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APRILIA ETV MILLE CAPONORD ABS - 2003 Manual

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Summary of Contents for APRILIA ETV MILLE CAPONORD ABS - 2003

  • Page 1 ETV mille Caponord - ETV mille Caponord ABS use maintenance book aprilia part# 8104780...

  • Page 2: Foreword

    © 2003 aprilia s.p.a. - Noale (VE) FOREWORD INTRODUCTION NOTE This manual is an important and This manual is divided into sections, chap- integral part of your vehicle. Keep it with ters and paragraphs, by subject. The proce- your vehicle at all times, even if your vehi- dures described are laid out in single opera- ◆...

  • Page 3: Safety Warnings

    sure that the area in which you are operat- WARNING SAFETY WARNINGS ing is properly ventilated. Never run the en- Gasoline is extremely flammable and be- The following precautionary warnings are gine in enclosed spaces. comes explosive under certain condi- used throughout this manual in order to If it is necessary to work indoors, use an tions.

  • Page 4: Brake Fluid

    cal assistance. Should you accidentally BRAKE FLUID BATTERY HYDROGEN GAS splash clutch fluid into your eyes, flush AND ELECTROLYTE CAUTION with a large quantity of cool, clear water WARNING and immediately seek professional medi- Brake fluid is extremely poisonous. Do cal assistance.

  • Page 5: Warnings - Precautions - General Advice

    Carbon monoxide does not react in the not become involved in individual problems same way, but it is toxic and poisonous. between you, your dealer, or aprilia. To aprilia utilizes ≈lean∆ carburetor settings contact NHTSA, you may either call the...

  • Page 6: Tampering Warning

    If any of the following symptoms are ob- prohibited. Federal law prohibits the follow- served, immediately have your vehicle in- ing acts or causing thereof: spected and repaired by your Local aprilia a) The removal or rendering inoperative by Dealer. any person other than for purposes of...

  • Page 7: Information Contained In The Vehicle Identification Number

    DIGIT MEANING INFORMATION CONTAINED IN THE VEHICLE 1) Manufacturer»s identification alphanu- IDENTIFICATION NUMBER meric code. 2) Vehicle type. Description of the vehicle identification 3) Model. number (V.I.N.), stamped on the steering 4) Country for which the vehicle is intend- head of the frame (A) and on the identifica- tion plate (B).

  • Page 8: Position Of The Warning Adhesive Labels

    POSITION OF THE WARNING ADHESIVE LABELS use and maintenance ETV mille Caponord ABS...

  • Page 9: Warning Adhesive Labels Chart

    WARNING ADHESIVE LABELS CHART Ref. Ref. Description Description Muffler stamping. Follow use and maintenance ETV mille Caponord ABS...
  • Page 10 Follow Ref. Ref. Description Description Follow use and maintenance ETV mille Caponord ABS...
  • Page 11 Follow Ref. Ref. Description Description Follow use and maintenance ETV mille Caponord ABS...

  • Page 12: Evaporative Emission System

    Follow EVAPORATIVE EMISSION SYSTEM Ref. Description The system consists of: 1) Fuel tank. 2) Water drain line. 3) Fuel tank breather nipple. 4) Breather line (to tee). 5) Roll-over valve. 6) Breather line (to purge valve). 7) Purge valve (to carbon canister). 8) Breather line (to carbon canister).
  • Page 13 NOTE In case of malfunction of the fuel system, contact your Local aprilia Dealer. use and maintenance ETV mille Caponord ABS...

  • Page 14: Aprilia S.p.a. - Emission Control System Warranty Statement

    3007, or the California Air Resources cycle is defective, the part will be repaired Board at P.O. Box 8001, 9528 Telstar Av- or replaced by aprilia. This is your emis- enue, El Monte, CA 91734-8001. sion control system DEFECTS WARRAN-...

  • Page 15: Aprilia S.p.a. - Limited Warranty On Emission Control System

    Noale (VE) Italy (hereinafter ≈aprilia∆) war- the Clean Air Act and applicable regula- within 30 days, or a repair is not com- rants that each new 1999 and after aprilia tions of the United States Environmen- plete within 30 days. Any replacement...
  • Page 16 PRESS EMISSION CONTROL SYS- ment or by any individual. The warranty A. The liability of aprilia under this Emis- TEM WARRANTY TERMS STATED IN period begins on the date the motorcy- sion Control System Warranty is limited THIS WARRANTY.

  • Page 17: General Instructions

    √ I.M. = modification code (A, B, C, º); √ COUNTRY CODE = country of homolo- gation (I, UK, A, º). and are to be supplied to the Local aprilia Dealer as reference data for the purchase of spare parts or specific accessories of the model you have acquired.

  • Page 18: Table Of Contents

    SUPPORT STAND ........113 EVAPORATIVE EMISSION SYSTEM ....12 THE FRONT BRAKE LEVER......64 FRONT WHEEL ..........114 aprilia s.p.a. - EMISSION ADJUSTING THE SHIFT LEVER ...... 64 REAR WHEEL..........119 CONTROL SYSTEM ADJUSTING THE CLEARANCE DRIVE CHAIN ..........123 WARRANTY STATEMENT.........
  • Page 19 IDLE ADJUSTMENT ........139 SPARK PLUGS..........139 CHANGING FUSES......... 142 REMOVING THE FUSE BOX COVER .... 145 BATTERY............145 BATTERY STORAGE ........146 CHECKING AND CLEANING THE TERMINALS ..........147 REMOVING THE BATTERY......147 CHECKING THE ELECTROLYTE LEVEL......147 RECHARGING THE BATTERY ....... 148 INSTALLING THE BATTERY ......
  • Page 20 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance ETV mille Caponord ABS...
  • Page 21 safe drive...

  • Page 22: Basic Safety Rules

    BASIC SAFETY RULES The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your ve- hicle.
  • Page 23 Observe all rules of the road. Particularly Avoid obstacles that could damage the ve- Always ride with both hands on the han- pay attention to all warning, regulatory and hicle or make you lose control. dlebars and feet on the footrests. informational signs.
  • Page 24 If the throttle sticks open, it may cause a WARNING Your aprilia dealer is ready and able to collision with another vehicle, or an upset. In the event of a throttle sticking emer- help you with any safety problems that you...
  • Page 25 Have your vehicle repaired only with origi- This vehicle was not designed to be nal parts, and use only original aprilia or the risk of accident, and therefore of seri- equipped with a sidecar or to be used to aprilia approved accessories.
  • Page 26 Never race other vehicles with your vehi- Always ride at the appropriate speed and Gradually open and close the throttle, to cle. avoid unnecessary hard acceleration. This avoid spinning or skidding the rear wheel. not only is safer, but also reduces fuel Brake with both the front and rear brakes.

  • Page 27: Clothing

    Always observe posted and statutory CLOTHING Inevitably, the driver will look right at you, speed limits, but do not assume that you and yet swear that they did not see you Before riding your vehicle, ensure that can ride as fast as the speed limit under before they turned directly into your path.

  • Page 28: Accessories

    The owner of the vehicle is responsible for cessories not to work. Use only aprilia gen- Avoid using accessories that hamper ac- the choice, installation and use of any ac- uine accessories.
  • Page 29 Do not hang anything from your vehicle This makes it more likely that the front Never carry loosely packaged items, handlebars, fenders, or forks, because this wheel will come up off the ground, espe- make sure that everything that you carry will upset the handling of your vehicle, and cially on acceleration.

  • Page 30: Arrangement Of The Main Elements

    ARRANGEMENT OF THE MAIN ELEMENTS 1) Headlight. 6) Passenger saddle lock. 11) Electronic Control Unit 16) Side stand. 2) Left rear-view mirror. 7) Rider left footrest (spring (ECU). 17) Shift lever. 3) Clutch fluid reservoir. equipped,always extend- 12) Rear fork. 18) Engine oil filter.
  • Page 31 1) Rear light. 8) Front brake reservoir. 14) Coolant expansion tank. 19) Passenger right footrest 2) Glove/tool kit compartment. 9) Right rear-view mirror. 15) Rear brake pedal. (retractable). 3) Main fuse carrier (30A). 10) Secondary fuse carrier 16) Rider right footrest (spring 20) Carbon canister.

  • Page 32: Arrangement Of The Instruments/Controls

    ARRANGEMENT OF THE INSTRUMENTS/CONTROLS 1) Electrical controls on the left 2) Clutch lever. 6) Electrical controls on the 7) Ignition switch/steering side of the handlebar, see 3) Instruments and indicators. right side of the handlebar, lock/parking lights ( √ √ p.

  • Page 33: Instruments And Indicators

    INSTRUMENTS AND INDICATORS 1) Speedometer. 5) Amber ≈side stand down∆ 9) Right multifunction digital dis- 10) SET and MODE programing 2) Green direction indicator warning light LED ( ). play: push buttons. warning light LED ( 6) Red diagnostic warning light √...

  • Page 34: Instruments And Indicators Table

    In this case, immediately stop the engine and contact your Local aprilia Dealer. Failure to heed this warning can lead to engine seizure, upset, and serious injury or even death.
  • Page 35 System) warning light When an ABS defect or malfunction is detected during running, the light comes on and the ABS is automatically switched off. Contact an aprilia Official Dealer as soon as possible. Speedometer (MPH) Indicates the instantaneous, average or maximum road speed (in miles).
  • Page 36 After the ten seconds have elapsed, the display always returns to the function displayed before (fuel level or air temperature). When the digital display flashes showing the writing “_ _” or the CAUTION writing “ ”, contact your Local aprilia Dealer. Follow use and maintenance ETV mille Caponord ABS...
  • Page 37 If the situation on the dashboard remains the same after the coolant level has been checked, do not start the vehicle and contact your Local aprilia Dealer. After the first 625 mi (1000 km) and successively every 4600 mi (7500 km), the word “SERVICE”...

  • Page 38: Setting Push Buttons

    √ all the dashboard lighting LEDs come – °C/°F; LIGHTING is set and fixed by aprilia in the vehicle √ all the segments appear on the left dis- It is possible to select three different levels production phase, according to the play;...
  • Page 39 SWITCHING FROM TOTAL TO PARTIAL SETTING THE CLOCK (HOURS AND Press the push button SET (9) and se- ◆ MILE ODOMETER MINUTES) lect the desired hour (11). ◆ To confirm the time setting, press and re- NOTE Left display The setting of the clock can be lease the button MODE (10), and the Press and release the push button SET ◆...

  • Page 40: Controls

    CONTROLS 3) DIMMER SWITCH ( √ The dimmer switch has two positions: √ low beam ≈ ∆ position; √ high beam ≈ ∆ position. When the button is in the position indicated by the ≈ ∆, the park- ing lights, dashboard light and low beam are illuminated. When the button is in the position indicated by the ≈...
  • Page 41 Contact your Local aprilia Dealer for repairs. Failure to heed this warning can lead to a serious accident and subsequent injury or even CAUTION death.

  • Page 42: Ignition Switch

    IGNITION SWITCH POSITIONS Position Function removal The steering is It is locked. possible to It is neither remove the possible to key. (LOCK) start the Steering engine, nor to lock switch on the lights. IGNITION SWITCH Neither the It is engine, nor the possible to The ignition switch/steering lock ( - - -...

  • Page 43: Steering Lock

    NOTE OPERATION STEERING LOCK Turn the key (2) and steer the handlebar at the same time. To lock the steering: WARNING ◆ Press the key (2) and turn it counter- ◆ Place the vehicle on the stand, see p. 85 Never attempt to place the ignition clockwise (leftwards), steer the handle- (PLACING THE VEHICLE ON THE...

  • Page 44: Parking Lights

    AUXILIARY EQUIPMENT UNLOCKING/LOCKING THE PASSENGER SADDLE ◆ Place the vehicle on the stand, see p. 85 (PLACING THE VEHICLE ON THE STAND). ◆ Place the ignition key (1) into the pas- senger saddle lock (2). ◆ Turn the ignition key (1) clockwise, lift and withdraw the passenger saddle (3) from behind.

  • Page 45: Larger Surface For Luggage

    To unlock the glove/tool kit compart- LARGER SURFACE FOR LUGGAGE LOCKING/UNLOCKING THE ment cover (7): GLOVE/TOOL KIT COMPARTMENT WARNING COVER ◆ Place the ignition key (1) into the pas- It is strictly forbidden to carry the pas- senger saddle lock (2). ◆...

  • Page 46: Special Tools

    The glove/tool kit compartment is located: Special tools are needed to perform some specific operations on your vehicle. These √ under the saddle. tools are available from your Local aprilia To reach it: Dealer. ◆ Remove the glove/tool kit compartment...

  • Page 47: Accessories

    ACCESSORIES OUTLET WARNING The following accessories: This vehicle is equipped with an outlet (1) Excluding the original aprilia transport for plugs with 0.7874 in (20 mm) diameter. bags , do not install any other kind of √ center stand bag or case on the rear part of the vehi- √...

  • Page 48: Main Components

    WARNING MAIN COMPONENTS Gasoline is poisonous and carcinogen- FUEL ic and contains chemical substances that cause birth defects and other re- WARNING productive problems. If gasoline should Gasoline is extremely flammable and in be accidentally spilled on the skin or some conditions can become explo- clothes, immediately wash it off with sive.
  • Page 49 ◆ Lift the little cover (1). CAUTION WARNING ◆ Insert the key (2) in the cap lock (3). During the refueling operations, be Make sure that the fuel filler cap (4) is ◆ Turn the key (2) clockwise, pull it and careful to avoid damaging the inner properly closed.

  • Page 50: Lubricants

    In this case, immediately GINE OIL LEVEL AND TOPPING UP). stop the engine and contact your Local CAUTION aprilia Dealer. Failure to heed this warn- CAUTION ing can lead to engine seizure, upset, Be very careful when putting oil in your Have your Local aprilia Dealer change and serious injury or even death.

  • Page 51: Brakes

    WEAR). Have your brakes serviced by If you have any doubt regarding the per- Your vehicle is equipped with your Local aprilia Dealer. fect functioning of your brake system, disc brakes and two separate brake sys- or if the normal pre-ride checks indicate tems.

  • Page 52: Disc Brakes

    Arrange with your Local aprilia Dealer to DISC BRAKES flush the systems and change all of the WARNING brake fluid once every two years. NOTE As mentioned above, the brakes are the This vehicle is provided with front most important safety system on your and rear disc brakes with separate hy- vehicle.

  • Page 53: Front Brake

    (2,000 km), see p. 109 (CHECKING CHECKING THE SYSTEM THE BRAKE PAD WEAR). NOTE Have your Local aprilia Dealer check the Carry out these checks only on a firm, flat surface such as a concrete garage front and rear brake discs after the first floor.
  • Page 54 TOPPING UP ◆ Raise and remove the reservoir cover (5) Follow together with the two screws (3) (4). ◆ Ensure that the fluid contained in the res- Carefully read p. 51 (BRAKES) and p. 52 ◆ Remove the guide cover (6). ervoir exceeds the ≈MIN∆...
  • Page 55 (1) and top up until topping up, make sure that it is perfect- serviced by your Local aprilia Dealer. reaching it. ly clean. It may be necessary to have your dealer...

  • Page 56: Rear Brake

    If the fluid does not reach the “MIN” ervoir, in case some fluid should be REAR BRAKE mark: spilled. CHECKING THE SYSTEM CAUTION CAUTION NOTE Carry out these checks only on a When the disc pads wear out, the level Do not operate the rear brake pedal with firm, flat surface such as a concrete garage of the fluid decreases progressively to...
  • Page 57 a clean, sealed container. Never reuse used brake fluid. CAUTION If you use any container or funnel for topping up, make sure that it is perfect- ly clean. Any foreign matter getting into the brake reservoir may lead to severe damage. WARNING Do not add any additives or other sub- stances to the brake fluid.

  • Page 58: Abs

    Local aprilia Dealer. le. We thus strictly recommend that you vehicle stability. It may be necessary to have your dealer...
  • Page 59 10 A fuse (5) Whenever the front wheel is disassembled automatically disabled. To protect: or re-assembled, check the gap between Consult an Aprilia Official Dealer immedi- phonic wheel (2) and sensor (1) again. It ◆ ABS control unit ately. should be 1 mm (+0.85/-0.6) at the front...

  • Page 60: Clutch

    If you have any doubt regarding the per- fect functioning of your clutch system, or if the normal pre-ride checks indicate any discrepancy, contact your Local aprilia Dealer before riding. CLUTCH WARNING Do not ride your vehicle with worn or...
  • Page 61 WARNING Have your Local aprilia Dealer check the roads, or in any kind of competition. clutch conditions every 4,650 mi (7,500 Check the clutch line, make sure that it Have your Local aprilia Dealer check km).
  • Page 62 CHECKING THE SYSTEM If the fluid does not reach the “MIN” This will cause clutch fluid to squirt out mark: and spill. NOTE Carry out these checks only on a ◆ ◆ Top up the reservoir, see p. 62 (TOP- Using a short Phillips screwdriver, un- firm, flat surface such as a concrete garage PING UP).
  • Page 63 Any foreign matter getting into the clutch “MAX” level. any way, have your vehicle serviced by reservoir may lead to severe damage. your Local aprilia Dealer. NOTE In order to reach the “MAX” lev- It may be necessary to have your dealer...

  • Page 64: Adjusting The Clutch Lever

    (4) end and the If you wish to adjust the shift lever position, throttle grip (5), by rotating the adjuster please contact your Local aprilia Dealer. The positions ≈1∆ and ≈4∆ correspond to an (6).

  • Page 65: Adjusting The Clearance Of The Rear Brake Pedal

    ADJUSTING THE CLEARANCE ◆ Holding the head of the brake adjuster To check the specified clearance men- OF THE REAR BRAKE PEDAL bolt (3) with a wrench, tighten the lock tioned above: nut (2). ◆ Measure the distance traveled by the rear The clearance of the rear brake pedal (1) is ◆...

  • Page 66: Coolant

    CAUTION aprilia Dealer. Have the coolant changed by your Local The coolant is made up of 50% water and CHECKING AND TOPPING UP aprilia Dealer every 2 years. 50% antifreeze. WARNING This mixture is ideal for most running tem- WARNING...
  • Page 67 Have any damage or discrepancy re- rinse with cool water and immediately paired by your Local aprilia Dealer. Do NOTE T h e e x p a n s i o n t a n k ( 3 ) i s seek medical attention.

  • Page 68: Tires

    154 (TECHNICAL Check the conditions of the tire and the DATA), or that have been specifically approved by aprilia for this vehicle. inflation pressure at room temperature every 600 mi (1,000 km), see p. 154 (TECHNICAL DATA).

  • Page 69: Wheel Spokes Tension

    Local aprilia aprilia Dealer. Dealer. WARNING The operations necessary to this check is difficult and delicate, and require spe- cific skills and therefore should be car- ried out by your Local aprilia Dealer. use and maintenance ETV mille Caponord ABS...

  • Page 70: Exhaust Silencer

    If the bike is to be used off-road, on fective exhaust system components. See public land, it is the owner’s responsi- your Local aprilia Dealer. Tampering with bility to install a spark arrester ap- the exhaust system not only makes your...

  • Page 71: Instructions For Use

    INSTRUCTIONS FOR USE GETTING ON AND OFF THE VEHI- Get on and off the vehicle only from the left to be supported by the side stand. Attempt- side and always with extended side stand. ing to mount the vehicle with the stand ex- tended, and without the rider»s feet planted The instructions below must be followed firmly on the ground to support the vehicle,...
  • Page 72 ◆ ◆ passenger must always use the left foot- Have the passenger extend the two pas- Incline the vehicle until the stand rests rest to get on and off the vehicle. senger footrests. on the ground. ◆ ◆ Instruct the passenger how to safely get Grasp the handlebar firmly and get off Never get on or off the vehicle by stretch- on the vehicle.

  • Page 73: Preliminary Checking Operations

    Do not hesitate to consult your Local tial, when you release the throttle grip, that es, the engine keeps running with re- aprilia Dealer in case there is something it automatically return to the idle position. duced performance levels; immediately...

  • Page 74: Preliminary Checking Operations Chart

    PRELIMINARY CHECKING OPERATIONS CHART Component Check Page Front and rear disc Check brake operation, lever and pedal play, fluid levels. Check the pads for excessive wear, check the 4 (BRAKE FLUID), 51 (BRAKES), brakes. discs for condition. If the discs are unduly scored or show signs of heat discoloration, do not ride the vehi- 52 (DISC BRAKES), 53 (FRONT cle.

  • Page 75: Starting

    STARTING WARNING This vehicle is extremely fast and pow- erful, and must be used with the great- est care. Do not ride this vehicle if you are not an experienced, trained motor- cycle rider. This vehicle is capable of extremely high speeds and extremely high performance and must be used with due respect for these capabilities.
  • Page 76 ◆ position when the throttle grip is re- Hold the vehicle in place by applying the leased. Contact your Local aprilia Deal- front brake lever (11). ◆ Press the starter button ≈ ∆ (15) to start er for repairs. Failure to heed this warn- the engine.
  • Page 77 In this case, stop the engine immediately and contact your Local aprilia Dealer. Failure to heed this warning can lead to engine seizure, upset, and serious inju- STARTING AT VERY COLD AMBIENT If the engine starts: ry or even death.

  • Page 78: Riding

    RIDING WARNING CAUTION NOTE If you carry a passenger, instruct When the vehicle is new to you, practice Before riding away, carefully read him/her not to move around unduly, and looking in the rear view mirrors. the ≈safe drive∆ chapter, see p. 17 (SAFE to keep his/her body aligned with yours Reflecting surfaces are convex, there- DRIVE).
  • Page 79 Shift gears fairly quickly but without wheely) or jerk forwards. Never acceler- Local aprilia Dealer. Failure to heed great force. Develop a “feel” for shifting ate abruptly or excessively when releas- this warning can lead to engine seizure, with your left toe.
  • Page 80 In many cases, the engine keeps running with reduced per- formance levels; immediately contact your Local aprilia Dealer Before and during downshift, rotate the WARNING WARNING throttle clockwise to decelerate in order Do not operate the vehicle if the maxi- to avoid overspeeding the engine.

  • Page 81: Running-In

    vehicle in one place on an uphill grade RUNNING-IN WARNING will very quickly ruin the clutch and The internal parts of the engine and trans- Pay very close attention to any obsta- overheat the engine. mission must be properly run-in to ensure cles or variations of the road surface.

  • Page 82: Stopping

    faults found. Failure to heed this warning could lead to damage to your vehicle or engine seizure or other malfunction which could cause an upset and lead to serious injury or even death. ◆ Between the first 600 mi (1,000 km) and 900 mi (1,500 km) drive more briskly, changing speed and using maximum ac- celeration for only a few seconds.

  • Page 83: Parking

    the ignition switch. Before parking the vehicle: PARKING ◆ Choose a suitable parking area. Do not get too close to the cooling fan It is very important to choose a suitable ◆ Stop the vehicle, see p. 82 (STOPPING). (1). Even though it is not moving, they parking area, respecting the road signs could start automatically and suck NOTE...
  • Page 84 When you have to park your vehicle in a WARNING dark or badly lighted area (parking lot or Observe the instructions describing street), it is sometimes useful to leave the how to get off and on the vehicle, see p. parking lights on so that your vehicle will be 71 (GETTING ON AND OFF THE VEHI- easily visible.

  • Page 85: Placing The Vehicle On The Stand

    center stand. PLACING THE VEHICLE CAUTION ON THE STAND The lowering of the side stand is sug- ◆ Apply the load of your weight onto the le- Carefully read p. 83 (PARKING). gested, for safety reasons, in order to ver (4) (C) of the center stand and at the prevent the vehicle from falling down or same time move your center of gravity CENTER STAND...
  • Page 86 SIDE STAND CAUTION To place the vehicle on the side stand Proceed with care. while seated astride the vehicle, see p. 71 Release the handle grip (1) and the han- (GETTING ON AND OFF THE VEHICLE). dle (2) only after placing the vehicle on the side stand.

  • Page 87: Suggestions To Prevent Theft

    MAINTENANCE Carefully read p. 2 (FOREWORD) and (INTRODUCTION), p. 3 (SAFETY WARN- INGS) and (GENERAL SAFETY RULES), p. 5 (WARNINGS - PRECAUTIONS - GENERAL ADVICE). WARNING Risk of fire. Keep fuel and other flammable sub- stances away from the electrical com- ponents.
  • Page 88 When this occurs contact ry or even death. contact your Local aprilia Dealer. your Local aprilia Dealer, who will car- In all cases, personally carry out the ≈pre- ry out the operations indicated in the WARNING liminary checking operations∆...

  • Page 89: Regular Service Intervals Chart

    (6,000 km) (12,000 km) THESE OPERATIONS MAY BE CAR- [600 mi or 8 months or 16 months RIED OUT BY YOUR Local aprilia Deal- (1,000 km)] er, OR BY THE OWNER OF THE VEHI- CLE. Tightness of the battery terminals "...
  • Page 90 Every 3,750 mi (6,000 Every 7,500 mi (12,000 Component SHOULD ONLY BE PERFORMED BY Lo- [600 mi (1,000 km)] km) or 8 months km) or 16 months cal aprilia Dealer. " Rear shock absorber √ √ Transmission cables and controls "...

  • Page 91: Maintenance Record

    Engine Number see p. 95 (IDENTIFICA- TION DATA) Local aprilia Dealer Name Local aprilia Dealer Address Local aprilia Dealer Telephone Number Warranty Activation Date (from Retail Purchase Warranty Activation Form) The following is to help you keep an accu- Information recorded is not considered as Keep copies of work orders and/or receipts rate record of maintenance work.
  • Page 92 Follow Odometer Date Maintenance Performed Dealer Stamp reading Follow use and maintenance ETV mille Caponord ABS...
  • Page 93 Follow Odometer Date Maintenance Performed Dealer Stamp reading Follow use and maintenance ETV mille Caponord ABS...
  • Page 94 Follow Odometer Date Maintenance Performed Dealer Stamp reading use and maintenance ETV mille Caponord ABS...

  • Page 95: Identification Data

    FRAME NUMBER IDENTIFICATION DATA JOINTS WITH CLICK CLAMPS AND WITH SCREW-TYPE CLAMPS It is a good idea to write down the frame The frame number (A) is stamped on the and engine numbers in the space provid- right side of the fork head. CAUTION ed below.

  • Page 96: Screw-Type Clamps

    Check the conditions of the screw-type clamp and if necessary replace it with a new screw-type clamp of the same di- mensions (ask your Local aprilia Deal- er). When fastening the screw-type clamp, make sure that the joint is sufficiently stable.

  • Page 97: Air Cleaner

    ◆ Follow Remove the filter case cover (3). sary to remove the left fairing. ◆ Unscrew and remove the six screws (5) CAUTION ◆ Remove the left fairing, see p. 125 (RE- that fasten the filter cage (6). Inspect the air cleaner for tears. If the MOVING THE SIDE FAIRINGS).
  • Page 98 ◆ Correctly install filter cage (6), together with the air cleaner (7). ◆ Screw in and tighten the six screws (5). Local aprilia Dealer). WARNING CAUTION During this operation, always wear goggles CAUTION which provide your eyes with 360° protec-...

  • Page 99: Checking The Engine Oil Level And Topping Up

    If the check is carried out with cold en- gine, the oil level may temporarily lower below the “MIN” mark. This is not a problem, provided that the engine oil pressure warning light LED “ ” (A) does not come on, see p. 34 (IN- STRUMENTS AND INDICATORS TA- BLE).
  • Page 100 CAUTION If you use any container or funnel for topping up, make sure that it is perfect- ly clean. Any foreign matter getting into the oil tank may lead to severe damage. WARNING Do not add any additives or other sub- stances to the engine oil.

  • Page 101: Checking The Stand

    CENTER STAND CHECKING THE STAND Carefully read p. 87 (MAINTENANCE) Perform the following checks: and p. 104 (CHECKING THE SWITCH- WARNING ES). Make sure that the vehicle is stable. Your vehicle is equipped with: If it falls over, it may cause damage to √...

  • Page 102: Checking The Air Temperature Sensor

    SIDE STAND ◆ CHECKING THE AIR Make sure that the side stand presents no slack in either position (extended or TEMPERATURE SENSOR Perform the following checks: stowed). The vehicle is equipped with an air temper- ◆ Extend the side stand, making sure that WARNING ature sensor (5) placed on the right lower the action of the springs ensures com-...

  • Page 103: Checking The Functioning Of The Safety Switch On The Side Stand

    ◆ Check the safety switch (2) on the side WARNING vehicle. Contact your Local aprilia stand (1), see p. 104 (CHECKING THE Dealer. Exhaust gases contain carbon monox- SWITCHES). Perform the necessary ide, which is extremely poisonous if in- cleaning or repairs.

  • Page 104: Checking The Switches

    CHECKING THE SWITCHES ◆ Make sure that there is no dirt or mud on the switch. The switch pin must move Carefully read p. 87 (MAINTENANCE). freely and without interference, returning automatically to its unapplied position. Check the switches after the first 600 mi ◆...

  • Page 105: Inspecting The Front And Rear Suspensions

    Local aprilia Dealer. Have the front fork oil changed every 7,500 mi (12,000 km). Every 600 mi (1,000 km) and thereafter...

  • Page 106: Front Suspension

    FRONT SUSPENSION Have your Local aprilia Dealer change the fork oil seals after the first 18,750 mi (30,000 km) and thereafter every 14,000 mi (22,500 km). The main components of the front suspen- sion are the two hydraulic fork legs, con- nected to the frame through the steering tube, by the triple clamp and fork head.
  • Page 107 WARNING Before carrying out the following opera- tions, let the engine and the exhaust si- lencer cool down until they reach room temperature. Failure to observe this warning can lead to serious burns. CAUTION When adjusting the rear shock absorber, always start from the stiffest position.

  • Page 108: Rear Suspension

    Passenger adjustment (full load): sion damping to avoid unsteady shock for heavy load (for example: rider, passen- action. ger and luggage). If necessary, contact your Local aprilia Dealer. CAUTION Adjust the spring preload and the exten- REAR SHOCK ABSORBER ADJUSTMENT TABLE.

  • Page 109: Checking The Brake Pad Wear

    √ for the rear brake caliper, have both both braking systems. pads of the rear brake caliper replaced CHECKING WEAR OF THE BRAKE PADS by your Local aprilia Dealer. CAUTION ◆ Place the vehicle on the stand, see p. 85...

  • Page 110: Checking The Steering

    The operations necessary to this check re- cle in this condition, braking efficiency quire specific skills and therefore should be and safety are seriously compromised. carried out by your Local aprilia Dealer. This could lead to a crash with subse- quent serious injury or death. WARNING...

  • Page 111: Placing The Vehicle On The Front Support Stand

    PLACING THE VEHICLE ON THE ◆ ◆ Place the vehicle on the center stand Push (C) the stand (1) downwards until it FRONT SUPPORT STAND , see p. 85 (PLACING THE VEHICLE reaches the end of its stroke (see figure). ON THE STAND).

  • Page 112: Front Wheel

    WARNING your Local aprilia Dealer who will know other people. Check the conditions of the how to repair this damage. The disassembly and reassembly of the rim and have it replaced if it is damaged.
  • Page 113 NOTE two different diameters, pay extra care to Follow The right spacer ring (9) remains Axle clamp screw (7) (8) tightening install the right spacer ring (9) correctly. located in its seat on the wheel; but if it has torque: 7.23 ftlb (10 Nm). come out, replace it.
  • Page 114 between any part of the wheel and the ◆ Tighten the wheel nut (5) to its appropri- front fork. Do not attempt to line up the ate tightening torque. wheel and the axle clamps with your fin- Wheel nut (5) tightening torque: gers.
  • Page 115 Local aprilia ◆ Place the vehicle on the stand, see p. 85 Dealer. It may be necessary to have (PLACING THE VEHICLE ON THE Follow your dealer bleed the system, or there STAND). WARNING may be some other problem with the ◆...

  • Page 116: Rear Wheel

    Use latex, rubber or nitrile WARNING familiar with vehicle maintenance. You gloves for the maintenance operations may wish to have your Local aprilia Have the rim replaced by your Local that require contact with grease or oil. Dealer carry out these operations.
  • Page 117 Should you accidentally do this, take WARNING tion with the rear sprocket facing upwards your vehicle to your Local aprilia Dealer and in both cases secured against over- Keep your fingers well away from the who will know how to repair this damage.
  • Page 118 (ask your propriate stop pin (20) in the inner part of diameter of the sprocket (9), insert the fi- Local aprilia Dealer). the right side of the swinging arm. nal drive unit in the flexible coupling Insert the disc in the brake caliper care- holder (15).

  • Page 119: Drive Chain

    Move the wheel as far forward as possi- ◆ Install the washer (4) and tighten the serviced by your Local aprilia Dealer. It ble, to install the drive chain (8) on the wheel nut (3) finger tight. may be necessary to have your dealer rear sprocket (9).
  • Page 120 Always replace the chain and both and balancing of the wheel checked by sprockets with chain and sprockets of your Local aprilia Dealer. These are crit- identical type (ask your Local aprilia ical safety operations, and failure to ob- Dealer).
  • Page 121 – tighten the chain to decrease the components of identical type (ask your same position with regard to the refer- slack. Local aprilia Dealer). ence marks (2) and (3) on each side of The vehicle is equipped with two tensioner your vehicle.
  • Page 122 Lo- placed. care. Remember to keep your fingers cal aprilia Dealer. clear of the chain and sprocket. CAUTION NOTE Do not use the vehicle immedi-...

  • Page 123: Removing The Fuel Tank

    tem to come in contact with open REMOVING THE FUEL TANK ◆ Remove the rider saddle, see 128 (RE- flames, sparks or other heat sources. MOVING THE RIDER SADDLE). Carefully read p. 48 (FUEL) and p. 87 ◆ Unscrew and remove the two screws (1) (MAINTENANCE).
  • Page 124 (9) (10), carefully read p. 95 (JOINTS W I T H C L I C K C L A M P S A N D W I T H SCREW-TYPE CLAMPS). ◆ Release the clamps and remove the lines (9) (10) from the couplings on then fuel tank.

  • Page 125: Removing The Side Fairings

    NOTE REMOVING THE SIDE FAIRINGS ◆ Place the vehicle on the stand, see p. 85 Repeat these operations to re- (PLACING THE VEHICLE ON THE move the other side fairing (4). Carefully read p. 87 (MAINTENANCE). STAND). Upon reassembly: ◆ Unscrew and remove the three side WARNING CAUTION...

  • Page 126: Removing The Oil Pan Guard

    Unscrew and remove the two lower (6) TO THE CARBON CANISTER (7). components of identical type (ask your screws (1). Local aprilia Dealer). ◆ Mark the lines (4) (5) (6) and their cou- ◆ Unscrew and remove the two upper plings on the carbon canister, in order to screws (2).

  • Page 127: Removing

    Should you acci- dentally do this, take your vehicle to your Local aprilia Dealer who will know how to repair this damage. ◆ ✱ Remove the brake caliper (3) from the disc, leaving it attached to its line (4).

  • Page 128: Removing The Rider Saddle

    ◆ Remove the passenger saddle, see p. 44 vehicle serviced by your Local aprilia (8) is properly positioned and locked. (UNLOCKING/LOCKING THE PASSEN- Dealer. It may be necessary to have Should you forget and ride away with GER SADDLE).

  • Page 129: Rear-View Mirrors

    Periodically checking if the rear-view components of identical type (ask your If the rear-view mirror support rod (1) is mirrors are damag ed, see besid e Local aprilia Dealer). not aligned with the handlebar: (CHECKING THE REAR-VIEW MIR- ◆ Withdraw the boot (3).
  • Page 130 WARNING REMOVING THE REAR-VIEW MIRRORS WARNING NOTE Ensure that the rear-view mirror sup- After reassembly, correctly adjust the The following information may re- port rod (1) is locked in such a way that rear-view mirrors, see above (ADJUST- fer to only one rear-view mirror but is appli- MENT OF THE REAR-VIEW MIRRORS) the mirrors are secure and check the cable to both.

  • Page 131: Adjusting The Throttle Control

    One throttle cable only is equipped with Have your Local aprilia Dealer check engine stop switch located near the the play adjuster. the throttle cables after the first 600 mi throttle grip on the right handlebar.

  • Page 132: Adjusting The Cold Start (Choke) Control

    Local aprilia Dealer. roads, or in any kind of competition. Do not start the engine in closed or bad- ly-ventilated rooms.
  • Page 133 TO REMOVE THE SPARK PLUG CAUTION Never disconnect the spark plug cap with the engine running, since you may get an electric shock from the ignition system. Do not reverse the position of the two spark plug caps. Do not remove the two spark plug caps at the same time.
  • Page 134 TO INSTALL THE SPARK PLUG CAUTION ◆ With the gasket (12) in place, screw the When replacing a spark plug, always spark plug into the head finger tight. check the pitch (9) and length (10) of the ◆ Tighten the spark plug with the special thread.

  • Page 135: Changing Fuses

    If this occurs, take the ◆ Place the vehicle on the stand, see p. 85 vehicle to your Local aprilia Dealer. √ parking lights; (PLACING THE VEHICLE ON THE √ direction indicators; use and maintenance ETV mille Caponord ABS...
  • Page 136 Turn the ignition switch (3) in the ≈ ∆ using your vehicle. Take it to your Local CAUTION (OFF) position. aprilia Dealer for repair and service. Extract the fuses one by one, in such a ◆ Remove the passenger saddle, see p. 44 NOTE...

  • Page 137: Removing The Fuse Box Cover

    Since the battery gives off explosive hy- drogen gas, especially when it is being 6 7 8 9 charged, when you are charging a bat- 140 160 tery, make sure that the room is proper- x1000 Km/h ly ventilated. Do not inhale the gases re- leased during charging.

  • Page 138: Battery Storage

    30A fuses (2), economically available from your Local see p. 135 (CHANGING FUSES). This aprilia Dealer, and will ensure that your will prevent the discharge of the battery battery always remains in tip top condition. caused by the slight current consump- ◆...

  • Page 139: Checking And Cleaning The Terminals

    CHECKING AND CLEANING THE TERMINALS Carefully read p. 137 (BATTERY). ◆ Make sure that the ignition switch (1) is in ≈ ∆ (OFF) position. ◆ Remove the saddle, see p. 44 (UNLOCK- ING/LOCKING THE PASSENGER SAD- DLE). ◆ Remove the red rubber boot (3). ◆...

  • Page 140: Recharging The Battery

    ◆ RECHARGING THE BATTERY Charge at voltage amperage and time stated below. Carefully read p. 137 (BATTERY). Tipe of Voltage Amperage Time WARNING recharge (hours) This battery is completely sealed. Do Normal 8 √ 10 not attempt to remove the caps. Quick There is never any need to add water to this battery.

  • Page 141: Headlight Beam

    The headlight comprises two reflector Upon each light beam adjustement en- HEADLIGHT BEAM units: sure that: WARNING – the light beam of the two units is uni- √ right reflector unit (1); form; Do not use the vehicle if the lights are √...
  • Page 142 To the right reflector unit (1) adjuste- Follow Turn the knob clockwise (C) to adjust the ment: ◆ Sit astride the vehicle, see p. 71 (GET- beam lower (downwards). TING ON AND OFF THE VEHICLE). NOTE Turn the knob counterclockwise (D) to ad- Working from the right upperside ◆...
  • Page 143 Follow just the beam to the left. WARNING ADJUSTING THE HEADLIGHT BEAM To the left reflector unit (2) adjustement: Ensure that: HORIZONTALLY NOTE – the horizontal adjustment of the head- Working from the left upperside Carefully read p. 141 (HEADLIGHT light beam is correct;...

  • Page 144: Bulbs

    Do not leave fingerprints on the bulb, bulbs need changing, please see your Lo- poorer visibility that inevitably results cal aprilia Dealer. This operation is difficult since these may cause its overheating from darkness. Failure to observe this and consequent breakage.

  • Page 145: The Headlight Bulbs

    To change the bulbs: CHANGING naling). THE HEADLIGHT BULBS If one of the two low/high beam bulbs is ◆ Place the vehicle on the stand, see p. 85 burned out, the second low/high beam bulb (PLACING THE VEHICLE ON THE Carefully read p.
  • Page 146 NOTE NOTE PARKING LIGHT BULB (CENTRAL UP- Working from the right upperside Be sure to maintain the same ori- PER POSITION) (A) of the rear part of the fairing. entation as the old bulb when you install the new bulb. Do not try to force the bulb, it ◆...

  • Page 147: Changing The Front Direction Indicator Bulbs

    Always replace the components with ter with a mild soap. components of identical type (ask your NOTE Local aprilia Dealer). Before changing a bulb, check the fuses, see p. 135 (CHANGING FUSES). ◆ Correctly place the gasket (4) in its seat.

  • Page 148: The Rear Light Bulbs

    The stoplight is particularly impor- (PLACING THE VEHICLE ON THE components of identical type (ask your tant to prevent other vehicles from STAND). Local aprilia Dealer). rearending you. Obviously, failure to comply with these instructions could ◆ Correctly place the rear light gasket (4)

  • Page 149: Changing The Rear Direction Indicator Bulbs

    temperature. Failure to observe this warning can lead to serious burns. ◆ Unscrew and remove the screw (1). NOTE While removing the lens, use ex- tra care to be sure that you do not break the key. ◆ Remove the lens (2). ◆...

  • Page 150: Transport

    WARNING TRANSPO Before carrying out the following opera- tions, let the engine and the exhaust si- lencer cool down until they reach room temperature. Failure to observe this warning can lead to serious burns. ◆ Move to the rear side of the vehicle. NOTE Working from the inside of the lower part of the license plate holder (5).

  • Page 151: Draining The Fuel Tank

    CLEANING Clean your vehicle regularly. Your vehicle will look better and work better if you keep it clean. You will find you will need to clean it more frequently if it is used in the follow- ing conditions: √ Polluted areas (cities and industrial areas). √...

  • Page 152: Long Periods Of Inactivity

    Never use a high pressure washer, a steam cleaner, or an air augmented wa- ter jet to clean your vehicle, especially the wheel hubs, handlebar controls, brake reservoirs and cylinders, instru- ments, electrical components or ex- haust silencer. Such cleaning machinery will force wa- ter into critical portions of your vehicle, which could damage your vehicle through corrosion or short circuiting.
  • Page 153 Failure to observe this warning can lead available, you may wish to add a propri- to serious burns. etary fuel storage additive, available from your Local aprilia Dealer or auto- ◆ Place a plastic bag over the outlet pipe of mobile supply stores. Follow the instruc- the muffler, and tape or tie it tight.

  • Page 154: Technical Data

    TECHNICAL DATA DIMENSIONS Max. length ..........90.16 in (2,290 mm) Max. width............ 34.49 in (876 mm) Max. height (front part of the fairing included) ....56.54 in (1,436 mm) Seat height........... 32.28 in (820 mm) Wheelbase........... 60.79 in (1,544 mm) Min.
  • Page 155 CAPACITY Fuel (reserve included)......... 6.60 US gal (25 Fuel reserve ..........1.32 Ø 0.26 US gal (5 Ø 1 Engine oil: √ oil change ..........4.54 US qt (4,300 cm>) √ oil and oil filter change ......4.75 US qt (4,500 cm>) Fork oil (for each fork leg) ........
  • Page 156 FUEL SUPPLY Fuel............... unleaded petrol minimum octane rating (M+R)/2 method 90 FRAME Type..............two-beam frame with light alloy cast elements and extruded elements Rake ..............28° Trail (with front tire 110/80) ........5.08 in (129 mm) SUSPENSIONS Front: √ type ..............telescopic adjustable fork with hydraulic operation, fork leg Æ...
  • Page 157 IGNITION Ignition timing..........12.25° Ø 2° at 2,800 rpm SPARK PLUGS Number per cylinder ........Standard............NGK R DCPR9E Spark plug gap ..........0.024 √ 0.028 in (0.6 √ 0.7 mm) Resistance............ 5 kΩ ELECTRIC Battery ............12 V - 12 Ah SYSTEM Main fuses (# 2 fuses) ........

  • Page 158: Lubricant Chart

    LUBRICANT CHART Engine oil (recommended EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15W - 50. As an alternative to the recommended oils, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.

  • Page 159: Official Dealers And Service Centers

    When you demand aprilia Original Parts, you are purchasing products that have been developed and tested as early as the vehicle design stage. aprilia Original Parts systematically undergo strict quality control procedures to ensure total reliability and long service life.

  • Page 160: Importers

    Importers APRILIA via G. Galilei, 1 - 30033 Noale (VE) Italy Tel. +39(0)41 5829111 - Fax +39(0)41 441054 - Servizio Clienti aprilia +39(0)41 5079821 APRILIA WORLD SERVICE UK branch 15 Gregory Way - SK5 7ST Stockport - Cheshire Tel. 0044-161 475 1800 - Fax 0044-161 475 1825 - Email: massimo_granata@aprilia.com...
  • Page 161 Tel. 0032-9-2829410 - Fax. 0032-9-2810012 - Email: Kurt_Derynck@rad.be T.M.P. Hammervej 32 - 7900 - Nikobing Mors Tel. 0045-97-722233 - Fax. 0045-97-722143/33 - Email: thomas@aprilia.dk TUONTI NAKKILA OY P.o.B. 18 - 29250 - Nakkila Tel. 00358-2-5352500 - Fax. 00358-2-5372793 - Email: satu.saarinen@aprilia.fi RO GROUP INT.(sede operativa)

  • Page 162: Importers

    Tel. 0027-11-7868486 - Fax. 0027-11-7868482 - Email: motovelo@betech.co.za APRILIA DE MEXICO, SA. de CV. San Jeromino - 64640 - 552 Monterrey N.L. Tel. 0052-818333-4493 - Fax. 0052-818348-9398 - sbertu Email: javier@aprilia.com.mx BIKE KOREA CO. LTD. YeungSoo Bldg. 302 #206-25, Ohjang-Dong, Chung-Ku Seoul Tel.

  • Page 163: Importers

    Importers BERMUDA INTERNATIONAL LTD. 235, Middle Road - Southampton Tel. 001-4412385050 - Email: eurospice@ibl.bm MAJESTIC AUTO LIMITED 10th KM Stone - G.T. Road - P.O.Dujana - 203207 Dadri - Ghaziabad UP Tel. 0091-98100-19315 - Fax. 0091-98100-19300 MOTOMANIA, S.A. BOULEVARD LIBERACION 4-19, ZONA 9 1009 GUATEMALA CITY Tel.

  • Page 164: Wiring Diagram Etv Mille Caponord Abs

    WIRING DIAGRAM ETV mille Caponord ABS =CONNECTOR 1 6 7 8 aprilia =CONNECTOR 2 PASSING 100 140 160 =CONNECTOR 3 LOCK T AIR x 1000 VEGLIA BORLETTI SERVICE TIME ngine km/h ontrol MODE iagnosis Bi/N Bi/N Bi/N Bi/B Bi/B G/Gr...

  • Page 165: Wiring Diagram Key Etv Mille Caponord Abs

    WIRING DIAGRAM KEY ETV mille Caponord ABS 1) Multiple connectors. 16) Fuel pump relay. From ignition switch to: 56) Front left direction 2) Speed sensor. 17) Rear right direction √ rear stop switch (front indicator. 3) High beam relay. indicator. stop switch, stop light);...
  • Page 166 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance ETV mille Caponord ABS...
  • Page 167 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance ETV mille Caponord ABS...
  • Page 168 √ Do not dispose of oil, fuel, polluting substances and components in the envi- ronment. √ Do not keep the engine running if it isn»t necessary. √ Avoid disturbing noises.

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