Aprilia Futura 1000 - ENG

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RST mille USA

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/

3 ACRONYMS ..................................... 0-8-00

0 - 2 - 00 Release 00/2002 - 03
RST mille USA
INTRODUCTION

0.1 UPDATE RELEASE 00/2002-03 page # Release page # Release


Issue date of the first edition (Release 00) and
subsequent Releases: 1-33 -00 ...................... 00 2-36 -00 ...................... 00
First edition (Release 00)........................March 2002 1-34 -00 ...................... 00 2-37 -00 ...................... 00
1-35 -00 ...................... 00 2-38 -00 ...................... 00
0.1.1 INFORMATION ON UPDATING THE MANUAL
The manual must be updated every time a new “Release” 1-36 -00 ...................... 00 2-39 -00 ...................... 00
is received. 1-37 -00 ...................... 00 2-40 -00 ...................... 00
.
Insert the pages of the latest Release into the 1-38 -00 ...................... 00 2-41 -00 ...................... 00
manual, and eliminate the corresponding 2-1 -00 ........................ 00 2-42 -00 ...................... 00
obsolete pages (even if belonging to a previous
Release). 2-2 -00 ........................ 00 2-43 -00 ...................... 00
2-3 -00 ........................ 00 2-44 -00 ...................... 00
DANGER
Failure to update the manual and eliminate the 2-4 -00 ........................ 00 2-45 -00 ...................... 00
obsolete pages makes it more difficult to consult 2-5 -00 ........................ 00 2-46 -00 ...................... 00
the manual, and may lead to performing incorrect
operations on the vehicle, with serious 2-6 -00 ........................ 00 2-47 -00 ...................... 00
consequences for the safety of the vehicle and of 2-7 -00 ........................ 00 2-48 -00 ...................... 00
persons and property.
2-8 -00 ........................ 00 2-49 -00 ...................... 00
The manual consists of #10 sections, for a total of #358
pages, as listed below. 2-9 -00 ........................ 00 2-50 -00 ...................... 00

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
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1-11 -00 ...................... 00 1-32 -00 ...................... 00 2-35 -00 ...................... 00 3-8 -00 ........................ 00

CONT'D ➤

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CONT'D ➤

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5-8 -00 ........................ 00 6-38 -00 ...................... 00 7-26 -00 ...................... 00 7-66 -00 ...................... 00

CONT'D ➤

0 - 4 - 00 Release 00/2002 - 03
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INTRODUCTION

page # Release page # Release


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Release 00/2002 - 03 0 - 5 - 00
INTRODUCTION RST mille USA

0.2 HOW TO CONSULT THE MANUAL

RST mille USA


GENERAL INFORMATION

1.9 PLACING THE VEHICLE ON THE SUPPORT


STANDS

1.9.1 PLACING THE VEHICLE ON THE FRONT


SUPPORT STANDS
1
2
Place the vehicle on the central stand.
At the same time, insert the two pins (1) of the stand
(3) into the two holes (2) at the bottom of the front fork.
Rest one foot at the front of the stand (3). 3
Push the stand (3) all the way down.

1.9.2 PLACING THE VEHICLE ON THE CENTER


SUPPORT STAND

Carefully read 0.5.1 (PRECAUTIONS AND GENERAL


INFORMATION). 2

Code 8140176 (complete stand).


Remove the lower fairing, see 7.1.33 (REMOVING THE
LOWER FAIRING).
Place the vehicle on the appropriate front support stand , 7
see 1.9.1 (PLACING THE VEHICLE ON THE FRONT
SUPPORT STAND).
Hold the internal nut (1) steady in place.
Unscrew and remove the upper right rear engine 1
fastening screw (2).
6

Tightening torque nut (1) / screw (2): 50 Nm


(5.0 kgm). 5
3 4
IMPORTANT The screw (2) on the left side is longer.

Retrieve the nut (1).


Insert the upper right support pin (3) in the upper hole
on the right-hand side.
Insert the stud bolt (4) in the upper hole on the left-hand
side, and screw it all the way onto the pin (3).
Screw the upper left support pin (5) all the way onto the
stud bolt (4) and tighten.
Hold the internal nut (6) steady in place.
Unscrew and remove the lower engine fastening screw (7).

Release 00/2001 - 07 1 - 17 - 00

1) Vehicle (or engine) model 8) Chapter title (progressively numbered)


2) Section 9) Paragraph title (progressively numbered)
3) Progressive release number (“00” refers to the first 10) Description of the operation (always preceded by a
edition) diamond)
4) Year and month of Release publication 11) Description of the operation: an asterisk means the
5) Section number operation must be repeated on the opposite side of
6) Section page number the vehicle
7) Updated progressive page number

0 - 6 - 00 Release 00/2002 - 03

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RST mille USA
INTRODUCTION

0.3 FOREWORD 0.4 REFERENCE SERVICE LITERATURE


This manual contains information covering normal
servicing procedures. 0.4.1 ENGINE SERVICE MANUAL
In the future, the information and illustrations contained in aprilia part# (description)
this manual will be updated by means of “Releases”,
see 0.1 (UPDATE RELEASE 00/2002-03). 8140582 (1051-1) I
Since aprilia s.p.a. strives to always improve the quality
and usefulness of its vehicles, changes may be made to 8140584 (1053-1) F

the vehicles at any time. 8140585 (1054-1) D


Thus, it is imperative that users of this manual understand
that some information may be out of date for some vehicles. 8140583 (1052-1) E
Be sure that the information in this manual applies to the
8140586 (1055-1) UK
vehicle that you are servicing before you being any
service operations. 8140587 (1056-1) USA
Before consulting the manual, check the vehicle
model.This publication is intended for aprilia dealers and
their trained and qualified mechanics. 0.4.2 SPARE PARTS CATALOGUES
The description of many service and repair operations is aprilia part# (description)
intentionally omitted, as it is assumed that the users of
this manual have basic mechanical training, basic 390W I UK
knowledge of the procedures regarding motor vehicle 390Y I UK
repair, and have available to them all current information
published by aprilia concerning the vehicle. 3901 I UK
Without these things, the repair or servicing of the vehicle
could be affected and could lead to a dangerous condition 0.4.3 SPECIAL TOOLS MANUALS
or accident for the servicing mechanic or the operator.
This manual does not describe all of the procedures aprilia part# (description)
necessary to repair and service the vehicle in detail.
8202278 I F D E UK
Therefore, it is important to be particularly careful in order
to avoid any damage to the vehicle, its parts, or to cause
injury to the mechanic or the rider. 0.4.4 OPERATING AND MAINTENANCE MANUALS
Changes in the technical specifications and servicing aprilia part# (description)
procedures that become necessary as a result of
changes to aprilia vehicles will be documented and modelli 1998 -1999
distribuited to all aprilia dealers. 8102623 I F D
Therefore, it is necessary that the latest aprilia
information be kept available to the servicing mechanics. 8102857 P E UK
If you have questions regarding repair and servicing
procedures, contact the aprilia Consumer Service 8102858 NL DK SF

(A.C.S.). A.C.S. Technical counselors will be able to 8102859 GR J UK


assist you with any problems that you might face.
aprilia s.p.a. reserves the right to modify any of its 8104128 AUS
models in any manner at any time.
This manual is protected by copyright in all countries. 8104099 USA

Reproducing by any means, print or electronic, is models 2000


prohibited.
The mention of products or services supplied by entities 8104089 I F D
other than aprilia is made for information purposes only. 8104142 P E UK
aprilia is not responsible for the performance or use of
any product not specifically recommended or endorsed 8104143 NL DK SF
by aprilia.
8104141 GR J UK
For more information, see 0.4 (REFERENCE SERVICE
LITERATURE) 8104164 AUS

NOTE Before starting any service on the engine, 8104171 USA


please read relevant reference manuals, see 0.4
RSV01
(REFERENCE SERVICE LITERATURE).
First edition: March 2002 8104152 I F D
Produced and printed by:
Deca s.n.c.
8104269 P E UK
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Phone +39 - 0545 35235 8104267 NL DK SF
Fax +39 - 0545 32844
E-mail: [email protected]
www.decaweb.it
8104268 GR J UK

on behalf of: 8104270 AUS


Aprilia consumer service s.p.a.
via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italy 8104264 USA
Phone +39 - 041 57 86 101
Fax +39 - 041 57 86 100
www.aprilia.com

Release 00/2002 - 03 0 - 7 - 00
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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

CO = carbon monoxide PPC = Pneumatic Power Clutch

CPU = Central Processing Unit RON = “Research” method octane number

cu in = cubic inch SAE = Society of Automotive Engineers

d.c. = direct current sq in = square inch

DIN = German industrial standards TDC = top dead center


(Deutsche Industrial Norm) TEST = diagnostic check
DOHC = Double Overhead Camshaft T.E. = hexagonal head
ECU = Electronic Control Unit T.P. = flat head
ftlb = foot pound TSI = Twin Spark Ignition
ft = foot US gal = USA gallon
g = gram US qt = USA quart
rpm = revolutions per minute US fl oz = USA fluid ounce
HC = unburned hydrocarbons UPSIDE-
HH = hex head screw DOWN = upside-down forks
HS = hex socket-head screw V = Volt
in = inch W = Watt
ISC = Idle Speed Control Ø = diameter
ISO = International Standardization
Organization
kg = kilograms (1 kg = 2.2046224 lb)
kgm = kilograms per meter (1 kgm =10 Nm)
km = kilometers (1km = 0.62137119 mi)
km/h = kilometers per hour

0 - 8 - 00 Release 00/2002 - 03

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RST mille USA
INTRODUCTION

NOTES

Release 00/2002 - 03 0 - 9 - 00
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INTRODUCTION RST mille USA

NOTE

0 - 10 - 00 Release 00/2002 - 03

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RST mille USA
GENERAL INFORMATION

GENERAL INFORMATION 1

Release 00/2002 - 03 1 - 1 - 00
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GENERAL INFORMATION RST mille USA

GENERAL INFORMATION 1.13.2 USING CONSUMABLES..................... 1-26-00


1.14 SPECIAL TOOLS............................ 1-29-00
1.14.1 MISCELLANEOUS TOOLS................. 1-29-00
TABLE OF CONTENTS 1.14.2 ENGINE TOOLS .................................. 1-30-00
1.15 PLACING THE VEHICLE ON THE
1.1 INTRODUCTION .............................. 1-3-00 SUPPORT STANDS........................ 1-31-00

0 1.2 SAFETY WARNINGS........................ 1-3-00


1.3 GENERAL SAFETY RULES .............. 1-4-00
1.15.1 PLACING THE VEHICLE ON THE
FRONT SUPPORT STAND ................. 1-31-00
1.15.2 PLACING THE VEHICLE ON THE
1.3.1 CARBON MONOXIDE ........................... 1-4-00 CENTER SUPPORT STAND............... 1-32-00
1.3.2 GASOLINE............................................. 1-4-00
1.3.3 HOT COMPONENTS ............................. 1-4-00 1.16 INSTRUCTIONS FOR APPLYING
1 1.3.4 USED ENGINE OIL AND FORK OIL..... 1-4-00
1.3.5 BRAKE FLUID ....................................... 1-4-00
THE TRANSFERS .......................... 1-33-00
1.17 FASTENERS .................................. 1-35-00
1.3.6 CLUTCH CONTROL FLUID .................. 1-4-00
1.17.1 JOINTS WITH CLICK CLAMPS AND
1.3.7 COOLANT.............................................. 1-4-00
WITH SCREW-TYPE CLAMPS ........... 1-35-00
2 1.3.8 BATTERY HYDROGEN GAS AND
ELECTROLYTE ..................................... 1-4-00
1.3.9 PRECAUTIONS AND GENERAL
1.17.2 GENERAL VALUES OF
TIGHTENING TORQUES .................... 1-36-00
INFORMATION ...................................... 1-5-00
1.3.10 ELECTRICAL CONNECTORS .............. 1-6-00

3 1.3.11 FASTENERS TIGHTENING TORQUES 1-6-00


1.4 SPECIFIC SAFETY RULES .............. 1-7-00
1.4.1 FUEL ...................................................... 1-7-00
1.4.2 LUBRICANTS ........................................ 1-8-00
1.4.3 BRAKE................................................... 1-8-00
4 1.4.4 DISC BRAKES....................................... 1-9-00
1.4.5 CLUTCH CONTROL FLUID ................ 1-10-00
1.4.6 COOLANT............................................ 1-11-00
1.4.7 DRIVE CHAIN ...................................... 1-12-00

5 1.4.8 TIRES................................................... 1-12-00


1.4.9 AUTOMATIC CONVERTER ................ 1-13-00
1.4.10 CATALITIC CONVERTER................... 1-13-00
1.4.11 EXHAUST SILECER............................ 1-13-00
1.4.12 SPARK ARRESTER ............................ 1-13-00

6 1.5 RUNNING-IN RULES ..................... 1-14-00


1.6 HOW TO USE YOUR SERVICE AND
REPAIR MANUAL .......................... 1-15-00
1.6.1 HOW TO USE THIS MANUAL ............ 1-15-00
7 1.6.2 REQUESTING SPARE PARTS ........... 1-15-00
1.7 IDENTIFICATION DATA ................ 1-16-00
1.7.1 VEHICLE IDENTIFICATION NUMBER
(V.I.N.) (FRAME NUMBER) ................. 1-16-00

8 1.7.2 INFORMATION CONTAINED IN THE


VEHICLE IDENTIFICATION NUMBER 1-16-00
1.8 POSITION OF SERIAL NUMBERS . 1-17-00
1.8.1 FRAME NUMBER................................ 1-17-00

9 1.8.2 ENGINE NUMBER............................... 1-17-00


1.8.3 POSITION OF THE WARNING
ADHESIVE LABELS............................ 1-18-00
1.9 CALIFORNIA EVAPORATIVE
EMISSION SYSTEM ...................... 1-20-00
1.10 SPARE PARTS ............................... 1-21-00
1.11 SPECIFICATIONS .......................... 1-21-00
1.12 LUBRICANT CHART ...................... 1-24-00
1.13 CONSUMABLES ............................ 1-25-00
1.13.1 PRODUCT PROPERTIES ................... 1-25-00

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GENERAL INFORMATION

1.1 INTRODUCTION 1.2 SAFETY WARNINGS


This manual is divided into sections, chapters and Throughout this manual you will encounter the following
paragraphs, by subject. symbols:
The procedures described are laid out in single
operation, and each operation is indicated by a Š. DANGER
The numbered parts shown in the figures are identified in When you find this symbol on the vehicle or in the
the text with the number in parentheses or with the manual, this indicates that a potential for serious
symbol representing them. personal injury or death exists.
Example (the following text is generic and does not refer Failure to follow this warning may result in serious
to this specific vehicle): risk of personal injury or death, of the mechanic
working on the vehicle, the operator of the vehicle, or
the general public.
It also indicates thet serious and permanent damage
to the vehicle is possible.

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.

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GENERAL INFORMATION RST mille USA

1.3 GENERAL SAFETY RULES 1.3.6 CLUTCH CONTROL FLUID

1.3.1 CARBON MONOXIDE WARNING


The clutch control fluid can damage painted, plastic or
If it is necessary to run the engine in order to carry out a
rubber parts.
maintenance operation, ensure that the area in wich you
are operating is properly ventilated. When performing mainatenace operations on the
Never run the engine in enclosed spaces. clutch control system, place a clean shop towel on
If it is necessary to work indoors, use an exhaust these parts.
evacuation system.
Always wear goggles when servicing the clutch control
system with clutch control fluid.
DANGER Clutch control fluid is extremely destructive to your eyes.
The exhaust fumes contain carbon monoxide, a If you should accidentally get clutch control fluid in your
poisonous gas that can cause loss of consciousness eyes, flush immediately with a large quantity of cool
and even death. clear water and seek professional medical assistance
immediately.
1.3.2 GASOLINE
KEEP CLUTCH CONTROL FLUID AWAY FROM
Work in a well ventilated area. CHILDREN.
Keep cigarettes, flames or sparks away from the work
area and from the place where gasoline is stored. 1.3.7 COOLANT
In certain conditions, the ethylene glycol contained in the
DANGER engine coolant is flammable: its flame is invisible, but you
Gasoline is extremely flammable and becomes can be burned anyway.
explosive under certain conditions.
KEEP GASOLINE AWAY FROM CHILDREN. DANGER
Avoid spilling the engine coolant on the exhaust
1.3.3 HOT COMPONENTS system or on the engine conponents.
They may be hot enough to cause the coolant to
DANGER ignite and burn whithout a visible flame.
The engine and the components of the exhaust The coolant (ethylene glycol) can cause skin
system become very hot and remain hot for some irritation and is poisonous if swallowed.
time after the engine has been stopped. Engine coolant is sweet tasting, and therefore
Before handling these components, wear insulating extremely attractive to pets and other animals, as
gloves or wait until the engine and the exhaust well as being extremely toxic.
system have cooled down. Do not leave coolant in an open container where
animals may be able to drink it.
1.3.4 USED ENGINE OIL AND FORK OIL
KEEP COOLANT AWAY FROM CHILDREN.
DANGER Do not remove the radiator the cap when the engine is
hot.
Use latex gloves for the maintenance operations that
The coolant is under pressure and may cause burns.
require contact with used oil.
Used oil may cause skin cancer if repeatedly left in
contact with the skin for prolonged periods. 1.3.8 BATTERY HYDROGEN GAS AND ELECTROLYTE
Although this is unlikely unless you handle used oil on
a daily basis, it is advisable to thoroughly wash your DANGER
hands with soap and water after handling used oil. The battery gives off explosive gases; keep
KEEP OIL AWAY FROM CHILDREN. cigarettes, flames and sparks away from the battery.
Provide adequate ventilation when operating or
recharging the battery.
1.3.5 BRAKE FLUID
The battery contains sulphuric acid (electrolyte).
WARNING Contact with the skin or the eyes may cause serious
The brake fluid can damage painted, plastic or rubber burns.
parts. When performing maintenance operations on the Always wear tight fitting goggles and protective
brake system, place a clean shop towel on these parts. clothing when handling battery eloctrolyte.
Always wear goggles when servicing the brake It is particularly important for you to protect your eyes,
system with brake fluid. since even a minuscule amount of battery acid can
Brake fluid is extremely destructive to your eyes. destroy your vision.
If you should accidentally get brake fluid in your Should you accidentally get even the smallest amount
eyes, flush immediately with a large quantity of cool of battery acid on your skin or eyes, immediately flush
clear water and seek professional medical assistance with large quantities of clear cool water and
immediately. immediately seek professional medical attention.
KEEP BRAKE FLUID AWAY FROM CHILDREN. The electroliyte is poisonous. If the electrolyte is
accidentally swallowed, drink large quantities of water
or milk and then milk of magnesia or vegetable oil.
Seek professional medical attentiion immediately.
KEEP BATTERIES AND ELECTROLYTE AWAY FROM
CHILDREN.

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GENERAL INFORMATION

1.3.9 PRECAUTIONS AND GENERAL DISMANTLING THE COMPONENTS


INFORMATION - Do not loosen and/or tighten the screws and nuts using
pliers or other tools; always use the appropriate
Please scrupulously follow the recommendations below
wrench.
when repairing, disassembling and reassembling the
- Before disconnecting any line, cable, etc., mark each
vehicle.
part with a number or distinguishing mark.
- Each disconnected part must be marked clearly to
DANGER ensure that it may be reassembled in the same position
Do not use open flames at any time. from which it was taken.
Before beginning any maintenance work or - Clean and wash all dismantled components thoroughly,
inspecting the vehicle, stop the engine and remove using non-flammable solvents.
the ignition key. Wait for the engine and exhaust - Keep coupled parts together, since they have
system to cool completely. If possible, use the “adapted” to each other through normal wear and tear.
appropriate equipment to raise the vehicle, on a - Some components must be used together or replaced
solid, level floor. completely.
Be especially careful around any parts of the engine - Keep away from sources of heat.
and exhaust system that may still be warm, to avoid
burns.
The brakes also get quite hot in operation.
REASSEMBLING THE COMPONENTS
Be sure that the brakes have cooled thoroughly
before beginning any service operations. WARNING
No part of the vehicle is safe to hold in your mouth. Never reuse a circlip; when on is removed, it must be
replaced with a new on.
Unless explicitly stated otherwise, reassemble all
When mounting a new circlip, be careful not to
units by carrying out the disassembly operations in
spread its ends farther than strictly necessary to
reverse.
place it on the shaft.
Use common sense to interpret any overlap in cross-
After mounting a circlip, make sure that is completely
referenced instructions, to avoid unnecessarily
and firmly inserted in its seat.
removing components. Do not use abrasive pastes
to polish matte paints. Do not use compressed air to clean any bearing.
Handle fuel with the greatest caution. NOTE Bearings must rotate freely, without roughness
or noise, otherwise they must be replaced.
Never use fuel as a solvent for cleaning the vehicle.
- Use only ORIGINAL aprilia SPARE PARTS.
Use only water and neutral soap to clean all rubber
- Use only the recommended lubricants and
and plastic parts and the saddle. Never use alcohol,
consumables.
gasoline or other solvents.
- Lubricate the parts (whenever possible) before
Disconnect the negative battery cable (–) before reassembling them.
soldering. - When tightening screws and nuts, start with the largest
or innermost once, and cross-tighten.
When two or more people are working together, make
- Tighten gradually in a series of steps before applying
sure conditions are safe for each.
the final torque.
Be sure that all the mechanics working on any - Always replace lock nuts, gaskets, seals, circlips, O-
vehicle are thoroughly briefed as what each will be rings, cotter pins and screws with new ones if the
doing, and make sure that one mechanic is threads are damaged.
responsible for ensuring that all safety related items, - Clean all joining surfaces, oil seal edges and gaskets
such as tightening torques, are properly considered. before reassembling. Apply a light coating of lithium-
Carefully read paragraph 1.4 (SPECIFIC SAFETY based grease to the edges of the oil seals.
RULES). Reassemble oil seals and bearings with the brand
name or serial number facing outwards (visible side).
BEFORE DISMANTLING THE COMPONENTS - Copiously lubricate bearings before installation and
- Remove all dirt, mud, dust and foreign matter from the assembly.
vehicle before dismantling its components. - Make sure that all components have been correctly
- Where designated, use the special tools designed for installed and assembled.
this vehicle. - After any repair or periodic maintenance operation is
carried out, the vehicle must be test ridden in an area
DANGER away from traffic and other hazards.
Do not use makeshift tools for any operation which
calls for a special tool.
Faillure to heed this warning can lead to serious
personal injury such as when an ill-fitting wrench
slips, and you slam your hand into the workbench or
a part of the vehicle.

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GENERAL INFORMATION RST mille USA

1.3.10 ELECTRICAL CONNECTORS


The electrical connectors must be disconnected as
follows. Failure to follow these procedures will irreparably
damage the connector and wiring.
Š Press in the click tab.
WARNING
Do not pull the cables to disconnect the two
connectors.
Š Grasp the two connectors and disconnect them by
pulling in opposite directions.
Š If dirt, rust, dust, or moisture is seen on the connector,
blow out the connector with air.
Š Ensure that the cables are correctly crimped to the
terminals placed inside the connectors.
NOTE The two halves of the connector fit toghether
properly in only one orientation. Ensure that the
connector is properly aligned before attempting to
assemble it.
Š Press the connectors firmly together, listening for the
typical “click” sound for those connectors provided with
a click tab. Ensure that both halves of the connectors
are firmly pressed together.

1.3.11 FASTENERS TIGHTENING TORQUES

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.

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GENERAL INFORMATION

1.4 SPECIFIC SAFETY RULES

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.

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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.

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GENERAL INFORMATION

Failure to heed these warnings may lead to a serious


accident with consequent risk of serious injury or even
death.
The brakes are extremely important for your safety. Do
not use the vehicle if the brakes do not work perfectly.
1
Always check the brake efficiency before riding.
Sudden variations in clearance or an elastic
resistance in the brake levers may be due to trouble
in the hydraulic systems.
Pay special attention to the brake disc and friction
material, making sure that they are neither dirty nor
oily, especially after maintenance operations or
inspections.
Check the brake line, ensure that it is not twisted or
kinked, nor leaking.
KEEP BRAKE FLUID AWAY FROM CHILDREN.
DISPOSE OF USED BRAKE FLUID PROPERLY. SEE
THE GENERAL WARNINGS AT 1.3.5 (BRAKE FLUID).

1.4.4 DISC BRAKES

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.

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GENERAL INFORMATION RST mille USA

1.4.5 CLUTCH CONTROL FLUID


NOTE This vehicle is equipped with hydraulic clutch 1
control.

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.

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GENERAL INFORMATION

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.

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1.4.7 DRIVE CHAIN


DANGER
Every 600 mi (1,000 km) check the condition, the wear,
Some of the original equipment tires for this vehicle
the play (tension) and the lubrication of the drive chain.
are provided with wear indicators.
The vehicle is equipped with an endless chain. There are several kinds of wear indicators.
Contact your dealer to get the necessary information
There is no master link used.
on the wear check procedures.
Visually check the tire wear and if they are worn,
DANGER have them replaced.
An excessively loose chain can come off the
sprocket which can result in a serious accident and If a tire should go flat while you are riding the vehicle
serious damage to the vehicle from the upset and do not attempt to continue riding.
subsequent serious injury or even death. Avoid abrupt breaking and steering inputs, and avoid
Do not ride the vehicle with an improperly adjusted shutting the trottle quikly.
chain. Slowly decrease the throttle setting, moving to the
To inspect the condition of the chain, grasp the chain side of the road, using engine compression to slow
where it goes around the sprocket and try to pull it you to a stop.
away from the sprocket.
Non-compliance with these instructions may cause
If you can move it more than one-eighth of an inch accidents with consequent risk of injuries or even
away from the sprocket, the chain is worn out and the death.
chain and both front and rear sprockets must be
replaced. Do not install tires with an inner tube on rims for
tubeless tires, and viceversa.
WARNING
Lack of maintenance can cause premature wear of
the chain and damage to the sprockets.
Maintain your chain more often if your vehicle is
used on dusty or muddy roads.

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.

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GENERAL INFORMATION

1.4.9 AUTOMATIC CONVERTER


1 1
This vehicle is equipped with lights that come on
automatically as soon as the ignition switch (1) is turned to
position “ “ (ON) (low beam lights “ “ or high beam lights
“ “) position “ “ (PARKING) (only parking lights “ ”).
For this reason, there is no light switch on your
vehicle.The light can be switched off only by turning the
ignition switch (1) to position “ “ (OFF).
Before starting the vehicle, ensure that the dimmer switch
(2) is in the low beam light “ “ position.

1.4.10 CATALITIC CONVERTER

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.

1.4.11 EXHAUST SILECER

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.

1.4.12 SPARK ARRESTER

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.

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GENERAL INFORMATION RST mille USA

1.5 RUNNING-IN RULES


The internal parts of the engine and trasmission must be
properly run-in to ensure their long life and dependable
operation.
If possible, while breaking in your vehicle, ride on hilly
roads and/or roads with many curves so that the engine
and transmission undergo lots of speed changes.
It is also important that, during the run-in period, the
suspension and brakes be treated gently to allow the
mating parts to bed.
Therefore, avoid hard braking, high speeds or very
bumpy roads during the break in period.
NOTE Only after the first 900 mi (1,500 km) of running-
in you can expect the best performance from the vehicle.
During break in, obey the following rules:
Š Do not open the throttle abruptly or fully at low engine
speed. This rule applies even after break in has been
completed.
Š During the first 60 mi (100 km), apply the brakes with
caution, avoid sudden and prolonged braking.
This ensure correct bedding in of the pads on the discs.
Š During the first 600 mi ( 1,000 km), never exceed 6,000
rpm.

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.
Š 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.
Š 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).

Engine maximum rpm


for the running-in

Mileage mi (km) Max. rpm

0 - 600 (0 - 1,000) 6,000

600 - 900
7,500
(1,000 - 1,500)

over 900 ( 1,500) 10,500

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GENERAL INFORMATION

1.6 HOW TO USE YOUR SERVICE AND In this manual the various versions are indicated by the
REPAIR MANUAL following symbols:

1.6.1 HOW TO USE THIS MANUAL version with catalytic converter

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

1.6.2 REQUESTING SPARE PARTS P Portugal DK Denmark AUS Australia

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

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1.7 IDENTIFICATION DATA


Please supply the frame number when you purchase
spare parts.
NOTE Do not obliterate or alter the identification
numbers under any circumstance.
This is illegal in all countries.
In addition, alteration of the identification numbers
invalidates the warranty.

1.7.1 VEHICLE IDENTIFICATION NUMBER (V.I.N.)


(FRAME NUMBER)
Every vehicle produced by aprilia receives a vehicle A
identification number (V.I.N.) stamped:
- on the steering head of the frame (A), as shown above;
and also:
- on the identification plate (B) which is located on the
front portion near the steering head of the frame.

1.7.2 INFORMATION CONTAINED IN THE VEHICLE


IDENTIFICATION NUMBER
Description of the vehicle identification number (V.I.N.),
stamped on the steering head of the frame (A) and on the B
identification plate (B).

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.

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GENERAL INFORMATION

1.8 POSITION OF SERIAL NUMBERS


These numbers are required for vehicle registration.
NOTE Tampering with the serial numbers is subject to
serious sanctions under criminal and civil law. Altering
the frame number will void the warranty effective
immediately.

1.8.1 FRAME NUMBER


The frame number is stamped on the right side of the
steering column. This is also the Vehicle Identification
Number.

1.8.2 ENGINE NUMBER


The engine number is engraved on the rear, near the
countershaft sprocket.

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1.8.3 POSITION OF THE WARNING ADHESIVE LABELS

1 2 3 3a 4

9 10 11 12 13

9 16 15 14

6a 6 7 8

5a

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GENERAL INFORMATION

Ref. Description Ref. Description

00/00

1 8

FOR STATE OF CALIFORNIA ONLY.

00/00
9
1a

2 NOT PROVIDED FOR 49 STATES.


10
FOR STATE OF CALIFORNIA ONLY

11
2a

12

3
13

FOR STATE OF CALIFORNIA ONLY.

4 14

FOR STATE OF CALIFORNIA ONLY.


14a

4a FOR STATE OF CALIFORNIA ONLY.

15

15a

16 MUFFLER STAMPING

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1.9 CALIFORNIA EVAPORATIVE EMISSION SYSTEM


The system consists of: 16) Tee
1) Fuel tank 17) Cylinder synchronization line
2) Water drain line 18) Drain line (to manifold vacuum port)
3) Fuel tank breather nipple 19) Ported vacuum port (left part of throttle body)
4) Breather line (to tee) 20) Air box
5) Tee 21) Warm air inlet fitting (from air box)
6) Breather line (to purge valve) 22) Tee
7) Purge valve 23) Sensor line to fuel pressure regulator (Electronic
8) Breather line (to carbon canister) Contrl Unit)
9) Carbon canister 24) Warm air inlet (from air box)
10) Drain line (to restrictor) 25) Tee
11) Restrictor Ø 0.06 in (Ø 1.5 mm) 26) Warm air inlet (to carbon canister)
12) Drain line (from restrictor) 27) Warm air inlet (to one way valve)
13) Tee 28) One way valve
14) Vacuum line (from purge valve) 29) Warm air inlet (from one way valve)
15) Drain line

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

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GENERAL INFORMATION

1.10 SPARE PARTS


When making replacements, use only Original aprilia
Spare Parts.
Original aprilia spare parts are high quality, and are
designed and built explicitly for aprilia vehicles.

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 ➤

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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 ➤

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GENERAL INFORMATION

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
Œ
solo rider
Front
(standard)
METZELER ME Z4 B 120/70ZR17” Œ 36.2 (250) (2.5)

Rear
(standard)
METZELER ME Z4 180/55ZR17” Œ 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” Œ 36.2 (250) (2.5)

Rear
(alternatively)
PIRELLI MTR22 180/55ZR17” Œ 40.6 (280) (2.8)

Œ = Normal use; ❖= Competitive use

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 ➤

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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

1.12 LUBRICANT CHART

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-

F.A. 20W; compatible) or BRAKE 5.1, DOT 5 (DOT 4-


compatible).
alternatively FORK 5W or FORK 20W.
If you need an oil with characteristics halfway between DANGER
those offered by F.A. 5W and F.A. 20W or Use only fresh clutch fluid.
FORK 5W and FORK 20W, the two
Clutch fluid (recommended): F. F. , DOT 5 (DOT
products may be mixed together as described below:
4-compatible) or BRAKE 5.1, DOT 5 (DOT 4-
SAE 10W = F.A. 5W 67% of volume, + F.A. 20W
compatible).
33% of volume or
FORK 5W 67% of volume, + FORK DANGER
20W 33% of volume. Use only nitrite-free antifreeze and anticorrosive, that
SAE 15W = F.A 5W 33% of volume, + F.A. 20W ensures protection at -35 °C (-31 °F) at least.
67% of volume or
Engine coolant (recommended): ECO-BLUE -
FORK 5W 33% of volume, + FORK
20W 67% of volume. 40°C (-40°F) or COOL.

Bearings and other lubrication points


(recommended):
AUTOGREASE MP or GREASE 30.
As an alternative to the recommended product, use high-
quality grease for rolling bearings, working temperature
range -30°C…+140°C (-22°F...+248°F), dripping point
150°C…230°C (302°F...446°F), high protection against
corrosion, good resistance to water and oxidation.
Protection of battery poles: Neutral grease or Vaseline.

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GENERAL INFORMATION

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).

1.13.1 PRODUCT PROPERTIES


Product Use and Properties
LOCTITE® 243 blue Thread locker for screws and nuts up to M36, and to seal
connections for fluids, medium strength.
It can be used on parts which have not been completely degreased
The hardening time depends on the temperature and the material
(maximum one hour):
Resistance to temperatures in the range -55 to 150° C (-131° F to
302° F).
High strength thread locker for screw threads.
LOCTITE® 648 green The hardening time dipends on the temperature and the
material (maximum twelve hours).
Resistance to temperatures in the range -55 to 175° C (-131° F
to 347° F).
To remove nuts that have been fastened with Loctite 648, it may
be necessary to heat the assembled parts to a temperature of
250° C (482° F)
Solvent-free joint cement, to be used instead of gaskets where
components are held firmly together, and where a precise
LOCTITE® 574 orange
distance is required between the two components.
Applied in its liquid state, it hardens after assembly on contact
with the metal within a few hours.
A seal is created whose surface structure adapts to the surfaces
to be sealed.
Resistance to temperatures in the range – 55 to 200 °C (from – -
131 to 392 °F); where applied, it seals the surfaces against
corrosion.

LOCTITE® 8150

Paste to be used on components subjected to high


temperatures.

LOCTITE® Anti Seize 15378


Lubricant and anticorrosive, resistant to high temperatures.
Sprayed on both components, it ensures low sliding friction and
it also prevents corrosion.

MOLYKOTE® G-n Lubricating grease, used on connections and bearings subject


to heavy loads, and to lubricate threads and connections which
are heavily torqued, in order to prevent corrosion, which would
prevent subsequent disassembly.
To be applied to both joining surfaces.

SILASTIC 732 RTV


Acts as a sealant, used to prevent water from getting inside the
flywheel cover.

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1.13.2 USING CONSUMABLES


Product Code Description of use
- Assembling rivets on fork, dashboard/front fairing mount, saddle
support and frame.
- Assembling frame/engine and frame/fork adjusting bushings.
- Assembling fairlead screws on frame.
- Insertion steering head bearings.
- Steering head bushing upper retainer.
- On timing intermediate gear roller bearings.
- On lower balanceshaft thrust washer.
Engine oil (*) 8116050
- Clutch disengaging shaft.
- On valve stems and valve lifter buckets.
- On valve guide oil seals.
- On camshaft housings.
- On the timing chain tightener.
- On double starter gear and idler gear pins.
- On the sprag clutch gear/sprag clutch contact surface.
- On the sprag clutch inner contact surface.
- Fastening of steering damper bushing.
- Fastening of rear brake caliper lock pivot.
- Fastening of pinion.
- Fastening of rear brake lever pivot.
- Fastening of cooling electrofan on support.
- Fastening of fuel return line connection.
- Fastening of fuel filler cap.
- Throttle cable pullet fastening nut.
- Throttle cable support bracket fastening screws.
- Throttle valve pin fastening nut.
- Throttle valve potentiometer fastening screws.
LOCTITE® 243 (**) 0897651
- On coolant pump center fastening screw.
- On cylinder joining bracket fastening screws.
- On engine half-case bearing lock screws.
- On cylinder fastening studs.
- On crankshaft position sensor fastening screws.
- On index lever and plate fastening screws.
- On crankshaft fastening nut.
- On timing gear fastening screws.
- On upper balanceshaft balanceweight fastening nut.
- On intermediate timing gear bearing support lower fastening
screw.
- On coolant pump idler gear pin.
- On engine oil pump cap.
- On clutch gear metal slip fastening screws.
- Assemby sprag clutch flange/alternator rotor.
LOCTITE® 648 (**) 0899788 - On sprag clutch flange/alternator rotor fastening screws.
- On clutch housing fastening nut.
- On lower balanceshaft balanceweight fastening screw.
- On the alternator rotor inner taper.
- On the flywheel fastening screw.
- Fastening of coolant thermal switch.
- Fastening of coolant thermistors.
LOCTITE® 574 orange
0899784 - On neutral gear switch contact screw.
(**)
- On the outer surface of the engine oil pump motor.
- On cylinder base where it contacts the engine case.
- On the main shaft and countershaft.
LOCTITE® Anti Seize - On the main shaft and countershaft housings.
0297434
15378 (**) - On crankshaft and lower balanceshaft.
- On the main shaft housing and spline.

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GENERAL INFORMATION

Product Code Description of use


- On main bushing housings.
- On main bushings.
- On engine case bearing housings.
- On coolant pump shaft.
- On valve guide recesses in the head.
MOLYKOTE® G-n (**) 0297433 - On valve guide edges.
- On crankshaft and lower balanceshaft bushing housings.
- On crankshaft and lower balanceshaft housings.
- On connecting rod/piston pin bores.
- On camshafts and cams.
- On starter motor fastening housing.
- On cable bracket on flywheel cover.
SILASTIC 732 RTV (**) 0297386
- On camshaft sensor cable.
- Assembly of front and rear wheel seals.
- Assemby of swinging arm pivot bearings.
- Assembly of clutch master cylinder control rod.
- On rear wheel axle thread.
- On steering head bearings.
Bimol Grease 481 8116053
- Assembly of rear brake master cylinder control rod.
- On rear brake lever pivot.
- On intermediate timing gear thrust washer.
- Lower balanceshaft oil seal.
- Starter motor gear.
LUBERING ST Grease 8116038 - Assembly of cold-start control.
- Assembly of handlebar balanceweights grommet.
- Assembly of throttle cable adjuster grommets.
- Assembly of grommet on gearshift pedal.
- Insertion of radiator lower pins on supporting grommets.
Temporary lubricant AP-
- - Assembly of breather tube on radiator and three-way manifold.
LUBE
- Assembly of coolant couplings on radiators.
- Assembly of water and fuel drainage hoses on the fuel pump
flange.
- Assembly of throttle body torsion springs.
DID CHAIN LUBE
- Lubrication of drive chain.
Grease
“Biosolvente” Frame
8116031 - Washing of engine oil tank.
detergent
Cyanoacrylic glue
8116945 - Assembly of air cleaner filter case seal.
“ACRILON 28”
MOTUL Degreaser
- - Cleaning of frame and swinging arm.
MOTOWASH
Anti-seize paste
ANTI-SEIZE
8116043 - Assembling of caps for checking CO on exhaust pipes.
MOTAGEPASTE
AS 1800

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Product Code Description of use


- Cleaning of left handlebar prior to assembly or grip.
- Inserting of radiator breather tubes on “T”union.
- Assembly of HV coil support grommet.
- Assembly of side fairing grommets.
- Cleaning of lower part of engine.
- Assembly of start relay grommet.
- Assembly of flexible couplings on rear wheel sprocket.
- Assembly of grommets on engine oil radiator.
Alcohol -
- Assembly of coupling on coolant filler.
- Cleaning of engine oil tank prior to application of transfers.
- Assembly of dashboard/front fairing mount grommets.
- Assembly of grommet on rear brake lever.
- Assembly of lines on fuel filter (inside tank).
- Assembly of coolant radiator union coupling.
- Assembly of fuel lines on tank.
- Cleaning of fuel tank prior to application of transfers.

(*) = see 1.12 (LUBRICANT CHART).


(**) = see 1.13.1 (PRODUCT PROPERTIES).

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GENERAL INFORMATION

1.14 SPECIAL TOOLS


The appropriate special tools must be used in order to WARNING
properly disassemble, reassemble, and adjust parts. Before using special tools, consult any documents
The use of special tools avoids the potential risk of attached.
damage caused by inappropriate tools and/or improvised
methods. Below is a list of the special tools designed DANGER
especially for this specific vehicle. Do not attempt to use makeshift tools to work on this
When ordering generic special tools, refer to the special vehicle. To do so will not only ensure that you
tools manual. damage the vehicle, sometimes irreparably, but you
will also hurt yourself. Failure to use special tools
will certainly lead to injury to the mechanic.

1.14.1 MISCELLANEOUS TOOLS


Pos. Tool name and function Code
Complete tool kit for chassis, including:
– half-cylinders for installing oil seals, front fork
1 8140203
– steering adjustment socket wrench
– socket wrench for adjusting swinging arm pivot - engine mounts
2 Chain breaking/riveting tool 8140192
3 Center support stand 8140176
4 Axone 2000 8140595
5 Front support stand 8140195
6 Exhaust gas analyzer 8140196
7 Tubing kit for exhaust gas analyzer 8140202
8 Tool holder panel 8140199
9 Kit to extract bearings from Ø 0.39 in to Ø 1.18 in (Ø10 mm to Ø 30 mm) 8140180

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1.14.2 ENGINE TOOLS

Pos. Tool name and function Code


1 Complete engine tool kit 8140175
2 Countershaft oil seal assembly drift 0277680
3 Upper balanceshaft oil seal assembly drift 0277660
4 Coolant pump shaft housing oil seal assembly drift 0277670
5 Coolant pump shaft housing sliding ring assembly drift 0877257
6 Valve guide disassembly drift 0277510
7 Valve guide oil seal assembly drift 0277695
8 Valve guide assembly drift 0277210
9 Main shaft oil seal-clutch shaft oil seal assembly drift 8140155
10 Crankshaft bushing inserter drift 0277729
11 Crankshaft sleeve puller drift 0277720
12-14 Crankshaft bushing inserter drift 0277725
13 Crankshaft-clutch cover bushing inserter drift 0277727
15 Cap socket wrench 8140177
16 Flywheel cover removal tool 0277252
17 Flywheel removal hexagonal bolt 0277780
18 Threaded bolt to lock the crankshaft at TDC 0240880
19 Countershaft guide bushing 0277308
20 Vacuum gauge 8140256
21 Fuel-oil pressure gauge 8140181
22 Alternator rotor bolt removal bushing 8140182
23 Clutch locking tool 0277881
8140156 + 8140157 +
24 Clutch cover bushing extractor
0276377
25 Valve spring-pusher tool 0276479
26 Valve disassembly and reassembly clamp 8140179
27 Adhesive for tool holder panel 8157143
28 Engine lifting eye hook 8140183
29 Primary transmission nut disassembly bushing 8140184
30 Clutch disc extraction hook levers 8140185
31 Engine mount 8140188
32 Engine support stand 8140187
33 Piston ring compression tool 8140186

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GENERAL INFORMATION

1.15 PLACING THE VEHICLE ON THE


SUPPORT STANDS

1.15.1 PLACING THE VEHICLE ON THE FRONT


SUPPORT STAND
1
Š Place the vehicle on the center stand. 2
Š At the same time, insert the two pins (1) of the stand
(3) into the two holes (2) at the bottom of the front fork.
Š Rest one foot at the front of the stand (3). 3
Š Push the stand (3) all the way down.

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GENERAL INFORMATION RST mille USA

1.15.2 PLACING THE VEHICLE ON THE CENTER


SUPPORT STAND
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 2
code 8140176 (complete stand).
Š Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Place the vehicle on the appropriate front support 7
stand , see 1.15.1 (PLACING THE VEHICLE ON
THE FRONT SUPPORT STAND).
ŠHold the nut (1) in place.
ŠLoosen and remove the upper right rear engine bolt 1 6
(2).

Tightening torque nut (1) / bolt (2): 36 ftlb (50 Nm).


NOTE The bolt (2) on the left side is longer. 5 19
3 4
ŠRetrieve the nut (1). 12
Š Insert the upper right support pin (3) in the upper hole 17
on the right-hand side.
Š Insert the threaded shaft (4) in the upper hole on the
left-hand side, and bolt it all the way onto the pin (3).
Š Bolt the upper left support pin (5) all the way onto the 14
threaded shaft (4) and tighten.
ŠHold the nut (6) in place.
ŠLoosen and remove the upper right rear engine bolt 11 16
(7).

Tightening torque nut (6) / bolt (7): 36 ftlb (50 Nm).


NOTE The bolt (7), on the right side, is longer.
Š Insert the lower right support pin (8) in the lower hole
on the right-hand side. 20
10
Š Insert the threaded shaft (9) in the lower hole on the 9
left-hand side, and bolt it all the way onto the pin (8).
Š Bolt the lower left support pin (10) all the way onto the 8
13 18
threaded shaft (9) and tighten.
Š Place the support bracket (11), with its longer side
facing forward, on the two support pins (3-8).
Š Insert the two washers (12-13) and two nuts (14-15),
screwing them on by hand. 16
Š Tighten the two nuts (14-15). 15 11
Š Place the support bracket (16), with its longer side
facing forward, on the two support pins (5-10).
Š Insert the two washers (17-18) and two nuts (19-20),
screwing them on by hand.
Š Tighten the two nuts (19-20).

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GENERAL INFORMATION

1.16 INSTRUCTIONS FOR APPLYING THE


TRANSFERS
When removing parts from the frame:
4 2
WARNING
Handle all plastic and painted components with 3
care to avoid scraping or scratching them.
Work very carefully.
Do not damage the tabs and/or slots into which
they are fitted.
When applying the transfers, carefully follow the
instructions given below. 1
We recommend using the following tools:
- relatively stiff spatula (1);
NOTE Generally speaking, soft squeegee-type
spatulas do not remove enough water from under the
transfers.
- sponge or spray bottle (2) with water.
NOTE Add a bit of detergent (1-3%) to the water, 3
and shake to create bubbles.
Proceed as follows to apply a transfer:
Š Place the transfer (3) upside-down on a work
surface.
Š Keeping the transfer spread flat on the work
surface, remove the backing paper (4) completely.
NOTE We recommend using a spray bottle (2).
If using a sponge, sponge the surface without
pressing, to keep from ruining the glue.
Š Wet the surface of the adhesive with soapy water.
Š Apply the transfer (3) to the surface to be decorated
and move it to the desired position.
NOTE Always move the spatula in even strokes,
from the center of the transfer out.
Š Using the spatula (1), press down fairly hard and
move the spatula across the surface of the transfer
until all excess soap and water has been removed
from underneath. 1
NOTE Do not lift the corners and/or sides of the
transfer.
Š Use an absorbent cloth and, working from the
center out, dry the transfer.
Š Move the spatula over the transfer again with firm,
even strokes, pressing down as hard as possible.
Move the spatula in strokes from the center out,
being especially careful at the corners and sides, to
ensure that the entire surface adheres evenly.

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NOTE If using application tape (5)*, it must be removed


20-30 minutes after applying the transfer.
Š Remove the application tape (5) from the transfer 5
surface.
Š To ensure good adhesion, move the spatula over
the transfer again, concentrating in particular on the
edges and corners.
NOTE When transfers are applied wet, the glue is
not fully set for about 48 hours.
Š Once you have removed the application tape, make
sure there are no air bubbles on the surface.
If you do find surface air bubbles:
Š Use a pin or hobby knife (6) to puncture the edge
(7) of the air bubble.
Š With the spatula (1), start from the side opposite the
hole and scrape the bubble to allow any remaining
air to escape. 6

* Application tape is used to facilitate the application of


trademarks and letters, arranging them as desired on
the surface to be decorated, and to add extra firmness
to the adhesive backing during application.

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GENERAL INFORMATION

1.17 FASTENERS
Carefully read 1.3.1

1.17.1 JOINTS WITH CLICK CLAMPS AND WITH


SCREW-TYPE CLAMPS

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.
Š 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).

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GENERAL INFORMATION RST mille USA

1.17.2 GENERAL VALUES OF TIGHTENING


TORQUES
C B
The following table shows tightening torques for screws A
and bolts with metric ISO threads, as is used in this D
vehicle. These are general values to be used if no
specific value is given in this manual or other aprilia
service literature.

Screw or Tightening torque


bolt Wrench
thread ftlb Nm

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

For specific fasteners, see 2.41 (FASTENERS). If not


otherwise indicated, the tightening torques shown should
be used for clean and dry threads, at room temperature.
NOTE To avoid damage to the threads, tighten screws
and bolts as follows:
Š Run up the fasteners finger tight.
Š Applying half the prescribed tightening torque, tighten
the fasteners that are diametrically opposite each
other: (A) and (B); (C) and (D).
Š Repeat, applying the prescribed tightening torque.
NOTE In this way the pressure exerted by the fasteners
will be uniformly distributed across the joint surface.
Steel/aluminum fastening screw with similar
coefficent of elasticity:

Screw ftlb Nm
M4 2.2 3
M5 4.4 6
M6 8.7 12
M8 18 25
M10 36 50
M12 58 80

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GENERAL INFORMATION

NOTE

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GENERAL INFORMATION RST mille USA

NOTE

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

SCHEDULED MAINTENANCE AND


TUNING OPERATIONS 2

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA

SCHEDULED MAINTENANCE AND 2.18 CHECKING AND TOPPING UP


TUNING OPERATIONS THE CLUTCH FLUID...................... 2-32-00
2.19 BLEEDING THE BRAKE SYSTEMS 2-34-00
TABLE OF CONTENTS 2.20 CLUTCH CONTROL SYSTEM
BLEEDING ..................................... 2-38-00
2.1 SCHEDULED MAINTENANCE PLAN 2-4-00
2.21 CHANGING THE FRONT
2.1.1 SCHEDULED MAINTENANCE CHART 2-5-00
0 2.2 LUBRICATION POINTS ................... 2-7-00
BRAKE FLUID................................ 2-39-00
2.22 CHANGING THE REAR
2.3 MULTIFUNCTION COMPUTER ........ 2-8-00 BRAKE FLUID................................ 2-40-00
2.3.1 LEGEND ................................................ 2-8-00 2.23 CHANGING THE CLUTCH FLUID .. 2-41-00
2 2.3.2 PROGRAMMING KEYS ........................ 2-8-00
2.3.3 ADJUSTING THE DASHBOARD
LIGHTS .................................................. 2-8-00
2.24 ADJUSTING FRONT BRAKE LEVER
AND CLUTCH CONTROL LEVER ... 2-41-00
2.3.4 TOTAL/TRIP ODOMETER (MILEAGE
2.25 ADJUSTING THE CLEARANCE OF
COUNTER) SWITCHING....................... 2-9-00
THE REAR BRAKE LEVER............. 2-42-00
2 2.3.5 SWITCHING BETWEEN KM/MI,
L/GAL, °C/°F.......................................... 2-9-00
2.3.6 SWITCHING THE FUEL LEVEL/AIR
2.26 ADJUSTING THE GEARSHIFT
LEVER ........................................... 2-42-00
TEMPERATURE INDICATOR ............... 2-9-00
2.27 CHECKING THE BRAKE PAD
2.3.7 SETTING THE CLOCK (HOURS AND
WEAR............................................. 2-43-00
3 MINUTES) ............................................ 2-10-00
2.3.8 TABLE OF INSTRUMENTS AND 2.28 STEERING ..................................... 2-44-00
INDICATORS ....................................... 2-10-00 2.28.1 CHECKING THE BEARING PLAY...... 2-44-00
2.4 BATTERY....................................... 2-13-00 2.28.2 ADJUSTING THE BEARING PLAY .... 2-45-00

4 2.4.1 CHECKING AND CLEANING THE


TERMINALS ........................................ 2-14-00
2.4.2 RECHARGING THE BATTERY........... 2-15-00
2.29 INSPECTING THE FRONT
SUSPENSION ................................ 2-47-00
2.29.1 FRONT SUSPENSION ........................ 2-47-00
2.4.3 EXTENDED BATTERY STORAGE ..... 2-15-00 2.29.2 ADJUSTING THE FRONT FORK........ 2-48-00
2.5 ELECTRICAL COMPONENTS ........ 2-15-00
5 2.6 JUMP-STARTING .......................... 2-16-00
2.30 SWINGING ARM ............................ 2-49-00
2.30.1 ADJUSTING THE SWINGING ARM.... 2-49-00
2.7 SPARK PLUGS............................... 2-17-00 2.31 INSPECTING THE REAR
SUSPENSION ................................ 2-50-00
2.8 LIFTING THE FUEL TANK ............. 2-19-00
6 2.9 DRAINING FUEL FROM THE TANK 2-20-00
2.31.1 REAR SUSPENSION........................... 2-50-00
2.31.2 REAR SHOCK ABSORBER
ADJUSTMENT..................................... 2-50-00
2.10 AIR FILTER.................................... 2-21-00
2.31.3 CHECKING THE REAR SUSPENSION
2.11 THROTTLE .................................... 2-22-00 LINKAGE ............................................. 2-51-00

7 2.11.1 CHECKING THE OPERATION OF THE


THROTTLE CONTROL ....................... 2-22-00
2.32 FRONT WHEEL .............................. 2-52-00

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

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.39 COOLING SYSTEM PIPES............. 2-59-00


2.40 TIGHTENING NUTS AND BOLTS.. 2-60-00
2.41 FASTENERS.................................. 2-61-00
2.41.1 CLEANING AND LUBRICATION......... 2-67-00

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA

This section describes the procedures for carrying out


scheduled maintenance on the main vehicle
components.

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.

2.1 SCHEDULED MAINTENANCE PLAN


To keep the vehicle in top running condition, aprilia
recommends that you observe the prescribed
maintenance intervals for the various components.

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)

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.1.1 SCHEDULED MAINTENANCE CHART

Every 4687 mi Every 9375 mi


After break-in
Components (7500 km) or 12 (15000 km) or 24
[625 mi (1000 km)]
months months
Spark plugs c(*) e(*)
Side stand
Throttle cables c c
Rear suspension linkage bearings c
Steering bearings and steering c c
Wheel bearings c
Air filter c e
Engine oil filter e(*) e(*)
Engine oil filter (on tank) d d
Fork c c
Light operation/direction c
Hardware clearance R f
Grease on throttle body pin c c
Brake systems c c
Cooling system c
Light system c c
Safety switches c c
c
Clutch fluid
every 2 years: e
c
Brake fluid
every 2 years: e
c
Coolant
every 2 years: e
After the first 4687 mi (7500 km) and every 14000 mi (22500 km)
Fork oil
thereafter: e
Engine oil e e(*)
Brake pads If worn: e
Pistons every 3125 ml (5000 Km): c(**)
Tires c c
Tire pressure f every 15 days:c
Engine idle speed f f
Tighten nuts and bolts c c
Synchronize the cylinders c c
Suspensions and riding position c c
Engine oil pressure LED at every start-up:c
Brake fluid bleeding c
Clutch fluid bleeding c
CONT'D ➤

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Every 4687 mi Every 9375 mi


After break-in
Components (7500 km) or 12 (15000 km) or 24
[625 mi (1000 km)]
months months
Drive chain tension and lubrication every 625 mi (1000 km): c
Battery terminals and clamps c c
Fuel lines c every 4 years: e
Final drive assembly (chain, sprocket
countershaft sprocket
c
Brake and clutch lines c every 4 years: e
Cooling system lines c
Clutch wear c(*)
Brake pad wear before every trip and every 1250 mi (2000 km): c
c = check and clean, adjust, lubricate or replace if necessary; d = clean; e = replace; f = adjust.
Perform these maintenance operations more frequently if your vehicle is often used in rainy or very dusty
conditions, on unpaved roads, or in any kind of competition.
( ) = OPERATIONS THAT MAY BE CARRIED OUT BY THE OWNER
(*) = For competitive use replace every 3750 km (2343 mi).
(**) = Only in case of: - intensive track/racing use.

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.2 LUBRICATION POINTS LUBRICATION DIAGRAM LEGEND


1) Steering bearings
Proper lubrication is essential for proper vehicle
2) Clutch lever pivot
operation and long vehicle life.
3) Right rider foot rest pin
NOTE Before lubricating, clean all parts thoroughly to 4) Left rider foot rest pivot
remove any traces of rust, grease, dirt and dust. 5) Left passenger foot rest pivot
Exposed parts that might rust must be protected using 6) Rear wheel axle and bearings
motor oil or grease, see 1.12 (LUBRICANT CHART). 7) Drive chain
The "LUBRICATION DIAGRAM" shows the lubrication 8) Rear suspension linkage
points. 9) Side stand pivot
10) Right passenger foot rest pivot
11) Front wheel axle and bearings
12) Swinging arm pivot
■ = Grease
▲ = Oil

2 ▲
5 ■
4 ■
■ 1

7 ■

8 ■
■ 9 6 ■

10 ■

11 ■ ■ 12
■ 3

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS RST mille USA

2.3 MULTIFUNCTION COMPUTER

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

2.3.2 PROGRAMMING KEYS


1 2
WARNING
Do not attempt to program the computer while riding 4
the motorcycle. This could lead to an upset with
subsequent serious accident, serious injury or even 5
death.
The operations described below should only be carried
out with the vehicle stopped.
To do so while driving may lead to accidents.
NOTE All information below refers to operations to be
carried out while the vehicle is shut off.
6
Within three seconds after turning the ignition key (1) to
3
position “ “, the following dashboard lights will come on:
- all LED warning lights;
- all backlit LEDs;
- all segments of the left display;
- all segments and messages on the right multifunction
display;
This sequence of displays tests the proper operation of
all LEDs, messages, sections and instruments.
After about three seconds have passed, on the
dashboard only the engine oil pressure LED remains
(2) (which will shut off only after the engine is
started), and the following will appear on the display:
- total number of kilometers traveled (3);
- amount of fuel (4);
- coolant temperature (5) [up to 35° C (95° F) the symbol
"---" is displayed];
- hour and minutes (6).

2.3.3 ADJUSTING THE DASHBOARD LIGHTS


You may select from among three different levels of
dashboard light: 100%; 60%; 25%.
2
To adjust:

Set the light switch (1) to “ “;


Set to “ “ the light dimmer “ “-” ” (2).
NOTE Three seconds after the last selection, the SET
key returns to total/trip odometer (mileage counter)
switching mode.

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

Š Set the ignition switch to “ “ and, within three


seconds, press in sequence the SET key (3) to obtain
the three levels of lighting.
Š Select the desired lighting.

2.3.4 TOTAL/TRIP ODOMETER (MILEAGE COUNTER)


SWITCHING
Left display
Š Press and release the SET key (1); the corresponding
total or trip kilometers (miles) traveled will appear on
the display.
NOTE Each time the ignition switch is set to “ “, the
display will always show the total kilometers (miles).
To reset the trip odometer (mileage counter):
Š Display the trip mileage.
Š Press the SET key (1) for longer than three seconds;
the segments (2) will be reset.
2 1
NOTE The trip kilometers are reset to zero if the
battery is removed.

2.3.5 SWITCHING BETWEEN KM/MI, L/GAL, °C/°F


NOTE The km/mi, l/gal, °C/°F settings are set and
locked by aprilia while manufacturing the vehicle, based
on the country for which it is intended.
They cannot be changed later.

2.3.6 SWITCHING THE FUEL LEVEL/AIR


TEMPERATURE INDICATOR 2
3
Right multifunction display
Š Press and release the MODE key (1); the fuel level (2)
or air temperature indicator (3) will appear on the
display (numerical indication only).
NOTE Each time the ignition switch is set to “ “, the
display will always show the fuel level indicator (2).

1 1

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2.3.7 SETTING THE CLOCK (HOURS AND MINUTES)


2
DANGER
The clock may be set only with the vehicle stopped.
Š Press the MODE key (1) for longer than three seconds:
the segments for the hours (2) will flash 4
NOTE If the SET key (3) is pressed and released, the
change will take place one digit at a time; if instead the
SET key (3) is held down, the figures will scroll quickly in 3
a continuous cycle.
Š Press the SET key (3) and select the hour.
Š To confirm the hour setting, press and release the
MODE key (1): the segments for the minutes (4) will 1
flash.
Š Press the SET key (3) and select the minutes.
Š To confirm the minutes setting, press and release the
MODE key (1).
NOTE The clock is reset to zero if the battery is
removed.

2.3.8 TABLE OF INSTRUMENTS AND INDICATORS

Description Function

Direction indicator LED flashes when the turn signal is on.

High beam LED Lights when the high beam headlight is turned on or flashed.

Indicates the engine rpm.


Tachometer (rpm) Do not exceed maximum RPM (red line).
WARNING
Lights when the fuel tank contains 1.05 ± 0.26 gal (4 ± 1 l) of fuel.
Fuel reserve LED
When this occurs, refuel as soon as possible.

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 ➤

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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 ➤

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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).

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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.

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2.4.1 CHECKING AND CLEANING THE TERMINALS


3
Carefully read 2.4 (BATTERY).
Š Make sure the ignition switch is set to “ “.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Move the red rubber boot (1).
Š Make sure that the battery cable terminals (2) (3) are:
- in good condition (not corroded or encrusted with 2
deposits);
- covered with neutral grease or Vaseline.
If necessary:
Š Disconnect the negative cable (-) and positive cable
(+), in that order. 2 1
Š Clean with a wire brush to remove any traces of
corrosion.
Š Connect the positive cable (+) and negative cable (-), in
that order.
Š Coat the terminals with neutral grease or Vaseline.
Š Replace the saddle, see 7.1.1 (REMOVING THE
SADDLE).

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2.4.2 RECHARGING THE BATTERY 2.5 ELECTRICAL COMPONENTS


Carefully read 2.4 (BATTERY). Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
NOTE One symptom of a nearly dead battery is when
you hear a vibrating noise from the starter relay, when the Check after the first 625 mi (1,000 km) and every 4687 mi
start button “ “ is pressed. (7,500 km) or every 8 months thereafter.
Do not attempt to remove the battery caps; this could
Š Place the vehicle on the stand.
damage the battery.
Š Check to ensure that all lighting are working.
Š Remove the battery, see 7.1.9 (REMOVING THE Š Check the adjustment of the headlight beam, see 6.17
BATTERY). (ADJUSTING THE HEADLIGHT BEAM
Š Obtain a suitable battery charger. VERTICALLY). and 6.18 (ADJUSTING THE
Š Prepare the battery charger for the type of recharging HEADLIGHT BEAM HORIZONTALLY).
desired (see table). Š Make sure that all connectors are inserted properly.
Š Connect the battery to a battery charger. Š Make sure that all switches are correctly fastened and
in proper working order:
DANGER - see 6.8.5 (CHECKING THE SIDE STAND SWITCH);
Make sure the area is adequately ventilated during - see 6.8.7 (CHECKING THE SAFETY SYSTEM
recharging or while running the engine; avoid SWITCHES).
inhaling the fumes emitted while recharging the Š Make sure that the air sensor and speedometer sensor
battery. are securely attached to their mounts.
Š Switch on the battery charger.
DANGER
Voltage
Recharging Time (hours) The sensing area of the sensors must always be kept
(Amperes)
clean. Any caked mud, dirt, etc. can affect their
Normal 1.2 8 - 10 function.
Fast 12 0.5

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.

2.4.3 EXTENDED BATTERY STORAGE


Carefully read 2.4 (BATTERY).

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).
Š 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.
Š 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.

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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.
Š Make sure the ignition switch is set to “ “.
Š 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
Š Pull back the red rubber boot (1).
Š 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).
Š 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.
Š 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.
Š Stop both engines and disconnect the jumper cables,
proceeding in reverse order.

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2.7 SPARK PLUGS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check the spark plugs every 4687 mi (7500 Km) or every
8 months; replace them every 9375 mi (15000 Km) or
every 16 months. 1
Periodically remove the spark plugs, clean them to
remove any carbon deposits, and replace if necessary.
For competitive use, replace the spark plugs every 4687
mi (7500 Km) .
2
To access the spark plugs:

DANGER
Let the engine cool down to ambient temperature.
Š 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.
Š Remove the spark plug cap (1).
Š Remove all traces of dirt from the base of the spark
plug.
Š Place the special wrench supplied with the tool kit over
the spark plug.
Š Place the 13-mm open-end wrench supplied in the tool
kit over the hexagonal seat of the special spark plug
3
wrench.
Š 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).
Š 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

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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.
Š 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.
Š 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.
Š Tighten using the wrench provided in the tool kit, 1
turning each spark plug 1/2 turn to compress the
gasket.

Tightening torque for spark plug: 14 ftlb 2


(20 Nm).

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.
Š 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).
Š Refit the fuel tank.

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2.8 LIFTING THE FUEL TANK


4
Carefully read 1.4.1 (FUEL).
1
DANGER 3
Danger of fire.
Wait until the engine and exhaust silencer have
completely cooled down.
Š Unscrew and remove the two bolts (1).
2
1
Tightening torque for bolts (1): 2.21 ftlb (3 Nm) 3
Š Remove the grille (2).
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Unscrew and remove the two bolts (3) that fasten the
front part of the fuel tank (4). Recover the bushings and
washers.
5
Tightening torque for bolts (3): 5.90 ftlb (8 Nm)
Š Remove the fuel tank support rod (5) from the seats
4
provided under the saddle.
NOTE The rubber-covered end of the rod (5) must be
placed in the center hole of the steering head.
Š Liftthe front part of the fuel tank (4). Prop it into
position using the rod (5) as shown in the figure.

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2.9 DRAINING FUEL FROM THE TANK


Carefully read 1.4.1 (FUEL).

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.
Š Shut off the engine and wait for it to cool.
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Š 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.
Š 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.
Š Place the free end of the hose inside the container
prepared beforehand.
Š Insert the male quick-release coupling of the hose all
the way into the quick-release container (2). The
gasoline starts draining out immediately.
Š Open the tank cap.
Š Wait until all the gasoline has drained completely from
the tank.
Once all the gasoline has drained out:
Š Press the push-button to disconnect the male quick-
release coupling from the container (2).
Š 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).
Š Refit the fuel tank.
Š Close the tank cap.

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2.10 AIR FILTER


1 1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Inspect the air filter every 4687 mi (7500 Km) or 8
months, and replace it every 9375 mi (15000 Km) or 16 2
months, or more frequently if the vehicle is used on dusty
or wet roads.
In this case you may wish to partially clean the air filter
after traveling on such roads.
1
WARNING
Partial cleaning of the air filter is no substitute for
replacing the filter, nor does it postpone the need to
do so. Do not start the engine with the air filter
removed. Do not use gasoline or solvents to clean the
filter; this could cause a fire in the fuel system. Use
only a fire-proof solvent or detergent. This can cause
serious burns or destruction of your vehicle. 5
REMOVAL
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Š Unscrew and remove the seven fastening screws (1)
holding the filter case cover (2).

Tightening torque for screws (1): 1.47 ftlb (2 Nm).


Š Remove the filter case cover (2). 3
Š Extract the air filter (3).
WARNING
Thoroughly clean the air filter seat on the filter box to
remove any foreign matter. Plug the throttle body and
air filter seat openings with clean rags to prevent any
foreign matter from entering the intake tubes.
Š Make sure the gasket (5) is intact; replace if damaged.
PARTIAL CLEANING

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.
Š Hold the air filter (3) upright and strike it repeatedly
against a clean surface.
Š If necessary, clean the air filter (3) with a blast of 4
compressed air (aiming it outwards from inside the filter).
Š Clean the outside of the air filter (3) with a clean cloth.
CHANGING
Š Replace the air filter (3) with another of the same kind.
Š 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.

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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.

2.11.1 CHECKING THE OPERATION OF THE


THROTTLE CONTROL

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:
Š 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.
Š Check the idle speed, see 2.11.2 (ADJUSTING THE
IDLE SPEED).
Š Check the throttle control adjustment, see 2.11.3
(ADJUSTING THE THROTTLE CONTROL).

2.11.2 ADJUSTING THE IDLE SPEED


The idle speed may not be adjusted manually.
The idle speed is regulated by an electric step motor (1),
which changes the air flow by means of a small piston.
The control unit decides whether to open or close the
piston based on three parameters: 1
- position of the throttle valve.
- engine rpm.
- coolant temperature.

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2.11.3 ADJUSTING THE THROTTLE CONTROL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check the throttle control cables after the first 625 mi
(1,000 km) and every 4687 mi (7,500 Km) thereafter.
1
The play of the throttle adjuster must be 0.08 - 0.11 in
(2–3 mm), measured at the edge of the grip.
If not:
Š Place the vehicle on the stand.
Š Pull back the rubber boot (1).
Š Loosen the lock nut (2).
Š Rotate the adjuster (3) so as to restore the proper play.
Š After the adjustment, tighten the lock nut (2) and check
the play again.
Š Replace the rubber boot (1).
WARNING
After completing the adjustment, 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. Failure to heed this warning can lead to a
stuck throttle and runaway motor which can cause a 2
serious accident with subsequent serious injury or
even death.
3

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2.12 CHECKING AND TOPPING UP THE


ENGINE OIL LEVEL
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), see 1.4.1 (FUEL) and 1.4.2
(LUBRICANTS).
Periodically check the engine oil level. Change the oil
after the first 625 mi (1,000 km), and every 4687 mi
(7,500 Km) or 8 months thereafter, see 2.13 (CHANGING
THE ENGINE OIL AND OIL FILTER).
To check:
NOTE Place the vehicle on the center stand on a flat,
hard surface.

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.
Š Start the engine.
Š Ride the vehicle for approximately 10 miles, or 15-20
minutes.
Š Shut off the engine.
Š Place the vehicle on the center stand.
Š Keep the vehicle upright with both wheels resting on
the ground.
Š Through the slot on the left fairing, check the engine oil
level on the transparent tube (1).
MAX = maximum level. 3
MIN = minimum level.
Š The difference between "MAX" and "MIN" is
approximately 30.51 cuin (500 cm³). 2
Š 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:
Š Unscrew and remove the screw (2).
Š Remove the cover (3).
Š Unscrew and remove the filler cap (4).
Š Top up the reservoir to restore the proper level,
see 1.12 (LUBRICANT CHART).

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2.13 CHANGING THE ENGINE OIL AND OIL


FILTER
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), see 1.4.1 (FUEL) and 1.4.2
(LUBRICANTS).
Periodically check the engine oil level. Change the oil
after the first 625 mi (1,000 km), and every 4687 mi
(7,500 Km) or 8 months thereafter, see 2.13 (CHANGING
THE ENGINE OIL AND OIL FILTER).

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.
Š Remove the left fairing see 7.1.28 (REMOVING THE 1
SIDE FAIRINGS).
Š Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Place a container (1) with a capacity greater than 1
gallon (4000 cm³) under the drain plug (2) on the
reservoir (3).
Š Unscrew and remove the drain plug (2) from the
reservoir (3).
Š Unscrew and remove the filler cap (4). 4
Š Drain the oil and let it drip for a few minutes into the
container (1).
Š Check the gasket of the drain plug (2) on the reservoir
(3) and replace if necessary.
Š Screw and tighten the drain plug (2).

Tightening torque for drain plug (2): 11.06 ftlb


(15 Nm).
Š Move the container (1) under the engine oil drain
plug(4) on the engine.
Š Unscrew and remove the drain plug (5) from the
engine.
Š Drain the oil and let it drip for a few minutes into the
container (1).

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.
Š Remove any metal residue stuck to the drain plug (5),
reinstall and tighten the drain plug. 5 1

Tightening torque for drain plug (5): 8.85 ftlb


(12 Nm).
Š Use a cloth to wipe up any spilled or splashed oil.

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CHANGING THE ENGINE OIL FILTER


Change the engine oil filter after the first 625 mi (1,000
km) and every 4687 mi (7,500 Km) thereafter (or with
each engine oil change).
Š Unscrew the two screws (6) and remove the cover (7). 9
Š Remove the engine oil filter (8).
7
WARNING
Do not re-use oil filters. 8
Š Spread a thin film of oil on the O-ring (9) of the new
engine oil filter.
Š Insert the new engine oil filter. 6
Š Reassemble the cover (7), install and tighten the two
screws (6).
CLEANING THE OIL TANK FILTER
Clean the engine oil filter (10) on the tank every 9375 mi
(15000 km) (or every two engine oil changes).
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind.
Š Loosen the clamp (12) and disconnect the hose (13). 12
Š Unscrew and remove the oil tank filter (10) and clean 13
with a blast of compressed air.
NOTE You must partially remove the engine oil tank (3) 10
in order to slide out the engine oil filter.
Š Unscrew and remove the two screws (14).
Š Move the engine oil tank (3) outwards.
Š Remove the engine oil filter (10) on the tank and clean
with a blast of compressed air.

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
Š Carefully inspect the seal of the engine oil filter (10) on 3
the tank; screw on and tighten.

Tightening torque for the engine oil filter (10) on


the tank: 22.13 ftlb (30 Nm).
Š Replace the two screws (14). 14
Š Refit the pipe (13) and tighten the new clamps. 14
WARNING
Do not add additives or other substances to the oil. If
using a funnel or other tool, make sure it is perfectly
clean.
Š Pour approximately 3½ quarts (3500 cm³) of engine oil
through the filling opening (11), see 1.12 (LUBRICANT
CHART).
Š Screw on the filler cap (4).
Š Start the engine and let it idle for around one minute, to
allow the engine oil system to fill up completely.
13
Š Check the engine oil level and top up if necessary,
see 2.12 (CHECKING AND TOPPING UP THE 15
ENGINE OIL LEVEL).
10

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2.14 CHECKING AND TOPPING UP THE


COOLANT
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.4.6 (COOLANT).
Always check the coolant level before riding, and change
it every 2 years.

WARNING
The coolant level should be checked and topped up
only while the engine is cold. 1
Š Shut off the engine and wait for it to cool.
NOTE Place the vehicle on the center stand on a flat,
hard surface.
Š Keep the vehicle upright with both wheels resting on
the ground.
Š 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
Š Unscrew and remove the screw (2). 3
Š Remove the cover (3).
Š 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.
Š Top up with coolant, see 1.12 (LUBRICANT CHART)
until the level of fluid approximately reaches the
"FULL" mark.
Š Do not exceed this level, to keep fluid from leaking out
while the engine is running.
Š 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.

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2.15 CHANGING THE COOLANT


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.6 (COOLANT) and sect. 5
(COOLING SYSTEM).
Change the coolant every 2 years.
Š Remove the right air duct, see 7.1.31 (REMOVING
THE RIGHT AIR DUCT).
Š Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Remove the front spray-guard, see 7.1.32 2
(REMOVING THE FRONT FAIRING LOWER 1
LOCKUP).
Š Remove the expansion tank, see 5.8 (REMOVING
THE EXPANSION TANK).
Š Place a container (2) under the drain plug (1) to catch
the coolant; (capacity greater than 2.6 quarts).
Š Unscrew and remove the drain plug (1) and retrieve the
aluminum washer.

WARNING 3
Do not remove the filler cap (3) while the engine is
warm, because the coolant is under pressure at high
temperatures.
Š Remove the filler cap (3) to allow the fluid to flow more
freely from the system. 4
Š 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.
ŠReassemble the drain plug (1) with a new aluminum
washer.

Tightening torque for drain plug (1): 7.3 ftlb


(10 Nm).
Š Reassemble the expansion tank.
Š Top up from the filler neck (4) until full.
Š Squeeze and release the radiator hoses (5-6) a few 5
times to create a slight pressure and
Š enable the coolant to flow into the hoses.
Š Top up again until full.
NOTE The right level has been reached when the level
of fluid stabilizes just below the filler neck (4).
Š Replace the filler cap (3).
Š Top up to restore the proper level of fluid in the
expansion tank, see 2.14 (CHECKING AND TOPPING
UP THE COOLANT).
6
Š Start the engine and let it run until the cooling fan kicks
in. Let it cool, then check the level of fluid in the
expansion tank again.
Š Top up if necessary, see 2.14 (CHECKING AND
TOPPING UP THE COOLANT).
Total amount:
0.66 gal (2.6 quarts) (including the expansion tank).
NOTE It is not necessary to bleed the cooling system
on this vehicle.

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2.16 CHECKING AND TOPPING UP THE FRONT


BRAKE FLUID
Carefully read see 1.3.9 (PRECAUTIONS AND
GENERAL INFORMATION) and 1.3.5 (BRAKE FLUID).
Check the brake fluid every 4687 mi (7500 km) or 8
months, and change it every two years.

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.
Š Turn the handlebar all the way to the right.
Š Make sure the fluid contained in the reservoir exceeds
the "MIN" mark.
MIN = minimum level.
MAX = maximum level.
Š 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.
Š 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.
Š Turn the handlebar all the way to the left. 1
Š 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.

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Š Raise and remove the cover (4) complete with screws


(1-2). 4
Š Recover the guide cover (5).
Š Remove the gasket (6).
NOTE Avoid shaking the vehicle to keep from spilling
brake fluid while topping up. 2 1
WARNING
Do not add additives or other substances to the fluid. 6
5
If using a funnel or other tool, make sure it is
perfectly clean. .
7
NOTE As a reference point for reaching the “MAX” 3
level, top up just until the edge of the glass (7) is covered,
with the rim of the brake fluid reservoir parallel to the
ground.
Š Top up the reservoir (3) with brake fluid, see 1.12
(LUBRICANT CHART) until you have reached the right
level between the two markers, "MIN" and "MAX"

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.
Š To reassemble the components, follow the procedure in
reverse order.

2.17 CHECKING AND TOPPING UP THE REAR


BRAKE FLUID
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.5 (BRAKE FLUID).
Check the brake fluid every 4687 mi (7500 km) or 8
months, and change it every two years.

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.

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CHECK
NOTE Place the vehicle on the center stand on a flat, 3
hard surface.
Š Make sure the fluid contained in the reservoir exceeds
the "MIN" mark.
MAX
MIN = minimum level.
MAX = maximum level.
MIN
Š 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.
Š Use a short Philips screwdriver to unscrew the two
screws (1) of the brake fluid reservoir (2).
Š 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.
Š 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.
Š To reassemble the components, follow the procedure in
reverse order.

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2.18 CHECKING AND TOPPING UP THE


CLUTCH FLUID
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.4.5 (CLUTCH CONTROL
FLUID).
Check the clutch fluid every 7500 km (4687 mi) or 8
months, and change it every two years.
MAX
MIN
WARNING
If you notice that the clutch lever has excessive free
play, any sponginess or air bubbles in the system,
bleed the clutch system, see 2.20 (CLUTCH
CONTROL SYSTEM BLEEDING).
Clutch 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 clutch 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.
Š Turn the handlebar all the way to the left.
Š Make sure the fluid contained in the reservoir exceeds
the "MIN" mark.
MIN = minimum level.
MAX = maximum level.
Š If the fluid does not at least reach the "MIN" mark, top
up the reservoir.

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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.
Š Turn the handlebar all the way to the left.
Š 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.
Š Turn the handlebar all the way to the right.
Š 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.
Š Raise and remove the cover (3) complete with screws
(1-2).
Š Remove the gasket (4).
Š 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.
Š To reassemble the components, follow the procedure in
reverse order.

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2.19 BLEEDING THE BRAKE SYSTEMS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.5 (BRAKE FLUID).
For the maintenance intervals, see 2.1.1 (SCHEDULED
1
MAINTENANCE CHART).
If there is air in the brake hydraulic system, it will act as a
cushion, absorbing the pressure developed by the master
cylinder. This will severly limit the effectiveness of the
brakes.
You can tell when air is present, because the brake
control will feel spongy and braking effectiveness will be
reduced.

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.

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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).
Š 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).
Š Remove the dust cover.
Š Fit a piece of transparent plastic tubing over the clamp
bleeder nipples (1-2), and insert the other end into a
container.
Š Squeeze and release the brake lever several times,
and then hold it fully squeezed.
Š 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.
Š Tighten the bleeder nipple, squeeze the lever several
times, then hold it fully squeezed and loosen the
bleeder nipple again.
Š 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.
Š Tighten the bleeder nipple and remove the tubing.

Tightening torque for bleeder nipples (1):


6.64 ftlb (9 Nm).
C
Tightening torque for bleeder nipple (2):
10.33 ftlb (14 Nm).

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Š 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).
Š Replace the dust cover.
NOTE If the lever is still spongy, even if you do not see
any more air bubbles in the fluid flowing from the bleeder
nipple:
- bleed the caliper, see BRAKE CALIPER BLEEDING;
- bleed the master cylinder, see BRAKE MASTER
CYLINDER BLEEDING;

BRAKE CALIPER BLEEDING


NOTE Do not operate the two brake systems
simultaneously. The following steps refer to a single
brake system, but are applicable to both (with the
variations described). 1
For the front brake system, carry out the steps described
on both brake calipers.
Do not remove the two front brake calipers at the same
time.
Š For the front brake system only:
- partially remove the brake caliper, see 7.2.1
(REMOVING THE COMPLETE WHEEL) and position it
so that the bleeder nipple (1) is higher than the caliper
itself.
Š For the rear brake system only:
- the rear brake caliper has already been removed
during the system bleeding procedure;
- unscrew and remove the screw (3), retrieving the nut;
3
- you will need the help of a second mechanic to keep
the brake fluid reservoir (4) higher than the master
cylinder.
NOTE Have an (approximately 3 mm thick) shim to
place between the brake pads.
Š Place the shim between the pads and operate the lever 4
a few times.
Š Use the spacer or other tool to widen the caliper
pistons.

WARNING
Never adjust the caliper pistons directly, always on
the pads. Work gently to avoid damaging the pads.
Š 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.
Š 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).
Š Insert the shim between the pads. Squeeze the lever.
Š Spread the caliper pins again, loosening the bleeder
nipple and checking whether air bubbles escape along
with the fluid.
Š If there are still air bubbles, repeat the procedure until
there are no more bubbles in the fluid.

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NOTE Fill the reservoir with brake fluid as needed


while bleeding the brake caliper.
Throughout this operation, make sure brake fluid is
always present in the reservoir.
BRAKE MASTER CYLINDER BLEEDING
NOTE You may now bleed the brake master cylinder
using the same procedure as for bleeding the caliper.
Š Place the shim between the pads and operate the lever
a few times to pressurize the system.
Š Use the spacer or other tool to widen the caliper
pistons .

WARNING
Never adjust the caliper pistons directly, always on
the pads. Work gently to avoid damaging the pads.
Š Check whether any air bubbles escape into the
reservoir along with the fluid.
Š 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.
Š Now you can be certain that all air bubbles have been
bled from the master cylinder.

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2.20 CLUTCH CONTROL SYSTEM BLEEDING


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.4.5 (CLUTCH CONTROL
FLUID).
If necessary bleed air from the system after the first 625
mi (1000 km).
Any air in the hydraulic system will act as a cushion,
absorbing much of the pressure exerted by the master
cylinder and limiting the effectiveness of the clutch
cylinder.
You can tell when air is present because the clutch will
feel "spongy", and operating capacity will be reduced.

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.
Š Top up the clutch fluid in the reservoir, see 2.18
(CHECKING AND TOPPING UP THE CLUTCH
FLUID).
Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Remove dust cover.
Š Fit a piece of transparent plastic tubing over the
bleeder nipple (1), and insert the other end into a
container.
Š Squeeze and release the lever several times, and then
hold it fully squeezed.
Š 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.
Š Tighten the bleeder nipple (1), squeeze the lever
several times, then hold it fully squeezed and loosen
the bleeder nipple again.
Š 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.
Š Tighten the bleeder nipple (1) and remove the tubing.

Tightening torque for bleeder nipple (1): 6.64 ftlb


(9 Nm).
Š Top up to restore the proper level of clutch fluid in the
reservoir, see 2.18 (CHECKING AND TOPPING UP
THE CLUTCH FLUID).
Š Replace the dust cover.

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2.21 CHANGING THE FRONT BRAKE FLUID


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.5 (BRAKE FLUID).
Change the front brake fluid every two years.
1

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.
ŠRemove the dust cover.
ŠFit a piece of transparent plastic tubing over the
bleeder nipple (1) on the clamp, and insert the other
end into a container.
Š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).
Š Watch the reservoir (2) as the fluid flows out and
tighten the bleeder nipple (1) before it empties entirely.
Š Top up the reservoir (2), see 2.16 (CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID).
ŠLoosen the bleeder nipple (1) again by
approximately half a turn.
Š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.

Tightening torque for bleeder nipple (1): 6.64 ftlb


(9 Nm).
ŠReplace the dust cover.
Š Top up to restore the proper level of fluid in the
reservoir (2), see 2.16 (CHECKING AND TOPPING
UP THE FRONT BRAKE FLUID).

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2.22 CHANGING THE REAR BRAKE FLUID


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.5 (BRAKE FLUID).
1
Change the rear brake fluid every two years.

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.
Š Remove the dust cover.
Š Fit a piece of transparent plastic tubing over the
bleeder nipple (1) on the clamp, and insert the other
end into a container.
Š 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).
Š Watch the reservoir (2) as the fluid flows out and
tighten the bleeder nipple (1) before it empties entirely.
Š Top up the reservoir (2), see 2.19 (BLEEDING THE
BRAKE SYSTEMS).
Š Loosen the bleeder nipple (1) by approximately half a
turn.
Š 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.

Tightening torque for bleeder nipple (1):


10.33 ftlb (14 Nm).
Š Replace the dust cover.
Š Top up to restore the proper level of fluid in the
reservoir (2), see 2.17 (CHECKING AND TOPPING
UP THE REAR BRAKE FLUID).

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2.23 CHANGING THE CLUTCH FLUID


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.4.5 (CLUTCH CONTROL
FLUID).
Change the clutch fluid every two years.
1
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.
Š Remove the dust cover.
Š Fit a piece of transparent plastic tubing over the
bleeder nipple (1), and insert the other end into a
container.
Š Loosen the bleeder nipple (1) by approximately one
turn.
2
NOTE Throughout this operation, make sure there is
always fluid present in the reservoir; otherwise, after the
operation you will need to bleed the system, see 2.20
(CLUTCH CONTROL SYSTEM BLEEDING).
Š Watch the reservoir (2) as the fluid flows out and
tighten the bleeder nipple (1) before it empties entirely.
Š Top up the reservoir (2), see 2.18 (CHECKING AND
TOPPING UP THE CLUTCH FLUID).
Š Loosen the bleeder nipple (1) again by approximately
half a turn.
Š 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.

Tightening torque for bleeder nipple (1):


14.75 ftlb (20 Nm).
Š Replace the dust cover.
Š Top up to restore the proper level of fluid in the
reservoir (2), see 2.18 (CHECKING AND TOPPING
UP THE CLUTCH FLUID).

2.24 ADJUSTING FRONT BRAKE LEVER AND 3


CLUTCH CONTROL LEVER 1
You can adjust the distance between the end of the lever
(1) and the knob (2), turning the adjuster (3).
The positions “1” and “4” refer to an approximate
distance, between the ends of the lever and knob, of 105
and 85 mm, respectively.
Positions “2” a “3” refer to intermediate distances.
Š Push the control lever (1) forward and turn the adjuster
(3) until the desired number is aligned with the arrow.
2

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2.25 ADJUSTING THE CLEARANCE OF THE


REAR BRAKE LEVER
The brake lever is ergonomically positioned to suit most
riders during vehicle manufacture.
If you wish to customize the brake lever position:
2
Š Loosen the lock nut (1).
Š Fully tighten the brake adjuster (2). 1
Š Fully tighten the lock nut (3) on the master cylinder
push rod (4).
Š Tighten the master cylinder push rod (4) all the way, 4
then unscrew 3-4 turns to loosen.
Š Unscrew the brake adjuster (2) until the brake lever is 3
at the desired height.
Š Fix the brake adjuster (2) in place using the lock nut
(1).
Š Unscrew the master cylinder push rod (4) until it just
contacts the master cylinder piston.
Š Screw in the push rod to ensure a minimum clearance
of 0.02 - 0.04 in (0.5 - 1 mm) between the master
cylinder push rod (4) and the master cylinder piston.
NOTE Make sure there is enough play on the lever (5).
If not, the brake will remain slightly applied, causing the
brake components to wear out prematurely. Lever (5)
clearance: 0.16 in (4 mm) (measured at the end of the
lever).
Š Lock the master cylinder push rod in place using the
lock nut (3).
NOTE After completing the adjustment, make sure that 5
the wheel turns freely when the brake is released.

2.26 ADJUSTING THE GEARSHIFT LEVER


You may adjust the position of the gearshift lever using
the eccentric rod (1) as follows:
Š Place the vehicle on the center stand. 1
Š Lower the stand (2) for easier operation.
Š Loosen the nuts (3) 1 and (4).
Š Rotate the eccentric rod and adjust the height of the
gearshift lever. 3
Š Tighten the nuts (3) 1 and (4).
4
2

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2.27 CHECKING THE BRAKE PAD WEAR


The amount of wear that the brake pads experience
depends on how the vehicle is used, how aggressively it
is ridden, and the condition of the roads upon which it is
operated.
NOTE The following information may refer to a single
brake system, but is applicable to both.
To quickly check the wear on the pads:
1
Š Place the vehicle on the stand.
Š Visually inspect between the disc and pads, working:
- from the bottom front for the front brake calipers (1);
- from the bottom rear for the rear brake caliper (2).

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.
Š 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.

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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.

2.28.1 CHECKING THE BEARING PLAY


Š Place the vehicle on the center stand.
Š Shake the fork fore and aft.
Š There should be no play. If you detect any play, adjust
the bearing, see 2.28.2 (ADJUSTING THE BEARING
PLAY).

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2.28.2 ADJUSTING THE BEARING PLAY


2
carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š To make it easier to adjust the bearing play, we 3
recommend that you perform the three operations
listed below:
- Remove both knobs, see 7.1.11 (REMOVING THE
HANDGRIP FROM THE LEFT HANDLEBAR) and
7.1.14 (REMOVING THE THROTTLE CONTROL);
- Remove the electrical control on the left handlebar,
see 7.1.13 (REMOVING ELECTRICAL CONTROLS 5
ON THE LEFT HANDLEBAR); 4 1
- Remove both brake controls, see 7.1.12 (REMOVING
THE CLUTCH CONTROL) and see 7.1.15
(REMOVING THE FRONT BRAKE CONTROL).
Š Partially unscrew the bolt (4) fastening the handlebar
(2) to the fork (1).
Š Partially unscrew the bolt (5) fastening the fork head (3)
to the fork (1). 7
Š Unscrew and remove the upper bushing (6), retrieving
the spring washer (7).
Š Using a plastic mallet, tap from the bottom, pushing the
fork head (3) out from the top, complete with steering
lock ignition switch.
Š Bend the fork head (3) forward, inserting a cloth to
keep from damaging the dashboard. 6
Š Use a small blade screwdriver, straighten the tabs (the
ones folded upward) of the lock plate (9).
NOTE Have on hand the special tool code 8140203
(steering adjustment socket wrench).
Š Use the special socket wrench to loosen and remove
the ring-nut (10).
Š Remove the lock plate (9).
DANGER
During reassembly, the lock plate (9) must be
replaced. Never reuse a lock plate. Always replace
the lock plate removed with a new one. Failure to
observe this warning can result in loss of steering
integrity with subsequent loss of control of the
motorcycle, upset, serious injury, or even death.
9
Š Use the special socket wrench to tighten the adjusting
ring nut (8) to obtain the appropriate clearance.

Tightening torque for adjusting ring nut (8): 40


Nm (4.0 kgm).
Š Replace the lock plate (9) in such a way that the tabs
match up with the grooved sectors of the ring-nut (8). 10
Š Use the special socket wrench to tighten the locking
ring nut (10).
9
Locking ring nut tightening torque (10):
manually until contact + 1/4 turn. 8
NOTE Bend the tabs of the lock plate (9) upwards.
Š Bend the four tabs of the lock plate (9) upwards on the
grooved sector of the locking ring nut (10).
Š Replace the fork head (3), installing it correctly.

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Š Lubricate the thread and base of the bushing (6) with


motor oil, see 1.12 (LUBRICANT CHART).
Š Tighten the upper bushing (6), correctly replacing the
spring washer (7).
7
Tightening torque for upper bushing (6):
88.50 ftlb (120 Nm).
ŠInsert and tighten the screw (5).

Tightening torque for screw (5): 18.44 ftlb (25 Nm).


6
NOTE When reassembling lubricate the thread and
under the head of the screw (4).
ŠInsert and tighten the screw (4).

Tightening torque for screw (4): 18.44 ftlb (25 Nm). 2

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

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2.29 INSPECTING THE FRONT SUSPENSION

2.29.1 FRONT SUSPENSION


1
The front suspension is made up of a hydraulic fork
connected by two plates to the steering column.
To adjust the vehicle attitude, each tube of the fork is
equipped with an upper screw (1) to adjust the hydraulic
damping on extension, and a lower screw (2) to adjust
the spring preload.
The vehicle attitude, or riding position, may be further 2
adjusted by changing the height of the front fork.
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
Change the front fork oil after the first 4687 mi (7500 km),
and every 14,000 mi (22,500 km) thereafter.
Every 4687 mi (7500 km) carry out the following checks:
Š Applying the front brake lever, press on the handlebar
repeatedly to push the fork down.
The fork must slide smoothly and evenly, and there
must be no traces of oil on the fork tubes.
If the fork tends to “bottom out”, adjust as needed,
see 2.29.2 (ADJUSTING THE FRONT FORK) and
change the oil if necessary, see 7.8.1 (CHANGING THE
FORK OIL).
Make sure that the fork does not leak oil and that the
outer surface of the tubes is not scratched or grooved.
Front fork components normally cannot be repaired, but
must be replaced, see 7.8.3 (DISASSEMBLING THE
LOWER FORK TUBE/UPPER FORK TUBE UNIT).
Š Make sure that all parts are properly tightened and that
the front suspension is in good working order.

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2.29.2 ADJUSTING THE FRONT FORK


The front fork is adjusted at the factory to suit most riding
conditions for most riders at low and high speeds, with light
or heavy vehicle loads. However, it is possible to customize
the fork setting to accommodate the full range of operating 1
conditions that the vehicle is intended to be used for.
NOTE Choose the type of adjustment desired, based
on the information in the table, before touching the 2
adjusters.
SETTINGS:
Standard setting:
for normal loads (for example, rider and luggage).
Medium setting:
for heavy loads (for example passenger, rider and luggage).
Rigid setting:
for competitive riding.
Full-load setting:
for touring.

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

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2.30 SWINGING ARM


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Make sure the pivot bearings in the swinging arm are
firmly tightened..
To check:
Š Place the vehicle on the center stand.
Š Shake the wheel up and down, then from side to side
(see figure).
Š if you feel any extra play, proceed with adjusting the
swinging arm, see 2.30.1 (ADJUSTING THE
SWINGING ARM).
Š If the play persists, replace the bearings, see 7.9.2
(DISASSEMBLING THE SWINGING ARM).

2.30.1 ADJUSTING THE SWINGING ARM


3
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand. 1
Š Completely loosen the nut (1).
NOTE Have on hand the special tool code 8140203
(socket wrench for adjusting swinging arm pivot - engine
mounts). 2
Š Use the special socket wrench to completely loosen
the locking ring-nut (2).
Š Working from the right-hand side of the vehicle, rotate
the swinging arm pivot (3) clockwise, which will cause
the adjuster bushing (4) to rotate with it and push
against the swinging arm.

Tightening torque to apply to the pins (3):


2
8.85 ftlb (12 Nm).
Š Use the special socket wrench to tighten the locking
ring-nut (2).

Tightening torque for the lock nut (2): 44.25 ftlb 3


(60 Nm).
Š Tighten the nut (1).
4
Tightening torque for nut (1): 66.38 ftlb (90 Nm).

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2.31 INSPECTING THE REAR SUSPENSION

2.31.1 REAR SUSPENSION


3
The rear suspension is made up of a shock absorber-
spring assembly, connected to the frame by silent-block
and to the swinging arm by a system of levers. To adjust 2
the riding height of the vehicle, the shock absorber is
equipped with an adjuster screw (1) to adjust the
hydraulic damping on extension, and an adjuster knob (2)
to set the spring preload (3). 1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check after the first 625 mi (1,000 km) and then after
every 9375 mi (15,000 km), or every 16 months.
Š Make sure that all of the fasteners on the rear
suspension are correctly tightened and that the pivot
points are properly lubricated." (I don't really
understand what is asked for here.

2.31.2 REAR SHOCK ABSORBER ADJUSTMENT


The rear shock absorber is adjusted at the factory to suit
most riding conditions for most riders at low and high 1
speeds, with light or heavy vehicle loads.
It is, however, possible to customize the setting to best
suit the way in which the vehicle is to be used.

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.
Š Turn the screw (1) to adjust the hydraulic damping on
extension of the shock absorber (see table).
Š 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.

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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.

REAR SHOCK ABSORBER ADJUSTMENT TABLE


Rear suspension Standard setting Soft setting Rigid setting Medium setting
Hydraulic adjustment from fully closed (*) from fully closed (*) from fully closed (*) from fully closed (*)
in extension (1) open (**) 9 notches open (**) 10 notches open (**) 8 notches open (**) 7 notches
Spring preload knob from fully open (**) from fully open (**) from fully open (**) from fully open (**)
(2) close (*) 14 notches close (*) 4 notches close (**) 22 notches close (**) 34 notches

(*) =clockwise
(**) =counter-clockwise

2.31.3 CHECKING THE REAR SUSPENSION


LINKAGE
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check the condition of the bearings every 30,000 km
(18,750 mi).
NOTE Ask someone to help you hold the vehicle
upright.
Š Firmly grasp the rear of the vehicle, press downward
and release several times.
Š If the movement is not smooth and is accompanied by
creaking, and/or if you notice any play, replace the
bearings of the rear suspension linkage, see 7.10.2
(DISASSEMBLING THE REAR SUSPENSION
LINKAGE).
Š If, after you pressed the vehicle downwards, it returns
to its original position very slowly, check whether the
rear suspension is adjusted correctly, see 2.31.2
(REAR SHOCK ABSORBER ADJUSTMENT).
If the problem persists even after adjusting, it means that
the shock absorber is discharged; you should therefore
recharge it.

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2.32 FRONT WHEEL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Check every 4687 mi (7500 km).
Š Place the vehicle on the appropriate front support
stand , see 1.15.1 (PLACING THE VEHICLE ON
THE FRONT SUPPORT STAND).
Š Spin the wheel in both directions by hand.
Š Make sure the wheel turns smoothly and without
interference and/or noise. If not, replace the bearings,
see 7.2.2 (DISMANTLING THE WHEEL).
Š Should you notice any wobble as the wheel spins,
check the components in question, see 7.2.3
(CHECKING THE COMPONENTS).
Š If, after repeated spinning, the wheel comes to a stop in
the same position, it must be balanced.

2.33 REAR WHEEL


Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
Check every 4687 mi (7500 km).
Š Place the vehicle on the center stand.
Š Spin the wheel in both directions by hand.
Š Make sure the wheel turns smoothly and without
interference and/or noise. If not, replace the bearings,
see 7.2.2 (DISMANTLING THE WHEEL).
Š Should you notice any wobble as the wheel spins,
check the components in question, see 7.2.3
(CHECKING THE COMPONENTS).
Š If, after repeated spinning, the wheel comes to a stop in
the same position, it must be balanced.

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2.34 EXHAUST MANIFOLD NUTS


Carefully read see 1.3.9 (PRECAUTIONS AND
GENERAL INFORMATION).
1
Tighten the exhaust manifold nuts after the first 625 mi
(1000 km), and every 4687 mi (7500 km) or 8 months 1
thereafter.

DANGER
Let the engine cool down to ambient temperature.
Š Remove the side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS). 1
Š Remove the front grille, see 7.1.35 (REMOVING THE
RADIATOR SPOILER).
Š Torque the three nuts (1) of the front cylinder exhaust
manifold to specification.
Š 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

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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
Š Place the vehicle on the center stand. ASSEMBLY).
Š Set the gearshift lever to neutral.
Š Turn the rear wheel to check the chain play in other
positions.
Š 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.

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.35.1 CHECKING THE PLAY


To check the chain play:
Š Place the vehicle on the center stand.
Š Set the gearshift lever to neutral.
Š Make sure that the play is approximately 0.98 in
(25 mm), at a point between the sprocket and
countershaft sprocket in the lower chain run.
Š Move the vehicle forward, to check the chain play in
other positions as well; the clearance must remain
constant throughout the wheel rotation. 0.98 in
WARNING
If the clearance is greater in certain positions, this
means that some of the links are crushed or seized
up. To prevent the risk of seizing, lubricate the chain
frequently, see 2.41.1 (CLEANING AND
LUBRICATION).
If the clearance is even but more or less than 0.98 in
(25 mm), adjust as needed, see 2.35.3 (ADJUSTING
THE DRIVE CHAIN).

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.

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2.35.2 CHECKING THE WEAR OF THE CHAIN AND


SPROCKETS
Š Stretch the chain completely, see 2.35.3 (ADJUSTING
THE DRIVE CHAIN).
Š On one branch of the chain, count 17 pins (16 links) in
the area between the sprockets, and measure the
distance between the first and 17th pins.
If the distance is greater than the limit indicated below,
replace the chain, see 7.11 (DISASSEMBLING THE
DRIVE CHAIN).
Limit of wear: 10.06 in (255.5 mm) (MAX 0.5%).

2.35.3 ADJUSTING THE DRIVE CHAIN


If the checks reveal the need to adjust the chain tension:
Š Place the vehicle on the center stand.
Š Loosen the bolts (1) completely.
1
NOTE Have on hand the pin wrench (2) supplied with
the tool kit.
To loosen the chain:
Š Insert the pin wrench (2) as shown in figure (A).
To tighten the chain:
Š Insert the pin wrench (2) as shown in figure (B).
With the pin wrench (2) correctly inserted,
Š hook the pin wrench (2) to the ring-nut (3).
Š Insert the extension (4) in the pin wrench.
Š Use the pin wrench (2) to adjust the chain clearance.
Š Check the chain play, see 2.35.1 (CHECKING THE
PLAY). 1
Š Tighten the two screws (1). 1
4
Tightening torque for bolts (1): 25.81 ftlb
(35 Nm).
Lubricate the chain every 625 mi (1000 km) and
whenever necessary.
3 1
WARNING 2
After letting the chain dry, lubricate it thoroughly with
spray grease specifically developed for O-ring
chains, see 1.12 (LUBRICANT CHART).
NOTE Do not use the vehicle immediately after
lubricating the chain, give the lubricant a chance to dry,
otherwise the chain will spray the lubricant all over you
4
and your vehicle.

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

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.35.4 INSPECTING THE DRIVE CHAIN GUIDE PLATE


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
1
INFORMATION). 6
Š Place the vehicle on the stand. 7
Š Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
4
Š Unscrew and remove the two bolts (1).

Tightening torque for bolts (1): 7.37 ftlb (10 Nm).


Š Remove the voltage regulator (2), leaving it connected 3 2
to the main wiring.
5
Š Remove the guard (3).
Š Unscrew and remove the three screws (4) holding the
voltage regulator mount (5).

Tightening torque for screws (4): 8.85 ftlbv (12 Nm). 10


Š Retrieve the three bushings (6) and three shock mount
grommets (7).
Š Remove the housing (5) to retrieve the bushings.
Š Loosen the screw (8) and extract the gearshift lever (9)
Š Remove the clutch cylinder, see 3.2.1 (REMOVING 8 9
THE CLUTCH CYLINDER).
NOTE Release the side stand switch cable.
Š Remove the countershaft sprocket cover (10).
Š Remove the guide plate (11).
Š Make sure that the guide plate (11) is not worn or
damaged; if so, replace it with a new one.

11

2.35.5 INSPECTING THE DRIVE CHAIN SHOE


Š Place the vehicle on the center stand.
Š Make sure that the shoe (1) is not worn or damaged. If
so, replace it with a new one, see 7.1.57 (REMOVING
THE DRIVE CHAIN SHOE).

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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.

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

Do not grease the tires with inappropriate


substances.
The appropriate tire size is listed on the vehicle
registration. It is a punishable offense to use any
other size tire.
The use of tires other than those indicated may
adversely affect the handling and overall safety of the
vehicle.
Use only the tires originally selected by aprilia,
see 1.11 (SPECIFICATIONS).

2.37 FUEL LINES


Carefully read 1.4.1 (FUEL).
Check the fuel lines every 4687 mi (7500 km) or every 8
months.
1
Replace every four years.
Replace the fuel lines if you find any signs of wear,
cracks, etc.
- High-pressure delivery line (1) [~ 4.7 PSI(450 kpa) (4.5 2
bar)]. 4
- Return line (2).
NOTE Make sure that the male quick-release coupling
(3) has been correctly inserted into the container (4).
For more information, see sect. 4 (FUEL SYSTEM). 3

2.38 BRAKE AND CLUTCH CONTROL LINES


Carefully read 1.4.3 (BRAKE) and 1.4.5 (CLUTCH
CONTROL FLUID).
Check the lines every 4687 mi (7500 km) or every 8
months.
Replace every four years.
Replace the lines if you find any signs of wear,
cracks, etc.

2.39 COOLING SYSTEM PIPES


Carefully read 1.4.6 (COOLANT).
Check the cooling system pipes every 4687 mi (7500
km), or every 8 months.
Replace the cooling system lines if you find any
signs of wear, cracks, etc.

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2.40 TIGHTENING NUTS AND BOLTS


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.
Carefully check all fasteners, especially those
components essential to safety. Specifically:
- right/left handlebars;
- front brake lever;
- clutch lever;
- fuel delivery line;
- front fork to plates;
- front fork/wheel axle clamps;
- front wheel;
- front brake line fittings;
- front brake discs;
- front brake calipers;
- engine;
- countershaft sprocket;
- rear brake lever;
- swinging arm;
- swinging arm leverage;
- rear shock absorber;
- rear wheel;
- rear brake disc;
- rear brake caliper;
- rear brake line fittings.

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).

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

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 ➤

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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 ➤

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AIR FILTER CASE


Description Qty. Screw / nut ftlb Nm Notes
Air filter case cover fastener 7 M5 1.4 2
Air filter case to throttle body fastener 6 M6 5.2 7 lub
Intake ducts fastener to filter case fastener 4 SWP3.9 0.7 1
Idle speed adjustment motor 2 M5 2.9 4 L243
Filter box fastener plate on frame 2 M6 3.6 5
Filter box reducer diaphragm 1 SWP3.9 0.7 1
FRONT WHEEL
Description Qty. Screw / nut ftlb Nm Notes
Wheel axle nut 1 M25x1.5 59 80 Ingr.
REAR WHEEL
Description Qty. Screw / nut ftlb Nm Notes
Sprocket to sprocket holder fastener 6 M8 18 25
Wheel axle nut 1 M40x1.5 125.3 170 Ingr.
Flexible couplings to pivot screw fastener 1 M30x1.5 110.6 150 Ingr.
Flexible coupling safety screw 3 M3 0.8 1.2
lub
Wheel screw cover 1 M10 7.3 10 “O-
ring”
COOLING SYSTEM
Description Qty. Screw / nut ftlb Nm Notes
3-way manifold closing screw 1 M14x1.5 21.7 30 L572
Electric fan mount fastener 2+2 M6 4.4 6
Electric fan motor to mount fastener 3+3 SWP3.9 0.7 1 L243
Radiator coolant drain plugs 1+1 M6 7.3 10 L572
Expansion tank to coils mount fastener 2 M6 5.9 8
Expansion tank cap fastener 1 M28x3 man
Coolant filler neck fastener to radiator 1 M6 7.3 10
Rear expansion tank to frame fastener 1 M6 7.3 10
Radiator mounts on frame 6 M6 7.3 10
Oil radiator on mount 3 M6 7.3 10
Water radiators on mount 2 M6 7.3 10
BRAKE SYSTEMS
Front Brake System
Description Qty. Screw / nut ftlb Nm Notes
Right and left brake caliper fastener 2+2 M10x1.25 36 50 lub
Brake discs fastener 6+6 M8 21.7 30 L243
Front brake line fastener 3 M10x1 14.5 20
Three-way brake line bracket on steering plate 1 M5 2.2 3
CONT'D ➤

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Rear Brake System


Description Qty. Screw / nut ftlb Nm Notes
Brake caliper fastener 1 M8 18 25
Brake lever on platform mount 1 M8 10.8 15 L243
Pedal on brake lever 1 M8 18 25 L270
Brake master cylinder fastener 2 M6 7.3 10
Brake master cylinder control rod lock nut 1 M6 man
Brake disc fastener 6 M8 21.7 30 L243
Brake line fastener 2 M10x1 14.5 20
Stop switch on rider footrest mount 1 M6 7.3 10
EXHAUST SYSTEM
Description Qty. Screw / nut ftlb Nm Notes
Exhaust pipe to engine fastener 3+3 M8 18 25
Exhaust muffler fastener 1 M6 7.3 10
Equalizer on frame 1 M8 18 25 L243
Stand striker grommet on equalizer 1 M6 7.3 10
Handle grip on lt pipe 2 M6 4.4 6
Click-clamp on muffler engagement 2 M6 10.8 15 sil
FUEL TANK
Description Qty. Screw / nut ftlb Nm Notes
Pump mount to fuel delivery line fastener 1 M12x1.5 16.2 22
Cap to tank fastener 7 M5 3.6 5
Fuel pump flange fastener to tank 8 M5 4.4 6 L518
Front tank to frame fastener 2 M6 5.9 8 lub
Tank cover 2 M5 2.2 3
Fuel rail on fuel line 2 M5 3.6 5
ENGINE OIL RADIATOR AND TANK
Description Qty. Screw / nut ftlb Nm Notes
Oil tank on mounts 3 M6 7.3 10
Oil filter 1 M25x1.5 man.
Oil drain cap 1 M8 10.8 15
Oil level gauge fittings 2 M10x1 14.5 20
FRONT BODY
Description Qty. Screw / nut ftlb Nm Notes
Front mudguard 4 M5 3.6 5 lub
Left and right air duct 6 M5 1.4 2
Rearview mirrors on clamp 4 M6 5.9 8
Air vents on frame and clamp 6 M6 5.9 8
Front fairing to ducts (on upper part), lower fastener 2 M5 2.9 4
Front fairing to ducts, lower fastener 2 SWP3.9 0.7 1
Duct cover fastener 20 SWP3.9 0.7 1
CONT'D ➤

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Lower fairing on frame 4 M5 2.9 4


Lower fairing to upper fairing 8 M5 1.4 2
Windshield on front fairing 6 M5 1.4 2
Upper fairing to front fairing and air ducts 12 M5 2.2 3
Upper fairing to air duct 6 M5 2.2 3
Dashboard panel to fairing frame 2 M5 2.2 3
Dashboard panel to molding 2 SWP3.9 0.7 1
Mirror frames 4 M5 2.2 3
Dashboard to mount 4 M6 2.9 4
Molding on mount 2 M6 2.9 4
Fairing cap to radiator mount 4 M6 3.6 5
Fairing cap to air ducts 2 M5 2.2 3
Lower fairing to fairing cap 6 M5 2.2 3
Fairing cap to air ducts 2 M5 2.2 3
Lower steering closing plate to plate 3 M6 3.6 5
FRAME
Description Qty. Screw / nut ftlb Nm Notes
Rider footrest mount to frame 4 M8 18 25
Passenger footrest mount to saddle support 4 M8 18 25
Saddle support to frame 4 M10 33.2 45
Tank drift to saddle support 2 M8 man
Mount to frame 2 M6 7.3 10
Center stand spring pin 1 M6 7.3 10
Oil tank mount to frame 2 M6 7.3 10
Throttle balance line fastener 1 M6 7.3 10
REAR BODY
Description Qty. Screw / nut ftlb Nm Notes
License plate holder to mount 2 M5 2.9 4
Reflector fastening nut 2 M5 2.9 4
License plate mount holding screw 4 M5 3.6 5 L243
Exhaust heat guard holding screw 2 M5 2.9 4
License plate lamp holder to license plate mount 2 M5 1.4 2
License plate lamp to mount 1 M5 2.2 3
Front panel to saddle support 6 M6 2.9 4
4 M6 2.9 4
Rear saddle support panel
2 M5 2.2 3
Bag racks to saddle support 2 M8 10.8 15
Saddle fastener to saddle support 2 M6 7.3 10
Grab handle to saddle support 3 M8 7.3 10
Passenger grab straps to grab handle 4 M8 10.8 15
CONT'D ➤

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RIGHT/LEFT HANDLEBARS AND CONTROLS


Description Qty. Screw / nut ftlb Nm Notes
Anti-vibration weights fastener 2 M6 7.3 10
Anti-vibration weights ring-nut 2 M18x1.5 28.8 35
Right/left handlebars fastener to fork 2 M8 21.7 30 Ingr.
Right/left handlebars lock screw 2 M6 8.8 12
Left dimmer switch fastener 2 M5 1.4 2
Right dimmer switch Fastening 2 M5 1.4 2
Front brake control fastener 2 M6 7.3 10
Clutch cylinder fastener 2 M6 7.3 10
Clutch line fitting to pump and cylinder 2 M10x1 14.5 20
Gearbox rod to lever and control 2 M6 8.8 12 L243
Gearshift lever to left rider footrest mount 1 M8 10.8 15 L243
Gear shaft control 1 M6 7.3 10
Pedal on gearbox lever 1 M8 18 25 L270

Notes: Fasteners for which no specific torque is given


L243 = fastening with LOCTITE® 243
SCREW ftlb Nm
L518 = fasten with LOCTITE® 518
L572 = fasten with LOCTITE® 572 M4 2.2 3
L574 = fasten with LOCTITE® 574
M5 4.4 6
L648 = fasten with LOCTITE® 648
man. = manual fastening M6 8.8 12
Gr. = grease under tester
lub = lubricate M8 18 25
sil = black silicone (code 8216005) M10 36 50
M12 59 80

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SCHEDULED MAINTENANCE AND TUNING OPERATIONS

2.41.1 CLEANING AND LUBRICATION


Never use steam, high-pressure water jets and/or highly
flammable solvents to wash the chain.
Š Wash the chain with diesel fuel or kerosene.
If the chain tends to rust quickly, perform maintenance
operations more often.

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.

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NOTES

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ENGINE

ENGINE
3

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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

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ENGINE

3.1 TECHNICAL DATA

3.1.1 TECHNICAL SPECIFICATIONS


See 1.11 (SPECIFICATIONS).

3.1.2 MAINTENANCE INTERVALS


See 2.1.1 (SCHEDULED MAINTENANCE CHART).

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).

3.1.6 SPECIAL TOOLS


See 1.14 (SPECIAL TOOLS).

3.1.7 TIGHTENING TORQUES


See 2.41 (FASTENERS).

3.1.8 PRECAUTIONS TO OBSERVE WHEN


CARRYING OUT MAINTENANCE
OPERATIONS AND REPAIRS

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.

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3.1.9 GENERAL INFORMATION ABOUT


MAINTENANCE AND REPAIRS
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
3.2 ENGINE COMPONENTS THAT MAY BE
DISASSEMBLED WITHOUT REMOVING
THE ENGINE FROM THE FRAME
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
The parts listed below may be removed and reinstalled
without removing the engine from the frame.

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).

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ENGINE

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).

RIGHT SIDE LEFT SIDE


2 4 15 16
4 17 1 3 9 6 7

12
5

19
18

20 19 14 13 10 11 8

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3.2.1 REMOVING THE CLUTCH CYLINDER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 3
INFORMATION) and 1.4.5 (CLUTCH CONTROL
FLUID).
Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Remove the voltage regulator housing, see 2.35.4
(INSPECTING THE DRIVE CHAIN GUIDE PLATE). 3
Š Unscrew and remove the screws (3).

Tightening torque for screws (3): 8.8 ftlb (12 Nm).


Š Remove the cylinder (2).
WARNING
Take great care when removing the clutch cylinder,
the line remains attached. Do not touch the clutch
lever after the cylinder (2) has been removed. This 2
could cause the piston to fall from its bore and clutch
fluid would be spilled out.
To prevent this from happening, use a tie-wrap to
secure the piston in place.
Remove the flange (1) only if necessary.

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ENGINE

3.3 REMOVING THE COMPLETE ENGINE


FROM THE FRAME

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).
Š Set the ignition switch to “ “.
Š Place the vehicle on the stand.
Š 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
Š Remove the fuel tank, see 7.1.6 (REMOVING THE
FUEL TANK COMPLETELY).
Š Remove both side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS).
Š Remove both lower fairings, see 7.1.33 (REMOVING 1
THE LOWER FAIRING).
Š Remove the radiator spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).

WARNING
Mark the cables to avoid mix-ups when
reassembling.
Š 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.

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Š Unscrew and remove the screw (5) and disconnect the


cable from the neutral gear switch (6).
Š Disconnect the cable from the engine oil pressure 6
sensor (7).

7
5

WARNING
The brake fluid reservoir (9) must remain upright to
prevent any leakage.
Š Remove the clutch cylinder, see 3.2.1 (REMOVING
THE CLUTCH CYLINDER).
Š Remove the countershaft sprocket, see 7.1.57
(REMOVING THE DRIVE CHAIN SHOE).
Š Remove the expansion tank, see 5.8 (REMOVING
THE EXPANSION TANK).
9

ŠDisconnect the spark plug caps (10).


WARNING
Use a non-flammable solvent, brushes and rags to
clean the exterior of the engine.
Avoid damaging rubber and plastic parts with
corrosive or flammable cleansers and solvents.
Should it be necessary to use a steam cleaner, do not
aim the high-pressure jets of water, steam or air at
the following parts: wheel hubs, controls on the right
and left handlebars, front and rear brake master
cylinder, instruments and gauges, muffler outlets,
glove compartment, ignition switch/steering lock, 10
electrical components.

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ENGINE

Š Clean the outside of the engine thoroughly.


Š Remove the exhaust pipes, see 7.1.53 (REMOVING
THE EXHAUST MANIFOLDS).
ŠDisconnect the electrical connector (11) from the
electric fan.
Š Disconnect the electrical cables from the horn.
WARNING
When reassembling, make sure electrical connectors
are properly fitted.

WARNING
Mark both the coupling and lines to avoid mix-ups
11
when reassembling.
Š 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

Š Remove both radiators (16-17) while still connected,


see 5.2 (REMOVING THE RADIATORS), complete
with electric fans, horn and supports.

16 17

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Š Remove the complete throttle body (18), see 4.8


(THROTTLE BODY). 18

NOTE For space reasons, it is best to remove the


three-way manifold (19), see 5.7 (REMOVING THE 19
THREE-WAY MANIFOLD).

NOTE Use special pliers to hook the clamps (code


0277295); during reassembly, replace each clamp with a
new one of the same kind. 24
Š Release the click clamp (20 - 21 -22).
Š Remove the complete thermostat (23), see 5.5 22
(REMOVING THE THERMOSTAT) along with the
three couplings.
Š Slip the coupling (24) off the coolant pump. 20
WARNING
Release all cables and lines from the clamps holding 23
them in place along their path.
Have the same number of clamps ready to use when
reassembling. Plug all the engine openings, hoses
and hose couplings to prevent any foreign matter
from accidentally entering the engine.
Š Gather the electrical cables together and secure them
in place with adhesive tape so that they do not get in
the way of the engine being lifted out from underneath.

21

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ENGINE

Š Unscrew and remove the screws (25), saving the plate


(26). 26

Tightening torque for screws (25): 29 ftlb (40 Nm ).

25

27

NOTE Have on hand the special tool code


8140183 (engine lifting eye hook), a hoist (28) and lifting
29
slings (29).

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.
Š Install the special eye hook (27) (code 8140183) to lift
the engine and fasten it in place with the screws (25).
Š Hook the slings (29) to the hoist (28) and eye hook (27)
as shown in the figure.
Š 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.

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ENGINE RST mille USA

NOTE The fasteners holding the engine to the frame


must be removed in the order given:
LEFT SIDE A ➠ B ➠ C ➠ D.
RIGHT SIDE E ➠ F ➠ G ➠ H.

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

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ENGINE

Š Unscrew and remove the two bolts (30), retrieving the


corresponding washers (31). 33

Tightening torque for bolts (30): 29 ftlb (40 Nm ).


Š Hold the nut (32) in place while you unscrew and
remove the bolt (33).

Tightening torque for nut (32) and bolt (33): 36


ftlb (50 Nm).
Š Retrieve the spacer (34). 30
Š Hold the nut (35) in place while you unscrew and
remove the bolt (36).
36

Tightening torque for nut (35) and bolt (36): 36


ftlb (50 Nm).
Š Hold the nut (38) in place while you unscrew and
remove the bolt (37).

Tightening torque for nut (38) and bolt (37): 36


ftlb (50 Nm).

41 38

Š Hold the nut (41) in place while you unscrew and


remove the bolt (42).

Tightening torque for nut (41) and bolt (42): 36


ftlb (50 Nm).

41
42

Š Use the special socket wrench (48) (code 8140203) to


loosen and remove the lock nuts (43 - 39).

43
Tightening torque for lock nuts (43 -39): 36 ftlb 42
(50 Nm).

37

39

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Š Unscrew the adjuster bushings (40 - 44) and slide them


up against the frame.

Tightening torque for adjustment bushings (40 - 48


44): 7.3 ftlb (10 Nm).

WARNING
During reassembly screw the adjustment bushings
(40 - 44) in by hand, and slide them up against the
engine; torque them to specifications.
43
Š Hold the nut (38) in place while you unscrew and
remove the bolt (37).
Š Hold the nut (41) in place while you unscrew and
remove the bolt (42).
Š Make sure the slings (29) are stretched taut.
Š Unscrew and remove the two bolts (45), saving the
washers (46).

Tightening torque for bolts (45): 29 ftlb (40 Nm ).


Š Recover the two spacers (47). 39

43

40
44

45

46 47
45 46

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ENGINE

DANGER
The engine is now free and not fastened anywhere.
29

Be extremely careful when moving it; watch your


fingers and limbs.
Clear the floor on which the engine is to be set down
of any tools and clean thoroughly. Failure to observe
this warning can lead to serious bodily injury.
Š Raise the hoist arm a few millimeters to “release” the
engine from the frame.
Š Lower the hoist arm until the engine is resting on the
ground.
Š Secure the engine so that it will not tip over even if
poorly balanced.
Š Unhook the slings (29) from the hoist.
Š Slide the slings (29) off the frame.
Š Move the engine out from underneath the frame.
Š Connect the slings (29) back to the engine.

NOTE If you will be working on the engine, set it on the


stand (8) (code 8140187 + 8140188).

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
Š 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.

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3.4 INSTALLING THE COMPLETE ENGINE IN


THE FRAME
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
NOTE To reinstall the complete engine on the frame,
follow the same procedure used for its removal in reverse
order, see 3.3 (REMOVING THE COMPLETE ENGINE
FROM THE FRAME).
Nonetheless, before commencing, you must first perform
the steps described below.

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
Š Make sure the adjuster bushings (1 - 2) and all the way
up against the frame. 1
Š 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.
Š Make sure that all nuts/bolts securing the engine are
properly torqued.
Š Top up coolant, see 2.14 (CHECKING AND TOPPING
UP THE COOLANT).
Š Top up engine oil, see 2.12 (CHECKING AND
TOPPING UP THE ENGINE OIL LEVEL).
Š 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.

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ENGINE

NOTES

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NOTES

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FUEL SYSTEM

FUEL SYSTEM
4

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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

3 4.7.1 GENERAL INFORMATION ................... 4-8-00


4.7.2 SENSORS.............................................. 4-9-00
4.7.3 INJECTION, SYSTEM DIAGRAM ....... 4-11-00
4.7.4 ELECTRONIC CONTROL UNIT.......... 4-12-00
4.7.5 AUTOMATIC TESTING ....................... 4-13-00
4 4.7.6 ROUBLESHOOTING IN THE
ELECTRONIC SYSTEM USING
DISPLAYED INFORMATION .............. 4-13-00
4.8 THROTTLE BODY .......................... 4-14-00

5 4.8.1 REMOVING THE THROTTLE BODY .. 4-14-00


4.8.2 REMOVING THE INJECTORS ............ 4-15-00
4.9 DISASSEMBLING THE THROTTLE
BODY ............................................. 4-16-00

6 4.10 INSPECTING THE THROTTLE BODY 4-17-00


4.10.1 TESTING THE INJECTORS ................ 4-17-00
4.10.2 THROTTLE BODY............................... 4-17-00
4.10.3 THROTTLE VALVE POTENTIOMETER 4-17-00
4.10.4 SYNCHRONIZING THE CYLINDERS . 4-18-00
7 4.10.5 ADJUSTING THE CO .......................... 4-19-00
4.10.6 ALIGNING THE THROTTLE VALVE
POSITION SENSOR ............................ 4-21-00

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FUEL SYSTEM

4.1 FUEL TANK


The refueling cap is at the top of the tank, while the
following are installed at the bottom:
Š The fuel pump unit;
Š The water drain tube, which drains away any water
accidentally introduced into the fuel line from rain or
while washing;
Š The overflow drain, which accommodates overflow
gasoline in the event of overfilling.

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

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Carefully read 1.3.9 (PRECAUTIONS AND GENERAL


INFORMATION), see 1.4.1 (FUEL).

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
Š 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
Š Replace the delivery filter (6).
NOTE During this procedure, it is also advisable to 1
wash the tank thoroughly.
2

4.1.2 CHECK THE FUEL INTAKE


Check the fuel lines every 4687 mi (7500 km) or every
8 months; replace every 4 years. 3 1
2
DANGER
Be especially thorough in checking the delivery line
(1), return line (2), and their fittings; the working
pressure of the delivery line (1) is approximately
65.2 PSI (450 kPa) (4.5 bar).
Any fuel lines that are cracked or split must always be
replaced.
If you find any fuel leaks from the flange (3), they may be
caused by a damaged O-ring (4), therefore:
Š Remove the complete pump assembly, see 4.3
(COMPLETELY REMOVING THE FUEL INTAKE
PUMP UNIT); check its condition and replace if
necessary.
NOTE For more information see 6.7.2 (CHECKING
THE FUEL PUMP).

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FUEL SYSTEM

4.2 DRAINING FUEL FROM THE TANK


To drain the fuel tank, see 2.9 (DRAINING FUEL FROM
THE TANK).

4.3 COMPLETELY REMOVING THE FUEL


INTAKE PUMP UNIT 1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.1 (FUEL) and 4.1.1
(MAINTENANCE).
Š Remove the fuel tank, see 7.1.6 (REMOVING THE
FUEL TANK COMPLETELY).

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.
Š Unscrew and remove the bolts (1).
NOTE When reassembling, insert all bolts by hand and
cross-tighten.
3

Tightening torque for bolts (1): 4.4 ftlb (6 Nm).

WARNING
When removing the pump assembly (2), be careful
not to damage the fuel level sensor (3) and lines.
Š 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).

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4.4 REMOVING THE FUEL LEVEL SENSOR


Š Remove the complete fuel intake pump unit, see 4.3
(COMPLETELY REMOVING THE FUEL INTAKE
PUMP UNIT).
Š Disconnect the electrical connector (1).
WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Š Use a screwdriver to help you remove the fuel level
sensor (2) from the support (3).
1

4.5 REMOVING THE FUEL DELIVERY FILTER


3
Š Remove the complete fuel intake pump unit, see 4.3
6
(COMPLETELY REMOVING THE FUEL INTAKE
PUMP UNIT). 1
Š Unscrew and remove the screw (6) to free the
grounding cable.
4
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind.
Š Release the click clamp (1-2).
Š Slide the hose (3) off the filter (4). 2
Š Slide the filter (4) off the hose (5). 5

WARNING
Do not re-use filters.
Š Replace the filter (4) with another of the same kind.

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FUEL SYSTEM

4.6 REMOVING THE FUEL INTAKE PUMP


Š Remove the complete fuel intake pump unit, see 4.3
(COMPLETELY REMOVING THE FUEL INTAKE 4
PUMP UNIT).
Š Disconnect the electrical connector (1).
WARNING 1
When reassembling, make sure the electrical
connector (1) is fitted properly.
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp 2
with a new one of the same kind.
3
Š Release the click clamp (2).
Š Slide the fuel hose (4) from the pump (3).
Š Unscrew and remove the three bolts (5).
WARNING
When performing the operations listed below, take
care not to stretch or twist the electrical wires.

Š 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.
Š Remove the filter element (7).
WARNING
If the filter element (7) show traces of sediment, clean
it using compressed air.
Š Use a screwdriver to help you slide it out from the side 3
opposite the fuel pump (3).

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FUEL SYSTEM RST mille USA

4.7 ENGINE MANAGEMENT

4.7.1 GENERAL INFORMATION


The “heart” of engine management system consists of
the electronic control unit (Engine Control Unit), which
manages and optimizes ignition and fuel injection.
Š Ignition is managed based on specific user data. The
electronic control unit detects the exact ignition angle
from the engine rpm signals and position of the throttle
valves (volume of air).
Š Injection time (amount of fuel) is controlled by engine
speed, the throttle valve position (which in turn controls
the volume of air used by the engine and the manifold
pressure) and is corrected by various correction factors
provided by the various sensors.
Š Every time the engine is switched on, the electronic
control unit checks the sensors and ignition coils,
making sure that they are functioning properly If any
errors are detected, the message “EFI” flashes on the
display.
Š The safety devices inside the electronic control unit
shut down both ignition and fuel injection if the engine
speed exceeds the maximum allowable of 10,500 rpm,
or if the vehicle falls over. When the vehicle is placed
on the side stand and the gears engaged, ignition is cut
off to prevent the vehicle from starting.
NOTE Any alterations or changes made to the exhaust
system, intake system or engine control unit can result in
serious damage to the engine. Any modification,
installation or use of non-original parts shall completely
void the warranty and relieve the manufacturer of any and
all liability.

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FUEL SYSTEM

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.

Atmospheric pressure sensor


Location: inside the electronic control unit (3).
3
This sensor is connected to the air gap via a small hose.
It is a piezoelectric sensor that measures the absolute air
pressure. The measurement point is located to greatly
limit changes in pressure caused by engine induction
processes. The nominal pressure within the air gap
corresponds to the atmospheric pressure. The air gap
pressure is used to compensate for load density changes
in the fuel system.

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Throttle position sensor (4)


Location: on the throttle body (5).
This sensor is a potentiometer, and for greater precision
its position is determined by comparing the output
voltage with the input voltage (rated 5 V).
Once the throttle is open, the output voltage from the
sensor increases in a linear fashion. The throttle is the
main driving control, which regulates the volume of air
admitted to the engine. The throttle angle is therefore
used to assess the load and determine whether the rider
wishes to accelerate or decelerate.

5 4

Engine temperature sensor (6)


6
The engine temperature sensor is a thermistor with a
negative temperature coefficient. This means that its
resistance decreases as the temperature increases. This
sensor is positioned to provide a precise indication of the
engine running temperature. The EMS compensates for
the various engine operating properties within different
engine temperature ranges. For example, a cold engine
will need a different amount of fuel for start-up compared
to a warm engine.

Air temperature sensor


Location: in the left air duct (7).
Air temperature affects the density of the incoming air,
thereby altering the actual load on the engine and thus
the amount of fuel needed. Compensation is necessary
to limit the risk of explosion caused by high air intake
temperatures.

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FUEL SYSTEM

4.7.3 INJECTION, SYSTEM DIAGRAM

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

Power ground pins


P1G4,P2G3,P2G4 P2 C4 Frame weight

- +

BATTERY

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4.7.4 ELECTRONIC CONTROL UNIT


For more information, see 6.6 (CONNECTIONS TO THE
ELECTRONIC CONTROL UNIT).

65 PINK WHITE
80 BROWN
52 YELLOW BLACK
55 BROWN GREEN
53 YELLOW BLACK 28 GREY WHITE
H G F E D C B A
51 ORANGE WHITE 47 BROWN PINK
1 1
50 GREEN LIGHT BLUE 27 BLUE ORANGE
2 2
49 ORANGE LIGHT BLUE
3 3
48 YELLOW BLUE
4 4
H G F E D C B A

20 BLUE GREEN 22 BLUE GREEN


54 BLACK 62 GREY

21 BLUE GREEN 23 BLUE GREEN

30 BLUE GREEN
WELDED TO THE SHIELDING OF
THE 2 CABLES AND PROTECTED
WITH HEAT-SHRINK FILM

40 PINK 36 RED BLACK

43 LIGHT BLUE 2 BLUE


41 PURPLE
35 PINK BLACK
42 YELLOW

H G F E D C B A
44 BLUE WHITE 1 RED
1 1
46 GREEN GREY
2 2
45 GREY RED
3 3
17 RED BROWN
4 4
H G F E D C B A

37 BROWN YELLOW

38 BROWN WHITE

19 BLUE GREEN
25 BLUE BLACK
26 PURPLE BROWN

31 BLUE RED 39 WHITE PURPLE

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FUEL SYSTEM

4.7.5 AUTOMATIC TESTING


See 6.5 (IGNITION/INJECTION SYSTEM).

4.7.6 ROUBLESHOOTING IN THE ELECTRONIC


SYSTEM USING DISPLAYED INFORMATION

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.
Š 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

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4.8 THROTTLE BODY

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.

4.8.1 REMOVING THE THROTTLE BODY


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 1
INFORMATION). 2
Š Partially remove the fuel tank, see 7.1.5 (PARTIALLY
REMOVING THE FUEL TANK).
Š Remove the air filter case, see 7.1.8 (REMOVING THE
AIR FILTER CASE).
Š Disconnect the electrical connectors:
- right injector (1);
- left injector (2);
- throttle valve potentiometer (3).

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.
Š Release the click clamps (4-5).
Š Pull the lines (7-8) from the throttle body (6).

8
5
7

Š Disconnect the two throttle cables (9-10).


9
WARNING
When reassembling make sure that the two throttle
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).

10

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FUEL SYSTEM

Š Remove the pressure regulator hose (11).


Š Loosen the two clamps (14-15).
WARNING
Be extremely careful when removing the throttle
body (6), since it remains attached to the fuel tank 14
(13) by means of the fuel hose (12).
Before removing the throttle body, you must
thoroughly clean the two intake flanges, to prevent 15
foreign matter from entering the cylinders.
Š Firmly grasp the throttle body (6), and gradually wiggle
it back and forth while pulling upward, until you are able
to slide it off the inlet manifolds.
Š Place the complete throttle body assembly (6) and fuel 11
tank (13), still attached together, on a clean surface.
Š Plug the inlet manifolds to prevent foreign matter from
entering the cylinders.

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).

4.8.2 REMOVING THE INJECTORS


See 4.8.1 (REMOVING THE THROTTLE BODY).
To check, see 6.6.1 (CHECKING THE INJECTORS).

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4.9 DISASSEMBLING THE THROTTLE BODY


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Empty all fuel from the tank, see 2.9 (DRAINING FUEL
FROM THE TANK). 2
Š Remove the complete throttle body, see 4.8.1
(REMOVING THE THROTTLE BODY).
Š Unscrew and remove the two screws (1). 1

Tightening torque for screws (1): 2.6 ftlb (3.5 Nm ).


3
Š Remove the fuel pressure regulator (2) complete with
O-ring (3), left injector (4) and O-ring (5). 4
5
Š Unscrew and remove the two screws (6).

Tightening torque for screws (6): 26 ftlb (3.5 Nm).


6
Š Remove the fuel line (7) complete with O-ring (8), right
injector (9), and O-ring (10).

10

8
9

Š Unscrew and remove the two screws (11).

Tightening torque for screws (11): 0.8 ftlb (1.2 Nm).


Š Remove the potentiometer (12). 11
NOTE Replace all seals during reassembly. These
components are supplied in the repair kit.
12
WARNING
The lever mechanism of the throttle body cannot be
disassembled or adjusted. If you encounter any
problems, replace the entire throttle body, see 4.8.1
(REMOVING THE THROTTLE BODY).

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FUEL SYSTEM

4.10 INSPECTING THE THROTTLE BODY

4.10.1 TESTING THE INJECTORS

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).

4.10.2 THROTTLE BODY

WARNING
Use only neutral cleansers.
Use only proprietary gasket removers, degreasers or
cleansers that do not require heating.
Š Clean all openings and passages in the throttle body
with compressed air.

4.10.3 THROTTLE VALVE POTENTIOMETER

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.
Š 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).
Š Tighten the two hex bolts M410x12 (2). 2

Tightening torque for bolts (2): 2.6 ftlb (3.5 Nm).


Š TTo line up the throttle position sensor (1), see 4.10.6
(ALIGNING THE THROTTLE VALVE POSITION
SENSOR).

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4.10.4 SYNCHRONIZING THE CYLINDERS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 1
INFORMATION), see 1.4.1 (FUEL).
The cylinders need to be synchronized when the engine
no longer idles smoothly. The cylinders must be
synchronized before adjusting the CO, see 4.10.5
(ADJUSTING THE CO).
Š Ride a few miles until the engine reaches normal
running temperature.
4
WARNING
The cylinders must be synchronized when the engine
is warm: 5
Š coolant temperature 167-194 °F (75-90 °C);
Š ambient temperature 68-86 °F (20-30 °C).
NOTE Have the vacuum gauge (1) ready (code
8140256).

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.
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Š Pull out the two free tubes (2) on the left side of the
motorcycle, under the side panel.
Š Unplug the two free transparent lines (2) and connect
them to those of the vacuum gauge (1), using two 6-
mm fittings.
Š Completely close the two by-pass screws (3) on the
throttle body.
Š Start the vehicle and read the value for the front
cylinder on the vacuum gauge (1), with valve (4) open
and valve (5) closed.
Š Close the valve (4) and open the valve (5) on the
vacuum gauge (1), and read the pressure value for the
rear cylinder.
Š If the values are different between the two cylinders,
adjust one or both of the by-pass screws (3) to
synchronize.
Š 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.

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FUEL SYSTEM

4.10.5 ADJUSTING THE CO


Š Remove the radiator spoiler, see 7.1.35 (REMOVING 2
THE RADIATOR SPOILER).

WARNING
The CO must be adjusted when the engine is warm.
Š 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.
Š 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).
Š 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).
Š Make sure that the idle speed is 1250 ± 100 rpm. If not,
adjust as needed, see 2.11.2 (ADJUSTING THE IDLE 6
SPEED).
Š 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.
Š Insert the “OBD” module (7) in the Axone 2000.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Connect the Axone 2000 (5) via the connector (6)
under the saddle, and power the Axone 2000 (5) using
the vehicle battery.
Š Start the procedure from the rear cylinder.
Š Use the red on/off button to switch on the Axone 2000 UP ARROW
(5).
Š Select the Autotest icon on the display and press the BACK
ENTER
enter key. LEFT ARROW RIGHT ARROW
Š The next screen shows a series of data regarding the
DOWN ARROW
various control unit parameters.
"+" KEY
Š Press the + or – key, then use the UP and DOWN
arrows to select the item “Idle fuelling adjustment”, and "-" KEY
press enter. ON / OFF

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ŠA parameter appears at the top of the display in


percentage form, which should not be compared to the 2
CO value reading provided by the exhaust gas
analyzer (1).
Š Use the UP and DOWN arrows to change the
instrument parameter: if the value increases, the
injection time also increases, providing a richer blend
and thus increasing the value of CO; vice-versa, if the 1
parameter is reduced, the CO value falls.

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).

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FUEL SYSTEM

4.10.6 ALIGNING THE THROTTLE VALVE POSITION


SENSOR 1
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Connect the Axone 2000 (1) via the connector (2)
under the saddle, and power the Axone 2000 (1) using
the vehicle battery.
Š Start the vehicle.
Š Use the red on/off button to switch on the Axone 2000
(1).
Š Select the Autotest icon on the display and press the
enter key.
Š The next screen shows a series of data regarding the
various control unit parameters.
Š Press the "+" or "–" key, then use the UP and DOWN
arrows to select the item “Closed Throttle Position”,
and press enter.
Š A throttle valve alignment reference parameter appears
at the top of the display; use the UP arrow to increase
the value of the parameter until it stabilizes, at which
point the control unit acknowledges a stable idle
condition and enters the adaptive phase.
Š Press the enter key and exit the procedure.

UP ARROW

BACK
ENTER
LEFT ARROW RIGHT ARROW

DOWN ARROW
"+" KEY

"-" KEY
ON / OFF

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NOTES

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COOLING SYSTEM

COOLING SYSTEM 5

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COOLING SYSTEM RST mille USA

COOLING SYSTEM

TABLE OF CONTENTS
5.1 DESCRIPTION ................................. 5-3-00

0 5.2 REMOVING THE RADIATORS ......... 5-5-00


5.3 REMOVING THE ELECTRIC COOLING
FANS ............................................... 5-6-00
5.4 REMOVING THE COOLANT

5 THERMISTORS ................................ 5-7-00


5.5 REMOVING THE THERMOSTAT ...... 5-8-00
5.6 REMOVING THE FILLER NECK ....... 5-8-00

2 5.7 REMOVING THE THREE-WAY


MANIFOLD....................................... 5-9-00
5.8 REMOVING THE EXPANSION TANK. 5-9-00

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COOLING SYSTEM

5.1 DESCRIPTION The expanded volume of coolant, caused by the increase


in temperature, is compensated for by the expansion
The centrifugal coolant pump, which is positioned inside
tank.
of and driven by the engine, draws cooled coolant from
Refer to the “LOW” and “FULL” reference marks to check
the radiators, and distributes it throughout the various
and top up the coolant, see 2.14 (CHECKING AND
cooling galleries in the cylinders and heads to maintain
TOPPING UP THE COOLANT). For more information
the engine and its internal parts at the proper
about coolant, see 1.3.7 (COOLANT).
temperature.
The path of the coolant leaving the engine varies,
depending on coolant temperature, and is illustrated
below.

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

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COOLING SYSTEM RST mille USA

Path with coolant temperature below 167 °F (75°C).


From the pump, coolant enters the engine (temperature
taken by thermistors and shown on the right-hand
dashboard display). Coolant leaves the engine (right-
hand side) to the thermostat (completely closed), and B
back to the pump.

A C

Path with coolant temperature between 167 °F (75°C)


and 176 °F (80°C).
From the pump, coolant enters engine (temperature
taken by thermistors and shown on the right-hand B C D
dashboard display). Simultaneously, coolant leaves the
engine (right-hand side) and flows directly to the
thermostat; to the left radiator three-way manifold; and to B1
the right radiator thermostat (gradually opening), then
back to the pump. A E
G F

Path with coolant temperature greater than 176 °F


(80°C).
From the pump, coolant enters engine (temperature
taken by thermistors and shown on the right-hand
dashboard display). Coolant leaves the engine to three- A B C
way manifold (temperature taken by thermal switch: if
greater than 212 °F (100°C), it trips the electric fans; if
below 185 °F (85°C), shuts off the fans), to left radiator, to
right radiator, to thermostat (completely open), to pump. G D
WARNING F E
When the ignition switch is set to “ “, the electric
fans switch off regardless of the coolant
temperature.

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COOLING SYSTEM

5.2 REMOVING THE RADIATORS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.7 (COOLANT). 3
NOTE The following steps refer to a single radiator, but 1
are applicable to both.
Š Set the ignition switch to “ “.
Š Completely discharge the cooling circuit, see 2.15
(CHANGING THE COOLANT).
Š Disconnect the electrical connector (1). 2

WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Š Remove the radiator spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).
Š Remove both lower fairings, see 7.1.33 (REMOVING
THE LOWER FAIRING). 6
Š Remove both air ducts,see 7.1.30 (REMOVING THE
LEFT AIR DUCT) and 7.1.31 (REMOVING THE 4
RIGHT AIR DUCT).
Š Loosen and remove the click clamp (2).
Š Slip the coupling (3) off the radiator (4).
Š Loosen and remove the click clamp (5).
Š 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
Š Release the click clamp (7).
Š Slide the hose (8) off the radiator (4).
Š 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.
Š Tilt the radiator (4) slightly forward while lifting,
extracting the two lower anchorage pins (12-13) from
their recess on the radiator mount (11).
Š 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:
Š 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

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COOLING SYSTEM RST mille USA

5.3 REMOVING THE ELECTRIC COOLING


FANS
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
1
NOTE The following steps refer to a single fan, but are
applicable to both.
Š Set the ignition switch to “ ”.
Š Remove the left fairing in question, see 7.1.28
(REMOVING THE SIDE FAIRINGS).
Š Disconnect the electrical connector (1).
WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Š Unscrew and remove the two screws (2).
3
Tightening torque for screws (2): 4.4 ftlb (6 Nm ).
Š Recover the two nuts (3).
Š Tilt the complete electric fan (4) slightly back and, at
the same time, move it outwards, pulling the internal 2
holding pin from its seat on the radiator (5).
Š Remove the electric fan (4).
NOTE Replace the grommet (6) if you find it to be 3 2
damaged.
If necessary:
Š Unscrew and remove the four screws (7), saving the
washers.

Tightening torque for screws (7): 0.7 ftlb (1 Nm).


Š Slide out the grating protecting (8) the electric fan
motor (9). 6
NOTE Also remove the other fan if necessary.
For more information about the electric fans, see 6.9
(ELECTRIC COOLING FANS).
5

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RST mille USA
COOLING SYSTEM

5.4 REMOVING THE COOLANT


THERMISTORS.
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.4.6 (COOLANT).
NOTE The following steps refer to a single thermistor,
but are applicable to both.
3
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Š Loosen the two clamps (1-2).
WARNING 1 2
Be extremely careful when removing the throttle
body (3), since it remains attached to cables and
lines.
Š Firmly grasp the throttle body (3), complete with air
filter case, and gradually lift and slide it off the intake
flanges. 5
Š Move away and set the group on the left-hand side of
the vehicle.
Š Disconnect the electrical connector (4).
WARNING
When reassembling, make sure the electrical
connector (4) is fitted properly.
Š Unscrew and remove the thermistor (5).
Š Prepare a new thermistor and apply LOCTITE® 574 on
its thread.
Š Screw on the new thermistor (5) by hand, and tighten. 4
Š If any coolant spilled during removal, once the
operation is complete top up the coolant level, see 2.14
(CHECKING AND TOPPING UP THE COOLANT).
NOTE Where necessary, remove the other thermistor.
For more information about the thermistors, see 6.6.5
(CHECKING THE COOLANT THERMISTORS
OPERATION).

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COOLING SYSTEM RST mille USA

5.5 REMOVING THE THERMOSTAT


6
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.7 (COOLANT).
Š Completely
discharge the cooling circuit, see 2.15 4
(CHANGING THE COOLANT).
3
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind.
7
Š Release the click clamp (1). 2
Š Pull the hose (2) from the thermostat (3).
Š Loosen the clamps (4-5). 1
Š Firmly grasp the thermostat (3) and pull it free of the 5
two hoses (6-7) by wiggling the hoses back and forth.

WARNING
Plug all the coupling openings to prevent any foreign
matter from accidentally entering.

5.6 REMOVING THE FILLER NECK


6
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
1
INFORMATION) and 1.3.7 (COOLANT).
Š Completely
discharge the cooling circuit, see 2.15 7
(CHANGING THE COOLANT).
NOTE Use the special click clamp installation pliers 4
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind. 8
3
Š Release the click clamps (1-2).
Š Pull the hoses (3-5) from the filler neck (4).
2
WARNING
Plug all the hose openings (3-5) to prevent any 5
foreign matter from accidentally entering.
Š Loosen and remove the click clamp (6).
Š Slip the coupling (7) off the filler neck (4).
Š Unscrew and remove the screw (8) and recover the
bushing.
Š Remove the filler neck (4).

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RST mille USA
COOLING SYSTEM

5.7 REMOVING THE THREE-WAY MANIFOLD


5 6
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 1.3.7 (COOLANT).
3
Š Carry out the first four steps described in paragraph
4
5.4 (REMOVING THE COOLANT THERMISTORS.).
Š Completely discharge the cooling circuit, see 2.15 7
(CHANGING THE COOLANT). 1 2

NOTE Use the special click clamp installation pliers 8


(code 0277295); during reassembly, replace each clamp
with a new one of the same kind.
9
Š Release the click clamps (1-2-3).
Š Pull the three hoses (4-5-6) from the manifold (7).
Š Loosen and remove the click clamp (8) downward.
Š Firmly grasp the manifold (7) and slide it off the hose
(9), wiggling it back and forth as you pull.

WARNING
Plug all the coupling openings to prevent any foreign
matter from accidentally entering.

5.8 REMOVING THE EXPANSION TANK


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 2
INFORMATION) and 1.3.7 (COOLANT).
Š Remove the right fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind. 1 3
Š LLoosen and remove the click clamp (1).
Š Pull the hose (2) from the filler neck (3).
Š Bend the hose (2) back on itself, and tape it to the top
of the expansion tank.
Š Unscrew and remove the two fastening screws (4-5)
and retrieve the two bushings.
Š Remove the expansion chamber (6), keeping it straight.
Š If the inner and outer foam edging is damaged, replace 5
it.

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

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COOLING SYSTEM RST mille USA

NOTES

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RST mille USA
ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
6

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ELECTRICAL SYSTEM RST mille USA

ELECTRICAL SYSTEM 6.8.7 CHECKING THE SAFETY SYSTEM


SWITCHES .......................................... 6-27-00
6.9 ELECTRIC COOLING FANS ........... 6-28-00
TABLE OF CONTENTS 6.9.1 WIRING DIAGRAM.............................. 6-28-00
6.9.2 CHECKING THE ELECTRIC FAN
6.1 LOCATIONS OF ELECTRICAL OPERATION ........................................ 6-28-00
COMPONENTS................................. 6-3-00 6.10 DASHBOARD INDICATORS ........... 6-29-00
0 6.2 INTRODUCTION .............................. 6-5-00 6.10.1 WIRING DIAGRAM.............................. 6-29-00
6.10.2 AIR TEMPERATURE SENSOR........... 6-30-00
6.2.1 WIRE COLORS...................................... 6-5-00
6.2.2 ELECTRICAL CONNECTORS .............. 6-5-00 6.10.3 ENGINE OIL PRESSURE SENSOR.... 6-31-00
6.10.4 SPEED SENSOR ................................. 6-32-00
6.3 CHECKING THE RECHARGING
6 SYSTEM........................................... 6-6-00
6.3.1 CHECKING THE RECHARGING
6.10.5 FUEL LEVEL SENSOR ....................... 6-33-00
6.10.6 COOLANT TEMPERATURE SENSOR 6-34-00

VOLTAGE .............................................. 6-6-00 6.11 LIGHT SYSTEM ............................. 6-35-00


6.3.2 CHECKING THE OPEN-CIRCUIT 6.11.1 WIRING DIAGRAM.............................. 6-35-00

2 ALTERNATOR OPERATION ................ 6-6-00


6.3.3 RECHARGING SYSTEM DIAGRAM..... 6-7-00
6.3.4 CHECKING ALTERNATOR CONTINUITY 6-7-00
6.11.2 CHECKING THE LIGHT RELAY ......... 6-36-00
6.12 WARNING LIGHTS AND BUZZERS 6-37-00
6.12.1 WIRING DIAGRAM.............................. 6-37-00
6.3.5 CHECKING THE VOLTAGE
6.12.2 HORN TEST......................................... 6-38-00
REGULATOR......................................... 6-8-00
6.12.3 FLASHER TEST .................................. 6-38-00
3 6.4 INJECTION SYSTEM ....................... 6-9-00
6.4.1 FUEL INJECTION WIRING DIAGRAM . 6-9-00
6.13 WARNING LIGHTS AND BUZZERS 6-39-00
6.13.1 WIRING DIAGRAM.............................. 6-39-00
6.4.2 TROUBLESHOOTING........................... 6-9-00
6.13.2 SWITCHES .......................................... 6-40-00
6.4.3 CHECKING THE INJECTION RELAY. 6-10-00

4 6.4.4 CHECKING THE OVERTURN SENSOR 6-10-00


6.5 IGNITION/INJECTION SYSTEM .... 6-11-00
6.14 BATTERY....................................... 6-41-00
6.14.1 ACTIVATING THE BATTERY ............. 6-41-00
6.14.2 MAINTENANCE................................... 6-43-00
6.5.1 TROUBLESHOOTING......................... 6-12-00
6.14.3 CHECKING .......................................... 6-43-00
6.5.2 FAULT SITUATIONS........................... 6-12-00
6.14.4 RETURN UNDER WARRANTY........... 6-43-00
6.5.3 VERIFYING FAULT CODES ............... 6-12-00
5 6.5.4 TROUBLESHOOTING IN THE
ELECTRONIC SYSTEM USING
6.15 REPLACING THE BULBS............... 6-44-00
6.15.1 REPLACING THE HEADLIGHT BULBS 6-44-00
DISPLAYED INFORMATION .............. 6-13-00 6.15.2 REPLACING THE FRONT DIRECTION
6.6 CONNECTIONS TO THE ELECTRONIC INDICATOR LAMPS............................ 6-46-00

6 CONTROL UNIT............................. 6-14-00


6.6.1 CHECKING THE INJECTORS ............ 6-16-00
6.15.3 REPLACING THE TAILLIGHT BULBS 6-46-00
6.15.4 REPLACING THE LICENSE PLATE
LIGHT BULBS ..................................... 6-47-00
6.6.2 CHOKE MOTOR .................................. 6-16-00
6.6.3 CHECKING THE THROTTLE VALVE 6.16 CHANGING FUSES ........................ 6-48-00
POTENTIOMETER .............................. 6-17-00
7 6.6.4 CHECKING THE AIR THERMISTOR
OPERATION ........................................ 6-18-00
6.17 ADJUSTING THE HEADLIGHT BEAM
VERTICALLY ................................. 6-49-00
6.6.5 CHECKING THE COOLANT 6.18 ADJUSTING THE HEADLIGHT BEAM
THERMISTORS OPERATION............. 6-19-00 HORIZONTALLY ............................ 6-49-00

8 6.6.6 CHECKING THE IGNITION COILS ..... 6-20-00


6.6.7 CHECKING THE CRANKSHAFT
POSITION SENSOR ............................ 6-20-00
6.19 WIRING DIAGRAM - RST MILLE
FUTURA......................................... 6-50-00

6.7 FUEL PUMP SYSTEM .................... 6-21-00


6.7.1 WIRING DIAGRAM.............................. 6-21-00
9 6.7.2 CHECKING THE FUEL PUMP ............ 6-22-00
6.7.3 CHECKING THE FUEL PUMP RELAY 6-22-00
6.8 IGNITION SAFETY SYSTEM.......... 6-23-00
6.8.1 WIRING DIAGRAM.............................. 6-23-00
6.8.2 STARTING SAFETY OPERATING
LOGIC .................................................. 6-24-00
6.8.3 CHECKING THE START RELAY........ 6-24-00
6.8.4 CHECKING THE DIODE...................... 6-25-00
6.8.5 CHECKING THE SIDE STAND SWITCH 6-26-00
6.8.6 CHECKING THE DIODE MODULE ..... 6-26-00

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RST mille USA
ELECTRICAL SYSTEM

6.1 LOCATIONS OF ELECTRICAL COMPONENTS

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

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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

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ELECTRICAL SYSTEM

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.

6.2.1 WIRE COLORS


Ar orange
Az light blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple

6.2.2 ELECTRICAL CONNECTORS


Disconnect two electrical connectors as follows:
Š Press the safety latches, if provided.
WARNING
Do not pull on the wires to disconnect the two
connectors.
Š Grasp the two connectors and disconnect them by
pulling in opposite directions.
Š If you see any dirt, rust, moisture, etc., carefully clean
the inside of the connector using compressed air.
Š Make sure that the cables are correctly crimped to the
terminals placed inside the connectors.
NOTE The connector are keyed to ensure that they are
properly assembled.
Š If the connectors are properly connected, you will hear
the typical "click" sound for those connectors equipped
with safety latch.

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ELECTRICAL SYSTEM RST mille USA

6.3 CHECKING THE RECHARGING SYSTEM

6.3.1 CHECKING THE RECHARGING VOLTAGE


Š Check the battery voltage, see 2.4.2 (RECHARGING
THE BATTERY).
Š Start the engine and rev it to 4000 rpm.
Š Set the light switch to “ “ and the light dimmer to “ “ .
Š Set the light dimmer to “ “.
Š Use a tester to measure the DC voltage between the
positive (+) and negative (–) terminals of the battery.
If the tester indicates voltages below 13 V or above 15 V:
Š Check the open-circuit operation and continuity of the
alternator, see 6.3.2 (CHECKING THE OPEN-
CIRCUIT ALTERNATOR OPERATION), 6.3.4
(CHECKING ALTERNATOR CONTINUITY) and the
voltage regulator, see 6.3.5 (CHECKING THE
VOLTAGE REGULATOR). 5
Wiring diagram legend
4
NOTE For the positions of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).
1) Battery 3 2
2) Main fuses (30 A)
3) Alternator
4) Voltage regulator
5) Ignition switch ( - - - )
Standard charge voltage: 13 - 15 V (DC) at 4000 rpm.
1

6.3.2 CHECKING THE OPEN-CIRCUIT


ALTERNATOR OPERATION
Š Remove the left lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Disconnect the three-way connector (1) (brown)
voltage regulator cables.

WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Š Start the engine and rev it to 4000 rpm. 1
Š 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.

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RST mille USA
ELECTRICAL SYSTEM

6.3.3 RECHARGING SYSTEM DIAGRAM

Regulator
Flywheel

30 A + Battery
+
Main Fuse

Secondary
A B fuses

Clock Gasoline
headlight pump

6.3.4 CHECKING ALTERNATOR CONTINUITY


With the engine off:
Š Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Disconnect the three-way connector (1) (brown)
voltage regulator cables.

WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
1
Š 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): ∞.

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ELECTRICAL SYSTEM RST mille USA

6.3.5 CHECKING THE VOLTAGE REGULATOR


Š Remove the lower fairing, see 7.1.33 (REMOVING 2
THE LOWER FAIRING).
Š Disconnect the three-way connector (1) (brown).
Š Disconnect the six-way connector (2) (white).
WARNING
When reassembling, make sure the electrical
connectors (1-2) are fitted properly.
Š Use a tester (scale x 1MΩ) to measure the resistance
between the cables indicated in the table below, from
the regulator side (internal male terminals). 3
NOTE There are two green (V) and two red/white (Bi/ 1
R) wires. The two green wires are connected together,
and the two red/white wires are connected together.
Measurements may be made using either of the two
green, and either of the two red/white wires.

Positive terminal (+) of the tester on:

G G G V R/Bi

G ∞ ∞ 2-∞ ∞
Negative terminal (-)

G ∞ ∞ 2-∞ ∞
of the tester on:

G ∞ ∞ 2-∞ ∞

V ∞ ∞ ∞ ∞

R/Bi 2 - ∞ 2-∞ 2-∞ 3-∞

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).

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RST mille USA
ELECTRICAL SYSTEM

6.4 INJECTION SYSTEM

6.4.1 FUEL INJECTION WIRING DIAGRAM

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
Š Make sure that the 30-A main fuse and the 15-A fuse
“D” are intact.
Š 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).
Š Make sure the engine stop relay is in good working
order, see 6.7.3 (CHECKING THE FUEL PUMP
RELAY).
Š Check the injection relay, see 6.4.3 (CHECKING THE
INJECTION RELAY).
Š Check the overturn sensor, see 6.4.4 (CHECKING
THE OVERTURN SENSOR).

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ELECTRICAL SYSTEM RST mille USA

6.4.3 CHECKING THE INJECTION RELAY


To check the relay:
Š Remove the left fairing, see 7.1.28 (REMOVING THE - +
SIDE FAIRINGS). 12V
Š Power the two male terminals (85-86) with a voltage of
12 V.
Š Use a tester (in ohm meter mode) to check the + -
:
continuity between the other two terminals (87-30). 30
Correct value with relay energized: 0 Ω 87
Correct value with relay not energized: ∞ Ω
85 86
If the values do not match those indicated, replace the
relay in question.

WARNING
Observe the polarity, connecting the “+” pole to
terminal (86) and the “-” pole to terminal (85); there is
a diode inside.

6.4.4 CHECKING THE OVERTURN SENSOR A


Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).

WARNING
Have ready a bulb, max. 12 V/2W
Š Prepare a circuit like the one shown in the figure.
Š Close the switch “A” with the sensor set to horizontal; B
the bulb “B” will light.

Š Tilt the sensor by an angle greater than 60°; the bulb


should turn off.
Š Repeat the operation for the other side of the sensor. ˚ 60˚
To turn the bulb back on, open and close the switch “A”. 60
NOTE If the sensor does not work as described above,
replace it with a new one of the same type.

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ELECTRICAL SYSTEM

6.5 IGNITION/INJECTION SYSTEM

M/G B3(N) H1(Gr) Ar/Bi


M/Bi E3(N)
2 B/R 15
E4(N)

Ro/N H2(Gr) V/Az


B2(N)
3 14

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

7(12WAY) 9(12WAY) 10(12WAY)

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

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ELECTRICAL SYSTEM RST mille USA

6.5.1 TROUBLESHOOTING
Š Place the vehicle on the stand.
Š Set the ignition switch to “ “.
Š The message “ “ will appear on the display for
approximately three seconds.
Š If the LED “ “ turns off, the control unit has not found
any faults.

6.5.2 FAULT SITUATIONS


Š If the message “ “ remains lit and the message “off”,
even after carrying out the operations described in
paragraph 6.5.1 (TROUBLESHOOTING), the battery
is probably low.
Š if the message “ “ remains lit, even after carrying out
the operations described in paragraph 6.5.1
(TROUBLESHOOTING), the engine may be switched
on but will not start.
Š if the message “ “ continues to flash even after you
have carried out the operations described in 6.5.1
(TROUBLESHOOTING), proceed with checking the
sensors.

6.5.3 VERIFYING FAULT CODES


Š Raise the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Connect together the two TEST connectors (1), located
on the right-hand side of the motorcycle.
Š Check on the dashboard, in the clock face, to see 1
which numerical indications appear.
Š Check the following table to determine which problem
each fault code refers to.

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ELECTRICAL SYSTEM

FAULT CODE TABLE:

FAULT CODE COMPONENT CAUSE


Crankshaft position sensor – Sensor not connected.
12
(pick-up) – Sensor broken.
– Faulty wiring.
15 Throttle position sensor (TPS)

21 Engine temperature sensor

22 Air temperature sensor


23 Barometric pressure sensor Sensor faulty.

33 Coil 1 Coil not working or not wired


34 Coil 2
35 Coil 3

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).

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6.6 CONNECTIONS TO THE ELECTRONIC


CONTROL UNIT
NOTE For the locations of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).
For more information see 4.7.4 (ELECTRONIC
CONTROL UNIT).

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

NOTE The abbreviations (y) and (z) that appear


alongside the numbers in the diagram, mark
corresponding terminals on both connectors.
Y) Electronic control unit connector (26-way).
Z) Electronic control unit connector (16-way).

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Position Component Connector Terminal # Rated value Wire Color


P1 D4 Bi/Vi
9 Dashboard
P2 A1 M/Ro
15 Overturn sensor P2 E1 Ro/Bi
16 Fuel pump relay P2 E1 – Ro/Bi
P2 C2 M/V
25 Diode module
P2 D2 M
26 Clutch switch P2 C2 M/V
27 Neutral gear switch P2 D2 M
28 Side stand P2 C2 M/V
30 Start relay – – –
33 TEST connectors P2 D3 – Gr
Crankshaft position P1 B1 Bi/G
36 150 - 300 Ω
sensor P1 A1 B/G
P1 H4 M/R
39 Injection relay
P2 F3 N
Purge Valve (Calif P1 G1 M/Vi
40
only) P1 H4 M/R
Rear cylinder P1 H4 M/R
41 11 - 17 Ω
injector P1 H2 V/Gr
Front cylinder P1 H4 M/R
42 11 -17 Ω
injector P1 H3 Gr/R
P1 H4 M/R
43 Electric fans P2 G2 G/N
P2 G1 G/N
45 Gasoline pump P1 H1 B/Bi
P1 E4 B/R
46 Air thermistor –
P1 D1 R/N
P1 E4 B/R
47 Coolant thermistor 1,9 - 2,9 kΩ
P1 B2 Ro/N
P1 E4 2,8 - 3,4 kΩ B/R
Throttle valve
48 P1 E3 (variable depending M/Bi
potentiometer
P1 B3 on the angle) M/G
P1 H4 M/R
49 Rear cylinder coil 4-5Ω
P2 H4 G/B
P1 H4 M/R
50 Rear cylinder coil 4-5Ω
P2 H3 Ar/Az
P1 H4 M/R
51 Front cylinder coil 4-5Ω
P2 H2 V/Az
P1 H4 M/R
52 Front cylinder coil 4-5Ω
P2 H1 Ar/Bi
P1 F1 Az
P1 F2 G
54 Engine idle setting
P1 E2 Vi
P1 E1 Ro
P1 G4 B/V
P1 B4 B/N
Diagnostic
63 P1 F4 Vi/M
connector
P2 A2 B/Ar
P2 B2 Gr/Bi

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6.6.1 CHECKING THE INJECTORS


1 2
With the engine off:
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
NOTE The following steps refer to a single injector, but
are applicable to both.
Š Disconnect the two-way connector (1) (black) and
measure (on the injector side terminals).
Š Use a tester (scale x100 Ω), to measure the resistance
between the injector terminals.
2
Standard value: 11.5 – 13 Ω at 20 °C (68 °F).
If the resistance is infinite (∞) or below the
prescribed value, the injector (2) must be replaced.
Š Repeat the operations for the other injector.

6.6.2 CHOKE MOTOR


Š Raise the air filter case, see 7.1.8 (REMOVING THE
AIR FILTER CASE).
NOTE The stepper motor opens and closes the air
passages, to alter the air/gasoline mixture as needed.
Make sure the stepper motor (2) is working properly:
Š Unscrew and remove the two screws (1) and detach it 2
from the filter case.
Š Set the key to “ “ and then immediately to “ “. After
you have set the key to “ “, the white cylinder comes
1 1
all the way out (approximately 1.12 in), then returns in
by a few millimeters (approximately 0.77 in), performing
an automatic setting.
Š If this does not occur, check using a tester as an ohm
meter to measure the resistance between the two coils:
– between pins A and D, correct measurement: 50 Ω
±10%;
– between pins B and C, correct measurement: 50 Ω
±10%;
– between the other pins, infinite resistance (∞).

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6.6.3 CHECKING THE THROTTLE VALVE


POTENTIOMETER 1
With the engine off:
2

Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL


TANK).
Š Disconnect the three-way connector (black) (1).
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Š Set the ignition switch to ” ”.
Š Use a tester (scale Ω) to measure the resistance
between the terminals of the potentiometer (2). 3
MEASUREMENT (A)
Resistance between the two terminals A and B,
regardless of the position of the throttle valves:
Standard value: 1.2 kΩ ± 10%.
MEASUREMENT (B)
Resistance between the terminals, A and C:
With throttle valves completely closed, accelerating
gradually until they are fully open, the resistance will
change as follows.
Standard value: from 1.2 kΩ to 2.4 kΩ ± 10%.
NOTE To make it easier to unscrew the two screws (3),
which are cemented with LOCTITE® 243, heat them first
with a blast of warm air.
Š Unscrew and remove the screws (3).
Š Remove the potentiometer (2).
If the resistance values differ from those prescribed,
replace the potentiometer (2).

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6.6.4 CHECKING THE AIR THERMISTOR


OPERATION 1
Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Disconnect the two-way connector (1) (green).
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Š Remove the thermistor (2).
Š As shown in the figure, connect a tester (3) (in ohm
meter mode) to the thermistor (2).
Š Immerse the thermistor (4) in a container (3) of water.
Š In the same container, immerse a thermometer (5) with
a range of 0 -150°C (32 -302°F).
Š Place the container on a burner (6) and slowly heat the
fluid. 5
Š Check the temperature shown on the thermometer (5)
and the thermistor value shown on the tester.
Make sure that the value changes based on temperature,
as indicated.
+ -
:
Water temperature Standard values
(°C) (°F) (W) (± 10%) 4
2
0 32 5457 3
20 68 2375 6
40 104 1111
60 140 563,8
80 176 306,4
100 212 176,7
If the values do not change, or differ too much from
those given in the table, replace the thermistor (2).

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6.6.5 CHECKING THE COOLANT THERMISTORS


OPERATION
NOTE The temperature measured by the front cylinder
thermistor (right side) is sent to the right display; the one
measured by the rear cylinder thermistor (left side) is
sent to the electronic control unit.
Š Remove the thermistor (1), see 5.4 (REMOVING THE
COOLANT THERMISTORS.).
Š As shown in the figure, connect a tester (2) (in ohm
meter mode) to the thermistor (1). 1
Š Immerse the thermistor (1) in a container (3) containing
coolant.
Š In the same container, immerse a thermometer (4) with
a range of 0 -150°C (32 -302°F).
Š Place the container on a burner (5) and slowly heat the
fluid.
Š Check the temperature shown on the thermometer (4) 4
and the thermistor (1) value shown on the tester.
Make sure that the value changes based on temperature,
as indicated.

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).
Š Repeat the operations for the other thermistor.

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6.6.6 CHECKING THE IGNITION COILS


Š Remove the fuel tank, see 7.1.6 (REMOVING THE
FUEL TANK COMPLETELY).
NOTE The following steps refer to a single coil, but are
valid for all.
Š Disconnect the connector (1) from the coil ignition (2).
WARNING
When reassembling, make sure the electrical
2
connector (1) is properly connected. 1
Š Pull the cable from the coil (2).
Š Use a tester to measure (A) and (B) as shown in the
figure.
It is necessary to check the continuity of the primary and
secondary windings.
It is not necessary that the Ohm reading be precise, but if
the windings are intact, the resistance values must
approximately match those indicated. A B
Standard values:
measurement (A): 0.6 Ω ± 10% - + - +
: :
measurement (B): 10 kΩ ± 10%

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.
Š Repeat the operations for the other coils.

6.6.7 CHECKING THE CRANKSHAFT POSITION


SENSOR
With the engine off:
Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Disconnect the two-way connector and take the
measurements directly on the sensor.
Š Use a tester (scale x 1000 Ω) to measure the - +
resistance between the terminals of the sensor, :
observing the polarity as shown in the figure.
Standard value: 560 Ω ± 10%
Š If the resistance is infinite or different from the
prescribed value, the sensor must be replaced.

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6.7 FUEL PUMP SYSTEM

6.7.1 WIRING DIAGRAM


NOTE For the positions of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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

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6.7.2 CHECKING THE FUEL PUMP


To check the pump operation:
1
Š Remove the lower dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Open the cover (3) of the secondary fuse box.
Š Make sure that the fuse (1) is intact.
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
3

Š Disconnect the four-way connector (2) located on the


left-hand side of the vehicle.
2
WARNING
When reassembling, make sure the connector (2) is
fitted properly.
Š Connect the positive (+) green (V) and negative (-) blue
(B) wires (on the pump assembly side) to a 12-VDC
battery.
Š Make sure that the pump works properly and emits its
usual hum. Check the pressure gauge to make sure
the intake pressure is at least 50.76 PSI (350 kPa) (3.5
bar).

6.7.3 CHECKING THE FUEL PUMP RELAY 2


To check the relay:
Š Disconnect the four-way connector (1) (white) from the
relay (2).

WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.

Š Connect the two internal male terminals (A-B) to a 12 V


battery.
Š Use a tester (in ohm meter mode) to check the
continuity between the other two terminals (C-D).
Correct value with relay energized: 0 Ω
Correct value with relay not energized: ∞ Ω
If the values do not match those indicated, replace
the relay (2).
If all components are working properly, also check:
- overturn sensor, see 6.4.4 (CHECKING THE
OVERTURN SENSOR).
- Wiring is correct.

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6.8 IGNITION SAFETY SYSTEM

6.8.1 WIRING DIAGRAM


NOTE For the positions of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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

Wiring diagram legend


8) Diode module
9) Switch on clutch lever
10) Neutral gear switch
12) Starter button
16) Start relay
17) Starter motor
18) Battery
29) Secondary fuses (15A)
58) Stand down LED
59) Gear in neutral LED
70) Side stand switch
A) To battery / ignition switch
B) To the secondary fuses (15 A)

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6.8.2 STARTING SAFETY OPERATING LOGIC


NOTE With the engine stop switch set to “ “ the
starter motor does not turn over.

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

6.8.3 CHECKING THE START RELAY


To check the relay:
4
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE). 2
Š Disconnect the two-way connector (1) (white). 1
WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Š Lift up the relay and slide it out of its connectors (2).
Š Slip off the two rubber boots (3-4). 3
Š Disconnect the cables from the terminals on the relay
(2).

Š Apply 12 V to the two internal male prongs of the


connector (1) on the relay side.
Š Use a tester (in ohm meter mode) to check the relay
operation by measuring the resistance between the two
contact screws on the relay (2).
Correct value with relay energized: 0 Ω.
Correct value with relay not energized: ∞ Ω.
If the values do not match those indicated, replace
the relay (2).

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6.8.4 CHECKING THE DIODE


To check the diode:
Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Disconnect the two-way connector (1) (white) (under
the left fairing near the ECU).

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

Correct value (measurement A):0 Ω


Correct value (measurement B): ∞
If the tester does not have a diode test function, connect
to a 12 V battery, inserting a 12 V/2 W bulb on the
positive cable, connecting the diode as shown in the
figure.

WARNING
Never use bulbs over 2 W as they could damage the
diode.

Test (C): the bulb does not light.


Test (D): the bulb lights.

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6.8.5 CHECKING THE SIDE STAND SWITCH


The side stand (1) must be able to rotate freely, without
binding.
Carry out the following checks:
3
Š The springs (2) must not be damaged, worn, rusted or
weakened.
Š The side stand must pivot freely. Grease the joint if
necessary, see 1.12 (LUBRICANT CHART).
1
A safety switch (3) is installed on the side stand (1) to
prevent or stop the engine from running with the engine
in any gear except neutral, with the side stand (1) down.
2
To check the side stand safety switch (3):
Š Sit on the vehicle as though you were riding.
Š Retract the side stand (1).
Š Start the engine.
Š With the throttle grip released and the engine idling,
fully squeeze the clutch lever. Engage the first gear by
pushing the gearshift lever down.
Š Lower the side stand (1), which will activate the safety
switch (3).
At this point:
– the engine must stop;
– the side stand down LED “ “ must light on the
dashboard.
If this does not occur, replace the switch (3).

6.8.6 CHECKING THE DIODE MODULE


Š Remove the left fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Disconnect the five-way connector (1) (white) from the
module (2).

WARNING
When reassembling, make sure the electrical
connector (1) is properly connected.
Š 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).

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6.8.7 CHECKING THE SAFETY SYSTEM 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.

1) NEUTRAL GEAR SWITCH

Cables
Pos.
Screw
1
Neutral

2) SIDE STAND SWITCH

Cables 2
Side stand pos.
M V N

Lowered

Raised

3) CLUTCH LEVER SWITCH

Cables
Pos.
Gr M

Activated

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6.9 ELECTRIC COOLING FANS

6.9.1 WIRING DIAGRAM


NOTE For the locations of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

G1(G) G/N
3
H4(N) R/M

G2(G) G/N
3

4
5
E4(N) B/R

B2(N) Ro/N

Wiring diagram legend


1) ECU
2) Injection relay
3) Fans
4) Throttle sensor
5) Coolant thermistor

6.9.2 CHECKING THE ELECTRIC FAN OPERATION


NOTE The following steps refer to a single fan, but are
applicable to both. 1
Š Carry out the first three steps described in paragraph
5.3 (REMOVING THE ELECTRIC COOLING FANS).
NOTE Have a 12 V battery ready.
Š Connect the connector (black) (1) to the battery
Š Make sure that the fan turns freely.
If the fans are working properly, check:
- coolant thermistor, see 6.6.5 (CHECKING THE
COOLANT THERMISTORS OPERATION);
- injection system power supply;
- that they are correctly wired to the control unit.

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6.10 DASHBOARD INDICATORS

6.10.1 WIRING DIAGRAM


NOTE For the locations of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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

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6.10.2 AIR TEMPERATURE SENSOR


1
To check the air temperature sensor:
Š Remove the left dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Disconnect the two-way connector (1).
Š Check the sensor in a controlled environment with a
temperature of 20°C (68°F).

Š Measure the electrical resistance using an ohm meter


(scale 0-2kΩ) between the terminals of the connector
(1).
Correct value: 12.200 kΩ ± 12.700 kΩ
If the air temperature sensor is working properly, check 1
the dashboard:
Š Disconnect the 16-way connector (2), see 7.1.24
(REMOVING THE DASHBOARD).
Š Apply a resistance of 12.4 k Ω between terminals 2 and
9.
+ -
Š If the dashboard is working properly, it should indicate :

a temperature of 20 ± 1°C (68 ± 3°F).

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6.10.3 ENGINE OIL PRESSURE SENSOR


Š Remove the lower fairing, see 7.1.33 (REMOVING
2
THE LOWER FAIRING).
Š Disconnect the electrical terminal (1) from the sensor
(2) and ground it.

WARNING
When reassembling, make sure the electrical
terminal (1) is fitted properly. 1
Š With the ignition switch set to “ “, the red engine oil
pressure LED “ “ should light.
Š If the LED “ “ does not light as described, check the
sensor.
Š 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.

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6.10.4 SPEED SENSOR


If the speedometer does not work, proceed as follows:
Š Raise the fuel tank, see 2.8 (LIFTING THE FUEL
1
TANK).
Š Disconnect the two-way connector of the speed sensor
(1) located on the right side of the motorcycle.
Š Measure the electrical resistance between the two
terminals of the connector (1) on the sensor side:
Correct value 3.83 M Ω ± 5%

+ -
:

REVERSING THE POLARITY


Correct value: ∞
NOTE Replace the speed sensor if the values are
incorrect.
If the values are correct:
- Replace the dashboard, see 7.1.24 (REMOVING THE
DASHBOARD). + -
- Make sure the dashboard wires are properly :
connected.

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ELECTRICAL SYSTEM

6.10.5 FUEL LEVEL SENSOR


Check the sensor: 1
Š raise the fuel tank, see 2.8 (LIFTING THE FUEL
TANK).
Š Disconnect the white four-way connector (1) located
under the fuel tank (left side).
Š Measure the electrical resistance between the orange
and black wires on the sensor side:
Correct value with the fuel tank full: less than 14 Ω.
Correct value without fuel: between 240 and 400 Ω.
NOTE Replace the fuel level sensor if the values are
incorrect.
If the values are correct, test the dashboard operation by
connecting a resistance between the orange-black and
white-yellow wires of the 4-way connector (1) on the main
system side.
- With resistance = 10 Ω:
the dashboard shows 9 wedges and liters “F”.

- With resistance = 250 Ω:


the dashboard shows 0 wedges, liters flash “--”. and
the reserve LED is lit.

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ELECTRICAL SYSTEM RST mille USA

6.10.6 COOLANT TEMPERATURE SENSOR


Š Make sure the sensor is in good working order, 1
see 6.6.5 (CHECKING THE COOLANT
THERMISTORS OPERATION).
Š Test the dashboard operation by connecting a
resistance between the white-black and white-red
wires of the two-way connector (1):

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: “- - -”

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ELECTRICAL SYSTEM

6.11 LIGHT SYSTEM

6.11.1 WIRING DIAGRAM


NOTE For the locations of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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)

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6.11.2 CHECKING THE LIGHT RELAY


1
To check the relay (1):
Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Remove the relay in question.
Š Power the two male terminals (85-86) with a voltage of
12 V.
Š Use a tester (in ohm meter mode) to check the
continuity between the other two terminals (87-30).
Correct value with relay energized: 0 Ω
Correct value with relay not energized: ∞ Ω
If the values do not match those indicated, replace
the relay in question.

- +
12V

+ -
:
30
87
85 86

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ELECTRICAL SYSTEM

6.12 WARNING LIGHTS AND BUZZERS

6.12.1 WIRING DIAGRAM


NOTE For the positions of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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)

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6.12.2 HORN TEST


To check the horn efficiency:
Š Carry out the first three steps described in paragraph
7.1.27 (REMOVING THE HORN).
Š Connect the two horn connectors to a 12 V battery.
Š Adjust the adjuster screw if needed.

6.12.3 FLASHER TEST


If neither of the direction indicator lamps is working, there 2
is probably a problem with the flasher.
To test the flasher operation:
Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Disconnect the two connectors (1) of the flasher (2).
Š Jumper the two connectors (1).
Š Activate the direction indicator controls (3).
If the lights remain steadily lit, replace the flasher (2).
Š If necessary, check:
- the main fuses (30 A) and the electrical system.
1
If one of the indicator bulbs burns out, the other lamp and
the warning LED on the dashboard remain steadily lit
whenever the control (3) is activated.

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ELECTRICAL SYSTEM

6.13 WARNING LIGHTS AND BUZZERS

6.13.1 WIRING DIAGRAM


NOTE For the positions of the components, see 6.1
(LOCATIONS OF ELECTRICAL COMPONENTS).

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

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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.

1) BRAKE LIGHT SWITCH ON FRONT BRAKE

Cables
Pos.
V V/G

Activated

2) BRAKE LIGHT SWITCH ON REAR BRAKE

Cables
Pos.
Gr M

Activated

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ELECTRICAL SYSTEM

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).

6.14.1 ACTIVATING THE BATTERY


Š Remove the battery from the vehicle, see 7.1.9
(REMOVING THE BATTERY). 1

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
Š Place the battery on a flat surface.
Š Remove the adhesive sealing label (1).
Š Remove the sealed bag from the cardboard container
containing the six reservoirs (2).
Š 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.
Š Disconnect the row of stoppers (3) from the top of the
reservoirs (2).

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WARNING 2
Do not cut or make holes in the sealed parts on the
reservoirs (2).
Š Turn the reservoirs (2) upside down and place them so
that the sealed parts are over the openings of the
battery cells.
Š 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.
Š 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.
Š 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.
Š Lift the reservoirs (2) with care, disengaging them from
the battery.

Š Place the row of stoppers (3) over the battery cell


openings.
Š Press down firmly until the tops of the stoppers (3) are
flush with the top of the battery.
3
WARNING
NEVER attempt to remove the row of stoppers (3) for
any reason.
Š Connect the battery to a battery charger.
Š Subject the battery to a normal charge (see table).
Voltage
Type of charge Time (hours)
(Amperes)
Normal 1,2 8 ÷ 10
Fast 12 0,5
Š Re-install the battery on the vehicle upon return to the
customer.

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ELECTRICAL SYSTEM

6.14.2 MAINTENANCE
Š 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).
Š 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:
Š There are no signs of damage (external case cracked)
and no electrolyte leak.
Š The cables are firmly connected to the terminals.
Š 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.

6.14.4 RETURN UNDER WARRANTY


The warranty is void if the battery shows:
Š Damage (container dented, poles bent, etc.).
Š Widespread sulphation (incorrect activation and/or
misuse of the battery).

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6.15 REPLACING THE BULBS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).

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.

6.15.1 REPLACING THE HEADLIGHT BULBS


1 3 1
Š Place the vehicle on the stand.
NOTE Before replacing a bulb, check the fuses,
see 6.16 (CHANGING FUSES).
The headlight houses:
- two high beam bulbs (1) (side);
- one parking light bulb (2) (lower);
- one low beam bulb (3) (lower).
NOTE It is necessary to remove the right and left
dashboard panels when replacing the low beam and high
beam bulbs.
The lower saddle panel must be removed to replace the 2
parking light bulb.
To replace:
HIGH BEAM BULBS 1
NOTE Work on the same side as the bulb to be
replaced.
NOTE Remove one connector at a time to avoid
returning them to the incorrect position during
reassembly.
If the bulb sockets must all be removed at the same time,
take great care to reassemble them in the proper
position.
Š Remove the dashboard panel, see 7.1.20 (REMOVING 4 5
THE FRONT FAIRING).

WARNING
Do not pull the electrical cables to extract the bulb
socket.
Š Grasp the socket for the bulb to be replaced (4), pull
7 1
and disconnect it from the bulb (1).
Š Pull back the boot (5) with your fingers.
Š Release the retainer spring (6) located behind the bulb
seat (7).
Š 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.

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ELECTRICAL SYSTEM

PARKING LIGHT BULB


Š Remove the lower front panel, see 7.1.32 (REMOVING
THE FRONT FAIRING LOWER LOCKUP).

WARNING
Do not pull on the wires to remove the bulb socket.
Š Grasp the parking light socket (8), pull it and remove it
from its seat.
Š Remove the bulb (2) and replace it with another of the
same type.
8
2

LOW BEAM BULB


NOTE Remove one socket at a time to avoid returning 3
them to the incorrect position during reassembly.
If the bulb sockets must all be removed at the same time,
take great care to reassemble them in the proper
position.
Š Remove the right dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).

WARNING
Do not pull the electrical cables to extract the bulb
socket.
9 10
Š Grasp the bulb socket (8), pull it and disconnect it from
the bulb (3).
Š Pull back the boot (10) with your fingers.
Š Release the retainer spring (11) located behind the 12
bulb seat (12). 3
Š 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

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6.15.2 REPLACING THE FRONT DIRECTION


INDICATOR LAMPS
2
Š Place the vehicle on the stand.
Š Unscrew and remove the screw (1).
WARNING
While removing the lens, be extra careful not to break
the tab.
Š Remove the lens (2).
WARNING
Upon reassembly, place the lens correctly in its seat. 1
Tighten the screw (1) gently and carefully to avoid
damaging the lens.
Š Push the bulb (3) in slightly and rotate it counter-
clockwise.
Š Remove the bulb (3) from its seat.
WARNING
Insert the bulb in the bulb socket, carefully aligning
the two bulb pins with their guides in the socket. 3

Š Correctly install a new bulb of the same type.


To replace the rear direction indicator lamps, see 6.15.3
(REPLACING THE TAILLIGHT BULBS).

6.15.3 REPLACING THE TAILLIGHT BULBS


The taillight houses: 2 1 2
- two parking light/brake light bulbs (1).
- two rear direction indicator lamps (2).
To replace:
Before replacing a bulb, check the operation of the brake
light switches, see 6.13.2 (SWITCHES).

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.
Š 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.

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ELECTRICAL SYSTEM

PARKING LIGHT/BRAKE LIGHT BULBS


Š Unscrew and remove the two screws (3). 4
Š Partially remove the bulb socket (4).
Š Push the bulb (1) in slightly and rotate it counter-
clockwise.
Š Remove the bulb (1) from its seat.
5
WARNING
Insert the bulb in the socket, lining up the two bulb
pins with the corresponding guides on the socket. 3
Š Correctly install a new bulb of the same type.
REAR DIRECTION INDICATOR LAMPS
NOTE Remove one socket at a time to avoid returning
them to the incorrect position during reassembly.
If the bulb sockets must all be removed at the same time,
take great care to reassemble them in the proper
position.
Š Turn the bulb seat (5) counter-clockwise.
Š Push the bulb (2) in slightly and rotate it counter-
clockwise.
Š Remove the bulb (2) from its seat.
WARNING
Insert the bulb in the socket, lining up the two bulb
pins with the corresponding guides on the socket.
Š Correctly install a new bulb of the same type.

6.15.4 REPLACING THE LICENSE PLATE LIGHT


BULBS
Š Place the vehicle on the stand.
Š Unscrew and remove the screw (1), retrieving the nut.
Š Remove the light assembly (2).
WARNING 2
Do not pull on the wires to remove the bulb socket.

Š Grasp the socket (3), pull it and remove it from its seat.
Š Remove the bulb (4) and replace it with another of the
same type.
3

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6.16 CHANGING FUSES


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).

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:
Š Turn the ignition switch to “ “ to avoid an accidental
short-circuit.
Š Remove the lower dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Open the cover of the secondary fuse box (1).
Š Remove the fuses one by one, and check to see
whether the filament (2) is blown.
Š Before replacing the fuse, if possible, try to determine 2
the cause of the problem.
Š 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.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š 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

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ELECTRICAL SYSTEM

6.17 ADJUSTING THE HEADLIGHT BEAM


VERTICALLY
NOTE The procedure described here is in compliance 32.81 ft (10 m)
with the Italian standard that establishes the maximum
height of the headlight beam. For vehicles used in other
countries, you must observe local regulations.

9/10 H
H
To adjust the headlight beam:
Š Remove the right dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Sit on the vehicle as though you were riding.
Š 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.

6.18 ADJUSTING THE HEADLIGHT BEAM


HORIZONTALLY
NOTE The procedure described here is in compliance
with the Italian standard that establishes the maximum
height of the headlight beam. For vehicles used in other
countries, you must observe local regulations.
Before adjusting the headlight beam horizontally, you
must first adjust it vertically, see 6.17 (ADJUSTING THE
HEADLIGHT BEAM VERTICALLY).
To adjust the headlight beam:
Š Remove the left dashboard panel, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Sit on the vehicle as though you were riding.
Š Working from the left side of the front fairing, turn the
adjuster knob (2):
– turn clockwise to move the beam to the left;
– turn counter-clockwise to move the beam to the right.
USA 1
After completing the adjustment:
NOTE Make sure the headlight beam is properly
adjusted horizontally.

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.

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6.19 WIRING DIAGRAM - RST MILLE FUTURA.

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ELECTRICAL SYSTEM

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.

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NOTES

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RST mille USA
CHASSIS

CHASSIS
7

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CHASSIS RST mille USA

CHASSIS 7.1.42 REMOVING THE LICENSE PLATE


HOLDER .............................................. 7-36-00
7.1.43 REMOVING THE PASSENGER
FOOTREST SUPPORTS ..................... 7-36-00
TABLE OF CONTENTS 7.1.44 REMOVING THE PASSENGER
FOOTREST.......................................... 7-37-00
7.1 BODY ............................................... 7-4-00 7.1.45 REMOVING THE LEFT RIDER FOOTREST
7.1.1 REMOVING THE SADDLE.................... 7-6-00 SUPPORT ............................................ 7-37-00
0 7.1.2 REMOVING THE REAR SIDE PANELS 7-6-00
7.1.3 REMOVING THE FRONT SIDE PANELS 7-7-00
7.1.46 REMOVING THE RIGHT RIDER
FOOTREST SUPPORT ....................... 7-38-00
7.1.4 REMOVING THE BAG RACKS............. 7-7-00 7.1.47 REMOVING THE RIDER FOOTREST. 7-38-00
7.1.5 PARTIALLY REMOVING THE 7.1.48 COMPLETELY REMOVING THE
FUEL TANK ........................................... 7-8-00 GEARSHIFT LEVER............................ 7-39-00
7 7.1.6 REMOVING THE FUEL TANK
COMPLETELY....................................... 7-9-00
7.1.49 REMOVING THE REAR BRAKE LEVER 7-40-00
7.1.50 REMOVING THE EXHAUST SILENCER 7-41-00
7.1.7 REMOVING THE FUEL TANK CAP.... 7-10-00 7.1.51 REMOVING THE EXHAUST PIPES.... 7-42-00
7.1.8 REMOVING THE AIR FILTER CASE.. 7-11-00 7.1.52 REMOVING THE EXPANSION TANK 7-42-00
7.1.9 REMOVING THE BATTERY................ 7-12-00 7.1.53 REMOVING THE EXHAUST
2 7.1.10 REMOVING THE ELECTRONIC
CONTROL UNIT .................................. 7-13-00
MANIFOLDS ........................................ 7-43-00
7.1.54 REMOVING THE SIDE STAND........... 7-44-00
7.1.11 REMOVING THE HANDGRIP FROM 7.1.55 REMOVING THE ENGINE OIL TANK. 7-45-00
THE LEFT HANDLEBAR .................... 7-13-00 7.1.56 REMOVING THE ENGINE OIL
RADIATOR .......................................... 7-46-00
3 7.1.12 REMOVING THE CLUTCH CONTROL 7-15-00
7.1.13 REMOVING ELECTRICAL CONTROLS
ON THE LEFT HANDLEBAR .............. 7-16-00
7.1.57 REMOVING THE DRIVE CHAIN
SHOE ................................................... 7-47-00
7.1.14 REMOVING THE THROTTLE CONTROL 7-16-00 7.1.58 REMOVING THE UPPER CHAIN
7.1.15 REMOVING THE FRONT BRAKE HOUSING............................................. 7-48-00

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

8 7.1.30 REMOVING THE LEFT AIR DUCT ..... 7-27-00


7.1.31 REMOVING THE RIGHT AIR DUCT ... 7-28-00
7.5.1 CHANGING THE BRAKE PADS......... 7-66-00
7.5.2 CHECKING THE BRAKE DISCS ........ 7-67-00
7.1.32 REMOVING THE FRONT FAIRING 7.5.3 REMOVING THE BRAKE DISCS........ 7-67-00
LOWER LOCKUP................................ 7-28-00 7.5.4 REMOVING THE BRAKE MASTER
7.1.33 REMOVING THE LOWER FAIRING ... 7-29-00 CYLINDER ........................................... 7-67-00
9 7.1.34 REMOVING THE AIR INLET DUCT
CASES ................................................. 7-30-00
7.6 REAR BRAKE................................. 7-68-00
7.6.1 CHANGING THE BRAKE PADS......... 7-69-00
7.1.35 REMOVING THE RADIATOR SPOILER 7-30-00
7.6.2 REMOVING THE REAR BRAKE
7.1.36 REMOVING THE TAILLIGHT.............. 7-31-00
CALIPER.............................................. 7-70-00
7.1.37 REMOVING THE REAR GRAB HANDLE 7-32-00
7.6.3 CHECKING THE BRAKE DISC........... 7-71-00
7.1.38 REMOVING THE SADDLE LOCK....... 7-32-00
7.6.4 REMOVING THE BRAKE DISC .......... 7-72-00
7.1.39 COMPLETELY REMOVING THE SADDLE
7.6.5 REMOVING THE BRAKE MASTER
RELEASE ............................................ 7-33-00
CYLINDER ........................................... 7-73-00
7.1.40 REMOVING THE LOWER SADDLE
PANEL ................................................. 7-33-00 7.7 STEERING ..................................... 7-74-00
7.1.41 REMOVING THE SADDLE SUPPORT 7.7.1 DISASSEMBLING THE STEERING.... 7-75-00
LOWER MOLDED COVER.................. 7-34-00 7.7.2 CHECKING THE COMPONENTS ....... 7-75-00

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7.7.3 REASSEMBLING THE STEERING ..... 7-76-00


7.8 FRONT FORK ................................ 7-77-00
7.8.1 CHANGING THE FORK OIL ................ 7-78-00
7.8.2 REMOVING THE FORK TUBES.......... 7-78-00
7.8.3 DISASSEMBLING THE LOWER FORK
TUBE/UPPER FORK TUBE UNIT ....... 7-79-00
7.8.4 CHECKING THE COMPONENTS........ 7-84-00
7.8.5 REASSEMBLING THE UPPER/LOWER
FORK TUBE UNIT................................ 7-85-00
7.8.6 INSTALLING THE LOWER FORK
TUBE/UPPER FORK TUBE UNIT ....... 7-90-00
7.9 SWINGING ARM............................ 7-91-00
7.9.1 REMOVING THE SWINGING ARM ..... 7-91-00
7.9.2 DISASSEMBLING THE SWINGING
ARM...................................................... 7-92-00
7.9.3 CHECKING THE COMPONENTS........ 7-93-00
7.9.4 RE-INSTALLING THE SWINGING ARM 7-94-00
7.10 REAR SUSPENSION...................... 7-96-00
7.10.1 REMOVING THE SHOCK ABSORBER. 7-96-00
7.10.2 DISASSEMBLING THE REAR
SUSPENSION LINKAGE ..................... 7-97-00
7.10.3 DISASSEMBLING THE SUSPENSION
LINKAGE.............................................. 7-98-00
7.10.4 CHECKING THE COMPONENTS........ 7-99-00
7.11 DISASSEMBLING THE DRIVE
CHAIN ......................................... 7-100-00
7.11.1 CHAIN BREAKER/RIVET TOOL ....... 7-100-00
7.11.2 BREAKING THE CHAIN .................... 7-101-00
7.11.3 PLACING THE MASTER LINK .......... 7-102-00
7.11.4 RIVETING THE PINS ......................... 7-103-00

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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

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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

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7.1.1 REMOVING THE SADDLE


Š Place the vehicle on the center stand.
Š Insert the key (2) in the lock (3) to the left of the
dashboard.
Š Turn the key (2) counter-clockwise, raise and pull the
saddle (1) out from the back, complete with side
panels.
NOTE Before lowering and locking the saddle (1),
make sure you have not accidentally left the key (2) in the
glove/tool kit compartment. When reassembling the
saddle (1), make sure that the lock clicks into place.
If necessary:
Š Remove the front side panels, see 7.1.3 (REMOVING
THE FRONT SIDE PANELS).

7.1.2 REMOVING THE REAR SIDE PANELS


NOTE The following steps refer to removing a single
side panel, but are applicable to both.
Š Remove the saddle, see 7.1.1 (REMOVING THE
1
SADDLE).
Š Place the saddle on a flat surface.
Š Unscrew and remove the four screws (1).

Tightening torque for screws (1): 0.7 ftlb (1 Nm). 1


Š Remove the rear side panel (2).
NOTE If necessary, repeat the above steps to remove
the other rear side panel.

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7.1.3 REMOVING THE FRONT SIDE PANELS


1
NOTE The following steps refer to removing a single
side panel, but are applicable to both.
Š Remove both rear side panels, see 7.1.2 (REMOVING
THE REAR SIDE PANELS).
Š Unscrew and remove the five screws (1).

Tightening torque for screws (1): 0.7 ftlb (1 Nm).


NOTE When reassembling, replace the three adhesive
plates (2). 1

7.1.4 REMOVING THE BAG RACKS


NOTE The following steps refer to removing a single
rack, but are applicable to both.
3
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Unscrew and remove the screw (1) retrieving the
washer and bushing from inside.
1

4
Tightening torque for screws (1): 0.7 ftlb (1 Nm).
Š Unscrew and remove the screw (2), retrieving the
bushing.

Tightening torque for screw (2): 7.3 ftlb (10 Nm).


Š Unscrew and remove the two screws (3), retrieving the
washers.
Š Remove the bag rack (4).
NOTE When reassembling, the longer bushing (5)
must be placed at the bottom of the screw (2).
5

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7.1.5 PARTIALLY REMOVING THE FUEL TANK


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.1 (FUEL) and 4.1 (FUEL TANK).

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.
Š Set the ignition switch to “ ”.
Š Remove the saddle, see 7.1.1 (REMOVING THE
1
SADDLE).
Š Disconnect the connector electrical (1) from the fuel
intake pump.
NOTE When reassembling, make sure the electrical
connector (1) is fitted properly.
Š Slide the two drain tubes (2) upwards.
Š Unscrew and remove the two screws (9).
2
Tightening torque for screws (9): 2.2 ftlb (3 Nm).
Š Remove the grille (3).
Š 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.

Tightening torque for screws (4): 5.9 ftlb (8 Nm).


NOTE Place a cloth under the male quick-release
coupling (6) to catch any spilled fuel. 5
Š Press the push-button (8) to disconnect the male quick-
release coupling (6) from the female (7). 9
4
NOTE When reassembling make sure that the male
quick-release coupling is properly inserted in the female
(7).
Š Nearby, on the left side of the vehicle, prepare a flat
surface approximately (60 cm) above the ground, and 9
large enough to hold the tank (5). 9
4
WARNING
The tank (5) is not completely free, but remains
attached to the fuel lines, which should not be
disconnected unless absolutely necessary, see 7.1.6
(REMOVING THE FUEL TANK COMPLETELY).
Handle all painted components with care to avoid
scraping or scratching them. 6

8
7

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Š 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).

7.1.6 REMOVING THE FUEL TANK COMPLETELY


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.1 (FUEL) and 4.1 (FUEL TANK).
Š Drain any fuel remaining in the tank, see 2.9 3
(DRAINING FUEL FROM THE TANK). 4
Š Partially remove the fuel tank, see 7.1.5 (PARTIALLY
REMOVING THE FUEL TANK).
Š Turn the tank upside down.
NOTE Place an absorbent cloth under the banjo screw
(1) to catch any fuel that spills.
2 1
Š Loosen the banjo screw (1) by approximately half a
turn, then wait a few seconds to allow the system to
depressurize.
Š Unscrew and remove the banjo screw (1) and retrieve
the two gaskets (2).

Tightening torque for banjo screw (1): 16.2 ftlb


(22 Nm).

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.
Š Remove the tank completely.
Š If the lower front soundproofing and rear insulating
panels appear damaged, replace them.

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7.1.7 REMOVING THE FUEL TANK CAP


2
Carefully read 1.4.1 (FUEL) and 4.1 (FUEL TANK).
Š Place the vehicle on the center stand. 1
Š Unscrew and remove the three screws (1). 3

Tightening torque for screws (1): 3.6 ftlb (5 Nm).


NOTE You may leave the other three screws mounted,
since they are purely decorative.
Š Open the cap (2). 1

WARNING
When removing the screw (3), be careful not to drop 1
it into the tank.
Š Unscrew and remove the screw (3).

Tightening torque for screws (3): 3.6 ftlb (5 Nm).


Š Remove the plug (2) complete with ring-nut (4).
WARNING
Plug the tank opening to prevent any foreign matter
from accidentally entering.

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7.1.8 REMOVING THE AIR FILTER CASE


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 2
4
Š Remove the air filter, see 2.10 (AIR FILTER). 1
Š Release the clamp (1) and disconnect the hose (2). 7
Š Release the two clamps (3) and pull out the two lines
(4)
Š Unscrew the six screws (8).

Tightening torque for screws (8): 5.2 ftlb (7 Nm).


Š Raise the filter case (9).
Š Release the clamp (5) and disconnect the hose (6). 3
Š Disconnect the electrical connector (7) from the step
motor.

WARNING
When reassembling, make sure the electrical 5
connector is fitted properly.
Š 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

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7.1.9 REMOVING THE BATTERY


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), and 2.4 (BATTERY). 1
2
NOTE Removing the battery will reset the functions:
digital clock and red line setting
To restore these functions, see 2.3 (MULTIFUNCTION
COMPUTER).
Š Set the ignition switch to “ ”.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Unscrew and remove the screw (1) on the negative
terminal (-).
Š Move the negative cable (2) to one side.
Š Pull back the red rubber boot (3).
Š Unscrew and remove the screw (4) on the positive
terminal (+).
Š Move the positive cable (5) to one side.
3
WARNING
Do not force electrical cables.
Š Remove the start relay (6).
ŠUnscrew and remove the screw (7). 4

Tightening torque for screw (7): 3.6 ftlb (5 Nm).


Š Lift the bracket (8) holding the battery in place.
Š Firmly grasp the battery (9) and lift it out of its 5
compartment.

DANGER
Once it has been removed, store the battery in a safe
place and out of reach of children.
Š 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 (-).
Š When reassembling, the battery (9) must be placed in
its compartment with the terminals facing towards the
back of the vehicle.
7

6
9

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7.1.10 REMOVING THE ELECTRONIC CONTROL


UNIT
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 3
INFORMATION).
Š Set the ignition switch to “ ”.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Remove the left fairing, see 7.1.28 (REMOVING THE 3
SIDE FAIRINGS).
2 1
Š Disconnect the two connectors (1) leading to the
control unit (2).

WARNING
When reassembling, make sure the two electrical
connectors (1) are fitted properly.
Š Unscrew and remove the two screws (3).

Tightening torque for screws (3): 7.3 ftlb (10 Nm).


Š Remove the control unit (2).
WARNING
When replacing the control unit (2), you must also
align the throttle valve position sensor, see 4.10.3
(THROTTLE VALVE POTENTIOMETER).

7.1.11 REMOVING THE HANDGRIP FROM THE LEFT


HANDLEBAR
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 1
INFORMATION).
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Hold the balance weight in place with a pair of
adjustable pliers, wrapped in electrical tape to avoid
damaging the balanceweight (1).
Š Unscrew and remove the screw (2).
2
Tightening torque for screws (2): 8 ftlb (12 Nm).
Š Remove the balanceweight (1).
Š Slip off and remove the peg (3).
Š Slip off and remove the O-ring (4).

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Š Unscrew and remove the terminal (5).

Tightening torque for terminal (5): 25.8 ftlb (35 Nm).

Š Remove the pin (6) and the rubber bushing (7). 7

Š Insertthe tip of a compressed air gun between the


handlegrip (8) and the handlebar (9).
Š Moving the gun tip with a circular motion, blow air into
the space. At the same time, use your other hand to
grasp and pull off the grip (8).

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7.1.12 REMOVING THE CLUTCH CONTROL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 4
INFORMATION). 3
1
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Unscrew and remove the two screws (1) fastening the 2
clutch control (2).

Tightening torque for screws (1): 7.3 ftlb (10 Nm). 5


Š Remove the clutch lever clamp (3) and move the clutch
control (2).
NOTE When reassembling the clutch lever clamp (3)
must be placed with the arrow, engraved on the top,
facing upward.
Should you need to completely remove the clutch control
(2): 2 4
Š Follow the first three steps described in chapter2.21
(CHANGING THE FRONT BRAKE FLUID).
Š When all the fluid has drained out, unscrew and
remove the screw (4) and retrieve the two seals.

Tightening torque for screw (4): 14.5 ftlb (20 Nm).

WARNING
When reassembling, replace the two seals with two
1
3
new washers of the same type.
Š Use a small blade screwdriver to pry out and remove
clutch switch (5) from the two slots on the clutch control
lever (2).
Š Remove the clutch control (2).
2
If necessary remove the clutch cylinder,see 3.2.1
(REMOVING THE CLUTCH CYLINDER).

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7.1.13 REMOVING ELECTRICAL CONTROLS ON THE


LEFT HANDLEBAR
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 3
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Unscrew and remove the two screws (1) fastening the
two half-cylinders (2-3) from the bottom.
2
Tightening torque for screws (1): 1.4 ftlb (2 Nm).
Š Separate the two half-cylinders (2-3). 1
WARNING
When reassembling, first position the lower half-
cylinder (2), making sure that the positioning pin is
inserted in the corresponding hole on the handlebar.
Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Free the wiring from the two holding clamps (4).
NOTE Have the same number of clamps ready to use
when reassembling.
Š Disconnect the electrical connector (5) of the left
dimmer switch.

WARNING
4
When reassembling, make sure the connector (5) is
fitted properly.
Š Remove the two halves of the electrical controls (2-3).

7.1.14 REMOVING THE THROTTLE CONTROL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Follow the first nine steps described in chapter
7.1.11
(REMOVING THE HANDGRIP FROM THE LEFT 1
HANDLEBAR).
Š Unscrew and remove the two screws (1).

Tightening torque for screws (1): 1.4 ftlb (2 Nm).


Š Remove the rear half (2) of the throttle control housing.
Š Remove the air filter case, see 7.1.8 (REMOVING THE
AIR FILTER CASE). 2

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Š Loosen the lock nut (3).


Š Release the throttle cable adjuster (4) from its coupling. 3
Š Disconnect the throttle cable.
Š Repeat the last three steps for the other throttle cable
as well.

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).
Š Move the winch (5) and disconnect the two throttle
cables.
Š Slide off the throttle grip (6).

7.1.15 REMOVING THE FRONT BRAKE CONTROL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 3
INFORMATION).
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Unscrew and remove the two screws (2) fastening the
front brake control (3). 4

Tightening torque for screw (2): 7.3 ftlb (10 Nm).


Š Remove the front brake lever clamp (1) and move the
front brake control (3), which remains attached via the
1 2
brake line.
NOTE When reassembling the brake lever clamp (1)
must be placed with the arrow, engraved on the top,
facing upward.
Should you need to completely remove the front brake
control (3):
Š Carry out the first three steps described in the chapter
2.21 (CHANGING THE FRONT BRAKE FLUID).
Š When all the fluid has drained out, unscrew and
remove the screw (4) and retrieve the two seals.

Tightening torque for screw (4): 1.4 ftlb (2 Nm).

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WARNING
When reassembling, replace the two seals with two
new washers of the same type. 3
Š 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).
Š Remove the front brake control (3).

7.1.16 REMOVING ELECTRICAL CONTROLS ON THE


RIGHT HANDLEBAR 1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 2
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Disconnect the electrical connector (1) of the right
dimmer switch.

WARNING
When reassembling, make sure the connector (1) is
fitted properly.
Š Disconnect the connector (2).
WARNING
When reassembling, make sure the connector (2) is
fitted properly.
6
Š 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
Š 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.

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7.1.17 REMOVING THE IGNITION SWITCH/STEERING


LOCK
1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the stand.
Š Set the ignition switch to “ ”.
Š Remove the fork head, see 2.28.2 (ADJUSTING THE
BEARING PLAY).
Š Release the ignition block connector (1) from the main
wiring.

WARNING
When reassembling, make sure the connector (1) is
fitted properly.
Š Unscrew and remove the screw (2) retrieving the
bushing (3).
NOTE When reassembling, place the cable guide (4)
correctly.
Š Use a small hammer and chisel to notch the head of
the special screw (5), and turn it until it's loose.
Š 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.
Š Remove the ignition switch/steering lock (6), sliding it 5 3
out from underneath.
2

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7.1.18 REMOVING THE LEFT HANDLEBAR


Š Remove the knob, see 7.1.11 (REMOVING THE
HANDGRIP FROM THE LEFT HANDLEBAR)).
Š Remove the electrical control, see 7.1.13 (REMOVING
ELECTRICAL CONTROLS ON THE LEFT
HANDLEBAR).
Š Remove the clutch control, see 7.1.12 (REMOVING
THE CLUTCH CONTROL). 1
Š Unscrew and remove the screw (1).

Tightening torque for screw (1): 8.8 ftlb (12 Nm). 3


Š Loosen the screw (2).

Tightening torque for screw (2): 18 ftlb (25 Nm).


NOTE When reassembling, apply a little grease under
the head of the screw (2).
Š Slide the handlebar (3) from the fork. 3

7.1.19 REMOVING THE RIGHT HANDLEBAR


Š Remove the throttle control, see 7.1.14 (REMOVING
THE THROTTLE CONTROL).
Š Remove the brake control, see 7.1.15 (REMOVING
THE FRONT BRAKE CONTROL).
Š Carry out the last three steps described in paragraph
7.1.18 (REMOVING THE LEFT HANDLEBAR).

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7.1.20 REMOVING THE FRONT FAIRING


Š Place the vehicle on the center stand. 3
Š Set the ignition switch to “ ”.
ŠUnscrew and remove the two screws (1).

Tightening torque for screws (1): 2.2 ftlb (3 Nm).


ŠRemove the bezel (2).
NOTE If the rubber (3) is damaged, replace it.
ŠUnscrew and remove the two screws (4). 1
2
Tightening torque for screws (4): 2.2 ftlb (3 Nm).
Š Remove the right dashboard panel (5).
Š Raise the left dashboard panel (6) and disconnect the
saddle fastener cable (7).
Š Remove the left dashboard panel (6).
Š Unscrew and remove the two screws (14).
Š Remove the lower dashboard panel (15).
Š Remove the dashboard, see 7.1.24 (REMOVING THE 15
DASHBOARD).
ŠUnscrew and remove the three screws (8), retrieving 4
the three nuts.
Š Slide the front fairing glass (9) out.
Š Remove the upper dashboard molding, see 7.1.23 5
(REMOVING THE UPPER DASHBOARD MOLDING).
14 14
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Š Disconnect from the main wiring (10) the connectors
for the headlight (11), front direction indicators (12), 6 9
and air temperature sensor (13).

WARNING
When reassembling, make sure the electrical 8
connectors (11-12-13) are fitted properly. 7
Š Remove the entire front fairing, complete with headlight
and rearview mirrors.
Š Place the complete front fairing on a flat surface.
If necessary:
Š Remove the headlight, see 7.1.22 (REMOVING THE
HEADLIGHT).
Š Remove the mirrors, see 7.1.21 (REMOVING THE
MIRRORS).

12

12
13

11 10

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7.1.21 REMOVING THE MIRRORS


Š Remove the right or left dashboard panel, depending
on which mirror you wish to remove; see 7.1.20 2
(REMOVING THE FRONT FAIRING).
NOTE It is easier to remove the mirrors if you first
remove the dashboard, see 7.1.24 (REMOVING THE
DASHBOARD).
Š Disconnect the electrical connector (1), front direction
indicator.
Š Disconnect the electrical connector (2), and air
temperature sensor (only if you plan to remove the left 1
mirror).

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.
Š Unscrew and remove the two nuts (3).
Š Remove the mirror, pulling the wiring through the slot (4).
Š 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.

7.1.22 REMOVING THE HEADLIGHT


2
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 2
Š Place the vehicle on the center stand.
Š Remove the front fairing, 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Unscrew and remove the four screws (2), saving the 2
washers.

2
Tightening torque for screws (2): 1.4 ftlb (2 Nm).
Š 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.

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7.1.23 REMOVING THE UPPER DASHBOARD


MOLDING
Š Remove the front fairing glass, see 7.1.20
(REMOVING THE FRONT FAIRING). 2
Š Unscrew and remove the two fastening screws (1). 1

Tightening torque for screws (1): 2.9 ftlb (4 Nm).


Š Remove the molding (2) by sliding it out from behind.
1

7.1.24 REMOVING THE DASHBOARD


2
Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove the dashboard panels, see 7.1.20
(REMOVING THE FRONT FAIRING).
Š Unscrew and remove the two screws (2), retrieving the
two bushings and the anti-vibration grommets.

Tightening torque for screws (2): 2.9 ftlb (4 Nm).

WARNING
Replace the grommets if damaged. 3
Š Move the dashboard (3) out of the way.
Š 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.
Š Remove the dashboard (3).

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7.1.25 REMOVING THE DASHBOARD/FRONT


FAIRING MOUNT 1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove both side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS).
Š Remove the front fairing, see 7.1.20 (REMOVING THE
FRONT FAIRING).
Š Unscrew and remove the two screws (1), saving the
two nuts. 1
2
Tightening torque for screws (1): 1.4 ftlb (2 Nm).
Š Remove the fuse box (2).
Š Uncouple the two light relays (3), flasher (4) and the
overturn sensor (5), leaving them connected to the
wiring.
4 5
WARNING
Replace the grommets if damaged.

Š Unscrew and remove the two nuts (7).

Tightening torque for nuts (7): 7.3 ftlb (10 Nm).


Š Remove the two screws (8). 8
7

Š Remove the dashboard/front fairing mount (6).

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7.1.26 REMOVING THE FRONT MUDGUARD


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
2

Š Place the vehicle on the center stand.


ŠUnscrew and remove the two screws (1).
1
Tightening torque for screws (1): 3.6 ftlb (5 Nm).

WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Š Pull the mudguard (2) out from the front.

7.1.27 REMOVING THE HORN


Š Place the vehicle on the stand. 2
Š Remove the radiator spoiler, see 7.1.35 (REMOVING
THE RADIATOR SPOILER).
Š Disconnect the two horn connectors (1).
1
WARNING
When reassembling, make sure the two connectors
(1) are fitted together properly. 3
Š To remove the horn (3) complete with bracket, unscrew
and remove the two screws (2)

Tightening torque for screws (2): 18 ftlb (25 Nm).

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7.1.28 REMOVING THE SIDE FAIRINGS

WARNING
Wait until the engine and exhaust silencer have
completely cooled down.
Š Place the vehicle on the center stand.
Š Unscrew and remove the three inner screws (1). 1

Tightening torque for screws (1): 3.6 ftlb (5 Nm). 1


Š Unscrew and remove the five upper screws (2). 1

Tightening torque for screws (2): 2.2 ftlb (3 Nm).


Š Unscrew and remove the four lower screws (3).

Tightening torque for screws (3): 1.4 ftlb (2 Nm).

WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them. 2
Š 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.

7.1.29 REMOVING THE FRONT DIRECTION


INDICATORS
2
Š If you need to replace the front direction indicator,
proceed by removing the mirror, see 7.1.21
(REMOVING THE MIRRORS).
Š If you only need to replace the lens (2): - unscrew and
remove the screw (1).
Š If you need to remove the reflector (1): - follow the
instructions above; - remove the bulb, see 6.15.2
(REPLACING THE FRONT DIRECTION INDICATOR
LAMPS);
- remove the reflector. 1

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7.1.30 REMOVING THE LEFT AIR DUCT


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand.
Š Set the ignition switch to “ ”. 2
Š Remove the side fairing, see 7.1.28 (REMOVING THE
SIDE FAIRINGS).
Š Remove the headlight complete with half-housings,
see 7.1.22 (REMOVING THE HEADLIGHT). 2
Š Disconnect the electrical connector (1) from the air
thermistor. 2

WARNING 5
When reassembling, make sure the connector (1) is 2
fitted properly.
Š Unscrew and remove the ten screws (2).
5 1
Tightening torque for screws (2): 1.4 ftlb (2 Nm).
Š Unscrew and remove the screw (3), saving the washer.

Tightening torque for screws (3): 7.3 ftlb (10 Nm).


Š Partially remove the control unit case (4), and retrieve 2
the bushing if it slips out.
Š Remove the left air duct (5) from the insert.

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7.1.31 REMOVING THE RIGHT AIR DUCT


Š Carry out the first three steps described in the
paragraph 7.1.30 (REMOVING THE LEFT AIR 1
DUCT). 1
Š Unscrew and remove the ten screws (1). 2
3

Tightening torque for screws (1): 1.4 ftlb (2 Nm).


Š Unscrew and remove the screw (2).
1 1
Tightening torque for screws (2): 3.6 ftlb (5 Nm).
Š Remove the right air duct (3).

7.1.32 REMOVING THE FRONT FAIRING LOWER


1
LOCKUP
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 2
Š Place the vehicle on the center stand.
Š Unscrew and remove the three screws (1).
1
Tightening torque for screws (1): 3.6 ftlb (5 Nm).

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.
Š Remove the front fairing lower lockup (2).

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7.1.33 REMOVING THE LOWER FAIRING


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand. 5

DANGER
Wait until the engine and exhaust silencer have
completely cooled down.
4 2
Š Remove the side fairing from the side in question,
see 7.1.28 (REMOVING THE SIDE FAIRINGS). 1
Š Unscrew and remove the two lower screws (1).

Tightening torque for screws (1): 2.9 ftlb (4 Nm).


Š Unscrew and remove the screw (5).
Š Unscrew and remove the rear screw (2), saving the
bushing.
3
WARNING
When reassembling, make sure the bushing is fitted
properly. 7

Tightening torque for screws (2): 2.9 ftlb (4 Nm). 6


Š Unscrew and remove the screw (3). 4

Tightening torque for screws (3): 1.4 ftlb (2 Nm).


Š Unscrew and remove the screw (6).

Tightening torque for screw (6): 2.9 ftlb (4 Nm).

WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Š Remove the lower fairing (4) complete with guard (7).
NOTE If necessary, repeat the above steps to remove
the other lower fairing.

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7.1.34 REMOVING THE AIR INLET DUCT CASES


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 4
INFORMATION).
Š Remove the air duct on the side in question,see 7.1.30
(REMOVING THE LEFT AIR DUCT), or see 7.1.31
(REMOVING THE RIGHT AIR DUCT). 4
3
Š Open the two clamps (1) that fasten the electrical cable
(2) to the air inlet duct case (3).
1
WARNING
When reassembling make sure the cable is properly
placed in its collar.
Š Unscrew and remove the two screws (4). 2

Tightening torque for screws (4): 3.6 ftlb (5 Nm).


Š Remove the air inlet duct case (3).
NOTE If necessary, repeat the above steps to remove
the other air inlet duct case.

7.1.35 REMOVING THE RADIATOR SPOILER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand. 4

DANGER
Wait until the engine and exhaust silencer have
completely cooled down.
Š Unscrew and remove the two upper fastening screws
(1).

1
Tightening torque for screws (1): 3.6 ftlb (5 Nm).
ŠUnscrew and remove the side fastening screw (2).

Tightening torque for screw (2): 3.6 ftlb (5 Nm).


Š Unscrew and remove the two lower fastening screws
(3). 2
4
Tightening torque for screws (3): 3.6 ftlb (5 Nm).
4
WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
Š Move the radiator spoiler (4) forward and slide it out
3
from the side.
Š Replace the internal insulating panel if damaged.

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7.1.36 REMOVING THE TAILLIGHT


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand. 1
Š Set the ignition switch to “ ”.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Disconnect the connector electrical (1) from the
taillight.

WARNING
When reassembling, make sure the electrical
connector (1) is fitted properly.
Š Release the wiring from the two line fasteners (2) and
the clamp located under the grab handle.

Š Unscrew and remove the three fastening screws (3),


retrieving the anti-vibration grommets and bushings.

Tightening torque for screws (3): 5.2 ftlb (7 Nm).

WARNING
Handle all plastic and painted components with care
to avoid scraping or scratching them.
3

Š Remove the complete taillight (4).

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7.1.37 REMOVING THE REAR GRAB HANDLE


2
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
3
Š Carry out the first four steps described in paragraph
7.1.36 (REMOVING THE TAILLIGHT).
Š Unscrew and remove the three fastening screws (1).

Tightening torque for screws (1): 7.3 ftlb (10 Nm).

WARNING
Handle all plastic and painted components with care
1
to avoid scraping or scratching them.
Š Remove the rear grab handle (2) complete with taillight.
WARNING
When reassembling, make sure the taillight wiring is
positioned correctly.
Š Place the complete rear grab handle on a flat surface.
NOTE If necessary, disassemble the taillight by
unscrewing the three screws (3).

7.1.38 REMOVING THE SADDLE LOCK


3
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 4

Š Remove the saddle, see 7.1.1 (REMOVING THE


SADDLE). 1
Š Free the saddle release cable (1) by prying up the fork
(2) with a screwdriver.
Š Unscrew and remove the two screws (3) fastening the
saddle release device (4) to the rear housing.

Tightening torque for screws (3): 7.3 ftlb (10 Nm). 2


Š Remove the saddle release device (4).

3
4

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7.1.39 COMPLETELY REMOVING THE SADDLE


RELEASE 3
Š Remove the saddle release device, see 7.1.38
(REMOVING THE SADDLE LOCK).
Š Unscrew and remove the two screws (1). 2 2
1

Tightening torque for screws (1): 0.7 ftlb (1 Nm).


Š Unscrew and remove the screw (9).
1
Tightening torque for screws (9): 1.4 ftlb (2 Nm). 9 7
Š Raise the left plate (2).
Š Remove the saddle release cable (3) from its collar (4).
Š Slide the cable terminal from the switch.
Š Remove the hasp (5) and retrieve the plate (6).
Š Remove the saddle release switch (7) from the left
plate (2). 7

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

7.1.40 REMOVING THE LOWER SADDLE PANEL


Š Place the vehicle on the center stand.
Š Remove the saddle, see 7.1.1 (REMOVING THE
SADDLE).
Š Remove the saddle hook, see 7.1.38 (REMOVING
THE SADDLE LOCK).
Š Disconnect the connector electrical (1) from the
taillight.

WARNING 1
When reassembling, make sure the electrical
connector (1) is fitted properly.

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Š Release the wiring from the two line fasteners (2).


Š Move the wiring (4) to one side. 4
Š Remove both bag racks, see 7.1.4 (REMOVING THE
BAG RACKS). 2
Š Unscrew and remove the two screws (3). 3
3
Tightening torque for screws (3): 2.2 ftlb (3 Nm).
Š Remove the lower saddle panel.

7.1.41 REMOVING THE SADDLE SUPPORT LOWER


MOLDED COVER
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove the rear grab handle, see 7.1.37 (REMOVING
THE REAR GRAB HANDLE). 1
Š Remove the fuel tank, see 7.1.5 (PARTIALLY
REMOVING THE FUEL TANK).
Š Remove the tools provided and any other items from
the compartment.
Š Remove the battery, see 7.1.9 (REMOVING THE
BATTERY).
Š Remove the muffler, see 7.1.50 (REMOVAL EXHAUST
SILENCER).
Š Remove the lower saddle panel, see 7.1.40
(REMOVING THE LOWER SADDLE PANEL).
Š Pull the water drain tube (1) downward.
WARNING
When reassembling, make sure the drain tube is
positioned properly.
2

Š Release the starter relay mount (2) from its coupling.


Š Release the fuse holder (3) from its mount.
WARNING
When reassembling, make sure the electrical
components and corresponding wiring are properly
positioned. 3

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Š Unscrew and remove the two front fastening screws


(4).

Tightening torque for screws (4): 7.3 ftlb (10 Nm). 4


Š Unscrew and remove the three screws (5) retrieving
the three clips (6).

Tightening torque for screws (5): 2.9 ftlb (4 Nm).


ŠUnscrew and remove the screw (7).

Tightening torque for screw (7): 2.9 ftlb (4 Nm).


Š Lower the front part and raise the back of the saddle
support lower molded cover. (8).
Š Remove the saddle support lower molded cover (8) by
sliding it out from the back.
5
5
WARNING 9
Replace the adhesive gasket (9) if worn or 6
deteriorated.

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7.1.42 REMOVING THE LICENSE PLATE HOLDER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove both bag racks, see 7.1.4 (REMOVING THE
BAG RACKS).
Š Disconnect the license plate lamp connector (1). 1
WARNING
When reassembling make sure the license plate lamp
connector (1) is properly fitted.
Š Remove the complete license plate holder (2).
NOTE Remove the individual components if necessary.

7.1.43 REMOVING THE PASSENGER FOOTREST


SUPPORTS
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
1
Š Remove the saddle, see 7.1.1 (REMOVING THE 1
SADDLE).
Š Unscrew and remove the two screws (1).

Tightening torque for screws (1): 18 ftlb (25 Nm).

Š Remove the footrest support (2) complete with footrest.


Š Also remove the footrest (3) if necessary, see 7.1.47
(REMOVING THE RIDER FOOTREST).
2
NOTE If necessary, repeat the above steps to remove
the other passenger footrest support.

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7.1.44 REMOVING THE PASSENGER FOOTREST


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the stand.
DANGER
Wait until the engine and exhaust silencer have 2
completely cooled down. 1
Š Remove the retainer ring (1).
Š Slide out the pin (2). 4

WARNING 3
Take care not to lose the ball (5), ejected by the 6
5 7
spring (6), in the process.
Š 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.

7.1.45 REMOVING THE LEFT RIDER FOOTREST


SUPPORT 3
2
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the stand.
Š Remove the lower fairing, see 7.1.33 (REMOVING 2
THE LOWER FAIRING).
Š Unscrew and remove the screw (1) holding the
gearshift lever on the left footrest support.
1
Tightening torque for screw (1): 10.8 ftlb (15 Nm).
Š Slide out the lever, which remains attached via the rod.
Š Unscrew and remove the two screws (2).

Tightening torque for screws (2): 18 ftlb (25 Nm).


Š Remove the complete footrest support (3).

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7.1.46 REMOVING THE RIGHT RIDER FOOTREST


SUPPORT 3
Š Carry out the first two steps described in the paragraph
7.1.45 (REMOVING THE LEFT RIDER FOOTREST
SUPPORT).
Š Carry out the first three steps described in the
paragraph 7.1.49 (REMOVING THE REAR BRAKE 1
LEVER). 2
Š Unscrew and remove the two screws (1) holding the
rear brake master cylinder (2).

Tightening torque for screws (1): 7.3 ftlb (10 Nm).


Š Retrieve the guard (3).
Š Unscrew and remove the screw (4).

Tightening torque for screws (4): 7.3 ftlb (10 Nm).


5
Š Move the rear brake master cylinder (2) and rear brake
fluid reservoir (5), still fastened together, making sure 4
the latter remains upright, to prevent spills.
Š Unscrew and remove the two screws (6).
7
Tightening torque for screws (6): 18 ftlb (25 Nm).
Š Remove the footrest support (7) complete with brake
lever (8).
6
8
NOTE Also remove the brake lever (8) if necessary.

7.1.47 REMOVING THE RIDER FOOTREST


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
2
INFORMATION).
Š Place the vehicle on the stand. 1

DANGER
Wait until the engine and exhaust silencer have
completely cooled down. 3
Š Remove the retainer ring (1).
Š Slide out the pin (2).
Š Retrieve the footrest (3) and spring (4). 4

NOTE If necessary, repeat the above steps to remove


the other rider footrest.

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CHASSIS

7.1.48 COMPLETELY REMOVING THE GEARSHIFT


LEVER 1 2
WARNING
Before removing the gearshift lever, mark both the
lever and shaft so that you can place them correctly
when reassembling.
Š Place the vehicle on the center stand.
Š Remove the left lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Loosen the screw (1) and slide out the jaw (2) from the
gearbox pivot.

Tightening torque for screws (1): 7.3 ftlb (10 Nm).


Š Unscrew and remove the pin (3) retrieving the washer
(4).
Š Slide the gearshift pedal (5) out from the side,
complete with rods.
NOTE Also replace the individual elements if 3
necessary.

4 3
2

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7.1.49 REMOVING THE REAR BRAKE LEVER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the stand.
Š Move the retainer ring (1). 6
Š Turn the fork axle (2) downward.
Š Slide out the fork axle (2).
Š Release the spring (3) from the lever (4).
Š Remove the rear stop switch (5).
1
2
Tightening torque for rear stop switch (5):
7.3 ftlb (10 Nm).
Š Unscrew and remove the pin (6) and retrieve the
washer (7).
Š Remove the lever (4).
Š Remove the bushing (8) if necessary.
NOTE When reassembling, apply LOCTITE® 243 to the 3
thread of the pin (6).

4
Tightening torque for pin (6): 10.8 ftlb (15 Nm).

6
7
8

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7.1.50 REMOVING THE EXHAUST SILENCER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove the rear grab handle, see 7.1.37 (REMOVING
THE REAR GRAB HANDLE).
Š Disconnect the license plate lamp-taillight connector
(9).
1
WARNING 3
When reassembling make sure the license plate
lamp-taillight connector (9) is properly coupled.
9
ŠLoosen the clamp (1) fastening the muffler (2) to the
exhaust pipes (3).

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).
Š Unscrew and remove the screw (4), retrieving the nut
(5).

Tightening torque for screw (4): 7.3 ftlb (10 Nm).


4
Š Remove the exhaust silencer (2) complete with license
plate holder (8).
Š Retrieve the two grommets (6).
WARNING
Check the two grommets (6) and replace them if
damaged.
2
Š If necessary, unscrew and remove the four screws (7)
and remove the license plate holder complete with side 7
guards (8).

6 6

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7.1.51 REMOVING THE EXHAUST PIPES


2
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
2
Š Remove the exhaust silencer, see 7.1.50 (REMOVING
THE EXHAUST SILENCER).
Š Release the two springs (1) from their couplings on the 1
expansion tank.
Š Check the two springs (1) and replace if damaged.
Š Twist the exhaust pipes (2) back and forth to overcome 1
the resistance of any encrusted build-up.
Š Remove the exhaust pipes (2), sliding them upward.
NOTE Plug the drain opening of the expansion tank to
keep out any foreign matter.

7.1.52 REMOVING THE EXPANSION TANK


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 3
INFORMATION). 1 2
Š Remove both lower fairings, see 7.1.33 (REMOVING 1
THE LOWER FAIRING).
Š Remove the exhaust pipes, see 7.1.51 (REMOVING
THE EXHAUST PIPES). 5
Š Loosen the three nuts (3) so that the rear cylinder
exhaust manifold (2) can be moved slightly.

Tightening torque for nuts (3): 18 ftlb (25 Nm).


4
Š Release the two springs (1) from their couplings on the
expansion tank (4).
Š Unscrew and remove the screw (5).

Tightening torque for screw (5): 18 ftlb (25 Nm).


Š Move the expansion tank (4) back and forth to 2
5
overcome the resistance of any encrusted build-up.
Š Slide out the expansion tank (4).
1

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7.1.53 REMOVING THE EXHAUST MANIFOLDS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 5
INFORMATION). 3
1
Š Remove the expansion tank, see 7.1.52 (REMOVING 1 4
THE EXPANSION TANK).
Š Unscrew and remove the three nuts (1) fastening the 2
exhaust manifold flange (2) to the front cylinder.

Tightening torque for nuts (1): 18 ftlb (25 Nm).


Š Unscrew and remove the three nuts (3) fastening the
exhaust manifold flange (4) to the rear cylinder.

Tightening torque for nuts (3): 18 ftlb (25 Nm).

WARNING
When sliding the exhaust manifolds (4-2) out of their
cylinders, be very careful to avoid damaging the
threads of the studs.
Š Rotate the exhaust manifold (4) and remove as shown
in the figure.
Š Move the exhaust pipe (2) forward until the flange is out
of the stud-bolts on the front cylinder.
4
Š 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.

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7.1.54 REMOVING THE SIDE STAND


3
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 7
2
Š Place the vehicle on the center stand.
WARNING
Be very careful to avoid damaging the switch (1).
Never loosen the nut (2) with the switch (1) installed.
Š Release the two springs (3).
Š Unscrew and remove the screw (4) and retrieve the
washer (5).
4
6 1 5
Tightening torque for screw (4): 7.3 ftlb (10 Nm).
Š Slide out the switch (1).
WARNING
When reassembling, place the switch (1) correctly,
with the seat inserted in the special rotation-proof
pin.
Upon reassembly, apply Loctite® 243 to the switch
(1).
Perform this procedure with the side stand retracted.
Š Loosen and remove the nut (2).

Tightening torque for nut (2): 18 ftlb (25 Nm).


Š Unscrew and remove the pin (6).

Tightening torque for pin (6): 7.3 ftlb (10 Nm).


Š Remove the stand (7).

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7.1.55 REMOVING THE ENGINE OIL TANK


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 8
INFORMATION), see 1.4.1 (FUEL) and 1.4.2
(LUBRICANTS).
Š Remove the left air inlet duct case, see 7.1.34
(REMOVING THE AIR INLET DUCT CASES).
Š Drain out all engine oil, see 2.13 (CHANGING THE
ENGINE OIL AND OIL FILTER).
NOTE Use the special click clamp installation pliers
(code 0277295); during reassembly, replace each clamp 4
2
with a new one of the same kind.
Š Release the clamps (2-3).
Š Remove the couplings (4-5).
Š Unscrew and remove the upper fastening screw (6).

Tightening torque for screw (6): 7.3 ftlb (10 Nm).


NOTE Replace the grommet if damaged.
Š Loosen and remove the two nuts (7-8).
3
Tightening torque for nuts (7-8): 3.6 ftlb (5 Nm). 5
NOTE If the two silent-blocks are damaged, replace 12
them.
Š Slide the tank (9) out of the two silent-blocks.
Š Release the clamp (10).
Š Pull the oil hose (11) out.
Š Remove the complete tank (9).
Š Unscrew and remove the engine oil filter (12) on the
tank, and clean with compressed air.
Š Check the seal of the oil tank filter (9), screw on and 6
tighten.
Š If necessary, unscrew and remove the two screws (13),
remove the level tube (1), and retrieve the seals.

Tightening torque for screws (13): 14.5 ftlb (20 Nm).


NOTE If the level tube and seals gaskets are damaged,
replace them.

9 7

13 11

10

1
9

13

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7.1.56 REMOVING THE ENGINE OIL RADIATOR


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 6
INFORMATION), see 1.4.2 (LUBRICANTS). 2

Š Drainout all engine oil, see 2.13 (CHANGING THE


ENGINE OIL AND OIL FILTER).
NOTE Use the special click clamp installation pliers 7
(code 0277295); during reassembly, replace each clamp
with a new one of the same kind. 4
Š Release the clamps (2-3).
Š Remove the couplings (4-5).
Š Unscrew and remove the three fastening screws (6-7-8). 9

Tightening torque for screws (6-7-8):


7.3 ftlb (10 Nm).
NOTE Replace the grommets if damaged. 1
Š Remove the radiator (1).

8
3
5

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7.1.57 REMOVING THE DRIVE CHAIN SHOE


Š Remove the guide plate, see 2.35.4 (INSPECTING
THE DRIVE CHAIN GUIDE PLATE). 4
3
NOTE Engage first gear to block rotation of the 2
countershaft sprocket (4) and allow you to unscrew the
screw (1).
5
Š Unscrew and remove the screw (1) retrieving the two
washers (2-3).
NOTE When reassembling, apply LOCTITE® 243 to 1
the thread of the screw (1).

Tightening torque for screw (1): 36 ftlb (50 Nm).


NOTE To make it easier to remove the countershaft
sprocket (4), slightly loosen the chain tension, see 2.35.3
(ADJUSTING THE DRIVE CHAIN).
Š Slide the drive countershaft sprocket (4) from the shaft,
complete with chain. 7
Š Remove the drive countershaft sprocket (4). 8
NOTE When reassembling, apply LOCTITE® Anti-
Seize on the internal spline of the countershaft sprocket
(4).
Š Remove the upper chain housing, see 7.1.58
(REMOVING THE UPPER CHAIN HOUSING).
Š Unscrew and remove the screws (5-6). 6

Tightening torque for screws (5-6): 2.9 ftlb (4 Nm).


Š Remove the shoe (7), pulling it out from the front.
NOTE When reassembling, correctly position the slot
in the shoe (7) over the seat (8) on the swinging arm, and
apply LOCTITE® 243.

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7.1.58 REMOVING THE UPPER CHAIN HOUSING


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand.
Š Unscrew and remove the screw (1). 1

Tightening torque for screw (1): 2.9 ftlb (4 Nm). 2


Š Unscrew and remove the screw (2).

Tightening torque for screw (2): 2.9 ftlb (4 Nm).


3
Š Unscrew and remove the screw (3).

Tightening torque for screws (3): 2.9 ftlb (4 Nm).


Š Unscrew and remove the two screws (4).

Tightening torque for screws (4): 2.9 ftlb (4 Nm). 5


Š Remove the line fastener (5) by lifting it out.
Š Remove the outer guard (7).
Š Move the odometer cable and rear brake line from the
upper chain housing (6).
Š Remove the upper chain housing (6) by sliding it out
from behind. 3

1 4

4
5

6
7

7.1.59 REMOVING THE REAR HOUSING


5 4
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 4
INFORMATION). 5
Š Place the vehicle on the center stand.
Š Remove the saddle support lower molded cover,
see 7.1.41 (REMOVING THE SADDLE SUPPORT 3
LOWER MOLDED COVER).
1
Š Unscrew and remove the two screws (3).
Š Unscrew and remove the four screws (1) fastening the
rear subframe (2) to the frame.
2
1
Tightening torque for screws (4): 18 ftlb (25 Nm).
Š Remove the rear housing (2), sliding it out from the
back.

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NOTE If necessary, remove the components fastened


to the rear housing (2), i.e.: 5 4
4
Š Remove the two tank rotation grommets (4), retrieving 5
the two spacers (5).
Š Remove the passenger footrest supports, see 7.1.43
(REMOVING THE PASSENGER FOOTREST
SUPPORTS).
3
1

2
1

7.1.60 REMOVING THE FRAME


5
WARNING
The frame (1) must be removed only at an Authorized
Service Center or by an Aprilia Dealer.
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION). 4
WARNING
Removing the frame (1) is a particularly complex 1
operation. Therefore, inspect the vehicle carefully
before proceeding. This chapter lists the procedures
2
progressively and in sequential order. 6 3
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.
Š Remove the engine, see 3.3 (REMOVING THE
COMPLETE ENGINE FROM THE FRAME).
Š Place the vehicle on the appropriate central support
stand , see 1.15.2 (PLACING THE VEHICLE ON
THE CENTER SUPPORT STAND).
Š Remove the front fork complete with front wheel,
see 7.1.1 (REMOVING THE SADDLE).
Š Remove the dashboard mount, see 7.1.25
(REMOVING THE DASHBOARD/FRONT FAIRING
MOUNT).
Š Remove the air inlet duct cases, see 7.1.34
(REMOVING THE AIR INLET DUCT CASES).
Š Remove the complete rear housing (4), see 7.1.59
(REMOVING THE REAR HOUSING).
Š Remove the rear drive train complete with rear wheel,
see 7.9.1 (REMOVING THE SWINGING ARM).
Š Remove rear shock absorber, see 7.10.1 (REMOVING
THE SHOCK ABSORBER).
Š Remove the control unit mount (3).
ŠDisconnect the terminals from the ignition coils.
WARNING
When reassembling, make sure the electrical
terminals are properly fitted.
Š Recover the fairing support plate (5).

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NOTE Be extremely careful while removing the control


unit support, to avoid damaging the control unit.
5
Š Remove the radiator mount (6).
Š Remove both of the rider footrest supports, see 7.1.45
(REMOVING THE LEFT RIDER FOOTREST
SUPPORT) and see 7.1.46 (REMOVING THE RIGHT
RIDER FOOTREST SUPPORT).
4
NOTE Release all cables from the clamps holding
them in place along their path. Have the same number of
clamps ready to use when reassembling. 1
Š Disconnect the electrical connector for the side stand 2
switch. 6 3
NOTE When reassembling, make sure the electrical
connector is fitted properly.
NOTE Be extremely careful while removing the side
stand support (8), to avoid damaging the switch.
7
Š Unscrew and remove the three screws (7) and remove
the side stand support (8), complete with side stand
and switch.

Tightening torque for screws (7): 29 ftlb (40 Nm).


Š Sling the frame (1) appropriately, and hook the slings to
a hoist for support.
8
NOTE The slings and hoist must be sufficient to safely
support the entire frame (1).
Frame weight: 21.8 lb (9.9 Kg).
Š Raise the frame (1) just enough to be able to remove
the center support stand .
Š Remove the center stand.
When you have finished re-installing the frame, proceed
as follows:
Š Make sure that all components are correctly fastened.
Š Make sure the cables and wiring are properly placed
and firmly fastened in place.
Š Make sure the electrical connectors are properly fitted.
Š Make sure that no cables or lines are pulled when
turning the handlebars.

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.

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7.2 FRONT WHEEL

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).

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7.2.1 REMOVING THE COMPLETE WHEEL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.32 (FRONT WHEEL)).
1
WARNING
During disassembly, take care not to damage the
brake lines, discs and pads. 4
Š Place the vehicle on the front support stand ,
see 1.15.1 (PLACING THE VEHICLE ON THE FRONT
SUPPORT STAND)
2
WARNING
Make sure the vehicle is stable.
Š Have someone hold the handlebars steady, in riding
position, so that the steering is blocked.
ŠUnscrew and remove the two screws (1) holding the
front brake caliper (2).

Tightening torque for brake caliper screws (1):


36.8 ftlb (50 Nm).
3
ŠSlide the brake caliper (2) from the disc, leaving it
attached to the brake line.

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.
Š Loosen and remove the nut (4), and retrieve the washer.

Tightening torque for wheel axle nut (4): 59 ftlb


(80 Nm).
Š Partially loosen the two axle clamp screws (5).

Tightening torque for the axle clamp screws (5): 3


16.2 ftlb (22 Nm).
6
Š Slide the axle (3) out from the left.
Š Remove the wheel, pulling it out from the front, and
retrieving the left spacer (6). 5
Š If necessary, dismantle the wheel completely, see 7.2.2
(DISMANTLING THE WHEEL).

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.

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7.2.2 DISMANTLING THE WHEEL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 1
INFORMATION). 3
Š Remove the wheel, see 7.2.1 (REMOVING THE
COMPLETE WHEEL).
Š Clean both sides of the hub with a clean cloth.
Š Remove the right spacer (1).
NOTE During reassembly, the right spacer (1) must be
2
placed with the larger side facing the right fork tube.
ŠRemove the seal (2). 5
Š Use a special extractor to extract the left bearing (4).
Š Remove the flex ring (3).
Š Use a special extractor to extract the right bearing (5).
WARNING
Check the bearings after every disassembly and
replace if needed; see 7.2.3 (CHECKING THE 5
COMPONENTS).
Š Retrieve the internal spacer (6).
Š Thoroughly clean the inside of the hub. 6
NOTE Wash all components with clean solvent.
2
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. 4
Make sure that the following parts are perfectly
touching:
- the right bearing (5) on the hub;
- the spacer (6) on the right bearing (5);
- the left bearing (4) on the spacer (6).

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7.2.3 CHECKING THE COMPONENTS

WARNING
Make sure all components are undamaged,
especially those listed below.
BEARINGS
1
Š 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
Š Make sure the gaskets are intact; replaced if damaged
or excessively worn.
WHEEL AXLE
Š Use a dial indicator to check the eccentricity of the axle
(2). If the eccentricity exceeds the limit value, replace 60 70
80

the axle (2). 50

40
90

100

Maximum eccentricity: 0.009 in (0.25 mm). 30

20
110

120

10

WHEEL RIM
Š 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
Š 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

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7.2.4 REINSTALLING THE WHEEL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).

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.
Š Spread a light coating of lubricant grease along the entire
length of the axle (1), see 1.12 (LUBRICANT CHART).
Š Place the left spacer (7) in its seat on the wheel.
Š Place the wheel between the fork tubes.
WARNING
Danger of injury.
Do not insert your fingers to align the holes.
Š Move the wheel until the center hole is aligned with the
holes on the fork.
Š Fully insert the axle (1).
Š Place the washer and tighten the nut (3) by hand.
Š For block the axle (1) rotation, tighten the two axle
clamp screws (4). 7

Tightening torque for the axle clamp screws (4):


16.2 ftlb (22 Nm).
Š Fully torque the nut (3).

Tightening torque for wheel axle nut (3): 59 ftlb


(80 Nm).
Š Tighten the two axle clamp screws (5).

Tightening torque for the axle clamp screws (5):


16.2 ftlb (22 Nm).

WARNING 1
Be very careful to avoid damaging the brake pads.
Š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.
ŠScrew and tighten the two brake caliper fastener
screws (2).

Tightening torque for brake caliper screws (2):


36 ftlb (50 Nm).
Š Loosen the two axle clamp screws (4).
Š Applying the front brake lever, press on the handlebar 2
repeatedly to push the fork down. This will allow the
fork tube to settle properly into position. 3
Š Tighten the two axle clamp screws (4).

Tightening torque for the axle clamp screws (4):


16.2 ftlb (22 Nm).
6
WARNING 5
After reassembly, operate the front brake lever
repeatedly and make sure the brake system is in
good working order.

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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).

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7.3.1 REMOVING THE COMPLETE WHEEL


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and see 2.33 (REAR WHEEL).

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.
Š Place the vehicle on the center stand.
Use the spanner wrench to unscrew and remove the
cap (1).
Š Remove the snap ring (2).
Š Slide out the screw locking nut (3).
Š Engage first gear to keep the wheel from turning.
Š Insert the bushing (5) supplied with the tool kit into the
screw hole (4).
Š 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:
Š Set the gearshift lever to neutral.
Š Turn the wheel so that the key (7) is at the bottom.
Š Completely remove the wheel (8).
Š Retrieve the centering bushing (9).

8 9

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7.3.2 REASSEMBLING THE REAR WHEEL

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.
Š Turn the drive shaft so that the key (1) is at the top. 1
Š Mount the wheel (2) on the drive shaft, making sure
that the three drive pins (3) are correctly inserted in the
wheel slots. 3
Š Engage first gear to keep the wheel from turning.
Š Make sure the key (1) is present on the drive shaft 3
seat.
Š Place the centering bushing (4) correctly, mating the
slot (5) with the key (1).
Š Spread a light coating of grease lubricant on the thread
of the wheel fastening screw (6).
2
Š Screw in the wheel fastening screw (6) by hand.
Š Insert the bushing (8) in the screw hole (7).
Š 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).
Š Tighten the wheel fastening screw (6).

Š Insert the screw locking nut (9) into the screw hole (7),
seeking the correct position for complete insertion.

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CHASSIS

Š Place the snap ring (10) correctly.

10

Š Return the plug (11) to its place, using the spanner


wrench (12).

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.

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7.4 FINAL DRIVE ASSEMBLY

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

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7.4.1 REMOVING THE FINAL DRIVE ASSEMBLY


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
1
Š Remove the wheel, see 7.3.1 (REMOVING THE 3
COMPLETE WHEEL).
Š Remove the lower chain shoe, see 7.1.57 (REMOVING
THE DRIVE CHAIN SHOE).
Š Loosen the drive chain tension, see 2.35.3 4
(ADJUSTING THE DRIVE CHAIN).
NOTE To remove the sprocket (8), see 7.4.4 2
(REMOVING THE SPROCKET).
Š Unscrew and remove the three safety screws (1-2).

Tightening torque for safety screws (1-2): 110.6


ftlb (150 Nm).

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
Š Insert the bushing (5) supplied with the tool kit into the
screw hole (4).
Š Insert the torque wrench into the hexagonal slot of the
bushing (5).

Š Unscrew and remove the axle fastening screw (3);


retrieve the Belleville washer (6) if it has fallen out.

Tightening torque for axle screw (3): 110.6 ftlb


(150 Nm).

6
3

Š Remove the hub (7) complete with sprocket (8) from


the axle (12).

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Š Retrieve the O-ring (9).

Š Unscrew and remove the six screws (10).


10
NOTE To unscrew the screws (10), we recommend 10
using an impact wrench, which delivers the sharp blow
needed to release the screws from the LOCTITE® 243.
12
Š Unscrew and remove the six brake disc screws (10).
WARNING
When reassembling, apply LOCTITE® 243 to the
thread of the brake disc screws.
NOTE When reassembling, insert all screws by hand
and cross-tighten. 10

Tightening torque for brake disc screws (10):


22.1 ftlb (30 Nm).
Š Lower the brake disc (11).
Š Slide the axle (12), complete with brake disc (10), out
from the right side. 13
Š Remove the snap ring (13).
Š Remove the snap ring (14).
WARNING
When reassembling the snap rings (13-14), make
sure that you hear the typical “click” indicating that
the ring is correctly fastened.
Š Remove the brake caliper support (15) complete with
brake caliper, keeping them attached to the brake line.
If necessary:
Š Remove the eccentric cam, see 7.4.3 (REMOVING
THE ECCENTRIC CAM).
15

14

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7.4.2 CHECKING THE COMPONENTS

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
Š Make sure that the flexible coupling grommets (1) are 2
not damaged and/or excessively worn. Replace the
grommets (1) if necessary.
sprocket
Š 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
Š Check the condition of the tire, see 2.36 (TIRES).

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7.4.3 REMOVING THE ECCENTRIC CAM


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove the swinging arm pivot, see 7.4.1
(REMOVING THE FINAL DRIVE ASSEMBLY).
Š Loosen the two screws (1).

Tightening torque for nuts (1): 25.8 ftlb (35 Nm). 1


Š Remove the snap ring (2).
Š Slide the eccentric cam out from the left side.
NOTE Remove the individual components if necessary.

7.4.4 REMOVING THE SPROCKET


Š Place the vehicle on the center stand.
Š Loosen the drive chain tension, see 2.35.3
1
(ADJUSTING THE DRIVE CHAIN).
Š Unscrew and remove the six nuts (1).
1
NOTE When reassembling, insert all nuts (1) by hand
and cross-tighten to torque.

Tightening torque for nuts (1): 18.4 ftlb (25 Nm).


Š Slide the sprocket out from the left side of the vehicle.
1
1

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7.5 FRONT BRAKES

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.

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7.5.1 CHANGING THE BRAKE PADS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.27 (CHECKING THE BRAKE
PAD WEAR).
Š Place the vehicle on the center stand.
NOTE The following steps refer to a single clamp, but
are applicable to both. 1
Š Use a pair of pliers to grasp the head of one piston,
then the other, and turn them just far enough to bring
the two pin locks (1) into a position from which they
may be extracted.
Š Remove the two pin locks (1).
Š Remove the two pins (2).
Š Retrieve the protective cover (3).
NOTE Using a pair of pliers, take first one pad then the
other, and shake them gently back and forth to eliminate
any pressure by the caliper pistons, and make it easier to
remove the pads.
Š Extract the two pads (4). 3

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.
Š 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.
Š Place the protective cover (3) with the engraved arrow
facing upwards.
Š Insert the two pins (2).
Š Insert the two pin locks (1).
Š Check the brake fluid level, 2.16
(CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID).

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7.5.2 CHECKING THE BRAKE DISCS


NOTE The operations described below should be
carried out with the brake discs installed on the wheel;
they refer to a single disc, but are applicable to both.
Š Check the disc wear, using a micrometer gauge to
measure the minimum thickness at various points on
the disc.
If the smallest thickness is below the minimum value,
even in a single part of the disc, replace the disc.
Minimum disc thickness: 0.18 in (4.5 mm).
Š Use a dial indicator to make sure that the disc does not
wobble beyond the stated tolerance; otherwise replace
it, see 7.5.3 (REMOVING THE BRAKE DISCS).
Disc wobble tolerance: 0.01 in (0.3 mm).

7.5.3 REMOVING THE BRAKE DISCS


Carefully read 0.5.1 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Removethe front wheel, see 7.2.1 (REMOVING THE
COMPLETE WHEEL).
NOTE The following information refers to a single disc,
but is applicable to both.
To unscrew the screws (1), we recommend using an
impact wrench, which delivers the sharp blow needed to
release the screws from the LOCTITE® 243.
Š Unscrew and remove the six brake disc screws (1).
WARNING
When reassembling, apply LOCTITE® 243 to the
thread of the brake disc screws.
NOTE When reassembling, screw all the screws (1) by
hand and cross-tighten in the following order: A-B-C-D-E-
F. 2

Tightening torque for brake disc screws (1):


22.1 ftlb (30 Nm).
Š Remove the brake disc (2).

7.5.4 REMOVING THE BRAKE MASTER CYLINDER


See 7.1.15 (REMOVING THE FRONT BRAKE
A
CONTROL).

C
F

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7.6 REAR BRAKE

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.

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7.6.1 CHANGING THE BRAKE PADS


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 1
INFORMATION) and 2.27 (CHECKING THE BRAKE
PAD WEAR).
Š Place the vehicle on the center stand.
1
NOTE It will be easier to work if you remove the rear
wheel, 7.3.1 (REMOVING THE COMPLETE WHEEL).
2
Š Remove the two cotter pins (1).
Š Slide the pivot (2) out from the right side.
Š Remove the brake pads (3).
Š Retrieve the safety springs (4).
3
WARNING
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. 1
4 2
Š Insert two new pads, placing them so that their holes
are aligned with those on the clamp.
1
WARNING
Always replace both pads, and make sure they are
correctly positioned inside the clamp.
Š When reassembling, be sure to place the two safety
springs (4) correctly. 3
Š Check the brake fluid level, see 2.17 (CHECKING AND
TOPPING UP THE REAR BRAKE FLUID).

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7.6.2 REMOVING THE REAR BRAKE CALIPER


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Place the vehicle on the center stand.
NOTE For space reasons, it is advisable to remove the
rear wheel, see 7.3.1 (REMOVING THE COMPLETE
WHEEL).
Š Slide out the safety spring (1).
Š Unscrew and remove the screw (2). 2
1
Tightening torque for screw (2): 18 ftlb (25 Nm).
Š Turn the caliper (3) upwards.
Š Slide the caliper (3) out from the left.
Š The caliper (3) remains attached to the rear brake line
(4). 4
Š Ifnecessary, empty the rear brake system, see 2.22
(CHANGING THE REAR BRAKE FLUID). 5
Š Unscrew and remove the screw (5) and retrieve the two
gaskets (6). 6

Tightening torque for screw (5): 14.5 ftlb


(20 Nm).

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7.6.3 CHECKING THE BRAKE DISC


NOTE These operations should be carried out with the
brake disc installed on the wheel.
Š Check the disc wear, using a micrometer gauge to
measure the minimum thickness at various points on
the disc.
NOTE If the smallest thickness is below the minimum
value, even in a single part of the disc, replace the disc,
see 7.6.4 (REMOVING THE BRAKE DISC).
Minimum disc thickness: 0.18 in (4.5 mm).
Š Use a dial indicator to make sure that the disc does not
wobble beyond the stated tolerance; otherwise replace
it, see 7.6.4 (REMOVING THE BRAKE DISC).
Disc wobble tolerance: 0.01 in (0.3 mm).

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7.6.4 REMOVING THE BRAKE DISC


Carefully read see 1.3.9 (PRECAUTIONS AND
GENERAL INFORMATION).
3
Š Remove the final drive assembly, see 7.4.1
(REMOVING THE FINAL DRIVE ASSEMBLY). 2
Š Slip the brake caliper off the disc, see 7.6.2
(REMOVING THE REAR BRAKE CALIPER).
Š Remove the clamp plate (1).
Š Place the piston, complete with disc, on the vice,
inserting a soft material (aluminum) between the jaws.
NOTE To unscrew the screws (2), we recommend
using an impact wrench, which delivers the sharp blow 1 2
needed to release the screws from the LOCTITE® 243. 2
Š Unscrew and remove the six screws (2).
WARNING
When reassembling, apply LOCTITE® 243 to the A
thread of the screws (2).
C
NOTE When reassembling, insert all screws by hand
and cross-tighten in the following order: A-B-C-D-E-F.
F
Tightening torque for brake disc screws (2): E
21.7 ftlb (30 Nm).
Š Remove the brake disc (3).
D
B

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7.6.5 REMOVING THE BRAKE MASTER CYLINDER


Š Remove the right lower fairing, see 7.1.33 1
(REMOVING THE LOWER FAIRING).
Š Carry out the first three steps described in the
paragraph see 2.22 (CHANGING THE REAR BRAKE
FLUID).
Š When all the fluid has drained out, unscrew and
remove the screw (1) and retrieve the two seals. 2

Tightening torque for screw (1): 14.5 ftlb (20 Nm).


Š Loosen and remove the click clamp (2).
Š Pull the hose (3) from the fitting on the master cylinder. 3
Š Unscrew and remove the two screws (4).

Tightening torque for screws (4): 7.3 ftlb (10 Nm).


Š Retrieve the guard (5). 5
Š Slide the master cylinder (6) out.
NOTE When reassembling top up brake fluid, see 2.17
(CHECKING AND TOPPING UP THE REAR BRAKE
FLUID) and bleed the brake system, see 2.19
(BLEEDING THE BRAKE SYSTEMS).
4

6
2 3

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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).

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7.7.1 DISASSEMBLING THE STEERING


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.28 (STEERING).
Š Place the vehicle on a lift platform on the center stand.
Š Carry out the first eleven steps described in the chapter
see 2.28.2 (ADJUSTING THE BEARING PLAY).
Š Unscrew and remove the screw (1).
Š Retrieve the bracket (2).
Š Slide out both fork tubes, see 7.8.3 (DISASSEMBLING 1
THE LOWER FORK TUBE/UPPER FORK TUBE 2
UNIT).
Š Use the special socket wrench to loosen and
remove the lock ring adjuster (3).

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.
Š 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.
Š Retrieve the dust ring (4).
Š Remove the upper dust ring (5).
Š Extract the bearing (6).
Š 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

7.7.2 CHECKING THE COMPONENTS

WARNING
Make sure all components are undamanged,
especially those listed below.
BEARINGS AND GASKETS see 7.2.3 (CHECKING THE
COMPONENTS).

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7.7.3 REASSEMBLING THE STEERING


NOTE For reassembly, the vehicle and front fork must
be placed as for disassembly. Then proceed with the
same steps in reverse order from disassembly.
1
Š Spread a light coating of grease along the entire length
of the pivot (1), see 1.12 (LUBRICANT CHART).
Š Before fully tightening the adjusting ring nut (2), turn
the steering several times in both directions to allow the
bearings to settle.
Š Proceed with adjusting the bearing play, see 2.28.2
(ADJUSTING THE BEARING PLAY).
Š As you turn the handlebars, make sure that the cables
and tubes are not pulled taut, twisted and/or crossed.
Š Top up brake fluid, see 2.16 (CHECKING AND
TOPPING UP THE FRONT BRAKE FLUID).

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7.8 FRONT FORK

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

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7.8.1 CHANGING THE FORK OIL


Carefully read 1.4.2 (LUBRICANTS) and 2.29.2
(ADJUSTING THE FRONT FORK).
Š Carry out the operations marked with the symbol “ z ”
described in the chapter 7.8.3 (DISASSEMBLING
THE LOWER FORK TUBE/UPPER FORK TUBE
UNIT).
Š Carry out the operations marked with the symbol “ z ”
described in the chapter 7.8.5 (REASSEMBLING THE
UPPER/LOWER FORK TUBE UNIT).

7.8.2 REMOVING THE FORK TUBES


1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.29 (INSPECTING THE FRONT
SUSPENSION).
NOTE The following steps refer to a single upper/lower
fork tube unit, but are applicable to both.

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
Š Place the vehicle on the center support stand on a lift
platform, with the front wheel protruding beyond the
edge of the platform.
Š Use belts to fasten the rear drive train to the platform
so as to raise the front wheel.
Š Remove the front wheel, see 7.2.1 (REMOVING THE 7
COMPLETE WHEEL). It is not necessary to use the
front support stand .
Š Remove the front fender, see 7.1.26 (REMOVING THE
FRONT MUDGUARD).
Š 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).
Š Remove the front panel, see 7.1.32 (REMOVING THE 3
FRONT FAIRING LOWER LOCKUP).
Š Loosen the screw (3) fastening the fork head (4) to the
upper fork tube (5).

Tightening torque for screw (3): 18 ftlb (25 Nm).


5
Š Loosen the screw (6) fastening the handlebar (7) to the
upper fork tube (5). 8
9

Tightening torque for screw (6):21.7 ftlb(30 Nm).


10
Š Loosen the two screws (8) fastening the triple clamp (9)
to the upper fork tube (5).

Tightening torque for screws (8): 18 ftlb (25 Nm).


Š Remove the lower fork tube (10) and upper fork tube
(5) as a unit from the fork head (4) and triple clamp (9),
raising the lift platform.

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NOTE Where necessary, remove the other lower fork


tube/upper fork tube unit.

7.8.3 DISASSEMBLING THE LOWER FORK TUBE/


UPPER FORK TUBE UNIT
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.2 (LUBRICANTS) and 2.29 3
(INSPECTING THE FRONT SUSPENSION).
NOTE The right and left upper/lower fork tube units
have the same internal components. 4
The following steps refer to a single upper/lower fork tube 1
unit, but are applicable to both.
The operations marked with the symbol “z” also refer to
2
changing the fork oil.
ŠzRemove the upper/lower fork tube unit, 7.8.2
(REMOVING THE FORK TUBES).
ŠzThoroughly clean the entire upper/lower fork tube
unit.
C

NOTE Before proceeding with the operations that


follow, make sure you have on hand the special tools
(A), (B), (C) and a container with a capacity greater than
550 cm³.

WARNING
Proceed very carefully with disassembly operations.
ŠzTurn the upper screw adjuster (1) all the way counter-
clockwise to reduce the hydraulic damping on
5
extension.
ŠzRemove the retainer ring (2).
ŠzUnscrew and remove the spring preload adjuster (3).
ŠzRemove the spring preload (4) thruster.
ŠzPlace 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
ŠzLoosen the upper fork tube cap (5).
ŠzRemove the fork tube unit from the vice. A1
ŠzHolding the fork tube unit upright, completely
unscrew the upper fork tube cap (5).
ŠzUnscrew and remove the threaded pin (A1) from the 6
tool (A).
ŠzPlace the stationary part of the tool (A) so that the
tooth engages the hole on the spring spacer tube (6).
ŠzPlace 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

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WARNING
The following operations must be carried out by two
mechanics. Before starting, agree which mechanic 7 B
will handle which operations.
ŠzRest both hands on the tool (A).
ŠzPush downward, at the same time inserting the tool
(B) between the lock nut (7) and the washer (8).

8
A

ŠzWhile holding the damper rod (9), unscrew the upper


fork tube cap (5) using the appropriate wrench.

ŠzRest both hands on the tool (A).


ŠzPush downward, at the same time removing the tool
(B).
ŠzRemove the tools (A). B

ŠzRemove the washer (8).


ŠzRemove the slider bushing (10).
8

10

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NOTE Before removing them completely, hold the


spring spacer tube (6) and the spring (11) above the fork
tube, so that some of the oil remaining on these
components drains down inside the fork tube.
6
ŠzRemove the spring spacer tube (6) complete with
spring seat and slider ring.
ŠzSlip off and remove the spring (11). 11

ŠzTurn 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.
Š 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

Š Use a blade screwdriver to gently pry all around the


edge of the dust seal (15), to remove it from the upper
fork tube.

15

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Š Use a blade screwdriver to remove the retainer ring


(16).

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.
Š 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
Š Use a blade screwdriver to slightly widen the bushing
(17) and remove it from the lower fork tube (21).
21

Š Remove the following components from the tube (21) in


the given order:
- guide bushing (20);
- ring (19);
- gasket (18);
- stop ring (16);
- dust seal (15).

20
19
18
16
15

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Š Place the lower fork tube (21) in a vice, inserting a soft


material (aluminum) between the jaws. 21

Š Unscrew and remove the center screw (23) and


retrieve the copper washer (24).

24
23

Š Remove the complete damper (9) from the lower fork


tube (21).

WARNING
The damper (9) must not be disassembled.

21

Š Remove the centering bushing (25).


WARNING
Wash all components with clean solvent.

25

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7.8.4 CHECKING THE COMPONENTS


LOWER FORK TUBE
Š Inspect the sliding surface to make sure it is not 60 70
80

scratched or scored.
50 90

40 100

30 110

Slight scratches may be eliminated by sanding with


20 120

10

very fine (1200 grit) wet sandpaper.


If the scratches are deep, replace the tube (1).
Š Use a dial indicator to make sure any bending in the
fork tube (1) is less than the acceptable limit.
If greater than the limit, replace the fork tube.
1
Bending limit: 0.008 in (0.2 mm).

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
Š Make sure it is not damaged and/or cracked; if so,
replace.
2
SPRING
Š Make sure the spring (2) is intact, and that its length is
within the prescribed limit.
Š If the length does not match the prescribed limit,
replace the spring (2).
Minimum free length of the spring: 9.76 in (284 mm)
Š 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.
Š 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

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7.8.5 REASSEMBLING THE UPPER/LOWER FORK


TUBE UNIT
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION), 1.4.2 (LUBRICANTS) and 2.29
(INSPECTING THE FRONT SUSPENSION).
NOTE The operations marked with the symbol “z” also
describe the procedure for changing the fork oil.

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
Š 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).
Š Insert the centering bushing (2) on the bottom of the
damper rod (3).
Š Slide the damper rod (3) into the lower fork tube (1),
making sure it rests firmly on the base.
Š Place the copper washer (5) on the center screw (4).
Š Insert and tighten the center screw (4).
5
Tightening torque for center screw (4): 25.8 ftlb 4
(35 Nm).
Š Remove the lower fork tube (1) from the vice.
Š 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

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Š Slide the following components, in order, onto the lower


fork tube (1):
- dust seal (6);
- stop ring (7);
6

NOTE Slip on the gasket (8), with the labeled side


facing the retainer ring (7).
- gasket (8);
- ring (9);
- guide bushing (10).
Š Move the aforementioned five components down
towards the lower fork tube.
Š Remove the tape from the end of the lower fork tube
(1).
1

Š Use electrician's tape to hold the guide bushing (10) in


place.
Š Reassemble the slider bushing (11) on the lower fork 10
tube (1).

11

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Š Insert the lower fork tube (1) into the upper fork tube
(12).
Š Remove the tape.
Š Place the two halves of the tool (D) on the lower fork
tube (1), in front of the guide bushing (10).
Š Grip the tool (D) and push the guide bushing (10) into
position in its seat on the upper fork tube (12).
Š Remove the tool (D).

1 9
10
12

Š Install the ring (9), making sure it is in the correct


position.
Š Place the two halves of the tool (D) on the lower fork
tube (1), above the gasket (8).
Š Grasping the tool (D), force the gasket (8) into its seat
in the upper fork tube (12), making sure that it is driven D
fully home.
Š Remove the tool (D). 2
8

12

Š Install the retainer ring (7) into its appropriate seat on


the upper fork tube (12).
Š Place the two half-cylinders of the tool (D) on the lower
fork tube (1), above the dust seal (6).
D
Š Grasping the tool (D), push the dust seal (15) into its
appropriate seat on the upper fork tube (12), making
sure that it is correctly placed.
ŠzGrasp the lower fork tube (1) and slowly move it up 6
and down a few times. 1
NOTE The lower fork tube (1) must slide freely and
smoothly in the upper fork tube (12), without
encountering any resistance; if not, this means that the 12
6
guide bushing (10), slider bushing (11), or gasket (8) is
damaged.
ŠzKeeping the upper fork tube (22) upright, push the
upper fork tube (22) down to the end of its stroke.
ŠzPush the upper fork tube (22) down to the end of its
stroke. 13
Pour fork oil into the lower fork tube, see 1.12
(LUBRICANT CHART), until it reaches the correct
level. Insert a dipstick (13) into the lower fork tube to
measure the level. 12
4.64 ± 0.07 in

Amount of oil: 31.73 ± 0.15 cuin (520 ± 2.5 cm³). 1


Oil level: 4.64 ± 0.07 in (118 ± 2 mm) (from the edge of
the upper fork tube).
11
NOTE The upper fork tube (12) must be perfectly
upright in order to gauge the oil level accurately.
The oil level must be the same in both tubes.

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ŠzGrasp the upper fork tube (12) and slide it slowly up


and down about ten times, for approximately 6 inches
(150 mm), to allow any trapped air to escape.
ŠzPush the upper fork tube (12) down to the end of its 14
stroke. 15
ŠzWait a few minutes and check the oil level again; top
up if necessary.
ŠzInsert the following components in the tube (1) in the
given order:
- lower collar (14); 1
- lower spring seat (15);
- spring (16);
- spring spacer tube (17) complete with spring seat and
slider ring;
- slider (18);
- washer (19).
ŠzUnscrew and remove the threaded pin (A1) from the
tool (A).
ŠzPlace the stationary part of the tool (A) so that the
tooth engages the hole on the spring spacer tube (17). 17
ŠzPlace 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 (17).
16

19

10

17

A
A1
A

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WARNING
The following operations must be carried out by two
mechanics. 20 B
Before starting, agree which mechanic will handle
which operations.
ŠzRest both hands on the tool (A).
ŠzPush downward, at the same time inserting the tool
(B) between the lock nut (20) and the washer (19).
ŠzWhile 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).
ŠzRest both hands on the tool (A).
ŠzPush downward, at the same time removing the tool
(B).
ŠzRemove the tools (A).
ŠzPlace the lower fork tube- upper fork tube unit in a
vice using the two halves of the special tool (C).
ŠzScrew 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
ŠzInsert the spring preload thruster (22).
ŠzScrew on the spring preload adjuster (23).
ŠzPlace the retainer ring (24) in its seat.
ŠzUse 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

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7.8.6 INSTALLING THE LOWER FORK TUBE/UPPER


FORK TUBE UNIT
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.29 (INSPECTING THE FRONT
SUSPENSION). 4
Š Install the upper fork tube (1) and lower fork tube (2)
together on the triple clamp (3) and fork head (4).
Š Insert the axle (5) through both tubes to align the lower
fork tube holes.
Š Make sure that the upper fork tube (1) is correctly
inserted into the triple clamp (3) and fork head (4).
Š Tighten the two screws (6) fastening the triple clamp 3
(3) to the upper fork tube (1).

Tightening torque for screws (6): 18 ftlb (25 Nm).


ŠLubricate the thread of the screw (7), and tighten. 1

Tightening torque for screw (7): 21.7 ftlb


(30 Nm).
Š Tighten the screw (8) fastening the fork head (4) to the
upper fork tube (1). 2

Tightening torque for screw (8): 18 ftlb (25 Nm).


Š Lower the lift platform.
Š Remove the axle (5).
Š Reassemble the wheel, see 7.2.1 (REMOVING THE
COMPLETE WHEEL).
Š Remove the belts fastening the rear drive train to the
platform.

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

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7.9 SWINGING ARM

7.9.1 REMOVING THE SWINGING ARM 2


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.30 (SWINGING ARM).
Š Place the vehicle on the center stand.
Š Remove the rear wheel, see 7.3.1 (REMOVING THE
COMPLETE WHEEL).
Š Remove both side fairings, see 7.1.28 (REMOVING 1
THE SIDE FAIRINGS).
Š Remove both lower fairings, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Š Remove the countershaft sprocket case, see 2.35.4 3
(INSPECTING THE DRIVE CHAIN GUIDE PLATE).
Š Unscrew and remove the nut (1) and remove the pin
(2).
7
Tightening torque for nut (1): 36 ftlb (50 Nm).
4
Š Remove the double connecting rod (3) from the 6
swinging arm, leaving it attached to the frame.
Š Remove the sprocket hub, following the first ten steps 9
in paragraph 7.4.1 (REMOVING THE FINAL DRIVE
ASSEMBLY).
NOTE Engage first gear to prevent rotation of the
countershaft sprocket (4) and allow you to unscrew the 5
screw (5).
Š Unscrew and remove the screw (5), retrieving the two
washers (6-7), and remove the countershaft sprocket
(4).

Tightening torque for screw (5): 36 ftlb (50 Nm).


Š Remove the expansion tank, see 7.1.52 (REMOVING
THE EXPANSION TANK).
Š Remove rear shock absorber, see 7.10.1 (REMOVING
THE SHOCK ABSORBER). 8
Š Remove both the rider footrest supports, see 7.1.45
(REMOVING THE LEFT RIDER FOOTREST
SUPPORT) and 7.1.46 (REMOVING THE RIGHT
RIDER FOOTREST SUPPORT).
Š Remove the rear brake master cylinder and the rear
brake oil reservoir, see 7.6.5 (REMOVING THE
BRAKE MASTER CYLINDER).
Š Disconnect the odometer sensor connector (8) from
the main wiring.
NOTE When reassembling, make sure the connector
(8) is fitted properly.
Š Unscrew and remove the nut (9), retrieving the washer.
10

Tightening torque for nut (9): 65 ftlb (90 Nm).


NOTE Have on hand the special tool code 11
8140203 (socket wrench for adjusting swinging arm pivot
- engine mounts).
Š Use the special socket wrench to loosen and remove
the lock ring (10). 12
Š Working from the right-hand side of the vehicle, rotate
the swinging arm pivot (11) counter-clockwise, which
will cause the adjuster bushing (12) to rotate with it and
will loosen it completely.

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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.
Š Support the front part of the swinging arm, and
simultaneously remove the swinging arm pivot (11) out
from the right.
Š 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.
Š 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).

7.9.2 DISASSEMBLING THE SWINGING ARM


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION).
Š Remove the swinging arm, see 7.9.1 (REMOVING
8
THE SWINGING ARM).
Š Use a rag to clean both sides of the bearing housings.
Š Slip off the bushing (1). 1
Š Remove the seal (2).
Š Remove the seal (3).
Š Remove the snap ring (4).
Š Use a special extractor to remove the two bearings (5) 6
and the roller bearing (6).
2
NOTE Inspect the bearings each time the swinging
arm is disassembled. Replace if necessary.
Š Remove the internal shim (7) and retrieve the two O-
rings (8).
Š Thoroughly clean inside the bearing seat. 3
5
NOTE Wash all components with clean solvent.
WARNING 7
When reassembling, insert the bearings using a drift
with the same diameter as the outer ring of the
bearings. 4
Do not strike the balls and/or inner race.
8

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7.9.3 CHECKING THE COMPONENTS

WARNING
Make sure that none of the components are visibly 1
bent, broken, cracked and /or dented.
Replace any damaged components.
BEARINGS
Š 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
Š Make sure the gaskets are intact; replaced if damaged
60 70
80
50 90

40 100

or excessively worn. 30

20
110

120

10

SWINGING ARM PIVOT


0

Š Use a dial indicator to make sure that the swinging arm


pivot (2) eccentricity does not exceed the allowable
limit.
If not, replace the pivot (2).
Maximum pivot eccentricity: 0.012 in (0.3 mm).
2

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7.9.4 RE-INSTALLING THE SWINGING ARM


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.30.1 (ADJUSTING THE
SWINGING ARM). 4
Š Spread a light coating of lubricant grease along the
entire length of the swinging arm pivot (1), see 1.12
(LUBRICANT CHART). 1
Š Insert the adjuster bushing (2) in its seat and screw it
on by hand.
NOTE The adjuster bushing (2) must not protrude 2
beyond the inside edge of the frame.
Š Place the drive chain (3) over the front left part of the
swinging arm, and tape it in place.

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
Š 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).
Š Fit the lock ring (4) and screw it on by hand a few turns.
Š Place the washer (5) and nut (6) on the swinging arm
pivot, tightening them by hand.
Š Now adjust the swinging arm, see 2.30.1 (ADJUSTING
THE SWINGING ARM).
Š Remove the tape to release the chain (3)
Š 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
Š Insert the countershaft sprocket (7) complete with
chain (3) on the shaft.
NOTE Apply LOCTITE® 243 to the thread of the screw
(8).
Š Place the washers (9) and (10) over the screw (8).
Š Screw in and tighten the screw (8).

Tightening torque for screw (8): 36 ftlb (50 Nm).


Š Replace the voltage regulator, see 2.35.4
(INSPECTING THE DRIVE CHAIN GUIDE PLATE).
Š Adjust the drive chain tension, see 2.35.3
(ADJUSTING THE DRIVE CHAIN).
Š Connect the odometer sensor connector (13) to the
main wiring.
Š Replace the rear brake master cylinder and brake oil
reservoir, see 7.6.5 (REMOVING THE BRAKE
MASTER CYLINDER).

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Š Replace both rider footrest supports, see 7.1.45


(REMOVING THE LEFT RIDER FOOTREST
SUPPORT) and 7.1.46 (REMOVING THE RIGHT 16
RIDER FOOTREST SUPPORT).
Š Replace the rear shock absorber, see 7.10.1
(REMOVING THE SHOCK ABSORBER).
Š Replace the expansion tank, see 7.1.52 (REMOVING
THE EXPANSION TANK).
Š Replace the sprocket hub, see 7.4.1 (REMOVING THE
FINAL DRIVE ASSEMBLY). 15
Š Replace the rear wheel, see 7.3.1 (REMOVING THE
COMPLETE WHEEL).
Š Replace the double connecting rod (14) tightening the
nut (15) on the pivot (16). 14

Tightening torque for nut (16): 36 ftlb (50 Nm).


Š Replace the shift lever (11) on the serrated gearbox 11
pivot, making sure that it is properly aligned.
Š Tighten the screw (12).

Tightening torque for screw (12): 7.2 ftlb (10 Nm).


Š Replace both lower fairings, see 7.1.33 (REMOVING
12
THE LOWER FAIRING).
Š Replace both side fairings, see 7.1.28 (REMOVING
THE SIDE FAIRINGS).

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7.10 REAR SUSPENSION

7.10.1 REMOVING THE SHOCK ABSORBER


1
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.31.1 (REAR SUSPENSION).
Š Remove both lower fairings, see 7.1.33 (REMOVING
THE LOWER FAIRING). 3
Š Remove the tank, see 7.1.6 (REMOVING THE FUEL
TANK COMPLETELY).
Š Remove the exhaust pipes, see 7.1.51 (REMOVING
THE EXHAUST PIPES).
2
NOTE It will be easier and you will have more room to
work if you remove the rear wheel, see 7.3.1
(REMOVING THE COMPLETE WHEEL).
Š Remove both the passenger footrest supports,
see 7.1.43 (REMOVING THE PASSENGER 10
FOOTREST SUPPORTS).
Š Loosen the two upper screws (1). 5 4
10

Tightening torque for screws (1): 36 ftlb (50 Nm).


7
Š Unscrew and remove the two lower screws (2). Frame

Tightening torque for screws (2): 36 ftlb (50 Nm).


11
Š Pull the drain tube (3) from its slot.
12
WARNING 6
When reassembling, make sure the drain tube (3) is 12 11
fitted properly.
Š Raise the rear housing.
Š Working from the left side of the vehicle, loosen and
remove the nut (4) and push the screw (5) partially out.
NOTE Replace the nut (4) if you find it to be damaged.
Tightening torque for nut (4): 36 ftlb (50 Nm).
4
Š Remove the screw (5) from the opposite side.
Š Working from the right side of the vehicle, loosen and
remove the nut (6).
5 6
Tightening torque for nut (6): 36 ftlb (50 Nm).
Š Remove the screw (7) from the opposite side.
WARNING
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 (8).
Š Grasp the shock absorber (9) and remove it by pulling it
up and at the same time rotating it backwards.
Š Push the shim (10) inward on the upper attachment
clevis of the shock absorber. 8
Š Slide the two bushings (11) and the two O-rings (12)
onto the lower attachment clevis. 9
NOTE Wash all components with clean solvent.
Š Check the components, see 7.10.4 (CHECKING THE
COMPONENTS).

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7.10.2 DISASSEMBLING THE REAR SUSPENSION


LINKAGE
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.31.1 (REAR SUSPENSION). 3
2
Š Remove both the lower fairings, see 7.1.33 6
(REMOVING THE LOWER FAIRING).
Š Working from the right side of the vehicle, loosen and
remove the nut (1).

Tightening torque for nut (1): 36 ftlb (50 Nm). 1


Š Remove the screw (2) from the opposite side. 5
Š Loosen and remove the nut (3).

Tightening torque for nut (3): 36 ftlb (50 Nm).


Š Remove the screw (4) from the opposite side.
Š Loosen and remove the nut (5).
2
Tightening torque for nut (5): 36 ftlb (50 Nm).
Š Remove the screw (6) from the opposite side.
Š Remove the complete suspension linkage assembly 4
(7). 7
NOTE When reassembling, grease the linkage pivot
points, see 1.12 (LUBRICANT CHART). Be extremely
careful that all parts are correctly positioned, and check
several times that all joints move smoothly.
Š Perform a thorough inspection after reassembly,
see 2.31.3 (CHECKING THE REAR SUSPENSION
LINKAGE).

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7.10.3 DISASSEMBLING THE SUSPENSION


LINKAGE
Carefully read 1.3.9 (PRECAUTIONS AND GENERAL 2
INFORMATION).
5
Š Loosen and remove the nut (1).
7
8
Tightening torque for nut (1): 36 ftlb (50 Nm).
6
Š Remove the screw (2). 1
Š Remove the two double connecting rods (3-4).
Š Remove the two seals gaskets (5). 8
Š Use a special extractor to remove the two roller 10
9
bearings (6). 10 6 5
Š Retrieve the internal spacer (7).
Š Remove the two seals gaskets (8).
Š Remove the internal spacer (9).
Š Use a special extractor to remove the two roller 3
bearings (10).
NOTE Wash all components with clean solvent.
NOTE During reassembly, couple the single
connecting rod (11) to the double connecting rods (3-4) 4
as shown in the figure; the arrow on the top side must be
facing the direction in which the vehicle travels.

11

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7.10.4 CHECKING THE COMPONENTS

WARNING
Make sure that none of the components are visibly
bent, broken, cracked and /or dented.
Replace any damaged components.
BEARINGS
Š 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
Š Make sure the gaskets are intact; replaced if damaged
or excessively worn.
SHOCK ABSORBER
Š 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).

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7.11 DISASSEMBLING THE DRIVE CHAIN

7.11.1 CHAIN BREAKER/RIVET TOOL


NOTE This tool (code 8140192) is designed for
breaking/riveting chains with rivet-type links.

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

Tool legend: Chain legend:


1) Main body
13) Master plate
2) Tied hexagonal boss (for 27-mm wrench)
14) O-rings
3) Hex-head screw (for 19-mm wrench)
15) Rivet plate
4) Locating dowel
5) Rivet tool
6) “A” and “B” reference marking
7) Location holes for joining pins
8) Pin exit hole
9) Pusher
10) Breaking side
11) Joining side
12) Support plate

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7.11.2 BREAKING THE CHAIN


Carefully read 1.3.9 (PRECAUTIONS AND GENERAL
INFORMATION) and 2.35 (DRIVE CHAIN).
Š Remove the countershaft sprocket case, see 2.35.4 1 3
(INSPECTING THE DRIVE CHAIN GUIDE PLATE).
Š Loosen the chain tension, see 2.35.3 (ADJUSTING
THE DRIVE CHAIN).
NOTE Make sure that the tool is suited to the type of 2
chain installed on the vehicle and the size of the chain's
links.
Š Place the rivet tool (1) on the lower segment of the
chain, at a point between the front and rear sprocket.
Š Move the rivet tool (1) to align the central pin exit hole
with the chain pin to be pushed out.
Š Insert the largest diameter of the pusher (2) inside the
main body(3).
Š Fit the main body (3) on the rivet tool (1). 1 1
Š Move the main body (3) so that the locating dowel (4) is 4 3
in line with mark “A” on the rivet tool (1).
Š Turn the screw (5) by hand until the pusher (2) touches
the pin to be pushed out. 5
NOTE Make sure that the pusher (2) is perfectly
aligned with the pin to be pushed out.
Š Use a 27-mm wrench over the tied hexagonal boss on
the central body (3) to hold the body in place. 3
5
Š Use a 19-mm wrench to turn the screw (5) until it
pushes the chain pin all the way out.
Š Loosen the screw (5).
Š Repeat the above procedure on the adjacent pin on the
same link.
Š Remove the components of the disconnected link and
the four O-rings.
Š Remove the chain.
WARNING
If the chain is worn beyond its useful service life,
replace the entire assembly (countershaft sprocket,
rear sprocket and chain), see 7.4.1 (REMOVING THE
FINAL DRIVE ASSEMBLY).

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7.11.3 PLACING THE MASTER LINK

WARNING
Make sure that the master link is the same type as 6
the chain to be joined.
Š 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.
Š 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
Š Join the two ends of the chain and insert master link
pins. Insert an O-ring on the tip of each pin.
3
Š Slip the rivet plate over the pins.
Š Fit the support plate (6) on the rivet plate.
Š Fit the rivet tool (1) onto the chain.
Š Move the rivet tool (1) so that its side holes match the
heads of the pins on the joining plate.
Š Insert the smallest diameter of the pusher (2) into the 1
main body (3). 4
Š Fit the main body (3) on the rivet tool (1). 1
Š Move the main body (3) so that the locating dowel (4) is 3
in line with mark “A”.
Š Turn the screw (5) by hand until the pusher (2) touches
the support plate (6). 5
Š Hold the central body (3) stationary using a 1.06 in
(27 mm) wrench over the tied hexagonal boss. 3
Š Turn the screw (5) in as far as it will go, using a 0.74 in 5
(19-mm) wrench.

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7.11.4 RIVETING THE PINS


With the tool already in place on the chain:
4
Š Loosen the screw (1). 3
Š Remove the main body (2) from the rivet tool (3). 2
Š Remove the support plate (4).
Š Refit the main body (2) on the rivet tool (3).
Š Move the main body (2) so that the locating dowel (5) is
in line with mark “B” on the rivet tool (3).
Š Turn the screw (1) by hand until the pusher (6) touches
the pin to be riveted. 6
NOTE Make sure that the pusher (6) is perfectly
aligned with the pin to be riveted.

WARNING
Wear safety goggles or a shield to protect your eyes.
Š Hold the central body (2) stationary using a 1.06 in
(27-mm) wrench over the tied hexagonal boss.
Š 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).
Š Loosen the screw (1). 2
Š Repeat the above procedure on the adjacent pin on the 1
same link.

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NOTES

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GENERAL INFORMATION

GENERAL INFORMATION
8

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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

8 8.2 LOCATION, FASTENING, AND ROUTING


OF WIRING, CABLES AND LINES.. 8-11-00
8.2.1 FRONT BRAKE LINES........................ 8-11-00
8.2.2 REAR BRAKE LINES.......................... 8-11-00
8.2.3 FUEL SYSTEM LINES......................... 8-12-00
2 8.2.4 CLUTCH CONTROL LINE................... 8-13-00
8.2.5 PPC DEVICE PRESSURE LINES ....... 8-13-00
8.2.6 COOLING SYSTEM LINES ................. 8-14-00
8.2.7 ENGINE OIL LINES ............................. 8-16-00
8.2.8 BREATHER AND OVERFLOW
3 DRAINAGE LINES............................... 8-17-00
8.2.9 THROTTLE CONTROL CABLES........ 8-18-00
8.2.10 ELECTRICAL CABLES....................... 8-19-00
8.3 CHECKING THE ELECTRICAL

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

6 8.4.1 ENGINE................................................ 8-25-00


8.4.2 THROTTLE BODY COMPONENTS .... 8-25-00
8.4.3 FUEL SYSTEM .................................... 8-25-00
8.4.4 ELECTRICAL SYSTEM....................... 8-25-00
8.4.5 FRONT BRAKE SYSTEM ................... 8-25-00
7 8.4.6 REAR BRAKE SYSTEM...................... 8-25-00
8.4.7 COOLING SYSTEM............................. 8-25-00
8.4.8 WHEELS .............................................. 8-25-00
8.4.9 FRONT SUSPENSION ........................ 8-25-00
8.4.10 REAR SUSPENSION........................... 8-25-00
8 8.4.11 STEERING ........................................... 8-25-00
8.4.12 CAPACITY - FLUID PROPERTIES ..... 8-25-00
8.4.13 STRUCTURE (FRAME/SADDLE
SUPPORT/DASHBOARD MOUNT) .... 8-25-00

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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

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The engine is difficult or Engine stop switch set to Set to position
impossible to start
Check and restore the
Starting safety logic faulty
necessary conditions
Overturn sensor faulty Replace
Vent hole on tank cap clogged Clean
Battery charge low Recharge
Battery damaged Replace
Sprag clutch, sprag clutch gear worn or faulty Replace (*)
Double gear or intermediate gear of the starter motor
Replace (*)
worn or faulty
Starter motor pinion teeth damaged Replace (*)
Spark plugs dirty Replace
Spark plugs wet Clean or replace
Spark plugs loose Tighten
Spark plugs not to spec Replace

Fuel filters dirty or fuel system line clogged


Clean or replace
Fuel pump, relay or wiring faulty Replace
Fuel pressure regulator faulty Replace
Injectors faulty Replace
Valve clearance incorrect Adjust (*)

CONT'D ➤

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GENERAL INFORMATION

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The engine does not idle Idle rpm too slow Adjust
smoothly
Air filter dirty Clean
Intake manifold leaking Replace
Both cylinders poorly synchronized Synchronize the cylinders
Throttle valve shaft/housing worn Replace
See the subsection entitled "Engine difficult or impossible to start" for other possible
causes
The engine runs irregularly The fuel outlet fitting is dirty, limiting the flow of fuel to Clean and top up the fuel
at higher speeds the injector system
Intake ducts and lines clogged Check
Air leaking through the throttle body or intake manifold Replace
Clean the fuel system or
Fuel pressure too low
replace the pump
Faulty fuel pump Replace
Camshafts worn Replace (*)
See the subsection entitled "Engine difficult or impossible to start" for other possible
causes
Engine lacks power Spark plugs dirty Clean or replace
Spark plugs not to spec Replace
Insufficient valve clearance Adjust (*)
Exhaust system faulty Replace
Valve timing incorrect Adjust (*)
Valve springs faulty Replace (*)
Valve seats leaking Reface seat (*)
Intake coupling or intake system leaking Replace
Replace the clutch discs and
Clutch slippage
springs (*)
Use motor oil that
Motor oil does not meet specifications
meets specifications
Air filter dirty Replace
Faulty fuel pump Replace
Replace the fuel pressure
Fuel pressure too low
regulator or check the pump
Injector dirty Replace
Piston rings worn Replace (*)
CONT'D ➤

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GENERAL INFORMATION RST mille USA

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The engine overheats Insufficient coolant in the cooling system, system Top up with coolant, subject
leaking the system to a pressure test
Use coolant that meets
Coolant does not meet specifications
specifications
Radiator dirty or coolant hose clogged Clean
Air in the cooling system Bleed
Cooling fan motor faulty Repair or replace
Coolant pump or coolant pump control drive faulty Replace (*)
Not enough oil in the system Top up with motor oil
Oil pump or oil pump control faulty, or oil circuit
Replace or clean (*)
clogged
Use motor oil that meets
Motor oil does not meet specifications
specifications
Intake coupling or intake system leaking Replace
Faulty injector Replace
Faulty head gasket Replace (*)
The engine produces Clutch diaphragm leaking Replace (*)
excessive exhaust fumes
Valve stem gaskets worn Replace (*)
(blue smoke)
Valve stems or valve guides worn Replace (*)
Scratches or grooves on the cylinder wall Replace (*)
Piston rings or cylinder worn Replace (*)
Head gasket leaking Replace (*)
The engine vibrates Engine fastening loose Tighten
Bearing or bearing housing worn Replace
Incorrect balanceshaft timing Adjust (*)
Engine oil pressure too Not enough oil in the system Top up with motor oil
low (LED lights)
Oil does not meet specifications Replace
Faulty oil pressure sensor Replace (*)
Oil pressure regulating valve clogged or faulty (the
Clean or replace (*)
valve remains open)
Faulty oil pump control Replace (*)
CONT'D ➤

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GENERAL INFORMATION

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The engine makes too The noise seems to come from the timing system
much noise
Chain tightener shoe worn Replace (*)
Too much valve clearance Adjust (*)
Valve springs worn out or broken Replace (*)
Valve lifter buckets or camshaft worn Replace (*)
Timing chain worn Replace (*)
Timing gears worn Replace (*)
Faulty timing chain tightener Replace (*)
The noise seems to come from the piston
Gudgeon pin, bore or connecting rod worn Replace (*)
Piston rings or grooves worn or broken Replace (*)
The noise seems to come from the clutch or clutch case
Clutch discs worn Replace (*)
Clutch housing worn Replace (*)
Flexible couplings on clutch housing have excessive
Replace (*)
play
Noise with the clutch engaged, ball bearings in the
Replace (*)
support plate faulty
Primary transmission worn or broken Replace (*)
The noise seems to come from the flywheel case
Timing gears worn or broken Replace (*)
The noise seems to come from the crank gear
Connecting rod bearings worn Replace (*)
Crankshaft bushings or balanceshaft bearings worn Replace (*)
The noise seems to come from the gearbox
Gears or gearbox shafts worn or broken Replace (*)
Primary gear worn Replace (*)
Gearbox bearings worn Replace (*)
The noise is heard when the engine is started
Sprag clutch gear, gear or housing worn or faulty Replace (*)
Double gear or intermediate gear of the starter motor
Replace (*)
worn
Starter pinion teeth worn Replace (*)
The clutch “slips” Clutch discs worn or warped Replace (*)
Clutch springs worn out Replace (*)
Support plate worn or warped Replace (*)
Use motor oil that meets
Motor oil does not meet specifications
specifications
Clutch control hydraulic system faulty Replace
CONT'D ➤

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GENERAL INFORMATION RST mille USA

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The clutch does not Clutch fluid reservoir level Check
disengage
Use motor oil that meets
Motor oil does not meet specifications
specifications
Clutch discs stuck together Clean or replace (*)
Clutch discs or support plate warped Replace (*)
Clutch control hydraulic system faulty Replace
Clutch housing worn Replace (*)
The clutch sticks during Clutch discs worn or warped Replace (*)
engagement
Replace the clutch housing
Clutch disc guide grooves inside clutch housing worn
(*)
Disc guide grooves in clutch disc hub worn smooth Replace the disc hub (*)
Thrust-bearing lands of the clutch housing or support
Replace (*)
plate worn
The gearbox does not Dogs and recesses in the various gears worn Replace (*)
engage, or has trouble
Transmission shafts worn Replace (*)
engaging
Selector shaft gearshift mechanism faulty Repair or replace (*)
The gearshift forks are worn or bent Replace (*)
For other possible causes see the subsection entitled (The clutch does not
disengage)
The gears disengage Gearbox gears worn Replace (*)
during start-up or hard
The gearshift forks are worn or bent Replace (*)
acceleration
Detent springs worn out or broken Replace (*)
Always press the pedal all
Gears do not change smoothly or completely; the the way down when shifting
gearshift is bent or incorrectly adjusted. gears; replace the gearshift
(*)
Spark plugs overheated, Spark plugs not to spec Replace
burnt out or dirty
Spark plugs loose Tighten
Intake coupling or intake system leaking Replace
Fuel intake system faulty Repair or replace
The battery alternator is Faulty battery Replace the battery
not charged or is charged
Voltage regulator faulty Replace
incorrectly
Open, short circuit, or grounding of alternator windings Replace
Cables broken or short-circuited, or loose connections Repair, replace or tighten

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GENERAL INFORMATION

8.1.2 ELECTRICAL SYSTEM

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The spark plugs are soiled Incorrect engine oil level Check
immediately with carbon
Unsuitable fuel Use the recommended fuel
deposits
Air filter dirty Clean
The spark plugs get dirty Incorrect engine oil level Check
too soon
Piston rings worn Replace (*)
Piston or cylinder worn Replace (*)
Spark plug electrodes The engine overheats Adjust
overheated or burnt
Loose spark plugs Tighten
The alternator does not Connection terminals open, short-circuited, or loose Repair, replace or tighten
charge
Alternator coils short-circuited, grounded or broken Replace
Regulator/rectifier short-circuited or faulty Replace
The alternator charges but The terminals tend to short-circuit, break or spread
Repair or tighten
the current intensity is apart
below the prescribed value
Alternator stator coils grounded or broken Replace
Regulator/rectifier faulty Replace
Faulty battery Replace
The alternator charges too Short-circuit in the battery Repair or replace
much
Regulator/rectifier damaged or faulty Replace
Intermittent grounding of the regulator/rectifier Replace
Charge not constant Terminal insulation worn due to vibrations, with
Repair or replace
consequent temporary short circuits
Alternator contains short circuits Replace (*)
Regulator/rectifier faulty Replace

8.1.3 BATTERY

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


The battery runs down too Check the alternator, the
quickly regulator/rectifier, the circuit
Faulty recharging system connections and carry out
the appropriate steps to
proper recharging
Battery elements have lost much of their active Replace the battery and
material due to excessive charging repair the charging system
There are short circuits inside the battery due to
Replace the battery
excess sediment build-up
Dead battery Replace the battery
Replace the battery and
The battery has been hooked up to the system
Battery polarity reversed make sure it is hooked up
incorrectly
correctly

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8.1.4 BRAKES

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


Weak braking power Brake fluid leak from the hydraulic system Repair or replace
Worn pads Replace the pads
Pad contact surfaces dirty with oil, grease or brake
Replace the pads
fluid
Worn brake discs Replace the disc
Air in the hydraulic circuit Bleed the circuit
Brake discs dirty with oil, grease or brake fluid Clean
Foreign matter in the brake fluid Change the brake fluid
Disassemble and clean the
Brake master cylinder return hole clogged
brake master cylinder
The brakes squeal Restore surfaces with
Brake pad contact surfaces glazed
sandpaper
Pads mounted incorrectly Install correctly
Wheel bearing damaged Replace
Loose front or rear wheel axle nut Torque to specifications
Worn pads Replace
Excessive brake lever Air in the hydraulic circuit Bleed the circuit
stroke
Not enough brake fluid Replace
Unsuited brake fluid Replace
Brake caliper pistons jammed or stuck Disassemble and clean
Brake fluid leaking Connection fittings not tight enough Torque to specifications
Cracked lines Replace
Replace the master cylinder
Master cylinder piston and/or body worn
and/or the body

8.1.5 CHASSIS

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


Hard steering Steering adjustment ring-nut too tight Adjust
Steering bearings damaged Replace
Steering shaft bent Replace
Front tire pressure too low Adjust
Steering damper too stiff Replace
Uneven steering Steering bearings damaged Replace
Handlebar oscillates Unbalanced adjustment of fork tubes Adjust
Fork bent Replace
Front wheel rim and/or tire bent Replace
Front/rear wheel not balanced Balance
CONT'D ➤

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GENERAL INFORMATION

DEFECT SYMPTOM AND POSSIBLE CAUSES REMEDY


Front wheel wobbly Bent wheel rim Replace
Worn wheel bearings Replace
Tire faulty or wrong type Replace
Loose axle nut Tighten
Wrong kind of fork oil Replace
Fork too soft Incorrectly adjusted Adjust
Springs weakened Replace
Not enough fork oil Top up
Fork oil exhausted Replace
Fork too rigid Incorrectly adjusted Adjust
Fork oil too viscous Replace
Excess oil in the fork Remove the excess oil
Fork is noisy Not enough fork oil Top up
Suspension fitting screws and nuts loose Tighten
Rear wheel wobbly Bent wheel rim Replace
Worn wheel bearings Replace
Tire faulty or wrong type Replace
Worn fork bearings Replace
Suspension screws and nuts loose Replace
Rear wheel fastening nut loose Tighten
Rear suspension too soft Shock absorber spring weakened Replace
Incorrectly adjusted setting devices Adjust
Oil leak from shock absorber Replace
Nitrogen leaking from shock absorber Replace
Rear suspension too rigid Incorrectly adjusted setting devices Adjust
Shock absorber pivot bent Replace
Bent fork Replace
Worn fork bearings Replace
Worn suspension roller bearings Replace
Noisy rear suspension Suspension screws and nuts loose Tighten
Worn fork bearings Replace
Worn suspension roller bearings Replace

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GENERAL INFORMATION

8.2 LOCATION, FASTENING, AND ROUTING OF WIRING, CABLES AND LINES

8.2.1 FRONT BRAKE LINES 8.2.2 REAR BRAKE LINES

F G

C D

A
A B E F

C D G

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8.2.3 FUEL SYSTEM LINES

A
B
A
C

A C

B D

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GENERAL INFORMATION

8.2.4 CLUTCH CONTROL LINE 8.2.5 PPC DEVICE PRESSURE LINES

E
B

A C

B D E

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8.2.6 COOLING SYSTEM LINES

B
C

A E

A C

B D

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GENERAL INFORMATION

F G

E G

F H

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8.2.7 ENGINE OIL LINES

A C
B

A C

B D

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GENERAL INFORMATION

8.2.8 BREATHER AND OVERFLOW DRAINAGE


LINES

A C
B

A C

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8.2.9 THROTTLE CONTROL CABLES

A
B

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GENERAL INFORMATION

8.2.10 ELECTRICAL CABLES

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

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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

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RST mille USA
GENERAL INFORMATION

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

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RST mille USA
GENERAL INFORMATION

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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).

8.3.2 BATTERY RECHARGING PROBLEMS


- see 6.3.1 (CHECKING THE RECHARGING
VOLTAGE).
- see 6.3.2 (CHECKING THE OPEN-CIRCUIT
ALTERNATOR OPERATION).
- see 6.3.4 (CHECKING ALTERNATOR CONTINUITY).
- see 6.3.5 (CHECKING THE VOLTAGE REGULATOR).
- see 6.14 (BATTERY).

8.3.3 PROBLEMS WITH IGNITION AND/OR


STARTING
Check the diagnostics system installed on the vehicle,
[see 6.4.2 (TROUBLESHOOTING) (IF THE ENGINE
DOES NOT START)].
In addition:
- see 6.6.6 (CHECKING THE IGNITION COILS).
- see 6.6.7 (CHECKING THE CRANKSHAFT POSITION
SENSOR);
- see 6.4.4 (CHECKING THE OVERTURN SENSOR).
- see 6.6.4 (CHECKING THE AIR THERMISTOR
OPERATION).
- see 6.6.5 (CHECKING THE COOLANT
THERMISTORS OPERATION).
- see 6.6.3 (CHECKING THE THROTTLE VALVE
POTENTIOMETER).
- see 6.6.1 (CHECKING THE INJECTORS).
- see 6.7.2 (CHECKING THE FUEL PUMP).
- see 6.7.3 (CHECKING THE FUEL PUMP RELAY).
- see 6.8.2 (STARTING SAFETY OPERATING LOGIC).
- see 6.8.3 (CHECKING THE START RELAY).
- see 6.8.5 (CHECKING THE SIDE STAND SWITCH).
- see 6.8.6 (CHECKING THE DIODE MODULE).
- see 6.8 (IGNITION SAFETY SYSTEM).
- see 6.14 (BATTERY).

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RST mille USA
GENERAL INFORMATION

8.4 CHECKING THE ELECTRICAL SYSTEM 8.4.8 WHEELS


Rims
8.4.1 ENGINE
For technical data and specifications on the compo- See 1.11 (SPECIFICATIONS).
nents, see sect. 3 (ENGINE). Rim eccentricity:

8.4.2 THROTTLE BODY COMPONENTS See 7.2.3 (CHECKING THE COMPONENTS).


For technical data and specifications on the compo- Axle eccentricity:
nents, see 4.8 (THROTTLE BODY). See 7.2.3 (CHECKING THE COMPONENTS).

8.4.3 FUEL SYSTEM Tires:


- Material of lines entering/leaving the delivery filter (Øi = See 1.11 (SPECIFICATIONS).
0.2 in - Øe = 0.5 in) = NBR-SF-NBR DIN 73379.
- Material of high-pressure delivery line = TEFLON with 8.4.9 FRONT SUSPENSION
built-in metal plait and eyelet fittings at the ends.
- Material of low-pressure return line (Øi = 0.2 in Øe = See 1.11 (SPECIFICATIONS), 2.29.1 (FRONT
0.4 in ) = NBR-SF-NEOPRENE DIN 73379. SUSPENSION) and 7.8 (FRONT FORK).

8.4.4 ELECTRICAL SYSTEM 8.4.10 REAR SUSPENSION


See 1.11 (SPECIFICATIONS) and see sect. 6 See 1.11 (SPECIFICATIONS), 2.29.1 (FRONT
(ELECTRICAL SYSTEM). SUSPENSION), 7.9 (SWINGING ARM) and 7.10 (REAR
SUSPENSION).
8.4.5 FRONT BRAKE SYSTEM
- Disc material = steel. 8.4.11 STEERING
- Disc thickness = 0.19 in (minimum 0.17 in ).
See 2.28.1 (CHECKING THE BEARING PLAY) and 7.7
- Disc diameter = 11.8 in.
(STEERING).
- Number of clamp pins = 4 facing each other.
- Diameter of clamp pins = 1.1 in (lower) + 1.3 in (upper).
8.4.12 CAPACITY - FLUID PROPERTIES
- Pad type = sintered.
- Pad friction material (standard) = TOSHIBA TT2802. See 1.11 (SPECIFICATIONS) and 1.12 (LUBRICANT
- Pad friction material (alternative) = FERIT/FERODO ID CHART).
450.
- Pad surface area = 3.67 in². 8.4.13 STRUCTURE (FRAME/SADDLE SUPPORT/
- Diameter rubber lines (standard) = Øe 0.3 in – Øi 0.12 DASHBOARD MOUNT)
in. - Frame / Saddle support / Dashboard mount Material =
- Diameter of metal plait lines (alternative) = Øe 0.2 in - light alloy
Øi 0.1 in. - Frame weight = 21.8 lb
- Pump diameter = 0.6 in. - Torsion rigidity of frame = 4794.1 ftlb (6500 Nm/°).
- Steering angle = 26°
8.4.6 REAR BRAKE SYSTEM - Trail = 3.81 in.
- Disc material = steel. - Saddle support weight = 2.3
- Disc thickness = 0.19 in (minimum 0.17 in ). Dashboard mount weight = 1.653 lb
- Disc diameter = 10.0 in.
- Number of clamp pins = 2 facing each other.
- Diameter of clamp pins = 1.1 in.
- Pad friction material (standard) = FERIT/FERODO ID
450.
- Pad friction material (alternative) = TOSHIBA
TTH38GF FERIT/FERODO ID 450/452/459.
- Pad surface area = 2.48 in².
- Diameter rubber lines (standard) = Øe 0.3 in – Øi 0.12
in.
- Diameter of metal plait lines (alternative) = Øe 0.2 in -
Øi 0.1 in.
- Pump diameter = 0.4 in.

8.4.7 COOLING SYSTEM


See sect. 5 (COOLING SYSTEM)
- Working pressure 13.05 - 13.05 PSI (90 -120 kPa) (0.9
-1.2 bar).

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GENERAL INFORMATION RST mille USA

NOTES

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ANALYTICAL INDEX

ANALYTICAL INDEX
i

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ANALYTICAL INDEX RST mille USA

A Ref. Page C Ref. Page


ACTIVATING THE BATTERY 6.14.1 6-41 CABLES
AUXILIARY, STARTING 2.6 2-16
ADJUSTING
THROTTLE CONTROL 8.2.9 8-18
REAR SHOCK ABSORBER 2.31.2 2-50
ELECTRICAL 8.2.10 8-19
DRIVE CHAIN 2.35.3 2-55
CO 4.10.5 4-19 CAPACITY - FLUID PROPERTIES 8.4.12 8-26
THROTTLE CONTROL 2.11.3 2-23
CARBON MONOXIDE 1.2.6 1-6
IDLE SPEED 2.11.2 2-22
FRONT FORK 2.29.2 2-48 CHAIN
BEARING PLAY 2.28.2 2-45 CHECKING THE WEAR 2.35.2 2-55
BRAKE LEVER CLEARANCE DRIVE 2.35 2-54
REAR 2.25 2-42 DRIVE, ADJUSTING 2.35.3 2-55
DASHBOARD LIGHT 2.3.3 2-8 DRIVE, REMOVING 7.11 7-100
GEARSHIFT LEVER 2.26 2-42
CHAIN BREAKER/RIVET TOOL 7.11.1 7-100
FRONT BRAKE LEVER AND
CLUTCH LEVER 2.24 2-41 CHANGING
HORIZONTAL HEADLIGHT BEAM 6.18 6-49 FUSES 6.16 6-48
VERTICAL HEADLIGHT BEAM 6.17 6-49 BULBS 6.15 6-44
HEADLIGHT BULBS 6.15.1 6-44
ADJUSTING THE SWINGING ARM
TAILLIGHT BULBS 6.15.3 6-46
REAR 2.30.1 2-49
DIRECTION INDICATOR BULBS
AIR DUCT 7.1.30 7-27 FRONT 6.15.2 6-46
7.1.31 7-28 LICENSE PLATE LAMP BULBS 6.15.4 6-47
CLUTCH FLUID 2.23 2-41
AIR FILTER 2.10 2-21
FRONT BRAKE FLUID 2.21 2-39
AIR FILTER CASE, REMOVING 7.1.8 7-11 REAR BRAKE FLUID 2.22 2-40
COOLANT 2.15 2-28
AIR INLET DUCT CASES,
FORK OIL 7.8.1 7-78
REMOVING 7.1.34 7-30
ENGINE OIL AND ENGINE OIL FILTER 2.13 2-25
AIR THERMISTOR, CHECKING BRAKE PADS 7.5.1 7-66
OPERATION 6.6.4 6-18 BRAKE PADS 7.6.1 7-69
ALTERNATOR CHASSIS 7.1 7-4
CHECKING CONTINUITY 6.3.4 6-7
CHECKING 6.14.3 6-43
CHECKING OPERATIONOPEN-CIRCUIT 6.3.2 6-6
FUEL INTAKE 4.1.2 4-4
AUTOMATIC TESTING 4.7.5 4-13 REAR SUSPENSION LINKAGE 2.31.3 2-51
IGNITION COILS 6.6.6 6-20
COMPONENTS 7.2.3 7-54
B Ref. Page 7.4.2 7-63
7.7.2 7-75
BATTERY 2.4 2-13
7.9.3 7-93
6.14 6-41
ACTIVATING 6.14.1 6-41 7.10.4 7-99
ALTERNATOR CONTINUITY 6.3.4 6-7
EXTENDED STORAGE 2.4.3 2-15
THE COMPONENTS 7.8.4 7-84
RECHARGING 2.4.2 2-15
REMOVING 7.1.9 7-12 THE DIODE MODULE 6.8.4 6-25
THE CLEARANCE 2.35.1 2-54
BEARINGS THE THROTTLE VALVE
CHECKING PLAY 2.28.1 2-44 POTENTIOMETER 6.6.3 6-17
ADJUSTING THE PLAY 2.28.2 2-45 THE INJECTION RELAY 6.4.3 6-10
THE OVERTURN SENSOR 6.4.4 6-10
BLEEDING
BRAKE SYSTEMS 2.19 2-34 THE CRANKSHAFT POSITION SENSOR
THE ENGINE 6.6.7 6-20
CLUTCH CONTROL SYSTEM 2.20 2-38
THE CHAIN WEAR, THE SPROCKET
BRAKE DISC, REMOVING 7.6.4 7-72 AND COUNTERSHAFT SPROCKET 2.35.2 2-55
THE BRAKE DISCS 7.5.2 7-67
BRAKE DISCS, REMOVING 7.5.3 7-67
THE BRAKE DISC 7.6.3 7-71
BRAKES AND CLEANING TERMINALS 2.4.1 2-14
FRONT 7.5 7-65 AND TOPPING UP CLUTCH FLUID 2.18.2 32-5
FLUID 1.2.3 1-4 AND TOPPING UP
BREAKING THE CHAIN 7.11.2 7-101 FRONT BRAKE FLUID 2.16 2-29
AND TOPPING UP
BREAKING-IN RULES 1.3 1-6 FRONT BRAKE FLUID 2.17 2-30
BULBS AND TOPPING UP COOLANT 2.14 2-27
OPEN-CIRCUIT OPERATION
HEADLIGHT, CHANGING 6.15.1 6-44
ALTERNATOR 6.3.2 6-6
TAILLIGHT, CHANGING 6.15.3 6-46
FRONT DIRECTION INDICATORS, ELECTRIC FAN OPERATION 6.9.2 6-28
AIR THERMISTOR OPERATION 6.6.4 6-18
CHANGING 6.15.2 6-46
THERMISTOR OPERATION COOLANT 6.6.5 6-19
LICENSE PLATE LAMP, CHANGING 6.15.4 6-47
REPLACING 6.15 6-44 BEARING PLAY 2.28.1 2-44

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ANALYTICAL INDEX

ELECTRICAL SYSTEM 8.3 8-25 ELECTRICAL SYSTEMS INJECTION 6.4.1 6-9


8.4 8-26 WIRING - RST MILLE FUTURA 6.19 6-50
INJECTORS 6.6.1 6-16 WIRING, LIGHT SYSTEM 6.11.1 6-35
STAND SWITCH 6.8.5 6-26 WIRING, PUMP SYSTEM FUEL 6.7.1 6-21
SAFETY SYSTEM SWITCHES 6.8.7 6-27 WIRING, INDICATOR SYSTEM
DIODE MODULE 6.8.6 6-26 WARNING LIGHTS AND BUZZERS 6.13.1 6-39
FUEL PUMP 6.7.2 6-22 WIRING, INDICATOR SYSTEM
VOLTAGE REGULATOR 6.3.5 6-8 WARNING LIGHTS AND BUZZERS 6.12.1 6-37
START RELAY 6.8.3 6-24 WIRING, DASHBOARD
LIGHT RELAY 6.11.2 6-36 INDICATORS 6.10.1 6-29
FUEL PUMP RELAY 6.7.3 6-22 WIRING, SAFETY SYSTEM
RECHARGING SYSTEM 6.3 6-6 START-UP 6.8.1 6-23
RECHARGING VOLTAGE 6.3.1 6-6 RECHARGING SYSTEM 6.3.3 6-7
INJECTION SYSTEM 4.7.3 4-11
CHECKING ENGINE OIL LEVEL AND
TOP UP 2.12 2-24 DIODE, CHECKING 6.8.4 6-25
CHOKE MOTOR 6.6.2 6-16 DIODE MODULE, CHECKING 6.8.6 6-26
CLEANING AND LUBRICATION 2.41.1 2-66 DISASSEMBLY
SUSPENSION LINKAGE 7.10.3 7-98
CLUTCH CYLINDER,
DRIVE CHAIN 7.11 7-100
REMOVING 3.2.1 3-6
SWINGING ARM 7.9.2 7-92
CLUTCH CONTROL LINE 8.2.4 8-13 THROTTLE BODY 4.9 4-16
WHEEL 7.2.2 7-53
CO, ADJUSTING 4.10.5 4-19
LOWER/UPPER FORK TUBES 7.8.3 7-79
COMPLETE SADDLE RELEASE, REMOVING 7.1.39 7-33. STEERING 7.7.1 7-75
COMPONENTS DRAINING
AT HIGH TEMPERATURES 1.2.7 1-6 FUEL FROM THE TANK 4.2 4-5
THAT MAY BE DISASSEMBLED FUEL FROM THE TANK 2.9 2-20
WITHOUT REMOVING THE ENGINE
FROM THE FRAME 3.2 3-4
ELECTRICAL 2.5 2-15 E Ref. Page
ELECTRICAL, LOCATIONS 6.1 6-3 ELECTRIC FANS
THROTTLE BODY 8.4.2 8-26
CHECKING OPERATION 6.9.2 6-28
CONNECTIONS TO THE CONTROL UNIT COOLING 6.9 6-28
ELECTRONIC 6.6 6-14 COOLING, REMOVING 5.3 5-6
COOLING, DIAGRAM ELECTRICAL 6.9.1 6-28
CONNECTORS
ELECTRONIC CONTROL UNIT 4.7.4 4-12 ENGINE 8.4.1 8-26
ELECTRICAL 6.2.2 6-5 INSTALLING ON THE FRAME 3.4 3-16
OIL 1.2.2 1-4
CONSUMABLES, PRODUCTS 1.7 1-11
REMOVING FROM THE FRAME 3.3 3-7
CONTROL
ENGINE MANAGEMENT 4.7 4-8
THROTTLE, REMOVING 7.1.14 7-16
THROTTLE, CHECKING OPERATION 2.11.1 2-22 ENGINE OIL RADIATOR, REMOVING 7.1.56 7-46
CLUTCH, FLUID 1.2.5 1-5
EXHAUST MANIFOLDS, REMOVING 7.1.53 7-43
CLUTCH, REMOVING 7.1.12 7-15
EXHAUST MANIFOLD NUTS 2.34 2-53
CONTROLS
ELECTRICAL ON THE HANDLEBAR EXHAUST SILENCER, REMOVING 7.1.50 7-41
RIGHT, REMOVING 7.1.16 7-18
EXPANSION TANK, REMOVING 5.8 5-9
ELECTRICAL ON THE HANDLEBAR
LEFT, REMOVING 7.1.13 7-16 EXTENDED BATTERY STORAGE 2.4.3 2-15

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

COOLANT, FLUID 1.2.4 1-5 FAULT CODES, CHECKING 6.5.3 6-12

CYLINDERS, SYNCHRONIZING 4.10.4 4-18 FAULT SITUATIONS 6.5.2 6-12


FILLER NECK 5.6 5-8
D Ref. Page FILTER
AIR 2.10 2-21
DASHBOARD,
FUEL DELIVERY,
ADJUSTING THE LIGHTING 2.3.3 2-8 REMOVING 4.5 4-6
REMOVING 7.1.24 7-23
ENGINE OIL, CHANGING 2.13 2-25
DASHBOARD INDICATORS 6.10 6-29
FOOTREST
DESCRIPTION 5.1 5-3 PASSENGER, REMOVING 7.1.44 7-37
RIDER, REMOVING 7.1.47 7-38
DIAGRAM

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ANALYTICAL INDEX RST mille USA

FORK CHAIN GUIDE PLATE 2.35.4 2-56


FRONT 7.8 7-77 FRONT SUSPENSION 2.29 2-47
FRONT, ADJUSTING 2.29.2 2-48 REAR SUSPENSION 2.31 2-50
REAR 7.9 7-91
INSTALLATION
REAR, ADJUSTING 2.30.1 2-49
COMPLETE ENGINE ON THE FRAME 3.4 3-16
RE-INSTALLING 7.9.4 7-94
LOWER/UPPER FORK TUBES 7.8.6 7-90
REMOVING 7.9.1 7-91
DISASSEMBLING 7.9.2 7-92 INSTRUCTIONS FOR APPLYING
REAR 2.30 2-49 TRANSFERS 1.10 1-19
FRAME, REMOVING 7.1.60 7-49 INSTRUMENTS, TABLE 2.3.8 2-10
FRONT FAIRING, REMOVING 7.1.20 7-21 INTRODUCTION 6.2 6-5
FRONT MUDGUARD, REMOVING 7.1.26 7-25
FUEL 1.2.1 1-3 K Ref. Page
WARNINGS 1.2 1-3
KNOB ON THE HANDLEBAR
DRAINING THE TANK 2.9 2-20 LEFT, REMOVING 7.1.11 7-13
FUEL LEVEL,
REMOVING THE SENSOR 4.4 4-6
L Ref. Page
FUEL TANK CAP,
REMOVING 7.1.7 7-10 LEGEND 2.3.1 2-8

FUSES, REPLACING 6.16 6-48 LEVER


GEARSHIFT, ADJUSTING 2.26 2-42
GEARBOX CONTROL, REMOVING 7.1.48 7-39
G Ref. Page FRONT BRAKE CONTROL,ADJUSTING 2.24 2-41
REAR BRAKE CONTROL,
GENERAL INFORMATION 4.7.1 4-8 ADJUSTING THE CLEARANCE 2.25 2-42
GENERAL OPERATING INFORMATION REAR BRAKE CONTROLREMOVING 7.1.49 7-40
FOR MAINTENANCE AND REPAIRS 3.1.9 3-3 CLUTCH CONTROL, ADJUSTING 2.24 2-41
GROUP LICENSE PLATE HOLDER, REMOVING 7.1.42 7-36
THROTTLE 4.8 4-14
LIFTING THE FUEL TANK 2.8 2-19
THROTTLE, INSPECTING 4.10 4-17
THROTTLE, REMOVING 4.8.1 4-14 LIGHT
THROTTLE, DISASSEMBLING 4.9 4-16 HEADLIGHT, REMOVING 7.1.22 7-22
FINAL DRIVE 7.4 7-60 TAILLIGHT, REMOVING 7.1.36 7-31
FINAL DRIVE, REMOVING 7.4.1 7-61
LIGHTS, SETTINGS
DASHBOARD 2.3.3 2-8
H Ref. Page LINES
FUEL 2.37 2-58
HANDLEBAR
BRAKE AND CLUTCH CONTROL 2.38 2-58
RIGHT, REMOVING 7.1.19 7-20
COOLING SYSTEM 2.39 2-58
LEFT, REMOVING 7.1.18 7-20
LINKAGE
HEADLIGHT BEAM
REAR SUSPENSION,REMOVING 7.10.2 7-97
ADJUSTING HORIZONTALLY 6.18 6-49
SUSPENSION, DISASSEMBLING 7.10.3 7-98
ADJUSTING VERTICALLY 6.17 6-49
LOWER FAIRING, REMOVING 7.1.33 7-29
HIGH TEMPERATURE, COMPONENTS 1.2.7 1-6
LUBRICANTS 3.1.5 3-3
HORN, REMOVING 7.1.27 7-25
WARNINGS 1.2 1-3
TABLES 1.6 1-10
I Ref. Page LUBRICATION POINTS 2.2 2-7
IGNITION AND/OR STARTING,PROBLEMS 8.3.3 8-25
IGNITION COILS, CHECKING 6.6.6 6-20 M Ref. Page
IGNITION SWITCH/STEERING LOCK, MAINTENANCE 4.1.1 4-4
REMOVING 7.1.17 7-19 6.14.2 6-43
INDICATORS DIRECTION 7.1.29 7-26 PERIODIC, SCHEDULE 2.1 2-4
TABLE 2.3.8 2-10 SCHEDULED, DIAGRAM 2.1.1 2-5
INJECTION, SYSTEM DIAGRAM 4.7.3 4-11 MAINTENANCE INTERVALS 3.1.2 3-3
INJECTORS, MIRRORS, REMOVING 7.1.21 7-22
CHECKING 6.6.1 6-16
MISCELLANEOUS TOOLS 1.8.1 1-15
REMOVING 4.8.2 4-15
MULTIFUNCTION COMPUTER 2.3 2-8
INSPECTION
THROTTLE BODY 4.10 4-17
DRIVE CHAIN SHOE 2.35.5 2-56

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ANALYTICAL INDEX

O Ref. Page R Ref. Page


OIL RADIATORS, REMOVING 5.2 5-5
FORK, CHANGING 7.8.1 7-78
RADIATOR SPOILER, REMOVING 7.1.35 7-30
ENGINE 1.2.2 1-4
ENGINE AND TOPPING UP, LEVEL 2.12 2-24 REAR BRAKE 7.6 7-68
ENGINE, CHANGING 2.13 2-25
REAR BRAKE CALIPER, REMOVING 7.6.2 7-70
OTHER COMPONENTS, WARNINGS 1.2 1-3
REAR HOUSING, REMOVING 7.1.59 7-48
REAR GRAB HANDLE, REMOVING 7.1.37 7-32
P Ref. Page
REASSEMBLY
PADS REAR WHEEL, WHEEL
BRAKES, CHANGING 7.5.1 7-66 REAR, REASSEMBLY 7.3.2 7-58
BRAKES, CHECKING WEAR 2.27 2-43 UPPER/LOWER FORK TUBE UNIT 7.8.5 7-85
BRAKE, CHANGING 7.6.1 7-69 STEERING 7.7.3 7-76
PANEL RECHARGING
LOWER 7.1.32 7-28 BATTERY 2.4.2 2-15
LOWER SADDLE, REMOVING 7.1.40 7-33 BATTERY, PROBLEMS 8.3.2 8-25
PATH, FASTENING, WIRING, RECHARGING VOLTAGE, CHECKING 6.3.1 6-6
CABLES AND LINES 8.2 8-11
RE-INSTALLING
PLATE SWINGING ARM 7.9.4 7-94
CHAIN GUIDE 2.35.4 2-56 WHEEL 7.2.4 7-55
UNDER THE SADDLE, REMOVING 7.1.41 7-34
RELAY
POSITION OF SERIAL NUMBERS 1.1 1-3 STARTER, CHECKING 6.8.3 6-24
INJECTION, CHECKING 6.4.3 6-10
POSITIONING
LIGHTS, CHECKING 6.11.2 6-36
ELECTRICAL COMPONENTS 6.1 6-3
THE VEHICLE ON THE FUEL PUMP, CHECKING 6.7.3 6-22
SUPPORT STAND 1.9 1-17 REMOVING
THE VEHICLE ON THE SHOCK ABSORBER 7.10.1 7-96
FRONT SUPPORT STAND 1.9.1 1-17 BATTERY 7.1.9 7-12
THE VEHICLE ON THE REAR SUSPENSION LINKAGE 7.10.2 7-97
CENTRAL SUPPORT STAND 1.9.2 1-18 FILLER NECK 5.6 5-8
MASTER LINK 7.11.3 7-102 LOWER FAIRING 7.1.33 7-29
POTENTIOMETER SIDE FAIRINGS 7.1.28 7-26
UPPER CHAIN HOUSING 7.1.58 7-48
THROTTLE VALVE, CHECKING 6.6.3 6-17
AIR FILTER CASE 7.1.8 7-11
THROTTLE VALVE 4.10.3 4-17
SIDE STAND 7.1.54 7-44
PRECAUTIONS TO OBSERVE ELECTRONIC CONTROL UNIT 7.1.10 7-13
WHEN CARRYING OUT MAINTENANCE LOWER FRONT PANEL 7.1.32 7-28
OPERATIONS AND REPAIRS 3.1.8 3-3 LOWER SADDLE PANEL 7.1.40 7-33
CLUTCH CYLINDER 3.2.1 3-6
PROBLEMS
HORN 7.1.27 7-25
IGNITION AND/OR STARTING 8.3.3 8-25
THREE-WAY MANIFOLD 5.7 5-9
BATTERY RECHARGING 8.3.2 8-25
EXHAUST MANIFOLDS 7.1.53 7-43
AUXILIARY SYSTEMS 8.3.4 8-25
ELECTRICAL CONTROLS ON THE
PROCEDURES RIGHT HANDLEBAR 7.1.16 7-18
MAINTENANCE AND REPAIR, ELECTRICAL CONTROLS ON THE
GENERAL INFORMATION 3.1.9 3-3 LEFT HANDLEBAR 7.1.13 7-16
MAINTENANCE AND REPAIR, THROTTLE CONTROL 7.1.14 7-16
PRECAUTIONS TO OBSERVE 3.1.8 3-3 FRONT BRAKE CONTROL 7.1.15 7-17
FRONT BRAKE CONTROL,
PRODUCTS
1.7 1-11 REMOVING 7.1.15 7-17
CONSUMABLES
CLUTCH CONTROL 7.1.12 7-15
PROPERTIES 1.7.1 1-11
COMPLETE GEARSHIFT LEVER 7.1.48 7-39
USE 1.7.2 1-12
COMPLETE FUEL TANK 7.1.6 7-9
PROGRAMMING KEYS 2.3. 2 2-8 COMPLETE SADDLE RELEASE 7.1.39 7-33
RIGHT AIR DUCT 7.1.31 7-28
PROGRAMMING, KEYS 2.3.2 2-8
LEFT AIR DUCT 7.1.30 7-27
PROPERTIES 1.5 1-7 SPROCKET 7.4.4 7-64
CONSUMABLES 1.7.1 1-11
REMOVING
PUMP DASHBOARD 7.1.24 7-23
FUEL INTAKE, REMOVING 4.6 4-7 FRONT FAIRING 7.1.20 7-21
FUEL INTAKE, BRAKE DISCS 7.5.3 7-67
REMOVING THE COMPLETE UNIT 4.3 4-5 BRAKE DISC 7.6.4 7-72
FUEL, CHECKING 6.7.2 6-22 ECCENTRIC CAM 7.4.3 7-64
BRAKES, REMOVING 7.5.4 7-67 ELECTRIC FANS COOLING 5.3 5-6
BRAKE, REMOVING 7.6.5 7-73 HEADLIGHT 7.1.22 7-22

Release 00/2002 - 03 i - 5 - 00
ANALYTICAL INDEX RST mille USA

TAILLIGHT 7.1.36 7-31 SCHEDULED MAINTENANCE PLAN 2.1 2-4


FRONT SIDE PANELS 7.1.3 7-7
SEALANTS 3.1.4 3-3
REAR SIDE PANELS 7.1.2 7-6
FUEL DELIVERY FILTER 4.5 4-6 SENSOR
SWINGING ARM 7.9.1 7-91 FALL, CHECKING 6.4.4 6-10
COMPLETE PUMP ASSEMBLY FUEL LEVEL 6.10.5 6-33
FUEL INTAKE 4.3 4-5 CRANKSHAFT POSITION,
THROTTLE BODY 4.8.1 4-14 CHECKING 6.6.7 6-20
FINAL DRIVE ASSEMBLY 7.4.1 7-61 ENGINE OIL PRESSURE 6.10.3 6-31
FRONT DIRECTION INDICATORS 7.1.29 7-26 AIR TEMPERATURE 6.10.2 6-30
INJECTORS 4.8.2 4-15 COOLANT TEMPERATURE 6.10.6 6-34
IGNITION SWITCH/STEERING LOCK 7.1.17 7-19 SPEED 6.10.4 6-32
REAR BRAKE LEVER 7.1.49 7-40
SENSOR ALIGNMENT
REAR GRAB HANDLE 7.1.37 7-32
THROTTLE VALVE POSITION 4.10.6 4-21
KNOB ON THE HANDLEBAR LEFT 7.1.11 7-13
SENSORS 4.7.2 4-9
COMPLETE ENGINE FROM THE FRAME 3.3 3-7
UPPER DASHBOARD MOLDING 7.1.23 7-23 SERIAL NUMBERS, POSITIONS 1.1 1-3
FRONT MUDGUARD 7.1.26 7-25
SETTING THE CLOCK (HOURS AND MINUTES) 2.3.7 2-10
PARTIAL FUEL TANK 7.1.5 7-8
DRIVE CHAIN SHOE 7.1.57 7-47 SHOCK ABSORBER 2.31.2 2-50
SADDLE SUPPORT LOWER REMOVING 7.10.1 7-96
MOLDED COVER 7.1.41 7-34
SHOE
REAR BRAKE CALIPER 7.6.2 7-70
DRIVE CHAIN, INSPECTION 2.35.5 2-56
PASSENGER FOOTREST 7.1.44 7-37
DRIVE CHAIN, REMOVING 7.1.57 7-47
RIDER FOOTREST 7.1.47 7-38
FUEL PUMP 4.6 4-7 SIDE FAIRINGS, REMOVING 7.1.28 7-26
BRAKE MASTER CYLINDER 7.5.4 7-67
SIDE PANELS
BRAKE MASTER CYLINDER 7.6.5 7-73
FRONT, REMOVING 7.1.3 7-7
LICENSE PLATE HOLDER 7.1.42 7-36
REAR, REMOVING 7.1.2 7-6
ENGINE OIL RADIATOR 7.1.56 7-46
RADIATORS 5.2 5-5 SIDE STAND
COMPLETE WHEEL 7.2.1 7-52 FRONT SUPPORT,
7.3.1 7-57 PLACING THE VEHICLE 1.9.1 1-17
SUPPORT,
AIR INLET DUCT CASES 7.1.34 7-30
PLACING THE VEHICLE 1.9 1-17
SADDLE 7.1.1 7-6
CENTRAL SUPPORT,
RIGHT HANDLEBAR 7.1.19 7-20
PLACING THE VEHICLE 1.9.2 1-18
LEFT HANDLEBAR 7.1.18 7-20
SIDE, REMOVING 7.1.54 7-44
FUEL LEVEL SENSOR 4.4 4-6
ENGINE OIL TANK 7.1.55 7-45 SIDE STAND SWITCH,
SADDLE LOCK 7.1.38 7-32 CHECKING 6.8.5 6-26
EXHAUST SILENCER 7.1.50 7-41
SPARE PARTS 1.4 1-7
MIRRORS 7.1.21 7-22
RADIATOR SPOILER 7.1.35 7-30 SPARK PLUGS 2.7 2-17
LOWER/UPPER FORK TUBES 7.8.2 7-78 NO SPARK 8.3.1 8-25
BAG RACKS 7.1.4 7-7
SPECIAL TOOLS 1.8 1-15
PASSENGER FOOTREST SUPPORTS 7.1.43 7-36
DASHBOARD/FRONT FAIRING MOUNT 7.1.25 7-24 SPECIFICATIONS, GENERAL
RIDER FOOTREST SUPPORT RIGHT 7.1.46 7-38 TIGHTENING TORQUES 1.11 1-21
RIDER FOOTREST SUPPORT LEFT 7.1.45 7-37
SPROCKET AND COUNTERSHAFT
FUEL TANK CAP 7.1.7 7-10
SPROCKET, CHECKING WEAR 2.35.2 2-55
REAR HOUSING 7.1.59 7-48
FRAME 7.1.60 7-49 SPROCKET, REMOVING 7.4.4 7-64
COOLANT THERMISTORS 5.4 5-7
STARTING
EXHAUST PIPES 7.1.51 7-42
WITH JUMPER CABLES 2.6 2-16
THERMOSTAT 5.5 5-8
SAFETY SYSTEM 6.8.6 23-27
EXPANSION TANK 5.8 5-9
STEERING 2.28 2-44
RETURN UNDER WARRANTY 6.14.4 6-43
8.4.11 8-26
RIVETING THE PINS 7.11.4 7-103 7.7 7-74
REASSEMBLING 7.7.3 7-76
RST MILLE FUTURA, WIRING DIAGRAM 6.19 6-50
DISASSEMBLING 7.7.1 7-75
STRUCTURE (FRAME/SADDLE SUPPORT/
S Ref. Page DASHBOARD MOUNT ) 8.4.13 8-26
SADDLE, REMOVING 7.1.1 7-6 SUPPLY SYSTEMS
FUEL, CHECKING 4.1.2 4-4
SADDLE LOCK, REMOVING 7.1.38 7-32
ELECTRICAL, INJECTION DIAGRAM 6.4.1 6-9
SAFETY OPERATING LOGIC
STARTING 6.8.2 6-24 SUPPORT OR MOUNT
DASHBOARD/FRONT FAIRING,
SCHEDULED MAINTENANCE CHART 2.1.1 2-5 REMOVING 7.1.25 7-24

i - 6 - 00 Release 00/2002 - 03
RST mille USA
ANALYTICAL INDEX

RIGHT RIDER FOOTREST, THROTTLE CONTROL OPERATION 2.11.1 2-22


REMOVING 7.1.46 7-38 FLASHER 6.12.3 6-38
LEFT RIDER FOOTREST, BRAKE PAD WEAR 2.27 2-43
REMOVING 7.1.45 7-37
THERMISTORS
SUPPORTS AND RACKS COOLANT, CHECKING OPERATION 6.6.5 6-19
BAG RACKS, REMOVING 7.1.4 7-7 COOLANT, REMOVING 5.4 5-7
PASSENGER FOOTREST,
THREE-WAY MANIFOLD, REMOVING 5.7 5-9
REMOVING 7.1.43 7-36
THROTTLE 2.11 2-22
SUSPENSION
ADJUSTING THE CONTROL 2.11.3 2-23
FRONT 2.29.1 2-47
8.4.9 8-26 THROTTLE BODY 4.10.2 4-17
FRONT, INSPECTING 2.29 2-47
THROTTLE VALVES, ALIGNMENT
REAR 8.4.10 8-26
SENSOR 4.10.6 4-21
REAR 7.10 7-96
REAR, CHECK LINKAGE 2.31.3 2-51 TIGHTENING NUTS AND BOLTS 2.40 2-59
REAR, INSPECTING 2.31 2-50
TIGHTENING TORQUES 3.1.7 3-3
SWITCHES 6.13.2 6-40 GENERAL SPECIFICATIONS 1.11 1-21
SAFETY SYSTEM, CHECKING 6.8.7 6-27
TIRES 2.36 2-57
SWITCHING
TOOLS
ODOMETER (MILEAGE COUNTER)
SPECIAL 1.8 1-15
TOTAL/PARTIAL 2.3.4 2-9
3.1.6 3-3
INDICATOR LEVEL SWITCHING
MISCELLANEOUS 1.8.1 1-15
FUEL / AIR TEMPERATURE 2.3.6 2-9
SWITCHING KM/MI, L/GAL, °C/°F 2.3.5 2-9 TRANSFERS, INSTRUCTIONS FOR
APPLYING 1.10 1-19
SYNCHRONIZING THE CYLINDERS 4.10.4 4-18
TROUBLESHOOTING 6.4.2 6-9
SYSTEM
INJECTION 6.4 6-9 TROUBLESHOOTING
IGNITION/INJECTION 6.5 6-11 FAULTS 3.1.3 3-3
6.4.2 6-9
SYSTEM
6.5.1 6-12
RECHARGING, CHECKING 6.3 6-6
8.1 8-3
IGNITION SAFETY 6.8 6-23
FAULTS, BATTERY 8.1.3 8-8
SYSTEM FAULTS, CHASSIS 8.1.5 8-9
CLUTCH CONTROL, BLEEDING 2.20 2-38 FAULTS, BRAKES 8.1.4 8-9
FUEL INTAKE 8.4.3 8-26 FAULTS, ELECTRICAL SYSTEM 8.1.2 8-8
COOLING 8.4.7 8-26 FAULTS, ENGINE 8.1.1 8-3
RECHARGING, DIAGRAM 6.3.3 6-7
TROUBLESHOOTING IN THE ELECTRONIC
ELECTRICAL 8.4.4 8-26
SYSTEM USING
FRONT BRAKING 8.4.5 8-26
DISPLAYED
REAR BRAKING 8.4.6 8-26
INFORMATION 4.7.6 4-13
LIGHTS 6.11 6-35
FUEL PUMP 6.7 6-21 TUBES, PIPES, AND HOSES
WARNING LIGHTS AND BUZZERS 6.13 6-39 BREATHER AND OVERFLOW
WARNING LIGHTS AND BUZZERS 6.12 6-37 DRAINAGE 8.2.8 8-17
FRONT BRAKES 8.2.1 8-11
SYSTEMS
REAR BRAKE 8.2.2 8-11
AUXILIARY, PROBLEMS 8.3.4 8-25
FUEL SYSTEM 8.2.3 8-12
BRAKING, BLEEDING 2.19 2-34
COOLING SYSTEM 8.2.6 8-14
ENGINE OIL 8.2.7 8-16
T Ref. Page PPC DEVICE PRESSURE 8.2.5 8-13
EXHAUST, REMOVING 7.1.51 7-42
TABLE
LUBRICANTS 1.6 1-10
INSTRUMENTS AND INDICATORS 2.3.8 2-10 U Ref. Page
TANK UPPER CHAIN HOUSING, REMOVING 7.1.58 7-48
FUEL 4.1 4-3
UPPER DASHBOARD MOLDING 7.1.23 7-23
FUEL, REMOVING COMPLETELY 7.1.6 7-9
FUEL, PARTIALLY REMOVING 7.1.5 7-8 UPPER FORK TUBE/
FUEL, LIFTING 2.8 2-19 LOWER FORK TUBE UNITS,
ENGINE OIL, REMOVING 7.1.55 7-45 INSTALLATION 7.8.6 7-90
DRAINING FUEL 4.2 4-5 UPPER/LOWER FORK TUBES,
REMOVING 7.8.2 7-78
TECHNICAL SPECIFICATIONS 3.1.1 3-3
UPPER/LOWER FORK TUBES,
TERMINALS AND CLAMPS, DISASSEMBLING 7.8.3 7-79
CHECKING AND CLEANING 2.4.1 2-14
UPPER/LOWER FORK TUBE UNIT,
TESTING REASSEMBLING 7.8.5 7-85
HORN 6.12.2 6-38
USING CONSUMABLES 1.7.2 1-12
FAULT CODES 6.5.3 6-12

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

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