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arlurt View Drop Down
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    Posted: 10 Mar 2019 at 11:05
Thought I'd better figure out how to post photos and share a couple of my bike as it was when I bought it for myself for Christmas.

 

 

 
It's a 2002 RSV Mille R 37,000 miles, in need of a little love and care.

The plan is to fix what's wrong with it, known jobs so far include:

Worn Titanium Nitride coating on the forks, fork bushes, and leaky seals
Dodgy headstock bearings
Worn front brake rotors
Sticking rear brake calliper and knackered rear disk
Loads of other minor issues

Tidy up the cosmetics:

Poor lacquer on all the carbon bits
Missing, dodgy and wrong decals
Rusty fasteners
Repaint components that have suffered neglect
Torn Seat
Cracked Screen

Make some of the improvements that are so popular on here:

Modded exhaust collector
FR200 Chip
Open Exhaust
Large Intake Boot, and maybe the Airbox Mod

The jobs are under-way, the whole front end is off the bike, fork tubes and sliders with a local specialist for re-coating the Ti-Ni and new bushes.  The clip-ons and yokes have  been stripped and repainted.  New (taper roller) headstock bearings fitted with a spacer here and there to stop the seals dragging on the roller cages, and a new top dust seal.  Brake and clutch master cylinders are stripped, should go back together later today once I stop messin' about on the computer!

 

I've re-lacquered the front mudguard, side air ducts and instrument glare shield, much improved. And I've had a go at making my own decals for the side air-ducts.  The colours not a great match but I think they're better than not being there, and total cost was only £3 on coloured vinyl and some of my time.


I'm spending a fair amount of time on eBay, looking for the parts I need.  The postman has brought me a pair of Brembo rotors, a rear disk, a new front brake reservoir, an exhaust collector to send to Redratbike for "Modding", an FR200 chip, and an Aprilia Racing Titanium exhaust. There have been countless little bags of fasteners, and paint, and bearings, and seals.  So most days I come home to a nice surprise of some sort or other.

Of course I wanted an Akrapovic exhaust but after several weeks looking I haven't found one at a price I can justify, so I'm hoping the Aprilia Titanium will do the job.  I've seen several people on here say they're very loud, maybe I'll have to experiment with baffles for normal pottering about.

I'm here to draw on other's experience too, which has helped me decide what I want to do with the bike.  I've seen some talk about a larger airbox boot as a useflu mod?  I might have one already, what do the large and small versions look like?

Anyway, better go and do something useful.

Thanks for your help.


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arlurt View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 11:21
The forum I spent a lot of time on years ago used to allow you to embed images by putting img before a link, and /img after, so that the actual image appeared, rather then a link.  Is this not possible any more?

One of the users mentioned "Premium Membership" , what would that do for me if it's available?

Thanks.
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arlurt View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 11:29
And I always spot the typo's after I've posted, are we allowed to edit our posts to the mistakes later?  Embarrassed
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 12:36
Hi arlut, I'm not far from you in Bedale and working at Linton-on-Ouse.
Looks like you're heading in the right direction with your bike Thumbs Up 
Look here at post #3 for larger air boot:
https://www.apriliaforum.com/forums/showthread.php?58808-Tuono-air-box
I've got premium membership...you get access to another part of the forum (which is rarely used these days tbh, but includes being able to download service manuals) and being able to upload photos using the forum server. To be honest most people on here pay the fiver a year to show support for AP as much as anything.
The main thing about the forum is the amount of knowledge freely available from participating members.  

People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 13:54
Hi Stevex,

Thanks for your reply.

The www.Apriliaforum.com seems to be off line, might that be temporary or a problem at my end?

I've just opened the ECU to fit my FR200 chip to find it's already got an after-market EPROM in there. The fitted EPROM is marked "SCUBA EB42" and "GRT".  Anyone know anything about it?



When I took the standard exhaust off the bike I did notice it was held on with "MIVV" springs so thought maybe it had a can on it at some time.  It's also had an open air-box conversion, but just the alloy rim, and a taller K&N filter.  The rubber seal was missing.

I knew the airbox job wasn't right as the alloy rim on the top of the airbox didn't fit against the underside of the petrol tank, no where near a seal, and riding the bike home when I bought it there was a strong smell from the engine breather that was finding it's way out somewhere.  Having done a bit of research, it seems there should've been a floppy rubber seal sandwiched between the alloy ring and the tope edge of the lower airbox half, but this is just missing.  For the moment I'll run the standard airbox with the K&N that fits inside.  Unless someone can advise otherwise?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 15:32
GRT is Gabro who can be found on AF1's site.
He's the main supplier of chips for our bikes, together with Forza's FR100 & 200.
He does seem to do custom mapped chips, so I'm guessing the PO of your bike has talked to him prior to being supplied with the chip you have fitted; it may be mapped for an open air box.
Although I have the big air boot, FR200, modded collector and straight through pipe, I've stayed with the OEM air box and just replaced the K&N with an OEM air filter. 
From what I've seen on this forum, open air boxes do have the rubber seal you're talking about. If the K&N was fitted as per standard at the air inlet, the lack of a seal may be letting in contaminants, so probably good job you've re installed the air box. If you post up pics of your set up, someone with better info than me will advise you.
btw, I've no probs connecting to AF1 with your link.
bbtw, try 'Image-works' for decals, they do loads of Aprilia stuff, are very good and quite cheap.
People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinmeadows Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 16:02
that gabro chip as a top chip message gabro on facebook for its spec. as for your airbox seal it sounds like you are missing the seal have a look on aprilia performance site at the top of the page and you can see what you should have !!
living life in the fairly fast lane rsv mille 2000 & rsv factory 2004, no more until i get a bigger garage ............
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Post Options Post Options   Thanks (0) Thanks(0)   Quote colinmeadows Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 16:10
see this for the large air boot http://www.rsvr.net/gen-1-airbox_topic26069.html
living life in the fairly fast lane rsv mille 2000 & rsv factory 2004, no more until i get a bigger garage ............
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 16:44
Thanks everyone.

Interesting about the Gabro chip that's fitted, I'll contact him to see what it is.

I've had a frustrating afternoon, trying to get the fuel tank to fit properly, do they distort with age?  It's as far back as it will go on the rear mount, and still almost touching the top yoke at the front.  On full lock the inner ends (where they go round the fork leg) of the clip ons touch the tank, and the front of the tank is sat on the headstock bearing dust seal.  I took the rear under-tray out as the back of the tank seemed to be up against the battery box, but that hasn't made much difference.

As an easy job, I thought I'd take the hugger off to clean it up and re-lacquer, but I had to use a chisel and mole grips to get three of the bolts out, and the fourth just sheared!  The hugger is OK, no damage, three bolt holes will clean up fine, the sheared one will take a bit of work.

I've had enough for today, time for an early door beer or two.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 16:55
Looking through the MoTs, the bike was doing the usual two or three thousand miles each year, then in 2014/15 it did 11,000 miles.  I guess it was daily transport for a while , and that's probable what's made it show it's age.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 18:26
The plastic tanks do swell as the nylon absorbs water drawn in by the ethanol in the petrol. 
One solution is to drain the tank, remove the pump and put the tank somewhere warm for a couple of months to let the water evaporate. The tank will then revert to its normal size!
I find it easier to fit the front two mounting bolts first, then try to get the rear ones in.
People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 10 Mar 2019 at 19:54
Thanks again Stevex.

I haven't had to consider a variable geometry petrol tank before, they've generally been steel.  It was a question in hope that the frame wasn't bent, thinking that was why it didn't seem to fit properly.

I'l bolt the front down and crowbar the back in to place, though the rubbers on the front mount are always going to allow it to shuffle forward a bit.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar 2019 at 09:46
It seems the large airbox boot isn't available as a new part anymore, don't suppose anyone has a spare one they'd like to sell...?
 
Gabro got back to me, simply said the SCUBA EB42 chip I have is for an RSV with an "After-Market Can".  I guess that makes sense if the bike had a "MIVV" exhaust as the springs suggest, but not with my OEM standard exhaust.  I'll keep the GRT chip safe and stick with the new FR200 chip, which with the modded collector, Aprilia Racing Can, K&N and Airbox changes should be a better matched set.
 
I've joined up as a "Premium" user, hoping it'll make using photos easier, and it's be nice if I could edit out my typos...?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 11 Mar 2019 at 11:20
Good news, I've found a large airbox boot, bought and paid for. All the places I tried for a new item suggest that they're no longer available. 
 
They're a tricky item to find on eBay at the right price.  Anyone listing just the boot, generally knows what they've got, and charges appropriately.
 
So you go hunting for the parts where the seller thinks it's just another bit of old motorbike to sell, and they're described in all sorts of different ways, as boots, ducts and rubber pipes.
 
My "Top Tip" for the day,  look for airboxes with the right rubber boot attached...  Wink
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 08:45
Playing with the RSV in the workshop last night, while it's pretty much naked of plastics I started to work my way through the wiring looking for issues.  When I bought the bike, there was an obvious look of relief on the face of the seller when it started so that I could take it away.  It's failed to start at first attempt a few times since I bought it, but always stared eventually.
 
I've seen that there are battery upgrades, Starter cable upgrades, Reg/Rec Mods and all sorts mentioned on the forums, but the general view seems to be that the bike is borderline on the starting and electrical system.  It'll be fine so long as everything is good order....?
 
I've found corrosion on the connections to the starter solenoid, starter motor and in the reg/rec connector blocks.  The battery is run-of-the-mill, but recently new so I'll hang on to it for the moment.  I was looking at remaking the battery and starter cable terminations, and replacing the rotten rubber boots but have now decided that a new set of battery/starter cables is the right way to go, thanks Johnboy for your help.
 
I've seen somewhere that owners are removing the connector blocks between the reg/rec and the loom and soldering the units in, is this really the best solution or can I get away with cleaning up the terminals and tightening the crimps?
 
Another thing I found is a large diode in the loom to the left clip-on switch gear. The diode is a DIY replacement, I assume for an OE item that was there before, what does it do?  I've cleaned it up, heat-shink sleeved it and remade the sleeving on that loom.
 
I need the bike to be reliable, or as reliable as an Italian bike can be.  I plan on going away on it for a week in June, and don't want to be the butt of all the jokes if it decides to embarrass me.
 
While I'm in electrical mode, is there anything else I should be looking at?  Confused
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Post Options Post Options   Thanks (0) Thanks(0)   Quote twinfan Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 13:31
While you a doing (johnboys) cables,  an upgraded starter solenoid will help 150Amp  AP do them
on my licence it says "tear down the dotted line" so I DO!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 13:53
I've seen others talking about the 150A starter solenoid upgrade.
 
 
How does it differ from what's on the bike as standard?  I can't see any markings on the one that's fitted, is there any way to tell if I've already got one...?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 17:10
Two more bits of carbon re-lacquered and nicely dried in the kitchen while she's away... Wink





The front mudguard is fighting me all the way.  I think silicone polish has got in to the carbon weave and is causing pin-holes in the lacquer.  Third attempt at it tonight, I think I'll just have to live with it.  The red Aprilia sticker is fine by the way, the camera flash just washes the colour out.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 17:51
The diode could be a mod done by the PO to allow high and low beams to come on together.
Info here from post #20 onwards:


Yep, large air boots are relatively rare now and the going rate is about £50.
Some people have removed the cylindrical white connector in the V and the brown connector at the voltage regulator due to poor crimp mating which generate heat and can burn the connectors out. I've still got mine fitted and they are in good condition, I'm guessing the PO has ensured they're a tight fit at the terminals.
I've actually just bought a Fireblade voltage regulator (FH014AA) to replace the Aprilia original, as being a MOSFET it generates a lot less heat and is more reliable. As part of this mod I'll remove the brown connector. Beware there are loads of copies of the Shindengen rr's out there, which is why I bought used from a known bike.
Great info here:

https://www.apriliaforum.com/forums/showthread.php?211850-Voltage-Rectifier-Regulator-upgrade-(Honda-Yamaha-rectifiers)

The original starter solenoid is not up to the job of supplying enough current to the starter motor, the 150A upgrade will sort it, but again beware, lots of chinese rip off copies out there. With Johnboy's cable kit you'll notice a big difference.
Be aware poor starting can knacker the sprag clutch, so make it a priority to put right.
People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote greenman1966 Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 18:17
AF1 sell the large airboot.
And for a lot less than people want 2nd hand.
They also have the gen 1coolant bottles, again cheaper than 2nd hand.
 
Dennis in NZ
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 18:51
Thanks both.

I'll strip the Reg Rec connectors and see what the crimps are like.  There's quite a bit of corrosion on a couple of the spade connectors, so I'll clean that off for a start and nip up the female spades.  If it's all dodgy I can get some new crimps, or solder it up.

I've bought a complete Falco airbox which shows a large airbox boot in the photos.  I've paid £30 for it, including shipping,, and though it looks pretty mucky I'm hoping it will be serviceable.  Assuming they're interchangeable, which they look to be, I'll fit the boot and look at cutting up the airbox top to make an open airbox as I've seen in one of the posts on here.  I'd rather go that way than the alloy plate and floppy rubber seal  idea that the bike should've had when I bought it.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote spiceweasel Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 19:13
Arn't the air  inlets on the rsv round & the falco oval?
www.apriliaperformance.co.uk
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www.apriliaownersclub.co.uk
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Post Options Post Options   Thanks (0) Thanks(0)   Quote aaressveeguy Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 19:16
how do you relaquer carbon? My cf huggers are starting to show their age. ..
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevex Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 19:30
Originally posted by aaressveeguy aaressveeguy wrote:

how do you relaquer carbon? My cf huggers are starting to show their age. ..

I sanded mine with wet and dry, making sure you end up with a smooth finish, then de grease and lacquer. Don't try to remove the old lacquer, you just need to ensure the surface is smooth.
Do it right and it'll look like new.
People say I don't know Jack Sh1t; but I do, he lives next door.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 19:32
I don't know spiceweasel, the pictures on the listing aren't great, I'll see when it arrives.  Maybe I'll have some work to do, but even oval they won't be as restrictive as the boot I have.

For re-lacquering the carbon bits I've just given them a good thorough clean in hot water with strong detergent, very brief wipe over with a solvent rag, and flatted then back with wet'n'dry.  Then two or three coats of rattle-can lacquer.

The carbon bits were really dull, particularly the hugger and front mudguard, I guess they get the worst of it.  You wouldn't have thought they were the proper stuff until you had them off the bike and found how light and rigid they are.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote legend88 Quote  Post ReplyReply Direct Link To This Post Posted: 12 Mar 2019 at 21:04
Nice job on the hugger. Some of the OE carbon fibre has pin holes in it and people have reported problems when trying to re lacquer.

Sadly you will find the Falco airboot to be different. As said the inlets are oval and will not line up with the air duct holes in frame.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 13 Mar 2019 at 00:11
Thanks Legend88, I'll post a picture or two of the Falco bits when I get them.

Still might not be a total loss, this is the picture from the listing...


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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 13 Mar 2019 at 11:56
The sheared hugger fastener has been dealt with, another unexpected hour wasted.



It can't be a coincidence that the battery box drain is above the fastener that sheared.  Quite a bit of corrosion in that area, maybe just a mix of water, salt, heat and dis-similar metals...
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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 14 Mar 2019 at 18:26
My Ti Can has arrived!  It was a bit grubby, a couple of scuffs on the stainless steel bands at each end, but basically straight.  I've spent a bit of time with a flap-wheel in the Dremel, then a fine wire brush and the scuffs are much better.  Then it got a rub with a pan scourer and some Jiff and I'm almost happy with it.  It'll get a final polish up when I get it on the bike, should be good enough.







Now, if I can just get the bike back together I can see if it's really as loud as everyone says it is!!  Confused

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Post Options Post Options   Thanks (0) Thanks(0)   Quote arlurt Quote  Post ReplyReply Direct Link To This Post Posted: 15 Mar 2019 at 09:00
Has anyone got any experience of re-packing exhausts?  If I hold the can vertically, and then turning it upside down, end to end, I can hear something fairly heavy sliding up and down inside.  I'm guessing that the packing material has shrunk and is now free to move about inside the can.  I'll pop one end off and see what's happening inside...
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