APRILIA RSV MILLE SPORT - PART 3 1999 Manual
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WARNING
Risk of fire.
Keep fuel and other flammable sub-
stances away from the electrical com-
ponents.
Before beginning any maintenance op-
eration or any inspection of the vehicle,
stop the engine, extract the key from
the ignition block, wait until the engine
and the exhaust system have cooled
down and if possible lift the vehicle by
means of the proper equipment, on firm
and flat ground.
Before proceeding, make sure that the
room in which you are working is prop-
erly ventilated.
Keep away from the red-hot parts of the
engine and of the exhaust system, in or-
der to avoid burns.
The vehicle is made up of not edible
parts. Never bite, suck, chew or swallow
any part of the vehicle for any reason.
CAUTION
If not expressly indicated otherwise, for
the reassembly of the units repeat the
disassembly operations in reverse or-
der.
In case any maintenance operation has
to be carried out, it is advisable to use
latex gloves.
Routine maintenance operations can usu-
ally be carried out by the user, but some-
times the use of specific tools and specific
technical skills may be required.
In case periodic maintenance operations,
assistance or technical advice are needed,
contact an aprilia Official Dealer, who will
ensure you prompt and accurate servicing.
Ask your aprilia Official Dealer to test the
vehicle on the road after a repair or period-
ic maintenance operation.
In any case, personally carry out the "Pre-
liminary checking operations" after any
maintenance operation, see p. 42 (PRE-
LIMINARY CHECKING OPERATIONS).
CAUTION
After the first 1000 km (625 mi) and suc-
cessively every 7500 km (4687 mi), the
writing "SERVICE" (1) appears on the
right display.
In this case, perform the operations pre-
scribed in the regular service intervals
chart; in case of use on racetracks, car-
ry out these operations more frequent-
ly, see p. 52 - 53 (REGULAR SERVICE
INTERVALS CHART).
use and maintenance RSV mille Sport Production
51
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Summary of Contents for APRILIA RSV MILLE SPORT - PART 3 1999
- Page 1 The vehicle is made up of not edible chart; in case of use on racetracks, car- Ask your aprilia Official Dealer to test the parts. Never bite, suck, chew or swallow ry out these operations more frequent- vehicle on the road after a repair or period- any part of the vehicle for any reason.
- Page 2 OPERATIONS TO BE CARRIED OUT BY THE Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER) After running-in Every 7500 km Every 15000 km Component [1000 km (625 mi)] (4687 mi) or 8 months (9375 mi) or 16 months Spark plugs S (* *) Air filter...
- Page 3 OPERATIONS TO BE CARRIED OUT BY THE Official Dealer After running-in Every 7500 km Every 15000 km Component [1000 km (625 mi)] (4687 mi) or 8 months (9375 mi) or 16 months Rear suspension linkage bearings Steering bearings and steering Wheel bearings Tappet clearance Braking systems...
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Page 4: Frame Number
FRAME NUMBER ENGINE NUMBER The frame number is stamped on the right The engine number is stamped on the rear It is a good rule to write down the frame side of the steering column. part of the engine, near the pinion. and engine numbers in the space provided in this manual. - Page 5 Carefully read p. 39 (ENGINE OIL) and p. 51 (MAINTENANCE). Periodically check the engine oil level, change the oil after the first 1000 km (625 mi) and successively every 3500 km (2187 mi), see p. 56 (CHANGING THE ENGINE OIL AND THE OIL FILTER). In case of use on racetracks, change every 1000 km (625 mi).
- Page 6 CAUTION The engine oil and the oil filter change operations may be difficult for unskilled operators. If necessary, contact an Official Dealer. If you want to carry them out personal- ly, follow the instructions given below. Carefully read p. 39 (ENGINE OIL) and p.
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Page 7: Changing The Engine Oil Filter
Screw and tighten the screws (5) and Screw and tighten the drain plug (4). Connect the pipe (13) and tighten the (6). new clamp (11). Driving torque of the drain plug (4) posi- tioned on the engine: 12 Nm (1,2 kgm). CLEANING THE ENGINE OIL FILTER CAUTION ON THE TANK... - Page 8 Check the air cleaner every 7500 (4687 NOTE Have someone help you keep the Position the vehicle on the appropriate mi)km or 8 months, change it every 15000 vehicle in vertical position with the two rear support stand, see beside (POSI- km (9375 mi) or more frequently if the vehi- wheels on the ground.
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Page 9: The Fuel Tank)
REMOVAL PARTIAL CLEANING Replace the air cleaner (3) with a new one of the same type. Lift the fuel tank, see p. 66 (LIFTING CAUTION Every 7500 km (4687 mi), remove the THE FUEL TANK). plug (4). Do not press or strike the metal net of Unscrew and remove the seven screws Empty its content into a container and the air cleaner (3). -
Page 10: Front Support Stand
DISASSEMBLY CAUTION Position the vehicle on the appropriate Never pull the front brake lever after re- CAUTION rear support stand, see p. 58 (POSI- moving the calipers, otherwise the pis- The disassembly and reassembly of the TIONING THE VEHICLE ON THE REAR tons may go out of their seats, thus front wheel may be difficult for unskilled SUPPORT STAND ). - Page 11 WARNING Upon reassembly of the brake caliper, replace the caliper fastening screws (1) with two new screws of the same type. Screw and tighten the two screws (1) that fasten the brake caliper. Brake caliper screw (1) driving torque: 50 Nm (5 kgm) With pulled front brake lever, press the handlebar repeatedly, thrusting the fork downwards.
- Page 12 NOTE To remove the rear wheel it is Make the wheel advance and release the necessary to use the appropriate rear sup- drive chain (4) from the crown gear (5). CAUTION port stand . CAUTION The disassembly and reassembly of the Check the position of the chain tighten- rear wheel may be difficult for unskilled ers (6-7), in order to be able to reas-...
- Page 13 REASSEMBLY Make the wheel advance and position Position the washer and tighten the nut the drive chain (4) on the crown gear (5). (1) manually. CAUTION Check the chain tension, see p. 64 WARNING Before proceeding with the reassembly, (DRIVE CHAIN). make sure that support plate (8) of the Danger of injury.
- Page 14 CAUTION Carry out the maintenance operations more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy roads. CHECKING THE SLACK To check the slack, proceed as follows: Stop the engine. Position the vehicle on the side stand on firm and level ground.
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Page 15: Cleaning And Lubrication
CHECKING THE WEAR OF CHAIN, CLEANING AND LUBRICATION PINION AND CROWN CAUTION Further, check the chain and sprockets The drive chain is provided with O rings and make sure that they do not present: among the links, in order to keep the –... - Page 16 Remove the rider saddle, see beside (REMOVING THE RIDER SADDLE). Position the vehicle on the side stand on Carefully read p. 30 (FUEL) and p. 51 Unscrew and remove the two screws (4) firm and level ground. (MAINTENANCE). that fasten the front part of the fuel tank Partially raise the rear side edge of the (5).
- Page 17 Let the side stand down. Withdraw the two pipes (7-8) from the Carefully read p. 51 (MAINTENANCE). Carefully read p. 51 (MAINTENANCE). hole provided on the fairing. WARNING CAUTION NOTE To remove the lower fairing, it is Wait until the engine and the exhaust si- Handle the plastic and painted compo- necessary to use the appropriate rear sup- lencer have completely cooled down.
- Page 18 CAUTION After reassembly, correctly adjust the Position the vehicle on the side stand on rear-view mirrors and tighten the nuts in firm and level ground. Position the vehicle on the side stand on such a way as to ensure their stability. Unscrew and remove the two screws (1).
- Page 19 The whole unit must be correctly positio- ned on the support. Carefully read p. 51 (MAINTENANCE). Move the front part of the fairing (4) sli- ghtly forward. Position the vehicle on the side stand on Raise the protection element (5). firm and level ground.
- Page 20 CAUTION CAUTION Upon reassembly: Plug the openings with a clean cloth, to Carefully read p. 51 (MAINTENANCE). prevent any foreign matters from get- – The two conveyors (5) must be posi- ting into the suction ducts. Remove the air cleaner, see p. 58 (AIR tioned correctly and adhere perfectly CLEANER).
- Page 21 WARNING – Front pad (3). Check the wear of the brake pads, espe- – Rear pad (4). cially before every trip. NOTE Have the pads changed by your aprilia Official Dealer. use and maintenance RSV mille Sport Production...
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Page 22: Adjusting The Front Fork
Carefully read p. 51 (MAINTENANCE). NOTE Have the front fork oil changed by an aprilia Official Dealer, who will ensure you prompt and accurate servicing. Have the front fork oil changed every 10000 km (6250 mi). Every 7500 km (4687 mi), carry out the fol-... -
Page 23: Normal Use
CAUTION DESCRIPTION NORMAL USE RACETRACK USE To calculate the number of clicks of the Upper screw adjusters By rotating them By rotating them adjusters (1-2), always start from the anticlockwise clockwise most rigid setting (complete clockwise Function Decrease of the hydraulic Increase of the hydraulic rotation of the adjuster). -
Page 24: Adjusting The Rear Shock Absorber
Adjust the metal ring (3) to adjust the ADJUSTING spring preload (see table). THE REAR SHOCK ABSORBER The rear suspension consists of a spring- After the adjustment, tighten the metal shock absorber unit, fixed to the frame by ring (4). means of a uni-ball and to the rear fork by The standard setting of the rear shock ab- Adjust the metal ring (1) to adjust the... - Page 25 CAUTION DESCRIPTION NORMAL USE RACETRACK USE Metal ring adjuster (1) By rotating it By rotating Adjust the spring preload and the hy- anticlockwise it clockwise draulic braking with extended shock ab- sorber according to the conditions of Function Decrease of the hydraulic Increase of the hydraulic use of the vehicle.
- Page 26 DESCRIPTION Knop adjuster (2) By rotating it By rotating anticlockwise it clockwise Function Decrease of the hydraulic Increase of the hydraulic braking braking Recommended kind Normal or uneven roads Smooth surfaces or of road racetracks Standard adjustment about 5 clicks The steering damper (1) is provided with a knob (2) for the adjustment of the hydraulic braking (see table).
- Page 27 The operations necessary to adjust the NOTE If necessary, contact your aprilia cold start control “ ” require specific Official Dealer. skills and therefore should be carried out by an Official Dealer.
- Page 28 Push the socket spanner on the spark If the spark plug has crackings on the insu- plug. lating material, corroded electrodes or Carefully read p. 51 (MAINTENANCE). excessive deposits, it must be changed. NOTE When the socket spanner is pu- Check the spark plugs every 7500 km Make sure that the washer is in good shed, the rubber part inside it will surround...
- Page 29 Make sure that there are no dirt or mud CAUTION deposits on the switch; the pin must be Carefully read p. 51 (MAINTENANCE). Use the recommended type of spark able to move without interferences, re- plugs only, see p. 92 (TECHNICAL DA- turning automatically to its initial position.
- Page 30 The side stand (1) is provided with a safety Engage the first gear, pushing the shift- switch (3) that has the function to prevent ing lever (6) downwards. or interrupt the operation of the engine with Carefully read p. 51 (MAINTENANCE) Lower the side stand (1), thus operating the gears on and the side stand (1) down.
- Page 31 NOTE This vehicle is provided with a If necessary: maintenance-free battery and no operation Disconnect first the negative (–) and then Carefully read p. 51 (MAINTENANCE). is necessary, excepting occasional checks the positive cable (+). and the recharge when required. WARNING Brush with a wire brush to eliminate any sign of corrosion.
- Page 32 Unscrew and remove the screw (1) on Position the battery on a flat surface, in a the negative terminal (–). cool and dry place. CAUTION Move the negative cable (2) sidewards. WARNING Remove the red protection element (3). To remove the battery it is necessary to Unscrew and remove the screw (4) on set to zero the digital clock and the red Upon reassembly, connect first the pos-...
- Page 33 Carefully read p. 81 (BATTERY). CAUTION Do not remove the battery plugs: with- out plugs the battery may be damaged. Remove the battery, see p. 82 (REMOV- ING THE BATTERY). Prepare an appropriate battery charger. Set the charger for the desired type of re- charge (see table) Connect the battery with a battery charg- WARNING...
- Page 34 In this case it is advisable to consult an put a new fuse in the proper seat. battery. aprilia Official Dealer. Recharge it completely with a normal If an electric component does not work or charge, see p. 83 (RECHARGING THE works irregularly, or if the vehicle fails to BATTERY).
- Page 35 Remove the rider saddle, see p. 66 (RE- ARRANGEMENT ARRANGEMENT MOVING THE RIDER SADDLE). OF THE 15A SECONDARY FUSES OF THE 30A MAIN FUSES Carry out the operations previously de- A) From voltage regulator to: F) From battery to: ignition. scribed for the secondary fuses also for high beam relay, low beam relay.
- Page 36 To adjust the headlight beam: CAUTION Working on the rear left side of the front Before changing a bulb, move the igni- NOTE part of the fairing, adjust the appropriate To check the direction of the tion switch to position “ ” and wait a screw (1) by means of a short cross-tip headlight beam, specific procedures must few minutes, so that the bulb cools...
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Page 37: Parking Light Bulb
To change the bulbs, proceed as fol- HIGH BEAM BULBS lows: Remove the front part of the fairing, see NOTE p. 69 (REMOVING THE FRONT PART Carefully read p. 86 (BULBS). The removal of the front part of OF THE FAIRING). the fairing is necessary when the parking li- The headlight contains: Move the protection element (5) of the... -
Page 38: Low Beam Bulb
LOW BEAM BULB Press the bulb (14) slightly and rotate it anticlockwise. Move the protection element (9) with your hands. Extract the bulb (14) from its seat. Carefully read p. 86 (BULBS). Position the vehicle on the side stand on CAUTION CAUTION firm and level ground. -
Page 39: Checking The Switches
NOTE During transport, the vehicle must be kept in vertical position, it must be firmly anchored and the 1st gear must be en- gaged, in order to avoid any leak of fuel, oil, coolant. CAUTION In case of failure, do not tow the vehicle, but ask for assistance. -
Page 40: Checking Operations)
Clean the vehicle frequently if it used in CAUTION particular areas or conditions, such as: To clean the lights, use a sponge soaked Polluted areas (cities and industrial are- with water and a neutral detergent, rub- as). bing the surfaces delicately and rinsing Areas characterized by an high percent- frequently with plenty of water. -
Page 41: After A Period Of Inactivity
Proceed as follows: AFTER A PERIOD OF INACTIVITY Remove the battery, see p. 82 (REMOV- Uncover and clean the vehicle, see p. 90 CAUTION ING THE BATTERY) and p. 84 (LONG (CLEANING). INACTIVITY OF THE BATTERY). If the vehicle remains unused for more Check the charge of the battery, see than twenty days, disconnect the 30A Wash and dry the vehicle, see p. - Page 42 DIMENSIONS Max. length ............2080 mm Max. length (with number-plate extension) ..2130 mm Max. width.............. 720 mm Max. height (front part of the fairing included) 1170 mm Seat height............. 825 mm Distance between centres........1415 mm Min. ground clearance ........... 127 mm Weight ready for starting ........
- Page 43 TRANSMISSION Type ............... mechanical, 6 gears with foot control on the left side of the engine GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 31/60 = 1 : 1.935 14/35 = 1 : 2.500 17 / 42 = 1 : 2.470 11,948 16/28 = 1 : 1.750 8,368...
- Page 44 " ; REAR TYRE Type ............... 180 / 55 ZR - 17 190 / 50 ZR - 17” PIRELLI DRAGON EVO MTR22 Model ..............Alternative .............. PIRELLI MTR 08 CORSA Inflation pressure solo rider........250 kPa (2,5 bar) SPARK PLUGS Standard ..............
- Page 45 Engine oil (recommended): EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15 W - 50 . As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.
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- Page 51 1) Electronic unit E - Electronic unit, fuel pump relay, en- 62) High beam warning light gine stop relay. 63) Dashboard bulbs 2) Cam position sensor 64) Revolution counter 3) Throttle valve position sensor 30) Ignition switch 65) Multifunction display (right side) 4) Suction pressure sensor 31) Low beam relay 66) Multifunction display (left side)
- Page 52 – 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.