APRILIA RSV MILLE - PART 3 1999 User manual

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NOTE The cooling fans (21) function only
when the ignition key (2) is in the “+” (ON)
position.
aCAUTION
Do not leave the ignition key in the “-”
(OFF) position since the cooling fans
will not run regardless of the coolant
temperature. This will cause the cool-
ant temperature to continue to rise.
If, before shutting off the engine, you hear
the cooling fans functioning, stop the en-
gine but leave the ignition key to “+”(ON)
position. This will allow the cooling fans to
draw air through the radiators, and lower
the temperature. Turn the ignition key to
“-”(OFF) position only when the cooling
fans have stopped.
If, while riding, the right side of the multi-
function display shows a temperature of 115
–120 °C (239 –248 °F) (19), stop riding the
vehicle, stop the engine, turn the ignition
key to “+”(ON) position and wait until the
cooling fans have stopped, then turn the ig-
nition key to “-”(OFF) position and check
the coolant level, see p. 56 (COOLANT).
If the symbol “///”(20) is displayed, stop
riding the vehicle and let the engine run at
3,000 rpm for approximately two minutes,
thus allowing the coolant to circulate normal-
ly in the cooling system. Then move the en-
gine stop switch to position “m”(OFF) and
check the coolant level, see p. 56 (COOL-
ANT).
If the symbol “///”(20) is still displayed
after the coolant level has been checked,
contact your Local aprilia Dealer.
aWARNING
Do not operate the vehicle if the maxi-
mum temperature [120 °C (248 °F)] is ex-
ceeded. Serious engine damage or even
seizure may result which can cause an
upset and serious injury or even death.
Whenever the ignition key (2) is turned to
“+”(ON), the right side of the multifunction
display will show “HIL”(9B) for about
three seconds.
aCAUTION
If the symbol “HIL”(9B) is displayed
during the normal running of the en-
gine, this means that the electronic unit
has detected an anomaly. In many cas-
es, the engine keeps running with re-
duced performance levels; immediately
contact your Local APRILIADealer.
aWARNING
Avoid opening and closing the throttle
repeatedly and continuously. Failure to
head this warning can cause you to ac-
cidentally lose control of your vehicle.
When you have to brake, close the
throttle and apply both brakes simulta-
neously in order to obtain the best
brake performance.
By applying only the front brake or only
the rear brake, you reduce the braking
performance considerably and run the
risk of locking up one wheel which can
cause an upset and subsequent serious
injury or even death.
If you stop on an uphill, use brakes only
to slow the vehicle and to keep it in
place. Slipping the clutch to keep the
vehicle in one place on an uphill grade
will very quickly ruin the clutch and
overheat the engine.
Before entering a turn, slow down, us-
ing the brakes and the engine, to a con-
stant speed and then accelerate slightly
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through the turn. Avoid braking at the
last moment. This can cause you to
lose control of your vehicle.
If the brakes are operated continuously
on downhill grades, the discs and pads
will overheat, reducing the braking effi-
ciency. Use engine compression and
downshift to retard your vehicle while
going downhill. Use the brakes as little
as possible to maintain a safe speed.
Never coast downhill with the engine off
and/or the clutch disengaged or the
transmission in neutral.
On roads that are wet or covered with
snow, ice or mud, ride very slowly,
avoiding braking or accelerating or ma-
neuvering quickly. Hold the handlebars
firmly.
Failure to heed these warnings can
cause an upset with subsequent seri-
ous injury or death.
Pay very close attention to any obsta-
cles or variations of the road surface.
Uneven roads, rails, manhole covers,
painted traffic stripes, traffic dots all be-
come slippery when wet. Avoid particu-
larly steel plates which are sometimes
used during road maintenance. They
become more slippery than ice once
they are wet by rain. If you must ride on
such surfaces, decrease your speed
and operate the throttle, brakes and
steering very gently.
Always use the turn signals any time
you intend to change lanes or change
direction, and avoid sudden or abrupt
turning.
Switch off the direction indicators as
soon as you have changed direction.
Overtake and pass only with care, espe-
cially in rainy weather when a water
cloud created by larger vehicles reduces
visibility and the slip stream could cause
you to lose control of your vehicle.
25..).').
The internal parts of the engine and trans-
mission must be properly run-in to ensure
their long life and dependable operation.
If possible, while breaking in your vehicle,
ride on hilly roads and/or roads with many
curves so that the engine and transmis-
sion undergo lots of speed changes. It is
also important that, during the run-in peri-
od, the suspension and brakes be treated
gently to allow the mating parts to bed.
Therefore, avoid hard braking, high
speeds or very bumpy roads during the
break in period.
NOTE Only after the first 937 mi (1500
km) of running-in you can expect the best
performance from the vehicle.
During break in, obey the following rules:
◆Do not open the throttle abruptly or fully
at low engine speed. This rule applies
even after break in has been completed.
◆During the first 62 mi (100 km), apply the
brakes with caution, avoid sudden and
prolonged braking. This ensures correct
bedding in of the pads on the discs.
◆During the first 625 mi (1,000 km), never
exceed 6,000 rpm.
aWARNING
After the vehicle has been operated for
625 mi (1,000 km) perform the “checking
operations”shown in column “After run-
ning-in”of the REGULAR SERVICE IN-
TERVALS CHART, see p. 74. Rectify any
faults found. Failure to heed this warn-
ing could lead to damage to your vehicle
or engine seizure or other malfunction
which could cause an upset and lead to
serious injury or even death.
◆Between the first 625 mi (1,000 km) and
937 mi (1,500 km) drive more briskly,
changing speed and using maximum ac-
celeration for only a few seconds. Never
exceed 7,500 rpm.
◆After the first 937 mi (1,500 km) if you
have followed the above break in sched-
ule, the engine should be fully broken in,
and will deliver maximum performance.
However, never exceed the maximum al-
lowed rpm (10,500 rpm).
Engine maximum rpm
for the running-in
Mileage mi (km) Max. rpm
0 –625 (0 –1,000) 6,000
625 –937
(1,000 –1,500) 7,500
over 937 (1,500) 10,500
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69
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34/00).'
aWARNING
If possible, avoid stopping abruptly,
slowing down suddenly and braking at
the last moment.
Failure to comply with these instruc-
tions may cause an accident with con-
sequent risk of serious injuries or even
death.
◆Release the throttle grip (1) (Pos. A),
gradually put on the brakes and at the
same time shift down in order to de-
crease the speed, see p. 64 (RIDING).
Once the speed has decreased, before
stopping the vehicle:
◆Pull in the clutch lever (2) (Pos. B) in or-
der to prevent the engine dying.
When the vehicle has come to rest:
◆Position the shift lever (3) in neutral
(green warning light “q”(4) on).
◆Release the clutch lever (2) (Pos. C).
◆If you are stopping just briefly and not
shutting down the engine, keep one
brake applied.
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0!2+).'
aWARNING
Park the vehicle only on firm flat
ground, otherwise it could fall over.
Do not lean the vehicle against walls, do
not lay it on the ground.
Park your vehicle away from children
and pedestrians, so that they will not
come in contact with hot parts.
Do not leave your vehicle unattended
with the engine running or with the key
in the ignition switch.
Do not sit on the vehicle when the side
stand is down.
Do not get too close to the cooling fans
(A). Even though they are not moving,
they could start automatically and suck
clothing, hair, etc. into the fan.
If the vehicle falls over, it will leak gaso-
line which is extremely flammable.
Flames or sparks could cause a fire
which could destroy not only your vehi-
cle but also buildings around it and
cause injury or even death to people as
well.
◆Stop the vehicle, see p. 69 (STOPPING).
◆Move the engine stop switch (1) to the
“m”(OFF) position.
aCAUTION
Do not leave the ignition on if you have
stopped the engine by moving the en-
gine stop switch to the “m”(OFF) posi-
tion as this will discharge the battery.
When the vehicle has come to rest after
stopping the engine with the engine
stop switch, turn the ignition switch (3)
to the “m”(OFF) position.
◆Rotate the key (2) and move the ignition
switch (3) to the “m”(OFF) position.
◆Position your vehicle on the stand, see
p. 71 (POSITIONING THE VEHICLE ON
THE STAND).
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NOTE Never leave the key inthe ignition
switch.
◆Lock the steering, see p. 40 (STEERING
LOCK) and extract the key.
When you have to park your vehicle in a
dark or badly lighted area (parking lot or
street), it is sometimes useful to leave the
parking lights on so that yourvehicle will be
easily visible.
To leave the parking lights on: see p. 40
(PARKING LIGHTS).
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aWARNING
Position the vehicle on firm and flat
ground.
SIDE STAND
◆Grab the left handle grip (4) and the pas-
senger grab strap (5).
◆Put the side stand (6) down with your
right foot. Make sure it is extended com-
pletely and all the way forward.
◆Lean the vehicle to the left until the stand
rests firmly on the ground.
◆Turn the handlebars completely against
the left stop.
aWARNING
Make sure the vehicle is stable when
parked. If it falls down, it will certainly
be damaged and could injure others as
well.
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NEVER leave the key (1) in the ignition
switch (2), always use the steering lock “s”
(LOCK).
Try to park your vehicle in a safe place, if
at all possible, in a garage or other pro-
tected place.
Lock your vehicle up using a chain and
padlock around the rear wheel. Chain the
rear wheel to the swinging arm.
Make sure that all legal requirements: reg-
istration, license plates, insurance, etc. are
in order.
Write down your name, address and tele-
phone number and the vehicle identifica-
tion number in the space below, to facili-
tate finding the owner in case your vehicle
is recovered after theft.
SURNAME: ...............................................
NAME: ......................................................
ADDRESS: ...............................................
...................................................................
TELEPHONE NO.: ...................................
NOTE Very often stolen vehicles are
identified thanks to the data written in the
use/maintenance manual.
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Carefully read p. 2 (FOREWORD) and
(INTRODUCTION), p. 3 (SAFETY WARN-
INGS) and (GENERAL SAFETY RULES),
p. 5 (WARNINGS - PRECAUTIONS -
GENERAL ADVICE).
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, remove the key (1)
from the ignition switch (2), wait until
the engine and the exhaust system have
cooled down and if possible lift the ve-
hicle by means of the proper equip-
ment, on firm and flat ground.
Before proceeding, make sure that the
room in which you are working is prop-
erly ventilated.
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Be careful to avoid hot parts of the en-
gine and exhaust system. They are hot
enough to cause serious burns.
Avoid the temptation to hold any part of
the vehicle in your mouth. The coatings
and platings used are, in some cases,
toxic.
aCAUTION
In general, reassembly is performed in
the reverse order of the disassembly in-
structions given here.
For some maintenance operations, es-
pecially those in which your hands are
likely to come in contact with coolant,
or engine oil, or gasoline, or brake fluid,
it is advisable to use thin disposable
gloves, such as those made of latex,
rubber or nitrile.
The routine maintenance operations de-
scribed in this manual can usually be per-
formed by the user. However, in some
cases, specific tools and technical exper-
tise may be required.
Do not hesitate to contact your Local aprilia
Dealer who has all the latest factory infor-
mation and tools to properly service your
vehicle.
Remember that many service operations, if
done improperly, can be very hazardous.
If you haveany questions about your ability
to carry out the operations described here,
contact your Local aprilia Dealer.
In all cases, personally carry out the “pre-
liminary checking operations”after any
maintenance, see p. 61 (PRELIMINARY
CHECKING OPERATIONS).
aWARNING
Remember that tightening torque of all
fasteners on the wheels, brakes, axles,
suspension are extremely important to
ensure safety, and must be maintained
at the prescribed values.
Check the tightening torques of the fas-
teners regularly, and always use a
torque wrench when installing them.
Failure to adhere to this warning could
cause the loosening and subsequent
loss of critical fasteners, which could
cause a wheel to lock or cause other
handling problems with consequent
overturning, and the risk of serious inju-
ry or even death.
aWARNING
Fasteners must be neither overtight-
ened or undertightened. If they are
overtightened, the threads may be dam-
aged and the fasteners will be de-
stroyed, whereas if they are undertight-
ened, they can vibrate and become lost.
Obviously, under these circumstances,
a serious accident with resultant seri-
ous injury or death could ensue.
aCAUTION
After the first 625 mi (1,000 km) and suc-
cessively every 4,687 mi (7,500 km), the
word “SERVICE”(3) appears on the right
display. In this case contact your Local
APRILIADealer, who will carry out the op-
erations indicated in the regular service
intervals chart, see p. 74 (REGULAR SER-
VICE INTERVALS CHART).
To make the word “SERVICE”disappear,
press the “LAP”push button (4) and then
the push button R(5) and keep them
pressed for about 5 seconds.
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74 use and maintenance RSV mille -
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THESE OPERATIONS MAY BE CARRIED OUT BY YOUR Local APRILIADealer, OR BY THE OWNER OF THE VEHICLE
(*) = For competition use, change every 2,343 mi (3,750 km).
Component After running-in
[625 mi (1,000 km)] Every 4,687 mi (7,500 km) or 8 months Every 9,375 mi (15,000 km) or 16 months
Tightness of the battery terminals C C
Spark plugs C (*) S
Drive chain, tension and lubrication every 625 mi (1,000 km): C
Air cleaner CS
Fork C
Light operation/direction C
Light system C C
Safety switches C C
Clutch fluid C
Brake fluid C
Coolant every 625 mi (1,000 km): C
Engine oil every 312 mi (500 km): C
Tires C every 625 mi (1,000 km): C
Tire pressure R every month: R
Engine idling rpm R R
Engine oil pressure warning light LED “\”at every start: C
Front and rear brake pad wear before every trip and every 4,687 mi (7,500 km): C
C = check and clean, adjust, lubricate or change, if necessary; P = clean; S = change; R = adjust.
Perform these maintenance operations at one-half of he specified intervals, if your vehicle is often used in rainy or very dusty
conditions, on unpaved roads, or in any kind of competition.
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THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED OUT BY Local APRILIADealer.
(*) = For competition use, change every 2,343 mi (3,750 km).
Component After running-in
[625 mi (1,000 km)] Every 4,687 mi (7,500 km) or 8 months Every 9,375 mi (15,000 km) or 16 months
Accelerator cables (adjustment) C
Rear suspension linkage bearings C
Steering bearings and steering C C
Wheel bearings C
Engine oil filter S S (*)
Engine oil filter (on oil tank) P P
Engine oil S S (*)
Tappet clearance R R
Braking systems C C
Cooling system C
Clutch fluid C every 2 years: S
Brake fluid C every 2 years: S
Brake pads if worn: S
Coolant every 2 years: S
Fork oil After the frist 4,687 mi (7,500 km): S / every 14,000 mi (22,500 km): S
Wheels/tires C
Nut, bolt, screw tightening C C
Suspensions and attitude C C
Brake fluid bleeding 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 these maintenance operations at one-half of he specified intervals, if your vehicle is often used in rainy or very dusty
conditions, on unpaved roads, or in any kind of competition.
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)$%.4)&)#!4)/.$!4!
It is a good idea to write down the frame
and engine numbers in the space provid-
ed below. Use the frame number (VIN) to
identify your vehicle when ordering spare
parts.
aWARNING
In all states and countries, it is against
the law to alter the Vehicle Identification
Number (VIN). You can incur severe
penalties by doing this. Also, this will
immediately invalidate your warranty.
FRAME NUMBER
The frame number is stamped on the right
side of the fork head.
Frame no.
ENGINE NUMBER
The engine number is stamped on the rear
part of the left engine crankcase.
Engine no.
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Carefully read p. 72 (MAINTENANCE).
aWARNING
Do not use gasoline or flammable sol-
vents to wash the air cleaner, in order to
avoid fire or explosion.
Inspect the air cleaner to ensure that it has
not become clogged every 4,687 mi (7,500
km) or 8 months of use. Renew the air
cleaner every 9,375 mi (15,000 km).
The air cleaner must be inspected more
frequently, cleaned if necessary, and re-
placed more frequently if the vehicle is
used on dusty or wet roads.
More frequent cleaning of the air cleaner is
suggested, especially if your bike is used
under very dusty conditions.
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aCAUTION
The air cleaner must not be used for
more than 9,375 mi (15,000 km) regard-
less of how many times it has been
cleaned in the interval. Under very
dusty or dirty conditions, it is advisable
to replace the air filter more often.
Before the cleaning operation, it is neces-
sary to remove the air cleaner from the ve-
hicle.
REMOVAL
◆Lift the fuel tank, see p. 94 (LIFTING
THE FUEL TANK).
aCAUTION
Before unscrewing and removing the
screws (1), clean the filter case cover (2)
and the filter case (5) with a clean cloth.
Prevent any foreign matter from getting
into the inlet tubes. This could cause
severe engine damage.
◆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 to
prevent any foreign matter from enter-
ing the intake tubes.
CLEANING
aCAUTION
Take great care not to deform the perfo-
rated metal outside screen. It is very
fragile and can be easily damaged. Nev-
er use a screwdriver or other sharp hard
tool to remove the air cleaner itself.
aWARNING
During this operation, always wear gog-
gles which provide your eyes with 360°
protection. Be very careful using com-
pressed air jets, they can cause serious
personal injury if directed towards your
body.
◆Grasp the air cleaner vertically and strike
it repeatedly on a clean hard horizontal
surface.
◆If available, clean the air cleaner with a
compressed air jet, directing it from the
inside of the filter towards the outside.
◆Clean the outer part of the air cleaner
with a cloth.
CHANGING
◆Replace the air cleaner with a new one
of the same type.
◆Make sure that the gasket (4) of the filter
case (5) is intact; if it is damaged, re-
place it.
◆Every 4,687 mi (7,500 km) remove the
plug (6) so that any dirt that may have
accumulated inside the filter case can be
removed.
aCAUTION
When cleaning the air cleaner, make
sure that there are no tears. Otherwise,
replace the air cleaner.
Make sure that the air cleaner is posi-
tioned correctly, in such a way as to pre-
vent non-filtered air from entering.
Premature wear of the piston rings, pis-
tons and cylinders is caused by an im-
properly installed air cleaner.
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Carefully read p. 46 (LUBRICANTS),
p. 72 (MAINTENANCE) and p. 122 (LU-
BRICANT CHART) .
aWARNING
It is critical to the safe operation of your
vehicle that the proper lubricants, main-
tained at the proper levels, are used.
Failure to heed this warning can lead to
an engine seizure with subsequent acci-
dent, serious injury or death.
aWARNING
Remember that the tightening torque of
all fasteners on the wheels, brakes, ax-
les, and other components of the sus-
pension system is very important to en-
sure the safety of the vehicle, and must
be kept at the prescribed values.
Check the tightening torque of the fas-
teners regularly, and always use a
torque wrench when reinstalling them.
Failure to comply with this warning
could allow one of these components to
be lost which could lock a wheel or
cause other handling problems with
consequent overturning and risk of se-
rious injury or even death.
CHECKING
NOTE Position the vehicle on firm and
flat ground.
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. 30 (IN-
STRUMENTS AND INDICATORS TA-
BLE).
aWARNING
Exhaust gases contain carbon monox-
ide, which is extremely poisonous if in-
haled.
Do not start the engine in closed or bad-
ly-ventilated rooms.
Failure to observe this warning may
cause loss of consciousness or even
lead to death by asphyxia.
◆Check the oil when the engine is warm,
having been ridden for at least 10 mi (16
km).
NOTE If the engine is cold, warm it up
for riding, preferably on a hilly road, for ap-
proximately 10 mi (16 km) before checking
the oil.
◆Stop the engine before checking the oil.
aWARNING
Should your vehicle overturn, it will leak
gasoline, which is extremely flammable.
Flames or sparks may cause a fire,
which could destroy not only the vehi-
cle, but also the building in which it is
located, and cause serious injuries or
even death.
◆Keep the vehicle in vertical position, with
the two wheels resting on the ground.
NOTE If you attempt to check the oil with
the vehicle leaned in either direction from
the vertical, your measurement will be in-
accurate.
NOTE If the engine oil tank is dirty, wipe
it with a clean cloth so that you can see the
“MIN”and “MAX”marks.
◆Look through the appropriate slot (1) in
the left fairing. Check the level of the oil
in the sight gauge (2).
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MAX = maximum level
MIN = minimum level
The difference between “MAX”and
“MIN”is about 0.53 US qt (500 cm#).
◆The level is correct if the oil reaches ap-
prox the “MAX”mark.
aWARNING
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 tank:
aWARNING
When warmed up, the engine contains
hot oil and the engine oil tank (3) is
warm; therefore, while carrying out the
operations described here below be
particularly careful, in order to avoid
burns.
aCAUTION
Use thick gloves to prevent burns.
◆Remove the left fairing, see p. 96 (RE-
MOVING THE SIDE FAIRINGS).
aCAUTION
Before unscrewing and removing the
filler cap (4), clean it and the area of the
tank around it with a clean cloth. Pre-
vent any foreign matter from falling into
the oil tank, this could cause serious
engine damage.
Do not use any flammable solvents
such as alcohol or gasoline when wip-
ing the oil tank. The oil tank is hot
enough to cause ignition of flammable
solvents.
Use only a nature fiber cloth, i.e. cotton.
Man made fabrics such as polyester,
etc. could ignite.
◆Unscrew and remove the filler cap (4).
aCAUTION
When topping up, never exceed the
“MAX”level.
◆Top up the engine oil tank (3) through the
filler neck (5), with high-quality engine oil,
see p. 122 (LUBRICANT CHART).
◆Replace and tighten the filler cap (4).
aWARNING
Tighten the filler cap (4) snugly to in-
sure no oil leak.
◆Replace the left fairing, see p. 96 (RE-
MOVING THE SIDE FAIRINGS).
aWARNING
Never ride your vehicle with low engine
oil, or with contaminated oil, or with un-
approved oil. Any of these will greatly
accelerate wear of your engine, and
cause irreparable damage.
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Carefully read p. 72 (MAINTENANCE)
and p. 81 (CHECKING THE SWITCHES).
The side stand (1) must rotate about its
pivot smoothly and easily.
Perform the following checks:
◆The springs (2) must be free from dam-
age, wear, or rust, and must fully and
firmly retract the side stand when the
weight of the vehicle is lifted off of it.
◆The side stand (1) must rotate freely
about its pivot. If necessary, lubricate
the pivot, see p. 122 (LUBRICANT
CHART).
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The side stand (1) is equipped with a safe-
ty system, operated by safety switch (3).
This system prevents the motor from being
started while the stand is extended unless
the transmission is in neutral. It also kills
the engine if the stand is extended while
the engine is running, unless the transmis-
sion is in neutral.
To check the proper functioning of the safe-
ty switch (3):
◆Sit on the vehicle in the normal riding po-
sition.
◆Retract the side stand (1).
aWARNING
Exhaust gases contain carbon monox-
ide, which is extremely poisonous if in-
haled.
Do not start the engine in closed or bad-
ly-ventilated rooms.
Failure to observe this warning may
cause loss of consciousness or even
lead to death by asphyxia.
◆Start the engine, see p. 62 (STARTING).
◆Release the throttle grip (4) (Pos. A).
With the engine idling, pull in the clutch
lever (5) completely.
◆Engage first gear, pushing the shift lever
(6) downwards.
◆Extend the side stand (1).
NOTE Extending the side stand must kill
the engine and the “side stand down”warn-
ing light “\”(7) must come on. If the en-
gine continues to run:
◆Check the safety switch (3) on the side
stand (2), see p. 81 (CHECKING THE
SWITCHES). Perform the necessary
cleaning or repairs.
◆Repeat the check.
aWARNING
If the engine does not stop when the
side stand is extended, do not ride your
vehicle. Contact your Local APRILIA
Dealer.
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81
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#(%#+).'4(%37)4#(%3
Carefully read p. 72 (MAINTENANCE).
Check the switches after the first 625 mi
(1,000 km) and thereafter every 4,687 mi
(7,500 km).
The vehicle is equipped with four switch-
es:
–stoplight switch on the rear brake pedal
(1);
–stoplight switch on the front brake lever
(2);
–safety switch on the side stand (3);
–clutch lever switch (4).
◆Make sure that there is no dirt or mud on
the switch. The switch pin must move
freely and without interference, returning
automatically to its unapplied position.
◆Check the spring (5); it must not be dam-
aged, worn or stretched.
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).30%#4).'4(%&2/.4
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aCAUTION
The front fork oil change operation
should be entrusted to your Local APRIL
IADealer.
Carefully read p. 72 (MAINTENANCE).
Have the front fork oil changed after the
4,687 mi (7,500 km) and thereafter every
14,000 mi (22,500 km).
Every 4,687 mi (7,500 km), carry out the
following checking operations:
◆Apply the front brake lever and push up
and down on the handlebar repeatedly,
pushing the fork up and down.
The fork must move smoothly and easily,
there must be no trace of oil on the fork
tubes.
◆Check the torque of all the fasteners on
the front fork and inspect the entire front
fork to make sure that it is in good condi-
tion without leaks or damage. Repeat for
the rear suspension and swinging arm.
aCAUTION
Do not ride your vehicle if either sus-
pension is damaged in any way, contact
your Local APRILIADealer.
&2/.43530%.3)/.
The front suspension consists of an hy-
draulic fork connected to the steering col-
umn by means of two plates.
For the setting of the vehicle attitude, each
rod of the fork is provided with an upper
screw (1) for the adjustment of the hydrau-
lic damping on extension, a lower screw (2)
for the adjustment of the hydraulic damp-
ing on compression and an upper nut (3)
for the adjustment of the spring preload.
NOTE It is possible to adjust the attitude
of the vehicle, by changing the height of its
front part.
For this type of adjustment, contact your
Local aprilia Dealer.
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83
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ADJUSTING THE FRONT FORK
The front fork is adjusted at the factory to
suit most riding conditions for most riders.
However, it is possible to adjust the fork set-
ting to your preference, and to accommo-
date the full range of operating conditions
that the vehicle is intended to be used for.
aCAUTION
When adjusting the front fork, always
start from the most rigid setting. Do not
rotate adjusters (1) and (2) beyond their
limit position, to avoid damaging the
threads.
Use the notches (1) and (2) provided on
the adjusters as reference marks for the
adjustment of hydraulic damping on ex-
tension and hydraulic damping on com-
pression.
Turn the adjusters (1) and (2) 1/8 turn at
a time and turn the adjusting nut (3) one
notch at a time. Then, test the vehicle
on the road, to ensure you have ob-
tained the optimal adjustment.
Make sure that the spring preload and
hydraulic damping, both on extension
and compression, is the same for both
sides. A different shock absorber set-
ting on the left and right side will de-
crease the stability of the vehicle.
When the spring preload is increased, it
is necessary to also increase the hy-
draulic damping, both on extension and
compression, to avoid a jerky unsteady
shock action while riding.
Upper screw adjusters
(1) (2.25 turns in total) By rotating them clockwise (H) By rotating them counterclockwise (S)
Function Increase of the hydraulic
damping on extension Decrease of the hydraulic damping on extension
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment From the completely clockwise position, 1.5 turns counter-
clockwise
Lower screw adjusters
(2) (2 turns in total) Byrotatingthemclockwise (H) By rotating them counterclockwise (S)
Function Increase of the hydraulic
damping on compression Decrease of the hydraulic damping on compression
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment From the completely clockwise position, 1.5 turns counter-
clockwise
Upper adjusting
nuts (3)
(8 notches in total)
Byrotatingthemclockwise
(screwing) By rotating them counterclockwise
(unscrewing)
Function Spring preload increase Spring preload decrease
Attitude The vehicle is more rigid The vehicle is less rigid
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment Turn the adjusting nut 5 notches counterclockwise from the
fully clockwise setting
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The rear suspension consists of a hydrau-
lic shock absorber - spring unit, which is
mounted to the frame with a uniball, and to
the swinging arm by means of a system of
levers.
The ride height of the rear of the vehicle
can be set using the spring preload adjust-
ing ring nut (3) and locking ring nut, (4).
The rear suspension can be tuned by ad-
justing the extension damping with a spring
adjuster (1), the damping on compression
can be adjusted by a knob (2).
ADJUSTING
THE REAR SHOCK ABSORBER
The rear shock absorber is set at the facto-
ry to satisfy most riding conditions, at either
low or high speed, and with either a light or
full load. However, it is possible to tune the
suspension to your preference by using the
above mentioned adjustments.
aCAUTION
When adjusting the rear shock absorber,
always start from the stiffest position.
This is the fully clockwise position of the
extension damper adjusting screw (1)
and the compression damper knob (2).
Do not rotate the extension damper ad-
justment screw (1) beyond its limit, this
will damage the screw and destroy your
shock absorber.
Always make sure, when adjusting
screw (1), that it clicks in to an adjust-
ment notch, and is not at a position inter-
mediate between adjustment notches.
The distance between the top of the ad-
justment ring and the top of the threads
must not exceed 1.10 ± 0.20 in (28 ± 5
mm). Adjusting the nut further down on
the shock will compress the spring ex-
cessively, and result in an uneven
bumpy ride. Also, it will be impossible to
adequately adjust the extension damp-
ing using screw (1).
◆Loosen the locking ring nut (4) by means
of the appropriate spanner wrench.
◆Adjust the adjusting ring nut (3) (see fig-
ure).
◆If necessary, adjust the extension damp-
ing screw (1) (see table p. 85).
◆Once the ride height has been properly
adjusted, tighten the lock ring nut (4)
completely.
◆Slightly loosen the lock nut (5).
Rotate the adjuster (6) one turn at a time
so that the adjusting screw (1) faces out
to the left side of the vehicle.
◆Using the appropriate wrench, turn the
adjuster (6) (which adjusts the center to
center distance of the shock absorber
unit) (see table p. 85).
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85
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NOTE Adjust the spring preload and the
extension damping according to the vehi-
cle use. When the spring preload is in-
creased, it is also necessary to increase
the extension damping in order to avoid a
bumpy uneven ride.
Especially at higher preload settings, it is
advisable to use full extension damping
(screw (1) fully clockwise) or only a couple
of clicks clockwise, to avoid a bumpy un-
even ride. If necessary, contact your Local
aprilia Dealer.
Never remove the plug(7) or attempt to ad-
just the valve covered by it. This may
cause nitrogen to escape which will de-
stroy the function of the shock absorber
and could upset the handling of your vehi-
cle, leading to an accident with subsequent
injury or even death.
Never exceed 2-3 clicks with the extension
damping adjustment (1) or 5-6 clicks with
the compression damping adjustment knob
(2), or one turn with the preload adjusting
nut (3) at any given adjustment attempt.
Ride the vehicle for more than just a few
miles on the road between each adjust-
ment, to determine the adjustments most
suitable to your use.
Screw adjuster (1)
(27 clicks) By rotating it clockwise (H) By rotating it counterclockwise (S)
Function Increase of the hydraulic
damping on extension Decrease of the hydraulic damping on extension
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment Turn the screw adjuster 14 clicks counterclockwise from its
most clockwise position
Knob adjuster (2)
(40 clicks) By rotating it clockwise (+) By rotating it counterclockwise (–)
Function Increase of the hydraulic
damping on compression Decrease of the hydraulic damping on compression
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment Turn the knob 10 clicks clockwise from its completely open,
most counterclockwise position
Adjusting ring nut (3) By screwing it By unscrewing it
Function Spring preload increase Spring preload decrease
Attitude The vehicle is more rigid The vehicle is less rigid
Recommended kind of
road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Adjusting nut (6) By unscrewing it By screwing it
Function Increasethecenter-to-center
mount distance Decrease the center-to- center mount distance
Attitude The vehicle is higher The vehicle is lower
Recommended kind
of road Roads with uneven surface Smooth or normal roads
Notes Rider and passenger Solo rider
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Carefully read p. 47 (BRAKES), p. 48
(DISC BRAKES) and p. 72 (MAINTE-
NANCE).
NOTE Your vehicle is equipped with
disc brakes and two separate brake sys-
tems.
The front brake system is equipped with
two discs, one on the right and one on the
left side of the front wheel.
The rear brake system is equipped with a
single disc on the right side of the wheel.
The following information may refer to a
single braking system, but is applicable for
both braking systems.
Check the brake pad wear after the first
625 mi (1,000 km), before every trip and
thereafter every 4,687 mi (7,500 km).
The amount of wear that the brake pads
experience depends on how the vehicle is
used, how aggressively it is driven, and
the condition of the roads upon which it is
operated. Wear will be faster than normal
when the vehicle is driven aggressively, or
on dusty or wet roads.
aWARNING
Check the wear of the brake pads be-
fore every trip.
CHECKING WEAR OF THE BRAKE
PADS
◆Place the vehicle on the stand, see p. 71
(POSITIONING THE VEHICLE ON THE
STAND).
◆Perform a visual check of the friction ma-
terial thickness. Use a flashlight. See
the arrows (1) and (2) above.
If the friction material on one pad of a pair,
front (3) or rear (4), is worn to 0.06 in (1.5
mm) or less, replace both pads.
aWARNING
Excessive wear of the friction material
would cause the contact of the pad met-
al support with the disc, with conse-
quent metallic noise and production of
sparks from the caliper; braking effi-
ciency and safety will be seriously com-
promised. This could lead to a crash,
with subsequent serious injury or
death.
aWARNING
Have the pads changed by your Local
APRILIADealer.
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