User manual APRILIA 1115-2

[. . . ] RSV mille INTRODUCTION 0 1 2 3 4 5 6 7 8 GENERAL INFORMATION SERVICE AND SETTING UP ENGINE FUEL SUPPLY SYSTEM COOLING SYSTEM ELECTRIC SYSTEM CHASSIS REPAIR INFORMATION ANALYTICAL INDEX @ 236 mille U WORKSHOP manual aprilia part# 8140688 Release 00/2002-10 0 - 1 - 00 INTRODUCTION RSV mille 0 INTRODUCTION 4!", % /& #/. 4%. 43 50$!4% /& 2%, %!3% . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-3-00 0. 1. 1 INFORMATION ON THE UPDATING OF THE MANUAL . . . . . . . . . . . . . . . 0. 4. 1 ENGINE SERVICE AND REPAIR MANUALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0. 5. 1 PRECAUTIONS AND GENERAL INFORMATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [. . . ] Moreover, the injection time also depends on the induction pipe pressure, especially when the throttle valve opening angle is limited (during idling). The throttle valve potentiometer measures the position of said valves and acts as the main parameter in determining the injection time and ignition angle. Follow FUEL SUPPLY SYSTEM Release 00/2002-10 4 - 9 - 00 FUEL SUPPLY SYSTEM Follow RSV mille Coolant thermistor (15) Location: on rear head cylinder (16). 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. 4 - 10 - 00 Release 00/2002-10 RSV mille 4. 7. 3 INJECTION SYSTEM DIAGRAM FUEL SUPPLY SYSTEM Key 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Electronic 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) Coolant temperature 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) Release 00/2002-10 4 - 11 - 00 FUEL SUPPLY SYSTEM 4. 7. 4 ENGINE CONTROL UNIT CONNECTORS For further information, see 6. 17 (CONNECTIONS TO THE ENGINE CONTROL UNIT). RSV mille 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 Rear cylinder injector Front cylinder injector Earth Earth Rear cylinder ignition coil Rear cylinder ignition coil 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 Front cylinder ignition coil Front cylinder ignition coil 16-pin connector (2) Terminal labelConnections ling N+ Driving shaft position sensor "+" G+ Camshaft position sensor Intake pressure sensor and throttle VCC valve potentiometer VTA Throttle valve potentiometer PM Intake pressure sensor THW Coolant thermistor MS 2 Earth VM Fuel pump NDriving shaft position sensor "" GCamshaft position sensor Air thermistor THA Intake pressure sensor DON Fall sensor MS 1 Earth 4 - 12 - 00 Release 00/2002-10 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 aWARNING Take care around the high voltage in the ignition system. Whenever work is performed in the ignition system, always make sure the ignition switch is set to "1" 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 20 C (68 F). General instructions regarding the elimination of faults: as soon as the fault has been located, remove the defective component. 4. 7. 12 COOLANT THERMISTORS 4. 7. 8 DRIVING SHAFT POSITION SENSOR Fault code "12". N Check for pressure loss in the connection pipes (1) (2) (3) and make sure the flow is regular. 4. 7. 14 IGNITION COILS Fault code "33", "34", "35", "36". See 6. 4. 4 (CHECKING THE IGNITION COILS). NOTE Where necessary, pressure sensor or engine control unit. replace the 4. 7. 11 THROTTLE VALVE POTENTIOMETER Fault code "15". See 6. 4. 10 (CHECKING THE THROTTLE VALVE POTENTIOMETER). Release 00/2002-10 4 - 13 - 00 FUEL SUPPLY SYSTEM 4(2/44, % "/$9 RSV mille 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. 5. 1 (PRECAUTIONS AND GENERAL INFORMATIONS). N Partially remove the fuel tank, see 7. 1. 5 (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. Follow 4 - 14 - 00 Release 00/2002-10 RSV mille Follow FUEL SUPPLY SYSTEM aCAUTION NOTE Have the appropriate special tool m to hand: aprilia part# 0277295 (hose clamp installation pliers). Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions, see 0. 4. 2 (SPARE PARTS CATALOGUES). Do not attempt to reinstall the removed hose clamp, since it is unusable. Do not replace the removed hose clamp with a screw clamp or with other types of clamp. N Release the hose clamp (9). [. . . ] Clutch control hydraulic system faulty Replace The clutch does not "dis- Control fluid tank level Check engage" Use motor oil conforming to Motor oil not to spec. Clutch discs stuck together Clean or replace (*) Clutch discs or support plate distorted Replace (*) Clutch control hydraulic system faulty Replace Clutch housing worn Replace (*) The clutch sticks during Clutch discs worn or distorted Replace (*) engagement Replace the housing Clutch disc guide grooves inside clutch housing worn clutch (*) Smooth disc guide grooves in clutch disc hub worn Replace the disc hub (*) Thrust-bearing surfaces of the clutch housing or support plate Replace (*) worn Gears cannot be engaged Engagement teeth of speed gears worn Replace (*) or are difficult to engage Propeller shafts worn Replace (*) Selector shaft gearshift mechanism faulty Repair or replace (*) The gearshift forks are worn or distorted Replace (*) See the subsection entitled (The clutch does not "disengage") for other possible causes Follow Release 00/2002-10 8 - 5 - 00 Follow SYMPTOM AND POSSIBLE CAUSES Gearshift gears worn The gearshift forks are worn or distorted The positioning springs are exhausted or broken RSV mille DEFECT The gears disengage when the vehicle is started or whilst accelerating hard REMEDY Replace (*) Replace (*) Replace (*) When shifting up or down, always press the gearshift Gearchanging lacks coordination or is incomplete; the gearshift lever pedal down all the lever is distorted or adjusted incorrectly way; replace the gearshift lever (*) Spark plugs overheated, Spark plugs not to spec Replace burnt out or dirty Spark plugs loose Tighten Intake couplings or intake system leaking Replace Fuel supply system faulty Repair or replace The battery alternator is Battery faulty Change the battery not charged or is charged Voltage regulator faulty Replace incorrectly Break in current, short-circuit or earthing of alternator windings Replace Break in cables or cables short-circuited, connections loose Repair, change or tighten 8. 1. 2 ELECTRIC SYSTEM SYMPTOM AND POSSIBLE CAUSES Motor oil level incorrect Unsuitable fuel Air cleaner dirty Spark plugs gets dirty too Motor oil level incorrect quickly Piston segments worn Piston or cylinder worn Spark plugs electrodes The engine overheats overheated or burnts Spark plug loose Alternator does not Connection terminals interrupted, in short circuit or loose charge Alternator coils in short circuit, earthed or interrupted Voltage regulator in short circuit or defective The alternator does The terminals are subject to short circuit, interruption or charge but the current excessive separation intensity is lower than the Alternator stator coils earthed or interrupted prescribed value Voltage regulator faulty Battery faulty Alternator charges too Short circuit inside battery much Voltage regulator damaged or defective Unstable earth of voltage regulator Charge not constant Terminal insulation worn due to vibrations, with consequent temporary short circuits Internal generator short circuits Voltage regulator faulty DEFECT Spark plugs becomes dirty immediately with carbon deposits REMEDY Check Use the prescribed fuel Clean Check Replace (*) Replace (*) Adjust Tighten Repair, change or tighten Replace Replace Repair or tighten Replace Replace Replace Repair or replace Replace Replace Repair or replace Replace (*) Replace 8 - 6 - 00 Release 00/2002-10 RSV mille 8. 1. 3 BATTERY DEFECT Battery runs down too quickly SYMPTOM AND POSSIBLE CAUSES Recharging system defective REMEDY Check the alternator, the regulator/rectifier, the circuit connections and carry out operations necessary to restore correct recharge Change the battery and repair charging system Change the battery Change the battery Change the battery and make sure new one is connected properly Battery polarity inverted Battery elements have lost much active potential consequent on excessive charge Presence of short circuits inside battery owing to excessive accumulation of sediments Old battery Battery has been incorrectly connected to the system 8. 1. 4 BRAKES DEFECT Poor braking power SYMPTOM AND POSSIBLE CAUSES REMEDY Brake fluid leakage from hydraulic system Repair or replace Brake pads worn Change pads Contact surfaces of pads soiled by oil, grease or brake Change pads fluid Brake discs worn Change disc Air in hydraulic circuit Bleed the circuit Brake discs dirty with oil, grease or brake fluid Clean Foreign matter in brake fluid Change brake fluid Brake pump return hole clogged Disassemble and clean brake pump Pad contact surfaces hardened Restore surfaces with sandpaper Pads installed backwards Install correctly Wheel bearing damaged Replace Front or rear wheel pin loose Tighten to prescribed driving torque Brake pads worn Replace Air in hydraulic circuit Bleed the circuit Insufficient brake fluid Replace Unsuitable brake fluid Replace Brake caliper pins locked Disassemble and clean Insufficient tightening of connection fittings Tighten to prescribed driving torque Cracked pipes Replace Pumping element and/or body worn Change the pumping element and/or body Brakes squeak Excessive stroke of brake lever Brake fluid leakage Release 00/2002-10 8 - 7 - 00 RSV mille 8. 1. 5 CHASSIS DEFECT Hard steering SYMPTOM AND POSSIBLE CAUSES Steering adjustment ring nut too tight Steering bearings broken Steering axis deformed Insufficient front tyre pressure Steering shock absorber stiff Steering bearings damaged Fork tube adjustment incorrect Fork deformed Front wheel pin deformed or tyre deformed Front/rear wheel not balanced Wheel rim deformed Wheel bearings worn Tyre defective or unsuitable type Wheel pin nut loose Fork oil unsuitable Adjustments incorrect Fork oil unsuitable (viscosity too low) Springs weakened Fork oil insufficient Fork oil exhausted Adjustments incorrect Fork oil too viscous Too much oil in fork Fork oil insufficient Suspension coupling screws and nuts loose Wheel rim deformed Wheel bearings worn Tyre defective or unsuitable type Fork bearings worn Suspension screws and nuts loose Rear brake fastening nut loose Rear fork pin fastening ring loose Shock absorber spring weakened Adjusting devices incorrectly adjusted Oil leakage from shock absorber Shock absorber leaking nitrogen Adjusting devices incorrectly adjusted Shock absorber pin deformed Fork deformed Fork bearings worn Suspension roller bearings worn Suspension screws and nuts loose Fork bearings worn Suspension roller bearings worn REMEDY Adjust Replace Replace Adjust Replace Replace Adjust Replace Replace Balance Replace Replace Replace Tighten Replace Adjust Replace Replace Top up Replace Adjust Replace Remove excess oil Top up Tighten Replace Replace Replace Replace Replace Tighten Tighten Replace Adjust Replace Replace Adjust Replace Replace Replace Replace Tighten Replace Replace Steering not fluid Handlebar oscillates Rear wheel oscillates Fork too soft Fork too rigid Noisy fork Rear wheel oscillates Rear suspension too soft Rear suspension too rigid Rear suspension noisy 8 - 8 - 00 Release 00/2002-10 RSV mille 25.  &!34%. ). 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' #!", %3 !. $ 0)0%3 8. 2. 1 FRONT BRAKE PIPES 8. 2. 2 REAR BRAKE PIPES Release 00/2002-10 8 - 9 - 00 RSV mille 8. 2. 3 FUEL SYSTEM PIPES 8 - 10 - 00 Release 00/2002-10 RSV mille 8. 2. 4 CLUTCH CONTROL PIPE 8. 2. 5 PPC DEVICE PRESSURE PIPES Release 00/2002-10 8 - 11 - 00 RSV mille 8. 2. 6 COOLING SYSTEM PIPES Follow 8 - 12 - 00 Release 00/2002-10 RSV mille Follow Release 00/2002-10 8 - 13 - 00 RSV mille 8. 2. 7 ENGINE OIL PIPES 8 - 14 - 00 Release 00/2002-10 RSV mille 8. 2. 8 BREATHER AND IMPURITY DRAINAGE PIPES Release 00/2002-10 8 - 15 - 00 RSV mille 8. 2. 9 ACCELERATOR CONTROL CABLES 8. 2. 10 COLD START CABLE 8 - 16 - 00 Release 00/2002-10 RSV mille 8. 2. 11 ELECTRIC CABLES Key 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) Ignition switch Secondary fuse box Front right indicator connector Stop light switch connector on front brake control lever Right dip switch connector Dashboard connector Blinking Front left indicator connector Clutch control lever switch connector Left dip switch connector Lights diode/LAP Headlight connector Horn 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) 24) 25) Left electrofan connector Thermal switch Right electrofan connector Electric fan relay High beam relay Dipped beam relay Engine oil pressure sensor Side stand switch connector Coolant temperature thermistor Generator/pick-up connector Rear cylinder coil "1" Rear cylinder coil "2" Follow Release 00/2002-10 8 - 17 - 00 RSV mille Follow Key 1) 2) 3) 4) 5) 6) 7) Battery Battery earth cable Supply cable Fall sensor Main fuses Start relay Electronic unit Diode module Fuel pump relay Engine stop relay Rear light connector Arrangement for the installation of the anti-theft device 13) Rear right indicator connector 14) Rear left indicator connector Follow 8) 9) 10) 11) 12) 8 - 18 - 00 Release 00/2002-10 RSV mille Follow Key 1) 2) 3) 4) 5) 6) 7) 8) 9) Intake pressure sensor connector Right injector connector Speed sensor connector Fuel pump connector TEST connectors Engine earth cable Air thermistor Starter Stoplight switch on the rear brake control lever 10) 11) 12) 13) 14) 15) 16) 17) Coolant temperature thermistor "Neutral" gearbox switch Front cylinder "1" coil connector Front cylinder "2" coil connector Camshaft position sensor connector Left injector connector Throttle valve potentiometer Voltage regulator Follow Release 00/2002-10 8 - 19 - 00 RSV mille Follow Follow 8 - 20 - 00 Release 00/2002-10 RSV mille Follow Release 00/2002-10 8 - 21 - 00 RSV mille #(%#+). ' 4(% %, %#42)#!, 3934%See 6. 2 (ELECTRIC COMPONENTS LAYOUT) and 8. 2. 11 (ELECTRIC CABLES) for the location of the electric components. 8. 3. 1 SPARK PLUGS (no spark) First check: Check the 15 A secondary fuses. 8. 3. 2 BATTERY RECHARGING PROBLEMS See: 6. 3. 1 (CHECKING THE RECHARGING VOLTAGE). [. . . ]