APRILIA RSV Mille 1000 1999 Technical Training Course
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APRILIA RSV Mille 1000 1999 Technical Training Course

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Aprilia Consumer Service Spa
Technical Service and Training
Release 4 july 99
RSV 1000 Technical Training Course
This material is didactic and
may be changed following the technical
development of the product

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Summary of Contents for APRILIA RSV Mille 1000 1999

  • Page 1 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 RSV 1000 Technical Training Course RSV Mille This material is didactic and may be changed following the technical development of the product...
  • Page 2 Japanese competitors. A product which represents, to all effects, a decision in style for the buyer and, for Aprilia, the first stage of further development linked with highpowered bikes. For Aprilia, "the sense of wonder' means breaking...
  • Page 3 Technical Service and Training Release 4 july 99 Design Concept: Aprilia’s aim in making RSV Mille was to create a motorcycle with extremely compact dimensions, one that could cleave the air in an optimumn fashion and protect the rider against the impact of the wind and high speeds.
  • Page 4 Release 4 july 99 THE ENGINE The engine fitted on the RSV Mille is a completely new type, conceived and developed by Aprilia's engineers. It is a 60°V-formation longitudinal two cylinder engine, with 4 distribution valves per cylinder and a double camshaft at the head, controlled by a mixed chain and gear system.
  • Page 5 Release 4 july 99 The dry sump A further innovation brought by Aprilia in producing this new engine is the use of dry-sump lubrication, which allows a more rigid and compact engine block that the "wet-sump" solution. The system makes use of a second trochoid pump for recovery and an external oil tank, as well as a radiator positioned in front of the engine.
  • Page 6 Technical Service and Training Release 4 july 99 lnjection The need for suitable control of the powerful engine of the RSV Mille led the Aprilia designers to adopt an electronic management system built into the engine. All the fondamental operating parameters constantly...
  • Page 7 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 The exhaust The exhaust system of the RSV Mille originates as the reply to four very precise requests: light weight, aerodynamic line, respect for the environment and for approval standards.
  • Page 8 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 As regards respect for the environment, the engine of the RSV Mille complies with the parameters of the future European standards (EURO 1, which comes into force in 1999); this result is achieved without the aid of any type of catalyst, as a further guarantee of performance and attention to these problems.
  • Page 9 The best engineers in the Aprilia racing department designed the frame, giving it the most in terms of planning and knowledge of structures, choice of...
  • Page 10 Release 4 july 99 COMPONENTS Every slightest detail of the RSV Mille receives the same meticulous care from Aprilia, to transfer dove, care and enthusiasm into every bike that the company produces. Many parts contribute to make the RSV Mille a...
  • Page 11 ISO 9001 certification obtained for ali production phases. To assure you that this bike is reliable and a really good buy, Aprilia covers the RSV Mille with a MotoGo Three-Year Guarantee.
  • Page 12 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 01: INJECTION SYSTEM 1.1 PREFACE: INTRODUCTION ON THE INJECTION-IGNITION SYSTEM The injection-ignition system is of the " alpha/n, D/J" type, in which motor speed and throttle position are used as the main parameters for the quantity of aspirated air; knowing the quantity of air, the fuel level is dosed as a function of the performance required.
  • Page 13 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Operation phases. NORMAL OPERATION When the engine has a normal temperature, the control unit –ECU- calculates the phase, the injection time and the spark advance through interpolation of the corresponding store maps, as function of the r.p.m/pressure (..and other input)
  • Page 14 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 1.2 RSV 1000 FUEL INJECTION SYSTEM The main features of the RSV MILLE fuel injection system are as follows: Possibility of setting the right air/fuel mixture in real time on the basis of the throttle valve opening, the inlet manifold pressure and the engine running speed.
  • Page 15 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 The control unit software switches between the DJ map and the alpha/n map on the basis of the engine running conditions. The injection volume also depends on the other factors provided by the compensation devices, illustrated later on.
  • Page 16 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Compensation devices: Positioned inside the control unit box. Reads the Patm. The control unit normally reduces the injection volume 1. Atmospheric pressure sensor in low atmospheric pressure conditions This sensor reads the coolant temperature.
  • Page 17 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Timing control The times are controlled by the reading of the position of the crankshaft and the position of the camshaft. The control unit also detects the starting phase, injecting the fuel into the cylinders asynchronously.
  • Page 18 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Injection stop control Rpm limiter: Software control. The control unit stops the injection if the rpm are excessive. Deceleration: The injector function is disabled during deceleration with the throttle valve closed.
  • Page 19 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Safety systems Kick back Prevention: At about 300 rpm (if the rpm have been over 800 rpm) the control unit de- energizes the coil signal to prevent a possible kick-back in the pistons when turning the bike off.
  • Page 20 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 1.3 SELF-DIAGNOSTICS FUNCTION: The self-diagnostics function is part of the ECU software and is a valid aid to trouble-shooting in the electronic injection system. HOW THE FUNCTION WORKS: With the control unit and dashboard connected and the key “on”, the multi-function LCD displays...
  • Page 21 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 2-If everything is functioning perfectly, the following figures may appear on the display: -1, 0, 1 (throttle valve opening standard values – SEE CO SETTING) 3- If there are any faults, the fault codes will appear in sequence. The sequence will keep repeating until you exit the Dealer Mode.
  • Page 22 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 1.4 FAULTS TABLE FAULT CODE COMPONENT INVOLVED CAUSE NOTES Sensor not connected, faulty CAMSHAFT SENSOR START ENGINE wiring, sensor broken (t>4 sec) CRANKSHAFT SENSOR Sensor not connected, faulty...
  • Page 23 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 TROUBLE SHOOTING: WHAT TO DO IF THE ENGINE DOESN’T START AND NO FAULT IS SHOWN ON THE SELF-DIAGNOSTICS SYSTEM Check the fuel pump Check the injectors Check that the anti-theft system connector is connected...
  • Page 24 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 START AND RUN POSSIBILITY: If a fault is detected, the control unit may: stop the bike allow running but not starting allow running and starting as described in the table:...
  • Page 25 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 OPERATION - DASHBOARD KEYS [A] [B] [R] [C] [D] SEGMENTS OPERATION CHECK: Press keys [A] and [B] and turn the key from OFF to ON: all segments stay lit as long as [A] and [B] are pressed.
  • Page 26 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 6. MULTIFUNCTION Coolant temperature and clock => [D] => Battery voltage => [D] => Set hours (Press LAP) => Set minutes (Press LAP) => Set °C/°F (Press LAP) => go back to b) Stop watch Press and hold [LAP] and then (within 0.7 seconds) press key [D] to start the stop watch.
  • Page 27 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 2: IGNITION SYSTEM The ignition system is controlled by the control unit. The system is a normal one, known as a digital transistorised ignition system, which sets the correct timing on the basis of the engine rpm and throttle position.
  • Page 28 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CONTROL STRATEGY In the ignition phase, the control unit reads the starting, as shown in the separate figure. BATTERIA The ignition phase starts in this way (asynchronous/synchronous phase): 1.
  • Page 29 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 2. Cylinder recognition The camshaft and pick up sensors send signals that are clipped by the ECU. camshaft sensor sends signal each cycle (INT-COMPRESS- IGNITION/EXPANSION-EXHAUST), corresponding to an angle of 720°...
  • Page 30 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 IGNITION: The HT coils control is linked to the pick up signal after the recognition of the cylinders (see figure above). At low rpm (< 540) the ignition is set by the clipped signal of the pick up. The CPU gives consensus to the ignition only.
  • Page 31 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 3 : DESCRIPTION OF ELECTRONIC INJECTION SYSTEM The RSV1000 electronic injection system is made up of the following components: 1. Electronic control unit 2. Sensors (shaft position, temperature, pressure...) 3.
  • Page 32 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 3.1 THE E.C.U.: ELECTRONIC CONTROL UNIT The injection system and ignition system operation are controlled by the Nippodenso ECU, code no. 265470 (not final!!!). The control unit is connected to the rest of the bike’s electrical system by two ‘fast’ connectors. As well as being fed with power and receiving signals from the sensors through these connectors, the control unit also controls the injectors and l.t.
  • Page 33 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 In addition, the following systems/components are inside the control unit: coils/injectors control power circuit Atmospheric pressure sensor CO regulation trimmer Trimmer regolazione CO CO ECU SETTING This material is didactic and...
  • Page 34 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 ECU ELECTRONIC WIRING DIAGRAM: This material is didactic and may be changed following the technical development of the product...
  • Page 35 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 ONNECTORS: The control unit is connected to the electrical circuit by plug-in connectors that plug into the ECU printed circuit. The connectors connect the control unit to the sensors and actuators (injectors, coils) via the wiring.
  • Page 36 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 4 POSITIONING OF SENSORS AND INJECTORS: The position of each of the sensors is shown in the figure: This material is didactic and may be changed following the technical...
  • Page 37 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CAMSHAFT SENSOR: The cam sensor is an inductive sensor installed in the front cylinder head and is identical to the pick-up. This sensor is of fundamental importance and allows the ECU to recognise the exact sequence of each single cylinder, resetting the internal count to zero during the asynchronous ignition phase.
  • Page 38 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 THROTTLE SENSOR: The throttle sensor, a highly reliable potentiometer, is a 4-pin resistive sensor. The sensor sends a voltage signal, proportional to the opening angle of the throttle valve, to the control unit. The sensor is positioned in the throttle assembly, as shown in the figure.
  • Page 39 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CRANKSHAFT SENSOR: PICK - UP An inductive sensor, already familiar from other models, positioned inside the magneto flywheel. Sends a voltage pulse to the control unit for every 60° of rotation and is of fundamental importance, together with the camshaft pulse, in allowing the ECU to set the injection and ignition times.
  • Page 40 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 TIP OVER SENSOR: This is a mechanical ring-switch which stays in contact with the plastic section as long as the bike is in a normal position. When the bike leans, the ring moves and, if the angle is greater than 44 degrees, it activates the switch terminals.
  • Page 41 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 ENGINE COOLANT TEMPERATURE SENSOR: This temperature sensor has a variable resistance which decreases with the increase in temperature. The ECU provides the sensor with a +5 Volt signal...
  • Page 42 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 MANIFOLD PRESSURE SENSOR: This sensor reads the pressure in the air cleaner box and provides a linear voltage in the range of 1 to 4.2 Volts to the control unit. It must be supplied with a continuous voltage of +5 Volts (provided by the control unit). The operating pressure ranges from13.3 to 120 Kpa (abs).
  • Page 43 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 INJECTORS: Each cylinder has an injector. The location in the throttle assembly is shown in the figure: The injector used is made up of the following components: Mesh filter...

  • Page 44: Starter Motor

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 OTHER RELEVANT ELECTRICAL COMPONENTS: STARTER MOTOR: The characteristic operating curves are shown below: This material is didactic and may be changed following the technical development of the product...
  • Page 45 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 DIODE MODULE: The figure shows the electrical wiring in the module. The continuity of the diodes can be checked with a tester or with a 4.5 - 12 Volt battery with an arbitrary load of max. 2 Watts.

  • Page 46: Voltage Regulator

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 VOLTAGE REGULATOR: The voltage regulator is situated at the rear of the bike on the right, in contact with the bodywork. NEGATIVO POSITIVO This material is didactic and...
  • Page 47 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 TRASLATION OF LEGENDA FOR RS 1000 ELECTRIC WIRING DIAGRAM MULTIPLE CONNECTORS CAMSHAFT SENSOR FLASHER THROTTLE SENSOR FUEL PUMP INTAKE AIR PRESSURE SENSOR FUEL WARNING LIGHT SENSOR WATER THERMISTOR (ECU)
  • Page 48 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 3.2 FUEL CIRCUIT The fuel circuit is made up of the following components: 1 fuel pump 2 fuel feed pipe 3 pressure regulator 4 injector. The fuel pump is immersed in the fuel tank and pumps the pressurised fuel to the feed pipe, where the pressure regulator keeps the fuel pressure about 3 bars higher than the intake pressure.
  • Page 49 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 The regulator - shown in the figure - has the following components: a vacuum-operated diaphragm and spring, and a steel ball valve with the valve seat mounted on the spring.
  • Page 50 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 POSITIONING OF ELECTRICAL COMPONENTS ON BIKE: VOLTAGE REGULATOR COIL SPEED SENSOR This material is didactic and may be changed following the technical development of the product...
  • Page 51 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 THROTTLE SENSOR DIODE UNIT ABS. PRESS. SENSOR POWER RELAY Temperature sensor DIAG CONNECTOR Oil switch STAND SWITCH COIL This material is didactic and may be changed following the technical...
  • Page 52 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 5: ELECTRICAL CHECKS Refer to the key below when consulting this chapter: Ar= orange V/Az Az= light blue B= blue Bi/R Bi= white G= yellow Bi/R Gr= grey...
  • Page 53 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CHECK 3: H.T. COIL CHECK: Use the tester in the Ohms scale to check the continuity of the windings. The approx. values are as follows: L.T. SIDE: 3-6 OHMS H.T.
  • Page 54 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Fitting the throttle sensor: (Please see section 9 for CO regulation) With the engine off, turn the ignition key to ON. When positioned in the throttle body, enable the control unit diagnostics function.
  • Page 55 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CHECK 7: PRESSURE SENSOR CHECK: The readings below, taken one by one, must give a value of 15 kOhms Ohmmeter between 1-3 Ohmmeter between1-2 CHECK 8: DIODE MODULE CHECK:...
  • Page 56 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...
  • Page 57 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CHECK 9: FUEL PUMP CHECK: Lift the fuel tank Disconnect the pump assembly 3 way connector Feed the green (+) and blue (-) wires coming from the side of the pump assembly with 12 Vdc.
  • Page 58 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 LIGHT WIRING DIAGRAM PASSING/LAP CLAXON LIGHTS LIGHTS P LIGHTS H H - Lo H – HI TURN R TURN L FANALE POST. FANALE ANTERIORE 72 72 63 DISPLAY CRONOMETRO...
  • Page 59 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CHECK 10: WIRING AND COMPONENTS CHECK The main electrical components’ connections to the ECU are shown in the outline wiring diagram in fig.: 68: TEST CONNECTOR CAMSHAFT 19 LEFT...
  • Page 60 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 In more detail, the terminals refer to the components shown in the table; the standard ohmic values are also given: DESCRIPTION OF NUM. CONNECTOR STANDARD WIRE COLOUR TERMINALS...
  • Page 61 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...
  • Page 62 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...
  • Page 63 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 DASHBOARD ELECTRIC WIRING DIAGRAM: LEGENDA: D=15 AMP FUSE FUEL WARNING LIGHT SENSOR OIL PRESSURE SWITCH WATER TEMP. THERMISTOR SPEED SENSOR FUEL WARNING LIGHT OIL PRESSURE WARNING LIGHT REV COUNTER...
  • Page 64 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CHECK 11: SPEEDOMETER CHECK: Check the connections WITH THE ENGINE OFF: 1) With the key ON, measure the voltage between the green/purple and blue/orange wires without disconnecting the connectors. The reading should be more than 9 Volts 2) Measure the voltage between the grey/white and blue/orange wires without disconnecting the connectors.
  • Page 65 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...
  • Page 66 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 6 FRAME The RSV1000 frame is a highly rigid aluminium structure, with a flexural rigidity of 650 Kgm/°. It is made up of a series of shell-cast parts: steering tube, engine front mounting plate, swingarm pin mounting plate, where the rear of the shock absorber is also attached, and press-forged aluminium plate parts;...
  • Page 67 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 NOTE: FOR THE REMOVAL AND REFITTING OF THE ENGINE AND SWINGARM ON THE FRAME, SPECIAL WRENCHES MUST BE USED FOR UNSCREWING THE RING-TYPE LOCKNUTS ON THE 2 ENGINE FIXING POINTS (RH SIDE) AND ON THE RH SIDE OF THE SWINGARM PIN.
  • Page 68 The brakins systems of RSVmille are the best you can have on a production bike. Aprilia has developed them together with Brembo, company leader in this sector, and this braking systems offers an excellent MODULARITA’ through a 4 position adjusting lever. The braking pads are studied for informing the rider when the thickness of the braking element is lower than 1 mm.
  • Page 69 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 8 REAR SHOCK ABSORBER The rear shock absorber of the RSVmille is a modern complete adjustable unit, like the front suspension. The shock absorber has a separate oil tank and a gas chamber to compensate the volume variations of oil due to temperature.
  • Page 70 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...
  • Page 71 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 FRONT FORK SPECIFICATION BEARING PIPE DIAMETER: 43 mm STROKE: 127 mm REBOUND ADJ.: COMPRESSION EFFECT: MAX 2 TURN SPRING PRE-LOAD: MAX 2 TURN SPRING PRE-LOAD: MAX 25 mm // MIN. 10 mm SPRING OPERATION: 284 mm OIL Q.TY: 520 CC...
  • Page 72 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 09 PBTL SYSTEM The PBTL system on the RSV 1000 reduces the ‘braking’ torque transmitted by the engine during deceleration. OPERATING PRINCIPLE: Line 1 is connected to the intake passage whereas line 2 – downstream of the retaining valve – is connected to the airbox via the throttle valve.
  • Page 73 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 10 TIMING SETTING OF RSV MILLE ENGINE REAR CYL # 2 FRONT CYL # 1 This material is didactic and may be changed following the technical development of the product...
  • Page 74 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 1. FIXING CRANKSHAFT 1.2 INSERT FIXING SCREW,AFTER 1.1 REMOVE THE SCREW INDICATED WITH REACHING THE TDC OF THE THE ARROW – CLUTCH SIDE REQUESTED CYLINDER 1.3 DETAIL OF THE FIXING POINTS ON THE...
  • Page 75 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 2. TIMING SETTING OF THE REAR CYLINDER (# 2) ALIGNEMENT OF THE CAMSHAFT 2.1 ALIGNEMENT OF THE INTERMEDIATE GEAR GEARS WITH THE PRINTED REFERENCES USING THE PRINTED REFERENCES...
  • Page 76 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 TIMING SETTING OF THE FRONT CYLINDER (# 1) 3.2 ALIGNEMENT OF INTERMEDIATE GEAR 3.1 ALIGNEMENT OF CRANKSHAFT AND WITH THE PAINTED REFERENCE ON THE PRIMARY BALANCESHAFT WITH PAINTED...

  • Page 77: Technical Data

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 SECTION 11: GENERAL DATA RSV MILLE TECHNICAL DATA This material is didactic and may be changed following the technical development of the product...
  • Page 78 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 1. TECHNICAL DATA This material is didactic and may be changed following the technical development of the product...
  • Page 79 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

  • Page 80: Lubricant Chart

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 2. LUBRICANT CHART This material is didactic and may be changed following the technical development of the product...

  • Page 81: Preliminary Checking Operations

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 3.PRELIMINARY CHECKING OPERATIONS: This material is didactic and may be changed following the technical development of the product...
  • Page 82 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 4. SERVICE MAINTENANCE CHART This material is didactic and may be changed following the technical development of the product...
  • Page 83 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 4.FRAME TORQUE SETTINGS AIR FILTER BOX Description Qnty Screw\nut ref. Securing of the air box cover Securing of the air box to the throttle body Securing of the air intakes...
  • Page 84 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 CLUTCH LEVER Description Qnty Screw\nut ref. Securing of the clutch lever liquid pipe M10X1 Securing of the clutch liquid tank support Securing of the clutch liquid tank\clutch pump...
  • Page 85 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Securing of intakes to the frame and to the support SWP 3.9 Higer securing of lat. Fairing f.1;r.2 0,1;0,2 Securing of front fairing dashboard lockup Securing of front fairing\dashboard support...

  • Page 86: Engine Torque Settings

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 5 ENGINE TORQUE SETTINGS ENGINE CARTER Description (were and what) Qnty Screw\nut ref. Ballbearing holder (flyweel side)- Flat head screw M6X13 L243 Ballbearing holder (clutch side)- Flat head screw...
  • Page 87 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 Valve cover cilinder 2- Cilinder head screw M6X45 Valve cover cilinder 2- Cilinder head screw M6X55 cilinder head 2- Locking screw M18X1,5 L243 Cilinder head\exhaust system- Stud screw...

  • Page 88: Wiring Diagram

    Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 6 WIRING DIAGRAM This material is didactic and may be changed following the technical development of the product...
  • Page 89 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 6.1 WIRING DIAGRAM KEY This material is didactic and may be changed following the technical development of the product...
  • Page 90 Aprilia Consumer Service Spa Technical Service and Training Release 4 july 99 This material is didactic and may be changed following the technical development of the product...

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