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USER MANUAL RXV 5.5 APRILIA
Congratulations on your new RXV .
This innovative motorcycle is designed to provide high performance and great fun under all usage conditions - in other words, with an intent to revolutionise the concept of enduro motorcycles. aprilia's first and foremost commitment is to build motorcycles with high technological content, that are extremely safe to ride and will retain their value over time
IMPORTANT NOTICE ON VEHICLE USE AND LEGAL WARRANTY
aprilia RXV motorcycles have been conceived and designed for race-track and off-road competitions. As à result, they meet the rules and class requirements currently adopted by major intemational motorcycling associations.
The RXV model has been specifically designed for off-road endurance racing (enduro) and not mainly for motorcrossing.
Having the motorcycle serviced at the recommended intervals as specified in the maintenance charts provided in this manual is critical to avoiding premture wear and severe failures. To preserve motorcycle performance and avoid severe damage, have the recommended maintenance procedures performed by Authorised aprilia Dealers or Service Centres.
The RXV come in a derated version which can be legally used on public roads and is covered by a legal warranty. In order to maintain the warranty, the recommended maintenance must be performed at the specified intervals by Authorised aprilia Dealers or Service Centres and each service must be recorded in the warranty booklet.
Please note that these motorcycles are not suitable for road use. Gear ratios, cooling system, suspension set-up, braking system and engine power delivery are designed and tuned up for racing, and the operating conditions encountered in competiions differ greatiy from those experienced when riding on public roads.
Below is à short non-exhaustive list of typical operating conditions that may lead to severe engine damage: long stops at traffic lights, motonway trips with the engine steadily running at maximum rpm, or drafting vehicles.
Any changes or modifications to the motorcycle, especially performance enhancing modifications, will make the motorcycle illegal to ride on public roads and void the legal warranty. A modified motorcycle may be used for racing in organised races approved by comptent authorities.
For your oun safety, use only genuine aprilia parts and accessories. aprilia disclaims al liabiliies for the event non-genuine parts are used and for resulting damage.
APRILIA WOULD LIKE TO THANK YOU
for choosing one of its products. We have compiled this bookletto provide à comprehensive overview of your vehicle's quality features. Please, read it carefully before riding the vehicle for the firsttime. It contains information, tips and precautions for using your vehicle. Italso describes features, details and devices to assure you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new vehicle well and that it will continue to give you satisfactory service for many years to come. This bookletis an integral part ofthe vehicle and must be handed over to the new owner in the event of sale.
The instructions in this booklethave been compiled primarily to offer a simple and clear guide to using the vehicle; italso describes routine maintenance procedures and regular checks that should be carried out on the vehicle at an Aprilia Dealer or Authorised Workshop. This booklet also contains instructions for simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical knowledge; for these operations, please take your vehicle to an Aprilia Dealer or Authorised Workshop.
De instructies in deze handieiding zijn voorbereid om vooral een eenvoudige en duidelike leidraad te zin voor het gebruik; men vindt eveneens de handelingen van het klein onderhoud en van de periodieke controles die bij een Dealer of Erkende aprilia Garage moeten uitgevoerd worden. De handleiding bevat tevens instructies voor een aantal eenvoudige herstellingen. De herstellingen die niet uitgebreid in deze uitgave zijn beschreven, vereisen dat men over speciale gereedschappen en/of specifieke technische kennis beschikt; voor het uitvoeren van deze herstellingen raadtmen aan om zich te wenden tot een Dealer of Erkende aprilia Garage.
B 5 E Personal safety
Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment
Sections marked with this symbol indicate the correct use ofthe vehicle to prevent damaging the environ- ment.
The incomplete or non-observance of these regula- tions leads to the risk of serious damage to the vehicle and sometimes even the invalidity ofthe guarantee.
The symbols shown above are very important. They are used to highlight those parts of the booklet that should be read with particular care. As you can see, each sign consists of a different graphic symbol, mak- ing it quick and easy to locate the various topics. Before starting the engine, read this bookletthorough- ly and the "SAFE RIDING" section in particular. Your safety as well as others does not only depend on the quickness of your reflexes and agility, but also on how well you know your vehicle, the state of maintenance ofthe vehicle itself and your knowledge of the rules for SAFE RIDING. For your safety, get to know your vehicle well so as to safely ride and master itin road traffic IMPORTANT This booklet is an integral part of the vehicle, and must be handed to the new owner in the event of sale.
Persoonlike veiligheid
GENERAL RULES. 9 Carbon monoxide. 10 Fuel.. 10 Hot components 11 Coolant.. 11 Used engine oil and gearbox oil 13 Brake and clutch fluid... 14 Battery hydrogen gas and electrolyt 14 Reporting of defects that affect safety. 16
Arrangement of the main components. 25 Dashboard... 27 Analog instrument panel 28 Light unit. 28 Digital Icd display. 30 Ignition switch... 35 Locking the steering wheel 35 Hom button. 36 Switch direction indicators. 36 High/low beam selector. 37 Start-up button 37 Engine stop switch... 38 Opening the saddle 39 Identification... 39 USE 43 Checks … 44 47
Rear shock absorbers adjustment. 49
Front fork adjustment. Running in.
Starting up the engine. 57
ALGEMENE NORMEN. Koolmonoxide. Brandstof.… Warme onderdelen Koelvioeistof.. Gebruikte motorolie en koppelingsolie. Rem- en koppelingsvloeistof.… Elektrolyt en waterstofgas van de accu Communicatie van de defecten die invloed hebben op de vei- ligheid...
VOERTUING Plaats van de hoofdcomponenten.. Legenda.. Analoog istumentenpaneel Groep controlelampjes… Digitaal display. Startschakelaar. Stuurslot vergrendelen: Drukknop claxon.….……. Schakelaar richtingaanwizers. Lichtschakelaar. Startknop… Stopschakelaar motor. Zadel openen. Identificatie. GEBRUIK Controles. TANKEN.… Regulering achterdempers. Regulering voorvorken. Inrijden..….
Stopping the engine. Anti-theft device. Stand...
Safe driving. 64 Load.
MAINTENANCE 71 Engine oil level 72
Engine oil change... Gearbox oil level... Spark plug dismantiement Removing the air filter. Cooling fluid level... Checking the brake oil level. Battery...
Fuses Lamps. Front light grou Headlight adjustment. Front and rear disc brake Periods of inactivity. Cleaning the vehicle... Transport... Transmission chain Chain backlash check. Chain backlash adjustment. Checking wear of chain, front and rear sprockets. Chain lubrication and cleaning,
TECHNICAL DATA, Kit equipment.
Chap. 01 General rules
1 General rules / 1 Algemene normen
If you need to keep the engine running in order to perform a procedure, please en- sure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use à smoke-extraction system
KEEP OUT OF THE REACH OF CHIL-
The engine and the exhaustsystem com- ponents get very hot and remain in this condition for à certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or waituntilthe engine and the exhaust sys- tem have cooled down.
The coolant contains ethylene glycol which, under certain conditions, can be- come flammable. When ethylene glycol burns, it produces an invisible flame which can nevertheless cause bus.
KEEP OUT OF THE REACH OF CHIL-
Used engine oil and gearbox oil
CAUTION AIN IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VE- HICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGU- LAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
Brake and clutch fluid
A THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFA- CES. WHEN SERVICING THE BRAK- ING SYSTEM PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOG- GLES WHEN SERVICING THE BRAK- ING SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDEN- TAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHIL-
DREN Battery hydrogen gas and electrolyte
CAUTION A BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID, IT CAN CAUSE
KEEP OUT OF THE REACH OF CHIL-
Reporting of defects that affect safety
GENERAL PRECAUTIONS AND IN-
FORMATION When repairing, dismanting and reas- sembling the vehicle follow the recom- mendations reported below carefully.
BEFORE REMOVING COMPONENTS
+ Before dismantling compo- nents, remove dirt, mud, dust and foreign bodies from the ve- hicle. Use the special tools de- signed for this bike, as required.
+ Do notloosen and/or tighten screws and nuts using pliers or other tools than the especially designed wrench.
+ Mark positions on all connection joints (pipes, cables etc.) before
+ Los en/ofsluit de bouten en de moeren niet met tangen of an-
separating them, and identify them with distinctive symbols.
+ Each componentneeds to be cleariy marked in order to be identified during reassembly.
+ Clean and wash the dismantied components carefully using à low-flammability detergent.
+ Keep coupled parts together since they have "adjusted" to each other due to normal wear and tear.
+ Some components must be used together or replaced alto- gether.
+ Keep away from heat sources.
REASSEMBLY OF COMPONENTS CAUTION BEARINGS MUST BE ABLE TO RO- TATE FREELY, WITHOUT J AMMING AND/OR NOISE: OTHERWISE, THEY NEED TO BE REPLACED.
1 General rules / 1 Algemene normen
Only use ORIGINAL APRILIA SPARE PARTS Comply with lubricant and con- sumables use guidelines. Lubricate parts (whenever pos- sible) before reassembling them.
When tightening nuts and screws, start from the ones with the largest section or from the internal ones, moving diagonal- Iy. Tighten nuts and screws in successive steps before apply- ing the tightening torque Always replace self-locking nuts, washers, sealing rings, cir- clips, O-rings (OR), split pins and screws with new ones if their tread is damaged
When assembling the bearings, make sure to lubricate them well
Check that each component is assembled correcty.
After a repair or routine mainte- nance procedure, carry out pre- ride checks and testthe vehicle on private grounds or in an area with low traffic density.
Clean all coupling surfaces, oil guard rims and gaskets before refitng them. Smear a light lay- er of lthium-based grease on the oil guard rims. Reassemble oil guards and bearings with the brand or lot number facing out- ward (visible side).
Reinig alle koppelingsviakken, de randen van de oliekeerringen en de pakkingen véér de her-
ELECTRIC CONNECTORS Electric connectors must be disconnec- ted as described below: failure to comply with this procedure causes irreparable damage to both the connector and the cable hamess:
Press the relevant safety hooks, if any.
+ Gripthe ho connectors and dis- connectthem by pulling them in opposite directions.
+ Ifthere are signs of dirt rust, hu- midity, etc., clean the connector internal parts carefully using à pressurised air jet.
+ Make sure thatthe cables are correctiy cramped to the con- nector internal terminal ends.
+ Theninsertthe two connectors making sure that they couple correct (ifthe relevant hooks are provided, you will hear them “click” into place).
Arrangement of the main components (02_02)
10. Rear left side fairing
Side stand Left rider footrest
Front left side fairing
Front right side fairing
Coolant right side radiator Coolant expansion tank cap Right rear-view mirror
Auxlliary fuses housing
Rear right side fairing
Pump with rear brake fluid res- ervoir
Right rider footrest
Rear brake control lever
Dashboard (02_03) KEY
2. Clutch control lever
6._ Right rear-view mirror
2. Neutral gear warning light (green)
3. Engine oil pressure warning
light (red) (not active)
Multifunctional digital display.
Low fuel warning light (orange)
High-beam warning light (blue)
Neutral gear indicator «2 »
It comes on when neutral is selected.
Multifunction LCD display «4» Speedometer (km/h - MPH) Displays driving speed in three digits and in real time.
Odometer km/mi Displays the partial or total number of kilometres/miles covered
Comes on when 2.2 +1 | (0.48 + 0.22 Ukgal) of fuel are left in the fuel tank.
CAUTION LA AVOID DEPLETING THE FUEL RE- SERVE AT ALL COSTS, OR YOU WILL DAMAGE THE FUEL PUMP.
High-beam warning light «6 »
It comes on when the high-beam light is activated or the high-beam light is flash- ed
Turn indicator warning light «7 »
It flashes when the turning indication is activated
tal Icd display (02_05, 02_06, 02_07, 02_08, 02_09, 02 10,02 11,02 12, 02 13, 02 14,02 15)
Each time the instrument panel turns on, there is à 2-second check for the display and all warning lights: afterwards, the in- strument panel shows the last function set.
Each time the SCROLL button is press- ed, the functions are displayed in the fol- lowing sequence:
SPEED -OD0O The vehicle current speed is shown in km/h or mph on the leftside ofthe display.
The number of kilometres or miles cov- ered, according to the setting, is shown on the right side of the display.
SPEED -H The vehicle current speed is shown in km/h ormph on the leftside ofthe display.
The hours of engine operation are shown on the right side of the display
SPEED -CLK The vehicle current speed is shown in km/h ormph on the leftside ofthe display.
The time is shown on the rightside ofthe display.
CLOCK SETTING The hours increase if you hold down the SCROLL button for at least 3 seconds.
The minutes increase once the button is released after 3 seconds
The vehicle current speed is shown in km/h or mph on the leftside ofthe display.
The number of kilometres or miles part- ally covered, according to the setting, is shown on the right side of the display.
The vehicle current speed is shown in km/h or mph on the leftside ofthe display.
A chronometer is shown on the right side of the display.
Hold down the SCROLL button for at least 3 seconds to activate this function
1st activation - start 2nd activation - stop
3rd activation - reset
The vehicle current speed is shown in km/h ormph on the leftside ofthe display.
The average speed is shown on the right side of the display. This information is generated when TRIP 1 is activated.
The vehicle current speed is shown in km/h ormph on the leftside ofthe display.
The maximum speed in the current unit of measurement is shown on the right side ofthe display.
Hold down the SCROLL button for at least 3 seconds to reset this function.
The vehicle current speed is shown in km/h ormph on the leftside ofthe display.
The number of kilometres or miles part- ally covered, according to the setting, is shown on the right side of the display.
Hold down the SCROLL button for at least 3 seconds to reset this function.
SPEED -RPM The vehicle current speed is shown in km/h or mph on the leftside ofthe display.
The numbers for engine revolutions per minute are shown on the right side of the display.
UNIT OF MEASUREMENT CONVER-
SION Start the vehicle while holding down the SCROLL button until the "km/h" symbol is displayed.
The "Km/h" and "Mph Miles” symbols will be shown alternately.
Push the SCROLL button again when the desired unit of measurement is shown.
Druk nogmaals op de SCROLL knop wanneer de gewenste meeteenheid weergegeven wordt
Ignition switch (02_16) The ignition switch is in front of the left radiator.
The vehicle is supplied with two keys {one is the spare key).
The lights go off when the ignition switch is setto «OFF».
NOTE THE LIGHTS TURN ON AUTOMATI CALLY UPON THE ENGINE START- UP.
Locking the steering wheel (02_17) To lock the steering:
+ Tum the handlebar completely to the left.
Push in the key and tum itanticlockwise (to the left}, move the handlebar slowly to the right until he key is tumed to the right while still pressed.
SITIE «ON» BEVINDT High/low beam selector (02_20)
Ithe light switch «2» is set to the upper position, this activates the high-beam light; if it is set to the lower position, the low-beam light is switched on. In case of danger and/or emergency itis possible to actate high-beam flashing using the «b button.
Start-up button (02_21)
By pressing the starter button «2», the starter motor makes the engine rotate.
Itacts as an engine cut-off or emergency stop switch. With switch «1» setto «ON» is possible to start the engine: by press- ing itinto the «OFF» position, the engine stops.
Opening the saddle (02_23, 02_24)
+ Tum the fastening clip. + Push the saddle forwards.
+ Remove the saddle.
Identification (02_25, 02_26)
Write down the chassis and engine num- ber in the specific space of this booklet. The chassis number can be used to order spare parts.
ATE THE WARRANTY ENGINE NUMBER The engine number is stamped on the base ofthe left side engine crankcase.
CHASSIS NUMBER The chassis number is stamped on the right side of the headstock.
LET OP IA VOER VOOR HET WEGRIJ DEN AL- TIJD EEN CONTROLE VAN HET VOERTUIG UIT OM EEN CORRECTE EN VEILIGE WERKZAAMHEID TE GA- RANDEREN. HET NIET UITVOEREN VAN DEZE HANDELINGEN KAN ERN- STIGE LETSELS AAN UZELF OF SCHADE AAN HET VOERTUIG VER- OORZAKEN. AARZEL NIET OM ZICH TE WENDEN TOT EEN Officièle aprilia Dealer, WANNEER MEN DE WERKING VAN BEPAALDE COMMANDO'S NIET BEGRIJ PT OF WANNEER MEN ONRE- GELMATIGHEDEN IN DE WERKING MERKT OF VERMOEDT. DE NODIGE TIJD VOOR EEN CONTROLE IS UI- TERST BEPERKT, EN DE VEILIGHEID KOMT OP DE EERSTE PLAATS.
VOORAFGAANDE CONTROLES Front and rear disc brake
Check operation. Check brake
lever travel when stationary and brake fluid level. Check for leaks. Check brake pads for wear. If necessary top-up with brake fluid.
Voorste en achterste schiffrem
Check that the throttle functions smoothly and can be fully opened and closed in all steering positions. Adjust and/or lubricate if necessary.
Controleer of hij zacht werkt en of men hem volledig kan openen en sluiten, in alle posites van het stuur. Registreer en/of smeer indien nodig.
Check and/or top-up as required.
Check that tyres are in good condition. Check infiation pressure and check for tyre wear and damage
Remove any foreign objects stuck in the tread.
Olie motorversnellingsbak
Controleer en/of vul bi indien nodig.
Check they function smoothly.
Lubricate joints and adjust travel if necessary.
Check for proper operation. Check control lever empty travel. The clutch must work without gripping and/or slipping.
Check that the rotation is uniform, smooth and there are no signs of clearance or slackness.
Controleer de werking en de lege loop van de commandohendel. De koppeling moet zonder rukken en/ of slippen werken.
Check its operation. Check that there is no friction when the side stand is pulled up and down and that the springs' tension makes it snap back to its rest position. Lubricate joints and couplings as required
Check that the fastener elements are not loose.
Controleer de speling.
Drive chain Check it for backlash. Fuel tank Check the level and refil if necessary. Check the circuit for leaks or obstructions. Check that the tank cover closes correcty. Coolant The coolant level in the radiator
must be such as to cover the grids.
Engine stop switch (RUN - OFF)
Lights, warning lights, horn, rear stop light switch and electrical devices
Check function of hom and lights. Replace bulbs or repair any faults noted.
Use premium unleaded petrol as per DIN 51 607, minimum octane rating of 95 (NORM) and 85 (NOMM).
+ Unscrew and remove the fuel tank cap (1) + Refuel.
CAUTION AIN FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND CAN BECOME EX- PLOSIVE UNDER SPECIFIC CONDI- TIONS. IT IS THEREFORE RECOM- MENDED TO CARRY OUT REFUEL- LING AND MAINTENANCE PROCE- DURES IN A VENTILATED AREA WITH THE ENGINE OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOID ANY CON- TACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHIL- DREN
FUEL TANK CAPACITY (including re- serve):
7.51(1.65 Ukgal) Reservoir reserve:
Rear shock absorbers adjustment (03_02, 03_03, 03_04,03_05)
The rear suspension consists of à spring- shock absorber unit linked to the frame via silent-block and to the rear fork via à linkage system. To adjust the setting, the shock absorber is fitted with a set screw that adjusts hydraulic rebound damping (1), with a set screw (2) that adjusts hy- draulic compression damping (low speed), with a knob (6) that adjusts hy- draulic compression damping (high speed) and a ring nut that adjusts spring preloading (3) and à locking ring nut (4).
REAR SHOCK ABSORBER ADJ UST-
MENT The standard setting of the rear shock absorber is adjusted so as to satisfy all main high and low speed riding condi- tions, both with reduced and full vehicle load. It is at any rate possible to insert personal settings, depending on vehicle utilisation
+ Using the specific spanner, slighüy loosen the locking ring nut (4).
+ Operate on the adjusting ring nut (3) to adjust the spring pre- loading (B).
+ When the optimal adjustment level has been obtained, screw the locking nut ring (4) com- pletely.
+ Operate on screw (2) to adjust hydraulic compression damping atlow speeds (see chart).
+ Operate on knob (6) to adjust hydraulic compression damping athigh speeds (see chart)
adjustment, (high speeds), knob 6)
14 clicks from fully closed
Regeling in compressie (hoge
14 klikken vanafhelemaal gesloten
Front fork adjustment (03_06, 03_07)
FRONT SUSPENSION The front suspension consists of à hy- draulic fork connected to the headstock by means of two plates. To adjustthe ve- hicle setting, each fork stem is equipped with an upper screw «1» to adjust re- bound damping and with a lower screw «2» to adjust compression damping.
FRONT FORK ADJ USTMENT CAUTION TO PREVENT DAMAGE, DO NOT FORCE THE ADJUSTER (1-2) BE- YOND THE RESPECTIVE END OF TRAVEL IN EITHER DIRECTION. SET BOTH STEMS WITH THE SAME SPRING PRELOAD AND DAMPING TOLERANCES: RIDING THE VEHICLE WITH A DIFFERENT ADJUSTMENT FOR THE TWO STEMS REDUCES ITS STABILITY. IF YOU INCREASE SPRING PRELOAD, YOU ALSO NEED TO INCREASE REBOUND DAMPING TO PREVENT SUDDEN J ERKS WHILE RIDING.
The standard setting of the front fork is adjusted s0 as to satisfy all main high and low speed riding conditions, both with re- duced and full vehicle load. It is at any rate possible to insert personal settings, depending on vehicle usage.
Front suspension standard adjustment:
+ Rebound damping adjustment, screw (1}: open (**) 12 clicks from fully closed (*);
+ Compression damping adjust- ment, screw (2): open (**) 12 clicks from fully closed (*) (H);
+ Stems (A) (**) protrusion from top plate (excluding cover): 1 notch
(= Clockwise (*)= Anticlockwise
CAUTION A SPORT SETTINGS MAY BE USED ON- LY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAF- FIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. USING SPORT SETTINGS AND RID- ING THE VEHICLE ON ROADS AND MOTORWAYS WITH THESE SET- TINGS IS STRICTLY FORBIDDEN.
Running in Engine run-in is essential to ensure en-
gine long life and correct operation. Twisty roads and gradients are ideal to
run in engine, brakes and suspensions effectively. Vary your riding speed during the run-in. In this way, you allow for the work of components to be ‘loaded" and then “unloaded", thus cooling the engine parts. Even ifitis important to "strain" en- gine components during run-in, make sure not to overdo this.
Follow the guidelines detailed below:
+ Do nottwistthe throttle grip abruptiy and completely when the engine is working at a low revs, either during or after run- in.
+ forthe first3 operating hours, do not exceed 50% of the throttle grip travel and never go over 8000 rpm,
+ forthe next 12 hours, do notex- ceed 75% of the throttie grip travel
NOTE EVEN AFTER THE RUNNING-IN PERI- OD, AVOID RUNNING THE ENGINE TO TOP SPEED, WHEN THE LIMITER CUTS IN:
+ Getonto the bike in riding posi- tion.
+ Make sure thatthe stand has been fully retracted.
+ Make sure the light switch (1) is setto "low-beam".
+ Setthe engine stop switch (2) to RUN
+ Push the ignition switch (4) (a red LED lights up in the switch)
At this stage: + The ignition screen is shown on the displayed for two seconds. + Allwaming lights in the instru- ment panel tu on for two sec- onds.
+ Block atleastone wheel by op- erating one brake lever.
+ Operate the clutch lever com- pletely and setthe gearshiftlev- erto neutral [green warning light (N) on].
+ Press the starter button «3» without opening the throttie and release itas soon as the engine starts.
LET OP VERTREK NIET BRUUSK WANNEER DE MOTOR KOUD STAAT. OM DE EMISSIE VAN VERVUILENDE STOF- FEN IN DE LUCHT EN HET BRAND- STOFVERBRUIK TE BEPERKEN, RAADT MEN AAN OM DE MOTOR OP TE WARMEN, DOOR DE EERSTE KI- LOMETERS AF TE LEGGEN AANEEN BEPERKTE SNELHEID.
Stopping the engine (03_13)
Itis very important to select an adequate parking spot, in compliance with road sig- nals and the guidelines described below.
CAUTION A PARK ON SAFE AND LEVEL GROUND TO PREVENT THE VEHICLE FROM FALLING.
DO NOT SEAT ON THE VEHICLE WHEN THE STAND IS LOWERED.
To park the vehicle:
+ Select an appropriate parking spot.
+ Setthe ignition switch «2» to «OFF».
The red LED next to the switch should turn off.
+ Getoffthe vehicle. *__Restthe vehicle onits stand.
Anti-theft device (03_14)
The Six Days version is supplied with an antitheft device (1) to be applied to the rear brake disc (2) (padlock with key lock)
To place the vehicle on the stand:
+ Grasp the left grip «1» and put the right hand on the upper rear part of the vehicle «2»
+ Push the side stand «3» with your right foot, and extend it completely.
+ With the stand fully extended, lean the vehicle to the side until the stand rests on the ground.
+ Tumthe handlebar fully left- wards.
CAUTION MAKE SURE THE GROUND WHERE YOU HAVE PARKEDIS UNOCCUPIED, FIRM AND LEVEL.
Safe driving (03_16, 03_17, 03_18,03_ 19,03 20,03 21, 03_22,03 23,03 24,03 25, 03_26, 03 27)
MAIN SAFETY RULES To ride the vehicle itis necessary to com- ply with all legal requirements (driving license, minimum driving age, psycho- physical performance, insurance, taxes and fees, registration, license plate, etc.).
You should practise using the vehicle in traffic-free areas and/or private property until you have become thoroughly ac- quainted with the vehicle.
Driving under the influence of medica- tion, alcohol and narcotic drugs or psy- chotropic substances dramatically_in- creases the risk of accidents.
Do notride your vehicle if you feel tred or drowsy and always keep safe psycho- physical riding conditions.
The main cause of motorcycle accidents is users’ inexperience.
NEVER lend the vehicle to beginners and always make sure that the rider complies with allnecessary requirements for a safe riding.
Strictiy obey all national and local traffic signs and rules.
Avoid any abrupt and dangerous swerves for your own as well as others’ safety (for example: rearing up on the
Leen het voertuig NOOIT aan beginners, en controleer in elk geval of de bestuur- der in het bezit is van alle vereisten voor het rijden.
back wheel, riding over the speed limit, etc.) Besides, always assess and bearin mind the road surface conditions, visibil- it, etc.
Do notknock obstacles that can damage the vehicle or cause loss of control.
Do not ride on the course of the vehicle in front just to improve your own speed.
CAUTION ALWAYS RIDE WITH BOTH HANDS ON THE HANDLEBAR AND FEET ON THE FOOTRESTS (OR THE RIDER'S FOOTRESTS)IN THE ADEQUATE RID- ING POSITION.
Never stand on your feet or stretch your- self while riding.
The rider should always be attentive, never getdistracted orinfluenced by peo- ple, things or actions (never smoke, eat, drink, read, etc.) while riding.
Always use fuel and lubricants specific for the vehicle, ofthe type recommended in the "LUBRICANTS TABLE". Check fuel, oil and coolant frequently for correct level
In case of an accident or after the vehicle has fallen down or suffered à sudden bump, make sure the control levers, pip- ing, cables, brake circuit and main parts ofthe vehicle have not been damaged.
If necessary, take the vehicle to an Off- cial aprilia Dealer to check especially the frame, handlebar, suspensions, safety components and any device the user cannot assess without the aid of à spe- cialist.
Report any malfunction to the engineers and/or mechanics in order to faciltate their work.
Never ride the vehicle ifthe damage jeop- ardises safety.
Do not modify the position, angle or col- ourof: license plate, tum indicators, light- ing devices and hom.
Any changes to the vehicle will void the warranty.
Rij absoluut niet met het voertuig wan- neer de aangebrachte schade de veilig- heid schaadt.
Any change introduced to the vehicle and the removal of original parts may jeop- ardise the vehicle performance and therefore reduce safety or even render the vehicle inappropriate for legal riding.
Comply with all national and local laws and regulations on vehicle equipment.
In particular do not introduce technical changes leading to improve performance and under no circumstances alter the original specifications of the vehicle.
Never race with vehicles.
Never ride off-road.
CLOTHING Before riding off, remember to put on the helmet and fasten it correctiy. Make sure itis a homologated model, that it is un- damaged, of the right size and that the visoris clean:
Wear appropriate protective clothes, preferably light-coloured and/or in refiec- äive material. In this way you will be easily visible to other drivers, thus reducing the risk of being hit, and you will be better protected in case of falling.
Always wear tight-fiting clothes without open cuffs: avoid hanging stings, belts or tes; these orany other objects should not interfere with a safe riding when getting entangled with the riding elements or due to a special movement.
Never carry in your pockets objects that can be potentially dangerous in case of fall, like: pointed objects such as keys, pens, glass containers, etc. (the same rule applies to passengers).
ACCESSORIES User is personally responsible for the in- stallation and use ofthe accessories.
While assembling accessories, make sure that they do not cover the sound or light alarm devices or affect their correct functioning, do not limit the suspension travel or the steering angle, do not ob- struct control actuation or reduce the ground clearance and inclination angle at comers.
Do not use accessories that hinder ac- cess to the controls as they may increase the reaction time in case of an emergen- y.
Fairings and large windshields fited to the vehicle may cause aerodynamic forces that affect the vehicle stability while riding, mainly at high speeds.
Make sure the accessory is firm and se- cured to the vehicle and that it does not pose any risks while riding the vehicle.
Do notadd or modify electrical equipment that exceed the vehicle capacity as this may result in a sudden stop or a danger- ous lack of power required to keep the sound and light alarm devices operative.
4 Maintenance / 4 Onderhoud
Engine oil level (04_01, 04_02)
Checking and topping up engine oil level
CAUTION LA DO NOT SPILL OIL!
NOTE IN ORDER TO WARM-UP THE ENGINE AND BRING THE OIL TO THE RIGHT TEMPERATURE, RIDE THE VEHICLE FOR A SHORT PERIOD OF TIME (10 - 15 MIN), KEEP THE ENGINE RUNNING AT IDLE FOR AT LEAST 30 SECONDS AFTER YOU HAVE COME TO A HALT, THEN CUT OFF THE ENGINE.
+ Hold the vehicle level with the two wheels on the ground
+ Check the oil level
using the relevant transparent dipstick
+ The correct oil level is nearthe MAX mark.
+ Top-up the oil in the reservoir unël you reach the correct level
NOTE USE OIL RECOMMENDED IN THE PRODUCTS TABLE.
Engine oil change (04_03, 04_04, 04_05, 04_06)
+ Parkthe vehicle on firm and lev- el ground. + Restthe vehicle on its stand.
+ Stopthe engine and letitcool off so that the oil in the crankcase fiows down and cools as well
+ Remove the oil sump guard.
+ Unscrew and take outthe oil fil. er plug (1)
+ Place à container to collectthe oil underneath the engine oil drainage plug on the fiywheel side.
+ Unscrew and remove the oil drainage plug (2) and then drain allthe engine oil
4 Maintenance / 4 Onderhoud
Unscrew the engine oil filter cov- er (4)
Remove the engine oil filter cov- er (4) and collect the O-ring, Remove the engine oil filter. Place à container undemeath the engine oil drainage plug (3) of the recovery reservoir. Unscrew and remove the oil drainage plug (3) from the re- covery reservoir and drain all the engine oil.
Fit a new engine oil filter.
Screw the engine oil filter cover (a).
Screw and tighten the oil drain- age/filler plugs (2)(3)
Pour approx. 1000 cm? (61.02 cu.in) of engine oil through the filler opening.
Screw and tighten the oil filer plug (1).
Startthe engine and letit run for several minutes:
Draai de afvoerivuldoppen van de olie (2) en (3) vast, en sluitze. Voer het bijvullen uit langs de vulboring, met ongeveer 1000 cc (61.02 cu.in) motorolie. Draai de vuldop van de olie (1) vast, en sluit hem.
Unscrew and take outthe oil fill- er plug (1)
Top up with other 250 cm? (15.25 cu.in) of oil.
Screw and tighten the plug (1). Startthe engine and letit run for several minutes.
Stop the engine and leave itcool off.
Check engine oil level
Start de motor, en laathem voor enkele minuten opwarmen.
Gearbox oil level (04_07, 04_08, 04_09, 04 10)
Wait some minutes for the oil to fiow from the transmission to the clutch.
Keep the vehicle uprightwiththe two wheels on the ground. Remove the rear brake lever by undoing the screwr (1); collect the washer.
Unscrew and remove the cap/ dipstick (2).
The oil level is correct when itis close to the cap/dipstick (2)
IF À FUNNEL OR ANY OTHER ELE- MENT IS USED, MAKE SURE IT IS PERFECTLY CLEAN.
+ Waitsome minutes to allow the oil to flow from the clutch to the transmission. Then check the oil level again.
+ Refitthe rear brake lever, re- member to insertthe washer be- tween the lever and the crank- case, by tightening the screw @.
REPLACEMENT NOTE TO ENSURE EASIER AND FULL OIL DRAINAGE THE OIL MUST BE HOT AND THEREFORE MORE FLUID.
+ Lower the oil pan guard. + Place a container with suitable capacity under the drainage
+ Unscrew and remove the drain- age plug (4).
+ Drain the oil into the container: allow several minutes for oil to drain out completely.
+ Checkandifnecessary, replace the drainage plug (4) sealing washers.
+ Screw and tighten the drainage plug (4).
+ Remove the rear brake lever by undoing the screw (1); collect the washer.
+ Unscrew and remove the cap/ dipstick (2).
+ Pourin new oil until itreaches the cap/dipstick opening (2)
+ Waitsome minutes to allow the oil to flow from the clutch to the transmission.
+ Then check the oil level again.
+ Tighten the filler cap (3).
+ Refitthe rear brake lever, re- member to insertthe washer be- teen the lever and the crank- case, by tightening the screw Q).
NOTE USE OIL RECOMMENDED IN THE PRODUCTS TABLE.
Spark plug dismantiement (04_11, 04 12, 04 13)
At regular intervals, remove the spark plugs and clean off any carbon deposits or replace them as required.
In orderto gain access to the spark plugs:
CAUTION BEFORE CARRYING OUT THE FOL- LOWING OPERATIONS AND IN OR- DER TO AVOID BURNS, LEAVE EN- GINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE.
+ Place the vehicle on the stand.
NOTE LA THE VEHICLE HAS À SPARK PLUG (2) FOR EACH CYLINDER. THE FOLLOW- ING STEPS RELATE TO JUST ONE SPARK PLUG BUT APPLY TO BOTH.
+ Remove the tube (1) of spark plug (2).
+ Clean off any trace of dirt from the spark plug (2) base.
+ _Insertthe spanner supplied in the tool kit into the hexagonal head of spark plug (2).
+ Plaats de sleutel die wordt bij- geleverd bij de gereedschapskit op de zeskantige zit van de bou- gie (2).
+ Unscrew spark plug (2) and re- move it from its seat, making sure no dust or dirt gets into the cylinder.
Checking and cleaning:
CAUTION LA DO NOT USE METAL BRUSHES AND/ OR ABRASIVE PRODUCTS TO CLEAN SPARK PLUGS; USE ONLY À SHORT BLAST OF COMPRESSED AIR.
+ Check thatthe electrodes and the insulator of the spark plug (2) do not show signs of carbon deposits or corrosion. Ifneces- sary, clean them using à short blast of compressed air. Replace spark plug (2) if is insulator is cracked, the electrodes show signs of corrosion or excessive deposits orthe top ofthe central electrode gets rounded
+ Checkthe gap between electro- des with a feeler thickness gauge.
Electrode gap 0.7 +0.8 mm (0.027 +0.031 in)
If the electrode gap is different from the prescribed gap, replace the spark plug 2).
+ Make sure the washeris in good conditions.
+ Manual screw the spark plug (2) to avoid damaging the thread.
+ Tighten using the spanner sup- plied in the tool kit Make each Spark plug (2) complete 1/2 of a turn to compress the washer.
CAUTION LA IT IS ESSENTIAL TO TIGHTEN THE SPARK PLUG (2) PROPERLY. A LOOSE SPARK PLUG MAY CAUSE ENGINE OVERHEATING AND RESULT IN SEVERE DAMAGE.
Loc torques (N*m Spark plug USA
+ Position the spark plug tube (1) correctiy so that it does not get detached due to engine vibra- tons.
Removing the air filter (04_14, 04_15)
+ Remove the saddle.
+ Remove the side fairings.
+__Liftthe tank paying attention to the fuel pipe
+ Release the air filter cover by gripping and lifing the handles from both sides.
+ Take the filter casing cover off together with the air filter paying attention notto damage the con- trol unit connector (remove it if necessary).
NOTE DURING FUEL TANK LIFTING AND REFITTING, MANUALLY PLACE THE FUEL PIPE AND CHECK ITS COR- RECT POSITIONING.
CAUTION LA IN THE EVENT OF A FALL, CLEAN THE AIR FILTER AND ITS HOUSING CAREFULLY, REMOVING ANY TRACES OF OIL WHICH MAY HAVE ENTERED FROM THE OIL TANK THROUGH THE OIL VAPOURS BREATHER PIPES.
4 Maintenance / 4 Onderhoud
Cooling fluid level (04_16, 04_17)
Do not use the vehicle if the coolant is below the minimum level.
CAUTION A COOLANT IS TOXIC IF INGESTED; CONTACT WITH YOUR EYES OR SKIN MAY CAUSE IRRITATION. IF THE FLU- ID GETS IN CONTACT WITH THE EYES OR SKIN, RINSE REPEATEDLY WITH PLENTY OF WATER AND SEEK MEDICAL ADVICE. IF SWALLOWED, INDUCE VOMITING, RINSE MOUTH AND THROAT WITH PLENTY OF WA- TER AND SEEK MEDICAL ADVICE IM- MEDIATELY.
Coolant solution is 50% water and 50% antifreeze fluid.
This is the ideal mixture for most operat- ing temperatures and provides good cor- rosion protection.
Itis advisable to use the same mixture even in hot weather as this minimises loss due to evaporation and the need of frequent top-ups:
Less water evaporation means fewer mineral salts depositing in the radiators, which helps preserve the efficiency ofthe cooling system.
When the extemaltemperature drops be- low zero degrees centigrade, check the cooling system frequentiy and add more antifreeze solution if needed (up to 60% max).
Use distilled water in the coolant mixture to avoid damaging the engine.
Checking and topping up
CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOP- PING-UP THE COOLANT LEVEL.
+ Shutoffthe engine and wait until it cools off.
+ Parkthe vehicle on firm and lev- el ground.
+ Keepthe vehicle uprightwiththe two wheels on the ground.
+ Tum the radiator cap (1) anti- clockuise just one click.
+ Wait for some seconds so that any pressure in the system may be purged.
+ Tumthe radiator cap (1) anti- clockuise again and remove it.
+ Make sure the fluid covers the radiator plates completely.
+ Also check the level in the ex- pansion tank (under the engine sump cover) through the appro- priate sight glass.
+ The level should be between the MIN and MAX reference marks.
CAUTION LA DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID.
IF À FUNNEL OR ANY OTHER ELE- MENT IS USED, MAKE SURE IT IS PERFECTLY CLEAN.
+ Ifrequired, top-up with coolant until the radiator plates are cov- ered. Do not exceed this level: otherise, the coolant will spill during engine operation. When using à funnel or any other ele- ment, make sure itis perfect clean.
4 Maintenance / 4 Onderhoud
Checking the brake oil level (04_18, 04_19, 04_ 20, 04 21)
Check the brake fluid level following the instructions on the scheduled mainte- nance table.
The information provided below relates to an individual braking system but is appli- cable to both.
NOTE THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OPERATED BY AN INDEPEND- ENT HYDRAULIC CIRCUIT.
CAUTION A KEEP OUT OF THE REACH OF CHIL- DREN.
USE THE BRAKE FLUID SPECIFIED IN THE RECOMMENDED PRODUCT TA- BLE.
Brake fluid decreases gradually in the reservoir as the brake pads wear down, to compensate the wear automatically.
The front brake fluid reservoir (1) is placed near the front brake lever connec- tion.
The rear brake fluid reservoir (2) is inte- grated in the brake pump fastened to the frame, on the right side, near the fork.
Check the brake fluid level in the reser- voirs before setting off.
CAUTION DO NOT USE YOUR VEHICLE IF A FLUID LEAK IN THE BRAKING CIR- CUIT IS DETECTED.
Front brake Checking
+ Place the vehicle upright and keep the handlebar right.
+ Make sure the fluid level in the reservoir (1) is above the MIN level reference mark.
Ifthe fluid does not reach the MIN. mark
LET OP HET PEIL VAN DE VLOEISTOF VER- MINDERT PROGRESSIEF MET DE SLI] TAGE VAN DE PASTILLES.
+ Checkthe brake pads and discs for wear.
If the pads and/or the disc do not need replacing, top up the fluid.
CAUTION RISK OF BRAKE FLUID SPILLING. DO NOT PULL THE FRONT BRAKE LEV- ER WHEN THE SCREWS (3) ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR CAP (4) HAS BEEN REMOVED.
+ Undothe screws (3)ofthe brake fluid reservoir using a short Phil lips screwdriver.
+ Liftand remove the cover (4) to- gether with the screws (3) and the gasket (5)
CAUTION LA TO AVOID SPILLING BRAKE FLUID DURING TOP-UP, DO NOT SHAKE THE VEHICLE. DO NOT ADD ADDI TIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
+ Top up the reservoir «1» with the brake fluid, until you go be- yond the MIN minimum level mark.
+ Keep the vehicle upright.
+ Check thatthe liquid contained in the reservoiris higher than the MIN. mark.
MIN = minimum level Ifthe fluid does not reach the MIN. mark
CAUTION BRAKE LEVEL DECREASES GRADU- ALLY AS BRAKE PADS WEAR DOWN.
4 Maintenance / 4 Onderhoud
+ Checkthe brake pads and discs for wear.
If the pads and/or the disc do not need replacing, top up the fluid
CAUTION RISK OF BRAKE FLUID SPILLING. DO NOT PULL THE FRONT BRAKE LEV- ER WHEN THE SCREWS (6) ARE LOOSE OR, PRIMARILY, WHEN THE BRAKE FLUID RESERVOIR CAP (7)IS REMOVED.
+ Using a wrench, unscrew the two screws (6) ofthe brake fluid reservoir (2)
+ Liftand remove the cover (7) to- gether with the screws (6) and the gasket (8).
CAUTION LA TO AVOID SPILLING BRAKE FLUID DURING TOP-UP, DO NOT SHAKE THE VEHICLE. DO NOT ADD ADDI TIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
+ Top-up the reservoir (2) with the brake fluid until the level is over the MIN level reference mark.
Battery (04_22, 04_23, 04_24)
+ Remove the saddle.
+ Unscrew and remove the nega- tive wire fastening screw, keep- ing the washer.
+ Unscrew and remove the nega- tive wire fastening screw, keep- ing the washer.
+ Remove the battery.
4 Maintenance / 4 Onderhoud
Checking the fuses is necessary when- ever an electrical component fails to op- erate or is malfunctioning or when the engine does not start.
Check the auxiliary fuses first and then the main 30A fuse
+ Setthe ignition switch to (OFF) to avoid an accidental short cir- cuit.
+ Remove the right side fairing by undoing the two screws (1) and slide if off from its seat.
+__Liftthe cover (2) ofthe auxiliary fuse box.
SECONDARY FUSES DISTRIBUTION
*__ Take out one fuse at a time and check whetherthe filament (3) is broken.
+ Before replacing the fuse, find and soive, if possible, the rea- son that caused the problem.
+ lfthe fuse is damaged, replace itwith one of the same amper- age.
NOTE IF THE SPARE FUSE IS USED, RE- PLACE WITH ONE OF THE SAME TYPE IN THE CORRESPONDING FIT- TING.
+ Remove the leftside cover, fol- lowing the same procedure as for the right side cover.
+ Follow the same steps descri- bed above forthe auxiliary fuses also for the main fuses.
+ Verwijder de zekeringen één voor één, en controler of de draad (3) onderbroken is.
NOTE BEFORE CHANGING A BULB, CHECK THE FUSES.
Front light group (04_ 30, 04_31, 04 32, 04 33, 04 34) In the front headlight there are:
+ Two tail light bulbs «1». + One low-beam/ high-beam light bulb «2»
+ Restthe vehicle on its stand.
+ Undo the two upper screws.
+ Slide offthe front cou from the mudguard seats.
+ Slide offthe tail light bulb and replace it with another of the same type.
High/low beam light bulb«2»
+ Hold the bulb electrical connec- tor «3», pull and disconnect it from the bulb holder.
+ Slide offthe cover «4» from the parabole fiting and from the bulb connectors.
+ Release the two ends ofthe re- taining spring «5» located in the bulb holder.
+ Extractthe bulb from its fittng.
+ Fita bulb ofthe same type ade- quately
4 Maintenance / 4 Onderhoud
For a quick check ofthe correct direction
ofthe front light beam:
+ Place the vehicle 10m away from a vertical wall and make sure the ground is level.
+ Tum on the low-beam light, sit on the scooter and check that the light beam projected to the wall is a lite below the headlight horizontal straight line (about 9/10 ofthe total height).
To adjust the light beam:
+ Working from both sides, undo screw «1».
+ Adjustthe headiamp until the desired position is obtained
+ Working from both sides, tighten screw «1».
Front and rear disc brake (04_37, 04 38, 04 39, 04_40)
NOTE THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OPERATED BY AN INDEPEND- ENT HYDRAULIC CIRCUIT.
The front braking system has single disc (left side)
The rear braking system has single disc (right side).
The information provided below relates to an individual braking system but is appli- cable to both
Brake fluid decreases gradually in the reservoir (1-2) as the brake pads wear down, to compensate the wear automat- ically.
The front brake reservoir «1» is placed near the front brake lever connection. The rear brake fluid reservoir «2» is inte- grated in the brake pump fastened to the frame near the fork.
Check the brake fluid level in the reser- voirs «1» «2» and check brake pads for wear before setting off.
Checking brake pads for wear
Disc brake pad wear depend on the use, the riding style and the roads.
CAUTION WEAR IS GREATER WHEN RIDING ON DIRTY AND WET ROADS OR OF- FERED.
To carry out a quick pad check:
+ Restthe vehicle on its stand. Check the front brake calliper pads:
+ Visually inspectthe area be- tween brake disc and brake pads looking from the bottom up the front end;
Checking the rear brake calliper pads:
+ Visually inspectthe area be- tween brake disc and brake pads looking from the bottom up the rear end;
NOTE EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET INTO CONTACT WITH THE DISC, WHICH RESULTS IN A METALLIC NOISE AND SPARKS IN THE CALLIPER; THEREFORE, BRAK- ING EFFICIENCY AND DISC SAFETY AND INTEGRITY ARE AT RISK.
When the lining material of even just one of the brake pads is worn down to nearly 1.5 mm (0.06 in) (or even if one of the wear indicators is no longer visible), re- place both brake pads.
Take some measures to avoid the side effects of not using the vehicle. Also, car- ty out general maintenance and checks before garaging the vehicle as one can forget to do so aftenwards.
Remove the battery. Wash and dry the vehicle Inflate tyres.
Store the vehicle in cool, dry place, with minimum tempera- ture variations and not exposed to sun rays.
+ Wrap and tie a plastic bag around the muffler exhaust end to keep moisture out.
NOTE PLACE A SUITABLE SUPPORT UN- DER THE VEHICLE TO KEEP BOTH WHEELS OFF THE GROUND.
+ Coverthe vehicle. Avoid using plastic or waterproof materials.
Uncover and clean the vehicle
NOTE TAKE THE PLASTIC BAGS OFF THE EXHAUST PIPE OPENING.
+ Uncover and clean the scooter.
+ Check battery charge and in- stall.
+ Refilthe fuel tank.
+ Carry outthe pre-ride checks.
CAUTION LA TEST RIDE THE VEHICLE AT MODER- ATE SPEED FOR AFEWKILOMETRES IN AN AREA AWAY FROM TRAFFIC.
Cleaning the vehicle
Clean the scooter frequentiy if ex- posed to adverse conditions, such as:
+ Airpollution (cities and industrial areas).
+ Salinity and humidity in the at- mosphere (seashore areas, hot and wet weather)
+ Special environmental/season- al conditions (use of salt, anti-
+ Zoutgehalte en vochtigheid uit de atmosfeer (zeegebieden, warm en vochtig kimaat).
icing chemical products on the roads in winter)
+ Pay special attention to prevent deposits on the bodywork, such as industrial dusts and pollu- tants, tar spots, dead insects, birds droppings, etc. Avoid park- ing under trees. During some seasons, resins, fruits or leaves containing aggressive chemical substances that may damage the paintwork may fall from trees
CAUTION LA BEFORE WASHING THE VEHICLE, COVER THE ENGINE AIR INTAKES AND THE EXHAUST PIPES.
During transportthe vehicle must be well secured in an upright position and first gear must be engaged, to avoid fuel, oil and coolant leaks.
IN CASE OF FAILURE, DO NOT HAVE THE VEHICLE TOWED. ASK FOR ROAD ASSISTANCE SERVICE.
The RXV model features à chain with master link.
Place the vehicle on the stand. Engage neutral gear.
Check that vertical oscillation at the middle point between pinion and crown on the lower part of the chain is of about 20 +25 mm (0.79 +0.98 in)
+ Move the vehicle foward 50 as to check vertical oscillation in other positions too. The slack should remain constant during all wheel rotation phases.
Ifthe slack is uniform, but higher or lower than 20 +25 mm (0.79 +0.98 in), adjust it as required
TO AVOID RISK OF SEIZURE, LUBRI- CATE THE CHAIN ON A REGULAR BASIS.
Chain backlash adjustment (04_43, 04 44)
If you need to adjust chain tension after the check:
+ Restthe vehicle on its stand. + Loosen the nut (1) completely. + Loosen both lock nuts (4).
+ Actuate on the setscrews (5) and adjust the chain backlash checking that the references (2 - 3) match on both sides ofthe vehicle
+ Tighten both lock nuts (4).
+ Tighten the nut (1).
+ Check chain clearance.
Tightening torque for wheel nut (1): 120 Nm (12.0 kgm).
Checking wear of chain, front and rear sprockets (04_45, 04_46, 04_47)
Also check the following parts and make sure thatthe chain, pinion and crown do not have:
+ Dry, rusty, fiattened or jammed chain links.
+ Missing sealing rings.
+ Excessively wo or damaged pinion or crown teeth.
LET OP SMEER DE KETTING REGELMATIG, VOORAL WANNEER MEN DROGE OF VERROESTE DELEN OPMERKT. DE SAMENGEDRUKTE OF AFGESLA- GEN SCHAKELS MOETEN GE- SMEERD WORDEN EN OPNIEUW IN WERKCONDITIES GEBRACHT WOR- DEN. WANNEER DIT NIET MOGELIJK ZOU ZIJN, WENDT MEN ZICH TOT EEN Officièle aprilia Dealer, DIE ZAL ZORGEN VOOR DE VERVANGING.
Chain lubrication and cleaning
Lubricate the chain whenever necessary. Lubricate the chain with chain spray grease. Do notwash the chain with water jets, vapour jets, high-pressure water jets and highly fammable solvents.
BE EXTREMELY CAREFUL WHEN AD- JUSTING, LUBRICATING, WASHING AND REPLACING THE CHAIN.
Max. height (to windshield)
Minimum ground clearance
Kerb weight (of every fluid )
116.5 kg (256.84 Ib)
Fuel tank capacity (including reserve)
100 mm (3.94 in) of clearance (for each stem, measured without spring and under compression)
1.11 (0.24 Ukgal) (50% water + 50% antifreeze solution with ethylene glycol)
CHASSIS Tubular steel perimeter frame and aluminium vertical members
Capaciteit van de koelvioeistof
1,11(0.24 gal) (50% water +50%
Front suspension travel
Oscillating fork and adjustable hydraulic single shock absorber
© 270 mm (@ 10.63 in) disc brake with hydraulic transmission
300 mm (11.81 in) (bruikbaar)
Rear brake © 240 mm (@ 9.45 in) disc brake with hydraulic transmission
Wheel rims with spokes
Front wheel rim 1.60 x 21
Rear wheel rim 2.15 x 18
Rear tyre inflation pressure
4-stroke, twin-cylinder, 4 valves per cylinder, single overhead camshaft
overall cylinder capacity
Primaire: 22/56 = 1: 2,545 Eind: 15/50 = 1: 3,200
Clutch multiple-disc oil-bathed clutch
Lubrication system Separate twin-sump lubrication system with external reservoir
Gearbox mechanical, 5 speeds with foot lever on the left hand side of the engine
Gear ratio Primary: 22/56 = 1 : 2.545 Final: 15/50 = 1 : 3.200
1st 12/31 =1 : 2.583 (secondary) 1: 21.042 (total)
2nd 13/25 =1 : 1.923 (secondary) 1: 15.664 (total)
3rd 15/23 =1 : 1.533 (secondary) 1: 12.489 (total)
ath 19/24 =1 : 1.263 (secondary)
ste 12/31= 1: 2,583 (secundaire) 1: 21,042 (totale)
per cylinder, single overhead camshaft
Overall engine capacity
80 mm /55,0 mm (3.15 in /2.16 in)
1st 12/31 =1 : 2.583 (secondary) 1ste 12/31= 1: 2,583 (secundaire) 1: 21.042 (total) 1: 21,042 (totale)
0.7 +0.8 mm (0.028 in +0.031 in)
Chap. 06 Spare parts and accessories
6 Spare parts and accessories / 6 Onderdelen en accessoires
RXV models are supplied with à number of accessories not installed:
idle speed adjustment AA|A |A |A |A |A |A |A |A TA
Coolant level in radiator and expansion tank
Engine oil and engine oil filter
Brake system screw torque
Brake discs thickness
Brake pads thickness
Electrical contacts and switches
Light operation/direction
Electrical system operation
Tyre pressure and wear conditions
Wheel spokes and rim coaxiality
Tightening of wheel pin nuts and screws Û Û Û Û Û Û Û Û Û Û Engine mounting screws torque [ [ [ [ [ I [ [ [ I Tightening of chassis screws and nuts Û Û Û Û Û Û Û Û Û Û Fork dust guards -lelcicicicicicici clic
Fork legs * - Û Û Û Û Û Û Û Û Û
Fork [ [ [ [ [ I [ [ [ I Tightening of fork plates and feet screws Û Û Û Û Û Û Û Û Û Û Shock absorber pins tightening [ [ [ [ [ I [ [ [ I Shock absorber Û Û Û Û Û Û Û Û Û Û
Steering bearings clearance [ [ [ [ [ I [ [ [ I Headstock dust guards ceclcicicicicicicicic
Drive chain 1 0 1 1 0 1 1 1 0 1
Chain link, chain sprocket and chain guide [ [ [ [ [ I [ [ [ I Steering bearings Liirfrfrlfililrlrefrlrlc
Rear wheel bolt and bearings -lififrlifrfrrfrlcle
Pressure relief and non-retum valve spring
Connecting rod and main bushings
Pistons and piston rings
Spring washers, caps, bowls
Chain tensioner toothing
Fork (comprehensive maintenance) = -Jif-f-fil-f-ful-
l'INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R:REPLACE, A: ADJUST, L: LUBRICATE
Luchtifiter in spons
A A A A A A Air filter and filter casing
idle speed adjustment
A R A R A R A R A R A R Clutch springs
Coolant level in radiator and expansion tank
Engine oil and engine oil filter
Brake system screw torque
Brake discs thickness
Brake pads thickness
Electrical contacts and switches
Light operation/direction
Electrical system operation
Tyre pressure and wear conditions
Wheel spokes and rim coaxiality
Tightening of wheel pin nuts and screws
Engine mounting screws torque
Tightening of chassis screws and nuts
Tightening of fork plates and feet screws
Shock absorber pins tightening
Steering bearings clearance
Headstock dust guards
Hours of operation 15 | 30 | 45 | 60 | 75 | 90 | 105 | 120 | 135 | 150 Throttle cables L L L L L L L L L L Rider footrest pins L L L L L L L L L L Rear suspension linkage system L L L L L L L L L L Side stand bolt L L L L L L L L L L Front wheel bolt and bearings L L L L L L L L L L Rear fork bolt L L L L L L L L L L Rear wheel bolt and bearings L L L L L L L L L L Sponge air filter - - R - - - R - - SPARK PLUGS . - - R - - - R - - Complete gearbox - - - 1 - u u Pressure relief and non-retum valve spring [TT -]- [ lee |. Cylinder liners - - - 1 u - u Connecting rod and main bushings 2 - - - - 1 - u u u Start-up gears - - - 1 - - u Oil pump gears 2 - - - - 1 - u u u Head lubrication nozzles - - - C - - - Pistons and piston rings 2 - - - - R - u u u
Spring washers, caps, bowls
Chain tensioner toothing
Fork (comprehensive maintenance)
Shock absorber (comprehensive maintenance)
Crankshaft and connecting rod bearing clearance
l:'INSPECT AND CLEAN, ADJ UST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* End of run-in # Carry out bleeding
+ Replace every year
KAART VAN HET PERIODIEK ONDERHOUD VOOR VOERTUIGEN IN VRIJE VERSIE VOOR SPORTIEF- EN HOBBYGEBRUIK.
Throttie bodies A A A A A A A A A A A Air filter and filter casing l l 1 l l 1 ! l l 1 !
pnousepuo puede9 z / aaueuaquieu pauuwe1601 d £
Fuel piping Û Û Û Û Û Û Û Û Û Û Û idle speed adjustment AlAljAl|lA |A |A |A |A |A |A Aa
Gearbox oil RIRIR|IR|RIR|IR|R|R RER Clutch springs - [ I [ [ I [ [ [ I [
Clutch discs . 1 l l 1 l ! l 1 l !
Clutch control l l 1 l l 1 ! l l 1 !
Coolant level in radiator and expansion tank l 1 l l 1 l ! l 1 l !
System seals . l 1 l l 1 ! l l 1 !
Engine oil and engine oil filter R R R R R R R R R R R
Brake system screw torque
Brake discs thickness
Brake pads thickness
Electrical contacts and switches
Light operation/direction
Electrical system operation
Tyre pressure and wear conditions
Wheel spokes and rim coaxiality
Tightening of wheel pin nuts and screws
Engine mounting screws torque
Tightening of chassis screws and nuts
Tightening of fork plates and feet screws
Hours of operation 15 | 30 | 45 | 60 | 75 | 90 | 105 | 120 | 135 | 150 Shock absorber pins tightening ! ! l ! ! l l ! ! l Shock absorber ! ! l ! ! l l ! ! l Steering bearings clearance ! ! l ! ! l l ! ! l Headstock dust guards [a C € [a C € [a [a C € Drive chain ! ! l ! ! l l ! ! l Chain link, chain sprocket and chain guide ! ! l ! ! l l ! ! l Steering bearings L L L L L L L L L L Clutch lever pin L L L L L L L L L L Throttle cables L L L L L L L L L L Rider footrest pins L L L L L L L L L L Rear suspension linkage system L L L L L L L L L L Side stand bolt L L L L L L L L L L Front wheel bolt and bearings L L L L L L L L L L Rear fork bolt L L L L L L L L L L Rear wheel bolt and bearings L L L L L L L L L L Sponge air filter - R - - R - - SPARK PLUGS . - R . - . R . - .
Pressure relief and non-retum valve spring
Connecting rod and main bushings
Pistons and piston rings
Spring washers, caps, bowls
Chain tensioner toothing
Fork (comprehensive maintenance)
Shock absorber (comprehensive maintenance)
Crankshaft and connecting rod bearing clearance
7 Programmed maintenance / 7 Gepland onderhoud
- IF DISTORTIONS, DAMAGES OR WEAR EXCEEDING THE TOLERATED VALUES ARE FOUND, REPLACE THE INVOLVED COMPONENTS
- BEFORE CARRYING OUT ANY OP- ERATION, CLEAN YOUR VEHICLE CAREFULLY
- RIDING ON SANDY OR DUSTY ROADS OR UNDER EXTREME SITUA- TIONS MAY WEAR DOWN SOME COMPONENTS EVEN BEFORE THE SCHEDULED CHECK.
Use top-branded oils that meet or exceed the requirements of CCMC G-4 API SG, SAE 10W-60 specifications.
Ready for use mixed biodegradable coolant with ‘long life" technology and characteristics (red). Freezing protection up to -40°C. In
compliance with the CUNA 956-16 standard.
As an alternative to the recommended fluid, other fluids that meet or exceed the required specifications may be used. SAE ] 1703, NHTSA 116 DOT 4, ISO 4925 S ynthetic fluid
AGIP MP GREASE Grease for bearings, joints, couplings and leverages
As an altemative to the recommended product, use top-branded grease for roller bearings with an operating temperature range of -30°C... +140°C (-22°F...+284°F), a drop point of 150° C.230°C (302°F..446°F), high corrosion protection qualities and good water and rust resistance
AGIP FORK 7.5W Fork oil
G Gearbox oil: 13, 77
Identification: 39 Instrument panel: 28
TABLE OF CONTENTS M Maintenance: 71, 137, 138
Scheduled maintenance: 138
THE VALUE OF SERVICE As a resultof continuous technical updates and specific mechanic training programs for aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correct.
The reliabilty of the vehicle also depends on its mechanical state. Checking the vehicle before riding, is regular maintenance and using only Original aprilia Spare Parts are essential! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly on the inset map in our Official Website: www.aprilia.com
Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were developed and tested during the actual vehicle design stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee reliabilty and durabilty.
The descriptions and ilustrations given in this publication are not binding; While the basic characteristics as described and ilustrated in this booklet remain unchanged, april reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all Countries. The avaiability of individual versions/models should be confirmed with the official aprilia sales network. © Copyright 2008- aprilia. All rights reserved. Reproduction of this publication in whole or in partis prohibited. april - After sales service.
The aprilia trademark is property of Piaggio & C. S.p.A.