APRILIA RSV MILLE R TUONO - 2003 Manual
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APRILIA RSV MILLE R TUONO - 2003 Manual

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Summary of Contents for APRILIA RSV MILLE R TUONO - 2003

  • Page 1 8104702...

  • Page 2: Foreword

    MAIN INDEPENDENT CONTROLS given in this manual. If you have any questions about your vehicle, contact your local aprilia Dealer, as he will have the First edition: april 2003 very latest technical information available from the factory. Reprint:...

  • Page 3: Safety Warnings

    accidentally get gasoline into your eyes, flush SAFETY WARNINGS GENERAL SAFETY RULES with large quantities of cool, clear water and The following precautionary warnings are CARBON MONOXIDE immediately seek professional medical used throughout this manual in order to assistance. If it is necessary to run the engine in order convey the following messages: to carry out maintenance operation, make Safety Warning: When you see...

  • Page 4: Brake Fluid

    BRAKE FLUID seek professional medical assistance. BATTERY HYDROGEN GAS Should you accidentally splash clutch AND ELECTROLYTE fluid into your eyes, flush with a large quantity of cool, clear water and Brake fluid is extremely poisonous. Do not immediately seek professional medical ever allow brake fluid to be ingested or The battery gives off noxious and assistance.

  • Page 5: Warnings - Precautions - General Advice

    INFORMATION ON THE NOISE W A R N I N G S - P R E C A U T I O N S - AND EXHAUST GAS EMISSION GENERAL ADVICE CONTROL SYSTEM ROAD REGULATIONS AND USE OF THE VEHICLE 25,*,1 2) 7+( (0,66,216 7KLV YHKLFOH KDV EHHQ GHVLJQHG DQG SURGXFHG IRU XVH RQO\ RQ SDYHG URDGV ,W...

  • Page 6: Vehicle Identification Number (V.i.n.) (Frame Number)

    This product should be checked for (FRAME NUMBER) IDENTIFICATION NUMBER repair or replacement if the vehicle Every vehicle produced by aprilia receives Description of the vehicle identification noise has increased significantly a vehicle identification number (V.I.N.) number (V.I.N.), stamped on the steering through use.
  • Page 7 DIGIT MEANING 1) Manufacturer’s identification alphanumeric code. 2) Vehicle type. 3) Model. 4) Country for which the vehicle is intended. 5) #= Check digit number. 6) Model year. FOR STATE OF CALIFORNIA ONLY: FOR STATE OF CALIFORNIA ONLY: 7) Assembling factory designation (N = NOALE-VE- , S = SCORZÉ...

  • Page 8: Position Of The Warning Adhesive Labels

    POSITION OF THE WARNING ADHESIVE LABELS use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 9: Warning Adhesive Labels Chart

    WARNING ADHESIVE LABELS CHART Ref. Description Ref. Description NOT PROVIDED FOR 49 STATES. FOR STATE OF CALIFORNIA ONLY. to be continued use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 10 Ref. Description Ref. Description FOR STATE OF CALIFORNIA ONLY. to be continued use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 11 Ref. Description FOR STATE OF CALIFORNIA ONLY. Muffler stamping. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 12: Position Of The Warning Adhesive Labels

    POSITION OF THE WARNING ADHESIVE LABELS use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 13: Warning Adhesive Labels Chart

    WARNING ADHESIVE LABELS CHART Ref. Description Ref. Description NOT PROVIDED FOR 49 STATES. FOR STATE OF CALIFORNIA ONLY. to be continued use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 14 Ref. Description Ref. Description FOR STATE OF CALIFORNIA ONLY. to be continued use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 15 Ref. Description FOR STATE OF CALIFORNIA ONLY. Muffler stamping. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 16: California Evaporative Emission System

    25) Warm air inlet (from one way valve) 26) Warm air inlet (to carbon canister) NOTE In case of malfunction of the fuel system, contact your local aprilia Dealer. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 17: California Evaporative Emission System

    25) Warm air inlet (from one way valve) 26) Warm air inlet (to carbon canister) NOTE In case of malfunction of the fuel system, contact your local aprilia Dealer. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 18: Aprilia S.p.a. - Emission Control System Warranty Statement

    Board at P.O. Box 8001, 9528 Telstar repaired or replaced by aprilia. This is your Avenue, El Monte, CA 91734-8001. em is s i o n c o n t r ol s y s t e m D E F E C T S WARRANTY.

  • Page 19: Control System

    An emergency situation occurs aprilia s.p.a., Via G. Galilei, 1, 30033 United States of America in compliance when an authorized aprilia dealer is Noale (VE) Italy (hereinafter “aprilia”)
  • Page 20 ,1)250$7,21 VI.$'',7,21$/ DSULOLD DSULOLD III./,0,7(' /,$%,/,7< DSULOLD DSULOLD DSULOLD VSD DSULOLD 86$ ,QF aprilia GHDOHU DSULOLD DSULOLD IV./(*$/ 5,*+76 DSULOLD DSULOLD XVH DQG PDLQWHQDQFH 569 PLOOH 78212  569 PLOOH 5 78212...

  • Page 21: General Instructions

    , s e e p . 5 1 homologation (I, UK, A, …). (LUGGAGE RACK FASTENINGS). and are to be supplied to the aprilia Failure to heed these warnings may lead Official Dealer as reference data for the...

  • Page 22: Table Of Contents

    BULBS ................132 WARRANTY STATEMENT ..........18 PARKING................81 CHANGING THE FRONT AND REAR DIRECTION APRILIA S.P.A. - LIMITED WARRANTY ON EMISSION POSITIONING THE VEHICLE ON THE STAND ....82 INDICATOR BULBS ............134 CONTROL SYSTEM ............19 SUGGESTIONS TO PREVENT THEFT ......82 CHANGING THE TAIL LIGHT BULB........
  • Page 23 safe drive...

  • Page 24: 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 vehicle. Two wheeled vehicles obviously do not provide some of the protection provided by automobiles, therefore it is essential that...
  • Page 25 Observe all rules of the road. Particularly Avoid obstacles that could damage the Always ride with both hands on the pay attention to all warning, regulatory and vehicle or make you lose control. handlebars and feet on the footrests. informational signs. Do not tailgate, do not attempt to increase Never shift gear without using the clutch, if Avoid showing off (i.e., popping wheelies).
  • Page 26 Use only the vehicle’s specific fuels and lubricants indicated in the “LUBRICANT Your aprilia dealer is ready and able to CHART”; check the oil, fuel and coolant help you with any safety problems that you levels regularly.
  • Page 27 Have your vehicle repaired only with This vehicle was not designed to be Do not modify any of the safety equipment original parts, and use only original aprilia equipped with a sidecar or to be used to of your vehicle, especially such safety or aprilia approved accessories.
  • Page 28 Never race other vehicles with your Always ride at the appropriate speed and Gradually open and close the throttle, to vehicle. 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 29: Clothing

    Always observe posted and statutory CLOTHING before they turned directly into your path. speed limits, but do not assume that you Ride alert! Before riding your vehicle, ensure that your can ride as fast as the speed limit under all riding gear is in good condition.

  • Page 30: Accessories

    Official Dealer. Do not hang anything from your vehicle use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 31 handlebars, fenders, or forks, because this especially on acceleration. Therefore, you Never carry loosely packaged items, make will upset the handling of your vehicle, and should avoid hard acceleration and hard sure that everything that you carry on your could prevent you from avoiding an braking.

  • Page 32: Location Of Key Components

    LOCATION OF KEY COMPONENTS 1) Left rear-view mirror 8) Passenger left footpeg 14) Engine oil tank 21) Non-adjustable steering 2) Engine oil filter (snaps closed/open) 15) Engine oil level damper (adjustable 9) Drive chain 16) Engine oil tank cap steering damper 3) Left side body panel 4) Rider seat 10) Rear swinging arm...
  • Page 33 1) Glove/tool kit compartment 8) Fuel tank filler cap 15) Right side fairing 23) Rider right footpeg 2) Passenger seat 9) Air cleaner 16) Right radiator guard 24) Rear shock absorber 3) Passenger grab strap 10) Right rear-view mirror 17) Nylon protection 25) Passenger right footpeg 4) Electronic control unit 11) Front brake fluid reservoir...

  • Page 34: Location Of Key Components

    LOCATION OF KEY COMPONENTS 1) Left rear-view mirror 8) Passenger left footpeg 14) Engine oil tank 21) Adjustable steering damper 2) Engine oil filter (snaps closed/open) 15) Engine oil level 22) Headlight 3) Left side body panel 9) Drive chain 16) Engine oil tank cap 23) Front fairing 4) Rider seat...
  • Page 35 1) Glove/tool kit compartment reservoir cap 14) Warning horn 21) Rear brake pump 2) Passenger seat 8) Fuel tank filler cap 15) Right side fairing 22) Rear brake control lever 3) Passenger grab strap 9) Air cleaner 16) Right radiator guard 23) Rider right footpeg 4) Electronic control unit 10) Right rear-view mirror...

  • Page 36: Arrangement Of The Instruments/Controls

    ARRANGEMENT OF THE INSTRUMENTS/CONTROLS 1) Ignition switch/steering lock ( 7) Clutch lever 2) Cold start lever ( ) 8) Instruments and indicators 3) Dimmer switch ( 9) Front brake lever 4) Direction indicator switch ( 10)Throttle grip 5) Horn push button ( 11)Start push button ( ) 6) Passing push button ( )/LAP push button (multifunction)

  • Page 37: Instruments And Indicators

    INSTRUMENTS AND INDICATORS 1) Green direction indicator warning light ( 7) Right multifunction digital display (coolant temperature - clock - 2) Blue high beam warning light ( battery voltage - chronometer - diagnostic) 3) Revolution counter 8) Red engine oil pressure warning light LED ( 4) Red line warning light LED (max) 9) Green neutral indicator warning light ( ) 5) Amber low fuel warning light ( )

  • Page 38: Instruments And Indicators Table

    Comes on whenever the ignition switch is in position “ ” and the engine is not running, thus checking the functionality of the LED. If the light LED does not come on in this phase, contact an aprilia Official Dealer. Engine oil pressure warning light If the engine oil pressure warning light LED “...
  • Page 39 " see p. 40 (MUL- and check the coolant level, see p. 63 (COOLANT). If the writing “ ” is still TIFUNCTION displayed after the coolant level has been checked, contact an aprilia COMPUTER). Official Dealer. Multifunction digital display If the maximum allowed temperature (248 °F -...

  • Page 40: Multifunction Computer

    When the ignition key (1) is rotated to right display. In this case contact an – the coolant temperature is set in °C; aprilia Official Dealer, who will carry out – the digital clock is set to zero; position “ ”, the following warning lights –...
  • Page 41 distance “trip 2” (17): with the odometer set ◆ Press the push button to change the the distance “trip 1” (10), press the push on the “AVS” function, press the push unit of measurement from “km” to “mi” button for about one second. The button for about 1 second.
  • Page 42 NOTE It is not possible to set the red SETTING THE RED LINE THRESHOLD For the adjustment, proceed as follows: line at values lower than 2000 rpm or (WITH ENGINE OFF ONLY) higher than 12000 rpm. ◆ Press the push button , release it and W h e n t h e m a x i m u m r p m s e t i s press it...
  • Page 43 If the writing “ ” is displayed with a temperature below 266°F (130°C), there may be a failure of the electric circuit. In this case, contact an aprilia Official use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 44 SETTING THE HOUR SETTING THE MINUTES SETTING °F OR °C ◆ ◆ ◆ When the push button is pressed for When the push button is pressed for When the push button is pressed for the second time, the hour segments (21) the third time, the minute segments (22) the fourth time, the segments of the start blinking in the lower part of the right...
  • Page 45 ; i m m e d i a t e l y seconds. contact an aprilia Official Dealer. use and maintenance RSV mille TUONO...

  • Page 46: Main Independent Controls

    MAIN INDEPENDENT CONTROLS 3) DIMMER SWITCH ( When it is in position “ ” the parking lights, the dashboard light and the low beam are always on. When it is in position “ ”, the high beam comes on. 4) PASSING PUSH BUTTON ( )/LAP PUSH BUTTON (multifunction) N O T E...

  • Page 47: Controls At The Right Hand Grip

    When, for emergency, the vehicle has come to rest after throttle grip is released. Contact your local aprilia Dealer for stopping the engine with the engine stop switch, turn the repairs.

  • Page 48: 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. Neither the It is IGNITION SWITCH STEERING LOCK engine, nor the possible to...

  • Page 49: Steering Lock

    ◆ Press turn STEERING LOCK OPERATION counterclockwise (leftwards), steer the handlebar slowly until the key (2) To leave the parking lights on: reaches position “ ” (LOCK). ◆ Lock steering, beside ◆ Remove the key (2). Never attempt to place the ignition (STEERING LOCK) without extracting s w i t c h i n t h e l o c k e d “...

  • Page 50: Unlocking/Locking The Passenger Seat

    To lock the seat (2), proceed as follows: ◆ Introduce its front part under the passenger grab strap (3). ◆ Position the seat and press it, making the lock snap. Before leaving, make sure that the seat (2) is properly locked. U N L O C K I N G / L O C K I N G T H E GLOVE/TOOL KIT COMPARTMENT...

  • Page 51: Luggage Rack Fastenings

    The tool kit (1) includes: – 3, 4, 5, 6 mm bent hexagon spanners (2); – 8 – 10 mm double fork spanner (3); – 11 – 13 mm double fork spanner (4); – 22 mm simple box spanner (5); –...

  • Page 52: Special Tools

    SPECIAL TOOLS To perform some specific operations, it is advisable to use the following special tools (to be requested to an aprilia Official Dealer): Tool Operations Pins (1) for the rear service stand, see p. To position the vehicle 96 (ASSEMBLING...

  • Page 53: Main Components

    MAIN COMPONENTS FUEL G a s o l i n e p o i s o n o u s a n d carcinogenic and contains chemical substances that cause birth defects and o t h e r r e p r o d u c t i v e p r o b l e m s . I f Gasoline is extremely flammable and in gasoline should be accidentally spilled s o m e...
  • Page 54 ◆ Lift the little cover (1). ◆ Insert the key (2) in the cap lock (3). ◆ Turn the key (2) clockwise, pull it and After refueling, replace the fuel filler cap Make sure that the fuel filler cap (4) is open the fuel filler cap (4).

  • Page 55: Lubricants

    Use high-quality 15W – 50 oil, see p. 144 (LUBRICANT CHART). In case of oil leakage do not ride your vehicle. Before using the vehicle, have it repaired by your local aprilia Dealer. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 56: Brakes

    Dealer before riding. Wet conditions seriously degrade the The rear brake system is equipped with a performance of your brakes. When the...

  • Page 57: Disc Brakes

    Have the brake discs checked by your The following information refers to a single they must always be perfectly working; local aprilia Dealer after the first 625 mi braking system, but is valid for both. check them before every trip.

  • Page 58: Front Brake

    ◆ Raise and remove the cover (3) together with the screws (1) and the gasket (4). In order not to spill the brake fluid while topping up, do not shake the vehicle. Do not put additives or other subtances into the fluid. If you use a funnel or other similar items, make sure that they are perfectly clean.

  • Page 59: Rear Brake

    REAR BRAKE If the fluid does not reach the “MIN” mark: Do not operate the rear brake pedal with CHECKING THE SYSTEM the reservoir filler cap (2) removed. This NOTE When the disc pads wear out, the level Carry out these checks only on a will cause brake fluid to squirt out and of the fluid decreases progressively to firm, flat surface such as a concrete garage...
  • Page 60 Dealer. It may be necessary to have your dealer Do not fill the reservoir to “MAX” with bleed the system, or there may be some worn pads;...

  • Page 61: Clutch Fluid - Recommendations

    62 (CLUTCH); have it If the “feel” or position of the clutch changed by your local aprilia Dealer lever changes, this may be due to some T h e c l u t c h c o n t r o l f l u i d m u s t b e every two years.

  • Page 62: Clutch

    Top up the reservoir (1) by adding clutch aprilia Dealer every 4687 mi (7500 km). f l u i d , s e e p . p . 1 4 4 ( L U B R I C A N T...

  • Page 63: Coolant

    Have the coolant changed by your local Have the coolant changed by your local off the cooling system. This will reduce aprilia Dealer. aprilia Dealer every 2 years. damage to the engine. The coolant is made up of 50% water and 50% antifreeze.
  • Page 64 (1) is included coolant. that there are no leaks in the circuit. between the “FULL” and “LOW” marks, Have it repaired by your local aprilia by checking through the appropriate slot on the right fairing”. Dealer. Do not put additives or other subtances FULL = maximum level into the fluid.

  • Page 65: Tires

    Dealer or by a dampened and is therefore transmitted indicators.

  • Page 66: Engine Oil

    In case of leakages or malfunctions, the engine oil pressure in the circuit is contact your local aprilia Dealer. insufficient. Periodically check the engine oil level, see In this case, check the engine oil level, p.

  • Page 67: Adjusting The Front Brake Control Lever And The Clutch Control Lever

    (3) until the desired wheel rotates freely with released number is positioned in correspondence brake. with the reference arrow. Check the braking efficiency. If necessary, contact your local aprilia Dealer. use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 68: Adjusting The Rear Brake Control Lever And The Gear Shift Lever

    Position the vehicle on the stand, see p. If the noise produced by the exhaust 82 (POSITIONING THE VEHICLE ON system increases, immediately contact THE STAND). your local aprilia Dealer. ◆ Partially unscrew the screw (1). ◆ Rotate the eccentric (2) in order to find the optimal position of the pedal (3).

  • Page 69: Instructions For Use

    INSTRUCTIONS FOR USE ’ G E T T I N G O N A N D O F F T H E VEHICLE Do not apply the load of your weight or of the passenger’s weight onto the side The instructions below must be followed with stand.
  • Page 70 I n a n y c a s e , p e r f o r m a c o n t r o l l e d movement with your right leg, which must Make sure that the parking surface is avoid striking and safely pass the rear part free from obstacles, firm and flat.

  • Page 71: Preliminary Checking Operations

    Do not hesitate to consult your local performance levels; immediately contact a collision with another vehicle, or an aprilia Dealer in case there is something your local aprilia Dealer. upset. y o u d o n o t u n d e r s t a n d a b o u t t h e...
  • Page 72 Never use your vehicle if the throttle does not automatically fully return to the idle position when the throttle grip is released. Contact your local aprilia Dealer for repairs. Failure to heed this warning can lead to a serious accident and subsequent injury or even death.

  • Page 73: Preliminary Checking Operations

    PRELIMINARY CHECKING OPERATIONS Component Check Page Check the functioning, the idle stroke of the control levers, the fluid level and make sure there are no leaks. 56, 57, 58, Front and rear disc brakes Check the wear of the pads. 59, 118 If necessary, top up the fluid reservoir.

  • Page 74: Starting

    At this point: 10 a – The engine oil pressure LED warning light (red) " " (4) comes on on the 10 b dashboard and remains on until the engine has been started; – the red line warning light LED “max” (red) (5) comes on on the dashboard for approximately three seconds and the revolution counter pointer (6) shifts to the...
  • Page 75 The red line threshold is set at 6000 rpm ◆ Press the start push button “ ” (17) substances and the consumption of by aprilia. Increase the threshold without accelerating and release it as fuel, warm the engine up by proceeding gradually as you get acquainted with soon as the engine starts.
  • Page 76 (18). levels; immediately contact your local If the engine starts: aprilia Dealer. ◆ Release the start push button “ ” (17) and the throttle grip (18). ◆...

  • Page 77: Departure And Drive

    DEPARTURE AND DRIVE To leave: ◆ Start the engine, see p. 74 (STARTING). If you drive without passenger, make ◆ Adjust the inclination of the rear-view sure that the passenger footpegs are mirrors correctly. This vehicle is considerably powerful folded. and must be used gradually and with While riding, keep your hands on the the greatest care.
  • Page 78 I n t h i s c a s e , s t o p t h e e n g i n e immediately and contact your local aprilia Dealer. The downshifting should be carried out in the following situations: ◆...
  • Page 79 Dealer. force considerably, thus running the r i s k o f l o c k i n g o n e w h e e l a n d Do not turn the ignition switch to consequently losing grip.

  • Page 80: Running-In

    After the first 625 mi (1000 km), have ensure its duration and correct functioning. obstacle or variation of the ground. your local aprilia Dealer carry out the If possible, drive on hilly roads and/or checks indicated in the column “After...

  • Page 81: Stopping

    The fall or excessive inclination of the vehicle may cause the fuel to flow out of the tank. The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive. Do not apply the load of your weight or of the passenger’s weight onto the side stand.

  • Page 82: Positioning The Vehicle On The Stand

    S U G G E S T I O N S T O P R E V E N T THEFT NEVER leave the ignition key inserted and always use the steering lock. Park the vehicle in a safe place, possibly in a garage or a protected place.

  • Page 83: Maintenance

    Dealer who has all the latest d e s t r o y e d , w h e r e a s i f t h e y a r e...
  • Page 84 4,650 mi (7,500 km), the word “SERVICE” (3) appears on the right display. When this occurs contact your local aprilia Dealer, who will carry out the operations indicated in the regular service intervals chart, see p. 85 ( R E G U L A R S E R V I C E I N T E R V A L S CHART).

  • Page 85: Regular Service Intervals Chart

    OPERATIONS TO BE CARRIED OUT BY km ]) months THE local aprilia Dealer (WHICH CAN Spark plugs (*) B E C A R R I E D O U T E V E N B Y T H E USER).
  • Page 86 OPERATIONS TO BE CARRIED OUT BY After running- Every 4687 mi Every 9375 mi THE local aprilia Dealer. Component in [625 mi (7500 km) or 12 (15000 km) or (1000 km)] months 24 months Rear shock absorber = check and clean, adjust, lubricate or...

  • Page 87: Maintenance Record

    Engine Number see p. 91 (IDENTIFICATION 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 accurate record of maintenance work.
  • Page 88 continued ➤ Odometer Date Maintenance Performed Dealer Stamp reading to be continued ➤ use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 89 continued ➤ Odometer Date Maintenance Performed Dealer Stamp reading to be continued ➤ use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 90 continued ➤ Odometer Date Maintenance Performed Dealer Stamp reading to be continued ➤ use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 91: Identification Data

    The frame number can be used for the For the removal it is sufficient to use simple requested to your local aprilia Dealer. purchase of spare parts. pliers, while for the installation it is necessary...
  • Page 92 ◆ The level is correct when the oil almost reaches the “MAX” mark. Never exceed the “MAX” mark, nor leave the oil below the “MIN” mark, in order to avoid serious damage to the engine. If necessary, top up the engine oil by proceeding as follows: ◆...

  • Page 93: Changing The Engine Oil And The Oil Filter

    The engine oil and the oil filter change particularly careful, in order to avoid operations may be difficult for unskilled burns. operators. If necessary, contact your aprilia ◆ Remove the lower fairing, see p. 107 Official Dealer. (REMOVING THE LOWER FAIRING).
  • Page 94 CLEANING THE ENGINE OIL FILTER ON new one having the same dimensions, and let it idle for about one minute, in THE TANK to be requested to an aprilia Official order to ensure the filling up of the Dealer. N O T E P e r f o r m t h e m a i n t e n a n c e engine oil circuit.

  • Page 95: Air Cleaner

    Upon reassembly, before positioning the filter case cover (3), make sure that you have not left the cloth or other objects inside the filter case (6). Make sure that the filtering element is positioned correctly, in such a way as to prevent non-filtered air from entering.

  • Page 96: Assembling The Pins For The Rear Service Stand

    POSITIONING THE VEHICLE ON CHANGING THE REAR SERVICE STAND Make sure that the vehicle is stable. ◆ Assemble the two pins (7), see p. 96 POSITIONING THE VEHICLE ON Do not use filters that have already (ASSEMBLING THE PINS FOR THE THE FRONT SERVICE STAND been used.

  • Page 97: Front Wheel

    The spacer (6) remains in its seat on the ◆ Put a support (1) under the tire, in such a If necessary, contact your aprilia wheel; if it comes off, reposition it way as to keep the wheel in its position Official Dealer.
  • Page 98 ◆ Tighten the two wheel shaft clamp aprilia Official Dealer, in order to avoid screws (4) (right side). accidents that may be harmful for you The arrow on the wheel side indicates W h e e l s h a f t c l a m p s c r e w d r i v i n g and/or other people.

  • Page 99: Front Brake Calipers

    While disassembling and reassembling functioning of the braking system. In this case consult your aprilia Official the wheel, be careful not to damage the Dealer, who will carry out the proper brake lines, the discs and the pads.

  • Page 100: Front Brake Calipers

    Remove the front service stand , see causing the outflow of the brake fluid. p. 96 (POSITIONING THE VEHICLE ON In this case consult your aprilia Official While disassembling and reassembling THE FRONT SERVICE STAND Dealer, who will carry out the proper...

  • Page 101: Rear Wheel

    Check the conditions of the wheel rim ◆ and change it if it is damaged. Withdraw the wheel shaft (5) from the left If necessary, contact your aprilia side. NOTE Official Dealer. To remove the rear wheel it is...
  • Page 102 In this case The removal of the final drive unit parallel to the wheel axis, inserting the consult your aprilia Official Dealer, is not necessary if the wheel is in the cush drive rubbers corresponding seats on...
  • Page 103 (17) Do not introduce your fingers to align aprilia Official Dealer, in order to avoid in the inner part of the rear swinging the holes. accidents that may be harmful for you arm right section.

  • Page 104: Drive Chain

    (2-3) are provided, which contact an aprilia Official Dealer. To can be seen inside the chain tensioner To change the chain, contact an aprilia prevent the risk of seizures, lubricate seats on the rear swinging arm sections, Official Dealer, who will ensure you t h e c h a i n f r e q u e n t l y , s e e p .
  • Page 105 If this is not possible, contact an rings of the chain. aprilia Official Dealer, who will provide NOTE for changing the chain. Do not use the vehicle soon after ◆...

  • Page 106: Removing The Rider Seat

    REMOVING THE RIDER SEAT LIFTING THE FUEL TANK Remove the passenger seat, see p. 5 0 ( U N L O C K I N G / L O C K I N G T H E ◆ Position the vehicle on the stand, see p. Carefully read p.

  • Page 107: Removing The Side Fairings

    REMOVING THE SIDE FAIRINGS REMOVING THE LOWER FAIRING R E M O V I N G T H E S I D E B O D Y PANELS Carefully read p. 83 (MAINTENANCE). Carefully read p. 83 (MAINTENANCE). ◆ Remove the rider seat, see p. 106 NOTE To remove the lower fairing, it is (REMOVING THE RIDER SEAT).

  • Page 108: Removing The Rear-View Mirrors

    REMOVING THE REAR-VIEW MIRRORS After reassembly, correctly adjust the ◆ Position the vehicle on the stand, see p. rear-view mirrors and tighten the nuts in 82 (POSITIONING THE VEHICLE ON such a way as to ensure their stability. THE STAND). After reassembly: ◆...

  • Page 109: Removing The Front Fairing

    REMOVING THE FRONT FAIRING Unscrew and remove the two upper screws (2). ◆ Position the vehicle on the stand, see p. Handle plastic and paint-finished parts 82 (POSITIONING THE VEHICLE ON w i t h c a r e t o a v o i d s c r a t c h i n g o r THE STAND).

  • Page 110: Removing The Side Stand

    (4) disconnects the electric circuit; to It is forbidden to disconnect or remove restore it, connect the wiring (6) (aprilia the safety switch (4) separately from the part # 8124943), which is available at any Do not force cables, pipes, connectors stand.
  • Page 111 NOTE ◆ Withdraw the cable (9) completely. Store the following components ◆ Put back the fuel tank, see p. 106 together: complete stand, screws (11) and (LIFTING THE FUEL TANK). washers (12), in order to be able to install ◆ Put back the left side body panel, see p.

  • Page 112: Inspecting The Front And Rear Suspensions

    625 mi (1000 km) and successively every Have the fork oil seals changed by 9375 mi (15000 km): Carefully read p. 83 (MAINTENANCE). an aprilia Official Dealer after the first ◆ With pulled front brake lever, press the 1875 mi (30000 km) and successively...
  • Page 113 ADJUSTING THE FRONT FORK Do not force the rotation of the adjusters (1-2) beyond the end of stroke in both directions, in order to avoid any damage. Set the same spring preload and hydraulic damping for both legs: a different setting of the legs decreases the stability of the vehicle while riding.
  • Page 114 (**) = anticlockwise competent authorities. (***) = Have this type of adjustment carried out exclusively by an aprilia Official Dealer It is strictly prohibited to carry out adjustments for the use of the vehicle on racetracks and then ride it on roads or motorways.
  • Page 115 STEERING DAMPER ADJUSTABLE STEERING DAMPER The standard model is equipped with The adjustable steering damper (2) is For the adjustment, always start from a non-adjustable steering damper (1). provided with a knob (3) for the adjustment t h e m o s t r i g i d s e t t i n g ( c o m p l e t e anticlockwise rotation of the knob).

  • Page 116: Rear Suspension

    To calculate the number of clicks of the adjusters (1-2), always start from the most rigid setting (complete clockwise rotation of the adjuster). D o n o t f o r c e t h e r o t a t i o n o f t h e adjusters (1-2) beyond the end of stroke in both directions, in order to avoid any damage.
  • Page 117 If necessary, contact an aprilia official Deler. The adjustments for the use of the vehicle on racetracks must be carried out...

  • Page 118: Checking The Brake Pad Wear

    Have the pads changed by your local ◆ Place the vehicle on the stand, 82 discs, one on the right and one on the left aprilia Official Dealer (POSITIONING THE VEHICLE ON THE side of the front wheel. The rear brake STAND).

  • Page 119: Adjusting The Cold Start Control ( )

    (3) and check the idle stroke again. ◆ Turn the adjusting knob (1). ◆ an aprilia Official Dealer after the first Put back the protection element (2). – BY SCREWING IT (clockwise), you 625 mi (1000 km) and successively every increase the rpm;...

  • Page 120: Spark Plugs

    SPARK PLUGS Carefully read p. 83 (MAINTENANCE). Even if only one spark plug needs Carry out all the operations indicated on the first spark plug and then repeat changing, always replace all of them. N O T E P e r f o r m t h e m a i n t e n a n c e them on the second spark plug of the o p e r a t i o n s w i t h h a l f t h e f r e q u e n c y To reach the spark plugs:...
  • Page 121 Do not try to recover the spark plug gap in any way. The gap must be 0.024±0.028 inc (0.6 – 0.7 mm), otherwise it is necessary to change the spark plug. ◆ Make sure that the washer (8) is in good conditions.

  • Page 122: Checking The Side Stand

    To check the proper functioning of the r e a r s e r v i c e s t a n d , s e e p . 9 6 aprilia Official Dealer. safety switch (3), proceed as follows:...

  • Page 123: Battery

    NOTE BATTERY This vehicle is provided with a If necessary, proceed as follows: maintenance-free battery and no servicing Carefully read p. 83 (MAINTENANCE). ◆ Remove battery, is necessary, excepting occasional checks (REMOVING THE BATTERY). and the recharge when required. ◆ Brush the cable terminals (2) and the CHECKING AND CLEANING THE battery terminals (3) with a wire brush, in...

  • Page 124: Removing The Battery

    ◆ ◆ REMOVING THE BATTERY Unscrew and remove the screw (4) on Put back the rider seat, see p. 106 the positive terminal (+). (REMOVING THE RIDER SEAT). ◆ Move the positive cable (5) on the side. NOTE For the installation of the battery, ◆...

  • Page 125: Checking The Electrolyte Level

    RECHARGING THE BATTERY Carefully read p. 123 (BATTERY). Do not remove the battery plugs: without plugs the battery may be damaged. ◆ Remove battery, (REMOVING THE BATTERY). ◆ Prepare an appropriate battery charger. ◆ Set the charger for the desired type of recharge (see table).

  • Page 126: Installing The Battery

    N O T E ◆ INSTALLING THE BATTERY T h e b a t t e r y ( 1 ) m u s t b e Connect the positive terminal (+) by positioned in its compartment with the means of the screw (4). Carefully read p.

  • Page 127: Long Inactivity Of The Battery

    LONG INACTIVITY OF THE BATTERY If the vehicle remains unused for more than twenty days, disconnect the 30A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer. NOTE The removal of the 30A fuses requires the setting to zero of the following functions: digital clock and red line setting.

  • Page 128: Changing The Fuses

    In this case it is advisable to consult an aprilia Official Dealer. If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses.
  • Page 129 A R R A N G E M E N T T H E 1 5 A ARRANGEMENT OF THE 30A MAIN SECONDARY FUSES FUSES A) From voltage regulator to: F) From battery to: ignition. high beam relay, low beam relay. G) From battery to: ignition.

  • Page 130: Adjusting The Vertical Headlight Beam

    A D J U S T I N G T H E V E R T I C A L After the adjustment: To adjust the headlight beam: HEADLIGHT BEAM ◆ Position the vehicle on the stand, see p. NOTE To check the direction of the 82 (POSITIONING THE VEHICLE ON Make sure that the vertical adjustment...

  • Page 131: Bulbs

    Before changing a bulb, move the If you need assistance or technical advice, ignition switch to position “ ” and wait consult your aprilia Official Dealer, who a few minutes, so that the bulb cools can ensure you prompt and accurate down.

  • Page 132: Changing The Headlight Bulbs

    CHANGING THE HEADLIGHT To ch an ge the b ul bs , pro ce ed as BULBS follows: To extract the bulb electric connector, ◆ Carefully read p. 131 (BULBS). Position the vehicle on the stand, see p. do not pull its wires. 82 (POSITIONING THE VEHICLE ON The headlight contains: ◆...
  • Page 133 ◆ PARKING LIGHT BULB LOW BEAM BULB Extract the bulb from its seat. ◆ Remove the front fairing, see p. 109 NOTE NOTE Extract the connectors one by Insert the bulb in the bulb socket, (REMOVING THE FRONT FAIRING). one, in such a way as to avoid positioning making the respective positioning seats (A) them wrongly upon reassembly.

  • Page 134: Changing The Front And Rear Direction Indicator Bulbs

    Insert the bulb in the bulb socket, making the two bulb pins coincide with the relevant guides on the socket. ◆ Correctly install a new bulb of the same type. If the bulb socket (4) goes out of its seat, insert it correctly, making the bulb socket taper opening coincide with the screw seat.

  • Page 135: Changing The Tail Light Bulb

    ◆ CHANGING THE TAIL LIGHT BULB Position the vehicle on the stand, see p. 82 (POSITIONING THE VEHICLE ON Insert the bulb in the bulb socket, Carefully read p. 131 (BULBS). THE STAND). making the two bulb pins coincide with NOTE The tail light houses two parking ◆...

  • Page 136: Transport

    TRANSPORT Transport your vehicle in neutral gear only. Never drain the fuel tank, either partially Failure to heed this warning could or completely. This may cause damage c a u s e s e r i o u s d a m a g e t o t h e to the inner components of the fuel transmission due to vibration of the tank, or to other parts of the fuel...

  • Page 137: Cleaning

    CLEANING Clean the vehicle frequently if it used in To remove dirt and mud from the painted particular areas or conditions, such as: surfaces use a low- pressure water jet, After the vehicle has been washed, its – Polluted areas (cities and industrial areas). carefully wet the dirty parts, remove mud braking functions could be temporarily –...

  • Page 138: Long Periods Of Inactivity

    LONG PERIODS OF INACTIVITY To clean the lights, use a sponge Do not direct high-pressure water or air s o a k e d w i t h w a t e r a n d a n e u t r a l jets or steam jets on to the following If this vehicle is not used for more than d e t e r g e n t , r u b b i n g t h e s u r f a c e s...
  • Page 139 Remove the plastic bag from the f o r g o t t e n o r n e g l e c t e d t o d o t h i s with your aprilia Official Dealer. outlet pipe of the muffler.

  • Page 140: Technical Data

    TECHNICAL DATA DIMENSIONS Max. length............. 81.496 Inc (2070 mm) Max. length (with number plate-holder extension) ....84.252 Inc (2140 mm) Max. width .............. 31.496 Inc (800 mm) Max. height (front part of the fairing included)..46.024 Inc (1169 mm) Seat height ............. 32.283 Inc (820 mm) Wheel base ............
  • Page 141 GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 31/60 = 1: 1.935 15/34 = 1: 2.267 17/42 = 1: 2.471 1: 10.839 19/31 = 1: 1.632 1: 7.802 20/26 = 1: 1.300 1: 6.216 22/24 = 1: 1.091 1: 5.216 25/24 = 1: 0.960 1: 4.591 26/23 = 1: 0.885...

  • Page 142: Tires

    TIRES ✱ ✱✱ ▲ = di serie = di serie = Utilizzo normale; = Utilizzo sportivo Pressure kPa (Psi) Wheel Make Model Type Size Alternative Rider and Solo rider passenger Front METZELER SPORTTEC 120/70-ZR 17" 250 (36.77) 250 (36.77) Rear METZELER SPORTTEC 180/55-ZR 17"...
  • Page 143 FUEL SUPPLY Type ............... electronic injection (Multipoint) SYSTEM Choke..............Ø 2.008 Inc (51 mm) Fuel ................ premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 FUEL SUPPLY (N.O.M.M.). SPARK PLUGS Standard ..............NGK R DCPR9E Spark plug gap............0.024 ±0.028 Inc (0.6 – 0.7 mm) Ω...

  • Page 144: Lubricant Chart

    LUBRICANT CHART (Recommended) engine oil: EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15W - 50. As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I. S.G. specifications can be used. (Recommended) fork oil: F.A.

  • Page 145: Authorised Dealers And Service Centres

    AUTHORISED DEALERS AND SERVICE CENTRES THE VALUE OF SERVICE Thanks to ongoing technical updates and product-specific technical training, aprilia Authorised Network engineers are familiar with every detail of this motorcycle and have the special equipment required for correct maintenance and repair.

  • Page 146: 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 5786269 APRILIA WORLD SERVICE UK branch 15 Gregory Way - SK5 7ST Stockport - Cheshire Tel. 0044-161 475 1800 - Fax 0044-161 475 1825 - Email: emcaprilia@aol.com...

  • Page 147: Importers

    Tel. 0041-1-4348686 - Fax 0041-1-434 8606 - Email: info@mohag.ch N.V./S.A. RAD Landegemstraat 4 - Industriegebied - B-9031 - Drongen-Baarle Tel. 0032-9-2829410 - Fax. 0032-9-2810012 - Email: aprilia@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.

  • Page 148: 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. 0052-8333-4493 - Fax. 0052-8348-9398 - sbertuEmail: javier@aprilia.com.mx BIKE KOREA CO. LTD. YeungSoo Bldg. 302 #206-25, Ohjang-Dong, Chung-Ku Seoul Tel.
  • Page 149 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 150: Wiring Diagram Rsv Mille - Rsv Mille R Tuono

    WIRING DIAGRAM RSV MILLE - RSV MILLE R TUONO use and maintenance RSV mille TUONO - RSV mille R TUONO...

  • Page 151: Wiring Diagram Key Rsv Mille - Rsv Mille Rtuono

    WIRING DIAGRAM KEY RSV MILLE - RSV MILLE R TUONO 1) Electronic unit D - Parking lights, stoplights, horn, 58) Side stand down warning light 2) Cam position sensor dashboard lights, direction 59) Neutral warning light 3) Throttle valve position sensor indicators.
  • Page 152 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 153 NOTE ASK FOR GENUINE SPARE PARTS ONLY use and maintenance RSV mille TUONO - RSV mille R TUONO...
  • Page 154 – Do not dispose of oil, fuel, polluting substances and components in the environment. – Do not keep the engine running if it isn’t necessary. – Avoid disturbing noises.

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