ETV mille Rally

UPDATES

UPDATES

9

9-1

UPDATES

ETV mille Rally

SUMMARY
9.1. CHARACTERISTICS ....................................................................................................................... 3 9.1.1. TECHNICAL DATA.................................................................................................................. 3 9.1.2. ROUTINE MAINTENANCE SCHEDULE................................................................................. 6 9.2. BODYWORK .................................................................................................................................... 8 9.2.1. RELEASING / FIXING THE REAR SADDLE .......................................................................... 8 9.2.2. REMOVING THE RIDER’S SADDLE ...................................................................................... 9 9.2.3. REMOVING THE FRONT FAIRING...................................................................................... 10 9.2.4. REMOVING THE FRONT INDICATORS .............................................................................. 12 9.2.5. REMOVING THE UPPER SUMP GUARD ............................................................................ 13 9.2.6. REMOVING THE LOWER SUMP GUARD ........................................................................... 14 9.2.7. REMOVING THE SIDE GUARDS ......................................................................................... 15 9.2.8. REMOVING THE INNER GUARD......................................................................................... 16 9.2.9. REMOVING THE SUMP GUARD PROTECTION................................................................. 17 9.2.10. REMOVING THE CHAIN GUARD......................................................................................... 18 9.3. FRONT FORK ................................................................................................................................ 19 9.3.1. EXPLODED VIEW OF FRONT FORK .................................................................................. 19 9.3.2. REMOVING SLEEVES - RODS ............................................................................................ 20 9.3.3. CHECKING THE COMPONENTS......................................................................................... 24 9.3.4. REFITTING SLEEVES - RODS............................................................................................. 26

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Dry guard with separate oil tank and cooling radiator With dry filtration cartridge Liquid Mechanical.1.) 9-3 .R. lead-free petrol. UPDATES CHARACTERISTICS TECHNICAL DATA DIMENSIONS Max length Max width (at handlebar) Max height (at front fairing) Height at saddle Wheelbase Minimum ground clearance Normal running weight ENGINE Model Type Number of cylinders Total cylinder capacity Bore / Stroke Compression ratio Starting unit Engine rpm when idling Clutch Lubrication system Air filter Cooling GEARBOX Type CAPACITY Fuel (including reserve) Fuel reserve Engine oil Fork oil Cooling liquid Seats Maximum load carried GEAR RATIO Ratio 1st 2nd 3rd 4th 5th 6th TRANSMISSION CHAIN Type Model FUEL SUPPLY SYSTEM Type Choke FUEL SUPPLY Fuel Primary 31/60 = 1: 1.605 1:9.524 1:7.203 1:4.1. with hydraulic control on the left side of the handlebar.935 2300 mm 876 mm 1452 mm 860 mm 1554 mm 261 mm 250 kg V990 Two cylinder.M. 4-stroke.5: 1 Electrical 1200 ± 100 rpm Multi-disc.8125 Total Ratio 1:13.5 litres (50% water + 50% anti-freeze with ethylene glycol) 2 182 kg (rider + passenger + luggage) Secondary 14/35 = 1: 2.631 Endless (without connecting link) and with sealed links 525 Electronic injection (Multi-point) 47 mm Ø Super.5 mm 10. in compliance with DIN 51 607.090 23/22 = 1: 0.50 16/28 = 1: 1.445 1:5.) and 85 (N.O.368 22/24 = 1: 1. 60° longitudinal V with 4 valves per cylinder and 2 cam shafts under the head 2 998 cm3 97 mm / 67.956 27/23 = 1: 0. 9.ETV mille Rally 9.932 1:4.750 19/26 = 1: 1. and PPC device.O.1.M.4 ± 0.M. in an oil bath. 6-speed. minimum octane rating 95 (N. controlled by a pedal on the left of the engine 25 litres 4 ± 1 litres Gearbox oil 4300 cm3 – gearbox oil and oil filter 4500 cm3 680 ± 2 cm3 (for each sleeve) 2.851 Final Ratio 16/45 = 1: 2.

indicating the maximum speed.2) (**) Mixed off road – all-round: 250 (2. the affixing of the blue sticker (supplied with the tyres) to the speedometer. callipers with 4.UPDATES ETV mille Rally FRAME Type Steering angle of inclination Trail SUSPENSION Front Stroke Rear Wheel Stroke BRAKES Front Rear WHEEL RIMS Type Front Rear TYRES Wheel Front (standard) Rear (standard) Front (alternative) Rear (alternative) Wheel Front (alternative) Rear (alternative) Twin-chassis with cast and extruded.9) 250 (2. be very careful when riding on asphalted roads due to the lack of grip and stability on these roads.6 – 0.7 mm 5 kΩ 12 V – 12 Ah 30 A 15 A 12 V – 470 W 9-4 . with differently shaped arms and a single.2) Off road only: 220 (2.5) 290 (2. is obligatory.5) 250 (2. SPARK PLUGS Standard Gap on spark plug electrodes Resistance ELECTRICAL SYSTEM Battery Main fuses Secondary fuses Generator (with permanent magneto) NGK R DCPR9E 0.8° 129 mm Telescopic upside-down fork.5) (*) Maximum permissible speed = 170 km/h (**) Pressure for off road riding to be adapted to suit type of terrain WARNING! When METZELER KAROO type tyres are fitted.50 x 19" 4.5) 220 (2.0) (**) Mixed off road – all-round: 220 (2. hydro-pneumatic shock absorber. 200 mm Double floating disc on the hub – 300 mm Ø.5) 290 (2. differently sized pistons – 30 mm Ø – 32 mm Ø Disc brake – 272 mm Ø – caliper with double 34 mm Ø piston Spoked for tubeless tyres.00 x 17" Pressure kPa (bar) Rider only Rider and Passenger 220 (2. adjustable hydraulic operation. 27. 50 mm Ø sleeves 195 mm Oscillating swing arm in light ally.9) Brand PIRELLI PIRELLI METZELER METZELER Brand METZELER METZELER Type SCORPION S/T MT 90 SCORPION S/T MT 90 TOURANCE TOURANCE Type KAROO (*) KAROO (*) Size 110/80R 19" 150/70R 17" 110/80R 19" 150/70R 17" Size 110/80R 19" 150/70R 17" Pressure kPa (bar) Rider only Off road only: 200 (2.2) 250 (2. adjustable. shaped light alloy parts. 2. When using “off-road / all-round” tyres.2) 250 (2.

ETV mille Rally LIGHT BULBS Bright / dim headlamp (halogen) Front parking light Indicator light Number plate light Rear parking light / stop light Dashboard backlighting LEDS Gearbox in neutral Indicator light Fuel reserve Bright headlight Stand down Engine oil pressure Diagnostics UPDATES 12 V – 60/55 W H4 V 12 V – 3 W 12 V – 10 W 12 V – 5 W 12 V – 5 / 21 W LED LED LED LED LED LED LED LED 9-5 .

UPDATES ETV mille Rally 9. Key 1 = check and clean and adjust. Components Spark plug Air filter Engine oil filter Engine oil filter (on oil tank) Front fork Light functioning / alignment Light system Safety switches Clutch control fluid Brake fluid Cooling liquid Engine oil Tyres Tyre pressure (**) Tightness of battery terminals Engine oil pressure LED Tension and lubrication of the transmission chain Wear on the brake pads On completing runEvery 7500 km Every 15000 km ning in [1000 km (625 (4687 miles) or 12 (9375 miles) or miles)] months 24 months 1 3 1 3 3 3 2 2 1 1 1 1 1 1 1 1 1 1 3 3 1 Every 1000 km (625 miles): 1 4 Every 1000 km (625 miles): 4 1 Each time the bike is started up: 1 Every 1000 km (625 miles): 1 1 Before each trip and every 2000 km (1250 miles): 1 9-6 . or replace where necessary. 2 = clean 3 = replace 4 = adjust IMPORTANT! These maintenance tasks must be done twice as frequently is the bike is used in rainy or dusty areas. lubricate.2.1. (**) = Check every fortnight or at the intervals indicated. or over uneven ground. ROUTINE MAINTENANCE SCHEDULE WORK TO BE DONE BY AN Official aprilia Dealer (THAT CAN BE DONE BY THE USER). or when used for sports riding.

or over uneven ground. or when used for sports riding.ETV mille Rally UPDATES WORK TO BE DONE BY AN Official aprilia Dealer Key 1 = check and clean. (*) PLEASE NOTE! There are grains inside the nipples. Components Rear shock absorber Transmission cables and controls Minimum carburation (CO) Linkage bearings in the rear suspension Steering bearings and play in the steering Wheel bearings Brake discs General running of the bike Adjustment of play on the valves Braking systems Cooling system Clutch control fluid Brake fluid Cooling liquid Front fork oil Front fork oil seals Brake pads Wheels/tyres Tightness of bolts Tightness of battery terminals Synchronisation of cylinders Suspension and alignment Final transmission (chain. 2 = clean 3 = replace 4 = adjust IMPORTANT! These maintenance tasks must be done twice as frequently is the bike is used in rainy or dusty areas. or replace where necessary (as per the instructions in the Workshop Manual). and pinion) Fuel hoses Tightening of nipples / spokes (*) Wear on the clutch On completing running in [1000 km (625 miles)] 1 1 1 1 4 1 Every 7500 km (4687 miles) 1 1 1 1 1 1 1 1 Every 2 years: 3 After the first 7500 km (4687 miles) and then every 22500 km (14000 miles): 3 After the first 30000 km (18750 miles) and then every 22500 km (14000 miles): 3 When worn: 3 1 1 1 1 1 4 4 1 1 1 1 1 1 1 Every 4 years: 3 Every 15000 km (9375 miles) or 24 months 1 1 4 - 9-7 . lubricate. chain ring. and adjust.

• Turn the key clockwise. PLEASE NOTE: The tool kit and document holder space is situated under the rear saddle.1. • • BODYWORK RELEASING / FIXING THE REAR SADDLE Put the bike up on the central stand. • • Insert the two front hooks in their respective seatings.UPDATES ETV mille Rally 9. and lift and remove the rear saddle. 9. To fix the rear saddle: IMPORTANT! Before lowering and fixing the rear saddle.2. 9-8 . Insert the key in the saddle lock. check that you have not left the key in the tool kit and document holder space.2. To gain access to it: • Remove the cover for the tool kit and document holder space. Lower the rear saddle and push down until the lock is heard clicking closed.

2. • • • REMOVING THE RIDER’S SADDLE Remove the rear saddle (see 9. Lift and remove the saddle.1 RELEASING / FIXING THE REAR SADDLE). UPDATES IMPORTANT! When refitting position the front saddle locking cable correctly in the relevant prong on the tank.2. Unscrew and remove the two rear bolts that secure the saddle.ETV mille Rally 9. 9-9 . and retrieve the bushings.2.

• Remove the lower dashboard bracket. 9 .UPDATES ETV mille Rally 9. • Unscrew and remove the four bolts that secure the lower dashboard bracket. • • Unscrew and remove the four bolts that secure the upper dashboard bracket.2. Remove the upper dashboard bracket.3. • • REMOVING THE FRONT FAIRING Unscrew and remove the four bolts that secure the windshield – front fairing.10 . Remove the windshield – front fairing.

9 . and remove the two lower fixing bolts.11 . UPDATES • Remove both side covers.ETV mille Rally • Work on both sides.

holding the locknut with a suitable set spanner.2.UPDATES ETV mille Rally 9. 9 . Disconnect the electrical connector for the relevant indicator.4. Remove the indicator.3 REMOVING THE FRONT FAIRING).12 . Unscrew the indicator fixing bolt. • • • • REMOVING THE FRONT INDICATORS Remove the side fairing.2. complete with the indicator (see 9.

UPDATES • Remove the upper sump guard.2. 9 .ETV mille Rally 9.13 .5. • REMOVING THE UPPER SUMP GUARD Unscrew and remove the five fixing screws (two on each side and one in the front).

9 .2.14 .6. Remove the lower sump guard.UPDATES ETV mille Rally 9. • • REMOVING THE LOWER SUMP GUARD Unscrew and remove the four fixing screws.

ETV mille Rally 9. UPDATES • Unscrew and remove the front fixing screw. 9 . • REMOVING THE SIDE GUARDS Unscrew and remove the rear screw and bush.15 .2.7. • Remove the side guard.

16 .UPDATES ETV mille Rally 9. • REMOVING THE INNER GUARD Unscrew and remove the two rear screws.2. • • Unscrew and remove the two front screws. Remove the inner guard.8. 9 .

Remove the upper sump guard (see 9.6 – REMOVING THE LOWER SUMP GUARD). UPDATES • • Remove the hose clamp that holds the breather pipes on the left. Unscrew and remove the two rear fixing bolts.5 – REMOVING THE UPPER SUMP GUARD). • • • • REMOVING THE SUMP GUARD PROTECTION Remove the side guards (see 9. Remove the sump guard protection.2. Remove the two side fairings.9.2.7 – REMOVING THE SIDE GUARDS).17 .2. 9 .2.ETV mille Rally 9. Remove the lower sump guard (see 9. • • Unscrew and remove the two front fixing bolts.

Remove the guard. 9 .2.18 . • REMOVING THE CHAIN GUARD Unscrew and remove the front fixing screw.10.UPDATES ETV mille Rally 9. • • Unscrew and remove the lower fixing screw.

33. 34. 29. O-Ring 27. Bush 18. Complete left plunger 16.19 . 49. Screw 12. 30.3.3. 38. 52. 47. Bush 5. Complete right plunger 15. 51. 45. 42. 31. Sleeve 19. 36. Right sleeve 2. Left sleeve 4. Nut 14. Right plug 23. UPDATES FRONT FORK EXPLODED VIEW OF FRONT FORK Key: 1. Reference pin 17. Spring 25. 44. 50. Complete stroke limit stop 10. 9. Screw 3. 53. Ball 24. Ring Spring Pipe Casing Pin Rod Complete right rod Spring Piston ring Right piston Spacer Spacer Spacer Spacer Nut Cup Spacer Spacer Spacer Left piston Spacer Nut Complete left rod Left casing Left plug Complete right sleeve Complete left sleeve 9 . 35. 41.1. Ring 6. 54. 48.ETV mille Rally 9. 32. Dust cover 9. 37. Stop Ring 8. 40. 43. 46. Dowel + O-Ring 28. Oil seal 7. Screw 20. O-Ring 13. O-Ring 22. 39. Dowel 26. O-Ring 21. Seal washer 11.

prepare a receptacle that can hold more than 750 cm3.RODS IMPORTANT! Although the two sleeves work differently.20 . and refitted in the same way. REMOVING SLEEVES . • • Remove the sleeve – rod unit. 9 . • Position the sleeve (3) in a vice with protected jaws. serviced. holding the plug (1) still using a hexagonal spanner. Use a hexagonal spanner to unscrew the plug (1) that closes off the top.UPDATES ETV mille Rally 9. • • • Unscrew the return-nut indicated by the arrow.3. • Remove the plastic bush (4).2. Be careful not to damage the O-Ring (2) while removing it. Therefore. Remove the plug. Push the rod inside the sleeve. IMPORTANT! Before proceeding with the tasks below. Carefully clean the entire sleeve – rod. Do not tip it over or put at too great an angle while disassembling it. WARNING! The sleeve – rod unit contains oil. the instructions given below are to be taken as applying to both sleeves. their component parts are similar and so they can be removed.

ETV mille Rally • Remove the spring (5). 9 .21 . UPDATES • Pour the oil out into a container as indicated in the figure. Allow all the oil to run off the coils of the spring into the sleeve. • Unscrew the lower central bolt for the plunger seal. • Remove the pre-tensioned pipe. housed in the sleeve. so as not to have to top up or replace the oil.

• Remove the plunger (8) from the sleeve (3) complete with the bush (9).UPDATES ETV mille Rally • Remove the central bolt (6) and remove the copper washer (7). IMPORTANT! If you find that the plunger (8) has been damaged. • • Using a thin screwdriver. Grip the rod (3) and remove it from the sleeve (12) by pulling firmly.22 . replace it altogether. • Using a straight-tipped screwdriver as a lever. 9 . remove the stop ring (11) from the inside of the sleeve (12). remove the dust scraper (10).

UPDATES 9 . The guide ring (13) and the guide bush (16) can be removed using a small screwdriver.ETV mille Rally • • The guide ring (13) acts as a stop. Remove the following from the sleeve (12): the gasket ring (14).23 . the washer (15) and the guide bush (16). after which the washer (15) and the gasket ring (14) can be removed from the rod (3).

replace the rod (1).jpg 9 . replace the spring (2). The score marks referred to above can be removed using wet sandpaper (grain size 1).24 . SPRING • • Check the integrity of the spring (2). as its structure would be weakened making its use on the bike dangerous. If any signs of excessive wear or damage are spotted. If it exceeds the limit.2 mm. being careful not to scratch their surfaces. and make sure that its length is within the limit. APRmo_ETV_Rally#9##_0006_01.3. Using an indicator check that any curvature on the rod (1) is within the limit. DANGER A curved rod must NEVER be straightened. If the length is not within the limit.UPDATES ETV mille Rally 9. If the score marks are deep. • - Check the state of the following components: Guide Ring (3) Guide Bush (4) Plunger (5) Plastic Bush (6). replace the component involved. If any are found. replace the rod.3. SLEEVE • Check that the sleeve does not show any signs of damage and/or cracks. WARNING! Remove any signs of dirt from the bushes. Curvature limit: 0. ROD • CHECKING THE COMPONENTS • Check that the sliding surfaces have not been scored or scratched. replace it. Minimum length of unloaded spring: 395 mm.

UPDATES 9 .25 .ETV mille Rally • Replace the following components with new parts: Gasket Ring (7) Dust scraper (8) O-Ring on the plug (9).

push the gasket ring (4) into the sleeve all the way to the stop. Using the purpose-made feeder (A).26 . before refitting the gaskets and the bushes. complete with the bush (10). lubricated. putting soft material (aluminium) between the sleeve and the jaws.3. Washer (5) Guide Bush (6) Guide Ring (7) • • • • Place the sleeve (8) in a vice.RODS IMPORTANT! Before proceeding with the tasks below.4. • Push the plunger (9) all the way into the sleeve (1). prepare the special OPT tool (A) and. • - Fit the following components on the rod (19 in the order shown: Dust scraper (2) Stop Ring (3) Gasket Ring (4).UPDATES ETV mille Rally 9. REFITTING SLEEVES . Then install the stop ring (3) and the dust scraper (2). spread a film of front fork oil over it. 9 . Insert the rod (1) into the sleeve (8) and then move the guide bush (6) and washer (5) against the sleeve.

• Insert the pre-loaded pipe (13) into the sleeve (1).27 . which can be checked by putting a graduated rod (14) into the sleeve (1).ETV mille Rally • Position the copper washer (12) on the bolt (11). • Pour the front fork oil into the sleeve (1) up to the correct level. IMPORTANT! To measure the oil level correctly. the sleeve (1) must be perfectly upright and complete with the sleeve packing.5 cm³ Oil level: 130 ± 2 mm (from the brim of the sleeve). Quantity of oil: 680 ± 2. The oil level must be the same in both sleeves. 9 . UPDATES • Insert the bolt into the sleeve and tighten.

• Screw the plug into the sleeve and tighten.28 . Screw the plug onto the plunger shaft and tighten. 9 . • • Check that the O-Ring (17) is in place on the upper sleeve plug.UPDATES ETV mille Rally • Insert the spring (15) into the sleeve (1) complete with the bush (16).