APRILIA SL MILLE Instruction manual

SL mille _
IINTRODUCTION
IREPAIR INFORMATION
I GENERAL INFORMATION
ISERVICE AND SETTING UP
ICOOLING SYSTEM
IELECTRIC SYSTEM
ICHASSIS
IANALYTICAL INDEX
I FUEL SUPPLY SYSTEM
Ii ENGINE
__ -----II
____ ------JI
___ -E
_____________ E
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__ -----IE
________ Ii
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Release 00/2001-05 -------
------- II -1- 00

INTRODUCTION SL
mille
INTRODUCTION
TABLE OF CONTENTS
I0.1 UPDATE OF RELEASE 00/
2001·0S 0-3-00
0.1.1 INFORMATION ON THE UPDATING OF
THE
MANUAL 0-3-00
0.1.2 UPDATED MANUAL GENERAL LIST 0-3-00
0.2 HOW TO CONSULT THE MANUAL 0-5-00
0.3 FOREWORD 0-6-00
0.4 SAFETY WARNINGS 0-6-00
0.4.1 PRECAUTIONS AND GENERAL
INFORMATIONS 0-6-00
0.4.2 DISASSEMBLING THE COMPONENTS 0-7-00
0.4.3 REASSEMBLING THE COMPONENTS 0-7-00
O.S·HOW TO USE YOUR SERVICE
AND REPAIR MANUAL 0-7-00
0.5.1 ADVICE FOR CONSULTATION 0-7-00
11- 2 -00
--------- Release 00/2001-05

SL mille
INTRODUCTION
0.1.2 UPDATED MANUAL GENERAL LIST
Insert the pages of the last Release in the manual
'andellminate the corresponding obsolete pages
(even if belonging to a previous Release).
0.1.1
INFORMATION ON THE UPDATING OF THE
MANUAL
The manual must be updated every time a new IIRe-
lease
ll
is received.
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The manual consists of ,# 10 sections, for a total amount
of #328 pages,.as listed below.
NOTE For the nomenclature of the standard page of
the manual (and specifically for the definition of the page
number) see 0.2 (HOW TO CONSULT THE MANUAL).
The
failure to update manual and to eliminate
the obsolete pages makes it more difficult to con-
sult the manual and may lead to the performance
of incorrect operations on the vehicle, with serious
consequences for' the safety of the vehicle and of
persons and property.
page# Release
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0.1 UPDATE OF RELEASE 00/2001·05
Date of the first edition (Release 00) and of the following
Releases:
'First edition (Release 00) may 2001
Follow~
Release 00/2001-05 ----------
11- 3-00

INTRODUCTION
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SL mille
Release 00/2001-05

SLmille
0.2 HOW TO CONSULT THE MANUAL
(2)1-----I
SLroille
(;;;'\.8 '---- [1.8 .POSITIONING THE VEHICLE ON THE
"'V SUPPORT STAND
(;:;\9 [1.8.1 ASSEMBLING THE PINS FOR THE REAR SUP-
\:!.) PORT STAND mil
NOTE Have the appropriate special tool r:Iiito hand:
-
aprilia part# 8140194 (rear support stand complete
with pins).
f1O\. ----------l[. Position the vehicle on the side stand on firm and level
~ ground. '
• * Position the pin (1) on the appropriate seat on the re-
arfork.
fi1\. [.* Screw and tighten the screw (2). in the appropriate
~ threaded hole in the rear fork.
1.8.2 POSITIONING THE VEHICLE ON THE REAR
SUPPORT STAND m:ii
NOTE Have theappropriate special tool r:Iiito hand:
-
aprilia part# 8140194 (rear support stand complete
with pins).
• Fit the relevant pins, see 1.8.1 (ASSEMBLING THE
PINS FOR THE REAR SUPPORT STAND r:Iii).
NOTE Have someone help you keep the vehicle in ver-
tical position with the two wheels on the ground.
• * Loosen the knob (3).
•
*Move the fork supportta), positioning it so that the
width corresponds to the distance between the two pins
(1) on the
rear fork.
•
*Tighten the knob (3).
• At the same time introduce the two fork-shaped seats
(4) of the stand (5) under 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.
1.8.3 POSITIONING THE VEHICLE ON THE FRONT
SUPPORT STAND m:ii
NOTE Have the appropriate special tool r:Iiito hand:
-
aprilia part# 8140195 (front support stand).
• Position the vehicle on the appropriate rear support
stand, see 1.8.2 (POSITIONING THE VEHICLE ON
THE REAR SUPPORT STAND r:Iii).
• 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.
INTRODUCTION
.--------0
GENERAL INFORMATION
5
~I----o-------t,-----.l-----,I ,1
Release 00/2001-04 ----------
--0
I~---- -0
------- D-13-00
1) Vehicle (or engine) model
2) Section
3) Release consecutive number
(1100
11
indicates the first
edition)
4) Year and month of publication of the Release
5) Section number
6) Section page consecutive number
7) Updated page consecutive number
8) Chapter title (numbered consecutively)
9) Paragraph title (numbered consecutively)
10) Description of the operation (always preceded by a
rhombus)
11) Description of the operation: the star means that the
operation must be repeated on the other side of the
vehicle.
Release 00/2001-05
11- 5-00

INTRODUCTION
0.3 FOREWORD
- This manual supplies the main information for normal
servicing procedures. _
- Inthe future, the information and illustrations that make
up this manual will be updated by means of "Heleas-
esll , seeOt (UPDATE OF RELEASE 00/2001-05).
- This publication is intended for the
aprllla Dealers and
their qualified engineers; many notions were voluntarily
omitted, because they were considered superfluous.
Since it is not possible to include complete mechanical
information in this publication, the persons using this
manual must have a basic' mechanical training and a
basic knowledge ofthe procedures regarding motor ve-
hicles repair systems.
Without this knowledge, the repair or servicing of the
vehicle may be ineffective or even dangerous.
The manual does not describe all the procedures for
the.repair and servicing of the vehicle in detail, there-
fore it is important to be particularly careful, in order to
avoid any damage to components and persons.
In order to grant its customers more and more satisfac-
tion in the use of the
vehicle,aprilia s.p.a. will keep
improving its products and
the relevant documenta-
tion.
The main technical modifications and the modifica-
tions in the vehicle repair procedures are communicat-
ed to all
aprllla Outlets and Branches the world over.
These modifications will be described in the succes-
sive editions of this manual.
In case of need or incase there are any doubts regard-
ing the repair and servicing procedures, contact the
aprltla Consumer Service (A.C.S.), which will give you
any information required and will also inform you about
any updating and technical modifications of the vehi-
cle.
For further information, refer to:
8140582 (Engine service andrepairmanual V990 1051-1)
392Y (Spare parts catalogue SL mille)
8102721 (Use and maintenance manual SL mille)
8202278 (Special tools manual)
aprllia s.p.a. reserves the rightto modify its models at any
time, without prejudice to the main characteristics here
described.
All rights as to electronic storage, reproduction and total
or partial adaptation, with any means, are reserved for all
Countries.
The mention to products or services supplied by third par-
ties is made only for information purposes and it isn't bind-
ing in any case.
aprilla takes no responsibility as to the performance or
use of
said products.
Firstedition: may 2001
Produced and printed by:
stp editing division
Soave (VERONA) - Italy
Tel. +39 - 045 76 11 911
Fax +39 - 045 76
12241
E-mail: [email protected]
www.stp.it
On behalf of:
aprilia Consumer Service s.p.a.
via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italia
Tel. +39 - 041
5786101
Fax +39 - 041 5786100
www.aprilia.com
SL mille
0.4 SAFETY WARNINGS
The following precautionary warnings are used through-
out this manual In order to convey the following.messag-
es:
I\. Safety warning. When you find this symbol on
.. the vehicle or in the manual, be.careful to the po-
tential risk of personal injury. Non-compliance with
the indications given in the messages preceded by
this symbol may result in grave risks for your and oth-
er people's safety and for the vehicle!
Indicates apotential hazard
which may result in seri-
ous injury or even death.
Indicates apotential
which may result in
minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual precedes im-
portant information or instructions.
0.4.1
PRECAUTIONS AND GENERAL INFORMA-
TIONS
Follow with care these recommendations when repairing,
disassembling and reassembling the vehlcle.
use of naked
flames is forbidden for any type of
operation.
Before
beginning any maintenance operation 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.
Keep away from the red-hot parts of the engine and
of the exhaust system, in order to avoid burns.
Do not. hold any mechanical piece or other parts of
the vehicle with your mouth: the components are not
edible and some of them are noxious or even toxic.
If not expressly indicated otherwise, for the reassem-
bly of the units repeat the disassembly operations in
reverse order.
Any reference to operations from other chapters
must be interpreted logically in order to avoid com-
ponents being removed unnecessarily.
Do not use polishing pastes on matt paints.
Never use fuel as a
solvent for cleaning the vehicle.
Do not use alcohol, petrol or solvents to clean the
rubber and. plastic parts and the saddle: use only wa-
ter and mild soap.
Disconnect the negative cable (-) from the battery
when electric welding.
When two or more persons are working together,
make sure that each is working in sate conditions.
BEFORE DISASSEMBLY
- Remove any dirt, mud, dust and foreign matters from
the vehicle before disassembling the components.
- Use, when necessary, the special tools designed for
this vehicle.
11-6-00
Release 00/2001-05

SL mille
INTRODUCTION
0.4.2 DISASSEMBLING THE COMPONENTS
- Do not loosen and/or tighten the screws and nuts using
pliers or other tools: instead, always use the proper
spanner.
- Before disconnecting the joints (pipes, cables, etc.),
mark the positions on all of them and mark them with
different distinguishing signs.
Each piece must be marked clearly, in order not to
have problems during installation.
- Clean and wash carefully any disassembled parts with
low inflammability detergents.
- Keep the parts that are used in pairs together, since
they have adapted to each other following
the normal
wear.
Some componentsmust be used together or replaced
completely.
- Keep away from heat sources.
0.4.3 REASSEMBLING THE COMPONENTS
0.5 HOW TO USE YOUR SERVICE AND REPAIR
MANUAL
0.5.1 ADVICE FOR CONSULTATION
- This manual is divided into section and chapters, each
one of which corresponds to a category of main com-
ponents.
To consult them, see the sections' index, see page 0-1.
- If not expressly indicated otherwise, for the reassembly
of the units repeat the disassembly operations in re-
verse order.
- The terms "right" and "left" are referred to the rider
seated on the vehicle in the normal riding position.
- For normal maintenance operations and for the use of
the vehicle, consult the "USE AND MAINTENANCE"
manual.
*The operations preceded by this symbol must
be repeated on the opposite side of the vehi-
cle.
In this manual the various versions are indicated by the
following symbols:
•Croatia
•Australia
cD United States
of America
QBrazil
•South
Africa
• New Zealand
• Canada
cD Malaysia
•Chile
•Singapore
•Slovenia
ED Switzerland
•Denmark
•Japan
• Israel
•South Korea
em- Greece
.. Holland
•Belgium
•Germany
• France
• Spain
E automatic light switching version (Automatic Switch-on
Device)
mm optional
VERSION:
•Italy
•United King-
dom
•Austria
•Portugal
CD Finland
Never use a seeger ring twice. When a seeger ring is
removed, it
must be replaced with a new one. When
assembling a new seeger ring be careful
not to
stretch its
ends more than strictly necessary to put it
on the shaft.
After installing a seeger ring, make sure that it is
completely and
firmly inserted in its seat.
Do
not use compressed air to clean the bearings.
NOTE The bearings must rotate freely, without halting
ala noise otherwise they must be replaced.
- Use only original aprilia SPARE PARTS.
- Use the recommended lubricants.
-Whenever possible, lubricate the parts before reas-
sembly.
- When tightening screws and nuts, begin with those
having greater diameters or with inner ones, proceed-
ing diagonally.
Tighten screws or nuts in successive passages before
applying driving torque.
- Always replace lock nuts, seals, sealing rings, snap
rings, O-rings, split pins and screws, whenever the
thread appears damaged, with new ones.
- Before the assembly, clean allthe connection surfaces,
the oil seal edges and the gaskets.
Apply a thin layer of lithium-based grease on the oil
seal edges
..
Put back the oil seals and the bearings with the mark or
serial number facing towards the outside (visible side).
- When installing the bearings, lubricate them abundant-
ly.
- Make sure that each component has been reassem-
bled correctly.
- After a repairor periodic maintenance operation, carry
out the preliminary checks and test the vehicle in a pri-
vatearea or, in any case, in a low-traffic area.
Release 00/2001-05
----------
11-7-00

INTRODUCTION
NOTE·
SL mille
11- 8 -00
--------- Release 00/2001-05

SL mille _
IGENERAllNFORMATION I
Release 00/2001-05 D -1 -00

I
GENERAL INFORMATION
I
GENERAL INFORMATION
TABLE OF CONTENTS
1.1 POSITION OF THE SERIAL
NUMBERS 1-3-00
1.1.1 FRAME NUMBER 1-3-00
1.1.2 ENGINE NUMBER 1-3-00
1.2 INSTRUCTIONS FOR USE OF
FUEL, LUBRICANTS, COOLANT AND
OTHER COMPONENTS 1-3-00
1.2.1 FUEL........................................................ 1-3-00
1.2.2 ENGINE OIL 1-4-00
1.2.3 FORK OIL 1-4-00
1.2.4 BRAKE FLUID 1-4-00
1.2.5 COOLANT 1-5-00
1.2.6 CLUTCH FLUID ; 1-5-00
1.2.7 CARBON MONOXiDE............................. 1-6-00
1.2.8 HOT C.OMPONENTS 1-6-00
1.3 RUNNING-IN RULES 1-6-00
1.4 SPARE PARTS 1-7-00
1.5 TECHNICAL SPECIFICATIONS 1-7-00
1.6 LUBRICANT CHART 1-10-00
1.7 SPECIAL TOOLS. 1-11-00
1.7.1 MISCELLANEOUS TOOLS 1-11-00
1.7.2 ENGINE TOOLS 1-12-00
1.8 POSITIONING THE VEHICLE ON
THE SUPPORT STAND 1-13-00
1.8.1 ASSEMBLING THE PINS FOR THE
REAR SUPPORT STAND
•............... 1-13-00
1.8.2 POSITIONING THE VEHICLE ON THE
REAR SUPPORT STAND
•............... 1-13-00
1.8.3 POSITIONING THE VEHICLE ON THE
FRONT SUPPORT STAND
•............ 1-13-00
1.8.4 POSITIONING THE VEHICLE ON THE
CENTRE SUPPORT STAND
•.......... 1-14-00
1.9 CONSUMABLES 1-15-00
1.9.1 PRODUCT PROPERTIES 1-15-00
1.9.2 USE OF CONSUMABLES ;.. 1-16-00
1.10 GENERAL SPECIFICATIONS OF
THE DRIVING TORQUES 1-18-00
1.11 FASTENING ELEMENTS 1-19-00
1.12 INSTRUCTIONS FOR APPLYING
TRANSFERS 1-24-00
1.13 ABBREVIATIONS /
SYMBOLS /INITIALS 1-26-00
SL mille
0- 2 -00
--------- Release 00/2001-05

SL mille
1.1 POSITION OF THE SERIAL NUMBERS
These numbers are necessary for the registration of the
vehicle.
NOTE Do not alter the identification numbers if you do
not want to incur severe penal and administrative sane-
tions.ln particular, the alteration of the frame number re-
sults in the immediate invalidity of the guarantee.
1.1.1 FRAME NUMBER
The frame number is stamped on the right side of the
steering column.
1.1.2 ENGINE NUMBER
The engine number is stamped on the rear part of the en-
gine, near the pinion.
1.2 INSTRUCTIONS FOR USE OF.FUEL,
LUBRICANTS, COOLANT AND OTHER
COMPONENTS
1.2.1 FUEL
The fuel used
for internal combustion engines is ex-
tremely inflammable and in particular conditions it
can become explosive.
It is
important to carry out the refuelling and the
maintenance operations in a well-ventilated area,
with the engine off.
Do
not smoke while refuelling or near fuel vapours, in
any case avoid any contact with naked flames,
sparks and any other heat source to prevent the fuel
from catching fire or from exploding.
Further, prevent fuel from flowing
out of the fuel filler,
as it
could catch fire when getting in contact with the
red-hot surfaces of the engine.
In case
some fuel has accidentally been spilt, make
sure that the area has completely dried and before
starting the vehicle verify that there is no fuel inside
the fuel filler neck.
Since petrol
expands under the heat of the sun and
due to the effects of sun radiation.
Never
fill the tank to the brim.
Screw
the plug up carefully after refuelling.
Avoid any contact of the fuel with the skin and the in-
halation of vapours; do not swallow fuel or pour it
from areceptacle into another by means of a tube .
. 00 NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min.D.N. 95
(N.D.R.M.) and 85 (N.D.M.M.).
GENERAL INFORMATION
---~-_._ .. -----
Release 00/2001-05 ----------
D-3 -00

GENERAL INFORMATION
1.2.2 ENGINE OIL
Engine oil may cause serious damage to the skin if
handled daily and for long periods.
Wash
your hands carefully after use.
Do
not dispose of the oil in the environment.
Deliver it to or have it collected by the nearestoil sal-
vage
center or by the supplier.
In
case any maintenance operation has to be carried
out, it is
advisable to use latex gloves.
Change engine oil after the first 1000 km (625 mi) and
successively every 7500 km (4687 mi) (*), see 2.14
(CHANGING THE ENGINE OIL AND THE OIL FILTER).
(*) = In case of use' on racetracks, change every 3750
km (2343 mi).
Engine
oil (recommended):
m EXTRA RAID 4, SAE 15W - 50 or [I1A9IilP TEC 4T,
SAE 15 W - 50.
As an alternative to the recommended
oil,it is possible to
use high-quality oils with characteristics in compliance
with or superior to the CCMC G-4,
A.P.1. SG. specifica-
tions.
1.2.3
FORK OIL
Fork oil may cause serious damage to the skin if han-
dled
daily and for long periods.
Wash
your hands carefully after use.
Do
not dispose of the oil in the environment.
Deliver it to or have it collected by the nearest oil sal-
vage
center or by the supplier.
In
case any maintenance operation has to be carried
out, it is
advisable to use latex gloves.
By chanqlnqthe damper settings and/or the viscosity
of the oil contained in them, the suspension re-
sponse may be altered partially.
Standard oil viscosity: SAE 20 W.
The
viscosity ratings which can be chosen based on
the
type of fork stiffness desired (SAE 5W soft, 20W
stiff).
The
two products can be used in different percentag-
es
until the desired response is obtained.
One of the properties of mF.A. and :!BA9IiIP FORK is
that their viscosity alters little with changes in tem-
perature and their damping response thereforere-
mains constant.
Fork oil (recommended):
Fork oil mF.A. 5W
orm F.A. 20W;
as an alternative
tllA9IilP FORK 5W or [iBA9IilP FORK
20W.
If you need an oil
with intermediate characteristics in
comparison with the mF.A. 5W and mF.A. 20W or
:'IIA9IilP FORK 5W and ,IBA9IilP FORK 20W, these can be
mixed as indicated below:
SAE 1
OW= mF.A. 5W 67% of the volume, +mF.A.
20W33
%of the volume or
,IIA9IilP FORK 5W 67% of the
volume, +
tHAgilP FORK 20W 33% of the volume.
SAE
15W =mF.A. 5W 33% of the volume, +mF.A.
20W
67% of the volume or IIlA9IiIP FORK 5W 33% of the
volume, +IIJAgilP FORK 20W
67% of the volume.
SL
mille
1.2.4 BRAKE FLUID
NOTE This vehicle is provided with front and rear disc
brakes, with separate hydraulic circuits. The following in-
formation refers to a single braking system, but isvalid for
both.
If the
brake fluid gets in contact with the skin or the
eyes, it can cause
serious irritations.
Carefully wash the parts of your body that get in con-
tact with the liquid .. Consult a doctor or an oculist if
the
liquid gets lncontact with your eyes.
DONaT DISPOSE OF THE FLUID IN THE ENVIRON-
MENT.
KEEP
AWAY FROM CHILDREN.
When
using the brake fluid, take care not to spill it on
the plastic or painted parts, since it can damage
them. '
Every 7500 km (4687
mil check the level of the brake
fluid, see 2.17 (CHECKING THE FRONT BRAKE FLU-
ID
LEVEL AND TOPPING UP) and 2.18 (CHECKING
AND TOPPING UP THE REAR
BRAKE FLUID); change
the
fluid every two years, see 2.22 (CHANGING THE
FRONT
BRAKE FLUID) and 2.23 (CHANGING THE
REAR
BRAKE FLUID).
Brake fluid (recommended):
mF.F., DOT 5 (compatible DOT 4) or AgilP BRAKE
5.1, DOT 5 (compatible DOT 4).
To
avoid serious damage to the. braking system, do
not use fluids other than the recommended ones nor
mix different fluids for topping up.
Do
not use brake fluid taken from old or already
opened containers.
Sudden variations in clearance or an elastic resist-
ance in the brake levers may be due to trouble in the
, hydraulic circuits.
Make sure that the brake discs and the friction pads
are
completely free of grease or oil, especially after
maintenance or checking operations.
Check that the brake cables are neither twisted nor
worn out.
Prevent water or dust from accidentally getting into
the circuit.
In case maintenance operations are to be performed
on the hydraulic circuit, it is advisable to use latex
gloves. '
0- 4 -00
Release 00/2001-05

SL mille
1.2.5 COOLANT
The coolant is
noxious: do not swallow it; if the cool-
ant gets in contact with the skin or the eyes, it can
cause
serious irritations. If the coolant gets in con-
tact with your skin or eyes, rinse with plenty of water
and
consult adoctor.
If
it is swallowed, induce vomit, rinse mouth and
throat with plenty of water and consult a doctor with-
out delay.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRON-
MENT.
KEEP AWAY FROM CHILDREN.
Be careful
not to spill the coolant on the red-hot parts
of
the engine: it may catch fire and send out invisible
flames.
In
case any maintenance operation should be re-
quired, it is advisable to use latex gloves.
Do
not use the vehicle if the coolant is belowthe min-
imum prescribed level.
Before setting off, and every 15000 km (9375 mi), check
the level of the coolant, see 2.15 (CHECKING AND TOP-
PING UP COOLANT); change the coolant every two
years, see 2.16 (CHANGING THE COOLANT).
The coolant is composed of
50% water and 50% anti-
freeze. This mixture is ideal for most running tempera-
tures and ensures good protection against corrosion.
It is advisable to keep the same mixture in the hot season
as well, since in this way losses due to evaporation are
reduced and it is not necessary to top up so frequently.
The mineral salt deposits left in the radiator by evaporat-
ed water are thus lessened and the efficiency of the cool-
ing system remains unaltered.
If the outdoor temperature is below 0°, check th cooling
circuit frequently and inf necessary increase the anti-
freeze concentration (up to maximum 60%).
For the cooling solution use distilled water, in order not to
damage the engine.
Engine coolant (recommended):
mECOBLU - 40°C or ~.A9IilP COOL.
On the basis of the desired freezing temperature of the
coolant mixture, add to the water the percentage of cool-
ant indicated in the following table:
45
55
NOTE The characteristics of the various antifreeze liq-
uids are different. Be sure to read the label on the prod-
uct to learn the degree of protection it guarantees.
Use only antifreeze and anticorrosive without nitrite
in order to ensure protection at at least -35°C.
GENERAL INFORMATION
1.2.6 CLUTCH FLUID
NOTE This vehicle is provided with hydraulic clutch
control.
If the clutch fluid gets in contact with the skin or the
eyes, it can cause serious irritations.
Carefully wash the parts of
your body that get in con-
tact with
the liquid. Consult a doctor or an oculist if
the liquid gets in contact with
your eyes.
DO NOT DISPOSE OF THE FLUID IN THE ENVIRON-
MENT.
KEEP AWAY FROM CHILDREN.
When using the clutch fluid, take care not to
spill it on
the plastic and painted parts, since it damages them.
Every 7500 km (4687 mi) check the level of the clutch
fluid, see 2.19 (CHECKING AND TOPPING UP THE
CLUTCH FLUID); change
the fluid every two years,
see 2.24 (CHANGING THE CLUTCH FLUID).
Clutch
fluid (recommended):
mF.F., DOT 5 (compatible DOT 4) or ~~AQlilP BRAKE
5.1, DOT 5 (compatible DOT 4).
To avoid serious damage to the system, do not use
fluids other than the recommended ones nor mix dif-
ferent
fluids for topping up.
Do
not use clutch fluid taken from old or already
opened containers.
Sudden
variations in clearance or an elastic resist-
ance in the clutch levers may be due to trouble in the
hydraulic circuits.
Check that the clutch hoses are
not twisted or worn.
Prevent water or
dust from accidentally getting into
the circuit.
In case maintenance operations are to be performed
on the
hydraulic circuit, it is advisable to use latex
gloves.
Release 00/2001-05 ----------
D- 5 -00

GENERAL INFORMATION
1.2.7 CARBON MONOXIDE
If it is necessary to let the engine run in order to carry out
some work, make sure that the area in which you are op-
erating is properly ventilated.
Never run the engine in enclosed spaces.
If it is necessary to work indoors, use an exhaust evacua-
tion system.
The exhaust fumes contain carbon monoxide, apoi-
sonous gas that can cause loss of consciousness
and even death.
Run the engine in an open area or, if it is necessary to
work indoors, use an exhaust evacuation system.
1.2.8 HOT COMPONENTS
The engine and
the components of the exhaust sys-
tem
become very hot and remain hot for some time
after the engine has been stopped.
Before
handling these components, wear insulating
gloves or wait until the engine and the exhaust sys-
tem have cooled down.
SL mille
1.3 RUNNING-IN RULES
The running-in of the engine is essential to ensure its du-
ration and correct functioning.
If possible, drive on hilly roads and/or roads with many
bends, so
that the engine, the suspensions and the
brakes undergo a more effective running-in.
During running-in, change speed.
In this way the components are first "loaded" and then
"relieved" and the engine parts can thus cool down.
Even if it is important to stress the engine components
during runninq-in, take care not to exceed.
Only afterthe first 1500 km (937 mil of running-in is it
possible to obtain
the best performance.
Keep to the following indications:
• Do not open the throttle completely if the speed is low,
both during and after the running-in.
• During the first 100 km (62 mi) put on the brakes with
caution, avoiding sharp and prolonged brakings.
This ensures a correct bedding-in of the pads on the
brake disc.
• During the first 1000 km (625 mi) never exceed 6000
rpm. (see table).
After the first 1000 km (625 mil perform the checking
operations indicated in the "after running-in" col-
umn, see 2.1.1 (REGULAR SERVICE INTERVALS
CHART) in order to avoid injuring yourself or others
alo damaging the vehicle.
• Between the first 1000 km (625 mi) and 1500 km (937
mi) drive more briskly, change speed and use the max-
imum acceleration only for a few seconds, in order to
ensure better coupling of the components; never ex-
ceed 7500 rpm (see table).
• After the first 1500 km (937 mi) you can expect better
performance from the engine, however, without ex-
ceeding the maximum allowed (10500 rpm).
(
11- 6 -00
0-1000 (0 - 625)
1000
-1500 (625 - 937)
over 1500 (937)
6000
7500
10500
Release 00/2001-05

GENERAL INFORMATION
SL mille
1.4 SPARE PARTS
For any replacement, use aprilia Genuine Spare Parts
only.
aprilia Genuine Spare Parts are high-quality parts, ex-
pressly desiqned and manufactured for aprilia vehicles.
Failure to use aprilia Genuine Spare Parts may re-
sult in incorrect performance and damages.
1.5 TECHNICAL SPECIFICATIONS
Max. length
Max. length (rear mudguard extension included) mil
Max. width
Max. height (front part of the fairing included)
Seat height
Distance between centres
Min. ground clearance
Weight ready for starting (fuel and fluid included)
2065 mm
2170 mm
750mm
1180 mm
820mm
1415 mm
140 mm
222 kg
Model
Type
Number of cylinders
Total displacement
Max. rated power (to driving shaft)
Max. rated power (to driving shaft) •
Max. torque
Max.
torque.
Bore/stroke
Compression ratio
V990
60° longitudinal V-type, two-cylinder, 4-stroke, with 4 valves
per cylinder, OOHC.
2
997.6 ern"
86.5 kW (118 HP) at 9250 rpm
77 kW (104 HP) at 9250 rpm
96.5 Nm (9.78 kgm) at 7250 rpm
'90 Nm (9.17 kgm) at 7000 rpm
97 mm / 67.5 mm
11.4 ±0.5: 1
Average piston speed 22.5 m/s at 10000 rpm
Camshaft during intake stroke 262°, valve lifting= 10.6 mm
Camshaft during exhaust stroke 259°, valve lifting= 10.6 mm
Valve advance (with valve clearance 1mm) opening during intake stroke 20° before TOC
closing during intake stroke 62° after BOC
opening during exhaust stroke 64° before TOC
closing during exhaust stroke 15° after BOC
Valve clearance during intake stroke
Valve clearance during exhaust stroke
#Engine revolutions at minimum rpm
#Engine revolutions at peak rpm
Ignition
Starting
Spark advance
Starter motor gear ratio
Clutch
Transmission
0.12-0.17 mm
0.23-0.28 mm
1250 ±100 rpm
10250 ±100 rpm
electronically controlled
electric
At start: 5° before TOC, additional advance depending on
specific consumption levels
i= 49/9 *30/11 *64/30 = 31.677
multidisc in oil bath, with hydraulic control on the left side of
the handlebar and PPC device
- # 9 lined discs; thick 3.5 mm
- # 9 internal discs; thick 1.5 mm
Mechanical, 6 gears with foot control on the left side of the
engine
Follow~
Release 00/2001-05 ----------
0-7 -00

GENERAL INFORMATION
Follow~
SL mille
Lubrication system
Lubrication pressure
Air cleaner
Cooling
Coolant pump gear ratio
Coolant pump delivery (with thermal expansion valve open)
Thermal expansion valve opening start temperature
Engine dry weight
dry pan with separate oil tank, #2 trochoidal pumps and cool-
ing radiator
min 500 kPa (5 bar)
at max
80°C (176 OF) and 6000 rpm
with dry filter cartridge
liquid-cooled
iwp=28/27 *
28/28 =1.037
90 flmin and 9000 rpm
65 ±2 °C (149 ±5
OF)
-- 67 kg
Fuel (reserve included)
Fuel reserve
Engine oil
Fork oil (per rod)
Coolant
Seats
Vehicle max. load (driver +passenger +luggage)
19 f
4.5 ±1t
oil change 3700 cm3
oil and oil filter change 3900 ern"
520 ±2.5 cm3
2.5 f (50% water + 50% antifreeze with ethylene glycol)
2
182 kg
GEAR RATIOS
#sprocket teeth
Primary
31160 =1: 1,935 Secondary
14/35 =1: 2,500
16/28 =1: 1,750
19/26 =1: 1,368
22/24 =1: 1,090
23/22 =1: 0,956
27/23 =1: 0,851
16
Final ratio
16/41 =1: 2,563 Total ratio
12,399
8,679
6,787
5,411
4,744
4,225
Drive chain
Front
Stroke
Rear
Wheel stroke
endless type (with no connection link) with sealed links, model
525, dimensions 5/8 11 x
5/16
11
UPSIDE-DOWN telescopic adjustable fork with hydraulic
operation, rod 043 mm
127 mm
oscillating rear fork in light alloy with differentiated profile arms
and hydropneumatic adjustable mono-shock absorber
129 mm
in light alloy with withdrawable pin
3.50 X1711
6.00 X17"
Follow~
0- 8 -00
Release 00/2001-05

SL mille
Follow~
GENERAL INFORMATION
Front
PIRELLI DRAGON EVa
MTR21 120/65-ZR17"
...
x220 (2.2) 240 (2.4) 220-230
(series) CaRSA
(2.2-2.3)
Rear
PIRELLI DRAGON EVa
MTR22 180/55-ZR17"
...
250 (2.5) 270 (2.7)
(series) CORSA
Front METZELER STELL RADIAL MEZ3
120/70-17
11
~ :-:
Rear METZELER STELL RADIAL MEZ3
180/55-17
11
~
Front MICHELIN PILOT SPORT
120/65-ZR17
11
~
220 (2.2) 240 (2.4)
Rear
MICHELIN PILOT SPORT
190/50-ZR 1711
~
250 (2.5) 270 (2.7)
Front BRIDGESTONE BATTLAX BT56
120/70-17
11
~
220 (2.2) 240 (2.4)
Rear
BRIDGESTONE BATT LAX BT56
190/50-17
11
~
. 250 (2.5) 270 (2.7)
~ =Normal use; :-: =Use on racetracks
Battery
Main fuses
Secondary fuses
Generator (with permanent magnet)
Starter
12 V
-12 Ah
30 A
15 A
12 V - 400 W
12 V 10.9 kW
Low beam (halogen)
High beam (halogen)
Front parking light
Direction indicators
Rear parking lights/Stoplight
Number plate light
Revolution counter
Right multifunction display
Left multifunction display
12
V-55 W
12
V-55 W
12V-5W
12V-10W
12 V - 5/21 W
12V-3W
12 V - 2 W
12V-2W
12V-2W
Neutral
Direction indicators
Fuel reserve
High beam
Stand down
Engine oil pressure
Red line
Release 00/2001-05 --------- ..........
12V-3W
12 V - 3 W
12V-3W
12 V - 2 W
12 V - 3 W
LED
LED
0- 9 -00

GENERAL INFORMATION SL mille
1.6 LUBRICANT CHART
Engine oil (recommended): mEXTRA RAID 4, SAE 15W - 50 or :.Agnp TEC 4T SAE 15W - 50.
As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the
CCMC G-4, A.P.1.SG specifications.
Fork oil (recommended): mF.A. 5W or In F.A. 20 W fork oil;
an alternative ;_Agup FORK 5W or
:H.AgoP FORK 20W fork oil.
If you need an oil with intermediate characteristics in 'comparison with the mF.A. 5W and mF.A. 20 W or
~.Agip FORK 5W and
_Agjfip FORK 20W, these can be mixed as indicated below:
SAE 10W =
In F.A. 5W 670/0 of the volume, +mF.A. 20W 330/0 of the volume or
::.Agip FORK 5W 67% of the volume +'MAgip FORK 20W 33% of the volume.
SAE 15W =
In F.A. 5W 33% of the volume, +mF.A. 20W 670/0 of the volume or
::IIAgip FORK 5W 33% of the volume +:RAgip FORK 20W 67% of the volume.
Bearings and other lubrication points (recommended): mAUTOGREASE MP or ';:~AgilP GREASE 30.
As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30 °C...+
140°C,
dripping point 150 °C...230 DC, high protection against corrosion, good resistance to water and oxidation.
Protection of the battery poles: neutral grease or vaseline.
Spray grease for chains (recommended): In CHAIN SPRAY or :[RAgip CHAIN LUBE.
Use new brake fluid only.
Brake fluid (recommended): mF.F., DOT 5 (DOT 4 compatible) or ,R
UIP BRAKE 5.1, DOT 5 (DOT 4 compatible).
Use new clutch fluid only.
Clutch fluid (recommended):
In F.F., DOT 5 (DOT 4 compatible) or :~Agip BRAKE 5.1, DOT 5 (DOT 4 compatible).
Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35°C at least.
Engine coolant (recommended): mECOBLU
-40°C or :~AgilP COOL.
11-
10 - 00 Release 00/2001-05

GENERAL INFORMATION
SL mille
1.7 SPECIAL TOOLS mil
In order to perform assembly,reassembly and settings
correctly, special tools suitable for the task must be used.
The use of special tools avoids the potential risk of dam-
age as a result of inappropriate tools and/or improvised
methods.
Below is a list of the special tools designed especially for
this specific vehicle.
If necessary, request the multi-purpose special tools, see
aprilia part# 8202278 (Special tools manual).
Before using the special tools, consult any docu-
ments attached.
.----- -- ---- - ---
.
. ~~
QJ
Cf
I
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I
I
·
·
·
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
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-----------------------------------
~-------~-----------------------,
1.7.1 MISCELLANEOUS TOOLS
Complete tool kit for frame parts including:
8140203 (semi-shells for assembling oil seals, front fork)
8140203 (socket spanner for adjusting steering)
8140203 (socket
spannerfor adjusting fork pin - engine mounts)
28140192 (chain disassembly/reassembly tool)
38140176 (centre stand)
48140194 (rear support stand complete with pins)
58140195 (front support stand)
68140196 (exhaust fume analyser)
78140202 (exhaust fume analyser pipe kit)
88140199 (tool holder panel)
98140180 (Kit for bearings in the range
010 mm to 0 30 mm)
10 8134396 (fuel tank support rod)
Release 00/2001-05 ----------
------- 0 -11 -00