APRILIA ETV mille Workshop Manual
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APRILIA ETV mille Workshop Manual

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ETV mille
1188 3
00/2004-04
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Summary of Contents for APRILIA ETV mille

  • Page 1 ETV mille 1188 3 00/2004-04 workshopmanual...
  • Page 2 INTRODUCTION ETV mille INTRODUCTION GENERAL INFORMATION PERIODIC MAINTENANCE AND ADJUSTMENTS ENGINE FUEL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM CHASSIS REPAIR INFORMATION - 1 - Release 00/2004 - 04...

  • Page 3: Table Of Contents

    INTRODUCTION ETV mille INTRODUCTION CONTENTS 0.1 RELEASE 00/2004-04 UPDATE ..0-3-00 0.1.1 MANUAL UPDATES......0-3-00 0.1.2 LIST OF MANUAL PAGES AND UPDATE NUMBERS ......0-3-00 0.2 REFERENCE GUIDE ......0-6-00 0.3 FOREWORD ........0-7-00 0.4 REFERENCE MANUALS ....0-7-00 0.4.1 ENGINE WORKSHOP MANUALS ..0-7-00 0.4.2 PARTS CATALOGUES ......

  • Page 4: Release 00/2004-04 Update

    INTRODUCTION ETV mille 0.1 RELEASE 00/2004-04 UPDATE pag.# Release pag.# Release Issue date of original release (Release 00) and 2-7 -00 ......00 2-47 -00 ...... 00 subsequent releases: 2-8 -00 ......00 2-48 -00 ...... 00 Original release (Release 00)....April 2004 2-9 -00 ......
  • Page 5 INTRODUCTION ETV mille pag.# Release pag.# Release pag.# Release pag.# Release 4-1 -00 ......00 6-9 -00 ......00 6-49 -00 ...... 00 7-31 -00 ...... 00 4-2 -00 ......00 6-10 -00 ...... 00 6-50 -00 ...... 00 7-32 -00 ...... 00 4-3 -00 ......
  • Page 6 INTRODUCTION ETV mille pag.# Release pag.# Release 7-71 -00 ...... 00 8-13 -00 .......00 7-72 -00 ...... 00 8-14 -00 .......00 7-73 -00 ...... 00 8-15 -00 .......00 7-74 -00 ...... 00 8-16 -00 .......00 7-75 -00 ...... 00 8-17 -00 .......00 7-76 -00 ......

  • Page 7: Reference Guide

    INTRODUCTION ETV mille 0.2 REFERENCE GUIDE GENERAL INFORMATION ETV mille 1.9 PLACING THE MOTORCYCLE ON THE SERVICE STAND 1.9.1 PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND Place the motorcycle on the centre stand. Slide both pins (1) of the front wheel stand into the holes (2) at front fork bottom end of the same time.

  • Page 8: Foreword

    (description) manual are updated through subsequent releases, 8140582 (1051-1) vedi 0.1 (RELEASE 00/2004-04 UPDATE). - This manual is intended for use by aprilia Dealers and 8140584 (1053-1) their qualified mechanics. Certain information has been 8140585 (1054-1) omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics.

  • Page 9: Safety Information

    - Use ORIGINAL aprilia SPARE PARTS only. removal or dismantling procedure. Where a procedure is - Use the specified lubricants and consumables. cross-referred to relevant sections in the manual, proceed - Where possible, lubricate a part before assembly.

  • Page 10: Safety Information

    INTRODUCTION ETV mille 0.6 SAFETY INFORMATION - After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then 0.6.1 CONVENTIONS USED IN THE MANUAL operate the motorcycle in a private estate area or in a safe area away from traffic.

  • Page 11: Abbreviations/Symbols

    INTRODUCTION ETV mille T.C.E.I. 0.7 ABBREVIATIONS/SYMBOLS/ = cheese-headed Allen screw T.E. CONVENTIONS = hexagonal head T.P. = flat head screw = Number = Top Dead Centre < = is less than TEST = diagnostic check > = is more than = Twin Spark Ignition <...
  • Page 12 INTRODUCTION ETV mille NOTES - 11 - Release 00/2004 - 04...
  • Page 13 INTRODUCTION ETV mille NOTES - 12 - Release 00/2004 - 04...
  • Page 14 GENERAL INFORMATION ETV mille GENERAL INFORMATION - 1 - Release 00/2004 - 04...
  • Page 15 GENERAL INFORMATION ETV mille GENERAL INFORMATION CONTENTS 1.1 LOCATION OF SERIAL NUMBERS .. 1-3-00 1.1.1 FRAME NUMBER........1-3-00 1.1.2 ENGINE NUMBER......... 1-3-00 1.2 WARNINGS CONCERNING FUEL, LUBRICANTS, COOLANT AND OTHER COMPONENT PARTS ..1-3-00 1.2.1 FUEL ............1-3-00 1.2.2 ENGINE OIL........... 1-4-00 1.2.3 FRONT FORK FLUID ......

  • Page 16: Location Of Serial Numbers

    GENERAL INFORMATION ETV mille 1.1 LOCATION OF SERIAL NUMBERS These numbers are necessary for vehicle registration. NOTE Altering the identification numbers of vehicle or engine is a legal offence punishable by heavy fines and penalties. In addition, altering the frame number (VIN) results in immediate warranty invalidation.

  • Page 17: Engine Oil

    GENERAL INFORMATION ETV mille 1.2.2 ENGINE OIL 1.2.4 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc CAUTION brakes. Each braking system is operated by an Prolonged or repeated contact with engine oil may independent hydraulic circuit. The information provided cause severe skin damage.

  • Page 18: Coolant

    GENERAL INFORMATION ETV mille 1.2.5 COOLANT 1.2.6 CLUTCH FLUID NOTE This vehicle is fitted with a hydraulically CAUTION operated clutch. Coolant is toxic when ingested and is an irritant, contact with eyes or skin may cause irritation. CAUTION In the event of contact with eyes, rinse repeatedly Clutch fluid is an irritant.

  • Page 19: Carbon Oxide

    GENERAL INFORMATION ETV mille 1.2.7 CARBON OXIDE 1.3 RUNNING-IN RECOMMENDATIONS When an operation must be performed with the engine Proper engine running-in is essential to preserving running, position the motorcycle out of doors or in a well- engine life and performance over time.

  • Page 20: Spare Parts

    GENERAL INFORMATION ETV mille 1.4 SPARE PARTS Use original aprilia spare parts only to replace original components. Original aprilia spare parts are high-quality components designed and built expressly for aprilia motorcycles. WARNING Using any parts OTHER THAN original aprilia parts may lead to loss of performance and damage.
  • Page 21 GENERAL INFORMATION ETV mille Mechanical 6-speed transmission with foot control on Transmission left-hand side of engine Dry-sump lubrication system with remote oil tank, # 2 Lubrication system trochoidal pumps and cooler min 500 kPa (5 bar) Lubrication pressure 80 °C (176 °F) max. and 6000 rpm...
  • Page 22 GENERAL INFORMATION ETV mille BRAKES Twin-disc brake with Æ 300-mm floating discs, four- Front piston calipers with Æ 30-mm/ Æ 32-mm diameter Rear Disc brake - Æ 272 mm, dual-piston caliper - Æ 34 WHEELS Type Tubeless tyres rim Front 2.50 x 19"...

  • Page 23: Lubricant Chart

    GENERAL INFORMATION ETV mille 1.6 LUBRICANT CHART LUBRICANT PRODUCT EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15W - 50. Engine oil As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I. S.G. specifications can be used.

  • Page 24: Consumables

    GENERAL INFORMATION ETV mille 1.7 CONSUMABLES Use only the products specified below for motorcycle maintenance. These products have demonstrated suitability for all usage conditions specified by the manufacturer after long-time testing. NOTE The products for which a part number is given...

  • Page 25: Product Applications

    GENERAL INFORMATION ETV mille 1.7.2 PRODUCT APPLICATIONS Product Part number Applications - Swinging arm rivets, instrument panel/front fairing mount, seat subframe and frame (on assembly). - Frame-to-engine and frame-to-swinging arm adjusting bushes (on assembly). - Cable guide screws to frame (on assembly).
  • Page 26 GENERAL INFORMATION ETV mille Product Part number Applications - Coolant thermal switch. - Coolant thermistors. Orange LOCTITE ® 0899784 - Contact screw of neutral switch. (**) - Outer surface of engine oil pump motor. - Cylinder footprint on crankcase. - Transmission primary and secondary shaft.
  • Page 27 GENERAL INFORMATION ETV mille Product Part number Applications Anti-seize compound ANTI-SEIZE 8116043 - Plugs of exhaust take-up points. MOTAGEPASTE AS 1800 - For cleaning left-hand handlebar before fitting twistgrip. - Radiator breather hoses into T union. - Ignition coil mount rubber (on assembly).

  • Page 28: Special Tools

    GENERAL INFORMATION ETV mille 1.8 SPECIAL TOOLS Special tools have been developed to ensure proper disassembly, re-assembly and adjustment without the risk of damaging any components. Using inadequate tools and/or improvised procedures may lead to irreparable damage. Model-specific special tools for this vehicle are listed below.

  • Page 29: Engine Tools

    GENERAL INFORMATION ETV mille 1.8.2 ENGINE TOOLS Ref. Tool designation and application Part number 8140175 Full engine tool kit Drift to fit transmission secondary shaft seal 0277680 Drift to fit seal into secondary balancing shaft location 0277660 Drift to fit seal into coolant pump shaft location...

  • Page 30: Placing The Motorcycle On The Service Stands

    GENERAL INFORMATION ETV mille 1.9 PLACING THE MOTORCYCLE ON THE SERVICE STANDS 1.9.1 PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND Place the motorcycle on the centre stand Slide both pins (1) of the front wheel stand (3) into the holes (2) at front fork bottom end at the same time.

  • Page 31: Placing The Motorcycle On The Centre Stand

    GENERAL INFORMATION ETV mille 1.9.2 PLACING THE MOTORCYCLE ON THE CENTRE STAND Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Part no. 8140176 (complete stand). Place the motorcycle on the front wheel stand see 1.9.1 (PLACING THE MOTORCYCLE ON THE FRONT WHEEL STAND).

  • Page 32: How To Apply The Decals

    GENERAL INFORMATION ETV mille 1.10 HOW TO APPLY THE DECALS Whenever you remove any body parts: WARNING Handle plastic and paint-finished parts with care to avoid scratching or damage. Proceed carefully. Do not damage the snap-on tabs and matching recesses.
  • Page 33 GENERAL INFORMATION ETV mille NOTE Where decals come with application tape (5) remove tape 20-30 minutes after decal application. Peel off the application tape (5) from decal surface. Pass the spatula across the decal again √ particularly over corners and edges √ to ensure proper adhesion.

  • Page 34: Torque Figures

    GENERAL INFORMATION ETV mille 1.11 TORQUE FIGURES The table below reports the standard torque figures for metric size screws and bolts in accordance with ISO standards. Screw or Tightening torque bolt Spanner thread M 10 M 12 M 14 M 16 13.0...
  • Page 35 GENERAL INFORMATION ETV mille NOTE - 22 - Release 00/2004 - 04...
  • Page 36 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille PERIODIC MAINTENANCE AND ADJUSTMENTS - 1 - Release 00/2004 - 04...
  • Page 37 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille PERIODIC MAINTENANCE AND 2.18 BLEEDING THE BRAKE CIRCUITS 2-35-00 ADJUSTMENTS 2.19 BLEEDING THE CLUTCH....2-40-00 2.20 CHANGING THE FRONT BRAKE CONTENTS FLUID ..........2-41-00 2.21 CHANGING THE REAR BRAKE 2.1 PERIODIC MAINTENANCE CHART . 2-4-00 FLUID ..........
  • Page 38 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.40 MAINTAINING FASTENERS AT THE CORRECT TIGHTENING TORQUE 2-61-00 2.41 FASTENERS......... 2-62-00 2.41.1 CLEANING AND LUBRICATION..2-68-00 - 3 - Release 00/2004 - 04...

  • Page 39: Periodic Maintenance Chart

    Unless expressly specified otherwise, reassembly is carried out by reversing the disassembly procedure. 2.1 PERIODIC MAINTENANCE CHART In order to preserve the motorcycle in sleek running order, aprilia recommends that you strictly observe the periodic maintenance intervals recommended for the different component parts. WARNING Upon reaching the first 1000 km (625 mi) and every 7500 km (4687 mi) afterwards, a wording "SERVICE"...
  • Page 40 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.1.1 PERIODIC MAINTENANCE CHART Post running-in Every 7500 km Every 15000 km Component checks (4687 mi) or 12 (9375 mi) or 24 [1000 km (625 mi)] months months Rear shock absorber " Spark plugs...
  • Page 41 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Post running-in Every 7500 km Every 15000 km Component checks (4687 mi) or 12 (9375 mi) or 24 [1000 km (625 mi)] months months Cylinder synchronisation Suspension and set-up at each start-up: Engine oil pressure LED light...

  • Page 42: Lubrication Points

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille KEY TO THE LAYOUT OF LUBRICATION POINTS LUBRICATION POINTS 1)Steering bearings Proper lubrication is critical to ensuring smooth operation 2)Clutch lever spindle and preserving vehicle life. 3)Rider right-hand footpeg NOTE Before lubricating any part, clean off any 4)Rider left-hand footpeg oxidation deposits, grease, dirt or dust.

  • Page 43: Multifunction Computer

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.3 MULTIFUNCTION COMPUTER 2.3.1 KEY A Left-hand digital display (odometer, shows total km/ miles covered) B Right-hand multifunction digital display (fuel level/air temperature √ coolant temperature √ clock/injection diagnostics) C SET and MODE programming buttons.

  • Page 44: How To Toggle Between Odometer/Trip Meter

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille & " and press the SET Set the ignition switch to " button (3) repeatedly within the next three seconds to try out the three light settings. & Select the desired lighting intensity. 2.3.4 HOW TO TOGGLE BETWEEN ODOMETER/...

  • Page 45: Setting The Clock (Hours And Minutes)

    Normally, the engine will keep running though performance may be somewhat impaired. The wording “EFI” only lights up on the multifunction digital display during service inspections by Aprilia Franchised Dealers. Speedometer (kph) Gives road speed.
  • Page 46 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Description Function Digital Odometer/trip meter Gives motorcycle's total mileage (in kilometres or miles) display (left- (km - mi) or distance covered since last resetting. hand side) Gives fuel level in the tank. The display provides both an analogue (scale) and numeric (litres or gallons) indication of fuel quantity.
  • Page 47 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Description Function Shows engine coolant temperature, see 2.3.2 (PROGRAMMING BUTTONS). The display provides both an analogue (scale) and numeric (°C/°F) temperature indication. Characters ≈---∆ are displayed until coolant heats up to 35 °C (97 °F).

  • Page 48: Battery

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.4 BATTERY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully . There are two types of batteries available in the market: - batteries that require maintenance, fitted with cell plugs; - maintenance-free batteries, which have no cell plugs as they do not need inspecting or topping-up.

  • Page 49: Cleaning And Checking Battery Terminals And Lead Connections

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.4.1 CLEANING CHECKING BATTERY TERMINALS AND LEAD CONNECTIONS Read 2.4 (BATTERY) carefully. & Ensure the ignition switch is in the " " position. & Remove the rider seat, see 7.1.2 (REMOVING THE RIDER SEAT).

  • Page 50: Charging The Battery

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.4.2 CHARGING THE BATTERY 2.5 ELECTRIC COMPONENTS Read 2.4 (BATTERY) carefully. Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. NOTE You can tell that the battery is nearly flat when you hear a rattling sound from the starter relay when...

  • Page 51: Jump-Starting

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.6 JUMP-STARTING Read 2.4 (BATTERY) carefully. CAUTION Jump-starting should be the last resort when the battery is low or dead and cannot be recharged. Do not attempt to start the engine by pushing or towing the motorcycle.

  • Page 52: Spark Plugs

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.7 SPARK PLUGS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Check the spark plugs every 7500 km (4687 mi) or 8 months. Change them every 15000 Km (9375 mi) or 16 months. At regular intervals, remove the spark plugs and clean off any carbon deposits or replace them as required.
  • Page 53 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille WARNING Ensure that the replacement spark plug is the suitable length and thread. A short thread will cause carbon to build up on the thread in the head. When you fit a proper spark plug at a later time, the engine will damage.

  • Page 54: Draining The Fuel Tank

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.8 DRAINING THE FUEL TANK Read 1.2.1 (FUEL) carefully. CAUTION Fire hazard. Allow the engine and exhaust silencers to cool down completely. Fuel vapours are harmful to human health. Ensure that the area is properly ventilated before proceeding.

  • Page 55: Air Cleaner

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.9 AIR CLEANER Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Check the air cleaner every 7500 km (4687 mi) or 12 months. Change it every 15000 km (9375 mi) or more frequently when you ride on dusty or wet roads.
  • Page 56 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille REMOVAL & Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). & Release and remove the eight retaining screws (2) of the air box cover (3). Torque wrench setting for screws (2): 3 Nm (0.3 kgm).

  • Page 57: Throttle

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.10 THROTTLE Inspect after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards. 2.10.1 CHECKING THROTTLE PROPER OPERATION CAUTION Throttle operation may be impaired when the throttle cables are damaged, bent in tight turns or twisted.
  • Page 58 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.10.3 THROTTLE CABLE PLAY ADJUSTMENT Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Inspect after the first 1000 km (625 mi) and every 7500 km (4687 mi) afterwards. Periodically inspect the throttle cables. There should be 2–3 mm free play in the throttle twistgrip cable (measured at twistgrip edge).

  • Page 59: Checking And Topping Up Engine Oil Level

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.11 CHECKING AND TOPPING UP ENGINE OIL LEVEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.2 (ENGINE OIL) carefully. Check engine oil level at regular intervals. Change oil after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards, see 2.12 (ENGINE OIL AND...

  • Page 60: Engine Oil And Filter Change

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.12 ENGINE OIL AND FILTER CHANGE Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.2 (ENGINE OIL) carefully. Check engine oil level at regular intervals. Change oil after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards, see 2.12 (ENGINE OIL AND...
  • Page 61 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille ENGINE OIL FILTER CHANGE Change the engine oil filter after the first 1000 km (625 mi) and every 7500 km (4687 mi) afterwards (or at each oil change). & Release the two screws (6) and remove the guard (7).

  • Page 62: Checking And Topping Up Coolant Level

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.13 CHECKING AND TOPPING UP COOLANT LEVEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.5 (COOLANT) carefully. Check coolant level before each ride. Change coolant every 2 years. WARNING FULL Check and top up coolant level when the engine is cold.

  • Page 63: Coolant Change

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.14 COOLANT CHANGE Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION), 1.2.5 (COOLANT) and Sect. 5 (COOLING SYSTEM) carefully. Change coolant every 2 years. & Remove both side fairings, see 7.1.18 (REMOVING THE FRONT FAIRING). & Remove radiator spoiler, see 7.1.23 (REMOVING THE UPPER SUMP GUARD) &...

  • Page 64: Checking And Topping Up Front

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.15 CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.4 (BRAKE FLUID) carefully. Check brake fluid every 7500 km (4687 mi) or 8 months, change it every two years.
  • Page 65 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille TOP-UP WARNING Danger: brake fluid could leak out. Never operate the front brake lever when the screws (2) have been loosened or when the reservoir cover is not in place. WARNING Place a cloth under the brake fluid reservoir to col- lect any fluid spillage.
  • Page 66 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.16 CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.4 (BRAKE FLUID) carefully. Check brake fluid every 7500 km (4687 mi) or 8 months, change it every two years.
  • Page 67 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille TOP-UP WARNING Danger: brake fluid could leak out. Never operate the rear brake lever when the brake fluid reservoir cap has been loosened or is not in place. CAUTION Avoid long exposure of brake fluid to air.
  • Page 68 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.17 CHECKING AND TOPPING UP CLUTCH FLUID LEVEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and see 1.2.6 (CLUTCH FLUID) carefully. Check clutch fluid every 7500 km (4687 mi) or 8 months; change it every two years.
  • Page 69 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille TOP-UP WARNING Danger: clutch fluid could leak out. Never operate the clutch lever when the clutch fluid reservoir cap has been loosened or is not in place. CAUTION Avoid long exposure of clutch fluid to air.
  • Page 70 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.18 BLEEDING THE BRAKE CIRCUITS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.4 (BRAKE FLUID). See 2.1.1 (PERIODIC MAINTENANCE CHART) for service intervals. Any air trapped in the hydraulic circuit will act as a cushion and take up most of the pressure applied by the master cylinder.
  • Page 71 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille HOW TO BLEED THE BRAKING SYSTEM There are three bleeding procedures to be performed strictly in the order given: √ BLEED THE HYDRAULIC CIRCUIT NOTE Read the description of the hydraulic circuit bleeding procedure for instructions on how to determine whether the brake caliper and the master cylinder need bleeding, too.

  • Page 72: Checking And Topping Up Rear Brake Fluid Level

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille & Add brake fluid to the reservoir until bringing fluid up to correct level, see 2.15 (CHECKING AND TOPPING UP FRONT BRAKE FLUID LEVEL) and see 2.16 (CHECKING AND TOPPING UP REAR BRAKE FLUID LEVEL).
  • Page 73 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille &' Slowly operate the brake lever (for the front brake, or the brake pump rod for the rear brake) more than once, in order to fill the system with brake fluid and to carry out a first partial bleeding.
  • Page 74 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille & Position the protection cap on the bleeder valve (1-2). DISPOSE FLUID ENVIRONMENT. & Empty the container (11) into a suitable receptacle for the collection of used brake fluid. CHECKS TO BE CARRIED OUT AFTER BLEEDING...

  • Page 75: Checking And Topping Up Clutch Fluid Level

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.19 BLEEDING THE CLUTCH Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.6 (CLUTCH FLUID) carefully. Bleed the clutch system after the first 1000 km (625 mi) if needed. Any air trapped in the hydraulic circuit will act as a cushion and take up most of the pressure applied by the master cylinder.

  • Page 76: Changing The Front Brake Fluid

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.20 CHANGING THE FRONT BRAKE FLUID Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.4 (BRAKE FLUID) carefully. Change the front brake fluid every two years. WARNING Handle with care: contact with brake fluid will alter the chemical properties of paintwork, plastic and rubber parts, etc.

  • Page 77: Changing The Rear Brake Fluid

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.21 CHANGING THE REAR BRAKE FLUID Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.4 (BRAKE FLUID) carefully. Change the rear brake fluid every two years. WARNING Handle with care: contact with brake fluid will alter the chemical properties of paintwork, plastic and rubber parts, etc.

  • Page 78: Changing The Clutch Fluid

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.22 CHANGING THE CLUTCH FLUID Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.6 (CLUTCH FLUID) carefully. Change the clutch fluid every two years. WARNING Handle with care: contact with clutch fluid will alter the chemical properties of paintwork, plastic and rubber parts, etc.

  • Page 79: Adjusting Rear Brake Lever Play

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.24 ADJUSTING REAR BRAKE LEVER PLAY Rear brake pedal position is set at the factory so as to afford maximum ease of operation. However, the lever may be adjusted to suit rider's preferences as follows: &...

  • Page 80: Checking Brake Pads For Wear

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.26 CHECKING BRAKE PADS FOR WEAR The rate at which brake pads will wear depends on usage, riding style and road surface condition. NOTE The following information applies to both braking systems. This is a quick inspection procedure to determine brake pads wear: &...

  • Page 81: Steering

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.27 STEERING Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Inspect after the first 1500 km (937 mi) and every 7500 km (4687 mi) or 8 months afterwards. The steering is fitted with rolling bearings to ensure smooth handling.
  • Page 82 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille & Straighten the tabs (those bent upwards) of the safety washer (6) using a small flat-blade screwdriver. NOTE Make sure you have the special tool 8140203 (socket for steering adjustment) ready at hand. &...

  • Page 83: Inspecting The Front Suspension

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.28 INSPECTING THE FRONT SUSPENSION 2.28.1 FRONT SUSPENSION The front suspension is managed by a hydraulic fork, which is held to the steering stem by two yokes. Factory setting is designed to suit the broadest possible range of riding conditions, meaning low and high speed, whether riding solo or carrying a full load.

  • Page 84: Rear Swinging Arm

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.29 REAR SWINGING ARM Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Periodically check that the nut-and-spindle assembly and the needle roller bearings of the swinging arm are properly tightened. Inspection procedure: & Place the vehicle on the centre stand &...

  • Page 85: Rear Suspension Inspection

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.30 REAR SUSPENSION INSPECTION 2.30.1 REAR SUSPENSION The rear suspension is managed by a spring/damper unit that is connected to the frame and to the rear swinging arm through silent-blocks and a linkage system, respectively.

  • Page 86: Inspecting The Rear Suspension Linkage System

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Rotate the adjuster screw (1) gradually by 2-3 click positions at a time. Rotate the adjuster knob (2) by 5- 6 click positions at a time. Test ride the vehicle on the road repeatedly until achieving ideal setting.

  • Page 87: Front Wheel

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Press down the vehicle tail. If the tail is slow to spring back up when released, check rear suspension adjustment, see 2.30.2 (REAR SHOCK ABSORBER ADJUSTMENT). If the problem persists, it means that the shock absorber is depressurised.

  • Page 88: Adjusting Wheel Spoke Tension

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.33 ADJUSTING WHEEL SPOKE TENSION Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Check after the first 1000 Km (621 mi) and every 7500 km (4660 mi) afterwards. Place the motorcycle on the stand. NOTE Spoke tension can be adjusted with the wheel installed.

  • Page 89: Exhaust Manifold Nuts

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.34 EXHAUST MANIFOLD NUTS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Tighten the exhaust manifold nuts after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards. CAUTION Let the engine cool down completely.

  • Page 90: Chain Slack Inspection

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille WARNING If chain rollers are damaged, chain link pins are loose and/or any O-rings are missing or deteriorated, renew the drive chain and the front and rear sprockets as a set, see 7.3.3 (DISMANTLING THE FINAL DRIVE ASSEMBLY).

  • Page 91: Checking Chain And Sprockets

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.35.2 CHECKING CHAIN AND SPROCKETS FOR WEAR & Stretch the chain taut, see 2.35.3 (CHAIN SLACK ADJUSTMENT) . & Count 17 link pins (16 link-to-link sections) along one portion of the chain and measure the distance between the 1st and the 17th link.

  • Page 92: Cleaning And Lubrication

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.35.4 CLEANING AND LUBRICATION Never wash the drive chain using steam cleaners, high- pressure water nozzles or highly flammable solvents. & Wash the drive chain with fuel oil or kerosene. NOTE If the chain tends to become rusty quickly, service more frequently.

  • Page 93: Drive Chain Guide Plate Inspection

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.35.5 DRIVE CHAIN GUIDE PLATE INSPECTION Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. & Place the vehicle on the stand. & Remove the gear shift lever, see 7.1.39 (REMOVING THE GEAR SHIFT LEVER ASSEMBLY) &...

  • Page 94: Tyres

    Using tyres other than the specified sizes may change vehicle behaviour, impair handling and make the vehicle unsafe to ride. Use only the first-equipment tyre types selected by aprilia, see 1.5 (SPECIFICATIONS). - 59 - Release 00/2004 - 04...

  • Page 95: Fuel Lines

    PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.37 FUEL LINES Read 1.2.1 (FUEL) carefully. Check the fuel lines every 7500 km (4687 mi) or 8 months. Renew every four years. - Always change a worn, cracked or damaged fuel line. - High-pressure delivery pipe (1) [~ 450 kpa (4,5 bar)].
  • Page 96 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.40 MAINTAINING FASTENERS AT THE CORRECT TIGHTENING TORQUE Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Check after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards. Ensure that all fasteners are properly tightened. Take special care with safety-related items, namely: - handlebars secured to top yoke;...
  • Page 97 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.41 FASTENERS Check and tighten as required after the first 1000 km (625 mi) and every 7500 km (4687 mi) or 8 months afterwards. WARNING The fasteners reported in the chart must be tightened...
  • Page 98 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Fuel delivery pipe to throttle body Gear shift lever FRAME Description Qty. Screw/nut Notes Seat subframe top mounting point Seat subframe bottom mounting point Fairing subframe fixings Fairing side plate Chain roller screw REAR SWINGING ARM Description Qty.
  • Page 99 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille REAR SUSPENSION Shock absorber Description Qty. Screw/nut Notes Shock absorber to frame Linkage system Single linkage to frame Single / dual linkage to frame Dual linkage to swinging arm Dual linkage to shock absorber...
  • Page 100 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Lower radiator brackets to frame fixing Cooling fan to radiator TCB 4.2 L243 Expansion reservoir fixing Expansion reservoir guard fixing Expansion reservoir cap fixing M28x3 man. Hose clips (part no. 8104097) BRAKING SYSTEMS Front braking system Description Qty.
  • Page 101 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Rear tank to frame fixings Engine oil tank and cooler Description Qty. Screw/nut Notes Oil tank fixings Oil filter tang M25x1.5 Oil drain plug Oil sight glass fixings M10x1 Oil cooler fixings Oil cooler plate fixing...
  • Page 102 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille Headlight to lugs TCB 5.5 Tail light fixings Front turn indicator fixings Rear turn indicator fixings Cockpit to bridge Number plate light fixings Cat»s eye fixing IGNITION SWITCH AND LOCK Description Qty. Screw/nut Notes...
  • Page 103 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille 2.41.1 CLEANING AND LUBRICATION Never wash the drive chain using steam cleaners, high- pressure water nozzles or highly flammable solvents. & Wash the drive chain with fuel oil or kerosene. If the chain tends to become rusty quickly, service more frequently.
  • Page 104 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille NOTE - 69 - Release 00/2004 - 04...
  • Page 105 PERIODIC MAINTENANCE AND ADJUSTMENTS ETV mille NOTE - 70 - Release 00/2004 - 04...
  • Page 106 ENGINE ETV mille ENGINE - 1 - Release 00/2004 - 04...
  • Page 107 ENGINE ETV mille ENGINE CONTENTS 3.1 SPECIFICATIONS AND TECHNICAL INFORMATION ........ 3-3-00 3.1.1 TECHNICAL DATA........ 3-3-00 3.1.2 MAINTENANCE INTERVALS ....3-3-00 3.1.3 TROUBLESHOOTING......3-3-00 3.1.4 SEALANTS ..........3-3-00 3.1.5 LUBRICANTS ........3-3-00 3.1.6 SPECIAL TOOLS ........3-3-00 3.1.7 TORQUE FIGURES ....... 3-3-00 3.1.8 PRECONDITIONS FOR MAINTENANCE...

  • Page 108: Specifications And Technical Information

    ENGINE ETV mille 3.1 SPECIFICATIONS AND TECHNICAL INFORMATION 3.1.1 TECHNICAL DATA See 1.5 (SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 2.1.1 (PERIODIC MAINTENANCE 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 See 1.8 (SPECIAL TOOLS).

  • Page 109: Engine Components That Can Be Removed With The Engine Installed In The Frame

    ENGINE ETV mille 3.2 ENGINE COMPONENTS THAT CAN BE REMOVED WITH THE ENGINE INSTALLED IN THE FRAME Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) carefully. The parts listed below can be removed leaving the engine in the frame. WARNING Necessary removal procedures are listed in the proper sequence in this section.
  • Page 110 ENGINE ETV mille LEFT-HAND SIDE RIGHT-HAND SIDE - Rear cylinder spark plugs (6-7), see 2.7 (SPARK - Front cylinder coolant thermistor (15), see 5.4 PLUGS). (REMOVING THE COOLANT THERMISTORS). - Drive sprocket cover (8), see 2.35.5 (DRIVE CHAIN - Front cylinder spark plugs (16-17), see 2.7 (SPARK GUIDE PLATE INSPECTION).

  • Page 111: Clutch Slave Cylinder Removal

    ENGINE ETV mille 3.2.1 CLUTCH SLAVE CYLINDER REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) and 1.2.6 (CLUTCH FLUID) carefully. Release and remove the screws (1). Torque wrench setting for screws (1): 10 Nm (1.0 kgm). Withdraw the slave cylinder assembly (2).

  • Page 112: Taking The Engine Out Of The Frame

    ETV mille 3.3 TAKING THE ENGINE OUT OF THE FRAME WARNING Engine removal must be undertaken at an Authorised Service Centre or an Authorised Aprilia Dealer. Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) carefully. 67 Kg WARNING Engine removal is a complex operation. Plan work ahead and identify the locations of affected parts on the vehicle before proceeding.
  • Page 113 ENGINE ETV mille Release and remove the screw (5). Disconnect the lead of the neutral switch (6). Remove the expansion reservoir, see 5.6 (REMOVING THE EXPANSION RESERVOIR). Slip off the dust cap (7) and disconnect the lead of the engine oil pressure sensor (8) at sensor end.
  • Page 114 ENGINE ETV mille Clean the outer surface of the engine thoroughly. Remove the exhaust pipes, see 7.1.42 (REMOVING THE EXHAUST PIPES). Disconnect the cooling fan connector (14). Disconnect the warning horn wiring (15). WARNING Take care to refit each connector to the matching connector on assembly.
  • Page 115 ENGINE ETV mille NOTE Make sure to have the special clip pliers (part no. 0277295) ready at hand. Renew all clips on assem- bly. Use clips of the same type fitted originally. Release the head of the hose clip (22).
  • Page 116 ENGINE ETV mille NOTE Engine-to-frame fixings must be removed in this order: LEFT-HAND SIDE: A ➠ ➠ ➠ RIGHT-HAND SIDE: E ➠ ➠ ➠ - 11 - Release 00/2004 - 04...
  • Page 117 ENGINE ETV mille Release and remove the two screws (30) and collect the washers (31). Torque wrench setting for screws (30): 50 Nm (5.0 kgm). Hold the check nut (32) steady. Release and remove the screw (33). Torque wrench setting for check nut (32) and screw (33): 50 Nm (5.0 kgm).
  • Page 118 ENGINE ETV mille Screw out the adjusting bushes (40 - 44) until bringing them fully home in the frame. Torque wrench setting for adjusting bushes (40 - 44): 10 Nm (1.0 kgm). WARNING On assembly, screw in the adjusting bushes (40 - 44) manually until bringing them fully home in the engine and then tighten to the specified torque.
  • Page 119 ENGINE ETV mille CAUTION The engine is now supported on the hoist only. All fixings have been removed. Handle with care. Be careful to avoid injury to your hands, arms and legs. Clear all tools from the area. Thoroughly clean the area of the floor where the engine is to be placed.

  • Page 120: Fitting The Engine In The Frame

    ENGINE ETV mille 3.4 FITTING THE ENGINE IN THE FRAME Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) carefully. NOTE To refit the engine in the frame, reverse the removal procedure, see 3.3 (TAKING THE ENGINE OUT OF THE FRAME). Before proceeding, however, you will have to perform the operations detailed below.
  • Page 121 ENGINE ETV mille NOTES - 16 - Release 00/2004 - 04...
  • Page 122 FUEL SYSTEM ETV mille FUEL SYSTEM - 1 - Release 00/2004 - 04...
  • Page 123 FUEL SYSTEM ETV mille FUEL SYSTEM CONTENTS 4.1 FUEL TANK ........4-3-00 4.1.1 MAINTENANCE........4-4-00 4.1.2 INSPECTING THE FUEL LINES ... 4-4-00 4.2 DRAINING THE FUEL TANK ... 4-5-00 4.3 REMOVING THE FUEL PUMP ASSEMBLY ........4-5-00 4.4 REMOVING THE FUEL SENSOR..4-6-00 4.5 REMOVING THE FUEL DELIVERY...

  • Page 124: Fuel Tank

    FUEL SYSTEM ETV mille 4.1 FUEL TANK The fuel tank is fitted with a top-mounted filler cap, whereas the tank bottom accommodates the following components: the fuel pump assembly; a drain hose to drain water from the filler cap when it rains or after washing;...

  • Page 125: Maintenance

    FUEL SYSTEM ETV mille Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.1 (FUEL) carefully. CAUTION Fuel vapours are harmful to human health. Ensure that the area is well ventilated before proceeding. Do not inhale fuel vapours. Avoid contact with skin. Do not smoke or use bare flames.

  • Page 126: Draining The Fuel Tank

    FUEL SYSTEM ETV mille 4.2 DRAINING THE FUEL TANK See 2.8 (DRAINING THE FUEL TANK) for instructions on how to drain the fuel tank. 4.3 REMOVING THE FUEL PUMP ASSEMBLY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION), 1.2.1 (FUEL) 4.1.1 (MAINTENANCE) carefully.

  • Page 127: Removing The Fuel Sensor

    FUEL SYSTEM ETV mille 4.4 REMOVING THE FUEL SENSOR Remove fuel pump assembly, see 4.3 (REMOVING THE FUEL PUMP ASSEMBLY). Disconnect the connector (1). WARNING Make sure to refit the connector (1) to the matching connector on assembly. Ease the fuel sensor (2) out of the mount (3) levering with a screwdriver.

  • Page 128: Fuel Pump Removal

    FUEL SYSTEM ETV mille 4.6 FUEL PUMP REMOVAL Remove fuel pump assembly, see 4.3 (REMOVING THE FUEL PUMP ASSEMBLY). Disconnect the connector (1). WARNING Make sure to refit the connector (1) to the matching connector on assembly. NOTE Make sure to have the special clip pliers (part no.

  • Page 129: Engine Management

    FUEL SYSTEM ETV mille 4.7 ENGINE MANAGEMENT 4.7.1 GENERAL INFORMATION Engine operation is managed by an on-board computer (Engine Control Unit) to guarantee optimal ignition and fuel injection. Ignition is managed according to consumption. The ECU determines the exact ignition timing according to engine rpm and throttle position (the latter gives a measure of intake air quantity).

  • Page 130: Sensors

    FUEL SYSTEM ETV mille 4.7.2 SENSORS Flywheel pick-up (1) Location: housed in flywheel cover (2). This sensor detects the movement of a pre-determined phonic wheel on the crankshaft. The phonic wheel is characterised by an individual length, which is three times the distance/air gap, to provide a reference point on the wheel.
  • Page 131 FUEL SYSTEM ETV mille Throttle position sensor (4) Location: throttle body (5). This sensor is a potentiometer. Throttle position is determined by comparing output voltage to supply voltage (rating is 5 V) for greater accuracy. As the throttle opens, the sensor output voltage increases in a linear pattern.

  • Page 132: Fuel Injection Layout

    FUEL SYSTEM ETV mille 4.7.3 FUEL INJECTION LAYOUT Kill Switch COOLING FAN 1 BATTERY PWONLY COOLING FAN 2 FUEL PUMP 0.5 mm² Raychem 67 P1 A1 EXHAUST CAMSHAFT POSITION SENSOR VALVE P1 B1 P1G1 P1 B2 COOLANT FRONT CYLINDER THERMISTOR...

  • Page 133: Engine Control Unit Connectors

    FUEL SYSTEM ETV mille 4.7.4 ENGINE CONTROL UNIT CONNECTORS See 6.6 (HOOK-UP DIAGRAM OF ENGINE CONTROL UNIT) for more details. 65 PINK-WHITE 80 BROWN 52 YELLOW-BLACK 55 BROWN-GREEN 53 YELLOW-BLACK 28 GREY-WHITE 47 BROWN-PINK 51 ORANGE-WHITE 27 BLUE-ORANGE 50 GREEN-LIGHT BLUE...

  • Page 134: Automatic Operation Test

    FUEL SYSTEM ETV mille 4.7.5 AUTOMATIC OPERATION TEST See 6.5 (IGNITION/INJECTION SYSTEM). 4.7.6 ELECTRONIC SYSTEM TROUBLESHOOTING BASED ON DISPLAY INFORMATION CAUTION Be careful: the ignition system is under high voltage. Never disconnect the connectors while the engine is running. Unless expressly specified otherwise in the relevant...

  • Page 135: Throttle Body

    FUEL SYSTEM ETV mille 4.8 THROTTLE BODY WARNING The throttle body linkage cannot be adjusted or removed individually. In the event of a malfunction, replace the complete throttle body assembly, see 4.8.1 (THROTTLE BODY REMOVAL). The two screws M4x12 (1) securing the throttle position sensor are coated with paint at the factory and may only be removed when replacing the sensor.

  • Page 136: Removing The Injectors

    FUEL SYSTEM ETV mille Move apart the clip (15). Disconnect the pressure regulator tube (11). Slacken the two clips (14 - 13). WARNING Clean the two intake flanges thoroughly before removing the throttle body, or dirt may fall into the cylinders.

  • Page 137: Dismantling The Throttle Body

    FUEL SYSTEM ETV mille 4.9 DISMANTLING THE THROTTLE BODY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Drain the fuel tank, see 2.8 (DRAINING THE FUEL TANK). Remove throttle body assembly, see 4.8.1 (THROTTLE BODY REMOVAL). Release and remove the two screws (1).

  • Page 138: Throttle Body Inspection

    FUEL SYSTEM ETV mille 4.10 THROTTLE BODY INSPECTION 4.10.1 TESTING INJECTOR OPERATION CAUTION Fuel is explosive and highly flammable. Keep fuel away from any sources of ignition, heat or flames. NOTE Injectors may also be inspected in the machine. Check the following components: - wiring and connections;...

  • Page 139: Cylinder Synchronisation

    FUEL SYSTEM ETV mille 4.10.4 CYLINDER SYNCHRONISATION Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.1 (FUEL) carefully. Erratic idling sign improper cylinder synchronisation. The cylinders must be synchronised before setting the CO rate, see 4.10.5 (SETTING THE CO RATE). Take a short ride (allow a few kilometres» riding distance) to warm engine up to normal operating temperature.

  • Page 140: Setting The Co Rate

    FUEL SYSTEM ETV mille 4.10.5 SETTING THE CO RATE Remove the radiator spoiler, see 7.1.24 (REMOVING THE LOWER SUMP GUARD). WARNING The CO rate must be set with a hot engine. Coolant temperature should be 75-90 °C (167-194 °F). NOTE...
  • Page 141 FUEL SYSTEM ETV mille The top portion of the display shows a parameter given in percentage. This is not the CO rate. Do not compare this parameter with the CO reading displayed by the exhaust emission analyser (1). Press the UP and DOWN arrow keys to modify the parameter on the Axone 2000 display as required.

  • Page 142: Setting The Throttle Position Sensor

    FUEL SYSTEM ETV mille 4.10.6 SETTING THE THROTTLE POSITION SENSOR Remove the pillion seat, see 7.1.1 . Connect the meter Axone 2000 (1) to the connector (2) placed underneath the seat. To feed the meter Axone 2000 (1), connect to the motorcycle battery.
  • Page 143 FUEL SYSTEM ETV mille NOTES - 22 - Release 00/2004 - 04...
  • Page 144 COOLING SYSTEM ETV mille COOLING SYSTEM - 1 - Release 00/2004 - 04...
  • Page 145 COOLING SYSTEM ETV mille COOLING SYSTEM CONTENTS 5.1 DESCRIPTION ......... 5-3-00 5.2 REMOVING THE RADIATOR.... 5-5-00 5.3 REMOVING THE COOLING FAN ..5-6-00 5.4 REMOVING THE COOLANT THERMISTORS ........ 5-7-00 5.5 REMOVING THE THERMAL EXPANSION VALVE ......5-8-00 5.6 REMOVING THE EXPANSION RESERVOIR ........

  • Page 146: Description

    COOLING SYSTEM ETV mille 5.1 DESCRIPTION An engine-driven centrifugal pump accommodated in the When coolant expands from heat, the expansion engine circulates coolant through the system. The pump reservoir takes up excess coolant. takes in the coolant and directs it through the ducts into ≈LOW∆...
  • Page 147 COOLING SYSTEM ETV mille Coolant circulation when coolant temperature is below 75°C (167 °F). The pump circulates coolant to the ducts (thermistors detect temperature, temperature reading appears on right-hand display of instrument panel) √ coolant flows out of ducts (on right-hand side of engine) to thermal expansion valve (valve is fully closed) and back to the pump.

  • Page 148: Removing The Radiator

    COOLING SYSTEM ETV mille 5.2 REMOVING THE RADIATOR Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) and 1.2.5 (COOLANT) carefully. Set the ignition switch to ≈ ∆. Drain all coolant from the cooling circuit, see 2.14 (COOLANT CHANGE). Remove the fairings, see 7.1.18 (REMOVING THE FRONT FAIRING).

  • Page 149: Removing The Cooling Fan

    COOLING SYSTEM ETV mille WARNING Remove any build-up, dirt, etc. caught between the radiator fins blowing with compressed air. Straighten any bent fins using a small Phillips screwdriver. Renew the hoses (2-8) if cracked or sheared. Before refitting the radiator, wash it inside using clean water only.

  • Page 150: Removing The Coolant Thermistors

    COOLING SYSTEM ETV mille 5.4 REMOVING THE COOLANT THERMISTORS Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) and 1.2.5 (COOLANT)carefully. NOTE The procedure described below applies to both thermistors. Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). Slacken the two clips (1-2).

  • Page 151: Removing The Thermal Expansion Valve

    COOLING SYSTEM ETV mille 5.5 REMOVING THE THERMAL EXPANSION VALVE Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) and 1.2.5 (COOLANT) carefully. Drain the cooling system, see 2.14 (COOLANT CHANGE). NOTE Make sure to have the special clip pliers (part no. 0277295) ready at hand. On refitting, renew all clips using the same type fitted originally.

  • Page 152: Removing The Expansion Reservoir

    COOLING SYSTEM ETV mille 5.6 REMOVING THE EXPANSION RESERVOIR Read 0.5.1 (GENERAL PRECAUTIONS AND INFOR- MATION) and 1.2.5 (COOLANT) carefully. Remove front fairing panel, see 7.1.18 (REMOVING THE FRONT FAIRING). NOTE Make sure to have the special clip pliers (part no.
  • Page 153 COOLING SYSTEM ETV mille NOTE - 10 - Release 00/2004 - 04...
  • Page 154 ELECTRICAL SYSTEM ETV mille ELECTRICAL SYSTEM - 1 - Release 00/2004 - 04...
  • Page 155 ELECTRICAL SYSTEM ETV mille ELECTRICAL SYSTEM 6.9.2 COOLING FAN TEST ......6-31-00 6.10 SAFETY LOCKOUT SYSTEM ..6-32-00 6.10.1 WIRING DIAGRAM......6-32-00 CONTENTS 6.10.2 AIR TEMPERATURE SENSOR... 6-33-00 6.10.3 ENGINE OIL PRESSURE SENSOR..6-34-00 6.10.4 SPEED SENSOR ......... 6-35-00 6.1 LAYOUT OF ELECTRICAL 6.10.5 FUEL SENSOR........

  • Page 156: Layout Of Electrical Components

    ELECTRICAL SYSTEM ETV mille 6.1 LAYOUT OF ELECTRICAL COMPONENTS - 3 - Release 00/2004 - 04...
  • Page 157 ELECTRICAL SYSTEM ETV mille 1) Engine Control Unit 27) Spark plugs 2) Front cylinder coils 28) Front parking light bulb 3) Rear cylinder coils 29) Neutral switch 4) Warning horn 30) Front right indicator 5) Cooling fan 31) Auxiliary fuses (15 A)

  • Page 158: Foreword

    ELECTRICAL SYSTEM ETV mille 6.2 FOREWORD Please read the following information before reading this section. NOTE For ease of reference, the same numbering is used in the specific wiring diagrams and in the general schematics. 6.2.1 WIRING COLOUR CODES Orange...

  • Page 159: Charge System Inspection

    ELECTRICAL SYSTEM ETV mille 6.3 CHARGE SYSTEM INSPECTION 6.3.1 CHECKING CHARGE VOLTAGE Check battery voltage, see 2.4.2 (CHARGING THE BATTERY). Start the engine and rev it up to 4000 rpm. Set the light switch to ≈ ∆ and the light dip switch to ≈...

  • Page 160: Charge System Layout

    ELECTRICAL SYSTEM ETV mille 6.3.3 CHARGE SYSTEM LAYOUT Rectifier Flywheel Battery + 30 A Main fuse Auxiliary fuses Headlamp Fuel pump Clock 6.3.4 ALTERNATOR CONTINUITY TEST With the engine off: Remove the right-hand lower fairing, see 7.1.3 (REMOVING THE SIDE BODY PANELS).

  • Page 161: Rectifier Test

    ELECTRICAL SYSTEM ETV mille 6.3.5 RECTIFIER TEST Remove the right-hand lower fairing, see 7.1.3 (REMOVING THE SIDE BODY PANELS). Disconnect the three-way connector (1) (coloured brown). Disconnect the six-way connector (2) (coloured white). WARNING Make sure to refit the connectors (1-2) to the matching connectors on assembly.

  • Page 162: Injection System

    ELECTRICAL SYSTEM ETV mille 6.4 INJECTION SYSTEM 6.4.1 INJECTION SUPPLY WIRING DIAGRAM R/Bi Az/Gr Ro/Bi (Grey) (Grey) (Black) Ro/Bi B3(Grey) E4(Black) Key: 1) Battery 7) Bank angle sensor 2) Key-operated switch 8) Power supply to injectors, fans, coils, purge valve...

  • Page 163: Injection Relay Test

    ELECTRICAL SYSTEM ETV mille 6.4.3 INJECTION RELAY TEST Test the relay for proper operation as follows: Remove the rider seat, see 7.1.2 (REMOVING THE RIDER SEAT). Feed 12 Volts to the two male terminals (85-86). Check continuity between the other two terminals (87- Ω...

  • Page 164: Ignition/Injection System

    ELECTRICAL SYSTEM ETV mille 6.5 IGNITION/INJECTION SYSTEM Ar/Bi B3(N) H1(Gr) M/Bi E3(N) E4(N) V/Az Ro/N H2(Gr) B2(N) D1(N) Ar/Az H3(Gr) A1(N) Bi/G B1(N) H4(N) H4(Gr) F1(N) Gr/R H3(N) F2(N) E2(N) V/Gr E1(N) H2(N) D3(Gr) D4(N) A1(Gr) 7(12 9(12 10(12 WARNING...

  • Page 165: Troubleshooting

    ELECTRICAL SYSTEM ETV mille 6.5.1 TROUBLESHOOTING Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. The wording " " will appear on the display for about three seconds. If the ≈ ∆ light goes out, it means that the Ecu has detected no faults.

  • Page 166: Electronic System Troubleshooting Based On Display Information

    ELECTRICAL SYSTEM ETV mille FAULT CODE CHART: FAULT CODE AFFECTED COMPONENT CAUSE √ Sensor disconnected. Crankshaft position sensor (pick-up) √ Sensor broken. Throttle position sensor (TPS) √ Wiring fault. Engine temperature sensor Air temperature sensor √ Sensor fault. Atmospheric pressure sensor √...

  • Page 167: Hook-Up Diagram Of Engine Control Unit

    ELECTRICAL SYSTEM ETV mille 6.6 HOOK-UP DIAGRAM OF ENGINE CONTROL UNIT NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the different components. Please read 4.7.4 (ENGINE CONTROL UNIT CONNECTORS) for more detailed information. P1H2 P1H3 P2H1 P2H2 P2H3...
  • Page 168 ELECTRICAL SYSTEM ETV mille Position Component Connector Terminal # Rating Wiring colour Bi/Vi Instrument panel M/Ro Bank angle sensor Ro/Bi Fuel pump relay Ro/Bi Diode module Clutch switch Neutral switch Side stand Starter relay √ √ √ TEST connectors Bi/G Crankshaft position 150 - 300 Ω...

  • Page 169: Injector Test

    ELECTRICAL SYSTEM ETV mille 6.6.1 INJECTOR TEST With the engine off: Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). NOTE The procedure described below applies to both injectors. Disconnect the two-way connector (1) (coloured black) and measure the resistance across the terminals at the injector end.

  • Page 170: Throttle Position Sensor Test

    ELECTRICAL SYSTEM ETV mille 6.6.3 THROTTLE POSITION SENSOR TEST With the engine off: Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). Disconnect the three-way connector (coloured black) (1). WARNING Make sure to refit the connector (1) to the matching connector on assembly.

  • Page 171: Air Thermistor Test

    ELECTRICAL SYSTEM ETV mille 6.6.4 AIR THERMISTOR TEST Remove the air box, see 7.1.6 (AIRBOX REMOVAL). Disconnect the two-way connector (1) (coloured green). WARNING Make sure to refit the connector (1) to the matching connector on assembly. Remove the thermistor (2).

  • Page 172: Coolant Thermistor Test

    ELECTRICAL SYSTEM ETV mille 6.6.5 COOLANT THERMISTOR TEST NOTE The temperature reading detected by the front cylinder thermistor (on right-hand side) is sent to the right-hand display; the temperature reading detected by the rear cylinder thermistor (on left-hand side) is transmitted to the Ecu.

  • Page 173: Ignition Coil Test

    ELECTRICAL SYSTEM ETV mille 6.6.6 IGNITION COIL TEST Remove the air box to inspect front ignition coils, see 7.1.6 (AIRBOX REMOVAL). Remove the seat to inspect rear ignition coils, see 7.1.2 (REMOVING THE RIDER SEAT). NOTE The procedure described below applies to all ignition coils.

  • Page 174: Crankshaft Position Sensor Test

    ELECTRICAL SYSTEM ETV mille 6.6.7 CRANKSHAFT POSITION SENSOR TEST With the engine off: Disconnect the two-way connector (1) and attach the multimeter leads direct to the sensor (2). Set the multimeter to the x 1000 Ω range and measure resistance across sensor terminals. Observe terminal polarity (see diagram).

  • Page 175: Fuel Pump System

    ELECTRICAL SYSTEM ETV mille 6.7 FUEL PUMP SYSTEM 6.7.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. Ar/V √ Ro/Bi (Grey) B/Bi (Black) Key: 1) Battery 2) Fuel pump relay 3) Pump 4) Fuse...

  • Page 176: Fuel Pump Test

    ELECTRICAL SYSTEM ETV mille 6.7.2 FUEL PUMP TEST To test fuel pump operation: Take off the cover (3) of the auxiliary fuse box. Check the fuse (1). Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). Disconnect the four-way connector (2) located on the left-hand side of the vehicle.

  • Page 177: Safety Lockout System

    ELECTRICAL SYSTEM ETV mille 6.8 SAFETY LOCKOUT SYSTEM 6.8.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. M/Vi Gr/B Vi/N Engine Kill Diode Key to diagram 8) Diode module 9) Clutch lever switch 10) Neutral light switch...

  • Page 178: Safety Lockout System Operation

    ELECTRICAL SYSTEM ETV mille 6.8.2 SAFETY LOCKOUT SYSTEM OPERATION NOTE When the engine kill switch is set to ≈ ∆, the starter motor will not run. CLUTCH IGNITION STARTER TRANSMISSION SIDE STAND STAND LIGHT LEVER ENGINE MOTOR PULLED IN RELEASED...

  • Page 179: Starter Relay Test

    ELECTRICAL SYSTEM ETV mille 6.8.3 STARTER RELAY TEST To test relay operation: Remove plate under seat, see 7.1.31 (REMOVING THE SEAT LOWER MOULDED COVER). Lift the starter relay (2). WARNING Replace the rubber seal if damaged. Disconnect the two-way connector (1) (coloured white).

  • Page 180: Diode Test

    ELECTRICAL SYSTEM ETV mille 6.8.4 DIODE TEST To test diode operation: Remove left-hand side fairing, see 7.1.18 (REMOVING THE FRONT FAIRING). Disconnect the two-way connector (1) (coloured white) located under the left-hand fairing panel, near the ECU. WARNING Make sure to refit the connector (1) to the matching connector on assembly.

  • Page 181: Side Stand Switch Test

    ELECTRICAL SYSTEM ETV mille 6.8.5 SIDE STAND SWITCH TEST Ensure that there is no obstruction to side stand (1) rotation. Check for the following: Inspect the springs (2) for any sign of damage, wear, rust or weakening. The side stand should rotate freely. Grease the joint if needed, see 1.6 (LUBRICANT CHART).

  • Page 182: Diode Module Test

    ELECTRICAL SYSTEM ETV mille 6.8.6 DIODE MODULE TEST Remove the rider seat, see 7.1.2 (REMOVING THE RIDER SEAT) Disconnect the five-way connector (1) (coloured white) from the module (2). WARNING Make sure to refit the connector (1) to the matching connector on assembly.

  • Page 183: Testing The Safety Lockout System Switches

    ELECTRICAL SYSTEM ETV mille 6.8.7 TESTING THE SAFETY LOCKOUT SYSTEM SWITCHES Check for switch continuity using a multimeter. Please refer to the relevant diagram. Replace any switch found to deviate from the specified mode of operation. 1) NEUTRAL SWITCH Leads...

  • Page 184: Cooling Fan

    ELECTRICAL SYSTEM ETV mille 6.9 COOLING FAN 6.9.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. G1(G) H4(N) G2(G) E4(N) Ro/N B2(N) 1) Electronic Control Unit 2) Injection relay 3) Fan 4) Throttle position sensor 5) Coolant thermistor 6.9.2 COOLING FAN TEST...

  • Page 185: Safety Lockout System

    ELECTRICAL SYSTEM ETV mille 6.10 SAFETY LOCKOUT SYSTEM 6.10.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. 16-WAY CONNECTOR 12-WAY CONNECTOR 11 16 2 5 4 3 6 Key: 1) Instrument panel 2) Ambient temperature sensor...

  • Page 186: Air Temperature Sensor

    ELECTRICAL SYSTEM ETV mille 6.10.2 AIR TEMPERATURE SENSOR To test air temperature sensor operation: Remove front fairing panel, see 7.1.18 (REMOVING THE FRONT FAIRING). Disconnect the two-way connector (1). Test sensor in a controlled environment at an ambient temperature of 20°C (68°F).

  • Page 187: Engine Oil Pressure Sensor

    ELECTRICAL SYSTEM ETV mille 6.10.3 ENGINE OIL PRESSURE SENSOR Remove the expansion reservoir, see 5.6 (REMOVING THE EXPANSION RESERVOIR). Disconnect the terminal (1) from the sensor (2) and connect it to ground. WARNING Make sure to refit the connector (1) to the matching connector on assembly.

  • Page 188: Speed Sensor

    ELECTRICAL SYSTEM ETV mille 6.10.4 SPEED SENSOR Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). Ensure that the speed sensor connector (1) is connected properly to the matching connector. Remove the front fairing, see 7.1.20 (HEADLIGHT REMOVAL). Ensure that the instrument panel connectors (2) are connected properly to the matching connectors.

  • Page 189: Fuel Sensor

    ELECTRICAL SYSTEM ETV mille 6.10.5 FUEL SENSOR Test sensor operation as follows: Remove the fuel tank, see 7.1.4 (REMOVING THE FUEL TANK). Disconnect the white four-way connector (1) placed underneath the fuel tank (on the left-hand side). Measure resistance across the orange and black wires at sensor end.

  • Page 190: Coolant Temperature Sensor

    ELECTRICAL SYSTEM ETV mille 6.10.6 COOLANT TEMPERATURE SENSOR Test sensor operation, see 6.6.5 (COOLANT THERMISTOR TEST). Test instrument panel operation by connecting a resistor across the white/black and white/red leads of the two-way connector (1): With 90 Ω resistor: Panel indication: 9 sectors light up (the last two sectors will be flashing).

  • Page 191: Light System

    ELECTRICAL SYSTEM ETV mille 6.11 LIGHT SYSTEM 6.11.1 WIRING DIAGRAM See 6.1 (LAYOUT OF ELECTRICAL COMPONENTS) for the location of the components. PASSING Key: 1) Right-hand light dip switch 8) 30-A fuses 2) Left-hand light dip switch 9) Battery 10) Number plate light...

  • Page 192: Light Relay Test

    ELECTRICAL SYSTEM ETV mille 6.11.2 LIGHT RELAY TEST To check for proper operation of the relays: Remove the headlight, see 7.1.20 (HEADLIGHT REMOVAL). Release and remove the two screws (1). Remove the relay box cover (2). Remove the relay to be tested.

  • Page 193: Visual And Acoustic Signalling System

    ELECTRICAL SYSTEM ETV mille 6.12 VISUAL AND ACOUSTIC SIGNALLING SYSTEM 6.12.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. PASSING Key: 1) Left-hand light dip switch 2) Warning horn 3) 15-A fuse 4) 30-A fuse...

  • Page 194: Warning Horn Test

    ELECTRICAL SYSTEM ETV mille 6.12.2 WARNING HORN TEST To test warning horn operation: Perform the first three steps of the procedure described in subsection 7.1.25 (WARNING HORN REMOVAL). Feed 12 Volts to the two connectors of the warning horn (1).

  • Page 195: Visual And Acoustic Signalling System

    ELECTRICAL SYSTEM ETV mille 6.13 VISUAL AND ACOUSTIC SIGNALLING SYSTEM 6.13.1 WIRING DIAGRAM NOTE See 6.1 (LAYOUT ELECTRICAL COMPONENTS) for the location of the components. Key: 1) Front brake light switch 2) Rear brake light switch 3) 15-A fuse 4) 30-A fuse...

  • Page 196: Switches

    ELECTRICAL SYSTEM ETV mille 6.13.2 SWITCHES Check switches for continuity using a multimeter. Please refer to the relevant diagram. Replace any switch found to deviate from the specified mode of operation. 1) FRONT BRAKE LIGHT SWITCH Wires Position Activated 2) REAR BRAKE LIGHT SWITCH...

  • Page 197: Battery

    ELECTRICAL SYSTEM ETV mille 6.14 BATTERY NOTE This motorcycle equipped with maintenance-free battery that only needs to be inspected and charged from time to time. In the event the battery needs replacing, install a battery of the same type and rating.
  • Page 198 ELECTRICAL SYSTEM ETV mille WARNING Do not cut or prick the sealed ends of the container (2). Turn over the container (2) and place the sealed ends over the openings of the battery cells. Press down on the container (2) to break the seals and let the fluid flow into the battery cells.

  • Page 199: Maintenance

    ELECTRICAL SYSTEM ETV mille 6.14.2 MAINTENANCE If the motorcycle is left unridden for over fifteen days, charge the battery at normal charge rate to avoid sulphation, see 2.4.2 (CHARGING THE BATTERY). Apply a light coat of neutral grease or vaseline to the battery terminals.

  • Page 200: Bulb Replacement

    ELECTRICAL SYSTEM ETV mille 6.15 BULB REPLACEMENT Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. WARNING Before proceeding to change a bulb, rotate the ignition switch to “ ” and wait for some minutes to allow it to cool down. Wear clean gloves or use a clean, dry cloth to handle bulbs.
  • Page 201 ELECTRICAL SYSTEM ETV mille PARKING LIGHT BULB WARNING Do not pull on the wiring to extract the bulb holder. Grasp the parking light bulb holder (7) and pull to extract. Remove the bulb (2) and fit a new bulb of equal rating.

  • Page 202: Replacing The Front Direction Indicator Bulbs

    ELECTRICAL SYSTEM ETV mille 6.15.2 REPLACING THE FRONT DIRECTION INDICATOR BULBS Place the motorcycle on the stand. Release and remove the three screws (1). WARNING Handle plastic and painted components with care, do not strive or damaged them. Remove the lens (2).

  • Page 203: Replacing The Rear Direction Indicator Bulbs

    ELECTRICAL SYSTEM ETV mille 6.15.3 REPLACING THE REAR DIRECTION INDICATOR BULBS Place the motorcycle on the stand. Release and remove the screw (1). WARNING The lens is retained by a locating peg. Remove carefully or the locating peg might break off.

  • Page 204: Tail Light Bulb Replacement

    ELECTRICAL SYSTEM ETV mille 6.15.4 TAIL LIGHT BULB REPLACEMENT The tail light accommodates: - two bulbs for parking / brake lights (1). To replace a bulb: Before changing a bulb, check the BRAKE light switches for proper operation, see 6.13.2 (SWITCHES).

  • Page 205: Replacing The Fuses

    ELECTRICAL SYSTEM ETV mille 6.16 REPLACING THE FUSES Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. WARNING Never attempt to repair a defective fuse. Never use a fuse of a rating other than specified. This could damage the electrical system or cause a short circuit, with the risk of fire.

  • Page 206: Beam Height Setting

    ELECTRICAL SYSTEM ETV mille 6.17 BEAM HEIGHT SETTING The headlight is made up of two light units: - Rh headlight unit (1); - Lh headlight unit (2). Each light unit has independent adjusters for beam setting. Adjust both light units and then ensure: - that the beam is uniform;...

  • Page 207: Beam Centring

    ELECTRICAL SYSTEM ETV mille 6.18 BEAM CENTRING NOTE Beam inspection procedures may vary from country to country. Observe the law in force in the country of the user. The headlight is made up of two light units: - Rh headlight unit (1);...

  • Page 208: Wiring Diagram

    ELECTRICAL SYSTEM ETV mille 6.19 WIRING DIAGRAM - ETV MILLE ELECTRONIC E.C.U. CONTROL UNIT GREY BLACK Gr/B Gr/Bi Gr/Bi B/Ar B/Ar Bi/N Ar/Az Bi/B Ar/Az Ar/Az V/Vi B/Ar V/Az Gr/Bi Ar/Bi M/Bi Ro/N B/Bi Ar/N Bi/G Gr/B Gr/Bi Ar/N Bi/G...
  • Page 209 ELECTRICAL SYSTEM ETV mille Key: 35) √ 1) Multi-pin connectors 36) Pick-up 2) Speed sensor 37) Generator 3) High beam relay 38) Rectifier 4) Low beam relay 39) Injection relay 5) Warning horn 40) √ 6) Left-hand light dip switch...
  • Page 210 ELECTRICAL SYSTEM ETV mille NOTES - 57 - Release 00/2004 - 04...
  • Page 211 ELECTRICAL SYSTEM ETV mille NOTES - 58 - Release 00/2004 - 04...
  • Page 212 CHASSIS ETV mille CHASSIS - 1 - Release 00/2004 - 04...
  • Page 213 CHASSIS ETV mille CHASSIS 7.1.37 REMOVING THE RIGHT-HAND RIDER FOOTPEG BRACKET ......7-37-00 7.1.38 REMOVING THE RIDER FOOTPEG... 7-38-00 7.1.39 REMOVING THE GEAR SHIFT LEVER CONTENTS ASSEMBLY ......... 7-38-00 7.1.40 REMOVING THE REAR BRAKE LEVER 7-39-00 7.1 BODYWORK........7-4-00 7.1.41 EXHAUST SILENCER REMOVAL ..7-40-00 7.1.42 REMOVING THE EXHAUST PIPES..
  • Page 214 CHASSIS ETV mille 7.7.5 STANCHION TUBE – SLIDER ASSEMBLY .......... 7-81-00 7.7.6 INSTALLING STANCHIONS AND SLIDERS ..........7-83-00 7.8 REAR SWINGING ARM....7-84-00 7.8.1 REMOVING THE REAR SWINGING ARM............7-84-00 7.8.2 DISMANTLING THE SWINGING ARM 7-86-00 7.8.3 COMPONENT INSPECTION....7-87-00 7.8.4 INSTALLING THE SWINGING ARM ...

  • Page 215: Bodywork

    CHASSIS ETV mille 7.1 BODYWORK Key: 1) Headlight 12) Rear fork 2) Left rear-view mirror 13) Drive chain 3) Clutch fluid reservoir 14) Passenger left footrest (snapping, closed/open) 15) Centre stand ! 4) Ignition switch/steering lock/parking lights 5) Engine oil tank cap...
  • Page 216 CHASSIS ETV mille Key: 1) Rear light 12) Front phonic wheel 2) Glove/tool kit compartment 13) Coolant expansion tank cap 3) Main fuse carrier (30A) 14) Coolant expansion 4) Rear shock absorber 15) Rear brake control lever 5) Fuel tank...

  • Page 217: Removing The Rider Seat

    CHASSIS ETV mille 7.1.1 RELEASING/LOCKING THE PASSENGER SEAT Place the motorcycle on the stand. Insert the key (1) into the seat lock. Rotate the key (1) clockwise. Lift the seat (2) and remove in a rearward motion. NOTE The glove/tool kit compartment is located under the passenger seat.

  • Page 218: Removing The Side Body Panels

    CHASSIS ETV mille 7.1.3 REMOVING THE SIDE BODY PANELS Remove the rider seat, see 7.1.2 (REMOVING THE RIDER SEAT). Release and remove the three screws (1). Torque wrench setting for screws (1): 5 Nm (0.5 kgm). Release and remove the screw (2) and collect the washer (3).

  • Page 219: Removing The Fuel Tank

    CHASSIS ETV mille 7.1.4 REMOVING THE FUEL TANK Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION), 1.2.1 (FUEL) and 4.1 (FUEL TANK) carefully. CAUTION Fire hazard! Allow for the engine and exhaust silencer to cool down completely. Fuel vapours are harmful to human health.
  • Page 220 CHASSIS ETV mille Disconnect the fuel pump connector (6). WARNING Ensure that the connector (6) is fitted to the matching connector on assembly. CAUTION A small amount of fuel will spill out of the quick- disconnect fittings (7-8) when they are disconnected.

  • Page 221: Fuel Tank Filler Cap Removal

    CHASSIS ETV mille 7.1.5 FUEL TANK FILLER CAP REMOVAL Read 1.2.1 (FUEL) and 4.1 (FUEL TANK) carefully. CAUTION Fuel vapours are harmful to human health. Ensure that the room is well ventilated before proceeding. Do not inhale fuel vapours. Do not smoke or use bare flames near fuel vapours.

  • Page 222: Airbox Removal

    CHASSIS ETV mille 7.1.6 AIRBOX REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove the air cleaner, see 2.9 (AIR CLEANER). Release the clip (1) and detach the hose (2). Release the two clips (3) and detach the two hoses (4).

  • Page 223: Battery Removal

    CHASSIS ETV mille 7.1.7 BATTERY REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.4 (BATTERY) carefully. NOTE When the battery is removed, the digital clock and red line setting will be reset to zero. See 2.3 (MULTIFUNCTION COMPUTER) for instructions on how to set clock and red line.

  • Page 224: Removing The Engine Control Unit

    CHASSIS ETV mille 7.1.8 REMOVING THE ENGINE CONTROL UNIT Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Set the ignition switch to ≈ ∆. Remove passenger seat, Read 7.1.1 (RELEASING/LOCKING THE PASSENGER SEAT). Disconnect the two connectors (1) from the Ecu (2).

  • Page 225: Removing The Left Handlebar

    CHASSIS ETV mille 7.1.9 REMOVING THE LEFT HANDLEBAR GRIP Unscrew and remove the screw (1). Unscrew and remove the screw (2). Tightening torque of the screws (2): 10 Nm (1.0 kgm). Collect the cup (3). Remove the hand guard. Remove the counterweight (4).

  • Page 226: Removing The Clutch Control

    CHASSIS ETV mille 7.1.10 REMOVING THE CLUTCH CONTROL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Release and remove the two screws (1) securing the clutch control (2). Torque wrench setting for screws (1): 10 Nm (1.0 kgm).
  • Page 227 CHASSIS ETV mille 7.1.11 REMOVING THE LEFT-HAND HANDLEBAR SWITCHGEAR Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Release and remove the two screws (1) that retain the housing halves (2-3) at the bottom end.

  • Page 228: Removing The Throttle Control

    CHASSIS ETV mille 7.1.12 REMOVING THE THROTTLE CONTROL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Perform the first five steps described in subsection 7.1.9 (REMOVING THE LEFT HANDLEBAR GRIP). Release and remove the two screws (1). Torque wrench setting for screws (1): 2 Nm (0.2 kgm).

  • Page 229: Removing The Front Brake Control

    CHASSIS ETV mille 7.1.13 REMOVING THE FRONT BRAKE CONTROL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Release and remove the two clamp screws (2) securing the front brake control (3).

  • Page 230: Removing The Right-Hand Handlebar Switchgear

    CHASSIS ETV mille 7.1.14 REMOVING THE RIGHT-HAND HANDLEBAR SWITCHGEAR Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Remove the headlight, see 7.1.20 (HEADLIGHT REMOVAL). Disconnect the two connectors (1) of the right-hand light dip switch and front brake.

  • Page 231: Removing The Ignition Switch/Steering Lock

    CHASSIS ETV mille 7.1.15 REMOVING THE IGNITION SWITCH/STEERING LOCK Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Remove the top yoke, see 2.27.2 (ADJUSTING PLAY IN THE BEARINGS). Remove the headlight, see 7.1.20 (HEADLIGHT REMOVAL).

  • Page 232: Removing The Handlebar

    CHASSIS ETV mille 7.1.16 REMOVING THE HANDLEBAR !" Remove the two clips (1). NOTE You will have to renew the clips on assembly. Make sure to have enough spare clips ready at hand. Remove the clutch control, see 7.1.10 (REMOVING THE CLUTCH CONTROL).

  • Page 233: Removing The Front Fairing

    CHASSIS ETV mille 7.1.18 REMOVING THE FRONT FAIRING Unscrew and remove the four bolts that secure the windshield √ front fairing. Remove the windshield √ front fairing. Unscrew and remove the four bolts that secure the upper dashboard bracket. Remove the upper dashboard bracket.
  • Page 234 CHASSIS ETV mille Work on both sides, and remove the two lower fixing bolts. Remove both side covers. - 23 - Release 00/2004 - 04...

  • Page 235: Removing The Instrument Panel

    CHASSIS ETV mille 7.1.19 REMOVING THE INSTRUMENT PANEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove front fairing panel, see 7.1.18 (REMOVING THE FRONT FAIRING). Release and remove the four fastening screws (1). Torque wrench setting for screws (1): 8 Nm (0.8 kgm).

  • Page 236: Removing The Front Mudguard

    CHASSIS ETV mille 7.1.21 REMOVING THE FRONT MUDGUARD Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the centre stand. !" Release and remove the screw (1). Torque wrench setting for screw (1): 5 Nm (0.5 kgm). Release and remove the screw (3).

  • Page 237: Removing The Upper Sump Guard

    CHASSIS ETV mille 7.1.23 REMOVING THE UPPER SUMP GUARD Unscrew and remove the five fixing screws (two on each side and one in the front). Remove the upper sump guard. 7.1.24 REMOVING THE LOWER SUMP GUARD Unscrew and remove the four fixing screws.

  • Page 238: Removing The Instrument Panel/ Front Fairing Subframe

    CHASSIS ETV mille 7.1.26 REMOVING THE INSTRUMENT PANEL/FRONT FAIRING SUBFRAME Place the motorcycle on the stand. Remove the fairings, see 7.1.18 (REMOVING THE FRONT FAIRING). Remove the headlight, see 7.1.20 (HEADLIGHT REMOVAL). Remove the instrument panel, see 7.1.19 (REMOVING THE INSTRUMENT PANEL).

  • Page 239: Removing The Front Fairing Lower Lockup

    CHASSIS ETV mille Remove all the clips (9) retaining the wiring harness to release the instrument panel/front fairing subframe (8). NOTE You will have to renew all the clips on assembly. Make sure to have enough spare clips ready at hand.

  • Page 240: Tail Light Removal

    CHASSIS ETV mille 7.1.28 TAIL LIGHT REMOVAL Remove number plate bracket, see 7.1.34 (REMOVING THE NUMBER PLATE BRACKET) Release the wiring from the clips (1). NOTE You will have to renew all the clips on assembly. Make sure to have enough spare clips ready at hand.

  • Page 241: Removing The Passenger Seat Lock

    CHASSIS ETV mille 7.1.30 REMOVING THE PASSENGER SEAT LOCK Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Lift the seat lower moulded cover, see 7.1.31 (REMOVING SEAT LOWER MOULDED COVER). Prise the clip (2) open with a screwdriver to release the seat releasing cable (1).

  • Page 242: Removing The Seat Lower Moulded Cover

    CHASSIS ETV mille 7.1.31 REMOVING THE SEAT LOWER MOULDED COVER Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove the rider seat, see 7.1.2 (REMOVING THE RIDER SEAT). Remove the grab rail, see 7.1.29 (GRAB RAIL REMOVAL). Release and remove the two front retaining screws (1).

  • Page 243: Removing The Rear Direction Indicators

    CHASSIS ETV mille 7.1.32 REMOVING THE REAR DIRECTION INDICATORS Perform the first two steps of the procedure described in subsection 7.1.28 (TAIL LIGHT REMOVAL). Release and remove the screw (1) and collect the nut (2). Release the cable from its mounting point.

  • Page 244: Removing The Seat End Cover

    CHASSIS ETV mille 7.1.33 REMOVING THE SEAT END COVER Lift the seat lower moulded cover, see 7.1.31 (REMOVING SEAT LOWER MOULDED COVER). Remove the battery, see 7.1.7 (BATTERY REMOVAL) Remove Engine Control Unit, see 7.1.8 (REMOVING THE ENGINE CONTROL UNIT)
  • Page 245 CHASSIS ETV mille Release and remove the two screws (9). Torque wrench setting for screws (9): 6 Nm (0.6 kgm). Release and remove the two screws (10). Torque wrench setting for screws (10): 6 Nm (0.6 kgm). Remove the seat end cover pulling in a rearward motion.

  • Page 246: Removing The Number Plate Bracket

    CHASSIS ETV mille 7.1.34 REMOVING THE NUMBER PLATE BRACKET Place the motorcycle on the stand. Set the ignition switch to ≈ ∆. Remove the seat lower moulded cover, see 7.1.31 (REMOVING SEAT LOWER MOULDED COVER). Disconnect the four connectors (1).

  • Page 247: Removing The Passenger Footpegs

    CHASSIS ETV mille 7.1.35 REMOVING THE PASSENGER FOOTPEGS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. CAUTION Allow the engine and exhaust silencer to cool down completely. Release and remove the two screws (1). Torque wrench setting for screws (1): 25 Nm (2.5 kgm).

  • Page 248: Removing The Left-Hand Rider Footpeg Bracket

    CHASSIS ETV mille 7.1.36 REMOVING THE LEFT-HAND RIDER FOOTPEG BRACKET Perform the steps marked with an ≈#≈ described in subsection see 7.1.43 (SIDE STAND REMOVAL). Release and remove the three screws (1). NOTE Lubricate the screws (1) with oil (part no.

  • Page 249: Removing The Rider Footpeg

    CHASSIS ETV mille 7.1.38 REMOVING THE RIDER FOOTPEG Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. CAUTION Allow for the engine and exhaust silencer to cool down completely. Remove the retaining ring (1). Withdraw the spindle (2).

  • Page 250: Removing The Rear Brake Lever

    CHASSIS ETV mille 7.1.40 REMOVING THE REAR BRAKE LEVER Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. Move the safety ring (1) aside. Rotate the pin (2) of the clevis pin fork downwards. Withdraw the pin (2) of the clevis pin fork.

  • Page 251: Exhaust Silencer Removal

    CHASSIS ETV mille 7.1.41 EXHAUST SILENCER REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the stand. CAUTION Allow the engine and exhaust silencer to cool down completely. Release the spring (1) from the hooks on the exhaust silencer (3).

  • Page 252: Removing The Exhaust Pipes

    CHASSIS ETV mille 7.1.42 REMOVING THE EXHAUST PIPES Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. CAUTION Allow engine cool down ambient temperature. Remove the exhaust silencer, see 7.1.41 (EXHAUST SILENCER REMOVAL). Remove the radiator spoiler, see 7.1.23 (REMOVING UPPER SUMP GUARD) see 7.1.24...

  • Page 253: Side Stand Removal

    CHASSIS ETV mille 7.1.43 SIDE STAND REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Place the motorcycle on the centre stand WARNING Take care not to damage the switch (1). The nut (2) should never be disturbed while the switch (1) is in place.

  • Page 254: Removing The Engine Oil Tank

    CHASSIS ETV mille 7.1.44 REMOVING THE ENGINE OIL TANK Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.2 (ENGINE OIL) carefully. Drain all engine oil, see 2.12 (ENGINE OIL AND FILTER CHANGE). Remove upper sump guard, see 7.1.23 (REMOVING THE UPPER SUMP GUARD).

  • Page 255: Oil Cooler Removal

    CHASSIS ETV mille 7.1.45 OIL COOLER REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 1.2.2 (ENGINE OIL) carefully. Drain all engine oil, see 2.12 (ENGINE OIL AND FILTER CHANGE). NOTE Make sure to have the special clip pliers (part no. 0277295) ready at hand. Renew all clips using new clips of the same type fitted originally on assembly.

  • Page 256: Removing The Chain Guard

    CHASSIS ETV mille 7.1.47 REMOVING THE CHAIN GUARD Unscrew and remove the front fixing screw. Unscrew and remove the lower fixing screw. Remove the guard. - 45 - Release 00/2004 - 04...

  • Page 257: Removing The Drive Chain Slider

    CHASSIS ETV mille 7.1.48 REMOVING THE DRIVE CHAIN SLIDER Remove the guide plate, see 2.35.5 (DRIVE CHAIN GUIDE PLATE INSPECTION). NOTE Engage the first gear to lock out sprocket (4) movement while turning out the screw (1). Release and remove the screw (1) and collect the two washers (2-3).

  • Page 258: Rear Subframe Removal

    CHASSIS ETV mille 7.1.49 REAR SUBFRAME REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove both side body panels, see 7.1.3 (REMOVING THE SIDE BODY PANELS). Remove the seat lower moulded cover, see 7.1.33 (REMOVING THE SEAT END COVER). Remove the exhaust pipes, see 7.1.42 (REMOVING THE EXHAUST PIPES).

  • Page 259: Removing The Side Guards

    CHASSIS ETV mille 7.1.50 REMOVING THE SIDE GUARDS Unscrew and remove the rear screw and bush. Unscrew and remove the front fixing screw. Remove the side guard. - 48 - Release 00/2004 - 04...

  • Page 260: Removing The Inner Guard

    CHASSIS ETV mille 7.1.51 REMOVING THE INNER GUARD Unscrew and remove the two rear screws. Unscrew and remove the two front screws. Remove the inner guard. - 49 - Release 00/2004 - 04...

  • Page 261: Removing The Sump Guard Protection

    CHASSIS ETV mille 7.1.52 REMOVING THE SUMP GUARD PROTECTION Remove the side guards see 7.1.50 (REMOVING THE SIDE GUARDS). Remove the two side fairings. Remove upper sump guard see 7.1.23 (REMOVING THE UPPER SUMP GUARD). Remove lower sump guard see 7.1.24 (REMOVING THE LOWER SUMP GUARD).

  • Page 262: Frame Removal

    CHASSIS ETV mille 7.1.53 FRAME REMOVAL WARNING Frame (1) removal must be carried out at an Authorised Service Centre or by Authorised a Dealers. prilia Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. WARNING Frame (1) removal is a complex operation. Plan work ahead and locate affected parts on the vehicle before proceeding.
  • Page 263 CHASSIS ETV mille !" Release and remove the two screws (9). Torque wrench setting for screws (9): 10 Nm (1.0 kgm). Remove the two cooler supports (4). !" Release and remove the screw (10). Torque wrench setting for screw (10): 12 Nm (1.2 kgm).

  • Page 264: Front Wheel

    CHASSIS ETV mille 7.2 FRONT WHEEL 1) Wheel spindle 2) Spacer 3) Washer 4) Nut $ = GREASE, see 1.6 (LUBRICANT CHART). 7.2.1 ADJUSTING WHEEL SPOKE TENSION See 2.33 (ADJUSTING WHEEL SPOKE TENSION) - 53 - Release 00/2004 - 04...

  • Page 265: Wheel Removal

    CHASSIS ETV mille 7.2.2 WHEEL REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.31 (FRONT WHEEL) carefully. WARNING Use great care when removing the wheel to avoid damaging the brake lines, brake discs and brake pads. Place the motorcycle on the front wheel stand see 1.9.1 (PLACING THE MOTORCYCLE ON THE...

  • Page 266: Wheel Hub Disassembly

    CHASSIS ETV mille 7.2.3 WHEEL HUB DISASSEMBLY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove the wheel, see 7.2.2 (WHEEL REMOVAL). Clean the wheel hub at both ends with a cloth. Remove the seal (1). Remove the left-hand bearing (2) using a suitable bearing extractor.

  • Page 267: Wheel Component Inspection

    CHASSIS ETV mille 7.2.4 WHEEL COMPONENT INSPECTION WARNING Check that all components are in perfect condition. Inspect the following components with special care. BEARINGS Rotate the inner ring (1) manually. The ring should turn smoothly, with no hardness or noise.

  • Page 268: Refitting The Wheel

    CHASSIS ETV mille 7.2.5 REFITTING THE WHEEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. WARNING Use great care when refitting the wheel to avoid damaging the brake lines, brake discs and brake pads. The arrow mark on the wheel side points in the direction of rotation.
  • Page 269 CHASSIS ETV mille Hold in the front brake lever and press down on the handlebars repeatedly to pump the front fork up and down. This will allow the fork legs to seat themselves properly. Tighten the two wheel spindle clamp bolts (3).

  • Page 270: Rear Wheel

    CHASSIS ETV mille 7.3 REAR WHEEL 1) Wheel spindle 2) Spacer 3) Wheel 4) Washer 5) Nut $ = GREASE, see 1.6 (LUBRICANT CHART). 7.3.1 ADJUSTING WHEEL SPOKE TENSION See 2.33 (ADJUSTING WHEEL SPOKE TENSION) - 59 - Release 00/2004 - 04...

  • Page 271: Wheel Removal

    CHASSIS ETV mille 7.3.2 WHEEL REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) see 2.32 (REAR WHEEL) carefully. CAUTION Allow the engine and exhaust silencer to cool down completely. Use great care when removing the wheel to avoid damaging the brake hoses, brake discs, brake pads and speed sensor cable.

  • Page 272: Dismantling The Final Drive Assembly

    CHASSIS ETV mille 7.3.3 DISMANTLING THE FINAL DRIVE ASSEMBLY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove the wheel, see 7.3.2 (WHEEL REMOVAL). NOTE If you just need to remove the rear chain sprocket, omit the next seven steps. Clean both ends of the hub with a clean cloth.

  • Page 273: Wheel Hub Disassembly

    CHASSIS ETV mille 7.3.4 WHEEL HUB DISASSEMBLY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. Remove the wheel, see 7.3.2 (WHEEL REMOVAL). Clean the wheel hub at both ends with a cloth. Remove the seal (1). Remove the circlip (2). Remove the left-hand bearing (3) first and then the right-hand bearing (4) using a suitable bearing extractor.

  • Page 274: Component Inspection

    CHASSIS ETV mille 7.3.5 COMPONENT INSPECTION WARNING Ensure that all components are in perfect condition. Check the following components with special care. Bearings, seals, wheel spindle and wheel rim, see 7.2.4 (WHEEL COMPONENT INSPECTION). CUSH DRIVE Inspect the cush drive rubbers (1) for damage or wear.

  • Page 275: Refitting The Wheel

    CHASSIS ETV mille 7.3.6 REFITTING THE WHEEL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. WARNING Ensure that the brake caliper (2) carrier (3) is in the correct position before proceeding to refit the wheel. The brake caliper carrier is positioned correctly when the lug (3) on the inner face of the swinging arm right-hand side locates into the slot in the carrier.

  • Page 276: Front Brake

    CHASSIS ETV mille 7.4 FRONT BRAKE Key: The front brake is discussed in further detail in the following sections: 1) Brake lever - see 1.2.4 (BRAKE FLUID); 2) Brake master cylinder - see 2.15 (CHECKING AND TOPPING UP FRONT 3) Brake pads BRAKE FLUID LEVEL);...

  • Page 277: Replacing The Brake Pads

    CHASSIS ETV mille 7.4.1 REPLACING THE BRAKE PADS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.26 (CHECKING BRAKE PADS FOR WEAR) carefully. ! Place the motorcycle on the stand. NOTE The operations described below apply to both brake calipers. ! Release and remove the two nuts (1).

  • Page 278: Brake Disc Inspection

    CHASSIS ETV mille 7.4.2 BRAKE DISC INSPECTION NOTE The operations described below are to be performed with the brake discs installed to the wheel and apply to both brake discs. ! Check for wear measuring disc thickness with a micrometer gauge at different positions along the disc.

  • Page 279: Rear Brake

    CHASSIS ETV mille 7.5 REAR BRAKE Key: The rear brake is discussed in further detail in the following sections: 1) Brake fluid reservoir - see 1.2.4 (BRAKE FLUID); 2) Brake hose, reservoir to master cylinder - see 2.16 (CHECKING AND TOPPING UP REAR 3) Brake disc BRAKE FLUID LEVEL);...

  • Page 280: Replacing The Brake Pads

    CHASSIS ETV mille 7.5.1 REPLACING THE BRAKE PADS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.26 (CHECKING BRAKE PADS FOR WEAR) carefully. ! Place the motorcycle on the stand. ! Release the brake hose from the clip (5). WARNING You will have to renew the clips on refitting. Make sure to have enough spare clips ready at hand.

  • Page 281: Brake Disc Inspection

    CHASSIS ETV mille 7.5.2 BRAKE DISC INSPECTION NOTE These operations are to be performed with the brake disc installed to the wheel. ! Check for wear measuring disc thickness with a micrometer gauge at different positions along the disc. NOTE Replace the disc if worn beyond the service limit even at just one position.

  • Page 282: Removing The Brake Master Cylinder

    CHASSIS ETV mille 7.5.4 REMOVING THE BRAKE MASTER CYLINDER ! Perform the first three steps of the procedure described in subsection 2.21 (CHANGING THE REAR BRAKE FLUID). ! Release and remove the two screws (4). Torque wrench setting for screws (4): 10 Nm (1.0 kgm).

  • Page 283: Steering

    CHASSIS ETV mille 7.6 STEERING Key: The steering is discussed in further detail in the following sections: 1) Top bush - see 2.27 (STEERING); 2) Washer - see 2.28 (INSPECTING THE FRONT SUSPENSION). 3) Top yoke 4) Lockring 5) Locking washer...

  • Page 284: Headstock Removal

    CHASSIS ETV mille 7.6.1 HEADSTOCK REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.27 (STEERING) carefully. ! Place the motorcycle on a lift with the front wheel protruding over the runway edge. Put the motorcycle on the centre stand ! Place a support under the front wheel.

  • Page 285: Component Inspection

    CHASSIS ETV mille 7.6.2 COMPONENT INSPECTION WARNING Check that all components are in perfect condition. Pay special attention to the following components: Bearings and seals, see 7.2.4 (WHEEL COMPONENT INSPECTION). 7.6.3 HEADSTOCK RE-ASSEMBLY NOTE Place motorcycle and headstock in the same position as for removal.

  • Page 286: Front Fork

    CHASSIS ETV mille 7.7 FRONT FORK Key: 1) Top cap 10) Oil seal 2) O-ring 11) Bush 3) Slider 12) Spring 4) Spacer tube 13) Dust seal 5) Spring 14) Retaining ring 6) Capscrew 15) Guide ring 7) Washer 16) Oil seal...

  • Page 287: Changing Front Fork Oil

    CHASSIS ETV mille 7.7.1 CHANGING FRONT FORK OIL Read 1.2.3 (FRONT FORK FLUID) carefully. ! Perform the operations identified with the symbol ≈#∆ described in subsection 7.7.3 (DISASSEMBLING THE STANCHION TUBES √ SLIDERS). ! Perform the operations identified with the symbol ≈#∆...

  • Page 288: Removing The Stanchion Tubes - Sliders

    CHASSIS ETV mille 7.7.3 DISASSEMBLING THE STANCHION TUBES – SLIDERS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION), 1.2.3 (FRONT FORK FLUID) and 2.28 (INSPECTING FRONT SUSPENSION) carefully. NOTE The same internal components are used in both fork legs. The operations described below apply to both fork legs.
  • Page 289 CHASSIS ETV mille ! Place the stanchion (8) in a vice with soft (aluminium) jaws. ! Release and remove the capscrew (6) and collect the copper washer (7). ! Extract the damping cylinder (9) complete with oil seal (10), bush (11) and spring (12) from the slider (3).
  • Page 290 CHASSIS ETV mille ! Use a thin screwdriver to prise off the retaining ring (14) located inside the stanchion (8). ! Grasp the slider (3) and pull firmly to separate it from the stanchion (8). ! The guide ring (15) acts as a stopper and will draw oil seal (16), washer (17) and guide bush (18) out of the stanchion (8) when it is extracted.

  • Page 291: Component Inspection

    CHASSIS ETV mille 7.7.4 COMPONENT INSPECTION STANCHION TUBE ! Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the stanchion (1) if badly scored. ! Check for stanchion buckling (1) using a dial gauge.

  • Page 292: Stanchion Tube - Slider Assembly

    CHASSIS ETV mille 7.7.5 STANCHION TUBE – SLIDER ASSEMBLY Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION), 1.2.3 (FRONT FORK FLUID) and 2.28 (INSPECTING FRONT SUSPENSION) carefully. NOTE The operations identified by the symbol ≈#∆ also apply to the fork oil change procedure.
  • Page 293 CHASSIS ETV mille ! Fit the copper washer (14) to the capscrew (13). ! Start the capscrew (13) in its hole and tighten to the specified torque. Torque wrench setting for capscrew (13): 50 Nm (5.0 kgm). ! Insert the spring (15) into the slider (1).

  • Page 294: Sliders

    CHASSIS ETV mille 7.7.6 INSTALLING STANCHIONS AND SLIDERS Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.28 (INSPECTING THE FRONT SUSPENSION) carefully. ! Insert the slider (1) complete with stanchion (2) through the bottom yoke (3) and the top yoke (4). ! Insert the wheel spindle (5) into both fork legs to keep the holes in the stanchions (2) aligned.

  • Page 295: Rear Swinging Arm

    CHASSIS ETV mille REAR SWINGING ARM 7.8.1 REMOVING THE REAR SWINGING ARM Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.29 (REAR SWINGING ARM) carefully. ! Place the motorcycle on the centre stand see 1.9.2 (PLACING THE MOTORCYCLE ON THE CENTRE STAND).
  • Page 296 CHASSIS ETV mille ! Remove the sprocket cover, see 2.35.5 (DRIVE CHAIN GUIDE PLATE INSPECTION). ! Release and remove the screw (12) and collect the two washers (13-14). Torque wrench setting for screw (12): 50 Nm (5.0 kgm). ! Slide the front chain sprocket (15) complete with chain off the shaft.

  • Page 297: Dismantling The Swinging Arm

    CHASSIS ETV mille 7.8.2 DISMANTLING THE SWINGING ARM Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. ! Remove the swinging arm, see 7.8.1 (REMOVING THE REAR SWINGING ARM). ! Clean both sides of the bearing housings using a cloth. ! Withdraw the bush (1).

  • Page 298: Component Inspection

    CHASSIS ETV mille 7.8.3 COMPONENT INSPECTION WARNING Visually inspect all components for distortion, damage, cracking and denting. Replace any damaged components. BEARINGS ! Rotate the inner ring (1) of each ball bearing manually. Rotate the bearing needle rollers. Inner ring and rollers must rotate smoothly, with no hardness or noise.

  • Page 299: Installing The Swinging Arm

    CHASSIS ETV mille 7.8.4 INSTALLING THE SWINGING ARM Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) 2.29.1 (SWINGING ADJUSTMENT) carefully. ! Lubricate the thread of the swinging arm spindle (1), with oil (part no. 8116050). ! Fit the adjusting bush (2) and screw it hand-tight.
  • Page 300 CHASSIS ETV mille ! Slide in the spindle (12) and place the double connecting link on the swingarm. ! Tighten the nut (13). Torque wrench setting for nut (13): 45 Nm (4.5 kgm). ! Fit the rear brake caliper (14) to the brake disc.

  • Page 301: Rear Suspension

    CHASSIS ETV mille REAR SUSPENSION 7.9.1 REAR SHOCK ABSORBER REMOVAL Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.30.1 (REAR SUSPENSION) carefully. ! Place the motorcycle on the centre stand ! Place a support under the rear wheel. The wheel must be resting lightly on the support and the rear shock absorber must not be compressed.
  • Page 302 CHASSIS ETV mille ! Unscrew and remove the four screws (10). ! Remove the two clamps (11). ! Move the reservoir aside. ! Grasp the shock absorber (8) and remove in a downward motion. ! Withdraw the spacer (12) on the shock absorber upper fork.

  • Page 303: Removing The Rear Suspension Linkages

    CHASSIS ETV mille 7.9.2 REMOVING REAR SUSPENSION LINKAGES Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.30.1 (REAR SUSPENSION) carefully. ! Working from the left-hand side of the motorcycle, release and remove the nut (1). Torque wrench setting for nut (1): 45 Nm (4.5 kgm).

  • Page 304: Dismantling The Rear Suspension Linkage System

    CHASSIS ETV mille 7.9.3 DISMANTLING REAR SUSPENSION LINKAGE SYSTEM Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) carefully. ! Release and remove the nut (1). Torque wrench setting for nut (1): 45 Nm (4.5 kgm). ! Withdraw the bolt (2). ! Remove the two double connecting links (3-4).

  • Page 305: Dismantling The Drive Chain

    CHASSIS ETV mille 7.10 DISMANTLING THE DRIVE CHAIN 7.10.1 CHAIN TOOL NOTE This special tool (part no. 8140192) doubles as rivet extractor and chain tool and is specific for rivet-type chains. WARNING Use only rivet-type chains on this motorcycle. Key to tool diagram:...

  • Page 306: Breaking The Chain

    CHASSIS ETV mille 7.10.2 BREAKING THE CHAIN Read 0.5.1 (GENERAL PRECAUTIONS INFORMATION) and 2.35 (DRIVE CHAIN) carefully. ! Remove the front sprocket cover, see 2.35.5 (DRIVE CHAIN GUIDE PLATE INSPECTION). ! Slacken chain, see 2.35.3 (CHAIN SLACK ADJUSTMENT). ! Place the motorcycle on the centre stand...

  • Page 307: Fitting The Connecting Link

    CHASSIS ETV mille 7.10.3 FITTING THE CONNECTING LINK WARNING Make sure that the connecting link is the same type as the chain. ! Wrap the chain around the sprockets. The chain open ends should be lowermost midway between the front and rear sprockets.

  • Page 308: Riveting The Link

    CHASSIS ETV mille 7.10.4 RIVETING THE LINK With the tool in position on the chain: ! Slacken the screw (1). ! Remove the tool body (2) from the rivet tool (3). ! Remove the supporting plate (4). ! Refit the tool body (2) to the rivet tool (3).
  • Page 309 CHASSIS ETV mille NOTE - 98 - Release 00/2004 - 04...
  • Page 310 REPAIR INFORMATION ETV mille REPAIR INFORMATION - 1 - Release 00/2004 - 04...
  • Page 311 REPAIR INFORMATION ETV mille REPAIR INFORMATION CONTENTS 8.1 TROUBLESHOOTING ...... 8-3-00 8.1.1 ENGINE..........8-3-00 8.1.2 ELECTRICAL SYSTEM ......8-8-00 8.1.3 BATTERY ..........8-8-00 8.1.4 BRAKES ..........8-9-00 8.1.5 CHASSIS ..........8-9-00 8.2 ROUTING AND CONNECTIONS OF WIRING, CABLES AND HOSES..8-11-00 8.2.1 FRONT BRAKE HOSES......

  • Page 312: Troubleshooting

    REPAIR INFORMATION ETV mille 8.1 TROUBLESHOOTING WARNING Any faults in the ignition coils, crankshaft position sensor, camshaft sensor, pressure sensors and THERMISTORS are automatically detected by the Engine Control Unit, which turns on a flashing "EFI" message on the multifunction display.
  • Page 313 REPAIR INFORMATION ETV mille TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Engine does not hold Idling speed setting too low Adjust idling speed Air cleaner clogged Clean Intake hose leaking Replace Cylinders incorrectly synchronised Synchronise the cylinders Throttle spindle/housing worn Replace See also "Engine does not start or is difficult to start "...
  • Page 314 REPAIR INFORMATION ETV mille TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Engine overheats Top up coolant level, Coolant level too low, cooling system leaking pressure-test the system Coolant does not meet specification Use the specified coolant Radiator clogged or coolant hose clogged...
  • Page 315 REPAIR INFORMATION ETV mille TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Engine is noisy Noise seems to come from the timing system Chain slider worn Replace (*) Valve clearance too loose Adjust (*) Valve springs worn or broken Replace (*) Valve buckets or camshaft worn...
  • Page 316 REPAIR INFORMATION ETV mille TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Clutch does not disengage Fluid level in the reservoir Check Engine oil does not meet specification Use the specified engine oil Clutch plates stick Clean or replace (*) Clutch plates or supporting plate warped...

  • Page 317: Electrical System

    REPAIR INFORMATION ETV mille 8.1.2 ELECTRICAL SYSTEM TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Spark plugs collect carbon Incorrect engine oil level Check build-up soon after fitment Fuel not adequate Use the specified fuel Air cleaner dirty Clean Spark plugs foul soon after...

  • Page 318: Brakes

    REPAIR INFORMATION ETV mille 8.1.4 BRAKES TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Loss of braking Brake hydraulic system leaking Repair or replace Brake pads worn Replace brake pads Contact surfaces of brake pads contaminated with oil, Replace brake pads grease or brake fluid...
  • Page 319 REPAIR INFORMATION ETV mille TROUBLE SYMPTOM AND POSSIBLE CAUSE REMEDY Front wheel wobbles Wheel rim warped Replace Wheel hub bearings worn Replace Tyre defective or does not meet specification Replace Wheel spindle nut loose Tighten Front fork oil does not meet specification...

  • Page 320: Routing And Connections Of Wiring, Cables And Hoses

    REPAIR INFORMATION ETV mille 8.2 ROUTING AND CONNECTIONS OF WIRING, CABLES AND HOSES 8.2.1 FRONT BRAKE HOSES 8.2.2 REAR BRAKE HOSES - 11 - Release 00/2004 - 04...

  • Page 321: Fuel System Hoses

    REPAIR INFORMATION ETV mille 8.2.3 FUEL SYSTEM HOSES - 12 - Release 00/2004 - 04...

  • Page 322: Clutch Hose

    REPAIR INFORMATION ETV mille 8.2.4 CLUTCH HOSE 8.2.5 PRESSURE TUBES FOR PPC DEVICE - 13 - Release 00/2004 - 04...

  • Page 323: Cooling System Tubes

    REPAIR INFORMATION ETV mille 8.2.6 COOLING SYSTEM TUBES - 14 - Release 00/2004 - 04...

  • Page 324: Throttle Cables

    REPAIR INFORMATION ETV mille 8.2.7 THROTTLE CABLES - 15 - Release 00/2004 - 04...

  • Page 325: Engine Oil Tubes

    REPAIR INFORMATION ETV mille 8.2.8 ENGINE OIL TUBES - 16 - Release 00/2004 - 04...

  • Page 326: Breather And Drain Hoses

    REPAIR INFORMATION ETV mille 8.2.9 BREATHER AND DRAIN HOSES - 17 - Release 00/2004 - 04...

  • Page 327: Wiring

    REPAIR INFORMATION ETV mille 8.2.10 WIRING 1) Flasher 10) Air temperature sensor 2) Headlight 11) Left-hand light dip switch connector 3) Bank angle sensor 12) Light dip/steering lock switch 4) Light relay 13) Oil pressure sensor 5) Warning horn 14) Rear brake light...
  • Page 328 REPAIR INFORMATION ETV mille 1) Battery positive terminal 2) Rear direction indicator 3) Rectifier 4) Tail light and number plate light 5) Main fuses 6) Starter relay - 19 - Release 00/2004 - 04...
  • Page 329 REPAIR INFORMATION ETV mille 1) Air thermistor 12) Front cylinder coil no. ≈1∆ 2) Engine Control Unit 13) Front cylinder coil no. ≈2∆ 3) Fuel pump relay 14) Rear cylinder coil no. ≈1∆ 4) Side stand switch 15) Rear cylinder coil no. ≈2∆...
  • Page 330 REPAIR INFORMATION ETV mille - 21 - Release 00/2004 - 04...
  • Page 331 REPAIR INFORMATION ETV mille - 22 - Release 00/2004 - 04...

  • Page 332: Electrical System Inspection

    REPAIR INFORMATION ETV mille 8.3.4 PROBLEMS WITH THE AUXILIARY SYSTEMS 8.3 ELECTRICAL SYSTEM INSPECTION - See 6.11.2 (LIGHT RELAY TEST). See 6.1 (LAYOUT OF ELECTRICAL COMPONENTS) - See 6.8.4 (DIODE TEST). location various components. - See 6.9.2 (COOLING FAN TEST).

  • Page 333: Electrical System Inspection

    REPAIR INFORMATION ETV mille 8.4 ELECTRICAL SYSTEM INSPECTION 8.4.1 ENGINE See Section 3 (ENGINE) for technical information on and specifications of engine components. 8.4.2 THROTTLE BODY COMPONENTS See 4.8 (THROTTLE BODY) for technical information on and specifications of engine components.

  • Page 334: Cooling System

    REPAIR INFORMATION ETV mille 8.4.7 COOLING SYSTEM See Section 5 (COOLING SYSTEM). Operating pressure 90-120 kPa (0.9-1.2 bar). 8.4.8 WHEELS Wheel rims: See 1.5 (SPECIFICATIONS). Wheel rim run-out limit: See 7.2.4 (WHEEL COMPONENT INSPECTION). Wheel spindle run-out limit: See 7.2.4 (WHEEL COMPONENT INSPECTION).
  • Page 335 REPAIR INFORMATION ETV mille NOTE - 26 - Release 00/2004 - 04...
  • Page 336 ETV mille - 1 - Release 00/2004 - 04...
  • Page 337 ETV mille CONTENTS 9.1 ABS..........9-3-00 9.1.1 DESCRIPTION........9-6-00 9.1.2 COMPONENT MAINTENANCE .... 9-7-00 9.1.3 REPLACING THE FRONT WHEEL SENSOR ..........9-7-00 9.1.4 REPLACING THE REAR WHEEL SENSOR ..........9-8-00 9.1.5 REMOVING THE ABS CONTROLLER . 9-8-00 9.1.6 BLEEDING ABS EQUIPPED BRAKES 9-9-00 9.1.7 TROUBLESHOOTING......

  • Page 338: Abs

    ETV mille Key: 1) Front wheel sensor 2) ABS controller 3) Front phonic wheel 4) Front brake calliper 5) Front brake master cylinder 6) Rear brake master cylinder 7) Rear wheel sensor 8) Rear phonic wheel 9) Speed sensor 10) Rear brake master cylinder...
  • Page 339 ETV mille DIAGRAM OF THE ABS CONTROL UNIT Key: The black arrow shows brake fluid path when the ABS system is not in operation. The white arrow shows brake fluid path when the ABS system is operating. 2) ABS controller...
  • Page 340 ETV mille ABS OPERATION General information: - The front and rear circuits are identical. - The ABS isolator valve (16-17) is normally open and is closed when the system activates to prevent wheel lockout. - The dump valve (14-15) is normally closed and is opened when the system activates to prevent wheel lockout.

  • Page 341: Description

    ETV mille 9.1.1 DESCRIPTION The anti-lock brake system prevents wheel lockout in emer- gency braking, thereby ensuring greater stability under braking as compared to conventional braking systems. Under particu- lar conditions, operating the brake may lead to wheel lockout and loss of traction, which makes it very difficult to maintain steering control.

  • Page 342: Component Maintenance

    ETV mille CAUTION Using other than original spare parts such as brake pads and discs on ABS equipped vehicles may impair braking efficiency and compromise safety. It is important to check that both tyres are at the correct infla- tion pressure. Both tyres must be at the same pressure.

  • Page 343: Replacing The Rear Wheel

    ETV mille 9.1.4 REPLACING THE REAR WHEEL SENSOR ! Disconnect the connector (1) of the rear wheel (3) from the main wiring harness. ! Unscrew and remove the screw (2) and remove the rear wheel sensor (3) CAUTION On refitting, make sure the mating sur- faces of sensor (3) and sensor housing are smooth and clean.

  • Page 344: Bleeding Abs Equipped Brakes

    ETV mille 9.1.6 BLEEDING ABS EQUIPPED BRAKES CAUTION Change brake fluid in both circuits every 2 years. Bleed the braking system whenever the base brake (out- side the ABS controller) feels spongy. Follow the stand- ard bleeding procedure, vedi 2.18 (BLEEDING THE BRAKE CIRCUITS).

  • Page 345: Troubleshooting

    ETV mille 9.1.7 TROUBLESHOOTING - When the key is turned to ON, the panel light comes on during the initial test routine and then √ if the ABS is on √ goes out. - When the controller ground pins are not connected, the light stays on steady (fault not detected by control unit), meaning that the ABS is off.
  • Page 346 ETV mille TROUBLESHOOTING TABLE Connect 12 V to pin 17 and ground to pin 16 Repair wiring or and check con- connector Abnormal ABS pump Recirculation pump troller connector operation for oxidisation Change ABS ABS pump failed controller Check controller...
  • Page 347 ETV mille AXONE SCREENS ON ETV CAPONORD ABS AXONE 5.0.1 OR SUBSEQUENT VERSIONS INDICATIVE MEASURE- SCREEN DESCRIPTION REMARKS VALUES MENT UNIT Controller code 29033 Model ETV1000_310103S Date of manufacture Date of manufacture of ABS controller VIEW MOTOR PARAMETERS Wheel at standstill will give a 2 Kph...
  • Page 348 ETV mille ABS valve relay See ≈Troubleshooting table∆ Front isolator valve See ≈Troubleshooting table∆ Rear isolator valve See ≈Troubleshooting table∆ Front dump valve See ≈Troubleshooting table∆ Rear dump valve See ≈Troubleshooting table∆ Controller See ≈Troubleshooting table∆ - 13 - Release 00/2004 - 04...

  • Page 349: Wiring Diagram

    ETV mille WIRING DIAGRAM CENTRALINA E.C.U. GRIGIO NERO Gr/B Gr/Bi Gr/Bi B/Ar B/Ar Bi/N Ar/Az Bi/B Ar/Az Ar/Az Vi/M B/Ar V/Az Gr/Bi Ar/Bi M/Bi Ro/N B/Bi Ar/N Bi/G Gr/B Ar/Bi Gr/Bi Ar/N Bi/G Bi/R Gr/R Bi/N B/Ar Gr/B V/Gr Bi/Vi...
  • Page 350 ETV mille Key: 1) Multi-pin connectors 58) Low beam bulb 2) Speed sensor 59) High beam bulb 3) High beam relay 60) High beam bulb 4) Low beam relay 61) Headlight 5) Warning horn 62) Front right indicator 6) Left dimmer switch...
  • Page 351 ETV mille NOTE - 16 - Release 00/2004 - 04...
  • Page 352 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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