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APRILIA Manuals
Motorcycle
SL MILLE
Workshop manual
APRILIA SL Mille Workshop Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Introduction
Table of Contents
Information on the Updating of the Manual
Updated Manual General List
How to Consult the Manual
Foreword
Safety Warnings
Precautions and General Informations
Disassembling the Components
Reassembling the Components
O.s·how to Use Your Service and Repair Manual
Advice for Consultation
General Information
Instructions for Use of
Other Components
Fuel
Engine Oil
Fork Oil
Brake Fluid
Coolant
Clutch Fluid
CARBON Monoxide
Hot Components
Position of the Serial Numbers
Frame Number
Engine Number
Running-In Rules
Spare Parts
Technical Specifications
Lubricant Chart
Special Tools
Miscellaneous Tools
Engine Tools
Positioning the Vehicle on the Support Stand
Assembling the Pins for the Rear Support Stand
Positioning the Vehicle on the Rear Support Stand
Front Support Stand
Positioning the Vehicle on the Centre Support Stand
Consumables
Product Properties
Use of Consumables
Fastening Elements
General Specifications of the Driving Torques
Instructions for Applying Transfers
Abbreviations / Symbols /Initials
Service and Setting up
Periodic Service Plan
Regular Service Intervals
Points Requiring Lubrication
Multifunction Computer
Segment Operation Check
SWITCHING from Km to MI (from Km/H to MPH) and VICEVERSA(LEFT DISPLAY)
Setting the Instantaneous, Maximum and Average Speed (Left Display)
Setting the Red Line Threshold
Multifunction
Display)
Standard Setting: Coolant Temperature and Digital Clock
Battery Voltage - Vbatt
Setting the Hour
Setting the Minutes
Setting °C or of
Chronometer (Right Display)
Diagnostics
Battery
Checking and Cleaning the Terminals
RECHARGING the Battery
LONG INACTIVITY of the Battery
Electric Components
Spark Plugs
Lifting the Fuel Tank
Draining the Fuel Tank
Air Cleaner
Accelerator
Checking the Operation of the Accelerator Control
Adjusting the Engine Idling Speed
Adjusting the Accelerator
Cold Start Cable
Checking the Engine Oil
Changing the Engine Oil
Checking and Topping up
Changing the Front Brake
Fluid
Checking the Front Brake Fluid Level and Topping up
Changing the Rear Brake
Adjusting the Gear Lever
Control Lever Clearance
Changing the Clutch Fluid
Checking the Brake Pad Wear
Steering
Checking the Bearing Slack Steering
Adjusting the Bearing Slack
Steering
Inspecting the Front and
Front Suspension
Adjusting the Front Fork
Adjusting the Height of the Forecarriage
Rear Fork
Adjusting the Rear Fork
Inspecting the Rear
Rear Suspension
Adjusting the Rear Shock Absorber
Checking the Rear
Front Wheel
Exhaust Manifold Nut
Rear Wheel
Drive Chain
Checking the Drive Chain
Checking the Driving Chain, Pinion and Sprocket Wear
Adjusting the Driving Chain
Drive Chain Tension and Lubrication
Inspecting the Driving Chain Guide Plate
Tyres
Condition of Tread
Inflation Pressure
COOLING SYSTEM Pipes
Nut, Bolt, Screw
Fuel Pipes
Brake and Clutch Pipes
Engine
Technical Information
Technical Data
Maintenance Intervals
Troubleshooting
Sealants
Lubricants
Special Tools
Driving Torque
Preconditions to be Met When Performing Maintenance and Repair Work
General Indications on Maintenance and Repair Work
Engine Parts Which Can be Disassembled Without Removing the Engine from the Frame
REMOVING the EXHAUST Pipes
Removing the Gearchange Control Connection Element
Remove the Pinion Cover
Removing the Clutch Control Cylinder
Removal the Driving Chain Guide Plate
Removing the Whole Engine from the Frame
Disassembling the Engine
Refitting the Whole Engine on the Frame
Engine Checks Subsequent to Reassembly
Bleeding the Engine Oil Circuit
Checking the Engine Oil Pressure
Synchronizing Cylinders
Fuel Supply System
Fuel Tank
Maintenance
CHECKING the FUEL Supply
Draining the Fuel Tank
REMOVING the FUEL LEVEL Sensor 4~5-00
Removing the Whole Fuel Supply Pump Unit
Removing the Delivery Filter
Removing the Fuel Supply Pump
Engine Management
Foreword
Sensors
Injection System Diagram
Engine Control Unit Connectors
Automatic Testing
Eliminating Electronic System Faults According to the Information Sent up on the Display
Camshaft Position Sensor
Driving Shaft Position Sensor
Intake Pressure Sensor
Throttle Valve Potentiometer
Coolant Thermistors
Air Thermistor
Ignition Coils
THROTTLE Body
Removing the Injectors
Removing the Throttle Body
DISASSEMBLING the THROTTLE Body
Inspecting the Throttle Body
Body
Replacing the Throttle Valve Control Lever
CHECKING THROTTLE VALVE CONTROL SHAFT END Play
ADJUSTING the THROTTLE Body
Adjusting the Throttle Valve Potentiometer
Synchronizing Cylinders
Cooling System
Engine Oil Cooler
Removing the Cooling
Removing the Coolant Thermal Switch
Removing the Coolant Thermistors
Checking the Thermal Expansion Valve
Removing the Thermal Expansion Valve
Removing the Filler Neck
Removing the Three-Way Manifold
Coolant Pump
Partial Removing the Expansion Tank
Electric System
Electric System
Introduction
Cable Colours
Electrical Connectors
Electric Components Layout
Checking the Recharging System
Voltage
Checking the Alternator Load Less Operation
Checking the Alternator Continuity
Checking the Voltage Regulator
Ignition System
Wiring Diagram
Troubleshooting (if the Engine Does Not Start)
Eliminating Electronic System Faults According to the Information Sent up on the Display
Checking the Ignition Coils
Checking the Pick-Up
Checking the Camshaft Position Sensor
Checking the Fall Sensor
Checking the Coolant Thermistor Operation
Checking the Air Thermistor Operation
Checking the Throttle Valve Potentiometer
Checking the Intake Pressure Sensor
Checking the Injectors
Fuel Pump System
Wiring Diagram
Checking the Fuel Pump
Checking the Fuel Pump Relay
Checking the Engine Shutoff Relay
Ignition Safety System
Wiring Diagram
STARTING SAFETY OPERATING Logic
Checking the Starting Relay
Checking the Side Stand and the Safety Switch
Checking the Diode Module
Light System
Wiring Diagram
Checking the Lights Relay
Checking the Lights I Lap Diode
(Multifunction)
Cooling Electrofan
Wiring Diagram
Checking the Electrofan Operation
Checking the Thermal Switch Operation
Checking the Electrofan Relay
Dashboard
Wiring Diagram
Low Fuel Warning Light
Coolant Temperature Display
Engine Oil Pressure Sensor
Speedometer
Revolution Counter
Battery
ACTIVATING the Battery
Maintenance
Check
Return under Guarantee
Bulbs
Changing the Headlight Bulbs
Changing the Front and Rear Direction Indicator Bulbs
Changing the Rear Light Bulb
Changing the Number Plate Bulb
Adjusting the Vertical Headlight Beam
Horizontal Adjustment of the Headlight Beam
Changing the Fuses
Checking the Switches
Connections to the Engine Control Unit
WIRING DIAGRAM • SL Mille
Chassis
Body
Removing the Rider Saddle
Unlocking/Lockingthe Passenger Seat
Complete Removal Ofthe Fuel Tank
Partial Removal of the Fuel Tank
Removing the Air Cleaner Case
Removing the Fuel Tank Filler Cap
REMOVING the Battery
Removing the Cold-Start Control
Removing the Grip on the Left
Handlebar
Removing the Clutch Lever
Removing the Electric Controls
Removing the Throttle Grip -7-12-00
Removing the Front Brake Lever
Removing the Electric Controls
Removing the Ignition Switch/ Steering Lock
Removing the Right and Left
Handlebars
Removing the Front Part of the Fairing
Removing the Rear-View Mirrors
Removing the Dashboard
Removing the Dashboard's Upper Protection Moulding
Removing the Headlight
Removing the Dashboard/Front Fairing Mount
Removing the Front Mudguard
Removing the Front Direction Indicators
Removing the Side Fairings
Removing the Air Conveyor
Removing the Front Fairing Lower Lockup
Removing the Lower Fairing
Removing the Radiator Spoiler
Removing the Rear Light
Removing the Passenger Handle
Removing the Rear Fairing
Removing the Passenger Seat Lock
Removing the Rear Direction Indicators
Removing the Saddle Support Lower Moulded Cover
Removing the Mudguard Extension
Removing the Number Plate Holder
Removing the Number Plate Holder Support
Removing the Passenger Footrest
Removing the Passenger Footrest Supports
Removing the Rider's Footrest
Removing the Rider Footrest- Gear Lever.left Support Unit
Removing the Rider Footrest- Rear Brake Control Lever Right Support Unit
Removing the Exhaust Silencer
Removing the Side Stand
Removing the Engine Oil Tank
Removing the Driving Chain Shoe
Removing the Engine Oil Radiator
Removing the Saddle Support
Removing the Frame
Front Wheel
Removing the Whole Wheel
Disassembling the Wheel
Checking the Components
WHEEL Reassembly
Rear Wheel
Removing the Whole Wheel
Disassembling the Final Drive Unit
Disassembling the Wheel
Checking the Components
WHEEL Reassembly
Tyres
TYRE Disassembly
Assembling the Tyre
Changing the Front Brake Pads
Checking the Front Brake Discs
Removing the Front Brake Discs
Removing the Front Brake Pump
Rear Brake
Changing the Rear Brake Pads
Checking the Rear Brake Disc
Removing the Rear Brake Disc
Removing the Rear Brake Pump
Steering
Disassembling the Steering
Checking the Components
Reassembling the Steering
Front Fork
Changing the Fork Oil
Removing the Wheel-Holder Tube - Slider Units
Disassembling the Wheel-Holder Tube - Slider Unit
Checking the Components
Reassembling the Wheel-Holder Tube- Slider Unit
Installing the Wheel-Holder Tube- Slider Units
Rear Fork
Disassembling the Rear Fork
Checking the Components
Reassembling the Rear Fork
Rear Suspension
Removing the Shock Absorber
Disassembling the Rear Suspension Linkage
Disassembling the Suspension Linkage
Disassembling the Driving Chain
Chain Breaker/Rivet Tool
Breaking the Chain
Positioning the Joining Link
Rivetting the Pins
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Table of
Contents
Previous
Page
Next
Page
1
2
3
4
5
Advertisement
Chapters
Introduction
3
General Information
11
Service and Setting Up
39
Engine
93
Fuel Supply System
111
Cooling System
141
Electric System
155
Chassis
207
Table of Contents
Troubleshooting
TECHNICAL INFORMATION
94
TROUBLESHOOTING (IF THE ENGINE DOES NOT START)
163
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