FOREWORD ­ 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. ­ This publication is meant for professional mechanics, therefore many notions have been intentionally omitted, as they were regarded as superfluous. For any further information, contact aprilia s.p.a. SERVICE DEPARTMENT. ­ For any further information see the ENGINE SERVICE MANUAL, No 933 (D-UK) / No 934 (I-E-F), the ENGINE SPARE PARTS CATALOGUE and the "CHASSIS PARTS" SPARE PARTS CATALOGUE, No 261V 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 is not binding in any case. aprilia s.p.a. takes no responsibility as to the performance or the use of said products. TABLE OF CONTENTS GENERAL INFORMATION 1 2 3 4 5 6 7 8 SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM HOW TO USE YOUR SERVICE AND REPAIR MANUAL x ELECTRICAL SYSTEM c x ADVICE FOR CONSULTATION ­ If not expressly described otherwise, the reassembly of the groups is to be carried out repeating the disassembly phases in the reverse order. ­ For each single operation on the engine, consult the specific manual. ­ For ordinary maintenance, consult the "USE AND MAINTENANCE" manual. Remember: 1 mile = 1.6 km 1 km = 0.625 miles CHASSIS PARTS REPAIR INFORMATION SYMBOLS Carefully observe the instructions preceded by the following warning signs: Safety norms and regulations to protect the pilot, the mechanic and other people from severe injuries or grave risks. Indications to make the operations easier. Technical information. The operations preceded by this symbol must be repeated on the opposite side of the vehicle. First edition: march 1997 Reprint: Produced and printed by: Studio Tecno Public Viale del Progresso - 37038 Soave (VR) - Italy Ph. 045 - 76 11 911 Fax 045 - 76 12 241 On behalf of: aprilia s.p.a. Via G. Galilei, 1 - 30033 Noale (VE) - Italy Ph. 041 - 58 29 111 Fax 041 - 44 10 54 a c 5 In this manual the various versions are indicated by the following symbols: & optional 2 catalytic version U United Kingdom version A Austria version C Switzerland version 0 -3 NOTE / NOTES / ANMERKUNGEN 0 -4 INFORMAZIONI GENERALI INFORMACIONES GENERALES GENERAL INFORMATION 1 2 3 4 5 6 7 8 1 -1 INFORMACIONES GENERALES GENERAL INFORMATION INFORMACIONES GENERALES 1 GENERAL INFORMATION 1 INDICE 1.1 POSICIÓN DE LOS NÚMEROS DE SERIE ............ Pag. 1-5 1.1.1 NÚMERO DE BASTIDOR..................... Pag. 1-5 1.1.2 NÚMERO DE MOTOR .......................... Pag. 1-5 1.2 ADVERTENCIAS PARA EL COMBUSTIBLE, LUBRICANTES Y LÍQUIDO REFRIGERANTE ............... Pag. 1-5 1.2.1 COMBUSTIBLE .................................... Pag. 1-5 1.2.2 ACEITE DEL MOTOR........................... Pag. 1-5 1.2.3 ACEITE PARA HORQUILLA................ Pag. 1-8 1.2.4 LÍQUIDO DE FRENOS ......................... Pag. 1-8 1.2.5 LÍQUIDO REFRIGERANTE .................. Pag. 1-8 1.3 NORMAS PARA EL RODAJE ............... Pag. 1-9 1.4 PRECAUCIONES E INFORMACIONES GENERALES ..... Pag. 1-9 1.5 PIEZAS DE REPUESTO ...................... Pag. 1-12 1.6 FICHA TECNICA ................................... Pag. 1-12 1.7 TABLA DE LOS LUBRICANTES ....... Pag. 1-15 1.8 EQUIPOS ESPECIALES ...................... Pag. 1-16 TABLE OF CONTENTS 1.1 POSITION OF SERIAL NUMBERS ..... Pag. 1-5 1.1.1 FRAME NUMBER ................................. Pag. 1-5 1.1.2 ENGINE NUMBER ............................... Pag. 1-5 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS AND COOLANT ........... Pag. 1-5 1.2.1 FUEL ..................................................... Pag. 1-5 1.2.2 ENGINE OIL.......................................... Pag. 1-5 1.2.3 FORK OIL ........................................... Pag. 1-10 1.2.4 BRAKE FLUID .................................... Pag. 1-10 1.2.5 COOLANT........................................... Pag. 1-10 1.3 RUNNING-IN RULES ........................... Pag. 1-11 1.4 PRECAUTIONS AND GENERAL INFORMATION ..................................... Pag. 1-11 1.5 SPARE PARTS ...................................... Pag. 1-12 1.6 TECHNICAL SPECIFICATIONS ................................ Pag. 1-12 1.7 LUBRICANT CHART............................ Pag. 1-15 1.8 SPECIAL TOOLS .................................. Pag. 1-16 1 2 3 4 5 6 7 8 1 -3 INFORMACIONES GENERALES 1.1 POSICIÓN DE LOS NÚMEROS DE SERIE Estos números son necesarios para matricular el vehículo. La alteración de los números de identificación puede provocar graves sanciones penales y administrativas y la invalidez de la garantía. 1.1.1 NÚMERO DE BASTIDOR El número del bastidor está impreso en el tubo de la dirección, en la parte derecha del vehículo. 1.1.2 NÚMERO DE MOTOR El número del motor está impreso en la parte trasera superior. GENERAL INFORMATION 1.1 POSITION OF SERIAL NUMBERS These numbers are necessary in order to register the vehicle. Do not alter the identification numbers if you do not want to incur severe penal and administrative sanctions and to cause the immediate invalidation of the guarantee. 1.1.1 FRAME NUMBER The frame number is printed on the vehicle right side of the steering tube. 1.1.2 ENGINE NUMBER The engine number is printed high up on the rear part of the vehicle. 1.2 INSTRUCTIONS FOR USE OF FUEL, LUBRICANTS AND COOLANT 1.2.1 FUEL The fuel used for internal combustion engines is extremely inflammable and in certain conditions can become explosive. It is advisable to perform the operations of refuelling and maintenance in a well-ventilated area with the engine switched off. Do not smoke while refuelling or when near fuel vapours and, in any case, avoid contact with naked flames, sparks and any other source of heat that might cause the fuel to catch fire or to explode. Avoid escape of fuel from the fuel filler as it could ignite on contact with the red-hot surfaces of the engine. In case fuel has accidentally been spilt, make sure that the area is completely dry before starting the vehicle. Never fill the tank to the brim as fuel expands under the heat of the sun and reacts to the effects of sun radiation . Close the cap securely after refuelling. Avoid contact of the fuel with the skin and inhalation of the fumes; do not swallow fuel or pour it from one container into another by means of a tube. Do not dispose of fuel in the environment. KEEP FUEL AWAY FROM CHILDREN. Normal version: premium grade petrol (4 Stars U) according to the DIN 51 600 standard, min. O.N. 98 (N.O.R.M.) and 88 (N.O.M.M.). Catalytic version 2: unleaded petrol according to the DIN 51 607 standard, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.). 1.2.2 ENGINE OIL 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. Check engine oil level every 500 km; see 2.12 (CHECKING THE ENGINE OIL LEVEL AND TOPPING UP). Change engine oil after the first 1000 km and successively every 6000 km; see 2.13 (CHANGING ENGINE OIL AND OIL FILTER). Recommended engine oil: IP SUPERBIKE 4, SAE 5W - 40. As an alternative to the recommended oil, high quality oils with performance conforming or superior to CCMC G-4, A.P.I.SG. specifications may be used. c c 1.2 ADVERTENCIAS PARA EL COMBUSTIBLE, LUBRICANTES Y LÍQUIDO REFRIGERANTE 1.2.1 COMBUSTIBLE El combustible para la propulsión de los motores de explosión, es muy inflamable y puede volverse explosivo en determinadas condiciones. Es oportuno reponer gasolina y realizar las operaciones de mantenimiento en una zona ventilada y con el motor apagado. No fume durante la provisión de gasolina y cerca de los vapores del combustible; evite el contacto con llamas, chispas y cualquier otra fuente que pueda causar el encendido o la explosión. Además, evite que el combustible salga de la boca de llenado, ya que éste podría incendiarse si toca las superficies candentes del motor. En caso que se vierta accidentalmente combustible, antes de arrancar el vehículo, controle que la zona esté completamente seca. El combustible se dilata con el calor y bajo la acción de los rayos solares. Por lo tanto, nunca llene el depósito hasta el tope. Cierre cuidadosamente la tapa al finalizar las operaciones de reposición. Evite el contacto del combustible con la piel, la inhalación de los vapores, la ingestión y el trasiego de un recipiente a otro por medio de un tubo. No esparsa el combustible en el medio ambiente. MANTÉNGASE LEJOS DEL ALCANCE DE LOS NIÑOS. Versión normal: Gasolina super (4 Stars U) DIN 51 600, mínimo octano 98 (N.O.R.M.) y 88 (N.O.M.M.). Versión catalítica 2: Gasolina super sin plomo según DIN 51 607, mínimo octano 95 (N.O.R.M) y 85 (N.O.M.M.). 1.2.2 ACEITE DEL MOTOR El aceite del motor puede causar graves daños a la piel si es manipulado por mucho tiempo y diariamente. Se aconseja lavarse las manos tras haberlo manipulado. No esparza el aceite en el medio ambiente. Entréguelo o hágalo retirar por la empresa de recuperación de aceites usados más cercana o por el proveedor. Controle cada 500 km el nivel del aceite del motor; véase 2.12 (CONTROL DEL NIVEL DEL ACEITE DEL MOTOR Y RELLENO). Cambie el aceite del motor tras los primeros 1000 km y sucesivamente cada 6000 km; véase 2.13 (CAMBIO DEL ACEITE MOTOR Y DEL FILTRO DEL ACEITE DEL MOTOR). Aceite del motor (aconsejado): IP SUPERBIKE 4, SAE 5W - 40. Como alternativa a el aceite aconsejado, pueden utilizarse aceites de marca con características conformes o superiores a las normas CCMC G-4, A.P.I. SG. a a a a 1 -5 GENERAL INFORMATION 1.2.3 FORK OIL 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. Recommended fork oil: IP F.A. 5W or IP F.A. 20W fork oil. If an intermediate performance is desired (between those of IP F.A. 5W and IP F.A. 20W) the products can be mixed as follows: 67% of volume SAE 10W IP F.A. 5W + 33% of volume IP F.A. 20W 33% of volume SAE 15W IP F.A. 5W + 67% of volume IP F.A. 20W 1.2.5 COOLANT The coolant can be harmful if swallowed or if it touches the skin or eyes. If it comes in contact with the skin or eyes, rinse thoroughly with large quantities of water. If the coolant is swallowed, induce vomiting and immediately consult a doctor. a a a a Do not remove the radiator cap when the engine is hot as the coolant is under pressure and at a very high temperature. KEEP COOLANT AWAY FROM CHILDREN. Do not use vehicle if the coolant level is below the minimum prescribed. Check coolant level every 1000 km and after long runs, see 2.14 (CHECKING AND TOPPING UP COOLANT); change it every 12000 km or every 2 years (whichever occurs first), see 2.15 (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. 1.2.4 BRAKE FLUID 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 BRAKE FLUID AWAY FROM CHILDREN c a a a 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. Recommended coolant: IP ECOBLU - 40° 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: Freezing point °C -20° -30° Coolant of the volume % 35 45 55 Use the brake fluid; it may chemically alter painted surfaces and the parts in plastic, rubber, etc. Recommended brake fluid: IP F.F. DOT 5 (DOT 4 compat ...