Precautions And General Informations; Before The Disassembly Of The Components; Disassembling The Components; Reassembling The Components - APRILIA RSV mille Workshop Manual

RSV mille
 3!&%49 7!2.).'3
The following precautionary warnings are used through-
out this manual in order to convey the following messag-
es:
a
Safety warning. When you find this symbol on
the vehicle or in the manual, be careful to the po-
tential risk of personal injury. Non-compliance with
the indications given in the messages preceded by
this symbol may result in grave risks for your and oth-
er people's safety and for the vehicle!
a
WARNING
Indicates a potential hazard which may result in seri-
ous injury or even death.
a
CAUTION
Indicates a potential hazard which may result in
minor personal injury or damage to the vehicle.
NOTE
The word "NOTE" in this manual precedes im-
portant information or instructions.
0.5.1 PRECAUTIONS AND GENERAL INFORMA-
TIONS
Follow with care these recommendations when repairing,
disassembling and reassembling the vehicle.
a
WARNING
The use of naked flames is forbidden for any type of
operation.
Before beginning any maintenance operation or any
inspection of the vehicle, stop the engine, extract the
key from the ignition block, wait until the engine and
the exhaust system have cooled down and if possible
lift the vehicle by means of the proper equipment, on
firm and flat ground.
Keep away from the red-hot parts of the engine and
of the exhaust system, in order to avoid burns.
a
WARNING
Do not hold any mechanical piece or other parts of
the vehicle with your mouth: the components are not
edible and some of them are noxious or even toxic.
If not expressly indicated otherwise, for the reassem-
bly of the units repeat the disassembly operations in
reverse order.
Any reference to operations from other chapters
must be interpreted logically in order to avoid com-
ponents being removed unnecessarily.
Do not use polishing pastes on matt paints.
Never use fuel as a solvent for cleaning the vehicle.
Do not use alcohol, petrol or solvents to clean the
rubber and plastic parts and the saddle: use only wa-
ter and mild soap.
Disconnect the negative cable (–) from the battery
when electric welding.
When two or more persons are working together,
make sure that each is working in safe conditions.
Carefully read 1.2 (INSTRUCTIONS FOR USE OF FU-
EL, LUBRICANTS, COOLANT AND OTHER COMPO-
NENTS).
Release 00/2002-10
0.5.2 BEFORE THE DISASSEMBLY OF THE
COMPONENTS
– Remove any dirt, mud, dust and foreign matters from
the vehicle before disassembling the components.
– Use, when necessary, the special tools designed for
this vehicle.

0.5.3 DISASSEMBLING THE COMPONENTS

– Do not loosen and/or tighten the screws and nuts using
pliers or other tools: instead, always use the proper
spanner.
– Before disconnecting the joints (pipes, cables, etc.),
mark the positions on all of them and mark them with
different distinguishing signs.
Each piece must be marked clearly, in order not to
have problems during installation.
– Clean and wash carefully any disassembled parts with
low inflammability detergents.
– Keep the parts that are used in pairs together, since
they have adapted to each other following the normal
wear.
Some components must be used together or replaced
completely.
– Keep away from heat sources.

0.5.4 REASSEMBLING THE COMPONENTS

a
CAUTION
Never use a seeger ring twice. When a seeger ring is
removed, it must be replaced with a new one. When
assembling a new seeger ring be careful not to
stretch its ends more than strictly necessary to put it
on the shaft.
After installing a seeger ring, make sure that it is
completely and firmly inserted in its seat.
Do not use compressed air to clean the bearings.
NOTE
The bearings must rotate freely, without halting
a/o noise otherwise they must be replaced.
– Use only original aprilia SPARE PARTS.
– Use the recommended lubricants.
– Whenever possible, lubricate the parts before reas-
sembly.
– When tightening screws and nuts, begin with those
having greater diameters or with inner ones, proceed-
ing diagonally.
Tighten screws or nuts in successive passages before
applying driving torque.
– Always replace lock nuts, seals, sealing rings, snap
rings, O-rings, split pins and screws, whenever the
thread appears damaged, with new ones.
– Before the assembly, clean all the connection surfaces,
the oil seal edges and the gaskets.
Apply a thin layer of lithium-based grease on the oil
seal edges.
Put back the oil seals and the bearings with the mark or
serial number facing towards the outside (visible side).
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