Service and repair manual

aprilia part # 8140172

RSV mille

MIN

956X

RSV mille

INTRODUCTION

0 1 2 3 4 5 6 7 8 9

GENERAL INFORMATION

SERVICE AND SETTING UP

ENGINE

FUEL SUPPLY SYSTEM

COOLING SYSTEM

ELECTRICAL SYSTEM

CHASSIS PARTS

REPAIR INFORMATION

UPDATES

ANALYTICAL INDEX

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RSV mille  &/2%7/2$ This manual supplies the main information for normal servicing procedures. The information and illustrations contained in this manual are updated to the moment of its publication. Before consulting the manual, check the vehicle model and the relevant updates in section 9 UPDATES. This publication is intended for the aprilia Dealers and their qualified engineers; many notions were voluntarily omitted, because they were considered superfluous. Since it is not possible to include complete mechanical information in this publication, the persons using this manual must have a basic mechanical training and a basic knowledge of the procedures regarding motor vehicles repair systems. Without this knowledge, the repair or servicing of the vehicle may be ineffective or even dangerous. The manual does not describe all the procedures for the repair and servicing of the vehicle in detail, therefore it is important to be particularly careful, in order to avoid any damage to components and persons. In order to grant its customers more and more satisfaction in the use of the vehicle, aprilia s.p.a. will keep improving its products and the relevant documentation. The main technical modifications and the modifications in the vehicle repair procedures are communicated to all aprilia Outlets and Branches the world over. These modifications will be described in the successive editions of this manual. In case of need or in case there are any doubts regarding the repair and servicing procedures, contact the aprilia Consumer Service (A.C.S.), which will give you any information required and will also inform you about any updating and technical modifications of the vehicle. For further information, refer to: SPARE PARTS CATALOGUE # 390 W; use and maintenance manual (aprilia part # 8102857 and 8102859); special tools manual. aprilia s.p.a. reserves the right to modify its models at any time, without prejudice to the main characteristics here described. All rights as to electronic storage, reproduction and total or partial adaptation, with any means, are reserved for all Countries. The mention to products or services supplied by third parties is made only for information purposes and it isn't binding in any case. aprilia takes no responsibility as to the performance or use of said products.  3!&%49 7!2.).'3 The following precautionary warnings are used throughout this manual in order to convey the following messages: warning. aSafety When you find this symbol on the vehicle or in

the manual, be careful to the potential risk of personal injury. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other peoples safety and for the vehicle!

Indicates a potential hazard which may result in serious injury or even death.

aWARNING aCAUTION

Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.

NOTE The word NOTE in this manual precedes important information or instructions.

0.2.1 PRECAUTIONS AND GENERAL INFORMATIONS Follow with care these recommendations when repairing, disassembling and reassembling the vehicle.

The use of naked flames is forbidden for any type of operation. Before commencing any service or inspection operation on the vehicle, switch off the engine and remove the key, wait until the engine and the exhaust system have cooled down and, if possible, raise the vehicle with the suitable equipment onto firm flat ground. In order to avoid burns, be careful not to touch any parts of engine or exhaust system which have not cooled down completely. The vehicle is constructed of inedible parts. Do not bite, suck, chew or swallow any part of the vehicle for any reason whatever. If not expressly described, the reassembly of the units is carried out by reversing the order of operations. Any reference to operations from other chapters must be interpreted logically in order to avoid components being removed unnecessarily. Never use fuel as a solvent for cleaning the vehicle. Disconnect the negative cable () from the battery when electric welding. When two or more persons are working together, make sure that each is working in safe conditions. BEFORE DISASSEMBLY Remove any dirt, mud, dust and foreign matters from the vehicle before disassembling the components. Use, when necessary, the special tools designed for this vehicle.

aWARNING

First edition: march 2000 Reprint:

Produced and printed by: editing division Soave (VERONA) - Italy Tel. +39 - 045 76 11 911 Fax +39 - 045 76 12 241 E-mail: [email protected] www.stp.it

On behalf of: aprilia Consumer Service s.p.a. via Noalese, 156 - 30036 Santa Maria di Sala (VE) - Italia Tel. +39 - 041 57 86 101 Fax +39 - 041 57 86 100 www.aprilia.com

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RSV mille DISASSEMBLING THE COMPONENTS Do not loosen and/or tighten the screws and nuts using pliers or other tools: instead, always use the proper spanner. Before disconnecting the joints (pipes, cables, etc.), mark the positions on all of them and mark them with different distinguishing signs. Each piece must be marked clearly, in order not to have problems during installation. Clean and wash carefully any disassembled parts with low inflammability detergents. Keep the parts that are used in pairs together, since they have adapted to each other following the normal wear. Some components must be used together or replaced completely. Keep away from heat sources. REASSEMBLING THE COMPONENTS  (/7 4/ 53% 9/52 3%26)#% !.$ 2%0!)2 -!.5!, ADVICE FOR CONSULTATION This manual is divided into section and chapters, each one of which corresponds to a category of main components. To consult them, see the INDEX. If not expressly indicated otherwise, for the reassembly of the units repeat the disassembly operations in reverse order. The terms right and left are referred to the rider seated on the vehicle in the normal riding position. For normal maintenance operations and for the use of the vehicle, consult the USE AND MAINTENANCE manual. # The operations preceded by this symbol must be repeated on the opposite side of the vehicle. In this manual the various versions are indicated by the following symbols:
light switching version _ automatic (Automatic Switch-on Device) & optional VERSION:

aCAUTION
Never use a seeger ring twice. When a seeger ring is removed, it must be replaced with a new one. When assembling a new seeger ring be careful not to stretch its ends more than strictly necessary to put it on the shaft. After installing a seeger ring, make sure that it is completely and firmly inserted in its seat. Do not use compressed air to clean the bearings.

NOTE The bearings must rotate freely, without halting a/o noise otherwise they must be replaced.
Use only original aprilia SPARE PARTS. Use the recommended lubricants. Whenever possible, lubricate the parts before reassembly. When tightening screws and nuts, begin with those having greater diameters or with inner ones, proceeding diagonally. Tighten screws or nuts in successive passages before applying driving torque. Always replace lock nuts, seals, sealing rings, snap rings, O-rings, split pins and screws, whenever the thread appears damaged, with new ones. Before the assembly, clean all the connection surfaces, the oil seal edges and the gaskets. Apply a thin layer of lithium-based grease on the oil seal edges. Put back the oil seals and the bearings with the mark or serial number facing towards the outside (visible side). When installing the bearings, lubricate them abundantly. Make sure that each component has been reassembled correctly. After a repair or periodic maintenance operation, carry out the preliminary checks and test the vehicle in a private area or, in any case, in a low-traffic area.

I Italy O Holland U United Kingdom C Switzerland A Austria Denmark P Portugal J Japan " Finland S Singapore Belgium B V Poland D Germany % Israel F France K South Korea Spain E M Malaysia Greece G R Chile

Q Bermuda States - United of America ^ Australia Brazil South Africa New Zealand [ Canada ` Croatia Slovenia

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RSV mille NOTE

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RSV mille

GENERAL INFORMATION

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GENERAL INFORMATION

RSV mille

GENERAL INFORMATION
4!",% /& #/.4%.43

 0/3)4)/. /& 4(% 3%2)!, .5-"%23 ... 1-3 1.1.1 FRAME NUMBER .......................................... 1-3 1.1.2 ENGINE NUMBER ......................................... 1-3  ).3425#4)/.3 &/2 53% /& &5%, ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 ................................ 1-3 1.2.1 FUEL .............................................................. 1-3 1.2.2 ENGINE OIL .................................................. 1-4 1.2.3 FORK OIL ...................................................... 1-4 1.2.4 BRAKE FLUID ............................................... 1-4 1.2.5 COOLANT ...................................................... 1-5 1.2.6 CLUTCH FLUID ............................................. 1-5 1.2.7 CARBON MONOXIDE ................................... 1-6 1.2.8 HOT COMPONENTS ..................................... 1-6  25..).' ). 25,%3 ..................................... 1-6  30!2% 0!243 ................................................ 1-7  4%#(.)#!, 30%#)&)#!4)/.3 ................... 1-7  ,5"2)#!.4 #(!24 ................................... 1-10  #/.35-!",%3 ........................................... 1-11 1.7.1 PRODUCT PROPERTIES ........................... 1-11 1.7.2 USE OF CONSUMABLES ........................... 1-12  30%#)!, 4//,3 & .................................... 1-15 1.8.1 MISCELLANEOUS TOOLS ......................... 1-15 1.8.2 ENGINE TOOLS ........................................... 1-16  0/3)4)/.).' 4(% 6%()#,% /. 4(% 3500/24 34!.$ ....................... 1-17 1.9.1 ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND & ..................... 1-17 1.9.2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND & ..................... 1-17 1.9.3 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND & ................... 1-17 1.9.4 SETTING THE VEHICLE ON THE CENTRE SUPPORT STAND & ................. 1-18  ).3425#4)/.3 &/2 !00,9).' 42!.3&%23 .......................... 1-19  '%.%2!, 30%#)&)#!4)/.3 /& 4(% $2)6).' 4/215%3 .................. 1-21  !""2%6)!4)/.339-"/,3).)4)!,3 1-22

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RSV mille  0/3)4)/. /& 4(% 3%2)!, .5-"%23 These numbers are necessary for the registration of the vehicle.

GENERAL INFORMATION

NOTE Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions. In particular, the alteration of the frame number results in the immediate invalidity of the guarantee.
1.1.1 FRAME NUMBER The frame number is stamped on the right side of the steering column.

1.1.2 ENGINE NUMBER The engine number is stamped on the rear part of the engine, near the pinion.

 ).3425#4)/.3 &/2 53% /& &5%, ,5"2)#!.43 #//,!.4 !.$ /4(%2 #/-0/.%.43 1.2.1 FUEL The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive. It is important to carry out the refuelling and the maintenance operations in a well-ventilated area, with the engine off. Do not smoke while refuelling or near fuel vapours, in any case avoid any contact with naked flames, sparks and any other heat source to prevent the fuel from catching fire or from exploding. Further, prevent fuel from flowing out of the fuel filler, as it could catch fire when getting in contact with the red-hot surfaces of the engine. In case some fuel has accidentally been spilt, make sure that the area has completely dried and before starting the vehicle verify that there is no fuel inside the fuel filler neck. Since petrol expands under the heat of the sun and due to the effects of sun radiation, never fill the tank to the brim. Screw the plug up carefully after refuelling. Avoid any contact of the fuel with the skin and the inhalation of vapours; do not swallow fuel or pour it from a receptacle into another by means of a tube. DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Use only unleaded premium grade petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

aWARNING

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GENERAL INFORMATION
1.2.2 ENGINE OIL 1.2.4 BRAKE FLUID

RSV mille

aWARNING
Engine oil may cause serious damage to the skin if handled daily and for long periods. It is advisable to wash your hands thoroughly after using. Do not dispose of oil in the environment. Deliver it to or have it collected by the nearest used oil recovery firm or by the supplier. In case any maintenance operation has to be carried out, it is advisable to use latex gloves. Change engine oil after the first 1000 km (625 mi) and successively every 7500 km (4687 mi) (*), see 2.14 (CHANGING THE ENGINE OIL AND THE OIL FILTER). (*) = In case of use on racetracks, change every 3750 km (2343 mi). Engine oil (recommended):

NOTE

This vehicle is provided with front and rear disc brakes, with separate hydraulic circuits. The following information refers to a single braking system, but is valid for both.

Brake fluid may cause irritation if it comes into contact with the skin or eyes. Carefully wash the part of the body that has come into contact with the fluid. Consult an oculist or a physician if the fluid comes into contact with your eyes. DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. When using the brake fluid, take care not to spill it on the plastic or painted parts, since it can damage them. Every 7500 km (4687 mi) check the level of the brake fluid, see 2.17 (CHECKING AND TOPPING UP THE FRONT BRAKES FLUID) and 2.18 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID); change the fluid every two years, see 2.22 (CHANGING THE FRONT BRAKE FLUID) and 2.23 (CHANGING THE REAR BRAKE FLUID). Brake fluid (recommended):

aWARNING

0 EXTRA RAID 4, SAE 15W - 50 or

TEC 4T, SAE 15 W - 50 . As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG. specifications. 1.2.3 FORK OIL

aWARNING
Fork oil may cause serious damage to the skin if handled daily and for long periods. It is advisable to wash your hands thoroughly after using. Do not dispose of oil in the environment. Deliver it to or have it collected by the nearest used oil recovery firm or by the supplier. In case any maintenance operation has to be carried out, it is advisable to use latex gloves. By changing the damper settings and/or the viscosity of the oil contained in them, the suspension response may be altered partially. Standard oil viscosity: SAE 20 W. The viscosity ratings which can be chosen based on the type of fork stiffness desired (SAE 5W soft, 20W stiff). The two products can be used in different percentages until the desired response is obtained. F.A. and FORK One of the properties of is that their viscosity alters little with changes in temperature and their damping response therefore remains constant. Fork oil (recommended): F.A. 5W or F.A. 20W; Fork oil as an alternative FORK 5W or FORK 20W. If you need an oil with intermediate characteristics in comF.A. 5W and F.A. 20W or parison with the FORK 5W and FORK 20W, these can be mixed as indicated below:

0 F.F., DOT 5 (compatible DOT 4) or

BRAKE 5.1, DOT 5 (compatible DOT 4). To avoid serious damage to the braking system, do not use fluids other than the recommended ones nor mix different fluids for topping up. Do not use brake fluid taken from old or already opened containers. Sudden variations in clearance or an elastic resistance in the brake levers may be due to trouble in the hydraulic circuits. Make sure that the brake discs and the friction pads are completely free of grease or oil, especially after maintenance or checking operations. Check that the brake hoses are not twisted or worn. Make sure that neither water nor dust accidentally enter the circuit. In case maintenance operations are to be performed on the hydraulic circuit, it is advisable to use latex gloves.

aCAUTION

SAE 10W = F.A. 5W 67% of the volume, + F.A. 20W 33% of the volume or FORK 5W 67% of the volume, + FORK 20W 33% of the volume. SAE 15W = F.A. 5W 33% of the volume, + F.A. 20W 67% of the volume or FORK 5W 33% of the volume, + FORK 20W 67% of the volume.

0 0

0 0

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RSV mille 1.2.5 COOLANT The coolant is noxious: do not swallow it; if the coolant gets in contact with the skin or the eyes, it can cause serious irritations. If the coolant gets in contact with your skin or eyes, rinse with plenty of water and consult a doctor. If it is swallowed, induce vomit, rinse mouth and throat with plenty of water and consult a doctor without delay. KEEP AWAY FROM CHILDREN. DO NOT DISPOSE OF THE COOLANT IN THE ENVIRONMENT. 1.2.6 CLUTCH FLUID

GENERAL INFORMATION

aWARNING

NOTE
control.

This vehicle is provided with hydraulic clutch

If the clutch fluid gets in contact with the skin or the eyes, it can cause serious irritations. Carefully wash the parts of your body that get in contact with the liquid. Consult a doctor or an oculist if the liquid gets in contact with your eyes. DO NOT DISPOSE OF THE CLUTCH FLUID IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. When using the clutch fluid, take care not to spill it on the plastic and painted parts, since it damages them. Every 7500 km (4687 mi) check the level of the clutch fluid, see 2.19 (CHECKING AND TOPPING UP THE CLUTCH FLUID); change the fluid every two years, see 2.24 (CHANGING THE CLUTCH FLUID). Clutch fluid (recommended):

aWARNING

Be careful not to spill the coolant on the red-hot parts of the engine: it may catch fire and send out invisible flames. In case maintenance operations are to be performed, it is advisable to use latex gloves. Do not use the vehicle if the brake fluid is below the minimum level. Before setting off, and every 15000 km (9375 mi), check the level of the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT); change the coolant every two years, see 2.16 (CHANGING THE COOLANT). The coolant is composed of 50% water and 50% antifreeze. This mixture is ideal for most running temperatures and ensures good protection against corrosion. It is advisable to keep the same mixture in the hot season as well, since in this way losses due to evaporation are reduced and it is not necessary to top up so frequently. The mineral salt deposits left in the radiator by evaporated water are thus lessened and the efficiency of the cooling system remains unaltered. If the outdoor temperature is below 0, check th cooling circuit frequently and inf necessary increase the antifreeze concentration (up to maximum 60%). Use distilled water for the cooling solution so as not to damage the engine. Engine coolant (recommended):

aWARNING

0 F.F., DOT 5 (compatible DOT 4) or

aCAUTION

BRAKE 5.1, DOT 5 (compatible DOT 4).

To avoid serious damage to the system, do not use fluids other than the recommended ones nor mix different fluids for topping up. Do not use clutch fluid taken from old or already opened containers. Sudden variations in clearance or an elastic resistance in the clutch levers may be due to trouble in the hydraulic circuits. Check that the clutch hoses are not twisted or worn. Make sure that neither water nor dust accidentally enter the circuit. In case maintenance operations are to be performed on the hydraulic circuit, it is advisable to use latex gloves.

0 ECOBLU - 40C or
Freezing point C -20 -30 -40

COOL.

On the basis of the desired freezing temperature of the coolant mixture, add to the water the percentage of coolant indicated in the following table: Coolant of the volume % 35 45 55

NOTE The characteristics of the various antifreeze liquids are different. Be sure to read the label on the product to learn the degree of protection it guarantees.
Use only antifreeze and anticorrosive without nitrite in order to ensure protection at at least -35C.

aCAUTION

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GENERAL INFORMATION
1.2.7 CARBON MONOXIDE If it is necessary to let the engine run in order to carry out some work, make sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces. If it is necessary to work indoors, use an exhaust evacuation system.  25..).' ). 25,%3

RSV mille

The running-in of the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads or roads with many curves where the engine, the suspensions and the brakes are submitted to a more efficacious running-in. During running-in, change speed. In this way the components are first loaded and then relieved and the engine parts can thus cool down. Even if it is important to stress the engine components during running-in, take care not to exceed.

aWARNING
The exhaust fumes contain carbon monoxide, a poisonous gas that can cause loss of consciousness and even death. Run the engine in an open area or, if it is necessary to work indoors, use an exhaust evacuation system. 1.2.8 HOT COMPONENTS

Only after the first 1500 km (937 mi) of running-in is it possible to obtain the best performance. Keep in mind these important indications:
N Do not open the throttle completely if the speed is low,

aCAUTION

aWARNING
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine has been stopped. Before handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.

both during and after the running-in.

N During the first 100 km (62 mi) put on the brakes with

caution, avoiding sharp and prolonged brakings. This ensures a correct bedding-in of the pads on the brake disc. N During the first 1000 km (625 mi) never exceed 6000 rpm.

After the first 1000 km (625 mi) perform the checking operations indicated in the after running-in column, see 2.1.1 (REGULAR SERVICE INTERVALS CHART) in order to avoid injuring yourself or others a/o damaging the vehicle.
N Between the first 1000 (625 mi) and 1500 km (937 mi)

aCAUTION

drive more briskly, change speed and use the maximum acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 7500 rpm (see table). N After the first 1500 km (937 mi) you can expect better performance from the engine, however, without exceeding the maximum allowed (10500 rpm). Engine maximum rpm recommended Mileage km (mi) 0 1000 (0 625) 1000 1500 (625 937) over 1500 (937) rpm 6000 7500 10500

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RSV mille  30!2% 0!243 For any replacement, use aprilia Genuine Spare Parts only. aprilia Genuine Spare Parts are high-quality parts, expressly designed and manufactured for aprilia vehicles. Failure to use APRILIA Genuine Spare Parts may result in incorrect performance and damages.  4%#(.)#!, 30%#)&)#!4)/.3
DIMENSIONS Max. length Max. length (with number plate-holder extension) & Max. width Max. height (front part of the fairing included) Seat height Distance between centres Min. ground clearance Weight ready for starting (fuel and fluid included) ENGINE Type Number of cylinders Total displacement Max. rated power (to driving shaft) Max. rated power (to driving shaft) F Max. torque Max. torque F Bore / stroke Compression ratio Average piston speed Camshaft during intake stroke Camshaft during exhaust stroke Valve advance (with valve clearance 1mm) opening during intake stroke closing during intake stroke opening during exhaust stroke closing during exhaust stroke Valve clearance during intake stroke Valve clearance during exhaust stroke Engine revolutions at minimum rpm Engine revolutions at peak rpm Ignition Starting Spark advance Starter motor Starter motor gear ratio Clutch 2080 mm 2140 mm 720 mm 1170 mm 820 mm 1415 mm 130 mm 221 kg

GENERAL INFORMATION

aCAUTION

60 longitudinal V-type, two-cylinder, 4-stroke, with 4 valves per cylinder, DOHC. 2 997.6 cm# 86.5 kW (116 HP) at 9250 rpm 70 kW (94 HP) at 9250 rpm 93 Nm (9.3 kgm) at 7000 rpm 82 Nm (8.2 kgm) at 7250 rpm 97 mm / 67.5 mm 11.4 0.5 : 1 22.5 m/s at 10000 rpm 262, valve lifting= 10.6 mm 259, valve lifting= 10.6 mm 20 before TDC 62 after BDC 64 before TDC 15 after BDC 0.12-0.17 mm 0.23-0.28 mm 1250 100 rpm 10250 100 rpm electronically controlled electric At start: 5 before TDC, additional advance depending on specific consumption levels 12 V / 0.9 kW 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 - # 9 lined discs; thick 3.5 mm - # 9 internal discs; thick 1.5 mm mechanical, 6 gears with foot control on the left side of the engine
FOLLOW

Gear

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GENERAL INFORMATION
FOLLOW

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=
dry pan with separate oil tank, 2 trochoidal pumps and cooling radiator min 500 kPa (5 bar) at max 80 C (176 F) and 6000 rpm with dry filter cartridge liquid-cooled iwp= 28/27 * 28/28 = 1.037 90 L /min and 9000 rpm 65 2 C (149 5 F)

ENGINE Lubrication system Lubrication pressure Air cleaner Cooling Coolant pump gear ratio Coolant pump delivery (with thermal expansion valve open) Thermal expansion valve opening start temperature Engine dry weight CAPACITY Fuel (reserve included) Fuel reserve Engine oil Fork oil (per rod) Coolant Seats Vehicle max. load (driver + passenger + luggage)
DRIVE

~ 65 kg
20 L 4.5 1

oil change 3700 cm# oil and oil filter change 3900 cm# 520 2.5 cm# 2.5 L (50% water + 50% antifreeze with ethylene glycol) 2 182 kg

GEAR RATIOS

Ratio 1st 2nd 3rd 4th 5th 6th

Primary 31/60 = 1 : 1.935

Secondary 14/35 = 1 : 2.500 16/28 = 1 : 1.750 19/26 = 1 : 1.368 22/24 = 1 : 1.090 23/22 = 1 : 0.956 27/23 = 1 : 0.851 17

Final ratio 17/42 = 1 : 2.470

Total ratio 11.948 8.368 6.543 5.216 4.573 4.073

# sprocket teeth Drive chain FUEL SUPPLY SYSTEM Type Choke FUEL SUPPLY Type Fuel FRAME Type Steering inclination angle Fore stroke SUSPENSIONS Front Stroke Rear Wheel stroke BRAKES Front Rear WHEEL RIMS Type Front Rear

endless type (with no connection link) with sealed links, model 525, dimensions 5/8" x 5/16"

electronic injection 51 mm

indirect injection (MULTIPOINT) premium grade unleaded petrol, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.)

two-beam frame with light alloy cast elements and extruded elements 25 97 mm

UPSIDE-DOWN telescopic adjustable fork with hydraulic operation, rod 43 mm 127 mm oscillating rear fork in light alloy with differentiated profile arms and hydropneumatic adjustable mono-shock absorber 135 mm with double floating disc - 320 mm, calipers with four pins with differentiated diameter disc brake - 220 mm, caliper with double pin

in light alloy with withdrawable pin 3.50 x 17" 6.00 x 17"

FOLLOW

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RSV mille
FOLLOW

GENERAL INFORMATION

=
Pressure kPa (bar) Recommended

TYRES

Wheel

Make

Model

Type

Size

Alternative Solo rider

L
Rider and passenger 240 (2.4) 270 (2.7) 240 (2,4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7) 240 (2.4) 270 (2.7)

4
Solo rider 220-230 (2.2-2.3) 220-230 (2.2-2.3) 200-210 (2.0-2.1) 200 (2.0) 190 (1.9) 210 (2.1) 190-200 (1.9-2.0)

Front Rear Front (series) Rear (series) Rear Front Rear Front Rear Front Rear Rear Front Rear Front Rear Front Rear Front Rear Front Rear

PIRELLI PIRELLI PIRELLI PIRELLI PIRELLI PIRELLI PIRELLI METZELER METZELER METZELER METZELER METZELER MICHELIN MICHELIN MICHELIN MICHELIN MICHELIN MICHELIN DUNLOP DUNLOP BRIDGESTONE BRIDGESTONE

DRAGON EVO DRAGON EVO DRAGON EVO DRAGON EVO DRAGON EVO DRAGON DRAGON RACING RACING STELL RADIAL STELL RADIAL STELL RADIAL HI-SPORT HI-SPORT PILOT RACE PILOT RACE PILOT SPORT PILOT SPORT SPORTMAX SPORTMAX BATTLAX BATTLAX

MTR21 CORSA MTR22 CORSA MTR21 CORSA MTR22 CORSA MTR22 CORSA (SC2) MTR01 CORSA MTR08 CORSA MEZ3B MEZ3A MEZ3 MEZ3 MEZ3 TX15D TX25 D207FRR D207RR BT56 BT56

120/70-ZR17" 190/50-ZR17" 120/65-ZR17" 180/55-ZR17" 180/55-ZR17" 120/70-ZR17" 180/55-ZR17" 120/70-17" 190/50-17"

220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5) 220 (2.2) 250 (2.5)

L L

L L

L L

120/65-17" 180/55-17" 180/55-17"

120/70-17" 190/50-17" 120/70-ZR17" 180/55-ZR17"

L L L

L L

L 120/65-ZR17" L 190/50-ZR17" L 120/70-17" L

190/50-17" 120/70-17" 190/50-17"

4 4

4 4

L L

L = Normal use ; 4 = Use on racetracks

SPARK PLUGS Standard Alternative Spark plug gap Resistance ELECTRIC SYSTEM Battery Main fuses Secondary fuses Generator (with permanent magnet) Starting motor 12 V - 12 Ah 30 A 15 A 12 V - 400 W 12 V / 0.9 kW
FOLLOW

NGK R DCPR9E NGK R DCPR8E 0.6 0.7 mm 5 k

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GENERAL INFORMATION
FOLLOW

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=
12 V - 55 / 55 W H4 12 V - 60 W H3 12 V - 5 W 12 V - 10 W 12 V - 5/21 W 12 V - 2 W 12 V - 2 W 12 V - 2 W

BULBS Low beam (halogen) High beam (halogen) Front parking light Direction indicators Rear parking light / number plate light / stoplight Revolution counter Left multifunction display Right multifunction display

WARNING LIGHTS Neutral Direction indicators Fuel reserve High beam Stand down Engine oil pressure Red line 12 V - 3 W 12 V - 3 W 12 V - 3 W 12 V - 2 W 12 V - 3 W LED LED

 ,5"2)#!.4 #(!24

Engine oil (recommended): EXTRA RAID 4, SAE 15W - 50 or TEC 4T SAE 15W - 50. As an alternative to the recommended oil, it is possible to use high-quality oils with characteristics in compliance with or superior to the CCMC G-4, A.P.I. SG specifications. Fork oil (recommended): F.A. 5W or F.A. 20 W fork oil; an alternative FORK 5W or FORK 20W fork oil. If you need an oil with intermediate characteristics in comparison with the F.A. 5W and FORK 20W, these can be mixed as indicated below:

0 F.A. 20 W or

FORK 5W and

SAE 10W = SAE 15W =

0 F.A. 5W 67% of the volume, + 0 F.A. 20W 33% of the volume or

FORK 5W 67% of the volume +

0 F.A. 5W 33% of the volume, + 0 F.A. 20W 67% of the volume or FORK 5W 33% of the volume + FORK 20W 67% of the volume. GREASE 30. Bearings and other lubrication points (recommended): 0 AUTOGREASE MP or
Protection of the battery poles: neutral grease or vaseline. Spray grease for chains (recommended):

FORK 20W 33% of the volume.

As an alternative to the recommended product, use high-quality grease for rolling bearings, working temperature range -30 C+140 C, dripping point 150 C230 C, high protection against corrosion, good resistance to water and oxidation.

0 CHAIN SPRAY or

CHAIN LUBE.

aWARNING
Brake fluid (recommended):

Use new brake fluid only. F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (DOT 4 compatible).

aWARNING
Clutch fluid (recommended):

Use new clutch fluid only. F.F., DOT 5 (DOT 4 compatible) or BRAKE 5.1, DOT 5 (DOT 4 compatible).

aWARNING

Use only antifreeze and anticorrosive without nitrite, ensuring protection at -35 C at least. Engine coolant (recommended):

0 ECOBLU -40 C or

COOL.

OILL-UK

1 - 10

RSV mille  #/.35-!",%3 Only use the products given below for any maintenance work. The materials mentioned have been tested for many years and are suitable for all the application conditions indicated by the manufacturer.

GENERAL INFORMATION

NOTE The consumables, which are coded, are available on application, see 1.7.2 (USE OF CONSUMABLES).
1.7.1 PRODUCT PROPERTIES Product LOCTITE 243 blue Use and properties
Adhesive in paste for screws and nuts up to M36 and for couplings with medium hold. 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 ( 99 to 302 F)

LOCTITE 648 green

Paste for strong fastening of screws. The hardening time depends on the temperature and the material (maximum twelve hours). Resistance to temperatures in the range -55 to 175 C ( 99 to 347 F). In order to release the part glued, it may be necessary to heat the coupled parts to a temperature of 250 C (482 F). Solvent-free seal in paste, to be used instead of seals where there is a high friction factor and where a precise 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 ( 99 to 392 F); where applied, it seals the surfaces against corrosion.

LOCTITE 574 orange

LOCTITE 8150

Paste to be used on components subjected to high temperature.

LOCTITE Anti Seize 15378

Lubricant and anticorodal resistant to high temperatures. It must be sprayed on both components and makes sure the sliding surfaces remain maintenance free for a long time. It prevents corrosion.

MOLYKOTE G-n
Lubricating paste to be used on support points subjected to heavy loads, for standard lubrication and on couplings under pressure, in order to prevent corrosion which would prevent subsequent disassembly. To apply on the two surfaces.

SILASTIC 732 RTV

It is used as a sealant, preventing water from getting inside the flywheel cover.

1 - 11

GENERAL INFORMATION
1.7.2 USE OF CONSUMABLES Product Engine oil (*) Code 8116050 Description of use

RSV mille

Assembly of rivets on fork, dashboard/front fairing mount, saddle support and frame. Assembly of frame/engine and frame/fork adjusting bushes. Assembly of fairlead screws on frame. Insertion of steering head bearings. Steering head upper bush. On timing intermediate gear roller bearings. On lower countershaft thrust washer. 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 freewheel gear/freewheel contact surface. On the freewheel inner contact surface. Fastening of steering shock absorber bush. Fastening of rear brake caliper lock pin. Fastening of pinion. Fastening of rear brake lever pin. Fastening of cooling electrofan on support. Fastening of fuel return pipe 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. On coolant pump centre fastening screw. On cylinder joining bracket fastening screws. On engine half-casing bearing lock screws. On cylinder fastening studs. On driving shaft position sensor fastening screws. On index lever and plate fastening screws. On driving shaft fastening nut. On timing gear fastening screws. On upper countershaft counterweight fastening nut. On intermediate timing gear bearing support lower fastening screw. On coolant pump idler gear pin. On engine oil pump plug. On clutch gear metal slip fastening screws. Assembly freewheel on magnetic wheel. On freewheel fastening screws. On clutch housing fastening nut. On lower countershaft counterweight fastening screw. On flywheel rotor inner cone. On flywheel fastening screw.
FOLLOW

LOCTITE 243 (**)

0897651

LOCTITE 648 (**)

0899788

1 - 12

RSV mille

GENERAL INFORMATION

= FOLLOW
Product LOCTITE 574 orange (**) Code 0899784 Description of use Fastening of coolant thermal switch. Fastening of coolant thermistors. On neutral gear switch contact screw. On the outer surface of the engine oil pump motor. On the cylinder s base where it rests on the engine casing. On gearshift primary and secondary shaft. On gearshift primary and secondary shaft housings. On driving shaft and countershaft. On the gearshift primary shaft housing and toothing. On main bush housings. On main bushes. On engine casing bearing housings. On coolant pump shaft. On valve guide slots on the head. On valve guide edges. On driving shaft and countershaft bush housings. On driving shaft and countershaft housings. On connecting rod/piston pin slots. On camshaft cams. On starter motor fastening housing.

LOCTITE Anti Seize 15378 (**)

0297434

MOLYKOTE G-n (**)

0297433

SILASTIC 732 RTV (**)

0297386

On cable bracket on flywheel cover. On camshaft sensor cable. Assembly of front and rear wheel seals. Assembly of fork pin bearings. Assembly of clutch pump control rod. On rear wheel pin thread. On steering head bearings. Assembly of rear brake pump control rod. On rear brake lever pin. On intermediate timing gear thrust washer. Upper countershaft oil seal. Starter motor gear.

Bimol Grease 481

8116053

LUBERING ST grease AP-LUBE temporary lubricant

8116038 -

Assembly of cold-start control. Assembly of handlebar counterweights rubber element. Assembly of throttle cable adjuster rubber elements. Assembly of rubber element on gearshift lever. Insertion of radiator lower pins on supporting rubber elements. Assembly of breather pipe on radiator and three-way manifold. Assembly of coolant couplings on radiators. Assembly of water and fuel drainage pipes on fuel pump flange. Assembly of throttle body torsion springs.

DID CHAIN LUBE grease Biosolvent frame detergent ACRILON 28 cyanoacrylic glue MOTUL MOTOWASH degreaser 8116031 8116945 -

Lubrication of driving chain. Washing of engine oil tank. Assembly of air filter casing seal. Cleaning of frame and fork.
FOLLOW

1 - 13

GENERAL INFORMATION

RSV mille

= FOLLOW
Product ANTI-SEIZE MOTAGEPASTE AS 1800 antiscuff paste Alcohol Code 8116043 Description of use Assembly of plugs for checking CO on exhaust pipes. Cleaning of left handlebar prior to assembly of grip. Insertion of radiator breather pipes on T union. Assembly of HV coil support rubber element. Assembly of side fairing rubber elements. Cleaning of lower part of engine. Assembly of start relay rubber element. Assembly of flexible couplings on rear wheel sprocket. Assembly of rubber elements on engine oil radiator. Assembly of coupling on coolant filler. Cleaning of engine oil tank prior to application of transfers. Assembly of dashboard/front fairing mount rubber elements. Assembly of rubber element on rear brake lever. Assembly of pipes on fuel filter (inside tank). Assembly of coolant radiator union coupling. Assembly of fuel pipes on tank. Cleaning of fuel tank prior to application of transfers.

(*) = see 1.6 (LUBRICANT CHART). (**) = see 1.7.1 (PRODUCT PROPERTIES).

1 - 14

RSV mille  30%#)!, 4//,3

GENERAL INFORMATION

&

In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised methods. Below is a list of the special tools designed especially for this specific vehicle. When ordering generic special tools, refer to the special tools manual.

Before using the special tools, consult any documents attached.

aCAUTION

1.8.1 MISCELLANEOUS TOOLS Pos. 1 Tool description and function Complete tool kit for frame parts including: semi-shells for assembling oil seals, front fork socket spanner for adjusting steering socket spanner for adjusting fork pin - engine mounts Chain disassembly/reassembly tool Centre stand Rear support stand Front support stand Exhaust fume analyser Exhaust fume analyser pipe kit Tool holder panel Kit for bearings in the range 10 mm to 30 mm Code 8140203 8140192 8140176 8140194 8140195 8140196 8140202 8140199 8140180

2 3 4 5 6 7 8 9

1 - 15

GENERAL INFORMATION
1.8.2 ENGINE TOOLS

RSV mille

Pos. 1 2 3 4 5 6 7 8 9 10 11 12-14 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Tool description and function Complete tool kit for engine including Gearshift secondary shaft oil seal assembly pad Secondary countershaft oil seal assembly pad Coolant pump shaft housing oil seal assembly pad Coolant pump shaft housing sliding ring assembly pad Valve guide disassembly pad Valve guide oil seal assembly pad Valve guide assembly pad Gearshift shaft oil seal - clutch shaft oil seal assembly pad Main countershaft bush inserter pad Driving shaft sleeve puller** pad Driving shaft bush inserter pad Driving shaft - clutch cover bush inserter pad Plug socket spanner Tool for removal flywheel cover Flywheel removal hexagonal bolt Threaded pin for retaining the driving shaft at TDC Gearshift secondary shaft guide bush Vacuometer Fuel - oil pressure gauge Rotor bolt removal bush Clutch blocking tool Clutch cover sleeve puller** Valves spring-pusher tool Valves disassembly and reassembly bow Adhesive for tool holder panel Engine lifting eye hook Primary transmission nut disassembly bush Clutch disc** extraction hook lever Engine support Engine support stand Piston ring compression tool Perforated bolt for fuel pressure test Intake flange for vacuometer

Codice 8140175 0277680 0277660 0277670 0877257 0277510 0277695 0277210 8140155 0277729 0277720 0277725 0277727 8140177 0277252 0277780 0240880 0277308 8140256 8140181 8140182 0277881 8140156 + 8140157 + 0276377 0276479 8140179 8157143 8140183 8140184 8140185 8140188 8140187 8140186 8140197 8140267

1 - 16

RSV mille  0/3)4)/.).' 4(% 6%()#,% /. 4(% 3500/24 34!.$ 1.9.1 ASSEMBLING THE PINS FOR THE REAR SUPPORT STAND

GENERAL INFORMATION

&

cod. 8140194 (stand + pin).

N Position the vehicle on the side stand on firm and level

ground. # Position the pin (1) on the appropriate seat on the rear fork. N # Screw and tighten the screw (2) in the appropriate threaded hole in the rear for.
N

1.9.2 POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND & cod. 8140194 (stand + pin).
N Fit the relevant pins, see 1.9.1 (ASSEMBLING THE

PINS FOR THE REAR SUPPORT STAND &). NOTE Have someone help you keep the vehicle in vertical position with the two wheels on the ground.
N # Loosen the knob (3). N # Move the fork support (4), positioning it so that the

width corresponds to the distance between the two pins (1) on the rear fork. N # Tighten the knob (3). N At the same time introduce the two fork-shaped seats (4) of the stand (5) under the two pins (1) provided on the vehicle. N Rest one foot on the rear part of the stand (5). N Push the stand (5) downwards until it reaches the end of its stroke.

1.9.3 POSITIONING THE VEHICLE ON THE FRONT SUPPORT STAND & cod. 8140195 (stand).
N Position the vehicle on the appropriate rear support

stand, see 1.9.2 (POSITIONING THE VEHICLE ON THE REAR SUPPORT STAND &). N Insert the two ends of the stand (6) in the two holes (7) positioned on the lower ends of the front fork. N Rest one foot on the front part of the stand (6). N Push the stand (6) downwards until it reaches the end of its stroke.

1 - 17

GENERAL INFORMATION
1.9.4 SETTING THE VEHICLE ON THE CENTRE SUPPORT STAND & Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). cod. 8140176 (complete stand).
N Remove the lower fairing, see 7.1.32 (REMOVING

RSV mille

THE LOWER FAIRING).

N Set the vehicle on the relevant front support stand, see

1.9.3 (SETTING THE VEHICLE ON THE FRONT SUPPORT STAND &). N # Hold the nut on the inside (1) still. N # Unscrew and remove the engine upper rear fastening screw (2). Driving torque of nut (1) / screw (2): 50 Nm (5.0 kgm).

NOTE The screw (2) on the left-hand side is longer. N # Retrieve the nut (1).
N Insert the upper right support pin (3) in the upper hole

on the right-hand side.

N Insert the stud bolt (4) in the upper hole on the left-hand

side and screw it all the way onto the pin (3).
N Screw the upper left support pin (5) all the way onto the N # Hold the nut on the inside (6) still. N # Unscrew and remove the engine lower rear fasten-

stud bolt (4) and tighten. ing screw (7).

Driving torque of nut (6) / screw (7): 50 Nm (5.0 kgm).

NOTE The screw (7) on the right-hand side is longer.

N Insert the lower right support pin (8) in the lower hole on

the right-hand side.

N Insert the stud bolt (9) in the lower hole on the left-hand

side and screw it all the way onto the pin (8).
N Screw the lower left support pin (10) all the way onto

the stud bolt (9) and tighten.

N Place the support bracket (11) with the longer side of the

base facing forwards, on the two support pins (5 - 10).

N Insert the two washers (12 - 13) and two nuts (14 - 15),

screwing them on by hand.

N Tighten the two nuts (14-15). N Place the support bracket (16) with the longer side

of the base facing forwards, on the two support pins (5 - 10). N Insert the two washers (17 - 18) and two nuts (19 - 20), screwing them on by hand. N Tighten the two nuts (19 - 20). N Remove the front and rear support stands.

1 - 18

RSV mille  ).3425#4)/.3 &/2 !00,9).' 42!.3&%23 When removing parts of the frame :

GENERAL INFORMATION

Handle plastic and painted parts carefully so not to scratch or damage them. Perform the work with the utmost care. Do not damage the tabs and/or the slots into which they are inserted. When applying the transfers, follow the instructions given below carefully. It is advisable to use the following tools: relatively stiff spatula (1);

aCAUTION

NOTE NOTE

Generally, soft, squeegee-type spatulas do not remove enough water from under the transfer. sponge or sprayer (2) with water.

Add detergent to the water (1 - 3%) and shake until you get soap bubbles. Apply as follows:

N Place the transfer (3) upside down on a work surface. N Keeping the transfer spread out on the work surface,

remove the protective backing (4) completely.

NOTE It is advisable to use a sprayer (2).

When using a sponge, dab the surface with the sponge, without pressing hard so as to avoid damaging the adhesive.
N Wet the surface of the adhesive with soapy water. N Apply the transfer (3) on the surface to be decorated

and move it into the right position.

NOTE Always move the spatula in constant strokes from the centre of the transfer out.
N Using the spatula (1), press down reasonably hard and

move the spatula across the surface of the transfer until the excess soap and water has been removed from underneath.

NOTE
fer.

Do not lift the corners and/or sides of the trans-

N Use an absorbent cloth and, working from the centre

out, dry the transfer.

N Move the spatula over the transfer again with firm, even

strokes, pressing down as hard as possible. Move the spatula in strokes from the centre out, taking special care with the corners and sides to make sure the whole surface sticks evenly.

1 - 19

GENERAL INFORMATION

RSV mille

NOTE

Where the transfer features application tape (5), the tape must be removed 20-30 minutes after the application of the transfer. The application tape is used to facilitate the application of trademarks and letters, arranging them in the correct place on the surface to be decorated, and to give the self-adhesive more body during application. transfer.

N Remove the application tape (5) from the surface of the N In order to assure good adhesion, move the spatula

over the transfer again, concentrating in particular on the edges and corners.

NOTE With the wet method, the final level of the transfer is reached approx. 48 hours after application.
N Once the application tape has been removed, make

sure there are no air bubbles anywhere on the surface. In the event air bubbles are encountered:
N Use a pin or paper cutter (6) to make a hole in the edge

(7) of the air bubble.

N Using the spatula (1), work from the edge opposite the

hole and push the bubble so the air escapes.

1 - 20

RSV mille  '%.%2!, 30%#)&)#!4)/.3 /& 4(% $2)6).' 4/215%3 The following table indicates the standard driving torques for screws and bolts with metric ISO thread. Screw or bolt thread M6 M8 M 10 M 12 M 14 M 16 Driving torque Spanner 10 12 14 17 19 22 Nm 6 15 30 55 85 130 kgm 0.6 1.5 3.0 5.5 8.5 13.0

GENERAL INFORMATION

For specific joints or couplings of the vehicle, see 2.41 (FASTENING ELEMENTS). If not specified otherwise, the indicated driving torques are valid for clean and dry threads, at room temperature.

NOTE

In order to avoid any deformation and/or imperfect coupling, tighten the screws or bolts by proceeding as described below:

N Manually screw all the fastening elements. N Applying half the prescribed driving torque, tighten the

elements that are diametrically opposite each other: (A) and (B); (C) and (D). N Repeat the previous operation by applying the prescribed driving torque.

NOTE In this way the pressure exerted by the fastening elements will be uniformly distributed on the joint surface.

1 - 21

GENERAL INFORMATION
 !""2%6)!4)/.3  39-"/,3  ).)4)!,3 # < > = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = = number is less than is greater than is equal to or less than is equal to or greater than approximately infinity degrees centigrade degrees Fahrenheit plus or minus alternating current ampere ampere-hour American Petroleum Institute high voltage AntiVibration Double Countershaft unit of pressure (1 bar = 100 kPa) bottom dead centre cubic centimetres carbon monoxide Central Processing Unit direct current Deutsche Industrie Norm Double Overhead Camshaft Engine Control Unit revolutions per minute unburnt hydrocarbons idle speed control International Standardization Organization kilograms kilograms per metre (1 kgm = 10 Nm) kilometres kilometres per hour kilo-ohms kiloPascal (1 kPa = 0.01 bar) kilowatt Clutch side

RSV mille

L
LAP LED m/s MAX mi MIN MPH MS M N.O.M.M. N.O.R.M. Nm PPC SAE TEST T.C.E.I. T.E. TDC T.P. TSI UPSIDEDOWN V W mbar

~
C F a.c. A Ah API HV AV/DC bar BDC cm# CO CPU d.c. DIN DOHC ECU rpm HC ISC ISO kg kgm km km/h k kPa kW KS

= = = = = = = = = = = = = = = = = = = = = = = = = = =

litres lap (race course) light emitting diode metres / second maximum mile minimum miles per hour Flywheel side megaohm Motor method octane number Research method octane number Newton-meter (1 Nm = 0.1 kgm) ohm Pneumatic Power Clutch Society of Automotive Engineers diagnostics test Allen hex-head top dead centre flat head Twin Spark Ignition upside-down rods Volt Watt diameter millibar (1mbar = 0.1 kPa)

1 - 22

RSV mille

1
SERVICE AND SETTING UP

2 -1

SERVICE AND SETTING UP

RSV mille  #(!.').' 4(% &2/.4 "2!+% &,5)$ .................. 2-29  #(!.').' 4(% 2%!2 "2!+% &,5)$ ..................... 2-30  #(!.').' 4(% #,54#( &,5)$ ........ 2-31  !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 !.$ 4(% '%!2 ,%6%2 ............................................ 2-31  !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 #,%!2!.#% .......... 2-32  #(%#+).' 4(% "2!+% 0!$ 7%!2 .. 2-32  34%%2).' .................................................. 2-33 2.28.1 CHECKING THE BEARING SLACK ......... 2-33 2.28.2 ADJUSTING THE BEARING SLACK ....... 2-33  ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/. ...................... 2-35 2.29.1 FRONT SUSPENSION .............................. 2-35 2.29.2 ADJUSTING THE FRONT FORK ............. 2-36 2.29.3 ADJUSTING THE HEIGHT OF THE FORECARRIAGE ....................... 2-37  2%!2 &/2+ ............................................... 2-38 2.30.1 ADJUSTING THE REAR FORK ................ 2-38  ).30%#4).' 4(% 2%!2 3530%.3)/. ...................... 2-39 2.31.1 REAR SUSPENSION ................................ 2-39 2.31.2 ADJUSTING THE REAR SHOCK ABSORBER ............. 2-39 2.31.3 CHECKING THE REAR SUSPENSION LINKAGE ...... 2-41  &2/.4 7(%%, ......................................... 2-41  2%!2 7(%%, ............................................ 2-42  %8(!534 -!.)&/,$ .543 ................ 2-42  $2)6% #(!). ............................................ 2-43 2.35.1 CHECKING THE SLACK .......................... 2-43 2.35.2 CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WER ............... 2-44 2.35.3 ADJUSTMENT .......................................... 2-44 2.35.4 CLEANING AND LUBRICATION .............. 2-44 2.35.5 INSPECTING THE DRIVING CHAIN GUIDE PLATE ...... 2-45 2.35.6 INSPECTING THE DRIVING CHAIN SHOE .................... 2-45  492%3 ......................................................... 2-46 2.36.1 CONDITION OF TREAD ........................... 2-46 2.36.2 INFLATION PRESSURE ........................... 2-46  &5%, 0)0%3 ............................................... 2-47  "2!+% !.$ #,54#( 0)0%3 ................ 2-47  #//,).' 3934%- 0)0%3 ..................... 2-47  4)'(4%.).' .543 !.$ 3#2%73 ..... 2-48  &!34%.).' %,%-%.43 ........................ 2-49

SERVICE AND SETTING UP

4!",% /& #/.4%.43  0%2)/$)# 3%26)#% 0,!. .......................... 2-3 2.1.1 REGULAR SERVICE INTERVALS CHART .. 2-4  0/).43 2%15)2).' ,5"2)#!4)/. ........ 2-5  -5,4)&5.#4)/. #/-054%2 .................. 2-6 2.3.1 SEGMENT OPERATION CHECK ................. 2-6 2.3.2 SWITCHING FROM km TO mi (from km/h to MPH) AND VICEVERSA (LEFT DISPLAY) .. 2-6 2.3.3 SETTING THE INSTANTANEOUS, MAXIMUM AND AVERAGE SPEED (LEFT DISPLAY) .. 2-7 2.3.4 SETTING THE RED LINE THRESHOLD (WITH ENGINE OFF ONLY) ......................... 2-8 2.3.5 MULTIFUNCTION (RIGHT DISPLAY) .......... 2-8 2.3.6 STANDARD SETTING: COOLANT TEMPERATURE AND DIGITAL CLOCK .................................. 2-9 2.3.7 BATTERY VOLTAGE - VBATT ..................... 2-9 2.3.8 SETTING THE HOUR .................................... 2-9 2.3.9 SETTING THE MINUTES .............................. 2-9 2.3.10 SETTING C OR F ..................................... 2-9 2.3.11 CHRONOMETER (RIGHT DISPLAY) ....... 2-10 2.3.12 DIAGNOSTICS .......................................... 2-10  "!44%29 ....................................................... 2-11 2.4.1 CHECKING AND CLEANING THE TERMINALS ........................................ 2-11 2.4.2 RECHARGING THE BATTERY .................. 2-12 2.4.3 LONG INACTIVITY OF THE BATTERY ...... 2-12  %,%#42)# #/-0/.%.43 ........................ 2-12  *5-0 34!24).' ......................................... 2-13  30!2+ 0,5'3 .............................................. 2-14  ,)&4).' 4(% &5%, 4!.+ ........................ 2-15  $2!).).' 4(% &5%, 4!.+ .................... 2-16  !)2 #,%!.%2 ............................................. 2-17  !##%,%2!4/2 ......................................... 2-18 2.11.1 CHECKING THE OPERATION OF THE ACCELERATOR CONTROL ...... 2-18 2.11.2 IDLING ADJUSTMENT ............................. 2-18 2.11.3 ADJUSTING THE ACCELERATOR CONTROL ............ 2-19  #/,$ 34!24 #!",% ............................... 2-19  #(%#+).' 4(% %.').% /), ,%6%, !.$ 4/00).' 50 ..................... 2-19  #(!.').' 4(% %.').% /), !.$ 4(% /), &),4%2 ............................. 2-20  #(%#+).' !.$ 4/00).' 50 #//,!.4 ............... 2-22  #(!.').' 4(% #//,!.4 ................... 2-22  #(%#+).' !.$ 4/00).' 50 4(% &2/.4 "2!+%3 &,5)$ ................ 2-24  #(%#+).' !.$ 4/00).' 50 4(% 2%!2 "2!+% &,5)$ ..................... 2-25  #(%#+).' !.$ 4/00).' 50 4(% #,54#( &,5)$ ............................... 2-26  ",%%$).' 4(% "2!+).' 3934%-3 2-27  ",%%$).' 4(% #,54#( 3934%-3 ... 2-28

2 -2

RSV mille This section describes the procedures for periodic service on the principal components of the vehicle.

SERVICE AND SETTING UP

aWARNING
Before beginning any service operations or inspection of the vehicle, switch off the engine and remove the key, wait until the engine and the exhaust system have cooled down and, if possible, lift the vehicles with the proper equipment onto firm and flat ground. In order to avoid burns, be careful not to touch any parts of the engine or exhaust system which have not cooled down completely. The vehicle is constructed of non-edible parts. Do not bite, suck, chew or low any part of the vehicle for any reason whatever. If not expressly described otherwise, reassembly of the units is carried out repeating the disassembly operations in the reverse order.

 0%2)/$)# 3%26)#% 0,!. aprilia recommends respecting the intervals indicated for the periodic service on the various components in order to ensure the best operating conditions of the vehicle.

aCAUTION
After the first 1000 km (625 mi) and successively every 7500 km (4687 mi), the writing SERVICE (1) appears on the right display. In this case, carry out the operations prescribed in the periodic service plan. If the bike is being used for competition, perform the operations more frequently, see 2.1.1 (REGULAR SERVICE INTERVALS CHART).

2 -3

SERVICE AND SETTING UP

2.1.1 2%'5,!2 3%26)#% ).4%26!,3 #(!24 Component Spark plugs Stand Throttle cables Rear suspension linkage bearings Steering bearings and steering Wheel bearings Air filter Engine oil filter Engine oil filter (on oil tank) Fork Light operation/direction Tappet clearance Throttle body pin greasing Braking systems Cooling system Light system Safety switches Clutch fluid Brake fluid Coolant After running-in [1000 km (625 mi)]    Every 7500 km (4687 mi) or 8 months  (*)       (*)               every 2 years:   every 2 years: 

RSV mille

Every 15000 km (9375 mi) or 16 months (*)

 

 

Fork oil Engine oil Brake pads Tyres Tyre pressure Engine idling rpm Nut, bolt, screw tightening Cylinders synchronization Suspensions and attitude Engine oil pressure warning light LED Brake fluid bleeding  Clutch fluid bleeding  Drive chain tension and lubrication every 1000 km (625 mi):  Battery terminals   Fuel pipes  every 4 years:  Brakes and clutch pipes  every 4 years:  Cooling system pipes  Brake pad wear before every trip and every 7500 km (4687 mi):   = check and clean, adjust, lubricate or change, if necessary;  = clean;  = change; 2 = adjust. Perform the maintenance operations with doubled frequency if the vehicle is used in rainy or dusty areas, on uneven surfaces or on racetracks. (III ) =OPERATIONS WHICH CAN BE CARRIED OUT EVEN BY THE USER (*) = In case of use on racetracks, change every 3750 km (2343 mi).

 every 2 years:  After the frist 7500 km (4687 mi) and every 22500 km (14000 mi):    (*) if worn:   every 1000 km (625 mi):   every 15 days:          at every start: 

2 -4

RSV mille  0/).43 2%15)2).' ,5"2)#!4)/. Correct lubrication is important for good performance and the long life of the vehicle.

SERVICE AND SETTING UP

LUBRICATION CHART KEY 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Steering bearings Clutch lever pin Lever cable for cold starting Rider left footrest pin Passenger left footrest pin Passenger seat lock Driving chain Rear suspension leverage Side stand pin Passenger right footrest pin Throttle grip Accelerator cables Front wheel pin and bearings Rear fork pin Rider right footrest pin Rear wheel pin and bearings

NOTE Before lubricating, completely clean all parts, removing rust, grease, dirt and dust. The exposed parts subject to rust are to be lubricated with motor oil or grease. See 1.6 (LUBRICANT CHART). The points to be lubricated are indicated in the LUBRICATION CHART.

I = Grease L = Oil LUBRICATION CHART

2 -5

SERVICE AND SETTING UP

 -5,4)&5.#4)/. #/-054%2 KEY A) Left multifunction digital display (speedometer - odometer). B) Multifunction computer programming push buttons. C) Right multifunction digital display (coolant temperature - clock - battery voltage - chronometer - diagnostic). When the ignition key (1) is rotated to position n, the following warning lights come on on the dashboard: red line warning light LED max (2); red engine oil pressure warning light LED j (3), which remains on until the engine starts. The pointer (4) of the revolution counter shifts to the maximum value (rpm) set by the user. After about three seconds the red line warning light LED max (2) goes off; the pointer (4) of the revolution counter returns to its initial position. The writing "()," (5) appears on the right side of the multifunction display for three seconds. In this way the component operation is tested.

RSV mille

8 7 6
V max AVS MPH km/h mi km

9 10 11 12 A max

5 4
VEGLIA
BORLETTI

rpm x 1000

DIAG SERVICE V BATT

2
9 10 11 12 8 A max 7 6 5 4
VEGLIA
BORLETTI
rpm x 1000

1
PU SH

aCAUTION
After the first 1000 km (625 mi) and successively every 7500 km (4687 mi), the writing SERVICE (5a) appears on the right display. In this case, carry out the operations prescribed in the periodic service plan, see 2.1.1 (REGULAR SERVICE INTERVALS CHART). To make the writing SERVICE disappear, press the LAP push button (6) and then the push button R and keep them pressed for about five seconds. With the ignition key (1) in position n the standard settings on the dashboard are the following: Right display: Clock (7), coolant temperature in C (8). Left display: Instantaneous speed in km/h (9), trip 1 (trip odometer) (10), total kilometres/miles odometer (11). Upon installation of the battery or of the 30A main fuses: the revolution counter pointer (4) makes twelve clockwise clicks, thus checking the operation of the revolution counter itself; the instantaneous, maximum and average speed function is set in km/h; the coolant temperature is set in C; the digital clock is set to zero; the red line is set at 6000 rpm, indicated by the coming on of the red line warning light LED max (red) (2).

N
3

NOTE
ments.

If necessary, carry out the appropriate adjust-

2.3.1 SEGMENT OPERATION CHECK

N Press the push buttons A and B at the same time. N Rotate the ignition key (1) from position m to position

All the segments will remain on until the push buttons A and B are released. 2.3.2 SWITCHING FROM km TO mi (from km/h to MPH) AND VICEVERSA (LEFT DISPLAY)
N Press the push button A until, after about five seconds, N Release the push button A. N Press the push button B to change the unit of meas-

n .

12 9

V max AVS MPH km/h mi km

10 11

all the writings (12) on the left display start blinking.

urement from km to mi (from km / h to MPH) or viceversa.

2 -6

RSV mille
N To confirm the setting, press the push button

SERVICE AND SETTING UP

about five seconds.

A for
1

2.3.3 SETTING THE INSTANTANEOUS, MAXIMUM AND AVERAGE SPEED (LEFT DISPLAY)

NOTE Two seconds after the vehicle has started moving, the instantaneous speed is automatically shown on the display, even if a different function is set.
When the ignition key is rotated to position n, the instantaneous speed (1) and the partial number of kilometres/miles covered trip 1 (2) appear on the left display. Resetting trip 1 (2): with the odometer set on the instantaneous speed function, press the push button R for about two seconds.

V max AVS MPH km/h mi km

2

N To display the maximum speed (3) and the distance

trip 1 (2), press the push button B for about one second. The writing V max (4), the maximum speed (3) and the distance trip 1 (2) are displayed.

Resetting the maximum speed (3): with the odometer set on the V max function, press the push button R for about two seconds.

V max AVS MPH km/h mi km

2

NOTE The measurement of the maximum speed is relevant to the distance covered from the last setting to zero of the maximum speed itself. The distance trip 1 (2) shown on the display indicates the number of kilometres/miles covered from the last setting to zero, to the distance trip 1.

5
2 (6), press the push button B again for about 1 second. The writing AVS (7), the average speed (5) and the distance trip 2 (6) are displayed. Resetting the average speed (5) and the distance trip 2 (6): with the odometer set on the AVS function, press the push button R for about one second.
N To display the average speed (5) and the distance trip

V max AVS MPH km/h mi km

6 7

NOTE The measurement of the average speed is relevant to the distance trip 2 (odometer). The distance trip 2 (6) shown on the display indicates the number of kilometres/miles covered from the last setting to zero. If more than 1000 km (625 mi) are covered without setting trip 2 to zero, the value of the average speed will be wrong.
N To display the instantaneous speed (1) and the dis-

tance trip 1 (2), press the push button B again.

2 -7

SERVICE AND SETTING UP

2.3.4 SETTING THE RED LINE THRESHOLD (WITH ENGINE OFF ONLY) When the maximum rpm set is exceeded, the red line warning light LED max (2) positioned on the dashboard starts blinking. If the push button C is pressed for less than one second, the pointer of the revolution counter (1) shifts to the red line value set for three seconds, after which it returns to its initial position. For the setting: N Press the push button C, release it and press it again C within three seconds. The pointer (1) moves increasing the value by 1000 rpm at each click, as long as C is kept pressed; when it has reached the maximum value, it starts again from the beginning. N Press the push button C until the desired rpm value has been set. N If the push button C is released and then pressed again within three seconds, intermittently, the pointer (1) moves increasing the value by 100 rpm at each click; when it has reached the maximum value, it starts again from the beginning.

RSV mille

9 10 11 12 8 A max 7 6 5 4
VEGLIA
BORLETTI
rpm x 1000

Engine maximum rpm recommended Mileage km (mi) 01000 (0625) 10001500 (625937) oltre 1500 (937) rpm 6000 7500 10500

NOTE It is not possible to set the red line at values lower than 2000 rpm or higher than 12000 rpm.

aCAUTION
Never exceed the recommended rpm, see table.
N To confirm, release the push button

C. After three seconds, the red line threshold setting is stored.

9 10 11 12
aprilia
max

NOTE The setting is confirmed by the coming on of the

red line warning light LED max (2).

8
2.3.5 MULTIFUNCTION (RIGHT DISPLAY) The right display (multifunction) includes the coolant temperature in C (F) and the digital clock as standard settings.

7 6
1

NOTE
blinks.

When the engine is cold, the writing

5 4
VEGLIA
BORLETTI

rpm x 1000

By pressing the push button D, the following functions can be obtained in sequence: Standard setting: temperature in C and digital clock

D
Battery voltage (V BATT)

D
Hour setting

8 7 6 5

9 10 11 12
aprilia
max

D
Minute setting

rpm x 1000

4
VEGLIA
BORLETTI

D
C or F setting

2 -8

RSV mille 2.3.6 STANDARD SETTING: COOLANT TEMPERATURE AND DIGITAL CLOCK The coolant temperature value (1) is shown in the upper part of the right display. It is possible to switch from C to F and viceversa, see 2.3.10 (SETTING C OR F). When the temperature is below 35C (95F), the writing (1) blinks on the right display. When the temperature is over 115C (239F), the value (1) blinks on the right display, even if a function different from the standard setting has been set. When the temperature is over 130C (266F), the writing /// (1) appears on the right display. If the writing LLL is displayed with a temperature below 130C (266F), there may be a failure of the electric circuit, see 6.10.3 (COOLANT TEMPERATURE DISPLAY). Thermometer range on the display: 35 130C (95 266 F). The digital clock (2) appears in the lower part of the right display. To set or modify hour and minutes, see 2.3.8 (SETTING THE HOUR) and 2.3.9 (SETTING THE MINUTES). 2.3.7 BATTERY VOLTAGE - VBATT
N If the push button

SERVICE AND SETTING UP

DIAG SERVICE V BATT

NOTE

DIAG SERVICE V BATT

D is pressed once, the battery voltage expressed in volt (3) appears in the lower part of the right display, while the coolant temperature (1) is displayed in the upper part. The writing V BATT (4) is displayed. The recharge circuit functions correctly if at 4000 rpm the battery voltage with low beam on is included between 13 and 15 V.

2.3.8 SETTING THE HOUR

D is pressed for the second time, the hour segments (5) start blinking in the lower part of the right display (digital clock). N To modify the hour setting, press the LAP push button (6) on the left part of the handlebar. N To confirm the hour setting, press the push button D.
N When the push button

2.3.9 SETTING THE MINUTES

D is pressed for the third time, the minute segments (7) start blinking in the lower part of the right display (digital clock). N To modify the minute setting, press the LAP push button (6) on the left part of the handlebar. N To confirm the minute setting, press the push button D.
N When the push button

2.3.10 SETTING C OR F

D is pressed for the fourth time, the segments of the coolant temperature in C or F (8) start blinking in the upper part of the display. N To modify from C to F setting, or vice versa, press the LAP push button (6) on the left part of the handlebar. N To confirm the setting, press the push button D.
N When the push button

2 -9

SERVICE AND SETTING UP

2.3.11 CHRONOMETER (RIGHT DISPLAY) The chronometer makes it possible to measure the time per lap with the vehicle on a racetrack and to store the data, in such a way as to be able to consult them successively. When the CHRONOMETER function has been selected, it is not possible to recall the following functions: maximum speed V max; average speed AVS; distance trip 2. N To operate the chronometer, press the LAP push button (1) and, within seven seconds, the push button D. N To start timing, press the LAP push button (1) and release it immediately. N To store the time acquired, press the LAP push button (1). The LAP push button (1) is not enabled for ten seconds and the last time stored (2) is shown on the display. After which, the chronometer with the current timing (3) is displayed, starting from ten seconds. N To display the first time stored (4), press the push button B. N To be able to see the stored times in sequence, press the LAP push button (1). The writings /, /, /, /, etc. (5) are displayed. N To start timing again, press the push button B.

RSV mille

DIAG SERVICE V BATT

NOTE It is possible to store max. forty times, after which the LAP push button (1) is not effective any longer.
N To set the memory to zero, press the push button

and the LAP push button (1) at the same time for two seconds.
N To leave the chronometer function, press the LAP

push button (1) and the push button D.

When the engine is cold, the writing is displayed.

The coolant temperature (6) and the digital clock (7) appear on the right display (multifunction).

NOTE

DIAG SERVICE V BATT

2.3.12 DIAGNOSTICS Whenever the ignition switch is turned to position n, the writing (), is displayed for about three seconds. If the writing (), is displayed during the normal operation of the engine, this means that the electronic unit has detected an anomaly. In many cases, the engine keeps running with reduced performance levels, see 6.4 (IGNITION SYSTEM).

aCAUTION

DIAG SERVICE V BATT

2 - 10

RSV mille  "!44%29 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). There are two kinds of commercially available batteries: batteries requiring maintenance featuring cell plugs; maintenance-free batteries with no cell plugs as they do not call for the electrolyte level to be checked and topped up.

SERVICE AND SETTING UP

NOTE This vehicle is provided with a maintenance-free

battery and no operation is necessary, excepting occasional checks and the recharge when required. When changing batteries, replace with a battery of the same type. For further information, see 6.11 (BATTERY).

Never invert the connection of the battery cables. Connect and disconnect the battery with the ignition switch in position m, otherwise some components may be damaged. Connect first the positive cable (+) and then the negative cable (). Disconnect following the reverse order.

aCAUTION

NOTE Check battery voltage with a portable tester. If voltage is less than 12V, the battery must be recharged. If the voltage drops below 8V, the electronic unit is not working and is preventing engine operation.
2.4.1 CHECKING AND CLEANING THE TERMINALS Carefully read 2.4 (BATTERY).
N Turn the ignition switch to position m. N Remove the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).
N Remove the red protection element (1). N Make sure that the cable terminals (2) and the battery

terminals (3) are: in good conditions (and not corroded or covered with deposits); covered with neutral grease or vaseline. If necessary:
N Disconnect first the negative () and then the positive

cable (+).
N Brush with a wire brush to eliminate any sign of corro-

sion.
N Reconnect first the positive (+) and then the negative

cable ().
N Cover the terminals of the cables and of the battery with

neutral grease or vaseline.

N Put back the saddle, see 7.1.1 (REMOVING THE RID-

ER SADDLE).

2 - 11

SERVICE AND SETTING UP

2.4.2 RECHARGING THE BATTERY Carefully read 2.4 (BATTERY). If the start relay emits a vibration-type noise when the start pushbutton is pressed r, it is a sure sign that the battery is almost completely flat.  %,%#42)# #/-0/.%.43

RSV mille

NOTE NOTE

Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1000 km (625 mi), and then every 7500 km (4687 mi) or 8 months.
N Position the vehicle on the stand. N Check all the lighting devices are working. N Check the direction of the headlight beam is correct,

Do not remove the battery plugs: without plugs the battery may be damaged.

N Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY). N Prepare an appropriate battery charger. N Set the charger for the desired type of recharge (see table). N Connect the battery with a battery charger.

aWARNING
During the recharging or the use, make sure that the room is properly ventilated and avoid inhaling the gases released during the recharging.
N Switch on the battery charger.

see 6.13 (ADJUSTING THE VERTICAL HEADLIGHT BEAM) and 6.14 (ADJUSTING THE HORIZONTAL HEADLIGHT BEAM -). N Make sure all connectors are inserted properly. N Make sure all switches are correctly fastened and in proper working order, see: 6.6.4 (CHECKING THE SIDE STAND AND THE SAFETY SWITCH). 6.16 (CHECKING THE SWITCHES). N Make sure the air sensor and speedometer sensor are correctly fastened and in proper working order.

Recharge Normal Quick

Voltage (amp) 1.2 12

Time (hours) 8 - 10 0.5

aCAUTION
The sensitive area on the sensors must be kept clean at all times. Any mud, dirt etc. on them is liable to alter the measurements and the subsequent data transfer.

aWARNING
Reassemble the battery only 5/10 minutes after disconnecting the recharge apparatus, since the battery continues to produce gas for a short lapse of time.

2.4.3 LONG INACTIVITY OF THE BATTERY Carefully read 2.4 (BATTERY).

aCAUTION
If the vehicle remains unused for more than twenty days, disconnect the 30A fuses, in order to avoid the deterioration of the battery caused by the current consumption due to the multifunction computer. The removal of the 30A fuses requires the setting to zero of the following functions: digital clock and red line setting. To reset these functions, see 2.3 (MULTIFUNCTION COMPUTER). If the vehicle remains unused for more than fifteen days, it is necessary to recharge the battery, in order to prevent its sulphation, see 2.4.2 (RECHARGING THE BATTERY):
N Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY) and put it in a cool and dry place. It is important to check the charge periodically (about once a month), during the winter or when the vehicle remains unused, in order to prevent the deterioration of the battery. N Recharge it completely with a normal charge, see 2.4.2 (RECHARGING THE BATTERY). If the battery remains on the vehicle, disconnect the cables from the terminals.

2 - 12

RSV mille  *5-0 34!24).' Carefully read 2.4 (BATTERY).

SERVICE AND SETTING UP

aWARNING
The vehicle should only be jump-started when the vehicles battery is partially/completely flat and recharging is not possible. Do not attempt to start the vehicle by pushing or towing it. The vehicle providing assistance must have a battery (the recharge source) with exactly the same rated voltage (data to be found on the battery) as the battery of the vehicle to be started (12V - 12 Ah). Follow the procedure below to the letter so as to avoid the danger of the battery exploding and possibly injuring people and/or property (this is liable to compromise the electric components of both vehicles).
N Make sure the ignition switch is set to m. N Remove the riders saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE). The cables of the battery of the vehicle to be started must not be disconnected.

NOTE

aCAUTION
Take care never to let the clamps of one cable touch those of another.
N Remove the red protection element (1). N Connect one end of jump lead to the positive pole (+) of

the battery on the vehicle providing assistance (A); and the other end on the positive pole (+) of the battery on the vehicle to be started (B). N Connect one end of the other jump lead to the negative pole () of the battery on the vehicle providing assistance (A); and earth the other end on the frame (far from the battery) of the vehicle to be started (B). DO NOT CONNECT TO THE NEGATIVE POLE ().

aWARNING
The jump leads must not be placed near any moving parts on either vehicle.

NOTE

During the starting phase, the vehicle providing assistance may be kept running.

N Start the vehicle.

NOTE Attempt to start the vehicle for no more than ten

seconds at a time, where necessary, repeating the attempt at intervals of approx. one minute. Once started, keep both engines running for approx. two minutes.
N Stop both engines and disconnect the jump leads fol-

lowing the same procedure in reverse order.

2 - 13

SERVICE AND SETTING UP

 30!2+ 0,5'3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the spark plugs every 7500 km (4687 mi) or 8 months, change them every 15000 km (9375 mi) or 16 months. Periodically remove the spark plugs and clean them carefully, removing carbon deposits; change them if necessary. In case of use on racetracks, change the spark plugs every 3750 km (2343 mi). To reach the spark plugs:

RSV mille

aWARNING
Allow the engine to cool down until it reaches room temperature.
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

NOTE The vehicle is equipped with two spark plugs per cylinder. The following operations refer to one spark plug only, but are valid for both.
To remove and clean the spark plug, proceed as follows:

aWARNING
Never disconnect the spark plug cap with the engine running, since you may get an electric shock from the ignition system.
N Remove the cap (1) of the spark plug (2). N Remove any trace of dirt from the spark plug base. N Introduce the special spanner provided in the tool kit on

the spark plug.

N Insert the 13 mm fork spanner provided in the tool kit in

the hexagonal seat of the spark plug spanner.

N Unscrew the spark plug and extract it from its seat, tak-

ing care to prevent dust or other substances from getting inside the cylinder.

aCAUTION
This vehicle is fitted with spark plugs featuring platinum-type electrodes. When cleaning, do not use wire brushes and/or abrasive products. Use e jet of compressed air only. centre electrode (3); insulator(4); side electrode (5).
N Make sure the spark plugs electrodes and insulator are

free of carbon deposits and do not feature signs of corrosion. Where necessary, clean with a jet of compressed air. If the spark plug should feature cracks on the insulator, corroded electrodes or excessive deposits, or if the centre electrode (3) has a rounded end (see figure), the spark plug must be replaced. You are strongly advised to replace spark plugs with standard plugs. Recommended spark plugs: NGK R DCPR9E (alternatively NGK R DCPR8E).

2 - 14

RSV mille

SERVICE AND SETTING UP

aCAUTION
When replacing a spark plug, check the pitch and length of the thread. If the threaded part is too short, carbon deposits will settle on the thread seat and may result in damage to the engine when the correct one is positioned back in place. Only use the recommended spark plug type, otherwise the performance and service life of the engine may be compromised. Use a feeler gauge (see figure) to check the distance between the electrodes to avoid damaging the platinum coating.
N Check the distance between the electrodes with a feel-

er gauge. The gap must be in the range 0.6 0.7 mm. Where necessary, adjust it by carefully bending the ground electrode. N Make sure the washer is in a good state of repair. With the washer fitted, screw the spark plug on by hand to avoid damaging the threads. N Tighten the spark plug by means of the spanner you will find in the tool kit, giving it half a turn to compress the washer. Spark plug driving torque: 20 Nm (2.0 kgm).

aCAUTION
The spark plug must be well tightened, otherwise the engine may overheat and be seriously damaged.
N Position the spark plug cap (1) properly, so that it does

not come off due to the vibrations of the engine.

N Put back the fuel tank.

 ,)&4).' 4(% &5%, 4!.+ Carefully read 1.2.1 (FUEL).

aWARNING
Risk of fire. Wait until the engine and the exhaust silencer have completely cooled down.
N Remove the passenger seat, see 7.1.2 (UNLOCKING /

LOCKING THE PASSENGER SEAT).

N Remove the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).
N Unscrew and remove the two screws (3) that fasten the

front part of the fuel tank (4).

N Remove the fuel tank support rod (7) from the relevant

anchorage seats (5-6).

NOTE

The rubber-covered end of the rod (7) must be introduced in the central hole of the steering pin.
N Lift the front part of the fuel tank (4) and introduce the

rod (7) as indicated in the figure.

2 - 15

SERVICE AND SETTING UP

 $2!).).' 4(% &5%, 4!.+ Carefully read 1.2.1 (FUEL).

RSV mille

aWARNING
Fire hazard. Wait until the engine and exhaust silencer have completely cooled down. Fuel vapours are harmful for health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Do not smoke or use naked flames. Do not pollute the environment with the incorrect disposal of fuel.
N Switch off the engine and allow it to cool. N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Procure a container with a capacity greater than the

amount of petrol 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 fuel spills.
N Disconnect the male quick-release coupling (1) from

the receptacle (2) by pressing the relevant button.

NOTE Procure a screwdriver-type pipe clamp (3) to replace the original one (of a special type).
N Loosen the clamp (4) and disconnect the pipe (5). N Place the free end of the pipe (5) inside the container

prepared beforehand.
N Insert the male quick-release coupling (1) of the pipe

(5) all the way into the quick-release receptacle (2). The petrol starts draining out immediately. N Open the tank cap. N Wait until all the petrol has drained out of the tank. Once all the petrol has drained out: N Refit the free end of the pipe (5), securing it in place using the clamp (3). N Insert the male quick-release coupling (1) into the receptacle (2).

NOTE

Make sure the male quick-release coupling (1) has been correctly inserted into the receptacle (2).

N Refit the fuel tank. N Close the tank cap again.

2 - 16

RSV mille  !)2 #,%!.%2 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the air cleaner every 7500 (4687 mi)km or 8 months, change it every 15000 km (9375 mi) or more frequently if the vehicle is used on dusty or wet roads. It is possible to clean the air cleaner partially after using the vehicle on this kind of roads.

SERVICE AND SETTING UP

aCAUTION
If the vehicle is used in dusty areas, clean the filtering element more frequently. Using the vehicle without the filtering element, or with the element damaged, considerably increases wear and tear on the engine. Make sure the filtering element is always in perfect condition. The life of the engine depends, for the most part, on this component.

aCAUTION
The partial cleaning of the filter does not exclude or postpone the replacement of the filter itself. Do not start the engine if the air cleaner has been removed. Do not clean the filtering element with petrol or solvents, since they may cause a fire in the fuel supply system, with serious danger for the persons in the vicinity and for the vehicle.

REMOVAL
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Unscrew and remove the seven screws (1) that fasten

the filter case cover (2).

N Remove the filter case cover (2). N Extract the air cleaner (3)

aCAUTION
Plug the opening with a clean cloth, in order to prevent any foreign matter to get ito. PARTIAL CLEANING

aCAUTION
Do not press or strike the metal net of the air cleaner (3). Do not use screwdrivers or alike.
N Seize the air cleaner (3) vertically and strike it more

than once on a clean surface.

N If necessary, clean the air cleaner (3) with a com-

pressed air jet (directing it from the inside towards the outside of the filter). N Clean the outer part of the air cleaner, (3) with a clean cloth. CHANGING
N Replace the air cleaner (3) with a new one of the same

type.
N Every 7500 km (4687 mi), remove the plug (4). Empty

its content into a container and deliver it to a salvage centre.

aCAUTION
When cleaning the filtering element, make sure that there are no tears. Otherwise, change the filtering element. Make sure that the filtering element is positioned correctly, in such a way as to prevent non-filtered air from entering. Remember that the untimely wear of the piston segments and the cylinder may be caused by a faulty or uncorrectly positioned filtering element.

2 - 17

SERVICE AND SETTING UP

 !##%,%2!4/2 Check after the first 1000 km (625 mi) and successively every 7500 km (4687 mi) or 8 months. 2.11.1 CHECKING THE OPERATION OF THE ACCELERATOR CONTROL

RSV mille

aWARNING
The use of the vehicle with damaged, excessively bent or twisted accelerator cable may hinder the regular operation of the accelerator and make you lose control of the vehicle while riding. Make sure that the rotation of the handlebar does not modify the engine idle speed and that the throttle grip returns smoothly and automatically to its original position after being released. If necessary, proceed as follows:

NOTE

For the lubrication of the components use the specific lubricant available on the market. lowing components: sheath; throttle grip adjuster (1); throttle body adjuster (2); throttle body pin (3); cable couplings (ends); accelerator control.

N Check the correct position and the lubrication of the fol-

N Check the idle speed, 2.11.2 (IDLING ADJUSTMENT). N Check the accelerator control adjustment, 2.11.3 (AD-

JUSTING THE ACCELERATOR CONTROL). 2.11.2 IDLING ADJUSTMENT Adjust the idling every time it is irregular. To carry out this operation, proceed as follows: N Ride for a few miles until reaching the normal running temperature. N Position the gear lever in neutral (green warning light N on). N Check the engine idling rpm on the revolution counter. The engine idling speed must be about 1250 100 rpm. If necessary: N Position the vehicle on the stand. N Introduce a small cut-headed screwdriver in the appropriate hole (4) provided on the right side cover. N Turn the adjusting knob (5). BY SCREWING IT (clockwise), you increase the rpm. BY UNSCREWING IT (anticlockwise), you decrease the rpm.
N Twist the throttle grip, accelerating and decelerating a

few times to make sure that it functions correctly and to check if the idling speed is constant. For other informations, see section 4 (FUEL SUPPLY SYSTEM).

2 - 18

RSV mille 2.11.3 ADJUSTING THE ACCELERATOR CONTROL The idle stroke of the throttle grip must be 2 3 mm, measured on the edge of the grip itself. If this is not the case, proceed as follows:
N Position the vehicle on the side stand. N Withdraw the protection element (6). N Loosen the lock nut (7). N Rotate the adjuster (8) in such a way as to restore the

SERVICE AND SETTING UP

prescribed value.
N After the adjustment, tighten the lock nut (7) and check

the idle stroke again.

N Put back the protection element (6).

aCAUTION
After the adjustment, make sure that the rotation of the handlebar does not modify the engine idling rpm and that the throttle grip returns smoothly and automatically to its original position after being released.  #/,$ 34!24 #!",% The cold start cable must be adjusted so that the hand lever (9) has 2 3 mm of freeplay; if adjustment is necessary, proceed as follows:
N Position the vehicle on the stand. N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Loosen the lock nut (10). N Rotate the adjuster (11) in order to restore the pre-

scribed value.
N After this adjustment, tighten the lock nut (10) and

check the freeplay once again.

aCAUTION
Once the adjustment has been made, check that the rotation of the handlebar does not influence the engine rpm.

 #(%#+).' 4(% %.').% /), ,%6%, !.$ 4/00).' 50 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). Periodically check the engine oil level, change the oil after the first 1000 km (625 mi) and successively every 7500 km (4687 mi), or 8 months, see 2.14 (CHANGING THE ENGINE OIL AND THE OIL FILTER). To carry out the checking:

NOTE Position the vehicle on the side stand on firm and level ground.

aCAUTION
The engine oil level must be checked with warm engine. If the check is carried out with cold engine, the oil level may temporarily lower below the MIN mark. This is not a problem, provided that the engine oil pressure warning light LED j does not come on.

2 - 19

SERVICE AND SETTING UP

N Start the engine. N Allow the engine to idle for about 15-20 minutes, or ride

RSV mille

the vehicle on a country road for approximately 15 km (9.5 mi). N Stop the engine. N Keep the vehicle in vertical position, with the two wheels resting on the ground. N Check the oil level in the transparent pipe (1) through the appropriate slot provided on the left fairing. MAX =maximum level MIN = minimum level. The difference between MAX and MIN amounts to approximately 500 cm#. N The level is correct when the oil almost reaches the MAX mark.

aCAUTION
Never exceed the MAX mark, nor leave the oil below the MIN mark, in order to avoid serious damage to the engine. Do not put additives or other substances into the oil. If you use a funnel or other similar items, make sure that they are perfectly clean. If necessary, top up the engine oil by proceeding as follows: N Remove the left fairing, see 7.1.26 (REMOVING THE SIDE FAIRINGS). N Unscrew and remove the filling cap (2). N Top up the tank and restore the correct level, see 1.6 (LUBRICANT CHART).  #(!.').' 4(% %.').% /), !.$ 4(% /), &),4%2 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.2 (ENGINE OIL). Periodically check the engine oil level, see 2.13 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP) change the oil after the first 1000 km (625 mi) and successively every 7500 km (4687 mi) or 8 month.

aCAUTION
If the vehicle is used in dusty areas, change the oil more frequently. In case of use on racetracks, change every 3750 km (2343 mi). TO CHANGE

NOTE The oil flows out completely and without problems when it is warm and therefore more fluid: to achieve this condition, the engine should run for approximately twenty minutes.

aWARNING
When warmed up, the engine contains hot oil; therefore, while carrying out the operations described here below be particularly careful, in order to avoid burns.

NOTE Position the vehicle on the side stand on firm and level ground.
N Remove the lower fairing, see 7.1.32 (REMOVING N Position a container (3) with more than 4000 cm# ca-

THE LOWER FAIRING).

pacity in correspondence with the drain plug (4) positioned on the tank. N Unscrew and remove the drain plug (4) positioned on the tank. N Unscrew and remove the filling cap (2). N Drain the oil and let it drop for a few minutes inside the container (3).

2 - 20

RSV mille
N Check and if necessary replace the sealing washer of

SERVICE AND SETTING UP

the drain plug (4) positioned on the tank.

N Screw and tighten the drain plug (4) on the tank.

Drain plug (4) driving torque: 15 Nm (1.5 kgm).

N Move the container (3) and position it under the engine

base, in correspondence with the drain plug positioned on the engine (5). N Unscrew and remove the drain plug positioned on the engine (5). N Drain the oil and let it drip inside the container (3) for a few minutes.

aCAUTION
Do not dispose of the oil in the environment. Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage center.
N Remove the metal residues from the drain plug (5)

magnet.
N Screw and tighten the drain plug (5).

Driving torque of the drain plug (5) positioned on the engine: 12 Nm (1.2 kgm). CHANGING THE ENGINE OIL FILTER Change the engine oil filter after the first 1000 km (625 mi) and successively every 7500 km (4687 mi) (or every time you change the oil). N Unscrew the two screws (6) and remove the cover (7). N Remove the engine oil filter (8).

aCAUTION
Do not use filters that have already been used.
N Spread an oil film on the sealing ring (9) of the new en-

gine oil filter.

N Fit the new engine oil filter. N Put back the cover (7), screw and tighten the two

screws (6). CLEANING THE ENGINE OIL FILTER ON THE TANK Clean the engine oil filter (10) on the tank every 15000 km (9375 mi) (or every two engine oil changes).

NOTE Prepare a pipe clamp (11) to replace the original

one (special type).
N Loosen the clamp (12) and disconnect the pipe (13). N Unscrew and remove the engine oil filter (10) positioned

on the tank and clean it with a jet of compressed air.

N Check the seal of the engine oil filter (10) positioned on

the tank; screw and tighten it. Engine oil filter (10) driving torque: 30 Nm (3.0 kgm). N Connect the pipe (13) and tighten the new clamp (11).

aCAUTION
Do not put additives or other substances into the oil. If you use a funnel or other similar items, make sure that they are perfectly clean.
N Pour about 3500 cm# of engine oil through the filling

opening (14), see 1.6 (LUBRICANT CHART).

N Tighten the filling cap (2). N Start the engine and let it idle for about one minute, in

order to ensure the filling up of the engine oil circuit.

N Check the oil level and top up if necessary, see 2.13

(CHECKING THE ENGINE OIL LEVEL AND TOPPING UP).

2 - 21

SERVICE AND SETTING UP

 #(%#+).' !.$ 4/00).' 50 #//,!.4 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Before departure, check the coolant level, change it every two years.

RSV mille

aCAUTION
Check the coolant level and top up the expansion tank with cold engine.
N Stop the engine and wait until it has cooled down.

NOTE Position the vehicle on the side stand on firm and level ground.
N Keep the vehicle in vertical position, with the two

wheels resting on the ground.

N Make sure that the coolant contained in the expansion

tank (1) is included between the FULL and LOW marks, by checking through the appropriate slot on the right fairing. If not, proceed as follows: N Unscrew and remove the cap (2).

aWARNING
The coolant is noxious: do not swallow it; if the coolant gets in contact with the skin or the eyes, it can cause serious irritations. Do not use your fingers or any other object to check if there is enough coolant.

aCAUTION
Do not put additives or other subtances into the fluid. If you use a funnel or other similar items, make sure that they are perfectly clean.
N Top up the expansion tank by adding coolant, see 1.6

(LUBRICANT CHART), until this almost reaches the FULL level. Do not exceed this level, otherwise the coolant will flow out while the engine is running. N Put back the filling cap (2).

aCAUTION
In case of excessive consumption of coolant and in case the tank (1) remains empty, make sure that there are no leaks in the circuit.  #(!.').' 4(% #//,!.4 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT). Replace the coolant every two years.
N Remove the upper panel of the right side fairing, see

7.1.27 (REMOVING THE SIDE FAIRING UPPER PANELS). N Remove the lower fairing, see 7.1.32 (REMOVING THE LOWER FAIRING). N Remove the expansion tank, see 5.9 (REMOVING THE EXPANSION TANK). N Place a container (4) under the drain screw (3) to catch the coolant (capacity over 2.5 L ). N Unscrew and remove the drain screw (3) retrieving the copper washer.

aCAUTION
Do not remove the filler cap (5) when the engine is hot as the coolant is under pressure and is very hot.
N Remove the filler cap (5) followed by the expansion

tank cap (2) to help the coolant out.

2 - 22

RSV mille
N Once all the coolant has drained out, move the contain-

SERVICE AND SETTING UP

er (4) under the right-hand radiator.

N Unscrew and remove the drain plug (6), retrieving the

aluminium washer.
N Once all the coolant has drained out, move the contain-

er under the left-hand radiator.

N Unscrew and remove the drain plug (7), retrieving the

aluminium washer. DO NOT DISPOSE OF COOLANT IN THE ENVIRONMENT.

NOTE

When reassembling, apply LOCTITE 574 on the thread of the drain screw (3). washer.

N Reassemble the drain screw (3) with a new copper

Driving torque of drain screw (3): 12 Nm (1.2 kgm).

NOTE

When reassembling, apply LOCTITE 572 on the thread of the drain plug (6-7). new aluminium washers.

N Reassemble the two radiator drain plugs (6-7) with two

Driving torque of drain plugs (6-7): 10 Nm (1.0 kgm).

N Top up through the filler neck (8) until full. N Squeeze and release the couplings (9-10) a few times

7 4

with your hands so as to create a slight pressure and enable the coolant to flow into the pipes. N Top up again until full.

NOTE

The level is correct when the coolant stabilizes immediately below the filler neck (8).

N Refit the filler cap (5). N Top up the coolant in the expansion tank, see 2.15

(CHECKING AND TOPPING UP COOLANT).

N Start the engine and let it run for a few minutes, then al-

low it to cool and check the level of coolant in the expansion tank again. N If necessary, top up, see 2.15 (CHECKING AND TOPPING UP COOLANT). Total quantity: 2.5 L (including the expansion tank).

NOTE

The bleeding of the system is not required for this vehicle. For further information, see section 5 (COOLING SYSTEM).

10

2 - 23

SERVICE AND SETTING UP

 #(%#+).' !.$ 4/00).' 50 4(% &2/.4 "2!+%3 &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Check the brakes fluid every 7500 km (4687 mi) or 8 months , change it every two yars.

RSV mille
N Fill the tank (2) with brake fluid, see 1.6 (LUBRICANT

CHART), until reaching the correct level between the MIN and MAX marks.

aCAUTION
When topping up, never exceed the MAX level. It is advisable to top up until reaching the MAX level only with new pads. When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear. N To reassemble the components, follow the reverse order.

aCAUTION
If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.20 (BLEEDING THE BRAKING SYSTEMS). The leak of brake fluid damages painted or plastic surfaces. Before setting out, make sure that the hoses are not twisted or holed and that there are no leakage from the connectors. Do not use or mix different types of silicone or oilbased liquids. Do not use brake fluids taken from old containers, or not sealed. Make sure that neither water nor dust accidentally enter the circuit. CHECKING

NOTE Position the vehicle on the side stand on firm and level ground.
N Position the vehicle on the stand. N Rotate the handlebar completely rightwards. N Make sure that the fluid level exceeds the MIN mark,

provide for topping up. MIN = minimum level. MAX = maximum level N If the fluid does not reach at least the MIN mark, provide for topping up. TOPPING UP

aCAUTION
The brake fluid may flow out of the tank. Do not operate the front brake lever if the screws (1) are loose or, most important, if the brake fluid tank cover has been removed. N Unscrew the two screws (1) of the brake reservoir (2) by means of a short, cross-headed screwdriver.

MAX
MAX

2
MIN

aWARNING
Avoid any prolonged exposure of the brake fluid to the air. The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity. Leave the brake fluid tank open ONLY for the time necessary for topping up. N Raise and remove the cover (3) together with the screws (1) and the gasket (4).

MIN

NOTE In order not to spill the brake fluid while topping up, do not shake the vehicle.

aCAUTION
Do not put additives or other subtances into the fluid. If you use a funnel or other similar items, make sure that they are perfectly clean.

2 - 24

RSV mille  #(%#+).' !.$ 4/00).' 50 4(% 2%!2 "2!+% &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Check the brake fluid every 7500 km (4687 mi) or 8 months, change it every two years.

SERVICE AND SETTING UP

N Top up the reservoir (1) by adding brake fluid, see 1.6

(LUBRICANT CHART), until reaching the correct level included between the MIN and MAX marks.

aCAUTION
It is advisable to top up until reaching the MAX level only with new pads. When the disc pads wear out, the level of the fluid decreases progressively to compensate for their wear. N To reassemble the components, follow the reverse order.

aCAUTION
If the brake lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.20 (BLEEDING THE BRAKING SYSTEMS). The leak of brake fluid damages painted or plastic surfaces. Before setting out, make sure that the hoses are not twisted or holed and that there are no leakage from the connectors. Do not use or mix different types of silicone or oilbased liquids. Do not use brake fluids taken from old containers, or not sealed. Make sure that neither water nor dust accidentally enter the circuit. CHECKING

NOTE Position the vehicle on the side stand on firm and level ground.
N Keep the vehicle in vertical position, so that the fluid

contained in the tank (1) is parallel to the plug (2).

N Make sure that the brake fluid contained in the reservoir

exceeds the MIN mark, by checking through the appropriate slot on the right fairing. MIN = minimum level. MAX = maximum level. N If the fluid does not reach at least the MIN mark, provide for topping up. TOPPING UP N Remove the right fairing, see 7.1.26 (REMOVING THE SIDE FAIRINGS).

aCAUTION
The brake fluid may flow out of the tank. Do not operate the rear brake lever if the brake fluid tank plug is loose or has been removed. N Unscrew the screw (3) completely. N Slightly move the whole reservoir (1) outwards.

aWARNING
Avoid any prolonged exposure of the brake fluid to the air. The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity. Leave the brake fluid tank open ONLY for the time necessary for topping up. N Unscrew and remove the plug (2). In order not to spill the brake fluid while topping up, keep the fluid in the tank parallel to the tank rim (in horizontal position). N Remove the gasket (4).

NOTE

2 4

aCAUTION
Do not put additives or other subtances into the fluid. If you use a funnel or other similar items, make sure that they are perfectly clean.

MAX
MAX

3
MIN

MIN

2 - 25

SERVICE AND SETTING UP

 #(%#+).' !.$ 4/00).' 50 4(% #,54#( &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Check the clutch fluid every 7500 km (4687 mi) or 8 months change it every two years.

RSV mille
N Top up the reservoir (1) by adding clutch fluid, see 1.6

(LUBRICANT CHART), until reaching the correct level included between the MIN and MAX marks.

aCAUTION
Do not exceed the MAX mark while topping up.
N To reassemble the components, follow the reverse or-

aCAUTION
If the clutch control lever features excessive free play, if it is excessively spongy or in the event of air bubbles in the circuit, bleed the system, see 2.21 (BLEEDING THE CLUTCH SYSTEMS). The leak of cluth fluid damages painted or plastic surfaces. Before setting out, make sure that the hoses are not twisted or holed and that there are no leakage from the connectors. Do not use or mix different types of silicone or oilbased liquids. Do not use clutch fluids taken from old containers, or not sealed. Make sure that neither water nor dust accidentally enter the circuit. CHECKING

der.

NOTE Position the vehicle on the side stand on firm and level ground. N Keep the vehicle in vertical position, so that the fluid contained in the tank (1) is parallel to the plug (2). N Make sure that the fluid level exceeds the MIN mark. MIN = minimum level MAX = maximum level N If the fluid does not reach the MIN mark, provide for topping up.
TOPPING UP

aCAUTION
The fluid may flow out. Do not operate the clutch control lever if the reservoir plug is loose or has been removed.

2 3

aWARNING
Avoid any prolonged exposure of the clutch fluid to the air. The clutch fluid is hygroscopic and when in contact with the air it absorbs its humidity. Leave the clutch fluid tank open ONLY for the time necessary for topping up.
N Unscrew and remove the plug (2).

MAX
MAX

MIN

MIN

NOTE Do not shake the vehicle, in order not to spill fluid while topping up.
N Remove the gasket (3).

aCAUTION
Do not put additives or other subtances into the fluid. If you use a funnel or other similar items, make sure that they are perfectly clean.

2 - 26

RSV mille  ",%%$).' 4(% "2!+).' 3934%-3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Bleed the braking system after the first 1000 km (625 mi). The air present in the hydraulic system acts as a bearing, absorbing most of the pressure exerted by the brake pump and reducing the effectiveness of the caliper action during braking. The presence of air is revealed by the sponginess of the brake lever and by the reduced braking capacity.

SERVICE AND SETTING UP

aCAUTION
Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT.

aWARNING
Considering the danger for both rider and vehicle, it is absolutely essential to bleed the hydraulic circuit once the brakes have been refitted and the braking system restored to its normal conditions. Proceed as follows:

NOTE Only for the front braking system.

First bleed the system using the bleeder (1) located on the pump, and then using the one (2) located on the caliper.
N Top up the brake fluid tank, see 2.17 (CHECKING AND

TOPPING UP THE FRONT BRAKES FLUID) and 2.18 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID). N Remove the plastic protection cap. N Insert a transparent plastic tube on the bleeder (1) on the pump and then on the bleeder (2) or (3) on the caliper and put the other end of the tube in a container. N Rapidly pull and release the brake lever several times, then keep it completely pulled. N Loosen the bleeder a quarter turn so that the brake fluid flows into the container; this eliminates the tension on the brake lever, allowing it to touch the handgrip. N Tighten the bleeder (1), pull the lever several times, then keep it completely pulled and unscrew the bleeding screw again. N Repeat this operation until the liquid flowing into the container is completely free of air bubbles.

NOTE During the bleeding of the braking system, fill the tank with as much brake fluid as needed. Make sure that the brake fluid is always present in the tank during the operation.
N Tighten the bleeder and remove the plastic tube.

Driving torque of bleeder (1): 15 Nm (1.5 kgm).

N Top up the brake fluid tank to the right level, see 2.17

(CH EC K IN G AN D T O PP IN G U P TH E FR O NT BRAKES FLUID) and 2.18 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID). N Refit the rubber protection cap.

2 - 27

SERVICE AND SETTING UP

 ",%%$).' 4(% #,54#( 3934%-3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Bleed the braking system after the first 1000 km (625 mi). The air present in the hydraulic system acts as a bearing, absorbing most of the pressure exerted by the brake pump and reducing the effectiveness of the clutch cylinder. The presence of air is revealed by the sponginess of the clutch lever and by the reduced the capacity.

RSV mille

aCAUTION
Handle clutch fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF CLUTCH FLUID IN THE ENVIRONMENT.

aWARNING
Considering the danger for both rider and vehicle, it is absolutely essential to bleed the hydraulic circuit once the clutch cylinder have been refitted and the system restored to its normal conditions. Proceed as follows:
N Top up the clutch fluid tank, see 2.19 (CHECKING AND

TOPPING UP THE CLUTCH FLUID) .

N Remove the left side fairing, see 7.1.26 (REMOVING

THE SIDE FAIRINGS).

N Remove the plastic protection cap. N Insert a transparent plastic tube on the bleeder (1) and

put the other end of the tube in a container.

N Rapidly pull and release the clutch lever several times,

then keep it completely pulled.

N Loosen the bleeder a quarter turn so that the clutch flu-

id flows into the container; this eliminates the tension on the clutch lever, allowing it to touch the handgrip. N Tighten the bleeder (1), pull the lever several times, then keep it completely pulled and unscrew the bleeding screw again. N Repeat this operation until the liquid flowing into the container is completely free of air bubbles.

NOTE During the bleeding of the clutch system, fill the tank with as much clutch fluid as needed. Make sure that the clutch fluid is always present in the tank during the operation.
N Tighten the bleeder and remove the plastic tube.

Driving torque of bleeder (1): 15 Nm (1.5 kgm).

N Top up the clutch fluid tank to the right level, see 2.19

(CHECKING AND TOPPING UP THE CLUTCH FLUID). N Refit the rubber protection cap.

2 - 28

RSV mille  #(!.').' 4(% &2/.4 "2!+% &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Change the front brake fluid every two year.

SERVICE AND SETTING UP

aCAUTION
Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT.
N # Remove the plastic protection cap. N # Insert a transparent plastic tube on the bleeder (1) of

the caliper and put the other end of the tube in a container. N # Loosen the bleeder (1) approx. one turn.

NOTE

Make sure that there is always fluid in the tank during the operation; otherwise, once finished, the braking system will need bleeding, see 2.20 (BLEEDING THE BRAKING SYSTEMS). tighten the bleeder (1) before it empties entirely.

N Keep an eye on the tank (2) as the fluid flows out and N Top up the tank (2), see 2.17 (CHECKING AND TOP-

PING UP THE FRONT BRAKES FLUID).

N # Loosen the bleeder (1) again approx. half a turn. N # Watch as the liquid flows out through the tube and as

soon as the colour of the fluid starts to change (from dark to light), tighten the bleeder (1) again and remove the tube. Driving torque of bleeder (1): 15 Nm (1.5 kgm).
N # Refit the rubber protection cap. N Top up the brake fluid tank (2) to the right level, see

2.17 (CHECKING AND TOPPING UP THE FRONT BRAKES FLUID).

2 - 29

SERVICE AND SETTING UP

 #(!.').' 4(% 2%!2 "2!+% &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.4 (BRAKE FLUID). Change the rear brake fluid every two year.

RSV mille

aCAUTION
Handle brake fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT.
N Remove the plastic protection cap. N Insert a transparent plastic tube on the bleeder (1) of

the caliper and put the other end of the tube in a container. N Loosen the bleeder (1) approx. one turn.

NOTE

Make sure that there is always fluid in the tank during the operation; otherwise, once finished, the braking system will need bleeding, see 2.20 (BLEEDING THE BRAKING SYSTEMS). tighten the bleeder (1) before it empties entirely.

N Keep an eye on the tank (2) as the fluid flows out and N Top up the tank (2), see 2.18 (CHECKING AND TOP-

PING UP THE REAR BRAKE FLUID).

N Loosen the bleeder (1) again approx. half a turn. N Watch as the liquid flows out through the tube and as

soon as the colour of the fluid starts to change (from dark to light), tighten the bleeder (1) again and remove the tube. Driving torque of bleeder (1): 15 Nm (1.5 kgm).
N Refit the rubber protection cap. N Top up the brake fluid tank (2) to the right level, see

2.18 (CHECKING AND TOPPING UP THE REAR BRAKE FLUID).

2 - 30

RSV mille  #(!.').' 4(% #,54#( &,5)$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID). Change the clutch fluid every two year.

SERVICE AND SETTING UP

aCAUTION
Handle clutch fluid with care; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. DO NOT DISPOSE OF CLUTCH FLUID IN THE ENVIRONMENT.
N Remove the plastic protection cap. N Insert a transparent plastic tube on the bleeder (1) and

put the other end of the tube in a container.

N Loosen the bleeder (1) approx. one turn.

NOTE

Make sure that there is always fluid in the tank during the operation; otherwise, once finished, the clutch system will need bleeding, see 2.21 (BLEEDING THE CLUTCH SYSTEMS).

N Keep an eye on the tank (2) as the fluid flows out and

tighten the bleeder (1) before it empties entirely. N Top up the tank (2), see 2.19 (CHECKING AND TOPPING UP THE CLUTCH FLUID). N Loosen the bleeder (1) again approx. half a turn. N Watch as the liquid flows out through the tube and as soon as the colour of the fluid starts to change (from dark to light), tighten the bleeder (1) again and remove the tube. Driving torque of bleeder (1): 15 Nm (1.5 kgm).
N Refit the rubber protection cap. N Top up the fluid tank (2) to the right level, see 2.19

(CHECKING AND TOPPING UP THE CLUTCH FLUID).

 !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 !.$ 4(% '%!2 ,%6%2 The control levers are positioned ergonomically during the assembly of the vehicle. If necessary, it is possible to adjust the position of the levers. N Position the vehicle on the side stand on firm and level ground. N Partially unscrew the screw (3). N Rotate the eccentric (4) in order to find the optimal position of the pedal (5). N Tighten the screw (3) and make sure that the eccentric is stable in its position.

2 - 31

SERVICE AND SETTING UP

 !$*534).' 4(% 2%!2 "2!+% #/.42/, ,%6%2 #,%!2!.#% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The brake control lever is positioned ergonomically during the assembly of the vehicle. If necessary, it is possible to adjust the brake control lever clearance:
N Remove the lower fairing, see 7.1.32 (REMOVING

RSV mille

THE LOWER FAIRING).

N Tighten the lock nut (1). N Unscrew the pump control rod (2) to ensure a minimum

clearance of 0.5 1 mm between the rod and the pump piston.

aCAUTION
Make sure that there is a certain idle stroke in the movement of the lever, to prevent the brake from remaining applied and the consequent untimely wear of the braking elements. Lever (3) idle stroke: 4 mm (measured at the lever end).
N Lock the pump control rod by means of the lock nut (1).

aCAUTION
After the adjustment, make sure that the wheel rotates freely with released brake.

 #(%#+).' 4(% "2!+% 0!$ 7%!2 The wear of the disc brake pads depends on the use, on the kind of drive and on the road.

NOTE

The following information refer to a single braking system, but are valid for both. To carry out a rapid checking of the wear of the pads, proceed as follows: N Position the vehicle on the side stand on firm and level ground. N Carry out a visual check between the disc and the pads, proceeding: from below, on the front part, for the front brake calipers (4); from below, on the rear part, for the rear brake caliper (5).

aCAUTION
The excessive wear of the friction material would cause the contact of the pad metal support with the disc, with consequent metallic noise and production of sparks from the caliper; braking efficiency, safety and soundness of the disc would thus be negatively affected.
N If the thickness of the friction material (even of one pad

only) has reduced to about 1 mm (or if even only one of the wear indicators is not visible any longer), change both pads. Front pad (6), see 7.5.1 (CHANGING THE BRAKES PADS). Rear pad (7) see 7.6.1 (CHANGING THE BRAKE PADS).

1m

1m

2 - 32

RSV mille  34%%2).' Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1500 km (937 mi) and then after every 7500 km (4687 mi) or 8 months. To assure improved 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 slack steering implies inadequate stability.

SERVICE AND SETTING UP

2.28.1 CHECKING THE BEARING SLACK

N Position the vehicle on the relevant centre support

stand, see 1.9.4 (SETTING THE VEHICLE ON THE CENTRE SUPPORT STAND &). N Shake the fork in the direction of travel. N In the event any slack is encountered, adjust the steering.

2.28.2 ADJUSTING THE BEARING SLACK Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The following procedure does not necessarily have to be performed with the front fairing removed, though it is advisable to remove it in order to gain more room for manoeuvre, see 7.1.20 (REMOVING THE FRONT PART OF THE FAIRING).
N # Unscrew and remove the screw (1) securing the han-

NOTE

dlebar (2) to the upper plate (3).

N Partially unscrew the screw (4) fastening the clutch fluid

tank (5).
N Move the clutch fluid tank (5) sideways. N # Unscrew the screw (6) securing the upper plate (3) to

the front fork (7).

N Unscrew and remove the upper bush (8). N Using a plastic hammer, tap the upper plate (3), com-

plete with ignition switch /steering lock, from underneath until it is pushed off upwards. N Bend the upper plate (3) over forwards, placing a cloth between it and the dashboard to avoid damage.

2 - 33

SERVICE AND SETTING UP

N Use a small flat-tip screwdriver to straighten the tabs

RSV mille

(those bent upwards) of the tab washer (9).

NOTE

Have the special tool & to hand cod. 8140203 (socket spanner for adjusting steering). move the lock ring (10).

N Use the special setscrew spanner to loosen and reN Remove the tab washer (9).

aCAUTION
When reassembling, the tab washer (9) must be replaced.
N Use the special setscrew spanner to tighten the adjust-

er ring (11) and eliminate the slack. Driving torque of adjuster ring (11): 40 Nm (4.0 kgm).
N Refit the tab washer (9), making sure the tabs coincide

with the grooved sectors of the metal ring (11).

N Use the special setscrew spanner to screw on and

tighten the lock ring (10). Tightening of lock ring (10): manual until contact + 1/4 turn.

NOTE Bend the tabs of the tab washer (9) upwards.

N Bend the four tabs of the tab washer (9) upwards onto

the grooved sectors of the lock ring (10).

N Refit the upper plate (3), making sure it is correctly

housed.
N Lubricate the thread and base on which the bush (8)

rests using motor oil, see1.6 (LUBRICANT CHART).

N Screw on and tighten the upper bush (8).

Driving torque of upper bush (8): 80 Nm (8.0 kgm).

N # Screw on and tighten the screw (6).

Driving torque of screw (6): 25 Nm (2.5 kgm).

N # Screw on and tighten the screw (1).

Driving torque of screw (1): 12 Nm (1.2 kgm).

N Refit the clutch fluid tank (5). N Tighten the screw (4).

Driving torque of screw (4): 12 Nm (1.2 kgm).

aCAUTION
Once the operation is complete, make sure that the rotation of the handlebar is smooth in order to avoid damage to the balls and the loss of manoeuvrability of the vehicle.

2 - 34

RSV mille  ).30%#4).' 4(% &2/.4 !.$ 2%!2 3530%.3)/. 2.29.1 FRONT SUSPENSION The front suspension consists of an hydraulic fork connected to the steering column by means of two plates. For the setting of the vehicle attitude, each rod of the fork is provided with an upper screw (1) for the adjustment of the hydraulic braking with extended shock absorber, a lower screw (2) for the adjustment of the hydraulic braking with compressed shock absorber and an upper nut (3) for the adjustment of the spring preload. The riding position of the vehicle can be further altered by varying the height of the forecarriage. Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Change the front fork oil after the first 7500 km (4687 mi) and successively every 22500 km (14000 mi). Every 7500 km (4687 mi), carry out the following checking operations: N With pulled front brake lever, press the handlebar repeatedly, thrusting the fork downwards. The stroke must be gentle and there must be no trace of oil on the rods. If the fork tends to bottom out, carry out a adjusting, see 2.29.2 (ADJUSTING THE FRONT FORK) and the oil must be changed if necessary, see 7.8.1 (CHANGING THE FORK OIL). Make sure the fork does not feature oil leaks and that the outer surface of the tubes is not marked with scratches or grooves. If this is the case, replace all the damaged parts that cannot be repaired, see 7.8.3 (DISASSEMBLING THE WHEEL-HOLDER TUBE - SLIDER UNIT). N Check the fastening of all the components and the functionality of the front suspension joints.

SERVICE AND SETTING UP

2 - 35

SERVICE AND SETTING UP

2.29.2 ADJUSTING THE FRONT FORK The standard setting of the front fork is such as to satisfy most driving conditions at low and high speed, either with reduced load and full load. However, it is also possible to adjust the setting according to the intended use of the vehicle.

RSV mille

aCAUTION
For the adjustment, always start from the most rigid setting [complete clockwise rotation of the adjusters (1-2)]. Do not rotate the adjusters (1-2) beyond their limit position, to avoid damaging the thread. Use the notches (1-2) provided on the adjusters as reference marks for the adjustment of the hydraulic braking with compressed and extended shock absorber. Give the adjusters (1-2) 1/8 turn at a time and turn the adjusting nut (3) one notch at a time. Test the vehicle repeatedly on the road, until obtaining the optimal adjustment. Set the same spring preload and hydraulic braking for both rods: a different setting of the rods decreases the stability of the vehicle while riding. When the spring preload is increased, it is necessary to increase also the hydraulic braking, in order to avoid sudden jerks while riding.

Front suspension Hydraulic adjustment with extended shock absorber, screw (1) Hydraulic adjustment with compressed shock absorber, screw (2) Spring preload, nut (3) (*) = clockwise (**) = anticlockwise

Standard adjustment from completely closed (*), open giving 1.5 turns (**) from completely closed (*) (H), open giving 1.5 turns (**) (S) at the 5th notch

Adjustment for racetrack use from completely closed (*), open giving 1 turn (**) from completely closed (*) (H), open giving 1 turn (**) (S) at the 4th notch

Possible adjustments from 0 to 2.5 turns

from 0 to 2.25 turns from 10 to 25 turns

2 - 36

RSV mille 2.29.3 ADJUSTING THE HEIGHT OF THE FORECARRIAGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Position the vehicle on the relevant centre support

SERVICE AND SETTING UP

stand, see 1.9.4 (SETTING THE VEHICLE ON THE CENTRE STAND &).

NOTE Procure suitable shims to place between the front tyre and the support (1). The number of shims depends on the desired riding position (maximum number: six, like the number of possible variations, 4 mm at a time).
Thickness for each element: 4 mm.
N Place a support (1) under the front tyre so as to keep

4 mm

the forecarriage in place once it is released.

N # Loosen the two screws (2) securing the lower plate

(3) to the slider (4). Driving torque of screw (2): 25 Nm (2.5 kgm).
N # Loosen the screw (5) securing the upper plate (6) to

the slider (4). Driving torque of screw (5): 25 Nm (2.5 kgm).

N # Loosen the screw (7) securing the handlebar (8) to

the slider (4). Driving torque of screw (7): 25 Nm (2.5 kgm).

aCAUTION
Due to the weight of the forecarriage, the following operations require the assistance of another operator. Agree on the operating procedures in advance. The removal must be carried out with the greatest care.
N Grip the forecarriage firmly and lift it slightly in the direc-

tion in which the sliders (4) are inserted on the two fastening plates (3-6). N Place one or more of the shims between the tyre and the support (1) depending on the desired variation. N Release the forecarriage.

NOTE

There are six notches to be found in the upper part of each fork slider, to be used as reference for the six different positions possible (see figure). plate is lined up with corresponds to the desired variation.

N Make sure the notch in the fork sliders which the upper

aCAUTION
The upper plate must be lined up with the same reference notch on both fork sliders. Any variation, whether up or down, must always be made in the range between the first reference notch and the last. Front suspension Protrusion of the rods (A) from the upper plate (plug excluded) Standard adjustment 8 mm (2 notches) Adjustment for racetrack use 12 mm (3 notches) Possible adjustments 2 - 4 notches

2 - 37

SERVICE AND SETTING UP

 2%!2 &/2+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Periodically check the tightening of the nut/ pin and of the needle bearings of the rear fork. To carry out this operation, proceed as follows:
N Position the vehicle on the relevant centre support

RSV mille

stand, see 1.9.4 (SETTING THE VEHICLE ON THE CENTRE STAND &). N Shake the fork in the direction of travel (see figure). If you find any slack, adjust the rear fork, see 2.30.1 (ADJUSTING THE REAR FORK). If the slack persists, adjust the bearings, see 7.9.2 (DISASSEMBLING THE REAR FORK). 2.30.1 ADJUSTING THE REAR FORK Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Position the vehicle on the relevant centre support

stand, see 1.9.4 (SETTING THE VEHICLE ON THE CENTRE SUPPORT STAND &). N Loosen the nut (1) completely. (socket spanner for adjusting fork pin engine mounts). ring (2) completely.

NOTE Have the special tool & to hand cod. 8140203

N Use the special setscrew spanner to loosen the lock N Working from the right-hand side of the vehicle, rotate

the fork pin (3) clockwise, which will cause the bush (4) to rotate with it, in turn pushing the fork to its stop. Driving torque to be applied on the pin (3): 12 Nm (1.2 kgm).
N Use the special setscrew spanner to tighten the lock

ring (2). Driving torque of lock ring (2): 60 Nm (6.0 kgm).

N Tighten the nut (1).

Driving torque of nut (1): 90 Nm (9.0 kgm).

2 - 38

RSV mille  ).30%#4).' 4(% 2%!2 3530%.3)/. 2.31.1 REAR SUSPENSION The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a uni-ball and to the rear fork by means of lever systems. For the setting of the vehicle attitude, the shock absorber is provided with a screw adjuster (1) for the adjustment of the hydraulic braking with extended shock absorber; a knob adjuster (2) for the adjustment of the hydraulic braking with compressed shock absorber; a ring nut for the adjustment of the spring preload (3) and a locking ring nut (4). The riding position of the vehicle can be further altered by varying the height of the rear axle by adjusting the lock nut (5) and adjuster nut (6). Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1000 km (625 mi), and subsequently every 15000 km (9375 mi) or 16 months. N Check all the rear suspension joints are working properly and that the relevant components are properly tightened. 2.31.2 ADJUSTING THE REAR SHOCK ABSORBER The standard setting of the rear shock absorber is such as to satisfy most driving conditions at low and high speed, either with reduced load and full load. However, it is also possible to adjust the setting according to the intended use of the vehicle.

SERVICE AND SETTING UP

aCAUTION
Adjust the spring preload and the hydraulic braking with extended shock absorber according to the conditions of use of the vehicle. When the spring preload is increased, it is necessary to increase also the hydraulic braking with extended shock absorber, in order to avoid sudden jerks while riding.

aCAUTION
For the adjustment, always start from the most rigid setting; screw adjuster (1) and knob adjuster (2) completely rotated clockwise. Do not rotate the screw adjuster (1) beyond its limit position, to avoid damaging the thread. Make sure that the screw adjuster (1) always snaps and is not in any intermediate position.
N Slightly unscrew the locking ring nut (4) by means of

the appropriate spanner.

N Act on the adjusting ring nut (3) (shock absorber spring

preload adjustment) (see figure).

N After the adjustment, tighten the metal ring (4). N Adjust the hydraulic braking with extended shock ab-

sorber by means of the screw (1) (see table).

N Adjust the knob (2) to adjust the hydraulic braking with

compressed shock absorber (see table). To vary the attitude of the vehicle, proceed as follows:
N Moderately loosen the lock nut (5).

NOTE Rotate the adjuster (6) by giving it one turn at a time, so that the adjusting screw (1) is always on the left side of the vehicle.
N Act on the adjuster (6) (see table).

aCAUTION
The lock nut (5) must be tightened with the indicated driving torque.
N After the adjustment, tighten the lock nut (5).

Lock nut (5) driving torque: 40 Nm (4.0 kgm)

2 - 39

SERVICE AND SETTING UP

RSV mille

aCAUTION
Adjust the spring preload and the hydraulic braking with extended shock absorber according to the conditions of use of the vehicle. When the spring preload is increased, it is necessary to increase also the hydraulic braking with extended shock absorber, in order to avoid sudden jerks while riding. Turn the screw adjuster (1) 2-3 clicks at a time, the knob adjuster (2) 5-6 clicks at a time and the adjusting ring nut (3) one turn at a time. Test the vehicle repeatedly on the road, until obtaining the optimal adjustment. To avoid affecting the operation of the shock absorber, neither remove the plug (7), nor adjust the underlying valve, since this may cause nitrogen to flow out, with consequent risk of accidents.

Rear suspension Shock absorber distance between centers (A) Spring length (preloaded) (B) Adjustment with extended shock absorber, screw (1) Adjustment with compressed shock absorber, knob (2) (*) = clockwise (**) = anticlockwise

Standard adjustment 322 1 mm 130 mm from completely closed (*), open giving 14 clicks (**) from completely closed (*), open giving 45 clicks (**)

Adjustment for racetrack use 322 1 mm 128 mm from completely closed (*), open giving 7-9 clicks (**) from completely closed (*), open giving 20-30 clicks (**)

Possible adjustments from 320 to 327 mm from 128 to 132 mm completely open: 25 clicks completely open: 45 clicks

2 - 40

RSV mille 2.31.3 CHECKING THE REAR SUSPENSION LINKAGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the conditions of the bearings every 30000 km (18750 mi).

SERVICE AND SETTING UP

NOTE Have someone help you keep the vehicle upright during this operation.
N Grip the rear part of the vehicle firmly (see figure),

press down and release a few times.

N If the movement is not smooth and is accompanied by

squeaks and/or if you notice any slack, change the bearings of the rear suspension linkage, see 7.10.2 (DISASSEMBLING THE REAR SUSPENSION LINKAGE). N If, after you pressed the vehicle downwards, it returns to its original position very slowly, check if the rear suspension is adjusted correctly, see 2.31.2 (ADJUSTING THE REAR SHOCK ABSORBER). N If, after the adjustment, the defect persists, this means that the shock absorber bumps through and must therefore be reloaded.

 &2/.4 7(%%, Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check every 7500 km (4687 mi).
N Position the vehicle on the special front support

stand

N Spin the wheel in either direction by hand. N Make sure that the wheel rotation is regular and that

&.

there are no obstacles or noise, otherwise change the bearings, see 7.2.2 (DISASSEMBLING THE WHEEL). N Should any wobbling be noticed as the wheel spins, check the relevant components, see 7.2.3 (CHECKING THE COMPONENTS). N If, after various spins, the wheel continues to stop in the same place, the wheel needs balancing.

2 - 41

SERVICE AND SETTING UP

 2%!2 7(%%, Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check every 7500 km (4687 mi).
N Position the vehicle on the special rear support stand N Spin the wheel in either direction by hand. N Make sure that the wheel rotation is regular and that

RSV mille

&.

there are no obstacles or noise, otherwise change the bearings, see 7.2.2 (DISASSEMBLING THE WHEEL). N Should any wobbling be noticed as the wheel spins, check the relevant components, see 7.2.3 (CHECKING THE COMPONENTS). N If, after various spins, the wheel continues to stop in the same place, the wheel needs balancing.

 %8(!534 -!.)&/,$ .543 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Tighten the exhaust manifold nuts after the first 1000 km (625 mi) and then every 7500 km (4687 mi) or 8 months.

aWARNING
Allow the engine to cool to room temperature.
N Remove the side fairings, see 7.1.26 (REMOVING THE

SIDE FAIRINGS).
N Remove the front grille, see 7.1.33 (REMOVING THE

RADIATOR SPOILER).
N Torque the three nuts (1) of the front cylinder exhaust

manifold to specification.
N Torque the three nuts (2) of the rear cylinder exhaust

manifold to specification. Driving torque of nuts: 25 Nm (2.5 kgm).

2 - 42

RSV mille  $2)6% #(!). Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check and, where necessary, lubricate every 1000 km (625 mi). The vehicle is equipped with an endless chain, in which a ring link joint is not used. Chain type: 525

SERVICE AND SETTING UP

aCAUTION
The drive chain is provided with O rings among the links, in order to keep the grease inside them. Carry out the adjustment, lubrication, cleaning and change of the chain with great care.
N Position the vehicle on the appropriate rear support N Position the shifting lever in neutral. N Turn the rear wheel slowly by hand. N Further, check the chain and sprockets and make sure

stand &.

that they do not present: damaged rollers; loose pins; dry, rusty, crushed or seized links; excessive wear; lacking O rings; sprocket or teeth excessively worn or damaged.

aCAUTION
If the chain rollers are damaged, the pins are loose and/or the O rings are damaged or lacking, it is necessary to change the whole chain unit (both sprockets and chain), see 7.3.2 (DISASSEMBLING THE FINAL DRIVE UNIT). 2.35.1 CHECKING THE SLACK To check the slack, proceed as follows:
N Position the vehicle on the appropriate rear support N Position the shifting lever in neutral. N Make sure that the vertical oscillation, in an intermedi-

25 mm

stand &.

ate point between pinion and crown in the lower part of the chain, is about 25 mm. N Move the vehicle forwards, or turn the wheel, in order to be able to check the vertical oscillation of the chain even when the wheel turns; the slack must be constant in all the rotation phases of the wheel.

aCAUTION
If in some positions the slack is higher than in others, this means that there are crushed or seized links. To prevent the risk of seizures, lubricate the chain frequently, see 2.35.4 (CLEANING AND LUBRICATION). If the slack is uniform, but higher or lower than 25 mm, adjust it, see 2.35.3 (ADJUSTMENT).

aCAUTION
An excessive slackening of the chain may cause noise or make the chain rattle, with consequent wear of the shoe and of the chain guide plate. Incorrect maintenance may cause the untimely wear of the chain and/or damages to the pinion and/or the crown. Carry out the maintenance operations more frequently if you use the vehicle in difficult conditions or on dusty and/or muddy roads.

2 - 43

SERVICE AND SETTING UP

2.35.2 CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WEAR
N To put a driving chain under tension, see 2.35.3 (AD-

RSV mille

JUSTMENT).
N Count 17 pins ( 16 steps) on a branch of the chain and

measure the distance between the two end pins. If the distance is larger than the limit indicated below, replace the chain, see 7.11 (DISASSEMBLING THE DRIVING CHAIN). Limit of wear: 255.5 mm (MAX 0.5%). 2.35.3 ADJUSTMENT If after the check it is necessary to adjust the chain tension, proceed as follows: N Position the vehicle on the appropriate rear support stand &. N Loosen the nut (1) completely.

NOTE For the wheel centering fixed reference marks (2-3) are provided, which can be seen inside the chain tightener seats on the rear fork arms, before the wheel pin.
N Loosen the two lock nuts (4). N Act on the adjusters (5) and adjust the chain slack,

making sure that the reference marks (2-3) are correctly positioned on both sides of the vehicle. N Tighten the two lock nuts (4). N Tighten the nut (1). Wheel nut driving torque: 120 Nm (12.0 kgm).
N Check the chain slack, see 2.35.1 (CHECKING THE

4 1 5

SLACK). 2.35.4 CLEANING AND LUBRICATION Never wash the chain with water jets, steam jets, highpressure water jets and highly inflammable solvents. N Wash the chain with naphtha or kerosene. If it tends to rust quickly, intensify the maintenance intervals.

aCAUTION
Do not use trichloroethylene, petrol, or other similar liquids: their dissolving power may be excessive for this chain and, even more important, they are liable to damage the O-rings that hold the grease in the gaps between the rollers and the pins. Lubricate the chain every 1000 km (625 mi) or whenever necessary. N After washing the chain and letting it dry, lubricate it with spray grease for chains provided with sealing rings, see 1.6 (LUBRICANT CHART).

4 5

NOTE Do not use the vehicle soon after lubricating the

chain, since due to the centrifugal force the lubricant would be sprayed outwards and dirty the surrounding areas.

aCAUTION
Commercially available lubricants for chains may contain substances which are damaging for the chains O-rings. The standard chain is of the type 525. When replacing the chain, you are strongly recommended to use a chain of the exact same type.

2 - 44

RSV mille 2.35.5 INSPECTING THE DRIVING CHAIN GUIDE PLATE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Position the vehicle on the stand. N Remove the lower fairing, see 7.1.32 (REMOVING

SERVICE AND SETTING UP

THE LOWER FAIRING).

N Remove the clutch lever, see 3.2.2 (REMOVING THE

GEARSHIFT PEDAL).
N Remove the clutch control cylinder, see 3.2.3 (REMOV-

ING THE CLUTCH CONTROL CYLINDER).

N Unscrew and remove the three screws (1).

Driving torque of screws (1): 12 Nm (1.2 kgm).

NOTE
the clip.

Release the cable of the side stand switch from

N Remove the pinion protection case (2). N Remove the guide plate (3). N Make sure the guide plate (3) is not worn or damaged;

if so, replace with a new one.

2.35.6 INSPECTING THE DRIVING CHAIN SHOE

N Position the vehicle on the stand. N Make sure the shoe (4) is not worn or damaged; if so,

replace with a new one, see 7.1.51 (REMOVING THE DRIVING CHAIN SHOE).

2 - 45

SERVICE AND SETTING UP

 492%3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check condition of tyres after the first 1000 km (625 mi) and then after every 7500 km (4687 mi) or 8 months. The inflation pressure must be checked every month and at room temperature. This vehicle is provided with tubeless tyres. 2.36.1 CONDITION OF TREAD

RSV mille

The size of the tyres is indicated in the log-book and any dissimilarity is punishable by law. Using tyres with different dimensions may cause the instability of the vehicle, endangering its driving safety and manoeuvrability. Use only tyres recommended by APRILIA, see 1.5 (TECHNICAL SPECIFICATIONS). For further information, see 7.4 (TYRES).

aCAUTION

aCAUTION
Check the surface and the wear of the tyres, since tyres in bad conditions can impair both the grip and the controllability of the vehicle. Change the tyre when it is worn out or in case of puncture on the tread side, if the puncture is larger than 5 mm. Some types of tyres homologated for this vehicle are provided with wear indicators. There are several kinds of wear indicators. For more information on how to check the wear, contact your Dealer. Do not install tyres with air tube on rims for tubeless tyres and viceversa. Make sure that the inflation valves (1) always have their sealing caps on, to prevent the tyres from suddenly going flat. Change, repair, maintenance and balancing operations are very important and therefore they must be performed by qualified technicians with appropriate tools. MINIMUM TREAD DEPTH LIMIT (A): front and rear ....................................... 2 mm (- 3 mm). 2.36.2 INFLATION PRESSURE

aCAUTION
Periodically check the tyre inflation pressure at room temperature. If the tyres are hot, the measurement is not correct. Carry out the measurement especially before and after long rides. If the inflation pressure is too high, the ground unevenness cannot be dampened and is therefore transmitted to the handlebar, thus compromising the driving comfort and reducing the road holding during turns. If, on the contrary, the inflation pressure is too low, the tyre sides (2) are under greater stress and the tyre itself may slip on the rim or it may become loose, with consequent loss of control of the vehicle. In case of sudden braking the tyres could even come off the rims. Further, the vehicle could skid while turning. Inflation pressure Front: ................................................... 220 kPa (2.2 bar) [at full load 24010 kPa (2.4 0,1 bar)] Rear: .................................................... 250 kPa (2.5 bar) [at full load 27010 kPa (2.70,1 bar)]

aCAUTION
After repairing a tyre, have the wheels balanced. If the tyres are new, they may still be covered with a slippery film: drive carefully for the first miles. Do not oil the tyres with unsuitable fluids.

2 - 46

RSV mille  &5%, 0)0%3 Carefully read 1.2.1 (FUEL). Check the fuel pipes every 7500 km (4687 mi) or 8 months. Replace every four years. If you should encounter signs of wear, cracking, etc., replace the fuel pipes. High-pressure delivery pipe [~ 450 kpa (4.5 bar)]. Return pipe (2).

SERVICE AND SETTING UP

4 1

NOTE Make sure the male quick-release coupling (3) is properly inserted in the receptacle (4).
For further details see section 4 (FUEL SYSTEM).

 "2!+% !.$ #,54#( 0)0%3 Carefully read 1.2.4 (BRAKE FLUID) and 1.2.6 (CLUTCH FLUID). Check the pipes every 7500 km (4687 mi) or 8 months. Replace every four years. If you should encounter signs of wear, cracking, etc., replace the pipes.

 #//,).' 3934%- 0)0%3 Carefully read 1.2.5 (COOLANT). Check the cooling system pipes every 7500 km (4687 mi) or 8 months. If you should encounter signs of wear, cracking, etc., replace the cooling system pipes.

2 - 47

SERVICE AND SETTING UP

 4)'(4%.).' .543 !.$ 3#2%73 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check after the first 1000 km (625 mi) and then every 7500 km (4687 mi) or every 8 months. Check all the fastening elements carefully, especially all those components essential for safety, i.e.: right/left handlebar; front brake lever; clutch lever; fuel delivery pipe; front fork to plates; front fork / wheel pin clamps; front wheel; front brake pipe fittings; front brake discs; front brake calipers; engine; pinion; rear brake lever; rear fork; rear fork leverage; rear shock absorber; rear wheel; rear brake disc; rear brake caliper; rear brake pipe fittings.

RSV mille

aCAUTION
The fastening elements must be torqued to specification and LOCTITE applied, where indicated, see 2.41 (FASTENING ELEMENTS).

2 - 48

RSV mille  &!34%.).' %,%-%.43 Check, and where necessary, tighten after the first 1000 km (625 mi) and then every 7500 km (4687 mi) or 8 months.

SERVICE AND SETTING UP

aCAUTION
The fastening elements featured in the table must be torqued to specification using a torque spanner and LOCTITE applied, where indicated. The elements marked ( ) are particularly important for safety. ENGINE Fastening of engine to frame
Description Front connection Left-side upper and lower rear connection Adjusting bush right-side upper and lower rear connection Lock ring right-side upper and lower rear connection Screw right-side upper and lower rear connection Q.ty 2+2 2 2 2 2 Screw / nut M10 M10 M20x1.5 M20x1.5 M10 Nm 40 50 12 50 50 kgm 4.0 5.0 1.2 5.0 5.0 Note

Elements fastened to the engine

Description Engine oil inlet flange Engine oil drain plug Rear brake lever mount fastening Rear brake pump mount fastening Pinion fastening Clutch control cylinder fastening Pinion case fastening Fastening of fuel delivery pipe to throttle body Coolant drain screw Coolant thermistors Q.ty 2 2 1 1 2 1 3 3 1 1 2 Screw / nut M6 M6 M6 M8 M8 M10 M6 M6 M12x1.5 M6 M14 Nm 12 12 10 17 17 50 12 6 22 10 30 kgm 1.2 1.2 1.0 1.7 1.7 5.0 1.2 0.6 2.2 1.0 3.0 L243 Note

Carter
Description Grooved ball bearings for selector roller / MS casing Grooved ball bearings for selector roller / KS casing Grooved ball bearings for propeller shaft / KS casing Coolant pump idler gear / KS casing MS casing / KS casing MS casing / KS casing MS casing / KS casing MS casing / KS casing Casing Casing Oil filter cover Casing / injector 75 Bearing flange KS / MS Bearing flange KS Bearing flange MS Bearing flange MS Q.ty 1 1 2 1 13 1 5 1 1 1 2 1 2 2 1 1 Screw / nut Screw T.P. M6 x 13 Screw T.P. M6 x 13 Screw T.P. M6 x 13 Pin 10 Screw T.C.E.I. M6 x 65 Screw T.C.E.I. M6 x 80 Screw T.C.E.I. M6 x 45 Screw T.C.E.I. M6 x 25 Magnetic screw M12 x 1.5 Contact screw M10 Screw T.C.E.I. M6 x 20 Screw T.C.E.I. M6 x 10 Screw T.E. M8 x 45 Screw T.E. M8 x 25 Screw T.C.E.I. M8 x 20 Screw T.C.E.I. M6 x 20 Nm 11 11 11 11 11 11 11 20 4 11 6 25 25 25 11 kgm 1.1 1.1 1.1 1.1 1.1 1.1 1.1 2.0 0.4 1.1 0.6 2.5 2.5 2.5 1.1 L574 Note L243 L243 L243 L648

L243
FOLLOW

2 - 49

SERVICE AND SETTING UP

FOLLOW

=
Driving shaft, countershaft, gearshift
Q.ty 2 1 1 1 Screw / nut Screw T.C.E.I. M6 x 20 Nut M22 x 1.5 Nut M33 x 1.5 Screw T.C.E.I. M10 x 20 Nm 11 150 230 50 kgm 1.1 15.0 23.0 5.0

RSV mille

Description Positioning lever / positioner disc Differential shaft under KS KS driving shaft Countershaft under MS

Note L243 L243 L648

Oil pump
Description Oil pump Q.ty 1 Screw / nut Without head screw with double diameter M12 x 1.5 Screw T.C.E.I. M6 x 45 Nm kgm Note L648 Calking Upper and lower surfaces: L574

Oil pump casing Oil pump lid

1 4

11

1.1

Clutch
Description Secondary KS shaft Clutch spring Disengagement rod Complete diaphragm ring Clutch gear / clutch housing Q.ty 1 6 1 8 3 Screw / nut Nut M24 x 1.5 Screw T.E. M6 x 25 Locking nutM12 Screw T.C.E.I. M5 x 20 Screw T.E. M8 x 16 Nm 170 11 30 5 30 kgm 17.0 1.1 3.0 0.5 3.0 Note L648

L648

Head, cylinders
Description Camshaft support / head 1 (front) Head 1 (front) Head 2 (rear) Camshaft support / head 2 (rear) Camshaft support / head 2 (rear) Camshaft support / head 2 (rear) Head 2 (rear) Head / exhaust Head 2 (rear) Head / case Q.ty 8 2 1 4 2 2 1 6 1 8 Screw / nut Screw T.C.E.I. M6 x 30 Exhaust pipe M18 x 1.5 Exhaust pipe M18 x 1.5 Screw T.C.E.I. M6 x 30 Screw T.C.E.I. M6 x 45 Screw T.C.E.I. M6 x 55 Plug screw M18 x 1.5 Stud bolt M8 x 16/20 Angular union Stud bolt M10 x 171 Nm kgm 11 1.1 Manual tightening Manual tightening 11 1.1 11 1.1 11 1.1 Manual tightening 10 10 1.0 1.0 Note L243 L243

L243 L648 L574 L243

Cylinder / head

Head / stud bolt

Head / chain compartment Head 2 (rear) / bearing flange Head 2 (rear) / bearing flange

4 2 2

Not varnished cylinder version 28-30 Nm T.E. screws with shoul- (2.9-3.0 Kgm) der M8 x 45 Varnished cylinder version 25-28 Nm (2.5-2.8 Kgm) Not varnished head version 58 Nm (5.8 Kgm) Varnished head version 50-55 Nm Nut M10 (5.0-5.5 Kgm) Varnished head version (with nut on outer side) 58 Nm (5.8 Kgm) Screw T.C.E.I. M6 x 12 1.2 100 Screw T.E. M6 x 35 11 1.1 Screw T.E. M6 x 20 11 1.1
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RSV mille
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SERVICE AND SETTING UP

Description Head 2 (rear) / differential transmission - exhaust camshaft Drive gear / induction camshaft Head 1 (front) / gear - exhaust camshaft Head 2 (rear) /differential transmission upper side Valve cover Head 1 (front) / chain guide shoe Head Induction flange Cylinder / chain tightener Head 1 (front) Head 2 (rear) Cylinder bracket support shoe Cylinder bracket support shoe

Q.ty 3 6 3 1 10 2 4 4 2 1 1 2 2

Screw / nut Screw T.E. M6 x 14 Screw T.C.E.I. M6 x 11.5 Screw T.C.E.I. M6 x 11.5 Nut M14 x 1 Spacer screw M6 x 23 Spacer screw M6 x 16 Spark plug Screw T.C.E.I. M8 x 25 Plug screw M16 x 1.5 Coolant temperature thermistor Coolant temperature thermistor Screw T.C.E.I. M10 x 40 Nut M10

Nm 11 11 11 50 9 11 18 19 30 20 20 40 40

kgm 1.1 1.1 1.1 5.0 0.9 1.1 1.8 1.9 3.0 2.0 2.0 4.0 4.0

Note L243 L243 L243 L243

L243

Ignition system, starter motor

Description Driving shaft position sensor / flywheel cover Flywheel cover / generator Magnetic gear - unidirectional case Free wheel flange Magnetic gear cone Ignition / driving shaft Ignition device cover / MS casing Ignition device cover Camshaft position sensor / head 1 (front) Starter motor Q.ty 2 3 3 1 12 1 2 2 Screw / nut Taptite screw M6 x 16 Screw T.C.E.I M6 x 40 Screw T.C.E.I M8 x 16 Screw T.C.E.I M16 x 30 Screw T.C.E.I M6 x 35 Plug screw M24 x 1.5 Taptite screw M5 x 12 Screw T.C.E.I M6 x 30 Nm 11 11 30 130 11 3 4 11 kgm 1.1 1.1 3.0 13.0 1.1 0.3 0.4 1.1 L243 Note L243 L648 L648 L648 L648

Clutch cover, coolant pump

Description Coolant pump Clutch cover Coolant pump casing Coolant pump casing Clutch cover Clutch cover Clutch cover Q.ty 1 1 1 3 11 3 1 Screw / nut Impeller Oil pressure switch M10 x 1 Screw T.C.E.I M6 x 25 Screw T.C.E.I M6 x 55 Screw T.C.E.I M6 x 35 Screw T.C.E.I M8 x 40 Screw T.C.E.I M8 x 65 Nm kgm Manual tightening 15 11 11 11 19 19 1.5 1.1 1.1 1.1 1.9 1.9 L243 only for left central screw Note

L243

REAR FORK
Description Fork pin metal ring Fork pin lock ring Fork pin nut Caliper mount locking pin Chain tightener screw and nut Brake pipe grommet fastening Chain case fastening Chain tightener shoe fastening Rear mudguard fastening Q.ty 1 1 1 1 1+1 2 2 2 2+2 Screw / nut M30x1.5 M30x1.5 M20x1.5 M12 M8 M5 M5 M5 M5 4 4 2 3 Nm 12 60 90 50 man. 0.4 0.4 0.2 0.3
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kgm 1.2 6.0 9.0 5.0

Note

L243

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SERVICE AND SETTING UP

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SIDE STAND
Q.ty 2 1 1 1 Screw / nut M10 M10x1.25 M6 M10x1.25 Nm 40 10 10 25 kgm 4.0 1.0 1.0 2.5 Note

Description Fastening of stand plate to frame Stand fastening pin Switch fastening screw Lock nut

FRONT SUSPENSION Front fork

Description Fastening of upper plate on fork tubes Fastening of upper plate on fork tubes Steering head metal ring Steering head lock ring Upper plate fastening bush Lower plate travel-end bush fastening screw Closing of fork / wheel pin clamps Q.ty 1+1 2+2 1 1 1 1+1 2-2 Screw / nut M8 M8 M35x1 M35x1 M29x1 M8 M8 Nm 25 25 40 80 22 22 kgm 2.5 2.5 4.0 8.0 2.2 2.2 Note

man. +90

Steering shock absorbers

Description Fastening of shock absorber collar on dashboard/front fairing mount Tube end lock nut Screw fastening collar on shock absorber Fastening of shock absorber tube on lower plate Q.ty 1 1 1 1 Screw / nut M6 M8 M5 M6 Nm 12 12 5 12 kgm 1.2 1.2 0.5 1.2 Note

REAR SUSPENSION Shock absorber

Description Fastening of shock absorber to frame Q.ty 1 Screw / nut M10 Nm 50 kgm 5.0 Note

Linkage
Description Fastening of single connecting rod to frame Fastening of single/double connecting rod to frame Fastening of double connecting rod fork Fastening of double connecting rod / shock absorber Q.ty 1 1 1 1 Screw / nut M10 M10 M10 M10 Nm 50 50 50 50 kgm 5.0 5.0 5.0 5.0 Note

ELECTRICAL SYSTEM
Description Fastening of battery clamping bracket Fastening of horn mount Fastening of speed sensor on rear brake caliper mount Fastening of rear indicators Fastening of electronic unit protection case Fastening of voltage regulator Fastening of front indicators Fastening of coil to mount Fastening of rear light to rear fairing end Fastening of headlight to front fairing Fastening of relay box to dashboard/front fairing mount Fastening of fuse box to dashboard/front fairing mount Fastening of earth to frame Q.ty 1 1 1 2 3 2 2 8 2 3 1 2 2 1 Screw / nut M6 M8x1.25 M6 M6 SWP3.9 M6 M6 M5 SWP3.9 SWP3.9 M6 M6 M6 M6 Nm 12 25 12 2-3 1 12 2-3 5 1.5 1.5 4 4 3 12 kgm 1.2 2.5 1.2 0.2-0.3 0.1 1.2 0.2-0.3 0.5 0.15 0.15 0.4 0.4 0.3 1.2
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Note

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RSV mille

SERVICE AND SETTING UP

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AIR FILTER CASING
Q.ty 7 6 4 1 Screw / nut M5 M6 SWP3.9 SWP3.9 Nm 4 8 1 1.5 kgm 0.4 0.8 0.1 0.15 Note

Description Fastening of air filter casing cover Fastening of air filter casing to throttle body Fastening of intake conveyors Fastening of air sensor support plate

FRONT WHEEL
Description Wheel pin nut Q.ty 1 Screw / nut M25x1.5 Nm 80 kgm 8.0 Note

REAR WHEEL
Description Fastening of sprocket on sprocket holder Wheel pin nut Q.ty 5 1 Screw / nut M10 M25x1.5 Nm 50 120 kgm 5.0 12.0 Note

COOLING SYSTEM
Description Thermal switch on 3-way manifold Fastening of electrofan mount Fastening of electrofan motor to mount Radiator coolant drain screws Fastening of expansion tank to coils mount Fastening of expansion tank cap Fastening of coolant filler neck Q.ty 1 2+2 3+3 1+1 2 1 1 Screw / nut M14x1.5 M6 M4 M6 M6 M28x3 M6 10 Nm 30 6 2 10 10 man. 1.0 kgm 3.0 0.6 0.2 1.0 1.0 L243 L572 Note L572

BRAKING SYSTEMS Front system

Description Fastening of right and left brake caliper Fastening of brake fluid tank Fastening of brake fluid tank bracket Fastening of brake discs Fastening of front brake pipe Brake fluid bleeder Q.ty 2+2 1 1 6+6 1 3 Screw / nut M10x1.25 M6 M6 M8 M10x1 M10x1 Nm 50 5 12 30 20 10 kgm 5.0 0.5 1.2 3.0 2.0 1.0 L243 Note

Rear system
Description Brake caliper fastening Brake lever pin Fastening of brake fluid tank Brake pump fastening Brake rod lock nut Brake disc fastening Brake pipe fastening Q.ty 2 1 1 2 1 5 1 Screw / nut M8 M8 M5 M6 M6 M8 M10x1 30 20 Nm 25 15 1 12 man. 3.0 2.0
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kgm 2.5 1.5 0.1 1.2

Note L243

L243

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SERVICE AND SETTING UP

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CLUTCH CONTROL
Q.ty 1 1 1 1 Screw / nut M10x1 M6 M5 M10x1 Nm 20 12 3 10 kgm 2.0 1.2 0.3 1.0 Note

Description Fastening of clutch fluid pipe Fastening of fluid tank bracket Fastening of clutch fluid tank on mount Clutch fluid bleeder

EXHAUST SYSTEM
Description Fastening of exhaust pipes to engine Exhaust silencer fastening Q.ty 3+3 1 Screw / nut M8 M8 Nm 25 25 kgm 2.5 2.5 Note

FUEL TANK Fuel pump flange

Description Fuel return fitting Fastening of pump mount to flange Fastening of electric terminals on flange Closing of fuel return Fastening of fuel delivery pipe on flange Petrol level sensor on pump mount Fastening of fuel pump cables on flange Q.ty 1 3 2 1 1 2 2 Screw / nut M6 M5 M5 M6 M12x1.5 SWP 2.9x12 M6 Nm 6 4 5 10 22 1.5 10 kgm 0.6 0.4 0.5 1.0 2.2 0.15 1.0 L243 Note L243

Tank
Description Fastening of cap on tank Fastening of fuel pump flange on tank Fastening of tank front on frame Fastening of tank rear on mount Q.ty 3 8 2 1 Screw / nut M5 M5 M6 M6 Nm 5 7 12 12 kgm 0.5 0.7 1.2 1.2 Note

ENGINE OIL TANK AND RADIATOR

Description Tank upper fastening screw Tank fastening nuts Oil filter Oil drain plug Oil level pipe fittings Radiator fastening screws Q.ty 1 2 1 1 2 3 Screw / nut M6 M6 M20x1.5 M8 M10x1 M6 Nm 10 10 30 15 20 12 kgm 1.0 1.0 3.0 1.5 2.0 1.2
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Note

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SERVICE AND SETTING UP

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FRAME / FAIRINGS
Q.ty 3 2 2 4 1+1 4 2 2 14 6 2+2 4 4 2 4 2 4 6 2+2 2 8 3 2 4 2 2 4 4 4 4 4 4 Screw / nut M6 M5 M5 M5 M6 M6 M5 M5 SWP 3.9 M6 M5 M5 M6 M6 M6 M6 M6 M5 M5 M6 SWP 2.9 M6 M6 M6 M6 M6 M8 M8 M5 M5 M10 M6 Nm 5 2 6 5 8 5 4 4 2 5 front 1 rear 2 2 5 5 5 5 4 2 upper 5 lower 3 12 1 5 12 12 10 12 25 25 6 6 50 12 kgm 0.5 0.2 0.6 0.5 0.8 0.5 0.4 0.4 0.2 0.5 0.1 0.2 0.2 0.5 0.5 0.5 0.5 0.4 0.2 0.5 0.3 1.2 0.1 0.5 1.2 1.2 1.0 1.2 2.5 2.5 0.6 0.6 5.0 1.2
FOLLOW

Description Radiator spoiler fastening Fastening of number plate holder to rear mudguard extension Fastening of reflector holder to number plate holder Front mudguard fastening Rearview mirror fastening screws Fastening of rearview mirror mounts and front fairing to mount Lower fastening of front fairing to conveyors Lower fastening of front fairing (on upper part) Fastening of conveyor covers Fastening of conveyors to frame and mount Fastening of side fairing upper panel Fastening of dashboards upper protection moulding Fastening of lower fairing to frame Fastening of silencer protection to lower fairing Fastening of sides Fastening of saddle support bush and lower moulded cover Fastening of saddle support lower moulded cover Fastening of rear fairing to saddle support lower moulded cover Fastening of rear fairing end to rear fairing Fastening of rear fairing / passenger grab strap Fastening of internal fairing and side fairing Fastening of dashboard to mount Fastening of riderss saddle Fastening of riderss saddle front mount Fastening of passenger seat lock Fastening of passenger seat lock key-operated control Fastening of passenger footrest supports Fastening of riderss footrest supports Fastening of riderss footrest protection Fastening of rear mudguard Fastening of saddle support Fastening of coil mounts

Note

2 - 55

SERVICE AND SETTING UP

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RSV mille

=
RIGHT/LEFT HANDLEBARS AND CONTROLS
Q.ty 2 2 2 2 1 1 2 2 Screw / nut M6 M18x1 M8 M6 M5 M4 M5 M5 Nm 12 35 25 12 1.5 1 8 8 kgm 1.2 3.5 2.5 1.2 0.15 0.1 0.8 0.8 Note

Description Fastening of anti-vibration weights Anti-vibration weights metal ring Fastening of right/left handlebars to the fork Handlebars lock screw Fastening of left dimmer switch Fastening of right dimmer switch Fastening of front brake lever Fastening of clutch lever

Notes: L243 = fasten with LOCTITE 243 L572 = fasten with LOCTITE 572 L574 = fasten with LOCTITE 574 L648 = fasten with LOCTITE 648 man. = fasten by hand Steel/aluminium fastening screws with similar coefficient of elasticity SCREW
M4 M5 M6 M8 M10 M12

Nm
3 6 12 25 50 80

kgm
0.3 0.6 1.2 2.5 5.0 8.0

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RSV mille

1 3
ENGINE

3 -1

ENGINE

RSV mille 3.6.13 REPLACING AND INSTALLING THE CONNECTING RODS ....................... 3-51 3.6.14 COUNTERSHAFT AND COUNTERSHAFT MECHANISM .............. 3-52 3.6.15 GEARSHIFT .............................................. 3-53 3.6.16 GEAR SELECTION ................................... 3-58 3.6.17 CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY................... 3-59 3.6.18 DISASSEMBLING THE COMPLETE CLUTCH HOUSING ..... 3-61 3.6.19 CLUTCH COVER ...................................... 3-62 3.6.20 SUPPORT BUSHES.................................. 3-62 3.6.21 COOLANT PUMP ...................................... 3-64 3.6.22 TIMING DRIVE ASSEMBLY ..................... 3-66 3.6.23 HEAD AND CAMSHAFT ........................... 3-67 3.6.24 DISASSEMBLING THE INTAKE AND EXHAUST VALVES ... 3-68 3.6.25 CAMSHAFT AND CAMSHAFT BUSHES . 3-69 3.6.26 UPPER COUNTERSHAFT ........................ 3-70 3.6.27 DISASSEMBLING AND ASSEMBLING THE UPPER COUNTERSHAFT BALL BEARINGS AND OIL SEAL ........... 3-71 3.6.28 VALVE GUIDE........................................... 3-72 3.6.29 VALVES..................................................... 3-74 3.6.30 CYLINDER................................................. 3-77 3.6.31 PISTON AND GUDGEON PIN .................. 3-78 3.6.32 STARTER MOTOR DRIVE ASSEMBLY ... 3-80 3.6.33 IGNITION GENERATOR ........................... 3-82 3.6.34 SPARK PLUGS ......................................... 3-84 3.6.35 DRIVING CHAIN PINION .......................... 3-84 3.6.36 STARTER MOTOR .................................... 3-84  2%!33%-",).' 4(% %.').% ................ 3-85 3.7.1 ASSEMBLING THE GEARSHIFT ............... 3-85 3.7.2 ASSEMBLING THE DRIVING SHAFT AND COUNTERSHAFT ............................... 3-86 3.7.3 ASSEMBLING THE ENGINE CASING ....... 3-87 3.7.4 ASSEMBLING THE GEAR SELECTION MECHANISM ............................................... 3-88 3.7.5 CHECKING THE GEAR SELECTION MECHANISM ............................................... 3-89 3.7.6 ASSEMBLING THE OIL PUMP .................. 3-90 3.7.7 ASSEMBLING THE DRIVE ASSEMBLY 2 (REAR) .................................................. 3-91 3.7.8 ASSEMBLING THE COOLANT PUMP DRIVE .................... 3-93 3.7.9 ASSEMBLING THE PRIMARY TRANSMISSION AND CLUTCH ................. 3-94 3.7.10 ASSEMBLING THE PISTON AND CYLINDER 2 (REAR)............................. 3-96 3.7.11 ADJUSTING VALVE CLEARANCE .......... 3-99 3.7.12 ASSEMBLING HEAD 2 (REAR) CAMSHAFT ............................................. 3-100 3.7.13 ASSEMBLING HEAD 2 (REAR) TIMING DRIVE ASSEMBLY.................... 3-101 3.7.14 ASSEMBLING HEAD 1 TIMING DRIVE ASSEMBLY ................................. 3-103 3.7.15 ASSEMBLING THE STARTER MOTOR DRIVE ASSEMBLY AND IGNITION SYSTEM.... 3-105 3.7.16 ASSEMBLING THE PISTON AND CYLINDER 1 (FRONT) ........................ 3-106 3.7.17 ASSEMBLING HEAD 1 (FRONT) CAMSHAFT ............................................. 3-109 3.7.18 ASSEMBLING HEAD 1 (FRONT) TIMING DRIVE ASSEMBLY.................... 3-110 3.7.19 ASSEMBLING THE VALVE COVER ...... 3-111 3.7.20 ASSEMBLING THE IGNITION COVER .. 3-112 3.7.21 ASSEMBLING THE CLUTCH HOUSING 3-113 3.7.22 ASSEMBLING THE STARTER MOTOR 3-115 3.7.23 ASSEMBLING THE DRIVING CHAIN PINION ................ 3-115  %.').% #(%#+3 35"3%15%.4 4/ 2%!33%-",9 ...................................... 3-116 3.8.1 BLEEDING THE ENGINE OIL CIRCUIT ... 3-116 3.8.2 CHECKING THE ENGINE OIL PRESSURE.................. 3-116 3.8.3 SYNCHRONIZING CYLINDERS ............... 3-116

ENGINE
4!",% /& #/.4%.43  4%#(.)#!,).&/2-!4)/. .......................... 3-3 3.1.1 TECHNICAL DATA ....................................... 3-3 3.1.2 MAINTENANCE INTERVALS ....................... 3-3 3.1.3 TROUBLESHOOTING ................................... 3-3 3.1.4 SEALANTS .................................................... 3-3 3.1.5 LUBRICANTS ................................................ 3-3 3.1.6 SPECIAL TOOLS & .................................... 3-3 3.1.7 DRIVING TORQUE ........................................ 3-3 3.1.8 PRECONDITIONS TO BE MET WHEN PERFORMING MAINTENANCE AND REPAIR WORK ..................................... 3-3 3.1.9 GENERAL INDICATIONS ON MAINTENANCE AND REPAIR WORK ... 3-3  %.').% 0!243 7()#( #!. "% $)3!33%-",%$ 7)4(/54 2%-/6).' 4(% %.').% &2/- 4(% &2!-% ............. 3-4 3.2.1 REMOVING THE EXHAUST PIPES .............. 3-6 3.2.2 REMOVING THE GEARSHIFT PEDAL ........ 3-7 3.2.3 REMOVING THE CLUTCH CONTROL CYLINDER .......... 3-7  2%-/6).' 4(% 7(/,% %.').% &2/- 4(% &2!-% ...................................... 3-8  2%&)44).' 4(% 7(/,% %.').% /. 4(% &2!-% ........................................... 3-17  $)3!33%-",).' 4(% %.').% ............... 3-18 3.5.1 ENGINE DISASSEMBLY SEQUENCE ....... 3-18 3.5.2 REMOVING THE STARTER MOTOR ......... 3-20 3.5.3 DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON .................................... 3-20 3.5.4 DISASSEMBLING CYLINDER 2 (REAR), HEAD AND PISTON .................................... 3-23 3.5.5 REMOVING THE FLYWHEEL COVER AND IGNITION SYSTEM ............................. 3-26 3.5.6 DISASSEMBLING CYLINDER 1 (FRONT) TIMING DRIVE ASSEMBLY ........................ 3-27 3.5.7 REMOVING THE DRIVING CHAIN PINION AND OIL FILTER CARTRIDGE ................... 3-28 3.5.8 REMOVING THE CLUTCH COVER ............ 3-29 3.5.9 DISASSEMBLING THE CLUTCH ............... 3-30 3.5.10 DISASSEMBLING THE COUNTERSHAFT MECHANISM AND PRIMARY TRANSMISSION ............. 3-31 3.5.11 DISASSEMBLING CYLINDER 2 (REAR) TIMING DRIVE ASSEMBLY ........ 3-32 3.5.12 DISASSEMBLING THE OIL PUMP........... 3-33 3.5.13 DISASSEMBLING THE GEAR SELECTION MECHANISM........................ 3-34 3.5.14 SPLITTING THE ENGINE CASING OPEN 3-35 3.5.15 DISASSEMBLING THE DRIVING SHAFT AND COUNTERSHAFT 3-35 3.5.16 DISASSEMBLING THE GEARSHIFT ....... 3-36  7/2+ /. 4(% ).$)6)$5!, 0!243 ...... 3-37 3.6.1 ENGINE CASING ........................................ 3-37 3.6.2 ENGINE HALF-CASING, CLUTCH SIDE ... 3-38 3.6.3 ENGINE HALF-CASING, FLYWHEEL SIDE. 3-38 3.6.4 ENGINE HALF-CASING BALL BEARINGS AND OIL SEALS ........... 3-39 3.6.5 ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT .. 3-41 3.6.6 REPLACING THE ENGINE CASING CYLINDRICAL PINS .................................... 3-45 3.6.7 NEUTRAL GEAR INDICATION................... 3-46 3.6.8 ASSEMBLING THE ENGINE HALF-CASING 3-46 3.6.9 COMPLETE OIL-SPRAY PIPE ................... 3-46 3.6.10 OIL PUMP AND OIL PUMP DRIVE ASSEMBLY ............................................... 3-47 3.6.11 DRIVING SHAFT ....................................... 3-49 3.6.12 DISASSEMBLING THE CONNECTING RODS........................ 3-50

3 -2

RSV mille  4%#(.)#!, ).&/2-!4)/. 3.1.1 TECHNICAL DATA See 1.5 (TECHNICAL SPECIFICATIONS). 3.1.2 MAINTENANCE INTERVALS See 2.1.1 (REGULAR SERVICE INTERVALS CHART). 3.1.3 TROUBLESHOOTING See 8.1 (TROUBLESHOOTING). 3.1.4 SEALANTS See 1.7 (CONSUMABLES). 3.1.5 LUBRICANTS See 1.6 (LUBRICANT CHART). 3.1.6 SPECIAL TOOLS

ENGINE

See 1.8 (SPECIAL TOOLS &). 3.1.7 DRIVING TORQUE See 2.41 (FASTENING ELEMENTS). 3.1.8 PRECONDITIONS TO BE MET WHEN PERFORMING MAINTENANCE AND REPAIR WORK

aWARNING
During the assembly phase, bear in mind the engines weight (approx. 65 kg) and centre of gravity: support accordingly. Take care around any potentially hazardous points where you might be squashed or cut.

aCAUTION
The maintenance of engines and systems calls for specific experience and the use of special tools. Any maintenance and repair work must be performed by suitably trained technical personnel only.

NOTE Comply with the instructions furnished by the manufacturer of the vehicle.
3.1.9 GENERAL INDICATIONS ON MAINTENANCE AND REPAIR WORK Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

3 -3

ENGINE
 %.').% 0!243 7()#( #!. "% $)3!33%-",%$ 7)4(/54 2%-/6).' 4(% %.').% &2/- 4(% &2!-% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The parts underlined can be removed and refitted without removing the engine from the frame.

RSV mille

aCAUTION
This chapter describes the relevant procedures progressively and in sequential order. Any reference to operations from other chapters must be interpreted logically in order to avoid components being removed unnecessarily. Only perform those operations necessary to remove the component in question. TOP SIDE Tappet cover (1), see 3.5.3 [DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON]. Tappet cover (2), head, cylinder and rear piston, see 3.5.4 [DISASSEMBLING CYLINDER 2 (REAR), HEAD AND PISTON]. Front (3) and rear (4) cylinder intake flange. Camshaft position sensor and camshafts, see 3.6.23 (HEAD AND CAMSHAFTS - DISASSEMBLY). Chain, chain tightener and front and rear cylinder timing drive assembly, see 3.5.6 [DISASSEMBLING CYLINDER 1 (FRONT) TIMING DRIVE ASSEMBLY] and 3.5.11 [DISASSEMBLING CYLINDER 2 (REAR) TIMING DRIVE ASSEMBLY]. Valves, see 3.6.24 (DISASSEMBLING THE INTAKE AND EXHAUST VALVES).

FRONT SIDE Front cylindrical exhaust pipe, see 3.2.1 (REMOVING THE EXHAUST PIPES). Starter motor (5), see 3.5.2 (REMOVING THE STARTER MOTOR).

REAR SIDE Rear cylindrical exhaust pipe, see 3.2.1 (REMOVING THE EXHAUST PIPES).

3 -4

RSV mille LEFT SIDE Rear cylinder spark plugs (6-7), see 2.7 (SPARK PLUGS). Drive pinion protection case (8), see 2.35.2 (CHECKING THE DRIVING CHAIN, PINION AND SPROCKET WEAR). Gearshift lever, see 3.2.2 (REMOVING THE GEARSHIFT PEDAL). Rear cylinder coolant thermistor (9), see 5.5 (REMOVING THE COOLANT THERMISTORS). Engine oil filter (10), see 2.14 (CHANGING THE ENGINE OIL AND THE OIL FILTER). Neutral gear switch (11). Clutch control cylinder (12), see 3.2.3 (REMOVING THE CLUTCH CONTROL CYLINDER). Flywheel cover (13) and ignition system, see 3.5.5 (REMOVING THE FLYWHEEL COVER AND IGNITION SYSTEM). Engine oil tank (14), see 7.1.49 (REMOVING THE ENGINE OIL TANK). RIGHT SIDE

ENGINE

Front cylinder coolant thermistor (15), see 5.5 (REMOVING THE COOLANT THERMISTORS). Front cylinder spark plugs (16 - 17), see 2.7 (SPARK PLUGS). Coolant pump (18), see 3.6.21 (COOLANT PUMP). Engine oil pressure sensor (19). Clutch cover (20) and clutch assembly, see 3.5.8 (REMOVING THE CLUTCH COVER) and 3.5.9 (DISASSEMBLING THE CLUTCH).

3 -5

ENGINE
3.2.1 REMOVING THE EXHAUST PIPES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

RSV mille

aWARNING
Allow the engine to cool to room temperature.
N Remove the exhaust silencer, see 7.1.47 (REMOVING

THE EXHAUST SILENCER).

N Remove the lower fairing, see 7.1.32 (REMOVING

THE LOWER FAIRING).

N Remove the radiator spoiler, see 7.1.33 (REMOVING

THE RADIATOR SPOILER).

N Unhook the two springs (1 - 2) from the relevant hooks

on the exhaust manifold (3).

N Remove the two springs (1 - 2).

aCAUTION
Check the two springs (1 - 2) and, where necessary, replace them.
N Loosen and remove the three nuts (4) fastening the

flange of the exhaust pipe (5) to the front cylinder. Driving torque of nuts (4): 25 Nm (2.5 kgm).
N Loosen and remove the three nuts (6) fastening the

flange of the exhaust pipe (7) to the rear cylinder. Driving torque of nuts (6): 25 Nm (2.5 kgm).

aCAUTION
When slipping the exhaust pipes (5 - 7) off the relevant cylinders, take care not to damage the thread of the fastening stud bolts.
N Move the exhaust manifold (3), together with the ex-

haust pipe (7), back and slightly downwards until the exhaust pipes flange is released from the stud bolts on the rear cylinder. N Twisting gradually one way and the other, lift the exhaust pipe (7) until it slides off the exhaust manifold (3). N Turn the exhaust pipe (7) and remove it as illustrated. N Twisting gradually one way and the other, slip the exhaust manifold (3) off the exhaust pipe (5). N Move the exhaust pipe (5) forwards until the flange is released from the stud bolts on the front cylinder. N Turn the exhaust pipe (5) and remove it as illustrated.

aCAUTION
Check and, where necessary, replace the gaskets (8 - 9) with two new ones of the same type. Plug the engines exhaust pipe openings so as to prevent any foreign bodies entering.

3 -6

RSV mille 3.2.2 REMOVING THE GEARSHIFT PEDAL

ENGINE

aCAUTION
Before removing the gearshift pedal, mark the pedal and shaft (see figure) so that it can be refitted correctly.
N Position the vehicle on the stand. N Loosen and remove the screw (1). N Slide off the gearshift pedal (2).

3.2.3 REMOVING THE CLUTCH CONTROL CYLINDER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.6 (CLUTCH FLUID).
N Remove the left side fairing, see 7.1.26 (REMOVING

THE SIDE FAIRINGS).

N Unscrew and remove the screws (3).

Driving torque of screws (3): 12 Nm (1.2 kgm).

N Slide off the cylinder (4).

aCAUTION
Perform the operations with the utmost care: the cylinder (4) remains connected to the pipe. Once the cylinder (4) has been removed, do not pull the clutch lever as the piston is liable to come out of its slot, resulting in the spillage of clutch fluid. For safetys sake, secure the piston, locking it in place with a plastic clamp (see figure).
N Where necessary, remove the flange (5).

3 -7

ENGINE
 2%-/6).' 4(% 7(/,% %.').% &2/4(% &2!-%

RSV mille

aCAUTION
The engine must be removed by an authorized centre or by an APRILIA Official Dealer only. Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

aCAUTION
The removal of the engine is a particularly complex operation. Therefore, inspect the vehicle carefully before proceeding. This chapter describes the relevant procedures progressively and in sequential order. Any reference to operations from other chapters must be interpreted logically in order to avoid components being removed unnecessarily. Only perform those operations necessary to remove the component in question. Before going ahead with the following operations, 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. Dry weight of the engine ~ 65 kg.
N Turn the ignition switch to position . N Position the vehicle on the relevant rear support stands N Disconnect the negative cable () and positive cable (+)

&.

from the battery, in that order.

aCAUTION
When refitting, first connect the positive cable (+) and then the negative one ().
N Remove the fuel tank, see 7.1.5 (COMPLETE REMOV-

AL OF THE FUEL TANK).

N Remove the two side fairings, see 7.1.26 (REMOVING

THE SIDE FAIRINGS).

N Remove the lower fairing, see 7.1.32 (REMOVING

THE LOWER FAIRING).

N Remove the radiator spoiler, see 7.1.33 (REMOVING

THE RADIATOR SPOILER).

aCAUTION
Mark the cables so as to prevent them being mixed up by mistake during refitting.
N Disconnect the following electric connectors in the or-

der given: generator (1); camshaft position sensor (2); front cylinder coolant thermistor (3); rear cylinder coolant thermistor (4).

aCAUTION
When refitting, make sure the electric connectors are plugged in properly.

3 -8

RSV mille
N Unscrew and remove the screw (5) and disconnect the

ENGINE

cable from the neutral gear switch (6).

N Move the protection element (7) aside and disconnect

the cable from the engine oil pressure sensor (8).

N Move the protection element (9) aside, unscrew and re-

move the nut (10), recover the washer and disconnect the starter motor cable. N Remove the rear brake lever and relevant mount (11), see 7.1.46 (REMOVING THE REAR BRAKE LEVER).

aCAUTION
Move the mount (11) and secure it in place, taking extreme care as it remains connected to the electric cable by means of the brake light switch (12).
N Remove the rear brake pump (13), see 7.6.4 (REMOV-

ING THE BRAKE PUMP).

aCAUTION
Move the rear brake pump (13) and secure it in place, taking extreme care as it remains connected to the brake fluid pipes. The brake fluid tank (14) must be held vertically to prevent the fluid spilling out.
N Remove the clutch control cylinder, see 3.2.3 (REMOV-

ING THE CLUTCH CONTROL CYLINDER).

N Remove the drive pinion, see 7.1.51 (REMOVING THE

DRIVING CHAIN SHOE).

N Remove the gearshift lever, see 3.2.2 (REMOVING

THE GEARSHIFT PEDAL).

N Remove the expansion tank, see 5.9 (REMOVING THE

EXPANSION TANK).

3 -9

ENGINE
N # Disconnect the spark plug caps (15).

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aCAUTION
Use a degreasing detergent, brushes and rags to clean the engines outer surfaces. Avoid damaging rubber and plastic parts with corrosive or penetrating detergents and solvents. Should the use of a steam cleaner prove necessary, do not point the high-pressure jets of water, steam or air at the following parts: wheel hubs, controls on the right and left handlebars, brake pumps, instruments and gauges, silencer openings, document compartment, ignition switch/steering lock, electrical components.
N Clean the outside of the engine thoroughly. N Remove the exhaust pipes, see 3.2.1 (REMOVING

THE EXHAUST PIPES).

N # Disconnect the electric connector (20) from the elec-

trofan.
N Disconnect the electric cables from the horn.

aCAUTION
When refitting, make sure the electric connectors are plugged in properly.

aCAUTION
Mark the coupling and pipes so as to prevent them being swapped over by mistake during refitting.
N Remove the engine oil tank (16), see 7.1.49 (REMOV-

ING THE ENGINE OIL TANK) together with the engine oil radiator (17), see 7.1.50 (REMOVING THE ENGINE OIL RADIATOR), disconnecting the pipes connecting them to the engine (18 - 19). N Remove the radiators (21 - 22) joined together, see 5.2 (REMOVING THE RADIATORS), complete with electrofans, horn and mounts.

3 - 10

RSV mille
N Remove the complete throttle body (23), see 4.8.2 (RE-

ENGINE

MOVING THE THROTTLE BODY).

NOTE The three-way manifold (24) may be kept fitted.

Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N To release the head off the pipe clamp (25 - 26 - 27). N Remove the complete thermal expansion valve (28),

see 5.6 (REMOVING THE THERMAL EXPANSION VALVE) together with the three couplings. N Slip the coupling (29) off the coolant pump.

aCAUTION
Free all the cables and pipes from the respective clamps located at intervals along their routes. Procure an equal number of clamps to be used for refitting. Plug all openings on the engine, pipes and couplings to prevent foreign bodies getting in.
N Gather the electric 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.

3 - 11

ENGINE
N Unscrew and remove the screws (30) and recover the

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plate (31).

NOTE

Have the appropriate special tool & (32) to hand cod. 8140183 (engine lifting eye hook), a hoist (33) and bands (34) for the lifting operation.

Driving torque of screws (30): 40 Nm (4.0 kgm).

aWARNING
The hoist (33) and the bands (34) for the lifting operation must be suitable for safely bearing the weight of the engine. The engine weight approx. 65 kg.
N Fasten the special engine lifting hook on and secure it

in place with the screws (30).

N Hook the bands (34) onto the hoist (33) and the hook

(32) as illustrated.

aWARNING
The entire engine and hoist setup must be stable, ensuring that the subsequent operations can be performed safety.
N Lift the hoist arm (33) until the bands (34) are taught.

aCAUTION
The hoist arm (33) must be lifted just enough for the engine to be held in place during the removal of the elements fastening it to the frame.

3 - 12

RSV mille

ENGINE

NOTE The elements fastening the engine to the frame must be removed in the order given:
RIGHT SIDE A B C D. LEFT SIDE E F G H.

3 - 13

ENGINE
N Holding the inside nut (35) still, loosen the screw (36).

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Driving torque of nut (35) and screw (36): 50 Nm (5.0 kgm).

N Holding the inside nut (39) still, loosen the screw (40).

Driving torque of nut (39) and screw (40): 50 Nm (5.0 kgm).

N Unscrew and remove the two screws (43) and recover

the relevant washers (44). Driving torque of screws (43): 40 Nm (4.0 kgm).
N Recover the two spacers (45). N Unscrew and remove the two screws (46) and recover

the washers (47). Driving torque of screws (46): 40 Nm (4.0 kgm).

3 - 14

RSV mille
N Use the special setscrew spanner

ENGINE

& (53) (cod. 8140203) to loosen and remove the lock rings (41 - 37).
Driving torque of lock rings (41 - 37): 50 Nm (5.0 kgm).

N Unscrew the adjusting bushes (38 - 42) all the way until

they touch the frame. Driving torque of adjusting bushes (38 - 42): 10 Nm (1.0 kgm).

aCAUTION
When reassembling, screw the adjusting bushes (38 42) on by hand all the way until they touch the engine before torquing them to specification.
N Holding the inside nut (35) still, loosen and remove the

screw (36).
N Holding the inside nut (39) still, loosen and remove the

screw (40).
N Holding the inside nut (51) still, loosen and remove the

screw (52). Driving torque of nut (51) and screw (52): 50 Nm (5.0 kgm).
N Holding the inside nut (48) still, loosen and remove the

screw (49). Driving torque of nut (48) and screw (49): 50 Nm (5.0 kgm).
N Recover the spacer (50).

3 - 15

ENGINE

RSV mille

aWARNING
The engine is now freed and has nothing fastening it. Handle with care: watch your fingers and limbs. Clear the floor, on which the engine is to be set down, of any tools and clean thoroughly.
N Lift the hoist arm by a few millimeters in order to re-

lease the engine from the frame.

N Lower the hoist arm until the engine is gently set down

on the floor.
N Secure the engine so that it does not fall over if poorly

balanced.
N Unhook the bands (34) from the hoist. N Slide the bands (34) out from the frame. N Move the engine from under the frame. N Hook the bands (34) back up to the engine.

NOTE If the engine is to be worked on, set it on the relevant stand & (54) (cod. 8140187 + 8140188).

aCAUTION
If no work is to be performed on the engine, leave it rested on the floor and attached to the bands (34) and hoist for extra safety.
N Clean the outside of the engine thoroughly.

aCAUTION
Use a detergent, brushes and rags to clean the engines outer surfaces. Avoid damaging rubber and plastic parts with corrosive or penetrating detergents and solvents.

3 - 16

RSV mille  2%&)44).' 4(% 7(/,% %.').% /. 4(% &2!-% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE

In order to refit the whole engine on the frame, the same procedure used for its removal must be followed in the reverse order, see 3.3 (REMOVING THE WHOLE ENGINE FROM THE FRAME). Nonetheless, before commencing, the operations indicated below must be performed.

aWARNING
Handle with care. Watch your fingers and limbs.
N Make sure the adjusting bushes (38 - 42) are un-

screwed all the way so that they touch the frame.

N Nudge the engine along gradually until the engine/

frame fastening holes (A - B - C - D) are perfectly aligned. Once the engine refitting procedure is complete, perform the operations indicated below. N Make sure all the nuts/screws securing the engine are properly torqued. N Top up the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT). N Top up the motor oil, see 2.13 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP). N If the engine has been overhauled, bleed the engine oil circuit, see 3.8.1 (BLEEDING THE ENGINE OIL CIRCUIT) and check the engine oil pressure, 3.8.2 (CHECKING THE ENGINE OIL PRESSURE). N Check the driving chain is taught and, where necessary, adjust, see 2.35.1 (CHECKING THE SLACK) and 2.35.3 (ADJUSTMENT).

aCAUTION
Perform a general check of all the components affected by the procedure, in particular make sure: the electric cables are fastened with relevant clamps;

aCAUTION
None of the cables must be twisted and/or squashed. the electric connectors are plugged in properly; the pipes and couplings are connected properly and secured with relevant clamps; the throttle cable and cold-start cable slide freely and are not pulled too tight when the handlebar is turned; the gearshift lever is positioned correctly; the rear brake lever is positioned correctly.

3 - 17

ENGINE
 $)3!33%-",).' 4(% %.').% 3.5.1 ENGINE DISASSEMBLY SEQUENCE

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aCAUTION
Any components removed must be set aside in groups according to the respective assembly position in order to make sure they are subsequently refitted in the right place.

NOTE

This diagram shows the operations to be performed and the sequence to be followed when disassembling the engine parts. In order to remove the parts outlined with short dashes, ( ) the engine must be removed from the frame.

NOTE Before going ahead with the disassembly of the

engine, gather the appropriate special tools, see 1.8.2 (ENGINE TOOLS).

3 - 18

RSV mille Key 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) 30) 31) 32) 33) 34) 35) Engine Starter motor Flywheel cover Oil filter cover Cylinder 1 tappet cover Camshaft position sensor Cylinder 2 tappet cover Complete diaphragm cover Stator Magnetic wheel Clutch Oil filter cartridge Cylinder 1 TDC position Cylinder 2 TDC position Diaphragm Complete support plate and disengagement rod Driving shaft position sensor Starter motor transmission Cylinder 1 timing chain tightener Top side differential transmission Coolant pump lid Clutch discs Cylinder 1 drive assembly Cylinder 1 camshafts Cylinder 1 timing drive gears Cylinder 2 timing chain tightener Coolant pump Clutch cover Cylinder 1 timing chain Cylinder 2 timing drive gears Complete support plate and disengagement rod Cylinder 1 head Cylinder 1 head with cylinder Cylinder 2 top side countershaft Cylinder 2 timing chain 36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 46) 47) 48) 49) 50) 51) 52) 53) 54) 55) 56) 57) 58) 59) 60) 61) 62) 63) 64) 65) Clutch discs Cylinder 1 camshafts Cylinder 1 piston Cylinder 2 camshafts Cylinder 2 head with cylinder Cylinder 2 head Primary transmission Cylinder 1 valves Cylinder 2 piston Cylinder 2 top side countershaft Countershaft gear Oil pump gear Oil pump Remove the engine half-casing Cylinder 2 camshafts Coolant pump transmission Complete gearshift shaft Countershaft Cylinder 2 valves Index plate Index lever Cylinder 2 drive assembly Driving shaft Connecting rod Gearshift rods Gearshift fork Gearshift, shift cam Drive gears Gearshift bearings Driving shaft, countershaft bearings

ENGINE

- Cylinder 1 = front cylinder - Cylinder 2 = rear cylinder

3 - 19

ENGINE
3.5.2 REMOVING THE STARTER MOTOR

RSV mille

NOTE The operations below can be performed without

removing the engine from the frame.
N Move the protection element aside, unscrew and re-

move the nut, recover the washer and disconnect the cable of the starter motor. N Unscrew and remove the two M6 T.C.E.I. screws (1). Driving torque of screws (1): 11 Nm (1.1 kgm).
N Pull out the starter motor (2).

3.5.3 DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

aCAUTION
The head must be disassembled together with the cylinder. This is the only way in which the head can be detached from the actual cylinder.
N Remove the two spark plugs (3) from the head, see 2.7

(SPARK PLUGS).
N Unscrew and remove the five complete M6 spacer

screws (4) and remove the head cover (5) together with the respective gasket.

N Unscrew and remove the two M10 T.C.E.I. screws (6)

and remove the support bracket (7).

N Remove the closing screw, made from plastic, com-

plete with O-ring housed in the centre of the flywheel cover (8). N Remove the M8 T.C.E.I. screw (9) complete with seal (10).

3 - 20

RSV mille
N Use a size 14 bent hexagon-head driver to turn the driv-

ENGINE

ing shaft anticlockwise (11) until the piston 1 is at TDC (ignition).

NOTE At the TDC (ignition), the reference marks IN (12) and EX (13) of the two gears prove parallel to the head uncoupling surface, and face each other. NOTE
Have the appropriate special tool & (14) to hand, (cod. 0240 880 threaded pin for retaining the driving shaft at TDC).

N Screw the special tool (14) into the slot previously occu-

pied by the M8 T.C.E.I. screw (9) by hand so that you can feel it fit perfectly inside the driving shaft fastening slot.

NOTE Turn the driving shaft both ways to make sure that the threaded bolt is engaged perfectly. The bolt should not be overtightened: max. 5 Nm (0.5 kgm).
N Unscrew and remove the closing screw (15) complete

with seal (16) and remove the complete chain tightener (17). N Unscrew and remove the two M6 spacer screws (18) and remove the chain guide bracket (19). N Unscrew and remove the three M6x10 T.C.E.I. screws (20). Before removal, the three T.C.E.I. M6 x 14 screws (20A) must be marked so that they are refitted in the right place; danger of major engine damage and physical injury.
N Unscrew

aWARNING

and remove the three M6 x 14 T.C.E.I. screws (20A). N Remove the two gears (21). N Let the timing chain (22) drop into the cylinders chain compartment. N Pull the chain guide shoe (23) out from above.

3 - 21

ENGINE
N Unscrew and remove the two M6 T.C.E.I. screws (24). N Unscrew and remove the four M10 nuts (25).

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aWARNING
Be careful to avoid possible injury caused by allowing hands to get trapped between the cylinder and the stud bolts (28).
N Remove the cylinder (26) together with the complete

head (27).

aCAUTION
When removing the cylinder, take care not to damage the cylinder. Be careful to keep the two locating dowels (29) from dropping inside the crankcase.

NOTE

See 3.6.23 (HEAD AND CAMSHAFT) for instructions on taking the complete head apart.

N Cover the opening in the base with a clean cloth. N Remove the cylinder base gasket from its slot and pull

out the two locating dowels (29).

aCAUTION
Do not apply any mechanical markings.
N Use a felt pen to mark the piston crown on the exhaust

side (30) to remind you which direction it should be reassembled in. In the same way, mark both the piston and the cylinder with a 1 so that the two components can be reconnected in the same point.

aCAUTION
In order to prevent unbalanced forces, the axis of the pistons gudgeon pin is positioned off-centre, towards the front of the vehicle. When reassembling, the piston must be positioned on the connecting rod facing the right way.
N Use a sharp screwdriver (31) to remove the seeger ring

(32) (securing the gudgeon pin).

N Use a special drift to push out the gudgeon pin (33).

aCAUTION
Hold the piston in one hand so that the connecting rod bush is not tilted and hence damaged.
N Remove the piston (34).

3 - 22

RSV mille 3.5.4 DISASSEMBLING CYLINDER 2 (REAR), HEAD AND PISTON Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE The following operations can be performed without removing the engine from the frame.

The head must be disassembled together with the cylinder. This is the only way in which the head can be detached from the actual cylinder.
N Remove the two spark plugs from the head, see 2.7

aWARNING

(SPARK PLUGS).
N Unscrew and remove the five complete M6 spacer

screws (1) and remove the head cover (2) together with the relevant gasket. N Remove the closing screw, made from plastic, complete with O-ring housed in the centre of the flywheel cover (3). N Remove the M8 T.C.E.I. screw (4) complete with seal.

When turning the driving shaft, guide the connecting rod and timing chain of cylinder 1 so as to prevent them from getting stuck inside the housing.
N Use a size 14 bent hexagon-head driver (5) to turn the

aCAUTION

driving shaft anticlockwise approx. 300 so that piston 2 is at TDC (ignition).

NOTE At the TDC (ignition), the reference marks IN (6) and EX (7) of the two gears prove parallel to the head uncoupling surface, and face each other.
N Screw the M8 threaded bolt (8) on by hand so that you

can feel it fit perfectly inside the driving shaft fastening slot.

NOTE Turn the driving shaft both ways to make sure that the threaded bolt is engaged perfectly. The bolt should not be overtightened; max. 5 Nm (0.5 kgm).
N Insert an appropriate drift (diam. 7.5 mm) (9) in the

countershaft hole (10).

N Unscrew and remove the M14x1 nut (11).

When loosening the T.E. nut (11), counter the force with the drift (9) so as not to strain the driving chain.
N Remove the counterweight (12) from the countershaft.

aCAUTION

3 - 23

ENGINE
N Slide the gear (13) out a couple of millimetres so that it

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no longer mates with the driving gear (14).

N Remove the gear (13) complete with key (15).

Be careful to keep the key (15) from dropping into the chain compartment. Cover the chain compartment with a clean cloth.
N Unscrew and remove the three M6 x 10 T.C.E.I. screws

aCAUTION

(16).

Before removal, the three T.C.E.I. M6 x 14 screws (16A) must be marked so that they are refitted in the right place; danger of major engine damage and physical injury.
N Unscrew and remove the three M6 x 14 T.C.E.I. screws

aWARNING

(16A).
N Unscrew and remove the closing screw (17) complete

with seal (18) and remove the complete chain tightener (19).

N Pull the chain guide shoe (20) out from above. N Unscrew and remove the two M6 T.C.E.I. screws (21)

with the relevant washers and remove the chain guide (22). N Remove both the driving gear (14) and the two gears (23). N Unscrew and remove the two M6 T.C.E.I. screws (23A). N Slide out the upper countershaft (10), rotating it upwards.

NOTE Set the two gears (23) aside so that they are not
mixed up and can later be refitted in the right place (the two gears are identical).
N Let the timing chain (24) drop into the cylinders chain

compartment.
N Unscrew and remove the two M6 T.C.E.I. screws (25)

and four M10 nuts (26).

3 - 24

RSV mille

ENGINE

aWARNING
Be careful to avoid possible injury caused by allowing hands to get trapped between the cylinder and the stud bolts (29).
N Remove the cylinder (27) together with the complete

head (28).

aCAUTION
When removing the cylinder, take care not to damage the cylinder. Be careful to keep the two locating dowels (30) from dropping inside the crankcase.

NOTE

See 3.6.23 (HEAD AND CAMSHAFT) for instructions on taking the complete head apart.

N Cover the opening in the base with a clean cloth. N Remove the cylinder base gasket from its slot and pull

out the two locating dowels (30).

aCAUTION
Do not apply any mechanical markings.
N Use a felt pen to mark the piston crown on the exhaust

side (31) to remind you which direction it should be assembled in. In the same way, mark both the piston and the cylinder with a 1 so that the two components can be reconnected in the same point. N Use a sharp screwdriver (32) to remove the seeger ring (33) (securing the gudgeon pin). N Use a special drift to push out the gudgeon pin (34).

aCAUTION
Hold the piston in one hand so that the connecting rod bush is not tilted and hence damaged.
N Remove the piston (35).

3 - 25

ENGINE
3.5.5 REMOVING THE FLYWHEEL COVER AND IGNITION SYSTEM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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NOTE The following operations can be performed without removing the engine from the frame.

aWARNING
When performing work on the ignition system: switch off the engine; disconnect the battery: always disconnect the negative pole () first; disconnect all the electrical connections; drain the engine oil tank completely, see 2.14 (CHANGING THE ENGINE OIL AND THE OIL FILTER). secure the driving shaft at TDC; unscrew and remove the twelve M6 T.C.E.I. screws (1).

NOTE Have the appropriate special tool & (2) to hand

N Screw the special tool (2) onto the flywheel cover (3). N Lift the flywheel cover (3). N Remove the gasket (4).

cod. 0277252 (tool for disassembling the flywheel cover).

NOTE The driving shaft must be retained at the TDC of

piston 1 or piston 2.
N Unscrew and remove the M14 T.C.E.I. screw (5) and

remove the washer (6).

NOTE Have the appropriate special tool & (7) to hand

(cod. 0277780 - flywheel removal bolt). (8).
N Screw the special tool (7) into the thread of the flywheel

Do not heat the hub of the magneto flywheel (8) over a flame; instead use a suitable jet of warm air.

aCAUTION

NOTE Heat, for five-ten minutes, the hub of the magneto flywheel (8) with a jet of warm air since the cone is also fastened with LOCTITE 648.
N Remove the flywheel with the freewheel flange (9), the

freewheel (10) and the freewheel mechanism (11).

N Remove the starter idler gear (12) and double gear

(13).

3 - 26

RSV mille 3.5.6 DISASSEMBLING CYLINDER 1 (FRONT) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE

The following operations can be performed without removing the engine from the frame.
N Unscrew and remove the M10 T.C.E.I. screw (1). N Remove the external counterweight (2), the drive pinion

(3), the internal counterweight (4) and the countershaft key (5). N Unscrew and remove the two M8 T.E. screws (6) and remove both spring washers (7). N Unscrew and remove the M6 T.C.E.I. screw (8) and remove the complete roller bearing flange (9).

NOTE

The cylinder and the head are still fitted on the engine. In order to remove the timing chain (14), the chain tightener and camshaft gears must be removed, see 3.5.3 [DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON]. During disassembly of the roller bearing flange (9), there is no need to remove the components (10-1112) from the actual flange. (11) and two roller bearings (12).

NOTE

N Pull out the spacer bush (10), the two locating dowels

NOTE As of engine # 527354, the locating dowels (11)

are no longer fitted: centring is achieved with the aid of the flange (9).
N Remove the chain tightener shoe (13), pulling it out

from above.

NOTE Mark the timing chain (14) with a coloured dot so that you are sure to refit it with the same direction of rotation.
N Pull the timing chain (14) out from below, complete with

the idler gear (15), and remove the washer (16).

3 - 27

ENGINE
3.5.7 REMOVING THE DRIVING CHAIN PINION AND OIL FILTER CARTRIDGE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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NOTE The following operations can be performed without removing the engine from the frame.
N Unscrew and remove the M10 T.E. screw (1). N Remove the washer (2), the spring washer (3) and the

pinion (4).

NOTE Where necessary, use the universal sleeve puller to remove the pinion, taking care not to damage the secondary shaft.

N Unscrew and remove the two M6 T.C.E.I. screws (5). N Remove the cover of the oil filter (6) and the O-ring (7). N Remove the oil filter cartridge (8) from the filter housing.

3 - 28

RSV mille 3.5.8 REMOVING THE CLUTCH COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE The following operations can be performed without removing the engine from the frame.
N Unscrew and remove the eight M5 T.C.E.I. screws (1)

and remove the complete diaphragm cover (2).

N Remove the diaphragm (3) from the clutch cover retain-

ers (4) and turn it approx. 20.

N Unscrew and remove the M12 stop nut (5) and remove

the washer (6), cup (7), diaphragm (3), support ring (8) and the washer (9).

NOTE In order to unscrew and remove the M12 stop nut (5), the clutch disengaging shaft must be held still with a bent hexagon-head driver.
N Unscrew and remove the four M6 T.C.E.I. screws (10)

and remove the coolant pump casing (11) complete with shaped seal.

NOTE The lower T.C.E.I. screw (12) (coolant drain plug) also features a seal.
See 3.6.21 (COOLANT PUMP) for instructions on disassembling the coolant pump.

NOTE If the M8 T.C.E.I. screw (15) has not been previously removed, to retain the shaft at TDC, this screw must also be removed.
N Unscrew and remove the eleven M6 T.C.E.I. screws

(13) and the three M8 T.C.E.I. screws (14).

aCAUTION
Be careful not to damage the gasket surfaces when lifting the clutch cover.
N Lift the clutch cover (16) carefully, using a screwdriver

to work the pull-out tabs (17), and remove it.

N Remove the gasket.

3 - 29

ENGINE
3.5.9 DISASSEMBLING THE CLUTCH Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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NOTE The following operations can be performed without removing the engine from the frame.
The driving shaft must be retained at TDC, see 3.5.3 [DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON].
N Unscrew and remove the six M6 T.E. screws (1). N Remove the washer (2), clutch springs (3) and support

NOTE

cups (4).

NOTE Have the special tools & (9) to hand (cod. 8140185 - clutch disc extraction hook levers). NOTE
The lower clutch discs can only be removed individually with the aid of the appropriate hook levers (9).
N Remove the lined discs (6) and steel discs (7) from the

N Remove the complete clutch disengaging shaft (5).

clutch housing (8).

NOTE Have the appropriate special tool hand (cod. 0277881 - clutch blocking tool).
(8) and on the clutch hub (11).

& (10) to

N Insert the clutch blocking tool (10) in the clutch housing

Insert the clutch blocking tool all the way into the clutch drum so as not to damage the basket when loosening the T.E. nut.
N Unscrew and remove the M24x1.5 T.E. nut (12). N Remove the clutch blocking tool (10), spring washer

aCAUTION

(13) and clutch hub (11).

N Remove the complete clutch housing (8) and the thrust

ring (14).

NOTE

The oil pump gear (15) is hooked onto the support plate (16) of the complete clutch housing (8). Take the complete clutch housing apart, see 3.6.17 (CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY).

Once disassembled, the oil pump gear (15) must always be replaced.
N Remove the washer (17) from the primary shaft.

aCAUTION

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RSV mille 3.5.10 DISASSEMBLING THE COUNTERSHAFT MECHANISM AND PRIMARY TRANSMISSION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE

The driving shaft must be retained at TDC, see 3.5.3 [DISASSEMBLING CYLINDER 1 (FRONT), HEAD AND PISTON].

N Unscrew and remove the M22x1.5 T.E. nut (1), remove

the spring washer (2) and countershaft counterweight (3). N Unscrew and remove the M33x1.5 T.E. nut (4) and remove the spring washer (5). N Remove the drive gear (6) from the driving shaft. N Remove the differential gears (7) from the driving shaft and countershaft together. N Detach the key (8), the upper washer (9) and coolant pump gear (10) from the countershaft. N Remove the coolant pump idler gear (11). N Detach the lower washer (12) from the countershaft.

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ENGINE
3.5.11 DISASSEMBLING CYLINDER 2 (REAR) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Remove the drive gear (1) from the driving shaft. N Unscrew and remove the three M8 T.E. screws (2) and detach the lock washers (3).

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NOTE

The cylinder and the head are still fitted on the engine. In order to remove the timing chain (10), the chain tightener and camshaft gears must be removed, see 3.5.4 [DISASSEMBLING CYLINDER 2 (REAR), HEAD AND PISTON]. with the two calibrated bushes (5) and spacer bush (6).

N Remove the complete roller bearing flange (4) together N Remove the chain tightener shoe (7), pulling it out from

above.
N Remove the two roller bearings (8). N Remove the intermediate drive gear (9) and timing

chain (10), pulling both out together downwards.

NOTE Mark the timing chain (10) with a coloured dot so

that you are sure to refit it with the same direction of rotation.
N Remove the washer (11).

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RSV mille 3.5.12 DISASSEMBLING THE OIL PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Remove the seeger ring (1). N Slide the oil pump gear (2) up and off.

ENGINE

Once disassembled, the oil pump gear (2) must always be replaced.

aCAUTION

NOTE Turn the oil pump shaft so that the pin can be slid out through the slot on the pump cover (5).
N Slide the pin (3) out of the oil pump shaft (4). N Unscrew and remove the four M6 T.C.E.I. screws (6)

and remove the complete oil pump (7) from the engine casing.

When removing the whole oil pump (7), it is advisable to leave the inside rotor (8) and pin (9) fitted since there is a danger of the pin (9) falling into the oil sump.
N Remove the suction pumps external rotor (10) from the

aWARNING

engine casing.

NOTE Take the oil pump apart, see 3.6.10 (OIL PUMP
AND OIL PUMP DRIVE ASSEMBLY).

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ENGINE
3.5.13 DISASSEMBLING THE GEAR SELECTION MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Unscrew the threaded pin M8 (1) retaining the driving

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shaft at TDC.

NOTE

Turn the driving shafts by hand to enable the gear to engage.

N Engage 6th gear.

N Remove the complete selector shaft (2). N Unscrew and remove the M6 T.C.E.I. screw (3) and re-

move the index plate (4).

NOTE Use a screwdriver to push the complete positioning lever (5) down to make it easier to remove the index plate.
N Unscrew and remove the M6 T.C.E.I. screw (6) and re-

move the washer (7), positioning lever (5), graduated ring (8) and positioning spring (9).

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RSV mille 3.5.14 SPLITTING THE ENGINE CASING OPEN Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Take the seeger ring (1) and thrust washer (2) off the secondary shaft. N Unscrew and remove the twenty M6 T.C.E.I. screws (3).

ENGINE

Comply with the following instructions: Use a plastic hammer to strike the primary and secondary shafts alternately until they are embedded in the flywheel side half of the engine casing. Make sure the engine half-casing is lifted parallel to the surface so that the main bearings are not tilted and hence damaged. Where necessary, use a screwdriver, inserted in the appropriate points (4), to help prise them apart. Take your time and work with extreme care. Never strike the gasket surface. Do not use excessive force. Should it prove impossible to separate the two halves of the casing, check for any screws which have not been loosened.

aCAUTION

NOTE

When lifting the engine half-casing, the washers of the secondary shaft may be attached on the inside of the clutch side half of the engine casing. ing the clutch side section.

N Split the two sections of the engine casing apart by lift-

3.5.15 DISASSEMBLING THE DRIVING SHAFT AND COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Turn the driving shaft (5) so that it does not mate with the countershaft (6). N Remove the countershaft (6). N Remove the driving shaft (5).

3 - 35

ENGINE
3.5.16 DISASSEMBLING THE GEARSHIFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Remove the two spindles (1). N Turn both gearshift forks (2) of the secondary shaft (3) outwards, moving them away from the guides of the selector cylinder (4), and remove them.

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N Turn the gearshift fork (5) of the primary shaft (6) out-

wards, moving it away from the guide of the selector cylinder (4), and remove the selector cylinder. N Push the 3rd and 4th gear selector gear (7) upwards and remove the fork (5) from the primary shaft. N Set the engine half-casing upright on the assembly bench.

NOTE

Keep both the secondary shaft and primary shaft still with one hand whilst tapping the secondary shaft (3) with a plastic hammer, working from the outside. This forces the two shafts out of their relevant housings complete with the gearshift gears.

N Disassemble the gearshift (8).

The secondary shafts seal is inevitably damaged whilst disassembling the gearshift and must, therefore, be replaced.

aCAUTION

NOTE
SHIFT).

Take the gearshift apart, see 3.6.15 (GEAR-

3 - 36

RSV mille  7/2+ /. 4(% ).$)6)$5!, 0!243 Take care not to burn yourself when handling hot engine parts.

ENGINE

aWARNING aCAUTION

If any of the components has exceeded one of the wear limits or if, during the visual inspection of a component, a defect is detected liable to compromise the operation of the engine, said component must be replaced. If the measurement values indicated are precise to one tenth of a millimetre or over, the temperature of the component must be in the range 20 to 25 C (68 to 77 F). 3.6.1 ENGINE CASING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

Do not use anti-sealer products, degreasers or cold detergents.

N Clean the two sections of the engine casing, ball bear-

aCAUTION

ings and all bearing housings thoroughly with a gentle solvent. N Clean all the gasket surfaces and check for damage.

NOTE Place the two halves of the engine half-casing on a flat surface to prevent damage.
N Make sure the two halves of the engine half-casing do

not feature cracks or signs of damage.

N Make sure all the threads are in a perfect state of repair. N Make sure all the oil seals remaining in their slots are

not worn or damaged.

N Check the slack of all the ball bearings and make sure

they slide smoothly and are not distorted in any way.

NOTE

Use motor oil to lubricate the ball bearings before performing the check. If the inner race does not turn easily and silently, or if it makes a noise, it means the bearing is defective and needs replacing.

N Remove the oil gauze (1). N Clean the oil gauze with naphta and check the mesh of

the gauze for possible signs of damage.

N Unscrew and remove the M6 T.C.E.I. screw (2), the

seal (3) and the nozzle (4).

3 - 37

ENGINE

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N Make sure the galleries are clear in all the lubrication holes (1 - 2 - 3 - 4 - 5 - 6 - 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16

- 17 - 18) in the two halves of the casing and, where necessary, clean them by blowing a jet of compressed air inside. 3.6.2 ENGINE HALF-CASING, CLUTCH SIDE

3.6.3 ENGINE HALF-CASING, FLYWHEEL SIDE

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RSV mille 3.6.4 ENGINE HALF-CASING - BALL BEARINGS AND OIL SEALS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY

ENGINE

NOTE

The oil seals can be disassembled and assembled without removing the engine from the vehicle.

N In order to remove and insert the ball bearings, heat the

engine casing to a temperature of approx. 80 - 100 C (176 - 212 F). N Lift and take out the oil seals: secondary gearshift shaft (1); selector shaft (2); clutch disengaging shaft (3).

NOTE
replaced.

As a rule, the disassembled oil seals should be

N Unscrew and remove the M6 FH screws (4) securing

the ball bearings.

N Remove the M6 x 13 flanged-head screw (5).

NOTE

In order to avoid damaging the gasket surface, an old engine casing gasket should be placed underneath the puller plate.

N Remove the primary shaft ball bearings (6) with the aid

of a universal sleeve puller (7).

N Remove the ball bearings using the relevant drift.

gearshift primary shaft (8), clutch side; gearshift secondary shaft (9), clutch side; shift cam (10), clutch side; gearshift secondary shaft (11), flywheel side. N Remove the shift cam ball bearings (12).

NOTE As a rule, the disassembled ball bearings should be replaced.

3 - 39

ENGINE
ASSEMBLY
N Check the interference between the bearing and the

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engine casing hole. Interference A min. 0.01 mm.

N Lubricate the external diameter of the bearings slightly

and, with due care, fit them all the way in on the outer ring using a suitable assembly punch: gearshift primary shaft (6), flywheel side; gearshift primary shaft (8), clutch side; gearshift secondary shaft (9), clutch side; shift cam (10), clutch side; gearshift secondary shaft (11), flywheel side.

The sealing washer of the gearshift primary shaft ball bearing (6), flywheel side, must face outwards.

aCAUTION

NOTE As a rule, the disassembled ball bearings should be replaced.

N Lubricate the internal diameter of the shift cam ball

bearing (12), flywheel side, slightly and, with due care, fit it all the way in on the inner ring using a suitable assembly punch. N Apply LOCTITE 243 on the screws (4, 5) securing the ball bearings and screw them into the engine casing. Driving torque of M6 T.P. screw (4): 11 Nm (1.1 kgm). Driving torque of M5x10 flanged-head screw (5): 11 Nm (1.1 kgm).

NOTE
hand:

Have the appropriate special tools & below to

(13) cod. 8140070 handle for pads; (14) cod. 0277680 (gearshift secondary shaft oil seal assembly pad); (15) cod. 8140155 (gearshift shaft oil seal - clutch shaft oil seal assembly pad).

NOTE

Before assembling the shaft sealing rings, their external diameter must be lubricated slightly. The closed side of the shaft sealing rings must face outwards. Grease the sealing lips.

The oil seal (1) of the secondary shaft must not touch the inner race of the bearing in any way as this would result in damage.
N Insert the oil seal (1) flush with the engine casing using

aCAUTION

the assembly pad (14).

N Insert the shaft sealing rings (2 - 3) all the way using the

assembly pad (15).

3 - 40

RSV mille 3.6.5 ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

The main bushes may only be replaced by authorized repair shops suitably skilled in the use of the relevant measuring equipment and tools.
N Check for any damage and signs of rolling or grooves

aCAUTION

on the bearings sliding surfaces or on the thrust-bearing surfaces of the driving shaft and countershaft. N Measure the internal diameter. Driving shaft (1): wear limit 46.035 mm. Countershaft (2): wear limit 32.060 mm.

Take a number of measurements, especially in the direction of the axis of both cylinders. None of the values must exceed the limit value.

aCAUTION

Measure the radial play of the driving shaft and countershaft, see 3.6.11 (DRIVING SHAFT) and 3.6.14 (COUNTERSHAFT AND COUNTERSHAFT MECHANISM).

aCAUTION

N Check for signs of wear or slipping on the axial thrust-

bearing surfaces (3 - 4), for the driving shaft, in both halves of the casing. End play of the driving shaft: wear limit max. 0.5 mm.

N Check for signs of wear or slipping on the axial thrust-

bearing surfaces (5 - 6), for the countershaft, in the clutch side half of the casing. End play of the counter shaft: wear limit max. 0.3 mm.

NOTE Since they are installed, determine the end play

of the driving shaft and/or countershaft with a comparator.

3 - 41

ENGINE
DISASSEMBLY
N Use a felt pen to mark the contact surfaces (7) of the

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main bushes on both halves of the engine casing so as to provide an external visual reference.

Do not perform any mechanical markings.

aCAUTION

NOTE
to hand:

Have the following appropriate special tools &

(8) cod. 0277720 (driving shaft sleeve puller pad); (9) cod. 2777530 (countershaft sleeve puller pad).
N Heat the engine casing to approx. 150 C (302 F) for

approx. fifteen minutes.

N Remove the main bushes from the inside out, setting

them on a press and using the assembly pads (8 - 9).

In order to insert and remove the main bushes, the engine casing must be supported by applying a spacer tube around the main bush housing on the outside for the engine to rest on.

aCAUTION

NOTE As a rule, the disassembled main bushes should be replaced in pairs.

3 - 42

RSV mille ASSEMBLY

N Clean the diameter of the main bush housing inside the

ENGINE

engine casing.
N Determine the main bush size group based on the col-

oured markings (10) on the engine casing.

The lower main bush (11) of the driving shaft, flywheel side, features a lubrication hole.

aCAUTION

NOTE The size group of the main bushes is also marked with a coloured dot.
N If the coloured marking applied on the engine casing is

no longer clearly legible, calculate the diameter based on the average of a number of different measurements.

Take a number of measurements, especially in the direction of the axis of both cylinders.

aCAUTION

Hole in the engine casing 49.899 - 49.908 mm 49.908 - 49.918 mm 49.918 - 49.929 mm

Driving shaft Main bushes marking red blue yellow

Engine casing marking red blue yellow

Hole in the engine casing 35.909 - 35.918 mm 35.918 - 35.928 mm 35.928 - 35.939 mm

Countershaft Main bushes marking red blue yellow

Engine casing marking red blue yellow

M = MOLYKOTE G-N.

3 - 43

ENGINE

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NOTE Have the appropriate special tools & to hand:

(12) cod. 0277725 (driving shaft bush inserter pad); (13) cod. 0277537 (countershaft bush inserter pad). N Heat the engine casing to approx. 150 C (302 F). N Coat the main bushes and bearing housings inside the engine casing with MOLYKOTE G-N. N Place the driving shaft and countershaft main bushes on the assembly pads (12 - 13) and fasten them with an O-ring (14) suitable for the purpose. N Line up the contact surface of the main bushes with the previously applied coloured marking (7). N With due care, insert the main bushes on a press, working from the inside out, until the installer punch touches. N Remove the O-ring (14) before the installer punch makes contact.

In order to insert and remove the main bushes, the engine casing must be supported by applying a spacer tube around the main bush housing.
N The lower main bush of the driving shaft, flywheel side,

aCAUTION

features a lubrication hole (11). Once assembled, make sure the lubrication hole (11) on the main bush is lined up with the engine casing. N The main bushes (1) of the driving shaft are fitted so that they are 2.0 mm further down than the thrust-bearing surfaces (3 - 4). N The main bushes (2) of the countershaft are fitted so that they are 1.5 mm further down than the thrust-bearing surface (5).

Should the main bushes be assembled incorrectly, they must be removed using the disassembly punch, as described above. Disassembled main bushes must not be reused. M = MOLYKOTE G-N.

aCAUTION

3 - 44

RSV mille 3.6.6 REPLACING THE ENGINE HALF-CASING CYLINDRICAL PINS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Use a micrometer to check the wear of the cylindrical

ENGINE

pins (1, 2) of the starter motor drive assembly and (3) coolant pump idler gear. Wear limit 9.990 mm

DISASSEMBLY
N Should the cylindrical pin prove worn, during disassem-

bly, heat the peripheral range of the cylindrical pin slot on the outer wall of the engine half-casing with a jet of hot air (4) (approx. 100 C - 212 F); next, pull the cylindrical pin out with a pair of pliers, rotating it upwards. ASSEMBLY
N With due care, insert the cylindrical pins all the way in

using a plastic hammer. Coat the cylindrical pin (3) of the coolant pump idler gear with LOCTITE 648.

NOTE Insert the cylindrical pin (5) of the needle spring

with the chamfered part external.

3 - 45

ENGINE
3.6.7 NEUTRAL GEAR INDICATION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Make sure the contact pin (1) of the contact screw (2)

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slides smoothly and check the preloading of the spring.

The cap on the pin must not be worn. Where necessary, replace the contact screw.
N If the contact screw (2) is replaced, it must be coated

aCAUTION

with LOCTITE 574. Driving torque of contact screw (2): 4 Nm (0.4 kgm). 3.6.8 ASSEMBLING THE ENGINE HALF-CASING
N Should a stud bolt (3) need replacing, coated with LOC-

TITE 243 and the new one must be screwed on all the way. Driving torque of stud bolt (3): 10 Nm (1.0 kgm).
N Screw on the nozzle (4). N Fasten the M6 T.C.E.I. screw (5) together with the seal

(6). Driving torque of screw (5): 6 Nm (0.6 kgm).

N Insert the oil gauze (7).

3.6.9 COMPLETE OIL-SPRAY PIPE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY
N Heat the peripheral range of the oil-spray pipe (8) on

the engine casing using a jet of hot air (approx. 100 C - 212 F) before removing it using a pair of pliers to rotate it up and out. ASSEMBLY

NOTE

There is a special slot (9) incorporated into the engine casing for correctly housing the oil-spray pipe (8).

Take care not to damage the nozzles (10).

N Keep the oil-spray pipe (8) in place and insert it into the

aCAUTION

engine casing, flywheel side (9). D = LOCTITE 574. B = LOCTITE 243.

3 - 46

RSV mille 3.6.10 OIL PUMP AND OIL PUMP DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

The oil pump gears, both driving (1) and driven (2), must always be replaced once they have been disassembled.

aCAUTION

NOTE

The oil pump drive gear (1) is attached to the support plate of the complete clutch housing. TAKING THE OIL PUMP APART

N Remove the suction pumps internal rotor (3) from the

oil pump shaft.

N Remove the pin (4). N Slip off the oil pump lid (5) and pin (6). N Remove the pressure pumps external rotor (7). N Remove the oil pump shaft (8) from the pressure pump

casing (9).
N Remove the pressure pumps internal rotor (10) and pin

(11).
N Unscrew the plug (12) and remove the compression

spring (13) with the adjusting piston (14).

3 - 47

ENGINE
CHECKING THE OIL PUMP
N Check the oil pump rotors, the sliding surfaces of the

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external rotors in both pump casings and the thrustbearing surfaces for any signs of grooving. N Measure the play between the external rotors (7 - 15), the engine casing (16) and the pressure pump casing (9) using a feeler gauge. Wear limit max. 0.25 mm.
N Measure the end play (17) of the rotors.

Wear limit max. 0.15 mm.

NOTE If the play exceeds one of the two wear limits, the defective component must be replaced.

N Make sure the adjusting piston (14) slides smoothly in

the oil pump lid.

N Check the adjusting piston and oil pump lid for any

signs of wear: adjusting piston (14); wear limit (18) min. 9.975 mm; oil pump lid (5); wear limit (19) max. 10.035 mm; compression spring (13); minimum lenght of the spring (20) when not compressed: 56,0 mm. N Engage the adjusting piston (14) with the cone end facing forwards and insert the compression spring in the slot on the oil pump lid (5).
N Apply LOCTITE 648 on the caps thread (12). N Screw on the cap (12) 2 mm further in than the outer

edge of the neck of the oil pump lid (5) and secure it in place by punching in four more points (21).

3 - 48

RSV mille 3.6.11 DRIVING SHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the wear of the driving shaft: section for main bushes (1); wear limit min. 45.955 mm; section for support bushes (2); wear limit min. 29.970 mm; housing of the freewheel gear bearing (3) wear limit min. 34.960mm; connecting rod small end (4); wear limit max. 22.030 mm; end play between connecting rod and crank arm (5); wear limit max. 0.60 mm; driving shaft eccentricity, flywheel side (6); limit max. 0.020mm; driving shaft eccentricity, clutch side (7); limit max. 0.020 mm.

ENGINE

NOTE Measure the eccentricity of the driving shaft between the ends. End play of the driving shaft max. 0.5 mm. Use a comparator to determine the end play of the driving shaft once the two halves of the casing are coupled.
N Determine the radial play (8) from the eye of the con-

NOTE

necting rod with a comparator. Wear limit: max. 0.060 mm.

N Measure the radial play of the two main bush halves

(1). Max. permissible radial play 0.060 mm.

NOTE If the max. permissible radial play is exceeded, the worn part must be replaced.
The radial play is determined based on the following values: maximum value of the main bushes diameter in the engine casing minus the driving shaft diameter at the main bush housing. N Measure the main bush diameter, see 3.6.5 (ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT). N Measure the radial play of the support bushes (2). Permissible radial play max. 0.065 mm.

NOTE The radial play of the support bushes is calculated based on the following values:
maximum value of the diameter of the bushes in the clutch cover minus the diameter of the driving shaft in the support bushes area.
N Measure the support bush diameter, see 3.5.8 (RE-

MOVING THE CLUTCH COVER).

If the max. permissible radial play is exceeded, the worn part must be replaced. The following components must also be checked for wear or broken material: N Key (9) and grooves in the driving shaft. N Colouring of a bearing housing. N Cone surface (10) of the driving shaft section on the flywheel side. N Clean the thread (11) of any LOCTITE residues and make sure it is in a perfect state of repair. N Check to make sure the bush (12) inside the connecting rod small end is correctly installed and centred (on the longitudinal axis).

aCAUTION

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ENGINE
3.6.12 DISASSEMBLING THE CONNECTING RODS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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Before disassembling the connecting rods (1) and covers (2), mark them so they are refitted in the same position (cylinder 1 and 2) and with the same direction of rotation.
N Unscrew and remove the M10x1 connecting rod

aCAUTION

screws (3) and detach the connecting rod cover (2), tapping lightly with a plastic hammer. N Remove the connecting rod screws with the cover and connecting rod (1). N Clean the driving shaft lubrication holes. N Check the bushes (4) for signs of wear, distortion and altered colouring. N Check the connecting rod housing for wear: connecting rod pins (5); wear limit min. 41.98 mm; connecting rod big end (6); wear limit max. 42.050 mm.

Measure the diameter of the connecting rod big end. Fasten the cover (2) with the connecting rod M10x1 screws (3). Driving torque screws (3): see 3.6.13 (REPLACING AND INSTALLING THE CONNECTING RODS).

aCAUTION

The fastening of the connecting rod M10x1 screws (3) will require the use of a setting dial (7) and a fitting for a size 12 socket spanner.

aCAUTION

NOTE

None of the values may exceed the limit value. In the event of wear, the whole connecting rod, complete with cover, must be replaced. (6). Wear limit max. 0.070 mm.

N Measure the radial play of the connecting rod big end

NOTE

The radial play of the driving shaft is calculated based on the following values: maximum value of the diameter of the bushes minus the diameter of the coupling shaft.

NOTE

The radial play of the connecting rod big end may also be measured with the aid of a plastic gauge. If a plastic gauge is used, the connecting rod must be kept still.

3 - 50

RSV mille 3.6.13 REPLACING AND INSTALLING THE CONNECTING RODS Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE The complete connecting rods supplied as spare parts include bushes in all three sizes (see table). The bushes are marked, according to size, in red, blue and yellow (4).
N Insert the bushes with the minimum thickness (red) be-

tween the connecting rod (1) and the cover (2), taking care to position them correctly (3). Line the bushes up on a flat surface. N Insert the connecting rod and cover on the driving shaft so that the two reference points (5) and piece number (6) coincide on the two connecting rods. N Fasten the cover (2) with the old M10x1 screws (7) in three phases. 1st pre-tightening phase: tighten the two screws with a driving torque of 2 Nm (0.2 kgm). 2nd tightening phase: tighten the two screws with a driving torque of 30 Nm (3.0 kgm). 3rd final tightening phase: tighten the two screws by 70.

The fastening of the M10x1 screws (7) will require the use of a goniometer (8) and a ring socket spanner.
N Measure the radial play (9) of the connecting rod end

aCAUTION

with a comparator. Radial play 0.020 - 0.045 mm. If the radial play is greater than 0.045 mm, the bushes of the size corresponding to the colours blue or yellow must be chosen based on the following table, and must be inserted in place of the red bushes. Bush colour Red Blue Yellow
N Unscrew the screws (7). N Lubricate the bushes and pins.

Thickness (mm) 1.471 - 1.476 1.476 - 1.481 1.481 - 1.486

NOTE Use new M10x1 screws (7) only.

N Lubricate the supporting surfaces of the heads of the

new screws (7).

N Fasten the cover (2) in the three phases described

above, using the two new M10x1 screws (7).

The fastening of the M10x1 screws (7) will require the use of a goniometer (8) and a ring socket spanner.
N Check the radial play (9) again.

aCAUTION

Radial play 0.020 - 0.045 mm.

N Make sure the connecting rods do not encounter any

friction during the stroke.

3 - 51

ENGINE
3.6.14 COUNTERSHAFT AND COUNTERSHAFT MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Check the wear of the countershaft: housing of bush (1); wear limit min. 31.980 mm; housing of thrust support bush (2); wear limit min. 19.990 mm; housing of bush (1); permissible radial play min. 0.060 mm; housing of support bush (2); permissible radial play min. 0.060 mm.

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NOTE The radial play of the countershaft is determined based on the following values:
maximum value of the main bush diameter in the engine casing or in the clutch cover minus the value of the bearing housing (1) or the support bush housing (2) of the countershaft. Measure the main bush diameter, see 3.6.5 (ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND CO UNTERSH AFT) and 3.5.8 (REMO VING THE CLUTCH COVER).

NOTE

If the max. permissible radial play is exceeded, the worn part must be replaced. Permissible radial play of the countershaft max. 0.30 mm.

NOTE

Once the two halves of the engine casing have been coupled, check the end play of the countershaft with a comparator.

The following components must also be checked for wear or broken material: axial thrust-bearing surfaces (3); key (4) and grooves in the countershaft; colouring of a bush housing. N Clean the thread of any LOCTITE residues and make sure it is in a perfect state of repair. N Check the sides of the teeth of the driving gear (5) and driven gear (6) for any signs of broken material or distortion.

NOTE

In order to check the main bushes, see 3.6.5 (ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT) and 3.5.8 (REMOVING THE CLUTCH COVER).

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RSV mille 3.6.15 GEARSHIFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

When taking the gearshift apart, set the disassembled components down according to the assembly position, assigning them to the corresponding shaft so as to be sure they are reassembled and installed correctly. Following disassembly, the seeger rings must always be replaced.

aCAUTION

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ENGINE
TAKING THE GEARSHIFT APART Secondary shaft Use crimpers to remove the seeger rings (4). N Remove the gearshift gears from the secondary shaft, starting with the idle gear of 1st gear (1) and then moving on to the shim washers (2), roller cages (3), seeger rings (4) and shim rings (5).

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Primary shaft Use crimpers to remove the seeger rings (7).

N Remove the gears from the primary shaft, starting with

the fixed gear of 2nd gear (6) and then moving on to the seeger rings (7), shim rings (8), the roller bearing (9) and shim washer (10).

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RSV mille
N Check the following components for wear: roller bearings (1); sides of the teeth (2) of all gears.

ENGINE

NOTE Small grey marks and tiny hollows are tolerated up to a maximum corresponding to approx. 0.5% of the sides surface area.
engagement teeth (3) and mating slots of gearshift gears; profile for spline shafts (4) of the secondary shaft and primary shaft; check all the gear selection gears (5), both on the secondary shaft and primary shaft, slide smoothly; housings of the idle gear bearings (6); triangular tooth profile (7) of the chain pinion; the grooves for seeger rings (8) on the secondary shaft and on the primary shaft must have sharp edges.

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ENGINE
N Check the housings of the secondary shaft and primary

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shaft for wear: wear limit (9) min. 19.972 mm; wear limit (10) min. 29.915 mm; wear limit (11) min. 29.965 mm; wear limit (12) min. 24.972 mm; wear limit (13) min. 29.03 mm; wear limit (14) min. 24.978 mm; permissible eccentricity (15) max. 0.02 mm.

NOTE

Should the sides of the teeth be worn, the relevant pair of gears must be replaced. Should the engagement teeth or mating slots prove worn, the relevant gears must be replaced, mating with each other. 6th gear.

N Check the internal diameter of the idle gears of 3rd, 4th and

Wear limit (16) max. 29.022 mm.

N Check for any signs of rolling or grooves on the bushes of

the idle gears of 2nd (17) and 5th gear, and measure the internal diameter of the gears. N Check for any signs of rolling or grooves on the bushes of the idle gears (15 - 16), and measure the internal diameter of the bearings. Wear limit max. 29.125 mm. N Make sure the lubrication hole (18) of the secondary shaft is clear.

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RSV mille ASSEMBLY

N Oil the secondary shaft, primary shaft, gearshift gears

ENGINE

and roller bearings slightly.

N Reassemble the secondary shaft and primary shaft in

the reverse order.

N Fit the seeger ring, using the plier for seeger ring only.

Do not reuse the seeger rings. The seeger rings must be replaced every time the gearshift is taken apart. Pull the ends of the seeger rings apart just enough to be able to slide the ring onto the shaft. If the seeger ring is pulled apart two much, its locking effect is irreparably reduced. Make sure the seeger rings are properly installed in the corresponding groove.
N Once the two gearshift shafts have been assembled,

aCAUTION

make sure the gears turn smoothly.

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ENGINE
3.6.16 GEAR SELECTION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Check the end play (1) of the gearshift forks inside the

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corresponding grooves in the selection gears. Wear limit max. 0.15 mm.

NOTE If the wear limit is exceeded, you must determine which component needs replacing by checking the gearshift forks and selection gears.
N Width of the groove (2) of the selection gears.

Wear limit max. 4.35 mm.

N Thickness (3) of the gearshift forks. Check the degree

of wear on the chromium-plated thrust-bearing surfaces of the gearshift forks. Wear limit max. 3.950 mm.

NOTE If the chromium finish is missing in some points, replace the fork in question.

N Check the diameters (4) of the gearshift fork guide pins.

Wear limit min. 5.850 mm.

N Check the eccentricity of the two fork shafts (5).

Max. permissible eccentricity 0.02 mm.

N Check the wear of the ratchet gear in the area in which

it comes into contact with the index plate pins. Wear limit (6): visual inspection.
N Check the eccentricity of the selector shaft (7) and also

check for any signs of rolling on the sliding surface of the shaft sealing ring. Max. permissible eccentricity 0.25 mm.
N The roller (8) of the positioning lever must turn freely. N Check the wear of the guide tracks (9) of the shift cam.

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RSV mille 3.6.17 CLUTCH AND PRIMARY TRANSMISSION ASSEMBLY

ENGINE

Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

N Check the lined discs (1) and steel discs (2) for cracks

or any distortion (3) by placing them on a flat surface. Max. permissible distortion (3): 0.15 mm.

NOTE The inside discs (2) must not feature grooves or temper colours.
N Measure the width (4) of the driving element and the

thickness of the lined discs (1).

N Measure the set of the nine lined discs.

Wear limit min. 30.9 mm.

N Measure the set of discs with all the discs together (5)

(made up of 10 steel discs and 9 lined discs). Wear limit (5) min. 46.3 mm.

N Measure the length of the individual clutch springs (6)

in the released position. Wear limit (6) min. 44.0 mm.

NOTE You are strongly recommended to replace all the clutch springs together with the set of lined discs.

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ENGINE
N Check the smoothness and slack of the ball bearings

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(7) on the spring plate (8) and, where necessary, replace them.

NOTE When removing and refitting the ball bearings, heat the spring plate to 80 - 100 C (176 - 212 F) and use a suitable assembly punch.

N Check the compression surface (9) of the spring plate

(8) for signs of wear and make sure it is flat. Max. permissible distortion (9): 0.1 mm.
N Check the depth (10) of the spring plate.

Wear limit (10) max. 33.5 mm.

N Check the eccentricity of the disengaging shaft (11),

also checking for signs of rolling on the oil seal sliding surface. N Check the diaphragm (12) for cracks and, where necessary, replace it. N Check the guide grooves on the clutch housing (13) and the external toothing of the clutch hub (14) for any dents (15). Max. dent depth (15): 0.3 mm.
N Check the bush of the clutch gear (16) for grooves and

damage; measure the internal diameter. Wear limit (17) max. 30.060 mm.
N Check the sides of the clutch gear teeth (16) and drive

gear teeth (18) for signs of broken material or distortion.

NOTE

Should the clutch gear or drive gear be worn, the primary transmission assembly pair must be replaced.

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RSV mille 3.6.18 DISASSEMBLING THE COMPLETE CLUTCH HOUSING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Slip off the oil pump drive gear (1).

ENGINE

The oil pump drive gear (1) must always be replaced once it has been disassembled.
N Unscrew and remove the three M8 T.E. screws (2) and

aCAUTION

remove the support plate (3).

N Remove the six compression rings (5) together with the

twelve spring pins (6) from the clutch gear (4).

N Remove the clutch gear (4) with the spring washer (7)

and the washer (8) from the clutch housing (9).

NOTE You are strongly recommended to replace all the compression springs (5) and spring pins (6) together.
N Measure the length of the spring housing in the clutch

housing (9). Wear limit (10) max. 32.65 mm. ASSEMBLY

N Insert the washer (8) and the spring washer (7) on the

clutch housing (9).

Make sure the spring washer is positioned correctly. Fit it with the concavity facing the clutch gear (4).
N Place the clutch gear (4) on the clutch housing and in-

aCAUTION

sert the six compression springs (5) in the clutch gear slot using the two spring pins (6) respectively. N Coat the M8 T.E. screws (2) with LOCTITE 648. N Apply the support plate (3) on the clutch gear (4) and fasten it with the three M8x16 T.E. screws (2). Driving torque of screws (2): 30 Nm (3.0 kgm). D = LOCTITE 648.

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ENGINE
3.6.19 CLUTCH COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Check the gasket surface for signs of damage and

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check the whole thread to make sure it is in a perfect state of repair. N Check the support bushes of the driving shaft (1) and countershaft (2) for signs of rolling or grooves. N Measure the diameter of the two support bushes. Driving shaft bushes: wear limit 30.040 mm. Countershaft bushes: wear limit 20.060 mm.

Take a number of measurements, especially in the direction of the axis of both cylinders. None of the values must exceed the limit value.
N Measure the radial play of the driving shaft and coun-

aCAUTION

tershaft, see 3.6.5 (ENGINE HALF-CASING - MAIN BUSHES, DRIVING SHAFT AND COUNTERSHAFT). 3.6.20 SUPPORT BUSHES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY
N Mark the contact surface (3) of the two bushes on the

NOTE Have the appropriate special tool & (4) to hand

N Remove the main bushes with the special tool (4).

clutch cover.

(cod. 8140156 + 8140157 + 0276377 - clutch cover sleeve puller).

As a rule, the main bushes should all be replaced together.

aCAUTION

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RSV mille ASSEMBLY

N Clean the diameter of the main bush housing and the

ENGINE

lubrication hole between the bush housings inside the clutch cover. N Determine the driving shaft bushes size group based on the coloured markings (5) on the clutch cover.

NOTE The size group of the main bushes is also marked with a coloured dot.
N If the coloured marking applied on the clutch cover is no

longer clearly legible, calculate the diameter based on the average of a number of different measurements.

Take a number of measurements, especially in the direction of the axis of both cylinders. Hole in the clutch cover 32.921 - 32.930 mm 32.930 - 32.940 mm 32.940 - 32.951 mm Bush cover marking red blue yellow Clutch cover marking red blue yellow

aCAUTION

N Heat the engine casing to approx. 130 C (266 F). N Coat the main bushes and the bush housings in the

NOTE Have the appropriate special tools & to hand:

(6) cod. 0277727 (clutch cover driving shaft bush inserter pad); (7) cod. 0277729 (main countershaft bush inserter pad). N Place the driving shaft and countershaft main bushes on the inserter pads (6 - 7), using a suitable O-ring (8) to hold them in place. N Line up the contact surface of the main bushes with the previously applied coloured marking (3). N With due care, insert the main bushes on a press until the installer punch touches.

clutch cover with MOLYKOTE G-N.

In order to insert the bushes, the clutch cover must be supported around the bush housing.
N Remove the O-ring (8) before the installer punch

aCAUTION

makes contact. The driving shaft main bushes must be flush with the thrust-bearing surface (9). The countershaft bushes are assembled 1.0 mm further down with respect to the thrust-bearing surface (10).

Once disassembled, the bushes must not be reused. M = MOLYKOTE G-N.

aCAUTION

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ENGINE
3.6.21 COOLANT PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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The coolant pump only needs disassembling in the event of oil or coolant leakage.
N Check the drainage hole (1) for any signs of oil or cool-

aCAUTION

ant leakage. DISASSEMBLY

N Hold the coolant pump gear (2) still whilst unscrewing

the impeller (3).

N Slide the coolant pump gear (2) up and off, and remove

the pin (4) together with the washer (5).

Take care not to damage the thread of the coolant pump shaft.
N Remove the coolant pump shaft (6) in the direction of

aCAUTION

the coolant pump gear (2).

NOTE Two holes are to be found in the clutch cover for

the purpose of disassembly.
N Remove the oil seal (7), together with the sliding seal-

ing ring (8), with a hole punch (9). INSPECTION

N Check the impeller (3) for signs of damage or distortion

and, where necessary, replace it.

N Check the coolant pump shaft (6) for signs of rolling

around the oil seal sliding area and, where necessary, replace it. N Measure the coolant pump shaft housing slot (10) on the clutch cover. Slot wear limit (10) max. 10.10 mm.
N Check the teeth of the coolant pump gear (2) for signs

of damage or broken material and check the distance of the grooves protruding from the central slot (11) due to accommodate the pin. Groove wear limit (11) max. 3.70 mm.
N Check the teeth of the coolant pump idler gear (12) for

signs of damage or broken material.

N Measure the housing slot (13).

Slot wear limit (13) max. 10.22 mm.

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RSV mille ASSEMBLY

ENGINE

NOTE Have the appropriate special tools & to hand:

(14) handle for pads; (15) cod. 0277670 (coolant pump shaft housing oil seal assembly pad); (16) cod. 0877257 (coolant pump shaft housing sliding ring assembly pad).

NOTE

The closed side of the oil seal must be fitted so that it faces the impeller (3).
N Insert the oil seal (7) all the way into the slot using the

assembly punch.

NOTE

The closed side of the oil seal must be fitted so that it faces the impeller (3). assembly pad.

N Insert the sliding sealing ring (8) all the way in using the

Take care not to damage the impeller (3).

N Screw the impeller (3) firmly onto the coolant pump

aCAUTION

shaft (6).
N Coat the coolant pump shaft (6) with MOLYKOTE G-

N and insert it from the outside all the way onto the oil seal assembly. N Install the washer (5) on the coolant pump shaft. N Install the pin (4) in the coolant pump shaft slot and engage the coolant pump gear (2).

NOTE You must feel the pin is perfectly inserted in the slot in the coolant pump gear.
N Tighten the impeller (3) by hand, holding the coolant

pump gear (2) still. M = MOLYKOTE G-N.

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ENGINE
3.6.22 TIMING DRIVE ASSEMBLY

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Set the cylinder 1 and 2 timing drive assemblies aside in distinct groups so that you are sure to refit the parts in the same housing when it comes to reassembly.
N Check the sides of the timing gear (1), drive gears (2)

aCAUTION

and intermediate drive gears (3) for broken materials or distortion. N Check the slots of the idler gears (3) for wear. Wear limit (4) max. 20.015 mm.
N Check the roller bearings (5) for wear. N Check the two bearing flanges (6) for wear around the

sliding area of the roller bearings (5). Wear limit (7) max. 15.98 mm.
N Check the chain guide shoe (8), chain tightener shoe

(9), chain guide (10) and chain guide bracket (11) for any traces of rolling. Max. depth of the rolling traces: 1.2 mm.
N Check the teeth of the two timing chains (12) for any

signs of distortion.
N Check the length of the timing chain (13) over a dis-

tance of 20 pins. Wear limit max. 166.2 mm.

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RSV mille 3.6.23 HEAD AND CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). ASSEMBLY
N Unscrew and remove the four shouldered M8 screws

ENGINE

(1) respectively and remove head 1 and 2 from the cylinder.

N Unscrew and remove the four M6 T.C.E.I. screws (2)

together with the respective washers (3) from head 2 and remove the chain guide (4) and the bush plate (5). N Remove the upper countershaft (6) from head 2. N nscrew and remove the eight M6 T.C.E.I. screws (7), together with the respective washers (8), and remove the camshaft U bolt (9) from head 1 and 2.

N Remove the intake camshaft (10) and exhaust cam-

shaft (11) from head 1 and 2. Set the disassembled components aside in groups according to the respective head so you are sure to refit them in the same position when it comes to reassembly.

NOTE

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ENGINE
3.6.24 DISASSEMBLING THE INTAKE AND EXHAUST VALVES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Before disassembling the valves, check head pressure

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loss on a plate (Bosch or Suntester). If the pressure loss is less than 5%, valve tightness is correct.

During the disassembly of the exhaust and intake valves, set aside the valve spring, valve spring housings and valve cotters and mark them accordingly based on the assembly position and the part they belong to, so that the same order is followed when the components are refitted.
N Remove the valve lifter buckets (1) and the adjusting

aCAUTION

NOTE have the appropriate special tools & to hand :

(5) cod. 8140179 (valve disassembly and reassembly bow); (6) cod. 0276479 (valve spring compression tool); N Compress the valve springs (3 - 4) using the clamping bow (5) and a valve spring compressor fitting (6), and remove the valve cotters (7). N Release the valve springs (3 - 4). N Remove the valve spring housings (8) of the two valve springs (3 - 4) and remove the valves (9). N Clean the combustion chamber, removing the residual combustion products and the deposits from the cooling cavity. N Check the thread of the spark plugs and the fastening thread, making sure they are in a perfect state of repair. N Check that the oil galleries are clear and, where necessary, clean them by blowing a jet of compressed air inside. N Check the gasket surfaces for any signs of damage and make sure they are flat. Max. permissible distortion: 0.03 mm.

shims (2).

NOTE Where necessary, trim the gasket surfaces on a

plate suitable for the purpose.
N Make sure the valve bucket (1) and guide in the head

are in a perfect state of repair. Bucket slot in the head (10): wear limit: max. 33.58 mm; Bucket (1): wear limit: min. 33.44 mm; Bucket radial play (1) wear limit: max. 0.08 mm.

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RSV mille 3.6.25 CAMSHAFT AND CAMSHAFT BUSHES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Check the cams (1) for broken material, signs of distor-

ENGINE

tion or wear and, where necessary, replace the camshaft. Measure the play of the camshafts:
N Place the camshafts in the head. N Apply a plastic gauge (2) on the bearing housings of the

camshafts.
N Apply the U bolts according to which shaft they are as-

signed to and fasten them with the M6 T.C.E.I. screws. Driving torque: 10 Nm (1.0 kgm).
N Remove the T.C.E.I. screws and the U bolts. N Measure the maximum width of the pressed plastic

gauge with the corresponding graduated scale (3). Wear limit: max. 0.060 mm.
N If the wear limit is exceeded, the bush housings on the

camshafts and on the head must be measured, and the worn part replaced. Camshaft bush housings: wear limit (4): min. 23.950 mm; Head bush housings: wear limit: max. 24.040 mm;
N Insert the intake and exhaust camshafts in the respec-

tive housings in the head and measure the end play with a comparator. End play of the camshafts: wear limit: max. 0.40 mm.
N If the wear limit is exceeded, the axial contact surfaces,

both of the camshafts and in the head, must be measured and the worn part replaced. Axial contact surfaces, (6) camshafts: wear limit: max. 27.77 mm; Axial contact surfaces, (7) head: wear limit: min. 27.10 mm.

NOTE

If the camshaft is replaced, the buckets must also be changed.

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ENGINE
3.6.26 UPPER COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Check the countershaft for wear.

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NOTE

The bush housing (1) is slightly tapered, hence the measurement must be taken half way along the housing. Bush housing (1): wear limit: min. 34.98 mm; Ball bearing pin (2): wear limit: min. 14.97 mm.

NOTE The bush (3) is slightly tapered.

N Check the internal diameter (3) of the bushes in the

plate and check for wear or cracks.

NOTE

Install the countershaft and measure the radial play with a comparator. Max. permissible radial play 0.70 mm.

N Measure the radial play of the bush.

N If the maximum permissible radial play is exceeded, the

worn part must be replaced.

NOTE

Should the bushes be worn, the whole bush plate must be replaced. ure the end play with a comparator. Wear limit: max. 0.040 mm.

N Install the countershaft in the head (2) (rear) and meas-

NOTE

If the end play wear limit is exceeded, replace the bush plate. SEMBLING HEAD 2 (REAR) CAMSHAFT].

N Install the countershaft in head 2 , see 3.7.12 [AS-

N Make sure the ball bearing (4) in the U bolt slides

smoothly and does not feature pitting, and check slack.

NOTE

Oil the ball bearings with motor oil before performing the check. If the inner race does not turn easily and silently, or if it makes a noise, it means the bearing is defective and needs replacing. wear or signs of damage.

N Check the oil seal (5) behind the ball bearing (4) for any

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RSV mille 3.6.27 DISASSEMBLING AND ASSEMBLING THE UPPER COUNTERSHAFT BALL BEARINGS AND OIL SEAL Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

NOTE Have the appropriate special tools & to hand:

(6) cod. 8140156 + 8140157 + 0276377 (clutch cover sleeve puller); (7) handle for pads; (8) cod. 877257 (coolant pump shaft housing sliding ring assembly pad). N Heat the camshaft U bolt to approx. 80 - 100 C (176 212 F).

NOTE Take care not to damage the camshaft U bolt.

N Remove the ball bearings (4) with the puller plate (6)

and with the expansion sleeve suitable for the bearing.

NOTE As a rule, the ball bearings and the oil seals should be replaced.
N Lift the oil seal (5).

NOTE

Before assembling, oil the external diameter of the oil seal slightly. The closed side of the oil seal must face outwards. Grease the sealing lips.

In order to avoid damaging the ball bearing, under no circumstances should the oil seal touch the bearings inner race.
N Insert the oil seal (5) all the way in using the assembly

aCAUTION

punch.
N Oil the external diameter of the ball bearing (4) slightly

and insert it all the way onto the outer ring with a suitable assembly punch. N Check the ball bearing housing (4) on the U bolt for signs of wear. Interference: min. 0.030 mm.

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ENGINE
3.6.28 VALVE GUIDE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Use a dial gauge to measure the wear of the valve

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guide (1). Wear limit (2): max. 6.05 mm.

NOTE

If the valve guide is worn, it can be replaced.

ASSEMBLY AND DISASSEMBLY

N Slip off the valve stem seal (3) and remove the valve

spring shim (4).

NOTE Replace the valve stem seal (3).

N To eliminate the valve guide with a reamer (5) as far as

the start of the notch (6).

NOTE The sharp edge of the valve guide must be eliminated as, otherwise, the head slot is in danger of being to slide when the valve guide is removed. Have the appropriate special tool & (7) to hand (cod. 0277510 valve guide disassembly pad).

NOTE Do not heat the head.

N Use the pad (7) to remove the rest of the guide valve in

the direction of the exhaust manifold.

N Check the valve guide slot for tailings.

NOTE Should any signs of picking-up be encountered,

the head must be replaced.

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RSV mille

ENGINE

La testata o il guidavalvola si danneggia se non si usa il MOLYKOTE G-N.

N Apply a coat of MOLYKOTE G-N on the head hole

aCAUTION

NOTE Have the appropriate special tool & (8) to hand

(cod. 0277695 valve guide oil seal assembly pad).
N Using the assembly pad (8), insert the new valve guide

and on the valve guide assembly edge.

in the head, working from the oil chamber towards the combustion chamber until the assembly punch reaches a level position.

NOTE

The exhaust valve and intake valve guides are different. The difference consists in the fact that the intake valve guide has a longer smoothed surface (9). trudes on the camshaft side. (10) Protrusion = 13.3 0.2 mm.

N Check how much the head (10) of the valve guide pro-

N Bore the valve guide with a 6 F7 reamer.

Hole of the valve guide 6.006 6.018 mm.

NOTE Use cutting fluid only to lubricate the reamer.

The reamer should only be turned in the cutting direction, never in the opposite direction, and cleaned of tailings at frequent intervals, again always removing it in the direction of the cut.
N Having bored the valve guide, clean the head thorough-

ly and grind the valve seat (11), smoothing the valve seat with a valve seat reconditioning device, and grind the valve, see 3.6.29 (VALVES - VALVE SEATS). N Check the contact mark using the relevant marking paste (Prussian blue).

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ENGINE
3.6.29 VALVES Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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The seat (1) on the head of the valve is reinforced by means of inductive hardening. For this reason, the seat cannot be reground and, instead, the valve must be replaced. Grinding with abrasive paste is nonetheless permitted, whilst it is prohibited to regrind a valve at the end on the valve stem.
N Clean the valves of all residual combustion products. N Check the seat (1) on the valve head with a line.

aCAUTION

The surface of the seat must not be concave; where necessary, replace it. N Check the diameter of the stem with a micrometer: intake valve: wear limit (2) min. 5.950 mm; exhaust valve: wear limit (2) min. 5.935 mm.
N Check the eccentricity of the valve:

valve stem: permissible eccentricity (3) max. 0.05 mm; valve head: permissible eccentricity (4) max. 0.05 mm.
N Check whether the fastening grooves (5) of the valve

cotters are in a perfect state of repair.

VALVE SPRINGS
N Measure and visually inspect the valve springs to check

for breakage, distortion or loss of tension; measure the length of the springs in the release position. Valve springs: wear limit (6) min. 43.4 mm; Valve springs: wear limit (7) min. 40.9 mm.

NOTE

Worn spring valves may result in a reduction in engine power and increased noise from the valve assembly.

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RSV mille VALVE SEATS

N Coat the valve seat surfaces with marking paste (Prus-

ENGINE

sian blue).
N Insert the corresponding valve (1) and turn the valve,

pressing down slightly with a valve grinder.

N Check the width of the valve seat (2-3) and the contact

mark, checking for any signs of wear. Intake valve: wear limit (2) max. 1.6 mm; Exhaust valve: wear limit (3) max. 1.8 mm.

NOTE The circular contact mark on the valve seat and

valve surfaces must be continuous and unbroken. If the width of the valve seat exceeds the wear limit or if the valve seat surface is not continuous, the valve seat can be ground. GRINDING THE VALVE SEATS A = intake B = exhaust

NOTE The valve seats can be ground with a valve seat

grinding device centred in the valve guide.
N Perform grinding at 45 with the valve seat grinding de-

vice until the whole valve seat is covered in tailing. During this operation, make sure no more material than necessary is removed. N Lastly, grind at 35 until the given diameter (4-5) is obtained. Intake valve (4) 35.3 mm; Exhaust valve (5) 30.3 mm.
N Next, grind the intake valve at 50 and the exhaust

valve at 80 with the grinding device until the given width (6-7) for the valve seat surface is obtained. Intake valve (6) 1.05 - 1.35 mm; Exhaust valve (7) 1.25 - 1.55 mm.
N Grind the valve (1) with the valve grinder and the valve

grinder paste.

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ENGINE
ASSEMBLING THE VALVES IN THE HEAD

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NOTE Have the appropriate special tools & to hand:

(3) cod. 0277210 (valve guide assembly pad): (8) cod. 0276479 (valve spring compression tool); (9) cod. 8140179 (valve disassembly and reassembly bow).

During assembly, make sure the valves and valve lifter buckets are refitted where they belong inside the head.
N Insert the valve spring housing cap (1) through the

aCAUTION

valve guide.
N Fit a new valve stem oil seal (2) with the assembly pad

(3).
N Oil the valve stem and carefully insert the valve (4) in-

side the valve guide.

NOTE Take care not to damage the valve stem oil seal
(2).
N Check head pressure loss on a plate (Bosch or Sun-

tester).

NOTE

If the pressure loss is less than 7%, this means valve tightness is correct.

N Fit the valve springs (5-6) and valve spring caps (7).

NOTE The intake and exhaust valve springs are identical, but must always be fitted so that the coloured marking is at the top since the winding of the springs is progressive.
N Preload the valve springs with the spring compressor

(8) and special clamping device (9) and insert them in the valve cotters (10).

NOTE

Apply grease on the valve cotters (10) to make assembly easier. valve cotters (10) are inserted perfectly in the valve grooves. Where necessary, use a plastic hammer to tap them in gently.

N When releasing the clamping device (9), make sure the

Make sure the valve springs are inserted properly. If the valves are fitted obliquely, they will inevitably cause the valve stems to break. O = Motor oil.

aCAUTION

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RSV mille 3.6.30 CYLINDER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N All the gasket surfaces must be cleaned and flat. Flat-

ENGINE

ness of the gasket surfaces: Max. permissible distortion: 0.04 mm.

N Make sure all the threads are in a perfect state of re-

pair.
N Examine the sliding surface of the cylinder to check for

any friction and scratches, and check whether the gasket surfaces feature signs of damage.

NOTE If there are evident grooves on the nikasil lining inside the cylinder, replace the cylinder complete with piston.
N Clean the cylinders cooling cavity of any lime scale. N Measure the bore of the cylinder in 3 places at a dis-

tance of 45 mm from the upper edge (1); consider the highest value for the wear limit. Cylinder A dimension when new: bore 97.000 - 97.012 mm. wear limit: max. 97.027 mm. Cylinder B dimension when new: bore 97.012 - 97.025 mm. wear limit: max. 97.040 mm.

NOTE NOTE

The size group A or B is punched onto the lower side of the cylinder (2).

In order to assess the wear limit, the assembly play must be determined, see 3.6.31 (PISTON AND GUDGEON PIN). cylinder are in a perfect state of repair. Chain tightener (3) / hole on the cylinder clearance (4): wear limit (hole diameter - chain tightener diameter): max. 0.08 mm; Hole for chain tightener in the cylinder: wear limit (4): max. 14.07 mm.

N Make sure the chain tightener (3) and the guide in the

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ENGINE
3.6.31 PISTON AND GUDGEON PIN Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Clean the piston crown (1) and the area above the up-

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per piston ring (2) of any residual combustion products.

N Check the piston for any cracks and the sliding surface

of the piston for signs of compression (picking-up). Where necessary, replace the piston.

NOTE Minor ridging on the piston lining is tolerable.

N Measure the piston diameter at a height of 10 mm (3)

across the gudgeon pin axis, using an external micrometer. Red piston: wear limit min. 96.918 mm. Green piston: wear limit min. 96.930 mm. Piston play - measurement: piston play =cylinder diameter minus piston diameter wear limit max. 0.090 mm.

NOTE If the wear limit is exceeded, a new piston must

be used or the cylinder replaced, complete with piston. If the piston is replaced, the two seeger rings securing the gudgeon pins must always be replaced, along with the actual gudgeon pins. Take special care when matching the cylinder - piston: Red piston - Cylinder A. Green piston - Cylinder B.
N Use an external micrometer to measure the diameter of

the gudgeon pin hole in the piston in the direction of lift and the diameter of the gudgeon pin at either end as well as in the middle. Gudgeon pin hole in the direction of lift: wear limit (4) max. 22.018 mm. Gudgeon pin: wear limit (5) min 21.998 mm.
N Check the wear of the gudgeon pin seeger rings with

the bent ends.

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RSV mille
N Use a feeler gauge to measure the end play (7-8-9) of

ENGINE

the piston rings inside the grooves. L-section ring wear limit (7) max. 0.12 mm; Tapered protruding ring: wear limit (8) max. 0.12 mm; Scraper ring wear limit (9) max. 0.10 mm.

The piston rings are fragile.

aCAUTION

N Carefully remove the piston rings from the piston.

NOTE

The piston ring groove can be cleaned using a scraper or an old piston ring.

N Clean the piston ring grooves and the oil return holes

(10) in the scraper ring groove, then blow a jet of compressed air inside. N Check the scraper ring (11), the tapered protruding ring (12) and the L-section ring (13) to make sure the sliding surface is cleaned.

N Measure the piston ring gap (14) with a feeler gauge.

wear limit max. 1.00 mm.

NOTE In order to measure the gap required, insert the piston ring in the cylinder and push it inside so that it is lined up with the piston. The cylinder bore must not feature any signs of wear.
N Measure the thickness of the rings with a micrometer.

L-section ring: wear limit (15) min. 0.85 mm; Tapered protruding ring: wear limit (16) min. 1.20 mm; Scraper ring: wear limit (17) min. 2.45 mm.
N Fit the scraper ring (11), the tapered protruding ring

(12) and the L-section ring (13) from the bottom up; the word TOP on the rings must face up.

NOTE Rotate the piston rings so that the three gaps are staggered by approx. 120.

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ENGINE
3.6.32 STARTER MOTOR DRIVE ASSEMBLY

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Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

NOTE

If the toothing of the double starter gear is distorted, the toothing of the starter motor must also be checked.

N Check the toothing of the double starter gear (1), idler

gear (2) and the freewheel gear (3) for broken material or distortion. N Check the bush of the freewheel gear (3) for signs of rolling and grooves. N Measure the gear bearing diameter. Double starter gear: wear limit (4) max. 10.10 mm. Idler gear: wear limit (5) max. 10.08 mm. Freewheel gear (6): wear limit max. 35.07 mm.

NOTE The bush inside the freewheel gear (3) must be inserted so that it is fixed and unable to move freely.
Should signs of distortion be encountered on the sliding surface, or materials found to be broken, the freewheel gear must be replaced.
N Check the sliding surface (7) of the freewheel for wear.

N Clean the cone (8) of the magnetic hub of any LOC-

TITE residues.

NOTE

If the cone or slot for the key are damaged, the magnetic hub must be replaced.
N Make sure the cone (8) and the slot (9) for the key are

in a perfect state of repair.

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RSV mille
N Remove the freewheel (10) from the relevant housing

ENGINE

(11) and check the rollers of the freewheel (10) for signs of wear. N Check whether the external helical spring is preloaded enough to keep the rollers in place. N Check the sliding surface of the freewheel inside the relevant housing (11) for signs of wear.

NOTE

Should the sliding surface feature signs of distortion or deep grooves, the freewheel housing must be replaced.

FREEWHEEL HOUSING - DISASSEMBLY

N Unscrew and remove the three M8x16 T.C.E.I. screws

(12) and detach the freewheel housing (11) from the magnetic wheel (13). FREEWHEEL HOUSING - ASSEMBLY Use LOCTITE 648 on the flat surface of the housing (11).
N Apply a coat of LOCTITE 648 on the flat surface of the

aCAUTION

freewheel housing (11) and place it in the centre of the magnetic wheel (13). N Apply a coat of LOCTITE 648 on the three M8x16 cheese-headed screws (12) and screw the freewheel housing onto the magnetic wheel. Driving torque of screws (12): 30 Nm (3.0 kgm). C = LOCTITE 648.

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ENGINE
3.6.33 IGNITION GENERATOR Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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NOTE The ignition generator produces alternating current which is then transformed into direct current by the regulator/rectifier, which then charges the battery.

Before performing any repair work on the ignition generator, take out the ignition key and disconnect the battery, disconnecting the negative pole () first. Take care around the high voltage in the ignition generator.

aWARNING

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RSV mille STATOR

N Disconnect the ignition generator connector (1) from

ENGINE

the electric wiring.

N Use an ammeter to measure the resistance between

the three output connections to be found on the connector (yellow cables). Standard resistance value in the range 0.2 - 0.5 at 20 C (68 F).

NOTE

If the resistance value does not fall within this range, the stator must be replaced. Disassembling the stator

N Unscrew and remove the stators three M6 T.C.E.I.

screws (2) and the two M6 screws (3) of the driving shaft position sensor. N Remove the stator (4) with the driving shaft position sensor (5) from the flywheel cover (7), along with the cable bracket (6). N Check the flywheel cover (7) is flat and make sure it features no signs of damage on the gasket surfaces. Assembling the stator
N Insert the stator in the flywheel cover and fasten it with

the three M6 T.C.E.I. screws (2), coating the screws with LOCTITE 243. Driving torque: 11 Nm (1.1 kgm).
N Coat the cable rubber (8) with SILASTIC 732 RTV and

place it in the ignition cover.

N Coat the two screws (3) with LOCTITE 243. N Fit the driving shaft position sensor (5) in place and fas-

ten it with the two M6 screws (3). Driving torque of screws (3): 11 Nm (1.1 kgm). Magnetic wheel:
N Clean the magnetic hub cone (9) of any LOCTITE res-

idues.
N Make sure the cone (9) and the slot (10) for the key are

in a perfect state of repair.

NOTE

If the cone or the slot for the key are damaged, the magnetic hub must be replaced. Q = SILASTIC 732 RTV. B = LOCTITE 243.

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ENGINE
3.6.34 SPARK PLUGS See 2.7 (Spark plugs).

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3.6.35 DRIVING CHAIN PINION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Remove the drive pinion (1), see 7.9.1 (REMOVING

THE REAR FORK).

N Check the pinions internal toothing (2) for wear. N Check the pinions external toothing (3) for wear and

signs of distortion.

NOTE

If the toothing of the driving chain is worn, the chain pinion must be replaced together with the driving chain.

3.6.36 STARTER MOTOR Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Remove the starter motor, see 3.5.2 (REMOVING THE

STARTER MOTOR).

NOTE

The starter motor is not normally subject to any particular wear and tear. In the event the carbon brushes are worn, they can be replaced using the available repair kit; if not, replace the complete starter motor.
N Check the starter motors toothing (4) for broken materi-

als, wear and distortion.

NOTE Where necessary, replace the starter motor.

N Check the starter motor mount O-ring (5) for wear and

any signs of damage, and replace it.

N Unscrew and remove the two M6 T.E. screws (6) and

remove the complete rear cover (7).

N The four carbon brushes must be allowed to move free-

ly.
N Check the preloading of the brush springs. N Check the length of the carbon brushes.

Wear limit min. 8.0 mm.

NOTE Kits are available containing rear covers complete with carbon brushes and seals.
N Fasten the complete rear cover with the two M6 T.E.

screws (6).

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RSV mille  2%!33%-",).' 4(% %.').% Carefully read 3.5.1 (ENGINE DISASSEMBLY SEQUENCE). .

ENGINE

Touching the engine while hot may cause burns.

aWARNING aCAUTION

When repairing the engine, always replace all the previously disassembled gaskets, seeger rings, O-rings and seals. Unless otherwise indicated, lubricate all the moving and sliding parts. 3.7.1 ASSEMBLING THE GEARSHIFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

NOTE Assemble the gears on the driving shafts, see 3.6.15 (GEARSHIFT - ASSEMBLY). NOTE

Have the appropriate special tool & (1) to hand (cod. 0277308 gearshift secondary shaft guide bush). ondary shaft (2).

N Insert the guide bush (1) on top of the gear of the secN Grease the secondary shaft seal between the two lips. N Apply a coat of LOCTITE Anti Seize on the housings

of the secondary shaft (2) and primary shaft (3).

N Insert the primary shaft (3) in the housing in the fly-

wheel side half of the engine casing.

N Insert the secondary shaft (2) in the housing in the fly-

wheel side half of the engine casing.

N Insert the complete gearshift assembly in its housing,

tapping the two shafts lightly all the way in with a plastic hammer. N Insert the washer (4) on the secondary shaft (2). N Oil the fork of 5th and 6th gear (5) and insert it in the selector gear of the primary shaft (3). N Oil the fork of 2nd and 4th gear (6) and the fork of 1st and 3rd gear (7) and insert them in the respective selector gears of the secondary shaft (2).

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ENGINE
N Oil the shift cam (8) and insert it in the relevant slot in

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the casing.
N Attach the 3 gearshift forks inside the respective guides

of the shift cam (8).

N Insert the two gearshift rods (9), pushing them all the

way into the respective slots in the flywheel side half of the engine casing.

3.7.2 ASSEMBLING THE DRIVING SHAFT AND COUNTERSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Apply a coat of MOLYKOTE G-N on the housings of

the bushes for the driving shaft and countershaft.

N Insert the driving shaft (10) in the housing in the fly-

wheel side half of the engine casing. Position the lower connecting rod (11) towards cylinder 2 (rear) and the upper connecting rod (12) towards cylinder 1 (front).

NOTE

Do not tilt the driving shaft during insertion so as to avoid damaging the main bushes inside the housing.
N Insert the countershaft (13) in the relevant housing.

aCAUTION

Do not tilt the countershaft during insertion so as to avoid damaging the bearing bushes inside the housing. M = MOLYKOTE G-N. E = LOCTITE Anti Seize.

aCAUTION

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RSV mille 3.7.3 ASSEMBLING THE ENGINE CASING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

Use a new gasket.

aCAUTION

N Apply the engine casing gasket (1) on the flywheel side

half of the engine casing.

NOTE The engine casing gasket must coincide with all

the engine casing holes over the whole area. Grease may be applied on the gasket to prevent the movement. Work with extreme care to assure a perfect seal.
N Make sure the washer (2) is on the driving shaft. N Coat the housings of the secondary shaft (3) and pri-

mary shaft (4) with LOCTITE Anti Seize.

N Coat the housings of the driving shaft (5) and counter-

shaft (6) with MOLYKOTE G-N.

N Make sure the oil-spray pipe (7) is fitted. N Make sure the oil gauze is inserted in the clutch side

half of the engine casing.

N Install the clutch side half of the engine casing (8) on

the flywheel side half.

NOTE

Where necessary, use a plastic hammer to tap on the casing rib, near of the shaft. Take care not to damage the gasket surface of the clutch cover (9).

N Rotate the engine casing towards the clutch side.

Screw on the screws in a crisscross pattern, tightening them gradually.

N Screw the twenty M6 T.C.E.I. screws onto the engine

aCAUTION

casing, i.e.: thirteen M6x65 screws (10); five M6x45 screws (11); one M6x80 screw (12); one M6x25 screw (13). Driving torque of screws (10-11-12-13): 11 Nm (1.1 kgm)

NOTE

Having tightened the engine casing screws, make sure the driving shaft, countershaft, primary shaft and secondary shaft can turn slightly.
N Check the end play of the driving shaft with a compara-

tor. Wear limit: max. 0.5 mm.

NOTE
cloth.

Cover the engine compartment with a clean

N Use a paper cutter to cut the parts of the gasket sticking

out from the engine casing (14) around the cylinder flange and where the cylinder is centred.

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ENGINE
N Screw on the magnetic plug (15).

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Driving torque of magnetic plug (15): 20 Nm (2.0 kgm).

N Insert a new oil filter cartridge (16) in the housing in the

casing.

Having changed the oil and oil filter, the engine must be started for approx. 15-20 seconds with the injectors disconnected to enable the oil pipes to fill.
N Insert the O-ring (17) in the slot on the oil filter cover

aCAUTION

(18) and fasten the oil filter cover with the two T.C.E.I. M6 screws (19). Driving torque of screws (19): 11 Nm (1.1 kgm). 3.7.4 ASSEMBLING THE GEAR SELECTION MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

NOTE

Lock the M6 T.C.E.I. screw (24) in place with a LOCTITE 243 product. washer (23) and secure them with the M6 T.C.E.I. screw (24).

N Fit the index spring (20), shim (21), index lever (22) and

Driving torque of screw (24): 11 Nm (1.1 kgm).

NOTE

Lock the M6 T.C.E.I. screw (27) in place with a LOCTITE 243 product. plate (25) in the shift cam slot (26), fastening it with the M6 T.C.E.I. screw (27).

N Press the index lever (22) down and insert the index

Driving torque of screw (27): 11 Nm (1.1 kgm).

N Oil the complete gearshift shaft (28) and insert it in the

relevant housing.
N Insert the thrust washer (29) and insert the seeger ring

(30) in the groove of the secondary shaft.

NOTE

Always replace the seeger ring. Make sure the ends are not pulled apart more than necessary (use a pair of pliers for seegar ring). B = LOCTITE 243.

3 - 88

RSV mille 3.7.5 CHECKING THE GEAR SELECTION MECHANISM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Make sure the needle spring (1) in the rotating lever (2)

ENGINE

and in the cylindrical pin (3) features no slack. If this is not the case, one of the needle springs (1) end must be bent.
N Engage all the gears and make sure the drive pins (4)

NOTE

of the index plate (5) are in the central position.

NOTE If this is not the case, one of the needle springs (1) end must be bent.

N Check the preloading of the positioning spring (6).

It must be quite hard to lift the positioning lever (7) of the shift cam index plate (5).

NOTE

Rotating the shift cam must cause the positioning spring (6) to push the positioning lever (7) into the relevant slot on the index plate (5). gearshift gears turn freely.

N Put the gearshift into neutral and make sure all the

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ENGINE
3.7.6 ASSEMBLING THE OIL PUMP Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). Make sure the LOCTITE product does not get inside the suction pump hole.
N Apply a thin film of LOCTITE 574 on the gasket sur-

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aCAUTION

face (1) of the oil pump casing.

N Insert the duly oiled external rotor (2) in the slot in the

casing.

NOTE The reference point must face down (towards the engine casing).
N Insert the pin (3) in the last hole at the bottom of the oil

pump shaft (4).

N Insert the internal rotor (5) in the oil pump shaft (4), with

the housing slot facing up.

N Insert the oil pump shaft (4) in the casing, complete with

internal rotor. Make sure the LOCTITE product does not get inside the pressure pump hole.
N Apply a thin film of LOCTITE 574 on the external gas-

aCAUTION

ket surface of the oil pump casing (6) and install it on the oil pump shaft (4). N Fasten the oil pump casing (6), complete with pin (7), inside the casing. N Insert the pin (8) in the central hole of the oil pump shaft. N Insert the duly oiled internal rotor (9) of the pressure pump on the oil pump shaft, with the driving groove facing down. N Insert the duly oiled external rotor (10) in the oil pump casing. N Fasten the oil pump cover (11) with the four T.C.E.I. screws (12). Driving torque of screws (12): 11 Nm (1.1 kgm).
N Insert the pin (13) in the hole of the oil pump shaft.

NOTE The oil pump cover features a groove (14) enabling the pin to be fitted. Line the pin up with the centre of the oil pump shaft.
D = LOCTITE 574.

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RSV mille

ENGINE

Once disassembled, the oil pump gear must always be replaced.

N Fit a new oil pump gear (15).

aCAUTION

NOTE You must feel the pin (13) engaging perfectly inside the groove on the oil pump gear.
N Fit the seeger ring (16) in the groove of the oil pump

shaft.

NOTE Make sure the seeger ring is inserted all the way
into the groove. Make sure the ends are not pulled apart any more than necessary.
N Check the rotation and end play of the oil pump shaft

(4). 3.7.7 ASSEMBLING THE DRIVE ASSEMBLY 2 (REAR) Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Turn the driving shaft so that the connecting rod of cyl-

NOTE

Have the appropriate special tool & (17) to hand (cod. 0240880 threaded bolt for retaining the driving shaft at TDC). (17).

inder 2 (rear) is at TDC.

N Lock the driving shaft in place with the threaded bolt

NOTE When cylinder 2 is at TDC, the fastening slot (18) of cylinder 1 is visible through the gap under the countershaft. The threaded bolt (17) must never be overtightened; max. 5 Nm (0.5 kgm).
N Use grease to assure adherence between the thrust

washer (19) and the intermediate drive gear (20). Hook up the timing chain (21) based on the reference marking applied during its disassembly.
N Place the timing chain (21) around the intermediate

NOTE

drive gear (20), guiding both through the chain compartment and inserting them in the housing. N = Lubricating grease.

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ENGINE
N Guide the chain tightener shoe (22) through the chain

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compartment and fasten it in the housing by means of the spacer bush (23). N Oil the two roller bearings (24) and push them onto the bearing pins of the bearing flange (25).

NOTE

Insert the bearing flange all the way in, tapping gently with a plastic hammer. The two calibrated bushes (29) must previously have been fastened in the casing. three M8 T.C.E.I. screws (26-27) and the spring washers (28), i.e.: two M8x45 screws (26); one M8x20 screw (27). Driving torque of screws (26-27): 25 Nm (2.5 kgm). O = Motor oil.

N Insert the bearing flange (25) and fasten it using the

N Check the rotation of the intermediate drive gear. N Insert the key (30) in the driving shaft. N The reference mark (31) on the intermediate drive gear

must coincide with the reference mark (32) on the casing. N Apply a coat of LOCTITE Anti Seize on the end of the driving shaft (33). N Push the drive gear (34) onto the driving shaft.

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RSV mille 3.7.8 ASSEMBLING THE COOLANT PUMP DRIVE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Coat the end of the countershaft (1) with LOCTITE

ENGINE

Anti Seize.
N Oil the housing at the end of the countershaft. N Insert the key (2) in the countershaft. N Insert the washer (3) with the flared side facing down. N Install the coolant pump gear (4) on the countershaft. N Insert the coolant pump idler gear (5) on the cylindrical

pin.
N Insert the washer (6) to the countershaft. N Install the driving gear (7) on the driving shaft.

NOTE The reference point must be visible.

N Insert the gear (8) on the countershaft.

NOTE The reference point must be visible and must coincide with the reference mark on the driving gear.
N Lift the countershaft all the way in the axial direction

and insert the counterweight (9) onto the countershaft.

NOTE The counterweight notch (10) must be engaged by the end of the key (2).
N Insert the spring washer (11) and tighten the M22x1.5

T.E. screw (12). Driving torque of screw (12): 150 Nm (15.0 kgm).

NOTE Make sure the position of the hole for the counterweight (9) is more or less at 10 oclock.
N Check the end play of the countershaft with a compara-

tor. Wear limit: max. 0.3 mm. O = Motor oil. E = LOCTITE Anti Seize.

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ENGINE
3.7.9 ASSEMBLING THE PRIMARY TRANSMISSION AND CLUTCH Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Coat the end of the driving shaft with LOCTITE Anti

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Seize.

NOTE The collar of the drive gear must face down.

N Insert the drive gear (1) on the driving shaft. N Fit the spring washer, then fasten and tighten the

M33x1.5 T.E. nut (2), coating it with LOCTITE 243. Driving torque of nut (2): 230 Nm (23.0 kgm).
N Insert the washer (3) on the primary shaft. N Coat the housing and toothing of the primary shaft (4)

with LOCTITE Anti Seize.

Once disassembled, always replace the oil pump gear.

N Place a new oil pump gear (5) on the preassembled

aCAUTION

clutch drum (6) and engage it.

N Insert the preassembled clutch drum (6) on the primary

shaft (4).

NOTE

Turn the oil pump gear (7) so that the toothing mates with the toothing of the pinion (5). the spring washer (10) on the primary shaft.

N Fit the serrated thrust ring (8), the clutch hub (9) and

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RSV mille

ENGINE

NOTE Have the appropriate special tool (cod. 0277281 clutch blocking tool).
N Insert the clutch blocking tool (11).

& to hand

Insert the clutch blocking tool (11) all the way in to the clutch basket so as not to damage the basket when the nut (12) is tightened.
N Screw on and tighten the T.E. nut (12), coating it with

aCAUTION

LOCTITE 648. Driving torque of nut (12): 170 Nm (17.0 kgm).

N Insert the clutch discs, starting with a steel one (13). N Insert a steel disc (13) followed by a lined disc (14), and

continuing alternately.

NOTE The first lined disc at the top (15) must be inserted in the staggered groove. The top lined disc (15) is recognizable as it has a dot punched onto it. Make sure this disc does not feature any slack, though it must not be locked in place. N Oil the friction disengaging shaft (16) and insert it in the primary shaft hole. N Insert the spring plate (17). N Insert the six clutch springs (18) in the spring plate and fasten them with the six washers (19) and the M6 T.C.E.I. screws (20). Driving torque of screws (20): 11 Nm (1.1 kgm). C = LOCTITE 648. O = Motor oil.

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ENGINE
3.7.10 ASSEMBLING THE PISTON AND CYLINDER 2 (REAR) Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Cover the engine compartment with a cloth. N Insert the two locating dowels (1). N Coat the four M10 stud bolts (2) with LOCTITE 243

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and screw them onto the engine casing. Driving torque of stud bolts (2): 10 Nm (1.0 Kgm)

N Coat the connecting rod small end and the hole of the

gudgeon pin inside the piston with MOLYKOTE G-N.

N Install the piston (3) on the connecting rod and push the

gudgeon pin (4) in, using a punch suitable for the job.

Observe the assembly direction indicated by the previously applied reference mark. If a new piston is used, the red or green reference point (5) on the piston crown must face in the direction of the exhaust (6), (only for 2 cylinder).
N Take special care when matching the cylinder - piston:

aCAUTION

Red piston - cylinder A; Green piston - cylinder B.

NOTE The cylinders size group A or B is stamped onto the lower side of the actual cylinder in the timing chain compartment area.
M = MOLYKOTE G-N.

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RSV mille

ENGINE

Use new bent-end gudgeon pin seeger rings (7) only.

N Insert the gudgeon pin seeger ring (7) in the piston,

aCAUTION

pushing down hard.

NOTE Support the piston (3).

Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook (8) is inserted in the slot of the actual piston.
N Where necessary, fit the second gudgeon pin seeger

ring (7), repeating the same procedure as described above.

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ENGINE
N Insert the two locating dowels (9) in the cylinder.

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aCAUTION
Use a new head gasket.
N Fit the head gasket (10) in place. N Place the preassembled head in the cylinder and tight-

en it on with the four shouldered T.E. screws (11). Non-painted cylinder version Driving torque of screws (11): 28-30 Nm (2.8-3.0 kgm) Painted cylinder version Driving torque of screws (11): 25-28 Nm (2.5-2.8 kgm)
N Apply a coat of LOCTITE 574 on the casing around

the gasket surface of the cylinder base gasket in the area of the line separating the two sections of the casing. N Apply the cylinder base gasket on the casing. N Oil the piston and the respective piston rings. N Turn the piston rings so that the meeting ends of the three rings are staggered by approx. 120.

NOTE

Have the appropriate special tool & (12) to hand (cod. 8140186 - piston ring compression tool). over the piston to preload the piston rings.

N Lower the ring compressor (12) or piston ring pliers N Place the chain tightener shoe (13) in the chain com-

partment of the cylinder (14) and push the cylinder over the piston so that the ring compressor is pushed down. N Remove the ring compressor (12). N Insert the timing chain (15) through the cylinders chain compartment.

NOTE

The timing chain can be guided inside using an O-ring or similar device to aid assembly. in all the way.

N Place the cylinder (14) on the engine casing, pushing it N Oil the thread of the stud bolts (2) and the contact sur-

faces.

NOTE Screw on the M10 T.E. nuts (16) and M6 T.C.E.I. screws (17) evenly and gradually, working in a crisscross pattern.
N Secure the cylinder together with the head with the four

M10 T.E. nuts (16) and two M6 T.C.E.I. screws (17). Non-painted head version: four M10 T.E. nuts (16), driving torque 58 Nm (5.8 kgm); two M6 T.C.E.I. screws (17), driving torque 12 Nm (1.2 kgm). Painted head version: two M10 T.E. nuts (16), external, driving torque 5055 Nm (5.0-5.5 kgm); two M10 T.E. nuts (16), chain compartment side, driving torque 58 Nm (5.8 kgm); two M6 T.C.E.I. screws (17), driving torque 12 Nm (1.2 kgm).

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RSV mille 3.7.11 ADJUSTING VALVE CLEARANCE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

ENGINE

Check and, where necessary, adjust the valve clearance: at periodic intervals, see 2.1.1 (REGULAR SERVICE INTERVALS CHART); every time the timing drive assembly is repaired or taken apart.; every time the head or camshaft is taken apart. The valve clearance adjustment must be performed with the engine at room temperature.

aCAUTION

NOTE The size is stamped on the adjustment shim.

Insert the adjustment shims with the writing facing down. Before fitting them, always measure the adjustment shims with a micrometer.
N Insert the adjustment shims (1) in the valve spring

housings (2).
N Oil the external diameter of the four valve lifter buckets

(3) and insert them in the head.

N Oil the four camshaft bushes (4) inside the head. N Fit the exhaust camshaft (5) and intake camshaft (6)

with the cam lobe facing up.

NOTE Difference on exhaust and intake camshafts:

up to engine # 524 388, the exhaust camshaft features a double shoulder (7); as of engine # 524 389, the intake camshaft features a distinguishing groove (R).
N Insert the camshaft by hand and measure the valve

clearance with a feeler gauge.

N Make a note of the value of the valve clearance meas-

ured.
N Measure the difference between the desired value and

the actual value. Valve clearance: intake valve 0.12 - 0.17 mm; exhaust valve 0.23 - 0.28 mm.
N Where necessary, replace the adjustment shim (1).

Intake valve: the 0.15 mm gauge must be inserted whilst the 0.20 mm one does not need to be inserted. Exhaust valve: the 0.25 mm gauge must be inserted whilst the 0.30 mm one does not need to be inserted. M = MOLYKOTE G-N. O = Motor oil.

aCAUTION

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ENGINE
3.7.12 ASSEMBLING HEAD 2 (REAR) CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Adjust the valve clearance, see 3.7.11 (ADJUSTING

RSV mille

VALVE CLEARANCE).
N Oil the housings of the output camshaft (1) and input

camshaft (2).
N Coat the cams with MOLYKOTE G-N and insert the

camshafts in the head.

NOTE Difference on exhaust and intake camshafts: up to engine # 524 388, the exhaust camshaft features a double shoulder (3); as of engine # 524 389, the intake camshaft features a distinguishing groove (R). NOTE
Tighten the camshaft U bolt gradually, starting from the inside and working in a crisscross pattern. washers (5) and the eight M6 T.C.E.I. screws (6, 7, 8): four M6x30 T.C.E.I. screws (6); two M6x45 T.C.E.I. screws (7); two M6x55 T.C.E.I. screws (8). Driving torque of screws (6-7-8): 11 Nm (1.1 kgm).
N Insert the countershaft (9). N Coat both countershaft bushes (10) with MOLYKOTE

N Fasten the main U bolt of the camshaft (4) with the four

G-N .
N Insert the bush flange (11). N Fit the chain guide (12) on the bush flange. N Fasten the bush flange (11) with the four M6 T.E.

screws (13 - 14) and the four washers (15): two M6x35 T.E. screws (13); two M6x20 T.E. screws (14). Driving torque of screws (13-14): 11 Nm (1.1 kgm). M = MOLYKOTE G-N. O = Motor oil. N = Lubricating grease.

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RSV mille 3.7.13 ASSEMBLING HEAD 2 (REAR) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The driving shaft must be locked at TDC of cylinder 2 (rear), see 3.5.11 [DISASSEMBLING CYLINDER 2 (REAR) TIMING DRIVE ASSEMBLY]. N Turn the camshafts so that the cam lobes (1) point away from each other. N Fit the timing gear (2) in the output camshaft (3) and line up the holes. NOTE In order to make assembly easier, the timing gear can be secured in place temporarily with an M6 T.C.E.I. screw. N Turn the timing gear (2) with the exhaust camshaft (3) until the EX reference mark (4) faces the centre of the intake camshaft. N Place the timing chain (5) over the timing gear (2) and under the chain guide (6). NOTE The timing chain must be taught on the traction side (7). N Engage the second timing gear (8) in the timing chain so that the IN reference mark (9) faces the EX reference mark (4) of the exhaust camshaft timing gear. N In this position, push the timing gear (8) onto the intake camshaft and line up the holes of the timing gear with those on the camshaft.

ENGINE

NOTE

The three T.C.E.I. M6 x 14 (11) screws must only be used for fastening the timing gear (10); danger of major engine damage and physical injury.
N Push the timing gear (10) onto the exhaust camshaft

aWARNING

and fasten it with the three M6x14 T.C.E.I. screws (11).

N Fasten the M6 T.C.E.I. screws (11), coating them with

LOCTITE 243. Driving torque of screws (11): 11 Nm (1.1 kgm).

N Secure the timing gear of the intake camshaft with

three M6x10 T.C.E.I. screws (12), fastening the T.C.E.I. screws with a coat of LOCTITE 243. Driving torque of screws (12): 11 Nm (1.1 kgm). B = LOCTITE 243. N = Lubricating grease.

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ENGINE
N Insert the chain guide (13) as far as it will go. N Oil the chain tightener (14) and fit it in the cylinder with

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the closed end facing the chain tightener shoe (15).

N Screw on the M18x1 T.E. screw (16) complete with

seal. Driving torque of screw (16): 20 Nm (2.0 kgm).

NOTE Be careful to keep the key from dropping into the

chain compartment. Cover the chain compartment accordingly.
N Insert the key (17) in the slot on the countershaft. N Push the differential gear (18) onto the countershaft so

that the two reference marks (19) are lined up with each other.

NOTE Make sure the sharp-edged side of the counterweight faces the countershaft.
N Push the counterweight (20) onto the countershaft. N Fasten the M14x1 T.E. nut (21) with a coat of LOC-

TITE 243 and tighten it. Driving torque of nut (21): 50 Nm (5.0 kgm).

Hold the countershaft still using a punch (22) suitable for the job.
N Coat the valve lifter bucket and camshaft cams with

aCAUTION

MOLYKOTE G-N. B = LOCTITE 243. N = Lubricating grease.

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RSV mille 3.7.14 ASSEMBLING HEAD 1 TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Unscrew the threaded bolt (1) for retaining the shaft at

ENGINE

TDC and turn the driving shaft (2) 300 anticlockwise so that the connecting rod (3) of cylinder 1 is at TDC.

NOTE Move the connecting rod (3) to a central position

so that it is not tilted in the casing.
N Screw the threaded bolt (1) back on.

NOTE Make sure the threaded bolt is inserted properly in the driving shaft handwheel slot. The threaded bolt (1) must not be overtightened: max. 5 Nm (0.5 kgm).
N Where necessary, press hard to insert the two locating

dowels (4) in the casing.

NOTE

As of engine # 527 354, the locating dowels (4) are no longer fitted; centring is achieved with the aid of the bearing support flange (11). on the intermediate timing gear (6).

N Using an amount of grease, place the thrust washer (5) N Place the timing chain (7) around the intermediate tim-

ing gear (6), guiding both through the chain compartment and seating them.

NOTE Attach the timing chain (7) based on the reference mark applied during disassembly.
N Guide the chain tightener shoe (8) though the chain

compartment and fasten it in the housing by means of the spacer sleeve (9). N Oil the two roller bearings (10) and push them onto the pin of the bearing support flange (11). N Insert the bearing support flange (11) push it on as far as it will go, tapping it with a hammer.

NOTE Coat the M6 T.C.E.I. screw (15) with a coat of LOCTITE 243.
N Insert the bearing flange (11) and fasten it with the two

M8 T.E. screws (12, 13), with the spring washers (14) and with the M6 T.C.E.I. screw (15). one M8x20 T.E. screw (12). one M8x45 T.E. screw (13). one M6x20 T.C.E.I. screw (15). Driving torque: M8 T.E. screws (12-13): 25 Nm (2.5 kgm); M6 T.C.E.I. screws (15): 11 Nm (1.1 kgm). B = LOCTITE 243. O =Motor oil. N = Lubricating grease.

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ENGINE
N Rotate the intermediate drive gear (6) so that the two

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reference marks (16) are lined up with each other.

N Place the counterweight (17) on the countershaft. N Insert the key (18) in the countershaft. N Push in the drive pinion (19) and counterweight (20).

NOTE

The half-moon shaped key (18) must be inserted in the upper counterweight slot. Make sure the reference mark on the intermediate drive gear coincides with the reference mark (16) on the bearing flange. LOCTITE 648 and screw it on to the countershaft. Driving torque of screw (21): 50 Nm (5.0 kgm).

N Fasten the M10 T.C.E.I. screw (21) with a coat of

C = LOCTITE 648.

NOTE The countershaft is timed by timing cylinder 2.

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RSV mille 3.7.15 ASSEMBLING THE STARTER MOTOR DRIVE ASSEMBLY AND IGNITION SYSTEM Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Oil the two pins (1) and coat the housing (2) of the free-

ENGINE

wheel gear on the driving shaft with MOLYKOTE G-N.

N Insert the double starter gear (3), idler gear (4) and

freewheel gear (5).

N Oil the surface (6) on the freewheel gear (5). N Grease the cone of the driving shaft and rotor (7). N Oil the freewheel (8) inside the relevant casing (9). N Coat the cone of the rotor (7) with LOCTITE 648. N Push the complete rotor (7) onto the driving shaft so

that the driving shaft key coincides with the slot on the flywheel hub.

NOTE

The double starter gear (3) must be rotated clockwise so that the freewheel can slide over the freewheel gear (5). During assembly, be careful not to let any LOCTITE product get inside the sleeve of the freewheel gear (5).

NOTE Complete the rotor (7) with the casing of the freewheel mechanism (9), see 3.6.33 (IGNITION GENERATOR).
N Fit the washer (10), fasten the M16 T.C.E.I. screw (11),

applying a coat of LOCTITE 648, and tighten it. Driving torque of screw (11): 130 Nm (13.0 kgm). C = LOCTITE 648. O = Motor oil.

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ENGINE
3.7.16 ASSEMBLING THE PISTON AND CYLINDER 1 (FRONT) Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Cover the engine compartment with a cloth. N Insert the two locating dowels (1). N Coat the four M10 stud bolts (2) with LOCTITE 243

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and screw them onto the engine casing. Driving torque of stud bolts (2): 15 Nm (1.5 Kgm).

N Coat the connecting rod small end and the hole of the

gudgeon pin inside the piston with MOLYKOTE G-N. N Install the piston (3) on the connecting rod and push the gudgeon pin (4) in, using a punch suitable for the job.

Observe the assembly direction indicated by the previously applied reference mark. If a new piston is used, the red or green reference point (5) on the piston crown must face in the direction of the intake (6).
N Take special care when matching the cylinder - piston:

aCAUTION

Red piston - cylinder A; Green piston - cylinder B.

NOTE The cylinders size group A or B is stamped onto the lower side of the actual cylinder in the timing chain compartment area.
M = MOLYKOTE G-N.

"1"

6 5 "1" "2"

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RSV mille

ENGINE

Use new bent-end gudgeon pin seeger rings (7) only.

N Insert the gudgeon pin seeger ring (7) in the piston,

aCAUTION

pushing down hard.

NOTE Support the piston (3).

Make sure the two gudgeon pin seeger rings are inserted perfectly in the groove of the piston and that the hook (8) is inserted in the slot of the actual piston.
N Where necessary, fit the second gudgeon pin seeger

ring (7), repeating the same procedure as described above.

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ENGINE
N Insert the two locating dowels (9) in the cylinder.

RSV mille

aCAUTION
Use a new head gasket.
N Fit the head gasket (10) in place. N Place the preassembled head in the cylinder and tight-

en it on with the four shouldered T.E. screws (11). Non-painted cylinder version: Driving torque of screws (11): 29 Nm (2.9 kgm). Painted cylinder version: Driving torque of screws (11): 27 Nm (2.7 kgm).
N Apply a coat of LOCTITE 574 on the casing around

the gasket surface of the cylinder base gasket in the area of the line separating the two sections of the casing. N Apply the cylinder base gasket on the casing. N Oil the piston and the respective piston rings. N Turn the piston rings so that the meeting ends of the three rings are staggered by approx. 120.

NOTE

Have the appropriate special tool & (12) to hand cod. 8140186 (piston ring compression tool). over the piston to preload the piston rings.

N Lower the ring compressor (12) or piston ring pliers N Place the chain tightener shoe (13) in the chain com-

partment of the cylinder (14) and push the cylinder over the piston so that the ring compressor is pushed down. N Remove the ring compressor (12). N Insert the timing chain (15) through the cylinders chain compartment.

NOTE

The timing chain can be guided inside using an O-ring or similar device to aid assembly.
N Place the cylinder (14) on the engine casing, pushing it

in all the way.

N Oil the thread of the stud bolts (2) and the contact sur-

faces.

NOTE

Screw on the M10 T.E. nuts (16) and M6 T.C.E.I. screws (17) evenly and gradually, working in a crisscross pattern. M10 T.E. nuts (16) and two M6 T.C.E.I. screws (17).

N Secure the cylinder together with the head with the four

Non-painted head version: four M10 T.E. nuts (16), driving torque 58 Nm (5.8 kgm); two M6 T.C.E.I. screws (17), driving torque 12 Nm (1.2 kgm). Painted head version: two M10 T.E. nuts (16), external, driving torque 53 Nm (5.3 kgm); two M10 T.E. nuts (16), chain compartment side, driving torque 58 Nm (5.8 kgm); two M6 T.C.E.I. screws (17), driving torque 12 Nm (1.2 kgm).

3 - 108

RSV mille 3.7.17 ASSEMBLING HEAD 1 (FRONT) CAMSHAFT Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Adjust the valve clearance, see 3.7.11 (ADJUSTING

ENGINE

VALVE CLEARANCE).
N Oil the housings of the exhaust camshaft (1) and intake

camshaft (2).
N Coat the cams with MOLYKOTE G-N and insert the

camshafts in the head.

NOTE Difference on exhaust and intake camshafts:

up to engine # 524 388, the exhaust camshaft features a double shoulder (3); as of engine # 524 389, the intake camshaft features a distinguishing groove (R).

NOTE Tighten the camshaft U bolt gradually, starting from the inside and working in a crisscross pattern.
N Fasten the U bolt of the camshaft (4) with the seven

washers (5) and seven M6x30 T.C.E.I. screws (6). Driving torque of screws (6): 11 Nm (1.1 kgm).

N Fit the camshaft sensor (7) and secure it in place with

two M5 Taptite screws (8), fastening them with a coat of LOCTITE 243. Driving torque of screws (8): 4 Nm (0.4 kgm).
N Insert the camshaft sensor cable in the guide race (9)

and fasten it with the cable clamp (10) and M6X30 T.C.E.I. screw (11). Driving torque of screw (11): 11 Nm (1.1 kgm). B = LOCTITE 243. Q = SILASTIC 732 RTV.

3 - 109

ENGINE
3.7.18 ASSEMBLING HEAD 1 (FRONT) TIMING DRIVE ASSEMBLY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

RSV mille

NOTE The driving shaft must be retained at TDC of cylinder 1 (front), see 3.5.6 [DISASSEMBLING CYLINDER 1 (FRONT) TIMING DRIVE ASSEMBLY].
N Turn the camshafts so that the cam lobes (1) point

away from each other.

N Fit the drive gear (2) in the exhaust camshaft (3) and

line up the holes.

NOTE

The drive gear of the exhaust camshaft has a transducer (4) for the camshaft sensor.

N Turn the timing gear (2) with the exhaust camshaft until

the EX reference mark (5) faces the centre of the intake camshaft. N Place the timing chain (6) over the timing gear (2).

NOTE
side (7).

The timing chain must be taught on the traction

N Secure the timing gear with the three M6 T.C.E.I.

screws (8), coating them with LOCTITE 243. Driving torque of screws (8): 11 Nm (1.1 kgm).
N Engage the second timing gear (9) in the timing chain

so that the IN reference mark (10) faces the EX reference mark (5) on the timing gear of the exhaust camshaft. N In this position, push the timing gear (9) onto the intake camshaft and line up the holes of the timing gear with those on the camshaft. N Secure the timing gear (9) with the three M6 T.C.E.I. screws (11), coating them with LOCTITE 243. Driving torque of screws (11): 11 Nm (1.1 kgm).

N Insert the chain guide shoe (12) as far as it will go. N Fit the chain guide bracket (13) and secure it with the

two M6 spacer screws (14). Driving torque of screws (14): 11 Nm (1.1 kgm).
N Oil the chain tightener (15) and fit it in the cylinder with

the closed end facing the chain tightener shoe (16).

N Screw on the M18x1 T.E. screw (17) complete with

seal. Driving torque of screws (17): 20 Nm (2.0 kgm).

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RSV mille 3.7.19 ASSEMBLING THE VALVE COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Coat the cable (1) of the camshaft sensor and rubber

ENGINE

element (2) with SILASTIC 732 RTV.

N Grease the head cover gasket (3) and insert it in the

groove on the head cover (4).

N Place the head cover on head 1 (front) and on head

2 (rear), securing it with the five M6 spacer screws (5). Driving torque of screws (5): 9 Nm (0.9 kgm).

N Secure the intake flange (6) with the two M8 T.C.E.I.

screws (7) and respective washers. Driving torque of screws (7): 19 Nm (1.9 kgm).
N Secure the support bracket (8) with the two M10

T.C.E.I. screws (9), fasten the two M10 nuts and apply LOCTITE 243. Driving torque of screws (9): 40 Nm (4.0 kgm). B = LOCTITE 243. Q = SILASTIC 732 RTV.

3 - 111

ENGINE
3.7.20 ASSEMBLING THE IGNITION COVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Where necessary, insert the locating dowel (1).

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NOTE Use a new gasket (2).

N Apply the gasket (2).

NOTE Have the appropriate special tool & (3) to hand

cod. 0277252 flywheel cover removal tool).
N Screw the tool (3) onto the ignition cover.

N Fit the ignition cover on the casing and screw it on with

the twelve M6 T.C.E.I. screws (5). Driving torque of screws (5): 11 Nm (1.1 kgm).
N Remove the tool (3) and tighten the plastic closing

screw (6) complete with O-ring.

N Screw on the four spark plugs inside the two heads us-

ing the special spanner. Driving torque of spark plugs: 18 Nm (1.8 kgm) (with head cold and thread not lubricated).

3 - 112

RSV mille 3.7.21 ASSEMBLING THE CLUTCH HOUSING Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Remove the threaded bolt (1) for retaining the shaft at

ENGINE

TDC.
N Insert the two locating dowels (2). N Fit the gasket (3) in place.

NOTE Use a new gasket.

N Coat the end of the driving shaft (4) and end of the

countershaft (5) with MOLYKOTE G-N.

N Fit the clutch cover (6), complete with coolant pump, on

the casing.

NOTE

Turn the impeller (8) to enable the toothing of the pump gear (7) to mate with the toothing of the coolant pump idler gear (9). T.C.E.I. screws (10) and four M8 T.C.E.I. screws (11, 12): eleven M6 x 35 screws (10); three M8 x 55 screws (11); one M8 x 65 screw (12). Driving torque: M6 T.C.E.I. screws (10) 11 Nm (1.1 kgm); M8 T.C.E.I. screws (11 - 12) 19 Nm (1.9 kgm).

N Screw on the clutch cover (6) using the eleven M6

NOTE
(12).

Fit the seal (13) on the M8x65 T.C.E.I. screw

NOTE Fit the seal (18) on the M6x25 T.C.E.I. screw (17) (coolant drain plug).
N Insert the shaped seal (14) in the coolant pump casing

(15) and fit it together with the clutch cover, securing it with the four M6 T.C.E.I. screws (16 - 17). Coat the M6 x 55 T.C.E.I. screw in the centre of the cover with LOCTITE 243. three M6 x 55 screws (16); one M6 x 25 screw (17). Driving torque of screws (16-17): 11 Nm (1.1 kgm). B = LOCTITE 243.

10

11 12

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ENGINE
N Fit the washer (19), support cup (20), diaphragm (21),

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cup (22) and spring washer (23) on the clutch disengaging shaft (24) and secure them with an M12 stop nut (25) previously coated with LOCTITE 648. Driving torque of nut (25): 30 Nm (3.0 kgm).

In order to tighten the stop nut, the diaphragm (21) must not be fixed in the clutch cover retainers (26).

aCAUTION

NOTE

Fit the support cup (20) and cup (22) on the clutch disengaging shaft with the rounded edge (27) facing out.

NOTE Hold the diaphragm (21) still on the clutch disengaging shaft (24), using a bent hexagon-head driver.

N Rotate the complete clutch disengaging shaft (24) and

fasten the diaphragm (21) in the clutch cover retainers (26).

26

21

N Insert the preassembled diaphragm disc (28) and se-

cure it with the eight M5 T.C.E.I. screws (29). Driving torque of screws (29): 5 Nm (0.5 kgm).

29 28

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RSV mille 3.7.22 ASSEMBLING THE STARTER MOTOR Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Grease the starter motor gear. N Coat the starter motor flanged housing with MOLYKO-

ENGINE

TE G-N.
N Centre the starter motor (1) in the casing, pushing it all

the way in and securing it with the two M6 T.C.E.I. screws (2). Driving torque of screws (2): 11 Nm (1.1 kgm). 3.7.23 ASSEMBLING THE DRIVING CHAIN PINION
N Coat the toothing of the secondary shaft with LOC-

TITE Anti Seize.

N Push in the chain pinion (3) with the collar facing in, and

secure it with the spring washer (4), washer (5) and M10 T.E. screw (6). Driving torque of screw (6): 50 Nm (5.0 kgm).
N Fit a new oil filter (7) in the engine compartment. N Fasten the oil filter cover (8) and O-ring (9) with two M6

T.C.E.I. screws (10). Driving torque of screws (10): 11 Nm (1.1 kgm).

N Clean the magnetic screw (11) of any deposits. N Screw on and tighten the magnetic screw (11).

Driving torque of screw (11): 20 Nm (2.0 kgm). M = MOLYKOTE G-N. N = Lubricating grease.

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ENGINE
 %.').% #(%#+3 35"3%15%.4 4/ 2%!33%-",9 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). 3.8.1 BLEEDING THE ENGINE OIL CIRCUIT
N Refill the engine with motor oil, see 2.14 (CHANGING

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THE ENGINE OIL AND THE OIL FILTER).

N Slip the two electric connectors off the two injectors (1-

2).
N Start the engine for a moment until the engine oil pres-

sure LED goes off.

N Insert the two electric connectors on the two injectors

(1-2).
N Top up with motor oil until the tank level reaches the

prescribed limit, see 2.13 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP). N Start the engine and let it idle for approx. 10 minutes. N Check the oil level again and, where necessary, top up. 3.8.2 CHECKING THE ENGINE OIL PRESSURE

NOTE Have the appropriate special tool & (3) to hand

cod. 8140181 (fuel-oil pressure gauge). gine oil pressure sensor (3). Engine oil pressure: min. 50 kPa (0.5 bar).
N Connect the oil pressure gauge (4) in place of the en-

NOTE Check the oil pressure at a temperature of 80 C (176 F) and at a speed of at least 1200 rpm.
If the oil pressure is below the minimum limit, check the oil pump and relevant drive assembly.
N During reassembly, coat the thread of the engine oil

aCAUTION

pressure sensor (3) with LOCTITE 243. Driving torque of sensor (3): 15 Nm (1.5 kgm). 3.8.3 SYNCHRONIZING CYLINDERS See 4.8.10 (CYLINDER SYNCHRONIZATION).

3 - 116

RSV mille

1 2 3
FUEL SUPPLY SYSTEM

4 -1

FUEL SUPPLY SYSTEM

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FUEL SUPPLY SYSTEM

4!",% /& #/.4%.43  &5%, 4!.+ ..................................................... 4-3 4.1.1 MAINTENANCE ............................................. 4-4 4.1.2 CHECKING THE FUEL SUPPLY .................. 4-4  $2!).).' 4(% &5%, 4!.+ ...................... 4-5  2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 ..................................................... 4-5  2%-/6).' 4(% &5%, ,%6%, 3%.3/2 . 4-5  2%-/6).' 4(% &5%, 3500,9 05-0 ... 4-6  2%-/6).' 4(% $%,)6%29 &),4%2 ........ 4-6  %.').% -!.!'%-%.4 .............................. 4-7 4.7.1 FOREWORD .................................................. 4-7 4.7.2 SENSORS ..................................................... 4-7 4.7.3 INJECTION SYSTEM DIAGRAM .................. 4-9 4.7.4 ENGINE CONTROL UNIT CONNECTORS . 4-10 4.7.5 AUTOMATIC TESTING ............................... 4-11 4.7.6 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY ......................4-11 4.7.7 CAMSHAFT POSITION SENSOR ...............4-11 4.7.8 DRIVING SHAFT POSITION SENSOR ....... 4-11 4.7.9 INTAKE PRESSURE SENSOR ................... 4-11 4.7.10 INTAKE PRESSURE SENSOR ................. 4-11 4.7.11 THROTTLE VALVE POTENTIOMETER ... 4-11 4.7.12 COOLANT THERMISTORS ...................... 4-11 4.7.13 AIR THERMISTORS .................................. 4-11 4.7.14 IGNITION COILS ....................................... 4-11  4(2/44,% "/$9 ........................................ 4-12 4.8.1 REMOVING THE INJECTORS .................... 4-12 4.8.2 REMOVING THE THROTTLE BODY .......... 4-12 4.8.3 DISASSEMBLING THE THROTTLE BODY .............................. 4-14 4.8.4 INSPECTING THE THROTTLE BODY ....... 4-16 4.8.5 REFITTING THE THROTTLE BODY .......... 4-17 4.8.6 REPLACING THE THROTTLE VALVE CONTROL LEVER ...................................... 4-19 4.8.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY ...................................... 4-21 4.8.8 ADJUSTING THE THROTTLE BODY ......... 4-22 4.8.9 ADJUSTING THE THROTTLE VALVE POSITION SENSOR .................................... 4-23 4.8.10 SYNCHRONIZING CYLINDERS ............... 4-24

4 -2

RSV mille  &5%, 4!.+ The filler cap is to be found on the top of the tank, whilst the bottom part houses: the fuel supply pump unit; a pipe for draining water from the filler cap in the event of rain or during washing; a pipe for draining off petrol in the event the tank is overfilled.

FUEL SUPPLY SYSTEM

Key 1) 2) 3) 4) 5) Fuel tank Filler cap Fuel supply pump unit Filler cap water drainage pipe Fuel overflow drainage pipe 6) 7) 8) 9) 10) Fuel level sensor Fuel delivery filter Fuel supply pump Fuel delivery pipe Fuel return pipe

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FUEL SUPPLY SYSTEM

Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.1 (FUEL).

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aWARNING
Fuel vapours are noxious for the health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Avoid any contact of the fuel with the skin. Do not smoke, nor use naked flames. Do not dispose of fuel in the environment.

4.1.1 MAINTENANCE
N When the fuel supply pump is to be removed, see 4.3

(REMOVING THE WHOLE FUEL SUPPLY PUMP UNIT), it is advisable to make sure the pipes (1 - 2 - 3 4) are intact and that the following are working properly: fuel level sensor (5), see 6.10.2 (LOW FUEL WARNING LIGHT); fuel supply pump (6), see 6.5.2 (CHECKING THE FUEL PUMP). N Change the delivery filter (7).

NOTE

During this procedure, it is also advisable to wash the tank completely.

4.1.2 CHECKING THE FUEL SUPPLY Check the fuel pipes every 7500 km (4687 mi) or 8 months; replace every 4 years.

aWARNING
Check the delivery pipe (8), return pipe (9) and relevant connections extremely carefully: the operating pressure of the delivery pipe (8) is approx. 450 kPa (4.5 bar). Any fuel pipes featuring cracks or cuts must be replaced, without exception. Fuel leaking from the flange (10) might be due to a damaged O-ring (11), consequently: N Remove the whole fuel supply pump unit, see 4.3 (REMOVING THE WHOLE FUEL SUPPLY PUMP UNIT), check its state of repair and, where necessary, replace it. N Open the filler cap and make sure the vent on the tank is not clogged. Where necessary, unclog it using a compressed air jet.

NOTE

For further details see 6.5.2 (CHECKING THE FUEL PUMP).

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RSV mille  $2!).).' 4(% &5%, 4!.+ See 2.9 (DRAINING THE FUEL TANK) for the fuel tank draining procedure.

FUEL SUPPLY SYSTEM

 2%-/6).' 4(% 7(/,% &5%, 3500,9 05-0 5.)4 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS), 1.2.1 (FUEL) and 4.1.1 (MAINTENANCE).
N Remove the fuel tank completely, see 7.1.5 (COM-

PLETE REMOVAL OF THE FUEL TANK).

aCAUTION
Handle the fuel tank with care and avoid scraping or damaging them.

NOTE Set the tank on a clean surface with the pump unit facing up.
N Unscrew and remove the screws (1).

NOTE When reassembling, screw all the screws on manually and tighten them in a crisscross pattern in the following order: A-B-C-D-E-F-G-H.
Driving torque of screws (1): 7 Nm (0.7 kgm).

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Lift the pump unit (2) just enough to be able to get at the

pipe clamps (3 - 4).

N Release the head off the pipe clamps (3 - 4).

aCAUTION
When removing the pump unit (2), take care not to damage the pipes and the fuel level sensor (5).
N Remove the whole pump unit (2).

 2%-/6).' 4(% &5%, ,%6%, 3%.3/2

N Remove the whole fuel supply pump unit, see 4.3 (RE-

MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).

N Release and remove the clamp (6).

Before removing the screws (7 - 8), make sure the relevant electric terminals fastened on them are positioned correctly. N Unscrew and remove the screw (7). N Unscrew and remove the screws (8). N Remove the sensor (5).

NOTE

When reassembling, position the terminals of the electric cables correctly, in the relevant fastening positions, using the screws (7 - 8).

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FUEL SUPPLY SYSTEM

 2%-/6).' 4(% &5%, 3500,9 05-0
N Remove the whole fuel supply pump unit, see 4.3 (RE-

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MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamp (1). N Pull the fuel pipe (3) off the pump (2). N Disconnect the electric connector (4).

aCAUTION
When reassembling, make sure the electric connector (4) is plugged in properly.
N Unscrew and remove the screws (5).

aCAUTION
When performing the operations below, take care not to entangle the electric cables.
N Bend the fuel filter (6) over sideways and keep it held

down.
N Lift the pump mount (7) just enough to be able to slide

out the fuel pump (2).

N Slide the fuel pump (2) off the mount (7) and recover

the O-ring (8).

aCAUTION
If the rubber element (9) supporting the pump proves damaged, replace it. If the filtering mesh (10) features traces of sediments, clean it using a compressed air jet directed so that the impurities do not get inside.

 2%-/6).' 4(% $%,)6%29 &),4%2

N Remove the whole fuel supply pump unit, see 4.3 (RE-

MOVING THE WHOLE FUEL SUPPLY PUMP UNIT).

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamps (11-12). N Slip the pipe (3) off the filter (6). N Slip the filter (6) off the pipe (13).

aCAUTION
Do not reuse a previously used filter.
N Replace the filter (6) with a new one of the same type.

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RSV mille  %.').% -!.!'%-%.4 4.7.1 FOREWORD The heart of the engines management consists in the electronic Engine Control Unit which manages and optimizes the ignition and injection of the fuel. The ignition management depends on the specific consumption levels. The engine control unit measures the exact ignition angle based on the engine rpm signals and on the position of the throttle valves (quantity of air). The engine control unit manages the injection time (quantity of fuel) based on the rpm signal, the throttle valve signal (quantity of air, pressure of induction pipe) and correction factors of the various sensors. Every time the engine is switched on, the engine control unit checks the sensors and ignition coils, making sure they are working correctly. If any anomalies are encountered, the message (), flashes on the display. The safety devices inside the engine control unit stop ignition and the injection of the fuel when the speed exceeds the permissible peak rpm, which is 10500 rpm, or if the vehicle falls over. When the vehicle is set on the side stand and a gear is engaged, ignition is stopped, preventing the vehicle from starting.

FUEL SUPPLY SYSTEM

aCAUTION
Any modifications or variations made to the exhaust system, intake system or the engine control unit may result in serious damage to the engine. The assembly, modification or use of non-original parts shall cause any warranty to become void and shall exempt the manufacturer from any liability. Key 1) Signals 2) Driving shaft position sensor (engine rpm) 3) Throttle valve potentiometer (position of the throttle valves) 4) Other sensors 5) Engine control unit 6) Standard data 7) Correction factors 8) Ignition coil (ignition angle) 9) Injector (injection time)

4.7.2 SENSORS Driving shaft position sensor (2) Location: in the flywheel cover (10) The signals are emitted by the transducers located on the rotor. The engine speed and the position of the driving shaft are calculated based on the signals emitted. Camshaft position sensor (11) Location: in head 1 (12) (front). The signal is emitted by a transducer located on the control gear of the output camshaft. Based on this signal, the engine control unit calculates the position of cylinder 1 (front) and 2 (rear) during the work cycle.

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FUEL SUPPLY SYSTEM

Intake pressure sensor (13) Location: in the intake manifold. The pressure measured in the induction pipe is converted into a voltage signal. Moreover, the injection time also depends on the induction pipe pressure, especially when the throttle valve opening angle is limited (during idling). Throttle valve potentiometer (3) Location: on the throttle body (14). The throttle valve potentiometer measures the position of said valves and acts as the main parameter in determining the injection time and ignition angle.

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Coolant thermistor (15) Location: on head 2 (16) (rear cylinder). The temperature sensor detects the coolant temperature and is required to correct the injection time. The injection time is increased if the coolant has not yet reached the working temperature.

Atmospheric pressure sensor Location: inside the engine control unit (5). The intake pressure measured by the sensor is converted into a voltage signal and is required by the engine control unit to correct the injection time. Air thermistor Location: in the intake pipe of the left-hand air conveyor. The resistance measured by the thermistor is converted into a voltage signal and is required by the engine control unit to correct the injection time.

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RSV mille 4.7.3 INJECTION SYSTEM DIAGRAM

FUEL SUPPLY SYSTEM

Key 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Engine control unit To voltage regulator Supply voltage Fuel suction from tank Fuel pump Fuel filter Intake pressure sensor Fuel pressure regulator Injectors Throttle valve potentiometer Camshaft position sensor 12) 13) 14) 15) 16) 17) 18) 19) Thermistors To multifunction display, right-hand side Driving shaft position sensor and generator Driving shaft position sensor and generator connector HV ignition coil cylinder 1 (front) HV ignition coil cylinder 2 (rear) Spark plug cylinder 1 (front) Spark plug cylinder 2 (rear)

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FUEL SUPPLY SYSTEM

4.7.4 ENGINE CONTROL UNIT CONNECTORS For further details see 6.17 (CONNECTIONS TO THE ENGINE CONTROL UNIT).

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26-pin connector (1) Terminal labelling +B E1 VSV # 21 # 11 E 01 E 03 IG 22 IG 21 TAC E2 FP WL T SS CLT STA E 02 IG 12 IG 11 Connections Battery connection positive pole + Earth (for control circuit) Empty Injector cylinder 2 (rear) Injector cylinder 1 (front) Earth Earth HV ignition coil cylinder 2 (rear) HV ignition coil cylinder 2 (rear) Revolution counter Sensor earth Fuel pump relay Multifunction display Test (automatic fault search, dealer mode) Side stand switch Clutch control lever switch Starter motor relay Earth HV ignition coil cylinder 1 (front) HV ignition coil cylinder 1 (front) N+ G+ VCC VTA PM THW MS 2 VM NGTHA DON MS 1 Terminal labelling

16-pin connector (2) Connections Driving shaft position sensor + Camshaft position sensor Intake pressure sensor and throttle valve potentiometer Throttle valve potentiometer Intake pressure sensor Coolant thermistor Earth Fuel pump Driving shaft position sensor Camshaft position sensor Air thermistor - Intake pressure sensor Fall sensor Earth

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RSV mille 4.7.5 AUTOMATIC TESTING See 6.4 (IGNITION SYSTEM). 4.7.6 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY

FUEL SUPPLY SYSTEM

4.7.12 COOLANT THERMISTORS Fault code 21 See 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION). 4.7.13 AIR THERMISTORS Fault code 22 See 6.4.9 (CHECKING THE AIR THERMISTOR OPERATION). 4.7.14 IGNITION COILS Fault code 33, 34, 35, 36 See 6.4.4 (CHECKING THE IGNITION COILS).

aWARNING
Take care around the high voltage in the ignition system. Never disconnect connections with the engine running. Whenever work is performed in the ignition system, always make sure the ignition switch is set to m and the battery disconnected, unless otherwise indicated (when disconnecting the battery, disconnect the negative pole first).

aCAUTION
All measurements must be taken with the components at a temperature of 20C (68F). General instructions regarding the elimination of faults: as soon as the fault has been located, remove the defective component. 4.7.7 CAMSHAFT POSITION SENSOR Fault code 11 See 6.4.6 (CHECKING THE CAMSHAFT POSITION SENSOR). 4.7.8 DRIVING SHAFT POSITION SENSOR Fault code 12 See 6.4.5 (CHECKING THE PICK-UP). 4.7.9 INTAKE PRESSURE SENSOR Fault code 13 See 6.4.11 (CHECKING THE INTAKE PRESSURE SENSOR). 4.7.10 INTAKE PRESSURE SENSOR Fault code 14 N Check for pressure loss in the connection pipes (1-2-3) and make sure the flow is regular. N Check the wiring and connections of the pressure sensor.

NOTE

Where necessary, replace the pressure sensor or engine control unit. 4.7.11 THROTTLE VALVE POTENTIOMETER Fault code 15 See 6.4.10 (CHECKING THE THROTTLE VALVE POTENTIOMETER).

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FUEL SUPPLY SYSTEM

 4(2/44,% "/$9

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aCAUTION
The screws (1) for the standard adjustment of the throttle valves and for increasing idling (2) are painted and cannot be adjusted. Only when the whole cable support bracket (3) is replaced can the two adjusting screws be turned. The two M4x12 screws (4) fastening the throttle valve potentiometer are painted and can only be removed in the event the actual sensor is replaced.

4.8.1 REMOVING THE INJECTORS See 4.8.2 (REMOVING THE THROTTLE BODY). See 6.4.12 (CHECKING THE INJECTORS) for the checking procedure.

4.8.2 REMOVING THE THROTTLE BODY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Partially remove the fuel tank, see 7.1.4 (PARTIAL RE-

MOVAL OF THE FUEL TANK).

N Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

N Disconnect the electric connectors:

right injector (5); left injector (6); intake pressure sensor (7); throttle valve potentiometer (8).

aCAUTION
When reassembling, make sure the electric connectors are plugged in properly.

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RSV mille

FUEL SUPPLY SYSTEM

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw). N Release the head off the pipe clamps (9 - 10). N Pull the pipes (12 - 13) off the throttle body (11). N Disconnect the two throttle cables (14 - 15).

aCAUTION
When reassembling, make sure the two throttle cable adjusters are properly fastened to the respective couplings and check and, where necessary, restore the correct freeplay, see 2.11.3 (ADJUSTING THE ACCELERATOR CONTROL).
N Disconnect the cold-start control cable (16).

aCAUTION
When reassembling, make sure the cold-start control cable adjuster is properly fastened to the respective coupling and check and, where necessary, restore the correct freeplay, see 2.12 (COLD START CABLE).
N Loosen the two clamps (17 - 18).

aCAUTION
When removing the throttle body (11), be careful to make sure it remains connected to the fuel tank (20) by means of the fuel pipe (19).
N Grip the throttle body (11) firmly and hitch it one way

and the other to lift it and slide it off the intake flanges.
N Place the whole throttle body (11) and fuel tank (20),

still connected together, on a clean surface.

aCAUTION
When reassembling: the fuel delivery pipe (19) must not be entangled or positioned where it is likely to be squashed by other components; should it appear damaged or deteriorated, it must be replaced; the fuel delivery pipe (19) must be placed so that it reaches the right-hand side of the throttle body (11), passing under said body between the two intake flanges; the throttle body (11) must be fitted perfectly on the intake flanges; the clamps (17 - 18) must be properly tightened.

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FUEL SUPPLY SYSTEM

4.8.3 DISASSEMBLING THE THROTTLE BODY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).
N Unscrew and remove the M8x1 nut (1) and remove the

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spring washer.

N Turn the throttle valve control lever (2) slightly, unscrew

and remove three hex-head M5x12 screws (3).

N Slip the whole support bracket (4) securing the throttle

cables, with the two bushes (5) and the torsion spring (6), off the throttle body. N Unscrew and remove the two M 6x16 screws (7) and remove the fuel pressure regulator (8) complete with Oring. N Unscrew and remove the three M6x25 screws (9) and remove the left injector support (10) - together with the relevant gasket (11), injector (12) and sealing ring (13) - from the throttle body.

NOTE

The injector s sealing ring (13) may be kept inserted in the slot on the throttle body.

4 - 14

RSV mille
N Unscrew and remove the two M6x25 screws (14) and

FUEL SUPPLY SYSTEM

the right injector support (15), together with the relevant gasket (16), injector (17) and sealing ring (18).

NOTE

The injectors sealing ring (18) may be kept inserted in the slot on the throttle body.

N Unscrew and remove the M8x1 nut (19) and remove

the spring washer (20), the pulley (21), the two bushes (22) and torsion spring (23). N Slide the fulcrum pin (24), together with the lock washer (25), out of the hole on the throttle cable support bracket and remove the two shaft sealing rings (26) with the torsion spring (27) and cold-start lever (28).

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FUEL SUPPLY SYSTEM

4.8.4 INSPECTING THE THROTTLE BODY TESTING THE INJECTOR

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aWARNING
The fuel is explosive and highly inflammable. Keep fuel away from ignition sparks, heat and flames.

NOTE The injection valves may also be checked whilst

fitted.
N Check the following components:

wiring and connections; injector or injection signal of the engine control unit, see 6.4 (IGNITION SYSTEM). Checking injector resistance: See 6.4.12 (CHECKING THE INJECTORS).

THROTTLE BODY

aCAUTION
Use neutral detergents only. For cleaning, use a product for removing sealing, a degreasing product or a detergent for cleaning when cold.
N Clean all the openings and pipes of the throttle body (1)

using compressed air.

aCAUTION
Once the intake pressure sensor (9) its installed, not utilice the compressed air for the pipes cleaning; danger for damages.
N Check the pipes of the intake pressure sensor (2),

watching out for any clogging.

N Check the throttle valves unit and the cable fastening

mechanism (3), watching out for any signs of mechanical damage.

NOTE

In the event the synchronization screws (4) or O-rings (5) are replaced, synchronize the cylinders, see 4.8.10 (CYLINDER SYNCHRONIZATION). when there are leaks.

N Only unscrew the two cylinder synchronizing screws (4) N When replacing the tie rod of the ball joint (6), disen-

gage the tie rod from the throttle valve control lever (7) and throttle cable pulley (8). N Once a new ball joint tie rod (6) has been fitted, make sure it moves freely.

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RSV mille 4.8.5 REFITTING THE THROTTLE BODY Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

FUEL SUPPLY SYSTEM

aCAUTION
After disassembling the throttle body, replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are supplied with the repair kit.
N Fit the new O-rings (1) and seals (2) on both injector. N Insert the injector (3) in the left injector support (4) and

in the right injector support (5).

N Fit the left injector support gasket (6), right injector sup-

port gasket (7) and the two seals (8) on the throttle body. N Install the complete left injector support (4) and right injector support (5) in the throttle body, fastening them with the new M6x25 screws respectively (9 - 10). Driving torque of screws (9 - 10): 9 Nm (0.9 kgm).
N If the synchronizing screws (11) and respective O-rings

(12) have been replaced, screw on the screws (11) fairly tight until they touch the stop and then unscrew them a single turn. Presetting of synchronizing screws (11): 1 turn.

aCAUTION
The precise adjustment of the screws (11) must be performed using a vacuum gauge, see 4.8.10 (CYLINDER SYNCHRONIZATION).
N Fasten the fuel pressure regulator (13) using the two

M6x16 screws (14). Driving torque of screws (14): 3.5 Nm (0.35 kgm).

NOTE Smear a film of grease over the surfaces of the fulcrum pin (18), see 1.6 (LUBRICANT CHART).
N Insert the cold-start lever (15), torsion spring (16) and

shaft sealing ring (17) on the fulcrum pin (18).

N Insert the complete fulcrum pin (18) in the throttle cable

support bracket.

NOTE Make sure the torsion spring is hooked to the cold-start lever (15) and cable support bracket.
N Spray chain grease onto the spring (16), see 1.6 (LU-

BRICANT CHART).

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FUEL SUPPLY SYSTEM

N Insert the shaft sealing ring (17) on the fulcrum pin (18). N Fit the two bushes (19) and torsion spring (20). N Fit the pulley (21) on the throttle cable support bracket.

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aCAUTION
Make sure that the ends of the torsion spring (20) are hooked onto the throttle cable support bracket and pulley (21).

NOTE

Spray a temporary lubricant AP-LUBE on the spring (20), see 1.7.2 (USE OF CONSUMABLES).

N Fit the spring washer (22).

NOTE
(23).

Apply LOCTITE 243 on the thread of the nut

N Screw on nut M8x1 (23) and tighten it.

Driving torque of nut (23): 3 Nm (0,3 kgm).

NOTE

Apply LOCTITE 243 on the thread of the screws (25). three M5x12 hex-head screws (25). Driving torque of screws (25): 3 Nm (0.3 kgm).

N Fasten the throttle cable support bracket (24) using the

N Fit the throttle valve control lever (26), see 4.8.6 (RE-

PLACING THE THROTTLE VALVE CONTROL LEVER).

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RSV mille 4.8.6 REPLACING THE THROTTLE VALVE CONTROL LEVER Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). DISASSEMBLY
N Remove the fuel tank partially, see 7.1.4 (PARTIAL RE-

FUEL SUPPLY SYSTEM

MOVAL OF THE FUEL TANK).

N Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

N Unscrew and remove the M8x1 nut (1) and remove the

spring washer.
N Slide out the control lever (2) and retrieve the two bush-

es (3) and torsion spring (4).

N Remove the control lever (2) from the tie rod of the ball

joint (5). ASSEMBLY

aCAUTION
For the vehicles with the following engine numbers, the throttle valve control lever (2) must be replaced with the new grey-coloured lever.
                                                                                                    

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FUEL SUPPLY SYSTEM

N Fit the two bushes (3) and torsion spring (4) on the

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throttle body.
N Fit the throttle valve control lever (2) on the throttle

valve spindle.

NOTE

Spray a temporary lubricant AP-LUBE on the spring (4), see 1.7.2 (USE OF CONSUMABLES).

aCAUTION
Make sure the ends of the torsion spring (4) are hooked onto the throttle body and throttle valve control lever (2).
N Fit the spring washer.

NOTE
(1).

Apply LOCTITE 243 on the thread of the nut

N Screw on the M8x1 nut (1) and tighten it.

Driving torque (1): 3 Nm (0.3 kgm).

NOTE

Once assembly is complete, make sure the levers rotate freely. The throttle valve control lever (2) must be returned to its original position by the torsion spring. Check for end play on the throttle valve control shaft, see 4.8.7 (CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY) and adjust as necessary, see 4.8.8 (ADJUSTING THE THROTTLE BODY).

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RSV mille 4.8.7 CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY
N Remove the fuel tank partially, see 7.1.4 (PARTIAL RE-

FUEL SUPPLY SYSTEM

MOVAL OF THE FUEL TANK).

N Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE).

NOTE Have an appropriate thickness gauge (1) to hand with a 0.05 mm scale.
With throttle valves closed:
N Use the thickness gauge (1) to measure the minimum

play between the lever (2) and the contact surface (3) on the throttle body in a number of points. End play: min. 0.1 mm.

aCAUTION
If the minimum value measured is less than 0.1 mm, the whole throttle body (cod. 295690) must be replaced. With throttle valves open:
N Repeat the above procedure.

End play: min. 0.15 mm.

aCAUTION
If the minimum value measured is less than 0.15 mm, the whole throttle body (cod. 295690) must be replaced.

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FUEL SUPPLY SYSTEM

4.8.8 ADJUSTING THE THROTTLE BODY
N Partially remove the fuel tank, see 7.1.4 (PARTIAL RE-

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MOVAL OF THE FUEL TANK).

N Remove the air filter casing, see 7.1.7 (REMOVING

THE AIR CLEANER CASE). SETTING IDLING

aCAUTION
The idling adjusting screw (1) is painted and cannot be adjusted. Only when the whole throttle cable support bracket is replaced can the adjusting screw (1) be turned again.
N Loosen the M5x0.5 nut (2). N Unscrew the adjusting screw (1) until the throttle valves

(3) are pressed up against the throttle body (4).

N Screw the adjusting screw (1) until it touches the stop

onto the throttle valve control lever (5), and turn it another 1/2 - 3/4 turn before tightening the M5x0.5 nut (2). Idling setting: 1/2 3/4 turn.

SETTING THE COLD-START DEVICE

aCAUTION
Whenever the whole throttle cable support bracket is replaced, the cold-start control adjusting screw (6) must be adjusted again once the idling adjusting screw (1) has been set.

NOTE

Have an appropriate thickness gauge.

N Loosen the M5x0.5 nut (7). N Pull back the cold-start lever (8) until it touches the

screw (6).
N Adjust the screw (6) so that the clearance between the

idling adjusting screw (1) and the throttle valve control lever (5) is in the range 1.6 to 1.8 mm. Adjustment: 1.6 1.8 mm.
N Secure the screw (6) by tightening the M5x0.5 nut (7).

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RSV mille 4.8.9 ADJUSTING THE THROTTLE VALVE POTENTIOMETER

FUEL SUPPLY SYSTEM

aCAUTION
The two sunk hexagon cheese-head screws fastening the throttle valve potentiometer (1) are painted during production and cannot be loosened. The throttle valve potentiometer can only be adjusted in the event of replacement.
N Place the throttle valve potentiometer (1) in a horizontal

position on the throttle valve shaft and rotate it downwards.

NOTE

Apply LOCTITE 243 on the thread of the screws (2).

N Screw on the two M4x12 T.C.E.I. sunk hexagon

cheese-head screws (2) and tighten the throttle valve potentiometer quite firmly, but so that the screws can still be turned further. N Turn the ignition switch to position n. N To connect the TEST connectors (3). N Turn the throttle valve potentiometer until the display longer reads "" .

aCAUTION
Any adjustment of the position sensor must be performed with the valves closed, meaning the throttle valve control lever (4) must touch the adjusting screw (5).
N Tighten the two M4x12 T.C.E.I. sunk hexagon cheese-

head screws (2). Driving torque of screws (2): 1.6 Nm (0.16 kgm).
N Turn the ignition switch to position m.

For further details see 6.4.11 (CHECKING THE INTAKE PRESSURE SENSOR).

4 - 23

FUEL SUPPLY SYSTEM

4.8.10 CYLINDER SYNCHRONIZATION Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.1 (FUEL). The cylinders must be synchronized whenever the engine runs smoothly no longer when idling. N Run a few kilometres until reaching the regular working temperature.

RSV mille

aCAUTION
The cylinder syncronization must be carried out with the engine warmed up: coolant temperature 80-100C (176-212F); room temperature 20-30C (68-86F).

NOTE

Have the following special tools & at hand: intake flange for vacuometer (1) (cod. 8140267); vacuometer (3) (cod. 8140256); exhaust gas tester (4) (cod. 8140196); set of pipes for exhaust gas tester (5) (cod. 8140202).

aWARNING
Fuel vapours are harmful for health. Before proceeding, make sure that the room in which you are working is properly ventilated. Do not inhale fuel vapours. Avoid contact of fuel with the skin. Do not smoke or use naked flames. Do not pollute the environment with the incorrect disposal of fuel.
N Lift the petrol tank, see 2.8 (LIFTING THE FUEL

TANK).
N Loosen and remove the two front and rear exhaust pipe

plugs (6-7).

NOTE Upon reassembly, apply LOCTITE 8150 on the threaded of the plugs (6-7)
N Connect the exhaust gas tester pipes (5): connect the two rigid pipes to the appropriate exhaust pipe outlets; connect the other pipe to the exhaust gas tester (4). N Start the engine and make sure the idling rpm is 1250 100 rpm. If this is not the case, adjust accordingly, see 2.11.2 (IDLING ADJUSTMENT). N Check the tester (5) for the CO values. They should correspond to the values indicated and be the same for both cylinders.

CO values for both cylinders: 0.8-1.3% at 1250 100 rpm.

N If the CO value measured in one or both of the cylin-

ders is different from the value indicated, adjust one or both of the screws (8-9) accordingly to restore the correct value. N Check the idling rpm and, if it does not correspond to 1250 100 rpm, adjust accordingly, see 2.11.2 (IDLING ADJUSTMENT) and then check the CO values again and, where necessary, repeat the sychronization procedure.

NOTE

If it is not possible to obtain the preset CO values, the sparking plugs must be replaced, see 2.7 (SPARK PLUGS).

4 - 24

RSV mille CHECKING THE CYLINDER VACUUM VALUES

FUEL SUPPLY SYSTEM

NOTE

The checking of the cylinder vacuum values on the new models no longer requires the intake flange to be replaced with the vacuometer attachment (1) since the throttle body is already fitted with the suitable connector (2).
N Loosen the two clamps (10-11).

aWARNING
Take extreme care when removing the throttle body (12) as it remains connected to cables and pipes.
N Grip the throttle body firmly (12), complete with air filter

casing (13), and shift it slightly one way and the other, lifting and sliding it off the intake flanges. N Move the throttle body off to the left-hand side of the vehicle. N Unscrew and remove the two screws (14) fastening the intake flange (15) to the front cylinder and recover the washers. N Remove the intake flange (15) of cylinder 1 (front). N Fit the vacuometer intake flange (1) in place, and position it so that the connector (16) is on the right-hand side of the vehicle. N Fit the two screws (14) back in place with their respective washers and tighten them. Torque settings of screws (14): 19 Nm (1.9 kgm).

aWARNING
The throttle body (12) must be fitted perfectly to the intake flanges. The clamps (10-11) must be properly tightened.
N Fit the throttle body (12) again, complete with air filter

casing (13), to the two intake flanges.

N Tighten the two clamps (10-11). N Slide the pipe (17) off the vacuum connector. N Hang the vacuometer (3) on the handlebars. N Insert the two ends of the vacuometer pipes (18-19) in

the connectors (16-20).

4 - 25

FUEL SUPPLY SYSTEM

N Check the vacuometer (3) for the vacuum value of a

RSV mille

cylinder and then of the other one.

NOTE

The vacuum value reading should be the same for both cylinders. Vacuum values for both cylinders: 300 30 mbar at 1250 100 rpm.

N Once the cylinders have been synchronized correctly

and the idling rpm adjusted, remove the vacuometer attachment (1) and fit the intake flange (15).

aWARNING
It is vital that the vacuometer intake flange (1) be replaced with the original intake flange (15).

aWARNING
Slight differences in the vacuum values between the two cylinders are acceptable only if the CO values fall within the range of the preset parameters (from 0.8 to 1.3%). If the CO values and/or the vacuum values do not fall within the range of the preset parameters, the adjusting procedures must be repeated to restore the correct values.

4 - 26

RSV mille

1 2 3 4
COOLING SYSTEM

5 -1

COOLING SYSTEM

RSV mille

COOLING SYSTEM
4!",% /& #/.4%.43  $%3#2)04)/. ................................................. 5-3  2%-/6).' 4(% 2!$)!4/23 .................... 5-5  2%-/6).' 4(% #//,).' %,%#42/&!.3 ................. 5-6  2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( ......... 5-7  2%-/6).' 4(% #//,!.4 4(%2-)34/23 ................ 5-7  2%-/6).' 4(% 4(%2-!, %80!.3)/. 6!,6% ....... 5-8 5.6.1 CHECKING THE THERMAL EXPANSION VALVE .......... 5-8  2%-/6).' 4(% &),,%2 .%#+ ................. 5-9  2%-/6).' 4(% 4(2%% 7!9 -!.)&/,$ .................... 5-9

 2%-/6).' 4(% %80!.3)/. 4!.+ ..... 5-10  #//,!.4 05-0......................................... 5-10

5 -2

RSV mille  $%3#2)04)/. The centrifugal pump (positioned inside the engine and driven by the latter) draws coolant and distributes it to the galleries in the cylinders and in the heads in order to cool the internal parts of the engine. The path of the coolant on leaving the engine varies depending on the temperature of the actual coolant, and is illustrated below. The coolant volume increase (caused by the temperature increase) is compensated for in the expansion tank.

COOLING SYSTEM

To check and top up the coolant, refer to the LOW and FULL reference marks, see 2.15 (CHECKING AND TOPPING UP COOLANT). For any information regarding the coolant, see 1.2.5 (COOLANT).

Key 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) Front cylinder thermistor Rear cylinder thermistor Breather pipe Coolant compensation pipes Filler hose Filler neck Engine hose (right side) - thermal expansion valve Rear cylinder hose - three-way manifold Front cylinder hose - three-way manifold Thermal switch Three-way manifold Three-way manifold hose - left radiator Radiator link hose Left radiator electrofan

15) 16) 17) 18) 19) 20)

Left radiator (vertical flow) Right radiator (vertical flow) Right radiator electrofan Thermal expansion valve hose - pump Right radiator hose - thermal expansion valve Three-way thermal expansion valve (type with heat-sensitive wax) 21) Centrifugal pump 22) Expansion tank = Direction of flow with thermal expansion valve open = Direction of flow with thermal expansion valve shut

5 -3

COOLING SYSTEM
Path with coolant temperature below 65C (149F). Pump A coolant enters the galleries (temperature taken by thermistors and sent up on the right-hand display on the dashboard) B coolant leaves the gallery (right-hand side of engine) C thermal expansion valve (completely shut) D pump.

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B A D C

Path with coolant temperature in the range 65 C (149F) to 80C (176F). Pump A coolant enters the galleries (temperature taken by thermistors and sent up on the right-hand display on the dashboard) B coolant leaves the galleries (at the same time, " coolant leaves the gallery, right-hand side of engine, and is conveyed directly to the thermal expansion valve) C three-way manifold D left radiator E right radiator F thermal expansion valve (gradually opening) G pump.

B
B1

A G F

Path with coolant temperature over 80C (176F). Pump A coolant enters the galleries (temperature taken by thermistors and sent up on the right-hand display on the dashboard) B coolant leaves the galleries C three-way manifold (temperature taken by thermal switch: if over 100C (212F), the operation of the electrofans is enabled; when it drops below 85C (185F), the electrofans are switched off) D radiatore sinistro left radiator F thermal expansion valve (comE pletely open) G pump. When the ignition switch is set to m the electrofans switch off regardless of the coolant temperature.

G F E

aCAUTION

5 -4

RSV mille  2%-/6).' 4(% 2!$)!4/23 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

COOLING SYSTEM

NOTE The following procedure refers to a single radiator, though it is applicable to both.
N Turn the ignition switch to position m . N Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

N Disconnect the electric connector (1).

When reassembling, make sure the electric connector (1) is plugged in properly.
N Remove the radiator spoiler, see 7.1.33 (REMOVING

aCAUTION

THE RADIATOR SPOILER).

N Loosen and move the clamp (2). N Pull the coupling (3) off the radiator (4). N Loosen and move the clamp (5). N Pull the coupling (6) off the radiator (4).

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamp (7). N Pull the pipe (8) off the radiator (4). N Unscrew and remove the screw (9), retrieving the bush

and the rubber element (10) if necessary.

NOTE
it.

If the rubber element (10) is damaged, replace

Proceed with care. Do not damage the radiator fins.

N Tilt the radiator (4) slightly forwards and at the same

aCAUTION

time lift it, sliding the two lower anchorage pins (12-13) from their slot on the radiator mount (11). N Remove the radiator (4) complete with the electrofan (14).

14

Plug the coupling openings so as to prevent any foreign bodies from falling in.

aCAUTION

NOTE

If the rubber elements (15) are damaged, replace them. If necessary:

10

N Remove the cooling electrofan, see 5.3 (REMOVING

THE COOLING ELECTROFANS).

Foreign bodies, filth, etc. sticking to the radiator fins must be removed by means of a jet of compressed air. Any bent fins are to be straightened using a small flat-tip screwdriver. If the couplings (3-6) feature cuts and/or cracks, they must be replaced. Before reassembly, thoroughly wash the inside of the radiator with clean water only.

aCAUTION

NOTE Where necessary, remove the other radiator.

13 15 11

12 15

5 -5

COOLING SYSTEM
 2%-/6).' 4(% #//,).' %,%#42/&!.3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

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NOTE

The following procedure refers to a single electrofan, though it is applicable to both.

N Turn the ignition switch to positionm . N Remove the relevant side fairing, see 7.1.26 (REMOV-

ING THE SIDE FAIRINGS).

N Disconnect the electric connector (1).

When reassembling, make sure the electric connector (1) is plugged in properly.
N Unscrew and remove the two screws (2).

aCAUTION

Driving torque of screws (2): 6 Nm (0.6 kgm).

N Retrieve the two nuts (3). N Tilt the whole electrofan (4) slightly forwards, at the

same time moving it outwards, pulling the internal anchorage pin out of its slot on the radiator (5). N Remove the electrofan (4).

NOTE If the rubber element (6) is damaged, replace it.

Where necessary:
N Unscrew and remove the three screws (7) and retrieve

the washers. Driving torque of screws (7): 2 Nm (0.2 kgm).

N Slide out the grating (8) protecting the electrofan motor

3 2

(9).

NOTE

Where necessary, remove the other electrofan. See 6.9 (COOLING ELECTROFAN) for further details.

5 4 6

7 7 8

5 -6

RSV mille  2%-/6).' 4(% #//,!.4 4(%2-!, 37)4#( Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Turn the ignition switch to position m . N Remove the left side fairing, see 7.1.26 (REMOVING

COOLING SYSTEM

2 1

THE SIDE FAIRINGS).

N Disconnect the electric connectors (1-2) from the ther-

mal switch (3).

When reassembling, make sure the electric connectors (1-2) are plugged in properly.
N Prepare a new thermal switch and apply LOCTITE

aCAUTION

572 on its thread.

N Unscrew and remove the thermal switch (3) and re-

trieve the gasket.

N Insert the gasket on the new thermal switch. N Screw the thermal switch (3) on by hand before tighten-

ing it. Driving torque of thermal switch (3): 30 Nm (3.0 kgm).

N If any coolant spilled during removal, once the opera-

tion is complete, top up the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT).

NOTE

See 6.9.3 (CHECKING THE THERMAL SWITCH OPERATION) for further details on the thermal switch.

Plug the hole on the three-way manifold so as to prevent any foreign bodies from falling in.

aCAUTION

 2%-/6).' 4(% #//,!.4 4(%2-)34/23 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).

NOTE The following procedure refers to a single thermistor, though it is applicable to both.
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the electric connector (4).

5 4

When reassembling, make sure the electric connector (4) is plugged in properly.
N Prepare a new thermistor and apply LOCTITE 574 on

aCAUTION

its thread.
N Unscrew and remove the thermistor (5). N Screw the thermistor (5) on by hand before tightening it.

Driving torque of thermistor (5): 30 Nm (3.0 kgm).

N If any coolant spilled during removal, once the opera-

tion is complete, top up the coolant, see 2.15 (CHECKING AND TOPPING UP COOLANT).

NOTE Where necessary, remove the other thermistor.

See 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION) for further details on the thermistors.

5 -7

COOLING SYSTEM
 2%-/6).' 4(% 4(%2-!, %80!.3)/. 6!,6% Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Drain the cooling circuit completely, see 2.16 (CHANG-

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6 4

ING THE COOLANT).

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamp (1). N Pull the pipe (2) off the thermal expansion valve (3). N Loosen the clamps (4-5). N Grip the thermal expansion valve (3) and pull it free of

the two couplings (6-7) one small step at a time.

Plug the coupling openings so as to prevent any foreign bodies falling in.

aCAUTION

8
5.6.1 CHECKING THE THERMAL EXPANSION VALVE Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Remove the thermal expansion valve, see 5.6 (RE-

10

MOVING THE THERMAL EXPANSION VALVE).

N Check the heat-sensitive wax for signs of cracking or

excessive wear: in this case, replace the whole valve (3).

3
Check the valve (3) is working properly as follows:
N Tie a piece of string around the valve (3). N Place a container (8) holding coolant on a burner (9). N Immerse the valve (3) in the container.

NOTE The valve (3) must be fully submersed without allowing it to touch the walls or bottom of the container (8).
N Secure the string so that the valve (3) remains in place. N Heat the coolant, using a thermometer (10) with a 0 to

150 C (32 to 302 F) range to check the rise in temperature. N Take note of the temperature reading when the valve (3) starts to open. Valve (3) opening temperature: 65 2 C (149 3.6 F).
N Continue heating the coolant. N When the temperature of the coolant reaches 80 C

(176 F), the valve (3) should have opened by at least 7 mm (39 mm measured from the edge). Valve (3) opening: 7 mm at 80 C (176 F).

NOTE If the valve does not meet both conditions (initial

opening temperature and maximum opening), it must be replaced.

5 -8

RSV mille  2%-/6).' 4(% &),,%2 .%#+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Drain the cooling circuit completely, see 2.16 (CHANG-

COOLING SYSTEM

1 7 6

ING THE COOLANT). Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamps (1-2). N Pull the pipe (3) off the neck (4). N Pull the coupling (5) off the neck (4).

NOTE

4 8 2 5

Plug the coupling openings so as to prevent any foreign bodies falling in.
N Move the pipe clamp (6). N Pull the pipe (7) off the neck (4). N Unscrew and remove the screw (8) and retrieve the

aCAUTION

bush.
N Remove the filler neck (4).

9 10

11

 2%-/6).' 4(% 4(2%% 7!9 -!.)&/,$ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Turn the ignition switch to position m . N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Remove the engine oil tank, see 7.1.49 (REMOVING

THE ENGINE OIL TANK).

N Drain the cooling circuit completely, see 2.16 (CHANG-

ING THE COOLANT).

N Disconnect the electric connectors (9-10) from the ther-

mal switch (11). When reassembling, make sure the electric connectors (9-10) are plugged in properly.

aCAUTION

17

16

14 13

NOTE Obtain appropriate pliers to attach the clamps, or screwdriver-type pipe clamps to replace the original ones (special type without screw).
N Release the head off the pipe clamps (12-13-14). N Pull the three pipes (15-16-17) off the manifold (18). N Loosen the pipe clamp (19) and move it downwards. N Grip the manifold (18) and slide it up off the coupling

(20) one small step at a time.

Plug the coupling openings so as to prevent any foreign bodies falling in. Where necessary:
N Unscrew and remove the thermal switch (11) and re-

aCAUTION

15

12 18 19 20

trieve the gasket.

NOTE When reassembling, apply the thread of the thermal switch.

LOCTITE

572 on

Driving torque of thermal switch (11): 30 Nm (3.0 kgm).

5 -9

COOLING SYSTEM
 2%-/6).' 4(% %80!.3)/. 4!.+ Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS) and 1.2.5 (COOLANT).
N Remove the right side fairing, see 7.1.26 (REMOVING

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1 2 3

THE SIDE FAIRINGS). N Move the pipe clamp (1). N Pull the pipe (2) off the filler neck (3). N Bend the pipe (2) back on itself and secure it in place on the top of the expansion tank with adhesive tape. N Unscrew and remove the fastening screw (4), keeping the rear brake fluid tank (5) in place. N Move the rear brake fluid tank (5) and secure it in place with adhesive tape. N Unscrew and remove the two fastening screws (6-7) and retrieve the two bushes. N Remove the expansion tank (8), keeping it the right way up. N If the inner and outer foam edging is damaged, replace it.

aWARNING
The coolant is noxious. Put the expansion tank (8) in a safe place. KEEP OUT OF THE REACH OF CHILDREN.

2 7

 #//,!.4 05-0 See 3.6.21 (COOLANT PUMP) for information on the coolant pump.

5 4

5 - 10

RSV mille

6 6 6 6 6
ELECTRICAL SYSTEM

6 -1

ELECTRICAL SYSTEM

RSV mille  #//,).' %,%#42/&!. ........................... 6-25 6.9.1 WIRING DIAGRAM ..................................... 6-25 6.9.2 CHECKING THE ELECTROFAN OPERATION .............. 6-25 6.9.3 CHECKING THE THERMAL SWITCH OPERATION ...... 6-26 6.9.4 CHECKING THE ELECTROFAN RELAY ... 6-26  ).$)#!4/23 /. 4(% $!3("/!2$ ... 6-27 6.10.1 WIRING DIAGRAM ................................... 6-27 6.10.2 LOW FUEL WARNING LIGHT .................. 6-27 6.10.3 COOLANT TEMPERATURE DISPLAY .... 6-28 6.10.4 CHECKING THE ENGINE OIL LOW PRESSURE SENSOR ..................... 6-28 6.10.5 SPEEDOMETER ....................................... 6-29 6.10.6 REV COUNTER ......................................... 6-29  "!44%29 ..................................................... 6-30 6.11.1 ACTIVATING THE BATTERY ................... 6-30 6.11.2 MAINTENANCE ........................................ 6-31 6.11.3 CHECKING ................................................ 6-31 6.11.4 RETURN UNDER GUARANTEE .............. 6-31  #(!.').' 4(% "5,"3 ......................... 6-32 6.12.1 CHANGING THE HEADLIGHT BULBS .... 6-32 6.12.2 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS ............ 6-33 6.12.3 CHANGING THE REAR LIGHT BULB ..... 6-33 6.12.4 CHANGING THE DASHBOARD BULBS/LIGHTS ....... 6-34  !$*534).' 4(% 6%24)#!, (%!$,)'(4 "%!- .... 6-35  !$*534).' 4(% (/2):/.4!, ......................... 6-35 (%!$,)'(4 "%!-

ELECTRICAL SYSTEM
4!",% /& #/.4%.43  ).42/$5#4)/. ............................................. 6-3 6.1.1 CABLE COLOURS ........................................ 6-3 6.1.2 ELECTRICAL CONNECTORS ...................... 6-3  %,%#42)# #/-0/.%.43 ,!9/54 ......... 6-4  #(%#+).' 4(% 2%#(!2').' 3934%- ...................... 6-6 6.3.1 CHECKING THE RECHARGING VOLTAGE .................... 6-6 6.3.2 CHECKING THE ALTERNATOR LOADLESS OPERATION ............................. 6-6 6.3.3 CHECKING THE ALTERNATOR CONTINUITY ............... 6-7 6.3.4 CHECKING THE VOLTAGE REGULATOR ...................... 6-7  )'.)4)/. 3934%- ........................................ 6-8 6.4.1 WIRING DIAGRAM ........................................ 6-8 6.4.2 TROUBLESHOOTING (IF THE ENGINE DOES NOT START) ........... 6-9 6.4.3 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY ....................................... 6-10 6.4.4 CHECKING THE H.V. COILS ...................... 6-11 6.4.5 CHECKING THE PICK-UP .......................... 6-11 6.4.6 CHECKING THE CAMSHAFT POSITION SENSOR .............. 6-11 6.4.7 CHECKING THE FALL SENSOR ................ 6-12 6.4.8 CHECKING THE COOLANT THERMISTOR OPERATION .... 6-12 6.4.9 CHECKING THE AIR THERMISTOR OPERATION ................ 6-13 6.4.10 CHECKING THE THROTTLE VALVE POSITION SENSOR ................................. 6-14 6.4.11 CHECKING THE INTAKE PRESSURE SENSOR ................ 6-15 6.4.12 CHECKING THE INJECTORS ................... 6-15  &5%, 05-0 3934%- ................................. 6-16 6.5.1 WIRING DIAGRAM ...................................... 6-16 6.5.2 CHECKING THE FUEL PUMP .................... 6-17 6.5.3 CHECKING THE FUEL PUMP RELAY ....... 6-17 6.5.4 CHECKING THE ENGINE SHUTOFF RELAY ................ 6-17  )'.)4)/. 3!&%49 3934%- ..................... 6-18 6.6.1 WIRING DIAGRAM ...................................... 6-18 6.6.2 STARTING SAFETY OPERATING LOGIC . 6-19 6.6.3 CHECKING THE STARTING RELAY ......... 6-19 6.6.4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH ....................... 6-20 6.6.5 CHECKING THE DIODE MODULE ............. 6-20  37)4#(%3 ..................................................... 6-21  ,)'(43 3934%- ......................................... 6-23 6.8.1 WIRING DIAGRAM ...................................... 6-23 6.8.2 CHECKING THE LIGHTS RELAY .............. 6-24 6.8.3 CHECKING THE LIGHTS / LAP DIODE (multifunction) ............................................ 6-24

 #(!.').' 4(% &53%3 .......................... 6-36  #(%#+).' 4(% 37)4#(%3 .................. 6-37  #/..%#4)/.3 4/ 4(% %.').% #/.42/, 5.)4 ........ 6-38  7)2).' $)!'2!- 236 MILLE .............. 6-40  7)2).' $)!'2!- 236 MILLE

.....6-42

6 -2

RSV mille  ).42/$5#4)/. The following key will be useful in consulting this section.

ELECTRICAL SYSTEM

NOTE The numbering to be found on the specific wiring diagrams corresponds to that on the general wiring diagram.

6.1.1 CABLE COLOURS Ar Az B Bi G Gr M N R Ro V Vi Orange Light blue Blue White Yellow Grey Brown Black Red Pink Green Violet

6.1.2 ELECTRICAL CONNECTORS The disconnection of two electrical connectors must be carried out by proceeding as follows:
N Press the appropriate safety couplings, if provided.

aCAUTION
Do not pull the cables to disconnect the two connectors. N Grasp the two connectors and disconnect them by pulling in opposite directions. N If dirt, rust, dampness, etc. can be noticed, carefully clean the inside of the connector by means of a pressurized air jet. N Make sure that the cables are correctly crimped to the terminals positioned inside the connectors.

NOTE The two connectors have one insertion direction

only, therefore it is important to couple them in the correct direction.
N Insert the two connectors, making sure that the cou-

pling direction is correct (if the appropriate safety couplings are provided, the typical click sound will be heard).

6 -3

ELECTRICAL SYSTEM
 %,%#42)# #/-0/.%.43 ,!9/54

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6 -4

RSV mille

ELECTRICAL SYSTEM

Key

NOTE The numbering corresponds to that on the general wiring diagram. 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 29) 30) Electronic unit Cam position sensor Throttle valve potentiometer Suction pressure sensor Coolant temperature thermistor Air thermistor Fall sensor Diode module Clutch control lever switch Neutral switch Right dimmer switch Left dimmer switch Engine stop relay Fuel pump relay Start relay Starter Battery Main fuses (30A) (ignition) Generator Pick up Voltage regulator Rear cylinder coil 1 Rear cylinder coil 2 Front cylinder coil 1 Front cylinder coil 2 Spark plugs Secondary fuses (15A) Ignition switch

31) 32) 33) 34) 35) 36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 46) 47) 48) 49) 51) 52) 53) 54) 55) 56) 67) 68) 69) 70)

Low beam relay High beam relay Cooling fan relay Front parking light bulb High beam bulbs Low beam bulb Front right direction indicator Front left direction indicator Thermal switch Cooling fans Rear light Dashboard Rear left direction indicator Front cylinder injector Rear cylinder injector Front stoplight switch Rear stoplight switch Rear right direction indicator Horn Blinking Fuel pump Low fuel sensor Engine oil pressure switch Coolant temperature thermistor Speed sensor Light diode / LAP TEST connectors Headlight Side stand switch

6 -5

ELECTRICAL SYSTEM
 #(%#+).' 4(% 2%#(!2').' 3934%6.3.1 CHECKING THE RECHARGING VOLTAGE
N Check battery voltage, see 2.4.2 (RECHARGING THE

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BATTERY).
N Start the engine and let it run until it reaches 4000 rpm. N Set the light switch to "o" and dimmer switch to b. N Set the dimmer switch to b. N Using a pocket tester, measure the direct voltage be-

tween the positive (+) and negative () terminals. If the tester indicates voltage values lower than 13V or higher than 15V:
N Check the loadless operation and the continuity of the

alternator, see 6.3.2 (CHECKING THE ALTERNATOR LOADLESS OPERATION) and 6.3.3 (CHECKING THE ALTERNATOR CONTINUITY). Also check the voltage regulator, see 6.3.4 (CHECKING THE VOLTAGE REGULATOR). Wiring diagram key

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.
18) 19) 20) 22) 30) Battery Main fuse (30A) Generator Voltage regulator Ignition switch (n - m - s)

Standard charging voltage: 13 to 15 V (d.c.) at 4000 rpm. 6.3.2 CHECKING THE ALTERNATOR LOADLESS OPERATION
N Remove the rear fairing, see 7.1.36 (REMOVING THE

REAR FAIRING).
N Disconnect the voltage regulator three-way cable con-

nector (1) (coloured brown).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Start the engine and let it run until it reaches 4000 rpm. N Using a pocket tester, measure the voltage (a.c.) from

the three internal male terminals [yellow cables (G)] in rotation. If the value indicated by the tester is lower than 60 V, the alternator is faulty and needs replacing. Standard loadless voltage: more than 60 V (a.c.) at 4000 rpm.

6 -6

RSV mille 6.3.3 CHECKING THE ALTERNATOR CONTINUITY When the engine is switched off:
N Remove the rear fairing, see 7.1.36 (REMOVING THE

ELECTRICAL SYSTEM

REAR FAIRING).
N Disconnect the voltage regulator three-way cable con-

nector (1) (coloured brown).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Using a pocket tester ( scale), check for breaks be-

tween the cables of the stator [on the internal female terminals, yellow cables (G)]. Also check the isolation of the stator mount. Standard resistance value: 0.1 - 1. Standard resistance value (between cables and stator mount): .

6.3.4 CHECKING THE VOLTAGE REGULATOR

N Remove the rear fairing, see 7.1.36 (REMOVING THE

REAR FAIRING).
N Disconnect the three-way connector (1) (coloured

brown).
N Disconnect the six-way connector (2) (coloured white).

aCAUTION
When reassembling, make sure the electric connectors (1-2) are plugged in properly.
N Using a pocket tester (scale x 1M), measure the re-

sistance between the cables indicated in the table below from the regulator side (internal male terminals).

NOTE

The green (V) and white/red (Bi/R) cables are double, though connected together. Take the measurements on either of the two. Positive terminal (+) of the tester on: G Negative terminal () of the tester on: G G G V R/Bi G G V 2- 2- 2- R/Bi

2-

2-

2- 3-

aCAUTION
This measuring method is approximate; if possible, check the correct operation of the recharging system using another regulator in perfect condition. If the resistance measured is incorrect, replace the voltage regulator (3).

6 -7

ELECTRICAL SYSTEM
 )'.)4)/. 3934%6.4.1 WIRING DIAGRAM

RSV mille

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.

Wiring diagram key A) Intake pressure sensor (inside electronic unit) 1) Electronic unit 2) Cam position sensor 3) Throttle valve potentiometer 4) Suction pressure sensor 5) Coolant thermistor 6) Air thermistor 7) Fall sensor 9) Clutch control lever switch 10) Neutral switch 15) Fuel pump relay 18) Battery

21) Pick up 23) Rear cylinder coil 1 24) Rear cylinder coil 2 25) Front cylinder coil 1 26) Front cylinder coil 2 30) Ignition switch 44) Front cylinder injector 45) Rear cylinder injector 52) Fuel pump 68) TEST connectors 70) Side stand switch

6 -8

RSV mille 6.4.2 TROUBLESHOOTING (IF THE ENGINE DOES NOT START) Locating a fault in the electrical system
N Position the vehicle on the stand. N Turn the ignition switch to positionn.

ELECTRICAL SYSTEM

The message (), comes up on the right-hand display for approx. three seconds. N Press the start pushbutton rfor more than four seconds. If the ignition system is malfunctioning, the message (), reappears.

DIAG SERVICE V BATT

NOTE If a fault is detected in the electronic system or if

the "(), " message flashes on the multifunction display, do not start the vehicle so as to avoid secondary damage. If the ignition system is malfunctioning and the message (), , fails to reappear, make sure there are no breaks in the white/purple (Bi/Vi) cable between the electronic unit and the display.
N Remove the right side panel, see 7.1.3 (REMOVING

THE SIDE COVERS).

N Connect the two one-way TEST connectors (1). N Turn the ignition switch to position n. N Start the engine or attempt to start it.

The message DIAG comes up on the left display along with a number corresponding to the reference code relating to the fault (see table); the fault detected may be caused by breaks in the cables and/or connections not made properly. Checking an electric system fault:

aCAUTION
Before commencing the automatic search for a fault, stop the engine.

DIAG SERVICE V BATT

NOTE When a fault comes up on the display, it is possible that the fault may also be attributable to the engine control unit.
The ECU may only be tested by connecting a new ECU. Should the engine control unit work properly, remember to refit the previous unit. The ECU features an anti-breakdown device which, where necessary, means the engine can be started and run despite there being a fault on the display.

6 -9

ELECTRICAL SYSTEM
Fault code 11 12 13 14 Excessive difference between Engine shut off. Sensor pipes (air pipe) the sensor signals. Sensor not connected. Sensor broken. Wiring faulty. To view (), Components on the display to be checked Press the starter button for more than four seconds. Starting motor running Yes Yes

RSV mille
Cause Engine runs No (the cylinder cannot be identified) No Yes (irregular running for throttle valves rotation insufficient) Yes Engine runs (emergency conditions)

Component Camshaft position sensor Driving shaft position sensor Intake pressure sensor Intake pressure sensor Throttle valve potentiometer Coolant thermistor Air thermistor Atmospheric pressure sensor (ECU inside) Ignition coil 1 of front cylinder Ignition coil 2 of front cylinder Ignition coils 1 and 2 of front cylinder Ignition coil 1 of rear cylinder Ignition coil 2 of rear cylinder Ignition coils 1 and 2 of rear cylinder

Sensor not connected. Sensor broken. Wiring faulty.

Connector, sensor cable and sensor.

No

Yes

15 21 22 23 33 34 33, 34 35 36 35, 36

Sensor faulty.

Connector, sensor cable Engine running and sensor. or engine shut off. Cannot be checked: replace the ECU.

Yes (cold-starting difficult) Yes Yes

Yes (altimetrical compensation lack) Yes (power loss)

Yes (power loss)

Ignition coil faulty or wiring not connected.

Engine running.

Connector, ignition cable. Yes Yes

Yes Yes (only one (only one cylinder, power cylinder, power loss) loss) Yes (power loss) Yes (power loss)

Yes Yes (only one (only one cylinder, power cylinder, power loss) loss) No No

Fall sensor

41

Sensor not connected. Sensor broken. Wiring faulty.

Engine running Connector, or engine shut sensor cable off. and sensor.

Yes

6.4.3 ELIMINATING ELECTRONIC SYSTEM FAULTS ACCORDING TO THE INFORMATION SENT UP ON THE DISPLAY

aWARNING
Take care around the high voltage in the ignition system. Never disconnect connections with the engine running. Whenever work is performed in the ignition system, always make sure the ignition switch is set to m and the battery disconnected, unless otherwise indicated (when disconnecting the battery, disconnect the negative pole first).

aCAUTION
All measurements must be taken with the components at a temperature of 20C (68F). General instructions regarding the elimination of faults: as soon as the fault has been located, remove the defective component.
N Perform the checks indicated in the following chapters:

If the engine does not start and the diagnostics fail to detect any fault, check (in the given order) whether: The fuel pump is working properly, see 6.5.2 (CHECKING THE FUEL PUMP); The injectors are working properly, see 6.4.12 (CHECKING THE INJECTORS); The connector for the antitheft device fitting is connected properly (located under the passenger seat and coloured white); The ignition switch is working properly, see 6.7 (SWITCHES); The engine shutoff switch is working properly, see 6.7 (SWITCHES); The main 30A fuses and secondary 15A fuses have blown, see 6.15 (CHANGING THE FUSES); The engine shutoff relay is working properly, see 6.5.4 (CHECKING THE ENGINE SHUTOFF RELAY); The battery is working properly, see 2.4 (BATTERY) and 6.11 (BATTERY); The safety logic is working properly, see 6.6 (IGNITION SAFETY SYSTEM); The fall sensor is working properly, see 6.4.7 (CHECKING THE FALL SENSOR).

6.4.6 (CHECKING THE CAMSHAFT POSITION SENSOR); 6.4.5 (CHECKING THE PICK-UP); 6.4.11 (CHECKING THE INTAKE PRESSURE SENSOR); 6.4.10 (CHECKING THE THROTTLE VALVE POTENTIOMETER); 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION).

6 - 10

RSV mille 6.4.4 CHECKING THE IGNITION COILS

N Remove both side fairings, see 7.1.26 (REMOVING

ELECTRICAL SYSTEM

THE SIDE FAIRINGS).

NOTE The following procedure refers to a single coil, though it is applicable to both.
N Disconnect the terminals (1-2) from the ignition coil (3).

aCAUTION
When reassembling, make sure the electric terminals (1-2) are connected up properly.
N Slip off the spark plug cap (4) (belonging to the coil of

interest) and disconnect it from the cable.

N Measure the values of (A) and (B) indicated in the fig-

ure by means of a pocket tester. It is important to check the continuity of the primary and secondary windings. The reading in Ohms does not necessarily have to be exact but if the windings are sound, the resistance values must correspond approximately to those indicated. Standard values: Measurement (A): 2.8 5.2 ; Measurement (B): 9.1 16.5 k.

aCAUTION
This measuring method is approximate; if possible, check the correct operation of the coil by replacing it with another one in perfect condition. N Repeat the procedure for the other coils. 6.4.5 CHECKING THE PICK-UP With the engine switched off: N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the two-way connector (5) (coloured white) and take the measurements (on the engine-side terminals).

aCAUTION
When reassembling, make sure the electric connector (5) is plugged in properly.
N Using a pocket tester (scale x 100 ), measure the re-

sistance between the terminals of the blue/yellow (B/G) and white/yellow (Bi/G) cables. Standard value: 150 350 . If the resistance is infinite () or lower than the prescribed level, the sensor must be changed. 6.4.6 CHECKING THE CAMSHAFT POSITION SENSOR With the engine switched off: N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the two-way connector (6) (coloured white) and take the measurements (on the engine-side terminals).

aCAUTION
When reassembling, make sure the electric connector (6) is plugged in properly. N Using a pocket tester (scale x 100 ), measure the resistance between the terminals of the blue/yellow (B/G) and white/yellow (Bi/G) cables. Standard value: 150 350 . If the resistance is infinite () or lower than the prescribed level, the sensor must be changed.

6 - 11

ELECTRICAL SYSTEM
6.4.7 CHECKING THE FALL SENSOR With the engine switched off:
N Remove the riders saddle, see 7.1.1 (REMOVING THE

RSV mille

RIDER SADDLE). Check whether the sensor (1) is fitted correctly (with the arrow inscribed on the rubber element pointing up).
N Disconnect the two-way connector (2) (coloured white/

grey) and take the measurements (on the sensor-side terminals).

aCAUTION
When reassembling, make sure the electric connector (2) is plugged in properly.
N Using a pocket tester (scale x 100 k), measure the re-

sistance between the terminals of the black and white/ black (N - Bi/N) cables. Standard value: resistance 62 k 15 %. N Remove the sensor (1) complete with rubber element from its housing and tilt it sideways at an angle of over 45 (simulating the condition of a vehicle resting on the ground). Standard value: 0 1 . If the resistance is any value other than that prescribed, the sensor (1) must be changed.
N Repeat the procedure, tilting the sensor in the opposite

direction. 6.4.8 CHECKING THE COOLANT THERMISTOR OPERATION

NOTE

The value of the temperature measured by the front cylinder thermistor (right-hand side) is sent up on the right-hand display; that measured by the rear cylinder thermistor (left-hand side) is sent to the electronic unit.
N Remove the thermistor (3), see 5.5 (REMOVING THE

COOLANT THERMISTORS).
N Connect a tester (4) (set as an ohmmeter) to the ther-

mistor (3), as illustrated in the figure.

N Immerse the thermistor (3) in a container (5) holding

coolant.
N Immerse a thermometer (6) with a 0 to 150 C (32 to

302 F) range in the same container.

N Place the container on a burner (7) and slowly warm up

the coolant.
N Check the temperature indicated on the thermometer

(6) and the thermistor (3) value indicated by the tester. Make sure that the value varies according to the temperature, as indicated. Coolant temperature (C) (F) 20 40 60 80 100 68 104 140 176 212

Standard values () ( 10%) 1960 - 2940 800 - 1200 400 - 700 200 - 400 120 - 250

If values do not vary, or if they depart excessively from those indicated in the table, change the thermistor (3).
N Repeat the procedure for the other thermistor.

6 - 12

RSV mille 6.4.9 CHECKING THE AIR THERMISTOR OPERATION

N Remove the left-hand conveyor cover, see 7.1.29 (RE-

ELECTRICAL SYSTEM

MOVING THE AIR CONVEYOR).

N Disconnect the two-way connector (1) (coloured

green).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Remove the thermistor (2). N Connect a tester (3) (set as an ohmmeter) to the ther-

mistor (2) as illustrated in the figure.

N Immerse the thermistor in a container (4) holding water. N Immerse a thermometer (5) with a 0 to 150 C (32 to

302 F) range in the same container.

N Place the container on a burner (6) and slowly warm up

the liquid.
N Check the temperature indicated on the thermometer

(5) and the thermistor value indicated by the tester. Make sure that the value varies according to the temperature, as indicated. Water temperature (C) (F) 20 40 60 80 100 68 104 140 176 212 Standard values () ( 10%) 1960 - 2940 800 - 1200 400 - 700 200 - 400 120 - 250

If values do not vary, or if they depart excessively from those indicated in the table, change the thermistor (2).

6 - 13

ELECTRICAL SYSTEM
6.4.10 CHECKING THE THROTTLE VALVE POTENTIOMETER With the engine switched off:
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the four-way connector (coloured black) (1).

RSV mille

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Turn the ignition switch to position . N Using a pocket tester, measure the supply voltage be-

tween the terminals of the potentiometer (2); measurement (A). Standard value: 4.5 - 5.5 V.
N Turn the ignition switch to position . N Using a pocket tester (scale k), measure the resist-

ance between the terminals of the potentiometer (2). MEASUREMENT (A) Resistance between the two terminals whatever the position of the throttle valves: Standard value: 2.87 5.33 k. MEASUREMENT (B) Starting with the throttle valve fully closed, accelerating progressively until completely open, the resistance should vary as follows; standard value: with throttle valves closed 0.34 - 5.69 k; with throttle valves open 2.87 - 8.41 k. In order to make it easier to unscrew the screws (3) secured using LOCTITE 243, heat them first with a hot air blower.
N Unscrew and remove the screws (3). N Remove the potentiometer (2). N Using a tester (k scale), measure the resistance be-

NOTE

tween the potentiometer terminals (2); measurement (B). Standard value: with throttle valves closed < 5.2 k; with throttle valves open 3.34 8.88 k. If the measurements result in any resistance values other than those given, replace the potentiometer (2).
N With the throttle valves in the closed position, place the

potentiometer in its housing (2).

NOTE Apply LOCTITE 243 on the thread of the screws (3).

N Screw the screws (3) on by hand so that they hold the

potentiometer (2) in place but do not prevent it from rotating. N Connect the TEST connectors. N Turn the ignition switch to position n. N Turn the potentiometer (2) until the display reads . N Tighten the screws (3). Driving torque of screws (3): 1.6 Nm (0.16 kgm). N Turn the ignition switch to position m. N Disconnect the TEST connectors.

6 - 14

RSV mille 6.4.11 CHECKING THE INTAKE PRESSURE SENSOR With the engine switched off:
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the three-way connector (1) (coloured

ELECTRICAL SYSTEM

black).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Turn the ignition switch to position . N Using a pocket tester, measure the supply voltage be-

tween the terminals of the sensor (2): measurement (A). Standard value: 4.5 5.5 V. N Turn the ignition switch to position m. N Using a pocket tester (scale k), measure the resistance between the terminals of the sensor (2).

NOTE Measurements (A), (B) and (C) must be taken individually, not at the same time. Measurements (A), (B) and (C) must produce the following values: Standard values: measurement (A) 12 k; measurement (B) 11.50 k; measurement (C) 4 k. If the resistance proves to be any value other than that prescribed, the sensor (2) must be changed.

6.4.12 CHECKING THE INJECTORS With the engine switched off:

N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK).

NOTE

The following procedure refers to a single injector, though it is applicable to both.

N Disconnect the two-way connector (3) (coloured grey)

and take the measurements (on the injector-side terminals). N Using a pocket tester (scale 100 ), measure the resistance between the terminals of the injector. Standard value: 11 17 a 20 C (68 F). If the resistance is infinite () or lower than the prescribed level, the injector (4) must be changed.
N Repeat the procedure for the other injector.

6 - 15

ELECTRICAL SYSTEM
 &5%, 05-0 3934%6.5.1 WIRING DIAGRAM

RSV mille

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.

Wiring diagram key 11) Arrangement for the installation of the anti-theft device 12) Right dimmer switch 14) Engine stop relay 15) Fuel pump relay 29) Secondary fuses (15 A) 52) Fuel pump A) To the battery / ignition switch B) To the HV coil C) To the injectors / electronic unit D) To the electronic unit

6 - 16

RSV mille 6.5.2 CHECKING THE FUEL PUMP In order to check the pump is operating properly:
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the pump units three-way connector (1)

ELECTRICAL SYSTEM

(coloured white).

aCAUTION
When refitting, make sure the electric connector (1) is plugged in properly. Place a cloth under the perforated screw (2) to catch any fuel spills.
N Loosen the perforated screw (2) by approx. half a turn

and wait a few seconds to allow the system to depressurize. N Unscrew and remove the perforated screw (2) and retrieve the two gaskets (3). Driving torque of perforated screw (2): 22 Nm (2.2 kgm).

aWARNING
When reassembling, use two new gaskets (3) and torque the perforated screw (2) to specification in order to ensure the tank is perfectly hermetic. This is essential as the injection pressure is approx. 450 kPa (4.5 bar) and any fuel leakage would prove highly dangerous as the leaking oil might end up on high-temperature parts of the engine.

NOTE

Have the appropriate special tool 8140181 (fuel-oil pressure gauge) to hand .

&

cod.

N Fit the appropriate special tool. N Insert the free end of the pipe inside a container. N Power the positive () green (V) and negative () blue

(B) cables with a voltage of 12 V (d.c.) (from the pump unit side). N Make sure the pump is working and produces the characteristic humming sound and check the pressure gauge gives a supply pressure reading of at least 350 kPa (3.5 bar). 6.5.3 CHECKING THE FUEL PUMP RELAY
N Remove the passenger seat, see 7.1.2 (UNLOCKING /

LOCKING THE PASSENGER SEAT). In order to check the operation of the relay:
N Disconnect the four-way connector (4) (coloured white)

from the relay (5).

aCAUTION
When reassembling, make sure the electric connector (4) is plugged in properly.
N Power the two internal male terminals ( - ) at 12 V. N Using a tester (set as an ohmmeter), check for breaks

between the other two terminals ( - ).

Correct value with relay powered: 0 . Correct value with relay not powered: . If the resulting values do not correspond to those featured, change the relay (5). 6.5.4 CHECKING THE ENGINE SHUTOFF RELAY The procedure is exactly the same as that used to check the fuel pump relay, see 6.5.3 (CHECKING THE FUEL PUMP RELAY).

6 - 17

ELECTRICAL SYSTEM
 )'.)4)/. 3!&%49 3934%6.6.1 WIRING DIAGRAM

RSV mille

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.
Wiring diagram key

8) 9) 10) 12) 16) 17) 18) 29) 58) 59) 70) A) B) C)

Diode module Clutch control lever switch Neutral switch Right dimmer switch Start relay Starter Battery Secondary fuses (15 A) Side stand down warning light Neutral warning light Side stand switch To the battery / ignition switch To the secondary fuses (15 A) To the electronic unit

6 - 18

RSV mille 6.6.2 STARTING SAFETY OPERATING LOGIC

ELECTRICAL SYSTEM

NOTE With the engine shutoff switch in position m the

starter motor does not turn over.
STAND WARNING LIGHT OFF RELEASED IN NEUTRAL PULLED UP LOWERED RELEASED PULLED UP LIFTED RELEASED GEAR ENGAGED PULLED UP LOWERED RELEASED ON NOT WORKING NOT TURNING OVER OFF ON WORKING TURNING OVER

GEAR POSITION

STAND POSITION

CLUTCH LEVER PULLED UP

ENGINE IGNITION

STARTER MOTOR

LIFTED

6.6.3 CHECKING THE STARTING RELAY To check operation of the relay:

N Remove the rider s saddle, see 7.1.1 (REMOVING

THE RIDER SADDLE).

N Disconnect the two-way connector (1) (coloured white).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Lift the relay and slip it off the relevant couplings (2). N Slip off the two rubber protections (3-4). N Disconnect the cables (5-6) from the relevant terminals

on the relay (2).

N From the relay side, power the two internal terminals of

connector (1) at 12V.

N Using a tester (acting as ohmmeter), check the for

breaks between the two screw contacts on the relay (2). Correct value with relay powered: 0 . Correct value with relay not powered: . If the values do not correspond to those indicated, change the relay (2).

6 - 19

ELECTRICAL SYSTEM
6.6.4 CHECKING THE SIDE STAND AND THE SAFETY SWITCH The side stand (1) must rotate without hindrances. Carry out the following checks: N The springs (2) must not be damaged, worn, rusty or weakened. N The side stand must rotate freely, if necessary grease the joint, see 1.6 (LUBRICANT CHART). The side stand (1) is provided with a safety switch (3) that has the function to prevent or interrupt the operation of the engine with the gears on and the side stand (1) down. To check the proper functioning of the safety switch (3), proceed as follows: N Seat on the vehicle in driving position. N Fold the side stand (1). N Start the engine. N With released throttle grip and engine idling, pull the clutch lever completely. N Engage the first gear, pushing the shifting lever downwards. N Lower the side stand (1), thus operating the safety switch (3). At this point:
the engine must stop; the side stand down warning light \ must come on.

RSV mille

Should this fail to happen, replace the switch (3).

6.6.5 CHECKING THE DIODE MODULE

N Remove the passenger seat, see 7.1.2 (UNLOCKING /

LOCKING THE PASSENGER SEAT).

N Disconnect the five-way connector (4) (coloured white)

from the module (5).

aCAUTION
When reassembling, make sure the electric connector (4) is plugged in properly.
N Power the various terminals at 12 V, placing a 12V - 2W

bulb on the positive cable (+), as indicated.

aCAUTION
Do not use bulbs over 2W, since the module may be damaged. 1 2 3 4 5  1 2 3 4 5

aCAUTION
The bulb should only light up in the positions indicated. If this is not the case, replace the module (5).

6 - 20

RSV mille  37)4#(%3 Using a tester, check the continuity of the switches, referring to the specific diagram below. Should any anomalies be encountered, change the corresponding switch set. RIGHT SIDE SWITCH SET 1) Engine stop switch 2) Start push button Pos. Ar/Gr Cables V/R G/R V/R

ELECTRICAL SYSTEM

r n
RUN OFF

LEFT SIDE SWITCH SET 3) Horn push button 4) Direction indicator switch 5) Dimmer switch 6) High beam signaller push button / LAP push button (multifunction) 7) Light switch (not provided for _) Pos. Gr V G N Cables Bi Bi/B R Az B/N

a / LAP f

p o b a l k
LEFT SIDE SWITCH SET _ 3) Horn push button 4) Direction indicator switch 5) Dimmer switchi 6) High beam signaller push button / LAP push button (multifunction) Pos. Gr V G N Cables Bi Bi/B R Az B/N

a / LAP f b a l k 6 - 21

ELECTRICAL SYSTEM
8) IGNITION SWITCH Pos. R Cables V/Gr V Bi/R

RSV mille

n m s
8) IGNITION SWITCH Pos. R

_
Cables V/Gr V Bi/R

n m s
9) FRONT BRAKE STOPLIGHT SWITCH Pos.
Operating

Cables Gr M

10) REAR BRAKE STOPLIGHT SWITCH Pos.

Operating

Cables G G

11) NEUTRAL GEAR SWITCH Cables Pos. Neutral Screw

12) STAND SWITCH Stand Down Up M Cables V N

13) CLUTCH LEVER SWITCH Pos.

Operating

Cables Gr M

6 - 22

RSV mille  ,)'(43 3934%6.8.1 WIRING DIAGRAM

ELECTRICAL SYSTEM

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.

Wiring diagram key 13) 29) 31) 32) 34) 35) 36) 41) 63) 67) 69) 72) A) B) Left dimmer switch Secondary fuses(15 A) Low beam relay High beam relay Front parking light bulb High beam bulbs Low beam bulb Rear light Dashboard bulbs Dimmer switch diode / LAP (multifunction) Headlight Rear parking light / stoplight bulbs To the battery / ignition switch To the right display / chronometer

6 - 23

ELECTRICAL SYSTEM
6.8.2 CHECKING THE LIGHTS RELAY To check operation of relay:
N Remove the relay box lid located on the left next to the

RSV mille

dashboard.
N Remove the relevant relay (identifiable thanks to the la-

bel on the lid): high beam light relay (1); dimmers relay (2). N Power the two internal male terminals ( 85 - 86 ) at 12V. N Using a tester (acting as ohmmeter), check for breaks between the other two terminals ( 87 - 30 ). Correct value with relay powered: 0 . Correct value with relay not powered: . If the values do not correspond to those indicated, change the relevant relay.

6.8.3 CHECKING THE LIGHTS / LAP DIODE (multifunction) To check operation of diode:
N Disconnect the three-way connector (3) (coloured

white) (under the rubber protection cap) to the left of the handlebar.

aCAUTION
When reassembling, make sure the electric connector (3) is plugged in properly.
N Using a tester (in diode test mode), check the values

between the two male terminals in the diode, as illustrated in the figure. Correct value (measurement A): 0 1 . Correct value (measurement B): . In the event the tester does not feature the diode test mode, power with a voltage of 12 V, placing a 12V - 2W bulb on the positive cable and connecting the diode as illustrated in the figure.

aCAUTION
Do not use bulbs over 2W, since the diode may be damaged. Test (C): the bulb does not light up. Test (D): the bulb lights.

6 - 24

RSV mille  #//,).' %,%#42/&!. 6.9.1 WIRING DIAGRAM

ELECTRICAL SYSTEM

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.

Wiring diagram key 29) 33) 39) 40) A) Secondary fuses (15A) Cooling fan relay Thermal switch Cooling fans To the battery / ignition switch

6.9.2 CHECKING THE ELECTROFAN OPERATION

NOTE

The following procedure refers to a single electrofan, though it is applicable to both. To check operation of electrofan (1):
N Remove the left-hand side fairing, see 7.1.26 (REMOV-

ING THE SIDE FAIRINGS).

N Disconnect the two electric terminals (2-3) from the N Turn the ignition switch to position n.

thermal switch (4) and connect them together.

aCAUTION
Then reassembling, make sure the electric terminals (2-3) are connected properly. If the electrofan does not work:
N Turn the ignition switch to position m. N Make sure the connector (5) is correctly inserted. N Rotate the fan manually, making sure the blades do not

touch the mount.

N Check the recharging system, see 6.3 (CHECKING

THE RECHARGING SYSTEM) and the secondary fuses (15A). N Repeat the procedure for the other electrofan.

6 - 25

ELECTRICAL SYSTEM
6.9.3 CHECKING THE THERMAL SWITCH OPERATION Thermal switch switch on switch off Temperature ~ 100 C (212F) ~ 85 C (185F)

RSV mille

NOTE The thermal switch switches to on at a temperature of ~ 100C (212F) and to off at ~ 85C (185F); within this range of values, it may switch to on or off indifferently.
N Remove the thermal switch (1), see 5.4 (REMOVING

THE COOLANT THERMAL SWITCH).

N Connect a tester (2) (set as an ohmmeter) to the ther-

mal switch (1) as illustrated in the diagram.

N Immerse the thermal switch (1) in a container (3) hold-

ing coolant.
N Immerse a thermometer (4) with a 0 150 C (32 302

F) range in the same container.

N Place the container on a burner (5) and slowly warm up

the coolant.
N Check that the temperature reading on the thermome-

ter (4) and the value indicated by the tester (2) correspond to the data in the table. Coolant temperature (C) (F) > 100 < 85 > 212 < 185 Standard values () ( 10%) 0

If the values depart excessively from those indicated in the table, change the thermal switch (1).

6.9.4 CHECKING THE ELECTROFAN RELAY The procedure is the same as that required to check the lights relay, see 6.8.2 (CHECKING THE LIGHTS RELAY).

6 - 26

RSV mille  ).$)#!4/23 /. 4(% $!3("/!2$ 6.10.1 WIRING DIAGRAM

ELECTRICAL SYSTEM

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.

Wiring diagram key 29) 53) 54) 55) 56) 57) 61) 64) 65) 66) A) B) Secondary fuses (D) (15 A) Low fuel sensor Engine oil pressure switch Coolant temperature thermistor Speed sensor Low fuel warning light Engine oil pressure warning light LED Revolution counter Multifunction display (right side) Multifunction display (left side) To the ignition switch To the electronic unit

6.10.2 LOW FUEL WARNING LIGHT

N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the three-way electric connector (1) (col-

oured white) of the fuel pump unit.

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Connect together the orange black (Ar/N) and blue (B) N With the ignition switch (2) set to n the g low fuel N If the g light does not come on as expected, make

cables from the system side.

warning light should come on after a second. sure the sensor (3) is working properly:

N Fill the tank with petrol.

With the sensor (3) fully submersed by petrol: the g light remains unlit. N Drain the fuel tank completely, see 4.2 (DRAINING THE FUEL TANK). With the sensor (3) fully submersed by petrol: the g light comes on after 30 to 60 seconds. If these conditions are not achieved, replace the sensor, see 4.4 (REMOVING THE FUEL LEVEL SENSOR).

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ELECTRICAL SYSTEM
6.10.3 COOLANT TEMPERATURE DISPLAY

RSV mille

NOTE In the event the message OOO, appears on the

right-hand display, with a temperature below 130 C (266 F), there might be a problem with the wiring or the coolant thermistor might have short-circuited (right-hand side of engine, see 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION).
N Lift the fuel tank, see 2.8 (LIFTING THE FUEL TANK). N Disconnect the two-way connector (1) (coloured green)

from the thermistor (2) (right-hand side of the engine).

aCAUTION
When reassembling, make sure the electric connector (1) is plugged in properly.
N Connect the following resistors to the connector (1) and

check the message sent up on the right-hand display. Message on right display C (10%) F (10%)

Resistance () > 1400 580 245 115 < 90

60 90 120 ///

140 194 248 ///

N If the messages are correct, check the coolant thermis-

tor on the right-hand side of the engine, see 6.4.8 (CHECKING THE COOLANT THERMISTOR OPERATION).

6.10.4 CHECKING THE ENGINE OIL LOW PRESSURE SENSOR

N Remove the lower fairing, see 7.1.32 (REMOVING

THE LOWER FAIRING).

N Slip off the rubber protection (3). N Disconnect the electric terminal (4) from the sensor (5)

and earth it.

aCAUTION
When reassembling, make sure the electric terminal (4) is connected properly.
N With the ignition switch set to n , the red low engine N If the j LED comes on as expected, check the senN With a tester (scale x 100 ) check for breaks between

oil pressure j LED should come on. sor is working properly.

the tongued terminal (6) and the casing of the sensor (5) (see figure). Correct value with engine off: 0 . Correct value with engine running:

If the values do not correspond to those indicated, check that the engine oil level is correct, see 2.13 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP) and change the sensor (5), if necessary.

6 - 28

RSV mille 6.10.5 SPEEDOMETER

N Position the vehicle on the special rear support stand N Place the clutch lever in neutral. N Check the electric connections are plugged in properly:

ELECTRICAL SYSTEM

&.

three-way connector (1) (coloured white) of the speed sensor and (2) of the dashboard. N Check the distance between the speed sensor (3) and the five screws (4) securing the rear brake disc. Distance between sensor (3) and screws (4): 1.5 1 mm.
N Make sure all five screws are present (4).

With the engine off and the ignition switch set to n , perform the following tests: Test 1st
N Without disconnecting the electric connectors, connect

a tester and measure the voltage between the green/ purple (V/Vi) and blue/orange (B/Ar) cables. Correct value:> 9V (d.c.). Test 2
nd

N Without disconnecting the electric connectors, connect

a tester and measure the voltage between the grey/ white (Gr/Bi) and blue/orange (B/Ar) cables. Correct value: > 6V (d.c.). Test 3rd
N Perform test second. N Spin the rear wheel by hand until one of the five screws

(4) is in line with the sensor (3). The tester should read zero V for approx. two seconds before returning to > 6 V. If test 1st gives an incorrect result, disconnect the senst sor (3) and repeat test 1 . If the wrong value persists, the dashboard is faulty and must be replaced with one in perfect condition. st nd If test 1 gives a correct result and test 2 an incorrect value, the sensor (3) is faulty and must be replaced. st nd If both tests 1 and 2 give a correct result and test rd 3 an incorrect value, the sensor (3) is faulty and must be replaced. If all three tests give a correct result and no speed comes up on the left-hand display, the dashboard is faulty and must be replaced with one in perfect condition.

6.10.6 REV COUNTER

N Remove the right side panel, see 7.1.3 (REMOVING N Turn the ignition switch to position n . N Use a tester to check for voltage between the green (V)

THE SIDE COVERS).

and blue/green (B/V) cables powering the rev counter.

N Use a tester in ohmmeter mode to check for any breaks

on the grey/purple cable (Gr/Vi) between the dashboard and the electronic unit; otherwise try replacing the dashboard with one in perfect condition. N If the rev counter still does not work even after the dashboard is replaced, the fault is to be found in the electronic unit.

6 - 29

ELECTRICAL SYSTEM
 "!44%29

RSV mille

NOTE This vehicle is provided with a maintenancefree battery and no operation is necessary, excepting occasional checks and the recharge when required.
When changing batteries, replace with a battery of the same type. Type: 12V - 12 Ah Carefully read 2.4 (BATTERY).

6.11.1 ACTIVATING THE BATTERY

N Remove the battery, see 7.1.8 (REMOVING THE BAT-

TERY).

aWARNING
The electrolyte in the battery is toxic and caustic and may cause burns on contact with the skin as it contains sulphuric acid. Wear protective clothing, a face mask and/or goggles during service operations. If electrolyte liquid comes in contact with the skin, wash with large quantities of running water. In case of contact with the eyes, wash with large quantities of water for fifteen minutes and consult an oculist without delay. If the liquid is accidentally swallowed, drink large amounts of water or milk, then continue drinking milk of magnesia or vegetable oil and promptly call a doctor. The battery gives off explosive gases, particularly during the phase of starting and/or recharging; keep it away from flames, sparks, cigarettes and any other source of heat. During recharging or using, make sure the room is properly ventilated and avoid inhaling the gases released during recharging. KEEP AWAY FROM CHILDREN. The battery fluid which is very corrosive. Do not pour or spill it, especially on the plastic parts.

aCAUTION
Make sure the electrolyte liquid is specific for the battery to be activated.
N Place the battery on a flat surface. N Remove the adhesive sealing label (1). N Remove the sealed bag from the cardboard container

containing the relevant six reservoirs (2).

N Take the reservoirs (2) out of the bag.

NOTE

Keep the row of stoppers (3) handy as you will need them later to plug the battery cells. reservoirs (2).

N Disconnect the row of stoppers (3) from the top of the

6 - 30

RSV mille

ELECTRICAL SYSTEM

aCAUTION
Do not cut or make holes in the sealed parts on the reservoirs (2). N Turn the reservoirs (2) upside down and place them so that the sealed parts are over the openings of the battery cells. N Press on the reservoirs (2) so that the seals break and the acid is allowed to pour into the battery cells.

NOTE

Make sure the reservoirs (2) are positioned above the battery as vertically as possible to enable the liquid to flow out. N Leave the reservoirs (2) in place on the battery for approx. twenty minutes, checking the liquid flows out properly.

aCAUTION
Do not remove the reservoirs (2) from the battery until all the liquid has poured out. N 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. N Lift the reservoirs (2) with care, disengaging them from the battery. N Place the row of stoppers (3) over the battery cell openings. N Press down firmly until the tops of the stoppers (3) are flush with the top of the battery.

aCAUTION
The row of stoppers (3) must NEVER be removed. N Connect the battery to a battery charger. N Subject the battery to a normal charge cycle (see table). Charge Normal Fast Voltage (Amperes) 1.2 12 Time (hours) 8 10 0.5

N Refit the battery on the vehicle on being returned to the

customer. 6.11.2 MAINTENANCE

N 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). N Smear a film of neutral grease or Vaseline on the terminals. 6.11.3 CHECKING Should any anomalies be encountered, first check the recharging circuit, making sure that it is working correctly, see 6.3 (CHECKING THE RECHARGING SYSTEM). In addition, make sure that: N There are no signs of damage (external case cracked) and no electrolyte leak. N The cables are firmly connected to the terminals. N Proceed with the normal charge for at least 10 hours.

aCAUTION
After recharging, check the no-load voltage; if it is lower than 12 V, it is absolutely necessary to change the battery. 6.11.4 RETURN UNDER GUARANTEE The guarantee is not valid if the battery features: N Damage (dented box, bent poles, etc.). N Widespread sulphation (incorrect activation and/or use of the battery).

6 - 31

ELECTRICAL SYSTEM
 #(!.').' 4(% "5,"3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

RSV mille

aCAUTION
Before changing a bulb, move the ignition switch to position m. Change the bulb wearing clean gloves or using a clean and dry cloth. Do not leave fingerprints on the bulb, since these may cause its overheating and consequent breakage. If you touch the bulb with bare hands, remove any fingerprint with alcohol, in order to avoid any damage. DO NOT FORCE THE ELECTRIC CABLES. 6.12.1 CHANGING THE HEADLIGHT BULBS
N Position the vehicle on the stand.

NOTE Before changing a bulb, check the fuses, see 6.15 (CHANGING THE FUSES).
The headlight contains: two high beam bulbs (1) (side); one parking light bulb (2) (upper); one low beam bulb (3) (lower).

NOTE The removal of the front part of the fairing is necessary when the parking light bulb and the high beam bulbs must be changed.
To change the bulbs, proceed as follows: PARKING LIGHT BULB N Remove the front part of the fairing, see 7.1.20 (REMOVING THE FRONT PART OF THE FAIRING).

aCAUTION
To extract the bulb socket, do not pull the electric wires.
N Grasp the parking light bulb socket (4), pull it and re-

move it from its seat.

N Withdraw the bulb (5) and replace it with one of the

same type. HIGH BEAM BULBS N Remove the front part of the fairing, see 7.1.20 (REMOVING THE FRONT PART OF THE FAIRING). N Move the protection element (6) of the bulb to be changed with your hands. N Withdraw the electric terminal (7). N Release the check spring (8) positioned at the rear of the bulb socket (9). N Extract the bulb (10) from its seat and replace it with a new one of the same type.

NOTE

Insert the bulb in the bulb socket, making the relevant positioning seats coincide. LOW BEAM BULB

N Move the protection element (11) with your hands. N Withdraw the bulb electric connector (12). N Rotate the bulb socket (13) anticlockwise and extract it

from its seat.

N Extract the bulb (14) from its seat and replace it with a

new one of the same type.

NOTE

Insert the bulb in the bulb socket, making the relevant positioning seats coincide.

6 - 32

RSV mille 6.12.2 CHANGING THE FRONT AND REAR DIRECTION INDICATOR BULBS
N Position the vehicle on the stand.

ELECTRICAL SYSTEM

NOTE

Before changing a bulb, check the fuses, see 6.15 (CHANGING THE FUSES).
N Unscrew and remove the screw (1).

aCAUTION
While removing the protection screen, proceed carefully in order not to break the lug.
N Remove the protection screen (2).

aCAUTION
Upon reassembly, correctly position the protection screen in its seat. Tighten the screw (1) moderately and carefully, to avoid damaging the protection screen.
N Press the bulb (3) slightly and rotate it anticlockwise. N Extract the bulb (3) from its seat.

NOTE Insert the bulb in the bulb socket, making the two bulb pins coincide with the relevant guides on the socket.
N Correctly install a new bulb of the same type.

NOTE

If the bulb socket (4) goes out of its seat, insert it correctly, making the bulb socket opening coincide with the screw seat.

6.12.3 CHANGING THE REAR LIGHT BULB

NOTE
bulbs (5).

The rear light houses two parking light/stoplight

The following operations refer to a single bulb, but are valid for both. N Position the vehicle on the stand.

NOTE

Before changing a bulb, check the fuses, see 6.15 (CHANGING THE FUSES) and the efficiency of the stoplight switches, see 6.16 (CHECKING THE SWITCHES).
N Unscrew and remove the two screws (6). N Remove the protection screen (7).

aCAUTION
Upon reassembly, correctly position the protection screen in its seat. Tighten the screw (6) carefully, without exerting too much pressure, in order to avoid damaging the protection screen.
N Press the bulb (8) slightly and rotate it anticlockwise. N Extract the bulb (8) from its seat.

NOTE Insert the bulb in the bulb socket, making the two bulb pins coincide with the relevant guides on the socket.
N Correctly install a new bulb of the same type.

6 - 33

ELECTRICAL SYSTEM
6.12.4 CHANGING THE DASHBOARD BULBS / LIGHTS

RSV mille

NOTE Before replacing a bulb/light, check the fuses, see 6.15 (CHANGING THE FUSES).
To change the bulb/light: N Remove the dashboard, see 7.1.23 (REMOVING THE DASHBOARD). N Unscrew and remove the eight fastening screws (1). N Remove the rear cover (2). N Slide out the relevant bulb holder and, where necessary, replace the bulb: Pos. 3 4 5 Pos. 6 7 8 9 10 Description Bulbs for right-hand display lighting Bulbs for left-hand display lighting Bulbs for rev counter lighting Warning light Description Side stand down Low fuel High beam Direction indicator Neutral

\
g a c q

aCAUTION
If the defect persists even after the bulb/light has been changed, check the relevant sensor/switch, see: 6.6.4 (CHECKING THE SIDE STAND AND THE SAFETY SWITCH); 6.10.2 (LOW FUEL WARNING LIGHT); 6.10.4 (CHECKING THE ENGINE OIL LOW PRESSURE SENSOR).

NOTE
Pos. 11 12

The two LEDs (11) and (12) cannot be removed.

LED

Description Engine oil pressure Red line

j
max

6 - 34

RSV mille  !$*534).' 4(% 6%24)#!, (%!$,)'(4 "%!-

ELECTRICAL SYSTEM

NOTE

To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used.

To rapidly check the correct direction of the beam, place the vehicle on flat ground, 10 m away from a wall. Turn on the low beam, sit on the vehicle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight (about 9/10th of the total height). To adjust the headlight beam:
N Working on the rear left side of the front part of the fair-

ing, adjust the apposite screw (1) by means of a short cross-tip screwdriver. By SCREWING IT (clockwise), you set the beam upwards. By UNSCREWING IT (anticlockwise), you set the beam downwards.

 !$*534).' 4(% (/2):/.4!, (%!$,)'(4 "%!-

NOTE

To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used. of the high beam, the vertical adjustment of the headlight beam must be performed, see 6.13 (ADJUSTING THE VERTICAL HEADLIGHT BEAM).

NOTE Before proceeding with the horizontal adjustment

N Working from the right-hand side of the vehicle, adjust

the relevant screw (2) by means of a short Phillips screwdriver. By SCREWING IT (clockwise) moves the beam to the left. By UNSCREWING IT (anticlockwise) moves the beam to the right.

6 - 35

ELECTRICAL SYSTEM
 #(!.').' 4(% &53%3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS).

RSV mille

aCAUTION
Do not repair faulty fuses. Never use fuses different from the recommended ones. The use of unsuitable fuses may cause damages to the electric system or, in case of short circuit, even a fire.

NOTE

If a fuse blows frequently, there probably is a short circuit or an overload in the electric system.

If an electric component does not work or works irregularly, or if the vehicle fails to start, it is necessary to check the fuses. Check first the 15A secondary fuses and then the 30A primary fuses. For the check: N Turn the ignition switch to position m, to avoid any accidental short circuit. N Remove the rider saddle, see 7.1.1 (REMOVING THE RIDER SADDLE). N Loosen the screw (1). N Move the safety clip (2). N Open the cover of the box (3) containing the secondary fuses. N Extract the fuses one by one and check if the filament (4) is broken. N Before replacing a fuse, try to find out the cause of the trouble, if possible. N Replace the damaged fuse with a new one having the same amperage.

NOTE If you use one of the spare fuses, put a new fuse in the proper seat.
N Remove the rider saddle, see 7.1.1 (REMOVING THE

RIDER SADDLE).
N Carry out the operations previously described for the

secondary fuses also for the main fuses.

NOTE

By removing the 30A fuse, you set the digital clock and the red line to zero. To reset these functions, see 2.3 (MULTIFUNCTION COMPUTER). ARRANGEMENT OF THE 15A SECONDARY FUSES A) From voltage regulator to: high beam relay, low beam relay. B) From voltage regulator to: coils, engine stop relay, fuel pump. C) From ignition switch to: electric fans, clock. D) From ignition switch to: parking lights, rear stoplights, horn, dashboard lights, direction indicators. E) From ignition switch to: electronic unit, fuel pump relay, engine stop relay.

NOTE

Three fuses are spare fuses.

ARRANGEMENT OF THE 30A MAIN FUSES F) From battery to: ignition. G) From battery to: ignition.

NOTE

One fuse is a spare fuse.

6 - 36

RSV mille  #(%#+).' 4(% 37)4#(%3 Carefully read 0.2.1 (PRECAUTIONS AND GENERAL INFORMATIONS). The vehicle is provided with four switches: 1) Stoplight switch on the rear brake control lever. 2) Stoplight switch on the front brake control lever.

ELECTRICAL SYSTEM

3) Safety switch on the side stand. 4) Switch on the clutch control lever.
N Make sure that there are no dirt or mud deposits on the

switch; the pin must be able to move without interferences, returning automatically to its initial position. N Make sure that the cables are connected correctly. N Check the spring (5): it must not be damaged, worn or weakened.

6 - 37

ELECTRICAL SYSTEM
 #/..%#4)/.3 4/ 4(% %.').% #/.42/, 5.)4

RSV mille

NOTE See 6.2 (ELECTRIC COMPONENTS LAYOUT) for the positioning of the components.
See 4.7.4 (ENGINE CONTROL UNIT CONNECTORS), for further details.

NOTE

The initials (y) and (z) appearing in the diagram, next to the relevant numbers, mark the respective terminals on both connectors. Y) Electronic unit connector (26-way). Z) Electronic unit connector (16-way).

6 - 38

RSV mille Pos. 2 Component Cam position sensor Z y 3 Throttle valve potentiometer Z Z y 4 Suction pressure sensor Z Z y 5 Coolant thermistor Z y 6 Air thermistor Z Z 7 Fall sensor Z 9 11 15 21 Clutch control lever switch Starting relay Fuel pump relay Pick up Z y 42 42 23 Earth Z Diagnostics Rev.counter Rear cylinder coil Rear cylinder coil y y 25 Front cylinder coil y y 26 Front cylinder coil y Z 44 Front cylinder injector y Z 45 68 Rear cylinder injector y TEST connectors y 7 19 9 8 26 8 25 1 13 1 y y y y y 24 7 - 16 17 14 1 12 1 4-5 4-5 4-5 4-5 11 -17 11 - 17 1 2-10-11-23 y y y y Z 14 20 21 22 16 9 150 - 300 13 7 > 10 k 6 15 10 15 3 4 15 3 5 15 1:9 - 2:9 k 10 - 15 k 2.8 - 3.4 k ( Angle variable) Connector Z Terminal # 2 Nominal value 150 - 300

ELECTRICAL SYSTEM
Cable colours Vi /N Gr/N B/R M/Bi M/G B/R M/Bi Ro B/R Ro/N B/R Ro/V Earth Ro/Bi M/V M/Vi G/R Ar/G Bi/G B/G B/V B/Vi Gr/Vi V/Gr Az/G V/Gr Ro/G V/Gr Ro/G V/Gr Ar/Bi V/N Gr/R V/N M/R V/Bi

6 - 39

ELECTRICAL SYSTEM

 7)2).' $)!'2!- 236 MILLE

DASHBOARD CONNECTOR (20-WAY)

ELECTRONIC UNIT CONNECTOR (26-WAY)

ELECTRONIC UNIT CONNECTOR (16-WAY)

6 - 40

RSV mille

RSV mille 7)2).' $)!'2!- +%9 236 MILLE 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) Electronic unit Cam position sensor Throttle valve potentiometer Suction pressure sensor Coolant thermistor Air thermistor Fall sensor Diode module Clutch control lever switch Neutral switch Arrangement for the installation of the anti-theft device Right dimmer switch Left dimmer switch Engine stop relay Fuel pump relay Start relay Starter Battery Main fuses (30A) (ignition) Generator Pick up Voltage regulator Rear cylinder coil 1 Rear cylinder coil 2 Front cylinder coil 1 Front cylinder coil 2 Spark plugs Secondary fuses (15A) A - High beam, low beam. B - ISC, coils, fuel pump. C - Electric fans, clock. D - Parking lights, stoplights, horn, dashboard lights, direction indicators. E - Electronic unit, fuel pump relay engine stop relay. 30) Ignition switch 31) Low beam relay 32) High beam relay 33) 34) 35) 36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 46) 47) 48) 49) 50) 51) 52) 53) 54) 55) 56) 57) 58) 59) 60) 61) 62) 63) 64) 65) 66) 67) 68) 69) 70) 71) 72)

ELECTRICAL SYSTEM

Cooling fan relay Front parking light bulb High beam bulbs Low beam bulb Front right direction indicator Front left direction indicator Thermal switch Cooling fans Rear light Dashboard Rear left direction indicator Front cylinder injector Rear cylinder injector Front stoplight switch Rear stoplight switch Rear right direction indicator Horn Multiple connectors Blinking Fuel pump Low fuel sensor Engine oil pressure switch Coolant temperature thermistor Speed sensor Low fuel warning light Side stand down warning light Neutral warning light Direction indicator warning light Engine oil pressure warning light LED High beam warning light Dashboard bulbs Revolution counter Multifunction display (right side) Multifunction display (left side) Light diode / LAP TEST connectors Headlight Side stand switch Red line warning light LED Rear parking light/stoplight bulbs

#!",% #/,/523 Ar Az B Bi G Gr M N R Ro V Vi Orange Light blue blue White Yellow Grey Brown Black Red Pink Green Violet

6 - 41

ELECTRICAL SYSTEM

 7)2).' $)!'2!- 236 MILLE

DASHBOARD CONNECTOR (20-WAY)

ELECTRONIC UNIT CONNECTOR (26-WAY) ELECTRONIC UNIT CONNECTOR (16-WAY)

6 - 42

_
RSV mille

RSV mille 7)2).' $)!'2!- +%9 236 MILLE 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) Electronic unit Cam position sensor Throttle valve potentiometer Suction pressure sensor Coolant thermistor Air thermistor Fall sensor Diode module Clutch control lever switch Neutral switch Arrangement for the installation of the anti-theft device Right dimmer switch Left dimmer switch Engine stop relay Fuel pump relay Start relay Starter Battery Main fuses (30A) (ignition) Generator Pick up Voltage regulator Rear cylinder coil 1 Rear cylinder coil 2 Front cylinder coil 1 Front cylinder coil 2 Spark plugs Secondary fuses (15A) A - High beam, low beam. B - ISC, coils, fuel pump. C - Electric fans, clock. D - Parking lights, stoplights, horn, dashboard lights, direction indicators. E - Electronic unit, fuel pump relay engine stop relay. Ignition switch Low beam relay High beam relay

ELECTRICAL SYSTEM

_
33) 34) 35) 36) 37) 38) 39) 40) 41) 42) 43) 44) 45) 46) 47) 48) 49) 50) 51) 52) 53) 54) 55) 56) 57) 58) 59) 60) 61) 62) 63) 64) 65) 66) 67) 68) 69) 70) 71) 72) Cooling fan relay Front parking light bulb High beam bulbs Low beam bulb Front right direction indicator Front left direction indicator Thermal switch Cooling fans Rear light Dashboard Rear left direction indicator Front cylinder injector Rear cylinder injector Front stoplight switch Rear stoplight switch Rear right direction indicator Horn Multiple connectors Blinking Fuel pump Low fuel sensor Engine oil pressure switch Coolant temperature thermistor Speed sensor Low fuel warning light Side stand down warning light Neutral warning light Direction indicator warning light Engine oil pressure warning light LED High beam warning light Dashboard bulbs Revolution counter Multifunction display (right side) Multifunction display (left side) Light diode / LAP TEST connectors Headlight Side stand switch Red line warning light LED Rear parking light/stoplight bulbs

30) 31) 32)

#!",% #/,/523 Ar Az B Bi G Gr M N R Ro V Vi Orange Light blue blue White Yellow Grey Brown Black Red Pink Green Violet

6 - 43

ELECTRICAL SYSTEM
NOTE

RSV mille

6 - 44