Page 1 Service and repair manual aprilia part # 8140172 RSV mille 956X...
Page 2 RSV mille INTRODUCTION GENERAL INFORMATION SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM CHASSIS PARTS REPAIR INFORMATION UPDATES ANALYTICAL INDEX...
Page 3 In order to grant its customers more and more satisfac- NOTE The word “NOTE” in this manual precedes im- tion in the use of the vehicle, aprilia s.p.a. will keep im- portant information or instructions. proving its products and the relevant documentation.
Page 4 Denmark Australia Í a/o noise otherwise they must be replaced. Portugal Japan Brazil " ° – Use only original aprilia SPARE PARTS. Finland Singapore South Africa Î – Use the recommended lubricants. Belgium Poland New Zealand – Whenever possible, lubricate the parts before reas-...
Page 5 RSV mille NOTE...
Page 6 RSV mille GENERAL INFORMATION...
Page 7: Table Of Contents
GENERAL INFORMATION RSV mille GENERAL INFORMATION 4!",% /& #/.4%.43 0/3)4)/. /& 4(% 3%2)!, .5-"%23 ... 1-3 1.1.1 FRAME NUMBER .......... 1-3 1.1.2 ENGINE NUMBER ......... 1-3 ).3425#4)/.3 &/2 53% /& &5%, ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 ........ 1-3 1.2.1 FUEL ..............
Page 8: Frame Number
GENERAL INFORMATION RSV mille 0/3)4)/. /& 4(% 3%2)!, .5-"%23 These numbers are necessary for the registration of the vehicle. NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanc- tions. In particular, the alteration of the frame number re- sults in the immediate invalidity of the guarantee.
Page 9: Engine Oil
GENERAL INFORMATION RSV mille 1.2.2 ENGINE OIL 1.2.4 BRAKE FLUID NOTE This vehicle is provided with front and rear disc WARNING brakes, with separate hydraulic circuits. Engine oil may cause serious damage to the skin if The following information refers to a single braking sys- handled daily and for long periods.
Page 10: Coolant
GENERAL INFORMATION RSV mille 1.2.5 COOLANT 1.2.6 CLUTCH FLUID NOTE This vehicle is provided with hydraulic clutch WARNING control. The coolant is noxious: do not swallow it; if the cool- ant gets in contact with the skin or the eyes, it can WARNING cause serious irritations.
Page 11: Carbon Monoxide
GENERAL INFORMATION RSV mille 25..).' ). 25,%3 1.2.7 CARBON MONOXIDE If it is necessary to let the engine run in order to carry out The running-in of the engine is essential to ensure its du- some work, make sure that the area in which you are op- ration and correct functioning.
Page 12 For any replacement, use aprilia Genuine Spare Parts only. aprilia Genuine Spare Parts are high-quality parts, ex- pressly designed and manufactured for aprilia vehicles. CAUTION Failure to use APRILIA Genuine Spare Parts may re- sult in incorrect performance and damages. 4%#(.)#!, 30%#)&)#!4)/.3 DIMENSIONS Max. length 2080 mm &...
Page 13 GENERAL INFORMATION RSV mille FOLLOW 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 Air cleaner with dry filter cartridge Cooling liquid-cooled Coolant pump gear ratio...
Page 14 GENERAL INFORMATION RSV mille FOLLOW TYRES Pressure kPa (bar) Recom- Wheel Make Model Type Size Alternative mended Solo Rider and Solo rider passenger rider MTR21 220-230 " Front PIRELLI DRAGON EVO 120/70-ZR17 – 220 (2.2) 240 (2.4) CORSA (2.2-2.3) MTR22 "...
Page 15 GENERAL INFORMATION RSV mille FOLLOW BULBS Low beam (halogen) 12 V - 55 / 55 W H4 High beam (halogen) 12 V - 60 W H3 Front parking light 12 V - 5 W Direction indicators 12 V - 10 W Rear parking light / number plate light / stoplight 12 V - 5/21 W Revolution counter...
Page 16: Product Properties
GENERAL INFORMATION RSV mille #/.35-!",%3 Only use the products given below for any mainte- nance work. The materials mentioned have been test- ed for many years and are suitable for all the applica- tion conditions indicated by the manufacturer. NOTE The consumables, which are coded, are availa- ble on application, see 1.7.2 (USE OF CONSUMABLES).
Page 17: Use Of Consumables
GENERAL INFORMATION RSV mille 1.7.2 USE OF CONSUMABLES Product Code Description of use Engine oil (*) 8116050 – 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 18 GENERAL INFORMATION RSV mille FOLLOW Product Code Description of use ® 0899784 – Fastening of coolant thermal switch. LOCTITE 574 orange (**) – Fastening of coolant thermistors. – On neutral gear switch contact screw. – On the outer surface of the engine oil pump motor. –...
Page 19 GENERAL INFORMATION RSV mille FOLLOW Product Code Description of use ANTI-SEIZE MOTAGEPASTE 8116043 – Assembly of plugs for checking CO on exhaust pipes. AS 1800 antiscuff paste Alcohol – Cleaning of left handlebar prior to assembly of grip. – Insertion of radiator breather pipes on “T” union. –...
Page 20: Miscellaneous Tools
GENERAL INFORMATION RSV mille & 30%#)!, 4//,3 In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of dam- age as a result of inappropriate tools and/or improvised methods.
Page 21: Engine Tools
GENERAL INFORMATION RSV mille 1.8.2 ENGINE TOOLS Pos. Tool description and function Codice Complete tool kit for engine including 8140175 Gearshift secondary shaft oil seal assembly pad 0277680 Secondary countershaft oil seal assembly pad 0277660 Coolant pump shaft housing oil seal assembly pad 0277670 Coolant pump shaft housing sliding ring assembly pad 0877257...
Page 22: Assembling The Pins For The Rear Support Stand
GENERAL INFORMATION RSV mille 0/3)4)/.).' 4(% 6%()#,% /. 4(% 3500/24 34!.$ 1.9.1 ASSEMBLING THE PINS FOR THE REAR SUP- & PORT STAND cod. 8140194 (stand + pin). 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 23: Setting The Vehicle On The Centre Support Stand
GENERAL INFORMATION RSV mille 1.9.4 SETTING THE VEHICLE & ON THE CENTRE SUPPORT STAND Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). cod. 8140176 (complete stand). Remove the lower fairing, see 7.1.32 (REMOVING THE LOWER FAIRING). Set the vehicle on the relevant front support stand, see 1.9.3 (SETTING THE VEHICLE ON THE FRONT SUP- &...
Page 24 GENERAL INFORMATION RSV mille ).3425#4)/.3 &/2 !00,9).' 42!.3&%23 When removing parts of the frame : CAUTION Handle plastic and painted parts carefully so not to scratch or damage them. Perform the work with the utmost care. Do not damage the tabs and/or the slots into which they are inserted.
Page 25 GENERAL INFORMATION RSV mille NOTE Where the transfer features application tape (5) , 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 26 GENERAL INFORMATION RSV mille '%.%2!, 30%#)&)#!4)/.3 /& 4(% $2)6).' 4/215%3 The following table indicates the standard driving torques for screws and bolts with metric ISO thread. Screw Driving torque or bolt Spanner thread M 10 M 12 M 14 M 16 13.0 For specific joints or couplings of the vehicle, see 2.41...
Page 27 GENERAL INFORMATION RSV mille !""2%6)!4)/.3 39-"/,3 ).)4)!,3 = number = litres < = is less than = lap (race course) > = is greater than = light emitting diode ≤ = is equal to or less than = metres / second ≥...
Page 28 RSV mille SERVICE AND SETTING UP...
Page 29 SERVICE AND SETTING UP RSV mille #(!.').' 4(% &2/.4 "2!+% &,5)$ ....2-29 SERVICE AND SETTING UP #(!.').' 4(% 2%!2 "2!+% &,5)$ ..... 2-30 #(!.').' 4(% #,54#( &,5)$ ..2-31 4!",% /& #/.4%.43 !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 !.$ 4(% 0%2)/$)# 3%26)#% 0,!.
Page 30: Regular Service Intervals Chart
0%2)/$)# 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 31 SERVICE AND SETTING UP RSV mille 2.1.1 2%'5,!2 3%26)#% ).4%26!,3 #(!24 Component After running-in Every 7500 km Every 15000 km [1000 km (625 mi)] (4687 mi) or 8 months (9375 mi) or 16 months (*) (*) Spark plugs Stand Throttle cables Rear suspension linkage bearings Steering bearings and steering...
Page 32 SERVICE AND SETTING UP RSV mille 0/).43 2%15)2).' ,5"2)#!4)/. LUBRICATION CHART KEY Correct lubrication is important for good performance and 1) Steering bearings the long life of the vehicle. 2) Clutch lever pin NOTE Before lubricating, completely clean all parts, re- 3) Lever cable for cold starting moving rust, grease, dirt and dust.
Page 33: Segment Operation Check
SERVICE AND SETTING UP RSV mille -5,4)&5.#4)/. #/-054%2 A) Left multifunction digital display 9 10 11 12 (speedometer - odometer). B) Multifunction computer programming push buttons. C) Right multifunction digital display (coolant temperature DIAG SERVICE V BATT - clock - battery voltage - chronometer - diagnostic). x 1000 V max km/h...
Page 34: Setting The Instantaneous, Maximum And Average Speed (Left Display)
SERVICE AND SETTING UP RSV mille To confirm the setting, press the push button about five seconds. 2.3.3 SETTING THE INSTANTANEOUS, MAXIMUM AND AVERAGE SPEED (LEFT DISPLAY) NOTE Two seconds after the vehicle has started mov- ing, the instantaneous speed is automatically shown on V max km/h the display, even if a different function is set.
Page 35: Setting The Red Line Threshold (With Engine Off Only)
The setting is confirmed by the coming on of the 9 10 11 12 red line warning light LED “ ” (2). aprilia 2.3.5 MULTIFUNCTION (RIGHT DISPLAY) The right display (multifunction) includes the coolant tem- perature in °C (°F) and the digital clock as standard set- tings.
Page 36: Standard Setting: Coolant Temperature And Digital Clock
SERVICE AND SETTING UP RSV mille 2.3.6 STANDARD SETTING: COOLANT TEMPERATURE AND DIGITAL CLOCK The coolant temperature value (1) is shown in the upper part of the right display. It is possible to switch from °C to °F and viceversa, see 2.3.10 (SETTING °C OR °F).
Page 37: 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 38: Checking And Cleaning The Terminals
SERVICE AND SETTING UP RSV mille "!44%29 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). There are two kinds of commercially available batteries: – 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 39: Recharging The Battery
SERVICE AND SETTING UP RSV mille %,%#42)# #/-0/.%.43 2.4.2 RECHARGING THE BATTERY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL Carefully read 2.4 (BATTERY). INFORMATIONS). NOTE If the start relay emits a vibration-type noise when the start pushbutton is pressed “ ”, it is a sure sign Check after the first 1000 km (625 mi), and then every that the battery is almost completely flat.
Page 40 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 41 SERVICE AND SETTING UP RSV mille 30!2+ 0,5'3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the spark plugs every 7500 km (4687 mi) or 8 months, change them every 15000 km (9375 mi) or 16 months. Periodically remove the spark plugs and clean them care- fully, removing carbon deposits;...
Page 42 SERVICE AND SETTING UP RSV mille CAUTION When replacing a spark plug, check the pitch and length of the thread. If the threaded part is too short, carbon deposits will settle on the thread seat and may result in damage to the engine when the correct one is positioned back in place.
Page 43 SERVICE AND SETTING UP RSV mille $2!).).' 4(% &5%, 4!.+ Carefully read 1.2.1 (FUEL). WARNING Fire hazard. Wait until the engine and exhaust silencer have com- pletely cooled down. Fuel vapours are harmful for health. Before proceeding, make sure that the room in which you are working is properly ventilated.
Page 44 SERVICE AND SETTING UP RSV mille !)2 #,%!.%2 CAUTION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL If the vehicle is used in dusty areas, clean the filtering INFORMATIONS). element more frequently. Check the air cleaner every 7500 (4687 mi)km or 8 Using the vehicle without the filtering element, or months, change it every 15000 km (9375 mi) or more fre- with the element damaged, considerably increases...
Page 45: Checking The Operation Of The Accelerator Control
SERVICE AND SETTING UP RSV mille !##%,%2!4/2 Check after the first 1000 km (625 mi) and succes- sively every 7500 km (4687 mi) or 8 months. 2.11.1 CHECKING THE OPERATION OF THE ACCELERATOR CONTROL WARNING The use of the vehicle with damaged, excessively bent or twisted accelerator cable may hinder the reg- ular operation of the accelerator and make you lose control of the vehicle while riding.
Page 46: Adjusting The Accelerator Control
SERVICE AND SETTING UP RSV mille 2.11.3 ADJUSTING THE ACCELERATOR CONTROL The idle stroke of the throttle grip must be 2 – 3 mm, measured on the edge of the grip itself. If this is not the case, proceed as follows: Position the vehicle on the side stand.
Page 47 SERVICE AND SETTING UP RSV mille Start the engine. Allow the engine to idle for about 15-20 minutes, or ride the vehicle on a country road for approximately 15 km (9.5 mi). Stop the engine. Keep the vehicle in vertical position, with the two wheels resting on the ground.
Page 48 SERVICE AND SETTING UP RSV mille Check and if necessary replace the sealing washer of the drain plug (4) positioned on the tank. Screw and tighten the drain plug (4) on the tank. Drain plug (4) driving torque: 15 Nm (1.5 kgm). Move the container (3) and position it under the engine base, in correspondence with the drain plug positioned on the engine (5).
Page 49 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 #//,!.4 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Before departure, check the coolant level, change it every two years. CAUTION Check the coolant level and top up the expansion tank with cold engine.
Page 50 SERVICE AND SETTING UP RSV mille Once all the coolant has drained out, move the contain- er (4) under the right-hand radiator. Unscrew and remove the drain plug (6), retrieving the aluminium washer. Once all the coolant has drained out, move the contain- er under the left-hand radiator.
Page 51 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% Fill the tank (2) with brake fluid, see 1.6 (LUBRICANT &2/.4 "2!+%3 &,5)$ CHART), until reaching the correct level between the “MIN” and “MAX” marks. Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID).
Page 52 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% 2%!2 Top up the reservoir (1) by adding brake fluid, see 1.6 "2!+% &,5)$ (LUBRICANT CHART), until reaching the correct level included between the “MIN” and “MAX” marks. Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID).
Page 53 SERVICE AND SETTING UP RSV mille #(%#+).' !.$ 4/00).' 50 4(% Top up the reservoir (1) by adding clutch fluid, see 1.6 #,54#( &,5)$ (LUBRICANT CHART), until reaching the correct level included between the “MIN” and “MAX” marks. Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID).
Page 54 SERVICE AND SETTING UP RSV mille ",%%$).' 4(% "2!+).' 3934%-3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Bleed the braking system after the first 1000 km (625 mi). The air present in the hydraulic system acts as a bearing, absorbing most of the pressure exerted by the brake pump and reducing the effectiveness of the caliper action during braking.
Page 55 SERVICE AND SETTING UP RSV mille ",%%$).' 4(% #,54#( 3934%-3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Bleed the braking system after the first 1000 km (625 mi). The air present in the hydraulic system acts as a bearing, absorbing most of the pressure exerted by the brake pump and reducing the effectiveness of the clutch cylin- der.
Page 56 SERVICE AND SETTING UP RSV mille #(!.').' 4(% &2/.4 "2!+% &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Change the front brake fluid every two year. CAUTION Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 57 SERVICE AND SETTING UP RSV mille #(!.').' 4(% 2%!2 "2!+% &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Change the rear brake fluid every two year. CAUTION Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc.
Page 58 SERVICE AND SETTING UP RSV mille #(!.').' 4(% #,54#( &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Change the clutch fluid every two year. CAUTION Handle clutch fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF CLUTCH FLUID IN THE ENVI- RONMENT.
Page 59 SERVICE AND SETTING UP RSV mille !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 #,%!2!.#% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The brake control lever is positioned ergonomically dur- ing the assembly of the vehicle. If necessary, it is possible to adjust the brake control lever clearance: Remove the lower fairing, see 7.1.32 (REMOVING THE LOWER FAIRING).
Page 60: Checking The Bearing Slack
SERVICE AND SETTING UP RSV mille 34%%2).' Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1500 km (937 mi) and then after eve- ry 7500 km (4687 mi) or 8 months. To assure improved handling, the steering is equipped with rolling bearings.
Page 61 SERVICE AND SETTING UP RSV mille Use a small flat-tip screwdriver to straighten the tabs (those bent upwards) of the tab washer (9). & NOTE Have the special tool to hand cod. 8140203 (socket spanner for adjusting steering). Use the special setscrew spanner to loosen and re- move the lock ring (10).
Page 62: Front Suspension
SERVICE AND SETTING UP RSV mille ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/. 2.29.1 FRONT SUSPENSION The front suspension consists of an hydraulic fork con- nected to the steering column by means of two plates. For the setting of the vehicle attitude, each rod of the fork is provided with an upper screw (1) for the adjustment of the hydraulic braking with extended shock absorber, a lower screw (2) for the adjustment of the hydraulic brak-...
Page 63: 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 also possible to adjust the setting accord- ing to the intended use of the vehicle.
Page 64: Adjusting The Height Of The Forecarriage
SERVICE AND SETTING UP RSV mille 2.29.3 ADJUSTING THE HEIGHT OF THE FORECARRIAGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the relevant centre support stand, see 1.9.4 (SETTING THE VEHICLE ON THE & CENTRE STAND NOTE Procure suitable shims to place between the front tyre and the support (1).
Page 65: Adjusting The Rear Fork
SERVICE AND SETTING UP RSV mille 2%!2 &/2+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Periodically check the tightening of the nut/ pin and of the needle bearings of the rear fork. To carry out this operation, proceed as follows: Position the vehicle on the relevant centre support stand, see 1.9.4 (SETTING THE VEHICLE ON THE &...
Page 66: Rear Suspension
SERVICE AND SETTING UP RSV mille ).30%#4).' 4(% 2%!2 3530%.3)/. CAUTION Adjust the spring preload and the hydraulic braking 2.31.1 REAR SUSPENSION with extended shock absorber according to the con- The rear suspension consists of a spring-shock absorber ditions of use of the vehicle. unit, fixed to the frame by means of a uni-ball and to the When the spring preload is increased, it is necessary rear fork by means of lever systems.
Page 67 SERVICE AND SETTING UP RSV mille 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 to increase also the hydraulic braking with extended shock absorber, in order to avoid sudden jerks while riding.
Page 68: Checking The Rear Suspension Linkage
SERVICE AND SETTING UP RSV mille 2.31.3 CHECKING THE REAR SUSPENSION LINKAGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the conditions of the bearings every 30000 km (18750 mi). NOTE Have someone help you keep the vehicle up- right during this operation. Grip the rear part of the vehicle firmly (see figure), press down and release a few times.
Page 69 SERVICE AND SETTING UP RSV mille 2%!2 7(%%, Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check every 7500 km (4687 mi). Position the vehicle on the special rear support stand & Spin the wheel in either direction by hand. Make sure that the wheel rotation is regular and that there are no obstacles or noise, otherwise change the bearings, see 7.2.2 (DISASSEMBLING THE WHEEL).
Page 70: Checking The Slack
SERVICE AND SETTING UP RSV mille $2)6% #(!). Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check and, where necessary, lubricate every 1000 km (625 mi). The vehicle is equipped with an endless chain, in which a ring link joint is not used. Chain type: 525 CAUTION The drive chain is provided with O rings among the...
Page 71: Checking The Driving Chain
SERVICE AND SETTING UP RSV mille 2.35.2 CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WEAR To put a driving chain under tension, see 2.35.3 (AD- JUSTMENT). Count 17 pins ( 16 steps) on a branch of the chain and measure the distance between the two end pins. If the distance is larger than the limit indicated below, replace the chain, see 7.11 (DISASSEMBLING THE DRIVING CHAIN).
Page 72: Inspecting The Driving Chain Guide Plate
SERVICE AND SETTING UP RSV mille 2.35.5 INSPECTING THE DRIVING CHAIN GUIDE PLATE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Position the vehicle on the stand. Remove the lower fairing, see 7.1.32 (REMOVING THE LOWER FAIRING). Remove the clutch lever, see 3.2.2 (REMOVING THE GEARSHIFT PEDAL).
Page 73: Condition Of Tread
7500 km (4687 mi) or 8 months. safety and manoeuvrability. The inflation pressure must be checked every month and Use only tyres recommended by APRILIA, see 1.5 at room temperature. (TECHNICAL SPECIFICATIONS). This vehicle is provided with tubeless tyres.
Page 74 SERVICE AND SETTING UP RSV mille &5%, 0)0%3 Carefully read 1.2.1 (FUEL). Check the fuel pipes every 7500 km (4687 mi) or 8 months. Replace every four years. If you should encounter signs of wear, cracking, etc., replace the fuel pipes. –...
Page 75 SERVICE AND SETTING UP RSV mille 4)'(4%.).' .543 !.$ 3#2%73 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1000 km (625 mi) and then every 7500 km (4687 mi) or every 8 months. Check all the fastening elements carefully, especially all those components essential for safety, i.e.: –...
Page 76 SERVICE AND SETTING UP RSV mille &!34%.).' %,%-%.43 Check, and where necessary, tighten after the first 1000 km (625 mi) and then every 7500 km (4687 mi) or 8 months. CAUTION The fastening elements featured in the table must be torqued to specification using a torque spanner and ®...
Page 77 SERVICE AND SETTING UP RSV mille FOLLOW Driving shaft, countershaft, gearshift Description Q.ty Screw / nut Note Positioning lever / positioner disc Screw T.C.E.I. M6 x 20 L243 Differential shaft under KS Nut M22 x 1.5 15.0 KS driving shaft Nut M33 x 1.5 23.0 L243...
Page 78 SERVICE AND SETTING UP RSV mille FOLLOW Description Q.ty Screw / nut Note Head “2” (rear) / differential transmission - exhaust camshaft Screw T.E. M6 x 14 L243 Screw Drive gear / induction camshaft L243 T.C.E.I. M6 x 11.5 Screw Head “1”...
Page 79 SERVICE AND SETTING UP RSV mille FOLLOW SIDE STAND Description Q.ty Screw / nut Note 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 Note Fastening of upper plate on fork tubes Fastening of upper plate on fork tubes...
Page 80 SERVICE AND SETTING UP RSV mille FOLLOW AIR FILTER CASING Description Q.ty Screw / nut Note Fastening of air filter casing cover Fastening of air filter casing to throttle body Fastening of intake conveyors SWP3.9 Fastening of air sensor support plate SWP3.9 0.15 FRONT WHEEL...
Page 81 SERVICE AND SETTING UP RSV mille FOLLOW CLUTCH CONTROL Description Q.ty Screw / nut Note 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 Screw / nut Note...
Page 82 SERVICE AND SETTING UP RSV mille FOLLOW FRAME / FAIRINGS Description Q.ty Screw / nut Note Radiator spoiler fastening Fastening of number plate holder to rear mudguard extension Fastening of reflector holder to number plate holder Front mudguard fastening Rearview mirror fastening screws Fastening of rearview mirror mounts and front fairing to mount Lower fastening of front fairing to conveyors Lower fastening of front fairing (on upper part)
Page 83 SERVICE AND SETTING UP RSV mille FOLLOW RIGHT/LEFT HANDLEBARS AND CONTROLS Description Q.ty Screw / nut Note Fastening of anti-vibration weights Anti-vibration weights metal ring M18x1 Fastening of right/left handlebars to the fork Handlebars lock screw Fastening of left dimmer switch 0.15 Fastening of right dimmer switch Fastening of front brake lever...
Page 84 RSV mille ENGINE...
Page 85 ENGINE RSV mille 3.6.13 REPLACING AND INSTALLING THE CONNECTING RODS ....... 3-51 ENGINE 3.6.14 COUNTERSHAFT AND COUNTERSHAFT MECHANISM ....3-52 3.6.15 GEARSHIFT ..........3-53 3.6.16 GEAR SELECTION ........3-58 4!",% /& #/.4%.43 3.6.17 CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY....3-59 ......3-3 R75@FA53D AF8GPE3RAGF 3.6.18 DISASSEMBLING 3.1.1 TECHNICAL DATA ........
Page 86: Technical Data
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 1.7 (CONSUMABLES). 3.1.5 LUBRICANTS See 1.6 (LUBRICANT CHART). 3.1.6 SPECIAL TOOLS &...
Page 87 ENGINE RSV mille %.').% 0!243 7()#( #!. "% $)3!33%-",%$ 7)4(/54 2%-/6).' 4(% %.').% &2/- 4(% &2!-% Carefully read 0.2.1 (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 88 ENGINE RSV mille LEFT SIDE RIGHT SIDE – Rear cylinder spark plugs (6-7), see 2.7 (SPARK – Front cylinder coolant thermistor (15), see 5.5 (RE- PLUGS). MOVING THE COOLANT THERMISTORS). – Drive pinion protection case (8), see 2.35.2 (CHECK- – Front cylinder spark plugs (16 - 17), see 2.7 (SPARK ING THE DRIVING CHAIN, PINION AND SPROCKET PLUGS).
Page 89: Removing The Exhaust Pipes
ENGINE RSV mille 3.2.1 REMOVING THE EXHAUST PIPES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). WARNING Allow the engine to cool to room temperature. Remove the exhaust silencer, see 7.1.47 (REMOVING THE EXHAUST SILENCER). Remove the lower fairing, see 7.1.32 (REMOVING THE LOWER FAIRING).
Page 90: Removing The Gearshift Pedal
ENGINE RSV mille 3.2.2 REMOVING THE GEARSHIFT PEDAL CAUTION Before removing the gearshift pedal, mark the pedal and shaft (see figure) so that it can be refitted cor- rectly. Position the vehicle on the stand. Loosen and remove the screw (1). Slide off the gearshift pedal (2).
Page 91 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 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The removal of the engine is a particularly complex operation.
Page 92 ENGINE RSV mille 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 93 ENGINE RSV mille Disconnect the spark plug caps (15). CAUTION Use a degreasing detergent, brushes and rags to clean the engines outer surfaces. Avoid damaging rubber and plastic parts with corro- sive or penetrating detergents and solvents. Should the use of a steam cleaner prove necessary, do not point the high-pressure jets of water, steam or air at the following parts: wheel hubs, controls on the right and left handlebars, brake pumps, instruments...
Page 94 ENGINE RSV mille Remove the complete throttle body (23), see 4.8.2 (RE- MOVING THE THROTTLE BODY). NOTE The three-way manifold (24) may be kept fitted. Obtain appropriate pliers to attach the clamps, or screw- driver-type pipe clamps to replace the original ones (spe- cial type without screw).
Page 95 ENGINE RSV mille Unscrew and remove the screws (30) and recover the plate (31). Driving torque of screws (30): 40 Nm (4.0 kgm). & NOTE Have the appropriate special tool (32) to hand cod. 8140183 (engine lifting eye hook), a hoist (33) and bands (34) for the lifting operation.
Page 96 ENGINE RSV mille NOTE The elements fastening the engine to the frame must be removed in the order given: RIGHT SIDE LEFT SIDE - 13...
Page 97 ENGINE RSV mille Holding the inside nut (35) still, loosen the screw (36). Driving torque of nut (35) and screw (36): 50 Nm (5.0 kgm). Holding the inside nut (39) still, loosen the screw (40). Driving torque of nut (39) and screw (40): 50 Nm (5.0 kgm).
Page 98 ENGINE RSV mille & Use the special setscrew spanner (53) (cod. 8140203) to loosen and remove the lock rings (41 - 37). Driving torque of lock rings (41 - 37): 50 Nm (5.0 kgm). Unscrew the adjusting bushes (38 - 42) all the way until they touch the frame.
Page 99 ENGINE RSV mille 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. Lift the hoist arm by a few millimeters in order to “re- lease”...
Page 100 ENGINE RSV mille 2%&)44).' 4(% 7(/,% %.').% /. 4(% &2!-% Carefully read 0.2.1 (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 101: Engine Disassembly Sequence
ENGINE RSV mille $)3!33%-",).' 4(% %.').% 3.5.1 ENGINE DISASSEMBLY SEQUENCE NOTE This diagram shows the operations to be per- CAUTION formed and the sequence to be followed when disassem- bling the engine parts. Any components removed must be set aside in groups according to the respective assembly posi- In order to remove the parts outlined with short dashes, tion in order to make sure they are subsequently re-...
Page 102 ENGINE RSV mille 36) Clutch discs 37) Cylinder “1” camshafts 1) Engine 38) Cylinder “1” piston 2) Starter motor 39) Cylinder “2” camshafts 3) Flywheel cover 40) Cylinder “2” head with cylinder 4) Oil filter cover 41) Cylinder “2” head 5) Cylinder “1”...
Page 103: Removing The Starter Motor
ENGINE RSV mille 3.5.2 REMOVING THE STARTER MOTOR NOTE The operations below can be performed without removing the engine from the frame. Move the protection element aside, unscrew and re- move the nut, recover the washer and disconnect the cable of the starter motor. Unscrew and remove the two M6 T.C.E.I.
Page 104 ENGINE RSV mille Use a size 14 bent hexagon-head driver to turn the driv- ing shaft anticlockwise (11) until the piston “1” is at TDC (ignition). NOTE At the TDC (ignition), the reference marks “IN” (12) and “EX” (13) of the two gears prove parallel to the head uncoupling surface, and face each other.
Page 105 ENGINE RSV mille Unscrew and remove the two M6 T.C.E.I. screws (24). Unscrew and remove the four M10 nuts (25). WARNING Be careful to avoid possible injury caused by allow- ing hands to get trapped between the cylinder and the stud bolts (28). Remove the cylinder (26) together with the complete head (27).
Page 106: Disassembling Cylinder "2" (Rear)
ENGINE RSV mille 3.5.4 DISASSEMBLING CYLINDER “2” (REAR), HEAD AND PISTON Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. WARNING The head must be disassembled together with the cylinder.
Page 107 ENGINE RSV mille Slide the gear (13) out a couple of millimetres so that it no longer mates with the driving gear (14). Remove the gear (13) complete with key (15). CAUTION Be careful to keep the key (15) from dropping into the chain compartment.
Page 108 ENGINE RSV mille WARNING Be careful to avoid possible injury caused by allow- ing hands to get trapped between the cylinder and the stud bolts (29). Remove the cylinder (27) together with the complete head (28). CAUTION When removing the cylinder, take care not to damage the cylinder.
Page 109: Removing The Flywheel Cover And Ignition System
ENGINE RSV mille 3.5.5 REMOVING THE FLYWHEEL COVER AND IGNITION SYSTEM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. WARNING When performing work on the ignition system: –...
Page 110: Disassembling Cylinder "1" (Front) Timing Drive Assembly
ENGINE RSV mille 3.5.6 DISASSEMBLING CYLINDER “1” (FRONT) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed without removing the engine from the frame. Unscrew and remove the M10 T.C.E.I. screw (1). Remove the external counterweight (2), the drive pinion (3), the internal counterweight (4) and the countershaft key (5).
Page 111: Removing The Driving Chain Pinion And Oil Filter Cartridge
ENGINE RSV mille 3.5.7 REMOVING THE DRIVING CHAIN PINION AND OIL FILTER CARTRIDGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. Unscrew and remove the M10 T.E. screw (1). Remove the washer (2), the spring washer (3) and the pinion (4).
Page 112: Removing The Clutch Cover
ENGINE RSV mille 3.5.8 REMOVING THE CLUTCH COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed with- out removing the engine from the frame. Unscrew and remove the eight M5 T.C.E.I. screws (1) and remove the complete diaphragm cover (2). Remove the diaphragm (3) from the clutch cover retain- ers (4) and turn it approx.
Page 113: Disassembling The Clutch
ENGINE RSV mille 3.5.9 DISASSEMBLING THE CLUTCH Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The following operations can be performed without removing the engine from the frame. NOTE The driving shaft must be retained at TDC, see 3.5.3 [DISASSEMBLING CYLINDER “1” (FRONT), HEAD AND PISTON].
Page 114: Disassembling The Countershaft Mechanism And Primary Transmission
ENGINE RSV mille 3.5.10 DISASSEMBLING THE COUNTERSHAFT MECHANISM AND PRIMARY TRANSMISSION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The driving shaft must be retained at TDC, see 3.5.3 [DISASSEMBLING CYLINDER “1” (FRONT), HEAD AND PISTON]. Unscrew and remove the M22x1.5 T.E. nut (1), remove the spring washer (2) and countershaft counterweight (3).
Page 115: Disassembling Cylinder "2" (Rear) Timing Drive Assembly
ENGINE RSV mille 3.5.11 DISASSEMBLING CYLINDER “2” (REAR) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the drive gear (1) from the driving shaft. Unscrew and remove the three M8 T.E. screws (2) and detach the lock washers (3). NOTE The cylinder and the head are still fitted on the engine.
Page 116: Disassembling The Oil Pump
ENGINE RSV mille 3.5.12 DISASSEMBLING THE OIL PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the seeger ring (1). Slide the oil pump gear (2) up and off. CAUTION Once disassembled, the oil pump gear (2) must al- ways be replaced. NOTE Turn the oil pump shaft so that the pin can be slid out through the slot on the pump cover (5).
Page 117: Disassembling The Gear Selection Mechanism
ENGINE RSV mille 3.5.13 DISASSEMBLING THE GEAR SELECTION MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Unscrew the threaded pin M8 (1) retaining the driving shaft at TDC. NOTE Turn the driving shafts by hand to enable the gear to engage. Engage 6 gear.
Page 118: Splitting The Engine Casing Open
ENGINE RSV mille 3.5.14 SPLITTING THE ENGINE CASING OPEN Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Take the seeger ring (1) and thrust washer (2) off the secondary shaft. Unscrew and remove the twenty M6 T.C.E.I. screws (3). CAUTION Comply with the following instructions: –...
Page 119: Disassembling The Gearshift
ENGINE RSV mille 3.5.16 DISASSEMBLING THE GEARSHIFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the two spindles (1). Turn both gearshift forks (2) of the secondary shaft (3) outwards, moving them away from the guides of the se- lector cylinder (4), and remove them. Turn the gearshift fork (5) of the primary shaft (6) out- wards, moving it away from the guide of the selector cylinder (4), and remove the selector cylinder.
Page 120: Engine Casing
ENGINE RSV mille 7/2+ /. 4(% ).$)6)$5!, 0!243 WARNING Take care not to burn yourself when handling hot en- gine parts. CAUTION If any of the components has exceeded one of the wear limits or if, during the visual inspection of a component, a defect is detected liable to compromise the operation of the engine, said component must be replaced.
Page 121: Engine Half-Casing, Clutch Side
ENGINE RSV mille Make sure the galleries are clear in all the lubrication holes (1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 - 17 - 18) in the two halves of the casing and, where necessary, clean them by blowing a jet of compressed air inside.
Page 122: Engine Half-Casing - Ball Bearings And Oil Seals
ENGINE RSV mille 3.6.4 ENGINE HALF-CASING - BALL BEARINGS AND OIL SEALS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY NOTE The oil seals can be disassembled and assem- bled without removing the engine from the vehicle. In order to remove and insert the ball bearings, heat the engine casing to a temperature of approx.
Page 123 ENGINE RSV mille ASSEMBLY Check the interference between the bearing and the engine casing hole. Interference “A” min. 0.01 mm. Lubricate the external diameter of the bearings slightly and, with due care, fit them all the way in on the outer ring using a suitable assembly punch: –...
Page 124: Engine Half-Casing - Main Bushes
ENGINE RSV mille 3.6.5 ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The main bushes may only be replaced by authorized repair shops suitably skilled in the use of the relevant measuring equipment and tools.
Page 125 ENGINE RSV mille DISASSEMBLY Use a felt pen to mark the contact surfaces (7) of the main bushes on both halves of the engine casing so as to provide an external visual reference. CAUTION Do not perform any mechanical markings. &...
Page 126 ENGINE RSV mille ASSEMBLY Clean the diameter of the main bush housing inside the engine casing. Determine the main bush size group based on the col- oured markings (10) on the engine casing. CAUTION The lower main bush (11) of the driving shaft, fly- wheel side, features a lubrication hole.
Page 127 ENGINE RSV mille & NOTE Have the appropriate special tools to hand: – (12) cod. 0277725 (driving shaft bush inserter pad); – (13) cod. 0277537 (countershaft bush inserter pad). Heat the engine casing to approx. 150° C (302° F). Coat the main bushes and bearing housings inside the ®...
Page 128: Replacing The Engine Casing
ENGINE RSV mille 3.6.6 REPLACING THE ENGINE HALF-CASING CYLINDRICAL PINS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Use a micrometer to check the wear of the cylindrical pins (1, 2) of the starter motor drive assembly and (3) coolant pump idler gear. Wear limit Ø...
Page 129: Neutral Gear Indication
ENGINE RSV mille 3.6.7 NEUTRAL GEAR INDICATION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Make sure the contact pin (1) of the contact screw (2) slides smoothly and check the preloading of the spring. CAUTION The cap on the pin must not be worn. Where necessary, replace the contact screw.
Page 130: Oil Pump And Oil Pump Drive Assembly
ENGINE RSV mille 3.6.10 OIL PUMP AND OIL PUMP DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The oil pump gears, both driving (1) and driven (2), must always be replaced once they have been disas- sembled. NOTE The oil pump drive gear (1) is attached to the support plate of the complete clutch housing.
Page 131 ENGINE RSV mille CHECKING THE OIL PUMP Check the oil pump rotors, the sliding surfaces of the external rotors in both pump casings and the thrust- bearing surfaces for any signs of grooving. Measure the play between the external rotors (7 - 15), the engine casing (16) and the pressure pump casing (9) using a feeler gauge.
Page 132: Driving Shaft
ENGINE RSV mille 3.6.11 DRIVING SHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the wear of the driving shaft: – section for main bushes (1); wear limit min. Ø 45.955 mm; – section for support bushes (2); wear limit min. Ø 29.970 mm; –...
Page 133: Disassembling The Connecting Rods
ENGINE RSV mille 3.6.12 DISASSEMBLING THE CONNECTING RODS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Before disassembling the connecting rods (1) and covers (2), mark them so they are refitted in the same position (cylinder “1” and “2”) and with the same di- rection of rotation.
Page 134: Replacing And Installing The Connecting Rods
ENGINE RSV mille 3.6.13 REPLACING AND INSTALLING THE CONNECTING RODS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The complete connecting rods supplied as spare parts include bushes in all three sizes (see table). The bushes are marked, according to size, in red, blue and yellow (4).
Page 135: Countershaft And Countershaft Mechanism
ENGINE RSV mille 3.6.14 COUNTERSHAFT AND COUNTERSHAFT MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the wear of the countershaft: – housing of bush (1); wear limit min. Ø 31.980 mm; – housing of thrust support bush (2); wear limit min. Ø 19.990 mm; –...
Page 136: Gearshift
ENGINE RSV mille 3.6.15 GEARSHIFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION When taking the gearshift apart, set the disassem- bled components down according to the assembly position, assigning them to the corresponding shaft so as to be sure they are reassembled and installed correctly.
Page 137 ENGINE RSV mille TAKING THE GEARSHIFT APART Secondary shaft Use crimpers to remove the seeger rings (4). Remove the gearshift gears from the secondary shaft, starting with the idle gear of 1 gear (1) and then mov- ing on to the shim washers (2), roller cages (3), seeger rings (4) and shim rings (5).
Page 138 ENGINE RSV mille Check the following components for wear: – roller bearings (1); – sides of the teeth (2) of all gears. NOTE Small grey marks and tiny hollows are tolerated up to a maximum corresponding to approx. 0.5% of the sides surface area.
Page 139 ENGINE RSV mille Check the housings of the secondary shaft and primary shaft for wear: – wear limit (9) min. Ø 19.972 mm; – wear limit (10) min. Ø 29.915 mm; – wear limit (11) min. Ø 29.965 mm; – wear limit (12) min. Ø 24.972 mm; –...
Page 140 ENGINE RSV mille ASSEMBLY Oil the secondary shaft, primary shaft, gearshift gears and roller bearings slightly. Reassemble the secondary shaft and primary shaft in the reverse order. Fit the seeger ring, using the plier for seeger ring only. CAUTION Do not reuse the seeger rings. The seeger rings must be replaced every time the gearshift is taken apart.
Page 141: Gear Selection
ENGINE RSV mille 3.6.16 GEAR SELECTION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the end play (1) of the gearshift forks inside the corresponding grooves in the selection gears. Wear limit max. 0.15 mm. NOTE If the wear limit is exceeded, you must deter- mine which component needs replacing by checking the gearshift forks and selection gears.
Page 142: Clutch And Primary Transmission Assembly
ENGINE RSV mille 3.6.17 CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the lined discs (1) and steel discs (2) for cracks or any distortion (3) by placing them on a flat surface. Max. permissible distortion (3): 0.15 mm. NOTE The inside discs (2) must not feature grooves or temper colours.
Page 143 ENGINE RSV mille Check the smoothness and slack of the ball bearings (7) on the spring plate (8) and, where necessary, re- place them. NOTE When removing and refitting the ball bearings, heat the spring plate to 80 - 100 °C (176 - 212 °F) and use a suitable assembly punch.
Page 144: Disassembling The Complete Clutch Housing
ENGINE RSV mille 3.6.18 DISASSEMBLING THE COMPLETE CLUTCH HOUSING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Slip off the oil pump drive gear (1). CAUTION The oil pump drive gear (1) must always be replaced once it has been disassembled. Unscrew and remove the three M8 T.E.
Page 145: Clutch Cover
ENGINE RSV mille 3.6.19 CLUTCH COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the gasket surface for signs of damage and check the whole thread to make sure it is in a perfect state of repair. Check the support bushes of the driving shaft (1) and countershaft (2) for signs of rolling or grooves.
Page 146 ENGINE RSV mille ASSEMBLY Clean the diameter of the main bush housing and the lubrication hole between the bush housings inside the clutch cover. Determine the driving shaft bushes size group based on the coloured markings (5) on the clutch cover. NOTE The size group of the main bushes is also marked with a coloured dot.
Page 147: Coolant Pump
ENGINE RSV mille 3.6.21 COOLANT PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The coolant pump only needs disassembling in the event of oil or coolant leakage. Check the drainage hole (1) for any signs of oil or cool- ant leakage.
Page 148 ENGINE RSV mille ASSEMBLY & NOTE Have the appropriate special tools to hand: – (14) handle for pads; – (15) cod. 0277670 (coolant pump shaft housing oil seal assembly pad); – (16) cod. 0877257 (coolant pump shaft housing sliding ring assembly pad). NOTE The closed side of the oil seal must be fitted so that it faces the impeller (3).
Page 149: Timing Drive Assembly
ENGINE RSV mille 3.6.22 TIMING DRIVE ASSEMBLY CAUTION Set the cylinder “1” and “2” timing drive assemblies aside in distinct groups so that you are sure to refit the parts in the same housing when it comes to reas- sembly. Check the sides of the timing gear (1), drive gears (2) and intermediate drive gears (3) for broken materials or distortion.
Page 150: Head And Camshaft
ENGINE RSV mille 3.6.23 HEAD AND CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). ASSEMBLY Unscrew and remove the four shouldered M8 screws (1) respectively and remove head “1” and “2” from the cylinder. Unscrew and remove the four M6 T.C.E.I. screws (2) together with the respective washers (3) from head “2”...
Page 151: Disassembling The Intake And Exhaust Valves
ENGINE RSV mille 3.6.24 DISASSEMBLING THE INTAKE AND EXHAUST VALVES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Before disassembling the valves, check head pressure loss on a plate (Bosch or Suntester). If the pressure loss is less than 5%, valve tightness is correct.
Page 152: Camshaft And Camshaft Bushes
ENGINE RSV mille 3.6.25 CAMSHAFT AND CAMSHAFT BUSHES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the cams (1) for broken material, signs of distor- tion or wear and, where necessary, replace the cam- shaft. Measure the play of the camshafts: Place the camshafts in the head.
Page 153: Upper Countershaft
ENGINE RSV mille 3.6.26 UPPER COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the countershaft for wear. NOTE The bush housing (1) is slightly tapered, hence the measurement must be taken half way along the hous- ing. – Bush housing (1): wear limit: min.
Page 154: Disassembling And Assembling The Upper Countershaft Ball Bearings And Oil Seal
ENGINE RSV mille 3.6.27 DISASSEMBLING AND ASSEMBLING THE UPPER COUNTERSHAFT BALL BEARINGS AND OIL SEAL Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). & NOTE Have the appropriate special tools to hand: – (6) cod. 8140156 + 8140157 + 0276377 (clutch cover sleeve puller);...
Page 155: Valve Guide
ENGINE RSV mille 3.6.28 VALVE GUIDE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Use a dial gauge to measure the wear of the valve guide (1). Wear limit (2): max. Ø 6.05 mm. NOTE If the valve guide is worn, it can be replaced. ASSEMBLY AND DISASSEMBLY Slip off the valve stem seal (3) and remove the valve spring shim (4).
Page 156 ENGINE RSV mille CAUTION La testata o il guidavalvola si danneggia se non si ® usa il MOLYKOTE G-N. ® Apply a coat of MOLYKOTE G-N on the head hole and on the valve guide assembly edge. & NOTE Have the appropriate special tool (8) to hand (cod.
Page 157: Valves
ENGINE RSV mille 3.6.29 VALVES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION The seat (1) on the head of the valve is reinforced by means of inductive hardening. For this reason, the seat cannot be reground and, in- stead, the valve must be replaced. Grinding with abrasive paste is nonetheless permit- ted, whilst it is prohibited to regrind a valve at the end on the valve stem.
Page 158 ENGINE RSV mille VALVE SEATS Coat the valve seat surfaces with marking paste (Prus- sian blue). Insert the corresponding valve (1) and turn the valve, pressing down slightly with a valve grinder. Check the width of the valve seat (2-3) and the contact mark, checking for any signs of wear.
Page 159 ENGINE RSV mille ASSEMBLING THE VALVES IN THE HEAD & NOTE Have the appropriate special tools to hand: – (3) cod. 0277210 (valve guide assembly pad): – (8) cod. 0276479 (valve spring compression tool); – (9) cod. 8140179 (valve disassembly and reassembly bow).
Page 160: Cylinder
ENGINE RSV mille 3.6.30 CYLINDER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). All the gasket surfaces must be cleaned and flat. Flat- ness of the gasket surfaces: Max. permissible distortion: 0.04 mm. Make sure all the threads are in a perfect state of re- pair.
Page 161: Piston And Gudgeon Pin
ENGINE RSV mille 3.6.31 PISTON AND GUDGEON PIN Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Clean the piston crown (1) and the area above the up- per piston ring (2) of any residual combustion products. Check the piston for any cracks and the sliding surface of the piston for signs of compression (picking-up).
Page 162 ENGINE RSV mille Use a feeler gauge to measure the end play (7-8-9) of the piston rings inside the grooves. – L-section ring wear limit (7) max. 0.12 mm; – Tapered protruding ring: wear limit (8) max. 0.12 mm; – Scraper ring wear limit (9) max.
Page 163: Starter Motor Drive Assembly
ENGINE RSV mille 3.6.32 STARTER MOTOR DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE If the toothing of the double starter gear is dis- torted, the toothing of the starter motor must also be checked. Check the toothing of the double starter gear (1), idler gear (2) and the freewheel gear (3) for broken material or distortion.
Page 164 ENGINE RSV mille Remove the freewheel (10) from the relevant housing (11) and check the rollers of the freewheel (10) for signs of wear. Check whether the external helical spring is preloaded enough to keep the rollers in place. Check the sliding surface of the freewheel inside the relevant housing (11) for signs of wear.
Page 165: Ignition Generator
ENGINE RSV mille 3.6.33 IGNITION GENERATOR Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The ignition generator produces alternating cur- rent which is then transformed into direct current by the regulator/rectifier, which then charges the battery. WARNING Before performing any repair work on the ignition generator, take out the ignition key and disconnect the battery, disconnecting the negative pole (–) first.
Page 166 ENGINE RSV mille STATOR Disconnect the ignition generator connector (1) from the electric wiring. Use an ammeter to measure the resistance between the three output connections to be found on the con- nector (yellow cables). – Standard resistance value in the range 0.2 - 0.5 Ω at 20 °C (68 °F).
Page 167: Spark Plugs
ENGINE RSV mille 3.6.34 SPARK PLUGS See 2.7 (Spark plugs). 3.6.35 DRIVING CHAIN PINION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the drive pinion (1), see 7.9.1 (REMOVING THE REAR FORK). Check the pinions internal toothing (2) for wear. Check the pinions external toothing (3) for wear and signs of distortion.
Page 168: Assembling The Gearshift
ENGINE RSV mille 2%!33%-",).' 4(% %.').% Carefully read 3.5.1 (ENGINE DISASSEMBLY SE- QUENCE). WARNING Touching the engine while hot may cause burns. CAUTION When repairing the engine, always replace all the pre- viously disassembled gaskets, seeger rings, O-rings and seals. Unless otherwise indicated, lubricate all the moving and sliding parts.
Page 169: Assembling The Driving Shaft And Countershaft
ENGINE RSV mille Oil the shift cam (8) and insert it in the relevant slot in the casing. Attach the 3 gearshift forks inside the respective guides of the shift cam (8). Insert the two gearshift rods (9), pushing them all the way into the respective slots in the flywheel side half of the engine casing.
Page 170: Assembling The Engine Casing
ENGINE RSV mille 3.7.3 ASSEMBLING THE ENGINE CASING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Use a new gasket. Apply the engine casing gasket (1) on the flywheel side half of the engine casing. NOTE The engine casing gasket must coincide with all the engine casing holes over the whole area.
Page 171: Assembling The Gear Selection Mechanism
ENGINE RSV mille Screw on the magnetic plug (15). Driving torque of magnetic plug (15): 20 Nm (2.0 kgm). Insert a new oil filter cartridge (16) in the housing in the casing. CAUTION Having changed the oil and oil filter, the engine must be started for approx.
Page 172: Checking The Gear Selection Mechanism
ENGINE RSV mille 3.7.5 CHECKING THE GEAR SELECTION MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Make sure the needle spring (1) in the rotating lever (2) and in the cylindrical pin (3) features no slack. NOTE If this is not the case, one of the needle springs (1) end must be bent.
Page 173: Assembling The Oil Pump
ENGINE RSV mille 3.7.6 ASSEMBLING THE OIL PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION ® Make sure the LOCTITE product does not get inside the suction pump hole. ® Apply a thin film of LOCTITE 574 on the gasket sur- face (1) of the oil pump casing.
Page 174: Assembling The Drive Assembly "2" (Rear)
ENGINE RSV mille CAUTION Once disassembled, the oil pump gear must always be replaced. Fit a new oil pump gear (15). NOTE You must feel the pin (13) engaging perfectly in- side the groove on the oil pump gear. Fit the seeger ring (16) in the groove of the oil pump shaft.
Page 175 ENGINE RSV mille Guide the chain tightener shoe (22) through the chain compartment and fasten it in the housing by means of the spacer bush (23). Oil the two roller bearings (24) and push them onto the bearing pins of the bearing flange (25). NOTE Insert the bearing flange all the way in, tapping gently with a plastic hammer.
Page 176: Assembling The Coolant Pump Drive
ENGINE RSV mille 3.7.8 ASSEMBLING THE COOLANT PUMP DRIVE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). ® Coat the end of the countershaft (1) with LOCTITE Anti Seize. Oil the housing at the end of the countershaft. Insert the key (2) in the countershaft. Insert the washer (3) with the flared side facing down.
Page 177: Assembling The Primary Transmission And Clutch
ENGINE RSV mille 3.7.9 ASSEMBLING THE PRIMARY TRANSMISSION AND CLUTCH Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). ® Coat the end of the driving shaft with LOCTITE Anti Seize. NOTE The collar of the drive gear must face down. Insert the drive gear (1) on the driving shaft. Fit the spring washer, then fasten and tighten the ®...
Page 178 ENGINE RSV mille & NOTE Have the appropriate special tool to hand (cod. 0277281 clutch blocking tool). Insert the clutch blocking tool (11). CAUTION Insert the clutch blocking tool (11) all the way in to the clutch basket so as not to damage the basket when the nut (12) is tightened.
Page 179: Assembling The Piston And Cylinder "2" (Rear)
ENGINE RSV mille 3.7.10 ASSEMBLING THE PISTON AND CYLINDER “2” (REAR) Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Cover the engine compartment with a cloth. Insert the two locating dowels (1). ® Coat the four M10 stud bolts (2) with LOCTITE and screw them onto the engine casing.
Page 180 ENGINE RSV mille CAUTION Use new bent-end gudgeon pin seeger rings (7) only. Insert the gudgeon pin seeger ring (7) in the piston, pushing down hard. NOTE Support the piston (3). Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook (8) is inserted in the slot of the actual piston.
Page 181 ENGINE RSV mille Insert the two locating dowels (9) in the cylinder. CAUTION Use a new head gasket. Fit the head gasket (10) in place. Place the preassembled head in the cylinder and tight- en it on with the four shouldered T.E. screws (11). –...
Page 182: Adjusting Valve Clearance
ENGINE RSV mille 3.7.11 ADJUSTING VALVE CLEARANCE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Check and, where necessary, adjust the valve clear- ance: – at periodic intervals, see 2.1.1 (REGULAR SERV- ICE INTERVALS CHART); – every time the timing drive assembly is repaired or taken apart.;...
Page 183: Assembling Head "2" (Rear) Camshaft
ENGINE RSV mille 3.7.12 ASSEMBLING HEAD “2” (REAR) CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Adjust the valve clearance, see 3.7.11 (ADJUSTING VALVE CLEARANCE). Oil the housings of the output camshaft (1) and input camshaft (2). ® Coat the cams with MOLYKOTE G-N and insert the camshafts in the head.
Page 184: Assembling Head "2" (Rear) Timing Drive Assembly
ENGINE RSV mille 3.7.13 ASSEMBLING HEAD “2” (REAR) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The driving shaft must be locked at TDC of cyl- inder “2” (rear), see 3.5.11 [DISASSEMBLING CYLIN- DER “2” (REAR) TIMING DRIVE ASSEMBLY]. Turn the camshafts so that the cam lobes (1) point away from each other.
Page 185 ENGINE RSV mille Insert the chain guide (13) as far as it will go. Oil the chain tightener (14) and fit it in the cylinder with the closed end facing the chain tightener shoe (15). Screw on the M18x1 T.E. screw (16) complete with seal.
Page 186: Assembling Head "1" Timing Drive Assembly
ENGINE RSV mille 3.7.14 ASSEMBLING HEAD “1” TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Unscrew the threaded bolt (1) for retaining the shaft at TDC and turn the driving shaft (2) 300° anticlockwise so that the connecting rod (3) of cylinder “1” is at TDC. NOTE Move the connecting rod (3) to a central position so that it is not tilted in the casing.
Page 187 ENGINE RSV mille Rotate the intermediate drive gear (6) so that the two reference marks (16) are lined up with each other. Place the counterweight (17) on the countershaft. Insert the key (18) in the countershaft. Push in the drive pinion (19) and counterweight (20). NOTE The half-moon shaped key (18) must be insert- ed in the upper counterweight slot.
Page 188: Assembling The Starter Motor Drive Assembly And Ignition System
ENGINE RSV mille 3.7.15 ASSEMBLING THE STARTER MOTOR DRIVE ASSEMBLY AND IGNITION SYSTEM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Oil the two pins (1) and coat the housing (2) of the free- ® wheel gear on the driving shaft with MOLYKOTE G-N.
Page 189: Assembling The Piston And Cylinder "1" (Front)
ENGINE RSV mille 3.7.16 ASSEMBLING THE PISTON AND CYLINDER “1” (FRONT) Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Cover the engine compartment with a cloth. Insert the two locating dowels (1). ® Coat the four M10 stud bolts (2) with LOCTITE and screw them onto the engine casing.
Page 190 ENGINE RSV mille CAUTION Use new bent-end gudgeon pin seeger rings (7) only. Insert the gudgeon pin seeger ring (7) in the piston, pushing down hard. NOTE Support the piston (3). Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook (8) is inserted in the slot of the actual piston.
Page 191 ENGINE RSV mille Insert the two locating dowels (9) in the cylinder. CAUTION Use a new head gasket. Fit the head gasket (10) in place. Place the preassembled head in the cylinder and tight- en it on with the four shouldered T.E. screws (11). –...
Page 192: Assembling Head "1" (Front) Camshaft
ENGINE RSV mille 3.7.17 ASSEMBLING HEAD “1” (FRONT) CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Adjust the valve clearance, see 3.7.11 (ADJUSTING VALVE CLEARANCE). Oil the housings of the exhaust camshaft (1) and intake camshaft (2). ® Coat the cams with MOLYKOTE G-N and insert the camshafts in the head.
Page 193: Assembling Head "1" (Front) Timing Drive Assembly
ENGINE RSV mille 3.7.18 ASSEMBLING HEAD “1” (FRONT) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). NOTE The driving shaft must be retained at TDC of cyl- inder “1” (front), see 3.5.6 [DISASSEMBLING CYLINDER “1” (FRONT) TIMING DRIVE ASSEMBLY]. Turn the camshafts so that the cam lobes (1) point away from each other.
Page 194: Assembling The Valve Cover
ENGINE RSV mille 3.7.19 ASSEMBLING THE VALVE COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Coat the cable (1) of the camshaft sensor and rubber element (2) with SILASTIC 732 RTV. Grease the head cover gasket (3) and insert it in the groove on the head cover (4).
Page 195: Assembling The Ignition Cover
ENGINE RSV mille 3.7.20 ASSEMBLING THE IGNITION COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Where necessary, insert the locating dowel (1). NOTE Use a new gasket (2). Apply the gasket (2). & NOTE Have the appropriate special tool (3) to hand cod.
Page 196: Assembling The Clutch Housing
ENGINE RSV mille 3.7.21 ASSEMBLING THE CLUTCH HOUSING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Remove the threaded bolt (1) for retaining the shaft at TDC. Insert the two locating dowels (2). Fit the gasket (3) in place. NOTE Use a new gasket. Coat the end of the driving shaft (4) and end of the ®...
Page 197 ENGINE RSV mille Fit the washer (19), support cup (20), diaphragm (21), cup (22) and spring washer (23) on the clutch disen- gaging shaft (24) and secure them with an M12 stop ® nut (25) previously coated with LOCTITE 648. Driving torque of nut (25): 30 Nm (3.0 kgm).
Page 198: Assembling The Starter Motor
ENGINE RSV mille 3.7.22 ASSEMBLING THE STARTER MOTOR Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Grease the starter motor gear. Coat the starter motor flanged housing with MOLYKO- ® G-N. Centre the starter motor (1) in the casing, pushing it all the way in and securing it with the two M6 T.C.E.I.
Page 199: Bleeding The Engine Oil Circuit
ENGINE RSV mille %.').% #(%#+3 35"3%15%.4 4/ 2%!33%-",9 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). 3.8.1 BLEEDING THE ENGINE OIL CIRCUIT Refill the engine with motor oil, see 2.14 (CHANGING THE ENGINE OIL AND THE OIL FILTER). Slip the two electric connectors off the two injectors (1- Start the engine for a moment until the engine oil pres- sure LED goes off.
Page 200 RSV mille FUEL SUPPLY SYSTEM...
Page 201 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!.+ ...... 4-5 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 .............
Page 202 FUEL SUPPLY SYSTEM RSV mille &5%, 4!.+ The filler cap is to be found on the top of the tank, whilst the bottom part houses: – the fuel supply pump unit; – a pipe for draining water from the filler cap in the event of rain or during washing;...
Page 203: Maintenance
FUEL SUPPLY SYSTEM RSV mille Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.1 (FUEL). WARNING Fuel vapours are noxious for the health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Avoid any contact of the fuel with the skin.
Page 204 FUEL SUPPLY SYSTEM RSV mille $2!).).' 4(% &5%, 4!.+ See 2.9 (DRAINING THE FUEL TANK) for the fuel tank draining procedure. 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.1 (FUEL) and 4.1.1 (MAINTE- NANCE).
Page 205 FUEL SUPPLY SYSTEM RSV mille 2%-/6).' 4(% &5%, 3500,9 05-0 Remove the whole fuel supply pump unit, see 4.3 (RE- MOVING THE WHOLE FUEL SUPPLY PUMP UNIT). NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
Page 206: 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 ignition management depends on the specific consumption levels.
Page 207 FUEL SUPPLY SYSTEM RSV mille Intake pressure sensor (13) Location: in the intake manifold. The pressure measured in the induction pipe is con- verted into a voltage signal. Moreover, the injection time also depends on the induc- tion pipe pressure, especially when the throttle valve opening angle is limited (during idling).
Page 208: Injection System Diagram
FUEL SUPPLY SYSTEM RSV mille 4.7.3 INJECTION SYSTEM DIAGRAM 1) Engine control unit 12) 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 15) Driving shaft position sensor and generator connector 5) Fuel pump...
Page 209: Engine Control Unit Connectors
FUEL SUPPLY SYSTEM RSV mille 4.7.4 ENGINE CONTROL UNIT CONNECTORS For further details see 6.17 (CONNECTIONS TO THE ENGINE CONTROL UNIT). 26-pin connector (1) 16-pin connector (2) Terminal Terminal Connections Connections labelling labelling Driving shaft position sensor “+” Battery connection positive pole “+” Camshaft position sensor Earth (for control circuit) Intake pressure sensor and throttle...
Page 210: Automatic Testing
FUEL SUPPLY SYSTEM RSV mille 4.7.5 AUTOMATIC TESTING 4.7.12 COOLANT THERMISTORS Fault code “21” See 6.4 (IGNITION SYSTEM). See 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION). 4.7.6 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP 4.7.13 AIR THERMISTORS ON THE DISPLAY Fault code “22”...
Page 211: 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 212 FUEL SUPPLY SYSTEM RSV mille NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw). Release the head off the pipe clamps (9 - 10). Pull the pipes (12 - 13) off the throttle body (11). Disconnect the two throttle cables (14 - 15).
Page 213: Disassembling The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.3 DISASSEMBLING THE THROTTLE BODY Carefully read 0.2.1 (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 hex-head M5x12 screws (3). Slip the whole support bracket (4) securing the throttle cables, with the two bushes (5) and the torsion spring (6), off the throttle body.
Page 214 FUEL SUPPLY SYSTEM RSV mille 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 215: 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 injection valves may also be checked whilst fitted. Check the following components: –...
Page 216: Refitting The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.5 REFITTING THE THROTTLE BODY Carefully read 0.2.1 (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. Fit the new O-rings (1) and seals (2) on both injector.
Page 217 FUEL SUPPLY SYSTEM RSV mille Insert the shaft sealing ring (17) on the fulcrum pin (18). Fit the two bushes (19) and torsion spring (20). Fit the pulley (21) on the throttle cable support bracket. CAUTION Make sure that the ends of the torsion spring (20) are hooked onto the throttle cable support bracket and pulley (21).
Page 218: Replacing The Throttle Valve Control Lever
FUEL SUPPLY SYSTEM RSV mille 4.8.6 REPLACING THE THROTTLE VALVE CONTROL LEVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY Remove the fuel tank partially, see 7.1.4 (PARTIAL RE- MOVAL OF THE FUEL TANK). Remove the air filter casing, see 7.1.7 (REMOVING THE AIR CLEANER CASE).
Page 219 FUEL SUPPLY SYSTEM RSV mille 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 AP-LUBE on the spring (4), see 1.7.2 (USE OF CONSUMABLES). CAUTION Make sure the ends of the torsion spring (4) are hooked onto the throttle body and throttle valve con-...
Page 220: Checking Throttle Valve Control Shaft End Play
FUEL SUPPLY SYSTEM RSV mille 4.8.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY Remove the fuel tank partially, see 7.1.4 (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 221: Adjusting The Throttle Body
FUEL SUPPLY SYSTEM RSV mille 4.8.8 ADJUSTING THE THROTTLE BODY Partially remove the fuel tank, see 7.1.4 (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 idling adjusting screw (1) is painted and cannot be adjusted.
Page 222: Adjusting The Throttle Valve
FUEL SUPPLY SYSTEM RSV mille 4.8.9 ADJUSTING THE THROTTLE VALVE POTENTIOMETER CAUTION The two sunk hexagon cheese-head screws fasten- ing the throttle valve potentiometer (1) are painted during production and cannot be loosened. The throttle valve potentiometer can only be adjusted in the event of replacement.
Page 223 FUEL SUPPLY SYSTEM RSV mille 4.8.10 CYLINDER SYNCHRONIZATION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.1 (FUEL). The cylinders must be synchronized whenever the engine runs smoothly no longer when idling. Run a few kilometres until reaching the regular working temperature.
Page 224 FUEL SUPPLY SYSTEM RSV mille CHECKING THE CYLINDER VACUUM VALUES NOTE The checking of the cylinder vacuum values on the new models no longer requires the intake flange to be replaced with the vacuometer attachment (1) since the throttle body is already fitted with the suitable connector (2).
Page 225 FUEL SUPPLY SYSTEM RSV mille Check the vacuometer (3) for the vacuum value of a cylinder and then of the other one. NOTE The vacuum value reading should be the same for both cylinders. Vacuum values for both cylinders: 300 ± 30 mbar at 1250 ± 100 rpm. Once the cylinders have been synchronized correctly and the idling rpm adjusted, remove the vacuometer at- tachment (1) and fit the intake flange (15).
Page 226 RSV mille COOLING SYSTEM...
Page 227 COOLING SYSTEM RSV mille COOLING SYSTEM 4!",% /& #/.4%.43 $%3#2)04)/..........5-3 2%-/6).' 4(% 2!$)!4/23 ....5-5 2%-/6).' 4(% #//,).' %,%#42/&!.3 ....5-6 2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( ..5-7 2%-/6).' 4(% #//,!.4 4(%2-)34/23 ....5-7 2%-/6).' 4(% 4(%2-!, %80!.3)/.
Page 228 COOLING SYSTEM RSV mille $%3#2)04)/. The centrifugal pump (positioned inside the engine and To check and top up the coolant, refer to the “LOW” and driven by the latter) draws coolant and distributes it to the “FULL” reference marks, see 2.15 (CHECKING AND galleries in the cylinders and in the heads in order to cool TOPPING UP COOLANT).
Page 229 COOLING SYSTEM RSV mille Path with coolant temperature below 65°C (149°F). Pump coolant enters the galleries (temperature taken by thermistors and sent up on the right-hand dis- play on the dashboard) coolant leaves the gallery (right-hand side of engine) thermal expansion valve (completely shut) pump.
Page 230 COOLING SYSTEM RSV mille 2%-/6).' 4(% 2!$)!4/23 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). NOTE The following procedure refers to a single radia- tor, though it is applicable to both. Turn the ignition switch to position “ ”...
Page 231 COOLING SYSTEM RSV mille 2%-/6).' 4(% #//,).' %,%#42/&!.3 Carefully read 0.2.1 (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“ ” . Remove the relevant side fairing, see 7.1.26 (REMOV- ING THE SIDE FAIRINGS).
Page 232 COOLING SYSTEM RSV mille 2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Turn the ignition switch to position “ ” . Remove the left side fairing, see 7.1.26 (REMOVING THE SIDE FAIRINGS). Disconnect the electric connectors (1-2) from the ther- mal switch (3).
Page 233 COOLING SYSTEM RSV mille 2%-/6).' 4(% 4(%2-!, %80!.3)/. 6!,6% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Drain the cooling circuit completely, see 2.16 (CHANG- ING THE COOLANT). NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
Page 234 COOLING SYSTEM RSV mille 2%-/6).' 4(% &),,%2 .%#+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Drain the cooling circuit completely, see 2.16 (CHANG- ING THE COOLANT). NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
Page 235 COOLING SYSTEM RSV mille 2%-/6).' 4(% %80!.3)/. 4!.+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Remove the right side fairing, see 7.1.26 (REMOVING THE SIDE FAIRINGS). Move the pipe clamp (1). Pull the pipe (2) off the filler neck (3). Bend the pipe (2) back on itself and secure it in place on the top of the expansion tank with adhesive tape.
Page 236 RSV mille ELECTRICAL SYSTEM...
Page 237: Position Sensor
ELECTRICAL SYSTEM RSV mille #//,).' %,%#42/&!......6-25 6.9.1 WIRING DIAGRAM ........6-25 ELECTRICAL SYSTEM 6.9.2 CHECKING THE ELECTROFAN OPERATION ....6-25 6.9.3 CHECKING 4!",% /& #/.4%.43 THE THERMAL SWITCH OPERATION ..6-26 6.9.4 CHECKING THE ELECTROFAN RELAY ... 6-26 ).42/$5#4)/.
Page 238: Cable Colours
ELECTRICAL 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 Light blue Blue White...
Page 239 ELECTRICAL SYSTEM RSV mille %,%#42)# #/-0/.%.43 ,!9/54...
Page 240 ELECTRICAL SYSTEM RSV mille NOTE The numbering corresponds to that on the gener- 31) Low beam relay al wiring diagram. 32) High beam relay 33) Cooling fan relay 1) Electronic unit 34) Front parking light bulb 2) Cam position sensor 35) High beam bulbs 3) Throttle valve potentiometer 36) Low beam bulb...
Page 241: Checking The Recharging Voltage
ELECTRICAL 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 " "...
Page 242: Checking The Alternator Continuity
ELECTRICAL SYSTEM RSV mille 6.3.3 CHECKING THE ALTERNATOR CONTINUITY When the engine is switched off: Remove the rear fairing, see 7.1.36 (REMOVING THE REAR FAIRING). Disconnect the voltage regulator three-way cable con- nector (1) (coloured brown). CAUTION When reassembling, make sure the electric connec- tor (1) is plugged in properly.
Page 243: Wiring Diagram
ELECTRICAL 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) Pick up 1) Electronic unit 23) Rear cylinder coil “1” 2) Cam position sensor 24) Rear cylinder coil “2”...
Page 244: Troubleshooting
ELECTRICAL 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“ ”. The message “ ” comes up on the right-hand dis- play for approx.
Page 245: Eliminating Electronic System Faults According To The Information Sent Up On The Display
ELECTRICAL SYSTEM RSV mille Starting Engine runs Fault Components To view “ ” Component Cause motor Engine runs (emergency code to be checked on the display running conditions) Camshaft position (the cylinder Sensor not Press the sensor cannot be Connector, connected.
Page 246: Checking The H.v. Coils
ELECTRICAL SYSTEM RSV mille 6.4.4 CHECKING THE IGNITION COILS Remove both side fairings, see 7.1.26 (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 247: Checking The Fall Sensor
ELECTRICAL SYSTEM RSV mille 6.4.7 CHECKING THE FALL SENSOR With the engine switched off: Remove the riders saddle, see 7.1.1 (REMOVING THE RIDER SADDLE). Check whether the sensor (1) is fitted correctly (with the arrow inscribed on the rubber element pointing up). Disconnect the two-way connector (2) (coloured white/ grey) and take the measurements (on the sensor-side terminals).
Page 248: Checking The Air Thermistor Operation
ELECTRICAL SYSTEM RSV mille 6.4.9 CHECKING THE AIR THERMISTOR OPERATION Remove the left-hand conveyor cover, see 7.1.29 (RE- MOVING THE AIR CONVEYOR). Disconnect the two-way connector (1) (coloured green). CAUTION When reassembling, make sure the electric connec- tor (1) is plugged in properly. Remove the thermistor (2).
Page 249: Checking The Throttle Valve
ELECTRICAL 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 (coloured black) (1). CAUTION When reassembling, make sure the electric connec- tor (1) is plugged in properly.
Page 250: Checking The Intake Pressure Sensor
ELECTRICAL SYSTEM RSV mille 6.4.11 CHECKING 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 When reassembling, make sure the electric connec- tor (1) is plugged in properly.
Page 251: Wiring Diagram
ELECTRICAL 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) Right dimmer switch 14) Engine stop relay 15) Fuel pump relay 29) Secondary fuses (15 A) 52) Fuel pump...
Page 252: Checking The Fuel Pump
ELECTRICAL SYSTEM RSV mille 6.5.2 CHECKING THE FUEL PUMP In order to check the pump is operating properly: Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). Disconnect the pump units three-way connector (1) (coloured white). CAUTION When refitting, make sure the electric connector (1) is plugged in properly.
Page 253: Wiring Diagram
ELECTRICAL 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 switch 12) Right dimmer switch 16) Start relay 17) Starter 18) Battery...
Page 254: Starting Safety Operating Logic
ELECTRICAL SYSTEM RSV mille 6.6.2 STARTING SAFETY OPERATING LOGIC NOTE With the engine shutoff switch in position “ ” the starter motor does not turn over. STAND GEAR POSITION STAND POSITION CLUTCH LEVER ENGINE IGNITION STARTER MOTOR WARNING LIGHT PULLED UP LIFTED RELEASED IN NEUTRAL...
Page 255: Checking The Side Stand And The Safety Switch
ELECTRICAL SYSTEM RSV mille 6.6.4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH The side stand (1) must rotate without hindrances. Carry out the following checks: The springs (2) must not be damaged, worn, rusty or weakened. The side stand must rotate freely, if necessary grease the joint, see 1.6 (LUBRICANT CHART).
Page 256 ELECTRICAL 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. RIGHT SIDE SWITCH SET 1) Engine stop switch 2) Start push button Cables Pos.
Page 257 ELECTRICAL SYSTEM RSV mille 8) IGNITION SWITCH Cables Pos. V/Gr Bi/R 8) IGNITION SWITCH Cables Pos. V/Gr Bi/R 9) FRONT BRAKE STOPLIGHT SWITCH Cables Pos. Operating 10) REAR BRAKE STOPLIGHT SWITCH Cables Pos. Operating 11) NEUTRAL GEAR SWITCH Cables Pos. Screw Neutral 12) STAND SWITCH...
Page 258: Wiring Diagram
ELECTRICAL SYSTEM RSV mille ,)'(43 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 34) Front parking light bulb 35) High beam bulbs 36) Low beam bulb...
Page 259: Checking The Lights Relay
ELECTRICAL SYSTEM RSV mille 6.8.2 CHECKING THE LIGHTS RELAY To check operation of 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 260: Wiring Diagram
ELECTRICAL 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 (15A) 33) Cooling fan relay 39) Thermal switch 40) Cooling fans A) To the battery / ignition switch 6.9.2 CHECKING THE ELECTROFAN OPERATION NOTE The following procedure refers to a single elec-...
Page 261: Checking The Electrofan Relay
ELECTRICAL 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); with- in this range of values, it may switch to on or off indiffer- ently.
Page 262: Wiring Diagram
ELECTRICAL 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 55) Coolant temperature thermistor 56) Speed sensor 57) Low fuel warning light...
Page 263: Coolant Temperature Display
ELECTRICAL SYSTEM RSV mille 6.10.3 COOLANT TEMPERATURE DISPLAY NOTE In the event the message “ ”, 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- MISTOR OPERATION).
Page 264: Speedometer
ELECTRICAL SYSTEM RSV mille 6.10.5 SPEEDOMETER Position the vehicle on the special rear support stand & Place the clutch lever in neutral. Check the electric connections are plugged in properly: three-way connector (1) (coloured white) of the speed sensor and (2) of the dashboard. Check the distance between the speed sensor (3) and the five screws (4) securing the rear brake disc.
Page 265: Activating The Battery
ELECTRICAL SYSTEM RSV mille "!44%29 NOTE This vehicle is provided with a maintenance- free battery and no operation is necessary, excepting oc- casional checks and the recharge when required. When changing batteries, replace with a battery of the same type. Type: 12V - 12 Ah Carefully read 2.4 (BATTERY).
Page 266: Maintenance
ELECTRICAL SYSTEM RSV mille CAUTION Do not cut or make holes in the sealed parts on the reservoirs (2). Turn the reservoirs (2) upside down and place them so that the sealed parts are over the openings of the bat- tery cells.
Page 267: Changing The Headlight Bulbs
ELECTRICAL SYSTEM RSV mille #(!.').' 4(% "5,"3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). CAUTION Before changing a bulb, move the ignition switch to position “ ”. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage.
Page 268: Changing The Front And Rear Direction Indicator Bulbs
ELECTRICAL 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 While removing the protection screen, proceed care- fully in order not to break the lug.
Page 269: Changing The Dashboard Bulbs/Lights
ELECTRICAL 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 the bulb/light: Remove the dashboard, see 7.1.23 (REMOVING THE DASHBOARD). Unscrew and remove the eight fastening screws (1). Remove the rear cover (2).
Page 270: (%!$,)'(4
ELECTRICAL SYSTEM RSV mille !$*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 271 ELECTRICAL SYSTEM RSV mille #(!.').' 4(% &53%3 Carefully read 0.2.1 (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 damages to the electric system or, in case of short circuit, even a fire.
Page 272 ELECTRICAL SYSTEM RSV mille #(%#+).' 4(% 37)4#(%3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The vehicle is provided with four switches: 1) Stoplight switch on the rear brake control lever. 2) Stoplight switch on the front brake control lever. 3) Safety switch on the side stand.
Page 273 ELECTRICAL SYSTEM RSV mille #/..%#4)/.3 4/ 4(% %.').% #/.42/, 5.)4 NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components. See 4.7.4 (ENGINE CONTROL UNIT CONNECTORS), for further details. NOTE The initials (y) and (z) appearing in the diagram, next to the relevant numbers, mark the respective termi- nals on both connectors.
Page 274 ELECTRICAL SYSTEM RSV mille Pos. Component Connector Terminal # Nominal value Cable colours Vi /N Ω Cam position sensor 150 - 300 Gr/N Ω Throttle valve 2.8 - 3.4 M/Bi potentiometer ( Angle variable) Suction pressure Ω 10 - 15 M/Bi sensor Ω...
Page 275: 7)2).' $)!'2!- 236 Mille
ELECTRICAL SYSTEM RSV mille 7)2).' $)!'2!- 236 MILLE - 40...
Page 276 ELECTRICAL SYSTEM RSV mille 7)2).' $)!'2!- +%9 236 MILLE 1) Electronic unit 33) Cooling fan relay 34) Front parking light bulb 2) Cam position sensor 35) High beam bulbs 3) Throttle valve potentiometer 36) Low beam bulb 4) Suction pressure sensor 37) Front right direction indicator 5) Coolant thermistor 38) Front left direction indicator...
Page 277: 7)2).' $)!'2!- 236 Mille
ELECTRICAL SYSTEM RSV mille 7)2).' $)!'2!- 236 MILLE - 42...
Page 278 ELECTRICAL SYSTEM RSV mille 7)2).' $)!'2!- +%9 236 MILLE 1) Electronic unit 33) Cooling fan relay 34) Front parking light bulb 2) Cam position sensor 35) High beam bulbs 3) Throttle valve potentiometer 36) Low beam bulb 4) Suction pressure sensor 37) Front right direction indicator 5) Coolant thermistor 38) Front left direction indicator...
Page 279 ELECTRICAL SYSTEM RSV mille NOTE - 44...

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APRILIA RSV mille 956X Service And Repair Manual

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