Aprilia Futura 1000 - ENG
Aprilia Futura 1000 - ENG
Aprilia Futura 1000 - ENG
INTRODUCTION
INTRODUCTION 0
GENERAL INFORMATION 1
SERVICE AND SETTING UP 2
ENGINE 3
FUEL SYSTEM 4
COOLING SYSTEM 5
ELECTRICAL SYSTEM 6
CHASSIS 7
TROUBLESHOOTING 8
ANALYTICAL INDEX
i
Release 00/2002 - 03 0 - 1 - 00
INTRODUCTION RST mille USA
INTRODUCTION
TABLE OF CONTENTS
0.1 UPDATE RELEASE 00/2002-03 ....... 0-3-00
0.1.1 INFORMATION ON UPDATING
0 THE MANUAL........................................ 0-3-00
0.1.2 UPDATED MANUAL GENERAL LIST .. 0-3-00
0.2 HOW TO CONSULT THE MANUAL .. 0-6-00
0.3 FOREWORD ..................................... 0-7-00
0 0.4 REFERENCE SERVICE
LITERATURE ................................... 0-7-00
0.4.1 ENGINE SERVICE MANUAL ................ 0-7-00
0.4.2 SPARE PARTS CATALOGUES............ 0-7-00
2 0.4.3 SPECIAL TOOLS MANUALS ............... 0-7-00
0.4.4 OPERATING AND MAINTENANCE
MANUALS ............................................. 0-7-00
0.5 ABBREVIATIONS/SYMBOLS/
0 - 2 - 00 Release 00/2002 - 03
RST mille USA
INTRODUCTION
NOTE For the nomenclature of a typical page of the 2-10 -00 ...................... 00 2-51 -00 ...................... 00
manual (and, specifically, for a definition of the page 2-11 -00 ...................... 00 2-52 -00 ...................... 00
number), see 0.2 (HOW TO CONSULT THE MANUAL).
2-12 -00 ...................... 00 2-53 -00 ...................... 00
0.1.2 UPDATED MANUAL GENERAL LIST
2-13 -00 ...................... 00 2-54 -00 ...................... 00
page # Release page # Release 2-14 -00 ...................... 00 2-55 -00 ...................... 00
0-1 -00 ........................ 00 1-12 -00 ...................... 00 2-15 -00 ...................... 00 2-56 -00 ...................... 00
0-2 -00 ........................ 00 1-13 -00 ...................... 00 2-16 -00 ...................... 00 2-57 -00 ...................... 00
0-3 -00 ........................ 00 1-14 -00 ...................... 00 2-17 -00 ...................... 00 2-58 -00 ...................... 00
0-4 -00 ........................ 00 1-15 -00 ...................... 00 2-18 -00 ...................... 00 2-59 -00 ...................... 00
0-5 -00 ........................ 00 1-16 -00 ...................... 00 2-19 -00 ...................... 00 2-60 -00 ...................... 00
0-6 -00 ........................ 00 1-17 -00 ...................... 00 2-20 -00 ...................... 00 2-61 -00 ...................... 00
0-7 -00 ........................ 00 1-18 -00 ...................... 00 2-21 -00 ...................... 00 2-62 -00 ...................... 00
0-8 -00 ........................ 00 1-19 -00 ...................... 00 2-22 -00 ...................... 00 2-63 -00 ...................... 00
0-9 -00 ........................ 00 1-20 -00 ...................... 00 2-23 -00 ...................... 00 2-64 -00 ...................... 00
0-10 -00 ...................... 00 1-21 -00 ...................... 00 2-24 -00 ...................... 00 2-65 -00 ...................... 00
1-1 -00 ........................ 00 1-22 -00 ...................... 00 2-25 -00 ...................... 00 2-66 -00 ...................... 00
1-2 -00 ........................ 00 1-23 -00 ...................... 00 2-26 -00 ...................... 00 2-67 -00 ...................... 00
1-3 -00 ........................ 00 1-24 -00 ...................... 00 2-27 -00 ...................... 00 2-68 -00 ...................... 00
1-4 -00 ........................ 00 1-25 -00 ...................... 00 2-28 -00 ...................... 00 3-1 -00 ........................ 00
1-5 -00 ........................ 00 1-26 -00 ...................... 00 2-29 -00 ...................... 00 3-2 -00 ........................ 00
1-6 -00 ........................ 00 1-27 -00 ...................... 00 2-30 -00 ...................... 00 3-3 -00 ........................ 00
1-7 -00 ........................ 00 1-28 -00 ...................... 00 2-31 -00 ...................... 00 3-4 -00 ........................ 00
1-8 -00 ........................ 00 1-29 -00 ...................... 00 2-32 -00 ...................... 00 3-5 -00 ........................ 00
1-9 -00 ........................ 00 1-30 -00 ...................... 00 2-33 -00 ...................... 00 3-6 -00 ........................ 00
1-10 -00 ...................... 00 1-31 -00 ...................... 00 2-34 -00 ...................... 00 3-7 -00 ........................ 00
1-11 -00 ...................... 00 1-32 -00 ...................... 00 2-35 -00 ...................... 00 3-8 -00 ........................ 00
CONT'D ➤
Release 00/2002 - 03 0 - 3 - 00
INTRODUCTION RST mille USA
CONT'D ➤
CONT'D ➤
0 - 4 - 00 Release 00/2002 - 03
RST mille USA
INTRODUCTION
Release 00/2002 - 03 0 - 5 - 00
INTRODUCTION RST mille USA
Release 00/2001 - 07 1 - 17 - 00
0 - 6 - 00 Release 00/2002 - 03
Release 00/2002 - 03 0 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
INTRODUCTION RST mille USA
0.5 ABBREVIATIONS/SYMBOLS/ACRONYMS
# = number kΩ = kiloohms
< = less than kPa = kiloPascal (1 kPa = 0.145 psi - 0.01 bar)
> = greater than KS = clutch side (Kupplungseite)
< = equal to or less than kW = kilowatts
> = equal to or greater than = liters (1 = 0.2641721 US gal)
~ = approximately LAP = lap (for competitive riding)
∞ = infinity LED = Light Emitting Diode
°C = degrees Celsius (centigrade) m/s = meters per second
°F = degrees Fahrenheit max = maximum
± = plus or minus mbar = millibar (1 mbar = 0.0145 psi - 0.1 kPa)
a.c. = alternating current mi = miles
A = ampere MIN = minimum
Ah = ampere per hour MPH = miles per hour
API = American Petroleum Institute MS = flywheel side (Magnetoseite)
HV = high voltage MΩ = megaohm
AV/ DC = Anti-Vibration Double Countershaft N.A. = Not Available
bar = unit of pressure MON = “Motor” method octane number
(1 bar =14.50 psi -100 kPa)
Nm = Newton-meter (1 Nm =0.723300129 ftlb)
BDC = bottom dead center
oz = ounce
cm³ = cubic centimeters
(1 cm³ = 0.0338139 US fl oz) Ω = ohm
0 - 8 - 00 Release 00/2002 - 03
NOTES
Release 00/2002 - 03 0 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
INTRODUCTION RST mille USA
NOTE
0 - 10 - 00 Release 00/2002 - 03
GENERAL INFORMATION 1
Release 00/2002 - 03 1 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 2 - 00 Release 00/2002 - 03
WARNING
This statement indicates a potential hazard which
may result in some personal injury, or damage to the
vehicle.
NOTE The term “NOTE” in the present manual calls
your attention to important information or instructions.
Release 00/2002 - 03 1 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 4 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
DANGER
Remember that the tightening torque of all fasteners
on the wheels, brakes, axles, and other components
of the suspension system is very important to ensure
the safety of the vehicle, and must be kept at the
prescribed values.
Check the tightening torque of the fasteners
regularly, and always use a torque wrench when
reinstalling them.
Failure to comply with this warning could allow one
of these components to be lost which could allow
one of these components to be lost which could lock
a wheel or cause other handling problems with
consequent overturning and risk of serious injury or
even death.
1 - 6 - 00 Release 00/2002 - 03
1.4.1 FUEL
DANGER
Gasoline is extremely flammable and in some
conditions can become explosive.
It is therefore necessary to refuel and carry out
maintenance operations involving the fuel system in a
well-ventilated area, with the engine off.
Do not refuel or do any maintenance on the fuel system
with the engine running.
Do not smoke while refueling or near fuel vapors.
Never allow any portion of the fuel system to come in
contact with open flames, sparks or other heat sources.
Be careful to avoid spilling fuel when you are refueling.
Spilled fuel could ignite when it contacts hot engine or
exhaust system surfaces.
If you accidentally spill some fuel, ensure that it is
wiped up or completely evaporated before starting the
vehicle.
Since gasoline expands in the fuel tank when the vehicle
is sitting in the open sun, never fill the tank completely to
the brim. Leave at least one inch of expansion space.
Avoid any contact of the fuel with your skin, and avoid
inhalation of fuel vapors.
Do not ever attempt to siphon fuel from one container to
another using your mouth as suction for a siphon hose.
Gasoline is poisonous and carcinogenic and contains
chemical substances that cause birth defects and other
reproductive problems. If gasoline should be
accidentally spilled on the skin or clothes, immediately
wash it off with soap and water and change clothes.
DANGER
Should you accidentally spill gasoline in your eyes,
flush with a large quantity of water and immediately Do not add any additives or other substances to the
contact a health professional. gasoline.
Should you accidentally get gasoline into your mouth, Do not refuel the tank completely; the fuel should never
do not induce vomiting. be touching the rim of filler cap seat hole.
Drink a large quantity of milk or clear water and After refueling, replace the fuel filler cap (1) in the
immediately contact a health professional. correct position and ensure that it is properly closed.
Never try to siphon gasoline by sucking it with your Use only unleaded gasoline with a minimum octane
mouth. rating of 92 (M+R)/2 .
Use a manual pump or a similar system.
FUEL TANK CAPACITY
If your vehicle overturns, it will leak gasoline which is (reserve included): 5.28 US gal (20l).
extremely flammable.
TANK RESERVE: 1.19 ± 0.26 us GAL (4.5 ± 1l).
Flames or sparks may ignite this which will not only
destroy the vehicle but also could do serious property
damage to surrounding property and cause serious
injuries or even death.
ALWAYS KEEP GASOLINE AWAY FROM CHILDREN.
DISPOSE OF UNWANTED GASOLINE PROPERLY, DO
NOT DUMP IT INTO STORM SEWERS OR INTO A
SINK OR TOILET.
WARNING
Before opening the fuel filler cap, if necessary, clean
the cap and the part around it with a clean cloth.
Prevent any foreign material from getting into the fuel
tank, this could lead to serious engine damage.
If you use any container or funnel for refueling, make
sure that it is perfectly clean. Any foreign matter getting
into the fuel tank may lead to severe damage.
Release 00/2002 - 03 1 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1.4.2 LUBRICANTS
DANGER
Proper vehicle lubrication is critical to safe operation. 1
Failure to maintain proper lubricant levels or to use the
proper type of clean, new lubricant, can lead to an
engine or transmission seizure with subsequent
accident, serious injury or death.
Use latex gloves for the maintenance operations that
require contact with used oil.
Used oil may cause skin cancer if repeatedly left in
contact with the skin for prolonged periods.
Although this is unlikely unless you handle used oil on
a daily basis, it is advisable to thoroughly wash your
hands with soap and water after handling used oil.
KEEP OIL AWAY FROM CHILDREN.
DISPOSE OF OIL PROPERLY. FORK OIL
WARNING DANGER
Be very careful when putting oil in your vehicle not to Changing the damper settings and/or the viscosity of
spill it. the damper oil changes suspension response and
Clean up any oil spilled immediately because oil can could upset vehicle handling. Always follow the
damage the finish of your vehicle.
recommendations in this manual for suspension
Also, oil on the tires creates an extremely slippery and
adjustments.
therefore dangerous situation.
In case of lubricant leakage do not ride the vehicle, but The standard fork oil viscosity is SAE 20W.
check to determine the cause of the leakage and repair it. Oil as light as SAE 5W may be used if a soft fork
stiffness is desired, and you may mix 5W with 20W in
ENGINE OIL
varying proportions to obtain a desired different fork
stiffness.
DANGER
If the engine oil pressure warning light LED “ “ Ensure that exactly the same mixture is used in each
(1) remains on (when the engine is running), or if it fork.
comes on during the normal running of the engine,
this means that the oil system is not developing One of the properties of F.A. or FORK is
sufficient pressure. that their viscosity changes very little with variations
In this case, immediately stop the engine and check in temperature, and their damping response remains
the engine oil level, see 2.13 (CHANGING THE fairly constant.
ENGINE OIL AND OIL FILTER) if the level is correct,
check the engine oil pressure sensor, see 6.10.3 1.4.3 BRAKE
(ENGINE OIL PRESSURE SENSOR). NOTE This vehicle è equipped with front and rear disc
Failure to heed this warning can lead to engine brakes, with separate hydraulic circuits.
seizure, upset, and serious injury or even death.
The following information refers to a single brake system,
WARNING but is applicable to both.
Perform these maintenance operations at one-half of
the specified intervals, if the vehicle is often used in DANGER
rainy or very dusty conditions, on unpaved roads or Do not ride the vehicle with worn or malfunctioning
in any kind of competition. brakes! The brakes are the most important safety
Periodically check the engine oil level, see 2.12 system of the vehicle, and using the vehicle with
(CHECKING AND TOPPING UP THE ENGINE OIL brakes that are anything less than perfect is very likely
LEVEL). to lead to a collision or upset, with consequent risk of
Renew the engine oil after the first 600 mi (1,000 Km), and serious injury or death.
thereafter every 4,600 mi (7,500 km) (*), see 2.13
Wet condition seriusly degrade the performance of
(CHANGING THE ENGINE OIL AND OIL FILTER).
your brakes.
(*) = For competition use, renew every 2,300 mi (3,750 km).
When the road is wet from rain, you should plan to use
NOTE Use high-quality 15W-50 oil, see 1.12 double the normal stopping distances since both the
(LUBRICANT CHART). brakes themselves and the traction of the tires on the
As an alternative to the recommended oil, it is possible to road are reduced by the presence of water.
use high-quality oils with characteristics in compliance Water on the brakes from washing your vehicle, or
with or superior to the CCMC G-4, A.P.I. SG. splashed up from wet roads, or crossing puddles or
specifications. ditches, can wet the brakes sufficiently to greatly
reduce their effectiveness.
1 - 8 - 00 Release 00/2002 - 03
DANGER
The brakes are the most important safety system on
your vehicle.
For your safety, they must be in perfect repair, so they
should be checked every time you ride the vehicle.
Oil or other fluid on a disc will contaminate the brake
pads.
Dirty pads must be discarded and replaced, a dirty or 2
oily disc must be cleaned with a high quality degreaser.
DANGER
Perform these maintenance operations at one-half of
the specified intervals, if the vehicle is often used in
rainy or very dusty conditions, on unpaved roads or
in any kind of competition.
Check the levels of the brake fluid in the reservoirs
after the first 600 mi (1,000 km) and thereafter every
4,600 mi (7,500 km); see 2.16 (CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID) and 2.17
(CHECKING AND TOPPING UP THE REAR BRAKE
FLUID); renew the brake fluid every two years,
see 2.21 (CHANGING THE FRONT BRAKE FLUID)
and 2.22 (CHANGING THE REAR BRAKE FLUID).
NOTE Use high-quality brake fluid, see 1.11 (Lubricant
chart).
Check the brake pad wear, as shown on 2.27
(CHECKING THE BRAKE PAD WEAR).
When the pads wear out the brake fluid level in the
reservoir decreases to automatically compensate for their
wear.
The front brake fluid reservoir (1) is located on the right
end of the handlebar near the front brake lever.
The rear brake fluid reservoir (2) is under the fairing on
the right side of the vehicle.
DANGER
Never use the vehicle if any portion of either brake
system is leaking.
Release 00/2002 - 03 1 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
DANGER
Do not ride the vehicle with worn or malfuctioning
clutch! The clutch is an important safety system of
the vehicle, and using the vehicle with clutch that is
anything less than perfect is very likely to lead to a
collision or upset, with consequent risk of serious
injury or death.
The clutch is extremely important for your safety. Do
not use the vehicle if the clutch does not work
perfectly. Always check the clutch efficiency before
riding.
Sudden variations in clearance or an elastic
resistance in the clutch lever may be due to trouble in
the hydraulic system.
KEEP CLUTCH FLUID AWAY FROM CHILDREN.
DISPOSE OF USED CLUTCH FLUID PROPERLY. SEE
THE GENERAL WARNINGS AT 1.3.6 (CLUTCH
CONTROL FLUID)
When using the fluid, take care not to spill it on the
plastic and painted parts, since it damages them.
Perform these maintenance operations at one-half of
the specified intervals, if the vehicle is often used in
rainy or very dusty conditions, on unpaved roads, or
in any kind of competition.
Check the levels of the clutch fluid in the reservoir
after the first 600 mi (1,000 km), and thereafter every
4,650 mi (7,500 km) [for competition use: thereafter
every 2,300 mi (3,750 km)], see 2.18 (CHECKING AND
TOPPING UP THE CLUTCH FLUID).
Renew the fluid every two years, see 2.23
(CHANGING THE CLUTCH FLUID).
Never use the vehicle if the clutch hydraulic system
is leaking.
WARNING
To avoid serious damage to the system, do not use
fluids other than the recommended ones nor mix
differents fluids for topping up.
Do not use clutch fluid taken from old or already
opened containers.
Check that the clutch control lines are not twisted or
worn.
Ensured that neither water nor dust accidentally
enter the system.
In case maintenance operations are to be performed
on the hydraulic system, it is advisable to use latex
gloves.
NOTE Use high-quality clutch control fluid, see 1.12
(LUBRICANT CHART)
The clutch control fluid reservoir (1) is located on the left
end of the handlebar near the clutch lever.
NOTE The hydraulic clutch is installed in conjunction
with PPC (pneumatic power clutch), an exclusive
patented system which avoids rear wheel hop.
1 - 10 - 00 Release 00/2002 - 03
1.4.6 COOLANT
WARNING
Do not use the vehicle if the coolant is below the
minimum prescribed level.
Before setting off, and every 9,300 mi (15,000 km), check
the level of the coolant, see 2.14 (CHECKING AND
TOPPING UP THE COOLANT); renew the coolant every
two years, see 2.15 (CHANGING THE COOLANT).
DANGER
Coolant is poisonous! Do not ingest coolant under
any circumstance.
Should you get coolant in your mouth, rinse with
cool water and immediately seek medical attention.
Coolant is also very dangerous to your skin and
eyes. DANGER
Should you accidentally get coolant on your clothing
Be aware of the risk of burns from the coolant.
or skin, change clothes immediately.
Check the coolant level and top up the expansion
Wash coolant from your skin with hot water and
tank only after the engine has thoroughly cooled.
soap.
Should you get coolant in your eyes, flush with Do not use your fingers or any object to check if
plenty of cool water and seek professional medical there is enough coolant.
help at once.
On the basis of the desired freezing temperature of the
Should someone swallow coolant accidentally,
coolant mixture, add to the water the percentage of
induce vomiting, rinse mouth with water, and
coolant indicated in the following table:
immediately seek professional medical attention.
DISPOSE OF THE COOLANT PROPERLY.
Freezing point Coolant of
BE SURE TO KEEP THE DRAINED COOLANT AWAY °C (°F) the volume %
FROM CHILDREN AND PETS.
IT IS SWEET TASTING, AS WELL AS EXTREMELY -20 (-4) 35
POISONOUS, AND IS VERY ATTRACTIVE TO
-30 (-22) 45
CHILDREN AND PETS.
Use extra caution not to spill the coolant on any hot -40 (-40) 55
parts of the engine. It is flammable, and can emit
invisible, noxious fumes. NOTE The characteristics of the various antifreeze
Always wear rubber or latex gloves when servicing liquids are different.
the cooling system. Be sure to read the label on the product to learn the
It is advisable to maintain 50% water/50% antifreeze year degree of protection it guarantees.
round. This way, losses due to evaporation are reduced,
and topping up the radiator need not be done very
WARNING
frequently. Thus, the mineral salt deposits left in the Use only a high quality antifreeze, specifically
radiator by evaporation are reduced, and the cooling intended for use with aluminum and magnesium
efficiency of the system uncompromised. If the outdoor engines, which contains no nitrite.
temperature is below 0ºC (32ºF), check the antifreeze
concentration in the coolant. Below 0º, increase the
antifreeze concentration to 60%.
WARNING
Use only distilled water topping off the cooling
system. This will reduce damage to the engine.
DANGER
The coolant is very hot.
Do not remove the filler cap (1) when the engine is
hot since the coolant is under pressure and it will
splash out violently.
If it gets in contact with the skin or with your
clothing, it may cause severe burns.
Release 00/2002 - 03 1 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1.4.8 TIRES
DANGER
If the tire is inflated to too high a pressure, an
uncomfortably harsh ride will result, and riding
confort will be compromised.
Also, road holding, especially during turns and in wet
condition, will likewise be compromised.
If the tire is underinflated (pressure is too low), the
tire may slip on the rim with consequent loss of
control.
Again road holding and handling characteristics will
be degraded, and brake performance will be reduced.
Insure that all tires are equipped with properly
installed valve caps.
Changing, repairing, maintenance and balancing
operations are very important and should be carried
out by qualified technicians with appropriate tools.
If the tires are new, they may still be covered with a
slippery film: ride carefully for the first few miles.
Never attempt to treat a tire with any kind of rubber
dressing.
Particulary avoid contact to the tire with any gasoline
fluid as this will cause rapid deterioration of the
rubber.
If a tires become contaminated with oil or gasoline,
you cannot clean it.
The tire must be replaced.
1 - 12 - 00 Release 00/2002 - 03
DANGER
The exhaust system of this vehicle is equipped with a
catalytic converter.
2
It becomes extremely hot, and cause serious burns
and forest fires.
Do not touch it! Keep flammable materials away.
If your vehicle is equipped with catalytic converter,
do not park near dry brush, wood, or in places easily
accessible to children, as the catalytic converter
becomes extremely hot during use.
Be careful to avoid any kind of contact before it has
completely cooled down.
The catalytic converter, if used, is a metal “platinum-
rhodium bivalent” type.
This device provides for the oxidation of the CO
(carbonmonoxide) and of the HC (unburned
hydrocarbons) contained in the exhaust gases, changing
them into carbon dioxide and steam, respectively.
WARNING
Do not use leaded gasoline, since it causes the
destruction of the catalytic converter.
DANGER
Tampering with the exhaust system is prohibited.
It is against the law for you to alter the exhaust system
in a manner that increases the noise, carefully
read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION)
Periodically inspect the entire exhaust system, including
the exhaust pipe and silencer, to ensure that no holes
have rusted through.
Using a wire or a small pick, ensure that the drain hole in the
bottom of the muffler is open.
If the noise of your vehicle has increased significantly, replace
the defective exhaust system components.
Tampering with the exhaust system not only makes your
vehicle loud, it will reduce its performance and shorten its life.
DANGER
If the bike is to be used off-road, on public land, it is
the owner’s responsibility to install a spark arrester
approved by the Us Forest Service for this engine
displacement or lager.
Release 00/2002 - 03 1 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
DANGER
After the vehicle has been operated for 600 mi ( 1,000
km) perform the “checking operations” shown in
column “After running-in” of the 2.1 (SCHEDULED
MAINTENANCE PLAN)
Rectify any faults found. Failure to heed this warning
could lead to damage to your vehicle or engine
seizure or other malfunction which could cause an
up-set and lead to serious injury or even death.
Between the first 600 mi ( 1,000 km) and 900 mi (1,500
km) ride more briskly, changing speed and using
maximum acceleration for only a few seconds. Never
exceed 7,500 rpm.
After the first 900 mi (1,500 km) if you have followed
the above break in schedule, the engine should be fully
broken in, and will deliver maximum performance.
However, never exceed the maximum allowed rpm
(10,500 rpm).
600 - 900
7,500
(1,000 - 1,500)
1 - 14 - 00 Release 00/2002 - 03
1.6 HOW TO USE YOUR SERVICE AND In this manual the various versions are indicated by the
REPAIR MANUAL following symbols:
This manual is divided into sections, chapters and Automatic Switch-on Device version
paragraphs, each one of which corresponds to a
category of main components. evaporative emission system
To consult them, see TABLE OF CONTENTS. optional
If not expressly indicated otherwise, for the reassembly of
the units repart the disassembly operations in reverse
order. VERSION:
The terms “right” and “left” are referred to the rider seated
on the vehicle in the normal riding position. I Italy GR Greece Mal Malaysia
For normal maintenence operations and for the use of the
vehicle, consult the “USE AND MAINTENANCE” manual. UK United
NL Netherlands RCH Chile
Kingdom
The operations preceded by this symbol must be
repeated on the opposite side of the vehicle. A Austria CH Switzerland HR Croatia
NOTE When asking your Dealer for spare parts, USA United
specify the spare parts code indicated on the SPARE SF Finland J Japan States of
PARTS IDENTIFICATION LABEL. America
Write down the identification code in the space here
below, in order to remember it in also case of loss or B Belgium SGP Singapore BR Brazil
deterioration of the label. Republic of
RSA
The label is placed under the saddle, see to be able to D Germany SLO Slovenia the South
read it, remove the saddle see 7.1.1 on the right part of Africa
the frame.
NZ New
F France IL Israel Zealand
ROK South
E Spain Korea
CDN Canada
Release 00/2002 - 03 1 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
ZD4DWE00#Y0000000
1 2 3 4567 8
B month/year
FOR STATE OF CALIFORNIA ONLY:
00/00
ZD4DWE10#Y0000000
1 2 3 4567 8
DIGIT MEANING
1) Manufacturer’s identification alphanumeric code. V.I.N.
2) Vehicle type.
3) Model.
4) Country for which the vehicle is intended. FOR STATE OF CALIFORNIA ONLY
5) #=Check digit number.
6) Model year. B month/year
7) Assembling factory designation
(N =NOALE-VE-,
S =SCORZÉ -VE-,
00/00
0 =NOT SPECIFIED).
8) Sequential serial number.
V.I.N.
1 - 16 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 2 3 3a 4
9 10 11 12 13
9 16 15 14
6a 6 7 8
5a
1 - 18 - 00 Release 00/2002 - 03
00/00
1 8
00/00
9
1a
11
2a
12
3
13
4 14
15
15a
16 MUFFLER STAMPING
Release 00/2002 - 03 1 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
20
4
19 21 18
17
16
23
6 15
7 22
5
24
29
28
13 14
12 8
11 9
27 25 10 26
1 - 20 - 00 Release 00/2002 - 03
WARNING
Use of spare parts NOT originally manufactured by
aprilia may cause performance problems and damage.
1.11 SPECIFICATIONS
DIMENSIONS
Max. length 85.472 in (2,170 mm)
Max. width 29.133 in (740 mm)
Max. height (at front fairing) 48.818 in (1,240 mm)
Saddle height 32.283 in (820 mm)
Wheelbase 56.495 in (1,435 mm)
Minimum ground clearance 5.314 in (135 mm)
Weight in riding condition (including fluids and fuel) 513.085 lb (235 kg)
ENGINE
60° longitudinal V-type, two-cylinder, 4-stroke, with 4
Type
valves per cylinder, DOHC.
Number of cylinders 2
Total displacement 60.878 cu in (997.62 cm³)
Max. rated power (to crankshaft) 86.5 kW (118 HP) at 9250 rpm
Max. rated power (to crankshaft) 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 lifting = 0.42 in (10.6 mm)
Camshaft during exhaust stroke 259°, valve lifting = 0.42 in (10.6 mm)
Valve advance (with valve clearance 1 mm)
opening during intake stroke 20° before TDC
closing during intake stroke 59° after BDC
opening during exhaust stroke 64° before TDC
closing during exhaust stroke 15° after BDC
Intake valve clearance 0.005-0.007 in (0.12-0.17 mm)
Exhaust valve clearance 0.009-0.011 in (0.23-0.28 mm)
Engine idling rpm 1250 ± 100 rpm
Maximum rpm 10500 ± 100 rpm
Ignition electronically controlled
Starting electric
At start: 5º before TDC. Additional advance automatic,
Spark advance
depending on operating conditions
Starter motor 12 V / 0.9 kW
Starter motor gear ratio i= 49/9 * 30/11 * 64/30 = 31.677
multidisc in oil bath with hydraulic control on the left side
of the handlebar and PPC device
Clutch
- 9 lined discs; 0.14 in (3.5 mm) thick
- 9 plain discs; 0.06 in (1.5 mm) thick
CONT'D ➤
Release 00/2002 - 03 1 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
ENGINE
mechanical, 6 gears with foot control on the left side of
Gearshift
the engine
dry sump with separate oil tank, 2 trochoidal pumps,
Lubrication system
cooling radiator
min 72.52 PSI (500 kPa) (5 bar) *max. 80 °C (176 °F)
Oil pressure
and 6000 rpm
Air filter dry filter cartridge
Cooling fluid-cooled
Coolant pump gear ratio i wp = 28/27 * 28/28 = 1.037
Coolant pump delivery (with thermostat open) 23.8 gal/min (90 l/min) at 9000 rpm
Thermostat valve opening temperature 65 ± 2 °C (149 ± 5 °F)
Engine dry weight ~ 143 lb (~ 67 kg)
CAPACITY
Fuel (including reserve) 6.60 gal (20.5 l)
Fuel reserve 1.06 ± 0.26 gol (4 ± 1 l)
oil change only: 3.9 qt (3700 cm3), oil and filter change:
Engine oil
4.1 qt (3900 cm3)
Fork oil (for each leg) 18.70 ± 0.08 fl oz (553 ± 2.5 cm³)
0.66 gal (2.5 l) (50% water + 50% nitrite-free anti-
Coolant
corrosion antifreeze, ethylene glycol)
Seats 2
Max. vehicle load (rider + passenger + luggage) 401.24 lb (182 kg)
DRIVE
Ratio Secondary Total ratio
1ª 14/35 = 1: 2.500 13.000
2ª 16/28 = 1: 1.750 9.102
Primary Final ratio
GEAR RATIOS 3ª 19/26 = 1: 1.368 7.117
31/60 = 1: 1.935 16/43 = 1: 2,687
4ª 22/24 = 1: 1.091 5.674
5ª 23/22 = 1: 1.957 4.975
6ª 27/23 = 1: 0.852 4.431
sprocket teeth 16
Endless type (with no master link) with sealed links,
Drive chain
model 525, dimensions 5/8" x 5/16"
FUEL SYSTEM
Type electronic injection
Choke Ø 1.85 in (Ø 51 mm)
POWER SUPPLY
Type indirect injection (MULTIPOINT)
Unleaded gasoline, super, minimum octane rating 92
Fuel
(R + M / 2)
FRAME
two-beam frame with light alloy cast elements and
Type
extruded elements
Rake 25.7°
Trail 3.82 in (97 mm)
CONT'D ➤
1 - 22 - 00 Release 00/2002 - 03
SUSPENSIONS
Upside-down telescopic fork, hydraulic damped, fork leg
Front
Ø 1.69 in (Ø 43 mm)
Stroke 4.72 in (120 mm)
light alloy rear swinging arm, and hydropneumatic
Rear
adjustable mono-shock absorber
Wheel stroke 4.72 in (120 mm)
BRAKES
double floating disc - Ø 11.81 in (300 mm), four piston
Front
caliper - Ø 1.18 (30 mm) and 1.33 (34 mm) pistons
single disc - Ø 10.03 in (255 mm), double piston caliper -
Rear
Ø 1.10 in (28 mm)
WHEEL RIMS
Type light alloy
Front 3.50 x 17"
Rear 5.50 x 17"
TIRES
Pressure PSI
(kPa) (Bar)
Wheel Brand Type Size Recommended
solo rider
Front
(standard)
METZELER ME Z4 B 120/70ZR17” 36.2 (250) (2.5)
Rear
(standard)
METZELER ME Z4 180/55ZR17” 40.6 (280) (2.8)
Front
MICHELIN PILOT SPORT 120/70ZR17” ❖ 36.2 (250) (2.5)
(standard)
Rear
MICHELIN PILOT SPORT 180/55ZR17” ❖ 40.6 (280) (2.8)
(standard)
Front
METZELER ME Z3 120/70ZR17” ❖ 36.2 (250) (2.5)
(alternatively)
Rear
METZELER ME Z3 180/55ZR17” ❖ 40.6 (280) (2.8)
(alternatively)
Front
(alternatively)
PIRELLI MTR21A 120/70ZR17” 36.2 (250) (2.5)
Rear
(alternatively)
PIRELLI MTR22 180/55ZR17” 40.6 (280) (2.8)
SPARK PLUGS
Standard NGK R DCPR9E
Spark plug gap 0.024 - 0.028 in (0.6 - 0.7 mm)
Resistance 5KΩ
ELECTRICAL SYSTEM
Battery 12 V - 12 Ah
Main fuses 30 A
Secondary fuses 15A
Alternator (with permanent magnet) 12 V - 470 W
Starter motor 12 V / 0.9 kW
CONT'D ➤
Release 00/2002 - 03 1 - 23 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
BULBS
Low beam (halogen) 12 V - 55 / 55 W H4
High beam (halogen) 12 V - 60 W H3
Front parking light 12 V - 5 W
Direction indicators 12 V - 10 W
Rear parking light/license plate light/brake light 12 V - 5/21 W
Tachometer LED
Right multi function display LED
Left multi function display LED
WARNING LIGHTS
Gearshift in neutral LED
Direction indicators LED
Fuel reserve LED
High beam LED
Side stand down LED
Engine oil pressure LED
Red line LED
Engine oil (recommended): EXTRA RAID 4, SAE Spray grease for chains (recommended): CHAIN
15W - 50 or TEC 4T SAE 15W - 50. As an SPRAY or CHAIN LUBE.
alternative to the recommended oils, it is possible to use
high-quality oils with performance characteristics DANGER
equivalent or superior to CCMC G-4,A.P.I. SG Use only fresh brake fluid.
specifications.
Fork oil (recommended): fork oil F. A . 5 W or Brake fluid (recommended): F.F., DOT 5 (DOT 4-
1 - 24 - 00 Release 00/2002 - 03
1.13 CONSUMABLES
Use only the products listed below for any maintenance work.
These materials have been tested for many years and are
suitable for use in all application conditions indicated by the
manufacturer.
NOTE Those consumables that are coded are available
upon request, see 1.13.2 (USING CONSUMABLES).
LOCTITE® 8150
Release 00/2002 - 03 1 - 25 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 26 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 27 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 28 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 29 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 30 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 31 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 32 - 00 Release 00/2002 - 03
Release 00/2002 - 03 1 - 33 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
1 - 34 - 00 Release 00/2002 - 03
1.17 FASTENERS
Carefully read 1.3.1
WARNING
Remove ONLY the clamps indicated in the
maintenance procedures.
The following text does not authorize the arbitrary
removal of the clamps present on the vehicle.
DANGER
Before removing a clamp, make sure that the
removal does not cause any fluid leakage; if so,
have appropriate plugs to prevent such leakage
on hand, and protect the other parts of the motor-
cycle which might come in contact with spilled
fluid.
CLICK CLAMPS
Plain pliers are acceptable for removal, but a special
installation tool is required.
These clamps are destroyed upon removal, so new
ones must be used upon reinstallation.
NOTE Have the appropriate special tool
available: - aprilia part #0277295 (click clamp
installation pliers).
WARNING
Upon installation, replace the click clamp that has
been removed with a new click clamp having the
same dimensions, see 0.4.2 (SPARE PARTS
CATALOGUES).
Do not attempt to reinstall the removed click
clamp, since it is unusable.
Do not replace the removed click clamp with a
screw-type clamp or with other types of clamps.
WARNING
Proceed with care, in order not to damage the
joint components.
Using pliers on the head of the click clamp, squeeze
it until it releases.
SCREW-TYPE CLAMPS
A screwdriver is used to remove and install screw
type clamps. These clamps are reusable.
WARNING
Check the conditions of the screw-type clamp and
if necessary replace it with a new screw-type
clamp of the same dimensions, see 0.4.2 (SPARE
PARTS CATALOGUES).
Release 00/2002 - 03 1 - 35 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
M6 10 4.34 6
M8 12 10.84 15
M 10 14 21.70 30
M 12 17 39.79 55
M 14 19 61.49 85
M 16 22 94.03 130
Screw ftlb Nm
M4 2.2 3
M5 4.4 6
M6 8.7 12
M8 18 25
M10 36 50
M12 58 80
1 - 36 - 00 Release 00/2002 - 03
NOTE
Release 00/2002 - 03 1 - 37 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
NOTE
1 - 38 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.11.2 ADJUSTING THE IDLE SPEED .......... 2-22-00 2.33 REAR WHEEL ................................ 2-52-00
2.11.3 ADJUSTING THE THROTTLE 2.34 EXHAUST MANIFOLD NUTS ......... 2-53-00
CONTROL............................................ 2-23-00
8 2.12 CHECKING AND TOPPING UP THE
ENGINE OIL LEVEL ....................... 2-24-00
2.35 DRIVE CHAIN ................................ 2-54-00
2.35.1 CHECKING THE PLAY ....................... 2-55-00
2.35.2 CHECKING THE WEAR OF THE
2.13 CHANGING THE ENGINE OIL AND CHAIN AND SPROCKETS.................. 2-56-00
OIL FILTER .................................... 2-25-00 2.35.3 ADJUSTING THE DRIVE CHAIN ........ 2-56-00
9 2.14 CHECKING AND TOPPING UP THE
2.35.4 INSPECTING THE DRIVE CHAIN
GUIDE PLATE ..................................... 2-57-00
COOLANT ...................................... 2-27-00
2.35.5 INSPECTING THE DRIVE CHAIN
2.15 CHANGING THE COOLANT ........... 2-28-00 SHOE ................................................... 2-57-00
2.16 CHECKING AND TOPPING UP 2.36 TIRES ............................................ 2-58-00
THE FRONT BRAKE FLUID ........... 2-29-00
2.37 FUEL LINES................................... 2-59-00
2.17 CHECKING AND TOPPING UP
2.38 BRAKE AND CLUTCH
THE REAR BRAKE FLUID.............. 2-30-00
CONTROL LINES ........................... 2-59-00
2 - 2 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
DANGER
Before beginning any maintenance work or
inspecting the vehicle, stop the engine and remove
the ignition key. Wait for the engine and exhaust
system to cool completely. If possible, use the
appropriate equipment to raise the vehicle, on a
solid, level floor.
Be especially careful around any parts of the engine
and exhaust system that may still be warm, to avoid
burns. There are no parts of this vehicle that are safe
for human consumption, therefore avoid the
temptation of holding parts in your mouth while you
are working on the vehicle. Some of the parts and
coatings used in the manufacture of this vehicle are
noxious, some are downright toxic. Keep all parts of
the vehicle out of your mouth at all times.
WARNING 1
The message "SERVICE" (1) will appear on the right-
hand display after the first 625 mi (1,000 km) and
every 4687 mi (7,500 km) thereafter.
When this occurs, carry out the operations listed in
the scheduled maintenance chart; if the vehicle is
used competitively, perform these operations more
often, see 2.1.1 (SCHEDULED MAINTENANCE
CHART)
2 - 4 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 6 - 00 Release 00/2002 - 03
2 ▲
5 ■
4 ■
■ 1
7 ■
8 ■
■ 9 6 ■
10 ■
11 ■ ■ 12
■ 3
Release 00/2002 - 03 2 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.3.1 LEGEND B
A Left digital display (odometer- mileage counter)
B Right digital multifunction display (fuel level/air
temperature - coolant temperature – clock/injection
system error codes)
C SET and MODE programming keys.
A
C
2 - 8 - 00 Release 00/2002 - 03
1 1
Release 00/2002 - 03 2 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
Description Function
High beam LED Lights when the high beam headlight is turned on or flashed.
Side stand down LED Lights when the side stand is lowered.
Lights whenever the ignition switch is set to “ “ and the engine is not
running, to perform a lamp test.
If the engine oil pressure LED “ “
WARNING remains on after starting the engine or
Engine oil pressure LED comes on while the engine is running at engine speeds above idle,
oil pressure is insufficient. Immediately stop riding and stop the
motor. Failure to observe this warning can lead to an engine seizure
with subsequent wheel seizure, loss of control, a serious accident,
serious injuries, and even death
Neutral gear N indicator LED Lights when the gearshift is set to neutral.
Lights for approximately three seconds whenever the ignition switch is set
to “ “, to perform a lamp test.
If the “EFI” diagnostics LED flashes, either
WARNING at start-up or during the normal engine
Diagnostics LED EFI
operation, it means that the electronic control unit has detected some
kind of error. In many cases the engine continues to run, with limited
performance. The message “EFI” appears on the multifunction digital
only during tests carried out by an Aprilia Dealer.
Speedometer [mi (km/h)] Indicates the vehicle speed
CONT'D ➤
2 - 10 - 00 Release 00/2002 - 03
Description Function
Digital
Odometer /
display (left Displays the trip or total mileage traveled.
mileage counter (km - mi)
side)
Displays the level of fuel in the tank.
The amount fuel is displayed on the analogue scale, with
the value expressed in gallons (numerical indication).
When the fuel tank is full, the scale is completely
highlighted, and the numerical indication displays the
message “F”.
As the fuel level falls, the scale highlighting and value in
gallons decrease.
When no segment of the scale is highlighted, the
numerical indication flashes the message “--” and the fuel
reserve LED flashes, meaning that the fuel tank contains
less than 4 ± 1 l (approx. 1 gallon). To alternate
Multifunction
Refuel as soon as possible. displays see
digital
Fuel level indicator 2.3.2
display NOTE When no segment of the scale is highlighted, (PROGRAM
(right side) the numerical indication flashes “8.8” and the fuel reserve
MING KEYS)
LED flashes.
Running out of fuel with
WARNING your vehicle can cause
loss of control with subsequent accident, upset and
serious injury or even death. Never allow the fuel
level in your motorcycle to become so low that you
will run out of fuel.
NOTE Alternatively, the digital sector may be used to
display the
air temperature (T°AIR), while the analogue indicator is
left inactive
When the digital display
WARNING flashes a temperature of
less than or equal to 3ºC, it is possible that ice might
form on the road. Slow down, avoid abrupt braking,
and be aware that if ice forms on the road, traction is
greatly reduced. Failure to observe this warning can
lead to loss of control with subsequent upset,
serious injury and even death. To alternate
Multifunction Regardless of the function displayed (fuel level or air displays see
digital Air temperature indicator temperature), when the air temperature is less than or 2.3.2
display T°AIR equal to 3 °C (37.4 °F) the display flashes the (PROGRAM
(right side) temperature for ten seconds (even if the temperature has MING KEYS)
returned above 3 °C (37.4 °F) in the meantime).
If the temperature remains below 3 °C (37.4 °F), the
above procedure is repeated three times at five-minute
intervals.
NOTE After the ten seconds have elapsed, the display
always returns to the previously displayed version (fuel
level or air temperature).
CONT'D ➤
Release 00/2002 - 03 2 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
Description Function
Displays the temperature of the coolant in the
engine, see 2.3.2 (PROGRAMMING KEYS).
The temperature is displayed on the analogue scale, with
the value expressed in °F (digital indicator).
Up to 97 °F, the symbol “---” is displayed.
The cooling fan power
WARNING switch is turned on and off
independently of the ignition switch position. To
lower the coolant temperature, the cooling fans also
run with the engine off, and shut off automatically.
If the maximum allowed temperature is exceeded
Coolant temperature (257 °F), the engine could suffer serious damage.
indicator (°C / °F) If a temperature of 241-257 °F is displayed and the the
next-to-last scale segment flashes, stop the engine, wait
for the cooling valves to shut off, and check the coolant To alternate
Multifunction
level, see 2.15 (CHANGING THE COOLANT). displays see
digital
If a temperature of 259-275 °F is displayed and the last 2.3.2
display
two segments of the scale flash, stop the vehicle and let (PROGRAM
(right side)
the engine idle for approximately two minutes, to allow MING KEYS)
coolant to circulate regularly within the system; then set
the engine stop switch to “ “ and check the coolant
level, see 2.15 (CHANGING THE COOLANT).
If the same conditions remain after the checking the
coolant level on the dashboard, do not start the vehicle.
The message "SERVICE" will appear after the first 625
mi (1,000 km) and every 4600 mi (15,000 km) thereafter.
Maintenance indicator
Carry out the operations listed in the scheduled
“service”
maintenance chart, see 2.1.1 (SCHEDULED
MAINTENANCE CHART).
Displays the hours and minutes based on settings,
Clock
see 2.3.2 (PROGRAMMING KEYS).
2 - 12 - 00 Release 00/2002 - 03
2.4 BATTERY
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
There are two kinds of commercially available batteries:
- batteries requiring maintenance featuring cell caps;
- maintenance-free batteries without cell caps. There is
no need to check or top up the electrolyte level.
NOTE This vehicle is equipped with a sealed
maintenance-free battery. It requires no maintenance
beyond occasional inspections and recharging if needed.
Always replace the battery with one of the same type.
For more information, see 6.14 (BATTERY).
WARNING
Never reverse the battery cable connections.
Connect and disconnect the battery with the ignition
switch set to “ “.
First connect the cable positive (+), then the negative
(-) cable.
Disconnect in reverse order.
NOTE Use a portable tester to check the battery
voltage. If voltage is less than 12V, the battery must be
recharged.
If the battery voltage drops below 8V, the electronic
control unit will prevent the engine from running.
Release 00/2002 - 03 2 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 14 - 00 Release 00/2002 - 03
DANGER
Do not re-install the battery until 5/10 minutes after
disconnecting from the charger, since the battery
continues to produce fumes for a short time.
WARNING
If this vehicle is not used for more than twenty days,
disconnect the 30-A fuses. This will prevent the
battery from running down due to the slight current
consumption of the multifunction computer.
Removing the 30-A fuses will reset the functions:
digital clock and red line setting.
To restore these functions, see 2.3 (MULTIFUNCTION
COMPUTER).
If your vehicle remains unused for more than a couple of
weeks, it will be necessary to recharge the battery, to
avoid sulfur damage, see 2.4.2 (RECHARGING THE
BATTERY).
Remove the battery, see 7.1.9 (REMOVING THE
BATTERY) and store it in a cool, dry place.
Over the winter, or whenever the vehicle remains unused,
periodically check the battery charge (once a month or
so), to prevent it from deteriorating.
Recharge it completely using a normal charger,
see 2.4.2 (RECHARGING THE BATTERY).
NOTE If the battery remains on the vehicle, disconnect
the cables from the terminals.
Release 00/2002 - 03 2 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.6 JUMP-STARTING
Carefully read 2.4 (BATTERY).
DANGER
The vehicle should only be jump-started when the
vehicle battery is partially or completely dead, and
recharging is not possible.
Do not attempt to start the vehicle by pushing or
towing it.
The vehicle providing the jump start must be
equipped with a battery having the exact same rated
voltage (as listed on the battery itself) as the battery
of the vehicle to be started (12V).
Follow the procedure below to the letter so as to
reduce the danger of the battery exploding and
possibly injuring people and/or causing property
damage. Failure to observe this warning will certainly 1
damage the electrical components of both vehicles.
Make sure the ignition switch is set to “ “.
Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
NOTE The battery cables of the vehicle to be started
must not be disconnected.
A
WARNING
The terminals of one cable must never come into
contact with those of the other.
B
Pull back the red rubber boot (1).
Connect the end of one jumper cable to the positive
pole (+) of the battery on the on the vehicle providing
assistance (A); the other end to the positive pole (+) of
the battery on the vehicle to be started (B).
Connect the end of the other jumper cable to the
negative pole (-) of the battery on the vehicle providing
aid (A); the other ends grounded on the frame (at a
point far from battery) of the vehicle to be started (B).
DO NOT CONNECT TO THE NEGATIVE (-) POLE.
DANGER
The jumper cables must not be allowed near any
moving parts on either vehicle.
NOTE The vehicle providing the jumpstart may keep its
engine running during the starting phase.
Starting the vehicle.
NOTE Attempts to start the vehicle should last for no
more than ten seconds at a time, and be repeated if
necessary at intervals of approximately one minute.
Once you have successfully jump-started the vehicle,
keep both engines running for a couple of minutes.
Stop both engines and disconnect the jumper cables,
proceeding in reverse order.
2 - 16 - 00 Release 00/2002 - 03
DANGER
Let the engine cool down to ambient temperature.
Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
NOTE The vehicle is equipped with two spark plugs
per cylinder.
The following steps refer to a single spark plug, but are
applicable to all.
To remove and clean:
DANGER
Never disconnect the spark plug cap while the
engine is running, as you could receive a powerful
electrical shock from the ignition system.
Remove the spark plug cap (1).
Remove all traces of dirt from the base of the spark
plug.
Place the special wrench supplied with the tool kit over
the spark plug.
Place the 13-mm open-end wrench supplied in the tool
kit over the hexagonal seat of the special spark plug
3
wrench.
Unscrew the spark plug and remove it from its seat,
being careful not to allow dust or other matter into the
cylinder.
WARNING
This vehicle is fitted with spark plugs featuring
platinum-type electrodes.
5
Never clean using metal brushes or abrasive
products, only a blast of compressed air. 4
- center electrode (3);
- insulation (4);
- side electrode (5).
Make sure that the spark plug electrodes and insulation
show no carbon deposits or signs of corrosion. If 3
necessary, clean using a blast of compressed air.
Replace the spark plug if the insulation is cracked, the
electrodes are corroded, or the plug shows excessive
deposits. If the center electrode (3) becomes rounded as
shown in the figure, replace the spark plug.
Always replace spark plugs with new ones of the same
standard.
Recommended spark plugs:
NGK R DCPR9E
Release 00/2002 - 03 2 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
When replacing a spark plug, always check the pitch 0.02 - 0.03 in
and length of the thread.
If the threaded portion is too short, carbon deposits
can build up on the internal thread of the head; this
may damage to the engine when the appropriate kind
is then installed.
Use only the recommended type of spark plugs, to
avoid jeopardizing the performance and life-span of
the engine.
Use a round wire feeler gauge (see figure) to check
the spark plug gap, to avoid damaging the platinum
coating.
Check the spark plug gap using a round wire feeler
gauge.
The gap should measure 0.02 - 0.03 in (0.6 - 0.7 mm).
Adjust if needed, by carefully bending the earth
electrode.
Make sure that the gasket is in good condition. With the
gasket in place, screw in the spark plug by hand to
avoid damaging the thread.
Tighten using the wrench provided in the tool kit, 1
turning each spark plug 1/2 turn to compress the
gasket.
WARNING
The spark plug must be well tightened, otherwise the
engine may overheat and be seriously damaged.
NOTE Upon reassembly, the rear cylinder spark plug
cables must be placed inside the oil breather tube.
Position the spark plug cap (1) correctly, so that it does
not vibrate off.
DANGER
Make sure the cap (1) is correctly placed on the spark
plug (2).
Refit the fuel tank.
2 - 18 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
DANGER
Danger of fire.
Wait until the engine and exhaust silencers have
completely cooled down. 1
Gasoline fumes are harmful to your health.
Before proceeding, make sure that the work area has 2
adequate ventilation.
Do not inhale the fuel fumes.
Do not smoke or use open flames.
Dispose of the fuel only at an approved fuel disposal
site. Do not dump it down a storm drain, etc.
Shut off the engine and wait for it to cool.
Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Procure a container with a capacity greater than the
amount of gasoline in the tank and place it on the floor
on the left-hand side of the vehicle.
NOTE Place a cloth under the male quick-release
coupling (1) to catch any spilled fuel.
Disconnect the male quick-release coupling (1) from
the container (2) by pressing the button.
NOTE Procure a hose complete with male quick-
release coupling.
Place the free end of the hose inside the container
prepared beforehand.
Insert the male quick-release coupling of the hose all
the way into the quick-release container (2). The
gasoline starts draining out immediately.
Open the tank cap.
Wait until all the gasoline has drained completely from
the tank.
Once all the gasoline has drained out:
Press the push-button to disconnect the male quick-
release coupling from the container (2).
Insert the male quick-release coupling (1) into the
container (2).
NOTE Make sure that the male quick-release coupling
(1) has been correctly inserted into the container (2).
Refit the fuel tank.
Close the tank cap.
2 - 20 - 00 Release 00/2002 - 03
WARNING
Do not press down or beat on the metal screen of the
air filter (3). Do not use screwdrivers or similar tools
on the filter itself.
Hold the air filter (3) upright and strike it repeatedly
against a clean surface.
If necessary, clean the air filter (3) with a blast of 4
compressed air (aiming it outwards from inside the filter).
Clean the outside of the air filter (3) with a clean cloth.
CHANGING
Replace the air filter (3) with another of the same kind.
Every 7500 km (4687 mi), remove the plug (4) and
remove any dirt that may have settled inside the filter
case.
WARNING
Check the filtering element while cleaning to make
sure there are no tears. If so, replace the filtering
element. Make sure that the filtering element is
correctly positioned so that it does not allow any
unfiltered air to pass through. Remember that early
wear on the piston rings and cylinder is often caused
by a faulty or poorly positioned filtering element.
Clean the filtering element more often if the vehicle is
used in dusty areas. Using the vehicle without the
filtering element, or with a damaged element, will
considerably increase wear and tear on the engine.
Make sure that the filtering element is always in
perfect condition, as long engine life depends on the
air cleaner being in perfect condition.
Release 00/2002 - 03 2 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.11 THROTTLE
Check after the first 625 mi (1,000 km) and then every
4687 mi (7,500 Km) or every 8 months thereafter.
DANGER 1
Using the vehicle with damaged, bent or tangled
throttle cables may prevents the throttle from
working properly, causing the rider to lose control of
the vehicle while riding.
DANGER
This can lead to an upset, with subsequent accident,
serious injury, or even death. Never ride your
motorcycle unless the throttle cables are in perfect
working order. 5
2
Make sure that turning the handlebar does not alter the
engine idle speed, and that when the throttle is released
it returns gently and automatically to its original position.
2
DANGER
If turning the handlebar alters the engine speed, do
not ride the vehicle until you have rectified the 3
problem. Failure to observe this warning can lead to
a runaway engine, loss of control, and subsequent
serious accident, injury, and even death.
If necessary:
Check the correct position and the lubrication of the
following components:
- sheath;
- throttle grip adjuster (1);
- throttle body adjuster (2);
- throttle body pin (3)
- cable fittings (ends);
- throttle control.
Check the idle speed, see 2.11.2 (ADJUSTING THE
IDLE SPEED).
Check the throttle control adjustment, see 2.11.3
(ADJUSTING THE THROTTLE CONTROL).
2 - 22 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 23 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
The engine oil level must be checked while the
engine is warm.
If you check the engine oil level when the engine is 1
cold, the oil might temporarily fall below the "MIN"
level.
This is not a problem as long as the oil pressure LED
“ “ does not light.
Start the engine.
Ride the vehicle for approximately 10 miles, or 15-20
minutes.
Shut off the engine.
Place the vehicle on the center stand.
Keep the vehicle upright with both wheels resting on
the ground.
Through the slot on the left fairing, check the engine oil
level on the transparent tube (1).
MAX = maximum level. 3
MIN = minimum level.
The difference between "MAX" and "MIN" is
approximately 30.51 cuin (500 cm³). 2
The level is correct if it is around the "MAX" mark. 4
WARNING
Do not go above the "MAX" marking or below the
"MIN" marking, as this could seriously damage the
engine.
Do not add additives or other substances to the oil.
If using a funnel or other tool, make sure it is
perfectly clean.
Top up the engine oil level if necessary:
Unscrew and remove the screw (2).
Remove the cover (3).
Unscrew and remove the filler cap (4).
Top up the reservoir to restore the proper level,
see 1.12 (LUBRICANT CHART).
2 - 24 - 00 Release 00/2002 - 03
WARNING
We recommend replacing the oil more often if the
vehicle is used in dusty areas.
For competitive use replace every 2343 mi (3750 km).
TO CHANGE
NOTE It is best to change the oil after the vehicle has
been thoroughly warmed up, that is, ridden at least 20 or
30 minutes. 3
DANGER
Before following the procedure described below, let
the engine and muffler cool to ambient temperature,
to prevent burns.
2
NOTE Place the vehicle on the center stand on a flat,
hard surface.
Remove the left fairing see 7.1.28 (REMOVING THE 1
SIDE FAIRINGS).
Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Place a container (1) with a capacity greater than 1
gallon (4000 cm³) under the drain plug (2) on the
reservoir (3).
Unscrew and remove the drain plug (2) from the
reservoir (3).
Unscrew and remove the filler cap (4). 4
Drain the oil and let it drip for a few minutes into the
container (1).
Check the gasket of the drain plug (2) on the reservoir
(3) and replace if necessary.
Screw and tighten the drain plug (2).
WARNING
Always dispose of oil in compliance with
environmental regulations.
Turn it over to the nearest firm specialized in
recovering used oil, or to the supplier.
Remove any metal residue stuck to the drain plug (5),
reinstall and tighten the drain plug. 5 1
Release 00/2002 - 03 2 - 25 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
When reassembling make sure that the fitting (15) of 4
the filter oil (10) is facing outwards. The pipe (13)
must not be in contact with the expansion tank. 11
Carefully inspect the seal of the engine oil filter (10) on 3
the tank; screw on and tighten.
2 - 26 - 00 Release 00/2002 - 03
WARNING
The coolant level should be checked and topped up
only while the engine is cold. 1
Shut off the engine and wait for it to cool.
NOTE Place the vehicle on the center stand on a flat,
hard surface.
Keep the vehicle upright with both wheels resting on
the ground.
Check through the slot provided on the right fairing to
make sure that the level of fluid in the expansion tank 4
(1) is between the "FULL" and "LOW" marks.
FULL = maximum level
LOW = minimum level
If not: 2 1
Unscrew and remove the screw (2). 3
Remove the cover (3).
Unscrew and remove the filler cap (4).
DANGER
Coolant is harmful if swallowed; contact with skin or
eyes may cause irritation.
Do not insert your finger or any foreign objects to
check for coolant.
See Safety Warnings, Section 1.2 (SAFETY
WARNINGS).
WARNING
Do not add additives or other substances to the fluid.
If using a funnel or other tool, make sure it is
perfectly clean.
Top up with coolant, see 1.12 (LUBRICANT CHART)
until the level of fluid approximately reaches the
"FULL" mark.
Do not exceed this level, to keep fluid from leaking out
while the engine is running.
Replace the filler cap (4).
WARNING
If coolant is used up too quickly and the expansion
tank (1) becomes empty, check for leaks in the
circuit.
Release 00/2002 - 03 2 - 27 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING 3
Do not remove the filler cap (3) while the engine is
warm, because the coolant is under pressure at high
temperatures.
Remove the filler cap (3) to allow the fluid to flow more
freely from the system. 4
When all of the fluid has drained out, empty the left
radiator.
DISPOSE OF THE FLUID IN COMPLIANCE WITH
ENVIRONMENTAL REGULATIONS.
NOTE When reassembling apply LOCTITE® 572 to the
thread of the two radiator drain plugs.
Reassemble the drain plug (1) with a new aluminum
washer.
2 - 28 - 00 Release 00/2002 - 03
WARNING
If you notice that the brake lever has excessive free
play, any sponginess or air bubbles in the system,
bleed the brake system, see 2.19 (BLEEDING THE
BRAKE SYSTEMS).
Brake fluid will damage the painted and plastic
surfaces.
Before riding, inspect the lines to make sure they are
not twisted or cracked, and that the fittings do not
leak.
Do not use or mix together different types of fluids
with a silicone or petroleum base.
Do not use brake fluid taken from old containers or
those that have been left standing open.
Take care to prevent water and dust from accidentally
entering the system.
CHECK
NOTE Place the vehicle on the center stand on a flat,
hard surface.
Turn the handlebar all the way to the right.
Make sure the fluid contained in the reservoir exceeds
the "MIN" mark.
MIN = minimum level.
MAX = maximum level.
If the fluid does not at least reach the "MIN" mark, top
up the reservoir.
TOPPING UP
WARNING
Danger of brake fluid leaking.
Do not operate the front brake lever with the screw
(1) loose or, especially, with the cover of the brake
fluid reservoir removed. This can cause fluid to
squirt a great distance, even into your eyes. Failure
to observe this warning could result in serious
physical injury.
Use a short Philips screwdriver to unscrew the screw
(1) of the brake fluid reservoir (3).
2
WARNING
Do not unscrew the screw (2) with the handlebar 3
wheel turned to the right, as fluid will leak out.
Turn the handlebar all the way to the left. 1
Unscrew the screw (2). MIN
WARNING
Avoid prolonged exposure of the brake fluid to open
air.
The brake fluid is hygroscopic and absorbs moisture
in contact with air.
Leave the brake fluid reservoir open ONLY as long as
necessary for topping up.
Release 00/2002 - 03 2 - 29 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
Never top up past the "MAX" level. Top up to “MAX”
only when new pads are installed. The level of fluid
gradually decreases as the pads become worn.
To reassemble the components, follow the procedure in
reverse order.
WARNING
If you notice that the brake lever has excessive free
play, any sponginess or air bubbles in the system,
bleed the brake system, see 2.19 (BLEEDING THE
BRAKE SYSTEMS).
Brake fluid will damage the painted and plastic
surfaces.
Before riding, inspect the lines to make sure they are
not twisted or cracked, and that the fittings do not
leak.
Do not use or mix together different types of fluids
with a silicone or petroleum base.
Do not use brake fluid taken from old containers or
those that have been left standing open.
Take care to prevent water and dust from accidentally
entering the system.
2 - 30 - 00 Release 00/2002 - 03
CHECK
NOTE Place the vehicle on the center stand on a flat, 3
hard surface.
Make sure the fluid contained in the reservoir exceeds
the "MIN" mark.
MAX
MIN = minimum level.
MAX = maximum level.
MIN
If the fluid does not at least reach the "MIN" mark, top
up the reservoir.
TOPPING UP
WARNING
Danger of brake fluid leaking.
Do not operate the rear brake lever with the brake
fluid reservoir cap loosened or removed.
DANGER 1 1
Avoid prolonged exposure of the brake fluid to open
air.
The brake fluid is hygroscopic and absorbs moisture 4
in contact with air.
Leave the brake fluid reservoir open ONLY as long as
necessary for topping up.
Use a short Philips screwdriver to unscrew the two
screws (1) of the brake fluid reservoir (2).
Raise and remove the cover (3) complete with screws 2
(1) and gasket (4).
NOTE To keep from spilling brake fluid while topping
up, keep the fluid in the reservoir parallel to the reservoir
rim (horizontal).
WARNING
Do not add additives or other substances to the fluid.
If using a funnel or other tool, make sure it is
perfectly clean.
Top up the reservoir (1) with brake fluid, see 1.12
(LUBRICANT CHART) until you have reached the right
level between the two markers, "MIN" and "MAX"
WARNING
Top up to “MAX” only when new pads are installed.
The level of fluid gradually decreases as the pads
become worn.
To reassemble the components, follow the procedure in
reverse order.
Release 00/2002 - 03 2 - 31 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 32 - 00 Release 00/2002 - 03
TOPPING UP
WARNING
Danger of fluid leaking. 3
1 2
Do not operate the clutch lever with the fluid
reservoir cap loosened or removed. This can cause
fluid to squirt a great distance, even into your eyes.
Failure to observe this warning could result in
serious physical injury. 5
4
DANGER
Avoid prolonged exposure of the clutch fluid to open
air.
The clutch fluid is hygroscopic and absorbs moisture
in contact with air.
Leave the clutch fluid reservoir open ONLY the time
necessary for topping up.
WARNING
Place a cloth under the clutch fluid reservoir to catch
any spills.
Turn the handlebar all the way to the left.
Use a short Philips screwdriver to unscrew the screw
(1).
WARNING
Do not unscrew the screw (2) with the handlebar
wheel turned to the left, as fluid will leak out.
Turn the handlebar all the way to the right.
Unscrew the screw (2).
WARNING
Avoid shaking the vehicle to keep from spilling fluid
while topping up.
Do not add additives or other substances to the fluid.
If using a funnel or other tool, make sure it is
perfectly clean.
Raise and remove the cover (3) complete with screws
(1-2).
Remove the gasket (4).
Top up the reservoir (5) with clutch fluid, see 1.12
(LUBRICANT CHART) until you have reached the right
level between the two markers, "MIN" and "MAX".
Never top up past the “MAX” level.
To reassemble the components, follow the procedure in
reverse order.
Release 00/2002 - 03 2 - 33 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
DANGER
After servicing the brakes, always check them for
function. If the stroke of the lever or pedal is
excessive, or if you detect that the effectiveness of
the brakes is reduced in any way, may be necessary
to bleed the system, or there may be some other
problem with the brake system. 1
Never ride your vehicle in traffic immediately after
servicing the brakes. Always apply the brake pedal or
lever several times before riding your vehicle. Then,
try your vehicle in a parking lot or other safe area
with little traffic to ensure that the brakes are working
properly. Failure to observe this warning can lead to
a serious accident with subsequent serious injury or
death.
DISPOSE OF THE FLUID IN COMPLIANCE WITH
ENVIRONMENTAL REGULATIONS.
KEEP OUT OF REACH OF CHILDREN.
WARNING 2
Handle brake fluid with care. Especially do not spill it
on painted or plastic parts. It can irreparably damage
the finish of such parts. It is also destructive to
rubber and other non-metallic materials used in the
vehicle. Do not dispose of brake fluid improperly. Do
not pour it into drains or storm sewers. Brake fluid
should be disposed of only at an approved recycling
center.
NOTE This vehicle is equipped with front and rear disc
brakes, with separate hydraulic circuits.
The front brake system is double disc (right and left side).
The rear brake system is single disc (right side).
FRONT BRAKE SYSTEM
The front brake system is equipped with two bleeder
nipples:
- one nipple (1) on each of the two front brake calipers.
Repeat the BLEEDING OPERATIONS on both nipples
(1).
REAR BRAKE SYSTEM
The rear brake system is equipped with a single bleeder
nipple (2), on the rear brake caliper.
2 - 34 - 00 Release 00/2002 - 03
BLEEDING OPERATIONS
There are three types of bleeding procedures, to be
A
carried out in the order listed below:
1st BRAKE SYSTEM BLEEDING D
NOTE The description of the system bleeding
procedures also includes instructions on how to
determine whether it is necessary to bleed the brake
caliper and the brake master cylinder.
2nd BRAKE CALIPER BLEEDING
3rd BRAKE MASTER CYLINDER BLEEDING
WARNING
Do not reverse the above order. To do so will result in C C
improper bleeding of the brakes. Follow the
instructions exactly. Failure to heed this warning can
lead to failure of the brake system, with subsequent
serious accident, serious injury, or even death.
GENERAL RULES
Before proceeding, make sure that:
NOTE Carry out the bleeding procedures with the vehicle
placed on the side stand and only on a firm, flat surface. B
A the master cylinder must be higher than any line or
caliper (C);
B the fluid reservoir must be higher than the master
cylinder (A); A C
C the caliper bleeder nipple (1-2) is higher than the
caliper itself;
D the brake line has no bends in the shape of an
overturned "U".
NOTE To bleed the rear brake system you must first
remove the rear brake caliper, see 7.6.2 (REMOVING
THE REAR BRAKE CALIPER).
Top up the brake fluid in the reservoir, see 2.16
(CHECKING AND TOPPING UP THE FRONT BRAKE 1 1
FLUID) and 2.17 (CHECKING AND TOPPING UP
THE REAR BRAKE FLUID).
Remove the dust cover.
Fit a piece of transparent plastic tubing over the clamp
bleeder nipples (1-2), and insert the other end into a
container.
Squeeze and release the brake lever several times,
and then hold it fully squeezed.
Loosen the bleeder nipple by 1/4 turn so that the brake
fluid flows into the container; this will eliminate tension C C
from the brake lever and bring it to the end of its stroke.
Tighten the bleeder nipple, squeeze the lever several
times, then hold it fully squeezed and loosen the
bleeder nipple again.
Repeat the operation until the fluid that flows into the
container is completely free of air bubbles.
NOTE Fill the reservoir with brake fluid as needed while
bleeding the hydraulic system. Throughout this operation, 1
make sure brake fluid is always present in the reservoir.
Tighten the bleeder nipple and remove the tubing.
Release 00/2002 - 03 2 - 35 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
Never adjust the caliper pistons directly, always on
the pads. Work gently to avoid damaging the pads.
Simultaneously open and close the bleeder nipple.
NOTE It is important that the caliper pistons be
widened and the valve opened and closed take place
simultaneously.
Top up to restore the proper level of brake fluid in the
reservoir, see 2.16 (CHECKING AND TOPPING UP
THE FRONT BRAKE FLUID) and 2.17 (CHECKING
AND TOPPING UP THE REAR BRAKE FLUID).
Insert the shim between the pads. Squeeze the lever.
Spread the caliper pins again, loosening the bleeder
nipple and checking whether air bubbles escape along
with the fluid.
If there are still air bubbles, repeat the procedure until
there are no more bubbles in the fluid.
2 - 36 - 00 Release 00/2002 - 03
WARNING
Never adjust the caliper pistons directly, always on
the pads. Work gently to avoid damaging the pads.
Check whether any air bubbles escape into the
reservoir along with the fluid.
If there are still air bubbles, repeat the procedure until
there are no more bubbles in the fluid.
NOTE Fill the reservoir with brake fluid as needed
while bleeding the hydraulic system.
Throughout this operation, make sure brake fluid is
always present in the reservoir.
Now you can be certain that all air bubbles have been
bled from the master cylinder.
Release 00/2002 - 03 2 - 37 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
Handle clutch fluid with care. Especially do not spill it
on painted or plastic parts. It can irreparably damage
the finish of such parts. It is also destructive to rubber
and other non-metallic materials used in the vehicle.
Do not dispose of clutch fluid improperly. Do not pour
it into drains or storm sewers. clutch fluid should be 1
disposed of only at an approved recycling center.
Top up the clutch fluid in the reservoir, see 2.18
(CHECKING AND TOPPING UP THE CLUTCH
FLUID).
Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Remove dust cover.
Fit a piece of transparent plastic tubing over the
bleeder nipple (1), and insert the other end into a
container.
Squeeze and release the lever several times, and then
hold it fully squeezed.
Loosen the bleeder nipple by 1/4 turn so that the fluid
flows into the container; this will eliminate tension from
the lever and bring it to the end of its stroke.
Tighten the bleeder nipple (1), squeeze the lever
several times, then hold it fully squeezed and loosen
the bleeder nipple again.
Repeat the operation until the fluid that flows into the
container is completely free of air bubbles.
NOTE Fill the reservoir with clutch fluid as needed
while bleeding the hydraulic system.
Throughout this operation, make sure there is always
fluid present in the reservoir.
Tighten the bleeder nipple (1) and remove the tubing.
2 - 38 - 00 Release 00/2002 - 03
WARNING
Handle the fluid with care: it can chemically alter
paint and plastic or rubber parts, etc.
DISPOSE OF THE FLUID IN COMPLIANCE WITH
ENVIRONMENTAL REGULATIONS.
Remove the dust cover.
Fit a piece of transparent plastic tubing over the
bleeder nipple (1) on the clamp, and insert the other
end into a container.
Loosen the bleeder nipple (1) by approximately one
turn.
NOTE Throughout this operation, make sure there is 2
always fluid present in the reservoir; otherwise, after the
operation you will need to bleed the system, see 2.19
(BLEEDING THE BRAKE SYSTEMS).
Watch the reservoir (2) as the fluid flows out and
tighten the bleeder nipple (1) before it empties entirely.
Top up the reservoir (2), see 2.16 (CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID).
Loosen the bleeder nipple (1) again by
approximately half a turn.
Watch as the fluid flows out through the tube. As
soon as you observe that the fluid flowing through the
tube is clear, and no longer dark, tighten the bleeder
nipple(1) again and remove the tube.
Release 00/2002 - 03 2 - 39 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
Handle the fluid with care: it can chemically alter
paint and plastic or rubber parts, etc.
DISPOSE OF THE FLUID IN COMPLIANCE WITH
ENVIRONMENTAL REGULATIONS.
Remove the dust cover.
Fit a piece of transparent plastic tubing over the
bleeder nipple (1) on the clamp, and insert the other
end into a container.
Loosen the bleeder nipple (1) by approximately one
turn.
NOTE Throughout this operation, make sure there is 2
always fluid present in the reservoir (2); otherwise, after
the operation you will need to bleed the system, see 2.19
(BLEEDING THE BRAKE SYSTEMS).
Watch the reservoir (2) as the fluid flows out and
tighten the bleeder nipple (1) before it empties entirely.
Top up the reservoir (2), see 2.19 (BLEEDING THE
BRAKE SYSTEMS).
Loosen the bleeder nipple (1) by approximately half a
turn.
Watch as the fluid flows out through the tube. As soon
as you observe that the fluid flowing through the tube is
clear, and no longer dark, tighten the bleeder nipple(1)
again and remove the tube.
2 - 40 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 41 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 42 - 00 Release 00/2002 - 03
DANGER
Excessive wear on the pad friction material would
cause the metal pad support to come into direct
contact with the disc, creating a metallic grinding
noise and producing sparks from the clamp; the 2
braking effectiveness, safety and integrity of the disc
would thus be compromised. Never ride a motorcycle
with worn out brake pads. Failure to observe this
warning can lead to loss of braking effectiveness,
with a collision, upset, and serious injury or even
death.
If the thickness of the friction material (even of a single
pad) is reduced to approximately 0.04 in (1 mm) (or if
even only one of the wear indicators is no longer
visible), replace both pads.
- Front pads (3), see 7.5.1 (CHANGING THE BRAKE
PADS).
- Rear pads (4) see 7.6.1 (CHANGING THE BRAKE
PADS).
DANGER 3 4
Never replace just one brake pad in a set. Always
replace them by pairs. Failure to observe this
warning can lead to loss of braking with resultant
collision, upset, and consequent serious injury or
even death.
Release 00/2002 - 03 2 - 43 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.28 STEERING
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
Check after the first 937 mi (1,500 km) and then after
every 4687 mi (7,500 km), or every 8 months.
To assure superior handling, the steering is equipped
with rolling bearings.
The steering must be adjusted correctly to provide
smooth rotation of the handlebar and safe driving. Tight
steering hinders the smooth rotation of the handlebar,
whereas play steering reduces stability.
2 - 44 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 45 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
After everything has been tightened, make sure the 3
handlebars rotate smoothly in both directions. If not,
they may damage the sliding seats and adversely
affect vehicle handling.
5
4 1
2 - 46 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 47 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
Do not force the adjuster screw (1) to turn beyond the
end of its stroke in both directions, to avoid damaging
the vehicle.
Ensure that the spring preload and hydraulic damping
is the same for both sides: the vehicle will become less
stable if there are different settings on the two sides.
When the spring preload is increased, it is necessary to
also increase the hydraulic damping, to avoid
harshness while riding.
WARNING
When adjusting, always start from the most rigid
setting [screw (1) turned fully clockwise].
Use the notches provided on the adjuster screw (1)
as reference marks for adjusting of hydraulic
damping on extension.
Gradually rotate the adjuster screw (1) 1/ 8 turn at a
time.
Test the vehicle repeatedly on the road until you have
determined the optimum setting.
WARNING
There is no adjustment available for the protrusion of
fork tubes (B). It is strictly prohibited to change the
riding position by adjusting this protrusion.
The standard setting has the fork tube (B) protruding
as far as the first notch.
TABLE
Full-load
Front suspension Standard setting Soft setting Rigid setting
adjustments
Hydraulic adjustment
from fully closed (*) from fully closed (*) from fully closed (*) from fully closed (*)
in extension,
open (**) 1.25 turns open (**) 1.5 turns open (**) 1 turn open (**) 1.25 turns
screw (1)
Spring preload, nut
(2) [notch reference to the 6th notch to the 7th notch to the 5th notch to the 7th notch
mark (A)]
(*) = clockwise
(**) = counter-clockwise
2 - 48 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 49 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
When adjusting, always start from the most rigid
setting; in this case, with the adjuster screw (1) and
adjuster knob (2) turned all the way clockwise.
Do not turn the adjuster screw (1) beyond its
maximum position, to avoid damaging the thread.
Make sure that the adjuster screw (1) is always set to
a notch and not in an intermediate position.
Turn the screw (1) to adjust the hydraulic damping on
extension of the shock absorber (see table).
Turn the knob (2) to adjust the hydraulic damping on
compression (see table).
WARNING
Adjust the spring preload and hydraulic damping on
extension of the shock absorber based on the 2
conditions in which the vehicle is used.
When the spring preload is increased, it is necessary
to also increase the hydraulic damping, both on
extension and compression, to avoid a jerky,
unsteady shock action while riding.
Gradually turn the adjuster screw (1) 2-3 notches at a
time and the adjuster knob (2) 5-6 notches at a time.
Test the vehicle repeatedly on the road until you have
determined the optimum setting.
2 - 50 - 00 Release 00/2002 - 03
DANGER
Do not remove the plug (4) for any reason. Do not
tamper with the valve. Doing either of these things 4
will destroy the function of shock absorber which
can lead to an unstable, unsteady ride, with
subsequent upset, accident and serious injury or
even death. Observe the instructions above. Never
ride your motorcycle with a defective or improperly
adjusted rear shock absorber.
(*) =clockwise
(**) =counter-clockwise
Release 00/2002 - 03 2 - 51 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 52 - 00 Release 00/2002 - 03
DANGER
Let the engine cool down to ambient temperature.
Remove the side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS). 1
Remove the front grille, see 7.1.35 (REMOVING THE
RADIATOR SPOILER).
Torque the three nuts (1) of the front cylinder exhaust
manifold to specification.
Torque the three nuts (2) of the rear cylinder exhaust
manifold to specification.
2
Tightening torque for nuts (1-2): 18.44 ftlb
(25 Nm). 2
Release 00/2002 - 03 2 - 53 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.35 DRIVE CHAIN A quick check to determine the condition of the chain and
sprockets may be made by grasping the chain and
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
attempting to pull it away from the rear sprocket. If you
INFORMATION).
can pull the chain away from the sprocket to the point
where you can see between the chain side plates and the
DANGER sprocket, the sprocket and chain are worn out, and both
Riding your motorcycle with a worn-out, improperly must be replaced.
adjusted, dirty, rusty, or otherwise defective chain
can cause the chain to come off of either the front or
DANGER
rear sprocket, which will jam and cause the rear
Keep your fingers and clothing well clear of the chain
wheel to lock. This can lead to loss of control, an
while you are adjusting it. Should you happen to get
upset, and subsequent accident with serious injury
any body part pinched between the chain and the
or even death. Carefully observe the precautions
sprocket while you are turning the rear wheel, that
and instructions given below. Never attempt to
body part will be severely mangled. Pay particular
substitute a different type of chain for the original
attention to keep your fingers clear. You will easily
type of chain.
lose a finger, should you pinch it between the chain
Check the drive chain every 625 mi (1000 km) and and the sprocket. We recommend wearing heavy
lubricate if needed. The vehicle is equipped with an leather gloves when carrying out these operations,
endless chain. There is no master link used. however, be aware that even heavy leather gloves will
Type of chain: 525 not protect your fingers from being mangled, should
they be caught between the chain and the sprocket.
WARNING
The drive chain is equipped with O-ring gaskets WARNING
between the links, to keep the grease inside. Use If the chain rollers are damaged, the pins loose and/
utmost care when adjusting, lubricating, washing or the O-rings damaged or missing, you must replace
and changing the chain. Failure to observe this the entire assembly (both sprockets and chain),
warning can destroy your chain. see 7.4.1 (REMOVING THE FINAL DRIVE
Place the vehicle on the center stand. ASSEMBLY).
Set the gearshift lever to neutral.
Turn the rear wheel to check the chain play in other
positions.
Visually inspect the chain, making sure that the chain
and sprockets show none of the defects listed below:
- damaged rollers;
- loose pins;
- dry, rusted, crushed or seized links;
- excess wear;
- missing O-rings;
- sprocket teeth excessively worn or damaged.
2 - 54 - 00 Release 00/2002 - 03
WARNING
An excessively loose chain may cause noise or make
the chain rattle, with consequent wear of the shoe
and of the chain guide plate. Lack of or incorrect
maintenance can cause premature wear of the chain
and/or damage the sprockets. Perform maintenance
operations more frequently if the vehicle is used in
harsh conditions, or on dusty, wet and/or muddy
roads.
Release 00/2002 - 03 2 - 55 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
There are some chain lubricants available containing
substances that will destroy the O-rings in your 2
chain.
The standard chain is type 525.
When replacing the chain, use the same kind.
3
2 - 56 - 00 Release 00/2002 - 03
11
Release 00/2002 - 03 2 - 57 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2.36 TIRES
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check after the first 625 mi (1,000 km) and then every
4687 mi (7,500 km), or every 8 months, thereafter.
Check the inflation pressure every month, at ambient 2
temperature.
This vehicle is equipped with tubeless tires.
TREAD CONDITION
1
WARNING
Check the surface state and wear, since tires in poor
condition do not adhere properly to the road and
adversely affect vehicle handling.
Replace the tire if worn or if the tread area contains
any puncture larger than 5 mm across. Some types of
tires, approved for use on this vehicle, come
equipped with wear indicators.
Various kinds of wear indicators are available.
Ask your local dealer for instructions on how to
check for wear.
Do not install tires with inner tube on rims for
tubeless tires and vice-versa. Make sure the inflation
valves (1) are always capped, to prevent the tires A
from deflating suddenly.
Changing, repairing, maintaining and balancing the
tires are all very important tasks; they must therefore
be carried out using the appropriate tools and
expertise.
MINIMUM TREAD DEPTH LIMIT (A):
front e rear ............................................... 0.12 in (3 mm).
INFLATION PRESSURE
Periodically check the inflation pressure of the tires at
ambient temperature.
If the tires are warm, the measurement will not be
correct. Always measure before and after any long trips.
If the inflation pressure is too high, the shocks of rough
terrain are not absorbed and are transmitted to the
handlebars, making for an uncomfortable ride and also
diminishing the vehicle's ability to adhere to curves.
If the tire is underinflated (pressure is too low), the
sidewalls (2) are under greater stress and the tire itself
may slip or detach from the rim with consequent loss of
control. The tires may slip off the rims if the rider brakes
suddenly.
Finally, the vehicle may skid on curves.
Inflation pressure, see 1.11 (SPECIFICATIONS).
WARNING
After repairing a tire, have the wheel balanced.
If the tires are new, they may be covered with a
slippery coating; drive carefully for the first few
miles.
2 - 58 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 59 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
WARNING
The fasteners must be torqued to specification and
LOCTITE® applied ONLY where indicated, see 2.41
(FASTENERS).
Lubricate only the parts indicated in table 2.41
(FASTENERS).
2 - 60 - 00 Release 00/2002 - 03
2.41 FASTENERS
Check after the first 625 mi (1,000 km) and then every
4687 mi (7,500 km) or every 8 months thereafter; tighten
if necessary.
WARNING
The fasteners listed in the table must be torqued to
specification using a torque wrench and LOCTITE®
where indicated.
The elements marked ( ) are especially important
to safety.
ENGINE
Engine/Frame Fastening
Description Qty. Screw / nut ftlb Nm Notes
Front fitting 2+2 M10 36 50
Left-side upper and lower rear fitting 2 M10 36 50
Adjusting bushing right side upper and lower rear fitting 2 M20x1.5 8 12 lub
Lock ring right side upper and lower rear fitting 2 M20x1.5 36 50
Screw right side upper and lower rear fitting 2 M10 36 50
Engine fasteners
Description Qty. Screw / nut ftlb Nm Notes
Engine oil inlet flange 2 M6 8 12
Engine oil drain cap 2 M6 8 12
Countershaft sprocket on gearbox shaft fastener 1 M10 36 50 L243
Clutch cylinder fastener 3 M6 8 12
Countershaft sprocket case fastener 3 M6 8 12
Guard plate on clutch cover 2 M5 3.6 5
SWINGING ARM
Description Qty. Screw / nut ftlb Nm Notes
Bushing for adjusting swinging arm pivot 1 M30x1.5 8 12 lub
Swinging arm pivot lock ring 1 M30x1.5 43.4 60
Swinging arm pivot nut 1 M20x1.5 65 90
caliper support stop pivot 1 M14x1.5 43.4 60 L243
Chain shoe on swinging arm 2 M5 2.9 4 L243
Upper and lower chain guard on swinging arm 7 M5 2.9 4 L243
Eccentric locking screw 2 M10 25.8 35
Brake line fairlead fastener 1 M5 2.9 4
Axle anti-rotation screw 1 M6 7.3 10 L243
SIDE STAND
Description Qty. Screw / nut ftlb Nm Notes
Stand plate to frame fastener 2 M10 29 40
Stand fastening pin 1 M10x1.25 7.3 10
Switch fastening screw 1 M6 7.3 10 L243
Lock nut 1 M10x1.25 21.7 30
CONT'D ➤
Release 00/2002 - 03 2 - 61 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
CENTER STAND
Description Qty. Screw / nut ftlb Nm Notes
Center stand to frame fastener 2 M10 36 50 L243
FRONT SUSPENSION
Front fork
Description Qty. Screw / nut ftlb Nm Notes
Fork head/fork tubes fastener 1+1 M8 18 25
Triple clamp/fork tubes fastener 2+2 M8 18 25
Steering column ring-nut 1 M35x1 29 40
Steering column locking ring nut 1 M35x1 man. +90°
Fork head upper retainer 1 M29x1 88.5 120
Triple clamp steering bush fastening screw 1+1 M8 16.2 22
Closing of fork/wheel axle clamps 2-2 M8 16.2 22
Key block on fork head 2 M8 18 25
REAR SUSPENSION
Damper absorber
Description Qty. Screw / nut ftlb Nm Notes
Damper absorber/frame fastener 1 M10 33.2 45 lub
Linkage
Single connecting rod to frame fastener 1 M10 33.2 45 lub
Single/double connecting rod to frame fastener 1 M10 33.2 45 lub
Double connecting rod fork fastener 1 M10 33.2 45 lub
Double connecting rod/shock absorber fastener 1 M10 33.2 45 lub
ELECTRICAL SYSTEM
Description Qty. Screw / nut ftlb Nm Notes
Battery clamping bracket fastener 2 M5 3.6 5
Horn mount fastener 1 M8 18 25
Speed sensor fastener 1 M6 7.3 10 L243
Taillight fastener 3 M6 5.2 7
Electronic unit fastener 5 M6 7.3 10
Voltage regulator fastener 2 M6 8 12
2 M5 1.4 2
Headlight fastener to front fairing
2 SWP 3.9 0.7 1
Coil mount to frame fastener 4 M6 7.3 10
Fuse box to dashboard/front fairing mount fastener 2 M5 1.4 2 L243
Relay cable to starter motor fastener 1 M6 3.6 5
Earth to engine fastener 1 M6 7.3 10
Relay cables 2 M6 3.6 5
CONT'D ➤
2 - 62 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 63 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 64 - 00 Release 00/2002 - 03
Release 00/2002 - 03 2 - 65 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
2 - 66 - 00 Release 00/2002 - 03
WARNING
Never use trichloroethylene, gasoline, or similar
fluids: they may be too powerful as solvents for this
chain and, more importantly, they may damage the O-
rings that retain grease in the gaps between rollers
and pins.
Release 00/2002 - 03 2 - 67 - 00
Downloaded from www.Manualslib.com manuals search engine
SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA
NOTES
2 - 68 - 00 Release 00/2002 - 03
ENGINE
3
Release 00/2002 - 03 3 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
ENGINE
TABLE OF CONTENTS
3.1 TECHNICAL DATA........................... 3-3-00
3.1.1 TECHNICAL SPECIFICATIONS ........... 3-3-00
0 3.1.2 MAINTENANCE INTERVALS ............... 3-3-00
3.1.3 TROUBLESHOOTING........................... 3-3-00
3.1.4 SEALANTS ............................................ 3-3-00
3.1.5 LUBRICANTS ........................................ 3-3-00
3.1.6 SPECIAL TOOLS .................................. 3-3-00
3 3.1.7 TIGHTENING TORQUES ...................... 3-3-00
3.1.8 PRECAUTIONS TO OBSERVE WHEN
CARRYING OUT MAINTENANCE
OPERATIONS AND REPAIRS.............. 3-3-00
3.1.9 GENERAL INFORMATION ABOUT
2 MAINTENANCE AND REPAIRS ........... 3-4-00
3.2 ENGINE COMPONENTS THAT MAY BE
DISASSEMBLED WITHOUT REMOVING
THE ENGINE FROM THE FRAME .... 3-4-00
3 3.2.1 REMOVING THE CLUTCH CYLINDER 3-6-00
3.3 REMOVING THE COMPLETE ENGINE
FROM THE FRAME .......................... 3-7-00
3.4 INSTALLING THE COMPLETE
4 ENGINE IN THE FRAME ................ 3-16-00
3 - 2 - 00 Release 00/2002 - 03
3.1.3 TROUBLESHOOTING
See 8.1 (TROUBLESHOOTING).
3.1.4 SEALANTS
See 1.13 (CONSUMABLES).
3.1.5 LUBRICANTS
See 1.12 (LUBRICANT CHART).
DANGER
During assembly keep in mind the weight
(approximately 147.7 lb) and the center of gravity of
the engine; support it appropriately.
Be careful around any points that present a hazard
for crushing or cutting body parts.
WARNING
147.7lb
Engine and system maintenance demands technical
training and knowledge, both general mechanical
knowledge and knowledge specific to this engine, as
well as familiarity with certain common and special
tools used in disassembly, repair, reassembly and
maintenance. Do not attempt any maintenance
operations for which you have not been specifically
trained. Failure to observe this warning can lead to
serious bodily injury, especially to your hands and
fingers. Always follow the instructions provided by
the vehicle manufacturer.
NOTE Follow the instructions provided by the vehicle
manufacturer.
Release 00/2002 - 03 3 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
WARNING
This chapter lists the procedures progressively and
in sequential order.
Use common sense to interpret any overlap in cross-
referenced instructions, to avoid unnecessarily
removing components.
Perform only those operations needed to remove the
component in question.
TOP
- Tappet cover (1), see 0.4.1 (ENGINE SERVICE
MANUAL).
- Tappet cover (2), head, cylinder and rear piston,
see 0.4.1 (ENGINE SERVICE MANUAL).
- Front (3) and rear (4) intake cylinder manifolds.
- Camshaft position sensor and camshafts, see 0.4.1
(ENGINE SERVICE MANUAL).
- Chain, chain tightener and front and rear cylinder
timing drive assembly, see 0.4.1 (ENGINE SERVICE
MANUAL).
- Valves, see 0.4.1 (ENGINE SERVICE MANUAL).
FRONT
- Front cylinder exhaust pipe, see 7.1.53 (REMOVING
THE EXHAUST MANIFOLDS).
- Starter motor (5), see 0.4.1 (ENGINE SERVICE
MANUAL).
REAR
- Exhaust pipe removal, see 7.1.53 (REMOVING THE
EXHAUST MANIFOLDS).
3 - 4 - 00 Release 00/2002 - 03
LEFT RIGHT
- Rear cylinder spark plugs (6-7), see 2.7 (SPARK - Front cylinder coolant thermistor (15), see 5.4
PLUGS). (REMOVING THE COOLANT THERMISTORS.).
- Countershaft sprocket guard (8), see 2.35.4 - Front cylinder spark plugs (16-17), see 2.7 (SPARK
(INSPECTING THE DRIVE CHAIN GUIDE PLATE). PLUGS).
- Gearshift lever, see 7.1.48 (COMPLETELY - Coolant pump (18), see 0.4.1 (ENGINE SERVICE
REMOVING THE GEARSHIFT LEVER). MANUAL).
- Rear cylinder coolant thermistor (9), see 5.4 - Engine oil pressure sensor (19).
(REMOVING THE COOLANT THERMISTORS.). - Clutch cover (20) and clutch assembly, see 0.4.1
- Engine oil filter (10), see 2.13 (CHANGING THE (ENGINE SERVICE MANUAL).
ENGINE OIL AND OIL FILTER).
- Neutral gear switch (11).
- Clutch cylinder (12), see 3.2.1 (REMOVING THE
CLUTCH CYLINDER).
- Flywheel cover (13) and ignition system, see 0.4.1
(ENGINE SERVICE MANUAL).
- Engine oil tank (14), see 7.1.55 (REMOVING THE
ENGINE OIL TANK).
12
5
19
18
20 19 14 13 10 11 8
Release 00/2002 - 03 3 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
3 - 6 - 00 Release 00/2002 - 03
WARNING
The engine must be removed ONLY at an Authorized
Service Center or by an Aprilia dealer.
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
WARNING
Engine removal is a particularly complex operation.
147.7lb
Therefore, inspect the vehicle carefully before
proceeding.
This chapter lists the procedures progressively and
in sequential order.
Use common sense to interpret any overlap in cross-
referenced instructions, to avoid unnecessarily
removing components. Perform only those
operations needed to remove the component in
question.
Before you proceed with the operations described
below, bear in mind that the engine must be removed
from the frame from underneath; the equipment for
the job must therefore be gathered and set in place
beforehand.
Engine dry weight ~ 147.7 lb (~ 67 kg).
Set the ignition switch to “ “.
Place the vehicle on the stand.
Disconnect the negative cable (-) and positive cable
(+) of the battery, in that order.
WARNING
When reassembling, first connect the positive cable
(+), then the negative cable (–). 2
Remove the fuel tank, see 7.1.6 (REMOVING THE
FUEL TANK COMPLETELY).
Remove both side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS).
Remove both lower fairings, see 7.1.33 (REMOVING 1
THE LOWER FAIRING).
Remove the radiator spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).
WARNING
Mark the cables to avoid mix-ups when
reassembling.
Disconnect the following electrical connectors in the
order listed: 3 4
– alternator (1);
– crankshaft position sensor (2);
– front cylinder coolant thermistor (3);
– rear cylinder coolant thermistor (4).
WARNING
When reassembling, make sure electrical connectors
are properly fitted.
Release 00/2002 - 03 3 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
7
5
WARNING
The brake fluid reservoir (9) must remain upright to
prevent any leakage.
Remove the clutch cylinder, see 3.2.1 (REMOVING
THE CLUTCH CYLINDER).
Remove the countershaft sprocket, see 7.1.57
(REMOVING THE DRIVE CHAIN SHOE).
Remove the expansion tank, see 5.8 (REMOVING
THE EXPANSION TANK).
9
3 - 8 - 00 Release 00/2002 - 03
WARNING
Mark both the coupling and lines to avoid mix-ups
11
when reassembling.
Remove the engine oil tank (12), see 7.1.55
(REMOVING THE ENGINE OIL TANK), along with the
engine oil radiator (13), see 7.1.56 (REMOVING THE
ENGINE OIL RADIATOR), disconnecting the lines
joining it to the engine (14-15).
12
14
15
13
16 17
Release 00/2002 - 03 3 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
21
3 - 10 - 00 Release 00/2002 - 03
25
27
27
DANGER
The lifting hoist (28) and slings (29) must be capable 29 28
of safely bearing the weight of the engine, which
weighs approximately 65 kg. Failure to observe this
warning can allow the engine and/or the motorcycle
to fall, with potential serious personal injury to the
mechanic. Use only appropriately rated lifting
27
equipment, in perfect condition. If the lifting
equipment is unstable, the motorcycle could fall
over, causing serious personal injury. Use only
equipment that is completely stable.
Install the special eye hook (27) (code 8140183) to lift
the engine and fasten it in place with the screws (25).
Hook the slings (29) to the hoist (28) and eye hook (27)
as shown in the figure.
Raise the hoist arm (28) until the slings (29) are
stretched taut.
WARNING
Raise the hoist arm (28) only enough to keep the
engine in position while removing the fasteners
holding it to the frame.
Release 00/2002 - 03 3 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
A-B C D
32
30
36
31
34 33 35
C
B F
B
A G
D E
E F G-H
37 45
47
42 41
43 44
40
38
46
39
3 - 12 - 00 Release 00/2002 - 03
41 38
41
42
43
Tightening torque for lock nuts (43 -39): 36 ftlb 42
(50 Nm).
37
39
Release 00/2002 - 03 3 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
WARNING
During reassembly screw the adjustment bushings
(40 - 44) in by hand, and slide them up against the
engine; torque them to specifications.
43
Hold the nut (38) in place while you unscrew and
remove the bolt (37).
Hold the nut (41) in place while you unscrew and
remove the bolt (42).
Make sure the slings (29) are stretched taut.
Unscrew and remove the two bolts (45), saving the
washers (46).
43
40
44
45
46 47
45 46
3 - 14 - 00 Release 00/2002 - 03
DANGER
The engine is now free and not fastened anywhere.
29
WARNING
If you do not need to work on the engine, leave it
resting on the floor and attached to the slings (29)
and hoist, for extra safety. 8
Clean the outside of the engine thoroughly.
WARNING
Use a cleanser, brushes and rags to clean the
exterior of the engine.
Avoid damaging rubber and plastic parts with
corrosive or non-flammable solvents.
Release 00/2002 - 03 3 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
DANGER
The engine is heavy and can easily crush your
fingers or other bodily parts. Always work with great
care using only approved engine lifting equipment.
Failure to observe this warning can result in great
bodily harm.
2
Make sure the adjuster bushings (1 - 2) and all the way
up against the frame. 1
Nudge the engine along gradually until the engine/
frame fastening holes(A - B - C - D) are all perfectly
aligned.
When you have finished re-installing the engine, proceed
as described below.
Make sure that all nuts/bolts securing the engine are
properly torqued.
Top up coolant, see 2.14 (CHECKING AND TOPPING
UP THE COOLANT).
Top up engine oil, see 2.12 (CHECKING AND
TOPPING UP THE ENGINE OIL LEVEL).
If the engine has been overhauled, bleed the engine oil
circuit and check the engine oil pressure. Check the
drive chain tension and adjust if necessary, see 2.35.1 B
(CHECKING THE PLAY) and 2.35.3 (ADJUSTING
THE DRIVE CHAIN).
WARNING
Perform a careful and thorough check of all
components removed when the engine was
disassembled from the frame, in particular,
- make sure that the electric cables are fastened with
147.7lb D
appropriate clamps.
A C
WARNING
None of the cables must be twisted and/or pinched.
- the electric connectors are connected properly;
- the lines and couplings are connected properly and
secured with appropriate clamps;
- the throttle cable and cold-start cable slide freely and
are not pulled too tight when the handlebar is turned;
- the gearshift lever is positioned correctly;
- the rear brake lever is positioned correctly.
3 - 16 - 00 Release 00/2002 - 03
NOTES
Release 00/2002 - 03 3 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
ENGINE RST mille USA
NOTES
3 - 18 - 00 Release 00/2002 - 03
FUEL SYSTEM
4
Release 00/2002 - 03 4 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
FUEL SYSTEM
TABLE OF CONTENTS
4.1 FUEL TANK ..................................... 4-3-00
4.1.1 MAINTENANCE..................................... 4-4-00
0 4.1.2 CHECK THE FUEL INTAKE.................. 4-4-00
4.2 DRAINING FUEL FROM THE TANK . 4-5-00
4.3 COMPLETELY REMOVING THE FUEL
INTAKE PUMP UNIT ....................... 4-5-00
4 4.4 REMOVING THE FUEL LEVEL
SENSOR........................................... 4-6-00
4.5 REMOVING THE FUEL DELIVERY
2 FILTER............................................. 4-6-00
4.6 REMOVING THE FUEL INTAKE
PUMP............................................... 4-7-00
4.7 ENGINE MANAGEMENT .................. 4-8-00
4 - 2 - 00 Release 00/2002 - 03
3
4
6 9
Legend
1) Fuel tank 6) Fuel sensor
2) Filling cap 7) Fuel delivery filter
3) Fuel intake pump unit 8) Fuel pump
4) Drainage lines 9) Fuel delivery line
5) Fuel return line
Release 00/2002 - 03 4 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
DANGER
Gasoline fumes are harmful to your health.
Before proceeding, make sure that the work area has
adequate ventilation. .
Do not inhale the fuel fumes.
Avoid skin contact with the gasoline.
Do not smoke or use open flames.
Always dispose of fuel in compliance with
environmental regulations.
4.1.1 MAINTENANCE
4
When the fuel pump assembly is to be removed,
see 4.3 (COMPLETELY REMOVING THE FUEL 3
INTAKE PUMP UNIT). We recommend that you make
sure the lines (1-2-3) are intact, and that the following
are in good working order:
- fuel level sensor (4) see 6.10.3 (ENGINE OIL 5
PRESSURE SENSOR);
- fuel intake pump (5), see 6.7.2 (CHECKING THE FUEL
PUMP). 6
Replace the delivery filter (6).
NOTE During this procedure, it is also advisable to 1
wash the tank thoroughly.
2
4 - 4 - 00 Release 00/2002 - 03
WARNING
Handle the reservoir with care; do not scrape to
avoid damaging the paint.
NOTE Place the tank on a clean surface, with the
pump assembly facing upwards.
Unscrew and remove the bolts (1).
NOTE When reassembling, insert all bolts by hand and
cross-tighten.
3
WARNING
When removing the pump assembly (2), be careful
not to damage the fuel level sensor (3) and lines.
Remove the complete pump assembly (2).
WARNING
When reassembling, make sure that the click-clamp (4)
is facing the opposite way from the fuel level sensor 2
support (5), so that the click-clamp (4) doesn't get in the
way of the fuel delivery line.
Upon reassembly, apply LOCTITE® 518 to the O-ring (6).
Release 00/2002 - 03 4 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
WARNING
Do not re-use filters.
Replace the filter (4) with another of the same kind.
4 - 6 - 00 Release 00/2002 - 03
Remove the snap ring (6) from the filter element (7).
7
WARNING 6
When reassembling, replace the snap ring (6) with a
new one of the same kind.
Remove the filter element (7).
WARNING
If the filter element (7) show traces of sediment, clean
it using compressed air.
Use a screwdriver to help you slide it out from the side 3
opposite the fuel pump (3).
Release 00/2002 - 03 4 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
4 - 8 - 00 Release 00/2002 - 03
4.7.2 SENSORS
Camshaft position sensor (1) 1
Location: in the flywheel cover (2).
This is a sensor that detects the movement of the
selected phonic wheel on the crankshaft. The selected
wheel has a unique pulse length, triple the distance/ 2
clearance, to act as a reference point on the wheel. Using
this reference point it is possible to calculate the
crankshaft position.
In a four-stroke engine, this alone is not enough
information about the reference point to allow us to
determine whether a cylinder near top dead center (TDC)
is in the intake or exhaust stage. To obtain this
information, it is necessary to obtain further details about
the position by applying a strategy of varying the engine
speed.
The information about the engine position is used to
determine the engine speed, and for any activities that
must be synchronized with the wheel rotation, such as
fuel injection.
Release 00/2002 - 03 4 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
5 4
4 - 10 - 00 Release 00/2002 - 03
Injection Kill
switch Switch +
COOLING FAN 1
- +
M
BATTERY -
+
M
M COOLING FAN 2
PW ONLY
-
+
FUEL PUMP
M
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
COOLING P1 B2 FRONT
THERMISTOR CYLINDER
P1H3 INJECTOR
P1 D1
MC 1000 REAR
AIR THERMISTOR
CYLINDER
ECM P1H2 INJECTOR
+VE P1 B3
VALVE POSITION
SENSOR SIG P1 E3
+VE
P1 E4
Supply via
Engine position sensor ignition switch
(prototypes only)
P2 C1
+VE
SIG
-VE
INJECTOR 1
AIR P2H1
PRESSURE
SENSOR
(IN ECM)
INJECTOR 2
P2H4
P1 D2
Tilt switch
INJECTOR 3
P2 H2
Supply via
Instrument
ignition switch INJECTOR 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
and side stand Neutral P2 D2 11 CAN_L
DIAGNOSTIC LINE K Diagnostic
SEZIONE 2.3 Side stand P2 A2 7 ISO 9141 K
P2 C2 P2 B2 Connectors
15 ISO 9141 L J1962
DIAGNOSTIC LINE L
16 12V Batt. + ve.
SEZIONE 3.1
4
- +
BATTERY
Release 00/2002 - 03 4 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
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
30 BLUE GREEN
WELDED TO THE SHIELDING OF
THE 2 CABLES AND PROTECTED
WITH HEAT-SHRINK FILM
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
4 - 12 - 00 Release 00/2002 - 03
DANGER
Take care around the high voltage in the ignition
system.
Never disconnect the connections with the engine
running. Whenever working on the ignition system,
unless otherwise indicated, always leave the ignition
switch set to “ “ and the battery disconnected
(when disconnecting the battery, disconnect the
negative pole “ “ first).
WARNING
All measurements should be taken with components
at a temperature of 68°F (20°C).
General troubleshooting instructions: as soon as you
have identified the fault, remove the defective
component.
If the “EFI” LED comes on while the vehicle is running,
it means the control unite has detected a fault.
FAULT CODE TABLE:
Code Description of fault
12 crankshaft (pick-up) position sensor malfunction
15 throttle position sensor (TPS) malfunction
18 CALIFORNIA ONLY
21 engine temperature sensor malfunction
22 air temperature sensor malfunction
23 barometric pressure sensor malfunction
33 coil 1 malfunction
34 coil 2 malfunction
35 coil 3 malfunction
36 coil 4 malfunction
41 overturn sensor signal malfunction
42 injector 1 malfunction
43 injector 2 malfunction
Release 00/2002 - 03 4 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
WARNING
The lever mechanism on the throttle body may not be
adjusted nor replaced. In case of malfunction,
replace the complete throttle body, see 4.8.1
(REMOVING THE THROTTLE BODY).
The two screws M4x12 (1) attaching the throttle valve
potentiometer to the throttle valve body are painted,
and may be removed only when replacing the sensor
itself.
WARNING
When reassembling, make sure the electrical
connectors are properly inserted.
NOTE Use the special click clamp installation pliers
6
(code 0277295); during reassembly, replace each clamp 3
with a new one of the same kind.
Release the click clamps (4-5).
Pull the lines (7-8) from the throttle body (6).
8
5
7
10
4 - 14 - 00 Release 00/2002 - 03
WARNING
During reassembly:
- the fuel delivery line (12) must not be twisted, or
placed where it is likely to be pinched by other
components; it must be replaced if found to be
13
damaged or deteriorated;
- the fuel delivery line (12) must be placed so that it
arrives on the right-hand side of the throttle body 6
(6), passing under the body between the two intake
flanges;
- the throttle body (6) must be fitted perfectly on the
intake flanges; 12
- the clamps (14-15) must be properly tightened.
When replacing the throttle body (6), you must align the
throttle valve position sensor, see 4.10.6 (ALIGNING
THE THROTTLE VALVE POSITION SENSOR).
Release 00/2002 - 03 4 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
10
8
9
4 - 16 - 00 Release 00/2002 - 03
DANGER
Gasoline is extremely flammable and becomes
explosive under certain conditions.
KEEP GASOLINE AWAY FROM CHILDREN.
NOTE The injectors may be tested even when
mounted.
Check the following components:
- electrical cables and connections;
- injector or injection signal of the electronic control unit,
see 6.5 (IGNITION/INJECTION SYSTEM).
Checking injector resistance:
See 6.6.1 (CHECKING THE INJECTORS).
WARNING
Use only neutral cleansers.
Use only proprietary gasket removers, degreasers or
cleansers that do not require heating.
Clean all openings and passages in the throttle body
with compressed air.
WARNING 1
The two HS bolts fastening the throttle valve 2
potentiometer (1) are painted over during the
manufacturing process, and cannot be loosened. The
throttle valve potentiometer may be adjusted only
when being replaced.
Place the throttle valve position sensor (1) horizontally
on the throttle valve shaft, and turn it downward.
NOTE Apply LOCTITE® 243 on the thread of the bolts
(2).
Tighten the two hex bolts M410x12 (2). 2
Release 00/2002 - 03 4 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
DANGER 3
Gasoline fumes are harmful to your health.
Before proceeding, make sure that the work area has
adequate ventilation.
Do not inhale the fuel fumes.
Avoid skin contact with the gasoline.
Do not smoke or use open flames.
Always dispose of fuel in compliance with
2
environmental regulations.
Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Pull out the two free tubes (2) on the left side of the
motorcycle, under the side panel.
Unplug the two free transparent lines (2) and connect
them to those of the vacuum gauge (1), using two 6-
mm fittings.
Completely close the two by-pass screws (3) on the
throttle body.
Start the vehicle and read the value for the front
cylinder on the vacuum gauge (1), with valve (4) open
and valve (5) closed.
Close the valve (4) and open the valve (5) on the
vacuum gauge (1), and read the pressure value for the
rear cylinder.
If the values are different between the two cylinders,
adjust one or both of the by-pass screws (3) to
synchronize.
Loosen the by-pass screw (3) on the cylinder with the
higher pressure, until it falls to the same level as the
other cylinder, with a tolerance of ± 5 millibar.
4 - 18 - 00 Release 00/2002 - 03
WARNING
The CO must be adjusted when the engine is warm.
Coolant temperature 167-194 °F (75-90 °C). 1
NOTE Have the following special tools ready:
- exhaust gas analyzer (1) (code 8140196);
- tubing kit for exhaust gas analyzer (2) (code 8140202).
- Axone 2000 (5) (code 8140595).
DANGER 5 7
Gasoline fumes are harmful to your health.
Before proceeding, make sure that the work area has
adequate ventilation.
Do not inhale the fuel fumes.
Avoid skin contact with the gasoline.
Do not smoke or use open flames.
Always dispose of fuel in compliance with
environmental regulations.
Unscrew and remove the two plugs (3-4) from the front
and rear exhaust pipes.
NOTE When reassembling apply LOCTITE® 8150 to 3
the threads of plugs (3-4).
Connect the tubing kit for exhaust gas analyzer (2):
- connect the two rigid tubes to the appropriate exhaust 4
tube outlets;
- connect the other tube to the exhaust gas analyzer (1).
Make sure that the idle speed is 1250 ± 100 rpm. If not,
adjust as needed, see 2.11.2 (ADJUSTING THE IDLE 6
SPEED).
Check the tester (1) for the CO values, which should
match those indicated and be the same for both
cylinders.
CO values for both cylinders:
- 1.5 - 2% at 1250 ± 100 rpm.
CO values for both cylinders USA :
- 1 - 1.5% at 1250 ± 100 rpm.
Insert the “OBD” module (7) in the Axone 2000.
Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Connect the Axone 2000 (5) via the connector (6)
under the saddle, and power the Axone 2000 (5) using
the vehicle battery.
Start the procedure from the rear cylinder.
Use the red on/off button to switch on the Axone 2000 UP ARROW
(5).
Select the Autotest icon on the display and press the BACK
ENTER
enter key. LEFT ARROW RIGHT ARROW
The next screen shows a series of data regarding the
DOWN ARROW
various control unit parameters.
"+" KEY
Press the + or – key, then use the UP and DOWN
arrows to select the item “Idle fuelling adjustment”, and "-" KEY
press enter. ON / OFF
Release 00/2002 - 03 4 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
WARNING
Slowly change the parameter on the instrument (no
more than 2 or 3 pulses at a time), and wait for the
CO value to stabilize on the exhaust gas analyzer (1). 5 7
Use the vehicle exhaust/tester (2) connection lines of
suitable length (2'-3').
Check the CO on both exhausts, and make sure that
the maximum difference is no greater than 1%.
NOTE If you are unable to obtain the prescribed CO
values, replace the spark plugs, see 2.7 (SPARK
PLUGS).
4 - 20 - 00 Release 00/2002 - 03
UP ARROW
BACK
ENTER
LEFT ARROW RIGHT ARROW
DOWN ARROW
"+" KEY
"-" KEY
ON / OFF
Release 00/2002 - 03 4 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
FUEL SYSTEM RST mille USA
NOTES
4 - 22 - 00 Release 00/2002 - 03
COOLING SYSTEM 5
Release 00/2002 - 03 5 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
COOLING SYSTEM RST mille USA
COOLING SYSTEM
TABLE OF CONTENTS
5.1 DESCRIPTION ................................. 5-3-00
5 - 2 - 00 Release 00/2002 - 03
6
3
4
1 2
10
5
4
7
21
4 8
20
13 14 11
19 9
18
12
17
16
15
Legend
1) Front cylinder thermistor 15) Left radiator (vertical flow)
2) Rear cylinder thermistor 16) Right radiator (vertical flow)
3) Breather tube 17) Right electric radiator fan
4) Compensation tubes 18) Thermostat-pump coupling
5) Filler hose 19) Right radiator-thermostat coupling
6) Filler neck 20) Three-way thermostat (pad type, of heat-sensitive
7) Engine hose (right side) - thermostat wax)
8) Rear cylinder hose - three-way manifold 21) Centrifugal pump
9) Front cylinder hose - three-way manifold
= Flow direction with thermostat open
10) Expansion tank
11) Three-way manifold = Flow direction with thermostat closed.
12) Three-way manifold - left radiator coupling
13) Radiator union coupling
14) Left electric radiator fan
Release 00/2002 - 03 5 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
COOLING SYSTEM RST mille USA
A C
5 - 4 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Remove the radiator spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).
Remove both lower fairings, see 7.1.33 (REMOVING
THE LOWER FAIRING). 6
Remove both air ducts,see 7.1.30 (REMOVING THE
LEFT AIR DUCT) and 7.1.31 (REMOVING THE 4
RIGHT AIR DUCT).
Loosen and remove the click clamp (2).
Slip the coupling (3) off the radiator (4).
Loosen and remove the click clamp (5).
Slip the coupling (6) off the radiator (4). 8
7
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind. 5
Release the click clamp (7).
Slide the hose (8) off the radiator (4).
Unscrew and remove the screw (9) and recover the
bushing and grommet (10) if necessary. 10
NOTE Replace the grommet (10) if you find it to be
damaged.
WARNING
Proceed with care. Do not damage the radiator fins.
Tilt the radiator (4) slightly forward while lifting,
extracting the two lower anchorage pins (12-13) from
their recess on the radiator mount (11).
Remove the radiator (4) complete with electric fan.
9
WARNING 4
Plug all the coupling openings to prevent any foreign
matter from accidentally entering.
NOTE Replace the grommets (14) if damaged.
If necessary:
Remove the electric cooling fan, see 5.3 (REMOVING
THE ELECTRIC COOLING FANS).
WARNING 12
Remove any foreign matter, dirt etc. stuck to the
radiator fins using compressed air. Straighten any
bent fins using a small blade screwdriver. If the 14
13
radiator hoses (3-6) are torn and/or cracked, they
must be replaced.
Before reassembly wash the inside of the radiator 14
thoroughly, using only clean water. 11
Release 00/2002 - 03 5 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
COOLING SYSTEM RST mille USA
5 - 6 - 00 Release 00/2002 - 03
Release 00/2002 - 03 5 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
COOLING SYSTEM RST mille USA
WARNING
Plug all the coupling openings to prevent any foreign
matter from accidentally entering.
5 - 8 - 00 Release 00/2002 - 03
WARNING
Plug all the coupling openings to prevent any foreign
matter from accidentally entering.
DANGER 6
Coolant is harmful.
Place the expansion tank (6) in a safe place.
See the safety warnings at 1.2 (SAFETY WARNINGS)
with regard to coolant.
KEEP OUT OF REACH OF CHILDREN.
4
Release 00/2002 - 03 5 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
COOLING SYSTEM RST mille USA
NOTES
5 - 10 - 00 Release 00/2002 - 03
ELECTRICAL SYSTEM
6
Release 00/2002 - 03 6 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 2 - 00 Release 00/2002 - 03
20 19
21 18 23 17 16
21
1 3
22
24
25
7 15
26 26
28 27
14
13
4 6 8 9 10 11 12
5 36
35 30
39 38 37 44 2
31
32
33
42 43 41 34
40 29
Release 00/2002 - 03 6 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
23
47 51 47 51
45
48
49
46 50
Legend
1) Electronic control unit 31) Secondary fuses (15A)
2) Front cylinder coils 32) Flasher
3) Rear cylinder coils 33) Overturn sensor
4) Horn 34) Ignition switch
5) Left fan 35) Right dimmer switch
6) Diode 36) Front stop switch
7) Air thermistor 37) Fuel pump/sensor group
8) Fuel pump relay 38) Test and diagnostics connector
9) Engine stop relay 39) Main fuses (30 A)
10) Injection relay 40) Rear stop switch
11) Diode module 41) Right rear direction indicator
12) Voltage regulator 42) Left rear direction indicator
13) Side stand switch 43) Taillight
14) Speed sensor 44) Stepper (choke)
15) License plate lamp 45) Injector
16) Start relay 46) Oil pressure sensor
17) Battery 47) Coolant temperature thermistor
18) Left dimmer switch 48) Starter motor
19) Clutch switch 49) Pick-up flywheel
20) Dashboard 50) Neutral switch
21) Front left direction indicator 51) Spark plugs
22) Air temperature sensor
23) Throttle sensor
24) Low beam relay
25) High beam relay
26) High beam bulbs
27) Low beam bulb
28) Front parking light bulb
29) Right fan
30) Front right direction indicator
6 - 4 - 00 Release 00/2002 - 03
6.2 INTRODUCTION
The following instructions will help you in consulting this
section.
NOTE The numbers that appear on the specific wiring
diagrams match those given in the overall wiring diagram.
Release 00/2002 - 03 6 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Start the engine and rev it to 4000 rpm. 1
Use a tester to measure the voltage (AC) from the
1
three internal male terminals [yellow cables (G)] in
rotation.
If the output voltage is less than 60 V, the alternator is
faulty and must be replaced.
Standard open-circuit voltage:
greater than 60 V (AC) at 4000 rpm.
6 - 6 - 00 Release 00/2002 - 03
Regulator
Flywheel
30 A + Battery
+
Main Fuse
Secondary
A B fuses
Clock Gasoline
headlight pump
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
1
Use a tester (scale Ω) to check the continuity between
the cables of the stator [on the internal female
1
terminals, yellow cables (G)].
Also check the isolation of the stator mount.
Standard resistance value: 0.1 -1Ω
Standard resistance value (between cables and
stator mount): ∞.
Release 00/2002 - 03 6 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
G G G V R/Bi
G ∞ ∞ 2-∞ ∞
Negative terminal (-)
G ∞ ∞ 2-∞ ∞
of the tester on:
G ∞ ∞ 2-∞ ∞
V ∞ ∞ ∞ ∞
WARNING
This measurement method is only approximate; if
possible, make sure the charger is in good working
order by using another regulator you know functions
properly.
If the resistance measured is incorrect, replace the
voltage regulator (3).
6 - 8 - 00 Release 00/2002 - 03
30 A
R/Bi
– +
1
2
D
15 A
Az/Gr
4 6
N R/M
Ro/Bi 8
E1 F3 H4
(Grey) (Grey) (Black)
9
Legend:
1) Battery 6) Injection relay
2) Key 7) Overturn sensor
3) Kill switch 8) Purge valve coil fan injector power USA .
4) Starter button 9) ECU
5) Engine stop relay
6.4.2 TROUBLESHOOTING
Make sure that the 30-A main fuse and the 15-A fuse
“D” are intact.
Make sure the kill switch device is working properly,
see 6.8 (IGNITION SAFETY SYSTEM) as well as the
key, see 6.5 (IGNITION/INJECTION SYSTEM).
Make sure the engine stop relay is in good working
order, see 6.7.3 (CHECKING THE FUEL PUMP
RELAY).
Check the injection relay, see 6.4.3 (CHECKING THE
INJECTION RELAY).
Check the overturn sensor, see 6.4.4 (CHECKING
THE OVERTURN SENSOR).
Release 00/2002 - 03 6 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
Observe the polarity, connecting the “+” pole to
terminal (86) and the “-” pole to terminal (85); there is
a diode inside.
WARNING
Have ready a bulb, max. 12 V/2W
Prepare a circuit like the one shown in the figure.
Close the switch “A” with the sensor set to horizontal; B
the bulb “B” will light.
6 - 10 - 00 Release 00/2002 - 03
R/N D1(N)
1 Ar/Az
4 H3(Gr)
13
B/G A1(N)
5 Bi/G B1(N) H4(N) R/M
H4(Gr) G/B
Az 12
F1(N)
H3(N) Gr/R
G F2(N)
6 10
Vi E2(N)
Ro E1(N) V/Gr
H2(N)
9
D3(Gr) D4(N) A1(Gr)
M/Ro
Gr
Bi/Vi
7
8
EFI
WARNING 11
LAMP DISPLAY
Legend
1) Electronic control unit (ECU) 9) Rear cylinder injector
2) Throttle sensor 10) Front cylinder injector
3) Coolant thermistor 11) Dashboard
4) Injection air thermistor 12) Rear cylinder coil - center spark plug
5) rpm sensor 13) Rear cylinder coil - side spark plug
6) Choke motor 14) Front cylinder coil - side spark plug
7) Test connector 15) Front cylinder coil - center spark plug
8) Injection relay
Release 00/2002 - 03 6 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6.5.1 TROUBLESHOOTING
Place the vehicle on the stand.
Set the ignition switch to “ “.
The message “ “ will appear on the display for
approximately three seconds.
If the LED “ “ turns off, the control unit has not found
any faults.
6 - 12 - 00 Release 00/2002 - 03
36 Coil 4
42 Injector 1 – Injector not working or not wired.
43 Injector 2
6.5.4 TROUBLESHOOTING IN THE ELECTRONIC If the engine does not start and the diagnostics system
SYSTEM USING DISPLAYED INFORMATION detects no fault, check, in the order listed, whether:
– the fuel pump is working properly, see 6.7.2
WARNING (CHECKING THE FUEL PUMP);
Take care around the high voltage in the ignition – the injectors are working properly, see 6.6.1
system. (CHECKING THE INJECTORS);
Never disconnect the connections with the engine – the antitheft setup connector (located under the
running. passenger saddle, white) is connected properly;
Whenever working on the ignition system, unless – the ignition switch is working properly, see 6.13.2
otherwise indicated, always leave the ignition switch (SWITCHES);
set to “ “ and the battery disconnected (when – the engine stop switch is working properly, see 6.13.2
disconnecting the battery, disconnect the negative (SWITCHES);
pole (-) first). – the 30-A main fuses and 15-A secondary fuses are
intact, see 6.16 (CHANGING FUSES);
WARNING – the engine stop relay is working properly, see 6.5.4
All measurements should be taken with components (TROUBLESHOOTING IN THE ELECTRONIC
at a temperature of 20°C (68°F). General SYSTEM USING DISPLAYED INFORMATION);
troubleshooting instructions: as soon as you have – the battery is working properly, see 2.4 (BATTERY)and
identified the fault, remove the defective component. 6.14 (BATTERY);
Carry out the checks described in the following chapters: – the safety operating logic is working properly, see 6.8
– 6.6.7 (CHECKING THE CRANKSHAFT POSITION (IGNITION SAFETY SYSTEM);
SENSOR); – the overturn sensor is working properly, see 6.4.4
– 6.6.3 (CHECKING THE THROTTLE VALVE (CHECKING THE OVERTURN SENSOR).
POTENTIOMETER);
– 6.6.5 (CHECKING THE COOLANT THERMISTORS
OPERATION).
Release 00/2002 - 03 6 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
45 39 40 43 43 41 42 52 51 50 49 16 2 33
P1H2 P1H3 P2H1 P2H2 P2H3 P2H4 P2E1 P1D4 P2A1 P2D3
P2G1
P1H4
P2G2
P1G1
P2F3
P1H1
P1F1 P1B4
P1F2 P1F4
54 P1E2 P2A2 P2G3 P2C3 P1A1 P1E3
P1G4 P2C4 P2G4 P2D2 P2C2 P1B1 P1D1 P1B2 P1B3 P1E4
P1E1 P2B2
36
25 9
46 47 48
63
27 26 28
30
H G F E D C B A H G F E D C B A
1 1 1 1
2 2 2 2
3 3 3 3
4 4 4 4
H G F E D C B A H G F E D C B A
6 - 14 - 00 Release 00/2002 - 03
Release 00/2002 - 03 6 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 16 - 00 Release 00/2002 - 03
Release 00/2002 - 03 6 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 18 - 00 Release 00/2002 - 03
Water temperature
+ -
Standard values :
(°C) (°F) (W) (± 10%)
0 32 5896 3
1
20 68 2500 2
40 104 1175 5
60 140 595,5
80 176 322,5
100 212 186,6
If the values do not change, or differ too much from
those given in the table, replace the thermistor (1).
Repeat the operations for the other thermistor.
Release 00/2002 - 03 6 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
This measurement method is only approximate; if
possible, make sure the coil is in good working order
by using another one you know functions properly.
Repeat the operations for the other coils.
6 - 20 - 00 Release 00/2002 - 03
Ar/V
– + 7
1
4 5
V/N
Ro/Bi
3
E1 6
B/Bi (Grey)
H1
(Black)
Legend:
1) Battery
2) Fuel pump relay
3) Pump
4) Overturn sensor
5) Engine stop relay
6) Electronic control unit (ECU)
7) Fuse
Release 00/2002 - 03 6 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
6 - 22 - 00 Release 00/2002 - 03
V V
29
8
58 59
Gr Gr
M/Vi
Gr/B
Vi/N
Engine Kill
12 M/N
G/R G/R
Diodo
16
M/V
M
70
10
B/V
9
18 17
Release 00/2002 - 03 6 - 23 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
STAND
GEAR STAND CLUTCH ENGINE STARTER
WARNING
POSITION POSITION LEVER IGNITION MOTOR
LIGHT
PULLED
RETRACTED OFF
RELEASED
IN NEUTRAL
PULLED TURNS OVER
EXTENDED ON WORKING
RELEASED
PULLED
RETRACTED OFF
GEAR RELEASED
ENGAGED DOES NOT
PULLED DOES NOT
EXTENDED ON TURN OVER
RELEASED WORK
6 - 24 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Use a tester (in diode test mode) to check the values
between the two internal male prongs of the diode as
shown in the figure. 1
WARNING
Never use bulbs over 2 W as they could damage the
diode.
Release 00/2002 - 03 6 - 25 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Connect the various terminals to a 12 V battery,
inserting 12 V/2 W bulb on the positive cable (+) as
indicated.
WARNING
Never use bulbs over 2 W to avoid damaging the
module.
+ 1 2 3 4 5
–
1
2
3 2
4
5
WARNING
The bulb must light only where indicated.
If not, replace the module (2).
6 - 26 - 00 Release 00/2002 - 03
Cables
Pos.
Screw
1
Neutral
Cables 2
Side stand pos.
M V N
Lowered
Raised
Cables
Pos.
Gr M
Activated
Release 00/2002 - 03 6 - 27 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
G1(G) G/N
3
H4(N) R/M
G2(G) G/N
3
4
5
E4(N) B/R
B2(N) Ro/N
6 - 28 - 00 Release 00/2002 - 03
CONNETTORE CONNETTORE
(16VIE) (12VIE)
2 9 11 16 1 2 5 4 3 6
Bi/Gr
Az/N
Gr/B
Bi/G
Bi/N
Bi/R
Ro
M
B/Ar
2 3 4
Legend:
1) Dashboard
2) External temperature sensor
3) Oil pressure sensor
4) Fuel level sensor
5) Speed sensor
6) Coolant temperature sensor
Release 00/2002 - 03 6 - 29 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 30 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical
terminal (1) is fitted properly. 1
With the ignition switch set to “ “, the red engine oil
pressure LED “ “ should light.
If the LED “ “ does not light as described, check the
sensor.
Use a tester (scale x 100 Ω) to check the continuity
between the terminal tab (3) and the sensor (2)
housing (see figure).
Correct value with engine off: 0 Ω 3
Correct value with engine running: ∞ Ω
If the resulting values do not match those listed, make
sure the engine oil level is correct, see 2.12 (CHECKING
AND TOPPING UP THE ENGINE OIL LEVEL) and
replace the sensor (2) if necessary.
Release 00/2002 - 03 6 - 31 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
+ -
:
6 - 32 - 00 Release 00/2002 - 03
Release 00/2002 - 03 6 - 33 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
With resistance = 90 Ω:
dashboard indicator: 9 wedges lit (the last two flashing).
degree indicator:
- from 126°C to 135°C.
- from 258.8°F to 275°F.
With resistance = 1600 Ω
dashboard indicator: 1 wedge lit.
degree indicator: “- - -”
6 - 34 - 00 Release 00/2002 - 03
1 2 4 3
PASSING
G/V
V
G/Gr
V/Ar
Ar
G
G/N
V/R
B/N
Gr
Az
G/V
Bi
R
N
V
Bi/R
G/N
R/B
G/R
G/V
V/R
G
V
Bi/R
G/N
G/R
G/Gr
G/V
V/R
R/B
R/Bi
V/N
G
V
G
G/N
Bi
N
V
G/N
G
V
C
A
5 6
14 13
8
10 15 11
12 - + 9
Legend:
1) Right dimmer switch 9) Battery
2) Left dimmer switch 10) License plate lamp
3) Right dimmer switch version 11) Low beam
4) Key 12) High beam
5) Low beam relay 13) Front parking light
6) High beam relay 14) Rear parking light
7) Fuses (15 A) 15) Dashboard light LED
8) Fuses (30 A)
Release 00/2002 - 03 6 - 35 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
- +
12V
+ -
:
30
87
85 86
6 - 36 - 00 Release 00/2002 - 03
PASSING
1
G/N
V/R
V/R
B/N
Gr
Az
Bi
R
B
V
V/R
B/N
7
Gr
Az
R
L B
C 3
12
5
8 11 10 9
13
- +
6
Legend:
1) Left dimmer switch
2) Horn
3) Fuse (15 A)
4) Fuse (30 A)
5) Key
6) Battery
7) Flasher
8) Rear right direction indicator bulb
9) Rear left direction indicator bulb
10) Front right direction indicator bulb
11) Front left direction indicator bulb
12) Dashboard
13) Direction indicators (LED)
Release 00/2002 - 03 6 - 37 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 38 - 00 Release 00/2002 - 03
G/V
2
V
Bi/R
G/N
R/B
G/R
G/V
V/R
G
V
G/V
V
C 3
4
7 8
- +
6
Legend:
1) Front stop switch
2) Rear stop switch
3) Fuse (15 A)
4) Fuse (30 A)
5) Key
6) Battery
7) Taillight
8) Brake lights
Release 00/2002 - 03 6 - 39 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6.13.2 SWITCHES
Use a tester to check the continuity of the switches,
referring to the specific diagram.
Should you detect anything out of order, replace the
corresponding group of switches.
Cables
Pos.
V V/G
Activated
Cables
Pos.
Gr M
Activated
6 - 40 - 00 Release 00/2002 - 03
6.14 BATTERY
NOTE This vehicle is equipped with a sealed
maintenance-free battery. It requires no maintenance
beyond standard inspections and recharging if needed.
Always replace the battery with one of the same type.
Type: 12V - 12 Ah
Carefully read 2.4 (BATTERY).
DANGER
Battery electrolyte is toxic and caustic, and can
severely burn your eyes or skin since it contains
sulfuric acid.
Always wear protective clothing, a safety mask and/
or goggles while activating the battery.
If the electrolyte fluid comes into contact with your
skin, rinse thoroughly with cool running water.
Should it accidentally contact your eyes, flush
immediately with running water for fifteen minutes,
then immediately seek professional medical
attention.
2
If someone should accidentally swallow battery
electrolyte, drink large amounts of milk or water, then
continue with milk of magnesia or vegetable oil. See
a physician immediately.
Since the battery gives off explosive hydrogen gas,
keep away from open flames, sparks or cigarettes, or
any other source of heat.
When you are charging or using a battery, make sure
that the room is properly ventilated; do not inhale the
gases released during charging.
KEEP OUT OF REACH OF CHILDREN
The battery fluid is corrosive.
Do not spill or spatter it, especially on plastic parts.
3
WARNING
Make sure that the electrolyte liquid being used is
specific for the battery to be activated.
2
Place the battery on a flat surface.
Remove the adhesive sealing label (1).
Remove the sealed bag from the cardboard container
containing the six reservoirs (2).
Remove the reservoirs (2) from the bag.
NOTE Keep the row of stoppers (3) handy as you will
need them later to cap the battery cells.
Disconnect the row of stoppers (3) from the top of the
reservoirs (2).
Release 00/2002 - 03 6 - 41 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING 2
Do not cut or make holes in the sealed parts on the
reservoirs (2).
Turn the reservoirs (2) upside down and place them so
that the sealed parts are over the openings of the
battery cells.
Press on the reservoirs (2) so that the seals break and
the acid is allowed to drain into the battery cells.
NOTE Ensure that the reservoirs (2) are placed above
the battery vertically, to enable all of the liquid to flow into
the battery.
Leave the reservoirs (2) in place on the battery for
approx. twenty minutes, making sure that the liquid
drains out smoothly.
WARNING
Do not remove the reservoirs (2) from the battery
until all of the liquid has drained.
Should any liquid still be left in the reservoirs (2) once
the twenty minutes are up, tap your fingers on the top
of the reservoirs to help the remaining liquid out.
Lift the reservoirs (2) with care, disengaging them from
the battery.
6 - 42 - 00 Release 00/2002 - 03
6.14.2 MAINTENANCE
If the vehicle remains unused for more than fifteen
days, the battery must be recharged to prevent
sulphation. Recharge the battery using a normal
charge, see 2.4.2 (RECHARGING THE BATTERY).
Smear a thin film of neutral grease or Vaseline on the
terminals.
6.14.3 CHECKING
Should you run into any difficulty with the battery
maintaining a charge, first check the recharging circuit to
make sure it is functioning correctly; see 6.3 (CHECKING
THE RECHARGING SYSTEM).
Also make sure that:
There are no signs of damage (external case cracked)
and no electrolyte leak.
The cables are firmly connected to the terminals.
Apply a normal charge for at least 10 hours.
WARNING
After recharging, check the open-circuit voltage
again: if it is below 12V, the battery must be replaced.
Release 00/2002 - 03 6 - 43 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
Before replacing a bulb, turn the ignition switch to
the “ “ position.
Always wear clean gloves or use a clean, dry cloth to
change the bulb.
Do not leave fingerprints on the bulb, since the oils
left by your skin may cause it to overheat and break.
If you touch the bulb with your bare hands, clean it
with alcohol to remove any fingerprints and thus
avoid unnecessary damage.
DO NOT FORCE THE ELECTRICAL CABLES.
WARNING
Do not pull the electrical cables to extract the bulb
socket.
Grasp the socket for the bulb to be replaced (4), pull
7 1
and disconnect it from the bulb (1).
Pull back the boot (5) with your fingers.
Release the retainer spring (6) located behind the bulb
seat (7).
Extract the bulb (1) from its seat and replace it with
another of the same type.
NOTE When inserting the bulb in bulb seat, line up the
positioning marks.
6 - 44 - 00 Release 00/2002 - 03
WARNING
Do not pull on the wires to remove the bulb socket.
Grasp the parking light socket (8), pull it and remove it
from its seat.
Remove the bulb (2) and replace it with another of the
same type.
8
2
WARNING
Do not pull the electrical cables to extract the bulb
socket.
9 10
Grasp the bulb socket (8), pull it and disconnect it from
the bulb (3).
Pull back the boot (10) with your fingers.
Release the retainer spring (11) located behind the 12
bulb seat (12). 3
Extract the bulb (3) from its seat and replace it with
another of the same type.
NOTE When inserting the bulb in bulb seat, line up the
positioning marks.
11
Release 00/2002 - 03 6 - 45 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
DANGER
The exhaust silencer becomes extremely hot during
operation. You could be burned if you attempt to
change the lightbulb before the silence cools
completely. Allow the silencer to cool completely
before attempting this operation. Failure to observe
this warning can lead to serious burns.
WARNING
Handle with care. Do not force electrical cables.
Partially
remove the taillight, see 7.1.36 (REMOVING
THE TAILLIGHT).
DANGER
Upon reassembly, make sure that the taillight wires
are positioned properly to avoid touching the muffler.
6 - 46 - 00 Release 00/2002 - 03
Grasp the socket (3), pull it and remove it from its seat.
Remove the bulb (4) and replace it with another of the
same type.
3
Release 00/2002 - 03 6 - 47 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
WARNING
Do not attempt to repair faulty fuses.
Never use any fuses other those specified. Such use
could damage the electrical system or even cause a
fire, in the event of a short-circuit.
NOTE If a fuse blows frequently, there is probably a
short circuit or overload in the electrical system.
Check the fuses whenever an electric component does
not work or works irregularly, or if the vehicle fails to start.
Check first the 15-A secondary fuses, then the 30-A main
fuses.
To check:
Turn the ignition switch to “ “ to avoid an accidental
short-circuit.
Remove the lower dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Open the cover of the secondary fuse box (1).
Remove the fuses one by one, and check to see
whether the filament (2) is blown.
Before replacing the fuse, if possible, try to determine 2
the cause of the problem.
Replace any blown fuse with a new fuse with the same
amperage rating.
NOTE If you use the spare fuse, replace it as soon as
convenient.
Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Follow the same procedure described above for B C D
secondary fuses to check and replace the main fuses. A
NOTE Removing the 30 A fuses will reset the E
functions: digital clock and red line setting. To reset these
functions, see 2.3 (MULTIFUNCTION COMPUTER).
LAYOUT OF THE 15-A SECONDARY FUSES
A From voltage regulator to: headlight, dashboard.
B From voltage regulator to: fuel pump. 1
C From ignition switch to: parking lights, rear brake lights,
horn, direction indicators.
D From ignition switch to: starting, safety logic.
E From ignition switch to: not used.
NOTE There are three spare fuses
LAYOUT OF THE 30-A MAIN FUSES
F
F From battery to: voltage regulator, fuse A, fuse B and
fuse C.
G From battery to: ignition switch, fuse C, fuse D.
NOTE There is one reserve fuse. G
6 - 48 - 00 Release 00/2002 - 03
9/10 H
H
To adjust the headlight beam:
Remove the right dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Sit on the vehicle as though you were riding.
Working from the right underside in back of the front
fairing, turn the adjuster knob (1):
– turn clockwise to adjust the beam lower;
– turn counter-clockwise to adjust the beam higher.
After completing the adjustment:
NOTE Make sure the headlight beam is properly
adjusted vertically.
DANGER
If the headlight is improperly adjusted, it could
temporarily blind oncoming drivers, or fail to
illuminate the road in front of you. Either of these
conditions could cause you to lose control of the
motorcycle, with subsequent upset, and serious
accident and injury or even death. Never ride you
motorcycle unless the headlight is properly adjusted.
Release 00/2002 - 03 6 - 49 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
6 - 50 - 00 Release 00/2002 - 03
Legend:
1) Multiple connectors 35) –
2) Speed sensor 36) Pick up
3) High beam relay 37) Alternator
4) Low beam relay 38) Voltage regulator
5) Horn 39) Injection relay
6) Left dimmer switch 40) –
7) Flasher 41) Rear cylinder injector
8) Air thermistor (dashboard) 42) Front cylinder injector
9) Dashboard 43) Cooling fans
10) Coolant temperature thermistor (dashboard) 44) Fuel reserve sensor
11) Engine oil pressure switch 45) Fuel pump
12) Right dimmer switch 46) Air thermistor (electronic control unit)
13) Ignition switch 47) Coolant temperature thermistor (electronic control
14) Engine stop relay unit)
15) Overturn sensor 48) Throttle valve position sensor
16) Fuel pump relay 49) Rear cylinder coil
17) Rear right direction indicator 50) Rear cylinder coil
18) Rear parking/brake light bulb 51) Front cylinder coil
19) Rear parking/brake light bulb 52) Front cylinder coil
20) Rear left direction indicator 53) Spark plugs
21) Taillight 54) Choke
22) Rear stop switch 55) Electronic control unit
23) Front stop switch 56) Front left direction indicator
24) License plate light bulb 57) Front parking light bulb
25) Diode module 58) Low beam bulb
26) Clutch lever switch 59) High beam bulbs
27) Neutral gear switch 60) High beam bulb
28) Side stand switch 61) Headlight
29) Starter motor 62) Front right direction indicator
30) Start relay 63) Fuel reserve LED
31) Battery 64) Side stand down LED
32) Main fuses (30 A) (Ignition) 65) Gear in neutral LED
33) TEST connectors 66) Direction indicators LED
34) Secondary fuses (15A) 67) Engine oil pressure LED
A - headlight, dashboard 68) High beam LED
B - fuel pump 69) Diagnostics LED
C - parking lights, rear brake lights, horn, direction 70) Tachometer
indicators 71) Multifunction display (right side)
D - starting, safety logic 72) Multifunction display (left side)
E -available 73) Diagnostics connection.
Release 00/2002 - 03 6 - 51 - 00
Downloaded from www.Manualslib.com manuals search engine
ELECTRICAL SYSTEM RST mille USA
NOTES
6 - 52 - 00 Release 00/2002 - 03
CHASSIS
7
Release 00/2002 - 03 7 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
4 CONTROL............................................ 7-17-00
7.1.16 REMOVING ELECTRICAL CONTROLS
ON THE RIGHT HANDLEBAR............ 7-18-00
7.1.59 REMOVING THE REAR HOUSING..... 7-48-00
7.1.60 REMOVING THE FRAME.................... 7-49-00
7.2 FRONT WHEEL .............................. 7-51-00
7.1.17 REMOVING THE IGNITION SWITCH/
STEERING LOCK................................ 7-19-00 7.2.1 REMOVING THE COMPLETE WHEEL 7-52-00
7.2.2 DISMANTLING THE WHEEL .............. 7-53-00
5 7.1.18 REMOVING THE LEFT HANDLEBAR 7-20-00
7.1.19 REMOVING THE RIGHT HANDLEBAR 7-20-00
7.1.20 REMOVING THE FRONT FAIRING .... 7-21-00
7.2.3 CHECKING THE COMPONENTS ....... 7-54-00
7.2.4 REINSTALLING THE WHEEL............. 7-55-00
7.1.21 REMOVING THE MIRRORS................ 7-22-00 7.3 REAR WHEEL ................................ 7-56-00
7.1.22 REMOVING THE HEADLIGHT............ 7-22-00 7.3.1 REMOVING THE COMPLETE WHEEL 7-57-00
6 7.1.23 REMOVING THE UPPER DASHBOARD
MOLDING ............................................ 7-23-00
7.3.2 REASSEMBLING THE REAR WHEEL. 7-58-00
7.4 FINAL DRIVE ASSEMBLY.............. 7-60-00
7.1.24 REMOVING THE DASHBOARD ......... 7-23-00
7.1.25 REMOVING THE DASHBOARD/FRONT 7.4.1 REMOVING THE FINAL DRIVE
FAIRING MOUNT ................................ 7-24-00 ASSEMBLY ......................................... 7-61-00
7 7.1.26 REMOVING THE FRONT MUDGUARD 7-25-00
7.1.27 REMOVING THE HORN ...................... 7-25-00
7.4.2 CHECKING THE COMPONENTS ....... 7-63-00
7.4.3 REMOVING THE ECCENTRIC CAM .. 7-64-00
7.1.28 REMOVING THE SIDE FAIRINGS ...... 7-26-00 7.4.4 REMOVING THE SPROCKET............. 7-64-00
7.1.29 REMOVING THE FRONT DIRECTION
INDICATORS ....................................... 7-26-00 7.5 FRONT BRAKES ............................ 7-65-00
7 - 2 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 3 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7.1 BODY
3 4
5
2
7 8
9 10 11 12
13
23 22 21 20 19 18 17 16 15 14
Legend:
1) Headlight
2) Air temperature sensor
3) Left rearview mirror
4) Saddle lock
5) Ignition switch / steering lock / parking lights
6) Clutch fluid reservoir
7) Engine oil reservoir cap
8) Left rider footrest
9) Battery
10) Main fuse holder (30A)
11) Saddle
12) Left passenger footrest (locking, closed /open)
13) Drive chain
14) Swinging arm
15) Center stand
16) Side stand
17) Gearshift lever
18) Electronic control unit
19) Engine oil filter
20) Engine oil reservoir
21) Lower left fairing
22) Engine oil level
23) Left fairing
7 - 4 - 00 Release 00/2002 - 03
8 9 10
1 2 3 4 6 7
5
15 11
14 13 12
17 16
Legend:
1) Taillight
2) Right passenger footrest (locking, closed /open)
3) Glove/tool kit compartment
4) Rear shock absorber
5) Fuel tank
6) Fuel tank cap
7) Air filter
8) Front brake fluid reservoir
9) Secondary fuse holder (15A)
10) Right rearview mirror
11) Horn
12) Coolant expansion tank
13) Coolant expansion tank plug
14) Rear brake lever
15) Right rider footrest
16) Rear brake master cylinder
17) Rear brake fluid reservoir
Release 00/2002 - 03 7 - 5 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 6 - 00 Release 00/2002 - 03
4
Tightening torque for screws (1): 0.7 ftlb (1 Nm).
Unscrew and remove the screw (2), retrieving the
bushing.
Release 00/2002 - 03 7 - 7 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER
Gasoline is extremely flammable and becomes
explosive under certain conditions.
KEEP GASOLINE AWAY FROM CHILDREN.
NOTE Is possible to partially remove the tank from the
vehicle even when it contains fuel.
Set the ignition switch to “ ”.
Remove the saddle, see 7.1.1 (REMOVING THE
1
SADDLE).
Disconnect the connector electrical (1) from the fuel
intake pump.
NOTE When reassembling, make sure the electrical
connector (1) is fitted properly.
Slide the two drain tubes (2) upwards.
Unscrew and remove the two screws (9).
2
Tightening torque for screws (9): 2.2 ftlb (3 Nm).
Remove the grille (3).
Unscrew and remove the two screws (4) holding the
front of the tank (5), retrieve the two bushings, and
replace the two grommets if they are damaged.
8
7
7 - 8 - 00 Release 00/2002 - 03
Firmly grasp the tank (5) from the front or back, raise it
and cautiously place it on the prepared surface, without
turning it over. 5
WARNING
When reassembling, make sure the tank is
positioned correctly (lines and electrical cable must
not be tangled and/or crushed).
DANGER
When reassembling, use two new gaskets (2) and
torque the banjo screw (1) as specified, so that the tank
will not leak. This is essential, as the injection pressure
is approximately 450 kPa (4.5 bar), and any fuel leakage
would create a highly dangerous situation, as the
leaking fuel could contact high temperature parts of the
engine.
A special seat (3) is provided to ensure that the banjo
(4) is correctly positioned during reassembly. The fuel
delivery line (4) must not be twisted, or placed where it
is likely to be pinched by other components; it must be
replaced if found to be damaged or deteriorated.
Remove the tank completely.
If the lower front soundproofing and rear insulating
panels appear damaged, replace them.
Release 00/2002 - 03 7 - 9 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
When removing the screw (3), be careful not to drop 1
it into the tank.
Unscrew and remove the screw (3).
7 - 10 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical 5
connector is fitted properly.
Remove the filter case (9), complete with intake
manifold (10).
NOTE Plug the openings with a clean rag to prevent
any foreign matter from entering the air passages.
The intake manifold (10) must be positioned correctly and
aligned perfectly with the air intake holes in the frame.
Make sure that the air filter case (9) rests snugly against
the throttle body, and that it is correctly inserted into the
intake manifold (10). Only then should the screws (8) be 6
torqued, and the clamp (11) tightened.
If you remove the two air inlet ducts (12), make sure the
two O-rings are correctly positioned to prevent any
foreign matter from entering the engine. 9
12 8
12
8 8
10
11
Release 00/2002 - 03 7 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER
Once it has been removed, store the battery in a safe
place and out of reach of children.
Store the battery on a flat surface and in a cool, dry
place.
WARNING
When reassembling, first connect the positive cable
(+), then the negative cable (-).
When reassembling, the battery (9) must be placed in
its compartment with the terminals facing towards the
back of the vehicle.
7
6
9
7 - 12 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the two electrical
connectors (1) are fitted properly.
Unscrew and remove the two screws (3).
Release 00/2002 - 03 7 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 14 - 00 Release 00/2002 - 03
WARNING
When reassembling, replace the two seals with two
1
3
new washers of the same type.
Use a small blade screwdriver to pry out and remove
clutch switch (5) from the two slots on the clutch control
lever (2).
Remove the clutch control (2).
2
If necessary remove the clutch cylinder,see 3.2.1
(REMOVING THE CLUTCH CYLINDER).
Release 00/2002 - 03 7 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
4
When reassembling, make sure the connector (5) is
fitted properly.
Remove the two halves of the electrical controls (2-3).
7 - 16 - 00 Release 00/2002 - 03
WARNING
When reassembling make sure that the two throttle 4
cable adjusters are properly fastened to their
respective couplings; check and, where necessary,
restore the correct clearance, see 2.11.3
(ADJUSTING THE THROTTLE CONTROL).
Move the winch (5) and disconnect the two throttle
cables.
Slide off the throttle grip (6).
Release 00/2002 - 03 7 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
When reassembling, replace the two seals with two
new washers of the same type. 3
Use a small blade screwdriver to pry out and remove
the front brake switch (5) from the two slots on the front
brake control lever (3).
Remove the front brake control (3).
WARNING
When reassembling, make sure the connector (1) is
fitted properly.
Disconnect the connector (2).
WARNING
When reassembling, make sure the connector (2) is
fitted properly.
6
Unscrew and remove the two screws (3-4) fastening
the two halves of the controls (5-6) from the bottom.
NOTE When reassembling, the shorter screw (3) must
be placed in front.
3
Separate and remove the two half-cylinders (5-6).
4 5
WARNING
When reassembling, first position the lower portion
of the control (5), making sure the positioning pin is
inserted in the corresponding hole on the handlebar.
7 - 18 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the connector (1) is
fitted properly.
Unscrew and remove the screw (2) retrieving the
bushing (3).
NOTE When reassembling, place the cable guide (4)
correctly.
Use a small hammer and chisel to notch the head of
the special screw (5), and turn it until it's loose.
Unscrew by hand and remove the screw (5). 6
NOTE When reassembling, use a new screw of the 4
same type; Torque the special screw until the head
shears off.
Remove the ignition switch/steering lock (6), sliding it 5 3
out from underneath.
2
Release 00/2002 - 03 7 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 20 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical 8
connectors (11-12-13) are fitted properly. 7
Remove the entire front fairing, complete with headlight
and rearview mirrors.
Place the complete front fairing on a flat surface.
If necessary:
Remove the headlight, see 7.1.22 (REMOVING THE
HEADLIGHT).
Remove the mirrors, see 7.1.21 (REMOVING THE
MIRRORS).
12
12
13
11 10
Release 00/2002 - 03 7 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
When reassembling, make sure the electrical
connectors (1-2) are fitted properly.
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Unscrew and remove the two nuts (3).
Remove the mirror, pulling the wiring through the slot (4).
Retrieve the gasket (5).
NOTE If necessary, repeat the above steps to remove
the other rearview mirror. 5
WARNING
After reassembly, adjust the rearview mirrors as 3
needed and tighten the nuts (3) to ensure their
4
stability.
2
Tightening torque for screws (2): 1.4 ftlb (2 Nm).
Remove the headlight (1) complete with half-housings, 1
and place it on a flat surface.
NOTE If necessary, unscrew and remove the two
screws supporting the two half-housings of the front
fairing.
7 - 22 - 00 Release 00/2002 - 03
WARNING
Replace the grommets if damaged. 3
Move the dashboard (3) out of the way.
Slip the boot off the connectors (1), and disconnect the
latter from the dashboard (3).
WARNING
When reassembling, make sure the electrical
connectors (1) are fitted together properly.
Remove the dashboard (3).
Release 00/2002 - 03 7 - 23 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 24 - 00 Release 00/2002 - 03
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Pull the mudguard (2) out from the front.
Release 00/2002 - 03 7 - 25 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
Wait until the engine and exhaust silencer have
completely cooled down.
Place the vehicle on the center stand.
Unscrew and remove the three inner screws (1). 1
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them. 2
Remove the side fairing (4). 3 2
WARNING
Replace the internal soundproofing panel if
damaged.
NOTE If necessary, repeat the above steps to remove 4
the other side fairing.
7 - 26 - 00 Release 00/2002 - 03
WARNING 5
When reassembling, make sure the connector (1) is 2
fitted properly.
Unscrew and remove the ten screws (2).
5 1
Tightening torque for screws (2): 1.4 ftlb (2 Nm).
Unscrew and remove the screw (3), saving the washer.
Release 00/2002 - 03 7 - 27 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
Be very careful to avoid damaging the brake lines. 1
Nudge the front fairing lower lockup (1) until you find
the best position for sliding it out.
Remove the front fairing lower lockup (2).
7 - 28 - 00 Release 00/2002 - 03
DANGER
Wait until the engine and exhaust silencer have
completely cooled down.
4 2
Remove the side fairing from the side in question,
see 7.1.28 (REMOVING THE SIDE FAIRINGS). 1
Unscrew and remove the two lower screws (1).
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Remove the lower fairing (4) complete with guard (7).
NOTE If necessary, repeat the above steps to remove
the other lower fairing.
Release 00/2002 - 03 7 - 29 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER
Wait until the engine and exhaust silencer have
completely cooled down.
Unscrew and remove the two upper fastening screws
(1).
1
Tightening torque for screws (1): 3.6 ftlb (5 Nm).
Unscrew and remove the side fastening screw (2).
7 - 30 - 00 Release 00/2002 - 03
WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Release the wiring from the two line fasteners (2) and
the clamp located under the grab handle.
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
3
Release 00/2002 - 03 7 - 31 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
Handle all plastic and painted components with care
1
to avoid scraping or scratching them.
Remove the rear grab handle (2) complete with taillight.
WARNING
When reassembling, make sure the taillight wiring is
positioned correctly.
Place the complete rear grab handle on a flat surface.
NOTE If necessary, disassemble the taillight by
unscrewing the three screws (3).
3
4
7 - 32 - 00 Release 00/2002 - 03
4
5
WARNING
When reassembling, make sure the reference 6
element (8) is correctly positioned in its seat on the
plate (6) and on the switch hasp (5).
8
7
WARNING 1
When reassembling, make sure the electrical
connector (1) is fitted properly.
Release 00/2002 - 03 7 - 33 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 34 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 35 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 36 - 00 Release 00/2002 - 03
WARNING 3
Take care not to lose the ball (5), ejected by the 6
5 7
spring (6), in the process.
Remove the footrest (3) and retrieve the two shims (4-
7), the ball (5) and the spring (6).
WARNING
Be careful not to reverse the position of the two
shims (4-7) during reassembly.
NOTE If necessary, repeat the above steps to remove
the other footrest.
Release 00/2002 - 03 7 - 37 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER
Wait until the engine and exhaust silencer have
completely cooled down. 3
Remove the retainer ring (1).
Slide out the pin (2).
Retrieve the footrest (3) and spring (4). 4
7 - 38 - 00 Release 00/2002 - 03
4 3
2
Release 00/2002 - 03 7 - 39 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
4
Tightening torque for pin (6): 10.8 ftlb (15 Nm).
6
7
8
7 - 40 - 00 Release 00/2002 - 03
WARNING
When reassembling, the muffler must rest against
the clamp(1) fastened to the exhaust pipe (3).
When reassembling, apply black silicone between
the muffler (2) and the exhaust pipes, see 2.41 5
(FASTENERS).
Unscrew and remove the screw (4), retrieving the nut
(5).
6 6
Release 00/2002 - 03 7 - 41 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 42 - 00 Release 00/2002 - 03
WARNING
When sliding the exhaust manifolds (4-2) out of their
cylinders, be very careful to avoid damaging the
threads of the studs.
Rotate the exhaust manifold (4) and remove as shown
in the figure.
Move the exhaust pipe (2) forward until the flange is out
of the stud-bolts on the front cylinder.
4
Turn the exhaust manifold (2) and remove it.
WARNING
Check and replace the gaskets (5), if necessary, with
two new ones of the same type.
NOTE Plug the engine exhaust openings to keep out
foreign matter.
Release 00/2002 - 03 7 - 43 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
7 - 44 - 00 Release 00/2002 - 03
9 7
13 11
10
1
9
13
Release 00/2002 - 03 7 - 45 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
8
3
5
7 - 46 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 47 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
1 4
4
5
6
7
7 - 48 - 00 Release 00/2002 - 03
2
1
Release 00/2002 - 03 7 - 49 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER
After the motorcycle is reassembled, turn the forks to
the full left and right positions with the engine
running. If turning from lock to lock causes any
change in the idle speed, the throttle cables are
improperly installed or adjusted. This problem must
be rectified before the motorcycle is used. Failure to
observe this WARNING can lead to a stuck throttle or
engine runaway, with subsequent upset, accident,
serious injury, or even death.
7 - 50 - 00 Release 00/2002 - 03
10 9
2
4
8
7 5
2
3
11
1
Legend
1) Wheel axle nut
2) Seal
3) Seal
4) Bearing
5) Internal spacer
6) Complete wheel
7) Circlip
8) Right spacer
9) Washer
10) Nut
11) Left spacer
= GREASE, see 1.12 (LUBRICANT CHART).
Release 00/2002 - 03 7 - 51 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
Do not work the front brake lever after removing the 5
caliper pistons, otherwise the clamp pins could come
out of their housings, causing brake fluid to leak out.
Loosen and remove the nut (4), and retrieve the washer.
DANGER
Never attempt to line up the wheel while reinstalling
it with your fingers. Use only a tapered bar or the
front axle itself. Failure to observe this WARNING
can result in serious personal injury to you, including
amputation of your fingers.
7 - 52 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 53 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
WARNING
Make sure all components are undamaged,
especially those listed below.
BEARINGS
1
Manually turn the inner race (1) of each ball bearing.
The rollers should turn smoothly and quietly. There
should be no axial clearance. Any bearings found to
have these faults must be replaced.
GASKETS
Make sure the gaskets are intact; replaced if damaged
or excessively worn.
WHEEL AXLE
Use a dial indicator to check the eccentricity of the axle
(2). If the eccentricity exceeds the limit value, replace 60 70
80
40
90
100
20
110
120
10
WHEEL RIM
Use a dial indicator to make sure that the radial (A) and
axial (B) eccentricity of the wheel rim (3) does not
exceed the limit value. Excess eccentricity is usually
caused by worn or damaged bearings. If the value 2
does not return to within the limit indicated after
changing the bearings, replace the wheel rim (3).
Maximum radial and axial eccentricity: 0.078 in
(2 mm)
TIRE
Check the status of the tire,see 2.36 (TIRES).
60 70
80
50 90
40 100
30 110
20 120
10
021
011
0
001
01
09
02
08
03
07
3
04
06
05
7 - 54 - 00 Release 00/2002 - 03
WARNING
During reassembly, take care not to damage the
brake lines, discs and pads.
The arrow on the wheel hub shows the rotation
direction. When reassembling, be careful to mount
the wheel properly.
Spread a light coating of lubricant grease along the entire
length of the axle (1), see 1.12 (LUBRICANT CHART).
Place the left spacer (7) in its seat on the wheel.
Place the wheel between the fork tubes.
WARNING
Danger of injury.
Do not insert your fingers to align the holes.
Move the wheel until the center hole is aligned with the
holes on the fork.
Fully insert the axle (1).
Place the washer and tighten the nut (3) by hand.
For block the axle (1) rotation, tighten the two axle
clamp screws (4). 7
WARNING 1
Be very careful to avoid damaging the brake pads.
Slip the brake caliper (6) onto the disc, and position it
so that the fastener holes are aligned with the holes on 4
the support.
WARNING
Replace the screws (2) fastening the clamp (6) with
two new screws of the same type.
Screw and tighten the two brake caliper fastener
screws (2).
Release 00/2002 - 03 7 - 55 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
Make sure the wheel is properly centered and 7.3 REAR WHEEL
balanced.
1
3
4 6
2
8
5
Legend
1) Wheel screw cover
2) O-ring
3) Snap ring
4) Wheel screw stop
5) Wheel screw
6) Wheel cable
7) Complete wheel
8) Wheel axle nut
= GREASE, see 1.12 (LUBRICANT CHART).
7 - 56 - 00 Release 00/2002 - 03
DANGER
Wait until the engine and exhaust silencer have 1
completely cooled down.
During disassembly, take care not to damage the
brake lines, discs and pads, and the speed sensor
cable.
Place the vehicle on the center stand.
Use the spanner wrench to unscrew and remove the
cap (1).
Remove the snap ring (2).
Slide out the screw locking nut (3).
Engage first gear to keep the wheel from turning.
Insert the bushing (5) supplied with the tool kit into the
screw hole (4).
Insert the torque wrench into the hexagonal slot of the
bushing (5). 4
2
Tightening torque for wheel fastening screw:
125.3 ftlb (170 Nm).
DANGER
The drive shaft has a key (7). Do not allow the key (7)
to fall out of its seat while the wheel is being
removed.
3
In this case:
Set the gearshift lever to neutral.
Turn the wheel so that the key (7) is at the bottom.
Completely remove the wheel (8).
Retrieve the centering bushing (9).
8 9
Release 00/2002 - 03 7 - 57 - 00
Downloaded from www.Manualslib.com manuals search engine
CHASSIS RST mille USA
DANGER 3
Before reassembly, make sure the key (1) is present
and correctly positioned. Place it correctly if it has
fallen from its seat. Do not forget to remount it.
Turn the drive shaft so that the key (1) is at the top. 1
Mount the wheel (2) on the drive shaft, making sure
that the three drive pins (3) are correctly inserted in the
wheel slots. 3
Engage first gear to keep the wheel from turning.
Make sure the key (1) is present on the drive shaft 3
seat.
Place the centering bushing (4) correctly, mating the
slot (5) with the key (1).
Spread a light coating of grease lubricant on the thread
of the wheel fastening screw (6).
2
Screw in the wheel fastening screw (6) by hand.
Insert the bushing (8) in the screw hole (7).
Insert the torque wrench into the hexagonal slot of the
bushing (8).
DANGER
Make sure that the wheel fastening screw (6) is
tightened to the prescribed torque. 4
5
Tightening torque for wheel fastening screw (6):
125.3 ftlb (170 Nm).
Tighten the wheel fastening screw (6).
Insert the screw locking nut (9) into the screw hole (7),
seeking the correct position for complete insertion.
7 - 58 - 00 Release 00/2002 - 03
10
WARNING
After reassembly, operate the rear brake lever
repeatedly and make sure the brake system is in
good working order.
Make sure the wheel is properly centered and 11 12
balanced.
Release 00/2002 - 03 7 - 59 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
9
8
4
3
1
2 6 19
5
18
20
15
14
21
16 10
12
24 25 11
13
17
22
27
23
26
Legend:
1) Eccentric cam 15) Spring washer
2) Bearing 16) Self-locking flanged nut
3) Roller cage 17) Flexible coupling grommet
4) Seal 18) Belleville washer
5) Snap ring 19) Roller cage
6) Thrust-bearing spacer 20) Center bearing
7) Snap ring 21) Ring
8) O-ring 22) O-ring
9) O-ring 23) Flexible coupling holder
10) Roller cage 24) Belleville washer
11) O-ring 25) Screw
12) Sprocket hub 26) Screw
13) Sprocket 27) Screw
14) Screw
7 - 60 - 00 Release 00/2002 - 03
WARNING
When reassembling make sure that the safety screw
(1) (the longer one) is all the way down in one of the
three holes in the wheel fastening screw (3).
5
Insert the bushing (5) supplied with the tool kit into the
screw hole (4).
Insert the torque wrench into the hexagonal slot of the
bushing (5).
6
3
Release 00/2002 - 03 7 - 61 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
14
7 - 62 - 00 Release 00/2002 - 03
WARNING
Make sure all components are undamaged, 1
especially those listed below.
BEARINGS, GASKETS, WHEEL AXLE AND RIM,
see 7.2.3 (CHECKING THE COMPONENTS).
FLEXIBLE COUPLINGS
Make sure that the flexible coupling grommets (1) are 2
not damaged and/or excessively worn. Replace the
grommets (1) if necessary.
sprocket
Check the teeth of the sprocket (2) and countershaft
sprocket. If excessively worn, replace sprocket,
countershaft sprocket and drive chain, see 7.4.1
(REMOVING THE FINAL DRIVE ASSEMBLY) and
7.1.57 (REMOVING THE DRIVE CHAIN SHOE).
WARNING
Replace all three to avoid premature wear on new
components.
TIRE
Check the condition of the tire, see 2.36 (TIRES).
Release 00/2002 - 03 7 - 63 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7 - 64 - 00 Release 00/2002 - 03
2
1
5
8
6
4
8
3
Legend:
1) Brake lever For more information:
2) Brake fluid pump
- see 1.3.5 (BRAKE FLUID);
3) Brake pads
- see 2.16 (CHECKING AND TOPPING UP THE
4) Brake discs
FRONT BRAKE FLUID);
5) Brake light switch
- see 2.19 (BLEEDING THE BRAKE SYSTEMS);
6) Brake fluid lines from pump to clamps
- see 2.27 (CHECKING THE BRAKE PAD WEAR);
7) Bleeder nipples
- see 8.4.5 (FRONT BRAKE SYSTEM).
8) Brake calipers
WARNING
When disassembling/reassembling the brake caliper,
replace the clamp fastening screws with two new
screws of the same type.
Release 00/2002 - 03 7 - 65 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING 2
Do not operate the brake lever after removing the
pads, otherwise the caliper pistons could come out
of their seat, causing brake fluid to leak out.
Insert two new pads, placing them so that their holes
are aligned with those on the clamp.
WARNING
Always replace both pads, and make sure they are
correctly positioned inside the clamp.
Place the protective cover (3) with the engraved arrow
facing upwards.
Insert the two pins (2).
Insert the two pin locks (1).
Check the brake fluid level, 2.16
(CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID).
7 - 66 - 00 Release 00/2002 - 03
C
F
Release 00/2002 - 03 7 - 67 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
10 1
2
9 3
Legend:
1) Brake fluid reservoir For more information:
2) Brake fluid line from tank to pump
- see 1.3.5 (BRAKE FLUID);
3) Brake disc
- see 2.17 (CHECKING AND TOPPING UP THE REAR
4) Bleeder nipple
BRAKE FLUID);
5) Brake caliper
- see 2.19 (BLEEDING THE BRAKE SYSTEMS);
6) Brake pads
- see 2.25 (ADJUSTING THE CLEARANCE OF THE
7) Brake fluid line from pump to caliper
REAR BRAKE LEVER);
8) Rear brake light switch
- see 2.27 (CHECKING THE BRAKE PAD WEAR);
9) Brake pedal
- see 8.4.6 (REAR BRAKE SYSTEM).
10) Brake master cylinder
WARNING
When disassembling/reassembling the brake caliper,
replace the clamp fastening screws with two new
screws of the same type.
7 - 68 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 69 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7 - 70 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 71 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7 - 72 - 00 Release 00/2002 - 03
6
2 3
Release 00/2002 - 03 7 - 73 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7.7 STEERING
3
5
7 4
9 6
8
9
8
10
Legend:
1) Upper bushing For more information:
2) Washer
- see 2.28 (STEERING);
3) Fork head
- see 2.29 (INSPECTING THE FRONT SUSPENSION).
4) Locking ring nut
5) Locking washer
6) Adjustment ring-nut
7) Protective cover
8) Dust seal
9) Bearings
10) Triple clamp
= GREASE, see 1.12 (LUBRICANT CHART).
7 - 74 - 00 Release 00/2002 - 03
WARNING
Due to the weight of the front fork, the following
operations must be carried out by two mechanics.
Before starting, agree which mechanic will handle 4 3
which operations.
Proceed very carefully with removal operations. 6
While removing the front fork, be careful that the 5
brake fluid line does not catch on anything.
While one person holds the front fork in position, slowly
raise the lift platform until you are able to slide the
steering head out of the front fork.
Retrieve the dust ring (4).
Remove the upper dust ring (5).
Extract the bearing (6).
Use a special extractor to remove the lower bearing (7)
and lower dust ring (8).
WARNING
When reassembling, insert the bearings using a drift
with the same diameter as the outer ring of the
bearings.
Do not strike the balls and/or inner race.
Make sure that the bearings are perfectly nestled.
Wash all components with clean solvent.
7
WARNING
Make sure all components are undamanged,
especially those listed below.
BEARINGS AND GASKETS see 7.2.3 (CHECKING THE
COMPONENTS).
Release 00/2002 - 03 7 - 75 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7 - 76 - 00 Release 00/2002 - 03
14
8 7
17 2
16
18 9 3
19
4
15 10
11 13
13
6
5
Legend:
1) Damper rod bushing
2) Retainer ring
3) Ring
4) Upper fork tube cap
5) Center screw
6) Copper washer
7) Complete damper
8) Bushing
9) Spring spacer tube
10) Spring
11) Lower spring seat
12) Lower collar
13) Upper fork tube
14) Sliding bushing
15) Lower fork tube
16) Ring
17) Bushing
18) Stop ring
19) Dust seal
Release 00/2002 - 03 7 - 77 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
Do not remove an upper/lower fork tube unit without
having first correctly reinstalled the other upper/
lower fork tube unit on the vehicle.
2
Place the vehicle on the center support stand on a lift
platform, with the front wheel protruding beyond the
edge of the platform.
Use belts to fasten the rear drive train to the platform
so as to raise the front wheel.
Remove the front wheel, see 7.2.1 (REMOVING THE 7
COMPLETE WHEEL). It is not necessary to use the
front support stand .
Remove the front fender, see 7.1.26 (REMOVING THE
FRONT MUDGUARD).
Unscrew and remove the two screws (1) and slide off both 6
brake calipers (2), leaving them fastened to the brake line.
4
5
Tightening torque for screws (1): 36 ftlb (50 Nm).
Remove the front panel, see 7.1.32 (REMOVING THE 3
FRONT FAIRING LOWER LOCKUP).
Loosen the screw (3) fastening the fork head (4) to the
upper fork tube (5).
7 - 78 - 00 Release 00/2002 - 03
WARNING
Proceed very carefully with disassembly operations.
zTurn the upper screw adjuster (1) all the way counter-
clockwise to reduce the hydraulic damping on
5
extension.
zRemove the retainer ring (2).
zUnscrew and remove the spring preload adjuster (3).
zRemove the spring preload (4) thruster.
zPlace the lower fork tube- upper fork tube unit in a
vice using the two halves of the special tool (C).
WARNING
The upper/lower fork tube unit contains oil; do not
turn it upside down or tilt it too far in any direction
during disassembly.
A 1
zLoosen the upper fork tube cap (5).
zRemove the fork tube unit from the vice. A1
zHolding the fork tube unit upright, completely
unscrew the upper fork tube cap (5).
zUnscrew and remove the threaded pin (A1) from the 6
tool (A).
zPlace the stationary part of the tool (A) so that the
tooth engages the hole on the spring spacer tube (6).
zPlace the threaded pin (A1) in the hole on the
stationary part of the tool (A), making sure that when it
is fully inserted it engages the hole in the spring spacer
tube (6).
A1
A
Release 00/2002 - 03 7 - 79 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
The following operations must be carried out by two
mechanics. Before starting, agree which mechanic 7 B
will handle which operations.
zRest both hands on the tool (A).
zPush downward, at the same time inserting the tool
(B) between the lock nut (7) and the washer (8).
8
A
10
7 - 80 - 00 Release 00/2002 - 03
zTurn over the lower fork tube together with the upper
fork tube, and empty the oil into the container (12).
1
9
3
12
4
1
NOTE “z” To make sure to get all of the oil out, pump
the damper rod (9) slowly up and down (eight to ten
times) in the upper fork tube.
You will know when you are done because the lower tube
will slide smoothly inside the upper tube.
If they have not already come out while emptying the
oil, remove the following in the order given:
- lower spring seat (13);
- lower collar (14).
13 14
15
Release 00/2002 - 03 7 - 81 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
16
WARNING 22
The operation described below will require some
17 20
force, since the slider bushing (17) needs to push the
gasket (18), ring (19), and guide bushing (20) off, 21
despite their resistance.
Remove the lower fork tube unit (21) from the upper
fork tube (22).
19 18
WARNING
When removing the slider bushing (17), be extremely
careful to avoid damaging it (especially the sliding
surface).
17
Use a blade screwdriver to slightly widen the bushing
(17) and remove it from the lower fork tube (21).
21
20
19
18
16
15
7 - 82 - 00 Release 00/2002 - 03
24
23
WARNING
The damper (9) must not be disassembled.
21
25
Release 00/2002 - 03 7 - 83 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
scratched or scored.
50 90
40 100
30 110
10
DANGER
NEVER try to straighten a bent fork tube. This can
weaken the tube, and cause it to fracture
unexpectedly. Replace bent tubes. If this happens,
control of the vehicle surely will be lost, and
inevitably followed by an upset and accident, with
serious injury or even death.
UPPER FORK TUBE
Make sure it is not damaged and/or cracked; if so,
replace.
2
SPRING
Make sure the spring (2) is intact, and that its length is
within the prescribed limit.
If the length does not match the prescribed limit,
replace the spring (2).
Minimum free length of the spring: 9.76 in (284 mm)
Check the status of the following components:
- slider bushing (3);
- guide bushing (4); 4
- damper (5).
Should you find any signs of excessive wear or damage,
replace the component in question.
NOTE Carefully clean the wearing surfaces of the 5
bushings, being careful not to scratch the surface. Any
embedded foreign matter must be gently removed.
Replace the following components with new ones: 3
- gasket (6);
- dust seal (7);
- the two O-rings on the regulator (8).
16
8
6
7
7 - 84 - 00 Release 00/2002 - 03
WARNING
During reassembly, be extremely careful to make 2
sure that the sliding surfaces are in perfect condition
(there must be no signs of wear, scratches, etc.);
otherwise replace the component.
Be extremely careful to prevent any foreign matter
from entering the tubes.
Do not re-use oil.
Always replace the gaskets when you are done.
Proceed very carefully with reassembly operations.
NOTE Before proceeding with the operations that
follow, make sure you have on hand the special tools
(A), (B), (C), and (D). Before re-mounting the gaskets and
bushings, lubricate them with a thin coating of fork oil,
see 1.12 (LUBRICANT CHART).
1
Place the lower fork tube (1) in a vice, with its opening
facing upwards, inserting a soft material (aluminum)
between the jaws. 3
NOTE Apply grease inside the centering bushing (2),
see 1.12 (LUBRICANT CHART).
Insert the centering bushing (2) on the bottom of the
damper rod (3).
Slide the damper rod (3) into the lower fork tube (1),
making sure it rests firmly on the base.
Place the copper washer (5) on the center screw (4).
Insert and tighten the center screw (4).
5
Tightening torque for center screw (4): 25.8 ftlb 4
(35 Nm).
Remove the lower fork tube (1) from the vice.
Carefully wrap the upper end of the lower fork tube with
a single layer of vinyl electrician’s tape, so as to protect
the seals as they are installed on the fork tube.
21
1
Release 00/2002 - 03 7 - 85 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
11
7 - 86 - 00 Release 00/2002 - 03
Insert the lower fork tube (1) into the upper fork tube
(12).
Remove the tape.
Place the two halves of the tool (D) on the lower fork
tube (1), in front of the guide bushing (10).
Grip the tool (D) and push the guide bushing (10) into
position in its seat on the upper fork tube (12).
Remove the tool (D).
1 9
10
12
12
Release 00/2002 - 03 7 - 87 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
19
10
17
A
A1
A
7 - 88 - 00 Release 00/2002 - 03
WARNING
The following operations must be carried out by two
mechanics. 20 B
Before starting, agree which mechanic will handle
which operations.
zRest both hands on the tool (A).
zPush downward, at the same time inserting the tool
(B) between the lock nut (20) and the washer (19).
zWhile holding the damper rod (3), tighten the upper 19
fork tube cap (21) using the appropriate wrench.
A
Tightening torque for the upper fork tube cap
(5)/ damper rod (9): 25.8 ftlb (35 Nm).
zRest both hands on the tool (A).
zPush downward, at the same time removing the tool
(B).
zRemove the tools (A).
zPlace the lower fork tube- upper fork tube unit in a
vice using the two halves of the special tool (C).
zScrew and tighten the upper fork tube cap (5) on the
upper fork tube.
21
Tightening torque for the upper fork tube cap
(5)/ upper fork tube: 25.8 ftlb (35 Nm). 3
zInsert the spring preload thruster (22).
zScrew on the spring preload adjuster (23).
zPlace the retainer ring (24) in its seat.
zUse the spring preload adjuster (23) and the upper
adjuster screw (25) to restore the correct attitude,
which must be the same as that of the other lower fork
tube/upper fork tube unit, see 2.29.2 (ADJUSTING
THE FRONT FORK).
B
23
22
25
21
24
Release 00/2002 - 03 7 - 89 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
After reassembly, squeeze the front brake and
bounce the fork repeatedly.
The forks must slide smoothly and evenly, and there
must be no traces of oil on the tubes.
DANGER
Before using the vehicle, make sure that the riding
position is correct, see 2.29.2 (ADJUSTING THE
FRONT FORK).
5
1 7 4
1
8
3
7 - 90 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 91 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
Due to the weight of the rear drive train, the following
12
operations must be carried out by two mechanics.
Before starting, agree which mechanic will handle
which operations.
Proceed very carefully with removal operations.
11
Support the swinging arm in front to keep it from
falling accidentally.
Support the front part of the swinging arm, and
simultaneously remove the swinging arm pivot (11) out
from the right.
Slide the adjuster bushing (12) from the pivot (11).
WARNING
While removing the rear drive train, be careful that
the drive chain does not catch on anything.
Remove the swinging arm, complete with axle, sliding it
out from behind.
NOTE Remove the rear wheel axle if necessary,
see 7.4.1 (REMOVING THE FINAL DRIVE ASSEMBLY).
7 - 92 - 00 Release 00/2002 - 03
WARNING
Make sure that none of the components are visibly 1
bent, broken, cracked and /or dented.
Replace any damaged components.
BEARINGS
Manually turn the inner race (1) of each ball bearing.
The rollers should turn smoothly and quietly.
There should be no axial clearance.
Any bearings found to have these faults must be
replaced.
WARNING
Apply grease to the balls (on the sides of each
bearing) and rollers, see 1.12 (LUBRICANT CHART).
GASKETS
Make sure the gaskets are intact; replaced if damaged
60 70
80
50 90
40 100
or excessively worn. 30
20
110
120
10
Release 00/2002 - 03 7 - 93 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
Due to the weight of the rear drive train, the
following operations must be carried out by two
9
mechanics. 10 5
Before starting, agree which mechanic will handle 7
8
which operations.
6
Support the front of the swinging arm, maneuver it so
that the holes are aligned, and at the same time insert
the pivot (1).
NOTE Make sure that the hex head on the pivot (1) is 3
correctly inserted in the hexagonal recess on the adjuster
bushing (2).
Fit the lock ring (4) and screw it on by hand a few turns.
Place the washer (5) and nut (6) on the swinging arm
pivot, tightening them by hand.
Now adjust the swinging arm, see 2.30.1 (ADJUSTING
THE SWINGING ARM).
Remove the tape to release the chain (3)
Fit the chain (3) back over the countershaft sprocket
(7).
NOTE Apply (7) LOCTITE® Anti-Seize on the internal
spline of the countershaft sprocket.
13
Insert the countershaft sprocket (7) complete with
chain (3) on the shaft.
NOTE Apply LOCTITE® 243 to the thread of the screw
(8).
Place the washers (9) and (10) over the screw (8).
Screw in and tighten the screw (8).
7 - 94 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 95 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
7 - 96 - 00 Release 00/2002 - 03
Release 00/2002 - 03 7 - 97 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
11
7 - 98 - 00 Release 00/2002 - 03
WARNING
Make sure that none of the components are visibly
bent, broken, cracked and /or dented.
Replace any damaged components.
BEARINGS
Manually turn the rollers, which should turn smoothly
and quietly. 1
There should be no axial clearance.
Any bearings found to have these faults must be
replaced.
WARNING
Apply grease to the rollers, see 1.6 (LUBRICANT
CHART).
GASKETS
Make sure the gaskets are intact; replaced if damaged
or excessively worn.
SHOCK ABSORBER
Make sure there are no oil leaks in the shock absorber,
and that its stroke is smooth and progressive.
If not, replace.
DANGER
The shock absorber contains pressurized nitrogen.
In order to avoid the risk of explosion, keep it away
from flames and/or sources of heat.
If replacing the shock absorber, discharge the
nitrogen by pressing on the valve stem under the
valve cap (1).
Release 00/2002 - 03 7 - 99 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
WARNING
Only chains with rivet-type links should be installed
on this vehicle.
4
6
7
2
5
1 3
12 13 14
9
11
10
15
14
WARNING
Make sure that the master link is the same type as 6
the chain to be joined.
Place the chain on the vehicle with the two ends to be
joined at a point between the front and rear sprockets
of the chain’s lower run.
lace one O-ring on each of the pins of the master link.
Grease the two pins on the master link, see 1.12 1
(LUBRICANT CHART). 2
Join the two ends of the chain and insert master link
pins. Insert an O-ring on the tip of each pin.
3
Slip the rivet plate over the pins.
Fit the support plate (6) on the rivet plate.
Fit the rivet tool (1) onto the chain.
Move the rivet tool (1) so that its side holes match the
heads of the pins on the joining plate.
Insert the smallest diameter of the pusher (2) into the 1
main body (3). 4
Fit the main body (3) on the rivet tool (1). 1
Move the main body (3) so that the locating dowel (4) is 3
in line with mark “A”.
Turn the screw (5) by hand until the pusher (2) touches
the support plate (6). 5
Hold the central body (3) stationary using a 1.06 in
(27 mm) wrench over the tied hexagonal boss. 3
Turn the screw (5) in as far as it will go, using a 0.74 in 5
(19-mm) wrench.
WARNING
Wear safety goggles or a shield to protect your eyes.
Hold the central body (2) stationary using a 1.06 in
(27-mm) wrench over the tied hexagonal boss.
Use a 0.74 in (19-mm) wrench to turn the screw (1) 3 3
until the edge of the pin has been riveted. 5
2
WARNING
Make sure that the pin has been riveted correctly; the
riveted edge of the pin must be evenly in contact with
1
the rivet plate all the way around, and its maximum
diameter must be 0.22 ± 0.005 in (5.65 ± 0.15 mm).
Loosen the screw (1). 2
Repeat the above procedure on the adjacent pin on the 1
same link.
NOTES
GENERAL INFORMATION
8
Release 00/2002 - 03 8 - 1 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
GENERAL INFORMATION
TABLE OF CONTENTS
8.1 TROUBLESHOOTING ...................... 8-3-00
8.1.1 ENGINE.................................................. 8-3-00
0 8.1.2 ELECTRICAL SYSTEM......................... 8-8-00
8.1.3 BATTERY .............................................. 8-8-00
8.1.4 BRAKES ................................................ 8-9-00
8.1.5 CHASSIS ............................................... 8-9-00
4 SYSTEM......................................... 8-24-00
8.3.1 SPARK PLUGS (NO SPARK) ............. 8-24-00
8.3.2 BATTERY RECHARGING PROBLEMS 8-24-00
8.3.3 PROBLEMS WITH IGNITION AND/OR
STARTING ........................................... 8-24-00
5 8.3.4 PROBLEMS WITH AUXILIARY
SYSTEMS ............................................ 8-24-00
8.4 CHECKING THE ELECTRICAL
SYSTEM......................................... 8-25-00
8 - 2 - 00 Release 00/2002 - 03
8.1 TROUBLESHOOTING
WARNING
Any faults with the ignition coils, crankshaft position
sensor, camshaft sensor, pressure sensors and
THERMISTORS are automatically detected by the
electronic control unit and reported on the
multifunction display with the flashing message
“EFI”.
For this reason, the malfunctions of these
components are not repeated in the troubleshooting
table; see the corresponding chapters in sect. 4
(FUEL SYSTEM) and sect. 6 (ELECTRICAL SYSTEM).
NOTE In the table below, all operations marked (*)
must be carried out with reference to the Engine Service
Manual, see 0.4.1 (ENGINE SERVICE MANUAL).
8.1.1 ENGINE
CONT'D ➤
8 - 3 - 00 Release 00/2002 - 03
Release 00/2002 - 03 8 - 4 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8 - 5 - 00 Release 00/2002 - 03
Release 00/2002 - 03 8 - 6 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8 - 7 - 00 Release 00/2002 - 03
8.1.3 BATTERY
Release 00/2002 - 03 8 - 8 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8.1.4 BRAKES
8.1.5 CHASSIS
8 - 9 - 00 Release 00/2002 - 03
Release 00/2002 - 03 8 - 10 - 00
Downloaded from www.Manualslib.com manuals search engine
RST mille USA
GENERAL INFORMATION
F G
C D
A
A B E F
C D G
Release 00/2002 - 03 8 - 11 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
A
B
A
C
A C
B D
8 - 12 - 00 Release 00/2002 - 03
E
B
A C
B D E
Release 00/2002 - 03 8 - 13 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
B
C
A E
A C
B D
8 - 14 - 00 Release 00/2002 - 03
F G
E G
F H
Release 00/2002 - 03 8 - 15 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
A C
B
A C
B D
8 - 16 - 00 Release 00/2002 - 03
A C
B
A C
Release 00/2002 - 03 8 - 17 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
A
B
8 - 18 - 00 Release 00/2002 - 03
6
4 8
1
4 10
5
7
11
Legend
1) Flasher
2) Headlight wiring
3) Fall sensor
4) Light relay
5) Front right direction indicator
6) Secondary fuse box
7) Right dimmer switch connector
8) Dashboard connectors
9) Front left direction indicator connector
10) Air temperature sensor
11) Left dimmer switch connector
Release 00/2002 - 03 8 - 19 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8 7
9 6
10
11
12 2
1
4
3
Legend
1) Horn
2) Oil pressure sensor
3) Voltage regulator
4) Engine earth
5) Main fuses
6) Start relay
7) Taillight
8) Positive battery pole
9) Rear brake light
10) Speed sensor connector
11) Coolant temperature sensor
12) Injection connectors
8 - 20 - 00 Release 00/2002 - 03
12
13 7
5
11
18
22
16
19
2 15
14
10
1
6
9
4
3
8 20 21
17
Legend
1) Air thermistor 12) Front cylinder coil “1”
2) Control unit 13) Front cylinder coil “2”
3) Fuel pump connector 14) Rear cylinder coil “1”
4) Side stand switch 15) Rear cylinder coil “2”
5) TEST connectors 16) Front cylinder injector
6) Left fan connector 17) Rear cylinder injector
7) Right fan connector 18) Throttle valve potentiometer
8) Diode 19) Relay
9) Pick-up 20) Injection relay
10) Coolant thermistor 21) Diode module
11) Clutch switch 22) Choke motor
Release 00/2002 - 03 8 - 21 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8 - 22 - 00 Release 00/2002 - 03
Release 00/2002 - 03 8 - 23 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
8.3 CHECKING THE ELECTRICAL SYSTEM 8.3.4 PROBLEMS WITH AUXILIARY SYSTEMS
- see 6.11.2 (CHECKING THE LIGHT RELAY).
For the location of the various electrical
- see 6.8.4 (CHECKING THE DIODE).
components, see 6.1 (LOCATIONS OF ELECTRICAL
- see 6.9.2 (CHECKING THE ELECTRIC FAN
COMPONENTS) and 8.2.10 (ELECTRICAL CABLES).
OPERATION).
- see 6.6.5 (CHECKING THE COOLANT
8.3.1 SPARK PLUGS (NO SPARK)
THERMISTORS OPERATION).
First check: - see 6.5.4 (TROUBLESHOOTING IN THE
- Check the 15-A secondary fuses. ELECTRONIC SYSTEM USING DISPLAYED
- Check spark plugs. INFORMATION).
Second check: - see 6.10.3 (ENGINE OIL PRESSURE SENSOR).
- Check 30-A main fuses. - see 6.10 (DASHBOARD INDICATORS).
- See 6.6.6 (CHECKING THE IGNITION COILS).
Third check:
See 6.6.7 (CHECKING THE CRANKSHAFT POSITION
SENSOR).
8 - 24 - 00 Release 00/2002 - 03
Release 00/2002 - 03 8 - 25 - 00
Downloaded from www.Manualslib.com manuals search engine
GENERAL INFORMATION RST mille USA
NOTES
8 - 26 - 00 Release 00/2002 - 03
ANALYTICAL INDEX
i
Release 00/2002 - 03 i - 1 - 00
i - 2 - 00 Release 00/2002 - 03
CONTROL UNIT
ELECTRONIC, CONNECTIONS 6.6 6-14 F Ref. Page
ELECTRONIC, CONNECTORS 4.7.4 4-12
ELECTRONIC, REMOVING 7.1.10 7-13 FASTENERS 2.41 2-60
Release 00/2002 - 03 i - 3 - 00
i - 4 - 00 Release 00/2002 - 03
RST mille USA
ANALYTICAL INDEX
Release 00/2002 - 03 i - 5 - 00
ANALYTICAL INDEX RST mille USA
i - 6 - 00 Release 00/2002 - 03
RST mille USA
ANALYTICAL INDEX
Release 00/2002 - 03 i - 7 - 00
ANALYTICAL INDEX RST mille USA
V Ref. Page
VALVE 5.5 5-8
VOLTAGE REGULATOR, CHECKING 6.3.5 6-8
W Ref. Page
WARNINGS FOR FUEL,
LUBRICANTS, COOLANT
AND OTHER COMPONENTS 1.2 1-3
WHEEL
FRONT 2.32 2-52
FRONT 7.2 7-51
COMPLETE, REMOVING 7.2.1 7-52
7.3.1 7-57
REAR 2.33 2-52
REAR 7.3 7-56
DISASSEMBLING 7.2.2 7-53
WHEELS 8.4.8 8-26
WIRE COLORS 6.2.1 6-5
i - 8 - 00 Release 00/2002 - 03
RST mille USA
ANALYTICAL INDEX
NOTES
Release 00/2002 - 03 i - 9 - 00
ANALYTICAL INDEX RST mille USA
NOTES
i - 10 - 00 Release 00/2002 - 03