APRILIA RSV4 RR Service Station Manual

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SERVICE STATION MANUAL

2Q000152

RSV4 RR/RF

Table of Contents

Summary of Contents for APRILIA RSV4 RR

Page 1 SERVICE STATION MANUAL 2Q000152 RSV4 RR/RF...
Page 2 THE VALUE OF SERVICE As a result of continuous updates and specific technical training programmes for Aprilia products, only Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out maintenance and repair operations correctly.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 RSV4 RR/RF Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 RSV4 RR/RF Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE.
Page 9 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.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-...
Page 11 RSV4 RR/RF Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Page 12 Final drive ratio 16 / 41 RACTION CONTROL Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control), which includes traction control, wheelie control, launch control and clutchless gear shift functions both going up and down the gears. Capacities APACITY Specification Desc./Quantity Fuel tank (reserve included) 18.5 l (4.07 UKgal;...
Page 13 RSV4 RR/RF Characteristics Specification Desc./Quantity Coolant 2.7 l (0.59 UK gal) Seats Maximum weight capacity 201 kg (443 lb) Drive chain RIVE CHAIN Specification Desc./Quantity Type With sealed master link Model Regina 110 links Electrical system LECTRICAL SYSTEM Specification Desc./Quantity...
Page 14 RSV4 RR/RF Characteristics USPENSION Specification Desc./Quantity Front fork - RSV4 1000 RR Race Pack/RF Öhlins upside down units with adjustable hydraulic damping and 43 mm (1.69 in) diam. stanchions with Tin surface coating) Front fork - RSV4 1000 RR Sachs upside-down stanchions with adjustable hydraulic damping and 43mm (1.69 in) diameter stanchions.
Page 15 RSV4 RR/RF Characteristics YRES Specification Desc./Quantity Tyre model Pirelli DIABLO Supercorsa SP V2 Pirelli DIABLO Supercorsa SP Front tyre 120/70 ZR17 (58W) Inflation pressure 1 passenger: 2.3 bar (230 KPa) (33.36 PSI) 2 passengers: 2.5 bar (250 KPa) (36.26 PSI)
Page 16 RSV4 RR/RF Characteristics Front side OOLING pos. Description Type Quantity Torque Notes Flanged hex. head screws for fasten- M6x20 10 Nm (7.38 lb ft) ing the water radiator support brack- et to the frame Flanged hex. head screws for fasten- M6x20 7 Nm (5.16 lb ft)
Page 17 RSV4 RR/RF Characteristics IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lb ft) mounting bracket (OHLINS FORKS) CHAR - 17...
Page 18 RSV4 RR/RF Characteristics RONT FORK HLINS pos. Description Type Quantity Torque Notes Fork feet hub fastening screws (Oh- 2 + 2 12 Nm (8.85 lb ft) lins) Speed sensor fastening screw 6 Nm (4.43 lb ft) Speed sensor bracket screws 8 Nm (5.90 lb ft)
Page 19 RSV4 RR/RF Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lb ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lb ft) chions Headstock ring nut - pre-tightening M35x1 70 Nm (51.63 lb ft)
Page 20 RSV4 RR/RF Characteristics RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel pin nut M25x1.5 80 Nm (59.00 lb ft) Front brake disk fastening screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 RONT BRAKE CALLIPER Pos.
Page 21 RSV4 RR/RF Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lb ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lb ft) mounting bracket to handlebar Front brake pump U bolt clamp 10 Nm (7.38 lb ft)
Page 22 RSV4 RR/RF Characteristics ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screws for fastening the handlebar 1 + 1 25 Nm (18.44 lb ft) collar to the forks sleeves Handlebar safety screw 10 Nm (7.38 lb ft) Anti-vibration counterweight fastener M18x1.5...
Page 23 RSV4 RR/RF Characteristics EADLAMP Pos. Description Type Quantity Torque Notes Screw for fastening the front head- SWP 4.9 2 Nm (1.48 lb ft) light to the front mudguard Headlamp fastener screw M5 x 12 2 Nm (1.48 lb ft) CHAR - 23...
Page 24 RSV4 RR/RF Characteristics NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 25 RSV4 RR/RF Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lb ft) Lug fixing screws 4 Nm (2.95 lb ft) Screws fixing the side fairings to the 1.5 Nm (1.11 lb ft)
Page 26 RSV4 RR/RF Characteristics LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lb ft) Central part CHAR - 26...
Page 27 RSV4 RR/RF Characteristics IDE STAND pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lb ft) Loct. 243 frame Linear switch retaining screws and 4 Nm (2.95 lb ft) nuts Rear stand bushing retaining screw 7 Nm (5.16 lb ft)
Page 28: Table Of Contents
RSV4 RR/RF Characteristics UEL TANK pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft) er's saddle to the fuel tank Filler to tank retaining screws 4 Nm (2.95 lb ft) Screws fastening fuel pump flange to 5 Nm (3.69 lb ft)
Page 29: Fuel Tank
RSV4 RR/RF Characteristics UEL TANK COVER Pos. Description Type Quantity Torque Notes Screws fastening front tank to frame 8 Nm (5.90 lb ft) Screws fastening tank structural sup- 3 Nm (2.21 lb ft) port to tank ENTRAL BODYWORK Pos. Description...
Page 30 RSV4 RR/RF Characteristics Pos. Description Type Quantity Torque Notes Screws fastening fairing to tank 2 + 2 2 Nm (1.48 lb ft) OOTRESTS Pos. Description Type Quantity Torque Notes Screws for fastening the rider's footr- 2 + 2 25 Nm (18.44 lb ft)
Page 31: Nm (2.95 Lb Ft)
RSV4 RR/RF Characteristics HASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 32: Nm (3.69 Lb Ft)
RSV4 RR/RF Characteristics OCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lb ft) Lock lever self-tapping screw 2 Nm (1.48 lb ft) Shear head screw (to the left of the...
Page 33 RSV4 RR/RF Characteristics RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screws M6x16 8 Nm (5.90 lb ft) Horn fixing screw 15 Nm (11.06 lb ft) Screw fastening the voltage regula- 6 Nm (4.43 lb ft)
Page 34 RSV4 RR/RF Characteristics LECTRICAL SYSTEM REAR pos. Description Type Quantity Torque Notes Screw fixing the ground lead to chas- 6 Nm (4.43 lb ft) Battery bracket fixing screw 2 Nm (1.48 lb ft) CHAR - 34...
Page 35 RSV4 RR/RF Characteristics EAR LEVER pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.90 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk, flat head, hex. socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 36 RSV4 RR/RF Characteristics pos. Description Type Quantity Torque Notes Screws for fastening the lower fairing 2 + 2 1 Nm (0.74 lb ft) to the bracket Screws for fastening the lower fairing 2 Nm (1.47 lb ft) to the stanchion Lower fairing fastening screws 2 Nm (1.47 lb ft)
Page 37 RSV4 RR/RF Characteristics Back side ISCHARGE pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lb ft) nuts Silencer clamp fixing screw - central 10 Nm (7.38 lb ft) manifold Screw used to secure the silencer to 25 Nm (18.44 lb ft)
Page 38 RSV4 RR/RF Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lb ft) "A" Nuts fastening sprocket on 50 Nm (36.88 lb ft) sprocket mount "B" Nuts fastening sprocket on 55 Nm (40.57 lb ft) sprocket mount "C"...
Page 39 RSV4 RR/RF Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lb ft) Rear brake pump retaining screws 8 Nm (5.90 lb ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lb ft)
Page 40: Nm (5.16 Lb Ft)
RSV4 RR/RF Characteristics EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Odometer sensor fixing screw 10 Nm (7.38 lb ft) Rear brake calliper support plate re- 50 Nm (36.88 lb ft) Loct. 243 taining pin Rear brake calliper fastening screw 25 Nm (18.44 lb ft)
Page 41 RSV4 RR/RF Characteristics EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 5 Nm (3.69 lb ft) For plastic mud- guard Rear mudguard fixing screws 3 Nm (2.21 lb ft) For carbon mud- guard CHAR - 41...
Page 42: Nm (1.84 Lb Ft)
RSV4 RR/RF Characteristics EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lb ft) Dual connecting rod fixing screw 50 Nm (36.88 lb ft) Screw fastening single connecting 50 Nm (36.88 lb ft)
Page 43 RSV4 RR/RF Characteristics EAR BODYWORK pos. Description Type Quantity Torque Notes Rear screws used to fasten the tail 3 Nm (2.21 lb ft) fairing to the rear headlight bracket Screws used to fasten the saddle SWP 2.9 1 Nm (0.74 lb ft)
Page 44 RSV4 RR/RF Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.90 lb ft) TE Flanged screw M6x20 10 Nm (7.38 lb ft) TE Flanged screw M6x35 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque.
Page 45 RSV4 RR/RF Characteristics ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.38 lb ft) Coil fastening screws 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft) CHAR - 45...
Page 46 RSV4 RR/RF Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft)
Page 47 RSV4 RR/RF Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Shoe fastening screws 20 Nm (14.75 lb ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.38 lb ft)
Page 48 RSV4 RR/RF Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lb ft) + 130° and under head with con PANKL Lubri- cant 01 (PLB01) Fastener ring nut for alternator side 100 Nm (73.76 lb ft)
Page 49 RSV4 RR/RF Characteristics pos. Description Type Quantity Torque Notes Flanged nut 30 ± 55 Nm (22.13 ± Molykote - Lubri- 40.57 lb ft) cate the thread and under the head. Conical cap * Move to 1mm un- der the table.
Page 50 RSV4 RR/RF Characteristics LUTCH pos. Description Type Quantity Torque Notes Flanged nut fixing clutch M20x1 150 Nm (110.63 lb ft) Loct. 243 Clutch springs SHC fixing screw M6x25 10 Nm (7.38 lb ft) IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674...
Page 51 RSV4 RR/RF Characteristics LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lb ft) Move to the torque, pins unscrew, bring back to torque. Cover fastening screws generator M6x40 12 Nm (8.85 lb ft)
Page 52 RSV4 RR/RF Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque.
Page 53 RSV4 RR/RF Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Secondary air solenoid screws 10 Nm (7.38 lb ft) ATER PUMP pos. Description Type Quantity Torque Notes Screws used to fasten the pump to M6x25 10 Nm (7.38 lb ft)
Page 54 RSV4 RR/RF Characteristics CHAR - 54...
Page 55 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 56 RSV4 RR/RF Special tools PECIFIC TOOLS Stores code Description 020845Y Engine support 020846Y Containment tray + plastic plugs 020847Y Flywheel extractor 020914Y Flywheel retainer 020849Y Clutch lock 020850Y Primary gear lock S-TOOLS - 56...
Page 57 RSV4 RR/RF Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension- er of the timing chain 020856Y Piston assembly ring...
Page 58 RSV4 RR/RF Special tools Stores code Description 020858Y Maintenance of the pistons in the cylin- ders AP8140199 Tool storage panel 020859Y Graphics for panels 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear- box control rod....
Page 59 RSV4 RR/RF Special tools Stores code Description 020864Y Engine mounting plate 020956Y Support for camshaft gear on head 020883Y Fitting/removing timing chain tensioner tool 020709Y Engine support AP8140187 U-bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide...
Page 60 RSV4 RR/RF Special tools Stores code Description 020364Y 25-mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft S-TOOLS - 60...
Page 61 RSV4 RR/RF Special tools Stores code Description 020877Y Calliper for clamps 020926Y Tool for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140147 Spacer retaining device AP8140148 Plunger-spacer separator plate...
Page 62 RSV4 RR/RF Special tools Stores code Description AP8140150 Bored shaft for bleeding plunger air AP8140190 Tool for steering tightening AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool S-TOOLS - 62...
Page 63 INDEX OF TOPICS MAIN AINTENANCE...
Page 64 Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. For this purpose, Aprilia has formulated a series of checks and scheduled services (at the owner's expense), are summarised in the table given in the following page. It is generally advisable to have any minor malfunctions rectified immediately by an Authorised Aprilia Dealer without waiting until the next service.
Page 65 Labour time (minutes) - RF/RR - My2016 The scheduled maintenance table refers to road use. In case of using the new RSV4 RR - RF on a competitive level, as for sport events and use on the track, in order to correctly mon-...
Page 66 RSV4 RR/RF Maintenance To carry out the correct verification "Flexible coupling pin nuts tightening" indicated in the scheduled maintenance table, refer to the corresponding procedure in chapter "Maintenance / Verification Flex- ible coupling" SCHEDULED MAINTENANCE TABLE ONLY FOR THE ASIA/PACIFIC MARKET...
Page 67 For this reason,when the general warning lamp (see figure) remains on in the steady state for more than 2 seconds, every 120 seconds, users should contact their local Authorised Aprilia Service Centre in order to arrange for the specific MAIN - 67...
Page 68 RSV4 RR/RF Maintenance maintenance procedure to be carried out, as indi- cated in the table. Connect the diagnostic tool, select parameters and states, and check that the equivalent track kil- ometres correspond to 6,000 km, or a multiple thereof Upon completing the specific track maintenance procedure, access the "adjustments"...
Page 69 RSV4 RR/RF Maintenance Spark plug FRONT SPARK PLUGS • Remove the base of the air filter box. • Undo and remove the screw. • Slide off the front coil. • Unscrew and remove the front spark plug. REAR SPARK PLUGS •...
Page 70 RSV4 RR/RF Maintenance Engine oil Check THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
Page 71 RSV4 RR/RF Maintenance • Place a container with suitable capaci- ty under the drainage plug. • Unscrew and remove the drainage plug. • Unscrew and remove the filler cap. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.
Page 72 RSV4 RR/RF Maintenance My2015 RSV4 1000 RR • Remove the fixing nut (1) of the rear wheel pin, recovering the washer (2) and the guide (3) • Remove the rear wheel pin (4), pulling it from the right side of the motorcycle...
Page 73 RSV4 RR/RF Maintenance • Make the wheel move forward and re- lease the gearing chain from the sprocket • Slide off the final transmission unit by pulling it parallel to the wheel axis OPERATE WITH CAUTION. IF THE FINAL TRANSMISSION...
Page 74 RSV4 RR/RF Maintenance • Using a torque wrench, check and if necessary tighten the nuts fixing the crown to the support to the prescribed torque My2016 RSV4 1000 RF/RR • Operating from the left side of the mo- torcycle, using a torque wrench, check...
Page 75 RSV4 RR/RF Maintenance • Disconnect the upper injector fuel de- livery union. • Lift the filter box cover on which the control unit is installed. • Do not rotate the cover excessively to avoid straining the pipes and cables. MAIN - 75...
Page 76 RSV4 RR/RF Maintenance • Remove the air filter. Checking the valve clearance FRONT HEAD • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 77 RSV4 RR/RF Maintenance REAR CYLINDER HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover. See also Removing the throttle body Spark plug Head cover removal • Use a feeler gauge to check the clear-...
Page 78 RSV4 RR/RF Maintenance Front cylinder head valves • Check the play on the front head valves and, if it is necessary to restore the correct play values, proceed as follows. • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft.
Page 79 RSV4 RR/RF Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 80 RSV4 RR/RF Maintenance ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1).
Page 81 RSV4 RR/RF Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 82 RSV4 RR/RF Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally.
Page 83 RSV4 RR/RF Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 84 RSV4 RR/RF Maintenance Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Check if the clearance between the cam on the shaft and the tappet is correct. • If not, repeat the valve clearance adjustment procedure. Rear cylinder head valves •...
Page 85 RSV4 RR/RF Maintenance • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 86 RSV4 RR/RF Maintenance 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling...
Page 87 RSV4 RR/RF Maintenance • Use a magnet to remove the tappet. CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE. • Retrieve the pad and replace with a suitable component to achieve the cor- rect valve clearance.
Page 88 RSV4 RR/RF Maintenance • Move the gear from the mounting tool to the camshaft. • Unscrew and remove the two screws (1). • Remove the tool. Specific tooling 020956Y Support for camshaft gear on head • Fit the U bolt and the oil pipe.
Page 89 RSV4 RR/RF Maintenance • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer •...
Page 90 RSV4 RR/RF Maintenance Calibrated pad thickness Pad thicknesses for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.77 mm (0.0697 in) 1.80 mm (0.0709 in) 1.82 mm (0.0716 in) 1.85 mm (0.0728 in) 1.87 mm (0.0736 in) 1.90 mm (0.0748 in) 1.92 mm (0.0756 in)
Page 91 RSV4 RR/RF Maintenance 2.25 mm (0.0886 in) 2.27 mm (0.0894 in) 2.3 mm (0.0905 in) 2.32 mm (0.0913 in) 2.35 mm (0.0925 in) 2.37 mm (0.0933 in) 2.4 mm (0.0945 in) 2.42 mm (0.0953 in) 2.45 mm (0.0964 in) 2.47 mm (0.0972 in) 2.50 mm (0.0984 in)
Page 92 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 93 SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE DIAGNOSIS INSTRUMENT THROUGH CONTROL UNIT BY SE- LECTING "SELF-ACQUISITION, APRILIA, RSV4" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 94 RSV4 RR/RF Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 95 RSV4 RR/RF Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION AXONE SHOULD BE WORKING PROPERLY AND UPGRADED AT LEAST TO THE 7.0.0 VERSION OR THE PGDS UPDATED AT LEAST TO THE 3.0.0 VERSION...
Page 96 RSV4 RR/RF Troubleshooting • 8. WHEN THE PUSH-BUTTON IS IN THE "RUN" POSITION, WHAT DOES THE "RUN- STOP SWITCH" STATE ICON ON THE DIAGNOSTIC TOOL DEVICE STATES PAGE INDICATE, ICON 0/1? If it indicates the "RUN" state, go to point 9, if it indicates "STOP", go to point 15 •...
Page 97 RSV4 RR/RF Troubleshooting THE NUMBER OF THE INDICATED RELAY REFERS TO THE ELECTRICAL CIRCUIT DIAGRAM. THE POSITION OF THE RELAY ON THE VEHICLE IS INDICATED IN THE CHAPTER "ELECTRICAL SYSTEM/COMPONENT LAYOUT/RELAY LAYOUT". • 1- WHEN THE IGNITION KEY IS TURNED TO THE "ON" POSITION, THE INSTRUMENT CLUSTER SWITCHES ON AND, WHILE NO "SERVICE"...
Page 98 RSV4 RR/RF Troubleshooting CHECK THAT ICON 0/1 ON THE DEVICE STATES PAGE INDICATES THE CORRECT STATE. In the event of a fault condition, go to point 10, if everything functions correctly, go to point 11 • 10. DEPENDING ON THE SPECIFIC FAULT, SEE CHAPTER "ELECTRICAL SYSTEM, CHECKS AND CONTROLS/NEUTRAL SENSOR"...
Page 99 RSV4 RR/RF Troubleshooting • 4. REPLACE CONTROL UNIT, SEE "ELECTRICAL SYSTEM/CHECK AND CONTROLS/ CONTROL UNIT " THE PART RELATED TO NEW CONTROL UNIT ACTIVATION PRO- CEDURE - END • 5. CHECK CONTINUITY red/blue CABLE up to secondary fuse D and red/white cable from...
Page 100 RSV4 RR/RF Troubleshooting • 4. CHECK ENGINE CABLE HARNESS - VEHICLE CABLE HARNESS CONNECTOR - INJECTION RELAY 33 CHECK • 1. CHECK CONTINUITY OF THE ORANGE/GREEN CABLE FROM THE LOWER INJEC- TOR AT PIN 3 OF THE INJECTION RELAY 33, ALSO CHECKING THE ENGINE CABLE...
Page 101 RSV4 RR/RF Troubleshooting • 2. WITH KEY SET TO OFF, DISCONNECT THE RELAY CONNECTOR AND CHECK IF THERE IS VOLTAGE ON RED/WHITE CABLE YES, go to 3; NO, restore the cable harness - END • 3. CHECK CORRECT OPERATION OF THE RELAY, THAT IS, PROVIDING VOLTAGE...
Page 102 RSV4 RR/RF Troubleshooting • 5. CHECK CONTINUITY OF PINK CABLE BETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT, CHECKING ALSO THE ENGINE - VEHICLE CABLE HAR- NESS CONNECTOR YES, go to 4; NO, restore the cable harness - END •...
Page 103 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 104 RSV4 RR/RF Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screws M6x16 8 Nm (5.90 lb ft) Horn fixing screw 15 Nm (11.06 lb ft) Screw fastening the voltage regula- 6 Nm (4.43 lb ft)
Page 105 RSV4 RR/RF Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lb ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.5 Nm (1.11 lb ft) mounting plate...
Page 106 RSV4 RR/RF Electrical system key: 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water temperature sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Intake ducts 11.Lower injectors 12.Air pressure sensor...
Page 107 RSV4 RR/RF Electrical system THE IDENTIFICATION OF THE RELAY CANNOT BE CARRIED OUT JUST ON THE BASIS OF THE INDICATIONS BELOW: IN ANY EVENT IT SHOULD OCCUR WITH THE IDENTIFICATION OF THE COLOUR OF THE RELAY CABLES. ELAY LAYOUT Component position...
Page 108 RSV4 RR/RF Electrical system • 2 Lambda probe • 2 Fan • 1 Regulator • 1 Demand sensor • 1 YT12A-BS battery • 1 SensorBox • 1 QuickShift Small parts and mountings • 10 290x4 Large black clamps • 12 160x2.5 Small black clamps •...
Page 109 RSV4 RR/RF Electrical system Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section Special checks for the correct connection and laying of cables It is extremely important that any security-locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Page 110 RSV4 RR/RF Electrical system • Check that the front turn indicator connectors are well inserted on the instrument holder support • SensorBox connector • Check the ground fixing on the engine and chassis • Check correct securing (torque) of the screws on the starter relay positive cables and the correct routing of the Battery-Starter Relay cable •...
Page 111 RSV4 RR/RF Electrical system WIRING TABLE C - FRONT HEADLIGHT PRE- ASSEMBLY The front headlight wiring must be pre-assembled on the headlight by means of a clamp 1. Headlamp wiring harness 2. Small black clamp WIRING TABLE C1 - FRONT HEADLIGHT PRE- ASSEMBLY 1.
Page 112 RSV4 RR/RF Electrical system 4. Right hand light switch WIRING TABLE E - INSTRUMENT SUPPORT ARCH AND FRONT PART Position the two clamps as indicated TABLE E1 - INSTRUMENT HOLDER SUPPORT AND FRONT PART With the first clamp for edges, take and block the...
Page 113 RSV4 RR/RF Electrical system WIRING TABLE E3 - INSTRUMENT SUPPORT ARCH AND FRONT PART Using the second pre-installed clamp on the in- strument support arch, group together all the ca- bles from the left hand side of the handlebar, and...
Page 114 RSV4 RR/RF Electrical system TABLE E7 - INSTRUMENT HOLDER SUPPORT AND FRONT PART Make the connections for all connectors: The ca- ble harness side ignition switch connector is dis- tinguished with red taping on its branch 1. Quick Shift control connector 2.
Page 115 RSV4 RR/RF Electrical system TABLE F - FRONT WHEEL ABS SENSOR PAS- SAGE (OHLINS FORK) Pass the wiring harness of the speed sensor for- ward to the brake pipe in the indicated point 1. ABS sensor 2. Cable grommets 3. Clamp...
Page 116 RSV4 RR/RF Electrical system WIRING TABLE G - COMPLETING THE FRONT MUDGUARD ASSEMBLY Position the front headlight connectors under the instrument support arch WIRING TABLE G - COMPLETING THE FRONT MUDGUARD ASSEMBLY Check that the indicator connectors are inserted correctly and that they do not protrude into the in- strument holder arch 1.
Page 117 RSV4 RR/RF Electrical system TABLE B - VEHICLE CABLE HARNESS Place the main wiring harness inside the conduits and close them using two clamps TABLE B1 - VEHICLE CABLE HARNESS Block the conduit to the chassis in the four indica-...
Page 118 RSV4 RR/RF Electrical system TABLE C - RELAY UNIT Check the correct insertion of the connectors on the relevant relays 1. Safety relay connector 2. Injection relay connector 3. Fan relay connector TABLE D - RADIATOR AREA right side: 1. Vehicle cable harness 2.
Page 119 RSV4 RR/RF Electrical system TABLE D1 - RADIATOR AREA The female faston of oil pressure sensor features a retaining tang. When disconnecting it, pay attention as it could be damaged. 1. Exhaust valve actuator cable harness routing 2. Oil pressure sensor cable harness routing 3.
Page 120 RSV4 RR/RF Electrical system WIRING TABLE E1 - STARTER MOTOR AND OIL BULB ZONE IF THE RELAY-STARTER MOTOR CABLE IS NOT ROUTED AND/OR SECURED CORRECT- LY IT MAY CAUSE THE VEHICLE TO CATCH FIRE. CHECK THAT THE CABLE ON THE...
Page 121 RSV4 RR/RF Electrical system TABLE H - ENGINE GROUND CABLE INCORRECT SECURING OF THE SCREW THAT LOCKS THE GROUND CABLE MAY CAUSE THE VEHICLE TO CATCH FIRE. TABLE H1 - ENGINE GROUND CABLE INCORRECT SECURING OF THE SCREW THAT LOCKS THE GROUND CABLES MAY CAUSE THE VEHICLE TO CATCH FIRE.
Page 122 RSV4 RR/RF Electrical system TABLE H3 - ENGINE GROUND CABLE 1. Routing of the Demand Slave wiring harness 2. Routing of the Demand Master wiring harness TABLE H4 1. Big clamp 2. Fan connector 3. Regulator wiring harness routing ELE SYS - 122...
Page 123 RSV4 RR/RF Electrical system TABLE H5 Check that the regulator wiring harness is secured well 1. Regulator connector 2. Regulator connector on the vehicle wiring har- ness 3. Big clamp 4. Flywheel wiring harness routing 5. Regulator wiring harness routing...
Page 124 RSV4 RR/RF Electrical system TABLE L - PINION CASING AREA CHECK THAT THE REAR LAMBDA PROBE CONNECTOR IS CONNECTED CORRECTLY 1. Quick Shift wiring harness routing 2. Gear sensor wiring harness routing 3. Rear lambda probe cable routing 4. Stand switch wiring harness routing 5.
Page 125 RSV4 RR/RF Electrical system TABLE M - REAR LAMBDA 1. Rear lambda probe wiring harness routing TABLE M1 - REAR LAMBDA THE CABLE GROMMET MUST BE POSITIONED UPWARD AND THE LAMBDA PROBE CABLE SHOULD PASS INSIDE ELE SYS - 125...
Page 126 RSV4 RR/RF Electrical system TABLE M2 - REAR LAMBDA CHECK THE CORRECT CONNECTION OF THE FRONT LAMBDA PROBE CONNECTOR 1. Front lambda probe wiring harness routing TABLE M3 - REAR LAMBDA 1. Front lambda probe cable of the main wiring harness 2.
Page 127 RSV4 RR/RF Electrical system TABLE N Set the connectors for stand switch, Quick Shift and gear sensor under the two corrugated pipes TABLE N1 Check that the clamp holds all cables and espe- cially the Quick Shift cable. The cable must be locked so that it does not slide and comes into contact with the exhaust.
Page 128 RSV4 RR/RF Electrical system TABLE A1 - LICENSE PLATE HOLDER PRE- FITTING Bring all cables, including connectors in the hole of the plate holder as in the picture and close all paying attention not to pinch the cables TABLE B - REAR ABS SPEED SENSOR PRE- FITTING 1.
Page 129 RSV4 RR/RF Electrical system TABLE C1 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard...
Page 130 RSV4 RR/RF Electrical system WIRING TABLE D1 - ABS ON SADDLE MOUNT- The reference taping is purely indicative, position the clamp so that it is aligned with the hole on the saddle mounting. (the clamp may not be posi- tioned above the taping) Position the clamp without tightening it but allow- ing it rotate of its own accord.
Page 131 RSV4 RR/RF Electrical system WIRING TABLE E - REAR SADDLE MOUNTING ZONE Preparing the battery support bracket with fuses 1. Battery support bracket 2. Vehicle wiring harness TABLE E1 - REAR SEAT POST AREA Fit the (individual) fan fuse on battery mounting...
Page 132 RSV4 RR/RF Electrical system TABLE E4 - REAR SEAT POST AREA 1. Taillight 2. Taillight connector 3. License plate frame wiring harness connector WIRING TABLE E5 - REAR SADDLE MOUNT- ING ZONE Insert the ECU diagnostic and the instrument clus-...
Page 133 RSV4 RR/RF Electrical system WIRING TABLE F - ENGINE BATTERY EARTH CABLE 1. Engine-battery earth cable 2. Cable grommet TABLE F1 - ENGINE BATTERY GROUND CA- 1. Battery - engine ground lead 2. Big clamp ELE SYS - 133...
Page 134 RSV4 RR/RF Electrical system TABLE G - VARIABLE INTAKE DUCT CON- TROL UNIT 1. Variable intake duct control unit 2. Variable intake duct control unit connector 3. Rubber blocks TABLE G1 - VARIABLE INTAKE DUCT CON- TROL UNIT 1. Intake duct control unit wiring harness routing 2.
Page 135 RSV4 RR/RF Electrical system General wiring diagram key: 1. Multiple connectors 2. Front right turn indicator (LED) 3. Complete headlamp 4. Front left turn indicator (LED) ELE SYS - 135...
Page 136 RSV4 RR/RF Electrical system 5. Right low beam light bulb 6. High beam bulb 7. Tail light bulb (LED) 8. Left low beam light bulb 9. High beam light relay 10.Low beam light relay 11.Left light switch 1 12.Instrument panel diagnosis 13.Instrument panel matrix II...
Page 137 RSV4 RR/RF Electrical system 43.Electronic transmission 44.Side stand switch 45.Gear sensor 46.Front cylinder pressure sensor 47.Rear cylinder pressure sensor 48.Front cylinder throttles 49.Rear cylinder throttles 50.Air temperature sensor 51.Water temperature sensor 52.Upper injectors 53.7SM control unit 54.Throttle grip position sensor 55.Engine speed sensor...
Page 138 RSV4 RR/RF Electrical system BEFORE STARTING ANY TROUBLESHOOTING PROCEDURES ON THE VEHICLE, CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V. CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector correct position on the component or on the coupling con- nector, making sure that the locking catch is re- leased.
Page 139 RSV4 RR/RF Electrical system mally, the tester will sound an audible signal to confirm continuity in the section of circuit tested. Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the resistance in the circuit is zero or of a few tenths of an Ohm.
Page 140 RSV4 RR/RF Electrical system DSB 01 Immobilizer fault • key code read but not recognised Error cause • The read code is not stored in the instrument panel memory Troubleshooting • Carry out key data storage procedure DSB 02 Immobilizer fault •...
Page 141 RSV4 RR/RF Electrical system Installation of new instrument panel In case the instrument panel is replaced by a new one, follow the procedure shown below so that the immobilizer system (key storage) and the exhaust butterfly valve (controlled by the ECU through the instrument panel) operate correctly.
Page 142 RSV4 RR/RF Electrical system • Exit • INSTRUMENT PANEL ERRORS • Error Clearing • VEHICLE SERVICING RESET • Update • CHANGE KEYS • KM / MILES INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connec- ted to it.
Page 143 RSV4 RR/RF Electrical system This error is signalled by the bulb icon, and the general warning light turns on as well. The instrument panel must keep all previous errors stored in its memory. DELETE ERRORS This option deletes all instrument panel errors; a further confirmation is requested. Use the diagnosis instrument to reset ECU errors.
Page 144 RSV4 RR/RF Electrical system • ESPAÑOL Service warning light reset VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check.
Page 145 RSV4 RR/RF Electrical system • Take the measurement; The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted, obtained by touching the two lugs.
Page 146 RSV4 RR/RF Electrical system • If there is a significant difference between one stage and another (other than 15 V), this means that the alternator is defective and must be replaced. CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE DETECTED WITH THE ENGINE COLD.
Page 147 RSV4 RR/RF Electrical system PERFORM THE CHECK DESCRIBED ABOVE WITH A BATTERY IN GOOD CONDITION (START VOLTAGE ABOUT 13V) MAKING SURE THAT THERE ARE NO ELEMENTS IN THE SHORT CIR- CUIT. Start-up system check Function Communicates to the control unit the will to start- up the engine.
Page 148 RSV4 RR/RF Electrical system • Fault in the switch (lock) of the engine start-up. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • Check the locking cause and restore. level indicators...
Page 149 RSV4 RR/RF Electrical system CAUTION THERE IS ONE SPARE FUSE (I). Control unit Removal • Remove the fuel tank. • Disconnect both control unit connec- tors • Unscrew and remove the three screws. • Remove the control unit. NOTE WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION.
Page 150 RSV4 RR/RF Electrical system CONTROL UNIT - Diagnosis Function It manages the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves...
Page 151 RSV4 RR/RF Electrical system Fuel additive capacity Fuel additive correction CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 152 RSV4 RR/RF Electrical system • The stop light logic relay (no. 25 in the electrical circuit diagram, in the front niche of the frame, right side, CHECK anyway the identification of the relay with the colour of the cables) is energised...
Page 153 RSV4 RR/RF Electrical system • Circuit not functioning Error cause • Replace the injection control unit 'Stop lights relay error P0610 • short circuit to positive / short circuit to negative / open circuit Error cause • Short-circuit to positive: excessive voltage has been detected on PIN 31. If short circuit to negative: no voltage has been detected.
Page 154 ATT status Troubleshooting • Perform the troubleshooting for the other detected errors. a-PRC (Aprilia Performance Ride Control) operating error P0700 • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit voltage too low for a-PRC controls Error cause •...
Page 155 RSV4 RR/RF Electrical system unit will acquire the throttle valve position. Connect with the diagnostic tool and check that the states of "Automatic throttle valve self-learning is "performed" and "Handle self-learning" is "Not per- formed" (the latter involved the display of the message Urgent service on the instrument panel). If the automatic throttle valve self-learning indicates "Not performed"...
Page 156 RSV4 RR/RF Electrical system Value drawn from the signal read without taking into account any recovery CAUTION PAY ATTENTION TO THE POSITIVE BATTERY CABLE, WHICH MUST PASS BELOW THE UPPER PART OF THE FRAME. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 157 RSV4 RR/RF Electrical system Location on the vehicle: On the fork, right stanchion, next to the brake cal- liper support. Connector location (if available): Under the right dynamic air intake. Pin-out: • PIN 1 - Power negative/Signal nega- tive (white) •...
Page 158 RSV4 RR/RF Electrical system Check continuity of white/brown cable across wiring-side sensor PIN 2 and ABS connector PIN 3: if NOT OK, restore cable harness; if OK, check ground insulation of the white/brown cable. If NOT OK, restore cable harness; if OK, check with sensor disconnected and key ON that power voltage is slightly below battery voltage.
Page 159 RSV4 RR/RF Electrical system Traction control. Location on the vehicle: Swingarm, right side, on the brake calliper support plate. Connector location (if available): Under the right side fairing. Pin-out: • PIN 1 - Power negative/Signal nega- tive (yellow) • PIN 2 - Power positive/Signal positive...
Page 160 RSV4 RR/RF Electrical system Check continuity of yellow/brown cable across wiring-side sensor PIN 2 and ABS connector PIN 3: if NOT OK, restore cable harness; if OK, check ground insulation of the yellow/brown cable. If NOT OK, restore cable harness; if OK, check with sensor disconnected and key ON that power voltage is slightly below battery voltage.
Page 161 RSV4 RR/RF Electrical system Variable geometry intake Function Extend or shorten the engine intake ducts to in- crease the intake air quantity according to the engine revs. Operation / Operating principle The system consists of: • two intake ducts for each manifold, which may be joined (long ducts) or separated (short ducts);...
Page 162 RSV4 RR/RF Electrical system the filter box next to the rear upper in- jectors. Electrical specifications: Electrical motor resistance. 4.5 +/- 0.5 Ω; PIN 1: 0V normal, Vbatt fault PIN 2: 0V ducts control down, 5V ducts control up. Pin out: 1.
Page 163 RSV4 RR/RF Electrical system • If shorted to positive: if a voltage higher than 5V is detected, disconnect the variable geom- etry control unit connector and check with key ON the voltage to PIN 2: if it is higher than 5 V, restore cable harness;...
Page 164 RSV4 RR/RF Electrical system 1. negative signal 2. positive signal 3. shielding with earth connection DIAGNOSTIC TOOL:PARAMETERS Engine rpm:rpm CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 165 RSV4 RR/RF Electrical system Twistgrip position sensor REMOVAL • Remove the left fairing. • Loosen the two throttle cable nuts. • Unscrew and remove the three plate fixing screws. • Remove the throttle cables. • Unscrew and remove the nut and the stud bolt.
Page 166 RSV4 RR/RF Electrical system Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit.
Page 167 RSV4 RR/RF Electrical system • C: Track C signal • D: Track D supply • E: Track D ground • F: Track D signal DIAGNOSIS INSTRUMENT: PARAMETERS Blue lower connector throttle grip position sensor - track A • Example value with key ON: 1107 mV •...
Page 168 RSV4 RR/RF Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Blue lower connector throttle grip position sensor - track A P0150 •...
Page 169 RSV4 RR/RF Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
Page 170 RSV4 RR/RF Electrical system cated by the diagnosis instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 171 RSV4 RR/RF Electrical system • incongruent signal Error cause • The value of the lower side sensor (tracks A-B) does not coincide with the value of the upper side sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor DIAGNOSIS INSTRUMENT: ADJUSTABLE PARAMETERS...
Page 172 RSV4 RR/RF Electrical system Electrical specifications: - Pin out: 1. Power supply 5V 2. Ground connection 3. Output signal DIAGNOSIS INSTRUMENT: PARAMETERS Front Cylinder Intake Pressure (2 and 4) • Example value with key ON: 1003 mbar • Example value with engine on: 720 mbar •...
Page 173 RSV4 RR/RF Electrical system • If shorted to positive: see that the parameter of the rear cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 174 RSV4 RR/RF Electrical system • signal not valid. Error cause • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted.
Page 175 RSV4 RR/RF Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, the pipe between sensor and throttle body is squashed or there is a hole in the intake manifold).
Page 176 RSV4 RR/RF Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Pressure too low at front cylinder manifold error P0218 •...
Page 177 RSV4 RR/RF Electrical system 2. B2 green/black: Ground connection DIAGNOSIS INSTRUMENT: PARAMETERS Engine temperature: • Example value with key ON: 25° C • Example value with engine on: 75° C • In case of recovery, this value is set by the control unit: if there is a malfunction after engine start-up, temperature decreases up to approximately 75°.
Page 178 RSV4 RR/RF Electrical system between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced.
Page 179 RSV4 RR/RF Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion Operation / operating principle...
Page 180 RSV4 RR/RF Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 181 RSV4 RR/RF Electrical system Lambda sensor (FRONT CYLINDER BANK) Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 182 RSV4 RR/RF Electrical system read by the control unit, but a recovery value is displayed Lambda correction • Example value with key ON: 0 % • Example value with engine on: -10% / +10% In closed loop, the value must be close to 1.00 (values not within the -15% / +15% interval indi- cate a fault).
Page 183 RSV4 RR/RF Electrical system • shorted to positive Error cause • Excessive voltage (battery voltage) has been detected at PIN 9 and 38 of the ENGINE connector. Caution: the 'lambda probe' parameter is not the real value that is read; a re- covery value is displayed instead.
Page 184 RSV4 RR/RF Electrical system injection relay (No. 33 in the electrical circuit diagram, placed under the saddle next to the battery positive, CHECK, however, the identification of the relay with the colour of the ca- bles). If there are also coil, lower and upper injector and secondary air errors, check the relay and its excitation and power line;...
Page 185 RSV4 RR/RF Electrical system Electrical specifications • Heater circuit: 7-9Ω at ambient temp. Pin out: 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground connection (white cable) 4. Heater power supply (white cable) DIAGNOSTIC TOOL:PARAMETERS Lambda probe •...
Page 186 RSV4 RR/RF Electrical system Lambda probe: Start-up_Lean_Rich_Fault due to rich value_Fault due to lean value • If the probe connector is removed (voltage almost equal to zero), the status is Fault due to lean value Lambda check: Open loop/Closed loop/Rich in closed loop/Lean in closed loop/enriched •...
Page 187 RSV4 RR/RF Electrical system • If circuit is open, shorted to negative: check circuit continuity from probe connector (PIN 3 and 4) toward the probe: if it is not OK, replace the probe; if it is OK, check the sensor connector and the Marelli control unit connector: if it is not OK, restore;...
Page 188 RSV4 RR/RF Electrical system Injector Lower injectors key: • 1. Lower Injector 1 • 2. Lower Injector 3 • 3. Lower Injector 2 • 4. Lower Injector 4 LOWER INJECTOR Function Provide the correct amount of fuel at the correct time.
Page 189 RSV4 RR/RF Electrical system Cylinder injection time 1 • Example value with engine on: 1.9 ms Cylinder injection time 2 • Example value with engine on: 1.9 ms Cylinder injection time 3 • Example value with engine on: 1.9 ms Cylinder injection time 4 •...
Page 190 RSV4 RR/RF Electrical system for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. Electrical continuity is required in the wiring for the relay to activate...
Page 191 RSV4 RR/RF Electrical system and the Marelli control unit connector: if not OK, restore. If OK, check cable continuity be- tween the ENGINE PIN 46 and component PIN - and restore the cable harness Lower injector cylinder 3 P0203 •...
Page 192 RSV4 RR/RF Electrical system Upper injectors key: • 5. Upper Injector 1 • 6. Upper Injector 3 • 7. Upper Injector 2 • 8. Upper Injector 4 UPPER INJECTOR Function Provide the correct amount of fuel at the correct time. The lower injectors work in the field of low engine revs, the upper injectors in the field of high engine revs.
Page 193 RSV4 RR/RF Electrical system DIAGNOSTIC TOOL: ACTIVATIONS Lower injector cylinder 1 • The injection relay (No. 33 in the electrical circuit diagram, placed under saddle, right side; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second.
Page 194 RSV4 RR/RF Electrical system • If shorted to positive: disconnect the injector connector, set key to ON, activate the compo- nent with the diagnostic tool and check the voltage on the orange/red cable on the injector connector (if there is voltage): if there is voltage, restore the filter box cable harness. If there is no voltage, replace the sensor •...
Page 195 RSV4 RR/RF Electrical system connector (if there is voltage): if there is voltage, restore the filter box cable harness. If there is no voltage, replace the sensor • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness.
Page 196 RSV4 RR/RF Electrical system Low fuel: it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol. Level in electrical circuit diagram: Injection load relay Location: • on the vehicle: on the tank.
Page 197 RSV4 RR/RF Electrical system • If shorted to positive: excessive voltage has been detected at PIN 73 of the VEHICLE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 73 of the VEHICLE connector.
Page 198 RSV4 RR/RF Electrical system 1. Power supply + Vbatt 2. Secondary circuit to ground 3. Activation from control unit DIAGNOSTICS INSTRUMENT: PARAMETERS Example value with key ON: Current ignition ad- vance Example value with engine on: Indicates the cyl- inder advance where combustion will take place.
Page 199 RSV4 RR/RF Electrical system Coil 1 P0351 • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 28 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 28 of the ENGINE connector.
Page 200 RSV4 RR/RF Electrical system • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 2 of the ENGINE connector.
Page 201 RSV4 RR/RF Electrical system Level in electrical circuit diagram: Throttle check and handle grip sensor (Demand) Location: • on the vehicle: inside the filter box • connector: on the throttle body, in lower position, near the throttle motors Pin out: 1.
Page 202 RSV4 RR/RF Electrical system is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low (around 5-7°) Front throttle Potentiometer 1 (voltage) • Example value with key ON: 873 mV • Example value with engine on: 561 mV Rear throttle Potentiometer 1 (voltage) •...
Page 203 RSV4 RR/RF Electrical system Front cylinders throttle Limp Home position • Example value with key ON: 878 mV Voltage stored in the control unit corresponding to the Limp home position Rear cylinders throttle Limp Home position • Example value with key ON: 888 mV...
Page 204 RSV4 RR/RF Electrical system • Performed/Not performed Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed one time, it will always remain performed unless a control unit EEPROM reset is carried out DIAGNOSTIC TOOL: ELECTRICAL ERRORS...
Page 205 RSV4 RR/RF Electrical system there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 206 RSV4 RR/RF Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 207 RSV4 RR/RF Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 208 RSV4 RR/RF Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 209 RSV4 RR/RF Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 210 RSV4 RR/RF Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 211 RSV4 RR/RF Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 212 RSV4 RR/RF Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 213 RSV4 RR/RF Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 214 RSV4 RR/RF Electrical system • connector: between the head cover and the left side of the filter casing (3 pin white connector). Electrical specifications: PIN 64: neutral indication: closed circuit (continu- ity); gear engaged: open circuit (infinite resist- ance). Gear circuit resistance: 1st gear\: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th gear...
Page 215 RSV4 RR/RF Electrical system to approx. 5V, replace the sensor (there is a short circuit to ground of the pink/black cable in the section between the sensor connector and the sensor or inside the sensor itself). Clutch lever sensor Function It tells the clutch lever position to the control unit.
Page 216 RSV4 RR/RF Electrical system • indication on the diagnostics instrument always Pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace sensor; if the circuit is open, it means that there is short circuit to ground...
Page 217 RSV4 RR/RF Electrical system • indication on the diagnostics instrument always down: check the connector: if not OK, re- store; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor •...
Page 218 RSV4 RR/RF Electrical system Fall sensor: Normal / Tip over • Indication on diagnostics instrument always Normal, even when the sensor is inverted: dis- connect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor; if there is continuity, check the connector: if not OK, restore cable harness;...
Page 219 RSV4 RR/RF Electrical system • on/off DIAGNOSTIC TOOL:ACTIVATIONS • The fan relay (No. 36 in the electrical circuit diagram, placed in the head- stock niche, left side; CHECK, howev- er, the identification of the relay with the colour of the cables) is energised for 10 seconds.
Page 220 RSV4 RR/RF Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / Operating principle The valve coil is excited to open the air passage of the filter box to the exhaust manifold...
Page 221 RSV4 RR/RF Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
Page 222 RSV4 RR/RF Electrical system RUN / STOP switch • Run/Stop NOTES • indication on the diagnostics instrument always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - Blue/Green and Yellow/Red: If there is not continuity, replace the sensor;...
Page 223 RSV4 RR/RF Electrical system The system consists of a throttle valve with a re- turn spring placed on the exhaust pipe. The valve is closed via two cables actuated by an electric motor, which, in turn, is connected electrically to the instrument panel.
Page 224 RSV4 RR/RF Electrical system Exhaust butterfly valve • Indefinite/in research/activation with key ON/ in operation/stopped for detected malfunction/ research of zero position. NOTE: If there is no problem, it appears: in operation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Exhaust butterfly valve stop research P0191 •...
Page 225 RSV4 RR/RF Electrical system • open circuit, thermal overload protection, shorted to negative, shorted to positive or short circuit between both cables. Error cause • If the circuit is open: too low current has been detected at PIN 36 - 37 of the instrument panel connector.
Page 226 RSV4 RR/RF Electrical system connector and if there is voltage, restore cable harness; if there is not voltage, replace in- strument panel, if there is not voltage, replace motor. • If shorted to negative, the circuit is open: check the valve connector and instrument panel connector: if not OK, restore;...
Page 227 RSV4 RR/RF Electrical system CAUTION BEFORE CARRYING OUT THIS OPERATION, CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12.5 V CAUTION WORK ON THE MOTOR OF THE EXHAUST THROTTLE VALVE ONLY WITH THE KEY SET TO "OFF" OR ONLY AFTER DISCONNECTING THE NEGATIVE POLE OF THE BATTERY.
Page 228 RSV4 RR/RF Electrical system • After having pressed the enter button for the zero position search, shut off the vehicle and leave the keys in OFF, even in the event that the instruments indicate the opposite. • With the appropriate adjuster screw, tension the upper cable to leave ap- proximately 1.8 mm (0.07 in) between...
Page 229 RSV4 RR/RF Electrical system Quick shift Function: To signal to the control unit the request for power- assisted gear shifting. Operation / Operating principle: Normally open switch that is closed to ground when the gearbox lever is activated (only when shifting up).
Page 230 RSV4 RR/RF Electrical system PIN 1 - Marelli ECU PIN 47): if OK, check pink cable and black cable insulation; if NOT OK, restore cable harness; if pink/black cable insulation is OK, replace the Marelli control unit; if NOT OK, restore cable harness.
Page 231 RSV4 RR/RF Electrical system "+" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error. "-" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS "+" button sensor P0720: •...
Page 232 RSV4 RR/RF Electrical system • Open contacts/Closed contacts Error cause: With open contacts, a voltage over zero is detected at the same time at PIN 18 and PIN 19 of the instrument panel. With closed contacts, zero voltage is detected at the same time at PIN 18 and PIN 19 of the instrument panel.
Page 233 RSV4 RR/RF Electrical system Inertial sensor platform (sensor box) Function: To transmit information about the motorcycle dy- namics to the Marelli control unit (e.g.: yaw rate). Electrical circuit diagram - Level in electrical circuit diagram: Traction control. Position on vehicle: Fastened to the fuel tank, under the seat.
Page 234 RSV4 RR/RF Electrical system Sensor box error (inertia sensor platform) P0713 • Faulty sensor/Signal not valid Troubleshooting: With faulty sensor, the component inside the control unit is damaged and replacement of the control unit is recommended. With signal not valid, the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error.
Page 235 RSV4 RR/RF Electrical system Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6/17 Lower cylinder 1 injector control output PIN 8 Front cylinder bank lambda sensor input 2 (+) PIN9 Rear cylinder bank lambda sensor input 1 (+) PIN 10 Track D hand grip input PIN 11 Water temp.
Page 236 RSV4 RR/RF Electrical system Front cylinder intake pressure sensor input PIN 49 Input for rear throttle potentiometer 2 signal PIN 50 Direct power supply to control unit PIN 52 Vehicle pinout key: Upper cylinder 1 injector control output PIN 53...
Page 237 RSV4 RR/RF Electrical system Upper cylinder 2 injector control output PIN 67 Upper cylinder 4 injector control output PIN 68 Start-up control output PIN 69 Side stand input PIN 70 Gear input PIN 72 Injection relay control output PIN 73...
Page 238 RSV4 RR/RF Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 238...
Page 239 RSV4 RR/RF Electrical system 4 High beam lights input 5 Normally open button "1" 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control 13 Normally closed button "+"...
Page 240 RSV4 RR/RF Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1...
Page 241 RSV4 RR/RF Electrical system Rear speed sensor input PIN 14 ABS warning light PIN 17 Battery for pump engine positive PIN 18 Can line Function It allows communication between the Marelli injection ECU and the instrument panel. Operation / operating principle...
Page 242 RSV4 RR/RF Electrical system CAN Line Electrical specifications: • between PIN 66 and 80 of the control unit: approx. 130 Ohm • between PIN 26 and 27 of the instrument panel: approx. 120 Ohm Pin out: • Line L: white/black cable between Marelli control unit PIN 66 and the black-bodied connector PIN 27 of the instrument panel.
Page 243 RSV4 RR/RF Electrical system • no signal. Error cause • No signal is received from the instrument panel. Troubleshooting • Check the connector of the instrument panel: if not OK, restore; if OK, check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness;...
Page 244 RSV4 RR/RF Electrical system the vehicle cable harness; if OK, check the continuity across instrument panel pin 27 and ABS control unit connector pin 11. If NOT OK, replace the cable harness; if OK, check for the correct power supply (12V) at pins 1 and 11 and ground at pins 38,39, 40 of the instru- ment panel connector.
Page 245 (Sensor box), the correct status we should find on the diagnostics instrument devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a vehicle equipped with inertia sensor platform (Sensor...
Page 246 RSV4 RR/RF Electrical system • CAN error during acquisition/Invalid value. Error cause • In case of CAN error during acquisition, system warns that the procedure can not be com- pleted due to a communication problem on the CAN line. In case of invalid value, it means that on key-ON an error of transcription occurred - from the non-volatile memory (EEPROM) to the volatile one (RAM) - of the value concerning the rear wheel radius.
Page 247 RSV4 RR/RF Electrical system • Disconnect the USB wiring connector (3) from the connector of the wiring harness on the vehicle (4) • Remove the fixing screw (6) of the sup- port bracket (7) paying attention to re- cover the elastic washer (8) •...
Page 248 RSV4 RR/RF Electrical system • Move the instrument panel to the right, so as to remove it from its seat. • Once released, move the instrument panel without disconnecting the con- nectors from it, so as to be able to easy access the wiring harness connector on the vehicle.
Page 249 RSV4 RR/RF Electrical system • Connect the vehicle wiring harness connector (7) to the USB wiring har- ness connector (8) and place it care- fully inside the instrumentation support compartment • Fix the USB supporting clamp (3) to the headlamp with the screw (9) provided with the...
Page 250 RSV4 RR/RF Electrical system • Undo and remove the fixing screws (3) and remove side fairing from the vehi- • Remove the nylon clamp (4) blocking the wiring harness of the control unit to the vehicle wiring harness • Repeat the test using the resistance...
Page 251 RSV4 RR/RF Electrical system • Disconnect the engine control unit wir- ing connector (6) from the connector (7) of the wiring harness on the vehicle • Remove the two elastic washers (8) and remove the control unit (9) paying attention to recover the four rubber...
Page 252 RSV4 RR/RF Electrical system • Apply the foam adhesive rubber (4) on the lower part of the control unit V4-MP • Place two flat rubber washers (6), sup- plied in the kit, on the control unit fixing pins (7) located on the inside of the side fairing.
Page 253 RSV4 RR/RF Electrical system • Connect the engine control unit wiring connector (11) to the connector (12) of the wiring harness on the vehicle. • Approach the side fairing complete with the control unit to the vehicle, con- nect the wiring harness (10) to the con- trol unit V4-MP using the connector.
Page 254 RSV4 RR/RF Electrical system • Turn the ignition switch of the motor- cycle ON with the PMP ECU correctly connected. • Open the App settings clicking on the icon • In the page settings click on the "Blue- Tooth" menu •...
Page 255 RSV4 RR/RF Electrical system • Turn the ignition switch of the motor- cycle ON with the PMP ECU correctly connected. • Open the App's "settings" by clicking on the icon. NOTE THE ICON CAN VARY FROM ONE TO ANOTHER ANDROID VERSION •...
Page 256 RSV4 RR/RF Electrical system Once the connection is established you can start the application by selecting the corresponding icon By turning off the instrument panel (key OFF) the application automatically closes CAUTION TO MAINTAIN A SUCCESSFUL CONNECTION IT IS ESSENTIAL THAT THE KEY SWITCH IS IN THE "ON"...
Page 257 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 258 RSV4 RR/RF Engine from vehicle EAR LEVER pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.90 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk, flat head, hex. socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 259 RSV4 RR/RF Engine from vehicle Removing the engine from the vehicle • Remove the spacer (1) and the nut (2) fixing the ride by wire support • Disconnect the ride by wire connectors • Move the clamps (4) and disconnect the water pipe with the connector from the engine in order to empty the system •...
Page 260 RSV4 RR/RF Engine from vehicle • Disconnect the connectors (6) of the electric fans • Use a container of suitable capacity, remove the clamp (7) and disconnect the oil connection pipe • Remove the clamp (8) fixing the oil pressure bulb wiring and exhaust valve to the water pipe •...
Page 261 RSV4 RR/RF Engine from vehicle • Remove the radiators by sliding them off from the right side of the motorcycle • Loosen the screw (11) and ease off the gear lever • Remove the three fixing screws (12) of the pinion cover (13)
Page 262 RSV4 RR/RF Engine from vehicle • Remove the fixing screw (14) of the ca- ble grommet (15) • Remove the fixing screw (16) and slide off the chain slider (17) • Remove the fixing screw (18) of the chain guide plate (19) •...
Page 263 RSV4 RR/RF Engine from vehicle • Disconnect the connector (21) of the quick-shift and release the wiring • Remove the two fixing screws (22) of the footrest complete with leverage • Disconnect the connector (23) of the side stand sensor and release the wir- •...
Page 264 RSV4 RR/RF Engine from vehicle • Disconnect the connectors of the lamb- da probes (25) • Loosen the nut (26) of the rear wheel • Working from both sides of the motor- cycle, loosen the locknuts (27) and act on the register screws (28) to loose the chain tension •...
Page 265 RSV4 RR/RF Engine from vehicle • Detach and remove the springs (29) fixing the front exhaust manifolds • Remove the four screws (30) fixing the manifolds to the front heads • Remove the two front manifolds (31) • Loose the clamp (32) that blocks the...
Page 266 RSV4 RR/RF Engine from vehicle • Remove the screw (33) and the nut locking the silencer at the rider footrest • Slide off the central manifold and re- move the silencer • Remove the fixing clamp (34) of the exhaust valve wiring •...
Page 267 RSV4 RR/RF Engine from vehicle • Disconnect the connector (35) of the exhaust valve • Remove the fixing screws (36) of the exhaust valve • Detach and remove the springs (37) fixing the rear exhaust manifolds • Remove the central exhaust manifold...
Page 268 RSV4 RR/RF Engine from vehicle • Remove the four fixing screws (39) of the rear exhaust manifolds • Remove the rear exhaust manifolds (40) • Detach the clutch cable (41), remove the nut (42) and take the cable com- plete with sheath (43) off from the guide in the housing •...
Page 269 RSV4 RR/RF Engine from vehicle • Remove the engine oil pressure sen- sor (46) • Undo and remove the screw (47) and release the ground cables • Detach the ground cable and unscrew and remove the nut (48) • Disconnect the engine wiring connec-...
Page 270 RSV4 RR/RF Engine from vehicle • Remove the clamp (50) that locks the main wiring at the ABS system pipes • Remove the screws (51) to remove the ABS protection plate • Remove the protection plate (52) of the ABS system •...
Page 271 RSV4 RR/RF Engine from vehicle • Completely unscrew the internal upper bush (54) • Remove the lower screw (55) fixing the engine to the chassis • Completely unscrew the internal lower bush (56) Installing the engine to the vehicle •...
Page 272 RSV4 RR/RF Engine from vehicle The hole position relative to the centreline of the insert is e=-5 mm (e= -0.197 in), therefore, the engine is fixed at minimum height possible. CAUTION THE LEFT AND RIGHT FRONT INSERTS ARE EQUAL AND MUST NOT BE PLACED IN THE IN- VERTED POSITION.
Page 273 RSV4 RR/RF Engine from vehicle • Working from the vehicle left side, in- stall the left upper engine attachment, tightening the three screws. • With the help of a second operator, secure the vehicle chassis with a hoist and onto a front and rear stand and lift the engine to place it in position.
Page 274 RSV4 RR/RF Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: •...
Page 275 RSV4 RR/RF Engine from vehicle • Refit the clamps on the saddle mount- ing. • Place the radiator frame, the washer and tighten the screw, fastening the frame to the engine. • Place the gear lever and tighten the screw.
Page 276 RSV4 RR/RF Engine from vehicle • Connect the quick-shift connector. • Connect the alternator connector. • Connect the voltage regulator connec- tor. • Position and fix the hand grip position sensor to the chassis. WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS.
Page 277 RSV4 RR/RF Engine from vehicle • Connect the neutral sensor. • Place the two fuel breather pipes. • Install the side stand. • Place the pinion and insert the trans- mission chain in the seat. • Tighten the rear wheel fixing nut.
Page 278 RSV4 RR/RF Engine from vehicle • Place the two washers and tighten the pinion fixing screw. • Place the pinion cover and tighten the three screws. • Connect the vehicle cable harness / engine cable harness connector. • Working on the right side of the vehicle, connect the exhaust valve control unit connector.
Page 279 RSV4 RR/RF Engine from vehicle • Place the ground on the frame. • Fit the washer and tighten the nut. • Place the cable grommet and the three cable leads as shown. • Tighten the cable grommet fixing screw. •...
Page 280 RSV4 RR/RF Engine from vehicle • Connect the timing sensor. • Connect the clutch cable. • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in).
Page 281 INDEX OF TOPICS NGINE...
Page 282 RSV4 RR/RF Engine key: 1. rear left cylinder; 2. front left cylinder; 3. rear right cylinder; 4. front right cylinder. Combustion sequence: 1 - 3 - 2 - 4 Combustion angle: cyl 1: 0° cyl 2: 180° cyl 3: 425°...
Page 283 RSV4 RR/RF Engine Gearbox Diagram EARBOX pos. Description Type Quantity Torque Notes Star fastening screw M6x20 10 Nm (7.38 lb ft) Loct. 243 Bearing retaining plate fastening M6x16 10 Nm (7.38 lb ft) Loct. 243 screw Flange fastening screws M8x25 25 Nm (18.44 lb ft)
Page 284 RSV4 RR/RF Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw. • Unscrew and remove the six screws.
Page 285 RSV4 RR/RF Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 286 RSV4 RR/RF Engine GEAR REMOVAL • Position the gear in neutral, checking that when the primary shaft rotates the secondary shaft does not move. • Remove the gearbox unit. • Slide off the gearbox primary shaft con- trol rod (1) •...
Page 287 RSV4 RR/RF Engine • Remove the forks (4) of the gearbox secondary shaft • Remove both gearbox shafts from the cover • Remove the shim washer (5) that is lo- cated on the secondary shaft between the shaft and the cover •...
Page 288 RSV4 RR/RF Engine • Remove the desmodromic shaft (7) • Remove the selector drum (8) DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE, ALTERNATOR SIDE • Remove the lower crankcase. • A suitable extractor must be used to remove the desmodromic gearbox control rod drum roller cage from the alternator side.
Page 289 RSV4 RR/RF Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in)
Page 290 RSV4 RR/RF Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.05 mm (0.0020 in) Minimum wear limit of the selection fork guide pins 6.8 mm (0.27 in)
Page 291 RSV4 RR/RF Engine • Position and tighten the screw (3) fixing the drum to the desmodromic shaft CAUTION SECURE THE SHIM WASHER (4) TO THE SECONDARY SHAFT WITH GREASE • Move the gearbox shafts together and fit them into the support •...
Page 292 RSV4 RR/RF Engine • Insert the forks (5) in the specific seats of the gearbox secondary shaft • Insert the gearbox secondary shaft control rod (6) checking the presence of the springs • Insert the fork (7) in the specific seat of the gearbox primary shaft •...
Page 293 RSV4 RR/RF Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for gearbox secondary shaft •...
Page 294 RSV4 RR/RF Engine Removing the gear selector • Drain the engine oil. • Remove the clutch cover. • Working from the clutch side, remove the selector control shaft. • Remove the gear locking pawl and re- trieve the washer and the spring.
Page 295 RSV4 RR/RF Engine • Remove the gearbox control rod spacer. • Remove the oil seal and the roller cage. • Install a new gearbox control rod roller cage on the spacer, using the specific tool without an adaptor. Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod....
Page 296 RSV4 RR/RF Engine Starter motor Removing the starter motor • Undo the fixing screws (1) of the starter motor, collecting the spacers (2) • Remove the starter motor (3) from its housing. Removing the idle gear • Remove the clutch cover.
Page 297 RSV4 RR/RF Engine Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed. If deformations or broken material are found on the sliding surface, replace the freewheel gear (2).
Page 298 RSV4 RR/RF Engine 2. External transmission gear 64 teeth; 3. Internal transmission gear 12 teeth; 4. Freewheel 49 teeth. • Fit the intermediate gear. • Fit the clutch cover. Generator side LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lb ft)
Page 299 RSV4 RR/RF Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 300 RSV4 RR/RF Engine Inspecting the cover components • Unscrew and remove the three Blow- by system fitting screws. • Remove the Blow-by system fitting. • Replace the O-ring with a new one of the same type • Remove the flywheel cover.
Page 301 RSV4 RR/RF Engine Installing the flywheel • Position the flywheel on the crankshaft. • Block flywheel rotation using the spe- cific tool. • Tighten the screw. Specific tooling 020914Y Flywheel retainer Flywheel cover installation • Insert the centring dowels in the cover.
Page 302 RSV4 RR/RF Engine Clutch side LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.90 lb ft) TE Flanged screw M6x20 10 Nm (7.38 lb ft) TE Flanged screw M6x35 12 Nm (8.85 lb ft)
Page 303 RSV4 RR/RF Engine Disassembling the clutch • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. • Remove the clutch cover. • Unscrew and remove the six screws by loosening them 1/4 of a turn at a time;...
Page 304 RSV4 RR/RF Engine • Remove the slipper unit. • Remove the clutch hub. • Remove the clutch hub cam tower. • Retrieve the shim. ENG - 304...
Page 305 RSV4 RR/RF Engine • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. • Remove the spacer. ENG - 305...
Page 306 RSV4 RR/RF Engine • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in)
Page 307 RSV4 RR/RF Engine Check the primary driven gear for damage and wear and, if necessary, replace the primary driven gear and the clutch bell all together. Make sure there is not excessive noise during op- eration; if necessary, replace the primary drive gear and the clutch bell all together.
Page 308 RSV4 RR/RF Engine • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded; if necessary, replace the springs all together. Characteristic Minimum wear limit in the release position of the individual clutch springs 46.8 mm (1.84 in)
Page 309 RSV4 RR/RF Engine • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion • Fit the shim washer.
Page 310 RSV4 RR/RF Engine • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • Fit the three slipper unit clips, offsetting them between each other; • Install the slipper unit correctly.
Page 311 RSV4 RR/RF Engine • Insert the disc with friction material and the black tooth into the bell. • Insert one of the metal discs into the bell. • Insert the flat washer. • Insert the belleville spring with the con- cave side facing outward.
Page 312 RSV4 RR/RF Engine • Insert the disc covered with the friction material into the bell. • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 313 RSV4 RR/RF Engine • Place the thrust plate. • Fit the clutch springs (3). • Insert the spring holder cap (2) onto the screws (1). • Tighten the six screws operating in stages and diagonally. Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING •...
Page 314 RSV4 RR/RF Engine • Warm up the cover. • Using a generic extractor, it is then possible to remove the bushing from the cover. INSTALLING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the installation of the bushing, it is necessary to warm up the cover.
Page 315 RSV4 RR/RF Engine • Screw the sixteen perimetric fixing screws with the washers. • Tighten the screws working in stages and diagonally. • Add engine oil up to the correct level. Heads ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.38 lb ft)
Page 316 RSV4 RR/RF Engine EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft) Reed valve covers fixing screws 6 Nm (4.43 lb ft) Water outlet coupling fixing screw 10 Nm (7.38 lb ft)
Page 317 RSV4 RR/RF Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Shoe fastening screws 20 Nm (14.75 lb ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.38 lb ft)
Page 318 RSV4 RR/RF Engine • Remove the head cover together with the sealing gasket INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure. Recommended products Three bond Sealing paste •...
Page 319 RSV4 RR/RF Engine Removing camshafts • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft. • Remove the O ring. See also Head cover removal Removing the flywheel cover •...
Page 320 RSV4 RR/RF Engine • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 321 RSV4 RR/RF Engine ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1).
Page 322 RSV4 RR/RF Engine • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 323 RSV4 RR/RF Engine Check the timing chain for damage or stiffness while moving. If necessary, replace the timing chain together with the camshaft gears. Check the timing chain guide sliders for damage. If necessary, replace the parts. Installing camshafts NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY.
Page 324 RSV4 RR/RF Engine • Move the gear from the mounting tool to the camshaft. • Unscrew and remove the two screws (1). • Remove the tool. Specific tooling 020956Y Support for camshaft gear on head • Fit the U bolt and the oil pipe •...
Page 325 RSV4 RR/RF Engine • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 326 RSV4 RR/RF Engine • If this is not the case, repeat the timing operations. Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Front head removal • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft.
Page 327 RSV4 RR/RF Engine • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. • Block crankshaft rotation using one of the specific tools.
Page 328 RSV4 RR/RF Engine • Slide and remove the gear from the in- take camshaft • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes.
Page 329 RSV4 RR/RF Engine • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1.
Page 330 RSV4 RR/RF Engine Front head check Check that: • The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal. • Check the status of the valve seats. • Check that the routing of the oil pipes is free and if required, clean them by blowing a jet of compressed air.
Page 331 RSV4 RR/RF Engine • Insert the chain tensioner into the crankcase, being careful to position it correctly. THE WASHER SHALL ONLY BE INSTALLED ON THE FRONT CHAIN TENSIONER WASHER • We recommend installing a washer be- tween the front crankcase and the chain tensioner to optimise the func- tionality of the timing system.
Page 332 RSV4 RR/RF Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order.
Page 333 RSV4 RR/RF Engine • Install both chain sliders and fasten them with the specific screws. • Rotate the crankshaft via the opening on the clutch cover. • Position cylinder 1 piston (LH, rear pis- ton) so that it is at the point where it crosses TDC.
Page 334 RSV4 RR/RF Engine NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 335 RSV4 RR/RF Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin.
Page 336 RSV4 RR/RF Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer •...
Page 337 RSV4 RR/RF Engine Removing camshafts • Remove the rear head cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC; • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel).
Page 338 RSV4 RR/RF Engine • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en-...
Page 339 RSV4 RR/RF Engine • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer •...
Page 340 RSV4 RR/RF Engine • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES • Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
Page 341 RSV4 RR/RF Engine • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally.
Page 342 RSV4 RR/RF Engine • Align the intake camshaft with the spe- cific hole on the U bolt. • Insert the specified pin. Specific tooling 020851Y Camshaft timing pin • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 343 RSV4 RR/RF Engine screw. This screw must be replaced at each reassembly. • Tighten the second camshaft gear fix- ing screw to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020851Y Camshaft timing pin...
Page 344 RSV4 RR/RF Engine 020914Y Flywheel retainer See also Head cover removal Removing the clutch cover Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en-...
Page 345 RSV4 RR/RF Engine • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes. • Remove the U bolts with the O rings and locator pins.
Page 346 RSV4 RR/RF Engine • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. • After loosening all nuts, remove them in order indicated above. •...
Page 347 RSV4 RR/RF Engine • The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal. • Check the status of the valve seats. • Check that the routing of the oil pipes is free and if required, clean them by blowing a jet of compressed air.
Page 348 RSV4 RR/RF Engine • Place a new gasket between the crank- case and the head. • Place the two dowel pins. • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6.
Page 349 RSV4 RR/RF Engine • Fit the camshaft gear • Keep the gear in position with the chain tightened THE SIDE WITH THE BEVELLED HOLE IN THE TIMING SYSTEM GEAR MUST ALWAYS FACE THE EXTERIOR OF THE HEAD. • Install both chain sliders and fasten them with the specific screws.
Page 350 RSV4 RR/RF Engine • Check the number engraved on the U bolts, which must correspond with the one engraved on the head. • If the U bolts between the two heads are inverted, camshaft seizure may oc- IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT, IF NECESSARY: REPLACE THE ENTIRE HEAD.
Page 351 RSV4 RR/RF Engine • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 352 RSV4 RR/RF Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 353 RSV4 RR/RF Engine • Extract the bucket tappets • Extract the adjusting shims • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs...
Page 354 RSV4 RR/RF Engine • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING. • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME.
Page 355 RSV4 RR/RF Engine 0.25 mm (0.0098 in) If the valve stem, when measured with a micro- meter, is worn to its limit and the clearance ex- ceeds the specified limit, replace the valve. Recheck the clearance after replacing the valve.
Page 356 RSV4 RR/RF Engine Valve installation The intake valves mount a double spring, while the exhaut valves have only one spring. The old intake valve springs are marked blue and the old exhaust springs are marked green. • Lubricate the valve stem and insert the valves on the valve guide.
Page 357 RSV4 RR/RF Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs •...
Page 358 RSV4 RR/RF Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Stud bolt 20 Nm (14.75 lb ft) Loctite 648 or 270 TE Flanged screw 25 Nm (18.44 lb ft) Lubricate the thread and under the head. TE Flanged screw 10 Nm (7.38 lb ft)
Page 359 RSV4 RR/RF Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lb ft) Loct. 243 RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lb ft) + 130°...
Page 360 RSV4 RR/RF Engine pos. Description Type Quantity Torque Notes con PANKL Lubri- cant 01 (PLB01) Fastener ring nut for alternator side 100 Nm (73.76 lb ft) Loct. 243 timing sprocket Primary fixing ring nut 200 Nm (147.51 lb ft) Loct. 243 Generator fixing screw M12x1.25...
Page 361 RSV4 RR/RF Engine • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. • Remove the key on countershaft ENG - 361...
Page 362 RSV4 RR/RF Engine • Remove the spacer. • Remove the countershaft on the oppo- site side. Balancing countershaft fitting • Install the spacer. THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE. • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear.
Page 363 RSV4 RR/RF Engine • Insert the countershaft from the alter- nator side. • Turn the countershaft until aligning the key seat on the countershaft and on the gear. • Insert the drive key. • Place the washer. • Turn the nut on the countershaft.
Page 364 RSV4 RR/RF Engine • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. See also Disassembling the clutch • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock •...
Page 365 RSV4 RR/RF Engine Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide.
Page 366 RSV4 RR/RF Engine • alternator; • water pump; • gearbox unit; • primary drive shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear; •...
Page 367 RSV4 RR/RF Engine • Turn the engine with the heads facing downward and loosen the screws in the following order: 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7.
Page 368 RSV4 RR/RF Engine Removing connecting rods - pistons • Remove both heads. • Open the crankcases. • Install the tool that keeps the crank- shaft in position. Specific tooling 020857Y Crankshaft support U-bolt See also Front head removal Rear head removal •...
Page 369 RSV4 RR/RF Engine • Slide off the pin • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Crankshaft removal • Separate the crankcases, removing the lower part •...
Page 370 RSV4 RR/RF Engine • Take out the crankshaft. Bearing removal BALANCING COUNTERSHAFT BEARING RE- MOVAL • Remove the lower crankcase. • Remove the countershaft. FLYWHEEL-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302°...
Page 371 RSV4 RR/RF Engine CLUTCH-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302° • Position the general tool to pull out bearings. • Remove the bearing. Crankshaft check...
Page 372 RSV4 RR/RF Engine Connecting rod check Characteristic Maximum wear limit of the connecting rod small end 17.03 mm (0.6705 in) Maximum connecting rod small end radial clearance 0.045 mm (0.0018 in) Maximum radial play between connecting rod and crankpin 0.55 mm (0.022 in) Maximum radial play of crankpin 0.08 mm (0.0031 in)
Page 373 RSV4 RR/RF Engine WITH CLASS SELECTION CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PER- FORMED AT 6 mm (0.24 in) FROM ITS BASE Characteristic Piston diameter Class A: 77.961-77.971 mm (3.0693-3.0697 in). Class B: 77.971-77.981 mm (3.0697-3.0701 in) Maximum clearance between the cylinder and piston 0.1 mm (0.0039 in)
Page 374 RSV4 RR/RF Engine CAUTION IT IS NOT POSSIBLE TO ORDER CERTAIN CONNECTING ROD AND CRANKSHAFTS CLASSES, THEREFORE, IF NECESSARY, REPLACE THE CONNECTING RODS OR CRANKSHAFTS, FOL- LOW THE TABLE BELOW. The permitted crankshaft-connecting rod balancing class combinations are listed in the following table:...
Page 375 RSV4 RR/RF Engine The connecting rod class is stamped on its left side, viewed from the front, from the side with the bevelling on the big end hole. Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings.
Page 376 RSV4 RR/RF Engine RANKCASE CATEGORY Specification Desc./Quantity Class A Bushing seat diameter 52.023 - 52.018 mm (2.0481 - 2.0479 Class B Bushing seat diameter 52.018 - 52.013 mm (2.0479 - 2.0477 Class C Bushing seat diameter 52.013 - 52.008 mm (2.0477 - 2.0475...
Page 377 RSV4 RR/RF Engine The flywheel side and clutch side main bearings are different from the central ones and therefore, so are the respective replacement part numbers. CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available for the connecting rods: •...
Page 378 RSV4 RR/RF Engine • Green For the coupling of the connecting rod with the crankshaft, according to the engraving on the counter- weights, observe the following table: USHINGS THICKNESS Bushing colours Thickness BLUE 1.547 - 1.552 mm YELLOW 1.552 - 1.557 mm GREEN 1.557 - 1.562 mm...
Page 379 RSV4 RR/RF Engine • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020364Y 25 mm adapter 020359Y 42 x 47 mm punch 020376Y Adaptor handle • Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase.
Page 380 RSV4 RR/RF Engine 020359Y 42 x 47 mm punch 020376Y Adaptor handle • Position the new bearings with their groove on the outside diameter facing outward with respect to the crankcase. In this way it will be possible to install the bearing retainer in the groove.
Page 381 RSV4 RR/RF Engine • Lubricate the crankshaft pins and in- sert them into their positions. • Install the connecting rod shank piston assembly in the relative cylinders. • Join the crankcases. • If the special tool was used, remove it to keep the pistons from coming out.
Page 382 RSV4 RR/RF Engine • Insert the tone wheel on the crank- shaft. The crankshaft and the tone wheel have a bevel that identifies the fitting direction. • Tighten the tone wheel fixing screw. • Remove the special tool. Specific tooling...
Page 383 RSV4 RR/RF Engine Pre-assemble the pistons on the workbench with the connecting rod shank and the relative semi- bushing. The pre-assembly procedure is identical for all four pistons and must be done as follows: • with the piston crown parallel to the...
Page 384 RSV4 RR/RF Engine ling on the connecting rod head must face outward of its crank pin. Specific tooling 020856Y Piston assembly ring • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces.
Page 385 RSV4 RR/RF Engine • Insert the maximum pressure valve in the crankcase, composed of two sep- arate parts • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste •...
Page 386 RSV4 RR/RF Engine • Pre-tighten the screws in the following order: 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 - 22 - 23.
Page 387 RSV4 RR/RF Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase Lubrication ENG - 387...
Page 388 RSV4 RR/RF Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque.
Page 389 RSV4 RR/RF Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor.
Page 390 RSV4 RR/RF Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle.
Page 391 RSV4 RR/RF Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat.
Page 392 RSV4 RR/RF Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor.
Page 393 RSV4 RR/RF Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump • Remove the upper gasket • Remove the rose pipe together with the gasket...
Page 394 RSV4 RR/RF Engine • Remove the metal gasket central fixing screw • Remove the metal gasket • Remove the lower gasket • Remove the overpressure valve together with gasket Blow-by The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid.
Page 395 RSV4 RR/RF Engine The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump. SAS valve ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Secondary air solenoid screws 10 Nm (7.38 lb ft)
Page 396 RSV4 RR/RF Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 396...
Page 397 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 398 RSV4 RR/RF Power supply Fuel pump Removing • Remove and empty the fuel tank. • Remove the pipe grommet. • Disconnect the fuel pipe from the fuel pump • Unscrew and remove the six fixing screws of the fuel pump •...
Page 399 RSV4 RR/RF Power supply Injection Diagram key: 1. Control unit position 2. Throttle grip position sensor P SUPP - 399...
Page 400 RSV4 RR/RF Power supply 3. Fall sensor 4. Exhaust valve 5. Clutch position sensor 6. Fuel pump (inside the tank) 7. Air temperature sensor 8. Air pressure sensor (MAP) 9. Lower injectors 10.Upper injectors 11.Coils (spark plug cover) 12.Engine throttle valves 13.Throttle valve position sensor...
Page 401 RSV4 RR/RF Power supply Removing the injector To optimise engine performance, there are four lower injectors on the throttle bodies and four up- per injectors on the filter box. Except during tran- sition stages, only the lower or the upper injectors are working at any given time.
Page 402 RSV4 RR/RF Power supply Removing the throttle body • Completely remove the air filter box. • Disconnect the injector fuel pipe. • Release the snap fit clamp on the col- lars from the engine. NOTE DO NOT RELEASE THE CLAMPS COMPLETELY. LEAVE IN AN INTERMEDIATE POSITION TO FACILITATE REFIT- TING.
Page 403 RSV4 RR/RF Power supply Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction. As all the internal components of the throttle body assembly (potentiometers and electrical motor) are contactless, no electrical diagnosis is possible.
Page 404 RSV4 RR/RF Power supply Variable geometry intake To access the variable geometry intake system, remove the air filter box cover. The system consists of: two intake ducts for each manifold, which may be joined (short ducts) or separated (long ducts)
Page 405 RSV4 RR/RF Power supply The drive voltage delivered to the motor is determined in relation to battery voltage and the motor is stopped once a given current limit is reached or if the time-out period of 500 ms has elapsed.
Page 406 INDEX OF TOPICS SUSP USPENSIONS...
Page 407 RSV4 RR/RF Suspensions Front RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel pin nut M25x1.5 80 Nm (59.00 lb ft) Front brake disk fastening screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 Removing the front wheel •...
Page 408 RSV4 RR/RF Suspensions • Remove the wheel hub fastening nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps. • Tap the wheel axle slightly with a rub- ber mallet so that the hole on the op- posite side is exposed.
Page 409 RSV4 RR/RF Suspensions • Replace both wheel bearings. CHECKING RADIAL AND AXIAL PLAY • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings are not conformant: • Replace both wheel bearings.
Page 410 RSV4 RR/RF Suspensions Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screws for fastening the handlebar 1 + 1 25 Nm (18.44 lb ft) collar to the forks sleeves Handlebar safety screw 10 Nm (7.38 lb ft) Anti-vibration counterweight fastener M18x1.5...
Page 411 RSV4 RR/RF Suspensions LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lb ft) Front fork (OHLINS FORKS) SUSP - 411...
Page 412 RSV4 RR/RF Suspensions RONT FORK HLINS pos. Description Type Quantity Torque Notes Fork feet hub fastening screws (Oh- 2 + 2 12 Nm (8.85 lb ft) lins) Speed sensor fastening screw 6 Nm (4.43 lb ft) Speed sensor bracket screws 8 Nm (5.90 lb ft)
Page 413 RSV4 RR/RF Suspensions FIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. IT IS STRICTLY FORBIDDEN TO RIDE A VEHICLE SET FOR RACING ON ROADS AND MOTORWAYS. TO COUNT THE NUMBER OF RELEASES AND/OR REVO- LUTIONS OF ADJUSTMENT SETTINGS (1 - 2) ALWAYS START FROM THE MOST RIGID SETTING (WHOLE CLOCKWISE ROTATION OF THE SETTING).
Page 414 RSV4 RR/RF Suspensions (*)= Clockwise (**)= Anticlockwise (***)= This type of adjustment must only be carried out by an Official aprilia Dealer CAUTION TO COUNT THE NUMBER OF CLICKS AND/OR TURNS FOR ADJUSTER SCREWS (1 -2) ALWAYS START FROM THE STIFFEST SETTING (ADJUSTER SCREW TURNED FULLY CLOCKWISE).
Page 415 RSV4 RR/RF Suspensions • Fix the fork in a vice, taking care not to damage the fork. • Set the minimum spring preloading. • Unscrew the upper cap from the sleeve using a specific Öhlins tool. • Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring.
Page 416 RSV4 RR/RF Suspensions • Unscrew the nut and remove it, exert- ing slight pressure on the pre-loading spring. • Remove the pre-loading spring retain- ing ring. • Remove the pre-loading spring. • Drain the fork oil into a specific con-...
Page 417 RSV4 RR/RF Suspensions • Using the appropriate tool fasten the fork in the vice. Specific tooling AP8140149 Protection for assembly opera- tions • Operating on the upper screw, unload the spring. • Loosen the cover without unscrewing it completely. •...
Page 418 RSV4 RR/RF Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring. • Insert a spanner in the lock nut of the cover. Specific tooling 020888Y Clamp for pre-load pipe • Unscrew the cap and remove it.
Page 419 RSV4 RR/RF Suspensions • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 420 RSV4 RR/RF Suspensions • Use a plain slot screwdriver to lift up the dust gaiter (3) in multiple points and re- move from the sleeve (2). • Use a plain slot screwdriver to remove the snap ring (4). • Use a plain slot screwdriver to remove the oil seal (5).
Page 421 RSV4 RR/RF Suspensions • Use the Öhlins tool to unscrew the pumping member pin fixing ring nut. • Remove the pumping member pin unit. • Remove the spring guide snap ring (1) • Remove the spring guide support ring •...
Page 422 RSV4 RR/RF Suspensions • Remove the rubber O ring. • Remove the guide bushing and the counterspring. (PROCEDURE FOR SACHS FORKS) • Discharge the fork, remove the internal dipstick of the pumping member pin (1) and the washer (2). •...
Page 423 RSV4 RR/RF Suspensions • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem.
Page 424 RSV4 RR/RF Suspensions • Remove the pumping member pin. Checking the components (PROCEDURE FOR OHLINS FORKS) Stem Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1). If the scratches are deep, replace the stem.
Page 425 RSV4 RR/RF Suspensions Check the condition of the following components: • slider bushing; • guide bushing; • plunger. If there is evidence of excessive wear or damage, replace the component concerned. CAUTION REMOVE ANY IMPURITIES FROM THE BUSHINGS, BEING CAREFUL NOT TO SCRATCH THEIR SURFACES.
Page 426 RSV4 RR/RF Suspensions A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK- ENED MAKING THE VEHICLE DANGEROUS TO USE. Characteristic Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it.
Page 427 RSV4 RR/RF Suspensions Replace the following components with new ones: • seal ring; • dust gaiter; • O-Ring on the cap. Reassembling the fork (PROCEDURE FOR OHLINS FORKS) • Insert the guide bushing and the coun- terspring. SUSP - 427...
Page 428 RSV4 RR/RF Suspensions • Insert the rubber O ring. • Insert the ring nut, on which the threa- ded pipe is attached, on the pumping member pin. • Insert the rubber buffer (6). • Insert the spring guide support ring (5),...
Page 429 RSV4 RR/RF Suspensions • Insert the pumping member pin unit. • Use the Öhlins tool to tighten the pumping member pin fixing ring nut to 40 Nm (29.50 lbf ft). • Install the following components on the wheel holder stanchion (1) in the order given: dust gaiter (3), retainer ring (4) and oil seal (5).
Page 430 RSV4 RR/RF Suspensions • Insert the retaining ring (4) into its housing on the sleeve (2). • Push the dust gaiter (3) into its seat on the sleeve (2), ensuring that it is loca- ted correctly. • Grip the stanchion and move it repeat- edly and slowly in opposite directions.
Page 431 RSV4 RR/RF Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
Page 432 RSV4 RR/RF Suspensions • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Insert the pumping member pin in the stem. • Fill the forks with oil, according to the indicated quantities.
Page 433 RSV4 RR/RF Suspensions • Using a hook spanner lock the pump- ing member pin and tighten the fixing screw on the fork end to the prescribed torque. Specific tooling 020889Y Wrench for locking pumping unit ring • Insert the spring guide and lock it in place using the respective snap ring.
Page 434 RSV4 RR/RF Suspensions • Tighten the nut as much as possible. • Insert the cover and tighten until it stops. • Remove the specific tools. • Screw the cover in the sleeve to the prescribed torque. Filling oil (PROCEDURE FOR OHLINS FORKS) •...
Page 435 RSV4 RR/RF Suspensions Oil level: 110 mm (4.33 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS.
Page 436 RSV4 RR/RF Suspensions • Tighten the cap using a wrench to block the lower spring ring nut. • Tighten the upper adjustment cap to bring it into contact with the lower nut on the cap. • Use the specific Öhlins tool to tighten the upper cap on the sleeve to 20 Nm (14.75 lbf ft).
Page 437 RSV4 RR/RF Suspensions Adjusting The steering damper may be adjusted by turning the knob (1). • Turn the knob (1) clockwise to stiffen the steering. • Turn the knob anticlockwise to loosen the steering. SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL...
Page 438 RSV4 RR/RF Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lb ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lb ft) chions Headstock ring nut - pre-tightening M35x1 70 Nm (51.63 lb ft)
Page 439 RSV4 RR/RF Suspensions • Unscrew and remove the top bolt on the headstock and retrieve the washer. • Loosen the screws fixing the fork stan- chions to the upper yoke. • Working from both sides, unscrew and remove the semi-handlebar screws.
Page 440 RSV4 RR/RF Suspensions • Rivet the safety washer on the head- stock. • Undo the counter-lock ring, remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly. • Tighten the lower lock ring to a torque of 70 Nm (51.63 lb ft).
Page 441 RSV4 RR/RF Suspensions tates smoothly and without excessive resistance. • If any problems are noted, repeat the procedures described above. NOTE DISCONNECT THE STEERING DAMPER WHEN ADJUST- ING THE STEERING FREE PLAY. Specific tooling AP8140190 Tool for steering tightening •...
Page 442 RSV4 RR/RF Suspensions • Fit the upper fork plate. Disassembling • Remove the steering assembly com- pletely. • Unscrew and remove the lower dowel fastening the collar. • Remove the lower collar. • Unscrew and remove the upper dowel fastening the collar.
Page 443 RSV4 RR/RF Suspensions Assembling • Fit the upper collar. • Partially tighten the dowel in the rela- tive threaded hole, so that it protrudes by no more than 2 or 3 mm into the conical surface. • Fit the bushing in its seat, ensuring that the seal (in the groove in the bushing) remains in place.
Page 444 RSV4 RR/RF Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lb ft) "A" Nuts fastening sprocket on 50 Nm (36.88 lb ft) sprocket mount "B" Nuts fastening sprocket on 55 Nm (40.57 lb ft) sprocket mount "C"...
Page 445 RSV4 RR/RF Suspensions • Tap the wheel axle slightly to extract the head from its seat. • Make the wheel move forward and re- lease the gearing chain from the sprocket. • Remove the wheel spindle together with the right hand chain tensioner skid.
Page 446 RSV4 RR/RF Suspensions • Block the rotation with a hex wrench on the threaded pin (1); Unscrew and re- move the DAX nut (2) • Repeat the operation to remove all nuts and corresponding pins. • Remove the sprocket (3) and the...
Page 447 RSV4 RR/RF Suspensions • Block the rotation of the pins with a hex wrench (1) (EVEN IF THE FLANGE IT- SELF DOES NOT ALLOW THE RO- TATION) and tighten to the prescribed torque, the nuts (2) diametrically op- posed in the order: (A) (B) (C) (D) (E).
Page 448 RSV4 RR/RF Suspensions REAR WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity (1). Replace the wheel axle if the eccentricity exceeds the limit value (1). Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM •...
Page 449 RSV4 RR/RF Suspensions • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: • Replace both bearings of the final drive unit.
Page 450 RSV4 RR/RF Suspensions There are notches (A) for engaging with the teeth of the extractor tool at the ends of the spacer (12). • Use the extractor tool to remove the right hand bearing (13). Specific tooling AP8140180 Bearing extractor •...
Page 451 RSV4 RR/RF Suspensions FINAL DRIVE UNIT - BEARING REMOVAL • Remove the final drive unit. • Clean the two sides of the hub with a cloth. • Remove the left spacer (15). • Remove the sealing gasket (16). • Remove the circlip (17).
Page 452 THE VEHICLE HAS A HEIGHT ADJUSTABLE SUSPENSION. FOR USE ON THE TRACK PLEASE OBSERVE THE VALUES RECOMMENDED FOR USE ON THE ROAD. TO CHANGE THE HEIGHT, YOU MUST CONTACT AN Official Aprilia Dealer. TO COUNT THE NUMBER OF RELEASES AND/OR REVOLUTIONS OF ADJUSTMENT SETTINGS ALWAYS START FROM THE MOST RIGID SETTING (WHOLE CLOCKWISE ROTATION OF THE SETTING).
Page 453 RSV4 RR/RF Suspensions • Once the adjustment is done, screw the ring nut (4). • Turn the (1) screw to adjust the shock absorber hydraulic rebound damping. • Turn the knob (2) to adjust the shock absorber hydraulic compression damping.
Page 454 RSV4 RR/RF Suspensions REAR SHOCK ABSORBER - RSV4 1000 RR R /RF - STANDARD A DJUSTMENT FOR ROAD USE ONLY Specification Desc./Quantity Shock absorber centre-to-centre distance (A) 312 mm (12.28 in) (preloaded) Spring (B) length 148.5 mm (5.85 in) Rebound adjustment, ring nut (1)
Page 455 RSV4 RR/RF Suspensions SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - RSV4 1000 RR - STANDARD A...
Page 456 RSV4 RR/RF Suspensions • Unscrew and remove the screw fixing the dual linkage rod to the single link- age. • Retrieve the nut. • Unscrew and remove the upper screw and retrieve the nut. • Remove the shock absorber from the right side.
Page 457 RSV4 RR/RF Suspensions Removing • Working from the left side of the vehicle, loosen and remove the nut (1). • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3). • Slide off the screw (4) from the opposite side.
Page 458 INDEX OF TOPICS CHAS HASSIS...
Page 459 RSV4 RR/RF Chassis HASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 460 RSV4 RR/RF Chassis Swinging arm EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lb ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lb ft) Fork pin nut M20x1.5 65 Nm (47.94 lb ft) AGIP GREASE Chain guard fastening screws 4 Nm (2.95 lb ft)
Page 461 RSV4 RR/RF Chassis • Unscrew and remove the three screws and remove the pinion cover. • Unscrew and remove the screw and retrieve the washer. • Slide off the pinion from the chain and remove. • Unscrew and remove the nut and re- trieve the washer.
Page 462 RSV4 RR/RF Chassis • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION. SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS. PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOW- ERING AND TO KEEP IT UPRIGHT.
Page 463 RSV4 RR/RF Chassis • If necessary, use a specific tool to re- move a pin from the drive chain. • Open and remove the chain. Checking • Remove the swingarm. • Clean the two sides of the bearing seats with a cloth.
Page 464 RSV4 RR/RF Chassis ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: • Replace both swingarm bearings. RADIAL AND AXIAL CLEARANCE CHECK •...
Page 465 RSV4 RR/RF Chassis The height of the swingarm pin relative to the chassis is adjusted with special inserts installed in the respective seats in the chassis. The hole is offset by -5 mm (-0.197 in) relative to the centreline of the insert, as a result the swingarm is in the low position.
Page 466 RSV4 RR/RF Chassis • Ensure that the hexagonal area on the pin head (2) is inserted correctly in the hexagonal seat inside the adjustment bushing (3). • Fit and hand-tighten the counter-lock ring nut by a few turns (1). •...
Page 467 RSV4 RR/RF Chassis • Screw the nut. • Refit the chain on the drive pinion CAUTION APPLY LOCTITE ANTI-SEIZE ON THE INTERNAL TOOTH- ING OF THE TRANSMISSION PINION. • Fit the pinion and the chain on the shaft. CAUTION APPLY LOCTITE 243 ON THE SCREW THREAD.
Page 468 RSV4 RR/RF Chassis • Install the rear wheel and the exhaust system. • Fit the pinion casing. • Adjust the chain tension Drive chain inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001.
Page 469 RSV4 RR/RF Chassis CLEARANCE CHECK To check clearance: • Shut off the engine. • Rest the vehicle on its stand. • Engage neutral gear. • Check that the vertical oscillation at a point between the pinion and the sprocket on the lower branch of the chain is around 30 mm (1,18 in).
Page 470 RSV4 RR/RF Chassis • dry, rusty, flattened or jammed chain links; • excessive wear; • missing sealing rings; • excessively worn or damaged pinion or sprocket teeth; IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSE AND/OR THE SEAL RINGS ARE DAMAGED OR MISSING, THE ENTIRE CHAIN UNIT (PINION, SPROCKET AND CHAIN) NEEDS TO BE REPLACED.
Page 471 RSV4 RR/RF Chassis • Unscrew and remove the two screws from the left rider footpeg protection. • Remove the rear wheel. • Unscrew and remove the upper screw fixing the chain slider and retrieve the washer. See also Removing the rear wheel •...
Page 472 RSV4 RR/RF Chassis Stand IDE STAND pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lb ft) Loct. 243 frame Linear switch retainer 4 Nm (2.95 lb ft) Rear stand bushing retaining screw 7 Nm (5.16 lb ft)
Page 473 RSV4 RR/RF Chassis • Remove the clamps. • Disconnect the stand connector. • Unscrew and remove the two screws. • Remove the side stand. CHAS - 473...
Page 474 RSV4 RR/RF Chassis Exhaust ISCHARGE pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lb ft) nuts Silencer clamp fixing screw - central 10 Nm (7.38 lb ft) manifold Screw used to secure the silencer to 25 Nm (18.44 lb ft)
Page 475 RSV4 RR/RF Chassis • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis; retrieve the collar, the washer and the nut.
Page 476 RSV4 RR/RF Chassis • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables. CAUTION ON REASSEMBLY, POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET.
Page 477 RSV4 RR/RF Chassis • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front exhaust manifolds and the catalytic converter • Move the radiator forward. •...
Page 478 RSV4 RR/RF Chassis REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers. • Remove both rear exhaust manifolds.
Page 479 RSV4 RR/RF Chassis • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler ADIATORE OLIO Pos.
Page 480 RSV4 RR/RF Chassis Pos. Descrizione Tipo Quantità Coppia Note Viti TE fl. per fissaggio staffa a telaio M6x20 10 Nm (7.38 lbf ft) Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe.
Page 481 RSV4 RR/RF Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 481...
Page 482 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 483 RSV4 RR/RF Braking system Key: 1. ABS control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main fuse 6. Injection ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.ABS control unit fuse ABS control unit pinout •...
Page 484 RSV4 RR/RF Braking system • PIN 12 (White/Brown) - Front speed sensor positive • PIN 13 (Yellow/Brown) - Rear speed sensor positive • PIN 14 (Yellow) - Rear speed sensor input • PIN 17 (Blue/Red) - ABS warning light •...
Page 485 RSV4 RR/RF Braking system ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9.
Page 486 RSV4 RR/RF Braking system Intakes and supplies 1. Supply to the rear brake calliper. 2. Intake from the rear brake pump. 3. Intake from the front brake pump. 4. Supply to the front brake calliper. ABS OPERATION General specifications: The front circuit is similar to the rear circuit.
Page 487 RSV4 RR/RF Braking system E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure reduction phase exceeds the pre-set time limit.
Page 488 RSV4 RR/RF Braking system - if the speed difference lasts long, the system may detect an error and deactivates the ABS system. As a consequence, the system works as any regular braking system. Riding with an active ABS system •...
Page 489 RSV4 RR/RF Braking system REPLACING THE ABS CONTROL UNIT • Before replacing the ABS control unit, mark the hoses so that they can be refit correctly on the new control unit. • Remove the ABS support (1), the heat shield plate (2) and finally the ABS con- trol unit.
Page 490 RSV4 RR/RF Braking system • Take care of hose position on the sup- port. 1. Goes to the pump. 2. Goes to the caliper. • After replacing hoses or the control unit the entire ABS system must be bled. To bleed the ABS system optimally, it is advisable to use devices such as vacuum pumps or similar.
Page 491 RSV4 RR/RF Braking system ABS PIPES ROUTING TABLE A - ABS PIPES ROUTING 1. Small clamps TABLE B - ABS PIPES ROUTING 1. Rear speed sensor cable. 2. Cable guide. 3. Cable grommet. 4. Cable grommet. TABLE C - ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure.
Page 492 RSV4 RR/RF Braking system Guide to diagnosis PREMISE Each time the key is ON, if, at least one current or stored* error is detected, the ABS warning light turns on permanently. The ABS system is deactivated automatically The system operates perfectly just as any other...
Page 493 RSV4 RR/RF Braking system 8. CHECK: • A. Cable continuity between PIN17 of the ABS control unit connector and PIN28 of the instrument panel. • B. Check connectors - refer to the operations described in the chapter If the previous checks are OK, the causes might be: •...
Page 494 RSV4 RR/RF Braking system P.A.D.S. characteristic Value/example Unit of Notes measure ment Front brake circuit pressure Quality test of the sensors When turning the wheel or acting on the brake, a variation of parameters must be detected. ACTIVATION screen page...
Page 495 RSV4 RR/RF Braking system P.A.D.S. characteristic. Value/example Units of Notes measure ment Front wheel speed sensor functional C1034 Signal not plausible diagnosis Inside error C1014 Solenoid valve relay failure Inside error C1015 Recirculation pump failure Inside error C1021 Control unit failure...
Page 496 RSV4 RR/RF Braking system • Select Self-diagnosis. • Go to the page Error codes. • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded).
Page 497 RSV4 RR/RF Braking system • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it. • Name the file with a name that contains the main information of the vehicle and the analysed component e.g.
Page 498 RSV4 RR/RF Braking system - Check the type and sizes of the fitted tyres. - Check the type and sizes of the fitted tone wheels. C1031 Rear wheel speed sensor electrical diagnosis - open circuit, shorted to negative or shorted to positive.
Page 499 RSV4 RR/RF Braking system The circuit is open: - Perform the check of the connectors on the components and the ABS control unit. - Check the good condition and the wiring continuity: • between ABS control unit PIN 3 and sensor PIN 1 (White cable) •...
Page 500 RSV4 RR/RF Braking system CAN LINE ERRORS U2921 Controller error U2922 Line failure (busoff) Error cause Communication problem on the CAN line: probable contact. Troubleshooting Check the good condition and the wiring continuity: • between ABS control unit PIN 2, instrument panel PIN 26 and injection control unit PIN 80 (Orange cable) •...
Page 501 RSV4 RR/RF Braking system Troubleshooting - Connect to the injection control unit diagnostics. - Check as shown in the figure if there is or not continuity between the switch contacts in the different opening/closing conditions: • with "+" button open, the "-" button must be closed •...
Page 502 RSV4 RR/RF Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
Page 503 RSV4 RR/RF Braking system Component maintenance The vehicle is fitted with a two-channel ABS sys- tem, i.e. it works on both the front and the rear wheel. Check periodically and each time the wheels are refitted, the tone wheel (2) or the sensor (1) re- placed, that the wheel distance is constant at each 360°.
Page 504 RSV4 RR/RF Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Odometer sensor fixing screw 10 Nm (7.38 lb ft) Rear brake calliper support plate re- 50 Nm (36.88 lb ft) Loct. 243 taining pin Rear brake calliper fastening screw 25 Nm (18.44 lb ft)
Page 505 RSV4 RR/RF Braking system Front brake calliper RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) Rear brake disc Removal • Remove the rear wheel. BRAK SYS - 505...
Page 506 RSV4 RR/RF Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION DURING REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 507 RSV4 RR/RF Braking system Removal • Remove the front wheel The following operations refers to a single disc but apply to both. • Unscrew and remove the six brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1).
Page 508 RSV4 RR/RF Braking system exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS.
Page 509 RSV4 RR/RF Braking system • Fit the two new pads in the correct po- sition. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CAL- LIPER. • Fit the front brake calliper on the disc.
Page 510 RSV4 RR/RF Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 511 RSV4 RR/RF Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency.
Page 512 RSV4 RR/RF Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 513 RSV4 RR/RF Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 514 RSV4 RR/RF Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lb ft) Rear brake pump retaining screws 8 Nm (5.90 lb ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lb ft)
Page 515 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 516 RSV4 RR/RF Cooling system Circuit diagram SYSTEM TYPE Self bleeding cooling circuit with aspirating centrifugal pump (1), three-way thermostat valve (2), cooling radiator (3) with electric fans (4) and expansion tank (5). key: COOL SYS - 516...
Page 517 RSV4 RR/RF Cooling system 1. Centrifugal pump 2. Thermostatic valve 3. Radiator 4. Electric fans 5. Expansion tank 6. With the thermostat open 7. With the thermostat closed 8. From front head 9. From rear head 10.To upper crankcase OOLING pos.
Page 518 RSV4 RR/RF Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws used to fasten the pump to M6x25 10 Nm (7.38 lb ft) the crankcase Electric fan • Remove the front underfairings and the hand grip position sensor •...
Page 519 RSV4 RR/RF Cooling system Fairing mounting panels Twistgrip position sensor • The retainer points of the electric fan are not the same as the hole (2), com- pared to the holes (1), has a different thickness and is therefore fixed from the internal side using a threaded "T"...
Page 520 RSV4 RR/RF Cooling system • Via the filler orifice on the expansion tank, fill with the quantity of coolant necessary to reach the FULL marking, then refit the cap. • Start the engine, run at idle speed and wait for the electric fans to activate (ap- prox.
Page 521 RSV4 RR/RF Cooling system • Unscrew and remove the two screws fastening the pump to the engine. • Remove the coolant pump. • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw.
Page 522 RSV4 RR/RF Cooling system • At each removal, replace the inner gas- ket between the pump casing and the cover and the O ring on the pump cas- ing. ENSURE THAT THE LIQUID PASSAGE ORIFICES ARE NOT OBSTRUCTED. Removing the radiator RADIATOR BRACKET REMOVAL •...
Page 523 RSV4 RR/RF Cooling system • Moving the bracket outwards, it is then possible to remove it by sliding it out. CAUTION DURING THE REFIT PHASE, MAKE SURE THAT THE MAIN CABLE HARNESS IS CORRECTLY POSITIONED ON THE CAVITY OF THE RADIATOR RETAINER BRACKET, IN ORDER TO PRE- VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF.
Page 524 RSV4 RR/RF Cooling system • Remove the two fixing screws of the radiator bracket. • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return...
Page 525 RSV4 RR/RF Cooling system • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Remove the radiator. COOL SYS - 525...
Page 526 INDEX OF TOPICS BODYW ODYWORK...
Page 527 RSV4 RR/RF Bodywork EADLAMP Pos. Description Type Quantity Torque Notes Screw for fastening the front head- SWP 4.9 2 Nm (1.48 lb ft) light to the front mudguard Headlamp fastener screw M5 x 12 2 Nm (1.48 lb ft) BODYW - 527...
Page 528 RSV4 RR/RF Bodywork NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 529 RSV4 RR/RF Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lb ft) Lug fixing screws 4 Nm (2.95 lb ft) Screws fixing the side fairings to the 1.5 Nm (1.11 lb ft)
Page 530 RSV4 RR/RF Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft) er's saddle to the fuel tank Filler to tank retaining screws 4 Nm (2.95 lb ft) Screws fastening fuel pump flange to 5 Nm (3.69 lb ft)
Page 531 RSV4 RR/RF Bodywork UEL TANK COVER Pos. Description Type Quantity Torque Notes Screws fastening front tank to frame 8 Nm (5.90 lb ft) Screws fastening tank structural sup- 3 Nm (2.21 lb ft) port to tank BODYW - 531...
Page 532 RSV4 RR/RF Bodywork ICENSE PLATE HOLDER pos. Description Type Quantity Torque Notes License plate light fixing screws 1 Nm (0.74 lb ft) Rear turn indicator fixing screws 2.5 Nm (1.84 lb ft) Taillight fixing screws 3 Nm (2.21 lb ft) Taillight cover self-tapping fixing SWP 3.9...
Page 533 RSV4 RR/RF Bodywork AIRING pos. Description Type Quantity Torque Notes Lower fairing central bracket fasten- 10 Nm (7.38 lb ft) ing screws RH lower fairing support bracket 12 Nm (8.85 lb ft) LH lower fairing support bracket 12 Nm (8.85 lb ft) Screws for fastening the side fairings 1.5 Nm (1.11 lb ft)
Page 534 RSV4 RR/RF Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Rear screws used to fasten the tail 3 Nm (2.21 lb ft) fairing to the rear headlight bracket Screws used to fasten the saddle SWP 2.9 1 Nm (0.74 lb ft)
Page 535 RSV4 RR/RF Bodywork OCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lb ft) Lock lever self-tapping screw 2 Nm (1.48 lb ft) Shear head screw (to the left of the...
Page 536 RSV4 RR/RF Bodywork OOTRESTS Pos. Description Type Quantity Torque Notes Screws for fastening the rider's footr- 2 + 2 25 Nm (18.44 lb ft) Loctite 243 ests to the frame Screws for fastening the passenger's 2 + 2 18 Nm (13.28 lb ft)
Page 537 RSV4 RR/RF Bodywork Seat • Remove the saddle cover/ passenger saddle • Remove the two rear fastening screws • Lift the rear saddle and slide it off the pin on the tank Driving mirrors • The following procedure is for a single rear view mirror, but is applicable to both mirrors.
Page 538 RSV4 RR/RF Bodywork • Guiding the turn indicator cable through the relative hole on the top fair- ing, remove the rear view mirror. Instrument panel • Remove the windshield. • Unscrew and remove the two screws. • Remove the instrument panel mount- ing cover.
Page 539 RSV4 RR/RF Bodywork WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION. THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED. Headlight assy. • Remove the top fairing complete •...
Page 540 RSV4 RR/RF Bodywork Headlight fairing • Previously remove the side fairings • Operating from the left side of the mo- torcycle, remove the rear screw (1) fix- ing the top fairing to the air deflector • Remove the upper screw (2) fixing the top fairing to the air deflector •...
Page 541 RSV4 RR/RF Bodywork • Move the top fairing forward to the min- imum space necessary to work on the front bulb connectors • Disconnect the front headlamp con- nectors (5) • Remove the top fairing complete SIDE AIR DEFLECTOR COVERS •...
Page 542 RSV4 RR/RF Bodywork • Detach and remove the side air deflec- tor covers from the top fairing • Remove the previously described screws also for the right side of the top fairing to remove the side air deflector covers PLEXIGLAS •...
Page 543 RSV4 RR/RF Bodywork • Unscrew and remove the two screws (2). • Remove the bracket (3). • Disconnect the connector (4). • Remove the taillight (5). Rider footrest plate LEFT RIDER FOOTREST REMOVAL - GEAR- BOX LEVER • Remove the fuel tank •...
Page 544 RSV4 RR/RF Bodywork • Remove the fixing screw (4) of the ca- ble grommet (5) • Cut the two clamps (6) that connect the wiring of the quick-shift to the wiring of the side stand and of the lambda probe •...
Page 545 RSV4 RR/RF Bodywork • If necessary, you can loosen and re- move the quick-shift fixing screw to change the O-rings. NOTE NOTE THE WIRING HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION Side body panels • Remove the rider saddle •...
Page 546 RSV4 RR/RF Bodywork Side fairings • Operating from the left side of the mo- torcycle, detaching the three clips (1) placed on the inner fairing. • Remove the four screws (2) • Detach the inner fixing clip (3) with the air deflector •...
Page 547 RSV4 RR/RF Bodywork AIR DEFLECTORS • The following operations are valid for both air deflectors • Remove the screw (1) fixing the de- flector to the lower fairing • Remove the deflector (2) Fairing mounting panels • Previously remove the side fairings LATERAL UNDERFAIRINGS •...
Page 548 RSV4 RR/RF Bodywork • Remove the upper fixing screw (4) of the left inner fairing • Detach the internal left fairing (5) from the central underfairing and remove it CENTRAL UNDERFAIRING • Remove the three clips (1) and the two screws (2) fixing the central underfair- ing to the top fairing.
Page 549 RSV4 RR/RF Bodywork REAR UNDERFAIRING • Carry out the tail fairing removal pro- cedure. • Remove the starter relay box (1) from the point indicated in the figure. • Remove the rear light unit. • Carry out the licence plate support re- moval procedure.
Page 550 RSV4 RR/RF Bodywork • Unscrew and remove the screw (5). • Unhook the underfairing (6) from the point indicated in the figure. • Remove the underfairing (6). License plate holder • Remove the plastic cover (1). BODYW - 550...
Page 551 RSV4 RR/RF Bodywork • Undo and remove the screw inside of the point indicated in the figure. • Unscrew the fixing screws (2) together with the nuts (3). • Disconnect the connector (4). • Remove the support (5). Air box FILTER BOX COVER REMOVAL •...
Page 552 RSV4 RR/RF Bodywork • Disconnect the air temperature sensor connector • Remove the screw fixing the wiring harness to the filter box and move it away • Unscrew and remove the eight air filter box cover screws BODYW - 552...
Page 553 RSV4 RR/RF Bodywork • Move the two rear coil connectors. • Remove the two clamps blocking the wiring harness to the filter box cover • Remove the four screws fixing the var- iable geometry intake system and re- move it •...
Page 554 RSV4 RR/RF Bodywork • Remove the intake ducts complete with support • Operating from both sides, unscrew and remove the air pressure sensors fixing screws • Operating from both sides, unscrew and remove the air pressure sensors fixing screws •...
Page 555 RSV4 RR/RF Bodywork • Disconnect the engine wiring connec- tor, previously placed on the filter box • Release the cable harness from the cable grommet on the filter box • Remove the filter box Rear mudguard • Unscrew and remove the two screws.
Page 556 RSV4 RR/RF Bodywork Lower cowl • Remove the side fairings • Operating from both sides, remove the front fixing screws (1) • Remove the lower fixing screw (2) holding the lug • Remove the clip (3) and the two screws...
Page 557 RSV4 RR/RF Bodywork • Remove the rider saddle. • Unscrew and remove the two rear screws. • Release the clamps. • Remove the two tank breather pipes. • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank.
Page 558 RSV4 RR/RF Bodywork Front mudguard • Working on both sides of the vehicle, undo and remove the two screws. • Release the brake pipe eliminating the clamp. • Remove the front mudguard. Instrument cluster support REMOVAL • Remove the instrument panel.
Page 559 RSV4 RR/RF Bodywork Instrument panel • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws. • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp.
Page 560 RSV4 RR/RF Bodywork • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws. Do not strain the connection between the two semi- arch braces, as this would prevent the removal of the clamp.
Page 561 RSV4 RR/RF Bodywork NOTE WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FA- CILITATING THE CONNECTOR'S INSERTION. THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED. Radiator cover • Remove the side fairings.
Page 562 RSV4 RR/RF Bodywork • Remove the two plastic inserts (2) from both sides of the motorcycle. • Unscrew and remove the screw (3). • Unhook the saddle opening cable (4) from its seat. • Remove the left (5) and right (6) tail fairing.
Page 563 RSV4 RR/RF Bodywork Side air deflectors The following procedure is for a single lateral duct but is applicable to both. • Remove the windshield. • Unscrew and remove the two fixing nuts. • Remove the duct from its seat on the frame.
Page 564 INDEX OF TOPICS PRE DE DELIVERY...
Page 565 RSV4 RR/RF Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 566 RSV4 RR/RF Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 567 RSV4 RR/RF Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 568 RSV4 RR/RF Pre-delivery Specific operations for the vehicle LICENSE PLATE HOLDER • Set three washers of suitable diameter between license plate and its holder to avoid damaging the license plate. WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP- PROVAL.
Page 569 RSV4 RR/RF Pre-delivery • Insert the key in the lock and turn it clockwise. • Remove the tail fairing. • Fit the two-seater saddle. Adjusting the rear-view window joint • With the mirror closed (base turned 90° in relation to the mirror) check that the...
Page 570 RSV4 RR/RF Pre-delivery • Cut the wiring harness clamp (if there is one), disconnect the wiring harness connector and pull the wiring harness away from the mirror. • Loosen the nut so its upper surface is about 0.5 mm (0.02 in) above the end of the threaded pin.
Page 571 RSV4 RR/RF Pre-delivery • Assemble the rear-view mirror. • Pass the wiring harness through the specific hole and place the rear-view mirror in its seat. • Tighten the two fixing nuts of the rear- view mirror. • Connect the connector.
Page 572 230 ABS: 240, 483, 493 Air filter: 74 Air temperature sensor: 179 Alternator: Aprilia V4-MP Tecnology: 249 Battery: 144, 155 Brake: 504–506, 508, 509, 513, 514 Brake calliper: 504, 505 Brake disc: 505, 506 Brake pads: 508, 509...
Page 573 Front cylinder head valves: 78 Front head: 318, 326, 330, 353, 366, 368 Front wheel: 407, 408, 414, 507 Fuel: 148, 195, 398, 556 Fuel pump: 148, 195, 398 Fuses: 148 Handlebar: 410 Head cover: 76–78, 84, 317, 319, 326, 337, 344 Headlight: 539, 540, 563 Identification: 11 Instrument panel: 141, 538, 559...
Page 574 Side stand: 216, 472 Side stand sensor: 216 Spark plug: 69, 76, 77 Speed sensor: 156 Stand: 216, 472 Start-up: 147, 296 Starter motor: 296 Steering damper: 436 Stepper motor: 403 Tank: 556 Throttle body: 76, 77, 200, 402, 403 Top fairing: Track: 67 Transmission: 12, 363, 366...

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Page 28: Table Of Contents

Page 29: Fuel Tank

Page 31: Nm (2.95 Lb Ft)

Page 32: Nm (3.69 Lb Ft)

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