Page 2: Table Of Contents
RSV mille INTRODUCTION GENERAL INFORMATION SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM ELECTRIC SYSTEM CHASSIS REPAIR INFORMATION ANALYTICAL INDEX 236 mille WORKSHOP manual aprilia part# 8140688 - 00 Release 00/2002-10...
Page 3: Introduction
INTRODUCTION RSV mille INTRODUCTION 4!",% /& #/.4%.43 50$!4% /& 2%,%!3% ............0-3 0.1.1 INFORMATION ON THE UPDATING OF THE MANUAL ....0-3 0.1.2 UPDATED MANUAL GENERAL LIST ... 0-3 (/7 4/ #/.35,4 4(% -!.5!, ..0-5 &/2%7/2$ ..........
Page 4: Information On The Updating Of The Manual
INTRODUCTION RSV mille 50$!4% /& 2%,%!3% page# Release page# Release 4 - 3 - 00 ....... 2 - 21 - 00 ........ Date of the first edition (Release 00) and of the following 2 - 22 - 00 ........
Page 5 INTRODUCTION RSV mille ã Follow page# Release page# Release page# Release 6 - 29 - 00 ........ 7 - 45 - 00 ....... 8 - 1 - 00 ........ 6 - 30 - 00 ........ 7 - 46 - 00 .......
Page 6 INTRODUCTION RSV mille (/7 4/ #/.35,4 4(% -!.5!, 1) Vehicle (or engine) model 7) Updated page consecutive number 2) Section 8) Chapter title (numbered consecutively) 3) Release consecutive number (“00” indicates the first 9) Paragraph title (numbered consecutively) edition)
Page 7: Engine Service And Repair Manuals
In order to grant its customers more and more satisfac- 0.4.3 SPECIAL TOOL MANUALS tion in the use of the vehicle, aprilia s.p.a. will keep improving its products and the relevant documenta- APRILIA part# (countries) tion.
Page 8: Precautions And General Informations
The bearings must rotate freely, without halting a/o noise otherwise they must be replaced. WARNING – Use only original aprilia SPARE PARTS. Do not hold any mechanical piece or other parts of – Use the recommended lubricants. the vehicle with your mouth: the components are not –...
Page 9: Advice For Consultation
INTRODUCTION RSV mille ã (/7 4/ 53% 9/52 3%26)#% !.$ 2%0!)2 Follow -!.5!, – When installing the bearings, lubricate them abundant- 0.6.1 ADVICE FOR CONSULTATION – Make sure that each component has been reassem- – This manual is divided into section and chapters, each bled correctly.
Page 10 INTRODUCTION RSV mille !""2%6)!4)/.3 39-"/,3 ).)4)!,3 = number PICK-UP = pick-up < = is less than = bottom dead centre > = is greater than = top dead centre ≤ = is equal to or less than = Pneumatic Power Clutch ≥...
Page 11 INTRODUCTION RSV mille NOTES - 10 - 00 Release 00/2002-10...
Page 12 RSV mille GENERAL INFORMATION - 00 Release 00/2002-10...
Page 13 1.7.3 FORK TOOLS ........1-15 1.7.4 ENGINE TOOLS ........1-16 1.7.5 MISCELLANEOUS TOOLS ....1-18 1.7.6 TOOLS USED FOR OTHER aprilia VEHICLES ......... 1-20 0/3)4)/.).' 4(% 6%()#,% /. 4(% 3500/24 34!.$ ......1-21 1.8.1 ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND m ....
Page 14: Frame Number
GENERAL INFORMATION RSV mille 0/3)4)/. /& 4(% 3%2)!, .5-"%23 These numbers are necessary for the registration of the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the guarantee.
Page 15: Fuel
GENERAL INFORMATION RSV mille ).3425#4)/.3 &/2 53% /& &5%, 1.2.2 ENGINE OIL ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 WARNING Engine oil may cause serious damage to the skin if 1.2.1 FUEL handled daily and for long periods. Wash your hands carefully after use.
Page 16: Brake Fluid
GENERAL INFORMATION RSV mille 1.2.4 BRAKE FLUID 1.2.5 COOLANT NOTE This vehicle is provided with front and rear disc WARNING brakes, with separate hydraulic circuits. The following in- The coolant is noxious: do not swallow it; if the cool- formation refers to a single braking system, but is valid for ant gets in contact with the skin or the eyes, it can both.
Page 17: Clutch Fluid
GENERAL INFORMATION RSV mille 1.2.6 CLUTCH FLUID 1.2.7 CARBON MONOXIDE NOTE This vehicle is provided with hydraulic clutch If it is necessary to let the engine run in order to carry out control. some work, make sure that the area in which you are op- erating is properly ventilated.
Page 18 CAUTION During running-in, change speed. Failure to use APRILIA Genuine Spare Parts may re- In this way the components are first “loaded” and then sult in incorrect performance and damages. “relieved” and the engine parts can thus cool down.
Page 19 GENERAL INFORMATION RSV mille 4%#(.)#!, 30%#)&)#!4)/.3 DIMENSIONS Max. length 2080 mm ò Max. length 2070 mm Max. length (with number plate-holder extension) m 2140 mm Max. width 720 mm ò Max. width 725 mm Max. height (front part of the fairing included)
Page 20 GENERAL INFORMATION RSV mille ã Follow ENGINE Transmission Mechanical, 6 gears with foot control on the left side of the engine Lubrication system dry pan with separate oil tank, # 2 trochoidal pumps and cooling radiator Lubrication pressure min 500 kPa (5 bar) at max 80 °C (176 °F) and 6000 rpm...
Page 21 GENERAL INFORMATION RSV mille ã Follow SUSPENSIONS Front UPSIDE-DOWN telescopic adjustable fork with hydrau- lic operation, rod Ø 43 mm Stroke 127 mm Rear oscillating rear fork in light alloy with differentiated pro- file arms and hydropneumatic adjustable mono-shock absorber...
Page 22 GENERAL INFORMATION RSV mille ã Follow TYRES ✱ = series w. ✱ ✱ = series W. Recom- Pressure kPa (bar) mended Normal use Alter- Wheel Make Model Type Size native Rider Road Track Track Solo rider pas- senger Front PIRELLI DRAGON EVO MTR21 CORSA 120/70-ZR 17"...
Page 23: Lubricant Chart (For Models Up To 2001)
GENERAL INFORMATION RSV mille ,5"2)#!.4 #(!24 1.6.1 LUBRICANT CHART (for models up to 2001) Engine oil (recommended): EXTRA RAID 4, SAE 15W - 50 or TEC 4T SAE 15W - 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.
Page 24: Lubricant Chart Ò
GENERAL INFORMATION RSV mille 1.6.2 LUBRICANT CHART ò Engine oil (recommended): EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15 W - 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.
Page 25: 30%#)!, 4//,3 M
APRILIA part# (tool description and function) Pos. 8140176 (complete support stand kit) 8146486 (front support stand) xxxxxxx N.A. [centre stand] 8705021 (rear support stand) xxxxxxx N.A. = available only with the aprilia kit part# 8140176 (complete support stand kit) - 14 - 00 Release 00/2002-10...
Page 26: Frame Tools
APRILIA part# (tool description and function) Pos. 8140203 (complete tool kit for frame including) 8140189 [oil seal fitting tool - Ø 43 hole. Kit accessory aprilia part# 8140151 (complete tool kit for fork includ- ing)] 8140190 (steering tightening tool) 8140191 (rear fork pin and engine support tightening tool) 1.7.3 FORK TOOLS...
Page 27: Engine Tools
GENERAL INFORMATION RSV mille 1.7.4 ENGINE TOOLS - 16 - 00 Release 00/2002-10...
Page 28 GENERAL INFORMATION RSV mille APRILIA part# (tool description and function) Pos. 8140175 (complete tool kit for engine including) 0277680 (gearshift secondary shaft oil seal assembly pad) 0277660 (upper countershaft oil seal assembly pad) 0277670 (coolant pump shaft housing oil seal assembly pad)
Page 29: Miscellaneous Tools
GENERAL INFORMATION RSV mille 1.7.5 MISCELLANEOUS TOOLS - 18 - 00 Release 00/2002-10...
Page 30 GENERAL INFORMATION RSV mille APRILIA part# (tool description and function) Pos. 8140196 [Plurigas (Italian)] 8140578 [Plurigas (English)] 8140192 (chain installation kit) 8140180 (bearing extractors) 8140202 (exhaust gas analysis probes) 8140267 (intake flange for vacuometer) 8140256 (vacuometer) 8140424 (OHLINS fork spanner)
Page 31: Tools Used For Other
GENERAL INFORMATION RSV mille 1.7.6 TOOLS USED FOR OTHER APRILIA 6%()#,%3 APRILIA part# (tool description and function) Pos. 0877650 (handle for pads) 0277265 (extractor for balance shaft, gearbox input and output shaft) – 8116050 (engine oil) 8116053 (grease v Bimol Grease 481) –...
Page 32: Assembling The Pins For The Rear Support Stand M
SUPPORT STAND m NOTE Have the appropriate special tool m to hand: – aprilia part# xxxxxxx N.A. [centre stand]. Position the vehicle on the side stand on firm and level ground. ~Position the pin (1) on the appropriate seat on the rear fork.
Page 33: Positioning The Vehicle On The Front Support Stand M
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE Have the appropriate special tool m to hand: – aprilia part# 8146486 (front support stand). Set the vehicle on the relevant front support stand, see 1.8.3 (POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND m).
Page 34: Product Properties
1.9.1 PRODUCT PROPERTIES APRILIA part# (product) Use and properties ® aprilia part# 0897651 [LOCTITE Adhesive in paste for screws and nuts up to M36 and for 243 blue (10 cm³)] couplings with medium hold. It can be used on parts which have not been completely degreased.
Page 35: Use Of Consumables
LOGUES). xxxxxxx N.A. = not available APRILIA part# (product) Description of use aprilia part# 8116050 (engine oil) (*) – Assembly of rivets on fork, dashboard/front fairing mount, saddle support and frame. – Assembly of frame/engine and frame/fork adjusting bushes. – Assembly of fairlead screws on frame.
Page 36 – On driving shaft and countershaft housings. – On connecting rod/piston pin slots. – On camshaft cams. – On starter motor fastening housing. aprilia part# 0297386 [SILASTIC 732 RTV (100 – On cable bracket on flywheel cover. g)] (**) – On camshaft sensor cable.
Page 37 – Assembly of coolant couplings on radiators. – Assembly of water and fuel drainage pipes on fuel pump flange. – Assembly of throttle body torsion springs. aprilia part# xxxxxxx N.A. (grease DID CHAIN – Lubrication of driving chain. LUBE) aprilia part# 8116031 (Fluid “Biosolvent” frame –...
Page 38: Joints With Hose Clamps And Screw Clamps
NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 39: General Specifications Of The Driving Torques
GENERAL INFORMATION RSV mille 1.10.2 GENERAL SPECIFICATIONS OF THE DRIVING TORQUES The following table indicates the standard driving torques for screws and bolts with metric ISO thread. Driving torque Screw or Spanner bolt thread 13.0 For specific joints or couplings of the vehicle, see 1.10.3 (DRIVING TORQUES).
Page 40: Driving Torques
GENERAL INFORMATION RSV mille NOTE 1.10.3 DRIVING TORQUES For the engine component driving torques, refer to the engine service and repair manual, see 0.4.1 (EN- Steel/aluminium fastening screws with similar coeffi- GINE SERVICE AND REPAIR MANUALS). cient of elasticity Screw or bolt Driving torque ®...
Page 41 GENERAL INFORMATION RSV mille ã Follow SIDE STAND Description Q.ty Screw/nut Notes Fastening of stand plate to frame Stand fastening pin M10x1.25 – Switch fastening screw Lock nut M10x1.25 – FRONT SUSPENSION Front fork Description Q.ty Screw/nut Notes Fastening of upper plate on fork tubes –...
Page 42 GENERAL INFORMATION RSV mille ã Follow ELECTRIC SYSTEM Description Q.ty Screw/nut Notes Fastening of voltage regulator – Fastening of front indicators 0.2-0.3 – Fastening of coil to mount – Fastening of rear light to rear fairing end SWP3.9 – SWP3.9 –...
Page 43 GENERAL INFORMATION RSV mille ã Follow CLUTCH CONTROL Description Q.ty Screw/nut Notes Fastening of clutch fluid pipe M10x1 – Fastening of fluid tank bracket – Fastening of clutch fluid tank on mount – Clutch fluid bleeder M10x1 – EXHAUST SYSTEM Description Q.ty...
Page 44 GENERAL INFORMATION RSV mille ã Follow FRAME/FAIRINGS Description Q.ty Screw/nut Notes Fastening of conveyor covers – front 1 Fastening of side fairing upper panel – rear 2 Fastening of dashboards upper protection moulding – Fastening of lower fairing to frame –...
Page 45 GENERAL INFORMATION RSV mille ã Follow THROTTLE BODY Description Q.ty Screw/nut Notes Injector support fastening screw – Pressure regulator fastening screw 0.35 – Throttle cable support bracket fastening screw – Throttle cable pullet fastening nut – Throttle valve control lever fastening nut –...
Page 46 GENERAL INFORMATION RSV mille ).3425#4)/.3 &/2 !00,9).' 42!.3&%23 When removing parts of the frame: CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them. Proceed with care. Do not damage the tangs and/or their seats.
Page 47 GENERAL INFORMATION RSV mille ã Follow NOTE Where the transfer features application tape ✱ , the tape must be removed 20-30 minutes after the application of the transfer. ✱ The application tape is used to facilitate the application of trademarks and letters, arranging them in the correct place on the surface to be decorated, and to give the self-adhesive more body during application.
Page 48 GENERAL INFORMATION RSV mille NOTES - 37 - 00 Release 00/2002-10...
Page 49 GENERAL INFORMATION RSV mille NOTES - 38 - 00 Release 00/2002-10...
Page 50: Service And Setting Up
RSV mille SERVICE AND SETTING UP - 00 Release 00/2002-10...
Page 51 SERVICE AND SETTING UP RSV mille 5@3F9AF9 R@7 8PGFR 4P3C7 SERVICE AND SETTING UP ............2-40 8DSA6 2-41 5@3F9AF9 R@7 P73P 4P3C7 8DSA6 ..2-42 5@3F9AF9 R@7 5DSR5@ 8DSA6 ! 36BSQRAF9 R@7 P73P 4P3C7 4!",% /& #/.4%.43 5GFRPGD D7T7P 3F6 R@7 973P ............
Page 52 0%2)/$)# 3%26)#% 0,!. aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle.
Page 53: Regular Service Intervals Chart
SERVICE AND SETTING UP RSV mille 2.1.1 REGULAR SERVICE INTERVALS CHART OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER). = check and clean, adjust, lubricate or change, if nec- essary;...
Page 54 SERVICE AND SETTING UP RSV mille ã Follow OPERATIONS TO BE CARRIED OUT BY THE APRILIA Official Dealer. = check and clean, adjust, lubricate or change, if nec- essary; = clean; = change; = adjust. NOTE...
Page 55: Lubrication Chart
SERVICE AND SETTING UP RSV mille 0/).43 2%15)2).' ,5"2)#!4)/. Correct lubrication is important for good performance and the long life of the vehicle. NOTE Before lubricating, completely clean all parts, re- moving rust, grease, dirt and dust. The exposed parts subject to rust are to be lubricated with motor oil or grease, see 1.6 (LUBRICANT CHART).
Page 56 SERVICE AND SETTING UP RSV mille ã Follow LUBRICATION CHART KEY 1) Steering bearings 2) Clutch lever pin 3) Lever cable for cold starting 4) Rider left footrest pin 5) Passenger left footrest pin 6) Passenger seat lock 7) Drive chain...
Page 57: Segment Operation Check
7500 km (4687 mi), the writing “SERVICE” (5a) ap- pears on the right display. In this case contact an APRILIA Official Dealer, who will carry out the operations indicated in the regular service intervals chart, see 2.1.1 (REGULAR SERV- ICE INTERVALS CHART).
Page 58: Switching From Km To Mi (From Km/H To Mph) And Viceversa (Left Display)
SERVICE AND SETTING UP RSV mille 2.3.2 SWITCHING FROM km TO mi (from km/h to MPH) AND VICEVERSA (LEFT DISPLAY) Press the push button l until, after about five seconds, all the writings (12) on the left display start blinking.
Page 59: Setting The Red Line Threshold (With Engine Off Only)
SERVICE AND SETTING UP RSV mille 2.3.4 SETTING THE RED LINE THRESHOLD (WITH ENGINE OFF ONLY) When the maximum rpm set is exceeded, the red line warning light LED “max” (2) positioned on the dash- board starts blinking. If the push button j is pressed for less than one second,...
Page 60: Multifunction (Right Display)
If the writing “ ” is displayed with a temperature below 130 °C (266 °F), there may be a failure of the electric circuit. In this case, contact an APRILIA Offi- cial Dealer. Thermometer range on the display: 35–130°C (95–266 °F).
Page 61: Setting The Hour
SERVICE AND SETTING UP RSV mille 2.3.8 SETTING THE HOUR When the push button g is pressed for the second time, the hour segments (21) start blinking in the lower part of the right display (digital clock). To modify the hour setting, press the “LAP” push button (6) on the left part of the handlebar.
Page 62: Chronometer (Right Display)
SERVICE AND SETTING UP RSV mille 2.3.11 CHRONOMETER (RIGHT DISPLAY) The chronometer makes it possible to measure the time per lap with the vehicle on a racetrack and to store the data, in such a way as to be able to consult them succes- sively.
Page 63: Checking And Cleaning The Terminals
SERVICE AND SETTING UP RSV mille "!44%29 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). There are two kinds of commercially available batter- ies: – batteries requiring maintenance featuring cell plugs; – maintenance-free batteries with no cell plugs as they do not call for the electrolyte level to be checked and topped up.
Page 64: Recharging The Battery
SERVICE AND SETTING UP RSV mille 2.4.2 RECHARGING THE BATTERY Carefully read 2.4 (BATTERY). NOTE If the start relay emits a vibration-type noise when the start pushbutton is pressed “+”, it is a sure sign that the battery is almost completely flat.
Page 65 SERVICE AND SETTING UP RSV mille %,%#42)# #/-0/.%.43 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Light operation/direction, light system, safety switch- for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). For the check, proceed as follows: Position the vehicle on the stand.
Page 66 SERVICE AND SETTING UP RSV mille *5-0 34!24).' Carefully read 2.4 (BATTERY). WARNING The vehicle should only be jump-started when the ve- hicles battery is partially/completely flat and recharg- ing is not possible. Do not attempt to start the vehicle by pushing or tow- ing it.
Page 67 SERVICE AND SETTING UP RSV mille 30!2+ 0,5'3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Spark plugs: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Check, clean or change all the spark plugs, one by one.
Page 68 SERVICE AND SETTING UP RSV mille ã Follow CAUTION When changing the spark plug, check the thread pitch and length. If the threaded part is too short, the carbon deposits will accumulate on the thread seat, and therefore the engine may be damaged during the installation of the right spark plug.
Page 69 SERVICE AND SETTING UP RSV mille ,)&4).' 4(% &5%, 4!.+ Carefully read 1.2.1 (FUEL). WARNING Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down. Remove the passenger seat, see 7.1.2 (UNLOCKING/ LOCKING THE PASSENGER SEAT).
Page 70 ã Follow NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 71: Fuel Supply System
SERVICE AND SETTING UP RSV mille !)2 #,%!.%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Air cleaner: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself.
Page 72: Checking The Operation Of The Accelerator Control
SERVICE AND SETTING UP RSV mille !##%,%2!4/2 2.11.1 CHECKING THE OPERATION OF THE ACCELERATOR CONTROL Transmission cables and controls: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). For the check, proceed as follows: WARNING The use of the vehicle with damaged, excessively...
Page 73: Adjusting The Accelerator Control
SERVICE AND SETTING UP RSV mille 2.11.3 ADJUSTING THE ACCELERATOR CONTROL Accelerator cables (adjustments): for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). For the check, proceed as follows: (*) = up to frame # ZD4MEE009YS000292 (**) = as of frame # ZD4MEE009YS000293 The idle stroke of the throttle grip must be 2 –...
Page 74 SERVICE AND SETTING UP RSV mille #(%#+).' 4(% %.').% /), ,%6%, !.$ 4/00).' 50 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). Engine oil, engine oil pressure warning light LED: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).
Page 75 SERVICE AND SETTING UP RSV mille #(!.').' 4(% %.').% /), !.$ 4(% /), &),4%2 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). Motor oil: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). ENGINE OIL DRAIN...
Page 76 2.1.1 (REGULAR SERVICE INTERVALS CHART). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 77: Cooling System
SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 #//,!.4 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Coolant, cooling system: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Check the coolant level and top up the expansion tank with cold engine.
Page 78 SERVICE AND SETTING UP RSV mille #(!.').' 4(% #//,!.4 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Coolant, cooling system: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). Remove the upper panel of the right fairing, see 7.1.29 (REMOVING THE SIDE FAIRING UPPER PANELS).
Page 79 SERVICE AND SETTING UP RSV mille ã Follow Top up through the filler neck (7) until full. Squeeze and release the couplings (8) (9) a few times with your hands so as to create a slight pressure and enable the coolant to flow into the pipes.
Page 80 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% &2/.4 "2!+% &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Brake fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.20 (BLEEDING...
Page 81 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% 2%!2 "2!+% &,5)$ Brake fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.20 (BLEEDING...
Page 82 SERVICE AND SETTING UP RSV mille ã Follow WARNING Avoid any prolonged exposure of the brake fluid to the air. The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity. Leave the brake fluid tank open ONLY for the time necessary for topping up.
Page 83 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% #,54#( &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Clutch fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION If the clutch control lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.21...
Page 84 SERVICE AND SETTING UP RSV mille ",%%$).' 4(% "2!+).' 3934%-3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Brake fluid bleeding, braking systems: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Sudden resistance or clearance problems on the clutch lever may be due to troubles in the hydraulic system.
Page 85: Bleeding Operations
SERVICE AND SETTING UP RSV mille ã Follow 2.20.1 BLEEDING OPERATIONS NOTE Carry out the bleeding operations with the vehi- cle positioned on the side stand and on firm and flat ground. Only for the rear braking system. Unscrew and remove the two screws (4) and recover the relevant washers.
Page 86: Checks To Be Carried Out After Bleeding The Braking Systems
SERVICE AND SETTING UP RSV mille ã Follow N ✱ Slowly operate the brake lever (12) (for the front brake, or the brake pump rod for the rear brake) more than once, in order to fill the system with brake fluid and to carry out a first partial bleeding.
Page 87: Bleeding Operations
SERVICE AND SETTING UP RSV mille ",%%$).' 4(% #,54#( 3934%-3 2.21.1 BLEEDING OPERATIONS NOTE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL Carry out the bleeding operations with the vehi- INFORMATIONS) and 1.2.6 (CLUTCH FLUID). cle positioned on the side stand and on firm and flat ground.
Page 88: Checks To Be Carried Out After Bleeding The Clutch Control System
SERVICE AND SETTING UP RSV mille ✱ Repeat the operations marked with “ ”, until no air bub- bles can be seen in the clutch fluid that flows out of the bleeder valve. NOTE During these operations the resistance met when pulling the clutch lever (5) will increase.
Page 89 SERVICE AND SETTING UP RSV mille #(!.').' 4(% &2/.4 "2!+% &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Brake fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 90 SERVICE AND SETTING UP RSV mille #(!.').' 4(% 2%!2 "2!+% &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Brake fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Handle fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 91 SERVICE AND SETTING UP RSV mille #(!.').' 4(% #,54#( &,5)$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Clutch fluid: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). CAUTION Handle fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 92 SERVICE AND SETTING UP RSV mille !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 #,%!2!.#% Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The brake control lever is positioned ergonomically dur- ing the assembly of the vehicle. If necessary, it is possible to adjust the brake control lever clearance: Remove the lower fairing, see 7.1.34 (REMOVING...
Page 93 SERVICE AND SETTING UP RSV mille #(%#+).' 4(% "2!+% 0!$ 7%!2 Brake pad wear,brake pads: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). The wear of the disc brake pads depends on the use, on the kind of drive and on the road.
Page 94 SERVICE AND SETTING UP RSV mille ã Follow CAUTION The excessive wear of the friction material would cause the contact of the pad metal support with the disc, with consequent metallic noise and production of sparks from the caliper; braking efficiency, safety and soundness of the disc would thus be negatively affected.
Page 95: Checking The Bearing Slack Steering
(those bent upwards) of the tab washer (1). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140203 (complete tool kit for frame in- cluding). Use the special setscrew spanner to loosen and re- move the lock ring (2).
Page 96 SERVICE AND SETTING UP RSV mille ã Follow Adjuster ring (3) driving torque: 40 Nm (4.0 kgm). Use the special setscrew spanner to tighten the adjust- er ring (3) and eliminate the slack. CAUTION When reassembling, the tab washer (1) must be re- placed.
Page 97: Front Suspension
SERVICE AND SETTING UP RSV mille ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). 2.29.1 FRONT SUSPENSION The front suspension consists of an hydraulic fork con- nected to the steering column by means of two plates.
Page 98: Adjusting The Front Fork
SERVICE AND SETTING UP RSV mille 2.29.2 ADJUSTING THE FRONT FORK The standard setting of the front fork is such as to satisfy most driving conditions at low and high speed, either with reduced load and full load. However, it is possible to adjust the setting according to how the vehicle is going to be used.
Page 99: Adjusting The Height Of The Forecarriage
SERVICE AND SETTING UP RSV mille 2.29.3 ADJUSTING THE HEIGHT OF THE FORECARRIAGE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the special centre stand, see 1.8.4 (POSITIONING THE VEHICLE ON THE CEN- TRE SUPPORT STAND m).
Page 100: Adjusting The Rear Fork
TRE SUPPORT STAND m). Loosen the nut (1) completely. NOTE Have the appropriate special tool m to hand: – aprilia part# 8140203 (complete tool kit for frame in- cluding). Use the special setscrew spanner to loosen the lock ring (2) completely.
Page 101: Rear Suspension
SERVICE AND SETTING UP RSV mille ).30%#4).' 4(% 2%!2 3530%.3)/. MODELS UP TO 2.31.1 REAR SUSPENSION The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems.
Page 102: Rear Suspension
SERVICE AND SETTING UP RSV mille ã Follow CAUTION Adjust the spring preload and the hydraulic braking with extended shock absorber according to the con- ditions of use of the vehicle. When the spring preload is increased, it is necessary...
Page 103: Adjusting The Rear Shock Absorber
SERVICE AND SETTING UP RSV mille ).30%#4).' 4(% 2%!2 3530%.3)/. ò 2.32.1 REAR SUSPENSION The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems.
Page 104 SERVICE AND SETTING UP RSV mille ã Follow CAUTION Adjust the spring preload and the hydraulic braking with extended shock absorber according to the con- ditions of use of the vehicle. When the spring preload is increased, it is necessary...
Page 105: Checking The Rear Suspension Linkage
SERVICE AND SETTING UP RSV mille 2.32.3 CHECKING THE REAR SUSPENSION LINKAGE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Rear suspension linkage bearings: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). For the check, proceed as follows: NOTE Have someone help you keep the vehicle up- right during this operation.
Page 106 SERVICE AND SETTING UP RSV mille 2%!2 7(%%, Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Wheel bearings: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). For the check, proceed as follows: Position the vehicle on the appropriate rear support stand, see 1.8.2 (POSITIONING THE VEHICLE ON...
Page 107: Checking The Drive Chain Slack
SERVICE AND SETTING UP RSV mille $2)6% #(!). Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Drive chain tension and lubrication, drive final trans- mission (chain, crown, pinion): for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). The vehicle is equipped with an endless chain, in which a ring link joint is not used.
Page 108: Checking The Driving Chain, Pinion And Sprocket Wear
SERVICE AND SETTING UP RSV mille 2.36.2 CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WEAR To put a driving chain under tension, see 2.36.3 (AD- JUSTING THE DRIVING CHAIN). Count 17 pins ( 16 steps) on a branch of the chain and measure the distance between the two end pins.
Page 109: Inspecting The Driving Chain Guide Plate
SERVICE AND SETTING UP RSV mille 2.36.5 INSPECTING THE DRIVING CHAIN GUIDE PLATE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Remove the lower fairing, see 7.1.34 (REMOVING THE LOWER FAIRING). Remove the gearshift lever, see 3.2.2 (REMOVING THE GEAR LEVER).
Page 110: Condition Of Tread
SERVICE AND SETTING UP RSV mille 492%3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Tyres, tyre pressure, wheels/tyres: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). This vehicle is provided with tubeless tyres. 2.37.1 CONDITION OF TREAD...
Page 111: Inflation Pressure
Using tyres with different dimensions may cause the instability of the vehicle, endangering its driving safety and manoeuvrability. Use only tyres recommended by APRILIA, see 1.5 (TECHNICAL SPECIFICATIONS). For further information, see 7.4 (TYRES). - 62...
Page 112 SERVICE AND SETTING UP RSV mille &5%, 0)0%3 Carefully read 1.2.1 (FUEL). Fuel pipes: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). If you should encounter signs of wear, cracking, etc., replace the fuel pipes. – High-pressure delivery pipe [~ 450 kpa (4.5 bar)].
Page 113 SERVICE AND SETTING UP RSV mille #(%#+).' 4(% 3)$% 34!.$ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Stand: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). The side stand (1) has two positions: – normal or lifted (Pos.A);...
Page 114 SERVICE AND SETTING UP RSV mille .54 "/,4 3#2%7 4)'(4%.).' Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.10 (FASTENING ELEMENTS). Nut, bolt, screw tightening: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). Check all the fastening elements carefully, especially all those components essential for safety, i.e:...
Page 115 SERVICE AND SETTING UP RSV mille NOTES - 66 - 00 Release 00/2002-10...
Page 116 RSV mille ENGINE - 00 Release 00/2002-10...
Page 117 ENGINE RSV mille ENGINE 4!",% /& #/.4%.43 4%#(.)#!, ).&/2-!4)/....3-3 3.1.1 TECHNICAL DATA ......... 3-3 3.1.2 MAINTENANCE INTERVALS ....3-3 3.1.3 TROUBLESHOOTING ......3-3 3.1.4 SEALANTS ..........3-3 3.1.5 LUBRICANTS .......... 3-3 3.1.6 SPECIAL TOOLS ........3-3 3.1.7 DRIVING TORQUES ....... 3-3 3.1.8 PRECONDITIONS TO BE MET...
Page 118 ENGINE RSV mille 4%#(.)#!, ).&/2-!4)/. 3.1.1 TECHNICAL DATA See 1.5 (TECHNICAL SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 2.1.1 (REGULAR SERVICE INTERVALS CHART). 3.1.3 TROUBLESHOOTING See 8.1 (TROUBLESHOOTING). 3.1.4 SEALANTS See 1.9 (CONSUMABLES). 3.1.5 LUBRICANTS See 1.6 (LUBRICANT CHART). 3.1.6 SPECIAL TOOLS See 1.7 (SPECIAL TOOLS m).
Page 119 ENGINE RSV mille %.').% 0!243 7()#( #!. "% $)3!33%-",%$ 7)4(/54 2%-/6).' 4(% %.').% &2/- 4(% &2!-% Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The parts underlined can be removed and refitted without removing the engine from the frame. CAUTION This chapter describes the relevant procedures pro- gressively and in sequential order.
Page 120 ENGINE RSV mille LEFT SIDE RIGHT SIDE – Rear cylinder spark plugs (6) and (7), see 2.7 (SPARK – Front cylinder coolant thermistor (16), see 5.5 (RE- PLUGS). MOVING THE COOLANT THERMISTORS). – Drive pinion protection case (8), see 2.36.5 (IN- –...
Page 121 ENGINE RSV mille 3.2.1 REMOVING THE EXHAUST PIPES Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Let the engine cool down until it reaches room tem- perature. Remove the exhaust silencer, see 7.1.49 (REMOVING THE EXHAUST SILENCER). Remove the lower fairing, see 7.1.34 (REMOVING THE LOWER FAIRING).
Page 122 ENGINE RSV mille ã Follow Twisting gradually one way and the other, slip the ex- haust manifold (3) off the exhaust pipe (5). Move the exhaust pipe (5) forwards until the flange is released from the stud bolts on the front cylinder.
Page 123 ENGINE RSV mille 3.2.3 REMOVING THE CLUTCH CONTROL CYLINDER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). COMPLETE REMOVAL Drain the clutch control system, see 7.1.55 (DRAINING THE CLUTCH CONTROL SYSTEM).
Page 124 ENGINE RSV mille ã Follow CAUTION Proceed with care; the clutch control cylinder (8) re- mains connected to the clutch control pipe (9). Once the clutch control cylinder (8) has been re- moved, do not pull the clutch lever as the piston is li- able to come out of its slot, resulting in the spillage of clutch fluid.
Page 125 2%-/6).' 4(% 7(/,% %.').% &2/- 4(% &2!-% CAUTION The engine must be removed by an authorized centre or by an APRILIA Official Dealer only. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The removal of the engine is a particularly complex operation.
Page 126 ENGINE RSV mille ã Follow Unscrew and remove the screw (5) and disconnect the cable from the “neutral” gear switch (6). Move the protection element (7) aside and disconnect the cable from the engine oil pressure sensor (8). Move the protection element (9) aside, unscrew and re- move the nut (10), recover the washer and disconnect the starter motor cable.
Page 127 ENGINE RSV mille ã Follow ~ Disconnect the spark plug caps (15). CAUTION To clean the outer parts of the engine use a degreas- er, brushes and wipers. Avoid damaging rubber and plastic parts with corro- sive or penetrating detergents and solvents.
Page 128 Loosen and move the clamp (25). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 129 Screws (30) driving torque: 40 Nm (4.0 kgm). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140183 (engine lifting eye hook) (32), a hoist (33) and lifting straps (34). Fasten the special engine lifting hook (32) on and se- cure it in place with the screws (30).
Page 130 ENGINE RSV mille ã Follow NOTE The elements fastening the engine to the frame must be removed in the order given: RIGHT SIDE LEFT SIDE ã Follow - 15 - 00 Release 00/2002-10...
Page 131 ENGINE RSV mille ã Follow Holding the inside nut (35) still, loosen the screw (36). Nut (35) and screw (36) driving torque: 50 Nm (5.0 kgm). Holding the inside nut (39) still, loosen the screw (40). Nut (39) and screw (40) driving torque: 50 Nm (5.0 kgm).
Page 132 ENGINE RSV mille ã Follow Use the special setscrew spanner m (53) (cod. 8140203) to loosen and remove the lock rings (41) (37). Lock rings (41) (37) driving torque: 50 Nm (5.0 kgm). Unscrew the adjusting bushes (38 - 42) all the way until they touch the frame.
Page 133 ENGINE RSV mille ã Follow WARNING The engine is now freed and has nothing fastening it. Handle with care: watch your fingers and limbs. Clear the floor, on which the engine is to be set down, of any tools and clean thoroughly.
Page 134 Have the appropriate special tools m to hand: – aprilia part# 8140188 (engine support) (1); – aprilia part# 8140187 (engine support stand) (2). Remove the entire engine from the frame, see 3.3 (RE- MOVING THE WHOLE ENGINE FROM THE FRAME).
Page 135 ENGINE RSV mille 2%&)44).' 4(% 7(/,% %.').% /. 4(% &2!-% Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE In order to refit the whole engine on the frame, the same procedure used for its removal must be fol- lowed in the reverse order, see 3.3 (REMOVING THE WHOLE ENGINE FROM THE FRAME).
Page 136 3.6.2 CHECKING THE ENGINE OIL PRESSURE NOTE Have the appropriate special tool m to hand: – aprilia part# 8140181 (fuel-oil pressure gauge-com- pression) (4). Connect the oil pressure gauge (4) in place of the en- gine oil pressure sensor (3).
Page 137 ENGINE RSV mille NOTES - 22 - 00 Release 00/2002-10...
Page 138 RSV mille FUEL SUPPLY SYSTEM - 00 Release 00/2002-10...
Page 139 FUEL SUPPLY SYSTEM RSV mille FUEL SUPPLY SYSTEM 4!",% /& #/.4%.43 &5%, 4!.+ ..........4-3 4.1.1 MAINTENANCE .......... 4-4 4.1.2 CHECKING THE FUEL SUPPLY ....4-4 $2!).).' 4(% &5%, 4!.+ ....4-4 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 ......4-5 2%-/6).' 4(% &5%, ,%6%,...
Page 140 FUEL SUPPLY SYSTEM RSV mille &5%, 4!.+ The filler cap is to be found on the top of the tank, whilst Carefully read 0.5.1 (PRECAUTIONS AND GENERAL the bottom part houses: INFORMATIONS) and 1.2.1 (FUEL). – the fuel supply pump unit;...
Page 141: Maintenance
FUEL SUPPLY SYSTEM RSV mille 4.1.1 MAINTENANCE NOTE ò The pipes (1) and (2) are not provided and the two couplings on the flange are plugged. When the fuel supply pump is to be removed, see 4.3 (REMOVING THE WHOLE FUEL SUPPLY PUMP...
Page 142 Screws (1) driving torque: 7 Nm (0.7 kgm). NOTE Have the special tool m to hand: ✱ – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 143 MOVING THE WHOLE FUEL SUPPLY PUMP UNIT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 144 MOVING THE WHOLE FUEL SUPPLY PUMP UNIT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 145: Foreword
FUEL SUPPLY SYSTEM RSV mille %.').% -!.!'%-%.4 4.7.1 FOREWORD The “heart” of the engine’s management consists in the electronic Engine Control Unit which manages and opti- mizes the ignition and injection of the fuel. – The electronic control unit detects the exact spark angle from the engine rpm and the position of the throttle valves (quantity of air).
Page 146: Sensors
FUEL SUPPLY SYSTEM RSV mille 4.7.2 SENSORS Driving shaft position sensor (2) Location: in the flywheel cover (10) The sensor detects the number of teeth present on the rotor. The engine speed and the position of the driving shaft are calculated based on the signals emitted.
Page 147 FUEL SUPPLY SYSTEM RSV mille ã Follow Coolant thermistor (15) Location: on rear head cylinder (16). The temperature sensor detects the coolant tempera- ture and is required to correct the injection time. The in- jection time is increased if the coolant has not yet reached the working temperature.
Page 148: Injection System Diagram
FUEL SUPPLY SYSTEM RSV mille 4.7.3 INJECTION SYSTEM DIAGRAM 1) Electronic unit 12) Coolant temperature thermistors. 2) To voltage regulator 13) To multifunction display, right-hand side 3) Supply voltage 14) Driving shaft position sensor and generator 4) Fuel suction from tank...
Page 149 FUEL SUPPLY SYSTEM RSV mille 4.7.4 ENGINE CONTROL UNIT CONNECTORS For further information, see 6.17 (CONNECTIONS TO THE ENGINE CONTROL UNIT). 16-pin connector (2) 26-pin connector (1) Terminal label- Terminal label- Connections Connections ling ling Driving shaft position sensor “+”...
Page 150: Automatic Testing
FUEL SUPPLY SYSTEM RSV mille 4.7.5 AUTOMATIC TESTING See 6.4 (IGNITION SYSTEM). 4.7.6 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY WARNING Take care around the high voltage in the ignition sys- tem. Never disconnect connections with the engine run- ning.
Page 151: Removing The Injectors
FUEL SUPPLY SYSTEM RSV mille 4(2/44,% "/$9 CAUTION The screws (1) for the standard adjustment of the throttle valves and for increasing idling (2) are paint- ed and cannot be adjusted. Only when the whole cable support bracket (3) is re- placed can the two adjusting screws be turned.
Page 152 ã Follow NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 153: Disassembling The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.3 DISASSEMBLING THE THROTTLE BODY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Unscrew and remove the M8x1 nut (1) and remove the spring washer. Turn the throttle valve control lever (2) slightly, unscrew and remove three T.E. M5x12 screws (3).
Page 154 FUEL SUPPLY SYSTEM RSV mille ã Follow Unscrew and remove the two M6x25 screws (14) and the right injector support (15), together with the relevant gasket (16), injector (17) and sealing ring (18). NOTE The injector’s sealing ring (18) may be kept in- serted in the slot on the throttle body.
Page 155: Inspecting The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.4 INSPECTING THE THROTTLE BODY TESTING THE INJECTOR WARNING The fuel is explosive and highly inflammable. Keep fuel away from ignition sparks, heat and flames. NOTE The injectors can be controlled electrically. Check the following components: –...
Page 156: Refitting The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.5 REFITTING THE THROTTLE BODY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION After disassembling the throttle body, replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are supplied with the repair kit.
Page 157 FUEL SUPPLY SYSTEM RSV mille ã Follow NOTE Make sure the torsion spring is hooked to the cold-start lever (15) and cable support bracket. Spray chain grease onto the spring (16), see 1.6 (LU- BRICANT CHART). Insert the shaft sealing ring (17) on the fulcrum pin (18).
Page 158: Replacing The Throttle Valve Control Lever
FUEL SUPPLY SYSTEM RSV mille 4.8.6 REPLACING THE THROTTLE VALVE CONTROL LEVER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY Partially remove the fuel tank, see 7.1.5 (PARTIAL RE- MOVAL OF THE FUEL TANK). Remove the air filter casing, see 7.1.7 (REMOVING THE AIR CLEANER CASE).
Page 159 FUEL SUPPLY SYSTEM RSV mille ã Follow Fit the two bushes (3) and torsion spring (4) on the throttle body. Fit the throttle valve control lever (2) on the throttle valve spindle. NOTE Spray a temporary lubricant on the spring (4), see 1.9.2 (USE OF CONSUMABLES).
Page 160: Checking Throttle Valve Control Shaft End Play
FUEL SUPPLY SYSTEM RSV mille 4.8.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY Partially remove the fuel tank, see 7.1.5 (PARTIAL RE- MOVAL OF THE FUEL TANK). Remove the air filter casing, see 7.1.7 (REMOVING THE AIR CLEANER CASE). NOTE Have an appropriate thickness gauge (1) to hand with a 0.05 mm scale.
Page 161: Adjusting The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.8 ADJUSTING THE THROTTLE BODY Partially remove the fuel tank, see 7.1.5 (PARTIAL RE- MOVAL OF THE FUEL TANK). Remove the air filter casing, see 7.1.7 (REMOVING THE AIR CLEANER CASE). SETTING IDLING CAUTION The screw (1) of the throttle valve end of stroke is painted and cannot be adjusted.
Page 162: Changing And Adjusting The Throttle Valve Potentiometer
FUEL SUPPLY SYSTEM RSV mille 4.8.9 CHANGING AND ADJUSTING THE THROTTLE VALVE POTENTIOMETER With the engine switched off: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the four-way connector (coloured black) (1). CAUTION The two screws M4x12 (2) that fasten the throttle...
Page 163: Cylinder Synchronization
“ ”. NOTE Have the appropriate special tool m to hand: – aprilia part# 8140267 (intake flange for vacuometer) (2); – aprilia part# 8140256 (vacuometer) (3). Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).
Page 164 FUEL SUPPLY SYSTEM RSV mille ã Follow N ✖ Loosen the two clamps (4) (5). CAUTION ✖ Take extreme care when removing the throttle body (6) as it remains connected to cables and pipes. N ✖ Grip the throttle body firmly (6), complete with air filter casing (7), and shift it slightly one way and the other, lift- ing and sliding it off the intake flanges.
Page 165 – room temperature 20 – 30 °C (68 – 86 °F). NOTE Have the appropriate special tools m to hand: – aprilia part# 8140196 [Plurigas (Italian)] (15) or aprilia part# 8140578 [Plurigas (English)] (15); – aprilia part# 8140202 (exhaust gas analysis probes) (16).
Page 166 FUEL SUPPLY SYSTEM RSV mille ã Follow Check the first five digits of the frame number and choose the suitable procedure according to the result of this check. PROCEDURE FOR THE VEHICLES WHOSE FRAME BEARS THE ZD4ME CODE For the CO values in the cylinders, adjust: –...
Page 167 FUEL SUPPLY SYSTEM RSV mille NOTES - 30 - 00 Release 00/2002-10...
Page 168 RSV mille COOLING SYSTEM - 00 Release 00/2002-10...
Page 169 COOLING SYSTEM RSV mille COOLING SYSTEM 4!",% /& #/.4%.43 $%3#2)04)/..........5-3 5.1.1 PATH WITH COOLANT TEMPERATURE BELOW 65 °C (149 °F) ............ 5-4 5.1.2 PATH WITH COOLANT TEMPERATURE IN THE RANGE 65 °C (149 °F) TO 80 °C (176 °F) ..........5-5 5.1.3 PATH WITH COOLANT...
Page 170 COOLING SYSTEM RSV mille $%3#2)04)/. The centrifugal pump (positioned inside the engine and To check and top up the coolant, refer to the “LOW” and driven by the latter) draws coolant and distributes it to the “FULL” reference marks, see 2.15 (CHECKING AND galleries in the cylinders and in the heads in order to cool TOPPING UP COOLANT).
Page 171: Path With Coolant Temperature Below 65 °C (149 °F)
COOLING SYSTEM RSV mille 5.1.1 PATH WITH COOLANT TEMPERATURE BELOW 65 °C (149 °F) From pump (1) "A" coolant inlet in engine (2) "B" temper- ature taken by thermistors (3) (4) and displayed on dash- board right display. "C" Coolant outlet from engine (right side) (5) "D"...
Page 172: Path With Coolant Temperature In The Range 65 °C (149 °F) To
COOLING SYSTEM RSV mille 5.1.2 PATH WITH COOLANT TEMPERATURE IN THE RANGE 65 °C (149 °F) TO 80 °C (176 °F) From pump (1) "A" coolant inlet in engine (2) "B" temper- ature taken by thermistors (3) (4) and displayed on dash- board right display.
Page 173: Path With Coolant Temperature Over 80 °C (176 °F)
COOLING SYSTEM RSV mille 5.1.3 PATH WITH COOLANT TEMPERATURE OVER 80 °C (176 °F) From pump (1) "A" coolant inlet in engine (2) "B" temper- ature taken by thermistors (3) (4) and displayed on dash- board right display. "C" Coolant outlet from engine (left side) (7) (8) "D"...
Page 174 Pull the coupling (6) off the radiator (4). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 175 COOLING SYSTEM RSV mille 2%-/6).' 4(% #//,).' %,%#42/&!.3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following procedure refers to a single elec- trofan, though it is applicable to both. Turn the ignition switch to position “1”. Remove the relevant side fairing, see 7.1.28 (REMOV- ING THE SIDE FAIRINGS).
Page 176 COOLING SYSTEM RSV mille 2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Turn the ignition switch to position “1”. Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Disconnect the electric connectors (1) (2) from the ther- mal switch (3).
Page 177: Checking The Thermal Expansion Valve
Drain the cooling circuit completely, see 2.16 (CHANG- ING THE COOLANT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 178 Drain the cooling circuit completely, see 2.16 (CHANG- ING THE COOLANT). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 179 (1) (2) are plugged in properly. NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 180 COOLING SYSTEM RSV mille 2%-/6).' 4(% %80!.3)/. 4!.+ Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Remove the right fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Move the pipe clamp (1). Pull the pipe (2) off the filler neck (3).
Page 181 COOLING SYSTEM RSV mille NOTES - 14 - 00 Release 00/2002-10...
Page 182 RSV mille ELECTRIC SYSTEM - 00 Release 00/2002-10...
Page 183 ELECTRIC SYSTEM RSV mille 37)4#(%3 ..........6-25 6.7.1 SWITCH SET ON RIGHT ELECTRIC SYSTEM HANDLEBAR ......... 6-25 6.7.2 SWITCH SET ON LEFT HANDLEBAR .. 6-26 6.7.3 SINGLE SWITCHES ....... 6-27 4!",% /& #/.4%.43 ,)'(4 3934%- ........6-28 6.8.1 WIRING DIAGRAM ........ 6-28 ).42/$5#4)/.
Page 184: Electric System
ELECTRIC SYSTEM RSV mille ).42/$5#4)/. The following key will be useful in consulting this section. NOTE The numbering to be found on the specific wiring diagrams corresponds to that on the general wiring dia- gram. 6.1.1 CABLE COLOURS orange...
Page 185 ELECTRIC SYSTEM RSV mille %,%#42)# #/-0/.%.43 ,!9/54 - 00 Release 00/2002-10...
Page 186 ELECTRIC SYSTEM RSV mille NOTE The numbering corresponds to that on the gen- 32) High beam relay eral wiring diagram. 33) Cooling fan relay 34) Front parking light bulb 1) Electronic unit 35) High beam bulbs 2) Cam position sensor...
Page 187: Checking The Recharging
ELECTRIC SYSTEM RSV mille #(%#+).' 4(% 2%#(!2').' 3934%- 6.3.1 CHECKING THE RECHARGING VOLTAGE Check battery voltage, see 2.4.2 (RECHARGING THE BATTERY). Start the engine and let it run until it reaches 4000 rpm. Set the light switch to “(” and dimmer switch to “8”.
Page 188: Checking The Alternator Continuity
ELECTRIC SYSTEM RSV mille 6.3.3 CHECKING THE ALTERNATOR CONTINUITY With the engine switched off: Remove the rear fairing, see 7.1.36 (REMOVING THE REAR FAIRING REAR END). Disconnect the three-way connector (1) (coloured brown). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 189: Wiring Diagram
ELECTRIC SYSTEM RSV mille )'.)4)/. 3934%- 6.4.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key A) Intake pressure sensor (inside electronic unit) 21) Driving shaft position sensor 1) Electronic unit 23) Rear cylinder coil “1”...
Page 190: Troubleshooting
ELECTRIC SYSTEM RSV mille 6.4.2 TROUBLESHOOTING (IF THE ENGINE DOES NOT START) Locating a fault in the electrical system Position the vehicle on the stand. Turn the ignition switch to position “2”. The message “(),” comes up on the right-hand dis- play for approx.
Page 191: Display
ELECTRIC SYSTEM RSV mille ã Follow To view Component Starting Engine runs Fault Component Cause “(),” on the s to be motor run- Engine runs (emergency code display checked ning conditions) No (the cylin- Camshaft position der cannot sensor be identified)
Page 192: Checking The Pick-Up
ELECTRIC SYSTEM RSV mille 6.4.3 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY WARNING Take care around the high voltage in the ignition sys- tem. Never disconnect connections with the engine run- ning. Whenever work is performed in the ignition system, always make sure the ignition switch is set to “1”...
Page 193 ELECTRIC SYSTEM RSV mille 6.4.4 CHECKING THE IGNITION COILS Remove both side fairings, see 7.1.28 (REMOVING THE SIDE FAIRINGS). NOTE The following procedure refers to a single coil, though it is applicable to both. Disconnect the terminals (1) (2) from the ignition coil (3).
Page 194: Position Sensor
ELECTRIC SYSTEM RSV mille 6.4.6 CHECKING THE CAMSHAFT POSITION SENSOR With the engine switched off: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the two-way connector (1) (coloured white) and take the measurements (on the engine-side termi- nals).
Page 195: Checking The Coolant Thermistor Operation
ELECTRIC SYSTEM RSV mille 6.4.8 CHECKING THE COOLANT THERMISTOR OPERATION NOTE The value of the temperature measured by the front cylinder thermistor (right-hand side) is sent up on the right-hand display; that measured by the rear cylinder thermistor (left-hand side) is sent to the electronic unit.
Page 196: Checking The Air Thermistor Operation
ELECTRIC SYSTEM RSV mille 6.4.9 CHECKING THE AIR THERMISTOR OPERATION Remove the left-hand conveyor cover, see 7.1.31 (RE- MOVING THE AIR CONVEYOR COVERS). Disconnect the two-way connector (1) (coloured green). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 197: Checking The Throttle Valve
ELECTRIC SYSTEM RSV mille 6.4.10 CHECKING THE THROTTLE VALVE POTENTIOMETER With the engine switched off: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the four-way connector (1) (coloured black). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 198 ELECTRIC SYSTEM RSV mille 6.4.11CHECKING THE INTAKE PRESSURE SENSOR With the engine switched off: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the three-way connector (1) (coloured black). CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 199: Checking The Injectors
ELECTRIC SYSTEM RSV mille 6.4.12 CHECKING THE INJECTORS With the engine switched off: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). NOTE The following procedure refers to a single injec- tor, though it is applicable to both. Disconnect the two-way connector (1) (coloured grey) and take the measurements (on the injector-side termi- nals).
Page 200: Wiring Diagram
ELECTRIC SYSTEM RSV mille &5%, 05-0 3934%- 6.5.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 11) Arrangement for the installation of the anti-theft device 12) Engine stop switch 14) Engine stop relay...
Page 201: Checking The Fuel Pump
NOTE Have the appropriate special tools m to hand: – aprilia part# 8140197 (perforated bolt for fuel pressure test fuel) (6); – aprilia part# 8140181 (fuel-oil pressure gauge-com- pression) (7) ;...
Page 202: Relay
ELECTRIC SYSTEM RSV mille 6.5.3 CHECKING THE FUEL PUMP RELAY Remove the passenger seat, see 7.1.2 (UNLOCKING/ LOCKING THE PASSENGER SEAT). In order to check the operation of the relay: Disconnect the four-way connector (1) (coloured white) from the relay (2).
Page 203: Wiring Diagram
ELECTRIC SYSTEM RSV mille )'.)4)/. 3!&%49 3934%- 6.6.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 8) Diode module 9) Clutch control lever switch 10) Neutral gear switch 12) Start push button...
Page 204: Starting Safety Operating Logic
ELECTRIC SYSTEM RSV mille 6.6.2 STARTING SAFETY OPERATING LOGIC NOTE With the engine shutoff switch in position “1” the starter motor does not turn over. STAND WARNING GEAR POSITION STAND POSITION CLUTCH LEVER ENGINE IGNITION STARTER LIGHT PULLED UP RELEASED...
Page 205: Checking The Side Stand And
ELECTRIC SYSTEM RSV mille 6.6.4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH The side stand (1) is provided with a safety switch (2) that has the function to prevent or interrupt the operation of the engine with the gears on and the side stand (1) down.
Page 206: Switch Set On Right Handlebar
ELECTRIC SYSTEM RSV mille 37)4#(%3 Using a tester, check the continuity of the switches, refer- ring to the specific diagram below. Should any anomalies be encountered, change the corre- sponding switch set. 6.7.1 SWITCH SET ON RIGHT HANDLEBAR 1) Engine stop switch...
Page 207: Switch Set On Left Handlebar
ELECTRIC SYSTEM RSV mille 6.7.2 SWITCH SET ON LEFT HANDLEBAR 1) Horn push button 2) Direction indicator switch 3) Dimmer switch 4) High beam signaller push button / LAP push button (multifunction) 5) Light switch (not provided for e) Cables Pos.
Page 208: Single Switches
ELECTRIC SYSTEM RSV mille 6.7.3 SINGLE SWITCHES 1) Ignition switch Cables Pos. V/Gr Bi/R & Cables Pos. V/Gr Bi/R & 2) Front brake stoplight switch Cables Pos. Operating 3) Rear brake stoplight switch Cables Pos. Operating 4) Neutral gear switch Cables Pos.
Page 209: Wiring Diagram
ELECTRIC SYSTEM RSV mille ,)'(4 3934%- 6.8.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 13) Left dimmer switch 29) Secondary fuses (15 A) 31) Low beam relay 32) High beam relay...
Page 210: Checking The Lights Relay
ELECTRIC SYSTEM RSV mille 6.8.2 CHECKING THE LIGHTS RELAY In order to check the operation of the relay: Remove the relay box lid located on the left next to the dashboard. Remove the relevant relay (identifiable thanks to the la- bel on the lid): –...
Page 211: Wiring Diagram
ELECTRIC SYSTEM RSV mille #//,).' %,%#42/&!. 6.9.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 29) Secondary fuses (15 A) 33) Electric fan relay 39) Thermal switch 40) Cooling fans...
Page 212: Checking The Electrofan Operation
ELECTRIC SYSTEM RSV mille 6.9.2 CHECKING THE ELECTROFAN OPERATION NOTE The following procedure refers to a single elec- trofan, though it is applicable to both. To check operation of electrofan (1): Remove the left fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS).
Page 213: Checking The Thermal Switch
ELECTRIC SYSTEM RSV mille 6.9.3 CHECKING THE THERMAL SWITCH OPERATION Thermal switch Temperature switch on ~ 100 °C (212 °F) switch off ~ 85 °C (185 °F) NOTE The thermal switch switches to on at a tempera- ture of ~ 100 °C (212 °F) and to off at ~ 85 °C (185 °F);...
Page 214: Wiring Diagram
ELECTRIC SYSTEM RSV mille ).$)#!4/23 /. 4(% $!3("/!2$ 6.10.1 WIRING DIAGRAM NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. Wiring diagram key 29) Secondary fuses (D) (15 A) 53) Low fuel sensor 54) Engine oil pressure switch...
Page 215 ELECTRIC SYSTEM RSV mille 6.10.2 LOW FUEL WARNING LIGHT Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the three-way electric connector (1) (col- oured white) of the fuel pump unit. CAUTION Upon reassembly, make sure that the electric con- nector (1) is correctly coupled.
Page 216: Display
ELECTRIC SYSTEM RSV mille 6.10.3 COOLANT TEMPERATURE DISPLAY NOTE In the event the message “OOO”, appears on the right-hand display, with a temperature below 130 °C (266 °F), there might be a problem with the wiring or the coolant thermistor might have short-circuited (right-hand side of engine, see 6.4.8 (CHECKING THE COOLANT THER-...
Page 217: Speedometer
ELECTRIC SYSTEM RSV mille 6.10.5 SPEEDOMETER Remove the right panel, see 7.1.3 (REMOVING THE SIDE COVERS). Make sure that the coupling of the speed sensor con- nector (1) is correct. Remove the front part of the fairing, see 7.1.22 (RE- MOVING THE FRONT PART OF THE FAIRING).
Page 218: Revolution Counter
ELECTRIC SYSTEM RSV mille 6.10.6 REVOLUTION COUNTER Remove the front part of the fairing, see 7.1.22 (RE- MOVING THE FRONT PART OF THE FAIRING). Turn the ignition switch to position “2”. NOTE Without disconnecting the dashboard connector (1). By means of a tester check, on the dashboard connec-...
Page 219: Activating The Battery
ELECTRIC SYSTEM RSV mille "!44%29 NOTE This vehicle is provided with a maintenance-free battery and no operation is necessary, excepting occa- sional checks and the recharge when required. When changing batteries, replace with a battery of the same type, see 1.5 (TECHNICAL SPECIFICATIONS) Carefully read 2.4 (BATTERY).
Page 220: Battery Maintenance
ELECTRIC SYSTEM RSV mille ã Follow Turn the reservoirs (2) upside down and place them so that the sealed parts are over the openings of the bat- tery cells. Press on the reservoirs (2) so that the seals break and the acid is allowed to pour into the battery cells.
Page 221 ELECTRIC SYSTEM RSV mille #(!.').' 4(% "5,"3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Risk of fire. Keep fuel and other flammable substances away from the electrical components. CAUTION Before changing a bulb, move the ignition switch to position “1”...
Page 222 ELECTRIC SYSTEM RSV mille ã Follow HIGH BEAM BULBS Remove the front part of the fairing, see 7.1.22 (RE- MOVING THE FRONT PART OF THE FAIRING). Move the protection element (5) of the bulb to be changed with your hands.
Page 223 ELECTRIC SYSTEM RSV mille ã Follow LOW BEAM BULB Move the protection element (10) with your hands. Withdraw the bulb electric connector (11). Rotate the bulb socket (12) anticlockwise and extract it from its seat. Extract the bulb (3) from its seat and replace it with a new one of the same type.
Page 224: Bulbs
ELECTRIC SYSTEM RSV mille 6.12.2 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS Position the vehicle on the stand. NOTE Before changing a bulb, check the fuses, see 6.15 (CHANGING THE FUSES). Unscrew and remove the screw (1). CAUTION removing the protection screen, proceed care- While fully in order not to break the cog.
Page 225: Changing The Dashboard Bulbs / Lights
ELECTRIC SYSTEM RSV mille 6.12.4 CHANGING THE DASHBOARD BULBS / LIGHTS NOTE Before replacing a bulb/light, check the fuses, see 6.15 (CHANGING THE FUSES). To change, proceed as follows: Remove the dashboard, see 7.1.25 (REMOVING THE DASHBOARD). Unscrew and remove the eight fastening screws (1).
Page 226: (%!$,)
ELECTRIC SYSTEM RSV mille !$*534).' 4(% 6%24)#!, (%!$,)'(4 "%!- NOTE To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used. To rapidly check the correct direction of the beam, place the vehicle on flat ground, 10 m away from a wall.
Page 227 ELECTRIC SYSTEM RSV mille #(!.').' 4(% &53%3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Do not repair faulty fuses. Never use fuses different from the recommended ones. The use of unsuitable fuses may cause damag- es to the electric system or, in case of short circuit, even a fire.
Page 228 ELECTRIC SYSTEM RSV mille #(%#+).' 4(% 37)4#(%3 Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The vehicle is provided with four switches: – Stoplight switch on the rear brake control lever (1). – Stoplight switch on the front brake control lever (2).
Page 229 ELECTRIC SYSTEM RSV mille #/..%#4)/.3 4/ 4(% %.').% #/.42/, 5.)4 NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. For further information, see 4.7.4 (ENGINE CONTROL UNIT CONNECTORS). NOTE The initials (y) and (z) appearing in the diagram, next to the relevant numbers, mark the respective termi- nals on both connectors.
Page 230 ELECTRIC SYSTEM RSV mille ã Follow Position Component Connector Terminal # Nominal value Cable colours Electronic unit – – – – Vi /N Camshaft position 150 – 300 Ω sensor Gr/N Throttle valve 2.8 – 3.4 kΩ (angle M/Bi potentiometer...
Page 231: 7)2).' $)!'2!- 236 Mille
ELECTRIC SYSTEM RSV mille 7)2).' $)!'2!- 236 MILLE - 50 - 00 Release 00/2002-10...
Page 232 ELECTRIC SYSTEM RSV mille 7)2).' $)!'2!- +%9 236 MILLE 1) Electronic unit 35) High beam bulbs 2) Cam position sensor 36) Low beam bulb 3) Throttle valve position sensor 37) Front right direction indicator 4) Intake pressure sensor 38) Front left direction indicator...
Page 233: 7)2).' $)!'2!- 236 Mille E
ELECTRIC SYSTEM RSV mille 7)2).' $)!'2!- 236 MILLE e - 52 - 00 Release 00/2002-10...
Page 234 ELECTRIC SYSTEM RSV mille 7)2).' $)!'2!- +%9 236 MILLE e 1) Electronic unit 35) High beam bulbs 2) Cam position sensor 36) Low beam bulb 3) Throttle valve position sensor 37) Front right direction indicator 4) Intake pressure sensor...
Page 235 ELECTRIC SYSTEM RSV mille NOTES - 54 - 00 Release 00/2002-10...
Page 236 RSV mille CHASSIS - 00 Release 00/2002-10...
Page 237 CHASSIS RSV mille 7.2.10 ASSEMBLING THE FRONT WHEEL BEARINGS ............. 7-50-00 CHASSIS 7.2.11 INSTALLING THE FRONT WHEEL ....7-51-00 ............. 7-52-00 # P73P U@77D 7.3.1 REMOVING THE REAR WHEEL ..... 7-53-00 7.3.2 REMOVING THE FINAL DRIVE UNIT ..... 7-54-00 7.3.3 CHECKING THE REAR WHEEL COMPONENTS ..........
Page 238 CHASSIS RSV mille "/$9 1) Left front brake disc 17) Passenger left footrest 2) Front wheel 18) Passenger seat 3) Front fork 19) Rear light 4) Left air conveyor cover 20) Saddle support lower moulded cover 5) Left air conveyor...
Page 239 CHASSIS RSV mille 32) Rear brake disc 47) Controls on the right part of the handlebar 33) Rear wheel 48) Right rear-view mirror 34) Exhaust silencer 49) Dashboard’s upper protection moulding 35) Number plate holder 50) Right air conveyor 36) Rear fairing rear end...
Page 240: Removing The Rider Saddle
CHASSIS RSV mille 7.1.1 REMOVING THE RIDER SADDLE Position the vehicle on the stand. ~ Partially raise the rear side edge of the saddle. ~ Unscrew and remove the screw (1) and take the bushing (2). Screw (1) driving torque: 12 Nm (1.2 kgm).
Page 241: Removing The Side Covers
CHASSIS RSV mille 7.1.3 REMOVING THE SIDE COVERS Put back the rider saddle, see 7.1.1 (REMOVING THE RIDER SADDLE). Unscrew and remove the two screws (1). CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them.
Page 242: Partial Removal Of The Fuel Tank
CHASSIS RSV mille 7.1.5 PARTIAL REMOVAL OF THE FUEL TANK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.1 (FUEL) and 4.1 (FUEL TANK). WARNING Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 243 CHASSIS RSV mille 7.1.6 COMPLETE REMOVAL OF THE FUEL TANK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.1 (FUEL) and 4.1 (FUEL TANK). WARNING Fuel vapours are noxious for your health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 244: Removing The Air Cleaner Case
CHASSIS RSV mille 7.1.7 REMOVING THE AIR CLEANER CASE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the air cleaner, see 2.10 (AIR CLEANER). Disconnect the pipe (1). Withdraw the suction pressure sensor (2) from its cou- pling. Unscrew and remove the six screws (3).
Page 245: Removing The Battery
CHASSIS RSV mille 7.1.8 REMOVING THE BATTERY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.4 (BATTERY). NOTE To remove the battery it is necessary to set to zero the digital clock and the red line setting. To reset these functions, see 2.3 (MULTIFUNCTION COMPUTER).
Page 246: Removing The Antivibration Weight
CHASSIS RSV mille 7.1.10 REMOVING THE ANTIVIBRATION WEIGHT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the ignition switch to position “1”. Hold the antivibration weight (1) with an adjustable spanner with the jaws covered with adhesive tape in or- der not to damage it.
Page 247: Removing The Grips
CHASSIS RSV mille 7.1.12 REMOVING THE GRIPS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The operations indicated below refer ONLY to the grip of the left part of the handlebar (1). WARNING Any attempt to remove the accelerator control grip (2) following the operations indicated below would dam- age the accelerator control.
Page 248: Removing The Clutch Lever
CHASSIS RSV mille 7.1.13 REMOVING THE CLUTCH LEVER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the side stand. Turn the ignition switch to position “1”. Remove the cold-start control, see 7.1.11 (REMOVING THE COLD-START CONTROL). COMPLETE REMOVAL Drain the clutch control system, see 7.1.55 (DRAINING...
Page 249: Removing The Electric Controls On The Left Handlebar
CHASSIS RSV mille ã Follow The following remain connected to the clutch control (8): – the clutch fluid reservoir (9); – the clutch fluid pipe (10); – the clutch switch (4) with the corresponding cable (11). CAUTION Do not force pipes and cables.
Page 250: Removing The Throttle Grip
CHASSIS RSV mille 7.1.15 REMOVING THE THROTTLE GRIP Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the antivibration weight unit from the right han- dlebar, see 7.1.10 (REMOVING THE ANTIVIBRATION WEIGHT). Unscrew and remove the two screws (1). Remove the rear half of the throttle control casing (2).
Page 251 CHASSIS RSV mille ã Follow Using a small flat-tip screwdriver, lift the stop light switch (10) and remove it from the two seats on the front brake control. Unscrew and remove the tank support screw (11). Driving torque of the tank support screw (11): 10 Nm (1.0 kgm).
Page 252: Removing The Electric Controls On The Right Handlebar
CHASSIS RSV mille 7.1.17 REMOVING THE ELECTRIC CONTROLS ON THE RIGHT HANDLEBAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the ignition switch to position “1”. Lift the protection element (1). Disconnect the right dip switch electric connector (2).
Page 253: Removing The Ignition Switch
CHASSIS RSV mille 7.1.18 REMOVING THE IGNITION SWITCH/ STEERING LOCK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Turn the steering all the way over to the left. Turn the ignition switch to position “1”.
Page 254: Removing The Fork Upper Plate
CHASSIS RSV mille 7.1.19 REMOVING THE FORK UPPER PLATE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). For the complete removal only: Remove the ignition switch/steering lock, see 7.1.18 (REMOVING THE IGNITION SWITCH/STEERING LOCK). For the partial removal: CAUTION At the end of the operations described, the plate re- mains connected to the ignition switch/steering lock.
Page 255: Removing The Right And Left
CHASSIS RSV mille ã Follow NOTE Upon reassembly, position the upper plate man- ually, and fit it without using any tool. Using a plastic hammer, tap the upper plate (3), com- plete with ignition switch /steering lock, from under- neath until it is pushed off upwards.
Page 256: Removing The Rear-View Mirrors
CHASSIS RSV mille 7.1.21 REMOVING THE REAR-VIEW MIRRORS Unscrew and remove the nut (1), take the washer (2), the spring (3) and the half sphere (4). Nut (1) driving torque: 8 Nm (0.8 kgm). CAUTION Handle the plastic and painted components with care to avoid scraping or damaging them.
Page 257: Removing The Headlight
CHASSIS RSV mille 7.1.23 REMOVING THE HEADLIGHT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the front part of the fairing, see 7.1.22 (RE- MOVING THE FRONT PART OF THE FAIRING). Unscrew and remove the screw (1). Screw (1) driving torque: 4 Nm (0.4 kgm).
Page 258: Removing The Dashboard/Front
CHASSIS RSV mille 7.1.26 REMOVING THE DASHBOARD/FRONT FAIRING MOUNT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the dashboard’s upper protection moulding, see 7.1.24 (REMOVING THE DASHBOARD’S UPPER PROTECTION MOULDING). Remove the dashboard, see 7.1.25 (REMOVING THE DASHBOARD). Remove the steering shock absorber, see 7.7.6 (RE- MOVING THE STEERING SHOCK ABSORBER).
Page 259: Removing The Side Fairings
CHASSIS RSV mille 7.1.28 REMOVING THE SIDE FAIRINGS CAUTION Wait until the engine and the exhaust silencer have completely cooled down. Position the vehicle on the stand. Rotate the six rapid fastening screws (1) by giving them 1/4 turn anticlockwise.
Page 260: Removing The Air Conveyor Covers
CHASSIS RSV mille 7.1.31 REMOVING THE AIR CONVEYOR COVERS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Turn the ignition switch to position “1”. Remove the side fairing, see 7.1.28 (REMOVING THE SIDE FAIRINGS). Remove the left fairing upper panel, see 7.1.29 (RE- MOVING THE SIDE FAIRING UPPER PANELS).
Page 261: Removing The Air Conveyor
CHASSIS RSV mille 7.1.33 REMOVING THE AIR CONVEYOR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the air conveyor cover, see 7.1.31 (REMOV- ING THE AIR CONVEYOR COVERS). Disconnect the electric connector (2) from the air ther- mistor (1) (on left side of vehicle only).
Page 262: Removing The Lower Fairing
CHASSIS RSV mille 7.1.34 REMOVING THE LOWER FAIRING Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the appropriate rear support stand, see 1.8.2 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m). CAUTION Wait until the engine and the exhaust silencer have completely cooled down.
Page 263: Removing The Radiator Spoiler
CHASSIS RSV mille 7.1.35 REMOVING THE RADIATOR SPOILER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. Unscrew and remove the two upper fastening screws (1).
Page 264 CHASSIS RSV mille 7.1.36 REMOVING THE REAR FAIRING REAR END Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Turn the ignition switch to position “1”. Remove the passenger seat, see 7.1.2 (UNLOCKING/ LOCKING THE PASSENGER SEAT). Disconnect the rear light electric connector (1).
Page 265: Removing The Rear Fairing
CHASSIS RSV mille 7.1.38 REMOVING THE REAR FAIRING Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Wait until the engine and the exhaust silencer have completely cooled down. Put back the rider saddle, see 7.1.1 (REMOVING THE RIDER SADDLE). Remove the rear fairing rear end, see 7.1.36 (REMOV- ING THE REAR FAIRING REAR END).
Page 266: Removing The Passenger Seat Lock
CHASSIS RSV mille 7.1.39 REMOVING THE PASSENGER SEAT LOCK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear fairing, see 7.1.38 (REMOVING THE REAR FAIRING). Unscrew and remove the two fastening screws (1) se- curing the key-operated control (2).
Page 267: Removing The Saddle Support Lower Moulded Cover
CHASSIS RSV mille 7.1.41 REMOVING THE SADDLE SUPPORT LOWER MOULDED COVER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear fairing, see 7.1.38 (REMOVING THE REAR FAIRING). Remove the fuel tank, see 7.1.5 (PARTIAL REMOVAL OF THE FUEL TANK).
Page 268 CHASSIS RSV mille ã Follow Open the clamp (14) securing the wiring on the left. CAUTION When reassembling, make sure the electric compo- nents and relevant wiring are refitted correctly. Unscrew and remove the two front fastening screws (15). Screws (15) driving torque: 4 Nm (0.4 kgm).
Page 269: Removing The Number Plate Holder
CHASSIS RSV mille 7.1.42 REMOVING THE NUMBER PLATE HOLDER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear direction indicators (1), see 7.1.40 (REMOVING THE REAR DIRECTION INDICATORS). Retrieve the number plate holder (2) assembly with the rear reflector.
Page 270: Removing The Rider's Footrest
CHASSIS RSV mille 7.1.45 REMOVING THE PASSENGER FOOTREST Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. Remove the stop ring (1). Slide out the pin (2).
Page 271: Removing The Rear Brake Lever
CHASSIS RSV mille 7.1.47 REMOVING THE RIDER’S FOOTREST Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. Remove the stop ring (1). Slide out the pin (2).
Page 272: Removing The Exhaust Silencer
CHASSIS RSV mille 7.1.49 REMOVING THE EXHAUST SILENCER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. WARNING Wait until the engine and the exhaust silencer have completely cooled down. Release the two springs (1) from their respective hooks on the exhaust silencer (2).
Page 273: Removing The Side Stand
– safety switch (4). NOTE The removal of the safety switch (4) disconnects the electric circuit; to restore it, connect the wiring (6) (aprilia part# 8124943), to the connector (5). CAUTION Neither lean the vehicle against walls, nor lay it on the ground.
Page 274: Removing The Engine Oil Tank
(CHANGING THE ENGINE OIL AND THE OIL FIL- TER). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 275: Removing The Engine Oil Radiator
(CHANGING THE ENGINE OIL AND THE OIL FIL- TER). NOTE Have the appropriate special tool m to hand: – aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same di- mensions, see 0.4.2 (SPARE PARTS CATALOGUES).
Page 276: Removing The Driving Chain Shoe
CHASSIS RSV mille 7.1.54 REMOVING THE DRIVING CHAIN SHOE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the drive pinion, see 7.1.53 (REMOVING THE DRIVE PINION). Unscrew and remove the screw (1). Unscrew and remove the screw (2). Remove the shoe (3) by pulling it off towards the front.
Page 277: Removing The Saddle Support
CHASSIS RSV mille 7.1.56 REMOVING THE SADDLE SUPPORT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the appropriate rear support stand, see 1.8.2 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND m). Remove the saddle support lower moulded cover, see 7.1.41 (REMOVING THE SADDLE SUPPORT LOWER...
Page 278: Removing The Frame
RSV mille 7.1.57 REMOVING THE FRAME CAUTION The frame (1) must be removed by an authorized cen- tre or by an APRILIA Official Dealer only. Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The removal of the frame (1) is a particularly complex operation.
Page 279 CHASSIS RSV mille ã Follow CAUTION Release all the cables from the fastening clamps po- sitioned along them. Prepare the same number of clamps, which will be re- quired for reassembly. Remove the side stand, see 7.1.50 (REMOVING THE SIDE STAND).
Page 280 CHASSIS RSV mille &2/.4 7(%%, 1) Wheel pin 2) Left spacer (up to frame # ZDMEE009YS000292) 3) Seal 4) Bearing 5) Inner spacer 6) Complete wheel 7) Snap ring 8) Right spacer 9) Washer 10) Nut I = GREASE, see 1.6 (LUBRICANT CHART).
Page 281: Removing The Front Wheel
CHASSIS RSV mille 7.2.1 REMOVING THE FRONT WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.33 (FRONT WHEEL). CAUTION While disassembling and reassembling the wheel, be careful not to damage the brake pipes, the discs and the pads. WARNING Riding with damaged rims may be dangerous for the rider, other persons and the vehicle.
Page 282: Checking The Front Wheel
CHASSIS RSV mille 7.2.2 CHECKING THE FRONT WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.2.3 FRONT WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel. CHECKING THE ROTATION Manually rotate the inner ring of each single bearing.
Page 283: Front Wheel Gaskets
CHASSIS RSV mille 7.2.4 FRONT WHEEL GASKETS Make sure the seals are intact; should they prove dam- aged or feature signs of excessive wear, change them. WARNING Always change both seals. Always replace the gaskets with gaskets of the same type.
Page 284: Disassembling The Front Wheel Bearings
NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Use a special extractor to extract the right bearing (5). Retrieve the inner spacer (4). Work from the left-hand side of the wheel: up to frame # ZD4MEE009YS000292.
Page 285 SEMBLING THE FRONT WHEEL BEARINGS). Work on the right side of the wheel: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Using the appropriate pad, insert the right bearing (5) completely. NOTE The right bearing must be inserted until its con- tact with the wheel hub shoulder is complete (Y).
Page 286: Installing The Front Wheel
CHASSIS RSV mille 7.2.11 INSTALLING THE FRONT WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION While reassembling the wheel, be careful not to dam- age the brake pipes, discs and pads. Spread a film of lubricating grease on the whole length of the wheel pin (1), see 1.6 (LUBRICANT...
Page 287 CHASSIS RSV mille 2%!2 7(%%, 1) Nut 2) Washer 3) Side spacers 4) Left chain tightener shoe 5) Bearings 6) Central spacer 7) Complete wheel 8) Snap ring 9) Seal 10) Right chain tightener shoe 11) Wheel pin I = GREASE, see 1.6 (LUBRICANT CHART).
Page 288: Removing The Rear Wheel
CHASSIS RSV mille 7.3.1 REMOVING THE REAR WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.34 (REAR WHEEL). WARNING Wait until the engine and the exhaust silencer have completely cooled down. While disassembling and reassembling the wheel, be careful not to damage the brake pipe, the disc and the pads.
Page 289: Removing The Final Drive Unit
CHASSIS RSV mille 7.3.2 REMOVING THE FINAL DRIVE UNIT Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). CAUTION Proceed with care. If the final drive unit (1) is installed on the flexible coupling holder (2), do not overturn or...
Page 290: Checking The Rear Wheel Components
CHASSIS RSV mille 7.3.3 CHECKING THE REAR WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.3.4 REAR WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel. CHECKING THE ROTATION Manually rotate the inner ring of each single bearing.
Page 291: Rear Wheel Gaskets
CHASSIS RSV mille 7.3.5 REAR WHEEL GASKETS Make sure the seals are intact; should they prove dam- aged or feature signs of excessive wear, change them. WARNING Always change both seals. Always replace the gaskets with gaskets of the same type.
Page 292: Final Drive Unit Bearings
CHASSIS RSV mille 7.3.10 FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings mounted on the fi- nal drive unit. CHECKING THE ROTATION Remove the left spacer (1). Remove the right spacer (2). Manually rotate the inner ring of each single bearing.
Page 293: Flexible Couplings
CHASSIS RSV mille 7.3.11 FLEXIBLE COUPLINGS Make sure the rubber elements (1) of the flexible cou- plings are not damaged and/or feature excessive wear. To carry out the check: Fit the whole final drive unit complet (2) on the wheel.
Page 294: Disassembling The Rear Wheel Bearings
NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Use a special extractor to extract the right bearing (5). Retrieve the inner spacer (4). Work from the left-hand side of the wheel:...
Page 295 SEMBLING THE REAR WHEEL BEARINGS). Work on the right side of the wheel: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Using the appropriate pad, insert the right bearing (5) completely. NOTE The right bearing must be inserted until its con- tact with the wheel hub shoulder is complete (Y).
Page 296: Disassembling The Final Drive Unit Bearings
NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Use a special extractor to extract the left bearing (4). Retrieve the inner spacer (5). Use a special extractor to extract the right bearing (6).
Page 297: Assembling The Final Drive Unit Bearings
ASSEMBLING THE FINAL DRIVE UNIT BEARINGS). Work from the left-hand side: NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Using the appropriate pad, insert the right bearing (6) completely. NOTE The right bearing must be inserted until its con- tact with the wheel hub shoulder is complete (Y).
Page 298: Removing The Flexible Couplings
CHASSIS RSV mille 7.3.17 REMOVING THE FLEXIBLE COUPLINGS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the final drive unit, see 7.3.2 (REMOVING THE FINAL DRIVE UNIT). NOTE The flexible couplings remain installed on the flexible coupling holder. Extract all the flexible coupling rubber elements.
Page 299: Removing The Crown Gear
CHASSIS RSV mille 7.3.18 REMOVING THE CROWN GEAR Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Crown gear self-locking nuts driving torque: 50 Nm (5.0 kgm). Working on the appropriate seat (1) with an hexagon spanner, lock the threaded pin (2), unscrew and re- move the self-locking nut (3) and the threaded pin (2).
Page 300: Removing The Flexible Coupling Holder
CHASSIS RSV mille 7.3.19 REMOVING THE FLEXIBLE COUPLING HOLDER W Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the final drive unit, see 7.3.2 (REMOVING THE FINAL DRIVE UNIT). Flexible coupling holder screw (1) driving torque: 50 Nm (5.0 kgm).
Page 301: Installing The Rear Wheel
CHASSIS RSV mille 7.3.21 INSTALLING THE REAR WHEEL Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). If the final drive unit has been removed: Put back the final drive unit, see 7.3.2 (REMOVING THE FINAL DRIVE UNIT). CAUTION Before proceeding with the reassembly, make sure that support plate (1) of the brake caliper (2) is posi- tioned correctly;...
Page 302: Tyre Disassembly
CHASSIS RSV mille 492%3 7.4.1 TYRE DISASSEMBLY Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.37 (TYRES). Unscrew and remove the closing cap (1). Deflate the inner tube completely. Unscrew and remove the valve lock ring (2). NOTE Mark the tyre with chalk, to show its position with respect to the rim and to the rotation direction.
Page 303: Assembling The Tyre
CHASSIS RSV mille 7.4.3 ASSEMBLING THE TYRE Eliminate any trace of dirt or rust from the valve seat. Apply the special lubricant for tyres, or soapy water, to the beads of the tyre. CAUTION Never apply grease, oil or petrol to the beads of the tyre for any reason whatsoever.
Page 304 CHASSIS RSV mille &2/.4 "2!+% NOTE This vehicle is provided with disc brakes with The front brake fluid tank is positioned on the right part of the handlebar, near the front brake lever coupling. two, front and rear braking systems having separate hy- draulic circuits.
Page 305: Changing The Front Brake Pads
CHASSIS RSV mille 7.5.1 CHANGING THE FRONT BRAKE PADS (models up to 2001) Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.27 (CHECKING THE BRAKE PAD WEAR). WARNING This vehicle is equipped with a double-disc front braking system (right side and left side).
Page 306: Changing The Front Brake Pads
CHASSIS RSV mille 7.5.2 CHANGING THE FRONT BRAKE PADS ò Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.27 (CHECKING THE BRAKE PAD WEAR). WARNING This vehicle is equipped with a double-disc front braking system (right side and left side).
Page 307: Checking The Front Brake Discs
CHASSIS RSV mille 7.5.3 CHECKING THE FRONT BRAKE DISCS Brake discs: for the maintenance intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). NOTE These operations must be performed with the brakes discs installed on the wheel; they refer to a single disc, though they are applicable to both.
Page 308: Removing The Front Brake Calipers
CHASSIS RSV mille 7.5.6 REMOVING THE FRONT BRAKE CALIPERS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following information refers to one brake caliper only, but is valid for both. WARNING A dirty disc soils the pads, with consequent reduc- tion of the braking efficiency.
Page 309 CHASSIS RSV mille ã Follow CAUTION Proceed with care, in order not to damage the brake pads. Withdraw the brake caliper (5) from the disc, leaving the caliper constrained to the pipe (6) (or releasing it if you are carrying out a COMPLETE REMOVAL).
Page 310: Draining The Braking Systems
CHASSIS RSV mille 7.5.7 DRAINING THE BRAKING SYSTEMS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Use latex gloves. Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF THE FLUID IN THE ENVIRON- MENT.
Page 311 CHASSIS RSV mille 2%!2 "2!+% NOTE This vehicle is provided with disc brakes with two, front and rear braking systems having separate hy- draulic circuits. The rear braking system is with single disc (right side). WARNING Do not use the vehicle if the braking system leaks flu-...
Page 312: Changing The Rear Brake Pads
CHASSIS RSV mille 7.6.1 CHANGING THE REAR BRAKE PADS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.27 (CHECKING THE BRAKE PAD WEAR). Position the vehicle on the stand. Remove the rear brake caliper, see 7.6.5 (REMOVING THE REAR BRAKE CALIPER).
Page 313: Removing The Rear Brake Disc
CHASSIS RSV mille 7.6.3 REMOVING THE REAR BRAKE DISC Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the rear wheel, see 7.3.1 (REMOVING THE REAR WHEEL). NOTE To unscrew the screws (1), it is advisable to use a percussion screwdriver, thanks to which it will be possi- ®...
Page 314: Removing The Rear Brake Pump
CHASSIS RSV mille 7.6.4 REMOVING THE REAR BRAKE PUMP Remove the lower fairing, see 7.1.34 (REMOVING THE LOWER FAIRING). For the partial removal, perform ONLY the operations in- dicated in paragraph “PARTIAL REMOVAL” (excluding the “COMPLETE REMOVAL”). COMPLETE REMOVAL Drain the rear braking system, see 7.5.7 (DRAINING THE BRAKING SYSTEMS).
Page 315: Removing The Rear Brake Caliper
CHASSIS RSV mille 7.6.5 REMOVING THE REAR BRAKE CALIPER Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING A dirty disc soils the pads, with consequent reduc- tion of the braking efficiency. Dirty pads must be re- placed, while dirty discs must be cleaned with a high- quality degreaser.
Page 316: Draining The Rear Braking System
CHASSIS RSV mille ã Follow PARTIAL REMOVAL Rear brake caliper screws (4) driving torque: 25 Nm (2.5 kgm). Unscrew and remove the two brake caliper (5) screws (4). CAUTION Proceed with care, in order not to damage the brake pads.
Page 317 CHASSIS RSV mille 34%%2).' For further details, see: 1) Upper bush – 2.28 (STEERING); – 2.29 (INSPECTING THE FRONT AND REAR SUS- 2) Washer PENSION). 3) Upper plate 4) Lock ring 5) Lock washer 6) Adjuster ring 7) Protective cover...
Page 318: Removing The Fork Together With The Front Wheel
(those bent upwards) of the tab washer (9). NOTE Have the appropriate special tool m to hand; – aprilia part# 8140203 (complete tool kit for frame in- cluding). Use the special setscrew spanner to loosen and re- move the lock ring (10).
Page 319 CHASSIS RSV mille ã Follow CAUTION Due to the weight of the forecarriage, the following operations require the assistance of another opera- tor. Fix the operating procedure before starting work. The removal must be carried out with the greatest care.
Page 320: Checking The Components
CHASSIS RSV mille 7.7.2 CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.7.3 STEERING BEARINGS Carry out the check with the bearings mounted on the steering tube. CHECKING THE ROTATION Manually rotate the inner ring of each single bearing.
Page 321: Removing The Steering Bearings
CHASSIS RSV mille 7.7.5 REMOVING THE STEERING BEARINGS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the fork together with the front wheel, see 7.7.1 (REMOVING THE FORK TOGETHER WITH THE FRONT WHEEL). Use a special extractor to extract the upper bearing (1).
Page 322 CHASSIS RSV mille &2/.4 &/2+ 1) Retainer ring 12) Lower collar 2) Spring preload adjuster 13) Slider 3) Spring preload pusher 14) Slide bush 4) Slider upper plug 15) Guide bush 5) Washer 16) Stop ring 6) Slide bush...
Page 323: Changing The Fork Oil
CHASSIS RSV mille 7.8.1 CHANGING THE FORK OIL Carefully read 1.2.3 (FORK OIL) and 2.29.2 (ADJUST- ING THE FRONT FORK). ✱ Carry out the operations marked with the symbol “ ” described at 7.8.3 (DISASSEMBLING THE WHEEL- HOLDER TUBE - SLIDER UNIT).
Page 324: Slider Units
Carefully clean the whole wheel-holder tube - slider unit. NOTE Have the appropriate special tools m to hand: – aprilia part# 8140151 (complete tool kit for fork includ- ing) (A) (B) (C). Prepare a container with capacity exceeding 550 cm#. CAUTION The disassembly must be performed very carefully.
Page 325 CHASSIS RSV mille ã Follow CAUTION The following operations must be performed by two persons. Fix the operating procedure before starting work. N ✱ Rest both hands on the tool (A). N ✱ Push downwards and at the same time insert the tool (B) between the locking nut (7) and the washer (8).
Page 326 CHASSIS RSV mille ã Follow N ✱ Withdraw and remove the spring (11). N ✱ Overturn the wheel-holder tube together with the slider, pouring the oil inside the container (12). NOTE ✱ In order to have all the oil flow out, slowly and alternately push the pumping element (9) in the slider (eight-ten times).
Page 327 CHASSIS RSV mille ã Follow Remove the stop ring (16) by means of a cut-tipped screwdriver. CAUTION The following operation must be performed with force, since the slide bushing (17) must push the gas- ket (18), the ring (19) and the guide bushing (20), which will all resist the withdrawing action.
Page 328 CHASSIS RSV mille ã Follow Position the wheel-holder tube (21) on a vice, interpos- ing clamps made of soft material (aluminium). Unscrew and remove the centre screw (23) and take the copper washer (24). Withdraw the complete pumping element (9) from the tube (21).
Page 329: Checking The Components
CHASSIS RSV mille 7.8.4 CHECKING THE COMPONENTS WHEEL-HOLDER TUBE Check the sliding surface, which must be neither lined, nor scratched. Slight lines can be eliminated by sanding the surface with wet sandpaper (grain 1). If the lines are deep, change the tube (21).
Page 330: Reassembling The Wheel-Holder Tube - Slider Unit
NOTE Have the appropriate special tools m to hand: – aprilia part# 8140151 (complete tool kit for fork includ- ing) (A) (B) (C) (D). Before reinstalling the gaskets and the bushes, spread a film of fork oil on them, see 1.6 (LUBRICANT CHART).
Page 331 CHASSIS RSV mille ã Follow Insert the following components on the wheel-holder tube (21), in the given order: – antidust gasket (15); – stop ring (16). NOTE Introduce the gasket (18), positioning the side with the writings towards the stop ring (16).
Page 332 CHASSIS RSV mille ã Follow Insert the tube (21) in the slider (22). Remove the adhesive tape. Position the two half-shells of the tool (D) on the wheel- holder tube (21), before the guide bushing (20). Grasping the tool (D), push the guide bushing (20) in the correct position in its seat on the slider (22).
Page 333 CHASSIS RSV mille ã Follow N ✱ Grasp the slider (22) and make it slide slowly and al- ternately, with a stroke of approx. 150 mm, about 10 times, thus letting out all the air that is inside the slider.
Page 334 CHASSIS RSV mille ã Follow CAUTION The following operations must be performed by two persons. Fix the operating procedure before starting work. N ✱ Rest both hands on the tool (A). N ✱ Push downwards and at the same time insert the tool (B) between the locking nut (7) and the washer (8).
Page 335 CHASSIS RSV mille 7.8.6 INSTALLING THE WHEEL-HOLDER TUBE - SLIDER UNITS Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.29 (INSPECTING THE FRONT AND REAR SUSPENSION). Insert the slider (1) complete with the wheel-holder tube (2) on the lower plate (3) and on the upper plate (4).
Page 336: Removing The Rear Fork
CHASSIS RSV mille 2%!2 &/2+ 7.9.1 REMOVING THE REAR FORK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.30 (REAR FORK). Choose the type of removal according to the operating needs. – Type “A” removal: for the inspection or change of the components that connect the rear fork to the frame;...
Page 337 Unscrew and remove the nut (12) and retrieve the washer (13). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140191 (rear fork pin and engine support tightening tool). Use the special setscrew spanner to loosen and re- move the lock ring (14).
Page 338: Checking The Components
CHASSIS RSV mille 7.9.2 CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particu- larly the following. 7.9.3 REAR FORK BEARINGS Carry out the check with the bearings mounted on the rear fork. CHECKING THE ROTATION Manually rotate the inner ring of each single bearing.
Page 339: Disassembling The Rear Fork Gaskets
Remove the seal (3). Remove the snap ring (4). NOTE Have the appropriate special tool m to hand: – aprilia part# 8140180 (bearing extractors). Use a special extractor to extract the two bearings (5) and roller bearing (6). CAUTION The bearings must be checked and, if necessary, changed every time they are disassembled.
Page 340: Reassembling The Rear Fork
CHASSIS RSV mille 7.9.7 REASSEMBLING THE REAR FORK Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.30.1 (ADJUSTING THE REAR FORK). Smear a film of grease over the entire length of the fork pin, see 1.6 (LUBRICANT CHART). Insert the adjuster ring (1) in its slot and screw it on by hand.
Page 341 CHASSIS RSV mille ã Follow ® NOTE Apply LOCTITE 243 on the thread of the screw (12). Insert the washer (13) and washer (14) on the screw (12). Screw and tighten the screw (12). Screw (12) driving torque: 50 Nm (5.0 kgm).
Page 342: Removing The Shock Absorber
CHASSIS RSV mille 2%!2 3530%.3)/. 7.10.1 REMOVING THE SHOCK ABSORBER (models up to 2001) Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.31.1 (REAR SUSPENSION). Position the vehicle on the special centre stand, see 1.8.4 (POSITIONING THE VEHICLE ON THE CEN- TRE SUPPORT STAND m).
Page 343: Removing The Shock Absorber
CHASSIS RSV mille 7.10.2 REMOVING THE SHOCK ABSORBER ò Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.31.1 (REAR SUSPENSION). Position the vehicle on the special centre stand, see 1.8.4 (POSITIONING THE VEHICLE ON THE CEN- TRE SUPPORT STAND m).
Page 344: Checking The Components
CHASSIS RSV mille 7.10.3 CHECKING THE COMPONENTS CAUTION Make sure that none of the components appear to be visibly distorted, broken, cracked and/or dented. Replace any damaged components. BEARINGS Manually rotate the rollers. It should rotate smoothly without jamming and/or noise.
Page 345: Disassembling The Rear Suspension Linkage
CHASSIS RSV mille 7.10.4 DISASSEMBLING THE REAR SUSPENSION LINKAGE Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.31.1 (REAR SUSPENSION). Working from the right-hand side of the vehicle, loosen and remove the nut (1). Nut (1) driving torque: 50 Nm (5.0 kgm).
Page 346: Chain Breaker/Rivet Tool
RSV mille $)3!33%-",).' 4(% $2)6).' #(!). 7.11.1 CHAIN BREAKER/RIVET TOOL m NOTE Have the appropriate special tool m to hand: – aprilia part# 8140192 (chain installation kit). NOTE This tool is designed for breaking/rejoining chains with rivet-type connecting links. CAUTION Only rivet-type connecting link chains should be fit- ted on this vehicle.
Page 347: Breaking The Chain
CHASSIS RSV mille 7.11.2 BREAKING THE CHAIN Carefully read 0.5.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 2.36 (DRIVE CHAIN). Remove the pinion protection case, see 2.36.5 (IN- SPECTING THE DRIVING CHAIN GUIDE PLATE). Slacken the chain, see 2.36.3 (ADJUSTING THE DRIVING CHAIN).
Page 348: Positioning The Joining Link
CHASSIS RSV mille 7.11.3 POSITIONING THE JOINING LINK CAUTION Make sure the joining link is of the same type as the chain to be joined up. Position the chain on the vehicle with the two ends to be joined up at a point between the sprocket and pinion on the chain’s lower course.
Page 349 CHASSIS RSV mille NOTES - 114 - 00 Release 00/2002-10...
Page 350 RSV mille REPAIR INFORMATION - 00 Release 00/2002-10...
Page 351 RSV mille TABLE OF CONTENTS REPAIR INFORMATION 4!",% /& #/.4%.43 42/5",%3(//4).' ......8-3 8.1.1 ENGINE ........... 8-3 8.1.2 ELECTRIC SYSTEM ....... 8-6 8.1.3 BATTERY ..........8-7 8.1.4 BRAKES ..........8-7 8.1.5 CHASSIS ..........8-8 25. &!34%.).' 7)2).' #!",%3 !.$ 0)0%3 ....... 8-9 8.2.1 FRONT BRAKE PIPES ......
Page 352 RSV mille 42/5",%3(//4).' CAUTION Any faults with the ignition coils, driving shaft posi- tion sensor, camshaft sensor, pressure sensors and thermistors are automatically detected by the engine control unit and reported on the multifunction display with the flashing message “...
Page 353 RSV mille ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Engine lacks power Spark plugs dirty Clean or replace Spark plugs are not to spec. Replace Insufficient valve clearance Adjust (*) Exhaust system faulty Replace Valve timing incorrect Adjust (*)
Page 354 RSV mille ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The engine runs too nois- The noise seems to be coming from the timing system Chain tightener shoe worn Replace (*) Excessive valve clearance Adjust (*) Valve springs exhausted or broken...
Page 355 RSV mille ã Follow DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY The gears disengage Gearshift gears worn Replace (*) when the vehicle is The gearshift forks are worn or distorted Replace (*) started or whilst acceler- The positioning springs are exhausted or broken...
Page 356: Battery
RSV mille 8.1.3 BATTERY DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Battery runs down too Recharging system defective Check the alternator, the quickly regulator/rectifier, the circuit connections and carry out operations necessary to restore correct recharge Battery elements have lost much active potential consequent...
Page 357 RSV mille 8.1.5 CHASSIS DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY Hard steering Steering adjustment ring nut too tight Adjust Steering bearings broken Replace Steering axis deformed Replace Insufficient front tyre pressure Adjust Steering shock absorber stiff Replace Steering not fluid...
Page 358: Front Brake Pipes
RSV mille 25. &!34%.).' 7)2).' #!",%3 !.$ 0)0%3 8.2.1 FRONT BRAKE PIPES 8.2.2 REAR BRAKE PIPES - 00 Release 00/2002-10...
Page 359: Fuel System Pipes
RSV mille 8.2.3 FUEL SYSTEM PIPES - 10 - 00 Release 00/2002-10...
Page 360: Clutch Control Pipe
RSV mille 8.2.4 CLUTCH CONTROL PIPE 8.2.5 PPC DEVICE PRESSURE PIPES - 11 - 00 Release 00/2002-10...
Page 361: Cooling System Pipes
RSV mille 8.2.6 COOLING SYSTEM PIPES ã Follow - 12 - 00 Release 00/2002-10...
Page 362 RSV mille ã Follow - 13 - 00 Release 00/2002-10...
Page 363: Engine Oil Pipes
RSV mille 8.2.7 ENGINE OIL PIPES - 14 - 00 Release 00/2002-10...
Page 364: Breather And Impurity Drainage Pipes
RSV mille 8.2.8 BREATHER AND IMPURITY DRAINAGE PIPES - 15 - 00 Release 00/2002-10...
Page 365: Accelerator Control Cables
RSV mille 8.2.9 ACCELERATOR CONTROL CABLES 8.2.10 COLD START CABLE - 16 - 00 Release 00/2002-10...
Page 366: Electric Cables
RSV mille 8.2.11 ELECTRIC CABLES 1) Ignition switch 14) Left electrofan connector 2) Secondary fuse box 15) Thermal switch 3) Front right indicator connector 16) Right electrofan connector 4) Stop light switch connector on front brake control le- 17) Electric fan relay...
Page 367 RSV mille ã Follow 1) Battery 8) Diode module 2) Battery earth cable 9) Fuel pump relay 3) Supply cable 10) Engine stop relay 4) Fall sensor 11) Rear light connector 5) Main fuses 12) Arrangement for the installation of the anti-theft de-...
Page 368 RSV mille ã Follow 1) Intake pressure sensor connector 10) Coolant temperature thermistor 2) Right injector connector 11) “Neutral” gearbox switch 3) Speed sensor connector 12) Front cylinder “1” coil connector 4) Fuel pump connector 13) Front cylinder “2” coil connector...
Page 369 RSV mille ã Follow ã Follow - 20 - 00 Release 00/2002-10...
Page 370 RSV mille ã Follow - 21 - 00 Release 00/2002-10...
Page 371: Spark Plugs (No Spark)
RSV mille #(%#+).' 4(% %,%#42)#!, 3934%- 8.3.4 AUXILIARY SYSTEM PROBLEMS – See: See 6.2 (ELECTRIC COMPONENTS LAYOUT) and 8.2.11 (ELECTRIC CABLES) for the location of the (SWITCHES). electric components. 6.8.2 (CHECKING THE LIGHTS RELAY). 6.8.3 [CHECKING THE LIGHTS / LAP DIODE (multi- function)].
Page 372: Engine
RSV mille 4%#(.)#!, $!4! !.$ 30%#)&)#!4)/.3 – Pad friction material (alternative) = TOSHIBA TT H38GF FERIT/FERODO ID 450/452/459. – ò Pad friction material (alternative) = TOSHIBA TT 8.4.1 ENGINE H38, TOSHIBA TT 2802. See 0.4.1 (ENGINE SERVICE AND REPAIR MANUALS) –...
Page 373 RSV mille NOTES - 24 - 00 Release 00/2002-10...
Page 374: Analytical Index
RSV mille ANALYTICAL INDEX - 00 Release 00/2002-10...
Page 375: Analytical Index
RSV mille 2EF 0AGE ANALYTICAL INDEX 8-9-00 CABLE AND PIPE FASTENING 8-9-00 CABLE AND PIPE LAYOUT 8-9-00 CABLE AND PIPE LAYOUT 2EF 0AGE 6.1.1 6-3-00 CABLE COLOURS 0-9-00 ABBREVIATIONS CABLES AND PIPES - (RUN, 2.11 2-23-00 ACCELERATOR 8-9-00 FASTENING, WIRING) ACCELERATOR - (REMOVING THE 6.4.6...
Page 376 RSV mille 2.40 2-63-00 6.9.4 6-32-00 COOLING SYSTEM PIPES ELECTRIC FAN RELAY 4.8.10 4-26-00 6.1.2 6-3-00 CYLINDER SYNCHRONIZATION ELECTRICAL CONNECTORS 4.8.10 4-26-00 8-22-00 CYLINDERS - (SYNCHRONIZATION) ELECTRICAL SYSTEM - (CHECK) 6.4.3 6-11-00 ELECTRONIC SYSTEM FAULTS 4.7.4 4-12-00 ELECTRONIC UNIT 2EF 0AGE 6.17...
Page 377 RSV mille ENGINE PARTS WHICH CAN BE 7.1.16 7-15-00 FRONT BRAKE LEVER - (REMOVAL) DISASSEMBLED WITHOUT REMOVING 3-4-00 THE ENGINE FROM THE FRAME FRONT BRAKE PADS (models up to 7.5.1 7-70-00 2001) - (CHANGE) 4.7.2 4-9-00 ENGINE SENSORS FRONT BRAKE PADS (RSV01) - 7.5.2...
Page 378 RSV mille 7.1.6 7-8-00 FUEL TANK - (COMPLETE REMOVAL) 2EF 0AGE 2-20-00 FUEL TANK - (EMPTYING) 2-17-00 JUMP-STARTING 7.1.5 7-7-00 FUEL TANK - (PARTIAL REMOVAL) 2-20-00 FUEL TANK - (RAISING) 2EF 0AGE 7.1.4 7-6-00 FUEL TANK - (REMOVING THE CAP) –...
Page 379 RSV mille 7.1.45 7-35-00 2.30 2-51-00 PASSENGER FOOTREST - (REMOVAL) REAR FORK PASSENGER FOOTREST SUPPORTS - 7-101-00 REAR FORK 7.1.44 7-34-00 (REMOVAL) 6.12.3 6-43-00 REAR LIGHT PASSENGER FOOTRESTS - 7.1.44 7-34-00 (REMOVING THE SUPPORTS) 7.1.37 7-29-00 REAR LIGHT - (REMOVAL) PASSENGER SEAT - (REMOVING THE 7.1.43...
Page 380 SPROCKET, CHAIN AND PINION - 2.36.2 2-59-00 (CHECKING THE WEAR) 1.7.5 1-18-00 TOOLS - (MISCELLANEOUS) 6.6.4 6-24-00 STAND - (CHECKING THE SWITCH) TOOLS - (USED FOR OTHER aprilia 1.7.6 1-20-00 VEHICLES) 6.6.4 6-24-00 STAND SWITCH 1.11 1-35-00 TRANSFERS START - (SAFETY SYSTEM 6.6.2...
Page 381 RSV mille 2EF 0AGE WHOLE FINAL DRIVE UNIT - 7.3.2 7-54-00 (REMOVAL) 6.18 6-50-00 WIRING DIAGRAM - RSV mille 6.19 6-52-00 WIRING DIAGRAM - RSV mille ASD 2EF 0AGE – – – 2EF 0AGE – – – 2EF 0AGE –...
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Page 383 RSV mille NOTES - 10 - 00 Release 00/2002-10...
Page 384 RSV mille NOTES - 11 - 00 Release 00/2002-10...
Page 385 RSV mille NOTES - 12 - 00 Release 00/2002-10...

APRILIA RSV mille Workshop Manual

Table of Contents

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