APRILIA RSV MILLE - PART 3 1999 Manual

APRILIA RSV MILLE - PART 3 1999 Manual

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NOTE
The cooling fans (21) function only
when the ignition key (2) is in the "
position.
CAUTION
Do not leave the ignition key in the "
(OFF) position since the cooling fans
will not run regardless of the coolant
temperature. This will cause the cool-
ant temperature to continue to rise.
If, before shutting off the engine, you hear
the cooling fans functioning, stop the en-
gine but leave the ignition key to "
position. This will allow the cooling fans to
draw air through the radiators, and lower
the temperature. Turn the ignition key to
-
"
" (OFF) position only when the cooling
fans have stopped.
If, while riding, the right side of the multi-
function display shows a temperature of 115
– 120 °C (239 – 248 °F) (19), stop riding the
vehicle, stop the engine, turn the ignition
+
key to "
" (ON) position and wait until the
cooling fans have stopped, then turn the ig-
+
-
nition key to "
" (ON)
the coolant level, see p. 56 (COOLANT).
///
If the symbol "
riding the vehicle and let the engine run at
-
"
3,000 rpm for approximately two minutes,
thus allowing the coolant to circulate normal-
ly in the cooling system. Then move the en-
gine stop switch to position "
check the coolant level, see p. 56 (COOL-
ANT).
///
If the symbol "
+
" (ON)
after the coolant level has been checked,
contact your Local aprilia Dealer.
Do not operate the vehicle if the maxi-
mum temperature [120 °C (248 °F)] is ex-
ceeded. Serious engine damage or even
seizure may result which can cause an
upset and serious injury or even death.
Whenever the ignition key (2) is turned to
+
"
" (ON), the right side of the multifunction
" (OFF) position and check
" (20) is displayed, stop
" (OFF) and
" (20) is still displayed
WARNING
HIL
display will show "
" (9B) for about
three seconds.
CAUTION
HIL
If the symbol "
" (9B) is displayed
during the normal running of the en-
gine, this means that the electronic unit
has detected an anomaly. In many cas-
es, the engine keeps running with re-
duced performance levels; immediately
contact your Local
WARNING
Avoid opening and closing the throttle
repeatedly and continuously. Failure to
head this warning can cause you to ac-
cidentally lose control of your vehicle.
When you have to brake, close the
throttle and apply both brakes simulta-
neously in order to obtain the best
brake performance.
By applying only the front brake or only
the rear brake, you reduce the braking
performance considerably and run the
risk of locking up one wheel which can
cause an upset and subsequent serious
injury or even death.
If you stop on an uphill, use brakes only
to slow the vehicle and to keep it in
place. Slipping the clutch to keep the
vehicle in one place on an uphill grade
will very quickly ruin the clutch and
overheat the engine.
Before entering a turn, slow down, us-
ing the brakes and the engine, to a con-
stant speed and then accelerate slightly
use and maintenance RSV mille
Dealer
.
67

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Summary of Contents for APRILIA RSV MILLE - PART 3 1999

  • Page 1 This will allow the cooling fans to contact your Local aprilia Dealer. If you stop on an uphill, use brakes only draw air through the radiators, and lower...
  • Page 2 through the turn. Avoid braking at the Switch off the direction indicators as exceed 6,000 rpm. last moment. This can cause you to soon as you have changed direction. WARNING lose control of your vehicle. Overtake and pass only with care, espe- After the vehicle has been operated for If the brakes are operated continuously cially in rainy weather when a water...
  • Page 3 Release the throttle grip (1) (Pos. A), When the vehicle has come to rest: gradually put on the brakes and at the Position the shift lever (3) in neutral WARNING same time shift down in order to de- (green warning light “ ” (4) on). crease the speed, see p.
  • Page 4 If the vehicle falls over, it will leak gaso- Stop the vehicle, see p. 69 (STOPPING). line which is extremely flammable. Move the engine stop switch (1) to the WARNING Flames or sparks could cause a fire “ ” (OFF) position. which could destroy not only your vehi- Par k the vehicle only on firm flat CAUTION...
  • Page 5: Side Stand

    NOTE Never leave the key in the ignition SIDE STAND switch. Grab the left handle grip (4) and the pas- Lock the steering, see p. 40 (STEERING senger grab strap (5). WARNING LOCK) and extract the key. Put the side stand (6) down with your Position the vehicle on firm and flat right foot.
  • Page 6 Write down your name, address and tele- phone number and the vehicle identifica- tion number in the space below, to facili- Carefully read p. 2 (FOREWORD) and NEVER leave the key (1) in the ignition tate finding the owner in case your vehicle (INTRODUCTION), p.
  • Page 7: Checking Operations)

    To make the word “SERVICE” disappear, Fasteners must be neither overtight- press the “LAP” push button (4) and then Do not hesitate to contact your Local aprilia ened or undertightened. If they are the push button (5) and keep them...
  • Page 8 THESE OPERATIONS MAY BE CARRIED OUT BY YOUR Local Dealer, OR BY THE OWNER OF THE VEHICLE After running-in Every 4,687 mi Every 9,375 mi Component [625 mi (1,000 km)] (7,500 km) or 8 months (15,000 km) or 16 months Tightness of the battery terminals Spark plugs C (*)
  • Page 9 THESE MAINTENANCE OPERATIONS SHOULD ONLY BE PERFORMED OUT BY Local Dealer. After running-in Every 4,687 mi Every 9,375 mi Component [625 mi (1,000 km)] (7,500 km) or 8 months (15,000 km) or 16 months Accelerator cables (adjustment) Rear suspension linkage bearings Steering bearings and steering Wheel bearings Engine oil filter...
  • Page 10: Frame Number

    FRAME NUMBER It is a good idea to write down the frame The frame number is stamped on the right Carefully read p. 72 (MAINTENANCE). and engine numbers in the space provid- side of the fork head. ed below. Use the frame number (VIN) to WARNING identify your vehicle when ordering spare Do not use gasoline or flammable sol-...
  • Page 11: The Fuel Tank)

    pressed air jets, they can cause serious personal injury if directed towards your body. Grasp the air cleaner vertically and strike it repeatedly on a clean hard horizontal surface. If available, clean the air cleaner with a compressed air jet, directing it from the inside of the filter towards the outside.
  • Page 12 CHECKING NOTE Position the vehicle on firm and Carefully read p. 46 (LUBRICANTS), flat ground. p. 72 (MAINTENANCE) and p. 122 (LU- CAUTION BRICANT CHART) . The engine oil level must be checked WARNING with warm engine. It is critical to the safe operation of your If the check is carried out with cold en- vehicle that the proper lubricants, main- gine, the oil level may temporarily lower...
  • Page 13 CAUTION MAX = maximum level Unscrew and remove the filler cap (4). MIN = minimum level Use thick gloves to prevent burns. CAUTION The difference between “MAX” and Remove the left fairing, see p. 96 (RE- When topping up, never exceed the “MIN”...
  • Page 14 This system prevents the motor from being Release the throttle grip (4) (Pos. A). started while the stand is extended unless With the engine idling, pull in the clutch Carefully read p. 72 (MAINTENANCE) the transmission is in neutral. It also kills lever (5) completely.
  • Page 15 Make sure that there is no dirt or mud on the switch. The switch pin must move Carefully read p. 72 (MAINTENANCE). freely and without interference, returning automatically to its unapplied position. Check the switches after the first 625 mi Check the spring (5);...
  • Page 16 For this type of adjustment, contact your Apply the front brake lever and push up and down on the handlebar repeatedly, Local aprilia Dealer. pushing the fork up and down. The fork must move smoothly and easily, there must be no trace of oil on the fork tubes.
  • Page 17: Adjusting The Front Fork

    ADJUSTING THE FRONT FORK Upper screw adjusters By rotating them By rotating them The front fork is adjusted at the factory to (1) (2.25 turns in total) clockwise (H) counterclockwise (S) suit most riding conditions for most riders. Function Increase of the hydraulic Decrease of the hydraulic However, it is possible to adjust the fork set- damping on extension...
  • Page 18: Adjusting The Rear Shock Absorber

    The rear suspension consists of a hydrau- lic shock absorber - spring unit, which is mounted to the frame with a uniball, and to the swinging arm by means of a system of levers. The ride height of the rear of the vehicle can be set using the spring preload adjust- ing ring nut (3) and locking ring nut, (4).
  • Page 19 If necessary, contact your Local Knob adjuster (2) By rotating it By rotating it aprilia Dealer. (40 clicks) clockwise (+) counterclockwise (–) Function Increase of the hydraulic...
  • Page 20 WARNING used, how aggressively it is driven, and the condition of the roads upon which it is Excessive wear of the friction material Carefully read p. 47 (BRAKES), p. 48 operated. Wear will be faster than normal would cause the contact of the pad met- (DISC BRAKES) and p.
  • Page 21 WARNING Push (Pos. B) the stand (2) downwards until it reaches the end of its stroke (see Lift the vehicle by grasping the two pins The operations necessary to this check figure). (1) only. require specific skills and therefore should be carried out by your Local Lift (Pos.
  • Page 22: Front Brake Calipers)

    CAUTION DISASSEMBLY Position the vehicle on the appropriate Never touch the front brake lever after WARNING rear support stand (1), see p. 87 removing the brake calipers from the The disassembly and reassembly of the (POSITIONING THE VEHICLE ON THE discs.
  • Page 23 NOTE Observe the arrangement of the cle (see figure). Remove the front support stand (2), left spacer ring (9) and of the right spacer Install the left spacer ring (9) in its seat see p. 87 (POSITIONING THE VEHICLE ring (10), in order to be able to reassemble on the whell (left side of the wheel).
  • Page 24 rear support stand (1), see p. 87 der to be able to reassemble them correctly. (POSITIONING THE VEHICLE ON THE Remove the right (6) and left (7) chain WARNING REAR SUPPORT STAND tensioners. The disassembly and reassembly of the WARNING WARNING rear wheel can be difficult for those unfa- miliar with vehicle maintenance.
  • Page 25 Position the wheel centrally in the swing- Remove the support (2) from under the CAUTION ing arm, on the support (2). rear tire. Never touch the rear brake pedal after re- Check the chain tension, see p. 92 WARNING moving the rear wheel. If you do, the cal- (DRIVE CHAIN).
  • Page 26: Checking The Play

    sprockets must be replaced. See your CHECKING THE PLAY Local Dealer. Carefully read p. 72 (MAINTENANCE). To check the play: Stop the engine. CAUTION Every 312 mi (500 km) check the condi- Place the vehicle on the stand, see p. 71 tions, the wear, the play (tension) and the Lack of maintenance can cause prema- (POSITIONING THE VEHICLE ON THE...
  • Page 27: Checking The Wear Of The Chain And Sprockets

    to minimize the possibility of this kind CHECKING THE WEAR OF THE CHAIN Finally, check the wear of the rear fork AND SPROCKETS protection shoe. of damage, see p. 93 (CLEANING AND LUBRICATION). In addition to the check, see p. 92 (CHECK- CLEANING AND LUBRICATION ING THE PLAY), inspect the chain and If the play is the same at several locations, but...
  • Page 28 CAUTION Never drain the fuel tank, either partially Position the vehicle on the stand, see Carefully read p. 44 (FUEL) and p. 72 or completely. This may cause damage p. 71 (POSITIONING THE VEHICLE ON (MAINTENANCE). to the inner components of the fuel tank, THE STAND).
  • Page 29 Unscrew and remove the two upper Lift the rubber boot (8). screws (4). Disconnect the electric connector (9) of the headlight. NOTE Carefully read p. 72 (MAINTENANCE). The position of the plate (5) and how it fits with the seat (6) on the sup- Position the vehicle on the stand, see WARNING port frame on the front part of the fairing for...
  • Page 30 CAUTION Upon reassembly, tighten the screws only moderately. Be careful not to over tighten the screws, this will damage the surrounding plastic and painted com- ponents. Carefully read p. 72 (MAINTENANCE). Position the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND).
  • Page 31 Unscrew and remove the two front Take the rear right profile (14). screws (11). NOTE Carefully read p. 72 (MAINTENANCE). Upon reassembly, the upper part Unscrew and remove the rear screw of the profile (14) must be fitted between NOTE To remove the lower fairing, it is (12).
  • Page 32: Front Support Stand

    Remove the brake caliper (2) from the disc, leaving it attached to its line (3). CAUTION Never touch the front brake lever after removing the brake caliper from the disc. If you do, the calipers pistons may be pushed out of their seats, and brake fluid will be spilled.
  • Page 33 Pull in the clutch lever (1) completely and If necessary, contact your Local injury or death. put the shift lever (2) in neutral so that aprilia Dealer. the green “ ” light (3) is on. use and maintenance RSV mille...
  • Page 34 If any fastener in the throttle system be- WARNING comes loose, likewise you will lose con- In the event of a throttle sticking emer- trol of your vehicle. gency, always kill the engine using the Carefully read p. 72 (MAINTENANCE). engine stop switch located near the Either situation can lead to an upset or This vehicle is equipped with two throttle...
  • Page 35 To adjust the cable: WARNING Place the vehicle on the stand, see p. 71 Exhaust gases contain carbon monox- (POSITIONING THE VEHICLE ON THE ide, which is extremely poisonous if in- STAND). The operations necessary to adjust the haled. Pull back the rubber boot (1). cold start control “...
  • Page 36: The Fuel Tank)

    the vehicle. However, spark plugs must be protection. Be very careful using com- cleaned and changed no less often than pressed air jets, they can cause serious Carefully read p. 72 (MAINTENANCE). described above. personal injury if directed towards your NOTE Your vehicle is equipped with two body.
  • Page 37 CAUTION TO CHECK AND CLEAN THE SPARK TO INSTALL THE SPARK PLUG PLUG Make sure the gasket is in good condi- Do not invert the spark plug caps (1) po- Inspect the spark plug, and insure that tion. With the gasket on, screw the spark sition.
  • Page 38 (2). the electrical system. If this occurs, take the parking lights, rear stoplights, horn, To check the fuses of the secondary vehicle to your Local aprilia Dealer. dashboard lights, direction indicators. fuses group (1): E) From ignition switch to: If an electric component does not work or Turn the ignition switch (3) in the “...
  • Page 39 CAUTION WARNING To check the the fuses of the main fus- es group (2): Extract the fuses one by one, in such a If you replace the fuse and it blows way as to avoid positioning them incor- Turn the ignition switch (3) in the “ ”...
  • Page 40 medical attention. Carefully read p. 72 (MAINTENANCE). If someone should accidentally swallow battery electrolyte, drink a large quanti- Your vehicle is equipped with a sealed ty of milk or cool clear water and contin- maintenance free battery. Except for the ue with milk of magnesia or vegetable tightness of the terminals, and required re- oil.
  • Page 41 Local If it is necessary to clean the battery termi- Remove the red protection rubber (3). aprilia Dealer, and will ensure that your nals: Disconnect first the negative (–) cable battery always remains in tip top condition.
  • Page 42 CAUTION WARNING Once it has been removed, store the The battery gives off noxious and explo- battery in a safe place and keep it away sive gases; keep it away from flames, from children. Even a completely sparks, cigarettes and any other source sealed, maintenance free battery can of heat.
  • Page 43 NOTE The procedure described here is To adjust the headlight beam: in compliance with the Italian standard that Working from the left underside of the establishes the maximum height of the front part of the fairing, adjust the screw WARNING headlight beam.
  • Page 44 To adjust the horizontal headlight beam With the screw (2) to right side of the your vehicle is equipped with: dashboard: – one screw (1) to left side of the dash- – turn the screw clockwise to adjust the NOTE The terms “right”...
  • Page 45 CAUTION Before changing a bulb, turn the igni- Carefully read p. 72 (MAINTENANCE). tion switch (1) to the “ ” (OFF) position and wait a few minutes so that the bulb WARNING cools down. Change the bulb wearing clean gloves Risk of fire.
  • Page 46 To change the bulbs: HIGH BEAM BULB (ONE UPPER RIGHT POSITION, ONE UPPER LEFT POSITION) PARKING LIGHT BULB (CENTRAL UP- NOTE PER POSITION) Remove the bulb sockets one by Carefully read p. 111 (BULBS). one in such a way as to avoid replacing NOTE The removal of the front part of Place the vehicle on the center stand,...
  • Page 47 NOTE Before changing a bulb, check the fuses, see p. 104 (CHANGING FUS- ES). Place the vehicle on the stand, see p. 71 (POSITIONING THE VEHICLE ON THE STAND). Unscrew and remove the screw (12). NOTE While removing the lens, use ex- tra care to be sure that you do not break the key.
  • Page 48 The rear light comprises two units. Each To remove the bulb (1), push the bulb unit contains: slightly forward and rotate it counter- clockwise. – one parking light / stoplight / license plate Carefully read p. 111 (BULBS). Pull it from its seat. bulb (1).
  • Page 49 Clean your vehicle regularly. Your vehicle will look better and work better if you keep it clean. You will find you will need to clean it more frequently if it is used in the following conditions: – Polluted areas (cities and industrial areas). –...
  • Page 50 To remove dirt and mud from the painted surfaces, use a low pressure water hose. Carefully wet the dirty parts and remove mud and dirt with a soft car sponge. You may use proprietary car shampoos (2-4% parts of shampoo in clear water), to make this easier.
  • Page 51 Test ride the vehicle at moderate speed etary fuel storage additive, available Position the vehicle on the appropriate in a low traffic area before you ride in from your Local aprilia Dealer or auto- front support stand , see p. 87 (POSI- heavy traffic.
  • Page 52 DIMENSIONS Max. length ..........81.89 in (2,080 mm) Max. length (rear mudguard extension included)....84.25 in (2,140 mm) Max. width............ 28.35 in (720 mm) Max. height (front part of the fairing included) ....46.06 in (1,170 mm) Seat height........... 32.28 in (820 mm) Wheelbase...........
  • Page 53: Gear Ratios

    CAPACITY Fuel (reserve included)......... 5.28 US gal (20 Fuel reserve ..........1.19 ± 0.26 US gal (4.5 ± 1 Engine oil............. oil change 3.91 US qt (3,700 cm#) – oil and oil filter change 4.12 US qt (3,900 cm#) Fork oil (for each fork leg) ......17.58 ±...
  • Page 54 FUEL SUPPLY Fuel .............. unleaded petrol minimum octane rating (R+M) / 2 method 90 FRAME Type ............. two-beam, with cast and stamped sheet elements Rake............. 25° Trail .............. 3.82 in (97 mm) SUSPENSIONS Front............. upside-down telescopic adjustable fork with hydraulic operation, fork leg Ø...
  • Page 55 Inflation pressure for rider, passenger and luggage........ 39.15 psi [(270 kPa) (2.70 bar )] IGNITION Ignition timing..........21.8° ± 2° at 2,800 rpm SPARK PLUGS Number per cylinder ........2 Standard............NGK R DCPR9E – alternative..........NGK R DCPR8E Spark plug gap ..........0.024 –...
  • Page 56 Engine oil (recommended): EXTRA RAID, SAE 15W – 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications. Fork oil (recommended): F.A.
  • Page 57 use and maintenance RSV mille...
  • Page 58 use and maintenance RSV mille...
  • Page 59 use and maintenance RSV mille...
  • Page 60 use and maintenance RSV mille...
  • Page 61 1) Electronic unit E - Electronic unit, fuel pump relay, en- 61) Engine oil pressure warning light LED gine stop relay 62) High beam warning light 2) Cam position sensor 63) Dashboard bulbs 3) Throttle valve position sensor 30) Ignition switch 64) Tachometer 4) Suction pressure sensor 31) Low beam relay...
  • Page 62 – Do not dispose of oil, fuel, polluting substances and components in the envi- ronment. – Do not keep the engine running if it isn’t necessary. – Avoid disturbing noises.

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