Aprilia - RST Mille Futura - English

RST mille
INTRODUCTION
INTRODUCTION 0
GENERAL INFORMATION 1
PERIODIC MAINTENANCE AND
ADJUSTMENTS 2
ENGINE 3
FUEL SYSTEM 4
COOLING SYSTEM 5
ELECTRICAL SYSTEM 6
CHASSIS 7
REPAIR INFORMATION 8
INDEX
i
Release 00/2001 - 11 0 - 1 - 00
INTRODUCTION RST mille
INTRODUCTION
CONTENTS
0.1 RELEASE 00/2001-11 UPDATE ....... 0-3-00
0
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
1
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 ......................... 0-7-00
2
0.4.3 SPECIAL TOOLS CATALOGUES ........ 0-7-00
0.4.4 OWNER'S MANUALS ........................... 0-7-00
0.5 SAFETY INFORMATION .................. 0-8-00
0.5.1 GENERAL PRECAUTIONS AND
INFORMATION ...................................... 0-8-00
3 0.5.2 BEFORE DISASSEMBLING ANY
COMPONENTS...................................... 0-8-00
0.5.3 DISASSEMBLING THE COMPONENTS .. 0-8-
00
4
0.5.4 REASSEMBLING THE COMPONENTS 0-8-00
0.6 SAFETY INFORMATION .................. 0-9-00
0.6.1 CONVENTIONS USED IN THE MANUAL 0-9-00
0.7 ABBREVIATIONS/SYMBOLS/
5 CONVENTIONS.............................. 0-10-00
0 - 2 - 00 Release 00/2001 - 11
RST mille
INTRODUCTION
0.1 RELEASE 00/2001-11 UPDATE page# Release page# Release

Issue date of original release (Release 00) and
2-5 -00 ........................ 00 2-49 -00 ...................... 00
subsequent releases:
2-6 -00 ........................ 00 2-50 -00 ...................... 00
Original release (Release 00)..................November 2001
2-7 -00 ........................ 00 2-51 -00 ...................... 00
0.1.1 MANUAL UPDATES
2-8 -00 ........................ 00 2-52 -00 ...................... 00
Always keep manual updated to the latest release you
have received. 2-9 -00 ........................ 00 2-53 -00 ...................... 00
2-10 -00 ...................... 00 2-54 -00 ...................... 00
Add the latest release pages to the manual and 2-11 -00 ...................... 00 2-55 -00 ...................... 00
destroy all superseded pages (even if they belong
to the release before last). 2-12 -00 ...................... 00 2-56 -00 ...................... 00
2-13 -00 ...................... 00 2-57 -00 ...................... 00
CAUTION
Failure to keep the manual up-to-date or to 2-14 -00 ...................... 00 2-58 -00 ...................... 00
eliminate superseded pages will make the manual 2-15 -00 ...................... 00 2-59 -00 ...................... 00
more difficult to consult and creates a risk of
improper servicing. 2-16 -00 ...................... 00 2-60 -00 ...................... 00
2-17 -00 ...................... 00 2-61 -00 ...................... 00
This manual is made up of 10 sections for a total of 376
pages (listed below). 2-18 -00 ...................... 00 2-62 -00 ...................... 00
NOTE Please see 0.2 (REFERENCE GUIDE) for 2-19 -00 ...................... 00 2-63 -00 ...................... 00
details of standard page nomenclature and page num-
bering. 2-20 -00 ...................... 00 2-64 -00 ...................... 00
2-21 -00 ...................... 00 2-65 -00 ...................... 00
0.1.2 LIST OF MANUAL PAGES AND UPDATE
NUMBERS 2-22 -00 ...................... 00 2-66 -00 ...................... 00
2-23 -00 ...................... 00 2-67 -00 ...................... 00
2-24 -00 ...................... 00 2-68 -00 ...................... 00
page# Release page# Release 2-25 -00 ...................... 00 3-1 -00 ........................ 00
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0-2 -00 ........................ 00 1-9 -00 .........................00 2-27 -00 ...................... 00 3-3 -00 ........................ 00
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0-6 -00 ........................ 00 1-13 -00 .......................00 2-31 -00 ...................... 00 3-7 -00 ........................ 00
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1-2 -00 ........................ 00 1-21 -00 .......................00 2-42 -00 ...................... 00 3-15 -00 ...................... 00
1-3 -00 ........................ 00 1-22 -00 .......................00 2-43 -00 ...................... 00 3-16 -00 ...................... 00
1-4 -00 ........................ 00 2-1 -00 .........................00 2-44 -00 ...................... 00 3-17 -00 ...................... 00
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1-7 -00 ........................ 00 2-4 -00 .........................00 2-48 -00 ...................... 00 4-2 -00 ........................ 00
CONTINUED ➤
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CONTINUED ➤
page# Release page# Release page# Release page# Release

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4-13 -00 ...................... 00 6-21 -00 ...................... 00 7-10 -00 ...................... 00 7-50 -00 ...................... 00
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4-16 -00 ...................... 00 6-24 -00 ...................... 00 7-13 -00 ...................... 00 7-53 -00 ...................... 00
4-17 -00 ...................... 00 6-25 -00 ...................... 00 7-14 -00 ...................... 00 7-54 -00 ...................... 00
4-18 -00 ...................... 00 6-26 -00 ...................... 00 7-15 -00 ...................... 00 7-55 -00 ...................... 00
4-19 -00 ...................... 00 6-27 -00 ...................... 00 7-16 -00 ...................... 00 7-56 -00 ...................... 00
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6-1 -00 ........................ 00 6-41 -00 ...................... 00 7-30 -00 ...................... 00 7-70 -00 ...................... 00
6-2 -00 ........................ 00 6-42 -00 ...................... 00 7-31 -00 ...................... 00 7-71 -00 ...................... 00
6-3 -00 ........................ 00 6-43 -00 ...................... 00 7-32 -00 ...................... 00 7-72 -00 ...................... 00
6-4 -00 ........................ 00 6-44 -00 ...................... 00 7-33 -00 ...................... 00 7-73 -00 ...................... 00
6-5 -00 ........................ 00 6-45 -00 ...................... 00 7-34 -00 ...................... 00 7-74 -00 ...................... 00
6-6 -00 ........................ 00 6-46 -00 ...................... 00 7-35 -00 ...................... 00 7-75 -00 ...................... 00
6-7 -00 ........................ 00 6-47 -00 ...................... 00 7-36 -00 ...................... 00 7-76 -00 ...................... 00
6-8 -00 ........................ 00 6-48 -00 ...................... 00 7-37 -00 ...................... 00 7-77 -00 ...................... 00
6-9 -00 ........................ 00 6-49 -00 ...................... 00 7-38 -00 ...................... 00 7-78 -00 ...................... 00
6-10 -00 ...................... 00 6-51 -00 ...................... 00 7-39 -00 ...................... 00 7-79 -00 ...................... 00
CONTINUED ➤
0 - 4 - 00 Release 00/2001 - 11
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INTRODUCTION
CONTINUED ➤
page# Release page# Release
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Release 00/2001 - 11 0 - 5 - 00
0.2 REFERENCE GUIDE
RST mille
INFORMAZIONI GENERALI
1.9 PLACING THE MOTORCYCLE ON THE

SERVICE STAND
1.9.1 PLACING THE MOTORCYCLE ON THE FRONT

WHEEL STAND
1
2
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.
Put one foot on the front end of the stand (3). 3
Press down on stand (3) until it rests fully on the
ground.
1.9.2 PLACING THE MOTORCYCLE ON THE

CENTRE STAND
Read paragraph 0.2.1 (GENERAL PRECAUTIONS

AND INFORMATION) carefully. 2
Part no. 8140176 (complete stand).

Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Place the motorcycle on the front wheel stand , see 7
1.9.1 (PLACING THE MOTORCYCLE ON THE
FRONT WHEEL STAND).
Hold the nut (1) steady on the inside.
Release and remove the rear upper right-hand 1 6
engine mounting bolt (2).
Torque wrench setting for nut (1) / bolt (2):50

Nm (5,0 kgm). 5
3 4
NOTE The bolt (2) on the left-hand side is longer
Collect the nut (1).
Slide the upper right-hand mounting boss (3) into the
upper hole on the right-hand side.
Fit the stud bolt (4) into the upper hole on the left-hand
side and screw it fully into the mounting boss (3).
Screw the upper left-hand mounting boss (5) fully onto
stud bolt (4) and tighten.
Hold the nut (6) on the inside steady.
Release and remove the rear lower engine mounting
bolt (7).
Release 00/2001 - 07 1 - 17 - 00
1) Motorcycle model (or engine type) 7) Page update number (progressive number)
2) Section title 8) Subsection number (progressive number)
3) Release progressive number (“00” identifies the original 9) Paragraph number (progressive number)
release) 10) Description of operation (always preceded by the
4) Year and month of issue of relevant release lozenge symbol)
5) Section number 11) Description of operation: the star means that the
6) Page number (pages are numbered sequentially, operation must be repeated on the opposite side of the
numbering begins anew in each section) motorcycle
0 - 6 - 00 Release 00/2001 - 11
RST mille
INTRODUCTION
0.3 FOREWORD 0.4 REFERENCE MANUALS

- This manual provides the information required for
normal servicing. 0.4.1 ENGINE WORKSHOP MANUALS
- The information and illustrations contained in this aprilia part# (description)
manual are updated through subsequent releases, see
0.1 (RELEASE 00/2001-11 UPDATE). 8140582 (1051-1) I
- This manual is intended for use by aprilia Dealers and 8140584 (1053-1) F
their qualified mechanics. Certain information has been
omitted intentionally, as this manual does not purport to 8140585 (1054-1) D
provide a comprehensive treatise on mechanics. The
8140583 (1052-1) E
persons who will use this manual must be fully
conversant with the basics of mechanics and with the 8140586 (1055-1) UK
basic procedures of motorcycle repair. Repairing or
inspecting a motorcycle when one does not possess 8140587 (1056-1) USA
such basic knowledge or training could result in

improper servicing and make the motorcycle unsafe to 0.4.2 PARTS CATALOGUES
ride. For the same reason, certain basic precautions aprilia part# (description)
have been omitted in the descriptions of repair and
inspection procedures. Take special care to avoid 390W ............... I UK
damage to motorcycle components or injury to
390Y ................ I UK
persons. aprilia s.p.a.'s mission is to constantly
enhance the riding pleasure of final users through the 3901 ................. I UK
on-going improvement of its products as well as of the RSV01
relevant technical literature. 0.4.3 SPECIAL TOOLS CATALOGUES
All aprilia Points of Sale and Subsidiaries worldwide
are kept updated on major engineering changes and aprilia part# (description)
modifications to repair procedures. Such changes and 8202278 I F D E UK
modifications are then reflected in the next release of
the relevant manual. When in doubt about an
0.4.4 OWNER'S MANUALS
inspection or repair procedure, please contact the
aprilia Consumer Service (A.C.S.) Department, who aprilia part# (description)
will be glad to provide full information on the procedure Model years 1998 -1999
in question as well as on any updates or engineering
changes affecting the motorcycle under consideration. 8102623 I F D
aprilia s.p.a. reserves the right to make changes to its 8102857 P E UK

products at any time, barring any such changes as may
8102858 NL DK SF
alter the essential features of a product as specified in
the relevant manual. 8102859 GR J UK
All rights of storage using electronic means, reproduction
and total or partial adaptation, whatever the means 8104128 AUS
adopted, are reserved in all countries. 8104099 USA

Any reference to products or services provided by
Model years 2000
outside suppliers is for information only and by no means
binding, and implies no warranties or responsibilities as 8104089 I F D
to the performance or use of any such products and/or
services. 8104142 P E UK
Please read 0.4 (REFERENCE MANUALS) for more 8104143 NL DK SF

detailed information. 8104141 GR J UK
Original release: November 2001
8104164 AUS
Produced and printed by:
DECA s.n.c. 8104171 USA
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844 RSV01
E-mail: [email protected]
www.decaweb.it 8104152 I F D
for:
8104269 P E UK
aprilia Consumer Service s.p.a.
via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italia
Tel. +39 - 041 57 86 101 8104267 NL DK SF
Fax +39 - 041 57 86 100
www.aprilia.com 8104268 GR J UK
8104270 AUS
8104264 USA
Release 00/2001 - 11 0 - 7 - 00
0.5 SAFETY INFORMATION Read 1.2 (WARNINGS CONCERNING FUEL,

LUBRICANTS, COOLANT AND OTHER COMPONENT
The following conventions are used to identify safety
PARTS) carefully.
information throughout the manual.
This symbol identifies safety-related information. 0.5.2 BEFORE DISASSEMBLING ANY
Whenever you see this symbol in the manual or COMPONENTS
attached to the motorcycle, use utmost care to avoid the - Clean off all dirt, mud, and dust and clear any foreign
risk of injury. Disregarding the instructions identified by objects from the vehicle before disassembling any
this symbol may put your safety, as well as that of other components.
persons or of the motorcycle at risk! - Use the model-specific special tools where specified.
CAUTION 0.5.3 DISASSEMBLING THE COMPONENTS

Disregarding these indications may lead to severe - Never use pliers or similar tools to slacken and/or
injury or death. tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their
WARNING positions before disconnecting them. Identify each
Disregarding these indications may lead to minor connection using a distinctive symbol or convention.
injury or motorcycle damage. - Mark each part clearly to avoid confusion when
refitting.
NOTE The term "NOTE" in this manual precedes - Thoroughly clean and wash any components you have
important information or instructions.
removed using a detergent with low flash point.
- Mated parts should always be refitted together. These
0.5.1 GENERAL PRECAUTIONS AND INFORMATION
parts will have seated themselves against one another
Follow these instructions closely when repairing, in service as a result of normal wear and tear and
disassembling or reassembling the motorcycle or its should never be mixed up with other similar parts on
components. refitting.
- Certain components are matched-pair parts and
CAUTION should always be replaced as a set.
Using bare flames is strictly forbidden when working on the - Keep the motorcycle and its components well away
motorcycle. Before servicing or inspecting the motorcycle: from heat sources.
stop the engine and remove the key from the ignition
switch; allow for the engine and exhaust system to cool 0.5.4 REASSEMBLING THE COMPONENTS
down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of WARNING
any parts of the engine or exhaust system which may still Never reuse a circlip or snap ring. These parts must
be hot to the touch to avoid scalds or burns. always be renewed once they have been disturbed.
When fitting a new circlip or snap ring, take care to
CAUTION move the open ends apart just enough to allow fit-
ment to the shaft.
Never put any mechanical parts or other vehicle
Make a rule to check that a newly –fitted circlip or
components in your mouth when you have both hands
snap ring has located fully into its groove.
busy. None of the motorcycle components is edible.
Some components are harmful to the human body or Never clean a bearing with compressed air.
toxic.
NOTE All bearings must rotate freely with no hardness
Unless expressly specified otherwise, motorcycle or noise. Replace any bearings that do not meet these
assemblies are refitted or re-assembled by reversing the requirements.
removal or dismantling procedure. Where a procedure is - Use ORIGINAL aprilia SPARE PARTS only.
cross-referred to relevant sections in the manual, proceed - Use the specified lubricants and consumables.
sensibly to avoid disturbing any parts unless strictly - Where possible, lubricate a part before assembly.
necessary. Never attempt to polish matte-finished - When tightening nuts and bolts, start with the largest or
surfaces with lapping compounds. innermost nut/bolt and observe a cross pattern.
Tighten evenly in subsequent steps until achieving the
Never use fuel instead of solvent to clean the motorcycle.
specified torque.
Do not clean any rubber or plastic parts or the seat with - Replace any self-locking nuts, gaskets, seals, circlips
alcohol, petrol or solvents. Clean with water and neutral or snap rings, O-rings, split pins, bolts and screws
detergent. which have a damaged thread.
Always disconnect the battery negative (–) lead before - Clean all joint surfaces, oil seal edges and gaskets
soldering any electrical components. before assembly.
- Apply a light coat of lithium grease along the edges of
When two or more persons service the same motorcycle oil seals. Fit oil seals and bearings with the brand or
together, special care must be taken to avoid personal serial number facing outwards (in view).
injury. - Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have
fitted are correctly in place.
0 - 8 - 00 Release 00/2001 - 11
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INTRODUCTION
- After repairing the motorcycle and after each service 0.6 SAFETY INFORMATION
inspection, perform the preliminary checks, and then
operate the motorcycle in a private estate area or in a 0.6.1 CONVENTIONS USED IN THE MANUAL
safe area away from traffic - This manual is divided in sections and subsections,
each covering a set of the most significant
components.
For quick reference, see the summary of sections on
page 0-1.
- Unless expressly specified otherwise, assemblies are
reassembled by reversing the dismantling procedure.
- The terms “left” and “right” are referred to the
motorcycle when viewed from the riding position.
- Motorcycle operation and basic maintenance are
covered in the “OWNER'S MANUAL”.
Any operations preceded by the star symbol must
be repeated on the opposite side of the
motorcycle.
In this manual any variants are identified with these
symbols:
Frame # ZD4DW......(STARTING FROM MODEL YEAR
2001).
ASD AUTOMATIC SWITCH-ON DEVICE
OPT Option
✿ Catalysed version
VERSION:
I Italy GR Greece Mal Malaysia
UK United
NL Netherlands RCH Chile
Kingdom
A Austria CH Switzerland HR Croatia
P Portugal DK Denmark AUS Australia
USA United
SF Finland J Japan States of
America
B Belgium SGP Singapore BR Brazil
RSA Republic of
D Germany SLO Slovenia South
Africa
NZ New
F France IL Israel Zealand
ROK South
E Spain CDN Canada
Korea
Release 00/2001 - 11 0 - 9 - 00
0.7 ABBREVIATIONS/SYMBOLS/ T.C.E.I. = cheese-headed Allen screw

CONVENTIONS T.E. =hexagonal head
# = Number T.P. =flat head screw
< = is less than TDC = Top Dead Centre
> = is more than TEST = diagnostic check
< = is less than or equal to TSI = Twin Spark Ignition
> = is more than or equal to UPSIDE-
~ = approximately DOWN = inverted fork
∞ = infinite V = Volt
°C = degrees Celsius (centigrade) W = Watt
°F = degrees Fahrenheit
± = plus or minus
A = Ampere
AC =Alternated Current
Ah =Ampere per hour
API = American Petroleum Institute
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
BDC = Bottom Dead Centre
CO = carbon oxide
CPU = Central Processing Unit
cu cm = cubic centimetres
DC = Direct Current
DIN = German industrial standards
(Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
HC = unburnt hydrocarbons
HT = High Tension
ID = inner diameter
ISC = Idle Speed Control
ISO = International Standardization Organization
kg = kilograms
kgm = kilograms per metre (1 kgm =10 Nm)
km = kilometres
km/h = kilometres per hour
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplung
seite")
kW = kiloWatt
kΩ = kiloOhm
l = litres
LAP = racetrack lap
LED = Light Emitting Diode
m/s = metres per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German
"Magnetoseite")
MΩ = megaOhm
N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton per metre (1 Nm =0.1 kgm)
Ø = Diameter
OD = outer diameter
Ω = ohm
PPC = Pneumatic Power Clutch
rpm = revolutions per minute
SAE = Society of Automotive Engineers
T.B.E.I. = crowned-head Allen screw
0 - 10 - 00 Release 00/2001 - 11
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INTRODUCTION
NOTES
Release 00/2001 - 11 0 - 11 - 00
NOTES
0 - 12 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
GENERAL INFORMATION 1
Release 00/2001 - 11 1 - 1 - 00
GENERAL INFORMATION RST mille
GENERAL INFORMATION
CONTENTS
1.1 LOCATION OF SERIAL NUMBERS .. 1-3-00
0
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 1.2.1 FUEL ...................................................... 1-3-00

1.2.2 ENGINE OIL........................................... 1-4-00
1.2.3 BRAKE FLUID ....................................... 1-4-00
1.2.4 COOLANT.............................................. 1-5-00
2
1.2.5 CLUTCH FLUID ..................................... 1-5-00
1.2.6 CARBON OXIDE ................................... 1-6-00
1.2.7 HOT COMPONENT PARTS .................. 1-6-00
1.3 RUNNING-IN RECOMMENDATIONS 1-6-00
3
1.4 SPARE PARTS ................................. 1-7-00
1.5 SPECIFICATIONS ............................ 1-7-00
1.6 LUBRICANT CHART ...................... 1-10-00
4
1.7 CONSUMABLES ............................ 1-11-00
1.7.1 PRODUCT FEATURES ....................... 1-11-00
1.7.2 PRODUCT APPLICATIONS ............... 1-12-00
1.8 SPECIAL TOOLS............................ 1-15-00
1.8.1 SUNDRY TOOLS ............................... 1-15-00
5 1.8.2 ENGINE TOOLS .................................. 1-16-00
SERVICE STANDS ......................... 1-17-00
6 FRONT WHEEL STAND ..................... 1-17-00

CENTRE STAND ................................ 1-18-00
1.10 HOW TO APPLY THE DECALS ...... 1-19-00
7 1.11 TORQUE FIGURES ........................ 1-21-00
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GENERAL INFORMATION
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.
1.1.1 FRAME NUMBER

The frame number (Vehicle Identification Number) is
etched on the right-hand side of the headstock.
1.1.2 ENGINE NUMBER

The engine number is etched at the rear end of engine, in
the area near the sprocket.
1.2 WARNINGS CONCERNING FUEL,

LUBRICANTS, COOLANT AND OTHER
COMPONENT PARTS
1.2.1 FUEL
CAUTION
The fuel used to operate engines is highly flammable
and becomes explosive under particular conditions.
Refuelling and engine service should take place in a
well-ventilated area with the engine stopped.
Do not smoke when refuelling or in the proximity of
sources of fuel vapours.
Avoid contact with bare flames, sources of sparks or
any other source which may ignite the fuel or lead to
explosion.
Take care not to spill fuel out of the filler, or it may
ignite when in contact with hot engine parts.
In the event of accidental fuel spillage, make sure the
affected area is fully dry before starting the engine.
Fuel expands from heat and when left under direct
sunlight. Never fill the fuel tank up to the rim.
Tighten the filler cap securely after each refuelling.
Avoid contact with skin. Do not inhale vapours. Do
not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
Use only premium-grade unleaded fuel with a minimum
octane rating of 95 (N.O.R.M.) and 85 (N.O.M.M.).
Release 00/2001 - 11 1 - 3 - 00
1.2.2 ENGINE OIL 1.2.3 BRAKE FLUID

NOTEThis 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. Wash your hands below applies to both braking systems.
thoroughly after handling engine oil.
Do not release into the environment. CAUTION
Dispose of engine oil through the nearest waste oil
Brake fluid is an irritant. Avoid contact with eyes or
reclamation firm or through the supplier.
skin.
Wear latex gloves during servicing.
In the event of accidental contact, wash affected
Change engine oil after the first 1000 km (625 mi) and body parts thoroughly. In the event of accidental
every 7500 km (4687mi) (*), see 2.13 (ENGINE OIL AND contact with eyes, contact an eye specialist or seek
FILTER CHANGE) afterwards. medical advice.
(*) = On motorcycles used in competition trials, oil should DO NOT RELEASE BRAKE FLUID INTO THE
be changed every 3750 km (2343 mi). ENVIRONMENT.
(Recommended) engine oil, see 1.6 (LUBRICANT KEEP AWAY FROM CHILDREN.
CHART)Front fork fluid
When handling brake fluid, take care not to spill it
onto plastic or paint-finished parts or they will
CAUTION damage.
Prolonged or repeated contact with front fork fluid Check brake fluid level every 7,500 km (4687 mi),
may cause severe skin damage. Wash your hands see 2.16 (CHECKING AND TOPPING UP FRONT
thoroughly after handling front fork fluid. Dispose of BRAKE FLUID LEVEL). See also 2.17 (CHECKING
front fork fluid through the nearest waste oil AND TOPPING UP REAR BRAKE FLUID LEVEL).
reclamation firm or through the supplier. Change brake fluid every two years, see 2.21
Wear latex gloves during servicing. (CHANGING THE FRONT BRAKE FLUID) and 2.22
Front suspension response can be modified to a (CHANGING THE REAR BRAKE FLUID).
certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil grade (Recommended) brake fluid, see 1.6 (LUBRICANT
is SAE 20 W. Different oil grades can be selected to CHART).
obtain a particular suspension response. (Choose
SAE 5W for a softer suspension, 20W for a stiffer CAUTION
suspension). The two grades can also be mixed in Do not use any brake fluids other than the specified
varying solutions to obtain the desired response. type. Never mix different types of fluids to top up
F.A. or Fork have special properties, level, as this will damage the braking system.
which enable them to retain virtually the same Do not use brake fluid from containers which have
viscosity regardless of temperature to give constant been kept open or in storage for long periods.
damping response. Any sudden changes in play or hardness in the brake
levers are warning signs of problems with the
(Recommended) front fork oil, see 1.6 (LUBRICANT
hydraulic circuits.
CHART).
Ensure that the brake discs and brake linings have
not become contaminated with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental ingress of water or dust into the
circuit. Wear latex gloves when servicing the
hydraulic circuit.
1 - 4 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
1.2.4 COOLANT 1.2.5 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. Avoid contact with eyes or
with abundant water and seek medical advice. In the
skin.
event of ingestion, induce vomiting, rinse mouth and
In the event of accidental contact, wash affected
throat with abundant water and seek medical advice
body parts thoroughly. In the event of accidental
immediately.
contact with eyes, contact an eye specialist or seek
DO NOT RELEASE INTO THE ENVIRONMENT. medical advice.
KEEP AWAY FROM CHILDREN. DO NOT RELEASE CLUTCH FLUID INTO THE
ENVIRONMENT.
CAUTION KEEP AWAY FROM CHILDREN.
Take care not to spill coolant onto hot engine parts. It
may ignite and produce invisible flames. Wear latex When handling clutch fluid, take care not to spill it
gloves when servicing. onto plastic or paint-finished parts or they will
Do not ride when coolant is below the minimum level. damage.
Check clutch fluid level every 7,500 km (4687 mi),
Check coolant level before each ride and every 15000 km see 2.18 (CHECKING AND TOPPING UP CLUTCH
(9375 mi), see 2.14 (CHECKING AND TOPPING UP FLUID LEVEL). Change clutch fluid every two years,
COOLANT LEVEL) as part of routine maintenance. see 2.23 (CHANGING THE CLUTCH FLUID).
Change coolant every two years, see 2.15 (COOLANT
CHANGE). (Recommended) clutch fluid, see 1.6 (LUBRICANT
Coolant mixture is a 50% solution of water and anti- CHART).
freeze. This is the ideal solution for most operating
temperatures and provides good corrosion protection.
This solution is also suited to the warm season, as it is
WARNING
less prone to evaporative loss and will reduce the need Do not use any clutch fluids other than the specified
for top-ups. In addition, less water evaporation means type. Never mix different types of fluids to top up
fewer minerals salts depositing in the radiator, which level, as this will damage the clutch system. Do not
helps preserve the efficiency of the cooling system. use clutch fluid from containers which have been
When temperature drops below zero degrees centigrade, open or kept in storage for long periods. Any sudden
check the cooling system frequently and add more anti- changes in play or hardness in the clutch lever are
freeze (up to 60% maximum) to the solution. warning signs of problems with the hydraulic circuit.
Use distilled water in the coolant mixture. Tap water will Make sure the clutch hose is not twisted or worn.
damage the engine. Avoid accidental ingress of water or dust into the
circuit.
(Recommended) engine anti-freeze, see 1.6 Wear latex gloves when servicing the hydraulic
(LUBRICANT CHART). circuit.
Refer to the chart given below and add water with the
quantity of anti-freeze to obtain a solution with the
desired freezing point:
Freezing point °C Coolant

% of volume
-20° 35
-30° 45
-40° 55
NOTE The different brands of anti-freeze available on

the market have varying specifications. Always read
product label to determine the degree of protection
afforded.
WARNING
Use only nitrite-free anti-freeze and corrosion
inhibitors with a freezing point of –35°C as a
minimum.
Release 00/2001 - 11 1 - 5 - 00
1.2.6 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.
ventilated area. Never operate the engine in an enclosed Twisty roads and gradients are ideal to break in engine,
place. suspension and brakes effectively.
Use an exhaust emission extraction plant when working Varying speed frequently is also recommended. This will
indoors. vary the amount of stress placed on vehicle components
continuously, allowing engine parts to cool down when
CAUTION less stressed. While it is important to put a certain
Exhaust emissions contain carbon oxide, which is a amount of stress to engine components during the
poisonous gas and may lead to loss of conscience or running-in period, it is equally important to spare the
even death. engine at this stage in vehicle's life.
Operate the engine out of doors or, if working
indoors, use an exhaust emission extraction plant. WARNING
Top acceleration performance is only obtained after
1.2.7 HOT COMPONENT PARTS covering the first 1500 km (937 mi).
Observe the following instructions:
CAUTION
The engine and exhaust component parts become Avoid harsh accelerations and do not flip the throttle
hot when the engine is running and will stay hot for open abruptly when the engine is running at low speed,
some time after the engine has been stopped. both during and after the running-in period.
Wear heat gloves before handling these components Apply the brakes gently and avoid hard, prolonged
or allow for the engine and exhaust system to cool braking until covering the first 100 km (62 mi).
down before proceeding. This will allow the brake pad lining to wear in properly
rubbing on the brake discs.
Never exceed 6000 rpm (see chart) during the first
1000 km (625 mi).
WARNING
After covering the first 1000 km (625 mi), perform the
checks listed in the “post running-in” column of the
PERIODIC MAINTENANCE CHART (see 2.1.1). Failure
to perform these checks may lead to personal injury
to yourself or third persons, or vehicle damage.
After the first 1000 km (625 mi) and until covering the
first 1500 km (937 mi), a somewhat brisker riding style
is acceptable. Vary your speed and use peak
acceleration for just a few instants, to allow the different
components to become properly seated against one
another.
Never exceed 7500-rpm engine speed (see table).
After 1500 km (937 mi), the engine will be ready for a
more demanding use. However, never exceed the
maximum engine speed allowed (10500 rpm).
Recommended maximum engine speed

Distance covered in
rpm
Km(mi)
0-1000 (0-625) 6000
1000-1500 (625-937) 7500
over 1500 (937) 10500
1 - 6 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
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.
1.5 SPECIFICATIONS
DIMENSIONS
Overall length 2170 mm
Overall width 740 mm
Overall height (front fairing) 1240 mm
Seat height 820 mm
Wheelbase 1435 mm
Minimum ground clearance 135 mm
Weight in running order (including fuel, coolants and 235 kg
ENGINE
4-stroke longitudinal 60° V twin-cylinder engine fitted
Type
with 4 valves per cylinder and 2 overhead camshafts
Number of cylinders 2
Total displacement 997.6 2cm³
Max rated crankshaft power 86,5 kW (118 HP) at 9250 rpm
Max rated crankshaft power 77 kW (104 HP) at 9250 rpm
Max torque 96.5 Nm (9.78 kgm) at 7250 rpm
Max torque 90 Nm (9.17 kgm) at 7000 rpm
Bore/stroke 97 mm / 67.5 mm
Compression ratio 11.8 ± 0.5: 1
Average piston speed 22,5 m/s at 10000 rpm
Camshaft during intake stroke 262°, valve lift = 10.6 mm
Camshaft during exhaust stroke 259°, valve lift = 10.6 mm
Timing advance (with 1-mm valve clearance) intake valve opens 20° before TDC
intake valve closes 59°after BDC
exhaust valve opens 64° before TDC
exhaust valve closes 15° after BDC
Valve clearance, intake 0.12-0.17 mm

Valve clearance, exhaust 0.23-0.28 mm
# Idling rpm 1250 ± 100 rpm
# Top speed rpm 10500 ± 100 rpm
Ignition computer ignition management
Starter electric starter
5° before TDC upon starting, advance is further
Spark advance:
increased to suit specific consumption.
Starter motor 12 V / 0.9 kW
Transmission ratio of starter motor i= 49/9 * 30/11 * 64/30 = 31.677
hydraulically operated wet multi-plate clutch with control
lever on left-hand handlebar and PPC device
Clutch
- # 9 friction plates, 3.5 mm thick
- # 9 clutch plates, 1.5 mm thick
CONTINUED ➤
Release 00/2001 - 11 1 - 7 - 00
ENGINE
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
Air cleaner with dry filter cartridge
Cooling system liquid cooling
Transmission ratio of coolant pump i wp = 28/27 * 28/28 = 1.037
Coolant pump delivery rate (when thermal expansion valve
90 l/min at 9000 rpm
is open)
Thermal expansion valve starts to open at 65 ± 2 °C (149 ± 5 °F)
Dry engine weight ~ 67 kg
CAPACITIES
Fuel (including reserve) 20.5 l
Fuel reserve 4±1l
Engine oil oil change 3700 cu cm oil and filter change 3900 cu cm
Front fork oil (each leg) 553 ± 2,5 cu cm
Coolant 2.5 l (50% water + 50% ethylene glycol anti-freeze)
Seat twin-seat 2
Max carrying load (rider + pillion rider + luggage) 182 kg
DRIVE
Secondary drive
Gear Total drive ratio
ratio
1st 13.000
14/35 = 1: 2.500
2nd 9.102
Primary drive ratio 16/28 = 1: 1.750 Final drive ratio
DRIVE RATIOS 3rd 7.117
31/60 = 1: 1.935 19/26 = 1: 1.368 16/43 = 1: 2.687
4th 5.674
22/24 = 1: 1.091
5th 4.975
23/22 = 1: 1.957
6th 4.431
27/23 = 1: 0.852
# Sprocket 16 teeth
Chain drive Endless O-ring chain, type 525, size 5/8" x 5/16"
FUEL SYSTEM
Type Electronic fuel injection
Venturi Ø 51 mm
INDUCTION
Type Indirect (MULTIPOINT) injection
Premium-grade unleaded petrol, minimum octane rating
Fuel
95 (N.O.R.M.) and 85 (N.O.M.M.)
FRAME
Dual-beam design made from light alloy cast members
Type
and extruded members
Rake 25.7°
Trail 97 mm
SUSPENSION
Adjustable telescopic UPSIDE-DOWN hydraulic fork
Front
with Ø 43-mm legs
Travel 120 mm
CONTINUED ➤
1 - 8 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
Light-alloy single-sided swinging arm and adjustable oil/

Rear
air-sprung mono-shock absorber
Wheel travel 120 mm
BRAKES
Twin-disc brake with Ø 300-mm floating discs, four-
Front
piston calipers with Ø 30-mm/ Ø 34-mm diameter
Rear Disc brake - Ø 255 mm, dual-piston caliper - Ø 28
WHEELS
Type Light-alloy wheel rim
Front 3.50 x 17"
Rear 5.50 x 17"
TYRES
Pressure in kPa
(bar)
Wheel Brand Type Size Recommended

solo riding
Front (standard) METZELER ME Z4 B 120/70ZR17” 250 (2.5)
Rear (standard) METZELER ME Z4 180/55ZR17” 290 (2.8)
Front (standard) MICHELIN PILOT SPORT 120/70ZR17” ❖ 250 (2.5)

Rear (standard) MICHELIN PILOT SPORT 180/55ZR17” ❖ 290 (2.8)
Front (option) METZELER ME Z3 120/70ZR17” ❖ 250 (2.5)
Rear (option) METZELER ME Z3 180/55ZR17” ❖ 290 (2.8)
Front (option) PIRELLI MTR21A 120/70ZR17” 250 (2.5)
Rear (option) PIRELLI MTR22 180/55ZR17” 280 (2.8)
= Road use ; ❖ = Competition
SPARK PLUGS
Standard NGK R DCPR9E
Electrode gap 0.6 -0.7 mm
Resistance 5KΩ
ELECTRIC SYSTEM
Battery rating 12 V - 12 Amps
Main fuses 30A
Auxiliary fuses 15A
Generator (permanent-wound magnet type) rating 12 V - 400 W
Starter motor rating 12 V / 0.9 kW
CONTINUED ➤
Release 00/2001 - 11 1 - 9 - 00
BULBS
Low beam (halogen lamp) 12 V - 55 / 55 W H4
High beam (halogen lamp) 12 V - 60 W H3
Front parking light 12 V - 5 W
Direction indicators 12 V - 10 W
Rear parking light / plate / stop light 12 V - 5/21 W
Rev. counter light LED
Right-hand multi-purpose display light LED
Left-hand multi-purpose display light LED
WARNING LIGHTS
Neutral light LED
Direction indicators LED
Low fuel LED
High beam LED
Stand light LED
Engine oil pressure LED
Red line LED
1.6 LUBRICANT CHART (Recommended) aerosol chain lubricant: CHAIN

(Recommended) engine oil: EXTRA RAID 4, SAE SPRAY or CHAIN LUBE.
15W - 50 or TEC 4T SAE 15W - 50. As an
alternative to recommended oils, top brand oils meeting CAUTION
or exceeding CCMC G-4, A.P.I. SG. specifications can be Use new brake fluid only.
used.
(Recommended) brake fluid: F.F., DOT 5 (DOT 4
(Recommended) fork oil: front fork oil F. A . 5 W or
F.A. 20W. compatible) or BRAKE 5.1, DOT 5 (DOT 4
As an alternative, use FORK 5W or FORK compatible).
20W. When you wish to obtain an intermediate response
between those offered by F.A. 5W and F.A. 20W CAUTION
Use new clutch fluid only.
oils or FORK 5W and FORK 20W oils,
you may mix the different products as follows: (Recommended) clutch fluid: F.F., DOT 5 (DOT 4
SAE 10W = F.A. 5W 67% of volume, + F.A. 20W
compatible) or BRAKE 5.1, DOT 5 (DOT 4
33% of volume, or
compatible).
FORK 5W 67% of volume, + FORK
20W 33% of volume.
CAUTION
SAE 15W = F.A. 5W 33% of volume, + F.A. 20W Use only nitrite-free anti-freeze and corrosion
67% of volume, or inhibitors with a freezing point of -35°C as a
FORK 5W 33% of volume, + FORK minimum.
20W 67% of volume.
(Recommended) engine coolant: ECO-BLU -
Bearings and other lubrication points
40°C or COOL.
(recommended):
AUTOGREASE MP or GREASE 30.
As an alternative to recommended grease, use top brand
rolling bearing grease that will resist a temperature range
of -30°C…+140°C, with dropping point 150°C…230°C,
high corrosion protection, good resistance to water and
oxidisation.
Battery lead protection: use neutral grease or vaseline.
1 - 10 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
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
are available at request, see 1.7.2 (PRODUCT
APPLICATIONS).
1.7.1 PRODUCT FEATURES
Product Usage and features

Blue LOCTITE® 243 Threadlocking adhesive for nuts and bolts up to M36, provides
medium-strength fit.
Suitable for use on less than perfectly degreased parts.
Cure time varies with temperature and substrate up to one hour
maximum.
Withstands temperatures in the – 55 to 150 °C range (– 99 to
302 °F).
High-strength retaining compound for bolts.
Green LOCTITE® 648 Cure time varies with temperature and substrate up to twelve
hours maximum.
Withstands temperatures in the – 55 to 175 °C range (– 99 to
347 °F).
Mated parts must be heated up to 250 °C (482 °F) before they
can be disassembled.
Solvent-free sealant. Eliminates the need for gaskets in joints
Orange LOCTITE® 574
exposed to high friction and where a specified gap needs to be
maintained between parts.
Liquid sealant, cures within a few hours after assembly when in
contact with metal to form a gasket whose surface structure
matches mating surfaces.
Resists temperatures from – 55 to 200 °C ( – 99 to 392 °F),
inhibits corrosion of sealed surfaces.
LOCTITE® 8150
High-temperature assembly paste.
LOCTITE® Anti Seize 15378

Lubricant and corrosion inhibitor, resists high temperatures.
When sprayed on both parts, provides long-term maintenance-
free operation of contact surfaces.
Inhibits corrosion.
MOLYKOTE® G-n
Lubricating compound for use on heavy-duty stressed parts, for
base lubrication and on fits under pressure to avoid corrosion
and sticking.
Apply on both contact surfaces.
SILASTIC 732 RTV
Sealant, prevents ingress of water into flywheel casing.
Release 00/2001 - 11 1 - 11 - 00
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).
- Headstock bearings.
- Headstock top bush.
- Roller bearings of timing idler gear.
Engine oil (*) 8116050 - Thrust washer of lower balancing shaft.
- Clutch disengagement shaft.
- Valve stems and buckets.
- Valve guide seals.
- Casing location of camshafts.
- Timing chain tensioner.
- Compound starter gear and idler gear pins.
- Freewheeling clutch-to-gear contact surfaces.
- Inner contact surface of freewheeling clutch.
- Steering retaining bush.

- Rear brake caliper detent.
- Front sprocket.
- Rear brake pedal spindle.
- Cooling fans to support.
- Fuel return line fitting.
- Fuel filler cap.
- Throttle cable pulley nut.
- Throttle cable bracket screws.
- Throttle valve spindle nut.
LOCTITE® 243 (**) 0897651 - Throttle position sensor screws.
- Coolant pump central screw.
- Cylinder connecting bracket screws.
- Engine casing bearing screws.
- Cylinder stud bolts.
- Crankshaft position sensor screws.
- Index lever and plate screws.
- Crankshaft nut.
- Timing gear screws.
- Nut securing counterweight to upper balancing shaft.
- Lower screw of timing idler gear bearing mount.
- Coolant pump idler gear shaft.
- Engine oil pump plug.
- Clutch gear metal plate screws.
- Freewheeling clutch to magnet wheel (on assembly).
- Freewheeling clutch screws.
LOCTITE® 648 (**) 0899788
- Clutch housing nut.
- Screw securing counterweight to lower balancing shaft.
- Flywheel rotor inner cone.
- Flywheel retaining screw.
1 - 12 - 00 Release 00/2001 - 11
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GENERAL INFORMATION

- Coolant thermal switch.
- Coolant thermistors.
Orange LOCTITE ® 574
0899784 - Contact screw of neutral switch.
(**)
- Outer surface of engine oil pump motor.
- Cylinder footprint on crankcase.
- Transmission primary and secondary shaft.
- Crankcase locations of transmission primary and secondary
LOCTITE Anti Seize
®
0297434 shafts.
15378 (**)
- Crankshaft and balancing shaft.
- Crankcase location and spline of transmission primary shaft.
- Crankcase locations of main bearing sleeves.
- Main bearing sleeves.
- Crankcase bearing locations.
- Coolant pump shaft.
- Valve guide seats in cylinder head.
- Valve guide edges.
MOLYKOTE® G-n (**) 0297433
- Crankcase locations of crankshaft and balancing shaft bearing
sleeves.
- Crankcase locations of crankshaft and balancing shaft.
- Bores accommodating piston pins.
- Camshaft cams.
- Starter motor mount.
- Cable bracket on flywheel cover.
SILASTIC 732 RTV (**) 0297386
- Camshaft sensor cable.
- Front and rear wheel seals (on assembly).
- Swinging arm shaft bearings (on assembly).
- Clutch master cylinder actuating rod (on assembly).
- Rear wheel shaft thread.
- Steering head bearings.
Bimol Grease 481 8116053
- Rear brake master cylinder actuating rod (on assembly).
- Rear brake pedal spindle.
- Thrust washer of timing idler gear.
- Upper balancing shaft seal.
- Starter motor gear.
LUBERING Grease ST 8116038 - Choke control (on assembly).
- Handlebar counterweight rubber (on assembly).
- Throttle cable adjuster rubbers (on assembly).
- Gearshift lever rubber (on assembly).
- Lower retaining pins of radiators to rubber mounts (on
AP-LUBE temporary
- assembly).
lubricant
- Breather hose to radiator and three-way manifold (on assembly).
- Coolant hose couplings to radiators (on assembly).
- Water and fuel drain hoses to fuel flange (on assembly).
- Throttle body torsion springs (on assembly).
DID CHAIN LUBE - Drive chain.
Grease
“Biosolvent” frame
8116031 - For washing the engine oil tank.
detergent
Cyanoacrilic paste
8116945 - Airbox gasket (on assembly).
“ACRILON 28”
MOTUL MOTOWASH
- - For cleaning frame and swinging arm.
Degreaser
Release 00/2001 - 11 1 - 13 - 00
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).
- Side body panel rubbers (on assembly).
- For cleaning bottom part of engine.
- Starter relay rubber (on assembly).
- Cush drive to rear wheel sprocket (on assembly).
- Engine oil cooler rubbers (on assembly).
Alcohol -
- Hose coupling to coolant filler cap (on assembly).
- For cleaning engine oil tank before decal application.
- Instrument panel/front fairing rubbers (on assembly).
- Rear brake pedal rubber (on assembly).
- Hoses to fuel filter (inside fuel tank) (on assembly).
- Coupling connecting coolant radiators (on assembly).
- Fuel lines to fuel tank (on assembly).
- For cleaning fuel tank before decal application.
(*) = see 1.6 (LUBRICANT CHART).

(**) =see 1.7.1 (PRODUCT FEATURES).
1 - 14 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
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. If needed, order the brand-
specific special tools (see Special Tools Catalogue).
WARNING
Always read the instructions supplied with the
special tools before use.
1.8.1 SUNDRY TOOLS

Ref. Tool designation and application Part number
Full frame kit including:
– split sleeve for fork seal fitment
1 8140203
– socket for steering adjustment
– socket for swinging arm spindle – engine mount adjustment
2 Tool for chain removal/fitment 8140192
3 Centre stand 8140176
4 Axone 2000 8140595
5 Front wheel stand 8140195
6 Exhaust emission tester 8140196
7 Emission tester tube kit 8140202
8 Tool board 8140199
9 Bearing extractor kit 10 - 30 mm Ø 8140180
Release 00/2001 - 11 1 - 15 - 00
1.8.2 ENGINE TOOLS
Ref. Tool designation and application Part number

1 Full engine tool kit 8140175
2 Drift to fit transmission secondary shaft seal 0277680
3 Drift to fit seal into secondary balancing shaft location 0277660
4 Drift to fit seal into coolant pump shaft location 0277670
5 Drift to fit sliding ring into coolant pump shaft location 0877257
6 Valve guide extractor 0277510
7 Drift for valve guide seal fitment 0277695
8 Drift for valve guide fitment 0277210
9 Drift to fit transmission shaft and clutch shaft seals 8140155
10 Drift to fit main balancing shaft bearing sleeves 0277729
11 Crankshaft bearing sleeve extractor 0277720
12-14 Drifts to fit crankshaft bearing sleeves 0277725
13 Drift to fit clutch cover – crankshaft bearing sleeves 0277727
15 Spark plug tool 8140177
16 Flywheel cover puller 0277252
17 Hexagon nut for flywheel removal 0277780
18 Threaded rod to hold crankshaft in TDC position 0240880
19 Transmission secondary shaft guide sleeve 0277308
20 Vacuum gauge 8140256
21 Fuel/oil pressure gauge 8140181
22 Rotor bolt extractor 8140182
23 Clutch anti-rotation tool 0277881
8140156 + 8140157 +
24 Extractors for clutch cover bearing sleeves
0276377
25 Tool to compress valve springs 0276479
26 Tool for valve removal/fitment 8140179
27 Adhesive template for tool board 8157143
28 Engine lifting eyebolt 8140183
29 Primary drive nut extractor 8140184
30 Clutch plate extractors 8140185
31 Engine stand 8140188
32 Engine stand pedestal 8140187
33 Tool to compress piston rings 8140186
1 - 16 - 00 Release 00/2001 - 11
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GENERAL INFORMATION

SERVICE STANDS
1.9.1 PLACING THE MOTORCYCLE ON THE FRONT

WHEEL STAND 1
2
Slide both pins (1) of the front wheel stand (3) into the
holes (2) at front fork bottom end at the same time.
Put one foot on the front end of the stand (3). 3
Press down on stand (3) until it rests fully on the
ground.
Release 00/2001 - 11 1 - 17 - 00

CENTRE STAND
Read 0.5.1 (GENERAL PRECAUTIONS AND
INFORMATION) carefully. 2
Part no. 8140176 (complete stand).
THE LOWER FAIRING).
Place the motorcycle on the front wheel stand , 7
see 1.9.1 (PLACING THE MOTORCYCLE ON THE
FRONT WHEEL STAND).
Hold the nut (1) steady on the inside.
Release and remove the rear upper right-hand 1 6
engine mounting bolt (2).
Torque wrench setting for nut (1) / bolt (2):

50 Nm (5.0 kgm). 5 19
3 4
NOTE The bolt (2) on the left-hand side is longer. 12
17
Collect the nut (1).
Slide the upper right-hand mounting boss (3) into the
upper hole on the right-hand side.
Fit the stud bolt (4) into the upper hole on the left-hand
side and screw it fully into the mounting boss (3). 14
Screw the upper left-hand mounting boss (5) fully onto
Hold the nut (6) on the inside steady. 11 16
Release and remove the rear lower engine mounting
bolt (7).
Torque wrench setting for nut (6) / bolt (7):

50 Nm (5.0 kgm).
20
NOTE The bolt (7) on the right-hand side is longer. 10
Slide the lower right-hand mounting boss (8) into the 9
lower hole on the right-hand side. 8
Fit the stud bolt (9) into the lower hole on the left-hand 13 18
side and screw it fully into the mounting boss (8).
Screw the lower left-hand mounting boss (10) fully onto
Fit the bracket (11) onto the mounting bosses (3-8).
The longer portion of the bracket base must be facing 15 16
11
forward.
Snug the two washers (12 - 13) and nuts (14 - 15)
finger-tight.
Tighten both nuts (14 - 15).
Fit the bracket (16) onto the mounting bosses (5-10)
with the longer portion of the base facing forward.
Snug the two washers (17 - 18) and nuts (19 - 20)
finger-tight.
Tighten both nuts (19 - 20).
Remove the wheel stands.
1 - 18 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
1.10 HOW TO APPLY THE DECALS

Whenever you remove any body parts:
WARNING 4
2
Handle plastic and paint-finished parts with care to
avoid scratching or damage. 3
Proceed carefully.
Do not damage the snap-on tabs and matching
recesses.
Strictly follow the instructions below.
We recommend using:
- a medium spatula (1); 1
NOTE Soft spatulas – such as those commonly used
on windscreen wipers - will leave excess water under the
decal.
- a sponge or spray dispenser (2) and water.
NOTE Add water with 1-3% detergent and shake to
obtain frothing.
3
Apply the decals as follows:
Place a decal (3) on a bench with the adhesive face up.
Keep the decal well stretched on the bench and
remove the protective film (4).
NOTE A spray dispenser (2) will work best.
If you are using a sponge, dab the decal surface lightly or
the adhesive will deteriorate.
Wet the adhesive face with soap water.
Place the decal (3) in the proper position on the part
you wish to decorate.
NOTE Always apply the spatula to the decal centre and
move it towards the edges with regular movements.
Rub the spatula (1) across the decal surface pressing
moderately until removing excess soap and water from
under the decal.
NOTE Take care not to lift the decal corners and edges
in the process.
Dry up the decal with an absorbent cloth. Apply cloth in 1
the centre and move outwards.
Rub the decal using the spatula with firm, regular
strokes. Apply the spatula in the centre and move
outwards. Take special care with corners and edges to
ensure proper adhesion across the whole surface.
Release 00/2001 - 11 1 - 19 - 00
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. 5
Pass the spatula across the decal again – particularly
over corners and edges – to ensure proper adhesion.
NOTE Decals applied using water will take about 48
hours to stick to part permanently.
Once you have removed the application tape, check for
any air trapped underneath the decal.
If there are any air bubbles:
Prick a hole on the edge (7) of the air bubble using a
pin or a cutter (6).
Apply the spatula (1) at the opposite end and move it
across the bubble to squeeze air out.
* Application tape is used to facilitate the application of

brands and lettering in the proper position and keeps
the sticker stiffer during application.
1 - 20 - 00 Release 00/2001 - 11
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GENERAL INFORMATION
1.11 TORQUE FIGURES

The table below reports the standard torque figures for C B
metric size screws and bolts in accordance with ISO A
standards. D
Screw or Tightening torque

bolt Spanner
thread Nm kgm
M6 10 6 0.6
M8 12 15 1.5
M 10 14 30 3.0
M 12 17 55 5.5
M 14 19 85 8.5
M 16 22 130 13.0
For model-specific torque figures, see 2.41 (FASTENERS).

Unless otherwise specified, torque figures are intended
for application to clean, dry threads at room temperature.
NOTE Follow the instructions below to avoid distortion
and/or improper fit:
Screw all fasteners finger-tight.
Tighten fasteners in a cross pattern - (A) and (B); (C)
and (D) - to half the specified torque.
Repeat sequence tightening to specified torque.
NOTE This way, the load generated by the fasteners is
applied evenly across joint surface.
Release 00/2001 - 11 1 - 21 - 00
NOTES
1 - 22 - 00 Release 00/2001 - 11
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PERIODIC MAINTENANCE AND ADJUSTMENTS
PERIODIC MAINTENANCE AND

ADJUSTMENTS 2
Release 00/2001 - 11 2 - 1 - 00
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PERIODIC MAINTENANCE 2.17 CHECKING AND TOPPING UP REAR

AND ADJUSTMENTS BRAKE FLUID LEVEL .................... 2-30-00
2.18 CHECKING AND TOPPING UP CLUTCH

CONTENTS FLUID LEVEL................................. 2-32-00
2.19 BLEEDING THE BRAKE CIRCUITS 2-34-00

2.1 PERIODIC MAINTENANCE CHART . 2-4-00
0
2.1.1 PERIODIC MAINTENANCE CHART..... 2-5-00 2.20 BLEEDING THE CLUTCH............... 2-38-00
2.2 LUBRICATION POINTS .................. 2-7-00 2.21 CHANGING THE FRONT BRAKE
FLUID ............................................ 2-39-00
2.3 MULTIFUNCTION COMPUTER ........ 2-8-00
2.3.1 KEY ........................................................ 2-8-00 2.22 CHANGING THE REAR BRAKE
1 2.3.2 PROGRAMMING BUTTONS................. 2-8-00

2.3.3 INSTRUMENT PANEL LIGHT
FLUID ............................................ 2-40-00
2.23 CHANGING THE CLUTCH FLUID .. 2-41-00

INTENSITY............................................. 2-8-00
2.3.4 HOW TO TOGGLE BETWEEN ODOMETER/ 2.24 ADJUSTING THE FRONT BRAKE LEVER
2 TRIP METER.......................................... 2-9-00 AND CLUTCH LEVER .................... 2-41-00

2.3.5 MEASUREMENT UNITS (KM/MI, L /GAL, 2.25 ADJUSTING REAR BRAKE LEVER
°C/°F) ..................................................... 2-9-00 PLAY.............................................. 2-42-00
2.3.6 HOW TO TOGGLE BETWEEN FUEL LEVEL/
AIR TEMPERATURE INDICATION....... 2-9-00 2.26 ADJUSTING THE GEAR SHIFT
3 2.3.7 SETTING THE CLOCK (HOURS AND

MINUTES) ............................................ 2-10-00
LEVER ........................................... 2-42-00
2.27 CHECKING BRAKE PADS FOR

2.3.8 INSTRUMENT AND INDICATOR WEAR............................................. 2-43-00
CHART................................................. 2-10-00
4
2.28 STEERING ..................................... 2-44-00
2.4 BATTERY....................................... 2-13-00
2.28.1 CHECKING PLAY IN THE BEARINGS. 2-44-00
2.4.1 CLEANING AND CHECKING BATTERY 2.28.2 ADJUSTING PLAY IN THE BEARINGS 2-45-00
TERMINALS AND LEAD
CONNECTIONS................................... 2-14-00 2.29 INSPECTING THE FRONT
5 2.4.2 CHARGING THE BATTERY................ 2-15-00

2.4.3 LONG INACTIVITY .............................. 2-15-00
SUSPENSION ................................ 2-47-00
2.29.1 FRONT SUSPENSION ....................... 2-47-00
2.29.2 FRONT FORK ADJUSTMENT ........... 2-48-00
2.5 ELECTRIC COMPONENTS ............. 2-15-00
2.30 REAR SWINGING ARM ................. 2-49-00
6
2.6 JUMP-STARTING .......................... 2-16-00
2.30.1 SWINGING ARM ADJUSTMENT ....... 2-49-00
2.7 SPARK PLUGS............................... 2-17-00
2.31 REAR SUSPENSION INSPECTION 2-50-00
2.8 LIFTING THE FUEL TANK ............. 2-19-00 2.31.1 REAR SUSPENSION.......................... 2-50-00
2.31.2 REAR SHOCK ABSORBER
7
2.9 DRAINING THE FUEL TANK ......... 2-20-00
ADJUSTMENT..................................... 2-50-00
2.10 AIR CLEANER................................ 2-21-00 2.31.3 INSPECTING THE REAR SUSPENSION
2.11 THROTTLE ................................... 2-22-00 LINKAGE SYSTEM ............................. 2-51-00
2.11.1 CHECKING FOR THROTTLE PROPER 2.32 FRONT WHEEL .............................. 2-52-00
8 OPERATION........................................ 2-22-00
2.11.2 IDLING ADJUSTMENT........................ 2-22-00
2.33 REAR WHEEL ................................ 2-52-00
2.11.3 THROTTLE CABLE PLAY 2.34 EXHAUST MANIFOLD NUTS ......... 2-53-00
ADJUSTMENT..................................... 2-23-00
2.35 DRIVE CHAIN ................................ 2-54-00
9 2.12 CHECKING AND TOPPING UP ENGINE
OIL LEVEL ..................................... 2-24-00
2.35.1 CHAIN SLACK INSPECTION.............. 2-54-00
2.35.2 CHECKING CHAIN AND SPROCKETS
2.13 ENGINE OIL AND FILTER CHANGE . 2-25-00 FOR WEAR.......................................... 2-55-00
2.35.3 CHAIN SLACK ADJUSTMENT .......... 2-55-00
2.14 CHECKING AND TOPPING UP COOLANT 2.35.4 DRIVE CHAIN GUIDE PLATE
LEVEL............................................ 2-27-00 INSPECTION ....................................... 2-56-00
2.15 COOLANT CHANGE....................... 2-28-00 2.35.5 CHAIN SLIDER INSPECTION ............. 2-56-00
2.16 CHECKING AND TOPPING UP FRONT 2.36 TYRES .......................................... 2-57-00

BRAKE FLUID LEVEL .................... 2-29-00
2 - 2 - 00 Release 00/2001 - 11
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2.37 FUEL LINES ................................. 2-58-00
2.38 BRAKE AND CLUTCH LINES ........ 2-58-00
2.39 COOLANT PIPES........................... 2-58-00
2.40 MAINTAINING FASTENERS AT THE

CORRECT TIGHTENING TORQUE 2-59-00
2.41 FASTENERS ................................. 2-60-00

2.41.1 CLEANING AND LUBRICATION......... 2-66-00
Release 00/2001 - 11 2 - 3 - 00
PERIODIC MAINTENANCE AND ADJUSTMENTS RST mille
Outlined in this section are the recommended procedures

for the periodic maintenance of the key components of
the motorcycle.
CAUTION
Before proceeding to maintain or inspect the
motorcycle, stop the engine and remove the ignition
switch key. Ensure that the engine and exhaust
system have cooled down. Wherever possible, place
the motorcycle on firm and level ground and lift it
using suitable equipment.
Be careful of any parts of the engine or exhaust
system which may still be hot. Contact with hot
engine or exhaust parts may cause severe burns.
All component parts of the vehicle are inedible.
Do not bite, suck, chew or swallow any vehicle parts.
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.
1
WARNING
Upon reaching the first 1000 km (625 mi) and every
7500 km (4687 mi) afterwards, a wording "SERVICE"
(1) will appear on the right-hand display.
When this occurs, look up the periodic maintenance
chart and perform the required maintenance. Note
that motorcycles used in competition trials need to
be maintained more frequently, see 2.1.1 (PERIODIC
MAINTENANCE CHART).
2 - 4 - 00 Release 00/2001 - 11
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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
Spark plugs c(*) e(*)
Stand
Throttle cables c c
Connecting rod and rear suspension
bearings
c
Steering bearings and steering c c

Wheel hub bearings c
Air cleaner c e
Engine oil filter e(*) e(*)
Engine oil filter (in fuel tank) d d
Front fork c c
Lights operation / setting c
Valve clearance R f
Throttle body shaft, grease c c
Brake system c c
Cooling system c
Lighting system c c
Safety switches c c
c
Clutch fluid
every 2 years: e
c
Brake fluid
every 2 years: e
c
Coolant
every 2 years:e
Front fork oil After the first 7500 km (4687 mi) and every 22500 km (14000 mi): e
Engine oil e e(*)
Brake pads If worn: e
Pistons every 5000 Km (3125 mi): c(**)
Tyres c c
Tyre pressures f every 15 days:c
Engine idling speed f f
Torque of nuts and bolts c c
Cylinder synchronisation c c
Suspension and suspension adjustments c c
Engine oil pressure LED each time engine is started: c
Brake fluid bleeding c
Clutch fluid bleeding c
CONTINUED ➤
Release 00/2001 - 11 2 - 5 - 00
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
Drive chain tension and lubrication every 1000 km (625 mi):c
Battery leads and terminals c c
Fuel lines c every 4 years: e
Final drive (chain, front and rear sprocket) c
Brake and clutch lines c every 4 years: e
Cooling system hoses c
Clutch wear c(*)
Brake pad wear before each ride and every 2000 km(1250 mi):c
c = inspect and clean, set or adjust, lubricate or replace as required; d = clean; e = replace; f= set or adjust.
Service the motorcycle more frequently when you ride in the rain, on dusty or bumpy roads, or in competition
trials.
( ) = THESE OPERATIONS CAN BE CARRIED OUT BY THE OWNER
(*) = If motorcycle is used in competition trials, change every 3750 km (2343 mi).
(**) = Only applies to motorcycles: - used on the racetrack – used in competitions.
2 - 6 - 00 Release 00/2001 - 11
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2.2 LUBRICATION POINTS KEY TO THE LAYOUT OF LUBRICATION POINTS

Proper lubrication is critical to ensuring smooth operation 1) Steering bearings
and preserving vehicle life. 2) Clutch lever spindle
3) Rider right-hand footpeg
NOTE Before lubricating any part, clean off any 4) Rider left-hand footpeg
oxidation deposits, grease, dirt or dust. 5) Passenger left-hand footpeg
Parts subject to oxidation must be lubricated with engine 6) Rear wheel spindle and hub bearings
oil or grease, see 1.6 (LUBRICANT CHART). 7) Drive chain
Lubrication points are shown in the “LAYOUT OF 8) Rear suspension levers
LUBRICATION POINTS”. 9) Side stand spindle
10) Passenger right-hand footpeg
11) Front wheel spindle and hub bearings
12) Swinging arm spindle
■ = Grease
▲ = Oil
2 ▲
5 ■
4 ■
■ 1
7 ■
8 ■
■ 9 6 ■
10 ■
11 ■ ■ 12
■ 3
Release 00/2001 - 11 2 - 7 - 00
2.3 MULTIFUNCTION COMPUTER
2.3.1 KEY B
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.
A
C
2.3.2 PROGRAMMING BUTTONS

Perform these operations when the motorcycle is at 1 2
standstill.
4
Performing these operations while riding may lead to an
accident.
5
NOTE The instructions given below are referred to the
motorcycle with the engine stopped.
Rotate the ignition switch key (1) to position . The

following instrument panel lights will come on within the
next three seconds:
- all warning LED lights;
- all backlighting LEDs; 6
- all segments of the left-hand display; 3
- all segments and messages of the right-hand
multifunction display.
This is part of an auto-test routine of LED, message,
segment and instrument operation.
After three seconds, all lights except the oil pressure LED
(2) (which stays on until engine is started up) will go
out and the display will show:
- total distance covered in kilometres (3);
- fuel level (4);
- coolant temperature (5) [characters "---" are displayed
until coolant warms up to 35° C (95° F)];
- time (hours and minutes format) (6).
2.3.3 INSTRUMENT PANEL LIGHT INTENSITY

There are three different settings available for instrument
panel light intensity: 100%; 60%; 25%.
2
How to set:
Set the light switch (1) to " ";

Set the light dip switch " "-" " (2) to " ".
NOTE Three seconds after the last selection, the SET
button will revert to odometer/trip meter toggle mode.
2 - 8 - 00 Release 00/2001 - 11
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Set the ignition switch to " " and press the SET
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/

TRIP METER
Left-hand display
Press and release the Set button (1). The display will
toggle between odometer and trip meter mode, that is,
show the motorcycle's total mileage (in kilometres or
miles) or the distance covered since the trip meter was
last reset.
NOTE Whenever the ignition switch is set to " ", the
display will revert to odometer mode (total mileage).
The trip meter is reset to zero as follows:
Set display to trip meter mode. 2 1
Hold down the SET button (1) for over three seconds
and all segments (2) will be reset to zero.
NOTE The trip meter will reset automatically each time
the battery is removed from the vehicle.
2.3.5 MEASUREMENT UNITS (KM/MI, L /GAL, °C/°F)
WARNING
Measurement units such as km/mi, l /gal, °C/°F are
set at the factory depending on country of
destination. Factory setting cannot be modified.
2.3.6 HOW TO TOGGLE BETWEEN FUEL LEVEL/

AIR TEMPERATURE INDICATION 2
3
Right-hand multifunction display
Press and release the MODE button (1). The display
will show the fuel level (2) or air temperature (3)
indication (in figures).
NOTE Whenever the ignition switch is set to " ", the
display will revert to fuel level indication (2).
1 1
Release 00/2001 - 11 2 - 9 - 00
2.3.7 SETTING THE CLOCK (HOURS AND MINUTES)

2
NOTE The clock can only be set when the motorcycle
is at standstill.
Hold down the MODE button (1) for over three
seconds. The hour segments (2) will start to flash.
4
NOTE Press and release the SET button (3) alternately
to change hours in one-unit increments. Hold down the
SET button (3) to cycle through hours quickly.
Press the SET button (3) and set hours. 3
Press and release the MODE button (1) to confirm. The
minute segments (4) will start to flash.
Press the SET button (3) and set minutes.
Press and release the MODE button (1) to confirm. 1
NOTE The clock will reset automatically whenever the
battery is removed from the vehicle.
2.3.8 INSTRUMENT AND INDICATOR CHART
Description Function
Direction indicator LED light Flashes when a direction indicator is operated.
Comes on when headlamp high beam is turned on or when the high beam
High beam LED light flasher is operated.
Gives engine speed in rpm.
Rev. meter (rpm) Never exceed maximum engine rpm.
WARNING
Comes on when fuel level in the tank drops to 4 ± 1 l.
Fuel reserve LED light
Refuel as soon as possible when this light comes on.
Side stand LED light Comes on when the side stand is down.
Comes on whenever the ignition switch is set to “ ” and the engine is

stopped to test LED operation.
Oil pressure LED light If the oil pressure LED “ ” stays on
WARNING after engine has been started up, or
comes on while the engine is running, it means that pressure in the
engine oil circuit is too low.
Neutral LED N light Comes on when gearbox is in neutral.
Comes on and stays on for about three seconds whenever the ignition
switch is set to " ” to test LED operation.
The diagnostics LED “EFI” will flash to
WARNING indicate that the on-board computer has
Diagnostics LED light EFI detected some failure event. This may occur while the engine is
running or as soon as the ignition switch is operated. 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.
CONTINUED ➤
2 - 10 - 00 Release 00/2001 - 11
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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.
When the tank is full, the total length of the scale is
highlighted and a letter "F" appears instead of figures.
As fuel level drops, an increasing portion of the scale will
go out and the figures (litres or gallons) will decrement. see 2.3.2
(PROGRAM-
Multifunction When all segments of the scale are off, flashing “--”
MING BUT-
digital characters are displayed instead of fuel quantity and the
TONS) for
display Fuel level indication low fuel LED will start to flash. This means that fuel level
instructions on
(right-hand has dropped below 4 ± 1 l.
Refuel as soon as possible. how to toggle
side)
When all segments of the between
WARNING indications.
scale are off, flashing
figures “8.8” appear instead of fuel quantity and the
low fuel LED starts to flash.
NOTE The digital sector can be toggled to air
temperature indication (T°AIR). The analogue scale is
turned off when air temperature is selected.
When temperature is 3 °C (37.4
CAUTION °F) or less, the digital display
indication will start to flash to warn against possible
black ice. When this is the case, drive at moderate
speed, apply the brakes gently and avoid any see 2.3.2
manoeuvres which may put the motorcycle into a skid. (PROGRAM-
Multifunction When temperature drops to or below 3 °C (37.4 °F), the MING BUT-
digital display Air temperature display will automatically switch to air temperature if TONS) for
(right-hand indication T°AIR currently set to fuel level indication. Air temperature instructions on
side) indication will flash for ten seconds (even if temperature how to toggle
has risen back above 3 °C (37.4 °F) in the meantime). between
If temperature stays below 3 °C (37.4 °F), automatic indications.
temperature indication will be repeated for three times at
five minutes' intervals.
NOTE After each flashing sequence, the display will
revert to current selection (fuel level or air temperature).
CONTINUED ➤
Release 00/2001 - 11 2 - 11 - 00
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).
The cooling fans operate
WARNING independently of the ignition
switch. Whether the engine is running or not, the
cooling fans will switch on and off automatically
whenever needed.
Exceeding the maximum temperature allowed (125 °C
Coolant temperature
or 257 °F) may lead to severe engine damage. see 2.3.2
indication (°C / °F)
If displayed temperature is 116 - 125 °C (241 - 257 °F) and (PROGRAM-
Multifunction the second last segment of the indicator scale is flashing, MING BUT-
digital display stop the engine. Wait for the cooling fans to switch off and TONS) for
(right-hand check coolant level, see 2.15 (COOLANT CHANGE). instructions on
side) When temperature reading is 126 - 135 °C (259 - 275 °F) how to toggle
and the last two segments of the indicator scale are between
flashing, stop the motorcycle and let the engine idle for a indications.
couple of minutes. This will allow coolant to circulate
throughout the cooling system. Set the engine kill switch to
“ ” and check coolant level, see 2.15 (COOLANT
CHANGE). Do not ride if coolant temperature indication
has not gone back to normal after checking level.
A wording "SERVICE" is displayed after the first 1000 km
(625 mi) and then every 7500 km (4600 ml).
“SERVICE” prompt Perform maintenance as specified in the periodic
maintenance chart, see 2.1.1 (PERIODIC MAINTENANCE
CHART).
Displays time in hours and minutes as pre-set, see 2.3.2
Clock
(PROGRAMMING BUTTONS).
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2.4 BATTERY
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.
NOTE This motorcycle is fitted with a maintenance-free
battery which seldom needs inspecting and may need
charging from time to time.
If necessary, replace with a battery of the same type.
See 6.14 (BATTERY) for more details.
WARNING
Be sure to connect each battery lead to the matching
terminal.
Set the ignition switch to " " before connecting or
disconnecting the battery.
Connect the positive (+) lead first, and then the
negative (-) lead.
Disconnect in the reverse order.
NOTE Check battery voltage using a hand-held tester.
The battery needs charging when voltage is less than
12V.
When voltage drops below 8V, the on-board computer
will not work and will inhibit engine operation.
Release 00/2001 - 11 2 - 13 - 00
2.4.1 CLEANING AND CHECKING BATTERY

TERMINALS AND LEAD CONNECTIONS 3
Read 2.4 (BATTERY) carefully.
Ensure the ignition switch is in the " " position.
Remove the seat, see 7.1.1 (SEAT REMOVAL).
Slide the red protective cap (1) aside.
Check that battery lead connections (2) and battery
terminals (3) are: 2
- in good condition (free from corrosion or any deposits);
- coated with neutral grease or vaseline.
If needed:
Disconnect the negative (-) and positive (+) leads in the
order. 2 1
Clean off corrosion deposits using a wire brush.
Reconnect the positive (+) and negative (-) leads in the
order.
Coat battery lead connections and terminals with
neutral grease or vaseline.
Refit the seat, see 7.1.1 (SEAT REMOVAL).
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2.4.2 CHARGING THE BATTERY 2.5 ELECTRIC COMPONENTS

Read 2.4 (BATTERY) carefully. Read 0.5.1 (GENERAL PRECAUTIONS AND
INFORMATION) carefully.
NOTE You can tell that the battery is nearly flat when
you hear a rattling sound from the starter relay when Inspect after the first 1000 km (625 mi) and every 7500
pressing the starter button . km (4687 mi) or 8 months afterwards.
Do not remove the battery plugs or the battery may Put the motorcycle on the stand.
damage. Check all lights for proper operation.
Remove the battery, see 7.1.9 (BATTERY REMOVAL). Check for proper beam setting, see 6.17 (BEAM
Be sure to have a suitable battery charger ready at HEIGHT SETTING) and 6.18 (BEAM CENTRING).
hand. Ensure all connectors are fitted securely in place.
Set the battery charger to the desired charge rate (see Ensure switches are properly fastened and check for
chart below). proper operation:
Connect the battery to the battery charger. - see 6.8.5 (SIDE STAND SWITCH TEST);
- see 6.8.7 (TESTING THE SAFETY LOCKOUT
CAUTION SYSTEM SWITCHES)).
Charge or use the battery in a well-ventilated place. Ensure the air and speedometer sensors are properly
Do not inhale the gases produced by the battery fastened and check for proper operation.
under charging.
WARNING
Switch on the battery charger. The sensing area of the sensors must be kept clean.
Any mud, dirt deposits, etc. will lead to misreading.
Charge rate Amperes Time (hrs)
Regular 1.2 8 - 10
Fast 12 0.5
CAUTION
The battery keeps producing gases for some time
after the battery charger has been switched off. Allow
5-10 minutes before proceeding to refit the battery.
2.4.3 LONG INACTIVITY

WARNING
When the motorcycle is to be left unused for over
twenty days, disconnect the 30-Amp fuses, otherwise
the multifunction computer will keep drawing current
and the battery will deteriorate.
Disconnecting the 30-Amp fuses will reset the digital
clock and red line setting.
See 2.3 (MULTIFUNCTION COMPUTER) for
instructions on how to set these functions again.
When the vehicle is left unused for over a fortnight,
charge the battery to avoid sulphation, see 2.4.2
(CHARGING THE BATTERY).
Remove the battery, see 7.1.9 (BATTERY REMOVAL)
and store it in a cool, dry place.
To avoid degradation in the wintertime or while the
motorcycle is stored away, check battery charge at
regular intervals (monthly).
Charge the battery fully at normal charge rate,
see 2.4.2 (CHARGING THE BATTERY).
NOTE If you are leaving the battery fitted in the
motorcycle, disconnect the leads from the terminals.
Release 00/2001 - 11 2 - 15 - 00
2.6 JUMP-STARTING
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.
The battery of the vehicle that is providing the jump-
start must have the same rating as the dead vehicle
battery (12V - 12 A, see rating data on battery).
Observe the instructions provided below closely or
the battery may explode, causing personal injury or
damage to property (the electric components of both
vehicles might damage).
Ensure that the ignition switch is set to " ". 1
NOTE Do not disconnect the battery leads of the
vehicle that is being jump-started.
WARNING
Never touch the connectors of the different leads or
cables together.
A
Slide the red protective cap (1) aside.
Attach one jumper cable to the positive (+) terminal of
the battery in the starting vehicle (A). Attach the other
end of the jumper cable to the positive (+) terminal of B
the dead vehicle battery (B).
Attach the other jumper cable to the negative (-)
terminal of the battery in the starting vehicle (A). Attach
the other end of the jumper cable to the frame of the
vehicle that is being jump-started (B) to provide a
ground connection. Select a location well away from
the battery.
DO NOT CONNECT ANY CABLES TO THE NEGATIVE
(-) TERMINAL.
CAUTION
Route the jumper cables well away from any moving
parts of either vehicles.
NOTE It is not necessary to stop the engine of the
starting vehicle during the jump-starting procedure.
Jump-start the dead vehicle.
NOTE If the engine of the dead vehicle does not start
right away, stop trying after 10 seconds and wait about
one minute before trying again.
When the engine starts, keep both vehicles' engines
running for about two minutes.
Stop both engines and disconnect the jumper cables in
reverse order.
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2.7 SPARK PLUGS

Check the spark plugs every 7500 km (4687 mi) or 8
months. Change them every 15000 Km (9375 mi) or 16
months. 1
At regular intervals, remove the spark plugs and clean off
any carbon deposits or replace them as required.
If the motorcycle is used in competition trials, change
spark plugs every 7500 Km (4687 mi).
2
In order to gain access to the spark plugs:
CAUTION
Allow the engine to cool down completely before
proceeding.
Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).
NOTE The motorcycle is fitted with two spark plugs per
cylinder.
The procedure outlined below applies to all spark plugs.
Removal and cleaning.
CAUTION
Never remove a spark plug cap while the engine is
running. Shock hazard: the ignition system produces
high voltages.
Pull the spark plug cap (1) off the spark plug (2).
Remove any traces of dirt from the spark plug base.
Fit the suitable spark plug tool (supplied with the tool
kit) to the spark plug.
Fit the 13-mm fork key (supplied with the tool kit) to the
hexagon of the spark plug tool.
Unscrew and extract the spark plug. Ensure that no
dust or foreign matter fall into the cylinder. 3
WARNING
This motorcycle uses spark plugs with platinum
electrodes.
Do not clean with wire brushes and/or abrasive
compounds. Clean with compressed air only.
- central electrode (3);
- insulator (4); 5
- side electrode (5).
4
Check electrodes and insulating material for carbon
deposits or corrosion. Blow with an air line if needed.
A spark plug must be changed when: the insulator is
cracked; the electrodes show traces of corrosion or
exceeding deposits; the tip of the central electrode (3) is
3
worn away and has achieved a radiused contour (see
diagram).
Replace with recommended spark plugs only.
Recommended spark plugs:
NGK R DCPR9E
Release 00/2001 - 11 2 - 17 - 00
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.
Use recommended spark plugs only. A spark plug of
the wrong grade may shorten engine life and cause
loss of performance.
Use a wire feeler gauge (see diagram) to check air
gap between electrodes. Any other tool will damage
the platinum coating of the electrodes.
Check the electrode gap with a wire feeler gauge.
Electrode gap should be 0.6 – 0.7 mm. If it needs
adjusting, bend the earth electrode carefully.
Make sure the washer is in good condition. Fit the
washer and screw the spark plug finger-tight to avoid
damaging the thread.
Tighten using the supplied tool. Screw in each spark
plug by one half turn to compress the washer.
1
Torque wrench setting for spark plugs: 20 Nm
(2.0 kgm).
WARNING
It is essential to tighten the spark plugs properly. A 2
loose spark plug will cause engine overheating and
result in severe damage.
NOTE When reassembling, take care to route the leads
of the rear cylinder spark plugs inboard of oil breather
hose.
Refitthe spark plug cap (1) securely onto the spark
plug (2), so that it will not work itself loose when
exposed to engine vibration.
CAUTION
Ensure the spark plug cap (1) is properly in place on
the spark plug (2).
Lower the fuel tank.
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2.8 LIFTING THE FUEL TANK

4
Read 1.2.1 (FUEL) carefully.
1 3
CAUTION
Fire hazard.
Allow the engine and exhaust silencer to cool down
completely.
Release and remove both screws (1).
2
1
Torque wrench setting for screws (1): 3 Nm 3
(0.3 kgm)
Remove the guard (2).
Release and remove the two front retaining screws (3)
of the fuel tank (4). Collect the bushes and washers.
5
Torque wrench setting for screws (3): 8 Nm
(0.8 kgm)
Release the service rod (5) of the fuel tank from its 4
retainers on the underside of the seat.
NOTE Fit the rubber-coated end of the service rod (5)
into the centre hole in the steering stem.
Pull the front end of the fuel tank (4) upwards to lift and
insert the service rod (5) as shown in the figure.
Release 00/2001 - 11 2 - 19 - 00
2.9 DRAINING THE FUEL TANK

CAUTION
Fire hazard.
Allow the engine and exhaust silencers to cool down
completely. 1
Fuel vapours are harmful to human health.
Ensure that the area is properly ventilated before 2
proceeding.
Do not inhale fuel vapours.
Do not smoke or use bare flames.
Do not release fuel into the environment.
Stop the engine and allow it to cool down.
Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).
Prepare a container of more than adequate capacity to
contain the amount of fuel in the tank. Place the
container on the floor on the left-hand side of the
motorcycle.
NOTE Place a cloth underneath the male quick-
disconnect fitting (1) to collect any fuel spillage.
Press the release button to disconnect male fitting (1)
from the female fitting (2).
NOTE Before proceeding, be sure to have a hose
equipped with a male quick-disconnect fitting ready at
hand.
Place the free end of the hose into the container you
have prepared previously.
Fit the male quick-disconnect fitting to the female
quick-disconnect fitting (2). The fuel will start to flow out
right away.
Open the filler cap.
Wait until all fuel has drained out of the fuel tank.
Once the fuel tank is empty:
Disconnect the hose male fitting from the female fitting
(2) by pressing the release button.
Fit the male quick-disconnect fitting (1) of the vehicle to
the female fitting (2).
NOTE Check that the male quick-disconnect fitting (1)
is securely in place on the female fitting (2).
Lower the fuel tank.
Refit the filler cap.
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2.10 AIR CLEANER

1 1
INFORMATION)carefully.
Check the air cleaner every 7500 km (4687 mi) or 8 months.
Change it every 15000 km (9375 mi) or 16 months or more 2
frequently when you ride on dusty or wet roads.
In this case, clean the air cleaner after each ride following
the procedure described below.
WARNING 1
Cleaning the filter does not eliminate the need to
change the filter at the specified intervals. Do not
start the engine when the air cleaner is not in place.
Do not clean the filter element with petrol or solvents.
These products may cause the fuel to ignite in the
fuel system, leading to personal injury and vehicle
damage.
REMOVAL 5
Lift the fuel tank, Read 2.8 (LIFTING THE FUEL TANK)
Release and remove the seven retaining screws (1) of
the air box cover (2).

(0.2 kgm)
Take off the air box cover (2).
Extract the air cleaner (3). 3
WARNING
Clean the air cleaner housing thoroughly, taking care
to remove any foreign matter. Block off the intake
funnels of the throttle body and the air cleaner
housing with clean cloths to prevent the ingress of
dirt.
Inspect the seal (5) and change it if damaged.
CLEANING THE FILTER ELEMENT
WARNING
Do not press or hit the air cleaner meshing (3).
Do not use a screwdriver or any other tools on the air
cleaner.
Hold the air cleaner (3) in a vertical position and tap it
repeatedly on a clean bench.
If needed, blow the air cleaner (3) with an air line. Aim 4
the gun from the inside of the meshing outwards.
Clean the outer surface of the meshing (3) with a clean
cloth.
REPLACEMENT
Replace the air cleaner (3) with a new air cleaner of the
same type.
Every 7500 km (4687 mi), remove the plug (4) and let
any dirt trapped inside the airbox drain out.
WARNING
When cleaning the air cleaner, ensure the meshing is
not torn. Always change a damaged air cleaner. Make
sure the air cleaner is properly in place or it will let
unfiltered air into the system. Note that early wear of
piston rings and cylinder is frequently due to a
defective or badly positioned air cleaner. Clean the
air cleaner more frequently when you ride on dusty
roads. Using the motorcycle without an air cleaner or
with a damaged air cleaner notably increases engine
wear. Ensure the air cleaner is in perfect condition at
all times; engine life largely depends on this
component.
Release 00/2001 - 11 2 - 21 - 00
2.11 THROTTLE
Inspect after the first 1000 km (625 mi) and every 7500
km (4687 mi) or 8 months afterwards.
2.11.1 CHECKING FOR THROTTLE PROPER

OPERATION
CAUTION 1
Throttle operation may be impaired when the throttle
cables are damaged, bent in tight turns or twisted.
Using the motorcycle in this condition may lead to
loss of control while riding.
Turn the handlebars and ensure that idling speed is
unaffected by handlebar movement. Open the throttle
and ensure that the twistgrip snaps closed smoothly
when released.
If needed: 5
2
Make sure the components listed below are in the
proper position and well lubricated:
- cable housing;
- twistgrip adjuster (1);
- throttle body adjusters (2); 2
- throttle body axle (3);
- cable end-caps;
- throttle control. 3
Check idling speed (rpm), see 2.11.2 (IDLING
ADJUSTMENT).
Check Throttle cable play adjustment, see 2.11.3
(THROTTLE CABLE PLAY ADJUSTMENT).
2.11.2 IDLING ADJUSTMENT

Manual adjustment for idling speed is not provided.
Idling is adjusted automatically through a stepper motor
(1) that operates a small piston inside an air passage.
The position of the piston inside the air passage is
determined by the on-board computer according to three 1
parameters:
- throttle position;
- engine rpm;
- coolant temperature.
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2.11.3 THROTTLE CABLE PLAY ADJUSTMENT

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).
If not so:
Place the motorcycle on the stand. 1
Take off the rubber gaiter (1).
Loosen the locknut (2).
Rotate the adjuster (3) until setting the specified free
play.
After adjusting, tighten the locknut (2) and check free
play again.
Refit the rubber gaiter (1).
WARNING
Turn the handlebars and ensure that idling speed is
unaffected by handlebar movement. Open the throttle
and ensure that the twistgrip springs back to the
closed position smoothly when released. 2
Release 00/2001 - 11 2 - 23 - 00
2.12 CHECKING AND TOPPING UP ENGINE

OIL LEVEL
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 2.13 (ENGINE OIL AND
FILTER CHANGE).
Check oil level as follows:
NOTE Place the motorcycle on firm and level ground
and put it on the centre stand.
WARNING
Check engine oil level when the engine is hot.
Oil level is lower in a cold engine than in operation
and may temporarily drop below "MIN".
This is acceptable, unless the oil pressure LED
" " is on. 1
Start the engine.
Let the engine idle for 15-20 minutes or ride outside
town covering about 15 km (9.5 mi).
Stop the engine.
Keep the motorcycle upright with both wheels on the
ground.
Look through the slot in the left-hand fairing to check oil
level in the oil sight glass (1).
MAX = maximum level;
MIN = minimum level.
The difference between the "MIN" and "MAX" levels is
about 500 cu cm. 3
Correct level is just below the "MAX" mark.
WARNING
Do not overfill (beyond the "MAX" mark) or let level 2
drop below the "MIN" mark, as this will cause severe 4
engine damage.
Do not add any additives or other products.
If you are using a funnel or other tool, ensure that it
is perfectly clean.
If needed, top up oil level as follows:
Release and remove the screw (2).
Take off the guard (3).
Release and remove the filler cap (4).
Adjust to correct level, see 1.6 (LUBRICANT CHART).
WARNING
is perfectly clean.
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2.13 ENGINE OIL AND FILTER CHANGE

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 2.13 (ENGINE OIL AND
FILTER CHANGE).
WARNING
Oil should be changed more frequently when riding
in dusty conditions.
On motorcycles used for competition trials, change
oil every 3750 km (2343 mi).
OIL AND FILTER CHANGE

NOTE Oil flows more easily when warm. Let the engine
warm up for about twenty minutes to facilitate total 3
drainage.
CAUTION
In order to avoid burns, allow the engine and silencer
to cool down completely before proceeding to
2
change oil and filter.
and put it on the centre stand. 1
Remove the left-hand side fairing, see 7.1.28
(REMOVING THE SIDE FAIRINGS).
Remove the left-hand lower fairing, see 7.1.33
(REMOVING THE LOWER FAIRING).
Place a container (1) under the drain plug (2) located
on the tank (3). Container capacity should be greater
than 4000 cu cm.
Undo and remove the drain plug (2) located on the tank 4
(3).
Undo and remove the filler cap (4).
Drain the oil into the container (1). Let the last of the oil
drip out for several minutes.
Inspect the sealing washer of the drain plug (2) located
on the tank (3) and replace it if needed.
Refit and tighten the drain plug (2).
Torque wrench setting for drain plug (2): 15 Nm

(1.5 kgm).
Place the container (1) under the crankcase, under the
engine drain plug (5).
Undo and remove the engine drain plug (5).
Drain the oil into the container (1). Let the last of the oil
drip out for several minutes.
WARNING
Do not release oil into the environment.
Dispose of oil through a waste oil reclamation firm.
Clean off any metal debris sticking to the drain plug (5)
magnet. Refit and tighten the plug.
5 1

(1.2 kgm).
Clean all parts contaminated with oil using a cloth.
Release 00/2001 - 11 2 - 25 - 00
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). 9
Remove the engine oil filter (8).
7
WARNING
Never reuse an oil filter. 8
Spread a film of oil on the seal (9) of the new engine oil
filter.
Insert the new oil filter. 6
Refit the guard (7). Refit and tighten the two screws (6).
CLEANING THE ENGINE OIL FILTER LOCATED ON
THE TANK
Clean the engine oil filter (10) located on the tank every
15000 km (9375 mi) (or every two oil changes).
NOTE Make sure you have the special clip pliers (part
no. 0277295) ready at hand. Change all clips when
reassembling (use clips of the same type as the original).
Slacken the clip (12) and disconnect the hose (13). 12
Release and remove the engine oil filter (10) located on 13
the tank and clean with an air line.
NOTE You will need to remove the engine oil tank (3) 10
fixings before you can extract the engine oil filter.
Release and remove the two screws (14).
Ease the engine oil tank (3) outwards.
Extract the engine oil filter (10) and clean with an air
line.
WARNING
When reassembling, ensure the fitting (15) of the oil 4
filter (10) is pointing outwards. The hose (13) must
not touch the expansion reservoir. 11
Inspect the seal of the engine oil filter (10) located on 3
the tank. Screw in the oil filter and tighten.
Torque wrench setting for engine oil filter (10)

located on the tank: 30 Nm (3.0 kgm).
Tighten the two screws (14). 14
Connect the hose (13). Fit a new clip and tighten. 14
WARNING
is perfectly clean.
Pour about 3500 cu cm of engine oil through the filler
opening (11), see 1.6 (LUBRICANT CHART).
Refit and tighten the filler cap (4).
Start the engine and keep it idling for about one minute
to let oil fill all points of the circuit.
Check oil level and top up if needed, see 2.12
13
(CHECKING AND TOPPING UP ENGINE OIL LEVEL).
15
10
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2.14 CHECKING AND TOPPING UP COOLANT

LEVEL
INFORMATION) and 1.2.4 (COOLANT)carefully.
Check coolant level before each ride. Change coolant
every 2 years.
WARNING
Check and top up coolant level when the engine is
cold. 1
The engine should be off and completely cold.
Keep the motorcycle upright with both wheels on the
ground.
Look through the slot in the right-hand fairing to ensure 4
that coolant level in the expansion reservoir (1) is
between the "FULL" and "LOW" marks.
FULL = maximum level
LOW = minimum level
2 1
If not so:
Release and remove the screw (2). 3
Release and remove the filler cap (4).
CAUTION
Coolant is toxic when ingested; contact with eyes or
skin may cause irritation.
Do not put your fingers or any tools into the filler
opening to check coolant level.
WARNING
is perfectly clean.
Add coolant mixture until bringing level just below the
"FULL" mark. see 1.6 (LUBRICANT CHART) for
coolant specifications.
Never overfill (top up beyond the "Full" mark), or
coolant will leak out when the engine is running.
Refit the filler cap (4).
WARNING
In the event the motorcycle is using up exceeding
coolant or the expansion reservoir (1) is empty,
check the circuit for leaks.
Release 00/2001 - 11 2 - 27 - 00
2.15 COOLANT CHANGE

INFORMATION), 1.2.4 (COOLANT) and Sect. 5
(COOLING SYSTEM) carefully.
Change coolant every 2 years.
Remove the right-hand air scoop, see 7.1.31
(REMOVING THE RIGHT-HAND AIR SCOOP).
THE LOWER FAIRING).
Remove the front splashguard, see 7.1.32 2
(REMOVING THE FRONT BOTTOM PANEL). 1
Remove the expansion reservoir, see 5.8 (REMOVING
THE EXPANSION RESERVOIR).
Place a container (2) with capacity greater than 2.5 l
under the drain plug (1) of the right-hand radiator to
collect the coolant.
Release and remove the drain plug (1). Collect the
aluminium washer.
WARNING 3
The coolant in the circuit is under pressure when hot.
Do not remove the filler cap (3) while the engine is
hot.
Remove the filler cap (3) to facilitate drainage. 4
When all coolant has drained out, proceed to drain the
left-hand radiator.
DO NOT RELEASE COOLANT INTO THE ENVIRONMENT.
NOTE When refitting, smear some LOCTITE® 572 on
the threads of the drain plugs of both radiators.
Refit the drain plug (1) and renew the aluminium

washer.

(1 kgm).
Refit the expansion reservoir.
Fill up with coolant mixture through the filler opening
(4).
Squeeze and release the couplings (5-6) repeatedly 5
with your hands. This will create a small amount of
pressure to help push coolant into the ducts.
Top up again until filling up.
NOTE Correct level is achieved when coolant has
settled just below the filler opening (4).
Refit the filler cap (3).
Top up coolant level in the expansion reservoir,
see 2.14 (CHECKING AND TOPPING UP COOLANT
LEVEL). 6
Start the engine and keep it running until the cooling
fans switch on. Allow engine to cool down and check
coolant level in the expansion reservoir again.
Top up if needed, see 2.14 (CHECKING AND
TOPPING UP COOLANT LEVEL).
Total quantity:
2.5 litres (including expansion reservoir).
NOTE The cooling system of this motorcycle requires
no bleeding.
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2.16 CHECKING AND TOPPING UP FRONT

BRAKE FLUID LEVEL
INFORMATION) and 1.2.3 (BRAKE FLUID) carefully.
Check brake fluid every 7500 km (4687 mi) or 8 months,
change it every two years.
WARNING
Bleed the circuit when the brake lever has exceeding
travel or feels soft or whenever you suspect that
there might be air trapped in the circuit; see 2.19
(BLEEDING THE BRAKE CIRCUITS).
Plastic or paint-finished parts will damage if brake
fluid is spilt on them.
Before each ride, ensure that the brake lines are not
twisted or cracked and check the fittings for leaks.
Never top up with or mix different types of silicone or
petroleum-based fluids.
Never use brake fluid from containers which have
been open or kept in storage for long periods.
Take care to avoid accidental ingress of water or dust
into the circuit.
INSPECTION
Rotate the handlebars to right full lock.
Check that fluid level in the reservoir is above the
"MIN" mark.
MAX = maximum level.
Top up when level is below the "MIN" mark.
TOP-UP
WARNING
Danger: brake fluid could leak out.
Never operate the front brake lever when the screw
(1) has been loosened or when the reservoir cover is
not in place.
Release the screw (1) of the brake fluid reservoir (3)
using a short Phillips screwdriver.
WARNING
Do not loosen the screw (2) when the handlebar is
rotated to the right or brake fluid will leak out.
Rotate the handlebar to left full lock.
Unscrew the screw (2). 2
WARNING
Avoid long exposure of brake fluid to air. 3
Brake fluid is hygroscopic and will absorb moisture
from the air. 1
Keep the brake fluid reservoir open JUST LONG MIN
ENOUGH to top up level.
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Lift and remove the cover (4) with the screws (1-2) in
place. 4
Collect the guide cover (5).
Remove the seal (6).
NOTE Do not rock the motorcycle from side to side
when topping up or brake fluid will spill out. 2 1
WARNING
Do not add any additives or other products. 6
5
If you are using a funnel or other tool, ensure it is
perfectly clean.
7
NOTE The “MAX" level is achieved when the sight 3
glass (7) is full. Note that actual level is indicated when
the brake fluid reservoir is level (parallel to the ground).
Top up the reservoir (3) with brake fluid, see 1.6
(LUBRICANT CHART) until bringing level between the
"MIN" and "MAX" marks.
WARNING
Do not overfill (top up beyond the "MAX" level).
Brake fluid level decreases gradually as brake pads
wear down. To achieve the correct level, always
renew the brake pads before topping up to "MAX"
level.
Reverse the disassembly procedure to reassemble.
2.17 CHECKING AND TOPPING UP REAR

BRAKE FLUID LEVEL
Check brake fluid every 7500 km (4687 mi) or 8 months,
WARNING
Bleed the circuit when the brake lever has exceeding
travel or feels spongy or whenever you suspect that
(BLEEDING THE BRAKE CIRCUITS).
Plastic or paint-finished parts will damage if brake
Before each ride, ensure that the brake lines are not
Never use brake fluid from containers which have
been open or kept in storage for long periods.
into the circuit.
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INSPECTION
NOTE Place the motorcycle on firm and level ground 3
"MIN" mark.
MAX
MIN
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 1 1
Avoid long exposure of brake fluid to air.
Brake fluid is hygroscopic and will absorb moisture
from the air. 4
Keep the brake fluid reservoir open JUST LONG
Release the two screws (1) of the brake fluid reservoir
(2) using a short Phillips screwdriver.
Lift and remove the cover (3) complete with screws (1)
and seal (4). 2
NOTE Ensure that the fluid level is parallel with
reservoir edge (in a horizontal position) to avoid spillage.
WARNING
perfectly clean.
Top up the reservoir (1) with brake fluid, see 1.6
WARNING
Brake fluid level decreases gradually as brake pads
wear down. To achieve the correct level, always
renew the brake pads before topping up to "MAX"
level.
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2.18 CHECKING AND TOPPING UP CLUTCH

FLUID LEVEL
INFORMATION) and see 1.2.5 (CLUTCH FLUID)
carefully.
Check clutch fluid every 7500 km (4687 mi) or 8 months;
MAX
MIN
WARNING
Bleed the circuit when the clutch lever has exceeding
travel or feels soft or whenever you suspect that
(BLEEDING THE CLUTCH).
Plastic or paint-finished parts will damage if clutch
Before each ride, ensure that the clutch lines are not
Never use clutch fluid from containers which have
been kept open or in storage for long periods.
into the circuit.
INSPECTION
NOTE Place the motorcycle on the centre stand.
Rotate the handlebars to left full lock.
"MIN" mark.
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TOP-UP
WARNING
3
Danger: clutch fluid could leak out. 2
1
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. 5
Clutch fluid is hygroscopic and will absorb moisture 4
from the air.
Keep the clutch fluid reservoir open JUST LONG
WARNING
Place a cloth under the clutch fluid reservoir to
collect any spillage
Rotate the handlebar to left full lock.
Release the screw (1) using a short Phillips
screwdriver.
WARNING
Do not loosen the screw (2) when the handlebar is
rotated to the left or clutch fluid will leak out.
Rotate the handlebar to right full lock.
Unscrew the screw (2).
WARNING
Do not rock the motorcycle from side to side when
topping up or clutch fluid will spill out.
perfectly clean.
Lift and remove the cover (3) complete with screws (1-
2).
Remove the seal (4)
Top up the reservoir(5) with clutch fluid, see 1.6
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2.19 BLEEDING THE BRAKE CIRCUITS

INFORMATION) and 1.2.3 (BRAKE FLUID).
1
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. This will hamper the operation of the
brake calipers and reduce braking efficiency.
A spongy feel of the brake lever and loss of braking mean
that there is air in the circuit.
CAUTION
This is a dangerous condition that makes the vehicle
unsafe to ride. Each time the brakes are removed, it
is indispensable to bleed the hydraulic circuit once
the brakes have been refitted and the braking system
is back to normal operating conditions.
Brake fluid is an irritant. Avoid contact with eyes or
skin. 1
In the event of accidental contact, wash the affected
area thoroughly. In the event of contact with eyes,
contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE
ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
WARNING
Handle with care: contact with brake fluid will alter
the chemical properties of paintwork, plastic and
rubber parts, etc.
Wear latex gloves during servicing.
Do not spill brake fluid on plastic or paint-finished
parts or they will damage. 2
NOTE This motorcycle is fitted with two (front and rear)

braking systems operated by two independent hydraulic
circuits.
The front twin-disc brake is fitted with one disc on either
side of the wheel.
The rear single-disc brake is fitted with one disc on the
right-hand side of the wheel.
FRONT BRAKING SYSTEM
The front braking system is fitted with two bleed nipples
(1), one for each of the front brake calipers.
Repeat the BLEEDING PROCESS for each bleed nipple
(1).
REAR BRAKING SYSTEM
The rear braking system is fitted with one bleed nipple (2)
located on the rear brake caliper.
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HOW TO BLEED THE BRAKING SYSTEM

A
There are three bleeding procedures to be performed
strictly in the order given:
1st – BLEED THE HYDRAULIC CIRCUIT D

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.
2nd – BLEED THE BRAKE CALIPER

3rd – BLEED THE MASTER CYLINDER.
WARNING C C
The three bleeding procedures must always be
performed in the specified order.
REQUIREMENTS
Before proceeding, ensure the following requirements are
met:
and put it on the centre stand. B
A the master cylinder is above the oil tube (meaning the
total length of the hose) and the brake caliper (C);
B the brake fluid reservoir is above the master cylinder
(A); C
C the caliper bleed nipple (1-2) is on top of the caliper;
A
D the oil tube is routed smoothly with no upside-down U-
turns.
NOTE In order to bleed the rear braking system, you
will first have to remove the rear brake caliper. See 7.6.2
(REAR BRAKE CALIPER REMOVAL).
Top up brake fluid level in the reservoir, see 2.16
(CHECKING AND TOPPING UP FRONT BRAKE
FLUID LEVEL) and see 2.17 (CHECKING AND 1
TOPPING UP REAR BRAKE FLUID LEVEL). 1
Remove the rubber cap.
Attach a clear plastic hose to the caliper bleed nipples
(1-2). Insert the other end of the hose into a container.
Pump the brake lever quickly. Repeat several times,
then keep the lever pulled in.
Slacken the bleed nipple by one quarter of a turn to let
the brake fluid drain into the container. This will remove
any tension from the lever and help it travel fully home.
Tighten the bleed nipple. Pump the lever repeatedly,
then hold in the lever and slacken the bleed nipple
C C
again.
Repeat process until the fluid draining into the
container is totally clear of air bubbles.
NOTE During the bleeding procedure, top up reservoir
with brake fluid up to Max level if needed. The reservoir
should not be empty during the bleeding procedure or air
will enter the system.
1
Tighten the bleed nipple and disconnect the hose.
Torque wrench setting for bleed nipples (1):

9 Nm (0.9 kgm).
Torque wrench setting for bleed nipple (2):

14 Nm (1.4 kgm).
C
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Add brake fluid to the reservoir until bringing fluid up to

correct level, see 2.16 (CHECKING AND TOPPING
UP FRONT BRAKE FLUID LEVEL) and see 2.17
(CHECKING AND TOPPING UP REAR BRAKE FLUID
LEVEL).
Refit the rubber cap.
WARNING
The lever may still feel too soft even after the circuit
has been bled and all air expelled from the system.
When this is the case, you will have to:
- bleed the brake caliper, see BLEEDING THE
BRAKE CALIPER; and
- bleed the brake master cylinder, see BLEEDING
THE BRAKE MASTER CYLINDER.
BLEEDING THE BRAKE CALIPER
NOTE Do not bleed both braking systems at the same
time. The procedure outlined below applies to both
braking systems. Any particular operations specific to
either one of the braking systems are described below.
When bleeding the front braking system, repeat the 1
process for both brake calipers.
Do not remove both front brake calipers at the same time.
Following instructions apply to the front braking
system only:
- remove the brake master cylinder, see 7.2.1 (WHEEL
REMOVAL) and leave it hanging on the brake line.
Arrange it so that the bleed nipple (1) is on top.
Following instructions apply to the rear braking
system only:
- the rear brake caliper has been removed previously
when bleeding the hydraulic circuit;
- release and remove the screw (3); collect the nut;
- an assistant will be required to keep the brake fluid 3
reservoir (4) above the master cylinder.
NOTE Be sure to have a shim (about 3-mm thick) ready
at hand. The shim will have to be placed between the
brake pads.
Place the shim between the brake pads and pump the
brake lever several times. 4
Use the shim or some other suitable tool to ease the
pistons apart.
WARNING
Do not push on the pistons directly. Push the pads
gently.
While pushing on the pads, open and close the bleed
nipple.
NOTE It is important that these operations – moving
the pistons apart, opening and then closing the bleed
nipple – be performed simultaneously.
UP FRONT BRAKE FLUID LEVEL) and see 2.17
(CHECKING AND TOPPING UP REAR BRAKE FLUID
LEVEL).
Work the lever again while placing the shim between
the brake pads.
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Move the pistons apart again and loosen the bleed

nipple at the same time. Look for any air bubbles in the
fluid.
Repeat the process until the fluid is totally clear of air
bubbles.
NOTE Top up reservoir with brake fluid up to Max level
if needed, while bleeding the brake caliper. The reservoir
BLEEDING THE BRAKE MASTER CYLINDER
NOTE Repeat process for the brake master cylinder
(see procedure described for the brake calipers).
Place the shim between the brake pads and work the
lever several times to introduce pressure in the system.
Use the shim or some other suitable tool to ease the
pistons apart.
WARNING
Do not push on the pistons directly. Push the pads
gently.
Look for any air bubbles in the fluid.
Repeat the process until the fluid is totally free of air
bubbles.
NOTE Top up reservoir with brake fluid up to Max level
if needed, while bleeding the brake master cylinder. The
reservoir should not be empty during the bleeding
procedure or air will enter the system.
The master cylinder bleeding procedure is now
complete.
Release 00/2001 - 11 2 - 37 - 00
2.20 BLEEDING THE CLUTCH

INFORMATION) and 1.2.5 (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. This will hamper the operation of the
clutch.
A spongy feel of the clutch lever and impaired clutch
operation mean that there is air in the circuit.
WARNING
Handle with care: contact with clutch fluid will alter
rubber parts, etc.
DO NOT RELEASE CLUTCH FLUID INTO THE
ENVIRONMENT.
This is a dangerous condition that makes the vehicle
unsafe to ride. Each time the clutch master cylinder 1
is removed, it is indispensable to bleed the hydraulic
circuit after refitting the master cylinder, when the
clutch is back to normal operating conditions. Bleed
the clutch as follows:
Top up clutch fluid level in the reservoir, see 2.18
(CHECKING AND TOPPING UP CLUTCH FLUID
LEVEL).
Remove the left-hand fairing, see 7.1.28 (REMOVING
THE SIDE FAIRINGS).
Attach a clear plastic hose to the bleed nipple (1).
Insert the other end of the hose into a container.
Pump the clutch lever quickly. Repeat several times,
then keep the lever pulled in.
Slacken the bleed nipple by one quarter of a turn to let
the clutch fluid drain into the container. This will remove
any tension from the lever and help it travel fully home.
Tighten the bleed nipple (1). Pump the lever repeatedly,
then keep it squeezed in and slacken the bleed nipple
again.
Repeat process until the fluid draining into the
container is totally free from air bubbles.
NOTE During the bleeding procedure, top up reservoir
with clutch fluid up to Max level if needed. The reservoir
Tighten the bleed nipple (1) and disconnect the bleed
hose.
Torque wrench setting for bleed nipples (1):

9 Nm (0.9 kgm).
UP CLUTCH FLUID LEVEL).
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2.21 CHANGING THE FRONT BRAKE FLUID

1
Change the front brake fluid every two years.
WARNING
rubber parts, etc.
ENVIRONMENT.

Loosen the bleed nipple (1) by about one turn.
NOTE Ensure that there is fluid in the reservoir at all 2
times during the operation, or you will have to bleed the
system when finished, see 2.19 (BLEEDING THE
BRAKE CIRCUITS).
Keep an eye on the reservoir (2) while fluid drains off.
Tighten the bleed nipple (1) before fluid has drained off
completely.
Top up the reservoir (2), see 2.16 (CHECKING AND
TOPPING UP FRONT BRAKE FLUID LEVEL).
Loosen the bleed nipple (1) again by about half turn.
Look at the fluid draining from the hose. When fluid
colour changes from dark to a lighter shade, tighten the
bleed nipple (1) and disconnect the bleed hose.
Torque wrench setting for bleed nipple (1): 9 Nm

(0.9 kgm).

Add fluid to the reservoir (2) until bringing
fluid to the
UP FRONT BRAKE FLUID LEVEL).
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2.22 CHANGING THE REAR BRAKE FLUID

1
Change the rear brake fluid every two years.
WARNING
rubber parts, etc.
ENVIRONMENT.
NOTE Ensure that there is fluid in the reservoir (2) at all
times during the operation, or you will have to bleed the 2
BRAKE CIRCUITS).
completely.
TOPPING UP REAR BRAKE FLUID LEVEL).
Torque wrench setting for bleed nipple (1):

14 Nm (1.4 kgm).
Add fluid to the reservoir(2) until bringing fluid up to
UP REAR BRAKE FLUID LEVEL).
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2.23 CHANGING THE CLUTCH FLUID

INFORMATION) and 1.2.5 (CLUTCH FLUID) carefully.
Change the clutch fluid every two years.
WARNING 1
Handle with care: contact with clutch fluid will alter
rubber parts, etc.
DO NOT RELEASE CLUTCH FLUID INTO THE
ENVIRONMENT.
NOTE Ensure that there is fluid in the reservoir (2) at all
times during the operation, or you will have to bleed the 2
CLUTCH).
completely.
TOPPING UP CLUTCH FLUID LEVEL).
Torque wrench setting for bleed nipple (1): 20

Nm (2.0 kgm).
Add fluid in the reservoir(2) until bringing fluid up to
UP CLUTCH FLUID LEVEL).
2.24 ADJUSTING THE FRONT BRAKE LEVER

AND CLUTCH LEVER 3
1
The position of the lever (1) relative to the twistgrip (2) is
adjusted by rotating the dial adjuster (3).
Setting “1” gives approximately 105-mm distance
between lever and twistgrip. Setting “4” gives about 85-
mm distance.
Settings “2” and “3” provide intermediate positions of
the lever.
Push the lever (1) forward and rotate the dial adjuster
(3) until aligning the desired setting mark with the
2
index.
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2.25 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:
2
Loosen the locknut (1).
Tighten the brake adjuster (2) all the way in. 1
Tighten the locknut (3) fully home onto the master
cylinder linkage (4).
Tighten the master cylinder linkage (4) fully, then 4
loosen it by 3-4 turns.
Loosen the brake adjuster (2) until setting the brake 3
lever at the desired height.
Lock out brake adjuster (2) movement by the locknut
(1).
Loosen the linkage (4) until it touches the master
cylinder piston.
Tighten the linkage allowing 0.5 –1 mm play between
master cylinder linkage (4) and master cylinder piston.
WARNING
Ensure that the brake lever (5) has some free play,
otherwise the brake will stay applied even when the
lever is released, leading to early wear of brake pads
and discs.
Free play of lever (5): 4 mm (measured at lever end).
Lock the master cylinder linkage by the locknut (3).
WARNING 5
When finished, apply brake and ensure the wheel
turns freely when brake is released.
2.26 ADJUSTING THE GEAR SHIFT LEVER

Gear shift lever position is controlled by a linkage (1).
Adjust as follows:
Place the vehicle on the centre stand. 1
Lowering the side stand (2) will help.
Loosen the nuts (3) and (4).
Rotate the linkage until setting the lever at the desired
height. 3
Tighten the nuts (3) and (4).
4
2
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2.27 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:
Place the vehicle on the stand. 1
Visually inspect the area between brake disc and brake
pads proceeding as follows:
- from the bottom up at the front end to check the front
brake calipers (1);
- from the bottom up at the rear end to check the rear
brake caliper (2).
WARNING
If brake pads were allowed to wear down until
uncovering the metal substrate, metal-to-metal
2
contact with the brake disc would lead to rattle and
the brake caliper sparking. This will result in loss of
braking and brake disc damage, causing a
dangerous riding condition.
When the lining material of even just one of the brake
pads is worn down to nearly 1 mm, or when one of the
wear indicators is worn away, change both brake pads.
- Front brake pads (3), see 7.5.1 (REPLACING THE
BRAKE PADS).
- Rear brake pads (4), see 7.6.1 (REPLACING THE
BRAKE PADS).
3 4
1m
1m m
m
Release 00/2001 - 11 2 - 43 - 00
2.28 STEERING
The steering is fitted with rolling bearings to ensure
smooth handling.
Proper steering adjustment is vital to smooth steering
movement and safe riding.
Any hardness in the steering will impair handling,
whereas a soft steering will result in poor stability.
2.28.1 CHECKING PLAY IN THE BEARINGS

Put the vehicle on the centre stand.
Rock the forks back and forth in the direction of travel.
If you feel any play, adjust the bearings, see 2.28.2
(ADJUSTING PLAY IN THE BEARINGS).
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2.28.2 ADJUSTING PLAY IN THE BEARINGS

2
Adjusting play in the bearings will be easier when the 3
following components are remsee 7.1.11 (REMOVING
THE LEFT-HAND TWISTGRIP)oved:
- Remove both twistgrips, see 7.1.11 (REMOVING THE
LEFT-HAND TWISTGRIP) and see 7.1.14
(REMOVING THE THROTTLE CONTROL).
- Remove the electric control device located on the left-
hand handlebar, see 7.1.13 (REMOVING THE LEFT- 5
HAND HANDLEBAR SWITCHGEAR). 4 1
- Remove both hydraulic controls, see 7.1.12
(REMOVING THE CLUTCH CONTROL) and 7.1.15
(REMOVING THE FRONT BRAKE CONTROL).
Slacken but do not remove the screw (4) securing the
handlebar (2) to the front fork (1).
Slacken but do not remove the screw (5) securing the
top yoke (3) to the front fork (1). 7
Release and remove the top bush (6) and collect the
shim (7).
Tap the underside of the top yoke (3) with a plastic
mallet to ease out the top yoke together with the
steering lock switch.
Lean the top yoke (3) forward. Place a cloth
underneath the top yoke to protect the instrument 6
panel.
Straighten the tabs (those bent upwards) of the safety
washer (9) using a small flat-blade screwdriver.
NOTE Make sure you have the special tool no.
8140203 (socket for steering adjustment) ready at hand.
Slacken and remove the nut (10) using the special
socket.
Remove the safety washer (9).
WARNING
Renew the safety washer (9) on assembly.
Screw in the adjuster nut (8) using the special socket to
take out play.
Torque wrench setting for adjuster nut (8): 9

40 Nm (4.0 kgm)
Fit the safety washer (9) so that the tabs are lined up
with the recesses in the nut (8).
Screw the locknut (10) and tighten using the special
socket.
Tightening procedure for locknut (10): screw in 10

manually until contact, and then tighten by one
quarter of a turn.
9
NOTE The tabs of the safety washer (9) should be bent
upwards.
8
Bend the four tabs of the safety washer (9) upwards
over the recesses of the locknut (10).
Replace the top yoke (3). Ensure that it becomes
properly seated in place.
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Apply engine oil to the thread and underside of the

bush (6), see 1.6 (LUBRICANT CHART).
Screw in and tighten the top bush (6). Take care to refit
the shim (7) in the proper position.
7
Torque wrench setting for top bush (6): 120 Nm
(12 kgm).
Screw in and tighten the screw (5).

6
Torque wrench setting for screw (5): 25 Nm (2.5 kgm).
WARNING
Lubricate the thread and the underside of screw head
of the screw (4).
2
Screw in and tighten the screw (4).
Torque wrench setting for screw (4): 25 Nm (2.5 kgm). 3
WARNING
When finished, ensure that the handlebars turn
smoothly or the sliding surfaces will damage
resulting in poor handling.
5
4 1
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2.29 INSPECTING THE FRONT SUSPENSION
2.29.1 FRONT SUSPENSION

1
The front suspension is managed by a hydraulic fork,
which is held to the steering stem by two yokes.
Each fork leg is fitted with top-mounted adjusters to
modIfy suspension response. An adjuster screw (1)
controls rebound damping, whereas an adjuster nut (2)
controls springs preload.
Vehicle response can be further modified by changing 2
front ride height.
Change front fork oil after the first 7500 km (4687 mi) and
every 22500 km (14000 mi) afterwards.
The following inspections should be performed every
7500 km (4687 mi):
Keep the brake lever squeezed in and press down
repeatedly on the handlebars to compress the front
fork. The front fork should compress in a smooth
motion. Inspect the fork legs for any traces of oil.
If the front fork has a tendency to bottom out, it needs
adjusting, see 2.29.2 (FRONT FORK ADJUSTMENT).
An oil change may also be necessary, see 7.8.1
(CHANGING FRONT FORK OIL).
Check the front fork for oil leaks and inspect the surface
of the fork legs for cracks or scoring.
Any damaged components should be repaired or – where
repair is not feasible – renewed, see 7.8.3
(DISASSEMBLING THE STANCHION TUBES –
SLIDERS).
Ensure that all parts are properly tightened and test the
front suspension for proper operation.
Release 00/2001 - 11 2 - 47 - 00
2.29.2 FRONT FORK ADJUSTMENT

Factory setting is designed to suit the broadest possible
range or riding conditions, meaning low and high speed,
whether riding solo or carrying a full load.
However, front suspension setting may be modified to
suit specific needs in accordance with vehicle usage. 1
NOTE Determine which kind of setting is needed

before disturbing the adjusters. The table below reports
2
available setting options.
SETTING OPTIONS:
Standard setting:
standard load conditions (for instance, rider and
luggage).
Mid-range setting:
heavy load conditions (rider, passenger and luggage).
Stiff setting:
sports-like riding style.
Full-load setting:
relaxed riding style (touring).
WARNING
Do not force the adjuster screw (1) beyond its limit
stops in either direction, or the thread may strip.
Set both fork legs to the same spring load and
rebound settings. A motorcycle whose fork legs are
set to different settings will be unstable.
When spring preload is increased, rebound damping
should be increased accordingly. Failure to do so
may result in the front end jerking unexpectedly
when riding.
WARNING
Before adjusting, first set the fork to the stiffest
setting [turn the screw (1) fully clockwise].
The notches on the adjuster screw (1) provide
convenient reference marks when setting rebound
damping.
Rotate the adjusting screw (1) gradually by one
eighth of a turn at a time.
Test ride the vehicle repeatedly until achieving the
ideal setting.
WARNING
Fork leg height over top yoke face (B) is not
adjustable.
Never attempt to modify steering geometry by raising
or lowering the fork legs in the yokes.
Fork leg height over top yoke face (B) is set at the
factory (standard setting is the first notch).
TABLE
Front suspension Standard setting Soft setting Stiff setting Full-load setting
screw in fully (*) screw in fully (*) screw in fully (*)
Rebound damping, screw in fully (*)
slacken (**) by 1.25 slacken (**) by 1.5 slacken (**) by 1.25
screw (1) slacken (**) by 1 turn
turn turn turn
Spring preload, nut
(2) [look at the
notches (A) for refer- 6th notch 7th notch 5th notch 7th notch
ence]
(*) = clockwise
(**) = anti-clockwise
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2.30 REAR SWINGING ARM

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.
Push and pull the rear wheel up and down, then rock it
from side to side (see figures).
If you feel any play, adjust the swinging arm,
see 2.30.1 (SWINGING ARM ADJUSTMENT).
If this fails to eliminate play, change the bearings,
see 7.9.2 (DISMANTLING THE SWINGING ARM).
2.30.1 SWINGING ARM ADJUSTMENT

3
Undo the nut (1) fully.
NOTE Make sure to have the special tool no.
8140203 (socket for swinging arm spindle – engine
mount adjustment). 2
Slacken the lockring (2) fully using the special socket.
Working from the right-hand side of the motorcycle,
rotate the swinging arm spindle (3) clockwise. The
adjusting bush (4) will rotate with the spindle and push
the swinging arm fully home.
Torque wrench setting for spindle (3): 12 Nm

(1.2 kgm). 2
Tighten the lockring (2) using the special socket.
Torque wrench setting for lockring (2): 60 Nm

(6 kgm).
Tighten the nut (1).
3
Torque wrench setting for nut (1): 90 Nm

(9.0 kgm).
4
Release 00/2001 - 11 2 - 49 - 00
2.31 REAR SUSPENSION INSPECTION
2.31.1 REAR SUSPENSION

3
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, 2
respectively.
To modify vehicle response, the rear shock absorber is
fitted with an adjuster screw (1) which controls rebound
damping and an adjuster knob (2) which controls spring 1
preload (3).
Check after the first 1000 km (625 ml) and every 15000
km (9375 ml) or 16 months afterwards.
Ensure that all parts are properly tightened and check
the joints of the rear suspension for proper operation.
2.31.2 REAR SHOCK ABSORBER ADJUSTMENT

Factory setting is designed to suit the broadest possible
range or riding conditions, meaning low and high speed, 1
whether riding solo or carrying a full load.
However, rear suspension setting may be modified to suit
specific needs in accordance with vehicle usage.
WARNING
Before adjusting, set both adjusters to the stiffest
settings. This means that both adjuster screw (1) and
adjuster knob (2) should be turned fully clockwise.
Do not force the adjuster screw (1) beyond its limit
stop or you may strip the thread.
Ensure that the adjuster screw (1) is always set
precisely at a click position. It should never be in an
intermediate position (midway between subsequent
click positions).
Turn the adjuster screw (1) to set rebound damping
(see table).
Turn the adjuster knob (2) to set compression damping
(see table).
WARNING 2
Spring preload and rebound damping of the rear
shock absorber should be set to suit vehicle usage.
When spring preload is increased, rebound damping
should be increased accordingly to avoid
unexpected jerking when riding.
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.
2 - 50 - 00 Release 00/2001 - 11
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Test ride the vehicle on the road repeatedly until

achieving ideal setting.
Never remove the capscrew (4) or attempt to service
4
the valve located underneath. The shock absorber
contains nitrogen, which would leak out if capscrew
or valve were disturbed. This would impair shock
absorber operation and lead to an accident.
REAR SHOCK ABSORBER SETTING CHART
Rear suspension Standard setting Soft setting Stiff setting Mid-range setting
fully tightened (*) fully tightened (*) fully tightened (*) fully tightened (*)
Rebound damping
turn out (**) by 9 click turn out (**) by 10 turn out (**) by 8 click turn out (**) by 7 click
(1)
positions click positions positions positions
fully slackened (**) fully slackened (**) fully slackened (**) fully slackened (**)
Spring preload, knob
tighten (*) by 14 click tighten (*) by 4 click tighten (**) by 22 tighten (**) by 34
(2)
positions positions click positions click positions
(*) =clockwise
(**) =anti-clockwise
2.31.3 INSPECTING THE REAR SUSPENSION

LINKAGE SYSTEM
Check bearings every 30000 km (18750 mi).
NOTE An assistant will be required to keep the vehicle
upright during the procedure.
Hold the tail of the motorcycle firmly with your hand.
Press down and release repeatedly.
If you feel any hardness or play, or hear squeaking
noises, change the bearings of the rear suspension
linkage system, see 7.10.2 (REMOVING THE REAR
SUSPENSION LINKAGES).
Press down the vehicle tail. If the tail is slow to spring
back up when released, check rear suspension
adjustment, see 2.31.2 (REAR SHOCK ABSORBER
ADJUSTMENT).
If the problem persists, it means that the shock absorber
is depressurised. Charge the shock absorber.
Release 00/2001 - 11 2 - 51 - 00
2.32 FRONT WHEEL

Check every 7500 km (4687 mi).
Place the vehicle on the front wheel stand ,
see 1.9.1 (PLACING THE MOTORCYCLE ON THE
FRONT WHEEL STAND).
Rotate the wheel manually in both directions.
The wheel should be spinning smoothly, with no
hardness or unusual noise. If not so, change the
bearings, see 7.2.2 (WHEEL HUB DISASSEMBLY).
If you detect any wobble, inspect wheel and tyre,
see 7.2.3 (WHEEL COMPONENT INSPECTION).
A spinning wheel that always stops in exactly the same
position needs balancing.
2.33 REAR WHEEL

Check every 7500 km (4687 mi).
Rotate the wheel manually in both directions.
The wheel should be spinning smoothly, with no
hardness or unusual noise. If not so, change the
bearings, see 7.2.2 (WHEEL HUB DISASSEMBLY).
If you detect any wobble, inspect wheel and tyre,
see 7.2.3 (WHEEL COMPONENT INSPECTION).
A spinning wheel that always stops in exactly the same
position needs balancing.
2 - 52 - 00 Release 00/2001 - 11
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2.34 EXHAUST MANIFOLD NUTS

1
Tighten the exhaust manifold nuts after the first 1000 km
(625 mi) and every 7500 km (4687 mi) or 8 months 1
afterwards.
CAUTION
Let the engine cool down completely.
Remove the side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS). 1
Remove the front spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).
Tighten the three nuts (1) of the front cylinder exhaust
manifold to the specified torque.
Tighten the three nuts (2) of the rear cylinder exhaust
manifold to the specified torque.
2
Torque wrench setting for nuts (1-2): 25 Nm
2
(2.5 kgm).
Release 00/2001 - 11 2 - 53 - 00
2.35 DRIVE CHAIN

Inspect and lubricate as required every 1000 km (625
mi). The vehicle is fitted with an endless chain that has
no master link.
Chain type: 525
WARNING
The drive chain links are fitted with O-rings that retain
the grease inside. Use the utmost care when
adjusting, lubricating, washing or replacing the chain.
Put the gearbox in neutral.
Rotate the rear wheel manually and slowly.
Visually inspect chain, front and rear sprockets looking
for:
- damaged chain rollers;
- loose chain link pins;
- dry, rusty, warped or seized links;
- exceeding wear;
- missing O-rings;
- exceedingly worn or damaged sprocket teeth.
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 7.4.1 (FINAL DRIVE
REMOVAL).
2.35.1 CHAIN SLACK INSPECTION

To check chain slack:
Put the gearbox in neutral.
Check chain slack in the lower straight portion of chain.
The vertical movement of the chain midway between
the sprockets should be approximately 25 mm.
Wheel the motorcycle forward to check slack at various
sections of the chain. Slack should be the same
throughout one full turn of the wheel. 25 mm
mm
WARNING
If slack is greater at particular positions of the chain,
it means that some links are warped or have seized.
To prevent seizure, lubricate the chain frequently,
see 2.41.1 (CLEANING AND LUBRICATION).
Chain slack must be adjusted whenever it differs from the
specified 25 mm, regardless of whether it is greater or
less than the 25-mm service limit, even when it is
consistent at all positions of the chain. See 2.35.3
(CHAIN SLACK ADJUSTMENT).
WARNING
Exceeding slack in the chain may cause the chain to
rattle or knock, resulting in a worn chain slider and
guide.
Improper maintenance may lead to early wear of the
chain and/or sprocket damage.
Service the final drive more frequently when the
motorcycle is used in demanding conditions or on
dusty/muddy roads.
2 - 54 - 00 Release 00/2001 - 11
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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.
Replace the chain if the length measured exceeds the
limit specified below, see 7.11 (DISMANTLING THE
DRIVE CHAIN).
Service limit: 255.5 mm (0.5% MAX).
2.35.3 CHAIN SLACK ADJUSTMENT

If the chain needs adjusting after the inspection, proceed
as follows:
Loosen the screws (1) completely.
NOTE Make sure you have the pin spanner (2)
supplied with the tool kit ready at hand.
To increase slack:
Apply the pin spanner (2) as shown in diagram (A).
To take out slack:
Apply the pin spanner (2) as shown in diagram (B).
When the pin spanner (2) is properly in place:
Hook the pin spanner (2) the lockring (3).
Fit the extension (4) to the pin spanner.
Rotate the pin spanner (2) to adjust chain slack.
Check chain slack, see 2.35.1 (CHAIN SLACK 1
INSPECTION).
1
Tighten the two screws (1). 4
Tighten the screws (1) to 35 Nm (3.5 kgm).

Lubricate the chain every 1000 km (625 mi) and
whenever it seems appropriate.
3 1
WARNING 2
Leave the chain to dry, then spray with aerosol
lubricant for O-ring chains, see 1.6 (LUBRICANT
CHART).
NOTE Do not ride when you have only just lubricated
the chain. Centrifugal force would cause the newly
applied lubricant to fly all over adjacent vehicle parts.
4
WARNING
The chain lubricants available on the market may
contain aggressive substances which will damage
the chain O-rings. 2
Standard chain type is 525.
Replace with a chain of the same type.
Release 00/2001 - 11 2 - 55 - 00
2.35.4 DRIVE CHAIN GUIDE PLATE INSPECTION

1
INFORMATION) carefully. 6
Remove the left-hand lower fairing, see 7.1.33
(REMOVING THE LOWER FAIRING). 4
Release and remove the two screws (1).

(1.0 kgm). 3 2
5
Remove the rectifier (2) but leave it attached to the
main wiring harness.
Release and remove the three screws (4) securing the
rectifier mount (5).
10
(1.2 kgm).
Collect the three bushings (6) and the three rubber
dampers (7).
8 9
Remove the rectifier mount (5) and collect the
bushings.
Slacken the screw (8) and withdraw the gear shift lever
clamp (9).
Remove the clutch slave cylinder, see 3.2.1 (CLUTCH
SLAVE CYLINDER REMOVAL).
NOTE Release the wire of the side stand switch from
its retainer.
Remove the sprocket cover (10).
Remove the guide plate (11).
Check the guide plate (11) for damage or wear.
Replace as required.
11
2.35.5 CHAIN SLIDER INSPECTION

Check the chain slider (1) for damage or wear. Replace
as required, see 7.1.57 (REMOVING THE DRIVE
CHAIN SLIDER).
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2.36 TYRES
Check tyre condition after the first 1000 km (625 mi) and
every 7500 km (4687 mi) or 8 months afterwards.
Tyre inflation pressures should be checked monthly with
2
the tyres at room temperature.
This vehicle is fitted with tubeless tyres.
TREAD CONDITION
1
WARNING
Inspect tread surface and check for wear. Badly worn
tyres adversely affect traction and handling.
Always change a worn tyre. A tyre that becomes
punctured in the tread area should be changed when
the puncture is larger than 5 mm.
Some of the tyre types approved for this vehicle are
fitted with wear indicators.
There are various types of wear indicators.
Enquire about correct wear inspection procedure
with your supplier.
Never use tube tyres on tubeless tyre rims, or
viceversa.
Always check that the caps are in place on the valves A
(1), or the tyres may deflate suddenly.
Tyre replacement and repair, and wheel servicing and
balancing are delicate operations. They should be
carried out using adequate tools and are best left to
experienced mechanics.
MINIMUM RECOMMENDED TREAD DEPTH (A):
front and rear tyre ……………………2 mm ( USA 3 mm).
INFLATION PRESSURES
Check the tyre inflation pressures at regular intervals
when the tyres are cold.
Checking pressure on hot tyres will result in inaccurate
measurement.
Take care to check tyres pressures before and after a
long journey.
An overinflated tyre will provide a harsh ride, reduce
riding comfort and stability when cornering.
An underinflated tyre will extend the contact patch to
include a larger portion of the tyre wall (2). When this is
the case, the tyre may slip on or become separated from
the rim, leading to loss of control. The tyre may even
jump off the rim under hard braking.
Lastly, the vehicle may skid in a bend.
See 1.5 (SPECIFICATIONS)for inflation pressures.
WARNING
The wheel must be balanced after each tyre repair.
New tyres may be coated with an oily film. Drive
carefully until covering several kilometres.
Never apply non-specific products to the tyres.
Approved tyre sizes are reported in the registration
document. Installing non-approved tyres is a legal
offence.
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).
Release 00/2001 - 11 2 - 57 - 00
2.37 FUEL LINES

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)].
- Return pipe (2).
NOTE Ensure that the male quick-disconnect fitting (3)
is properly seated in the female quick disconnect (4).
See Section 4 (FUEL SYSTEM) for more details.
2.38 BRAKE AND CLUTCH LINES

Read 1.2.3 (BRAKE FLUID) and 1.2.5 (CLUTCH
FLUID) carefully.
Check the brake and clutch lines every 7500 km (4687 1
mi) or 8 months.
Renew every four years.
Always change a worn, cracked or damaged line. 2
4
2.39 COOLANT PIPES

Read 1.2.4 (COOLANT) carefully.
Check the coolant pipes every 7500 km (4687 mi) or 8
months.
Always change a worn, cracked or damaged coolant
pipe.
2 - 58 - 00 Release 00/2001 - 11
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2.40 MAINTAINING FASTENERS AT THE

CORRECT TIGHTENING TORQUE
Check after the first 1000 km (625 mi) and every 7500
Ensure that all fasteners are properly tightened. Take
special care with safety-related items, namely:
- handlebars;
- front brake lever;
- clutch lever;
- fuel delivery pipe;
- front fork to yoke;
- front fork to front wheel spindle clamps;
- front wheel;
- front brake line fittings;
- front brake discs;
- front brake calipers;
- engine;
- sprocket;
- rear brake lever;
- swinging arm;
- swinging arm linkage system;
- rear shock absorber;
- rear wheel;
- rear brake disc;
- rear brake caliper;
- rear brake line fittings.
WARNING
All fasteners must be tightened to the specified
torque. Use LOCTITE ONLY where specified, see 2.41
(FASTENERS).
Lubricate only those parts indicated in the relevant
chart, see 2.41 (FASTENERS).
Release 00/2001 - 11 2 - 59 - 00
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
to the specified torque using a torque wrench and
applying LOCTITE® where specified.
Safety-related items ( ) are in brackets.
ENGINE
Engine to frame
Description Qty. Screw/nut Nm kgm Notes
Front mounting bolts 2+2 M10 50 5.0
Upper and lower rear mounting bolts on left-hand side 2 M10 50 5.0
Upper and lower rear mounting bolts on right-hand side of
2 M20x1.5 12 1.2 lub
adjuster bush
Upper and lower rear mounting bolts on right -hand side of
2 M20x1.5 50 5.0
locknut
Upper and lower rear mounting bolts on right-hand side of screw 2 M10 50 5.0
Parts installed to engine
Engine oil inlet flange 2 M6 12 1.2
Engine oil outlet flange 2 M6 12 1.2
Sprocket to transmission secondary shaft 1 M10 50 5.0 L243
Clutch slave cylinder fixing 3 M6 12 1.2
Sprocket cover fixing 3 M6 12 1.2
Fairing plate on clutch cover 2 M5 5 0.5
SWINGING ARM
Swinging arm spindle adjuster bush 1 M30x1.5 12 1.2 lub
Swinging arm spindle lockring 1 M30x1.5 60 6.0
Swinging arm spindle nut 1 M20x1.5 90 9.0
Caliper carrier retaining pin 1 M14x1.5 60 6.0 L243
Chain slider to swinging arm 2 M5 4 0.4 L243
Upper and lower chain guard to swinging arm 7 M5 4 0.4 L243
Eccentric adjuster pinch bolt 2 M10 35 3.5
Brake line gaiter fixing 1 M5 4 0.4
Wheel spindle anti-rotation screw 1 M6 10 1.0 L243
SIDE STAND
Stand bracket to frame 2 M10 40 4.0
Stand axle 1 M10x1.25 10 1.0
Switch retaining screw 1 M6 10 1.0 L243
CONTINUED ➤
2 - 60 - 00 Release 00/2001 - 11
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Locknut 1 M10x1.25 30 3.0

CENTRE STAND
Centre stand to frame 2 M10 50 5.0 L243
FRONT SUSPENSION
Front fork
Top yoke to fork legs 1+1 M8 25 2.5
Bottom yoke to fork legs 2+2 M8 25 2.5
Headstock nut 1 M35x1 40 4.0
Headstock locknut 1 M35x1 man. +90°
Top yoke fixing cap 1 M29x1 120 12.0
Screws securing steering lock stopper to bottom yoke 1+1 M8 22 2.2
Fork / wheel spindle clamps 2-2 M8 22 2.2
Ignition switch assembly to top yoke 2 M8 25 2.5
REAR SUSPENSION
Shock absorber
Shock absorber to frame 1 M10 45 4.5 lub
Linkage system
Single linkage to frame 1 M10 45 4.5 lub
Single / dual linkage to frame 1 M10 45 4.5 lub
Dual linkage to swinging arm 1 M10 45 4.5 lub
Dual linkage to shock absorber 1 M10 45 4.5 lub
ELECTRIC SYSTEM
Battery closure bracket fixings 2 M5 5 0.5
Horn mount fixing 1 M8 25 2.5
Speed sensor fixing 1 M6 10 1.0 L243
Tail light to grab rail fixings 3 M6 7 0.7
Computer fixings 5 M6 10 1.0
Rectifier fixings 2 M6 12 1.2
2 M5 2 0.2
Headlamp to front fairing fixings
2 SWP 3.9 1 0.1
Coil mount to frame fixings 4 M6 10 1.0
Fuse box to dashboard/front fairing subframe 2 M5 2 0.2 L243
Relay cable to starter motor 1 M6 5 0.5
Ground connection to engine 1 M6 10 1.0
Cables to relay 2 M6 5 0.5
CONTINUED ➤
Release 00/2001 - 11 2 - 61 - 00
AIRBOX
Airbox cover fixings 7 M5 2 0.2
Airbox to throttle body 6 M6 7 0.7 lub
Intake funnels to airbox 4 SWP3.9 1 0.1
Idling control stepper motor 2 M5 4 0.4 L243
Airbox to frame fixing plate 2 M6 5 0.5
Restriction diaphragm on airbox 1 SWP3.9 1 0.1
FRONT WHEEL
Wheel spindle nut 1 M25x1,5 80 8.0 Gr.
REAR WHEEL
Rear sprocket to flange 6 M8 25 2.5
Wheel spindle bolt 1 M40x1.5 170 17.0 Gr.
Cush drive axle bolt 1 M30x1.5 150 15.0 Gr.
Cush drive safety screws 3 M3 1.2 0.12
lub
Wheel bolt cap 1 M10 10 1.0
“OR”
COOLING SYSTEM
Three-way manifold locking screw 1 M14x1.5 30 3.0 L572
Cooling fan mount fixings 2+2 M6 6 0.6
Cooling fan motor to mount 3+3 SWP3.9 1 0.1 L243
Radiator drain screw 1+1 M6 10 1.0 L572
Expansion reservoir to mount 2 M6 8 0.8
Expansion reservoir cap fixing 1 M28x3 man
Radiator fillet cap fixing 1 M6 10 1.0
Expansion reservoir rear to frame 1 M6 10 1.0
Radiator brackets to frame 6 M6 10 1.0
Oil cooler to mount 3 M6 10 1.0
Coolant radiator to mount 2 M6 10 1.0
BRAKING SYSTEMS
Front braking system
Right-hand and left-hand brake caliper fixings 2+2 M10x1.25 50 5.0 lub
Brake disc fixings 6+6 M8 30 3.0 L243
Front brake line fixings 3 M10x1 20 2.0
Brake line triple bracket to yoke 1 M5 3 0.3
CONTINUED ➤
2 - 62 - 00 Release 00/2001 - 11
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Rear braking system

Brake caliper fixing 1 M8 25 2.5
Brake lever to footpeg bracket 1 M8 15 1.5 L243
Brake lever rubber 1 M8 25 2.5 L270
Brake master cylinder fixings 2 M6 10 1.0
Brake rod locknut 1 M6 man
Brake disc fixings 6 M8 30 3.0 L243
Brake line fixings 2 M10x1 20 2.0
Brake light switch to rider foopeg bracket 1 M6 10 1.0
EXHAUST SYSTEM
Exhaust pipes to engine fixings 3+3 M8 25 2.5
Silencer fixing 1 M6 10 1.0
Compensator to frame 1 M8 25 2.5 L243
Stand rubber stop to compensator 1 M6 10 1.0
Grab rail heat guard to left-hand tube 2 M6 6 0.6
Hose clip to silencer coupling 2 M6 15 1.5 sil
FUEL TANK
Fuel delivery pipe to pump mount 1 M12x1.5 22 2.2
Filler cap to fuel tank 7 M5 5 0.5
Fuel tank flange to fuel tank 8 M5 6 0.6 L518
Front tank to frame fixings 2 M6 8 0.8 lub
Tank cover 2 M5 3 0.3
Fuel rail to fuel line 2 M5 5 0.5
ENGINE OIL TANK AND COOLERS
Oil reservoir to mounts 3 M6 10 1.0
Oil filter 1 M25x1.5 man.
Oil drain plug 1 M8 15 1.5
Oil level tube fittings 2 M10x1 20 2.0
FRONT BODYWORK
Front mudguard 4 M5 5 0.5 lub
Left-hand and right-hand air scoops 6 M5 2 0.2
Rearview mirrors to bridge 4 M6 8 0.8
Air inlets to frame and bridge 6 M6 8 0.8
Fairing front bottom panel to front fairing 2 M5 4 0.4
Fairing front bottom panel to air inlet 2 SWP3.9 1 0.1
Air inlet closure 20 SWP3.9 1 0.1
CONTINUED ➤
Release 00/2001 - 11 2 - 63 - 00
Lower fairing to frame 4 M5 4 0.4

Lower fairing to upper fairing 8 M5 2 0.2
Windshield to front fairing 6 M5 2 0.2
Upper fairing to front fairing and air inlets 12 M5 3 0.3
Upper fairing to air inlet 6 M5 3 0.3
Cockpit facia panel to fairing 2 M5 3 0.3
Cockpit facia panel to protection moulding 2 SWP3.9 1 0.1
Rearview mirror protectors 4 M5 3 0.3
Cockpit to bridge 4 M6 4 0.4
Protection moulding to bridge 2 M6 4 0.4
Fairing stay to radiator mount 4 M6 5 0.5
Fairing stay to air inlets 2 M5 3 0.3
Lower fairing to fairing stay 6 M5 3 0.3
Fairing stay to air inlets 2 M5 3 0.3
Bottom yoke to plate 3 M6 5 0.5
FRAME
Rider footpeg bracket to frame 4 M8 25 2.5
Passenger footpeg bracket to seat subframe 4 M8 25 2.5
Seat subframe to frame 4 M10 45 4.5
Fuel dampers to seat subframe 2 M8 man
Bridge to frame 2 M6 10 1.0
Centre stand spring retainer 1 M6 10 1.0
Oil tank mount to frame 2 M6 10 1.0
Throttle balancing tube cable stopper 1 M6 10 1.0
REAR BODYWORK
Number plate holder to mount 2 M5 4 0.4
Cat's eye nuts 2 M5 4 0.4
Number plate holder retaining screws 4 M5 5 0.5 L243
Exhaust heat guard screws 2 M5 4 0.4
Number plate light mount on number plate holder 2 M5 2 0.2
Number plate light to mount 1 M5 3 0.3
Front closure to seat subframe 6 M6 4 0.4
4 M6 4 0.4
Seat subframe rear closure
2 M5 3 0.3
Sidebag mounts to seat subframe 2 M8 15 1.5
Seat closure to seat subframe fixings 2 M6 10 1.0
Grab rail to seat subframe 3 M8 10 1.0
Passenger grab handles to grab rail 4 M8 15 1.5
CONTINUED ➤
2 - 64 - 00 Release 00/2001 - 11
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HANDLEBARS AND CONTROLS

Vibration-damping weights 2 M6 10 1.0
Vibration-damping weight lockrings 2 M18x1.5 35 3.5
Handlebars to front fork 2 M8 30 3.0 Gr.
Handlebars safety screw 2 M6 12 1.2
Left-hand dimmer switch 2 M5 2 0.2
Right-hand dimmer switch 2 M5 2 0.2
Front brake control 2 M6 10 1.0
Clutch control 2 M6 10 1.0
Clutch line fitting to master cylinder 2 M10x1 20 2.0
Gear shift rod to gear shift lever and control 2 M6 12 1.2 L243
Gear shift lever to rider left-hand footpeg bracket 1 M8 15 1.5 L243
Control to gearbox shaft 1 M6 10 1.0
Gear shift lever pedal 1 M8 25 2.5 L270
Key: Steel / aluminium fastening screws with similar

L243 = apply LOCTITE® 243 coefficient of elasticity
L518 = apply LOCTITE® 518
L572 = apply LOCTITE® 572 SCREW Nm kgm
M4 3 0.3
man. = fix manually M5 6 0.6
gr. = grease underside of head
M6 12 1.2
lub = lubricate
sil = black silicone (part no. 8216005) M8 25 2.5
M10 50 5.0
M12 80 8.0
Release 00/2001 - 11 2 - 65 - 00
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.
WARNING
Do not use trichlorethylene, petrol or similar
products: these products may be too aggressive for
this type of chain or, more important, they may
damage the O-rings that retain the grease in the gaps
between rollers and pins.
2 - 66 - 00 Release 00/2001 - 11
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NOTES
Release 00/2001 - 11 2 - 67 - 00
NOTES
2 - 68 - 00 Release 00/2001 - 11
ENGINE RST mille
Screw out the adjusting bushes (40 - 44) until bringing

them fully home in the frame.
Torque wrench setting for adjusting bushes (40 48

- 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.
43
Hold the check nut (38) steady. Release and remove
the screw (37).
Hold the check nut (41) steady. Release and remove
the screw (42).
Ensure that the slings (29) are taut.
Release and remove the two screws (45) and collect
the washers (46).

(4.0 kgm). 39
Collect the two shims (47).
43
40
44
45
46 47
45 46
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ENGINE
CAUTION
29
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.
Raise the hoist arm by a few millimetres to ease the
engine off the frame.
Lower the hoist arm until placing the engine on the
floor.
Secure the engine to prevent it falling over.
Release the hoist slings (29).
Remove the slings (29) from the frame.
Move the engine aside from under the frame.
Fasten the slings (29) to the engine again.
NOTE If the engine needs servicing, place it in the spe-

cial stand (8) (part no. 8140187 + 8140188).
WARNING
Unless you need to service the engine, it will be safer
when left on the floor, still fastened to slings (29) and
hoist. 8
Clean the outer surface of the engine thoroughly.

WARNING
Clean the outer surface of the engine with a
degreasing detergent, brushes and rags.
Ensure that no rubber or plastic parts come in
contact with detergents and corrosive or penetrating
solvents.
Release 00/2001 - 11 3 - 15 - 00
ENGINE RST 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.
CAUTION
Handle with care.
Be careful to avoid injury to hands, arms and legs.
Ensure that the adjusting bushes (1 - 2) are fully home
in the frame.
Shift the engine gradually, with minimal movements,
until engine fixing holes align perfectly with those on
the frame (A - B - C - D). 2
Once the engine is back into frame, perform the following
operations.
1
Ensure that all engine mounting bolts and nuts are at

the correct torque.
Top up coolant level, see 2.14 (CHECKING AND TOP-
PING UP COOLANT LEVEL).
Top up engine oil level, see 2.12 (CHECKING AND
TOPPING UP ENGINE OIL LEVEL).
If you have overhauled the engine, bleed the engine oil
circuit and check oil pressure.
Check chain slack and adjust as required, see 2.35.1
(CHAIN SLACK INSPECTION) and 2.35.3 (CHAIN
SLACK ADJUSTMENT).
WARNING
Inspect any parts you have removed, paying special B
attention to these components:
- wiring must be properly fastened with wire ties.
WARNING
Wires and hoses must not be twisted and/or trapped
under other parts.
- electrical connectors must be fitted to the matching D
connectors;
- hoses, pipes and couplings must be securely in place
and fastened with suitable clips;
- throttle and cold-start cables must slide smoothly A C
inside their housings and must not bind when
handlebars are turned;
- gear shift lever must be properly positioned;
- rear brake lever must be properly positioned.
3 - 16 - 00 Release 00/2001 - 11
RST mille
ENGINE
NOTES
Release 00/2001 - 11 3 - 17 - 00
ENGINE RST mille
NOTES
3 - 18 - 00 Release 00/2001 - 11

WARNING

WARNING

WARNING

WARNING

WARNING
Kill
Switch +
- +
M COOLING FAN 1
BATTERY -
+
M
M PWONLY
COOLING FAN 2
-
+
M FUEL PUMP
0.5 mm² -
Raychem 67
P1 H1
P2 F3
Vign P2 E1
Vbat P1H4
P2 G1
P2 G2
+VE
CAMSHAFT POSITION P1 A1 EXHAUST
SENSOR VALVE
P1 B1 P1G1
-VE
COOLANT P1 B2 FRONT CYLINDER

THERMISTOR INJECTOR
P1H3
P1 D1
MC 1000 REAR CYLINDER
AIR THERMISTOR
INJECTOR
ECM P1H2
+VE P1 B3
THROTTLE POSITION
SENSOR SIG P1 E3
+VE
P1 E4
Supply via
Engine position sensor ignition switch
(prototypes only)
P2 C1
+VE
SIG
-VE
INJECTOR NO. 1
AIR P2H1
PRESSURE
SENSOR
(IN ECU)
INJECTOR NO. 2
P2H4
P1 D2
Tilt switch
INJECTOR NO. 3
P2 H2
Supply via
Instrument
ignition switch INJECTOR NO. 4
Cluster
P2 H3
Diagnostics signal P1 D4
D
Engine rotation P2 A1 D
P1 F1 C
Test switch P1 F2 C
P2 D3
B STEPPER
P1 E2 B
A MOTOR
P1 E1 A
Test switch
3 CAN_H
Clutch, neutral Neutral P2 D2 11 CAN_L
and side stand DIAGNOSTIC LINE K Diagnostics
Side stand P2 A2 7 ISO 9141 K
SECTION 2.3 P2 C2 P2 B2 connectors
15 ISO 9141 L J1962
DIAGNOSTIC LINE L
16 12V Batt. + ve.
SECTION 3.1
4
Power ground pins

P1G4,P2G3,P2G4 P2 C4 Frame ground
- +
BATTERY
65 PINK-WHITE
80 BROWN
52 YELLOW-BLACK
55 BROWN-GREEN
53 YELLOW-BLACK 28 GREY-WHITE
H G F E D C B A
51 ORANGE-WHITE 47 BROWN-PINK
1 1
50 GREEN-LIGHT BLUE 27 BLUE-ORANGE
2 2
49 ORANGE-LIGHT BLUE
3 3
48 YELLOW-BLUE
4 4
H G F E D C B A
20 BLUE-GREEN 22 BLUE-GREEN
54 BLACK 62 GREY
21 BLUE-GREEN 23 BLUE-GREEN
30 BLUE-GREEN
SOLDERED TO SHIELDING OF THE
TWO WIRES, HEAT-SHRINK
PROTECTION
40 PINK 36 RED-BLACK
43 LIGHT BLUE 2 BLUE

41 PURPLE
35 PINK-BLACK
42 YELLOW
H G F E D C B A
44 BLUE-WHITE 1 RED
1 1
46 GREEN-GREY
2 2
45 GREY-RED
3 3
17 RED-BROWN
4 4
H G F E D C B A
37 BROWN-YELLOW
38 BROWN-WHITE
19 BLUE-GREEN
25 BLUE-BLACK
26 PURPLE-BROWN
31 BLUE-RED 39 WHITE-PURPLE
CAUTION
WARNING

WARNING

WARNING

WARNING

WARNING
WARNING

WARNING
CAUTION
WARNING
WARNING

WARNING

CAUTION

WARNING
CAUTION

USA

ARROW UP

BACK
ENTER
LEFT ARROW RIGHT ARROW
ARROW DOWN
"+" KEY
"-" KEY
ON / OFF

WARNING

ARROW UP
BACK
ENTER
LEFT ARROW RIGHT ARROW
ARROW DOWN
"+" KEY
"-" KEY
ON / OFF
WARNING

WARNING

WARNING

WARNING
WARNING

WARNING

WARNING

WARNING

WARNING
WARNING

WARNING

WARNING

WARNING

WARNING

WARNING
CAUTION
WARNING
WARNING

WARNING

WARNING

WARNING

10 m
WARNING
9/10 H
H

USA

WARNING
USA

WARNING

CAUTION

WARNING

WARNING
WARNING
WARNING

WARNING
WARNING

WARNING
WARNING

CAUTION

WARNING

WARNING

WARNING
WARNING

WARNING

CAUTION
WARNING

WARNING

WARNING

WARNING
WARNING

WARNING

WARNING

WARNING
WARNING

WARNING

WARNING

WARNING
WARNING

z
z
WARNING

z
z
z
WARNING
z
z
z
z
z
WARNING
z
z
z
z
z
z
WARNING
z
z
z
z
z
z
z
z
z
z
z

WARNING
WARNING

WARNING

WARNING
50
60 70
80
90
40 100
30 110
20 120
10
WARNING

WARNING

z
WARNING

z
WARNING
z
z
z
z
z
z
z
z
z
z
WARNING
z
z
z
z
z
z
z
z
z
z
z
z

WARNING
CAUTION

WARNING

WARNING

WARNING
WARNING

WARNING
WARNING 60 70
80
50 90
40 100
30 110
20 120
10
WARNING

WARNING

Frame

WARNING

WARNING

WARNING
WARNING
CAUTION
WARNING

WARNING
WARNING

WARNING

WARNING

WARNING
➤
➤
➤
➤
➤

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RST mille

0.1 RELEASE 00/2001-11 UPDATE page# Release page# Release

page# Release page# Release page# Release page# Release

0.2 REFERENCE GUIDE

1.9 PLACING THE MOTORCYCLE ON THE

1.9.1 PLACING THE MOTORCYCLE ON THE FRONT

1.9.2 PLACING THE MOTORCYCLE ON THE

Read paragraph 0.2.1 (GENERAL PRECAUTIONS

Part no. 8140176 (complete stand).

Torque wrench setting for nut (1) / bolt (2):50

0.3 FOREWORD 0.4 REFERENCE MANUALS

such basic knowledge or training could result in

aprilia s.p.a. reserves the right to make changes to its 8102857 P E UK

adopted, are reserved in all countries. 8104099 USA

Please read 0.4 (REFERENCE MANUALS) for more 8104143 NL DK SF

0.5 SAFETY INFORMATION Read 1.2 (WARNINGS CONCERNING FUEL,

CAUTION 0.5.3 DISASSEMBLING THE COMPONENTS

I Italy GR Greece Mal Malaysia

A Austria CH Switzerland HR Croatia

P Portugal DK Denmark AUS Australia

B Belgium SGP Singapore BR Brazil

0.7 ABBREVIATIONS/SYMBOLS/ T.C.E.I. = cheese-headed Allen screw

1 1.2.1 FUEL ...................................................... 1-3-00

6 FRONT WHEEL STAND ..................... 1-17-00

7 1.11 TORQUE FIGURES ........................ 1-21-00

1.1 LOCATION OF SERIAL NUMBERS

1.1.1 FRAME NUMBER

1.1.2 ENGINE NUMBER

1.2 WARNINGS CONCERNING FUEL,

1.2.2 ENGINE OIL 1.2.3 BRAKE FLUID

1.2.4 COOLANT 1.2.5 CLUTCH FLUID

Freezing point °C Coolant

NOTE The different brands of anti-freeze available on

1.2.6 CARBON OXIDE 1.3 RUNNING-IN RECOMMENDATIONS

Recommended maximum engine speed

1.4 SPARE PARTS

Valve clearance, intake 0.12-0.17 mm

Light-alloy single-sided swinging arm and adjustable oil/

Front (standard) METZELER ME Z4 B 120/70ZR17”  250 (2.5)

Rear (standard) METZELER ME Z4 180/55ZR17”  290 (2.8)

Front (standard) MICHELIN PILOT SPORT 120/70ZR17” ❖ 250 (2.5)

Front (option) PIRELLI MTR21A 120/70ZR17”  250 (2.5)

Rear (option) PIRELLI MTR22 180/55ZR17”  280 (2.8)

 = Road use ; ❖ = Competition

1.6 LUBRICANT CHART (Recommended) aerosol chain lubricant: CHAIN

1.7.1 PRODUCT FEATURES

Product Usage and features

High-temperature assembly paste.

LOCTITE® Anti Seize 15378

SILASTIC 732 RTV

Sealant, prevents ingress of water into flywheel casing.

1.7.2 PRODUCT APPLICATIONS

Product Part number Applications

- Swinging arm rivets, instrument panel/front fairing mount, seat

- Steering retaining bush.

Product Part number Applications

Product Part number Applications

- For cleaning left-hand handlebar before fitting twistgrip.

(*) = see 1.6 (LUBRICANT CHART).

Front (standard) METZELER ME Z4 B 120/70ZR17” 250 (2.5)

Rear (standard) METZELER ME Z4 180/55ZR17” 290 (2.8)

Front (option) PIRELLI MTR21A 120/70ZR17” 250 (2.5)

Rear (option) PIRELLI MTR22 180/55ZR17” 280 (2.8)

= Road use ; ❖ = Competition