILIA art# (countries)
8140582 (1051-1) I
8140584 (1053-1) f
8140585 (1054-1) d
8140583 (1052-1) E
8140586 (1055-1) U
8140587 (1056-1) u
APRILIA art# (countries)
390W IU
390Y IU
3901 IU
APRILIA art# (countries)
8202278 IfdEU
APRILIA art# (countries)
models 1998 - 1999
8102623 Ifd
8102857 pEU
8102858 ODF
8102859 GJU
8104128 A
8104099 u
models 2000
8104089 Ifd
8104142 pEU
8104143 ODF
8104141 GJU
8104164 A
8104171 u
ò
8104152 Ifd
8104269 pEU
8104267 ODF
8104268 GJU
8104270 A
8104264 u
Release 00/2002-10
- 00

INTRODUCTION
0-7
RSV mille
 3!&%49 !2.).'3
The following precautionary warnings are used through-
out this manual in order to convey the following messag-
es:
Safety warning. When you find this symbol on
the vehicle or in the manual, be careful to the o-
tential risk of ersonal injury. Non-com liance with
the indications given in the messages receded by
this symbol may result in grave risks for your and oth-
er eo le’s safety and for the vehicle!
aWARNING
Indicates a otential hazard which may result in seri-
ous injury or even death.
aCAUTION
Indicates a otential hazard which may result in
minor ersonal injury or damage to the vehicle.
NOTE The word “NOTE” in this manual precedes im-
portant information or instructions.
0.5.1 PRECAUTIONS AND GENERAL INFORMA-
TIONS
Follow with care these recommendations when repairing,
disassembling and reassembling the vehicle.
aWARNING
The use of naked flames is forbidden for any ty e of
o eration.
Before beginning any maintenance o eration or any
ins ection of the vehicle, sto the engine, extract the
key from the ignition block, wait until the engine and
the exhaust system have cooled down and if ossible
lift the vehicle by means of the ro er equi ment, on
firm and flat ground.
Kee away from the red-hot arts of the engine and
of the exhaust system, in order to avoid burns.
aWARNING
Do not hold any mechanical iece or other arts of
the vehicle with your mouth: the com onents are not
edible and some of them are noxious or even toxic.
If not ex ressly indicated otherwise, for the reassem-
bly of the units re eat the disassembly o erations in
reverse order.
Any reference to o erations from other cha ters
must be inter reted logically in order to avoid com-
onents being removed unnecessarily.
Do not use olishing astes on matt aints.
Never use fuel as a solvent for cleaning the vehicle.
Do not use alcohol, etrol or solvents to clean the
rubber and lastic arts and the saddle: use only wa-
ter and mild soa .
Disconnect the negative cable (–) from the battery
when electric welding.
When two or more ersons are working together,
make sure that each is working in safe conditions.
Carefully read 1.2 (INSTRUCTIONS FOR USE OF FU-
EL, LUBRICANTS, COOLANT AND OTHER COMPO-
NENTS).
0.5.2 BEFORE THE DISASSEMBLY OF THE
COMPONENTS
– emove any dirt, mud, dust and foreign matters from
the vehicle before disassembling the components.
– Use, when necessary, the special tools designed for
this vehicle.
0.5.3 DISASSEMBLING THE COMPONENTS
– Do not loosen and/or tighten the screws and nuts using
pliers or other tools: instead, always use the proper
spanner.
– Before disconnecting the joints (pipes, cables, etc.),
mark the positions on all of them and mark them with
different distinguishing signs.
Each piece must be marked clearly, in order not to
have problems during installation.
– Clean and wash carefully any disassembled parts with
low inflammability detergents.
– Keep the parts that are used in pairs together, since
they have adapted to each other following the normal
wear.
Some components must be used together or replaced
completely.
– Keep away from heat sources.
0.5.4 REASSEMBLING THE COMPONENTS
aCAUTION
Never use a seeger ring twice. When a seeger ring is
removed, it must be re laced with a new one. When
assembling a new seeger ring be careful not to
stretch its ends more than strictly necessary to ut it
on the shaft.
After installing a seeger ring, make sure that it is
com letely and firmly inserted in its seat.
Do not use com ressed air to clean the bearings.
NOTE The bearings must rotate freely, without halting
a/o noise otherwise they must be replaced.
– Use only original a rilia SPA E PA TS.
– Use the recommended lubricants.
– Whenever possible, lubricate the parts before reas-
sembly.
– When tightening screws and nuts, begin with those
having greater diameters or with inner ones, proceed-
ing diagonally.
Tighten screws or nuts in successive passages before
applying driving torque.
– Always replace lock nuts, seals, sealing rings, snap
rings, O-rings, split pins and screws, whenever the
thread appears damaged, with new ones.
– Before the assembly, clean all the connection surfaces,
the oil seal edges and the gaskets.
Apply a thin layer of lithium-based grease on the oil
seal edges.
Put back the oil seals and the bearings with the mark or
serial number facing towards the outside (visible side).
Follow ã
a
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INTRODUCTION
0-8
RSV mille
Follow ã
– When installing the bearings, lubricate them abundant-
ly.
– Make sure that each component has been reassem-
bled correctly.
– After a repair or periodic maintenance operation, carry
out the preliminary checks and test the vehicle in a pri-
vate area or, in any case, in a low-traffic area.
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-!.5!,
0.6.1 ADVICE FOR CONSULTATION
– This manual is divided into section and chapters, each
one of which corresponds to a category of main com-
ponents.
To consult them, see the sections’ index, see page 0-1.
– If not expressly indicated otherwise, for the reassembly
of the units repeat the disassembly operations in re-
verse order.
– The terms “right” and “left” are referred to the rider
seated on the vehicle in the normal riding position.
– For normal maintenance operations and for the use of
the vehicle, consult the “USE AND MAINTENANCE”
manual.
The o erations receded by this symbol must
be re eated on the o osite side of the vehi-
cle.
In this manual the various versions are indicated by the
following symbols:
òframe # ZD4RP............(and in any case from model 2001)
eautomatic light switching version (Automatic Switch-on
Device)
mo tional
ocatalytic version
VERSION:
IItaly GGreece MMalaysia
UUnited King-
dom OHolland cChile
aAustria YSwitzerland HCroatia
pPortugal DDenmark AAustralia
FFinland JJa an uUnited States
of America
BBelgium SSinga ore ÄBrazil
dGermany sSlovenia RSouth Africa
fFrance iIsrael nNew Zealand
ES ain South Korea CCanada
★
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#= number
<= is less than
>= is greater than
≤= is equal to or less than
≥= is equal to or greater than
~= approximately
∞= infinity
°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit
±= plus or minus
a.c. = alternating current
A= ampère
Ah = ampere per hour
API = American Petroleum Institute
HV = high voltage
AV/DC = AntiVibration Double Countershaft
bar = unit of pressure (1 bar = 100 kPa)
d.c. = direct current
cm#= cubic centimetres
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial normative (Deutsche
Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Engine Control Unit
r m = revolutions per minute
HC = unburnt hydrocarbons
ISC = idle speed control
ISO = International Standardization Organization
kg = kilograms
kgm = kilograms per metre (1 kgm = 10 Nm)
km = kilometres
km/h = kilometres an hour
kΩ= kilo-ohms
kPa = kiloPascal (1 kPa = 0.01 bar)
KS = clutch side (Kupplungseite)
kW = kilowatt
L= litres
LAP = lap (race course)
LED = Light Emitting Diode
LEFT
SIDE = left side
m/s = metres an second
MAX = maximum
mbar = millibar (1mbar = 0.1 kPa)
mi = mile
MIN = minimum
MPH = miles per hour
MS = flywheel side (Magnetoseite)
MΩ= megaohm
N.A. = not available (Not Available)
N.O.M.M. = “Motor” method octane number
N.O.R.M. = “ esearch” method octane number
Nm = newton per meter (1 Nm = 0.1 kgm)
Ω= ohm
PICK-UP = pick-up
BDC = bottom dead centre
TDC = top dead centre
PPC = Pneumatic Power Clutch
RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostics test
T.B.E.I. = convex socket head
T.C.E.I. = hexagonal socket head
T.E. = hex-head
T.P. = flat head
TSI = Twin Spark Ignition
UPSIDE-
DOWN = upside-down rods
V= volt
W= watt
Ø= diameter
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