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

61
use and maintenance RSV mille Sport Production
REASSEMBLY
Carefully read p. 51 (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 reassem-
bly, make sure that the wheel is posi-
tioned correctly: the arrow must be visi-
ble on the left side of the vehicle.
◆Spread a film of lubricating grease on the
whole length of the wheel pin (7), see
p. 90 (LUBRICANT CHART).
◆If the left spacer ring (8) has come out of
its seat on the wheel during disassembly,
correctly position it there.
◆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 61 Thursday, December 16, 1999 5:21 PM

62 use and maintenance RSV mille Sport Production
2%!27(%%,
aCAUTION
The disassembly and reassembly of the
rear 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).
Before carrying out the following opera-
tions, let the engine and the silencer
cool down until they reach room tem-
perature, in order to avoid burns.
While disassembling and reassembling
the wheel, be careful not to damage the
brake pipe, the disc and the pads.
NOTE To remove the rear wheel it is
necessary to use the appropriate rear sup-
port stand .
DISASSEMBLY
◆Position the vehicle on 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 wheeladvance and releasethe
drive chain (4) from the crown gear (5).
aCAUTION
Check the position of the chain tighten-
ers (6-7), in order to be able to reas-
semble them correctly.
◆Remove the right (6) and left (7) chain
tighteners.
◆Remove the entire wheel withdrawing it
from behind.
aCAUTION
Do not operate the rear brake lever after
removing the wheel, since the pins may
go out of their seats and cause brake
fluid leakages.
In this case consult your APRILIA Official
Dealer, who will carry out the proper
maintenance operation.
Ing-02.fm Page 62 Thursday, December 16, 1999 5:21 PM

63
use and maintenance RSV mille Sport Production
REASSEMBLY
aCAUTION
Before proceeding with the reassembly,
make sure that support plate (8) of the
brake caliper (9) is positioned correctly;
the plate slot must be inserted in the ap-
propriate stop pin (10) in the inner part
of the rear fork right rod.
Insert the disc in the brake caliper care-
fully.
◆Spread a film of lubricating grease on the
whole length of the wheel pin (3), see
p. 95 (LUBRICANT CHART).
◆Position the right (6) and left (7) chain
tighteners in their seats on the rear fork
arms.
◆Position the wheel between the rear fork
rods on the support (2).
◆Make the wheel advance and position
the drive chain (4) on the crown gear (5).
aWARNING
Danger of injury.
Do not introduce your fingers 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 the left chain tight-
ener (7).
◆Position the washer and tighten the nut
(1) manually.
◆Check the chain tension, see p. 64
(DRIVE CHAIN).
◆Tighten the nut (1).
Wheel nut (1) driving torque:
120 Nm (12 kgm).
◆Make sure that the following components
are not dirty:
–tyre;
–wheel;
–brake discs.
aCAUTION
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 63 Thursday, December 16, 1999 5:21 PM

64 use and maintenance RSV mille Sport Production
$2)6%#(!).
Carefully read p. 51 (MAINTENANCE).
The vehicle is equipped with an endless
chain, in which a ring link joint is not used.
aCAUTION
An excessive slackening of the chain
may cause noise or make the chain rat-
tle, with consequent wear of the shoe
and of the chain guide plate.
Periodically check the slack and adjust
it if necessary, see beside (ADJUST-
MENT).
To change the chain, contact an APRILIA
Official Dealer, who will ensure you
prompt and accurate servicing.
Incorrect maintenance may cause the
untimely wear of the chain and/or dam-
ages to the pinion and/or the crown.
aCAUTION
Carry out the maintenance operations
more frequently if you use the vehicle in
difficult conditions or on dusty and/or
muddy roads.
CHECKING THE SLACK
To check the slack, proceed as follows:
◆Stop the engine.
◆Position the vehicle on the side stand on
firm and level ground.
◆Position the shifting lever in neutral.
◆Make sure that the vertical oscillation, in
an 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 seized links; in this case,
contact an APRILIA Official Dealer. To
prevent the risk of seizures, lubricate the
chain frequently, see p. 65 (CLEANING
AND LUBRICATION).
If the slack is uniform, but higher or lower
than 25 mm, adjust it, see beside (AD-
JUSTMENT).
ADJUSTMENT
NOTE To adjust the chain it is necessary
to use the appropriate rear support stand.
If after the check it is necessary to adjust
the chain tension, proceed as follows:
◆Position the vehicle on the appropriate
rear support stand, see p. 58 (POSI-
TIONING THE VEHICLE ON THE REAR
SUPPORT STAND ).
◆Loosen the nut (1) completely.
NOTE For the wheel centering fixed ref-
erence marks (2-3) are provided, which
can be seen inside the chain tightener
seats on the rear fork arms, before the
wheel pin.
Ing-02.fm Page 64 Thursday, December 16, 1999 5:21 PM

65
use and maintenance RSV mille Sport Production
◆Loosen the two lock nuts (4).
◆Act on the adjusters (5) and adjust the
chain slack, making sure that the refer-
ence marks (2-3) are correctly positioned
on both sides of the vehicle.
◆Tighten the two lock nuts (4).
◆Tighten the nut (1).
Wheel nut driving torque (1):
120 Nm (12 kgm).
◆Check the chain slack, see p. 64
(CHECKING THE SLACK).
CHECKING THE WEAR OF CHAIN,
PINION AND CROWN
Further, check the chain and sprockets
and make sure that they do not present:
–damaged rollers;
–loose pins;
–dry, rusty, crushed or seized links;
–excessive wear;
–lacking O rings;
–sprocket or teeth excessively worn or
damaged.
aCAUTION
If the chain rollers are damaged, the
pins are loose and/or the O rings are
damaged or lacking, it is necessary to
change the whole chain unit (both
sprockets and chain).
Lubricate the chain frequently, espe-
cially if there are dry or rusty parts.
The crushed or seized links must be lu-
bricated and made work again.
If this 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 jets,
steam jets, high-pressure water jets and
highly inflammable solvents.
◆Wash the chain with naphtha or kero-
sene. If it tends to rust quickly, intensify
the maintenance intervals.
Lubricate the chain every 1000 km (625
mi) or whenever necessary.
◆After washing the chain and letting it dry,
lubricate it with spray grease for chains
provided with sealing rings, see p. 95
(LUBRICANT CHART).
aCAUTION
The lubricants for chains available on
the market can contain substances that
are dangerous for the rubber sealing
rings of the chain.
NOTE Do not use the vehicle soon after
lubricating the chain, since due to the cen-
trifugal force the lubricant would be
sprayed outwards and dirty the surround-
ing areas.
Ing-02.fm Page 65 Thursday, December 16, 1999 5:21 PM

66 use and maintenance RSV mille Sport Production
2%-/6).'4(%2)$%23!$$,%
◆Position the vehicle on the side stand on
firm and level ground.
◆★Partially raise the rear side edge of the
saddle.
◆★Unscrew and remove the screw (1)
and take the bushing (2).
Screw (1) driving torque:
12 Nm (1.2 kgm).
◆Raise and remove the saddle (3).
NOTE Upon reassembly, insert the front
tang of the saddle in the appropriate seat.
aCAUTION
Before leaving, make sure that the sad-
dle (3) is properly positioned and locked.
,)&4).'4(%&5%,4!.+
Carefully read p. 30 (FUEL) and p. 51
(MAINTENANCE).
aWARNING
Risk of fire.
Wait until the engine 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)
that fasten the front part of the fuel tank
(5).
◆Take the fuel tank support stick (6) (sup-
plied together with the vehicle).
NOTE The rubber-covered end of the
stick (6) must be introduced in the central
hole of the steering pin.
◆Lift the front part of the fuel tank (5) and
introduce the stick (6) as indicated in the
figure.
Ing-02.fm Page 66 Thursday, December 16, 1999 5:21 PM

67
use and maintenance RSV mille Sport Production
2%-/6).'4(%3)$%&!)2).'3
Carefully read p. 51 (MAINTENANCE).
aWARNING
Wait until the engine and the exhaust si-
lencer have completely cooled down.
◆Position the vehicle on the side stand on
firm and level ground.
◆Raise the special ring and give the sixra-
pid fastening screws (1) 1/4 turn anti-
clockwise.
aCAUTION
Handle the plastic and painted compo-
nents with care and avoid scraping or
damaging them.
◆Remove the side fairing (2).
NOTE Repeat these operations to remo-
ve the other side fairing.
2%-/6).'4(%,/7%2&!)2).'
Carefully read p. 51 (MAINTENANCE).
NOTE To remove the lower fairing, it is
necessary to use the appropriate rear sup-
port stand .
◆Position the vehicle on the appropriate
rear 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 the fairing.
aCAUTION
Handle the plastic and painted compo-
nents with care and avoid scraping or
damaging them.
◆Remove the entire lower fairing (9) by
lowering it and with small movements try
to find the best position to withdraw it
from the side stand.
NOTE Upon reassembly, introduce the
two pipes (7-8) in the hole provided on the
fairing.
NOTE Upon reassembly, the upper part
of the support (6) must be fitted between
the lower fairing (9) and the support plate.
Ing-02.fm Page 67 Thursday, December 16, 1999 5:21 PM

68 use and maintenance RSV mille Sport Production
2%-/6).'4(%3)$%#/6%23
◆Position the vehicle on the side stand on
firm and level ground.
◆Unscrew and remove the two screws (1).
aCAUTION
Handle the composite material and
painted components with care and avo-
id scraping or damaging them
◆Remove the side cover (2).
NOTE Upon reassembly, make sure that
the rear coupling is positioned correctly.
Repeat these operations to remove 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-
ve the other rear-view mirror.
aCAUTION
After reassembly, correctly adjust the
rear-view mirrors and tighten the nuts in
such a way as to ensure their stability.
Ing-02.fm Page 68 Thursday, December 16, 1999 5:21 PM

69
use and maintenance RSV mille Sport Production
2%-/6).'4(%&2/.40!24
/&4(%&!)2).'
Carefully read p. 51 (MAINTENANCE).
◆Position the vehicle on the side stand on
firm and level ground.
◆Turn the ignition switch to position “m”.
◆Unscrew and remove the two lower
screws (1).
◆★Unscrew and remove the side screw
(2).
aCAUTION
Upon reassembly, tighten the screw (2)
moderately, since it is fixed on plastic.
◆★Unscrew and remove the two upper
screws (3).
NOTE Upon reassembly, rotate the rear-
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.
Handle the plastic and painted compo-
nents with care and avoid scraping or
damaging them.
Remove the front part of the fairing (4)
completely, together with the headlight and
the rear-view mirrors.
Ing-02.fm Page 69 Thursday, December 16, 1999 5:21 PM

70 use and maintenance RSV mille Sport Production
2%-/6).'
4(%!)2#,%!.%2#!3%
Carefully read p. 51 (MAINTENANCE).
◆Remove the air cleaner, see p. 58 (AIR
CLEANER).
◆Disconnect the pipe (1).
◆Withdraw the suction pressure sensor
(2) from its coupling.
◆Unscrew and remove the six screws (3).
aCAUTION
For the removal of the air cleaner case
(4) proceed with 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 sure that the air cleaner case
(4) rests completely on the throttle
body.
Ing-02.fm Page 70 Thursday, December 16, 1999 5:21 PM