aprilia rsv-tuono maintenance manual

8/13/2019 Aprilia RSV-Tuono Maintenance Manual

1/120

8104928

RSV 1000 TUONO R


2/120

2 use and maintenance RSV 1000 TUONO R

2005 aprilia s.p.a.- Noale (VE)First edition: October 2005

Reprint:

Produced and printed by:VALLEY FORGE DECA

Ravenna , Modena, Torino

DECA S.r.l.

Sede Legale ed Amministrativa

Via Vincenzo Giardini, 1148022 Lugo (RA) - Italia -Tel. 0545-216611Fax [email protected]

on behalf of:aprilia s.p.a.via G. Galilei, 1 - 30033 Noale (VE) - ItaliaTel. +39 - 041 58 29 111

Fax +39 - 041 44 10 54www.aprilia.com

SAFETY WARNINGS

The following precautionary warnings areused throughout this manual in order toconvey the following messages:

Safety warning. When you find thissymbol on the vehicle or in the

manual, be careful to the potential riskof personal injury. Non-compliance withthe indications given in the messagespreceded by this symbol may result ingrave risks for your and other peoples

safety and for the vehicle!

WARNINGIndicates a potential hazard which mayresult in serious injury or even death.

CAUTION

Indicates a potential hazard which mayresult in minor personal injury ordamage to the vehicle.

NOTE The word NOTE in this manualprecedes impor tant in format ion orinstructions.

TECHNICAL INFORMATION

The operations preceded by thissymbol must be repeated also on

the opposite side of the vehicle.If not expressly indicated otherwise, for thereassembly of the uni ts repeat thedisassembly operations in reverse order.

The terms right and left are referred tothe rider seated on the vehicle in thenormal riding position.

If the glove/tool kit compartment cover hasbeen installed (as an alternative to thepassenger sea t ) , the t ranspor t o fpassenger, luggage or objects is forbidden.

WARNINGRacing settings may only be usedduring official competitions or sportsevents authorised by the competentauthorities and taking place in closedcircuits or, anyway, away from publicroads.

It is strictly prohibited to carry outadjustments for the use of the vehicleon racetracks and then ride it on roadsor motorways.

WARNINGS - PRECAUTIONS -

GENERAL ADVICE

Before starting the engine, carefully readthis manual and in particular the sectionSAFE DRIVE.

Your and other peoples safety dependsnot only on your quickness of reflexes andon your agility, but also on what you knowabout the vehicle, on its efficiency and on

your knowledge of the basic information forSAFE DRIVE.

Therefore, get a thorough knowledge ofthe vehicle, in such a way as to be able toride in the traffic safely.


3/120


4/120
http://-/?-


5/120

safe drive


6/1206 use and maintenance RSV 1000 TUONO R

BASIC SAFETY RULES

To ride the vehicle it is necessary to be inpossession of a l l the requi rementsprescr ibed by law (dr iv ing l icence,

minimum age, psychophysical ability,insurance, state taxes, vehicle registration,number plate, etc.).

Gradually get to know the vehicle bydriving it first in areas with low traffic and/orprivate areas.

The use of medicines, alcohol and drugs or

psychotropic substances notably increasesthe risk of accidents.

Be sure tha t you a re in goodpsychophysical conditions and fit for ridingand pay particular attention to physicalweariness and drowsiness.

Most road accidents are caused by the

riders lack of experience.

NEVER lend the vehicle to beginners and,in any case, make sure that the rider hasall the requirements for driving.

Rigourously observe all road signs and

national and local road regulations.Avoid abrupt movements that can bedangerous for yourself and other people(for example: wheeling, speeding, etc.);and give due consideration to the roadsurface, v is ibi l i ty and other driv ingconditions.

Avoid obstacles that could damage thevehicle or make you lose control.

Avoid riding in the slipstream created bypreceding vehicles in order to increaseyour speed.

WARNINGAlways drive with both hands on thehandlebars and both feet on thefootrests (or on the riders footboards),

in the correct driving posture.

CAUTIONAvoid standing up or stretching yourlimbs while driving.


7/120

use and maintenance RSV 1000 TUONO R 7

The rider should pay attention and avoiddistractions caused by people, things andmovements (never smoke, eat, drink, read,etc.) while driving.

Use only the vehicles specific fuels andlubricants indicated in the LUBRICANTCHART; check all oil, fuel and coolantlevels regularly.

If the vehicle has been involved in anaccident, make sure that no damage hasoccurred to the control levers, pipes, wires,braking system and vital parts.

If necessary, have the vehicle inspected byan aprilia Authorised Dealerwho shouldcarefully check the frame, handlebars,suspensions, safety parts and all thedevices that you cannot check by yourself.

A lways remember to repor t anymalfunction to the technicians to help themin their work.

Never use the vehicle when the amount ofdamage it has suffered endangers yoursafety.

Never change the position, inclination orco lour o f : number p la te , d i rec t i onindicators, lights and horns.

Any modification of the vehicle will result inthe invalidity of the guarantee.

Any modification of the vehicle and/or theremoval of original components cancompromise vehicle performance levelsand safety or even make it illegal to ride.

We recommend respecting all regulationsand national and local provisions regardingthe equipment of the vehicle.

In particular, avoid all modifications thatincrease the vehicles performance levelsor alter its original characteristics.

Never race with other vehicles.

ONLY ORIGINALS


8/120


CLOTHING

Before starting, always wear a correctlyfastened crash helmet. Make sure that it ishomologated, in good condition, of the

right size and that the visor is clean.Wear protective clothing, preferably in lightand/or reflecting colours. In this way youwill make yourself more visible to the otherriders, thus notably reducing the risk ofbeing knocked down, and you will be moreprotected in case of fall.

This clothing should be very tight-fittingand fastened at the wrists and ankles;strings, belts and ties should not behanging loose; prevent these and otherobjects from interfering with driving bygetting entangled with moving parts ordriving mechanisms.

Do not keep objects that can be dangerousin case of fall, for example pointed objectslike keys, pens, glass vials etc. in yourpockets (the same recommendations alsoapply to a possible passenger).

ACCESSORIES

The owner of the vehicle is responsible forthe choice, installation and use of anyaccessory.

Avoid installing accessories that cover hornsor lights or that could impair their functions,limit the suspension stroke and the steeringangle, hamper the operation of the controlsand reduce the ground clearance and theangle of inclination in turns.

Avoid using accessories that hamper access

to the controls, since this can prolongreaction times during an emergency.

Big fairings and windshields installed on thevehicle may produce aerodynamic forcesthat affect the stability of the vehicle,especially when riding at high speed.

Make sure that the equipment is well

fastened to the vehicle and not dangerousduring driving.


9/120


10/120


ARRANGEMENT OF THE MAIN ELEMENTS

KEY

1) Fairing lug2) Side fairings3) Adjustable steering damper4) Left headlight5) Clutch fluid reservoir

6) Left rear-view mirror

7) Engine oil reservoir plug8) Left side body panel9) Rider seat10)Battery11)Main fuse carrier (30A)

12)Passenger seat-glove/toolkit compartment lock

13)Passenger left footrest(snapping, closed/open)

14)Drive chain15)Swinging arm16)Rider left footrest

17)Side stand18)Gear shift lever

19)Engine oil filter20)Engine oil tank21)Engine oil level

1

4

3

2

21 20

5 6 7 8 9 10 11

17 18 16 15 14

12

13

19


11/120


KEY

1) Rear shock absorber2) Passenger right footrest

(snapping, closed/open)3) Tail light4) Glove/tool kit compartment

5) Passenger seat / Seat cover6) E.C.U.

7) Secondary fuse carrier (15A)8) Right side body panel9) Fuel tank10)Coolant expansion tank cap11)Fuel tank filler cap

12)Air filter13)Right rear-view mirror

14)Front brake fluid tank15)Right headlight16)Right side fairings17)Horn18)Expansion tank

19)Rear brake fluid tank20)Rear brake master cylinder

21)Rear brake control lever22)Rider right footrest

22

2

3

1 21

10 11 9 12 134 5 6 7 8

20 19 18

16

17

15

14


12/120


ARRANGEMENT OF THE INSTRUMENTS/CONTROLS

KEY

1) Clutch lever2) Ignition switch/steering lock ( - - )3) Instruments and indicators4) Front brake lever5) Throttle grip6) High beam flasher - passing button ( )

7) Dimmer switch ( - )8) Turn indicator switch ( )9) Horn button ( )10)TRIP 1 / TRIP 2 / MODE switch11)Engine kill switch ( - )12)Starter button ( )

12 11

6

810 7

1 4

5

2 3

9


13/120


KEY

1) Revolution counter2) Green neutral light ( )3) Amber "stand down" light ( )4) Red general warning light ( )5) Multifunction digital display (coolant temperature - clock -

battery voltage - lap timer - engine oil pressure diagnostics( )

6) Blue high beam warning light ( )7) Amber low fuel warning light ( )8) Green turn indicator warning light ( )9) Red line light

1 2 3 4

56789

INSTRUMENTS AND INDICATORS


14/120


INSTRUMENTS AND INDICATORS TABLE

When the ignition key is turned to " " with the engine stopped, all warning lights come on for a LED check-up and go out after twoseconds. If one or more warning lights do not come on at this stage, contact an aprilia Authorised Dealer.

Description Function

Revolution counter rpmIndicates the number of revolutions of the engine per minute.

Never exceed the engine max. speed rate, see page 54 (RUNNING-IN).

Gear shift light Blinks when activation threshold (max. rpm) set by the user is exceeded, see page 19 (GEAR SHIFTINDICATOR).

Direction indicator warning light Blinks when the direction indicators are on.

High beam warning light Comes on when the high beam bulbs are on or when the headlight signaller is operated.

Side stand down light Turns on when the side stand is down.

Low fuel warning lightIt comes on when the quantity of fuel left in the tank is approx. 4,5 1 b.

In this case, top up as soon as possible, see page 29 (FUEL).

Neutral indicator warning light Comes on when the gear is in neutral.

Error warning light

Comes on when the ignition switch is set to " " with the engine stopped as a lamp test.

If the light does not come on in this phase, contact an aprilia Authorised Dealer.

When engine is off it indicates that immobiliser system is enabled.

If the light remains on after the engine start or comes on during thenormal operation of the engine, this means that a fault of the injection

system was detected and, if it is displayed simultaneously with the symbol " ", a low engineoil pressure was detected. In this case, stop the engine immediately and contact an apriliaAuthorised Dealer.

CAUTION

CAUTION


15/120


Multifunctiondigital display

Speedometer (km/h - MPH) Displays current, average or maximum riding speed (in kilometres or miles)depending on pre-setting, see page 16 (MULTIFUNCTION COMPUTER).

To togg le be -tween readouts,see page 16(MULTIFUNC-

TION COMPU-TER)

Odometer (KM - Mi) Gives total distance covered or distance covered since the trip meter was last reset(in km or miles).

Coolant temperature(C/F)

Displays engine coolant temperature, see page 16 (MULTIFUNCTIONCOMPUTER).If the pointer gets near the danger area, stop the engine, turn the key to " " andwait until the cooling fan is disconnected.

Do not leave the ignition switch on , since thecooling fans would stop regardless of the coolant

temperature and in this case the temperature would increase even further.Now turn the key to and check coolant level, see page 37 (COOLANT).Contact an aprilia Authorised Dealer.

If the maximum allowed temperature is exceeded(115 C - 239 F), the engine may be seriously

damaged.

Clock Displays time (hour and minutes) as preset, see page 16 (MULTIFUNCTIONCOMPUTER).

Bat tery vo l tage VBATT

Displays the battery voltage in Volts, see page 16 (MULTIFUNCTIONCOMPUTER).

Lap timer Displays the different lap times, as preset, see page 16 (MULTIFUNCTIONCOMPUTER).

Diagnosis

In case a serious failure is detected, one that might jeopardise the vehicle or the rider's safety, thepanel will show an icon indicating the failure cause (such as: oil pressure , maintenance intervals

).

If the wording " SERVICE" appears during normal engine operation,it means that the ECU or the instrument panel have detected a failure.

In many cases the engine keeps running with limited performance; contact an apriliaAuthorised Dealerimmediately.

Description Function

CAUTION

CAUTION

CAUTION


16/120


MULTIFUNCTION COMPUTER

Controls

1) Switch with three positions: TRIP1 /TRIP2 / MODE

2) SET button; briefly press it to scroll the

functions in the menus, press forseveral seconds to confirm selectedoption.

When you turn the ignition key to " ", thefollowing instrument panel lights will turnon for 2 seconds:

- All warning lights

- Backlighting

- The display shows the Tuono 1000 logo.The pointer of revolution counter (3)reaches the set gear shift value (rpm) andthen goes back immediately to zero.

During the initial check-up, all instrumentswill briefly show the current values of thecorresponding parameters.

When the key is on " ", the followingstandard settings are displayed:

-Clock or lap timer (*) (zone A)

-Current speed (zone B)

-Odometer (zone C)

-Coolant temperature (zone D)

(*) According to settings entered in MENU,see page 18 (MENU)the displayed valuemay vary.

1

23

Km/h

ODO Km

C

A

C

D

B


17/120


TRIP 1 AND 2

In TRIP 1 and 2 the data concerning trip 1and 2 are shown.

Displayed trip meter indication can befound next to value description.

Set se lec to r (1 ) to the pos i t i oncorresponding to TRIP configuration to bedisplayed (TRIP 1 or TRIP 1).

At the bottom (C) are the following data:

-TRIP METER 1/2-TRIP TIME 1/2

-MAXIMUM SPEED 1/2

-AVERAGE SPEED 1/2

Briefly press SET (2) to toggle betweenthese parameters. Press it for severalseconds to reset all data from selectedTRIP meter.

Mode

MODE configuration features the functionsallowing the user to interact with thesystem.

Set selector (1) to MODE position to select

MODE configuration.While the vehicle at rest, the following dataare alternately displayed every time theSET button (2) is pressed:

-CURRENT SPEED

-BATTERY VOLTAGE

Press SET (2) button for several secondsto enter the configuration menu:

-MENU

When reserve km indication is active, itreplaces the odometer.

BATTERY VOLTAGE

CURRENT SPEED Km/hTRIP TIME

MAXIMUM SPEED

AVERAGE SPEED

TRIP METERTRIP Km

C

MAX Km

C

AVG Km

C

TIME

C

Km/h

LAP

TRIP Km

C

TS


18/120


Menu

If vehicle is stopped and selector is set toMODE, configuration menu of the MENUpage can be accessed. To enter thisfunction, confirm MENU selection [pressSET button (2) for several seconds].

Configuration menu options are:

-EXIT

-SETTINGS

-LAP TIMER

-DIAGNOSTICS

-LANGUAGE

SETTINGS

When confirming SETTINGS selection(pressing SET button (2) for severalseconds) the fo l lowing opt ions aredisplayed:

-EXIT

-TIME SETTINGS

-GEAR SHIFT INDICATOR

-BACK LIGHTING

-CHANGE THE CODE

-CODE RECOVERY

-C/F

TIME SETTINGS

This mode allows you to set the clock. Inthis function, hours increase by one unitevery time the SET button (2) is pressed;when value is 12, it goes back to 1 if the

SET button (2) is pressed again.AM indication becomes PM or vice versawhen time goes from 11:59 to 12:00.

Press the SET button (2) for severalseconds to store the value and go tominutes setting mode. Minutes increase byone unit every time the SET button (3) ispressed; when value is 59, it goes back to0 if the SET button (2) is pressed again.Press the SET button (2) for severalseconds to complete the procedure; theinstrument panel sets back to SETTINGSmenu.

MENU

EXIT

LAP TIMER

DIAGNOSTICS

LANGUAGE

SETTINGS


19/120


GEAR SHIFT INDICATOR

This function allows you to set the value forthe gear shift indicator threshold. As soonas you enter this function, the displayshows GEAR SHIFT INDICATOR (ifEnglish is the selected language) and the

rev. counter index indicates the thresholdvalue.

Briefly press the SET (2) push-button toincrease threshold value by 100 RPM.Once the max. value has been reached,press the push-button again to decreasethe value and vice versa.

Press the SET button (2) for severalseconds to complete the operation; thedisplay sets back to SETTINGS menu.

When battery is connected for the firsttime, the instrument panel sets to running-in rpm value, the next time battery isconnected it sets to last set value.

RUNNING-IN RPM: 6000

MINIMUM RPM: 5000

MAXIMUM RPM: 12000

When the set threshold is exceeded, thealarm light (4) on the instrument panelflashes until the value goes below thethreshold.

BACK LIGHTING

Th is func t ion a l l ows you to se tbacklighting: three levels are available. Inth i s func t ion the d i sp lay showsBACKLIGHTING and every time SET (2)button is briefly pressed, the following

symbols are alternatively displayed:-LOW

-MEAN

-HIGH

Press the SET button (2) for severalseconds to complete the operation; the

instrument panel sets back to SETTINGSmenu.

4


20/120


21/120


VIEW TIMES

This function also displays the acquired laptimes. Briefly press the SET button (2) toscroll the pages with the times measured;press it for several seconds to set thedisplay to LAP TIME menu. If the battery is

disconnected, stored times are lost.DELETE TIMES

This function deletes the acquired laptimes. Deletion should be confirmed. Oncethe operation is over, the display goesback to LAP TIMER menu.

Lap time operation

Select ENABLE LAP TIMER and confirm(by pressing SET (2) button for severalseconds) and display top zone (A) isautomatically set for time recording. Briefly

press SET button (2) to start recording withthe lap timer.

Press again the SET button (2) within thefirst 10 seconds from when the timer starts,time measurement is cancelled and a newone is started. Press again the SET button(2) after 10 seconds have elapsed from

timer start, time measurement is stopped,stored and a new one is started. Stop thetime measurement session by pressing theSET (2) push-button for several seconds.

Acquisition ends as soon as 40 lap timesare stored; FULL is displayed. Stop thevehicle, see page 54 (STOPPING)and

enter the VIEW TIMES function of the LAPTIME menu to read the stored lap times.

Diagnosis

This function interfaces with the systemsfitted to the motorcycle to carry outdiagnosis. To enable it, you need a specialpassword only available to the aprilia

Authorised Service Centres .

Language

This function allows you to choose thelanguage of any message displayed.

Available options are:

-ITALIANO-ENGLISH

-FRANCAIS

-DEUTSCH

-ESPANOL

Once the operation is over, the display

goes back to LANGUAGE menu.

VIEW TIMES


22/120


SERVICE INTERVAL

When the scheduled service intervals arereached, an icon is displayed (symbol of aspanner).

Switches on first at: 1,000 km

Then switches on: every 10,000 kmThis indication can be eliminated as soonas aprilia Authorised Dealers andService Centrescarry out the necessaryscheduled maintenance operations.

ALARM DISPLAY

In case a serious failure is detected, onethat might jeopardise the vehicle or therider's safety, the display will show an iconindicating the failure cause, at the bottom(D).

A la rms are d i v ided in two g roupsdepending on their priority:

High priority: engine overtemperature,engine oil pressure, faults from E.C.U.,instrument panel faults.

Low priority: turn indicators and control unitdisconnect.

Should there be many alarms with samepriority level, the relevant icons aredisplayed alternatively.

High priority alarms do not allow you todisplay low priority ones.

If the alarm light and the SERVICE iconbriefly come on, it does not mean that thereis a failure.

KEY CONTROLS

Km/h

LAP

ODO Km

C

ENGINE OIL PRESSURE

ERRORS FROM ECUS ANDINSTRUMENT PANEL

ENGINE OVERTEMPERATURE(Flasing logo) C RH TURN INDICATOR

LH TURN INDICATOR

ECU DISCONNECT


23/120


KEY CONTROLS

CONTROLS ON THE RIGHT SIDEOF THE HANDLEBAR

NOTE The electric components onlyoperate when the ignition switch is in the" " position.

1) ENGINE STOP SWITCH ( -)

CAUTIONDo not operate the engine stop switch - while riding.

This switch serves as a safety oremergency switch.

With the switch pressed in position , it is possible to start theengine; the engine can be stopped bypressing the switch to position .

CAUTIONWith the engine stopped and theignition switch in position , thebattery may run flat.

CAUTIONWhen the vehicle has come to astandstill and you have stopped theengine, set the ignition switch toposition " ".

2) STARTER BUTTON ( )Wh en th e sta rt er but to n " " ispressed, the starter motor will crank theengine. For the starting procedure, seepage 48 (STARTING).

CONTROLS ON THE LEFT SIDE OFTHE HANDLEBAR

NOTE The electric components onlyoperate when the ignition switch is in the" " position.

3) Horn button ( )The horn is activated when the pushbutton is pressed.

4) Turn indicator switch ( )To indicate the turn to the left, move the

switch to the left; to indicate the turn tothe right, move the switch to the right.

Press the switch to turn off the directionindicator.

2

1

3 4

6 5


24/120


5) DIMMER SWITCH ( - )When it is in position , theparking lights, the dashboard light andthe low beam are always on.

When it is in position , the highbeam comes on.

Ensure that the dimmer switch is set to before starting the engine.

6) MULTIFUNCTION DISPLAYCONFIGURATION SELECTORSets the configurat ion shown ond isp lay , see page 16(MULTIFUNCTION COMPUTER).

7) High beam flasher - passing button( )It makes it possible to use the highbeam for signalling to forthcomingvehicles while overtaking and in case ofperil and/or emergency.

NOTE Release the button to turn off thehigh beam flasher.8) MULTIFUNCTION DISPLAY (SET)

BUTTON

NOTE To set functions, see page 16(MULTIFUNCTION COMPUTER).

IGNITION SWITCH

The ignition switch (1) is positioned on theupper plate of the steering column.

NOTE The key operates the ignitionswitch/steering lock, the fuel filler plug lock

and the glove/tool kit compartment cover.Two keys are supplied together with thevehicle (one spare key).

NOTE Do not keep the spare key on thevehicle.

NOTE Setting the ignition key toautomatically turns on the lights.

The lights will turn off when the ignitionswitch is set to " ".

3 4

6 5

7

8

1


25/120


STEERING LOCK

WARNINGNever turn the key to posit ion " "when riding, or you will lose control ofthe vehicle.

OPERATIONTo lock the steering:

u Turn the handlebar fully to the left.u Turn the key to " ".u Press the key in and turn it to

position.u

Remove the key.

Position Function Key removal

Steering lock

The steering is locked. It is notpossible to start the engine or switchon the lights.

It is possible to remove the key.The immobiliser system is activatedafter the key is removed(where immobiliser system is fitted).

Neither the engine, nor the lights willoperate.


The engine and the lights can beoperated.

It is not possible to remove the key.

The steering is locked.It is not possible to start the engine.The parking lights of headlight andtail light are turned on.



26/120


UNLOCKING/LOCKING THEPASSENGER SET/SEAT COVER

u Position the vehicle on the stand, seepage 56 (PLACING THE VEHICLE ONTHE STAND).

u Introduce the key (1) in the lock.u Turn the key (1) anticlockwise, raise the

passenger seat/seat cover (2) and easeit off in a forward motion.

The ta i l sec t ion o f the veh ic leaccommodates a convenient glove / tool kitcompartment, simply remove passengerseat/seat cover (2).

NOTE Before lowering and locking thepassenger seat/seat cover (2), make sure

that you have not left the key in theglove/tool kit compartment.

To lock the passenger seat/seat cover(2):

u Slide the lower front lugs underneath theframe tube of the rear subframe.

u Position passenger seat/seat cover andpress down until the lock snaps shut.

WARNINGBefore riding, make sure that thepassenger seat /seat cover (2) isproperly locked.

WARNINGPassenger seat can be replaced withseat cover, however it is not possible tocarry a passenger when seat cover ison. Carrying a passenger on seat coveris illegal and the passenger is verylikely to fall from the vehicle.

1

2

2


27/120


GLOVE/TOOL KIT COMPARTMENT

To reach the g love / tool k i tcompartment, proceed as follows:

u Remove passenger seat/seat cover, seepage 26 (UNLOCKING/LOCKING THE

PASSENGER SET/SEAT COVER).The tool kit (1) includes:

3, 4, 5, 6 mm bent Allen spanners (2); 11 - 13 mm double open-end spanner (3); 8 - 10 mm double socket spanner (4); 17 mm open-end spanner (5); 16 mm socket spanner for spark plug

(6);

double-ended (cross-headed/hexagon)

screwdriver (7); tool box (8). fuse puller (9).Maximum allowed weight: 1.5 kg.

LUGGAGE FIXING POINTS

The passenger seat can be used to carrysmall luggage, which must be strappeddown securely to the suitable fixing points(9).

Maximum allowed weight: 9 kg.

WARNINGCarry small luggage only and make sureit is fastened securely.

3

2

4

6

87

5

9

9

SPECIAL TOOLS


28/120


To perform some specific operations, it is advisable to use the following special tools (tobe requested to an aprilia Authorised Dealer):

Tool Operations

Pins (1) for rear support stand, see page 67(FITTING THE PINS FOR THE REARWHEEL STAND) .

Positioning of the vehicle on the rear stand.

Rear support stand (2), see page 67(POSITIONING THE VEHICLE ON THEREAR SUPPORT STAND) .

Engine oil and engine oil filter change.

Rear wheel disassembly.

Drive chain adjustment.

Removal of the lower fairing.Front support stand (3), see page 68(POSITIONING THE VEHICLE ON THEFRONT SUPPORT STAND) .

Front wheel disassembly.

Click clamp (4) installation pliers, see page 61(CLICK CLAMPS).

Click clamp installation.

MAIN COMPONENTS


29/120


MAIN COMPONENTS

FUEL

WARNING

The fuel used in internal combustionengines is highly flammable and canbecome explosive under particularconditions.It is important to refuel and service thevehicle in a well-ventilated area, with theengine off.Do not smoke while refuelling or near fuelvapours, in any case avoid contact withnaked flames, sparks and any other heatsource or source of ignition to preventfires or explosion.Avoid spilling fuel, as it may ignite whenin contact with hot engine parts.In case some fuel has accidentally been

spilt, make sure that the area hascompletely dried and before starting thevehicle verify that there is no fuel insidethe fuel filler neck.Since fuel expands under the heat of thesun and due to the effects of sunradiation, never fill the tank to the brim.

Screw the plug up carefully afterrefuelling. Avoid any contact of the fuelwith the skin and the inhalation ofvapours; do not swallow fuel or pour itfrom a receptacle into another by meansof a tube.

DO NOT DISPOSE OF FUEL IN THEENVIRONMENT.

KEEP AWAY FROM CHILDREN.

Use only premium-grade unleaded fuelwith a minimum octane rating of 95 (RON)and 85 (MON).

To refuel, proceed as follows:

u Raise the flap (1).u Insert the key (2) into the tank plug lock

(3).u Turn the key clockwise, pull and open

the fuel flap.FUEL TANK CAPACITY ( reserveincluded): 17.5 b

FUEL RESERVE: 4.5 1 b

CAUTIONDo not add any additives or othersubstances to the fuel.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

WARNINGDo not fill the tank completely; themaximum fuel level must remain belowthe lower edge of the filler neck (seefigure).

u Refuel.

After refuelling:

NOTE The plug can only be closedwhen the key (2) is inserted.

uOnce key (2) is inserted and turned

clockwise, press and close the plug.

WARNINGMake sure that the cap is properlyclosed.

u Release the key (2) and take it out.u Close the flap (1).


30/120


BRAKE FLUID -RECOMMENDATIONS

NOTE This vehicle is provided with frontand rear disc brakes, with separatehydraulic circuits.

The following information refers to a singlebraking system, but is valid for both.

WARNINGSudden changes in brake lever play or aspongy feel of the lever may indicateproblems with the hydraulic system.

If in doubt about the braking efficiencyof your bike or if you are not able toperform routine checks, contact youraprilia Authorised Dealer.

Ensure that the brake discs have notbecome contaminated with oi l orgrease, especially after maintenance orinspections.Check that the brake lines are neithertwisted nor worn out.

Prevent water or dust from accidentallygetting into the circuit.

In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.

If the brake fluid gets in contact with the

skin or the eyes, it can cause seriousirritations.

WARNINGCarefully wash the parts of your bodythat get in contact with the fluid.Consult a doctor or an oculist if the fluidgets in contact with your eyes.

DO NOT DISPOSE OF THE FLUID INTHE ENVIRONMENT.


CAUTIONWhen using the brake fluid, take carenot to spill it on the plastic or painted

parts, since it can damage them.

The rear brake fluid reservoir is locatedf


31/120


DISC BRAKES

WARNINGThe brakes are the parts that mostensure your safety and for this reasonthey must always be perfectly working;

check them before every trip.A dirty disc will soil the pads, leading toloss of braking efficiency.Dirty pads must be replaced, while dirtydiscs must be cleaned with a high-quality degreaser.The brake fluid must be changed every

two years by an aprilia AuthorisedDealer.Use brake fluid of the type specified inthe lubricant chart, see page 114(LUBRICANT CHART).

NOTE This vehicle is provided with discbrakes with two -front and rear- brakingsystems having separate hydraulic circuits.

The front brake is a twin-disc brake (onedisc on either side of the wheel).

The rear brake uses a single disc (fitted tothe right side of the wheel).

The following information refers to a singlebraking system, but is valid for both.

When the disc pads wear out, the level ofthe fluid decreases to automatical lycompensate for their wear.

The front brake fluid reservoir is mountednear the front brake lever coupling.

under right side fairing; remove the rightside fairing shielding the expansion tank tofind it.

NOTE Halve maintenance intervals ifyou are riding in rainy or dusty conditions,on rough road surfaces or when the vehicleis used in competitions.

Have the brake discs checked by anaprilia Authorised Dealerafter the first1000 km (625 mi) and successively every10000 km (6250 mi).

Before departure, check the brake fluidlevel in the reservoirs, see page 32(FRONT BRAKE), page 34 (REARBRAKE), and the wear of the pads, seepage 90 (CHECKING THE BRAKE PADSFOR WEAR).

u Check the brake pad wear, see page 90(CHECKING THE BRAKE PADS FOR


32/120


Have the brake fluid changed every twoyears by an aprilia Authorised Dealer.

WARNINGDo not use the vehicle if the brakingsystem leaks fluid.

FRONT BRAKE

CHECK

u Place the vehicle in vertical position andkeep handlebar in the direction of travel.

uMake sure that the fluid level exceedsthe MIN mark.

MIN= minimum levelIf the fluid does not reach at least the MINmark:

CAUTIONWhen the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear.

(CHECKING THE BRAKE PADS FORWEAR)and the disc wear.

If the pads and/or the disc do not needreplacing, provide for topping up.

TOPPING UPCarefully read page 30 (BRAKE FLUID -recommendations).

CAUTIONThe brake fluid may flow out of the tank.Do not operate the front brake lever if

the screws (1) have been loosened or,most important, with the brake fluidreservoir plug removed.

u Unscrew the screws (1) of the brake fluidreservoir (2) by means of a short, cross-headed screwdriver.

CAUTION CAUTION


33/120


CAUTIONAvoid any prolonged exposure of thebrake fluid to the air.

The brake fluid is hygroscopic andwhen in contact with the air it absorbs

its humidity.Leave the brake fluid tank open ONLYfor the time necessary for topping up.

u Raise and remove the cover (3) togetherwith the screws (1) and the gasket (4).

CAUTIONIn order not to spill the brake fluid whiletopping up, do not shake the vehicle.

Do not put addi t ives or other

substances into the fluid.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

u Top up the reservoir (2) by adding brakefluid, see page 114 (LUBRICANTCHART), until exceeding MIN levelmark.

CAUTIONWhile topping up, never pour too muchfluid.Fill up to max. level only with new brakepads.

If topped up to max. level with wornpads, brake fluid will spill out when youchange the pads at a later time.

Check the braking efficiency.

In case of excessive stroke of the brake

lever or reduced efficiency of thebraking system, contact an apriliaAuthorised Dealer, since it may benecessary to bleed the system.

WARNING


34/120


REAR BRAKE

CHECK

u Keep the vehicle upright, so as to keepthe fluid in the reservoir (1) level with theplug (2).

u Look through the special slot in the right

fairing to check that fluid level in thereservoir exceeds the "MIN" mark.

MIN= minimum level

MAX= maximum level

If the fluid does not reach at least the MINmark:

CAUTIONWhen the disc pads wear out, the levelof the fluid decreases progressively tocompensate for their wear.

u Check the brake pad wear, see page 90(CHECKING THE BRAKE PADS FORWEAR)and the disc wear.

If the pads and/or the disc do not needreplacing, provide for topping up.

TOPPING UP

Carefully read page 30 (BRAKE FLUID -recommendations).

u

Remove the right side fairing, see page78 (REMOVING THE SIDE FAIRINGS).

CAUTIONThe brake fluid may flow out of the tank.Do not operate the rear brake lever if thebrake fluid reservoir plug has beenloosened or removed.

WARNINGAvoid long exposure of brake fluid toair.The brake fluid is hygroscopic andwhen in contact with the air it absorbsits humidity.

Leave the brake fluid tank open ONLYfor the time necessary for topping up.

u Unscrew the screw (3) completely.u

Shift the complete reservoir (1)moderately outwards.u Unscrew and remove the plug (2).

CAUTIONIn order not to spill the brake fluid whiletopping up, keep the fluid in the tankparallel to the tank rim (in horizontalposition).

CAUTIONDo not add any additives or otherproducts to the fluid.If you use a funnel or other similaritems, make sure that they are perfectly

clean.u Remove the gasket (4).u Top up reservoir (1) with recommended

brake fluid, see page 114 (LUBRICANTCHART), until reaching correct level thatis in-between the marks MIN andMAX.

CAUTIONDo not tilt reservoir (1) even if plug (2) istightened.This might let air in the circuit and brakesystem would be impaired.

2

11

3

4

2

CLUTCH FLUID -RECOMMENDATIONS


35/120


CAUTIONTop up to "MAX" level only afterchanging the brake pads. Do not reachthe MAX level with worn out pads,since this will cause a fluid outflowwhen the pads are changed.

Check the braking efficiency.In case of excessive stroke of the brakelever or reduced efficiency of thebraking system, contact an apriliaAuthorised Dealer, since it may benecessary to bleed the system.

RECOMMENDATIONS

NOTE This vehicle is fitted with ahydraulically-controlled clutch.

CAUTIONAny sudden changes in p lay orhardness in the clutch lever are warningsigns of problems with the hydrauliccircuit.

If in doubt about the system efficiencyof your bike or if you are not able to

perform routine checks, contact youraprilia Authorised Dealer.

CAUTIONMake sure the clutch hose is not twistedor worn.Prevent water or dust from accidentally

getting into the circuit.In case maintenance operations are tobe performed on the hydraulic circuit, itis advisable to use latex gloves.Clutch fluid is an irritant. Avoid contactwith eyes or skin.In the event of accidental contact, flushaffected area thoroughly. Obtainmedical attention or, if fluid has beenspilled in the eyes, seek the assistanceof an ophthalmologist.

DO NOT DISPOSE OF THE FLUID INTHE ENVIRONMENT.


When handling clutch fluid, take carenot to spill it onto plastic or paint-

finished parts or they will damage.CAUTION

The clutch fluid must be changed everytwo years by an aprilia AuthorisedDealer.

Use the fluid recommended in the

lubr icants table , see page 114(LUBRICANT CHART).

The clutch fluid reservoir (1) is mountednear the clutch lever coupling.

1

NOTE Halve maintenance intervals ifyou are riding in rainy or dusty conditions


36/120


you are riding in rainy or dusty conditions,on rough road surfaces or when the vehicleis used in competitions.

Before moving off, check the reservoir

level, see page 36 (CLUTCH); have thefluid changed every two years by anaprilia Authorised Dealer.

WARNINGDo not ride if the clutch hydraulic circuitis leaking.

CLUTCH


Have the clutch checked every 10,000 km(6250 mi) by an aprilia AuthorisedDealer.

If the vehicle is used for racing:

have the clutch checked every 5000 km(3120 mi) by an aprilia AuthorisedDealer.

NOTE The engine is equipped with ahydraulically-operated clutch, aided by thepatented PPC (Pneumatic Power Clutch)system, which prevents rear wheelbouncing under braking.

CHECK

u Place the vehicle in vertical position andkeep handlebar in the direction of travel.

uMake sure that the fluid level exceedsthe MIN mark.

MIN= minimum level

MAX= maximum levelu Top up if the fluid does not reach at least

the MIN mark.

TOPPING UP

Carefully read page 35 (CLUTCH FLUID- recommendations).

CAUTIONDanger: clutch fluid could leak out.Never operate the clutch lever when thereservoir plug is loose or has beenremoved.

3

1

2

WARNING u Top up reservoir (1) with recommendedclutch fluid, see page 114 (LUBRICANT


37/120


Avoid long exposure of clutch fluid toair.

Clutch fluid is hygroscopic and willabsorb moisture from the air.

Keep the clutch fluid reservoir openJUST LONG ENOUGH to top up level.

u Unscrew and remove the plug (2).

CAUTIONDo not rock the motorcycle from side to

side when topping up or clutch fluid willspill out.

Do not put addi t ives or othersubstances into the fluid.

If you use a funnel or other similaritems, make sure that they are perfectly

clean.u Remove the gasket (3).

c utc u d, see page ( U CCHART), until reaching correct level thatis in-between the marks MIN andMAX.

CAUTIONNever exceed the "MAX" level.Check the clutch for proper operation.When the clutch lever has exceedingtrave l or i f you not ice a loss ofe f f ic iency , contact an apri l iaAuthorised Dealer. The clutch hydraulic

circuit may need bleeding. COOLANT

CAUTIONDo not ride when coolant is below theminimum level (LOW).

NOTE You will need to remove the rightside fairing in order to top up coolant level.NOTE Halve maintenance intervals ifyou are riding in rainy or dusty conditions,on rough road surfaces or when the vehicleis used in competitions.

Before departure, check the coolant level,see page 39 (CHECKING AND TOPPINGUP); have the coolant changed every twoyears: for this operation, contact anaprilia Authorised Dealer.

1


38/120


WARNINGCoolant is toxic when ingested. Contactwith eyes or skin may cause irritation.In the event of contact with eyes or skin,rinse repeatedly with abundant waterand seek medical advice. In the event of

ingestion, induce vomiting, rinse mouthand throat with abundant water andseek medical advice immediately.KEEP AWAY FROM CHILDREN.DO NOT DISPOSE OF THE FLUID INTHE ENVIRONMENT.Be careful not to spill the coolant on the

red-hot parts of the engine: it may catchfire and send out invisible flames.In case any maintenance operationshould be required, it is advisable touse latex gloves.

CAUTIONHave the pads changed by your apriliaAuthorised Dealer.

The coolant is composed of 50% water and50% antifreeze.

This mixture is ideal for most operatingtemperatures and ensures good protectionagainst corrosion.

It is advisable to keep the same mixturealso in the hot season, since in this waylosses due to evaporation are reduced andi t i s no t necessary to top up very

frequently.The mineral salt deposits left in the radiatorby evaporated water are thus reduced andthe efficiency of the cooling systemremains unchanged.

If the outdoor temperature is below 0 C,check the cooling circuit frequently and ifnecessary increase the ant i f reezeconcentration (up to maximum 60%).

For the cooling solution use distilled water,in order not to damage the engine.

WARNINGDo not remove the expansion tank plug(1) when the engine is hot, since thecoolant is under pressure and itstemperature is high.

If it gets in contact with the skin or with

clothes it may cause severe burnsand/or damage.

1

2


39/120


CHECKING AND TOPPING UP

WARNINGCheck the coolant level and top up theexpansion tank with cold engine.

u Stop the engine and wait until it has

cooled down.u Keep the vehicle in vertical position, with

the two wheels resting on the ground.u Look through the slot (2) in the right

fairing and check that coolant level in theexpansion tank is between the FULL eLOW marks.FULL= maximum level

LOW= minimum level

If not, proceed as follows:

u Remove the side fairing, see page 78(REMOVING THE SIDE FAIRINGS).

u Unscrew and remove the filling cap (1).

WARNINGCoolant is toxic when ingested. Contactwith eyes or skin may cause irritation.

Do not use your fingers or any otherobject to check if there is enoughcoolant.

CAUTIONDo not put addi t ives or othersubstances into the fluid.If you use a funnel or other similaritems, make sure that they are perfectlyclean.

u Top up the expansion tank by addingcoolant, see page 114 (LUBRICANTCHART),until this almost reaches theFULL level. Do not exceed this level,otherwise the fluid will flow out while theengine is running.

u

Put back the filling cap (1).

CAUTIONIn case of excessive consumption ofcoolant and in case the tank remainsempty, make sure that there are noleaks in the circuit. Have it repaired byan aprilia Authorised Dealer.

1


40/120

ENGINE OIL

WARNING


41/120


If the tyres are new, they may still becovered with a slippery fi lm: ridecarefully for the first miles. Do not oilthe tyres with unsuitable fluids. Oldtyres, even if not completely worndown, may become hard and providepoor grip.

In this case, replace them.

MINIMUM TREAD DEPTH LIMIT (3):

front and rear 2 mm ( 3 mm), anywaynot less than required by the regulations inforce in the country where the vehicle is

used.

WARNINGProlonged or repeated contact withengine oil may cause severe skin

damage.Wash your hands carefully after use.


DO NOT DISPOSE OF THE OIL IN THEENVIRONMENT.

Dispose of engine oil - stored in a

sealed container - through the nearestwaste oil reclamation firm or throughthe supplier.

In case any maintenance operationshould be required, it is advisable touse latex gloves.

CAUTIONIf the light comes on during regularengine operation and on the same timeeven the symbol is on, it meansthat the engine oil pressure in thecircuit is low.

In this case, check the engine oil level,see page 62 (CHECKING AND TOPPINGUP ENGINE OIL LEVEL); if the level isnot correct , s top the engineimmediately and contact an apriliaAuthorised Dealer.

CAUTIONProceed with care.Do not spill the oil!Take care not to smear any component,the area in which you are working andthe surrounding area. Remove any trace

of oil.In case of leakage or malfunctions,contact an aprilia Authorised Dealer.Periodically check the engine oil level, seepage 62 (CHECKING AND TOPPING UPENGINE OIL LEVEL).

To change engine oi l , see page 59

(REGULAR SERVICE INTERVALSCHART)and page 62 (CHECKING ANDTOPPING UP ENGINE OIL LEVEL).

NOTE Use high-quality 15W 50 oil,see page 114 (LUBRICANT CHART).

USA


42/120

EXHAUST MUFFLER/EXHAUSTSILENCER

If the noise produced by the exhaustsystem increases, immediately contactyour aprilia Authorised Dealer


43/120


ADJUSTING THE REAR BRAKELEVER AND THE GEAR CHANGELEVER

The posit ion of the control levers isdetermined based on ergonomic principlesat the factory.

If necessary, it is possible to adjust theposition of the levers.

u Position the vehicle on the stand, seepage 56 (PLACING THE VEHICLE ONTHE STAND).

u Partially unscrew the screw (1).u Rotate the eccentric (2) until finding the

optimal position for the pedal (3).u Tighten the screw (1) and make sure that

the eccentric retains its position.

CAUTIONIf the gear change lever needs furtheradjustment , contact an apri l ia

Authorised Dealer.

WARNINGTampering with the noise control

system is prohibited.Owners are warned that the law mayprohibit:

the removal or rendering inoperative byany person, other than for purposes ofmaintenance, repair or replacement, ofany dev ice or e lement o f des ign

incorporated into any new vehicle forthe purpose of noise control prior to itssale or delivery to the ultimate purchaseror while it is in use;

the use of the vehicle after such deviceor element of design has been removedor rendered inoperative by any person.

Check the exhaust si lencer and thesilencer pipes, making sure that there areneither signs of rust, nor holes and that theexhaust system works effectively.

your aprilia Authorised Dealer.

WARNINGBoth exhaust silencers are equippedwith catalytic converter and becomevery hot to the touch. Be careful!Danger of burns!

1

3

2

INSTRUCTIONS FOR USE


44/120


GETTING ON AND OFF THEVEHICLE

The instructions below must be followedwith the maximum care in order to avoid

any injury to persons and damage toproperty and to the vehicle, caused by thefalling of the rider or the passenger fromthe vehicle and/or the falling or overturningof the vehicle itself.

WARNING

Risk of falling and overturning.Proceed with care.

When getting on and off the vehicle, makesure nothing can impair your movements.Also, your hands should be free (replaceany objects, such as your helmet, gloves ordangling glasses before mounting or

dismounting). Get on and off the vehicleonly from the left side and always withextended side stand.

CAUTIONDo not apply the load of your weight orof the passengers weight onto the sidestand.

The stand has been designed to supportthe weight of the vehicle and a minimumload, without the rider and the passenger.

The purpose of placing the vehicle on theside stand before mounting is to keep thevehicle from falling or overturning. Thisdoes not mean that the side stand shouldbe used to support the weight of rider andpassenger.

While getting on and off, the weight of thevehicle may make you lose balance, andthe vehicle may fall or overturn.

NOTE The rider must always be the firstperson to get on the vehicle and the last toget off and it is the rider who controls thebalance and stability of the vehicle whenthe passenger gets on and off.


45/120

CAUTIONAfter covering the first 1000 km (625 mi)


46/120


PRE-RIDE CHECKS

WARNINGBefore starting, always perform vehiclepre-r ide checks, to ensure safeoperation see page 47 (PRE-RIDE

CHECKS CHART).Failure to comply with these checkingoperations can cause severe personalinjuries or damages to the vehicle.

Do not hesitate to consult your apriliaAuthorised Dealer in case there issomething you do not understand about

the operation of some controls or in caseyou suspect or discover some failures.

It does not take long to carry out a check-up and this operation ensures you muchmore safety.

NOTE This vehicle is equipped with anelectronic engine control unit capable ofdetecting abnormal operation in real timeand storing faults.

Each time the ignition key is set to , theword SERVICE (1) appears on the

right side of the multifunction display forapproximately three seconds.

CAUTIONI f the wording SERVICE (1) isd isplayed dur ing normal engineoperation, it means that the Engine

Control Unit has detected a fault.In many cases the engine keepsrunning with limited performance;contact an aprilia Authorised Dealerimmediately.

g ( )and every 10 ,000 km (6250 mi )afterwards, the "SERVICE" warning (2)appears on the right display.

In this case have an aprilia AuthorisedDealer perform all service operations asindicated in the scheduled maintenancechart, see page 59 (REGULAR SERVICEINTERVALS CHART).

PRE-RIDE CHECKS CHART

Component Check Page


47/120


Front and rear disc brakes

Check the operation, the idle stroke of the control levers, the fluid level and make sure there areno leaks.Check the wear of the pads.

If necessary, top up the fluid tank.

30,31,32,34, 90

ThrottleMake sure that it works smoothly and that it is possible to open and close it completely, in allsteering positions. Adjust and/or lubricate, if necessary.

91

Engine oil Check and/or top up if necessary. 41, 62

Wheels / tyresCheck the tyre surface, the inflation pressure, wear and tear and any damage.Remove any foreign matter that may be stuck in the tread grooves.

40

Brake leversMake sure that they work smoothly.

Lubricate the articulations and adjust the stroke if necessary.

43

ClutchCheck for proper operation, check clutch lever free play, clutch fluid level and check for leaks.If necessary, top up the fluid; the clutch must work without snatching and/or slipping.

35, 36

Steering Make sure that the steering rotates smoothly, without any clearance or looseness.

Side stand

Make sure that it operates correctly. Make sure that when the stand is let up or down there is nofriction and that the spring tension brings it back to its normal position.If necessary, lubricate joints and articulations.Make sure that the safety switch operates correctly.

94, 99

Fastening elements Make sure that the fastening elements are not loose. If necessary, adjust or tighten them.

Drive chain Check the slack. 75

Fuel tankCheck the fuel level and top up, if necessary.Check the circuit for leaks.Make sure that the fuel cap is correctly closed.

29, 77

CoolantThe coolant level in the expansion tank must be included between the FULL and LOWmarks.

37, 37

Engine stop switch( - )

Make sure that it operates correctly.22

Lights, warning lights, horn,rear brake light switches andelectrical devices

Check horn and indicators for proper operation. Change bulbs or fix a failure, if necessary. 99 103

1

3

4What should happen now is:

starting page is shown for 2 seconds onmultifunction display.


48/120


STARTING

This is a high-performance vehicle. Werecommend that you become familiarwith it gradually using the greatest care.

Do not position any object inside thefront fairing (between the handlebar and

the instrument panel), in order not tohinder the rotation of the handlebar andvisibility toward the instrument panel.

NOTE Before starting the engine,carefully read chapter safe drive, seepage 5 (SAFE DRIVE).

WARNINGExhaust emissions contain carbonoxide, which is a poisonous gas andextremely harmful if inhaled.Avoid starting the engine in closed orbadly-ventilated rooms.

CAUTIONFailure to heed this warning may causeloss of consciousness or even lead todeath by asphyxia.

NOTE With the side stand down, theengine can be started only if the gearbox is

in neutral; in this case, if you try to engagethe gears, the engine stops.

With the side stand up, it is possible to startthe engine either in neutral gear or withengaged gears and pulled in clutch lever.

u Get on the vehicle in riding position, seepage 44 (INSTRUCTIONS FOR USE).

uMake sure that the stand is completelyup.

uMake sure that the dimmer switch (1) isin position .

u Set the engine stop switch (2) to position .

u Turn the key (3) and set the ignition

switch to position .

3

652 4

p y All warning lights (4) on the instrument

panel and the backlighting come on for 2seconds.

The odometer pointer (5) points the lastred line threshold setting for 3 secondsand then returns to idle rpm.

During normal operation, all instrumentswill give the current reading.

CAUTIONIf the low fuel warning light (6) on

the instrument panel comes on, providefor topping up as soon as possible, seepage 29 (FUEL).


49/120


50/120


MOVING OFF - RIDING

WARNINGThe vehicle's engine del iversconsiderable power. Familiarise with thevehicle gradually and use the greatestcare.Do not position any object inside thefront fairing (between the handlebar andthe instrument panel), in order not tohinder the rotation of the handlebar andvisibility toward the instrument panel.

NOTE Before moving off, carefully readthe safe drive chapter, see page 5 (SAFE

DRIVE).

CAUTIONI f the low fuel l ight (1) on theinstrument panel comes on whilevehicle is running, it means that youstill have 4,5 1 of fuel in the tank.

Provide for topping up as soon aspossible, see page 29 (FUEL).

WARNINGIf you ride without passenger, makesure that the passenger footrests arefolded.

CAUTIONWhile riding, keep your hands on thegrips and your feet on the footrests.NEVER RIDE IN ANY POSITION OTHERTHAN THOSE INDICATED.

WARNINGIf you ride with a passenger, instruct

him/her so that he/she does not createproblems during manoeuvres.Before leaving, make sure that thestand is completely up.

To leave:

u Start the engine, see page 48(STARTING).

u Adjust the inclination of the rear-viewmirrors correctly.

CAUTIONWith the vehicle at rest, try to getacquainted with the use of the rear-viewmirrors. The reflecting surface isconvex, therefore the objects seem tobe farther away than they actually are.These mirrors offer a wide-angleview. It may take some time to learn toaccurately judge the distance of trafficbehind.uWith released throttle grip (2) (Pos.A) and

engine idling, pull the clutch lever (3)completely.

u Engage the first gear, by pushing thegear lever (4) downwards.

u Release the brake lever (pulled on thestarting).

1

2

3

4

CAUTIONI f the engine oil pressure logo comes on during regular engine


51/120


WARNINGRelease the clutch lever smoothly, oryou may stall the engine or cause thevehicle to jerk forwards.Never acce lera te abrupt ly orexcessively when releasing the clutch

lever, in order to prevent the clutchfrom slipping (slow release) or thefront wheel from raising rearing up(quick release).

u Slowly release the clutch lever (3) and atthe same time accelerate by slightlyturning the throttle grip (2) (Pos.B).

The vehicle will start moving.

u Ride at reduced speed for the first miles,in order to warm the engine up.

CAUTIONNever exceed the recommended rpm,see page 54 (RUNNING-IN).

u Increase the speed by gradually rotatingthe throttle grip (2) (Pos.B), without

exceeding the recommended rpm, seepage 54 (RUNNING-IN).

To engage the second gear:

CAUTIONProceed quickly.Never ride the vehicle at too low rpm.

u Release the throttle grip (2) (Pos.A), pullthe clutch lever (3) and lift the gear shiftlever (4). Release the clutch lever (3)and accelerate.

u Repeat the last two operations and shiftup.

comes on dur ing regular engineoperation, it means that engine oilpressure in the circuit is low.

In th is case , s top the engineimmediately and contact an apriliaAuthorised Dealer.

The downshifting should be carried outin the following situations:

uWhen riding downhill or when braking, in

order to increase the braking action byusing the compression of the engine.uWhen riding uphill, if the gear engaged is

not suitable to the speed (high gear,moderate speed) and the engine rpmdecreases.

CAUTIONShi f t the gears one by one; thesimultaneous downshifting of morethan one gear may make you exceed themaximum rpm (redline).

Before and during the downshifting,release the throttle grip and decelerate,in order to avoid the redline.

32

2

43

If coolant temperature readout is stillflashing after you have checked level,contact an aprilia Authorised Dealer.

WARNINGAvoid opening and closing the throttlerepeatedly and continuously so that

4


52/120


To shift down, proceed as follows:

u Release the throttle grip (2) (Pos.A).u If necessary, pull the brake levers

moderately and decrease the speed ofthe vehicle.

u Pull the clutch lever (3) and lower the

gear shift lever (4) to shift down.u If the brake levers are pulled, releasethem.

u Release the clutch lever and acceleratemoderately.

CAUTIONIf the coolant temperature readout of the

multifunction display is between 115C(239F) and 135C (275F), see page 16(MULTIFUNCTION COMPUTER), stop thevehicle and let the engine run at 3000rpm for approximately two minutes tokeep coolant circulating in the system;position the engine stop switch on

and check the coolant level, seepage 37 (COOLANT).

Do not set the ignition switch to ,as this would switch off the cooling

fans regardless of coolant temperatureand temperature would keep rising.

I f t he w or di ng S ER VI CE i sdisplayed on the right side duringnormal engine operation, it means thatthe Engine Control Unit has detected afault.

In many cases the engine keepsrunning with limited performance;contact an aprilia Authorised Dealerimmediately.

To avoid the overheating of the clutch,keep the engine running with vehicle atrest, engaged gears and pulled clutchlever for the shortest time possible.

repeatedly and continuously, so thatyou do not accidentally lose control ofthe vehicle. If you have to brake, close

the throttle and put on both brakes inorder to obtain uniform deceleration,properly exerting pressure on thebraking parts.

Using one brake only reduces brakingforce significantly and may lock a wheelresulting in loss of grip.

If you stop uphill, decelerate completelyand use the brakes only to keep thevehicle steady.

The use of the engine to keep thevehic le s teady may cause theoverheating of the clutch.

When approaching a bend, slow downor brake in good time. Take the bend atmoderate, steady speed or accelerateslightly. Late braking may put thevehicle into a skid.

2

3

If the brakes are operated continuouslyon downhill stretches, the frictionsurfaces may overheat, thus reducingthe braking efficiency Exploit the

Always signal your intention to changelanes or direction in good time usingthe direction indicators. Avoid suddenmanoeuvres


53/120


the braking efficiency. Exploit theengine compression and shift down byputting on both brakes intermittently.

Never ride downhill with the engine off!

When visibility is insufficient, switch onthe low beam even during the day, inorder to make your vehicle more visible.In case of wet ground or scarce wheelgrip (snow, ice, mud, etc.), ride slowly,

avoid ing sudden brak ing ormanoeuvres that could make you losegrip and fall down.

WARNINGPay the utmost a t tent ion to anyobstacle or variation of the ground.

Uneven road surfaces, rails, inspectioncovers, painted signals, constructionsite metal covers become slippery inrainy weather and must be negotiatedcarefully, smoothly and keeping thevehicle upright.

manoeuvres.

Switch off the direction indicators

immediately after changing direction.Be very careful when overtaking orbeing overtaken.

When it rains, large vehicles lift surfacewater, which affects visibi l i ty. Inaddition, the slip stream may make youlose control of the vehicle.

RUNNING-IN

The running-in of the engine is essential toensure its life and correct operation.

WARNINGAfter the first 1000 km (625 mi), have anaprilia Authorised Dealer carry out the


54/120


If possible, ride on hilly roads and/or roadswith many bends, so that the engine, the

suspensions and the brakes undergo amore effective running-in.

During running-in, change speed.

In this way the components are firstloaded and then relieved and theengine parts can thus cool down.

Even if it is important to stress the enginecomponents during running-in, take carenot to exceed.

NOTE Top performance is only obtainedafter covering the first 1500 km (937 mi).

Keep to the following indications:

u Do not open the throttle completely if the

speed is low, both during and afterrunning-in.

u Until you have covered the first 100 km(62 mi), use the brakes gently and avoidhard, prolonged braking. This ensures acorrect bedding-in of the pads on thebrake disc.

u During the first 1000 km (625 mi) neverexceed 6000 rpm.

ap a u o sed ea e ca y ou echecks indicated in the column Afterrunning-in of the regular service

intervals chart, see page 59 (REGULARSERVICE INTERVALS CHART), in orderto avoid hurting yourself or otherpeople and/or damaging the vehicle.

u Between the first 1000 (625 mi) and1500 km (937 mi) ride more briskly,change speed and use the maximum

acceleration only for a few seconds, inorder to ensure better coupling of thecomponents; never exceed 7500 rpm(see table).

u After the first 1500 km (937 mi), you canexpect higher performance from yourengine. However, never exceed the

maximum rpm allowed (11,000 rpm).

STOPPING

WARNINGIf possible, avoid stopping abruptly,slowing down suddenly and l imitbraking.

u Release the throttle grip (1) (Pos.A),gradually put on the brakes and at thesame t ime shi f t down in order todecrease the speed, see page 50(MOVING OFF - RIDING).

Once the speed has decreased, beforestopping the vehicle:

u Pull the clutch lever (2) in order toprevent the engine from stalling.When the vehicle has come to rest:

u Select neutral (green warning light " "on).

u Release the clutch lever (2).u In case of a brief stop, keep at least one

brake on.

Engine maximum rpm recommended

Mileage km (mi) rpm

0 1000 (0 625) 6000

1000 1500 (625 937) 7500over 1500 (937) 11000

12

Stay away from the cooling fans evenwhen they are not operating. Theymight switch on unexpectedly and yourclothing or hair might be caught in the

u Following the indications, wait until thepassenger has got off the vehicle beforedismounting.

u Lock the steering, see page 25

43 5


55/120


PARKING

It is very important to choose a suitableparking area, respecting the road signsand the indications given below.

WARNING

Park the vehicle on firm and levelground to prevent it falling over.Neither lean the vehicle against walls,nor lay it on the ground.Make sure that the vehic le andespecially its red-hot parts do notrepresent a danger for persons and

children. Do not leave the vehicleunattended when the engine is on or thekey is inserted into the ignition switch.

clothing or hair might be caught in thefans.

WARNINGThe fall or excessive inclination of thevehicle may cause the fuel to flow out ofthe tank.The fuel used for internal combustionengines is extremely inflammable andin particular conditions it can become

explosive.

WARNINGDo not apply the load of your weight orof the passengers weight onto the sidestand.

To park the vehicle:

u Choose a suitable parking area.u Stop the vehicle, see page 54

(STOPPING).u Set the engine stop switch (3) to position

.u Turn the key (4) and set the ignition

switch (5) to position " ".

WARNINGWhen getting on or off the vehicle, keepto the instructions given, see page 44(GETTING ON AND OFF THE VEHICLE).

g, p g(STEERING LOCK)and remove the key(4).

WARNINGMake sure that the vehicle is stable.

12


56/120


PLACING THE VEHICLE ON THESTAND

SIDE STAND

To place the vehicle on the side standwhile seated astride the vehicle, see page44 (INSTRUCTIONS FOR USE). If any

manoeuvre (for example, moving thevehicle) required the lifting of the stand, toplace the vehicle on the stand again,proceed as follows:

WARNINGMake sure that the parking surface isfree from obstacles, firm and flat.

u Choose a suitable parking area, seepage 55 (PARKING).

uGrasp the left grip (1) and place yourright hand on the rear upper part of thevehicle (2).

u Press the side stand with your right footand extend it completely (3).

u Incline the vehicle until the stand restson the ground.

u Steer the handlebar completely

leftwards.

WARNINGMake sure that the vehicle is stable.

3

SUGGESTIONS TO PREVENTTHEFT

CAUTION

IMMOBILISER (if fitted)

The vehicle is fitted with an immobiliserantitheft system by that isautomatically activated each time the

1


57/120


CAUTIONDo not use any brake lock devices.Fai lure to heed this warning canseriously damage the braking systemand lead to an accident thus provokingserious injuries or death.NEVER leave the key in the ignition switchand always use the steering lock.

Park the vehicle in a safe place, possibly ina garage or a protected place.

When possible, use an additional antitheftdevice.

Make sure that all documents are in orderand the road tax has been paid.

Wri te down your personal data andtelephone number in this page, to facilitate

the identification of the owner in case offinding after theft.

SURNAME:...............................................

NAME: ......................................................

ADDRESS: ...............................................

..................................................................

TELEPHONE NO.:....................................

NOTE Very often stolen vehicles areidentified thanks to the data written in the

use/maintenance manual.

automatically activated each time theignition key is removed from the switch.

Store the spare key in a safe place.Immobi l iser system keys cannot beduplicated. If both keys are lost, you willhave to have a number o f veh ic lecomponents replaced (rather than just thekey-operated locks).Embedded in the key grip is a transponder,an electronic device that modulates theradiofrequency signal emitted by a specialantenna built into the switch when the keyis turned to on. The modulated signal actsas a "password" that tells the control unitwhether an authorised key is being used tostart the engine.

NOTE The immobiliser system supportsup to four enabled keys.New keys can only be enabled at yourAuthorised dealer, who has the master keyavailable.The programming procedure wipes off allexisting key codes. An owner who wishesto have a new key enabled, will have to

bring all the keys he intends to be using tothe Dealer.

Immobiliser status is indicated by a light (1)on the instrument panel:

-Immobiliser off - light off

-Immobiliser on - light blinking

-Key not recognised - quick blinking

MAINTENANCE

WARNINGRisk of fire

Routine maintenance operations canusually be carried out by the user, but

ti ifi t l d ifi


58/120


Risk of fire.Keep fue l and other f lammable

substances away from the electricalcomponents.

Before beginning any maintenanceoperation or any inspection of thevehicle, stop the engine, extract the keyfrom the ignition switch, wait until theengine and the exhaust system have

cooled down and if possible lift thevehic le by means of the properequipment, on firm and flat ground.Before proceeding, make sure that theroom in which you are working isproperly ventilated.Keep away from the red-hot parts of theengine and of the exhaust system, inorder to avoid burns.Do not hold any mechanical piece orother parts of the vehicle with yourmouth: the components are not edibleand some of them are harmful or eventoxic.

CAUTIONIf not expressly indicated otherwise, forthe reassembly of the units repeat thedisassembly operations in reverseorder.

In case any maintenance operationshould be required, it is advisable to

use latex gloves.

sometimes specific tools and specifictechnical skills may be required.

In case periodic maintenance operations,assistance or technical advice are needed,contact an aprilia Authorised Dealer,who will ensure you prompt and accurateservicing.

Ask your aprilia Authorised Dealer totest the vehicle on the road after a repair or

periodic maintenance operation.In any case, personally carry out thePreliminary checking operations after anymaintenance operation, see page 47(PRE-RIDE CHECKS CHART).

NOTE This vehicle is equipped with anelectronic engine control unit capable ofdetecting abnormal operation in real timeand storing faults.

Each time the ignition key is set to ,the word SERVICE(1) appears on theright side of the multifunction display forapproximately three seconds.

CAUTIONI f t he wo rd in g S ER VI CE isdisplayed dur ing normal engineoperation, it means that the EngineControl Unit has detected a fault.

In many cases the engine keepsrunning with limited performance;contact an aprilia Authorised Dealerimmediately.

CAUTIONAfter covering the first 1000 km (625 mi)and every 10000 km (6250 mi )afterwards, the SERVICE (1)symbol appears on the right display.

In this case have an aprilia AuthorisedDealer perform all service operations as

indicated in the scheduled maintenancechart, see page 59 (REGULAR SERVICEINTERVALS CHART).

Km/h

LAP

ODO Km

C


59/120

OPERATIONS TO BE CARRIED OUT BYTHE aprilia Authorised Dealer

Key

= check and clean adjust lubricate or

ComponentAfter running-in[1000 km (625

mi)]

Every 5000 km(3125 mi) (only for

racing use

Every 10000 km(6250 mi) or 12

months

Every 20000 km(12500 mi) or 24

months

Rear shock absorber

every 10000 km


60/120


= check and clean, adjust, lubricate orreplace, i f necessary (according to

workshop manual specifications);= clean;

= change;

= adjust.

(*) = only for versions with magnesiumwheels: check that rim paint is in goodconditions.

NOTE Halve maintenance intervals ifthe vehicle is used in rainy or dustyconditions, on rough roads or for racing.

Gearboxevery 10000 km

(6250 mi):

Transmission cables and controls Rear suspension linkage bearings

Steering bearings and steeringclearance

Wheel bearings

Brake discs

General running of the vehicle

Adjusting the valve clearance

Braking systems

Cooling system

Clutch fluidevery 12 months:

every 24 months: Brake fluid

Coolant

Fork oilafter the first 10000 km (6250 mi) and

then every 20000 km (12500 mi):

Fork oil sealsafter the first 30000 km (18650 mi) and

then every 20000 km (12500 mi):

Brake pads if worn:

Wheels/tyres (*)

Nut, bolt, screw tightening

Cylinder synchronisation

Suspensions and track alignment

Final transmission (chain, rearsprocket, front sprocket)

Fuel pipes every 4 years:

Clutch wear

Pistons

JOINTS WITH CLICK CLAMPS ANDWITH SCREW CLAMPS

CAUTION

CAUTIONUpon installation, replace the clickclamp that has been removed with anew one having the same dimensions

1


61/120


IDENTIFICATION DATA

It is a good rule to write down the frameand engine numbers in the space providedin this manual.

The frame number can be used for thepurchase of spare parts.

NOTE Do not alter the identificationnumbers if you do not want to incur insevere penal and administrative sanctions.In particular, the alteration of the framenumber results in the immediate invalidityof the warranty.

FRAME NUMBER

The frame number (1) is stamped on theright side of the steering column.

Frame no. ________________________

ENGINE NUMBER

The engine number (2) is stamped on therear part, near the front sprocket.

Engine no. ________________________

Remove ONLY the clamps indicated inthe maintenance procedures.This text is not to be intended as anauthorisation to arbitrarily remove theclamps present on the vehicle.

WARNINGBefore removing a clamp, make surethat the removal does not involve any

f lu id leakage; i f so , prov ide forpreventing such leakage and protectthe components positioned near thejoint.

CLICK CLAMPS

For the removal it is sufficient to use simplepliers, while for the instal lation i t is

necessary to use a special tool (seebelow).

Before removing a clamp, prepare themater ia l necessary for the correc treassembly.

NOTE Have the appropriate special toolat hand:

clamp installation pliers, see page 28(SPECIAL TOOLS) .

new one having the same dimensions,to be requested to an apri l ia

Authorised Dealer.Do not attempt to reinstall the removedclick clamp.Do not replace the removed click clampwith a screw clamp or with other typesof clamp.

CAUTIONProceed with care, in order not todamage the joint components.

uWork with the pliers on the head of theclick clamp, forcing until you release it.

SCREW CLAMPS

For the removal and installation it is

sufficient to use a simple screwdriver.

CAUTIONCheck the conditions of the clamp andif necessary replace it with a new one ofthe same type and dimensions, to berequested to an aprilia AuthorisedDealer.When fastening the clamp, make surethat the joint is sufficiently stable.

2

NOTE To warm the engine and have theengine oil reach the operating temperature,do not let the engine idle with the vehicle atrest. According to the correct procedure, itis advisable to carry out the check after a

32


62/120


CHECKING AND TOPPING UPENGINE OIL LEVEL

Carefully read page 58 (MAINTENANCE)and page 41 (ENGINE OIL).

NOTE Halve maintenance intervals ifyou are riding in rainy or dusty conditions,

on rough road surfaces or when the vehicleis used in competitions.

Periodically check the engine oil level,change the oil after the first 1000 km (625mi) and successively every 10000 km(6250 mi), see page 63 (CHANGINGENGINE OIL AND THE ENGINE OIL

FILTER).

CAUTIONIn the vehicle is used for racing, changethe engine oil every 5000 km (3125 mi).Change oil more frequently if thevehicle is used in dusty conditions.

For the check, proceed as follows:

CAUTIONEngine oil level must be checked whenthe engine is warm. If you check levelwhen the engine is cold, oil level mayhave temporarily dropped below the"MIN" mark.This is not a problem, provided that theengine oil pressure symbol (A)does not show on multifunction display ,see page 14 (INSTRUMENTS ANDINDICATORS TABLE).

is advisable to carry out the check after atrip or after covering approximately 15 km

(10 mi) on a road outside town (this issufficient for the engine oil to reach theoperating temperature).

u Stop the engine, see page 54(STOPPING).

u Keep the vehicle in vertical position, withthe two wheels resting on the ground.

u Check oil level in the sight glass (2)visible through the special slot (1) in theleft fairing.

MAX= maximum levelMIN= minimum level.The difference between "MAX" and "MIN"amounts to approximately 500 cu. cm.

u The level is correct when the oil almostreaches the MAX mark.

CAUTIONNever exceed the MAX mark, nor letthe oil get below the MIN mark, inorder to avoid serious damage to the

engine.

1

A


63/120

u Place a container (1) holding more than4000 cu. cm under the drain plug (2) onthe reservoir.

u Unscrew and remove the drain plug (2)on the reservoir

CAUTIONDO NOT DISPOSE OF THE OIL IN THEENVIRONMENT. Dispose of engine oil -stored in a sealed container - through


64/120


on the reservoir.u Unscrew and remove the filler plug (3).

u Drain the oil and let it drip into thecontainer (1) for a few minutes.

u Check the sealing washer of thereservoir drain plug (2) and replace asrequired.

u Screw and tighten the drain plug (2) ontothe reservoir.

Drain plug (2) tightening torque: 15 Nm(1.5 kgm).

u Place the container (1) underneath theengine crankcase, under the enginedrain plug (4).

u Unscrew and remove the engine drainplug (4).

u

Drain the oil and let it drip into thecontainer (1) for a few minutes.

gthe nearest waste oil reclamation firm or

through the supplier.u Remove any metal debris collected by

the drain plug (4) magnet.u Screw and tighten the drain plug (4).

Drain plug (4) tightening torque: 12 Nm(1.2 kgm).

CHANGING THE ENGINE OIL FILTERNOTE Halve maintenance intervals ifyou are riding in rainy or dusty conditions,on rough road surfaces or when the vehicleis used in competitions.

u Change the engine oil filter every 10000

km (6250 mi) or anyway each time youchange the engine oil.u Release the two screws (5) and remove

the cover (6).u Remove the engine oil filter (7).

Never reuse a filter.

u Spread a film of oil on the seal (8) of the

new engine oil filter.u Insert the new oil filter.u Refit the cover (6). Refit and tighten the

two screws (5).

CAUTIONUpon installation, replace the clickclamp that has been removed with anew one having the same dimensions,

u Pour from opening (13) about 3500 cu.cm o f eng ine o i l , see page 114(LUBRICANT CHART).

u Refit and tighten the filler plug (3).u Start the engine, see page. 48


65/120


CLEANING THE ENGINE OIL FILTERLOCATED ON THE TANK


Clean the engine oil filter (7) located onthe tank after covering the first 1000 km(625 mi) and every 20000 km (12427 mi)(or every two oil changes) afterwards.

NOTE Have the appropriate special toolat hand:

clamp installation pliers, see page 28

(SPECIAL TOOLS) .

gto be requested to an apri l ia

Authorised Dealer.Do not attempt to reinstall the removedclick clamp.Do not replace a click clamp you haveremoved with a screw clamp (10) or withother types of clamps.

u Release the click clamp (11).u

Disconnect the hose (12).u Release and remove the engine oil filter(9) located on the reservoir and cleanwith an air line.

u Check the engine oil filter (9) seal, fit andtighten the filter.

Engine oil filter (9) tig

aprilia rsv-tuono maintenance manual

Documents