APRILIA RSV MILLE - PART 3 1999 User manual

52 use and maintenance SL mille
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 3750 km (2343 mi).
Component After running-in
[1000 km (625 mi)] Every 7500 km (4687 mi) or 8 months Every 15000 km (9375 mi) or 16 months
Spark plugs C (*) S (*)
Air filter CS
Engine oil filter S S (*)
Engine oil filter (on oil tank) P P
Light operation/direction C
Fork C
Light system C C
Safety switches C C
Clutch fluid C
Brake fluid C
Coolant C
Engine oil S S (*)
Tyres C every 1000 km (625 mi): C
Tyre pressure R every 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 Friday, December 17, 1999 11:16 AM

53
use and maintenance SL mille
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 After the frist 7500 km (4687 mi): S / every 22500 km (14000 mi): S
Brake pads if worn: S
Nut, bolt, screw tightening C C
Suspensions and attitude C C
Fuel pipes C every 4 years: S
C= check and clean, adjust, lubricate or change, if necessary; P= clean; S= change; R= adjust.
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 Friday, December 17, 1999 11:16 AM

54 use and maintenance SL mille
)$%.4)&)#!4)/.$!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 Friday, December 17, 1999 11:16 AM

55
use and maintenance SL mille
#(%#+).'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 7500 km (4687
mi), see p. 56 (CHANGING THE ENGINE
OIL AND THE OIL FILTER).
In case of use on racetracks, change every
3750 km (2343 mi).
TO CARRY OUT THE CHECKING:
aCAUTION
The engine oil level must be checked
with warm engine.
If the check is carried out with cold en-
gine, the oil level may temporarily lower
below the “MIN” mark.
This is not a problem, provided that the
engine oil pressure warning light LED
“j” does not come on, see p. 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 460 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. 90 (LUBRICANT CHART).
Ing-02.fm Page 55 Friday, December 17, 1999 11:16 AM

56 use and maintenance SL mille
#(!.').'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 7500 km (4687 mi).
aCAUTION
In case of use on racetracks, change
every 3750 km (2343 mi).
If the vehicle is used in dusty areas,
change the oil more frequently.
CHANGING THE ENGINE OIL:
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.
◆Position the vehicle on the side stand on
firm and level ground.
◆Position a container (1) with more than
4000 cm#capacity in correspondence
with the drain plug (2) positioned on the
tank.
◆Unscrew and remove the drain plug (2)
positioned on the tank.
◆Unscrew and remove the filling cap (3).
◆Drain the oil and let it drop for a few min-
utes inside the container (1).
◆Check and if necessary replace the seal-
ing washer of the drain plug (2) posi-
tioned on the tank.
◆Screw and tighten the drain plug (2) on
the tank.
Drain plug (2) driving torque:
15 Nm (1.5 kgm).
◆Move the container (1) and position it un-
der the engine base, in correspondence
with the drain plug positioned on the en-
gine (4).
◆Unscrew and remove the drain plug posi-
tioned on the engine (4).
◆Drain the oil and let it drip inside the con-
tainer (1) for a few minutes.
aCAUTION
Do not dispose of the oil in the environ-
ment. Put it in a sealed container and
take it to the filling station where you
usually buy it or to an oil salvage cent-
er.
◆Remove the metal residues from the
drain plug (4) magnet.
Ing-02.fm Page 56 Friday, December 17, 1999 11:16 AM

57
use and maintenance SL mille
◆Screw and tighten the drain plug (4).
Driving torque of the drain plug (4) posi-
tioned on the engine: 12 Nm (1,2 kgm).
CHANGING THE ENGINE OIL FILTER
Change the engine oil filter after the
first 1000 km (625 mi) and successively
every 7500 km (4687 mi) (or every time
you change the oil).
◆Unscrew the two screws (5) and remove
the cover (6).
◆Remove the engine oil filter (7).
aCAUTION
Do not use filters that have already
been used.
◆Spread an oil film on the sealing ring (8)
of the new engine oil filter.
◆Fit the new engine oil filter.
◆Put back the cover (6), screw and tighten
the two screws (5).
CLEANING THE ENGINE OIL FILTER
ON THE TANK
Clean the engine oil filter (9) on the tank
after the first 1000 km (625 mi) and suc-
cessively every 15000 km (9375 mi) (or
every two engine oil changes).
NOTE Prepare a pipe clamp (10) to re-
place the original one (special type).
◆Loosen the clamp (11) and disconnect
the pipe (12).
◆Unscrew and remove the engine oil filter
(9) positioned on the tank and clean it
with a jet of compressed air.
◆Check the seal of the engine oil filter (9)
positioned on the tank; screw and tighten
it.
Engine oil filter (9) driving torque:
30 Nm (3.0 kgm).
◆Connect the pipe (12) and tighten the
new clamp (10).
aCAUTION
Do not put additives or other substanc-
es into the oil.
If you use a funnel or other similar
items, make sure that they are perfectly
clean.
NOTE Use high-quality 15W-50 oil, see
p. 90 (LUBRICANT CHART).
◆Pour about 3500 cm#of engine oil
through the filling opening (13), 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 Friday, December 17, 1999 11:16 AM

58 use and maintenance SL mille
!33%-",).'4(%0).3&/24(%
2%!23500/2434!.$&
◆Position the vehicle on the side stand on
firm and level ground.
◆★Position the pin (1) on the appropriate
seat on the rear fork.
◆★Screw and tighten the screw (2) in the
appropriate threaded hole in the rear
fork.
0/3)4)/.).'4(%6%()#,%/.
4(%2%!23500/2434!.$&
NOTE Have someone help you keep the
vehicle in vertical position with the two
wheels on the ground.
◆★Loosen the knob (3).
◆★Move the fork support (4), positioning it
so that the width corresponds to the dis-
tance between the two pins (1) on the
rear fork.
◆★Tighten the knob (3).
◆Make the two housings on the stand (4)
coincide with the two pins (1) provided
on the vehicle.
◆Rest one foot on the rear part of the
stand (5).
◆Push the stand (5) downwards until it
reaches the end of its stroke.
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 (6) in the
two holes (7) positioned on the lower
ends of the front fork.
◆Rest one foot on the front part of the
stand (6).
◆Push the stand (6) downwards until it
reaches the end of its stroke.
Ing-02.fm Page 58 Friday, December 17, 1999 11:16 AM

59
use and maintenance SL mille
!)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 to clean 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.
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 opening with a clean cloth, in
order to prevent any foreign matter to
get ito the suction ducts.
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 Friday, December 17, 1999 11:16 AM

60 use and maintenance SL mille
&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 Friday, December 17, 1999 11:16 AM

61
use and maintenance SL mille
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 Friday, December 17, 1999 11:16 AM

62 use and maintenance SL mille
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 Friday, December 17, 1999 11:16 AM

63
use and maintenance SL mille
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. 90 (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 Friday, December 17, 1999 11:16 AM

64 use and maintenance SL mille
$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 Friday, December 17, 1999 11:16 AM

65
use and maintenance SL mille
◆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 correctlypositioned
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. 90
(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 Friday, December 17, 1999 11:16 AM

66 use and maintenance SL mille
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 passenger seat, see p. 27
(UNLOCKING / LOCKING THE PAS-
SENGER SEAT).
◆Remove the rider saddle, see beside
(REMOVING THE RIDER SADDLE).
◆Turn the handlebar in such a way as to
position the front wheel straight, in the
travel direction.
◆Unscrew and remove the two screws (4)
that fasten the front part of the fuel tank
(5).
◆Remove the fuel tank support rod (8)
from the relevant anchorage seats (6-7).
NOTE The rubber-covered end of the
stick (8) must be introduced in the central
hole of the steering pin.
◆Lift the front part of the fuel tank (5) and
introduce the rod (8) as indicated in the
figure.
Ing-02.fm Page 66 Friday, December 17, 1999 11:16 AM

67
use and maintenance SL mille
#(%#+).'4(%"2!+%0!$7%!2
Carefully read p. 31 (BRAKE FLUID -
recommendations), (DISC BRAKES)
and p. 51 (MAINTENANCE).
NOTE The following information refer to
a single braking system, but are valid for
both.
Check the brake pad wear every 7500 km
(4687 mi) and before every trip.
The wear of the disc brake pads depends
on the use, on the kind of drive and on the
road.
aWARNING
Check the wear of the brake pads, espe-
cially before every trip.
.
To carry out a rapid checking of the wear of
the pads, proceed as follows:
◆Position the vehicle on the side stand on
firm and level ground.
◆Carry out a visual check between the
disc and the pads, proceeding:
–from below, on the front part, for the front
brake calipers (1);
–from below, on the rear part, for the rear
brake caliper (2).
aCAUTION
The excessive wear of the friction mate-
rial would cause the contact of the pad
metal support with the disc, with conse-
quent metallic noise and production of
sparks from the caliper; braking effi-
ciency, safety and soundness of the
disc would thus be negatively affected.
◆If the thickness of the friction material
(even of one pad only) has reduced to
about 1 mm (or if even only one of the
wear indicators is not visible any longer),
change both pads.
–Front pad (3).
–Rear pad (4).
NOTE Have the pads changed by your
aprilia Official Dealer.
Ing-02.fm Page 67 Friday, December 17, 1999 11:16 AM

68 use and maintenance SL mille
).30%#4).'4(%&2/.4
!.$2%!23530%.3)/.3
Carefully read p. 51 (MAINTENANCE).
NOTE Have the front fork oil changed by
an aprilia Official Dealer, who will ensure
you prompt and accurate servicing.
Have the front fork oil changed after the
first 7500 km (4687 mi) and successively
every 22500 km (14000 mi).
Every 7500 km (4687 mi), carry out the fol-
lowing checking operations:
◆With pulled front brake lever, press the
handlebar repeatedly, thrusting the fork
downwards.
The stroke must be gentle and there
must be no trace of oil on the rods.
◆Check the fastening of all the compo-
nents and the functionality of the front
and rear suspension joints.
aCAUTION
If you notice irregularities in the opera-
tion or if the help of a qualified techni-
cian is necessary, contact your APRILIA
Official 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 braking with extended shock absorber,
a lower screw (2) for the adjustment of the
hydraulic braking with compressed shock
absorber and an upper nut (3) for the ad-
justment 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 an
aprilia Official Dealer.
ADJUSTING THE FRONT FORK
The standard setting of the front fork is
such as to satisfy most driving conditions
at low and high speed, either with reduced
load and full load.
However, it is also possible to adjust the
setting according to the intended use of the
vehicle.
Ing-02.fm Page 68 Friday, December 17, 1999 11:16 AM

69
use and maintenance SL mille
aCAUTION
For the adjustment, always start from
the most rigid setting (adjuster com-
pletely rotated clockwise).
Do not force the rotation of the adjust-
ers (1-2) beyond the end of stroke in
both directions, in order to avoid any
damage.
Use the notches (1-2) provided on the
adjusters as reference marks for the ad-
justment of the hydraulic braking with
compressed and extended shock ab-
sorber.
Give the adjusters (1-2) 1/8 turn at a time
and turn the adjusting nut (3) one notch
at a time. Test the vehicle repeatedly on
the road, until obtaining the optimal ad-
justment.
Set the same spring preload and hydrau-
lic braking for both rods: a different set-
ting of the rods decreases the stability of
the vehicle while riding.
When the spring preload is increased, it
is necessary to increase also the hydrau-
lic braking, in order to avoid sudden
jerks while riding.
Upper screw adjusters
(1) (2.25 turns in total) By rotating them clockwise (H) By rotating them anticlockwise (S)
Function Increase of the hydraulic
braking with extended shock
absorber
Decrease of the hydraulic
braking with extended shock
absorber
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment From end of stroke (completely closed), give 1.5
anticlockwise turns (opening).
Lower screw adjusters
(2) (2 turns in total) By rotatingthemclockwise (H) By rotating them anticlockwise (S)
Function Increase of the hydraulic
braking with compressed
shock absorber
Decrease of the hydraulic
braking with compressed
shock absorber
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment From end of stroke (completely closed), give 1.5
anticlockwise turns (opening).
Upper adjusting
nuts (3)
(8 notches in total)
Byrotatingthemclockwise
(screwing) By rotating them anticlockwise
(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 From end of stroke (completely closed), turn the adjusting
nut 5 notches anticlockwise (opening).
Ing-02.fm Page 69 Friday, December 17, 1999 11:16 AM

70 use and maintenance SL mille
2%!23530%.3)/.
The rear suspension consists of a spring-
shock absorber unit, fixed to the frame by
means of silent-blocks and to the rear fork
by means of lever systems.
For the setting of the vehicle attitude, the
shock absorber is provided with a screw
adjuster (1) for the adjustment of the hy-
draulic braking with extended shock ab-
sorber, a ring nut for the adjustment of the
spring preload (2) and a locking ring nut
(3).
ADJUSTING
THE REAR SHOCK ABSORBER
The standard setting of the rear shock ab-
sorber is such as to satisfy most driving
conditions at low and high speed, either
with reduced load and full load.
However, it is also possible to adjust the
setting according to the intended use of the
vehicle.
aCAUTION
For the adjustment, always start from
the most rigid setting.
Do not rotate the screw adjuster (1) be-
yond its limit position, to avoid damag-
ing the thread.
Make sure that the screw adjuster (1) al-
ways snaps and is not in any intermedi-
ate position.
The adjusting ring nut must not be
screwed for more than 44 mm from the
beginning of the thread (see figure).
MIN = 38 mm
MAX = 44 mm
If this measure is exceeded, even the
slightest unevenness on the road sur-
face will cause sudden jerks and it will
be useless to adjust the screw (1).
◆Slightly unscrew the locking ring nut (3)
by means of the appropriate spanner.
◆Act on the adjusting ring nut (2) (shock
absorber spring preload adjustment)
(see figure).
◆If necessary, adjust the screw (1) (ad-
justment of the hydraulic braking with ex-
tended shock absorber) (see table).
◆Once the optimal attitude has been ob-
tained, tighten the locking ring nut (3)
completely.
Ing-02.fm Page 70 Friday, December 17, 1999 11:16 AM

71
use and maintenance SL mille
aCAUTION
Adjust the spring preload and the hy-
draulic braking with extended shock ab-
sorber according to the conditions of
use of the vehicle.
When the spring preload is increased, it
is necessary to increase also the hy-
draulic braking with extended shock ab-
sorber, in order to avoid sudden jerks
while riding.
If the vehicle attitude is set for full-load
riding, it is advisable not to rotate the
screw (1) leftwards (anticlockwise), in
order to avoid sudden jerks while rid-
ing. If necessary, contact an APRILIA Of-
ficial Dealer.
Gradually turn the screw (1) adjuster
giving 2-3 clicks per time, and the ad-
justing ring (2) giving one turn per time.
Test the vehicle repeatedly on the road,
until obtaining the optimal adjustment.
Screw adjuster (1)
(27 clicks) By rotating it clockwise (H) By rotating it anticlockwise (S)
Function Increase of the hydraulic
braking with extended shock
absorber
Decrease of the hydraulic
braking with extended shock
absorber
Recommended kind
of road Smooth or normal roads Roads with uneven surface
Notes Rider and passenger Solo rider
Standard adjustment From end of stroke (completely closed), turn the screw
adjuster 15 clicks anticlockwise (opening).
Adjusting ring nut (2) 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
Ing-02.fm Page 71 Friday, December 17, 1999 11:16 AM