Need help, 1999 RSV1000 ignition and forks
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Category: RSV / RSVR / FACTORY
Forum Name: Technical Chat
Forum Description: Any technical problems or useful advise for other owners, remember this is just advice posted here, if you make something go BANG in a big way don't take anyone to court about it.
URL: http://www.rsvr.net/forum_posts.asp?TID=30260
Printed Date: 27 Mar 2026 at 00:38
Software Version: Web Wiz Forums 12.07 - https://www.webwizforums.com
Topic: Need help, 1999 RSV1000 ignition and forks
Posted By: PCthug
Subject: Need help, 1999 RSV1000 ignition and forks
Date Posted: 25 Jul 2025 at 18:35
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I have had my 1999 original tri-colour Mille since 2001, but not used it for a few years and now want to get it back on the road. I have ran into 2 issues that i need help/advice with. 1. I need to take the ignition barrel apart. The barrel has been damaged (has something stuck in it) so i need to take it apart or replace it. One of the bolts holding it on is a tamperproof one that the head has snapped off. I have tried to use a dremel to make a slot thinking it could use a flat head screwdriver. Unfortunately its still too tight (even using a 1/4 ratchet). I have undone the top pinch bolts and centre (17mm hex) and the top fork holder is lifting up slightly, but not enough due to the brake hydraulic cables. I have taken the front fairing/lights of the bike off for better access, but still proving difficult. How do people manage to do this? 2. When i took the wheels off to put new tyres on, 2 of the fork pinch bolts for the front wheel snapped (one either side). I will probably need to drill these out, but this is almost impossible whilst on the bike (I have already snapped 4 drill bits trying). Not only that, but the toffee allen bolts holding the front mudguard on are rounded. I have tried hammering a spline piece in to try and get some grip, but they are still not moving (3 of the 4). I will obviously need to take this off if i am to get the front forks off to drill the pinch bolts out. Also, how do i hold the bike up when the front forks are off? The rear is on a paddock stand. I did think about an axel stand on the engine but it started to rock and was not safe at all. Would it be best balancing it on the rear wheel, side stand and jack somewhere at the front?
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Replies:
Posted By: PCthug
Date Posted: 25 Jul 2025 at 18:38
| At the moment i am thinking the best thing to do is undo the brake and clutch banjo bolts in order to get a better angle at the ignition, but this is annoying as i have just replaced all the fluid and bled them. |
Posted By: Rich Simpson
Date Posted: 25 Jul 2025 at 19:48
| can you just remove or move the levers/bars? |
Posted By: Rich Simpson
Date Posted: 25 Jul 2025 at 19:51
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Abba stand with the front-en lift kit is what I've got for that job Or hire an engine lift crane (for cars) from your local tool hire shop and use it to sling the bike so it is hanging down.
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Posted By: redratbike
Date Posted: 25 Jul 2025 at 22:05
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Can you strap it from above to hold the front in the air -------------  |
Posted By: PCthug
Date Posted: 25 Jul 2025 at 23:52
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Ni idea how i missed this, but the top yoke is separate from the bars. I undid all 4 bolts and it came up as a single piece, so presumed it was. I will to see how they come apart.  |
Posted By: PCthug
Date Posted: 25 Jul 2025 at 23:55
here is a closer look |
Posted By: PCthug
Date Posted: 26 Jul 2025 at 01:11
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I am looking at the Abba stand now thanks. Its about £177 for the full kit. Someone close by is selling the stand for £40, so might go for that and get the bobbin and front lift kit separately.
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Posted By: PCthug
Date Posted: 28 Jul 2025 at 09:02
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Managed to get the top yoke off and taken the ignition barrel off. Unfortunately i could not get out whatever it in there which is stopping the key going in, so i need a new ignition/key. I dont need a new fuel cap or seat lock, just the ignition, but having trouble finding one (new or used). I have sent AP a DM to ask if they have one. I also bought the Abba stand that was being sold nearby, and may need to buy the front lift kit and fitting kit. Although i have used a straight metal threaded bar that has gone through the bike and works fine, but i still need a way of keeping the front off the ground. I could use an axle stand (or 2, to be extra safe) i guess.
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Posted By: Stevex
Date Posted: 28 Jul 2025 at 11:43
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Before I got the Skylift, I used an ABBA stand. I then used some 2x2 wood under the engine. Shaped the top to fit the engine profile, then added a flat piece of wood at the bottom of the 2x2 to give stability.
------------- People say I don't know Jack Sh1t; but I do, he lives next door. |
Posted By: JulesRSV
Date Posted: 01 Aug 2025 at 12:04
I'm sure AP will help but two other ideas 1. Take the barrel to a decent locksmith who may be able to help repair it 2. Check out the parts search on AF1 ( https://www.af1racing.com/2001-2002-Mille-Spare-Part-Catalog" rel="nofollow - https://www.af1racing.com/2001-2002-Mille-Spare-Part-Catalog ) which will give a good idea of cost and availability of new parts. The UK part number for "OEM Aprilia Ignition Lock Assembly" which is what you are after I think, is AP8102910 (no match) or the USA part is AP8124895 is https://www.af1racing.com/AP8104941-OEM-Aprilia-Ignition-Lock-Assembly---8104941" rel="nofollow - https://www.af1racing.com/AP8104941-OEM-Aprilia-Ignition-Lock-Assembly---8104941 cost $213 plus taxes, shipping etc. I'm no expert but hope that is of some use.
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PCthug wrote: