www . ser viceaprilia . com
workshop manual
ETV mille 1048 1
00/2002-02
8140547
UK
ETV mille
INTRODUCTION
0
- 1 - 00 Release 00/2002 - 01
0
INTRODUCTION
1
GENERAL INFORMATION
2
PERIODIC MAINTENANCE AND
ADJUSTMENTS
3
ENGINE
4
FUEL SYSTEM
5
COOLING SYSTEM
6
ELECTRICAL SYSTEM
7
CHASSIS
8
REPAIR INFORMATION
i
INDEX
ETV mille
INTRODUCTION
0
INTRODUCTION
CONTENTS
0
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0.1 RELEASE 00/2002-01 UPDATE ....... 0-3-00
0.1.1 MANUAL UPDATES.............................. 0-3-00
0.1.2 LIST OF MANUAL PAGES AND UPDATE
NUMBERS ............................................. 0-3-00
0.2 REFERENCE GUIDE ........................ 0-6-00
0.3 FOREWORD ..................................... 0-7-00
0.4 REFERENCE MANUALS .................. 0-7-00
0.4.1 ENGINE WORKSHOP MANUALS ........ 0-7-00
0.4.2 PARTS CATALOGUES ......................... 0-7-00
0.4.3 SPECIAL TOOLS CATALOGUES ........ 0-7-00
0.4.4 OWNER'S MANUALS ........................... 0-7-00
0.5 SAFETY INFORMATION .................. 0-8-00
0.5.1 GENERAL PRECAUTIONS AND
INFORMATION ...................................... 0-8-00
0.5.2 BEFORE DISASSEMBLING ANY
COMPONENTS...................................... 0-8-00
0.5.3 DISASSEMBLING THE COMPONENTS . 0-8-00
0.5.4 REASSEMBLING THE COMPONENTS 0-8-00
0.6 SAFETY INFORMATION .................. 0-9-00
0.6.1 CONVENTIONS USED IN THE MANUAL 0-9-00
0.7 ABBREVIATIONS/SYMBOLS/
CONVENTIONS.............................. 0-10-00
ETV mille
INTRODUCTION
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0.1 RELEASE 00/2002-01 UPDATE
Issue date of original release (Release 00) and
subsequent releases:
Original release (Release 00).................January 2002
0.1.1 MANUAL UPDATES
Always keep manual updated to the latest release you
have received.
This manual is made up of #10 sections for a total of
#376 pages (listed below).
NOTE Please vedi 0.2 (REFERENCE GUIDE) for
details of standard page nomenclature and page num-
bering.
0.1.2 LIST OF MANUAL PAGES AND UPDATE
NUMBERS
Add the latest release pages to the manual and
destroy all superseded pages (even if they belong
to the release before last).
CAUTION
Failure to keep the manual up-to-date or to
eliminate superseded pages will make the manual
more difficult to consult and creates a risk of
improper servicing.
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INTRODUCTION
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INTRODUCTION
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0.2 REFERENCE GUIDE
1) Motorcycle model (or engine type)
2) Section title
3) Release progressive number (“00” identifies the original
release)
4) Year and month of issue of relevant release
5) Section number
6) Page number (pages are numbered sequentially,
numbering begins anew in each section)
7) Page update number (progressive number)
8) Subsection number (progressive number)
9) Paragraph number (progressive number)
10) Description of operation (always preceded by the
lozenge symbol)
11) Description of operation: the star means that the
operation must be repeated on the opposite side of the
motorcycle
ETV mille
GENERAL INFORMATION
1 - 17 - 00 Release 00/2002 - 01
3
1
2
7
2
1
6
5
4
3
1.9 PLACING THE MOTORCYCLE ON THE
SERVICE STAND
1.9.1 PLACING THE MOTORCYCLE ON THE FRONT
WHEEL STAND
Place the motorcycle on the centre stand.
Place the motorcycle on the front wheel stand , see
1.9.1 (PLACING THE MOTORCYCLE ON THE
FRONT WHEEL STAND).
Slide both pins (1) of the front wheel stand into the
holes (2) at front fork bottom end of the same time.
Press down on stand (3) until it rests fully on the
ground.
PLACING THE MOTORCYCLE ON THE
CENTRE STAND
1.9.2
Read paragraph 0.5.1 (GENERAL PRECAUTIONS
AND INFORMATION) carefully.
Part no. 8140176 (complete stand).
Remove the lower fairing, see 7.1.33 (REMOVING
THE LOWER FAIRING).
Hold the nut (1) steady on the inside.
Release and remove the rear upper right-hand
engine mounting bolt (2).
Torque wrench setting for nut (1) / bolt (2):50
Nm (5,0 kgm).
NOTE The bolt (2) on the left-hand side is longer
Collect the nut (1).
Slide the upper right-hand mounting boss (3) into the
upper hole on the right-hand side.
Fit the stud bolt (4) into the upper hole on the left-hand
side and screw it fully into the mounting boss (3).
Screw the upper left-hand mounting boss (5) fully onto
stud bolt (4) and tighten.
Hold the nut (6) on the inside steady.
Release and remove the rear lower engine mounting
bolt (7).
Put one foot on the front end of the stand (3).
ETV mille
INTRODUCTION
0
- 7 - 00 Release 00/2002 - 01
0.3 FOREWORD
- This manual provides the information required for
normal servicing.
- The information and illustrations contained in this
manual are updated through subsequent releases,
vedi 0.1 (RELEASE 00/2002-01 UPDATE).
- This manual is intended for use by aprilia Dealers and
their qualified mechanics. Certain information has been
omitted intentionally, as this manual does not purport to
provide a comprehensive treatise on mechanics. The
persons who will use this manual must be fully
conversant with the basics of mechanics and with the
basic procedures of motorcycle repair. Repairing or
inspecting a motorcycle when one does not possess
such basic knowledge or training could result in
improper servicing and make the motorcycle unsafe to
ride. For the same reason, certain basic precautions
have been omitted in the descriptions of repair and
inspection procedures. Take special care to avoid
damage to motorcycle components or injury to
persons. aprilia s.p.a.'s mission is to constantly
enhance the riding pleasure of final users through the
on-going improvement of its products as well as of the
relevant technical literature.
All aprilia Points of Sale and Subsidiaries worldwide
are kept updated on major engineering changes and
modifications to repair procedures. Such changes and
modifications are then reflected in the next release of
the relevant manual. When in doubt about an
inspection or repair procedure, please contact the
aprilia Consumer Service (A.C.S.) Department, who
will be glad to provide full information on the procedure
in question as well as on any updates or engineering
changes affecting the motorcycle under consideration.
Aprilia s.p.a. reserves the right to make changes to its
products at any time, barring any such changes as may
alter the essential features of a product as specified in
the relevant manual.
All rights of storage using electronic means, reproduction
and total or partial adaptation, whatever the means
adopted, are reserved in all countries.
Any reference to products or services provided by outside
suppliers is for information only and by no means binding,
and implies no warranties or responsibilities as to the
performance or use of any such products and/or services.
Please read 0.4 (REFERENCE MANUALS) for more
detailed information.
Original release: January 2002
Produced and printed by:
DECA s.n.c.
via Risorgimento, 23/1 - 48022 Lugo (RA) - Italia
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: deca@decagroup.it
www.decaweb.it
for:
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
0.4 REFERENCE MANUALS
0.4.1 ENGINE WORKSHOP MANUALS
0.4.2 PARTS CATALOGUES
0.4.3 SPECIAL TOOLS CATALOGUES
0.4.4 OWNER'S MANUALS
aprilia part# (description)
8140582 (1051-1)
8140584 (1053-1)
8140585 (1054-1)
8140583 (1052-1)
8140586 (1055-1)
8140587 (1056-1)
aprilia part# (description)
390W ...............
390Y ................
3901.................
aprilia part# (description)
8202278
aprilia part# (description)
Model years 1998 -1999
8102623
8102857
8102858
8102859
8104128
8104099
Model years 2000
8104089
8104142
8104143
8104141
8104164
8104171
8104152
8104269
8104267
8104268
8104270
8104264
I
F
D
E
UK
USA
I UK
I UK
I UK
I F D E UK
I F D
P E UK
NL DK SF
GR J UK
AUS
USA
I F D
P E UK
NL DK SF
GR J UK
AUS
USA
RSV01
I F D
P E UK
NL DK SF
GR J UK
AUS
USA
ETV mille
INTRODUCTION
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0.5 SAFETY INFORMATION
The following conventions are used to identify safety
information throughout the manual.
This symbol identifies safety-related information.
Whenever you see this symbol in the manual or
attached to the motorcycle, use utmost care to avoid the
risk of injury. Disregarding the instructions identified by
this symbol may put your safety, as well as that of other
persons or of the motorcycle at risk!
CAUTION
Disregarding these indications may lead to severe
injury or death.
WARNING
Disregarding these indications may lead to minor
injury or motorcycle damage.
NOTE The term "NOTE" in this manual precedes
important information or instructions.
0.5.1 GENERAL PRECAUTIONS AND
INFORMATION
Follow these instructions closely when repairing,
disassembling or reassembling the motorcycle or its
components.
CAUTION
Using bare flames is strictly forbidden when working on the
motorcycle. Before servicing or inspecting the motorcycle:
stop the engine and remove the key from the ignition
switch; allow for the engine and exhaust system to cool
down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of
any parts of the engine or exhaust system which may still
be hot to the touch to avoid scalds or burns.
CAUTION
Never put any mechanical parts or other vehicle
components in your mouth when you have both hands
busy. None of the motorcycle components is edible.
Some components are harmful to the human body or
toxic.
Unless expressly specified otherwise, motorcycle
assemblies are refitted or re-assembled by reversing the
removal or dismantling procedure. Where a procedure is
cross-referred to relevant sections in the manual, proceed
sensibly to avoid disturbing any parts unless strictly
necessary. Never attempt to polish matte-finished
surfaces with lapping compounds.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with
alcohol, petrol or solvents. Clean with water and neutral
detergent.
Always disconnect the battery negative (–) lead before
soldering any electrical components.
When two or more persons service the same motorcycle
together, special care must be taken to avoid personal
injury.
Read 1.2 (WARNINGS CONCERNING FUEL,
LUBRICANTS, COOLANT AND OTHER COMPONENT
PARTS) carefully.
0.5.2 BEFORE DISASSEMBLING ANY
COMPONENTS
- Clean off all dirt, mud, and dust and clear any foreign
objects from the vehicle before disassembling any
components.
- Use the model-specific special tools where specified.
0.5.3 DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to slacken and/or
tighten nuts and bolts. Always use a suitable spanner.
- Mark all connections (hoses, wiring, etc.) with their
positions before disconnecting them. Identify each
connection using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when
refitting.
- Thoroughly clean and wash any components you have
removed using a detergent with low flash point.
- Mated parts should always be refitted together. These
parts will have seated themselves against one another
in service as a result of normal wear and tear and
should never be mixed up with other similar parts on
refitting.
- Certain components are matched-pair parts and should
always be replaced as a set.
- Keep the motorcycle and its components well away
from heat sources.
0.5.4 REASSEMBLING THE COMPONENTS
WARNING
Never reuse a circlip or snap ring. These parts must
always be renewed once they have been disturbed.
When fitting a new circlip or snap ring, take care to
move the open ends apart just enough to allow fit-
ment to the shaft.
Make a rule to check that a newly –fitted circlip or
snap ring has located fully into its groove.
Never clean a bearing with compressed air.
NOTE All bearings must rotate freely with no hardness
or noise. Replace any bearings that do not meet these
requirements.
- Use ORIGINAL aprilia SPARE PARTS only.
- Use the specified lubricants and consumables.
- Where possible, lubricate a part before assembly.
- When tightening nuts and bolts, start with the largest or
innermost nut/bolt and observe a cross pattern. Tighten
evenly in subsequent steps until achieving the
specified torque.
- Replace any self-locking nuts, gaskets, seals, circlips
or snap rings, O-rings, split pins, bolts and screws
which have a damaged thread.
- Clean all joint surfaces, oil seal edges and gaskets
before assembly.
- Apply a light coat of lithium grease along the edges of
oil seals. Fit oil seals and bearings with the brand or
serial number facing outwards (in view).
- Lubricate the bearings abundantly before assembly.
- Make a rule to check that all components you have
fitted are correctly in place.
ETV mille
INTRODUCTION
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- 9 - 00 Release 00/2002 - 01
- After repairing the motorcycle and after each service
inspection, perform the preliminary checks, and then
operate the motorcycle in a private estate area or in a
safe area away from traffic.
0.6 SAFETY INFORMATION
0.6.1 CONVENTIONS USED IN THE MANUAL
- This manual is divided in sections and subsections,
each covering a set of the most significant
components.
For quick reference, see the summary of sections on
page 0-1.
- Unless expressly specified otherwise, assemblies are
reassembled by reversing the dismantling procedure.
- The terms “left” and “right” are referred to the
motorcycle when viewed from the riding position.
- Motorcycle operation and basic maintenance are
covered in the “OWNER'S MANUAL”.
Any operations preceded by the star symbol must
be repeated on the opposite side of the
motorcycle.
In this manual any variants are identified with these
symbols:
Frame # ZD4DW......(STARTING FROM MODEL YEAR
2001).
AUTOMATIC SWITCH-ON DEVICE
Option
Catalysed version
VERSION:
Italy Greece Malaysia
United
Kingdom
Netherlands Chile
Austria Switzerland Croatia
Portugal Denmark Australia
Finland Japan
United
States of
America
Belgium Singapore Brazil
Germany Slovenia
Republic of
South
Africa
France Israel
New
Zealand
Spain
South
Korea
Canada
ASD
OPT
✿
I GR Mal
UK
NL RCH
A CH HR
P DK AUS
SF J
USA
B SGP BR
D SLO
RSA
F IL
NZ
E
ROK
CDN
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$41.99
2000-2003 Aprilia ETV 1000 Caponord Service & Repair Manual
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Full Search Facility
Print one or all pages of your manual
$41.99
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What's Included?
Lifetime Access
Fast Download Speeds
Online & Offline Access
Access PDF Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
Description
Thank you for considering this comprehensive Workshop Service Repair Manual for the Aprilia ETV 1000 Caponord spanning the years 2000 to 2003.
This manual is an invaluable resource, covering every Service & Repair Procedure necessary for professional mechanics and DIY enthusiasts alike.
With easy-to-follow step-by-step instructions and detailed pictures, this manual empowers you to save significantly on repair costs by undertaking the repairs yourself.
Upon purchase, the manual is yours to keep forever. You have the flexibility to print individual pages, chapters, or the entire manual. Additionally, you can conveniently access it on your tablet or smartphone.
All Models/Engines/Trim/Transmissions Types are comprehensively covered in this manual.
From A to Z, this high-quality Service Repair Workshop Manual encompasses every repair procedure, ensuring that every aspect of servicing and repairs is addressed.
Compatible with All PC & MAC Computers, tablets, and mobile phones, this downloadable Manual requires only adobe reader, which is commonly pre-installed. Alternatively, it can be downloaded for free.
Upon payment confirmation via Visa, MasterCard, or PayPal, the manual will be instantly emailed to the address provided during checkout.
Rest assured, your satisfaction is guaranteed.
