APRILIA RSV MILLE — REGULAR SERVICE MANUAL Pdf Download.

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Summary of Contents

Page 1

OPERATIONS TO BE CARRIED OUT BY THE Official Dealer (WHICH CAN BE CARRIED OUT EVEN BY THE USER) After running-in Every 7500 km Every 15000 km Component [1000 km (625 mi)] (4687 mi) or 8 months (9375 mi) or 16 months Spark plugs S (*) Air filter.

Page 2

OPERATIONS TO BE CARRIED OUT BY THE Official Dealer After running-in Every 7500 km Every 15000 km Component [1000 km (625 mi)] (4687 mi) or 8 months (9375 mi) or 16 months Rear suspension linkage bearings Steering bearings and steering Wheel bearings Tappet clearance Braking systems.

Page 3

FRAME NUMBER The frame number is stamped on the right It is a good rule to write down the frame side of the steering column. and engine numbers in the space provided in this manual. The frame number can be used for the pur- Frame no.

Page 4

Carefully read p. 43 (ENGINE OIL) and p. 55 (MAINTENANCE). Periodically check the engine oil level, change the oil after the first 1000 km (625 mi) and successively every 7500 km (4687 mi), see p. 60 (CHANGING THE ENGINE OIL AND THE OIL FILTER). In case of use on racetracks, change every 3750 km (2343 mi).

Page 5

CAUTION The engine oil and the oil filter change operations may be difficult for unskilled operators. If necessary, contact an Official Dealer. If you want to carry them out personal- ly, follow the instructions given below. Carefully read p. 43 (ENGINE OIL) and p.

Page 6

Put back the cover (6), screw and tighten Screw and tighten the drain plug (4). Connect the pipe (12) and tighten the the two screws (5). new clamp (10). Driving torque of the drain plug (4) posi- tioned on the engine: 12 Nm (1.2 kgm).

CLEANING THE ENGINE OIL FILTER CAUTION ON THE TANK.

Page 7

NOTE Position the vehicle on the side stand on Have someone help you keep the Position the vehicle on the appropriate firm and level ground. vehicle in vertical position with the two rear support stand, see beside (POSI- Position the pin (1) on the appropriate wheels on the ground.

Page 8

Check the air cleaner every 7500 (4687 mi)km or 8 months, change it every 15000 km (9375 mi) or more frequently if the vehi- cle is used on dusty or wet roads. It is possible to clean the air cleaner partially after using the vehicle on this kind of roads.

Page 9

DISASSEMBLY CAUTION Position the vehicle on the appropriate Never pull the front brake lever after re- CAUTION rear support stand, see p. 62 (POSI- moving the calipers, otherwise the pis- The disassembly and reassembly of the TIONING THE VEHICLE ON THE REAR tons may go out of their seats, thus front wheel may be difficult for unskilled SUPPORT STAND.

Page 10

WARNING Upon reassembly of the brake caliper, replace the caliper fastening screws (1) with two new screws of the same type. Screw and tighten the two screws (1) that fasten the brake caliper. Brake caliper screw (1) driving torque: 50 Nm (5 kgm) With pulled front brake lever, press the handlebar repeatedly, thrusting the fork downwards.

Page 11

NOTE To remove the rear wheel it is Make the wheel advance and release the necessary to use the appropriate rear sup- drive chain (4) from the crown gear (5). CAUTION port stand CAUTION The disassembly and reassembly of the rear wheel may be difficult for unskilled Check the position of the chain tighten- operators.

Page 12

REASSEMBLY Make the wheel advance and position Position the washer and tighten the nut the drive chain (4) on the crown gear (5). (1) manually. CAUTION Check the chain tension, see p. 68 WARNING Before proceeding with the reassembly, (DRIVE CHAIN). make sure that support plate (8) of the Danger of injury.

Page 13

CAUTION Carry out the maintenance operations more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy roads. CHECKING THE SLACK To check the slack, proceed as follows: Stop the engine. Position the vehicle on the side stand on firm and level ground.

Page 14

CHECKING THE WEAR OF CHAIN, CLEANING AND LUBRICATION PINION AND CROWN CAUTION Further, check the chain and sprockets The drive chain is provided with O rings and make sure that they do not present: among the links, in order to keep the #x2013;.

Page 15

Remove the passenger seat, see p. 29 (UNLOCKING / LOCKING THE Position the vehicle on the side stand on Carefully read p. 33 (FUEL) and p. 55 PASSENGER SEAT firm and level ground. (MAINTENANCE). Remove the glove/tool kit compart- Partially raise the rear side edge of the m e n t c o v e r. s e e p .

Page 16

CAUTION Handle the plastic and painted compo- Carefully read p. 55 (MAINTENANCE). Carefully read p. 55 (MAINTENANCE). nents with care and avoid scraping or damaging them. NOTE To remove the lower fairing, it is WARNING necessary to use the appropriate rear sup- Let the side stand down.

Page 17

CAUTION Position the vehicle on the side stand on After reassembly, correctly adjust the firm and level ground. Position the vehicle on the side stand on rear-view mirrors and tighten the nuts in Unscrew and remove the two screws (1). firm and level ground.

Page 18

Move the front part of the fairing (4) slightly forward. Raise the protection element (5). Position the vehicle on the side stand on Disconnect the electric connector (6) of firm and level ground. the headlight. Turn the ignition switch to position #x201C; #x201D;.

Unscrew and remove the two lower CAUTION screws (1).

Page 19

Carefully read p. 55 (MAINTENANCE). NOTE Have the front fork oil changed by an aprilia Official Dealer, who will ensure you prompt and accurate servicing. Have the front fork oil changed after the first 7500 km (4687 mi) and successively every 22500 km (14000 mi).

Page 20

Use the notches (1-2) provided on the adjusters as reference marks for the ad- (*) = Have this type of adjustment carried out exclusively by an aprilia Official Dealer. justment of the hydraulic braking with compressed and extended shock ab- sorber.

Page 21

(plug excluded) braking with compressed and extended shock absorber. (*) = Have this type of adjustment carried out exclusively by an aprilia Official Dealer. Give the adjusters (1-2) one notch at a time. Test the vehicle repeatedly on the road, until obtaining the optimal adjustment.

Page 22

Steering Standard Adjustment for Possible damper adjustment racetrack use adjustments #x2013; adjustable shock absorber #x2013; non-adjustable shock absorber from completely from completely from completely Adjustment open, close giving open, close giving open, close giving 5 clicks 8 clicks 17 clicks The steering damper (1) is provided with a knob (2) for the adjustment of the hydraulic braking (see table).

Page 23

The rear suspension consists of a spring- shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems. For the setting of the vehicle attitude, the shock absorber is provided with a screw adjuster (1) for the adjustment of the hy- draulic braking with extended shock ab- sorber;.

Page 24


CAUTION CAUTION Adjust the spring preload and the hy- To avoid affecting the operation of the draulic braking with extended shock ab- shock absorber, neither remove the sorber according to the conditions of plug (7), nor adjust the underlying use of the vehicle. valve, since this may cause nitrogen to flow out, with consequent risk of acci- When the spring preload is increased, it.

Page 25

Adjust the metal ring (3) to adjust the ADJUSTING spring preload (see table). THE REAR SHOCK ABSORBER After the adjustment, tighten the metal The rear suspension consists of a spring- ring (4). The standard setting of the rear shock ab- shock absorber unit, fixed to the frame by Adjust the metal ring (1) to adjust the hy- sorber is adjusted in such a way as to be.

Page 26

CAUTION CAUTION Adjust the spring preload and the hy- To avoid affecting the operation of the draulic braking with extended shock ab- shock absorber, neither remove the sorber according to the conditions of screw (7), nor adjust the underlying use of the vehicle. membrane, since this may cause nitro- gen to flow out, with consequent risk of When the spring preload is increased, it.

Page 27

WARNING #x2013; Front pad (3). #x2013; Rear pad (4). Check the wear of the brake pads, espe- cially before every trip. NOTE Have the pads changed by your aprilia Official Dealer. use and maintenance RSV mille — RSV mille R.

Page 28

Position the gear lever in neutral (green the idling speed is constant. being released. warning light #x201C; #x201D; on). NOTE If necessary, contact your aprilia Check the engine idling rpm on the revo- Official Dealer. lution counter. The engine idling speed must be about 1250 #xB1;.

Page 29

To check the proper functioning of the At this point: safety switch (3), proceed as follows: #x2013; the engine must stop; #x2013; the #x201C;side stand down#x201D; warning light #x201C; #x201D; Seat on the vehicle in driving position. Carefully read p. 55 (MAINTENANCE) must come on.

Page 30

If the spark plug has crackings on the in- sulating material, corroded electrodes or excessive deposits, it must be changed. Check the spark plug gap with a thick- ness gauge. The gap must be 0.6 #x2013; 0.7 mm; if neces- sary adjust it, carefully bending the earth electrode.

Page 31

NOTE This vehicle is provided with a If necessary: maintenance-free battery and no operation Disconnect first the negative (#x2013;) and then Carefully read p. 55 (MAINTENANCE). is necessary, excepting occasional checks the positive cable (+). and the recharge when required. WARNING Brush with a wire brush to eliminate any sign of corrosion.

Page 32

Unscrew and remove the screw (4) on WARNING the positive terminal (+). CAUTION Upon reassembly, connect first the pos- Move the positive cable (5) sidewards. itive cable (+) and then the negative ca- Unscrew and remove the screw (6). To remove the battery it is necessary to ble (#x2013;).

Page 33

Carefully read p. 86 (BATTERY). CAUTION Do not remove the battery plugs: with- out plugs the battery may be damaged. Remove the battery, see p. 87 (REMOV- ING THE BATTERY).

Prepare an appropriate battery charger. Set the charger for the desired type of re- charge (see table) Connect the battery with a battery charg- WARNING.

Page 34

CAUTION If the vehicle remains unused for more than twenty days, disconnect the 30A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer. NOTE The removal of the 30A fuses re- quires the setting to zero of the following functions: digital clock and red line setting.

Page 35

If you use one of the spare fuses, In this case it is advisable to consult an put a new fuse in the proper seat. aprilia Official Dealer. If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses.

Page 36

ARRANGEMENT ARRANGEMENT OF THE 15A SECONDARY FUSES OF THE 30A MAIN FUSES A) From voltage regulator to: F) From battery to: ignition. high beam relay, low beam relay. G) From battery to: ignition. B) From voltage regulator to: NOTE One fuse is a spare fuse. coils, engine stop relay, fuel pump.

Page 37

Carefully read p. 55 (MAINTENANCE). WARNING Risk of fire. Keep fuel and other flammable sub- stances away from the electrical com- ponents.

CAUTION Before changing a bulb, move the igni- tion switch to position #x201C; #x201D; and wait a few minutes, so that the bulb cools To adjust the headlight beam: down.

Page 38

HIGH BEAM BULBS PARKING LIGHT BULB Remove the front part of the fairing, see Remove the front part of the fairing, see p. 73 (REMOVING THE FRONT PART p. 73 (REMOVING THE FRONT PART Carefully read p. 92 (BULBS). OF THE FAIRING). OF THE FAIRING).

Page 39

LOW BEAM BULB Press the bulb (14) slightly and rotate it anticlockwise. Move the protection element (9) with your hands. Extract the bulb (14) from its seat. Carefully read p. 92 (BULBS).

Position the vehicle on the side stand on CAUTION CAUTION firm and level ground.

Page 40

NOTE During transport, the vehicle must be kept in vertical position, it must be firmly anchored and the 1st gear must be en- gaged, in order to avoid any leak of fuel, oil, coolant. CAUTION In case of failure, do not tow the vehicle, but ask for assistance.

Page 41

Clean the vehicle frequently if it used in CAUTION particular areas or conditions, such as: To clean the lights, use a sponge soaked Polluted areas (cities and industrial are- with water and a neutral detergent, rub- as). bing the surfaces delicately and rinsing Areas characterized by an high percent- frequently with plenty of water.

Page 42

Proceed as follows: AFTER A PERIOD OF INACTIVITY Remove the battery, see p. 87 (REMOV- Uncover and clean the vehicle, see p. 96 CAUTION ING THE BATTERY) and p. 89 (LONG (CLEANING). INACTIVITY OF THE BATTERY). If the vehicle remains unused for more Check the charge of the battery, see than twenty days, disconnect the 30A Wash and dry the vehicle, see p.

Page 43

DIMENSIONS Max. length. 2080 mm Max. length (with number plate-holder extension) 2140 mm Max. width. 720 mm Max. height (front part of the fairing included) 1170 mm Seat height. 820 mm Distance between centres.

1415 mm Min. ground clearance. 130 mm Weight ready for starting.

Page 44

GEAR RATIOS Ratio Primary Secondary Final ratio Total ratio 31/60 = 1. 1.935 14/35 = 1. 2.500 17 / 42 = 1. 2.470 11.948 16/28 = 1. 1.750 8.368 19/26 = 1. 1.368 6.543 22/24 = 1. 1.090 5.216 23/22 = 1. 0.956 4.573.

Page 45

TYRES Normal use ; Use on racetracks Pressure kPa (bar) Recom- Wheel Make Model Type Size Alternative mended Rider and Solo rider Solo rider passenger 220-230 Front PIRELLI DRAGON EVO MTR21 CORSA 120/70-ZR17 #x2013; 220 (2,2) 240 (2,4) (2,2-2,3) .

Page 46

TYRES Normal use ; Use on racetracks Pressure kPa (bar) Recom- Wheel Make Model Type Size Alternative mended Rider and Solo rider Solo rider passenger 220-230 Front PIRELLI DRAGON EVO MTR21 CORSA 120/70-ZR17 #x2013; 220 (2,2) 240 (2,4) (2,2-2,3) Front 220-230 .

Page 47

SPARK PLUGS Standard. NGK R DCPR9E #x2013; Alternative. NGK R DCPR8E Spark plug gap. 0.6 #x2013; 0.7 mm Resistance. 5 k #x2126; ELECTRIC Battery. 12 V — 12 Ah SYSTEM Battery. 12 V — 10 Ah Main fuses.

Page 48

Engine oil (recommended): EXTRA RAID 4, SAE 15W — 50 or TEC 4T, SAE 15 W — 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I.

Aprilia RSV Mille

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