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APRILIA RST mille Futura 2001 Service Manual

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RST mille
USA
Release 00/2002 - 03
INTRODUCTION
GENERAL INFORMATION
SERVICE AND SETTING UP
ENGINE
FUEL SYSTEM
COOLING SYSTEM
ELECTRICAL SYSTEM
CHASSIS
TROUBLESHOOTING
ANALYTICAL INDEX
INTRODUCTION
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1
2
3
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Summary of Contents for APRILIA RST mille Futura 2001

  • Page 1 INTRODUCTION RST mille INTRODUCTION GENERAL INFORMATION SERVICE AND SETTING UP ENGINE FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM CHASSIS TROUBLESHOOTING ANALYTICAL INDEX - 1 - Release 00/2002 - 03...

  • Page 2: Table Of Contents

    INTRODUCTION RST mille INTRODUCTION TABLE OF CONTENTS 0.1 UPDATE RELEASE 00/2002-03 ..0-3-00 0.1.1 INFORMATION ON UPDATING THE MANUAL........0-3-00 0.1.2 UPDATED MANUAL GENERAL LIST .. 0-3-00 0.2 HOW TO CONSULT THE MANUAL .. 0-6-00 0.3 FOREWORD ........0-7-00 0.4 REFERENCE SERVICE LITERATURE ........

  • Page 3: Update Release 00/2002-03

    INTRODUCTION RST mille 0.1 UPDATE RELEASE 00/2002-03 page # Release page # Release Issue date of the first edition (Release 00) and 1-33 -00 ...... 00 2-36 -00 ...... 00 subsequent Releases: 1-34 -00 ...... 00 2-37 -00 ...... 00 First edition (Release 00)......March 2002 1-35 -00 ......
  • Page 4 INTRODUCTION RST mille CONT'D ➤ page # Release page # Release page # Release page # Release 6-39 -00 ...... 00 7-27 -00 ...... 00 3-9 -00 ......00 5-9 -00 ......00 3-10 -00 ...... 00 5-10 -00 ...... 00 6-40 -00 ......
  • Page 5 INTRODUCTION RST mille page # Release page # Release 7-67 -00 ...... 00 8-4 -00 ......00 7-68 -00 ...... 00 8-5 -00 ......00 7-69 -00 ...... 00 8-6 -00 ......00 7-70 -00 ...... 00 8-7 -00 ......00 7-71 -00 ...... 00 8-8 -00 ......00 7-72 -00 ......

  • Page 6: How To Consult The Manual

    INTRODUCTION RST mille 0.2 HOW TO CONSULT THE MANUAL GENERAL INFORMATION RST mille 1.9 PLACING THE VEHICLE ON THE SUPPORT STANDS 1.9.1 PLACING THE VEHICLE ON THE FRONT SUPPORT STANDS Place the vehicle on the central stand. At the same time, insert the two pins (1) of the stand (3) into the two holes (2) at the bottom of the front fork.

  • Page 7: Foreword

    (A.C.S.). A.C.S. Technical counselors will be able to 8102859 assist you with any problems that you might face. 8104128 aprilia s.p.a. reserves the right to modify any of its models in any manner at any time. 8104099 This manual is protected by copyright in all countries.

  • Page 8: Abbreviations/Symbols/Acronyms

    INTRODUCTION RST mille 0.5 ABBREVIATIONS/SYMBOLS/ACRONYMS = number kΩ = kiloohms < = less than = kiloPascal (1 kPa = 0.145 psi - 0.01 bar) > = greater than = clutch side (Kupplungseite) < = equal to or less than = kilowatts >...
  • Page 9 INTRODUCTION RST mille NOTES - 9 - Release 00/2002 - 03...
  • Page 10 INTRODUCTION RST mille NOTE - 10 - Release 00/2002 - 03...
  • Page 11 GENERAL INFORMATION RST mille GENERAL INFORMATION - 1 - Release 00/2002 - 03...
  • Page 12 GENERAL INFORMATION RST mille GENERAL INFORMATION 1.13.2 USING CONSUMABLES..... 1-26-00 1.14 SPECIAL TOOLS......1-29-00 1.14.1 MISCELLANEOUS TOOLS....1-29-00 1.14.2 ENGINE TOOLS ........1-30-00 TABLE OF CONTENTS 1.15 PLACING THE VEHICLE ON THE 1.1 INTRODUCTION ......1-3-00 SUPPORT STANDS......1-31-00 1.2 SAFETY WARNINGS......1-3-00 1.15.1 PLACING THE VEHICLE ON THE FRONT SUPPORT STAND ....

  • Page 13: Introduction

    GENERAL INFORMATION RST mille 1.1 INTRODUCTION 1.2 SAFETY WARNINGS Throughout this manual you will encounter the following This manual is divided into sections, chapters and symbols: paragraphs, by subject. The procedures described are laid out in single DANGER operation, and each operation is indicated by a . When you find this symbol on the vehicle or in the The numbered parts shown in the figures are identified in manual, this indicates that a potential for serious...

  • Page 14: General Safety Rules

    GENERAL INFORMATION RST mille 1.3 GENERAL SAFETY RULES 1.3.6 CLUTCH CONTROL FLUID WARNING 1.3.1 CARBON MONOXIDE The clutch control fluid can damage painted, plastic or If it is necessary to run the engine in order to carry out a rubber parts. maintenance operation, ensure that the area in wich you are operating is properly ventilated.

  • Page 15: Precautions And General Information

    Handle fuel with the greatest caution. or noise, otherwise they must be replaced. Never use fuel as a solvent for cleaning the vehicle. - Use only ORIGINAL aprilia SPARE PARTS. Use only water and neutral soap to clean all rubber - Use...

  • Page 16: Electrical Connectors

    GENERAL INFORMATION RST mille 1.3.10 ELECTRICAL CONNECTORS The electrical connectors must be disconnected as follows. Failure to follow these procedures will irreparably damage the connector and wiring. Press in the click tab. WARNING Do not pull the cables to disconnect the two connectors.

  • Page 17: Specific Safety Rules

    GENERAL INFORMATION RST mille 1.4 SPECIFIC SAFETY RULES 1.4.1 FUEL DANGER Gasoline is extremely flammable and in some conditions can become explosive. It is therefore necessary to refuel and carry out maintenance operations involving the fuel system in a well-ventilated area, with the engine off. Do not refuel or do any maintenance on the fuel system with the engine running.

  • Page 18: Lubricants

    GENERAL INFORMATION RST mille 1.4.2 LUBRICANTS DANGER Proper vehicle lubrication is critical to safe operation. Failure to maintain proper lubricant levels or to use the proper type of clean, new lubricant, can lead to an engine or transmission seizure with subsequent accident, serious injury or death.

  • Page 19: Disc Brakes

    GENERAL INFORMATION RST mille Failure to heed these warnings may lead to a serious accident with consequent risk of serious injury or even death. The brakes are extremely important for your safety. Do not use the vehicle if the brakes do not work perfectly. Always check the brake efficiency before riding.

  • Page 20: Clutch Control Fluid

    GENERAL INFORMATION RST mille 1.4.5 CLUTCH CONTROL FLUID NOTE This vehicle is equipped with hydraulic clutch control. DANGER Do not ride the vehicle with worn or malfuctioning clutch! The clutch is an important safety system of the vehicle, and using the vehicle with clutch that is anything less than perfect is very likely to lead to a collision or upset, with consequent risk of serious injury or death.

  • Page 21: Coolant

    GENERAL INFORMATION RST mille 1.4.6 COOLANT WARNING Do not use the vehicle if the coolant is below the minimum prescribed level. Before setting off, and every 9,300 mi (15,000 km), check the level of the coolant, see 2.14 (CHECKING AND TOPPING UP THE COOLANT);...

  • Page 22: Drive Chain

    GENERAL INFORMATION RST mille 1.4.7 DRIVE CHAIN DANGER Every 600 mi (1,000 km) check the condition, the wear, Some of the original equipment tires for this vehicle the play (tension) and the lubrication of the drive chain. are provided with wear indicators. The vehicle is equipped with an endless chain.

  • Page 23: Automatic Converter

    GENERAL INFORMATION RST mille 1.4.9 AUTOMATIC CONVERTER This vehicle is equipped with lights that come on automatically as soon as the ignition switch (1) is turned to position “ “ (ON) (low beam lights “ “ or high beam lights “...

  • Page 24: Running-In Rules

    GENERAL INFORMATION RST mille 1.5 RUNNING-IN RULES The internal parts of the engine and trasmission 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 transmission undergo lots of speed changes.

  • Page 25: How To Use Your Service And Repair Manual

    GENERAL INFORMATION RST mille 1.6 HOW TO USE YOUR SERVICE AND In this manual the various versions are indicated by the REPAIR MANUAL following symbols: version with catalytic converter 1.6.1 HOW TO USE THIS MANUAL Automatic Switch-on Device version This manual is divided into sections, chapters and paragraphs, each one of which corresponds to a evaporative emission system category of main components.

  • Page 26: Identification Data

    In addition, alteration of the identification numbers invalidates the warranty. 1.7.1 VEHICLE IDENTIFICATION NUMBER (V.I.N.) (FRAME NUMBER) Every vehicle produced by aprilia receives a vehicle identification number (V.I.N.) stamped: - on the steering head of the frame (A), as shown above; and also: - on the identification plate (B) which is located on the front portion near the steering head of the frame.

  • Page 27: Engine Number

    GENERAL INFORMATION RST mille 1.8 POSITION OF SERIAL NUMBERS These numbers are required for vehicle registration. NOTE Tampering with the serial numbers is subject to serious sanctions under criminal and civil law. Altering the frame number will void the warranty effective immediately.

  • Page 28: Position Of The Warning Adhesive Labels

    GENERAL INFORMATION RST mille 1.8.3 POSITION OF THE WARNING ADHESIVE LABELS 11 12 13 - 18 - Release 00/2002 - 03...
  • Page 29 GENERAL INFORMATION RST mille Ref. Description Ref. Description 00/00 FOR STATE OF CALIFORNIA ONLY. 00/00 NOT PROVIDED FOR 49 STATES. FOR STATE OF CALIFORNIA ONLY FOR STATE OF CALIFORNIA ONLY. FOR STATE OF CALIFORNIA ONLY. FOR STATE OF CALIFORNIA ONLY. MUFFLER STAMPING - 19 - Release 00/2002 - 03...

  • Page 30: California Evaporative Emission System

    GENERAL INFORMATION RST mille 1.9 CALIFORNIA EVAPORATIVE EMISSION SYSTEM The system consists of: 16) Tee 1) Fuel tank 17) Cylinder synchronization line 2) Water drain line 18) Drain line (to manifold vacuum port) 3) Fuel tank breather nipple 19) Ported vacuum port (left part of throttle body) 4) Breather line (to tee) 20) Air box 5) Tee...

  • Page 31: Spare Parts

    RST mille 1.10 SPARE PARTS When making replacements, use only Original aprilia Spare Parts. Original aprilia spare parts are high quality, and are designed and built explicitly for aprilia vehicles. WARNING Use of spare parts NOT originally manufactured by aprilia may cause performance problems and damage.
  • Page 32 GENERAL INFORMATION RST mille ENGINE mechanical, 6 gears with foot control on the left side of Gearshift the engine dry sump with separate oil tank, 2 trochoidal pumps, Lubrication system cooling radiator min 72.52 PSI (500 kPa) (5 bar) *max. 80 °C (176 °F) Oil pressure and 6000 rpm Air filter...
  • Page 33 GENERAL INFORMATION RST mille SUSPENSIONS Upside-down telescopic fork, hydraulic damped, fork leg Front Ø 1.69 in (Ø 43 mm) Stroke 4.72 in (120 mm) light alloy rear swinging arm, and hydropneumatic Rear adjustable mono-shock absorber Wheel stroke 4.72 in (120 mm) BRAKES double floating disc - Ø...

  • Page 34: Lubricant Chart

    GENERAL INFORMATION RST mille BULBS Low beam (halogen) 12 V - 55 / 55 W H4 High beam (halogen) 12 V - 60 W H3 Front parking light 12 V - 5 W Direction indicators 12 V - 10 W Rear parking light/license plate light/brake light 12 V - 5/21 W Tachometer...

  • Page 35: Consumables

    GENERAL INFORMATION RST mille 1.13 CONSUMABLES Use only the products listed below for any maintenance work. These materials have been tested for many years and are suitable for use in all application conditions indicated by the manufacturer. NOTE Those consumables that are coded are available upon request, see 1.13.2 (USING CONSUMABLES).

  • Page 36: Using Consumables

    GENERAL INFORMATION RST mille 1.13.2 USING CONSUMABLES Product Code Description of use - Assembling rivets on fork, dashboard/front fairing mount, saddle support and frame. - Assembling frame/engine and frame/fork adjusting bushings. - Assembling fairlead screws on frame. - Insertion steering head bearings. - Steering head bushing upper retainer.
  • Page 37 GENERAL INFORMATION RST mille Product Code Description of use - On main bushing housings. - On main bushings. - On engine case bearing housings. - On coolant pump shaft. - On valve guide recesses in the head. MOLYKOTE G-n (**) 0297433 - On valve guide edges.
  • Page 38 GENERAL INFORMATION RST mille Product Code Description of use - Cleaning of left handlebar prior to assembly or grip. - Inserting of radiator breather tubes on “T”union. - Assembly of HV coil support grommet. - Assembly of side fairing grommets. - Cleaning of lower part of engine.

  • Page 39: Special Tools

    GENERAL INFORMATION RST mille 1.14 SPECIAL TOOLS WARNING The appropriate special tools must be used in order to Before using special tools, consult any documents properly disassemble, reassemble, and adjust parts. attached. The use of special tools avoids the potential risk of damage caused by inappropriate tools and/or improvised DANGER methods.
  • Page 40 GENERAL INFORMATION RST mille 1.14.2 ENGINE TOOLS Pos. Tool name and function Code Complete engine tool kit 8140175 Countershaft oil seal assembly drift 0277680 Upper balanceshaft oil seal assembly drift 0277660 Coolant pump shaft housing oil seal assembly drift 0277670 Coolant pump shaft housing sliding ring assembly drift 0877257 Valve guide disassembly drift...
  • Page 41 GENERAL INFORMATION RST mille 1.15 PLACING THE VEHICLE ON THE SUPPORT STANDS 1.15.1 PLACING THE VEHICLE ON THE FRONT SUPPORT STAND Place the vehicle on the center stand. At the same time, insert the two pins (1) of the stand (3) into the two holes (2) at the bottom of the front fork.
  • Page 42 GENERAL INFORMATION RST mille 1.15.2 PLACING THE VEHICLE ON THE CENTER SUPPORT STAND Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). code 8140176 (complete stand). Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Place the vehicle on the appropriate front support stand , see 1.15.1 (PLACING THE VEHICLE ON THE FRONT SUPPORT STAND).

  • Page 43: Instructions For Applying The Transfers

    GENERAL INFORMATION RST mille 1.16 INSTRUCTIONS FOR APPLYING THE TRANSFERS When removing parts from the frame: WARNING Handle all plastic and painted components with care to avoid scraping or scratching them. Work very carefully. Do not damage the tabs and/or slots into which they are fitted.
  • Page 44 GENERAL INFORMATION RST mille NOTE If using application tape (5) it must be removed 20-30 minutes after applying the transfer. Remove the application tape (5) from the transfer surface. To ensure good adhesion, move the spatula over the transfer again, concentrating in particular on the edges and corners.

  • Page 45: Fasteners

    Plain pliers are acceptable for removal, but a special installation tool is required. These clamps are destroyed upon removal, so new ones must be used upon reinstallation. NOTE Have the appropriate special tool available: aprilia part #0277295 (click clamp installation pliers). WARNING...

  • Page 46: General Values Of Tightening Torques

    The following table shows tightening torques for screws and bolts with metric ISO threads, as is used in this vehicle. These are general values to be used if no specific value is given in this manual or other aprilia service literature. Screw or...
  • Page 47 GENERAL INFORMATION RST mille NOTE - 37 - Release 00/2002 - 03...
  • Page 48 GENERAL INFORMATION RST mille NOTE - 38 - Release 00/2002 - 03...
  • Page 49 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille SCHEDULED MAINTENANCE AND TUNING OPERATIONS - 1 - Release 00/2002 - 03...
  • Page 50 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille SCHEDULED MAINTENANCE AND 2.18 CHECKING AND TOPPING UP THE CLUTCH FLUID...... 2-32-00 TUNING OPERATIONS 2.19 BLEEDING THE BRAKE SYSTEMS 2-34-00 TABLE OF CONTENTS 2.20 CLUTCH CONTROL SYSTEM BLEEDING ........2-38-00 2.1 SCHEDULED MAINTENANCE PLAN 2-4-00 2.21 CHANGING THE FRONT 2.1.1 SCHEDULED MAINTENANCE CHART 2-5-00 BRAKE FLUID........
  • Page 51 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.39 COOLING SYSTEM PIPES..... 2-59-00 2.40 TIGHTENING NUTS AND BOLTS.. 2-60-00 2.41 FASTENERS........2-61-00 2.41.1 CLEANING AND LUBRICATION..2-67-00 - 3 - Release 00/2002 - 03...

  • Page 52: Scheduled Maintenance Plan

    Keep all parts of the vehicle out of your mouth at all times. 2.1 SCHEDULED MAINTENANCE PLAN To keep the vehicle in top running condition, aprilia recommends that observe prescribed maintenance intervals for the various components.

  • Page 53: Scheduled Maintenance Chart

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.1.1 SCHEDULED MAINTENANCE CHART Every 4687 mi Every 9375 mi After break-in Components (7500 km) or 12 (15000 km) or 24 [625 mi (1000 km)] months months Spark plugs Side stand Throttle cables Rear suspension linkage bearings Steering bearings and steering Wheel bearings...
  • Page 54 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Every 4687 mi Every 9375 mi After break-in Components (7500 km) or 12 (15000 km) or 24 [625 mi (1000 km)] months months Drive chain tension and lubrication every 625 mi (1000 km): Battery terminals and clamps Fuel lines every 4 years:...

  • Page 55: Lubrication Points

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.2 LUBRICATION POINTS LUBRICATION DIAGRAM LEGEND 1) Steering bearings Proper lubrication is essential for proper vehicle 2) Clutch lever pivot operation and long vehicle life. 3) Right rider foot rest pin NOTE Before lubricating, clean all parts thoroughly to 4) Left rider foot rest pivot remove any traces of rust, grease, dirt and dust.

  • Page 56: Multifunction Computer

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.3 MULTIFUNCTION COMPUTER 2.3.1 LEGEND A Left digital display (odometer- mileage counter) B Right digital multifunction display (fuel level/air temperature - coolant temperature – clock/injection system error codes) C SET and MODE programming keys. 2.3.2 PROGRAMMING KEYS WARNING Do not attempt to program the computer while riding...

  • Page 57: Total/Trip Odometer (Mileage Counter) Switching

    2.3.5 SWITCHING BETWEEN KM/MI, L/GAL, °C/°F NOTE The km/mi, l/gal, °C/°F settings are set and locked by aprilia while manufacturing the vehicle, based on the country for which it is intended. They cannot be changed later. 2.3.6 SWITCHING...

  • Page 58: Setting The Clock (Hours And Minutes)

    In many cases the engine continues to run, with limited performance. The message “EFI” appears on the multifunction digital only during tests carried out by an Aprilia Dealer. Speedometer [mi (km/h)] Indicates the vehicle speed CONT'D ➤...
  • Page 59 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Description Function Digital Odometer / display (left Displays the trip or total mileage traveled. mileage counter (km - mi) side) Displays the level of fuel in the tank. The amount fuel is displayed on the analogue scale, with the value expressed in gallons (numerical indication).
  • Page 60 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Description Function Displays the temperature of the coolant in the engine, see 2.3.2 (PROGRAMMING KEYS). The temperature is displayed on the analogue scale, with the value expressed in °F (digital indicator). Up to 97 °F, the symbol “---” is displayed. The cooling fan power WARNING switch is turned on and off...

  • Page 61: Battery

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.4 BATTERY Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). There are two kinds of commercially available batteries: - batteries requiring maintenance featuring cell caps; - maintenance-free batteries without cell caps. There is no need to check or top up the electrolyte level. NOTE This vehicle is equipped with a sealed maintenance-free battery.

  • Page 62: Checking And Cleaning The Terminals

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.4.1 CHECKING AND CLEANING THE TERMINALS Carefully read 2.4 (BATTERY). Make sure the ignition switch is set to “ “. Remove the saddle, see 7.1.1 (REMOVING THE SADDLE). Move the red rubber boot (1). Make sure that the battery cable terminals (2) (3) are: - in good condition (not corroded or encrusted with deposits);...

  • Page 63: Recharging The Battery

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.4.2 RECHARGING THE BATTERY 2.5 ELECTRICAL COMPONENTS Carefully read 2.4 (BATTERY). Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). NOTE One symptom of a nearly dead battery is when you hear a vibrating noise from the starter relay, when the Check after the first 625 mi (1,000 km) and every 4687 mi start button “...

  • Page 64: Jump-Starting

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.6 JUMP-STARTING Carefully read 2.4 (BATTERY). DANGER The vehicle should only be jump-started when the vehicle battery is partially or completely dead, and recharging is not possible. Do not attempt to start the vehicle by pushing or towing it.

  • Page 65: Spark Plugs

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.7 SPARK PLUGS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Check the spark plugs every 4687 mi (7500 Km) or every 8 months; replace them every 9375 mi (15000 Km) or every 16 months. Periodically remove the spark plugs, clean them to remove any carbon deposits, and replace if necessary.
  • Page 66 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille WARNING 0.02 - 0.03 in When replacing a spark plug, always check the pitch and length of the thread. If the threaded portion is too short, carbon deposits can build up on the internal thread of the head; this may damage to the engine when the appropriate kind is then installed.

  • Page 67: Lifting The Fuel Tank

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.8 LIFTING THE FUEL TANK Carefully read 1.4.1 (FUEL). DANGER Danger of fire. Wait until the engine and exhaust silencer have completely cooled down. Unscrew and remove the two bolts (1). Tightening torque for bolts (1): 2.21 ftlb (3 Nm) Remove the grille (2).

  • Page 68: Draining Fuel From The Tank

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.9 DRAINING FUEL FROM THE TANK Carefully read 1.4.1 (FUEL). DANGER Danger of fire. Wait until the engine and exhaust silencers have completely cooled down. Gasoline fumes are harmful to your health. Before proceeding, make sure that the work area has adequate ventilation.

  • Page 69: Air Filter

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.10 AIR FILTER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Inspect the air filter every 4687 mi (7500 Km) or 8 months, and replace it every 9375 mi (15000 Km) or 16 months, or more frequently if the vehicle is used on dusty or wet roads.

  • Page 70: Throttle

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.11 THROTTLE Check after the first 625 mi (1,000 km) and then every 4687 mi (7,500 Km) or every 8 months thereafter. 2.11.1 CHECKING OPERATION THROTTLE CONTROL DANGER Using the vehicle with damaged, bent or tangled throttle cables may prevents the throttle from working properly, causing the rider to lose control of the vehicle while riding.

  • Page 71: Adjusting The Throttle Control

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.11.3 ADJUSTING THE THROTTLE CONTROL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Check the throttle control cables after the first 625 mi (1,000 km) and every 4687 mi (7,500 Km) thereafter. The play of the throttle adjuster must be 0.08 - 0.11 in (2–3 mm), measured at the edge of the grip.

  • Page 72: Checking And Topping Up The Engine Oil Level

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.12 CHECKING AND TOPPING UP THE ENGINE OIL LEVEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.1 (FUEL) 1.4.2 (LUBRICANTS). Periodically check the engine oil level. Change the oil after the first 625 mi (1,000 km), and every 4687 mi (7,500 Km) or 8 months thereafter, see 2.13 (CHANGING THE ENGINE OIL AND OIL FILTER).

  • Page 73: Changing The Engine Oil And Oil Filter

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.13 CHANGING THE ENGINE OIL AND OIL FILTER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.1 (FUEL) 1.4.2 (LUBRICANTS). Periodically check the engine oil level. Change the oil after the first 625 mi (1,000 km), and every 4687 mi (7,500 Km) or 8 months thereafter, see 2.13 (CHANGING THE ENGINE OIL AND OIL FILTER).
  • Page 74 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille CHANGING THE ENGINE OIL FILTER Change the engine oil filter after the first 625 mi (1,000 km) and every 4687 mi (7,500 Km) thereafter (or with each engine oil change). Unscrew the two screws (6) and remove the cover (7). Remove the engine oil filter (8).

  • Page 75: Checking And Topping Up The Coolant

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.14 CHECKING AND TOPPING UP THE COOLANT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.4.6 (COOLANT). Always check the coolant level before riding, and change it every 2 years. WARNING The coolant level should be checked and topped up only while the engine is cold.

  • Page 76: Changing The Coolant

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.15 CHANGING THE COOLANT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), 1.4.6 (COOLANT) and sect. 5 (COOLING SYSTEM). Change the coolant every 2 years. Remove the right air duct, see 7.1.31 (REMOVING THE RIGHT AIR DUCT). Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING).

  • Page 77: Checking And Topping Up The Front Brake Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.16 CHECKING AND TOPPING UP THE FRONT BRAKE FLUID Carefully read see 1.3.9 (PRECAUTIONS GENERAL INFORMATION) and 1.3.5 (BRAKE FLUID). Check the brake fluid every 4687 mi (7500 km) or 8 months, and change it every two years. WARNING If you notice that the brake lever has excessive free play, any sponginess or air bubbles in the system,...
  • Page 78 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Raise and remove the cover (4) complete with screws (1-2). Recover the guide cover (5). Remove the gasket (6). NOTE Avoid shaking the vehicle to keep from spilling brake fluid while topping up. WARNING Do not add additives or other substances to the fluid.
  • Page 79 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille CHECK NOTE Place the vehicle on the center stand on a flat, hard surface. Make sure the fluid contained in the reservoir exceeds the "MIN" mark. MIN = minimum level. MAX = maximum level. If the fluid does not at least reach the "MIN"...

  • Page 80: Checking And Topping Up

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.18 CHECKING AND TOPPING UP THE CLUTCH FLUID Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) 1.4.5 (CLUTCH CONTROL FLUID). Check the clutch fluid every 7500 km (4687 mi) or 8 months, and change it every two years. WARNING If you notice that the clutch lever has excessive free play, any sponginess or air bubbles in the system,...
  • Page 81 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille TOPPING UP WARNING Danger of fluid leaking. Do not operate the clutch lever with the fluid reservoir cap loosened or removed. This can cause fluid to squirt a great distance, even into your eyes. Failure to observe this warning could result in serious physical injury.
  • Page 82 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.19 BLEEDING THE BRAKE SYSTEMS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.5 (BRAKE FLUID). For the maintenance intervals, see 2.1.1 (SCHEDULED MAINTENANCE CHART). If there is air in the brake hydraulic system, it will act as a cushion, absorbing the pressure developed by the master cylinder.

  • Page 83: The Rear Brake Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille BLEEDING OPERATIONS There are three types of bleeding procedures, to be carried out in the order listed below: BRAKE SYSTEM BLEEDING NOTE The description of the system bleeding procedures also includes instructions on how to determine whether it is necessary to bleed the brake caliper and the brake master cylinder.
  • Page 84 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Top up to restore the proper level of brake fluid in the reservoir, see 2.16 (CHECKING AND TOPPING UP THE FRONT BRAKE FLUID) and 2.17 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID). Replace the dust cover.
  • Page 85 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille NOTE Fill the reservoir with brake fluid as needed while bleeding the brake caliper. Throughout this operation, make sure brake fluid is always present in the reservoir. BRAKE MASTER CYLINDER BLEEDING NOTE You may now bleed the brake master cylinder using the same procedure as for bleeding the caliper.

  • Page 86: Checking And Topping Up The Clutch Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.20 CLUTCH CONTROL SYSTEM BLEEDING Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) 1.4.5 (CLUTCH CONTROL FLUID). If necessary bleed air from the system after the first 625 mi (1000 km). Any air in the hydraulic system will act as a cushion, absorbing much of the pressure exerted by the master cylinder and limiting the effectiveness of the clutch cylinder.

  • Page 87: Changing The Front Brake Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.21 CHANGING THE FRONT BRAKE FLUID Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.5 (BRAKE FLUID). Change the front brake fluid every two years. WARNING Handle the fluid with care: it can chemically alter paint and plastic or rubber parts, etc.

  • Page 88: Changing The Rear Brake Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.22 CHANGING THE REAR BRAKE FLUID Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.5 (BRAKE FLUID). Change the rear brake fluid every two years. WARNING Handle the fluid with care: it can chemically alter paint and plastic or rubber parts, etc.

  • Page 89: Changing The Clutch Fluid

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.23 CHANGING THE CLUTCH FLUID Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) 1.4.5 (CLUTCH CONTROL FLUID). Change the clutch fluid every two years. WARNING Handle the fluid with care: it can chemically alter paint and plastic or rubber parts, etc.

  • Page 90: Adjusting The Clearance Of The Rear Brake Lever

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.25 ADJUSTING THE CLEARANCE OF THE REAR BRAKE LEVER The brake lever is ergonomically positioned to suit most riders during vehicle manufacture. If you wish to customize the brake lever position: Loosen the lock nut (1). Fully tighten the brake adjuster (2).

  • Page 91: Checking The Brake Pad Wear

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.27 CHECKING THE BRAKE PAD WEAR The amount of wear that the brake pads experience depends on how the vehicle is used, how aggressively it is ridden, and the condition of the roads upon which it is operated.

  • Page 92: Steering

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.28 STEERING Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATION). Check after the first 937 mi (1,500 km) and then after every 4687 mi (7,500 km), or every 8 months. To assure superior handling, the steering is equipped with rolling bearings.

  • Page 93: Adjusting The Bearing Play

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.28.2 ADJUSTING THE BEARING PLAY carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). To make it easier to adjust the bearing play, we recommend that you perform the three operations listed below: - Remove both knobs, see 7.1.11 (REMOVING THE HANDGRIP FROM THE LEFT HANDLEBAR) and 7.1.14 (REMOVING THE THROTTLE CONTROL);...
  • Page 94 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Lubricate the thread and base of the bushing (6) with motor oil, see 1.12 (LUBRICANT CHART). Tighten the upper bushing (6), correctly replacing the spring washer (7). Tightening torque for upper bushing (6): 88.50 ftlb (120 Nm).

  • Page 95: Inspecting The Front Suspension

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.29 INSPECTING THE FRONT SUSPENSION 2.29.1 FRONT SUSPENSION The front suspension is made up of a hydraulic fork connected by two plates to the steering column. To adjust the vehicle attitude, each tube of the fork is equipped with an upper screw (1) to adjust the hydraulic damping on extension, and a lower screw (2) to adjust the spring preload.

  • Page 96: Adjusting The Front Fork

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.29.2 ADJUSTING THE FRONT FORK The front fork is adjusted at the factory to suit most riding conditions for most riders at low and high speeds, with light or heavy vehicle loads. However, it is possible to customize the fork setting to accommodate the full range of operating conditions that the vehicle is intended to be used for.

  • Page 97: Swinging Arm

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.30 SWINGING ARM Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Make sure the pivot bearings in the swinging arm are firmly tightened.. To check: Place the vehicle on the center stand. Shake the wheel up and down, then from side to side (see figure).

  • Page 98: Inspecting The Rear Suspension

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.31 INSPECTING THE REAR SUSPENSION 2.31.1 REAR SUSPENSION The rear suspension is made up of a shock absorber- spring assembly, connected to the frame by silent-block and to the swinging arm by a system of levers. To adjust the riding height of the vehicle, the shock absorber is equipped with an adjuster screw (1) to adjust the hydraulic damping on extension, and an adjuster knob (2)

  • Page 99: Rear Suspension

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille DANGER Do not remove the plug (4) for any reason. Do not tamper with the valve. Doing either of these things will destroy the function of shock absorber which can lead to an unstable, unsteady ride, with subsequent upset, accident and serious injury or even death.

  • Page 100: Front Wheel

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.32 FRONT WHEEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Check every 4687 mi (7500 km). Place the vehicle on the appropriate front support stand , see 1.15.1 (PLACING THE VEHICLE ON THE FRONT SUPPORT STAND). Spin the wheel in both directions by hand.

  • Page 101: Exhaust Manifold Nuts

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.34 EXHAUST MANIFOLD NUTS Carefully read see 1.3.9 (PRECAUTIONS GENERAL INFORMATION). Tighten the exhaust manifold nuts after the first 625 mi (1000 km), and every 4687 mi (7500 km) or 8 months thereafter. DANGER Let the engine cool down to ambient temperature.

  • Page 102: Drive Chain

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.35 DRIVE CHAIN A quick check to determine the condition of the chain and sprockets may be made by grasping the chain and Carefully read 1.3.9 (PRECAUTIONS AND GENERAL attempting to pull it away from the rear sprocket. If you INFORMATION).

  • Page 103: Checking The Play

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.35.1 CHECKING THE PLAY To check the chain play: Place the vehicle on the center stand. Set the gearshift lever to neutral. Make sure that the play is approximately 0.98 in (25 mm), at a point between the sprocket and countershaft sprocket in the lower chain run.

  • Page 104: Checking The Wear Of The Chain And Sprockets

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.35.2 CHECKING THE WEAR OF THE CHAIN AND SPROCKETS Stretch the chain completely, see 2.35.3 (ADJUSTING THE DRIVE CHAIN). On one branch of the chain, count 17 pins (16 links) in the area between the sprockets, and measure the distance between the first and 17th pins.

  • Page 105: Inspecting The Drive Chain Guide Plate

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.35.4 INSPECTING THE DRIVE CHAIN GUIDE PLATE Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Unscrew and remove the two bolts (1). Tightening torque for bolts (1): 7.37 ftlb (10 Nm).

  • Page 106: Tires

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.36 TIRES Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Check after the first 625 mi (1,000 km) and then every 4687 mi (7,500 km), or every 8 months, thereafter. Check the inflation pressure every month, at ambient temperature.

  • Page 107: Fuel Lines

    The use of tires other than those indicated may adversely affect the handling and overall safety of the vehicle. Use only the tires originally selected by aprilia, see 1.11 (SPECIFICATIONS). 2.37 FUEL LINES Carefully read 1.4.1 (FUEL).

  • Page 108: Tightening Nuts And Bolts

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.40 TIGHTENING NUTS AND BOLTS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Check after the first 625 mi (1,000 km) and then every 4687 mi (7,500 km) or every 8 months thereafter. Carefully check fasteners, especially...
  • Page 109 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.41 FASTENERS Check after the first 625 mi (1,000 km) and then every 4687 mi (7,500 km) or every 8 months thereafter; tighten if necessary. WARNING The fasteners listed in the table must be torqued to ®...
  • Page 110 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille CENTER STAND Description Qty. Screw / nut ftlb Notes Center stand to frame fastener L243 FRONT SUSPENSION Front fork Description Qty. Screw / nut ftlb Notes Fork head/fork tubes fastener Triple clamp/fork tubes fastener Steering column ring-nut M35x1 Steering column locking ring nut...
  • Page 111 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille AIR FILTER CASE Description Qty. Screw / nut ftlb Notes Air filter case cover fastener Air filter case to throttle body fastener Intake ducts fastener to filter case fastener SWP3.9 Idle speed adjustment motor L243 Filter box fastener plate on frame Filter box reducer diaphragm...
  • Page 112 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Rear Brake System Description Qty. Screw / nut ftlb Notes Brake caliper fastener Brake lever on platform mount 10.8 L243 Pedal on brake lever L270 Brake master cylinder fastener Brake master cylinder control rod lock nut Brake disc fastener 21.7 L243...
  • Page 113 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille Lower fairing on frame Lower fairing to upper fairing Windshield on front fairing Upper fairing to front fairing and air ducts Upper fairing to air duct Dashboard panel to fairing frame Dashboard panel to molding SWP3.9 Mirror frames Dashboard to mount...
  • Page 114 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille RIGHT/LEFT HANDLEBARS AND CONTROLS Description Qty. Screw / nut ftlb Notes Anti-vibration weights fastener Anti-vibration weights ring-nut M18x1.5 28.8 Right/left handlebars fastener to fork 21.7 Ingr. Right/left handlebars lock screw Left dimmer switch fastener Right dimmer switch Fastening Front brake control fastener Clutch cylinder fastener...

  • Page 115: Cleaning And Lubrication

    SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille 2.41.1 CLEANING AND LUBRICATION Never use steam, high-pressure water jets and/or highly flammable solvents to wash the chain. Wash the chain with diesel fuel or kerosene. If the chain tends to rust quickly, perform maintenance operations more often.
  • Page 116 SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille NOTES - 68 - Release 00/2002 - 03...
  • Page 117 ENGINE RST mille ENGINE - 1 - Release 00/2002 - 03...
  • Page 118 ENGINE RST mille ENGINE TABLE OF CONTENTS 3.1 TECHNICAL DATA......3-3-00 3.1.1 TECHNICAL SPECIFICATIONS ... 3-3-00 3.1.2 MAINTENANCE INTERVALS ....3-3-00 3.1.3 TROUBLESHOOTING......3-3-00 3.1.4 SEALANTS ..........3-3-00 3.1.5 LUBRICANTS ........3-3-00 3.1.6 SPECIAL TOOLS ........3-3-00 3.1.7 TIGHTENING TORQUES ...... 3-3-00 3.1.8 PRECAUTIONS TO OBSERVE WHEN CARRYING OUT MAINTENANCE OPERATIONS AND REPAIRS....

  • Page 119: Technical Data

    ENGINE RST mille 3.1 TECHNICAL DATA 3.1.1 TECHNICAL SPECIFICATIONS See 1.11 (SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 2.1.1 (SCHEDULED MAINTENANCE CHART). 3.1.3 TROUBLESHOOTING See 8.1 (TROUBLESHOOTING). 3.1.4 SEALANTS See 1.13 (CONSUMABLES). 3.1.5 LUBRICANTS See 1.12 (LUBRICANT CHART). 3.1.6 SPECIAL TOOLS See 1.14 (SPECIAL TOOLS). 3.1.7 TIGHTENING TORQUES See 2.41 (FASTENERS).

  • Page 120: General Information About

    ENGINE RST mille 3.1.9 GENERAL INFORMATION ABOUT MAINTENANCE AND REPAIRS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATION). 3.2 ENGINE COMPONENTS THAT MAY BE DISASSEMBLED WITHOUT REMOVING THE ENGINE FROM THE FRAME Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). The parts listed below may be removed and reinstalled without removing the engine from the frame.
  • Page 121 ENGINE RST mille LEFT RIGHT - Rear cylinder spark plugs (6-7), see 2.7 (SPARK - Front cylinder coolant thermistor (15), see 5.4 PLUGS). (REMOVING THE COOLANT THERMISTORS.). - Countershaft sprocket guard (8), see 2.35.4 - Front cylinder spark plugs (16-17), see 2.7 (SPARK (INSPECTING THE DRIVE CHAIN GUIDE PLATE).

  • Page 122: Removing The Clutch Cylinder

    ENGINE RST mille 3.2.1 REMOVING THE CLUTCH CYLINDER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) 1.4.5 (CLUTCH CONTROL FLUID). Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Remove the voltage regulator housing, see 2.35.4 (INSPECTING THE DRIVE CHAIN GUIDE PLATE). Unscrew and remove the screws (3).

  • Page 123: Removing The Complete Engine From The Frame

    RST mille 3.3 REMOVING THE COMPLETE ENGINE FROM THE FRAME WARNING The engine must be removed ONLY at an Authorized Service Center or by an Aprilia dealer. Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). 147.7lb WARNING Engine removal is a particularly complex operation.
  • Page 124 ENGINE RST mille Unscrew and remove the screw (5) and disconnect the cable from the neutral gear switch (6). Disconnect the cable from the engine oil pressure sensor (7). WARNING The brake fluid reservoir (9) must remain upright to prevent any leakage. Remove the clutch cylinder, see 3.2.1 (REMOVING THE CLUTCH CYLINDER).
  • Page 125 ENGINE RST mille Clean the outside of the engine thoroughly. Remove the exhaust pipes, see 7.1.53 (REMOVING THE EXHAUST MANIFOLDS). Disconnect the electrical connector (11) from the electric fan. Disconnect the electrical cables from the horn. WARNING When reassembling, make sure electrical connectors are properly fitted.
  • Page 126 ENGINE RST mille Remove the complete throttle body (18), see 4.8 (THROTTLE BODY). NOTE For space reasons, it is best to remove the three-way manifold (19), see 5.7 (REMOVING THE THREE-WAY MANIFOLD). NOTE Use special pliers to hook the clamps (code 0277295);...
  • Page 127 ENGINE RST mille Unscrew and remove the screws (25), saving the plate (26). Tightening torque for screws (25): 29 ftlb (40 Nm ). NOTE Have on hand the special tool code 8140183 (engine lifting eye hook), a hoist (28) and lifting slings (29).
  • Page 128 ENGINE RST mille NOTE The fasteners holding the engine to the frame must be removed in the order given: LEFT SIDE A ➠ ➠ ➠ RIGHT SIDE E ➠ ➠ ➠ - 12 - Release 00/2002 - 03...
  • Page 129 ENGINE RST mille Unscrew and remove the two bolts (30), retrieving the corresponding washers (31). Tightening torque for bolts (30): 29 ftlb (40 Nm ). Hold the nut (32) in place while you unscrew and remove the bolt (33). Tightening torque for nut (32) and bolt (33): 36 ftlb (50 Nm).
  • Page 130 ENGINE RST mille Unscrew the adjuster bushings (40 - 44) and slide them up against the frame. Tightening torque for adjustment bushings (40 - 44): 7.3 ftlb (10 Nm). WARNING During reassembly screw the adjustment bushings (40 - 44) in by hand, and slide them up against the engine;...
  • Page 131 ENGINE RST mille DANGER The engine is now free and not fastened anywhere. Be extremely careful when moving it; watch your fingers and limbs. Clear the floor on which the engine is to be set down of any tools and clean thoroughly. Failure to observe this warning can lead to serious bodily injury.

  • Page 132: Installing The Complete Engine In The Frame

    ENGINE RST mille 3.4 INSTALLING THE COMPLETE ENGINE IN THE FRAME Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). NOTE To reinstall the complete engine on the frame, follow the same procedure used for its removal in reverse order, see 3.3 (REMOVING THE COMPLETE ENGINE FROM THE FRAME).
  • Page 133 ENGINE RST mille NOTES - 17 - Release 00/2002 - 03...
  • Page 134 ENGINE RST mille NOTES - 18 - Release 00/2002 - 03...
  • Page 135 FUEL SYSTEM RST mille FUEL SYSTEM - 1 - Release 00/2002 - 03...
  • Page 136 FUEL SYSTEM RST mille FUEL SYSTEM TABLE OF CONTENTS 4.1 FUEL TANK ........4-3-00 4.1.1 MAINTENANCE........4-4-00 4.1.2 CHECK THE FUEL INTAKE....4-4-00 4.2 DRAINING FUEL FROM THE TANK . 4-5-00 4.3 COMPLETELY REMOVING THE FUEL INTAKE PUMP UNIT ....... 4-5-00 4.4 REMOVING THE FUEL LEVEL SENSOR...........

  • Page 137: Fuel Tank

    FUEL SYSTEM RST mille 4.1 FUEL TANK The refueling cap is at the top of the tank, while the following are installed at the bottom: The fuel pump unit; The water drain tube, which drains away any water accidentally introduced into the fuel line from rain or while washing;...

  • Page 138: Maintenance

    FUEL SYSTEM RST mille Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.1 (FUEL). DANGER Gasoline fumes are harmful to your health. Before proceeding, make sure that the work area has adequate ventilation. . Do not inhale the fuel fumes. Avoid skin contact with the gasoline.

  • Page 139: Draining Fuel From The Tank

    FUEL SYSTEM RST mille 4.2 DRAINING FUEL FROM THE TANK To drain the fuel tank, see 2.9 (DRAINING FUEL FROM THE TANK). 4.3 COMPLETELY REMOVING THE FUEL INTAKE PUMP UNIT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), 1.4.1 (FUEL) 4.1.1 (MAINTENANCE).

  • Page 140: Removing The Fuel Level Sensor

    FUEL SYSTEM RST mille 4.4 REMOVING THE FUEL LEVEL SENSOR Remove the complete fuel intake pump unit, see 4.3 (COMPLETELY REMOVING THE FUEL INTAKE PUMP UNIT). Disconnect the electrical connector (1). WARNING When reassembling, make sure electrical connector (1) is fitted properly. Use a screwdriver to help you remove the fuel level sensor (2) from the support (3).

  • Page 141: Removing The Fuel Intake Pump

    FUEL SYSTEM RST mille 4.6 REMOVING THE FUEL INTAKE PUMP Remove the complete fuel intake pump unit, see 4.3 (COMPLETELY REMOVING THE FUEL INTAKE PUMP UNIT). Disconnect the electrical connector (1). WARNING When reassembling, make sure electrical connector (1) is fitted properly. NOTE Use the special click clamp installation pliers (code 0277295);...

  • Page 142: Engine Management

    FUEL SYSTEM RST mille 4.7 ENGINE MANAGEMENT 4.7.1 GENERAL INFORMATION The “heart” of engine management system consists of the electronic control unit (Engine Control Unit), which manages and optimizes ignition and fuel injection. Ignition is managed based on specific user data. The electronic control unit detects the exact ignition angle from the engine rpm signals and position of the throttle valves (volume of air).
  • Page 143 FUEL SYSTEM RST mille 4.7.2 SENSORS Camshaft position sensor (1) Location: in the flywheel cover (2). This is a sensor that detects the movement of the selected phonic wheel on the crankshaft. The selected wheel has a unique pulse length, triple the distance/ clearance, to act as a reference point on the wheel.
  • Page 144 FUEL SYSTEM RST mille Throttle position sensor (4) Location: on the throttle body (5). This sensor is a potentiometer, and for greater precision its position is determined by comparing the output voltage with the input voltage (rated 5 V). Once the throttle is open, the output voltage from the sensor increases in a linear fashion.

  • Page 145: Sensors

    FUEL SYSTEM RST mille 4.7.3 INJECTION, SYSTEM DIAGRAM Injection Kill switch Switch COOLING FAN 1 BATTERY COOLING FAN 2 PW ONLY FUEL PUMP 0.5 mm² Raychem 67 P1 A1 EXHAUST CAMSHAFT POSITION VALVE SENSOR P1 B1 P1G1 P1 B2 COOLING FRONT THERMISTOR CYLINDER...

  • Page 146: Electronic Control Unit

    FUEL SYSTEM RST mille 4.7.4 ELECTRONIC CONTROL UNIT For more information, see 6.6 (CONNECTIONS TO THE ELECTRONIC CONTROL UNIT). 65 PINK WHITE 80 BROWN 52 YELLOW BLACK 55 BROWN GREEN 53 YELLOW BLACK 28 GREY WHITE 47 BROWN PINK 51 ORANGE WHITE 27 BLUE ORANGE 50 GREEN LIGHT BLUE 49 ORANGE LIGHT BLUE...

  • Page 147: Automatic Testing

    FUEL SYSTEM RST mille 4.7.5 AUTOMATIC TESTING See 6.5 (IGNITION/INJECTION SYSTEM). 4.7.6 ROUBLESHOOTING IN THE ELECTRONIC SYSTEM USING DISPLAYED INFORMATION DANGER Take care around the high voltage in the ignition system. Never disconnect the connections with the engine running. Whenever working on the ignition system, unless otherwise indicated, always leave the ignition switch set to “...

  • Page 148: Throttle Body

    FUEL SYSTEM RST mille 4.8 THROTTLE BODY WARNING The lever mechanism on the throttle body may not be adjusted nor replaced. In case of malfunction, replace complete throttle body, see 4.8.1 (REMOVING THE THROTTLE BODY). The two screws M4x12 (1) attaching the throttle valve potentiometer to the throttle valve body are painted, and may be removed only when replacing the sensor itself.

  • Page 149: Removing The Throttle Body

    FUEL SYSTEM RST mille Remove the pressure regulator hose (11). Loosen the two clamps (14-15). WARNING Be extremely careful when removing the throttle body (6), since it remains attached to the fuel tank (13) by means of the fuel hose (12). Before removing the throttle body, you must thoroughly clean the two intake flanges, to prevent foreign matter from entering the cylinders.

  • Page 150: Disassembling The Throttle Body

    FUEL SYSTEM RST mille 4.9 DISASSEMBLING THE THROTTLE BODY Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Empty all fuel from the tank, see 2.9 (DRAINING FUEL FROM THE TANK). Remove complete throttle body, see 4.8.1 (REMOVING THE THROTTLE BODY). Unscrew and remove the two screws (1). Tightening torque for screws (1): 2.6 ftlb (3.5 Nm ).

  • Page 151: Inspecting The Throttle Body

    FUEL SYSTEM RST mille 4.10 INSPECTING THE THROTTLE BODY 4.10.1 TESTING THE INJECTORS DANGER Gasoline is extremely flammable and becomes explosive under certain conditions. KEEP GASOLINE AWAY FROM CHILDREN. NOTE The injectors may be tested even when mounted. Check the following components: - electrical cables and connections;...

  • Page 152: Synchronizing The Cylinders

    FUEL SYSTEM RST mille 4.10.4 SYNCHRONIZING THE CYLINDERS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.1 (FUEL). The cylinders need to be synchronized when the engine no longer idles smoothly. The cylinders must be synchronized before adjusting the CO, see 4.10.5 (ADJUSTING THE CO).

  • Page 153: Adjusting The Co

    FUEL SYSTEM RST mille 4.10.5 ADJUSTING THE CO Remove the radiator spoiler, see 7.1.35 (REMOVING THE RADIATOR SPOILER). WARNING The CO must be adjusted when the engine is warm. Coolant temperature 167-194 °F (75-90 °C). NOTE Have the following special tools ready: - exhaust gas analyzer (1) (code 8140196);...
  • Page 154 FUEL SYSTEM RST mille A parameter appears at the top of the display in percentage form, which should not be compared to the CO value reading provided by the exhaust gas analyzer (1). Use the UP and DOWN arrows to change the instrument parameter: if the value increases, the injection time also increases, providing a richer blend and thus increasing the value of CO;...

  • Page 155: Aligning The Throttle Valve Position Sensor

    FUEL SYSTEM RST mille 4.10.6 ALIGNING THE THROTTLE VALVE POSITION SENSOR Remove the saddle, see 7.1.1 (REMOVING THE SADDLE). Connect the Axone 2000 (1) via the connector (2) under the saddle, and power the Axone 2000 (1) using the vehicle battery. Start the vehicle.
  • Page 156 FUEL SYSTEM RST mille NOTES - 22 - Release 00/2002 - 03...
  • Page 157 COOLING SYSTEM RST mille COOLING SYSTEM - 1 - Release 00/2002 - 03...
  • Page 158 COOLING SYSTEM RST mille COOLING SYSTEM TABLE OF CONTENTS 5.1 DESCRIPTION ......... 5-3-00 5.2 REMOVING THE RADIATORS ..5-5-00 5.3 REMOVING THE ELECTRIC COOLING FANS ..........5-6-00 5.4 REMOVING THE COOLANT THERMISTORS ........ 5-7-00 5.5 REMOVING THE THERMOSTAT ..5-8-00 5.6 REMOVING THE FILLER NECK ..

  • Page 159: Description

    COOLING SYSTEM RST mille 5.1 DESCRIPTION The expanded volume of coolant, caused by the increase in temperature, is compensated for by the expansion The centrifugal coolant pump, which is positioned inside tank. of and driven by the engine, draws cooled coolant from Refer to the “LOW”...
  • Page 160 COOLING SYSTEM RST mille Path with coolant temperature below 167 °F (75°C). From the pump, coolant enters the engine (temperature taken by thermistors and shown on the right-hand dashboard display). Coolant leaves the engine (right- hand side) to the thermostat (completely closed), and back to the pump.
  • Page 161 COOLING SYSTEM RST mille 5.2 REMOVING THE RADIATORS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.7 (COOLANT). NOTE The following steps refer to a single radiator, but are applicable to both. Set the ignition switch to “ “. Completely discharge the cooling circuit, see 2.15 (CHANGING THE COOLANT).

  • Page 162: Removing The Electric Cooling

    COOLING SYSTEM RST mille 5.3 REMOVING THE ELECTRIC COOLING FANS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). NOTE The following steps refer to a single fan, but are applicable to both. Set the ignition switch to “ ”. Remove the left fairing in question, see 7.1.28 (REMOVING THE SIDE FAIRINGS).

  • Page 163: Removing The Coolant Thermistors

    COOLING SYSTEM RST mille 5.4 REMOVING THE COOLANT THERMISTORS. Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.4.6 (COOLANT). NOTE The following steps refer to a single thermistor, but are applicable to both. Raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

  • Page 164: Removing The Filler Neck

    COOLING SYSTEM RST mille 5.5 REMOVING THE THERMOSTAT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.7 (COOLANT). Completely discharge the cooling circuit, see 2.15 (CHANGING THE COOLANT). NOTE Use the special click clamp installation pliers (code 0277295); during reassembly, replace each clamp with a new one of the same kind.

  • Page 165: Removing The Three-Way Manifold

    COOLING SYSTEM RST mille 5.7 REMOVING THE THREE-WAY MANIFOLD Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 1.3.7 (COOLANT). Carry out the first four steps described in paragraph 5.4 (REMOVING THE COOLANT THERMISTORS.). Completely discharge the cooling circuit, see 2.15 (CHANGING THE COOLANT).
  • Page 166 COOLING SYSTEM RST mille NOTES - 10 - Release 00/2002 - 03...
  • Page 167 ELECTRICAL SYSTEM RST mille ELECTRICAL SYSTEM - 1 - Release 00/2002 - 03...
  • Page 168 ELECTRICAL SYSTEM RST mille ELECTRICAL SYSTEM 6.8.7 CHECKING THE SAFETY SYSTEM SWITCHES .......... 6-27-00 6.9 ELECTRIC COOLING FANS ... 6-28-00 6.9.1 WIRING DIAGRAM......6-28-00 TABLE OF CONTENTS 6.9.2 CHECKING THE ELECTRIC FAN OPERATION ........6-28-00 6.1 LOCATIONS OF ELECTRICAL COMPONENTS......... 6-3-00 6.10 DASHBOARD INDICATORS ...

  • Page 169: Locations Of Electrical Components

    ELECTRICAL SYSTEM RST mille 6.1 LOCATIONS OF ELECTRICAL COMPONENTS 20 19 42 43 - 3 - Release 00/2002 - 03...
  • Page 170 ELECTRICAL SYSTEM RST mille Legend 1) Electronic control unit 31) Secondary fuses (15A) 2) Front cylinder coils 32) Flasher 3) Rear cylinder coils 33) Overturn sensor 4) Horn 34) Ignition switch 5) Left fan 35) Right dimmer switch 6) Diode 36) Front stop switch 7) Air thermistor 37) Fuel pump/sensor group...

  • Page 171: Introduction

    ELECTRICAL SYSTEM RST mille 6.2 INTRODUCTION The following instructions will help you in consulting this section. NOTE The numbers that appear on the specific wiring diagrams match those given in the overall wiring diagram. 6.2.1 WIRE COLORS Ar orange Az light blue B blue Bi white G yellow...

  • Page 172: Checking The Recharging System

    ELECTRICAL SYSTEM RST mille 6.3 CHECKING THE RECHARGING SYSTEM 6.3.1 CHECKING THE RECHARGING VOLTAGE Check the battery voltage, see 2.4.2 (RECHARGING THE BATTERY). Start the engine and rev it to 4000 rpm. Set the light switch to “ “ and the light dimmer to “ “...

  • Page 173: Recharging System Diagram

    ELECTRICAL SYSTEM RST mille 6.3.3 RECHARGING SYSTEM DIAGRAM Regulator Flywheel + Battery 30 A Main Fuse Secondary fuses Clock Gasoline headlight pump 6.3.4 CHECKING ALTERNATOR CONTINUITY With the engine off: Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Disconnect the three-way connector (1) (brown) voltage regulator cables.
  • Page 174 ELECTRICAL SYSTEM RST mille 6.3.5 CHECKING THE VOLTAGE REGULATOR Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Disconnect the three-way connector (1) (brown). Disconnect the six-way connector (2) (white). WARNING When reassembling, make sure electrical connectors (1-2) are fitted properly. Use a tester (scale x 1MΩ) to measure the resistance between the cables indicated in the table below, from the regulator side (internal male terminals).

  • Page 175: Injection System

    ELECTRICAL SYSTEM RST mille 6.4 INJECTION SYSTEM 6.4.1 FUEL INJECTION WIRING DIAGRAM 30 A R/Bi – 15 A Az/Gr Ro/Bi (Grey) (Grey) (Black) Legend: 1) Battery 6) Injection relay 2) Key 7) Overturn sensor 3) Kill switch 8) Purge valve coil fan injector power 4) Starter button 9) ECU 5) Engine stop relay...

  • Page 176: Checking The Injection Relay

    ELECTRICAL SYSTEM RST mille 6.4.3 CHECKING THE INJECTION RELAY To check the relay: Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Power the two male terminals (85-86) with a voltage of 12 V. Use a tester (in ohm meter mode) to check the continuity between the other two terminals (87-30).

  • Page 177: Ignition/Injection System

    ELECTRICAL SYSTEM RST mille 6.5 IGNITION/INJECTION SYSTEM Ar/Bi B3(N) H1(Gr) M/Bi E3(N) E4(N) V/Az H2(Gr) Ro/N B2(N) D1(N) Ar/Az H3(Gr) A1(N) Bi/G B1(N) H4(N) H4(Gr) F1(N) Gr/R H3(N) F2(N) E2(N) V/Gr E1(N) H2(N) D3(Gr) D4(N) A1(Gr) 7(12 9(12 10(12 WARNING LAMP DISPLAY Legend...

  • Page 178: Troubleshooting

    ELECTRICAL SYSTEM RST mille 6.5.1 TROUBLESHOOTING Place the vehicle on the stand. Set the ignition switch to “ “. The message “ “ will appear on the display for approximately three seconds. If the LED “ “ turns off, the control unit has not found any faults.

  • Page 179: Troubleshooting In The Electronic System Using Displayed Information

    ELECTRICAL SYSTEM RST mille FAULT CODE TABLE: FAULT CODE COMPONENT CAUSE – Sensor not connected. Crankshaft position sensor – Sensor broken. (pick-up) – Faulty wiring. Throttle position sensor (TPS) Engine temperature sensor Air temperature sensor Barometric pressure sensor Sensor faulty. Coil 1 Coil not working or not wired Coil 2...

  • Page 180: Connections To The Electronic Control Unit

    ELECTRICAL SYSTEM RST mille 6.6 CONNECTIONS TO THE ELECTRONIC CONTROL UNIT NOTE For the locations of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). more information see 4.7.4 (ELECTRONIC CONTROL UNIT). P1H2 P1H3 P2H1 P2H2 P2H3 P2H4 P2E1 P1D4 P2A1 P2D3 P2G1 P1H4 P2G2...
  • Page 181 ELECTRICAL SYSTEM RST mille Position Component Connector Terminal # Rated value Wire Color Bi/Vi Dashboard M/Ro Overturn sensor Ro/Bi Fuel pump relay – Ro/Bi Diode module Clutch switch Neutral gear switch Side stand Start relay – – – TEST connectors –...

  • Page 182: Checking The Injectors

    ELECTRICAL SYSTEM RST mille 6.6.1 CHECKING THE INJECTORS With the engine off: Raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK). NOTE The following steps refer to a single injector, but are applicable to both. Disconnect the two-way connector (1) (black) and measure (on the injector side terminals).

  • Page 183: Checking The Throttle Valve Potentiometer

    ELECTRICAL SYSTEM RST mille 6.6.3 CHECKING THROTTLE VALVE POTENTIOMETER With the engine off: Raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the three-way connector (black) (1). WARNING When reassembling, make sure electrical connector (1) is properly connected. Set the ignition switch to ”...

  • Page 184: Checking The Air Thermistor

    ELECTRICAL SYSTEM RST mille 6.6.4 CHECKING THERMISTOR OPERATION Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Disconnect the two-way connector (1) (green). WARNING When reassembling, make sure electrical connector (1) is properly connected. Remove the thermistor (2). As shown in the figure, connect a tester (3) (in ohm meter mode) to the thermistor (2).

  • Page 185: Checking The Coolant Thermistors Operation

    ELECTRICAL SYSTEM RST mille 6.6.5 CHECKING THE COOLANT THERMISTORS OPERATION NOTE The temperature measured by the front cylinder thermistor (right side) is sent to the right display; the one measured by the rear cylinder thermistor (left side) is sent to the electronic control unit. Remove the thermistor (1), see 5.4 (REMOVING THE COOLANT THERMISTORS.).

  • Page 186: Checking The Ignition Coils

    ELECTRICAL SYSTEM RST mille 6.6.6 CHECKING THE IGNITION COILS Remove the fuel tank, see 7.1.6 (REMOVING THE FUEL TANK COMPLETELY). NOTE The following steps refer to a single coil, but are valid for all. Disconnect the connector (1) from the coil ignition (2). WARNING When reassembling,...

  • Page 187: Fuel Pump System

    ELECTRICAL SYSTEM RST mille 6.7 FUEL PUMP SYSTEM 6.7.1 WIRING DIAGRAM NOTE For the positions of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). Ar/V – Ro/Bi (Grey) B/Bi (Black) Legend: 1) Battery 2) Fuel pump relay 3) Pump 4) Overturn sensor 5) Engine stop relay 6) Electronic control unit (ECU) 7) Fuse...

  • Page 188: Checking The Fuel Pump

    ELECTRICAL SYSTEM RST mille 6.7.2 CHECKING THE FUEL PUMP To check the pump operation: Remove the lower dashboard panel, see 7.1.20 (REMOVING THE FRONT FAIRING). Open the cover (3) of the secondary fuse box. Make sure that the fuse (1) is intact. Raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

  • Page 189: Ignition Safety System

    ELECTRICAL SYSTEM RST mille 6.8 IGNITION SAFETY SYSTEM 6.8.1 WIRING DIAGRAM NOTE For the positions of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). M/Vi Gr/B Vi/N Engine Kill Diodo Wiring diagram legend 8) Diode module 9) Switch on clutch lever 10) Neutral gear switch 12) Starter button 16) Start relay...

  • Page 190: Starting Safety Operating Logic

    ELECTRICAL SYSTEM RST mille 6.8.2 STARTING SAFETY OPERATING LOGIC NOTE With the engine stop switch set to “ “ the starter motor does not turn over. STAND GEAR STAND CLUTCH ENGINE STARTER WARNING POSITION POSITION LEVER IGNITION MOTOR LIGHT PULLED RETRACTED RELEASED IN NEUTRAL...

  • Page 191: Checking The Diode

    ELECTRICAL SYSTEM RST mille 6.8.4 CHECKING THE DIODE To check the diode: Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Disconnect the two-way connector (1) (white) (under the left fairing near the ECU). WARNING When reassembling, make sure electrical connector (1) is properly connected.

  • Page 192: Checking The Side Stand Switch

    ELECTRICAL SYSTEM RST mille 6.8.5 CHECKING THE SIDE STAND SWITCH The side stand (1) must be able to rotate freely, without binding. Carry out the following checks: The springs (2) must not be damaged, worn, rusted or weakened. The side stand must pivot freely. Grease the joint if necessary, see 1.12 (LUBRICANT CHART).

  • Page 193: Checking The Safety System Switches

    ELECTRICAL SYSTEM RST mille 6.8.7 CHECKING THE SAFETY SYSTEM SWITCHES Use a tester to check the continuity of the switches, referring to the specific diagram. Should you detect anything out of order, replace the corresponding group of switches. 1) NEUTRAL GEAR SWITCH Cables Pos.

  • Page 194: Electric Cooling Fans

    ELECTRICAL SYSTEM RST mille 6.9 ELECTRIC COOLING FANS 6.9.1 WIRING DIAGRAM NOTE For the locations of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). G1(G) H4(N) G2(G) E4(N) Ro/N B2(N) Wiring diagram legend 1) ECU 2) Injection relay 3) Fans 4) Throttle sensor 5) Coolant thermistor 6.9.2 CHECKING THE ELECTRIC FAN OPERATION...

  • Page 195: Dashboard Indicators

    ELECTRICAL SYSTEM RST mille 6.10 DASHBOARD INDICATORS 6.10.1 WIRING DIAGRAM NOTE For the locations of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). CONNETTORE CONNETTORE (16VIE) (12VIE) 11 16 1 2 5 4 3 6 Legend: 1) Dashboard 2) External temperature sensor 3) Oil pressure sensor 4) Fuel level sensor 5) Speed sensor...

  • Page 196: Air Temperature Sensor

    ELECTRICAL SYSTEM RST mille 6.10.2 AIR TEMPERATURE SENSOR To check the air temperature sensor: Remove left dashboard panel, see 7.1.20 (REMOVING THE FRONT FAIRING). Disconnect the two-way connector (1). Check the sensor in a controlled environment with a temperature of 20°C (68°F). Measure the electrical resistance using an ohm meter (scale 0-2kΩ) between the terminals of the connector (1).

  • Page 197: Engine Oil Pressure Sensor

    ELECTRICAL SYSTEM RST mille 6.10.3 ENGINE OIL PRESSURE SENSOR Remove the lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Disconnect the electrical terminal (1) from the sensor (2) and ground it. WARNING When reassembling, make sure electrical terminal (1) is fitted properly. With the ignition switch set to “...

  • Page 198: Speed Sensor

    ELECTRICAL SYSTEM RST mille 6.10.4 SPEED SENSOR If the speedometer does not work, proceed as follows: Raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the two-way connector of the speed sensor (1) located on the right side of the motorcycle. Measure the electrical resistance between the two terminals of the connector (1) on the sensor side: Correct value 3.83 M Ω...

  • Page 199: Fuel Level Sensor

    ELECTRICAL SYSTEM RST mille 6.10.5 FUEL LEVEL SENSOR Check the sensor: raise the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the white four-way connector (1) located under the fuel tank (left side). Measure the electrical resistance between the orange and black wires on the sensor side: Correct value with the fuel tank full: less than 14 Ω.

  • Page 200: Coolant Temperature Sensor

    ELECTRICAL SYSTEM RST mille 6.10.6 COOLANT TEMPERATURE SENSOR Make sure the sensor is in good working order, see 6.6.5 (CHECKING COOLANT THERMISTORS OPERATION). Test the dashboard operation by connecting a resistance between the white-black and white-red wires of the two-way connector (1): With resistance = 90 Ω: dashboard indicator: 9 wedges lit (the last two flashing).

  • Page 201: Light System

    ELECTRICAL SYSTEM RST mille 6.11 LIGHT SYSTEM 6.11.1 WIRING DIAGRAM NOTE For the locations of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). PASSING Legend: 1) Right dimmer switch 9) Battery 2) Left dimmer switch 10) License plate lamp 11) Low beam 3) Right dimmer switch version 12) High beam 4) Key...

  • Page 202: Checking The Light Relay

    ELECTRICAL SYSTEM RST mille 6.11.2 CHECKING THE LIGHT RELAY To check the relay (1): Remove the front fairing, see 7.1.20 (REMOVING THE FRONT FAIRING). Remove the relay in question. Power the two male terminals (85-86) with a voltage of 12 V. Use a tester (in ohm meter mode) to check the continuity between the other two terminals (87-30).

  • Page 203: Warning Lights And Buzzers

    ELECTRICAL SYSTEM RST mille 6.12 WARNING LIGHTS AND BUZZERS 6.12.1 WIRING DIAGRAM NOTE For the positions of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). PASSING Legend: 1) Left dimmer switch 2) Horn 3) Fuse (15 A) 4) Fuse (30 A) 5) Key 6) Battery 7) Flasher...

  • Page 204: Horn Test

    ELECTRICAL SYSTEM RST mille 6.12.2 HORN TEST To check the horn efficiency: Carry out the first three steps described in paragraph 7.1.27 (REMOVING THE HORN). Connect the two horn connectors to a 12 V battery. Adjust the adjuster screw if needed. 6.12.3 FLASHER TEST If neither of the direction indicator lamps is working, there is probably a problem with the flasher.

  • Page 205: Warning Lights And Buzzers

    ELECTRICAL SYSTEM RST mille 6.13 WARNING LIGHTS AND BUZZERS 6.13.1 WIRING DIAGRAM NOTE For the positions of the components, see 6.1 (LOCATIONS OF ELECTRICAL COMPONENTS). Legend: 1) Front stop switch 2) Rear stop switch 3) Fuse (15 A) 4) Fuse (30 A) 5) Key 6) Battery 7) Taillight...

  • Page 206: Switches

    ELECTRICAL SYSTEM RST mille 6.13.2 SWITCHES Use a tester to check the continuity of the switches, referring to the specific diagram. Should you detect anything out of order, replace the corresponding group of switches. 1) BRAKE LIGHT SWITCH ON FRONT BRAKE Cables Pos.

  • Page 207: Battery

    ELECTRICAL SYSTEM RST mille 6.14 BATTERY NOTE This vehicle is equipped with a sealed maintenance-free battery. It requires no maintenance beyond standard inspections and recharging if needed. Always replace the battery with one of the same type. Type: 12V - 12 Ah Carefully read 2.4 (BATTERY).
  • Page 208 ELECTRICAL SYSTEM RST mille WARNING Do not cut or make holes in the sealed parts on the reservoirs (2). Turn the reservoirs (2) upside down and place them so that the sealed parts are over the openings of the battery cells. Press on the reservoirs (2) so that the seals break and the acid is allowed to drain into the battery cells.

  • Page 209: Maintenance

    ELECTRICAL SYSTEM RST mille 6.14.2 MAINTENANCE If the vehicle remains unused for more than fifteen days, the battery must be recharged to prevent sulphation. Recharge the battery using a normal charge, see 2.4.2 (RECHARGING THE BATTERY). Smear a thin film of neutral grease or Vaseline on the terminals.

  • Page 210: Replacing The Bulbs

    ELECTRICAL SYSTEM RST mille 6.15 REPLACING THE BULBS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). WARNING Before replacing a bulb, turn the ignition switch to the “ “ position. Always wear clean gloves or use a clean, dry cloth to change the bulb.
  • Page 211 ELECTRICAL SYSTEM RST mille PARKING LIGHT BULB Remove the lower front panel, see 7.1.32 (REMOVING THE FRONT FAIRING LOWER LOCKUP). WARNING Do not pull on the wires to remove the bulb socket. Grasp the parking light socket (8), pull it and remove it from its seat.

  • Page 212: Replacing The Front Direction

    ELECTRICAL SYSTEM RST mille 6.15.2 REPLACING FRONT DIRECTION INDICATOR LAMPS Place the vehicle on the stand. Unscrew and remove the screw (1). WARNING While removing the lens, be extra careful not to break the tab. Remove the lens (2). WARNING Upon reassembly, place the lens correctly in its seat.

  • Page 213: Replacing The License Plate Light Bulbs

    ELECTRICAL SYSTEM RST mille PARKING LIGHT/BRAKE LIGHT BULBS Unscrew and remove the two screws (3). Partially remove the bulb socket (4). Push the bulb (1) in slightly and rotate it counter- clockwise. Remove the bulb (1) from its seat. WARNING Insert the bulb in the socket, lining up the two bulb pins with the corresponding guides on the socket.

  • Page 214: Changing Fuses

    ELECTRICAL SYSTEM RST mille 6.16 CHANGING FUSES Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). WARNING Do not attempt to repair faulty fuses. Never use any fuses other those specified. Such use could damage the electrical system or even cause a fire, in the event of a short-circuit.

  • Page 215: Adjusting The Headlight Beam Vertically

    ELECTRICAL SYSTEM RST mille 6.17 ADJUSTING THE HEADLIGHT BEAM VERTICALLY 32.81 ft (10 m) NOTE The procedure described here is in compliance with the Italian standard that establishes the maximum height of the headlight beam. For vehicles used in other countries, you must observe local regulations.

  • Page 216: Wiring Diagram - Rst Mille Futura

    ELECTRICAL SYSTEM RST mille 6.19 WIRING DIAGRAM - RST MILLE FUTURA. - 50 - Release 00/2002 - 03...
  • Page 217 ELECTRICAL SYSTEM RST mille Legend: 1) Multiple connectors 35) – 2) Speed sensor 36) Pick up 3) High beam relay 37) Alternator 4) Low beam relay 38) Voltage regulator 5) Horn 39) Injection relay 6) Left dimmer switch 40) – 7) Flasher 41) Rear cylinder injector 8) Air thermistor (dashboard)
  • Page 218 ELECTRICAL SYSTEM RST mille NOTES - 52 - Release 00/2002 - 03...
  • Page 219 CHASSIS RST mille CHASSIS - 1 - Release 00/2002 - 03...
  • Page 220 CHASSIS RST mille CHASSIS 7.1.42 REMOVING THE LICENSE PLATE HOLDER ..........7-36-00 7.1.43 REMOVING THE PASSENGER FOOTREST SUPPORTS ..... 7-36-00 TABLE OF CONTENTS 7.1.44 REMOVING THE PASSENGER FOOTREST.......... 7-37-00 7.1 BODY ..........7-4-00 7.1.45 REMOVING THE LEFT RIDER FOOTREST SUPPORT ..........7-37-00 7.1.1 REMOVING THE SADDLE....
  • Page 221 CHASSIS RST mille 7.7.3 REASSEMBLING THE STEERING ..7-76-00 7.8 FRONT FORK ........ 7-77-00 7.8.1 CHANGING THE FORK OIL ....7-78-00 7.8.2 REMOVING THE FORK TUBES..7-78-00 7.8.3 DISASSEMBLING THE LOWER FORK TUBE/UPPER FORK TUBE UNIT ..7-79-00 7.8.4 CHECKING THE COMPONENTS..7-84-00 7.8.5 REASSEMBLING THE UPPER/LOWER FORK TUBE UNIT........

  • Page 222: Body

    CHASSIS RST mille 7.1 BODY Legend: 1) Headlight 2) Air temperature sensor 3) Left rearview mirror 4) Saddle lock 5) Ignition switch / steering lock / parking lights 6) Clutch fluid reservoir 7) Engine oil reservoir cap 8) Left rider footrest 9) Battery 10) Main fuse holder (30A) 11) Saddle...
  • Page 223 CHASSIS RST mille Legend: 1) Taillight 2) Right passenger footrest (locking, closed /open) 3) Glove/tool kit compartment 4) Rear shock absorber 5) Fuel tank 6) Fuel tank cap 7) Air filter 8) Front brake fluid reservoir 9) Secondary fuse holder (15A) 10) Right rearview mirror 11) Horn 12) Coolant expansion tank...

  • Page 224: Removing The Saddle

    CHASSIS RST mille 7.1.1 REMOVING THE SADDLE Place the vehicle on the center stand. Insert the key (2) in the lock (3) to the left of the dashboard. Turn the key (2) counter-clockwise, raise and pull the saddle (1) out from the back, complete with side panels.
  • Page 225 CHASSIS RST mille 7.1.3 REMOVING THE FRONT SIDE PANELS NOTE The following steps refer to removing a single side panel, but are applicable to both. Remove both rear side panels, see 7.1.2 (REMOVING THE REAR SIDE PANELS). Unscrew and remove the five screws (1). Tightening torque for screws (1): 0.7 ftlb (1 Nm).
  • Page 226 CHASSIS RST mille 7.1.5 PARTIALLY REMOVING THE FUEL TANK Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), 1.4.1 (FUEL) and 4.1 (FUEL TANK). DANGER Gasoline is extremely flammable and becomes explosive under certain conditions. KEEP GASOLINE AWAY FROM CHILDREN. NOTE Is possible to partially remove the tank from the vehicle even when it contains fuel.

  • Page 227: Removing The Fuel Tank

    CHASSIS RST mille Firmly grasp the tank (5) from the front or back, raise it and cautiously place it on the prepared surface, without turning it over. WARNING When reassembling, make sure tank positioned correctly (lines and electrical cable must not be tangled and/or crushed).

  • Page 228: Removing The Fuel Tank Cap

    CHASSIS RST mille 7.1.7 REMOVING THE FUEL TANK CAP Carefully read 1.4.1 (FUEL) and 4.1 (FUEL TANK). Place the vehicle on the center stand. Unscrew and remove the three screws (1). Tightening torque for screws (1): 3.6 ftlb (5 Nm). NOTE You may leave the other three screws mounted, since they are purely decorative.

  • Page 229: Removing The Air Filter Case

    CHASSIS RST mille 7.1.8 REMOVING THE AIR FILTER CASE Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the air filter, see 2.10 (AIR FILTER). Release the clamp (1) and disconnect the hose (2). Release the two clamps (3) and pull out the two lines Unscrew the six screws (8).
  • Page 230 CHASSIS RST mille 7.1.9 REMOVING THE BATTERY Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), and 2.4 (BATTERY). NOTE Removing the battery will reset the functions: digital clock and red line setting To restore these functions, see 2.3 (MULTIFUNCTION COMPUTER). Set the ignition switch to “ ”.

  • Page 231: Removing The Electronic Control Unit

    CHASSIS RST mille 7.1.10 REMOVING ELECTRONIC CONTROL UNIT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Set the ignition switch to “ ”. Remove the saddle, see 7.1.1 (REMOVING THE SADDLE). Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Disconnect the two connectors (1) leading to the control unit (2).
  • Page 232 CHASSIS RST mille Unscrew and remove the terminal (5). Tightening torque for terminal (5): 25.8 ftlb (35 Nm). Remove the pin (6) and the rubber bushing (7). Insert the tip of a compressed air gun between the handlegrip (8) and the handlebar (9). Moving the gun tip with a circular motion, blow air into the space.

  • Page 233: Removing The Clutch Control

    CHASSIS RST mille 7.1.12 REMOVING THE CLUTCH CONTROL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. Set the ignition switch to “ ”. Unscrew and remove the two screws (1) fastening the clutch control (2). Tightening torque for screws (1): 7.3 ftlb (10 Nm).

  • Page 234: Removing Electrical Controls On The Left Handlebar

    CHASSIS RST mille 7.1.13 REMOVING ELECTRICAL CONTROLS ON THE LEFT HANDLEBAR Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. Set the ignition switch to “ ”. Unscrew and remove the two screws (1) fastening the two half-cylinders (2-3) from the bottom.
  • Page 235 CHASSIS RST mille Loosen the lock nut (3). Release the throttle cable adjuster (4) from its coupling. Disconnect the throttle cable. Repeat the last three steps for the other throttle cable as well. WARNING When reassembling make sure that the two throttle cable adjusters are properly fastened to their respective couplings;...
  • Page 236 CHASSIS RST mille WARNING When reassembling, replace the two seals with two new washers of the same type. Use a small blade screwdriver to pry out and remove the front brake switch (5) from the two slots on the front brake control lever (3).
  • Page 237 CHASSIS RST mille 7.1.17 REMOVING THE IGNITION SWITCH/STEERING LOCK Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. Set the ignition switch to “ ”. Remove the fork head, see 2.28.2 (ADJUSTING THE BEARING PLAY). Release the ignition block connector (1) from the main wiring.

  • Page 238: Control

    CHASSIS RST mille 7.1.18 REMOVING THE LEFT HANDLEBAR Remove the knob, see 7.1.11 (REMOVING THE HANDGRIP FROM THE LEFT HANDLEBAR)). Remove the electrical control, see 7.1.13 (REMOVING ELECTRICAL CONTROLS LEFT HANDLEBAR). Remove the clutch control, see 7.1.12 (REMOVING THE CLUTCH CONTROL). Unscrew and remove the screw (1).
  • Page 239 CHASSIS RST mille 7.1.20 REMOVING THE FRONT FAIRING Place the vehicle on the center stand. Set the ignition switch to “ ”. Unscrew and remove the two screws (1). Tightening torque for screws (1): 2.2 ftlb (3 Nm). Remove the bezel (2). NOTE If the rubber (3) is damaged, replace it.
  • Page 240 CHASSIS RST mille 7.1.21 REMOVING THE MIRRORS Remove the right or left dashboard panel, depending on which mirror you wish to remove; see 7.1.20 (REMOVING THE FRONT FAIRING). NOTE It is easier to remove the mirrors if you first remove the dashboard, see 7.1.24 (REMOVING THE DASHBOARD).

  • Page 241: Removing The Upper Dashboard

    CHASSIS RST mille 7.1.23 REMOVING UPPER DASHBOARD MOLDING Remove front fairing glass, see 7.1.20 (REMOVING THE FRONT FAIRING). Unscrew and remove the two fastening screws (1). Tightening torque for screws (1): 2.9 ftlb (4 Nm). Remove the molding (2) by sliding it out from behind. 7.1.24 REMOVING THE DASHBOARD Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATION).

  • Page 242: Removing The Dashboard

    CHASSIS RST mille 7.1.25 REMOVING DASHBOARD/FRONT FAIRING MOUNT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove both side fairings, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Remove the front fairing, see 7.1.20 (REMOVING THE FRONT FAIRING). Unscrew and remove the two screws (1), saving the two nuts.

  • Page 243: Removing The Front Mudguard

    CHASSIS RST mille 7.1.26 REMOVING THE FRONT MUDGUARD Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. Unscrew and remove the two screws (1). Tightening torque for screws (1): 3.6 ftlb (5 Nm). WARNING Handle all plastic and painted components with care to avoid scraping or scratching them.

  • Page 244: Removing The Front Direction

    CHASSIS RST mille 7.1.28 REMOVING THE SIDE FAIRINGS WARNING Wait until the engine and exhaust silencer have completely cooled down. Place the vehicle on the center stand. Unscrew and remove the three inner screws (1). Tightening torque for screws (1): 3.6 ftlb (5 Nm). Unscrew and remove the five upper screws (2).
  • Page 245 CHASSIS RST mille 7.1.30 REMOVING THE LEFT AIR DUCT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. Set the ignition switch to “ ”. Remove the side fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Remove the headlight complete with half-housings, see 7.1.22 (REMOVING THE HEADLIGHT).

  • Page 246: Removing The Left Air Duct

    CHASSIS RST mille 7.1.31 REMOVING THE RIGHT AIR DUCT Carry out the first three steps described in the paragraph 7.1.30 (REMOVING THE LEFT AIR DUCT). Unscrew and remove the ten screws (1). Tightening torque for screws (1): 1.4 ftlb (2 Nm). Unscrew and remove the screw (2).
  • Page 247 CHASSIS RST mille 7.1.33 REMOVING THE LOWER FAIRING Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. DANGER Wait until the engine and exhaust silencer have completely cooled down. Remove the side fairing from the side in question, see 7.1.28 (REMOVING THE SIDE FAIRINGS).

  • Page 248: Removing The Radiator Spoiler

    CHASSIS RST mille 7.1.34 REMOVING THE AIR INLET DUCT CASES Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the air duct on the side in question,see 7.1.30 (REMOVING THE LEFT AIR DUCT), or see 7.1.31 (REMOVING THE RIGHT AIR DUCT). Open the two clamps (1) that fasten the electrical cable (2) to the air inlet duct case (3).

  • Page 249: Removing The Taillight

    CHASSIS RST mille 7.1.36 REMOVING THE TAILLIGHT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. Set the ignition switch to “ ”. Remove the saddle, see 7.1.1 (REMOVING THE SADDLE). Disconnect the connector electrical (1) from the taillight.
  • Page 250 CHASSIS RST mille 7.1.37 REMOVING THE REAR GRAB HANDLE Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Carry out the first four steps described in paragraph 7.1.36 (REMOVING THE TAILLIGHT). Unscrew and remove the three fastening screws (1). Tightening torque for screws (1): 7.3 ftlb (10 Nm). WARNING Handle all plastic and painted components with care to avoid scraping or scratching them.

  • Page 251: Removing The Saddle Lock

    CHASSIS RST mille 7.1.39 COMPLETELY REMOVING SADDLE RELEASE Remove the saddle release device, see 7.1.38 (REMOVING THE SADDLE LOCK). Unscrew and remove the two screws (1). Tightening torque for screws (1): 0.7 ftlb (1 Nm). Unscrew and remove the screw (9). Tightening torque for screws (9): 1.4 ftlb (2 Nm).
  • Page 252 CHASSIS RST mille Release the wiring from the two line fasteners (2). Move the wiring (4) to one side. Remove both bag racks, see 7.1.4 (REMOVING THE BAG RACKS). Unscrew and remove the two screws (3). Tightening torque for screws (3): 2.2 ftlb (3 Nm). Remove the lower saddle panel.
  • Page 253 CHASSIS RST mille Unscrew and remove the two front fastening screws (4). Tightening torque for screws (4): 7.3 ftlb (10 Nm). Unscrew and remove the three screws (5) retrieving the three clips (6). Tightening torque for screws (5): 2.9 ftlb (4 Nm). Unscrew and remove the screw (7).

  • Page 254: Removing The Rider Footrest

    CHASSIS RST mille 7.1.42 REMOVING THE LICENSE PLATE HOLDER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove both bag racks, see 7.1.4 (REMOVING THE BAG RACKS). Disconnect the license plate lamp connector (1). WARNING When reassembling make sure the license plate lamp connector (1) is properly fitted.
  • Page 255 CHASSIS RST mille 7.1.44 REMOVING THE PASSENGER FOOTREST Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. DANGER Wait until the engine and exhaust silencer have completely cooled down. Remove the retainer ring (1). Slide out the pin (2). WARNING Take care not to lose the ball (5), ejected by the spring (6), in the process.
  • Page 256 CHASSIS RST mille 7.1.46 REMOVING THE RIGHT RIDER FOOTREST SUPPORT Carry out the first two steps described in the paragraph 7.1.45 (REMOVING THE LEFT RIDER FOOTREST SUPPORT). Carry out the first three steps described in the paragraph 7.1.49 (REMOVING THE REAR BRAKE LEVER).

  • Page 257: Completely Removing The Gearshift Lever

    CHASSIS RST mille 7.1.48 COMPLETELY REMOVING THE GEARSHIFT LEVER WARNING Before removing the gearshift lever, mark both the lever and shaft so that you can place them correctly when reassembling. Place the vehicle on the center stand. Remove the left lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING).

  • Page 258: Removing The Rear Brake Lever

    CHASSIS RST mille 7.1.49 REMOVING THE REAR BRAKE LEVER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the stand. Move the retainer ring (1). Turn the fork axle (2) downward. Slide out the fork axle (2). Release the spring (3) from the lever (4). Remove the rear stop switch (5).

  • Page 259: Removing The Exhaust Silencer

    CHASSIS RST mille 7.1.50 REMOVING THE EXHAUST SILENCER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the rear grab handle, see 7.1.37 (REMOVING THE REAR GRAB HANDLE). Disconnect the license plate lamp-taillight connector (9). WARNING When reassembling make sure the license plate lamp-taillight connector (9) is properly coupled.

  • Page 260: Removing The Expansion Tank

    CHASSIS RST mille 7.1.51 REMOVING THE EXHAUST PIPES Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the exhaust silencer, see 7.1.50 (REMOVING THE EXHAUST SILENCER). Release the two springs (1) from their couplings on the expansion tank. Check the two springs (1) and replace if damaged. Twist the exhaust pipes (2) back and forth to overcome the resistance of any encrusted build-up.
  • Page 261 CHASSIS RST mille 7.1.53 REMOVING THE EXHAUST MANIFOLDS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the expansion tank, see 7.1.52 (REMOVING THE EXPANSION TANK). Unscrew and remove the three nuts (1) fastening the exhaust manifold flange (2) to the front cylinder. Tightening torque for nuts (1): 18 ftlb (25 Nm).

  • Page 262: Removing The Side Stand

    CHASSIS RST mille 7.1.54 REMOVING THE SIDE STAND Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. WARNING Be very careful to avoid damaging the switch (1). Never loosen the nut (2) with the switch (1) installed. Release the two springs (3).

  • Page 263: Removing The Engine Oil Tank

    CHASSIS RST mille 7.1.55 REMOVING THE ENGINE OIL TANK Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.1 (FUEL) 1.4.2 (LUBRICANTS). Remove the left air inlet duct case, see 7.1.34 (REMOVING THE AIR INLET DUCT CASES). Drain out all engine oil, see 2.13 (CHANGING THE ENGINE OIL AND OIL FILTER).

  • Page 264: Removing The Engine Oil Radiator

    CHASSIS RST mille 7.1.56 REMOVING THE ENGINE OIL RADIATOR Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), see 1.4.2 (LUBRICANTS). Drain out all engine oil, see 2.13 (CHANGING THE ENGINE OIL AND OIL FILTER). NOTE Use the special click clamp installation pliers (code 0277295);...

  • Page 265: Removing The Drive Chain

    CHASSIS RST mille 7.1.57 REMOVING THE DRIVE CHAIN SHOE Remove the guide plate, see 2.35.4 (INSPECTING THE DRIVE CHAIN GUIDE PLATE). NOTE Engage first gear to block rotation of the countershaft sprocket (4) and allow you to unscrew the screw (1). Unscrew and remove the screw (1) retrieving the two washers (2-3).

  • Page 266: Removing The Upper Chain Housing

    CHASSIS RST mille 7.1.58 REMOVING THE UPPER CHAIN HOUSING Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. Unscrew and remove the screw (1). Tightening torque for screw (1): 2.9 ftlb (4 Nm). Unscrew and remove the screw (2). Tightening torque for screw (2): 2.9 ftlb (4 Nm).

  • Page 267: Removing The Frame

    CHASSIS RST mille NOTE If necessary, remove the components fastened to the rear housing (2), i.e.: Remove the two tank rotation grommets (4), retrieving the two spacers (5). Remove the passenger footrest supports, see 7.1.43 (REMOVING PASSENGER FOOTREST SUPPORTS). 7.1.60 REMOVING THE FRAME WARNING The frame (1) must be removed only at an Authorized Service Center or by an...
  • Page 268 CHASSIS RST mille NOTE Be extremely careful while removing the control unit support, to avoid damaging the control unit. Remove the radiator mount (6). Remove both of the rider footrest supports, see 7.1.45 (REMOVING LEFT RIDER FOOTREST SUPPORT) and see 7.1.46 (REMOVING THE RIGHT RIDER FOOTREST SUPPORT).

  • Page 269: Front Wheel

    CHASSIS RST mille 7.2 FRONT WHEEL Legend 1) Wheel axle nut 2) Seal 3) Seal 4) Bearing 5) Internal spacer 6) Complete wheel 7) Circlip 8) Right spacer 9) Washer 10) Nut 11) Left spacer = GREASE, see 1.12 (LUBRICANT CHART). - 51 - Release 00/2002 - 03...
  • Page 270 CHASSIS RST mille 7.2.1 REMOVING THE COMPLETE WHEEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.32 (FRONT WHEEL)). WARNING During disassembly, take care not to damage the brake lines, discs and pads. Place the vehicle on the front support stand see 1.15.1 (PLACING THE VEHICLE ON THE FRONT SUPPORT STAND) WARNING...
  • Page 271 CHASSIS RST mille 7.2.2 DISMANTLING THE WHEEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the wheel, see 7.2.1 (REMOVING THE COMPLETE WHEEL). Clean both sides of the hub with a clean cloth. Remove the right spacer (1). NOTE During reassembly, the right spacer (1) must be placed with the larger side facing the right fork tube.

  • Page 272: Checking The Components

    CHASSIS RST mille 7.2.3 CHECKING THE COMPONENTS WARNING Make sure components undamaged, especially those listed below. BEARINGS Manually turn the inner race (1) of each ball bearing. The rollers should turn smoothly and quietly. There should be no axial clearance. Any bearings found to have these faults must be replaced.

  • Page 273: Reinstalling The Wheel

    CHASSIS RST mille 7.2.4 REINSTALLING THE WHEEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). WARNING During reassembly, take care not to damage the brake lines, discs and pads. The arrow on the wheel hub shows the rotation direction. When reassembling, be careful to mount the wheel properly.

  • Page 274: Rear Wheel

    CHASSIS RST mille Make sure the wheel is properly centered and 7.3 REAR WHEEL balanced. Legend 1) Wheel screw cover 2) O-ring 3) Snap ring 4) Wheel screw stop 5) Wheel screw 6) Wheel cable 7) Complete wheel 8) Wheel axle nut = GREASE, see 1.12 (LUBRICANT CHART).

  • Page 275: Removing The Complete Wheel

    CHASSIS RST mille 7.3.1 REMOVING THE COMPLETE WHEEL Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and see 2.33 (REAR WHEEL). DANGER Wait until the engine and exhaust silencer have completely cooled down. During disassembly, take care not to damage the brake lines, discs and pads, and the speed sensor cable.

  • Page 276: Reassembling The Rear Wheel

    CHASSIS RST mille 7.3.2 REASSEMBLING THE REAR WHEEL DANGER Before reassembly, make sure the key (1) is present and correctly positioned. Place it correctly if it has fallen from its seat. Do not forget to remount it. Turn the drive shaft so that the key (1) is at the top. Mount the wheel (2) on the drive shaft, making sure that the three drive pins (3) are correctly inserted in the wheel slots.
  • Page 277 CHASSIS RST mille Place the snap ring (10) correctly. Return the plug (11) to its place, using the spanner wrench (12). WARNING After reassembly, operate the rear brake lever repeatedly and make sure the brake system is in good working order. Make sure the wheel is properly centered and balanced.

  • Page 278: Final Drive Assembly

    RST mille 7.4 FINAL DRIVE ASSEMBLY Legend: 1) Eccentric cam 15) Spring washer 2) Bearing 16) Self-locking flanged nut 3) Roller cage 17) Flexible coupling grommet 4) Seal 18) Belleville washer 5) Snap ring 19) Roller cage 6) Thrust-bearing spacer 20) Center bearing 7) Snap ring 21) Ring...
  • Page 279 RST mille 7.4.1 REMOVING THE FINAL DRIVE ASSEMBLY Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove the wheel, see 7.3.1 (REMOVING THE COMPLETE WHEEL). Remove the lower chain shoe, see 7.1.57 (REMOVING THE DRIVE CHAIN SHOE). Loosen drive chain tension, see 2.35.3 (ADJUSTING THE DRIVE CHAIN).
  • Page 280 RST mille Retrieve the O-ring (9). Unscrew and remove the six screws (10). NOTE To unscrew the screws (10), we recommend using an impact wrench, which delivers the sharp blow ® needed to release the screws from the LOCTITE 243. Unscrew and remove the six brake disc screws (10).
  • Page 281 RST mille 7.4.2 CHECKING THE COMPONENTS WARNING Make sure components undamaged, especially those listed below. BEARINGS, GASKETS, WHEEL AXLE AND RIM, see 7.2.3 (CHECKING THE COMPONENTS). FLEXIBLE COUPLINGS Make sure that the flexible coupling grommets (1) are not damaged and/or excessively worn. Replace the grommets (1) if necessary.

  • Page 282: Removing The Final Drive Assembly

    RST mille 7.4.3 REMOVING THE ECCENTRIC CAM Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Remove swinging pivot, see 7.4.1 (REMOVING THE FINAL DRIVE ASSEMBLY). Loosen the two screws (1). Tightening torque for nuts (1): 25.8 ftlb (35 Nm). Remove the snap ring (2). Slide the eccentric cam out from the left side.

  • Page 283: Front Brakes

    RST mille 7.5 FRONT BRAKES Legend: 1) Brake lever For more information: 2) Brake fluid pump - see 1.3.5 (BRAKE FLUID); 3) Brake pads - see 2.16 (CHECKING AND TOPPING UP THE 4) Brake discs FRONT BRAKE FLUID); 5) Brake light switch - see 2.19 (BLEEDING THE BRAKE SYSTEMS);...

  • Page 284: Changing The Brake Pads

    RST mille 7.5.1 CHANGING THE BRAKE PADS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.27 (CHECKING THE BRAKE PAD WEAR). Place the vehicle on the center stand. NOTE The following steps refer to a single clamp, but are applicable to both. Use a pair of pliers to grasp the head of one piston, then the other, and turn them just far enough to bring the two pin locks (1) into a position from which they...

  • Page 285: Checking The Brake Discs

    RST mille 7.5.2 CHECKING THE BRAKE DISCS NOTE The operations described below should be carried out with the brake discs installed on the wheel; they refer to a single disc, but are applicable to both. Check the disc wear, using a micrometer gauge to measure the minimum thickness at various points on the disc.

  • Page 286: Rear Brake

    RST mille 7.6 REAR BRAKE Legend: 1) Brake fluid reservoir For more information: 2) Brake fluid line from tank to pump - see 1.3.5 (BRAKE FLUID); 3) Brake disc - see 2.17 (CHECKING AND TOPPING UP THE REAR 4) Bleeder nipple BRAKE FLUID);...
  • Page 287 RST mille 7.6.1 CHANGING THE BRAKE PADS Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.27 (CHECKING THE BRAKE PAD WEAR). Place the vehicle on the center stand. NOTE It will be easier to work if you remove the rear wheel, 7.3.1 (REMOVING THE COMPLETE WHEEL).

  • Page 288: Removing The Rear Brake Caliper

    RST mille 7.6.2 REMOVING THE REAR BRAKE CALIPER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Place the vehicle on the center stand. NOTE For space reasons, it is advisable to remove the rear wheel, see 7.3.1 (REMOVING THE COMPLETE WHEEL). Slide out the safety spring (1).

  • Page 289: Checking The Brake Disc

    RST mille 7.6.3 CHECKING THE BRAKE DISC NOTE These operations should be carried out with the brake disc installed on the wheel. Check the disc wear, using a micrometer gauge to measure the minimum thickness at various points on the disc. NOTE If the smallest thickness is below the minimum value, even in a single part of the disc, replace the disc,...

  • Page 290: Removing The Brake Disc

    RST mille 7.6.4 REMOVING THE BRAKE DISC Carefully read see 1.3.9 (PRECAUTIONS GENERAL INFORMATION). Remove final drive assembly, see 7.4.1 (REMOVING THE FINAL DRIVE ASSEMBLY). Slip the brake caliper off the disc, see 7.6.2 (REMOVING THE REAR BRAKE CALIPER). Remove the clamp plate (1). Place the piston, complete with disc, on the vice, inserting a soft material (aluminum) between the jaws.
  • Page 291 RST mille 7.6.5 REMOVING THE BRAKE MASTER CYLINDER Remove right lower fairing, see 7.1.33 (REMOVING THE LOWER FAIRING). Carry out the first three steps described in the paragraph see 2.22 (CHANGING THE REAR BRAKE FLUID). When all the fluid has drained out, unscrew and remove the screw (1) and retrieve the two seals.

  • Page 292: Steering

    RST mille 7.7 STEERING Legend: 1) Upper bushing For more information: 2) Washer - see 2.28 (STEERING); 3) Fork head - see 2.29 (INSPECTING THE FRONT SUSPENSION). 4) Locking ring nut 5) Locking washer 6) Adjustment ring-nut 7) Protective cover 8) Dust seal 9) Bearings 10) Triple clamp...

  • Page 293: Disassembling The Steering

    RST mille 7.7.1 DISASSEMBLING THE STEERING Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.28 (STEERING). Place the vehicle on a lift platform on the center stand. Carry out the first eleven steps described in the chapter see 2.28.2 (ADJUSTING THE BEARING PLAY). Unscrew and remove the screw (1).

  • Page 294: Reassembling The Steering

    RST mille 7.7.3 REASSEMBLING THE STEERING NOTE For reassembly, the vehicle and front fork must be placed as for disassembly. Then proceed with the same steps in reverse order from disassembly. Spread a light coating of grease along the entire length of the pivot (1), see 1.12 (LUBRICANT CHART).
  • Page 295 RST mille 7.8 FRONT FORK Legend: 1) Damper rod bushing 2) Retainer ring 3) Ring 4) Upper fork tube cap 5) Center screw 6) Copper washer 7) Complete damper 8) Bushing 9) Spring spacer tube 10) Spring 11) Lower spring seat 12) Lower collar 13) Upper fork tube 14) Sliding bushing...

  • Page 296: Changing The Fork Oil

    RST mille 7.8.1 CHANGING THE FORK OIL Carefully read 1.4.2 (LUBRICANTS) and 2.29.2 (ADJUSTING THE FRONT FORK). Carry out the operations marked with the symbol “ ” described in the chapter 7.8.3 (DISASSEMBLING THE LOWER FORK TUBE/UPPER FORK TUBE UNIT). Carry out the operations marked with the symbol “...

  • Page 297: Disassembling The Lower Fork Tube/Upper Fork Tube Unit

    RST mille NOTE Where necessary, remove the other lower fork tube/upper fork tube unit. 7.8.3 DISASSEMBLING THE LOWER FORK TUBE/ UPPER FORK TUBE UNIT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), 1.4.2 (LUBRICANTS) and 2.29 (INSPECTING THE FRONT SUSPENSION). NOTE The right and left upper/lower fork tube units have the same internal components.
  • Page 298 RST mille WARNING The following operations must be carried out by two mechanics. Before starting, agree which mechanic will handle which operations. Rest both hands on the tool (A). Push downward, at the same time inserting the tool (B) between the lock nut (7) and the washer (8). While holding the damper rod (9), unscrew the upper fork tube cap (5) using the appropriate wrench.
  • Page 299 RST mille NOTE Before removing them completely, hold the spring spacer tube (6) and the spring (11) above the fork tube, so that some of the oil remaining on these components drains down inside the fork tube. Remove the spring spacer tube (6) complete with spring seat and slider ring.
  • Page 300 RST mille Use a blade screwdriver to remove the retainer ring (16). WARNING The operation described below will require some force, since the slider bushing (17) needs to push the gasket (18), ring (19), and guide bushing (20) off, despite their resistance. Remove the lower fork tube unit (21) from the upper fork tube (22).
  • Page 301 RST mille Place the lower fork tube (21) in a vice, inserting a soft material (aluminum) between the jaws. Unscrew and remove the center screw (23) and retrieve the copper washer (24). Remove the complete damper (9) from the lower fork tube (21).

  • Page 302: Checking The Components

    RST mille 7.8.4 CHECKING THE COMPONENTS LOWER FORK TUBE Inspect the sliding surface to make sure it is not scratched or scored. Slight scratches may be eliminated by sanding with very fine (1200 grit) wet sandpaper. If the scratches are deep, replace the tube (1). Use a dial indicator to make sure any bending in the fork tube (1) is less than the acceptable limit.

  • Page 303: Reassembling The Upper/Lower Fork Tube Unit

    RST mille 7.8.5 REASSEMBLING THE UPPER/LOWER FORK TUBE UNIT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION), 1.4.2 (LUBRICANTS) and 2.29 (INSPECTING THE FRONT SUSPENSION). NOTE The operations marked with the symbol “ ” also describe the procedure for changing the fork oil. WARNING During reassembly, be extremely careful to make sure that the sliding surfaces are in perfect condition...
  • Page 304 RST mille Slide the following components, in order, onto the lower fork tube (1): - dust seal (6); - stop ring (7); NOTE Slip on the gasket (8), with the labeled side facing the retainer ring (7). - gasket (8); - ring (9);...
  • Page 305 RST mille Insert the lower fork tube (1) into the upper fork tube (12). Remove the tape. Place the two halves of the tool (D) on the lower fork tube (1), in front of the guide bushing (10). Grip the tool (D) and push the guide bushing (10) into position in its seat on the upper fork tube (12).
  • Page 306 RST mille Grasp the upper fork tube (12) and slide it slowly up and down about ten times, for approximately 6 inches (150 mm), to allow any trapped air to escape. Push the upper fork tube (12) down to the end of its stroke.
  • Page 307 RST mille WARNING The following operations must be carried out by two mechanics. Before starting, agree which mechanic will handle which operations. Rest both hands on the tool (A). Push downward, at the same time inserting the tool (B) between the lock nut (20) and the washer (19). While holding the damper rod (3), tighten the upper fork tube cap (21) using the appropriate wrench.

  • Page 308: Installing The Lower Fork Tube/Upper Fork Tube Unit

    RST mille 7.8.6 INSTALLING THE LOWER FORK TUBE/UPPER FORK TUBE UNIT Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.29 (INSPECTING THE FRONT SUSPENSION). Install the upper fork tube (1) and lower fork tube (2) together on the triple clamp (3) and fork head (4). Insert the axle (5) through both tubes to align the lower fork tube holes.

  • Page 309: Swinging Arm

    RST mille 7.9 SWINGING ARM 7.9.1 REMOVING THE SWINGING ARM Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.30 (SWINGING ARM). Place the vehicle on the center stand. Remove the rear wheel, see 7.3.1 (REMOVING THE COMPLETE WHEEL). Remove both side fairings, see 7.1.28 (REMOVING THE SIDE FAIRINGS).

  • Page 310: Disassembling The Swinging Arm

    RST mille WARNING Due to the weight of the rear drive train, the following operations must be carried out by two mechanics. Before starting, agree which mechanic will handle which operations. Proceed very carefully with removal operations. Support the swinging arm in front to keep it from falling accidentally.

  • Page 311: Checking The Components

    RST mille 7.9.3 CHECKING THE COMPONENTS WARNING Make sure that none of the components are visibly bent, broken, cracked and /or dented. Replace any damaged components. BEARINGS Manually turn the inner race (1) of each ball bearing. The rollers should turn smoothly and quietly. There should be no axial clearance.

  • Page 312: Re-Installing The Swinging Arm

    RST mille 7.9.4 RE-INSTALLING THE SWINGING ARM Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) 2.30.1 (ADJUSTING SWINGING ARM). Spread a light coating of lubricant grease along the entire length of the swinging arm pivot (1), see 1.12 (LUBRICANT CHART). Insert the adjuster bushing (2) in its seat and screw it on by hand.
  • Page 313 RST mille Replace both rider footrest supports, see 7.1.45 (REMOVING LEFT RIDER FOOTREST SUPPORT) and 7.1.46 (REMOVING THE RIGHT RIDER FOOTREST SUPPORT). Replace rear shock absorber, see 7.10.1 (REMOVING THE SHOCK ABSORBER). Replace the expansion tank, see 7.1.52 (REMOVING THE EXPANSION TANK). Replace the sprocket hub, see 7.4.1 (REMOVING THE FINAL DRIVE ASSEMBLY).

  • Page 314: Rear Suspension

    RST mille 7.10 REAR SUSPENSION 7.10.1 REMOVING THE SHOCK ABSORBER Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.31.1 (REAR SUSPENSION). Remove both lower fairings, see 7.1.33 (REMOVING THE LOWER FAIRING). Remove the tank, see 7.1.6 (REMOVING THE FUEL TANK COMPLETELY). Remove the exhaust pipes, see 7.1.51 (REMOVING THE EXHAUST PIPES).

  • Page 315: Disassembling The Rear Suspension Linkage

    RST mille 7.10.2 DISASSEMBLING THE REAR SUSPENSION LINKAGE Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.31.1 (REAR SUSPENSION). Remove both lower fairings, see 7.1.33 (REMOVING THE LOWER FAIRING). Working from the right side of the vehicle, loosen and remove the nut (1). Tightening torque for nut (1): 36 ftlb (50 Nm).

  • Page 316: Disassembling The Suspension Linkage

    RST mille 7.10.3 DISASSEMBLING SUSPENSION LINKAGE Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION). Loosen and remove the nut (1). Tightening torque for nut (1): 36 ftlb (50 Nm). Remove the screw (2). Remove the two double connecting rods (3-4). Remove the two seals gaskets (5). Use a special extractor to remove the two roller bearings (6).

  • Page 317: Checking The Components

    RST mille 7.10.4 CHECKING THE COMPONENTS WARNING Make sure that none of the components are visibly bent, broken, cracked and /or dented. Replace any damaged components. BEARINGS Manually turn the rollers, which should turn smoothly and quietly. There should be no axial clearance. Any bearings found to have these faults must be replaced.

  • Page 318: Disassembling The Drive Chain

    RST mille 7.11 DISASSEMBLING THE DRIVE CHAIN 7.11.1 CHAIN BREAKER/RIVET TOOL NOTE This tool (code 8140192) is designed for breaking/riveting chains with rivet-type links. WARNING Only chains with rivet-type links should be installed on this vehicle. Tool legend: Chain legend: 1) Main body 13) Master plate 2) Tied hexagonal boss (for 27-mm wrench)

  • Page 319: Breaking The Chain

    RST mille 7.11.2 BREAKING THE CHAIN Carefully read 1.3.9 (PRECAUTIONS AND GENERAL INFORMATION) and 2.35 (DRIVE CHAIN). Remove the countershaft sprocket case, see 2.35.4 (INSPECTING THE DRIVE CHAIN GUIDE PLATE). Loosen the chain tension, see 2.35.3 (ADJUSTING THE DRIVE CHAIN). NOTE Make sure that the tool is suited to the type of chain installed on the vehicle and the size of the chain's...

  • Page 320: Placing The Master Link

    RST mille 7.11.3 PLACING THE MASTER LINK WARNING Make sure that the master link is the same type as the chain to be joined. Place the chain on the vehicle with the two ends to be joined at a point between the front and rear sprockets of the chain’s lower run.

  • Page 321: Riveting The Pins

    RST mille 7.11.4 RIVETING THE PINS With the tool already in place on the chain: Loosen the screw (1). Remove the main body (2) from the rivet tool (3). Remove the support plate (4). Refit the main body (2) on the rivet tool (3). Move the main body (2) so that the locating dowel (5) is in line with mark “B”...
  • Page 322 RST mille NOTES - 104 - Release 00/2002 - 03...
  • Page 323 GENERAL INFORMATION RST mille GENERAL INFORMATION - 1 - Release 00/2002 - 03...
  • Page 324 GENERAL INFORMATION RST mille GENERAL INFORMATION TABLE OF CONTENTS 8.1 TROUBLESHOOTING ...... 8-3-00 8.1.1 ENGINE..........8-3-00 8.1.2 ELECTRICAL SYSTEM......8-8-00 8.1.3 BATTERY ..........8-8-00 8.1.4 BRAKES ..........8-9-00 8.1.5 CHASSIS ..........8-9-00 8.2 LOCATION, FASTENING, AND ROUTING OF WIRING, CABLES AND LINES.. 8-11-00 8.2.1 FRONT BRAKE LINES......
  • Page 325 GENERAL INFORMATION RST mille 8.1 TROUBLESHOOTING WARNING Any faults with the ignition coils, crankshaft position sensor, camshaft sensor, pressure sensors and THERMISTORS are automatically detected by the electronic control unit reported multifunction display with the flashing message “EFI”. this reason, malfunctions these components are not repeated in the troubleshooting...
  • Page 326 GENERAL INFORMATION RST mille DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine does not idle Idle rpm too slow Adjust smoothly Air filter dirty Clean Intake manifold leaking Replace Both cylinders poorly synchronized Synchronize the cylinders Throttle valve shaft/housing worn Replace See the subsection entitled "Engine difficult or impossible to start"...
  • Page 327 GENERAL INFORMATION RST mille DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine overheats Insufficient coolant in the cooling system, system Top up with coolant, subject leaking the system to a pressure test Use coolant that meets Coolant does not meet specifications specifications Radiator dirty or coolant hose clogged Clean...
  • Page 328 GENERAL INFORMATION RST mille DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine makes too The noise seems to come from the timing system much noise Chain tightener shoe worn Replace (*) Too much valve clearance Adjust (*) Valve springs worn out or broken Replace (*) Valve lifter buckets or camshaft worn Replace (*)
  • Page 329 GENERAL INFORMATION RST mille DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The clutch does not Clutch fluid reservoir level Check disengage Use motor oil that meets Motor oil does not meet specifications specifications Clutch discs stuck together Clean or replace (*) Clutch discs or support plate warped Replace (*) Clutch control hydraulic system faulty...

  • Page 330: Electrical System

    GENERAL INFORMATION RST mille 8.1.2 ELECTRICAL SYSTEM DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The spark plugs are soiled Incorrect engine oil level Check immediately with carbon Unsuitable fuel Use the recommended fuel deposits Air filter dirty Clean The spark plugs get dirty Incorrect engine oil level Check too soon...
  • Page 331 GENERAL INFORMATION RST mille 8.1.4 BRAKES DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Weak braking power Brake fluid leak from the hydraulic system Repair or replace Worn pads Replace the pads Pad contact surfaces dirty with oil, grease or brake Replace the pads fluid Worn brake discs Replace the disc...
  • Page 332 GENERAL INFORMATION RST mille DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Front wheel wobbly Bent wheel rim Replace Worn wheel bearings Replace Tire faulty or wrong type Replace Loose axle nut Tighten Wrong kind of fork oil Replace Fork too soft Incorrectly adjusted Adjust Springs weakened...

  • Page 333: Location, Fastening, And Routing Of Wiring, Cables And Lines

    GENERAL INFORMATION RST mille 8.2 LOCATION, FASTENING, AND ROUTING OF WIRING, CABLES AND LINES 8.2.1 FRONT BRAKE LINES 8.2.2 REAR BRAKE LINES - 11 - Release 00/2002 - 03...

  • Page 334: Fuel System Lines

    GENERAL INFORMATION RST mille 8.2.3 FUEL SYSTEM LINES - 12 - Release 00/2002 - 03...

  • Page 335: Clutch Control Line

    GENERAL INFORMATION RST mille 8.2.4 CLUTCH CONTROL LINE 8.2.5 PPC DEVICE PRESSURE LINES - 13 - Release 00/2002 - 03...

  • Page 336: Cooling System Lines

    GENERAL INFORMATION RST mille 8.2.6 COOLING SYSTEM LINES - 14 - Release 00/2002 - 03...
  • Page 337 GENERAL INFORMATION RST mille - 15 - Release 00/2002 - 03...

  • Page 338: Engine Oil Lines

    GENERAL INFORMATION RST mille 8.2.7 ENGINE OIL LINES - 16 - Release 00/2002 - 03...

  • Page 339: Breather And Overflow Drainage Lines

    GENERAL INFORMATION RST mille 8.2.8 BREATHER OVERFLOW DRAINAGE LINES - 17 - Release 00/2002 - 03...

  • Page 340: Throttle Control Cables

    GENERAL INFORMATION RST mille 8.2.9 THROTTLE CONTROL CABLES - 18 - Release 00/2002 - 03...

  • Page 341: Electrical Cables

    GENERAL INFORMATION RST mille 8.2.10 ELECTRICAL CABLES Legend 1) Flasher 2) Headlight wiring 3) Fall sensor 4) Light relay 5) Front right direction indicator 6) Secondary fuse box 7) Right dimmer switch connector 8) Dashboard connectors 9) Front left direction indicator connector 10) Air temperature sensor 11) Left dimmer switch connector - 19 -...
  • Page 342 GENERAL INFORMATION RST mille Legend 1) Horn 2) Oil pressure sensor 3) Voltage regulator 4) Engine earth 5) Main fuses 6) Start relay 7) Taillight 8) Positive battery pole 9) Rear brake light 10) Speed sensor connector 11) Coolant temperature sensor 12) Injection connectors - 20 - Release 00/2002 - 03...
  • Page 343 GENERAL INFORMATION RST mille Legend 1) Air thermistor 12) Front cylinder coil “1” 2) Control unit 13) Front cylinder coil “2” 3) Fuel pump connector 14) Rear cylinder coil “1” 4) Side stand switch 15) Rear cylinder coil “2” 5) TEST connectors 16) Front cylinder injector 6) Left fan connector 17) Rear cylinder injector...
  • Page 344 GENERAL INFORMATION RST mille - 22 - Release 00/2002 - 03...
  • Page 345 GENERAL INFORMATION RST mille - 23 - Release 00/2002 - 03...

  • Page 346: Checking The Electrical System

    GENERAL INFORMATION RST mille 8.3 CHECKING THE ELECTRICAL SYSTEM 8.3.4 PROBLEMS WITH AUXILIARY SYSTEMS - see 6.11.2 (CHECKING THE LIGHT RELAY). location various electrical - see 6.8.4 (CHECKING THE DIODE). components, see 6.1 (LOCATIONS OF ELECTRICAL - see 6.9.2 (CHECKING ELECTRIC COMPONENTS) and 8.2.10 (ELECTRICAL CABLES).

  • Page 347: Checking The Electrical System

    GENERAL INFORMATION RST mille 8.4 CHECKING THE ELECTRICAL SYSTEM 8.4.8 WHEELS Rims 8.4.1 ENGINE See 1.11 (SPECIFICATIONS). For technical data and specifications on the compo- nents, see sect. 3 (ENGINE). Rim eccentricity: See 7.2.3 (CHECKING THE COMPONENTS). 8.4.2 THROTTLE BODY COMPONENTS For technical data and specifications on the compo- Axle eccentricity: nents, see 4.8 (THROTTLE BODY).
  • Page 348 GENERAL INFORMATION RST mille NOTES - 26 - Release 00/2002 - 03...
  • Page 349 ANALYTICAL INDEX RST mille ANALYTICAL INDEX - 1 - Release 00/2002 - 03...
  • Page 350 ANALYTICAL INDEX RST mille Ref. Page Ref. Page ACTIVATING THE BATTERY 6.14.1 6-41 CABLES AUXILIARY, STARTING 2-16 ADJUSTING THROTTLE CONTROL 8.2.9 8-18 REAR SHOCK ABSORBER 2.31.2 2-50 ELECTRICAL 8.2.10 8-19 DRIVE CHAIN 2.35.3 2-55 4.10.5 4-19 CAPACITY - FLUID PROPERTIES 8.4.12 8-26 THROTTLE CONTROL...
  • Page 351 ANALYTICAL INDEX RST mille ELECTRICAL SYSTEM 8-25 ELECTRICAL SYSTEMS INJECTION 6.4.1 8-26 WIRING - RST MILLE FUTURA 6.19 6-50 INJECTORS 6.6.1 6-16 WIRING, LIGHT SYSTEM 6.11.1 6-35 STAND SWITCH 6.8.5 6-26 WIRING, PUMP SYSTEM FUEL 6.7.1 6-21 SAFETY SYSTEM SWITCHES 6.8.7 6-27 WIRING, INDICATOR SYSTEM...
  • Page 352 ANALYTICAL INDEX RST mille FORK CHAIN GUIDE PLATE 2.35.4 2-56 FRONT 7-77 FRONT SUSPENSION 2.29 2-47 FRONT, ADJUSTING 2.29.2 2-48 REAR SUSPENSION 2.31 2-50 REAR 7-91 INSTALLATION REAR, ADJUSTING 2.30.1 2-49 COMPLETE ENGINE ON THE FRAME 3-16 RE-INSTALLING 7.9.4 7-94 LOWER/UPPER FORK TUBES 7.8.6 7-90...
  • Page 353 ANALYTICAL INDEX RST mille Ref. Page Ref. Page RADIATORS, REMOVING FORK, CHANGING 7.8.1 7-78 RADIATOR SPOILER, REMOVING 7.1.35 7-30 ENGINE 1.2.2 ENGINE AND TOPPING UP, LEVEL 2.12 2-24 REAR BRAKE 7-68 ENGINE, CHANGING 2.13 2-25 REAR BRAKE CALIPER, REMOVING 7.6.2 7-70 OTHER COMPONENTS, WARNINGS REAR HOUSING, REMOVING...
  • Page 354 ANALYTICAL INDEX RST mille TAILLIGHT 7.1.36 7-31 SCHEDULED MAINTENANCE PLAN FRONT SIDE PANELS 7.1.3 SEALANTS 3.1.4 REAR SIDE PANELS 7.1.2 FUEL DELIVERY FILTER SENSOR SWINGING ARM 7.9.1 7-91 FALL, CHECKING 6.4.4 6-10 COMPLETE PUMP ASSEMBLY FUEL LEVEL 6.10.5 6-33 FUEL INTAKE CRANKSHAFT POSITION, THROTTLE BODY 4.8.1...
  • Page 355 ANALYTICAL INDEX RST mille RIGHT RIDER FOOTREST, THROTTLE CONTROL OPERATION 2.11.1 2-22 REMOVING 7.1.46 7-38 FLASHER 6.12.3 6-38 LEFT RIDER FOOTREST, BRAKE PAD WEAR 2.27 2-43 REMOVING 7.1.45 7-37 THERMISTORS SUPPORTS AND RACKS COOLANT, CHECKING OPERATION 6.6.5 6-19 BAG RACKS, REMOVING 7.1.4 COOLANT, REMOVING PASSENGER FOOTREST,...
  • Page 356 ANALYTICAL INDEX RST mille Ref. Page VALVE VOLTAGE REGULATOR, CHECKING 6.3.5 Ref. Page WARNINGS FOR FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENTS WHEEL FRONT 2.32 2-52 FRONT 7-51 COMPLETE, REMOVING 7.2.1 7-52 7.3.1 7-57 REAR 2.33 2-52 REAR 7-56 DISASSEMBLING 7.2.2 7-53 WHEELS 8.4.8...
  • Page 357 ANALYTICAL INDEX RST mille NOTES - 9 - Release 00/2002 - 03...
  • Page 358 ANALYTICAL INDEX RST mille NOTES - 10 - Release 00/2002 - 03...

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