APRILIA RSV MILLE - PART 3 1999 User manual

51
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
2%'5,!23%26)#%).4%26!,3#(!24
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

53
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
)$%.4)&)#!4)/.$!4!
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

55
use and maintenance RSV mille Sport Production
#(%#+).'4(%%.').%/),,%6
%,!.$4/00).'50
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
#(!.').'4(%%.').%/),
!.$4(%/),&),4%2
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

57
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
0/3)4)/.).'4(%6%()#,%
/.4(%2%!23500/2434!.$
NOTE Have someone help you keep the
vehicle in vertical position with the two
wheels on the ground.
◆★Loosen the knob (1).
◆★Move the fork support (2), positioning it
so that the width corresponds to the dis-
tance between the two pins (3) on the
rear fork.
◆★Tighten the knob (1).
◆Introduce the two fork-shaped seats (2)
of the stand (4) under the two pins (3)
provided on the vehicle.
◆Rest one foot on the rear part of the
stand (4).
◆Push the stand (4) downwards until it
reaches the end of its stroke.
0/3)4)/.).'4(%6%()#,%/.
4(%&2/.43500/2434!.$&
◆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

59
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
&2/.47(%%,
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