Before disassembling components
Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required.
Components removal
Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench.
Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols.
Each component needs to be clearly marked to enable identification during reassembly.
Clean and wash the dismantled components carefully using a low-flammability detergent.
Keep mated parts together since they have "adjusted" to each other due to normal wear.
Some components must be used together or replaced altogether.
Keep away from heat sources.
Reassembling components
Caution! Bearings must rotate freely, without jamming and/or noise, otherwise, they need to be replaced.
Only use ORIGINAL Aprilia SPARE PARTS.
Comply with lubricant and consumables use guidelines.
Lubricate parts (whenever possible) before reassembling them.
When tightening nuts and screws, start either from the components with the largest diameter or from the innermost components, proceeding diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new parts if the thread is damaged.
When assembling the bearings, make sure to lubricate them well.
Check that each component is assembled correctly.
After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic.
Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand or batch number facing outward (visible side).
Electric connectors
Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness:
Press the relative safety clips, if applicable.
Grip the two connectors and disconnect them by pulling them in opposite directions.
If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air.
Ensure that the cables are correctly fastened to the internal connector terminals.
Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you will hear them "click" into place).
Caution! Do not disconnect connectors by pulling the cables.
Note. The two connectors can only be connected in one direction: connect them the right way round.
Tightening torques
Caution! Remember that the tightening torques for all fastening elements on wheels, brakes, wheel axles and any other suspension components play a key role in ensuring vehicle safety and must comply with specified values. check the tightening torques of fastening elements on a regular basis and always use a torque wrench to reassemble these components. failure to comply with these recommendations may cause one of these components to loosen or even detach, causing a wheel to lock or compromising vehicle handling. This may lead to falls, with the risk of serious injury or death.