APRILIA RSV4 RR 2017 Service Station Manual

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SERVICE STATION MANUAL

2Q000333

RSV4 RR-RF

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Summary of Contents for APRILIA RSV4 RR 2017

Page 1 SERVICE STATION MANUAL 2Q000333 RSV4 RR-RF...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
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 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 WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
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 "RECOMMENDED PRODUCTS" 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. This number consists of numbers and letters, as in the example shown below.
Page 12 27 / 34 (secondary) 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 upshifting and downshifting. CHAR - 12...
Page 13 RSV4 RR-RF Characteristics Capacities APACITY Specification Desc./Quantity Fuel tank (reserve included) 18.5 l (4.07 UKgal; 4.88 US gal) Fuel tank reserve 4 l (0.88 UK gal; 1.06 US gal) Engine oil oil and filter change 4.1 l (0.90 UK gal) Coolant 2.7 l (0.59 UK gal) Seats...
Page 14 RSV4 RR-RF Characteristics Frame and suspensions HASSIS Specification Desc./Quantity Type Adjustable aluminium, dual beam chassis with pressed and cast sheet elements. Steering rake 26.5° (measurements with reference to bare chassis) USPENSIONS Specification Desc./Quantity Front fork - RSV4 1000 RF Öhlins upside down units with adjustable hydraulic damping and 43 mm (1.69 in) diam.
Page 15 RSV4 RR-RF Characteristics Wheels and tyres HEEL RIMS Specification Desc./Quantity Front wheel rim 3.50 x 17" RSV4 1000 RR - forged for the RSV4 1000 RF ver- sion Rear wheel rim 6.00 x 17" RSV4 1000 RR - forged for the RSV4 1000 RF ver- sion YRES Specification...
Page 16 RSV4 RR-RF Characteristics Front side IQUID 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) ing the water radiator to the support...
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 FORKS HLINS Pos. Description Type Quantity Torque Notes Calliper bracket fixing screws (Oh- 2 + 2 12 Nm (8.85 lb ft) lins) Speed sensor fastening screw 6 Nm (4.43 lb ft) Cable gland fastening screw 8 Nm (5.90 lb ft) (SACHS FORKS) RONT FORKS ACHS...
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) Unscrew after pre- tightening...
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. Description Type Quantity...
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) Front brake lever pin fixing screw...
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 20 Nm (14.75 lb ft) RH light switch...
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) tening screws Screws used to fasten the instrument 8 Nm (5.90 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) side spacers Screws fastening the lower fairing to 2 Nm (1.48 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) RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Flanged button head hex socket M6x12 6 Nm (4.43 lb ft) screws for fastening the sensor to the bracket CHAR - 26...
Page 27 RSV4 RR-RF Characteristics Pos. Description Type Quantity Torque Notes Horn fixing screw 15 Nm (11.06 lb ft) Button head, hex. socket voltage M6x30 6 Nm (4.43 lb ft) regulator fixing screws Button head, hex socket screws for 6 Nm (4.43 lb ft) fastening the USB port bracket (if fit- ted) Flanged button head hex socket...
Page 28 RSV4 RR-RF Characteristics ADDLE Pos. Description Type Quantity Torque Notes Rider's saddle retaining screw 6 Nm (4.43 lb ft) Passenger's saddle retaining pin fas- 1.5 Nm (1.11 lb ft) tening screw CHAR - 28...
Page 29 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) fuel tank Screws fastening the rear fuel tank to...
Page 30 RSV4 RR-RF Characteristics ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Screws fastening fairing to tail fairing 1 Nm (0.74 lb ft) Screws fastening fairing to tank 2 + 2 2 Nm (1.48 lb ft) CHAR - 30...
Page 31 RSV4 RR-RF Characteristics ILTER BOX Pos. Description Type Quantity Torque Notes Flanged SWP petrol/injectors circuit M5x20 ... Nm (... lb ft) fastening screws Flanged SWP upper intake ducts re- M5x20 ... Nm (... lb ft) taining screws Flanged SWP lower intake ducts re- ...
Page 32: Table Of Contents
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 Manual Front couplings 2 + 2...
Page 33 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 Manual Tighten until the ignition lock)
Page 34: Nm (8.85 Lb Ft)
RSV4 RR-RF Characteristics EAR LEVER Pos. Description Type Quantity Torque Notes Pinion protection guard fastening 6 Nm (4.43 lb ft) screws Threaded spacer 8 Nm (5.90 lb ft) Countersunk, flat head, hex. socket M6x35 10 Nm (7.38 lb ft) Loct. screws Self-locking nut 25 Nm (18.44 lb ft)
Page 35: Nm (36.88 Lb Ft)
RSV4 RR-RF Characteristics Pos. Description Type Quantity Torque Notes Screws for securing the upper fairing self-tapping 1 Nm (0.74 lb ft) closure to the front headlight 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)
Page 36: Nm (2.95 Lb Ft)
RSV4 RR-RF Characteristics ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Starter relay cables fastening screws 4 Nm (2.95 lb ft) Back side CHAR - 36...
Page 37 RSV4 RR-RF Characteristics XHAUST Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lb ft) nuts Silencer clamp fastening screw - 20 Nm (14.75 lb ft) central manifold Screw used to secure the silencer to 25 Nm (18.44 lb ft) the RH footrest support Torx button head silencer aesthetic M6x10...
Page 38 RSV4 RR-RF Characteristics EAR BRAKE MASTER CYLINDER 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) Loctite 243 Tank filler cap...
Page 39 RSV4 RR-RF Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes ABS sensor fixing screw 6 Nm (4.43 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) Brake pipe bracket fastening screw 4 Nm (2.95 lb ft)
Page 40 RSV4 RR-RF Characteristics 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) Front chain guide fixing screw 4 Nm (2.95 lb ft)
Page 41 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) rod to chassis CHAR - 41...
Page 42 RSV4 RR-RF Characteristics 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 0.5 Nm (0.37 lb ft)
Page 43 RSV4 RR-RF Characteristics Pos. Description Type Quantity Torque Notes Nuts for fastening the number plate 4 Nm (2.95 lb ft) holder to the saddle mounting Screw for fastening the tail fairing to 3 Nm (2.21 lb ft) the taillight bracket V4-MP control unit retaining screws Self-tapping Di- 0.3 Nm (0.22 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) TE flanged coil fixing screw M6x12 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) Reed valve covers fixing screws...
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 Chain tensioner sliders fastening 20 Nm (14.75 lb ft) Loct. 243 screws Chain guide sliders fixing 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) Primary fixing ring nut 200 Nm (147.51 lb ft) Loct.
Page 49 RSV4 RR-RF Characteristics Pos. Description Type Quantity Torque Notes SHC screw M6x40 10 Nm (7.38 lb ft) Lubricate the head and under the head. Special nut 10 Nm (7.38 lb ft) Flanged nut 15 + 20 Nm (11.06 + Lubricate the head 14.75 lb ft) + 60°...
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) GNITION UNIT Pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1...
Page 51 RSV4 RR-RF Characteristics Pos. Description Type Quantity Torque Notes Starter motor SHC fastener screw M6x40 10 Nm (7.38 lb ft) Screw fastening cables to the starter 6 Nm (4.43 lb ft) motor ENERATOR COVER Pos. Description Type Quantity Torque Notes Cover fastening screws M6x25 12 Nm (8.85 lb ft)
Page 52 RSV4 RR-RF Characteristics UBRICATION SYSTEM 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 Cylindrical head, hex. socket secon- M6x16 10 Nm (7.38 lb ft) dary air solenoid screws CHAR - 53...
Page 54 RSV4 RR-RF Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lb ft) for fastening the pump to the crank- case CHAR - 54...
Page 55 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 56 RSV4 RR-RF Special tools PECIAL 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 020857Y Crankshaft support U-bolt S-TOOLS - 57...
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....020863Y Punch assembly cage with rollers des- modromic drum..
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 Sleeve for adaptors 020363Y 20mm oil seal guide S-TOOLS - 59...
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 AP8140149 Guard for assembly operations S-TOOLS - 61...
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 021011Y PADS - PMP Interface cable S-TOOLS - 62...
Page 63 INDEX OF TOPICS MAIN AINTENANCE...
Page 64 (e.g. use on pave, holes, speed bumps) can bring small adjustments that, in ex- treme cases, can cause a slight clearance to the handlebar. Therefore it is recommended to perform the check and adjustment operations at an Authorised Aprilia-Piaggio Workshop every 5,000 km (3,106.86 mi).
Page 65 RSV4 RR-RF Maintenance Km x 1,000 (mi x 1,000) 1 (0.6) EVERY EVERY (6.2) (12.4) (18.6) (24.9) MONTH MONTH Brake fluid Coolant Fork oil (6) (8) Engine oil (5) Headlight aiming Fork oil seals (5) Slipper mechanism Tyres - pressure / wear (2) Nut/bolt tightness (5) Flexible coupling pin nuts tightening Clutch cover, flywheel and sump screw tightness...
Page 66 (es. impiego su pavé, buche, rallentatori ecc.) possono verificarsi piccoli assestamenti che, in casi limite, possono fare insorgere un leggero gioco al manubrio. Si consiglia pertanto di effettuare l'operazione di controllo e regolazione in Officina Autorizzata Aprilia-Piaggio ad intervalli di 3106.86 mi (5000 km).
Page 67 RSV4 RR-RF Maintenance km x 1,000 or (months) maximum 1 (1) 10 (10) 20 (20) 30 (30) 40 (40) Crown wheel - sprocket (6) Steering bearings and steering play (8) Wheel bearings - Wheels (6) Diagnosis by tool Brake discs (6) - Pads wear (2) Air filter (6) Engine oil filter (6) Fork...
Page 68 (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 maintenance procedure to be carried out, as indi- cated in the table.
Page 69 RSV4 RR-RF Maintenance Upon completing the specific track maintenance procedure, access the "adjustments" section of the diagnostic tool and reset the equivalent kil- ometres, so that it is possible to extinguish the "warning lamp" and carry out the calculation for the next service. The "Equivalent KM reset counter"...
Page 70 RSV4 RR-RF Maintenance • Slide off the front coil. • Unscrew and remove the front spark plug. REAR SPARK PLUGS • Remove the fuel tank. • Unscrew and remove the rear coil fastener screw. • Slide off the rear coil. •...
Page 71 RSV4 RR-RF Maintenance • Shut off the engine and wait a few sec- onds. • Keep the vehicle upright with both wheels on the earth • Ensure that you are on a flat surface • Unscrew the engine oil level dipstick •...
Page 72 RSV4 RR-RF Maintenance • Unscrew and remove the filler cap. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and, if necessary, replace the drainage plug sealing washers. • Screw and tighten the drainage plug. •...
Page 73 RSV4 RR-RF Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER. •...
Page 74 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. • Remove the air filter.
Page 75 RSV4 RR-RF Maintenance • Turn the crankshaft from the hole on the clutch cover until the valves are not in tension. • Use a feeler gauge to check the clear- ance between the cam of the shaft and the relative tappet for both front head shafts.
Page 76 RSV4 RR-RF Maintenance • Position cylinder 1 piston (LH, rear piston) so that it is at the point where it crosses TDC. • rotate the crankshaft 150° in the engine rotation direction (direction of travel). • insert the respective pin, from the fly- wheel side, into the groove on the crankshaft.
Page 77 RSV4 RR-RF Maintenance Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft 150° in the direction of engine rotation (direction of travel) in order to align the hole on the intake camshaft with the specific hole on the U bolt;...
Page 78 RSV4 RR-RF Maintenance • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). Specific tooling 020956Y Support for camshaft gear on head • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer.
Page 79 RSV4 RR-RF Maintenance • Retrieve the pad and replace with a suitable component to achieve the cor- rect valve clearance. Refer to the table: "Calibrated pad thickness- es" to identify the suitable thickness. • Fit the tappet. See also Calibrated pad thickness •...
Page 80 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. • Block crankshaft rotation using one of the specific tools.
Page 81 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 82 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 83 RSV4 RR-RF Maintenance Specific tooling 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 020850Y Primary gear lock 020914Y Flywheel retainer...
Page 84 RSV4 RR-RF Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the intake camshaft gear tooth (indicated with one dot) is meshed with the trough of the exhaust camshaft gear (indicated with two dots). •...
Page 85 RSV4 RR-RF Maintenance • Fit the U bolts with nine O rings and lo- cator pins. • Position the screws (4), taking care to insert new washers on the screws near the spark plug holes. • Loosen the distribution gear's lock screw and move the gear itself from the mounting tool to the camshaft.
Page 86 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. • Block crankshaft rotation using one of the specific tools.
Page 87 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. Calibrated pad thickness Pad thicknesses for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.77 mm (0.0697 in)
Page 88 RSV4 RR-RF Maintenance 2.1 mm (0.0827 in) 2.12 mm (0.0835 in) 2.15 mm (0.0846 in) 2.17 mm (0.0854 in) 2.2 mm (0.0866 in) 2.22 mm (0.0874 in) 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)
Page 89 RSV4 RR-RF Maintenance 3.05 mm (0.1201 in) 3.07 mm (0.1209 in) 3.10 mm (0.1220 in) 3.12 mm (0.1228 in) 3.15 mm (0.1240 in) MAIN - 89...
Page 90 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 91 RSV4 RR-RF Electrical system RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Flanged button head hex socket M6x12 6 Nm (4.43 lb ft) screws for fastening the sensor to the bracket Horn fixing screw 15 Nm (11.06 lb ft) Button head, hex.
Page 92 RSV4 RR-RF Electrical system ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Starter relay cables fastening screws 4 Nm (2.95 lb ft) ELE SYS - 92...
Page 93 RSV4 RR-RF Electrical system Components arrangement Key: 1. Side stand sensor. 2. Fuel pump 3. Instrument panel 4. Left hand switch ELE SYS - 93...
Page 94 RSV4 RR-RF Electrical system 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 13.Exhaust valve 14.Lambda probe 15.Engine speed sensor 16.Headlamp 17.Rear turn indicators 18.Horn 19.Voltage regulator 20.Battery...
Page 95 RSV4 RR-RF Electrical system Location of the Component name Position on the vehicle: component in the electrical circuit diagram Injection relay Under the saddle near the battery, right side Fan control relay In the headstock niche, on the left Recovery logic relay (urgent service) In the headstock niche, on the right Electrical system installation Scope and applicability...
Page 96 RSV4 RR-RF Electrical system • 1 x SensorBox • 1 x QuickShift • 1 x V4-MP Control Unit (if present) Small parts and mountings • 9 x Large black 290x4 clamps • 8 x Small black 160x2.5 clamps • 1 x Rubber clamp •...
Page 97 RSV4 RR-RF Electrical system • Check the ground fastening on the starter motor, starter motor positive and relative hood. • Check the taillight connection. • Check the connection between the number plate holder wiring harness and the main wiring harness. •...
Page 98 RSV4 RR-RF Electrical system Front side WIRING TABLE A - RELAY SENSOR SUPPORT PRE-ASSEMBLY Position the relays in their rubber grommets and pre-assemble them on the support. 1. Relay 2. Relay grommets 3. Support WIRING TABLE B - REGULATOR PRE-ASSEM- 1.
Page 99 RSV4 RR-RF Electrical system 2. Traction control commands wiring harness 3. Clutch switch wiring harness 4. RH light switch wiring harness 5. Ride By Wire control wiring harness WIRING TABLE E - INSTRUMENT SUPPORT ARCH AND FRONT PART Position the two clamps as indicated WIRING TABLE E1 - INSTRUMENT SUPPORT ARCH AND FRONT PART Using the first edge clamp, secure the light switch...
Page 100 RSV4 RR-RF Electrical system WIRING TABLE E2 - INSTRUMENT SUPPORT ARCH AND FRONT PART Position the main wiring harness and secure it to the right hand instrument holder support using a grey reference clamp 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-...
Page 101 RSV4 RR-RF Electrical system WIRING TABLE E6 - INSTRUMENT SUPPORT ARCH AND FRONT PART Insert the connectors in their housings on the arch 1. Left turn indicator connector 2. Right hand turn signal connector WIRING TABLE F - FRONT WHEEL ABS SEN- SOR PASSAGE (OHLINS FORKS) 1.
Page 102 RSV4 RR-RF Electrical system WIRING TABLE F3 - FRONT ABS SENSOR WIRING Check that the front ABS sensor connector is con- nected correctly and positioned inside the instru- ment support arch together with all the other connectors present in that area. WIRING TABLE G - COMPLETING THE FRONT MUDGUARD ASSEMBLY Position the front headlight connectors under the...
Page 103 RSV4 RR-RF Electrical system WIRING TABLE H - USB PORT (IF FITTED) The USB port wiring harness must be routed be- hind instrument cluster and the port must be fas- tened by means of the support bracket. Central part TABLE A - IGNITION RELAY PRE-ASSEMBLY The positive battery cable must be connected to the hole identified by the letter B (Battery) using M5x8 screw...
Page 104 RSV4 RR-RF Electrical system TABLE B - FUEL TANK PRE-ASSEMBLY • Position the SENSOR BOX (1) on its support bracket (2), which is fixed to the fuel tank. TABLE C - PINION GUARD PRE-ASSEMBLY • Position the support (1) for the lambda probe connector and the quick shift wir- ing cable guide (2) on the pinion pro- tection guard.
Page 105 RSV4 RR-RF Electrical system WIRING TABLE D - VEHICLE WIRING HAR- NESS Position the main wiring harness inside the con- duits and close them using the two clamps WIRING TABLE D1 - VEHICLE WIRING HAR- NESS Secure the conduit to the frame at the four points indicated and fasten in using the central screws (1).
Page 106 RSV4 RR-RF Electrical system WIRING TABLE E - STARTER MOTOR AND OIL BULB ZONE 1. Earth wiring routing (behind the water pipe and starter motor) 2. Starter motor wiring harness routing (behind the water pipe) 3. Starter motor lug COVER THE STARTER MOTOR NUT AND THE SQUARE TERMINAL WITH DI-ELECTRIC, WA- TER-REPELLENT GREASE 4.
Page 107 RSV4 RR-RF Electrical system WIRING TABLE F - INTERCONNECTION BE- TWEEN ENGINE WIRING HARNESS AND MAIN WIRING HARNESS Check that the connectors have been connected correctly and that the purple slide is in the end stop position 1. Vehicle connector 2.
Page 108 RSV4 RR-RF Electrical system WIRING TABLE H1 - LH SIDE ZONE using a large clamp (1), secure the voltage regu- lator (2) wiring to the water radiator. WIRING TABLE H2 - LH SIDE ZONE 1. Small clamp. 2. Large clamp (must be large enough to clamp the hand-wheel cable, the regulator cable and the front lambda probe cable together).
Page 109 RSV4 RR-RF Electrical system WIRING TABLE H3 - LH SIDE ZONE The fan (1) and flywheel-regulator (2) connectors must be connected correctly and attached to their respective supports on the canister. WIRING TABLE I - EXHAUST VALVE MOTOR ZONE 1. Ride by wire wiring harness; 2.
Page 110 RSV4 RR-RF Electrical system WIRING TABLE I - EXHAUST VALVE MOTOR ZONE The fan (1) and ride by wire (2) wiring harnesses must be routed between the frame and the exhaust valve cables. WIRING TABLE I - EXHAUST VALVE MOTOR ZONE The fan (1) and ride by wire (2) wiring harness connectors must be connected correctly and at-...
Page 111 RSV4 RR-RF Electrical system WIRING TABLE I - EXHAUST VALVE MOTOR ZONE The fan wiring harness (1) must be fastened to the ride by wire control wiring harness (2) by a clamp (3). Check that the grey safety lock (4) on the ride by wire control connector, is locked in the lowered position.
Page 112 RSV4 RR-RF Electrical system WIRING TABLE M - PINION ZONE The quick shift wiring (1) must be routed through the cable guide (2) that has been pre-assembled on the pinion guard WIRING TABLE M1 - PINION GUARD ZONE 1. Side stand switch 2.
Page 113 RSV4 RR-RF Electrical system WIRING TABLE N - LAMBDA PROBES 1. Rear lambda probe wiring harness routing WIRING TABLE N1 - LAMBDA PROBES THE CABLE GLAND MUST BE POSITIONED TOWARDS THE TOP AND LAMBDA SENSOR CABLE MUST BE ROUTED THROUGH IT ELE SYS - 113...
Page 114 RSV4 RR-RF Electrical system WIRING TABLE N2 - LAMBDA PROBES CHECK THAT THE FRONT LAMBDA PROBE CONNECTOR HAS BEEN CONNECTED COR- RECTLY 1. Front lambda probe wiring harness routing WIRING TABLE N3 - LAMBDA PROBES 1. Front lambda probe cable from main wiring har- ness 2.
Page 115 RSV4 RR-RF Electrical system WIRING TABLE O - AIR FILTER HOUSING ZONE Position the side stand switch, Quick Shift and gear sensor connectors under the two corrugated tubes WIRING TABLE O1 - AIR FILTER HOUSING ZONE Check that the clamp fastens all the cables, espe- cially the Quick Shift cable.
Page 116 RSV4 RR-RF Electrical system WIRING TABLE O - AIR FILTER HOUSING ZONE Check that the quick shift sensor connector is con- nected correctly WIRING TABLE O - AIR FILTER HOUSING ZONE Check that the side stand switch connector is con- nected correctly.
Page 117 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 118 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 TABLE C2 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION When the connector is fully inserted, the measured...
Page 119 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 120 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 bracket tongue TABLE E2 - REAR SEAT POST AREA Fuse-box positioning on battery mounting bracket...
Page 121 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- ter diagnostic connectors in their respective hous- ings 1.
Page 122 RSV4 RR-RF Electrical system WIRING TABLE F - ENGINE BATTERY EARTH CABLE 1. Engine-battery earth cable 2. Cable grommet WIRING TABLE F1 - ENGINE BATTERY EARTH CABLE 1. Engine-battery earth cable 2. Large clamp 3. V4-MP control unit (if fitted) 4.
Page 123 RSV4 RR-RF Electrical system WIRING TABLE G - REAR STOP SWITCH 1. Rear stop switch connector 2. Large clamp WIRING TABLE H - SWINGARM ZONE 1. Rear brake switch wiring 2. Speed sensor wiring 3. Cable fasteners WIRING TABLE H1 - SWINGARM ZONE 1.
Page 124 RSV4 RR-RF Electrical system WIRING TABLE I - REAR ABS SENSOR Route the rear brake switch (2) and rear ABS sen- sor (3) wiring harness through the cable gland (1) ELE SYS - 124...
Page 125 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 - 125...
Page 126 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 14.Exhaust valve motor 15.Front stop switch...
Page 127 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 56.Coil 57.Spark plug...
Page 128 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 129 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. IMPORTANT: WHERE GROUND IS PROVIDED BY THE ECU, CHECK THAT THE ECU IS EFFEC- TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURING THE TEST.
Page 130 RSV4 RR-RF Electrical system • 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 B0004 Immobilizer fault • read key code not read (key not present or transponder not working) Error cause •...
Page 131 RSV4 RR-RF Electrical system • To carry out the one or more key pro- gramming procedures, up to a maxi- mum of four, you must connect the motorcycle to the diagnostic tool. • Turn key to "ON" and insert the USER CODE where required.
Page 132 RSV4 RR-RF Electrical system • The second key is stored and you will be asked to enter the third key (if you have one). The same operation will be repeated to store the fourth key. • To complete AND end the memorisa- tion procedure, set key to "OFF".
Page 133 RSV4 RR-RF Electrical system • Select "SELF-DIAGNOSIS"; • Select "ACTIVATIONS"; • Enable the command "SERVICE RE- SET". Battery recharge circuit RECHARGING SYSTEM • Remove the left side fairing; • Disconnect the three-way connector (1) (white). NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A" Measurement of resistance (with engine off) •...
Page 134 RSV4 RR-RF Electrical system • Resistance of the wires read on the display = 0.47 Ohm • Effective resistance stage 1 = 0.62-0.47 = 0.15 Ohm • If there is a significant difference between one stage and another (other than 0.15 Ohm), this means that the alternator is defective and must be replaced.
Page 135 RSV4 RR-RF Electrical system ERO LOAD VOLTAGE 2000 4000 6000 8000 Vm line-to-line voltage Reference values (V rms) 22 - 27 46 - 51 69 - 74 92 - 97 Short-circuit current • For a correct detection of the short-cir- cuit current, a connector must be pre- pared that generates a downstream short circuit between the three alterna-...
Page 136 RSV4 RR-RF Electrical system Start-up system check Function Communicates to the control unit the will to start- up the engine. Operation / Operating principle Press the start-up button to close the specific cir- cuit taking the PIN 58 of the control unit to a voltage equal to zero (ground closing).
Page 137 RSV4 RR-RF Electrical system • Fault in the switch (lock) of the engine start-up. A continuous voltage close to 0 was detected for a certain time (e.g. locked button). • The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting •...
Page 138 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 139 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 the control unit Position: •...
Page 140 RSV4 RR-RF Electrical system • Track A position sensor / - (track A handle position sensor) • Track B position sensor / - (track B handle position sensor) • % of handle openings / - (percentage of handle openings) • Rear thr.val.
Page 141 RSV4 RR-RF Electrical system • Ign. sw. ass. err. count / - (ignition switch assembly errors count) • Equiv. km rest counter / - (counter of the resets perform on the partial equivalent km) • Gear sensor voltage/ - • Front lambda 2 adap.
Page 142 RSV4 RR-RF Electrical system • Rear brake lever switch / - (rear brake lever switch) • ON-OFF cruise button/ - (indicates the status of the button concerning the cruise control on the steering wheel) • Cruise control SET + / - •...
Page 143 RSV4 RR-RF Electrical system • Circuit not functioning Error cause: • Replace the injection control unit. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light. NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. P0605 ROM Error Electrical diagnosis: •...
Page 144 RSV4 RR-RF Electrical system • If short circuit to negative: check the correct electrical characteristics of the relay by discon- necting it from the wiring harness, if not ok replace the relay, if ok restore the wiring harness (blue/pink cable) •...
Page 145 The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting • Perform the troubleshooting for the other detected errors. P1608 a-PRC (Aprilia Performance Ride Control) functional error Electrical diagnosis: • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit...
Page 146 RSV4 RR-RF Electrical system • Saved data download / - (saved data download CAUTION AFTER CANCELLING ALL THE DATA STORED DURING THE VEHICLE PRODUCTION PHASE (INCLUDING THE SELF-ADAPTIVE PARAMETERS), THE FOLLOWING MUST BE SELECTED: HANDLE SELF-LEARNING AND CHECK THE TWO "AUTOMATIC SELF-LEARNING OF THE FRONT THROTTLE VALVES"...
Page 147 RSV4 RR-RF Electrical system 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. DIAGNOSTIC TOOL: LOGIC ERRORS P0560 Battery voltage •...
Page 148 RSV4 RR-RF Electrical system Speed sensor FRONT VEHICLE ABS SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel. Operation / Operating principle: Magneto-resistive sensor: generates a square wave signal with an amplitude of approximately 1V between PIN3 and PIN12 of the ABS control unit.
Page 149 RSV4 RR-RF Electrical system • between PIN 3 of the ABS control unit and PIN 1 of the sensor (white cable) • between PIN 12 of the ABS control unit and PIN 2 of the sensor (white/brown cable) Short-circuit to negative: - Disconnect the sensor connector.
Page 150 RSV4 RR-RF Electrical system • Connect to the ABS control unit diagnosis. REAR VEHICLE SPEED SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel. Operation / Operating principle: Magneto-resistive sensor: generates a square wave signal with an amplitude of approximately 1V between PIN14 and PIN13.
Page 151 RSV4 RR-RF Electrical system Error cause: • Open circuit: circuit interruption detected. • Short-circuit to negative: null voltage detected on PIN 14 of the ABS control unit. • Short-circuit to positive: excessive voltage detected on PIN 14 of the ABS control unit. Troubleshooting: Open circuit: - Check the connectors on the component and on the ABS control unit.
Page 152 RSV4 RR-RF Electrical system • Connect to the ABS control unit diagnosis. Engine rpm sensor Function indicates the position and speed of the crankshaft at the Marelli control unit Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position Level in electrical circuit diagram: Engine speed sensor...
Page 153 RSV4 RR-RF Electrical system SOR, IF IT IS NOT OK REPAIR THE WIRING/REPLACE THE SENSOR, IF IT IS OK, CARRY OUT THE TEST ON PINS 20 TO 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR. DIAGNOSTIC TOOL: LOGIC ERRORS P0336 Engine rpm sensor Functional diagnosis: •...
Page 154 RSV4 RR-RF Electrical system 6. B track signal (light blue cable) DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0225 Track A handle position sensor Electrical diagnosis: • short circuit to positive / open circuit, short circuit to negative Error cause • Short-circuit to positive: an excessive voltage was detected at PIN 39 of the ENGINE con- nector.
Page 155 RSV4 RR-RF Electrical system • short circuit to positive:check the value indicated by the parameter handle position sensor track B: disconnect the connector and read the value indicated by the diagnostic tool: if the voltage does not vary, there is a short circuit on the wiring harness of the relative cable, if the voltage goes to zero, replace the handle sensor.
Page 156 RSV4 RR-RF Electrical system Intake pressure sensor Function The pressure sensors (one per bank), are funda- mental for calculation of generated torque, for cal- culation of ambient pressure and for correct ignition timing during start-up. Operation / operating principle Diaphragm sensor which translates the diaphragm position into electrical voltage when in contact with the intake air.
Page 157 RSV4 RR-RF Electrical system • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure (1 and 3) • Example value with key ON: 1004 mbar • Example value with engine on: 735 mbar •...
Page 158 RSV4 RR-RF Electrical system • Short-circuit to positive: excessive voltage has been detected on PIN 49. If open circuit, short circuit to negative: voltage equal to zero detected at PIN 49. Troubleshooting • Short-circuit to positive: check on the diagnostic tool if the parameter of the rear cylinders air Pressure Sensor reads approx.
Page 159 RSV4 RR-RF Electrical system activated. The most frequent cases can be: abnormal resistance in the sensor circuit (for example, rusted terminals) or sensor with poor performance. Troubleshooting • Check the filter box large connector, the Marelli control unit connector and the sensor con- nector;...
Page 160 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: there is a very evident defect in the intake and pressure reading sys- tem.
Page 161 RSV4 RR-RF Electrical system Engine temperature sensor Function It is used to indicate to the control unit the engine temperature, to optimise it behaviour and to cal- culate the engine friction for a better estimation of the to the delivered torque. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
Page 162 RSV4 RR-RF Electrical system • Example value with key ON: -40° C • Example value with engine on: 25° C • The value of the engine start-up temperature is saved. At key ON, the value -40°C is read. CAUTION 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.
Page 163 RSV4 RR-RF Electrical system Troubleshooting • Check the sensor connector and the ENGINE connector of the Marelli control unit. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then use the diagnostic tool to check if the temperature indicated is the same as the engine temperature.
Page 164 RSV4 RR-RF Electrical system Value determined from the signal read without tak- ing into consideration the recovery mode: the il- lustrative value refers to an open circuit 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 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 166 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 167 RSV4 RR-RF Electrical system • Short circuit to positive Error cause: • Excessive voltage detected (battery voltage) at PIN 9 and 38 of the ENGINE connector. Caution: the "lambda probe" parameter is not the actual read value but a recovery value is displayed.
Page 168 RSV4 RR-RF Electrical system ample, voltage not variable). If the indication is abnormal, perform the troubleshooting indicated below. Troubleshooting • Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: if NOT OK, restore;...
Page 169 RSV4 RR-RF Electrical system (REAR 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 170 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 171 RSV4 RR-RF Electrical system • Short circuit to positive. Error cause: • Excessive voltage detected (battery voltage) at PIN 10 and 22 of the ENGINE connector. Caution: the "lambda probe" parameter is not the actual read value but a recovery value is displayed.
Page 172 RSV4 RR-RF Electrical system with the key ON and the sensor connector disconnected, check if there is battery voltage at PIN 4: if NOT OK, check the continuity of the Red//Brown cable between the probe connector and the injection relay (no. 33 in the electrical circuit diagram, position under the saddle, close to the battery positive;...
Page 173 RSV4 RR-RF Electrical system • If no switching from high: the fault may be generated in the supply system (poor pin sealing) or in the probe. Check the wiring harness. if NOT OK restore; if OK, replace the lambda probe. •...
Page 174 RSV4 RR-RF Electrical system Coils and injectors Position: • on the vehicle: on the throttle body • connector: on injectors Electrical specifications: 14.8 Ω ± 5% (at ambient temp.) Pin out: • "+": supply • " ": ground DIAGNOSTIC TOOL:PARAMETERS Cylinder injection time 1 •...
Page 175 RSV4 RR-RF Electrical system and injector activation. Electrical continuity is required in the wiring for the relay to activate correctly: no errors are generated if the relay fails to activate Lower injector cylinder 3 • 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 176 RSV4 RR-RF Electrical system • short circuit to positive / short circuit to negative / open circuit Error cause • Short-circuit to positive: excessive voltage has been detected on ENGINE PIN 46. If short circuit to negative: no voltage has been detected. If open circuit: an interruption has been detected Troubleshooting •...
Page 177 RSV4 RR-RF Electrical system • short circuit to positive / short circuit to negative / open circuit Error cause • Short-circuit to positive: excessive voltage has been detected on ENGINE PIN 45. If short circuit to negative: no voltage has been detected. If open circuit: an interruption has been detected Troubleshooting •...
Page 178 RSV4 RR-RF Electrical system 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. Operation / Operating principle Injector coil is energised for the petrol passage to open Level in electrical circuit diagram:...
Page 179 RSV4 RR-RF Electrical system • 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 180 RSV4 RR-RF Electrical system • Short-circuit to positive: excessive voltage has been detected on VEHICLE PIN 67. If short circuit to negative: no voltage has been detected. If open circuit: an interruption has been detected Troubleshooting • Short-circuit to positive: disconnect the injector connector, set key to ON, activate the com- ponent with the diagnostic tool and check the voltage on the white/green cable on the injector connector: if there is voltage, restore the filter box cable harness.
Page 181 RSV4 RR-RF Electrical system • Short-circuit to positive: excessive voltage has been detected on VEHICLE PIN 68. If short circuit to negative: no voltage has been detected. If open circuit: an interruption has been detected Troubleshooting • Short-circuit to positive: disconnect the injector connector, set key to ON, activate the com- ponent with the diagnostic tool and check the voltage on the White/Blue cable on the injector connector: if there is voltage, restore the filter box cable harness.
Page 182 RSV4 RR-RF Electrical system as follows: connect in series a bulb of approxi- mately 2 W: it should turn on if the tank is in reserve, otherwise, it remains off. Pin out: 1. + 12 V 2. ground connection 3. ground connection 4.
Page 183 RSV4 RR-RF Electrical system Coil Function Spark generation Operation / Operating principle With inductive discharge Level in electrical circuit diagram: coils and injectors Position: • on the vehicle: on the big end covers. • connector: For each coil 3 way black connector.
Page 184 RSV4 RR-RF Electrical system DIAGNOSTIC TOOL: ACTIVATIONS Coil 1: The 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 cables) is energised for 5 seconds and the Brown/Yellow cable of the coil is closed to ground for 2 ms per each second.
Page 185 RSV4 RR-RF Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 28 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil. •...
Page 186 RSV4 RR-RF Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 2 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil. •...
Page 187 RSV4 RR-RF Electrical system • on the vehicle: inside the filter box • connector: on the throttle body, in lower position, near the throttle motors Pin out: 1. potentiometer signal 1 2. supply voltage + 5V 3. throttle valve control command (+) 4.
Page 188 RSV4 RR-RF Electrical system • Example value with key ON: 873 mV • Example value with engine on: 561 mV Rear throttle Potentiometer 1 (voltage) • Example value with key ON: 883 mV • Example value with engine on: 536 mV Front throttle Potentiometer 2 (voltage) •...
Page 189 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 Voltage stored in the control unit corresponding to the Limp home position Front throttle lower position...
Page 190 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 CAUTION IF ERRORS ARE DETECTED ON BOTH THROTTLE BODIES, CHECK ALSO THE CORRECT SUP- PLY OF THE CONTROL UNIT TO PIN 42.
Page 191 RSV4 RR-RF Electrical system insulated, check that the power supply (+5 V) is present at PIN 2 of the throttle body con- nector and that ground is present at PIN 6, if present correctly replace the throttle body Front bank throttle valve position potentiometer sensor P0220 •...
Page 192 RSV4 RR-RF Electrical system • short circuit to positive / short circuit to negative / open circuit, overcurrent, excessive internal temperature Error cause • Short-circuit to positive: excessive voltage detected on PIN 29 or 41 of the 7SM control unit. If short circuit to negative: no voltage has been detected.
Page 193 RSV4 RR-RF Electrical system connector of the throttle body and the control unit connector and check cable 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 194 RSV4 RR-RF Electrical system • Check the throttle body connector and the control unit connector. Check that the resistance of the cable between the throttle body connector (PIN 1) and the control unit (PIN 48) is a few tenths of ohm. Check that the resistance of the cable between the throttle body con- nector (PIN 4) and the control unit (PIN 50) is a few tenths of ohm.
Page 195 RSV4 RR-RF Electrical system 4) and the throttle control unit (PIN 21) is a few tenths of an Ohm. If one of the two is different, restore the wiring harness if ok replace the complete throttle body Rear throttle valve Limp Home self-acquisition P1400 •...
Page 196 RSV4 RR-RF Electrical system • Low power supply voltage Error cause • The throttle valve power supply voltage is too low to correctly perform the self-learning test (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 197 RSV4 RR-RF Electrical system • Check the cleanliness of the throttle body and the intake duct. If ok replace the throttle body Front throttle valve recovery conditions detection (Tair,Twater) P1409 • Ice possibly present Error cause • in conditions of low ambient temperature and engine temperature, a correct throttle valve rotation was not detected: possible presence of ice in the duct (at each key ON).
Page 198 RSV4 RR-RF Electrical system • Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure. If the error is displayed again, it may mean a mechanical problem at the throttle boy. • Check the cleanliness of the throttle body and the intake duct. Check if there are any me- chanical ruptures.
Page 199 RSV4 RR-RF Electrical system Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure (0.5 +/-0.2 bar) in the engine. Operation / Operating principle Switch normally closed (control unit signal to ground). The switch opens at pressure values above 0.5 ±...
Page 200 RSV4 RR-RF Electrical system • Check if oil pressure is low with the specific gauge. Neutral sensor Function Indicates to the control unit the position of the gearbox, from 1st gear to 6th gear, and if the gearbox is in neutral or drive. Operation / Operating principle The sensor is comprised of 2 circuits: one to indicate the gear engaged, whose potential difference varies depending on the engaged gear: in this way, depending on the detected electric voltage, the...
Page 201 RSV4 RR-RF Electrical system • Yes/No gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0914 Gear sensor Electrical diagnosis: • short circuit to positive or open circuit / short circuit to negative / signal not plausible. Error cause •...
Page 202 RSV4 RR-RF Electrical system Position: • on the vehicle: on the handlebar. • connector: on the sensor. Electrical specifications: • Clutch engaged: closed circuit (con- tinuity) • Clutch released: open circuit (infinite resistance). Pin out: 1. voltage 5V 2. ground lead CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 203 RSV4 RR-RF Electrical system • If there is one contact: the plausibility diagnosis cannot occur only at key ON but during operation. The control unit logic requires that the released/engaged and engaged/released witching time does not exceed a certain threshold. If the operating time is too long, the error is shown.
Page 204 RSV4 RR-RF Electrical system • connector: between the big end cover and the left side filter housing (2 way white connector) Pin out: 1. Ground 2. 12 V voltage Electrical specifications: • Side Stand Up: closed circuit (continu- ity) • Side Stand Down: open circuit (infinite resistance) CAUTION...
Page 205 RSV4 RR-RF Electrical system Electric fan circuit Function Activates coolant radiator fan Operation / Operating principle When the ECU detects a temperature of approxi- mately 101°C, it closes the connection between the fan control relay excitation circuit and ground Level in electrical circuit diagram: electric fan Position: •...
Page 206 RSV4 RR-RF Electrical system P0480 Cooling fan command Electrical diagnosis: • short circuit to positive/ short circuit to negative / open circuit Error cause: • Short-circuit to positive: excessive voltage has been detected at PIN 61 of the VEHICLE connector. •...
Page 207 RSV4 RR-RF Electrical system Electrical specifications: Resistance at ambient temperature: 21 +3/- 1 Ω Pin out: 1. Power supply V batt 2. Ground DIAGNOSTIC TOOL:PARAMETERS Secondary air valve duty cycle • Example value with key ON: 0 % • Example value with engine on: % Used only at 0 or 100% CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 208 RSV4 RR-RF Electrical system RUN/STOP switch Function Indicates the control unit if the rider wishes to en- able engine start-up or to keep the engine running. Operation / Operating principle If you want to stop the engine or to prevent it from starting, the switch must be open, meaning that PIN 78 of the VEHICLE connector of the Marelli control unit must not be grounded.
Page 209 RSV4 RR-RF Electrical system the Yellow/Red cable: if there is continuity with the ground, restore the wiring harness; if ok, turn the key to OFF and perform the VEHICLE connector and engine-vehicle wiring harness connector check: if not ok, restore; if ok, check the continuity of the Yellow/Pink cable be- tween the switch connector and the VEHICLE connector PIN C7 and PIN 78: if not ok, restore the wiring harness;...
Page 210 RSV4 RR-RF Electrical system • on the vehicle: The motor is located in the front lower part of the engine. The valve in the exhaust pipe. • connector: on the motor. Electrical specifications: • Electric motor resistance (PIN 4-5): 2-4 •...
Page 211 RSV4 RR-RF Electrical system • If the potentiometer signal is above the maximum threshold: a voltage of the maximum limit stop (open valve) was detected outside the established range. • If the potentiometer signal is under the minimum threshold: a voltage of the minimum limit stop (closed valve) was detected outside the established range.
Page 212 RSV4 RR-RF Electrical system • If open circuit: a too low current consumption was detected at PIN1/PIN10 of the instrument panel connector. • If thermal protection: anomaly at the instrument panel. • If short circuit to negative: voltage equal to zero has been detected. •...
Page 213 RSV4 RR-RF Electrical system Troubleshooting: • Short-circuit to positive: disconnect the valve connector and check with the key ON if there is ground continuity at PIN 5 of the connector: if there is voltage, disconnect the instrument panel connector as well, and if there is voltage, restore the wiring harness and if there is no voltage, replace the instrument panel;...
Page 214 RSV4 RR-RF Electrical system AFTER EACH MAINTENANCE OR CHECK OPERATION AT THE EXHAUST VALVE, PERFORM THE "EXHAUST VALVE CABLES CLEARANCE ADJUSTMENT" PROCEDURE. The system consists of a throttle valve with return spring on the exhaust. The valve is closed by means of the two cables moved by an electric motor in its turn electrically connected to the instrument panel.
Page 215 RSV4 RR-RF Electrical system ADJUSTING THE PLAY OF THE EXHAUST THROTTLE VALVE CABLES • Check that the battery voltage is NOT below 12V; • Check that the cylinders are in their seat and are NOT obstructed. If the cylinders are obstructed, put them in their seats straight;...
Page 216 RSV4 RR-RF Electrical system • Bring the two adjuster screws of the cables to zero, fully tightening them. CAUTION BRING BOTH NUTS OF THE TWO ADJUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE, WELDED TO THE SI- LENCER; • Connect the PADS and carry out the "valve zero" (actuator in the corresponding valve fully open position);...
Page 217 RSV4 RR-RF Electrical system • Use the closing cable adjuster screw up to the value corresponding to the value "X" (see values in the table); CAUTION TURN THE ADJUSTER SCREW FULLY ANTI-CLOCKWISE (DIRECTION FOR TENSIONING THE ADJUSTER SCREW), KEEPING THE COUNTER-NUT STILL. DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS, SINCE THE AD- JUSTMENT IS DISTORTED DUE TO THE PLAY.
Page 218 RSV4 RR-RF Electrical system XHAUST VALVE CLEARANCE Condition of use Closing cable - Value "X" Opening cable - Value "Y" New cables 4 +0.2mm (0.16 +0.0078 in) 1 -0.2mm (0.04 -0.0078 in) At 1,000 km (621.37 mi) and at every service 3 -0.2 mm (0.12 -0.0079 in) 1 +0.2 mm (0.04 +0.0079 in) NOTE...
Page 219 RSV4 RR-RF Electrical system Engaged released. DIAGNOSTIC TOOL: ELECTRICAL ERRORS P1900 Quick Shift sensor Electrical diagnosis: • Short circuit to negative (at key ON) / Short circuit to positive (at key ON) Error cause: • If short circuit to negative: voltage equal to zero is detected at PIN 11 at key ON. •...
Page 220 RSV4 RR-RF Electrical system • blocked signal in UP / blocked signal in DOWN / signal not plausible Error cause: • If the signal is blocked in UP: internal spring of the switch blocked in UP • If the signal is blocked in DOWN: internal spring of the switch blocked in DOWN •...
Page 221 RSV4 RR-RF Electrical system • PIN 1: + 12 V power supply (green- brown) • PIN 2: ground (black-black) • PIN 3: ground (brown-black) • PIN 4: + 12 V power supply (blue-blue) • PIN 5: + 12 V power supply (yellow- white) •...
Page 222 RSV4 RR-RF Electrical system panel: if voltage is below 1 V, it means that on the blue cable there is a short circuit to ground; if voltage is above 1 V (approximately battery voltage), replace the "-" button sensor. Indication on diagnostic tool "Invalid data due to open circuit error"; •...
Page 223 RSV4 RR-RF Electrical system • CASE 2): if this status is displayed only with control activated, it means that at that moment a voltage below 1V, instead of battery, is being detected at PIN 20 of the instrument panel; disconnect the gearshift control connector and read voltage at PIN 20 of the instrument panel: if voltage is below 1 V, it means that on the brown cable there is a short circuit to ground;...
Page 224 RSV4 RR-RF Electrical system • Pin 4: supply (brown) DIAGNOSTIC TOOL: ELECTRICAL ERRORS DIAGNOSTIC TOOL: LOGIC ERRORS P1901 Ax acceleration sensor plausibility Functional diagnosis: • 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.
Page 225 RSV4 RR-RF Electrical system 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. NOTE: The instrument panel does not indicate the presence of this error even in the ATT status.
Page 226 RSV4 RR-RF Electrical system Engine pinout key: • PIN 1 - Cylinder 4 coil control output • PIN 2 - Cylinder 3 coil control output • PIN 3 - Output for front throttle valve engine command (+) • PIN 4 - Sensor ground 2 ELE SYS - 226...
Page 227 RSV4 RR-RF Electrical system • PIN 5 - Power ground 1 • PIN 6 - Sensor ground 1 • PIN 7 - • PIN 8 - Cylinder 1 lower injector command output • PIN 9 - Lambda sensor 2 input (+) •...
Page 228 RSV4 RR-RF Electrical system • PIN 42 - Key input • PIN 43 - Secondary air valve command output • PIN 44 - Lambda 2 heater command output • PIN 45 - Cylinder 4 lower injector command output • PIN 46 - Cylinder 2 lower injector command output •...
Page 229 RSV4 RR-RF Electrical system • PIN 54 - • PIN 55 - • PIN 56 - Clutch sensor input • PIN 57 - Sensor ground 2 • PIN 58 - Engine start button input • PIN 59 - • PIN 60 - •...
Page 230 RSV4 RR-RF Electrical system • PIN B1 - Injection power supply • PIN B2 - CAN line (high) • PIN B3 - CAN line (low) • PIN B4 - Key • PIN B5 - Electric fan relay control • PIN B6 - •...
Page 231 RSV4 RR-RF Electrical system Dashboard Instrument panel pinout key: • PIN 1 - Valve command at the exhaust (A terminal) • PIN 2 - Antenna 1 • PIN 3 - Antenna 2 • PIN 4 - • PIN 5 - •...
Page 232 RSV4 RR-RF Electrical system • PIN 20 - Normally closed "+" DC switch • PIN 21 - • PIN 22 - Normally open "-" TC switch • PIN 23 - Rear stop switch • PIN 24 - Ground • PIN 25 - Ground •...
Page 233 RSV4 RR-RF Electrical system • PIN 4 - Key positive (ECU) • PIN 5 - K serial line for diagnosis • PIN 6 - • PIN 7 - • PIN 8 - • PIN 9 - Battery positive for valves •...
Page 234 RSV4 RR-RF Electrical system The communication protocol is CSMA/CD (Carrier Sense Multiple Access w/ Collision Detection). In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense). If during this period there is no activity on BUS, every nod has the same chance to send a message (Multiple Access).
Page 235 RSV4 RR-RF Electrical system • Carry out the Marelli control unit and the engine-vehicle wiring harness connectors check procedure: if not OK, restore; if OK, check the ground insulation of the two CAN lines from PIN 66 and PIN 80 of the VEHICLE connector: if not ok, restore the wiring harness; if ok, check the continuity of the CAN lines from the VEHICLE connector of the Marelli control unit to the instrument panel connector, or to the LH lights switch connector, or to the ABS mod- ulator connector: if not ok, restore the wiring harness;...
Page 236 RSV4 RR-RF Electrical system • Intermittent signal or communication error Error cause: • Probable bad contact in the CAN line. This error is not indicated even in the ATT status. Troubleshooting: • Perform the check procedure for the VEHICLE connector at PIN 66 and PIN 80 an of the PIN B2 and PIN B3 of the engine-vehicle wiring harness connector;...
Page 237 RSV4 RR-RF Electrical system connector; if NOT OK restore and if OK check the general operation of the Marelli control unit and of the LH light switch; in case of anomalies, replace the part concerned. NOTE THIS ERROR DISABLES THE CRUISE CONTROL. DIAGNOSTIC TOOL: LOGIC ERRORS U0121 "ABSENT NODE"...
Page 238 (Sensor box), the correct status we should find on the diagnostic tool devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a vehicle equipped with inertia sensor platform (Sensor box) and diagnostic tool...
Page 239 RSV4 RR-RF Electrical system THIS ERROR DISABLES THE TRACTION CONTROL. P0564 Cruise control button - Brake switch Electrical diagnosis: • (brake sensors errors) connect to the instrument panel diagnosis Error cause • Malfunction or communication interruption from the button on the light switch control. •...
Page 240 RSV4 RR-RF Electrical system • Unscrew and remove the two screws (2); Remove the instrumentation lid • 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 USB port connector.
Page 241 RSV4 RR-RF Electrical system Installazione • Unscrew and remove the screws (1) Remove the top fairing glass from the seats of the motorcycle • Unscrew and remove the two screws (2); Remove the instrumentation lid • Move the instrument panel to the right, so as to remove it from its seat.
Page 242 RSV4 RR-RF Electrical system • Insert the rubber gasket housing the USB port (4) into the support bracket (3). • Then insert the USB port (5) in the rub- ber gasket (4). • Operating from the left vehicle side, in- sert the nut in the corresponding hous- ing on the headlamp.
Page 243 RSV4 RR-RF Electrical system Aprilia V4-MP Tecnology Sincronizzazione To use the system V4-MP the synchronisation that differs depending on the operating system must be performed: iOS OPERATING SYSTEM • Turn the ignition switch of the motor- cycle ON with the PMP ECU correctly connected.
Page 244 RSV4 RR-RF Electrical system • Once BlueTooth is enabled, the smart- phone automatically searches devi- ces. When the PMP ECU has been recognized, it appears in the "MY DE- VICES" list as PMP. Click on "PMP" and wait for the smartphone to con- nect.
Page 245 RSV4 RR-RF Electrical system • Inside the "BlueTooth" page if Blue- Tooth is not active, proceed to activate it by pressing the button indicated by the arrow BlueTooth active -> green button. Wait for the smartphone to rec- ognize the PMP ECU until you see PMP in "Available devices"...
Page 246 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 247 RSV4 RR-RF Engine from vehicle EAR LEVER Pos. Description Type Quantity Torque Notes Pinion protection guard fastening 6 Nm (4.43 lb ft) screws Threaded spacer 8 Nm (5.90 lb ft) Countersunk, flat head, hex. socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 248 RSV4 RR-RF Engine from vehicle Removing the engine from the vehicle • Move the clamps (4) and disconnect the water pipe with the connector from the engine in order to empty the system • Move the clamp (5) and disconnect the water pipe from the radiator fluid tank •...
Page 249 RSV4 RR-RF Engine from vehicle • 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 250 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 251 RSV4 RR-RF Engine from vehicle • Remove the fixing screw (16) and slide off the chain slider (17) • Remove the fixing screw (18) of the chain guide plate (19) • Cut the two clamps (20) that connect the wiring of the quick-shift to the wiring of the side stand and of the lambda probe •...
Page 252 RSV4 RR-RF Engine from vehicle • 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- • Undo the two fixing screws and remove side stand (24) •...
Page 253 RSV4 RR-RF Engine from vehicle • 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 • Loose the clamp (32) that blocks the silencer at the central manifold •...
Page 254 RSV4 RR-RF Engine from vehicle • 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 silencer at the central manifold • Remove the screw (33) and the nut locking the silencer at the rider footrest ENG VE - 254...
Page 255 RSV4 RR-RF Engine from vehicle • Slide off the central manifold and re- move the silencer • Remove the fixing clamp (34) of the exhaust valve wiring • Disconnect the connector (35) of the exhaust valve • Disconnect the connector (35) of the exhaust valve ENG VE - 255...
Page 256 RSV4 RR-RF Engine from vehicle • 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 (38) • Remove the four fixing screws (39) of the rear exhaust manifolds ENG VE - 256...
Page 257 RSV4 RR-RF Engine from vehicle • 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 • Remove the rubber cap (44) •...
Page 258 RSV4 RR-RF Engine from vehicle • 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- tor (49) • Remove the clamp (50) that locks the main wiring at the ABS system pipes ENG VE - 258...
Page 259 RSV4 RR-RF Engine from vehicle • Remove the screws (51) to remove the ABS protection plate • Remove the protection plate (52) of the ABS system • Install the engine support and place a winch under it Specific tooling 020864Y Engine mounting plate •...
Page 260 RSV4 RR-RF Engine from vehicle • Remove the lower screw (55) fixing the engine to the chassis • Completely unscrew the internal lower bush (56) Installing the engine to the vehicle • Before aligning the engine retainers, place on the frame the internal and external right and left inserts, with the precautions described below.
Page 261 RSV4 RR-RF Engine from vehicle 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 -2.5 mm (- 0.098 in) relative to the cen- treline of the insert, as a result the swingarm is in the low position.
Page 262 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 263 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: • tighten the two front screws (1) to the prescribed torque.
Page 264 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 265 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 266 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 267 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 268 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. • Connect the starter motor, place the washer and tighten the nut.
Page 269 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). ENG VE - 269...
Page 270 INDEX OF TOPICS NGINE...
Page 271 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° cyl 4: 605°...
Page 272 RSV4 RR-RF Engine Gearbox EARBOX Pos. Description Type Quantity Torque Notes "Philips" cylindrical head hex. socket M6x20 10 Nm (7.38 lb ft) Loct. 243 screw Hex. socket flat head counter sunk M6x16 10 Nm (7.38 lb ft) Loct. 243 screw for fastening the bearing re- taining plates Flanged, hex.
Page 273 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. ENG - 273...
Page 274 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 275 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 276 RSV4 RR-RF Engine • 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 • Loosen and remove the screw (6) • Remove the desmodromic shaft (7) ENG - 276...
Page 277 RSV4 RR-RF Engine • 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 278 RSV4 RR-RF Engine Checking the secondary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side secon- dary shaft seat 29.97 mm (1.18 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in) Checking the desmodromic drum...
Page 279 RSV4 RR-RF Engine • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary. • Check the transmission fork movement and if it is not regular, replace the transmission forks. Assembling the gearbox •...
Page 280 RSV4 RR-RF Engine • Move the gearbox shafts together and fit them into the support • Grease the sliding bushes of the forks • 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 ENG - 280...
Page 281 RSV4 RR-RF Engine • Insert the fork (7) in the specific seat of the gearbox primary shaft • Insert the gearbox primary shaft con- trol rod (8) • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal.
Page 282 RSV4 RR-RF Engine • Remove the special tool from the alter- nator side. • Tighten the six screws that fasten the gearbox unit to the crankcase. Specific tooling 0277308 Guide bushing for gearbox secondary shaft • Insert the driving pin on the oil pump shaft.
Page 283 RSV4 RR-RF Engine GEARBOX CONTROL ROD ROLLER CAGE, CLUTCH SIDE • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side. Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod....
Page 284 RSV4 RR-RF Engine Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely. If necessary, replace the parts. Check the gear selector spring for damage and wear. If necessary, replace the part. Check the selector shaft and its teeth for damage and wear.
Page 285 RSV4 RR-RF Engine • Remove the starter motor (3) from its housing. Removing the idle gear • Remove the clutch cover. • Remove the intermediate gear. Start-up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL.
Page 286 RSV4 RR-RF Engine If deformations or broken material are found on the sliding surface, replace the freewheel gear (2). Check the freewheel sliding surface (2) for wear. Make sure that the woodruff key slot is in perfect condition. Remove the needle cage (3) and the roller cage (4) from their housings on the freewheel (2) and check the rollers/needles for wear.
Page 287 RSV4 RR-RF Engine • Fit the intermediate gear. • Fit the clutch cover. Generator side ENERATOR COVER Pos. Description Type Quantity Torque Notes Cover fastening screws M6x25 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque. Cover fastening screws M6x40 12 Nm (8.85 lb ft)
Page 288 RSV4 RR-RF Engine Removing the flywheel cover • Unscrew and remove the three fastening screws (1) from the soundproofing cover (2). • Remove the soundproofing cover (2). • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (3) and the three special screws (4).
Page 289 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 290 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 291 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) Tighten to torque, unscrew and re- tighten to torque.
Page 292 RSV4 RR-RF Engine 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) Removing the clutch cover • Drain the engine oil. •...
Page 293 RSV4 RR-RF Engine • Remove the clutch casing, retrieving the gasket, the two locator pins and the starter motor transmission gear. Disassembling the clutch • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. • Remove the clutch cover. •...
Page 294 RSV4 RR-RF Engine • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch lock • Remove the slipper unit. • Remove the clutch hub. • Remove the clutch hub cam tower. ENG - 294...
Page 295 RSV4 RR-RF Engine • Retrieve the shim. • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 295...
Page 296 RSV4 RR-RF Engine • Remove the spacer. • 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) Minimum wear limit of the complete clutch...
Page 297 RSV4 RR-RF Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness.
Page 298 RSV4 RR-RF Engine Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. • 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.
Page 299 RSV4 RR-RF Engine • Fit the needle cage. • 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 •...
Page 300 RSV4 RR-RF Engine • Install the clutch hub cam tower. • 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; •...
Page 301 RSV4 RR-RF Engine • Block clutch housing rotation using the specific tool. • Tighten the clutch housing fixing nut. Specific tooling 020849Y Clutch lock • Insert the disc with friction material and the black tooth into the bell. • Insert one of the metal discs into the bell.
Page 302 RSV4 RR-RF Engine • Insert the disc covered with friction ma- terial into the housing. • Insert the nitrided metal disc into the clutch housing. • Continue inserting, alternating a metal disc with one with friction material, end- ing with a friction material disc with a black tooth.
Page 303 RSV4 RR-RF Engine • Place the control rod together with the thrust bearing and the shim washer. • Place the thrust plate. • Fit the clutch springs (3). • Insert the spring holder cap (2) onto the screws (1). ENG - 303...
Page 304 RSV4 RR-RF Engine • Tighten the six screws operating in stages and diagonally. Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the removal of the bushing, it is necessary to thread the inside to allow the extractor to tighten sufficiently.
Page 305 RSV4 RR-RF Engine Specific tooling 020926Y Tool for fitting clutch bushing • Then insert the tool to push the bushing into the seat until it stops. • Position the starting transmission gear on the crankcase. • Position the gasket and the two dowel pins in the clutch cover.
Page 306 RSV4 RR-RF Engine Heads ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.38 lb ft) TE flanged coil fixing screw M6x12 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft) ENG - 306...
Page 307 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) Pre-impregnated or...
Page 308 RSV4 RR-RF Engine Head cover removal • Unscrew and remove the three screws with rubber washers • 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.
Page 309 RSV4 RR-RF Engine Front head 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. • Rotate the crankshaft via the opening on the clutch cover. •...
Page 310 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 311 RSV4 RR-RF Engine Specific tooling 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 020850Y Primary gear lock 020914Y Flywheel retainer...
Page 312 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). Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK •...
Page 313 RSV4 RR-RF Engine • Install the intake and exhaust cam- shafts 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 cam- shaft gear (indicated with two dots). CLEAN THOROUGHLY THE SEATS OF THE GEAR RE- TAINER SCREWS, ON THE INTAKE CAMSHAFT.
Page 314 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 315 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. • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned;...
Page 316 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 317 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 318 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. • Remove the front head, slipping it off the stud bolts.
Page 319 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 320 RSV4 RR-RF Engine WASHER • We recommend installing a washer be- tween the front crankcase and the chain tensioner to optimise the func- tionality of the timing system. • This washer is available as a spare part. • Fit the washer onto the front chain tensioner then install the chain tensioner in the relative seat in the crankcase.
Page 321 RSV4 RR-RF Engine • 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. • Tighten the two screws according to the sequence (a - b).
Page 322 RSV4 RR-RF Engine • rotate the crankshaft 150° in the engine rotation direction (direction of travel). • insert the respective pin, from the fly- wheel side, into the groove on the crankshaft. NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT.
Page 323 RSV4 RR-RF Engine • Fit the U bolts with the nine O rings and locator pins. • Install the oil pipe. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the ten screws (1 - 2) working in stages and diagonally.
Page 324 RSV4 RR-RF Engine 020981Y Lever for disarming the hydraulic tensioner of the timing chain • 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.
Page 325 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 326 RSV4 RR-RF Engine 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 the engine's rotation (direction of travel) to align the hole on the intake camshaft with the specific hole on the U bolt;...
Page 327 RSV4 RR-RF Engine • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). Specific tooling 020956Y Support for camshaft gear on head • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer.
Page 328 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 329 RSV4 RR-RF Engine • Fit the U bolts with nine O rings and lo- cator pins. • Position the screws (4), taking care to insert new washers on the screws near the spark plug holes. • Loosen the distribution gear's lock screw and move the gear itself from the mounting tool to the camshaft.
Page 330 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 331 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 332 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 333 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 334 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. • Remove the rear head, slipping it off the stud bolts.
Page 335 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 336 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 337 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 338 RSV4 RR-RF Engine • Fit the U bolts with the nine O rings and locator pins. • Install the oil pipe. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the ten screws (1 - 2) working in stages and diagonally.
Page 339 RSV4 RR-RF Engine 020981Y Lever for disarming the hydraulic tensioner of the timing chain • 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.
Page 340 RSV4 RR-RF Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them correctly upon refitting. •...
Page 341 RSV4 RR-RF Engine Rear head removal • Remove the cotters using a magnet. • 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. •...
Page 342 RSV4 RR-RF Engine REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL. VALVE STEM DEVIATION Lift up the valve approx. 10 mm (0.39 in) from its seat.
Page 343 RSV4 RR-RF Engine Coating may get slightly damaged in the indicated area. Valve installation The intake valves are fitted with dual springs, while he exhaust valves only have a single spring. The intake springs are marked in orange (1) (ex- ternal) and blue (2) (internal), whereas the exhaust springs (3) are marked in white.
Page 344 RSV4 RR-RF Engine • Fit the caps. • 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 345 RSV4 RR-RF Engine • Position the bucket tappets. Crankcase RANKCASE Pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lb ft) Loct. 270 TE Flanged screw M8x70 25 Nm (18.44 lb ft) Lubricate the head and under the head. TE Flanged screw M6x50 10 Nm (7.38 lb ft)
Page 346 RSV4 RR-RF Engine Pos. Description Type Quantity Torque Notes TSPEI screw fixing bearing stop M6x16 10 Nm (7.38 lb ft) Loct. 243 plates Stud bolt Bring to 33mm from the Loct. 648 surface SHC screw M6x40 10 Nm (7.38 lb ft) Lubricate the head and under the head.
Page 347 RSV4 RR-RF Engine 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) Primary fixing ring nut 200 Nm (147.51 lb ft) Loct.
Page 348 RSV4 RR-RF Engine • Block crankshaft rotation using the specific tool. Specific tooling 020850Y Primary gear lock See also Removing the clutch cover Removing the flywheel cover • Unscrew and remove the nut and col- lect the washer • Remove the countershaft from the al- ternator side.
Page 349 RSV4 RR-RF Engine • Remove the key on countershaft • 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. ENG - 349...
Page 350 RSV4 RR-RF Engine • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR. •...
Page 351 RSV4 RR-RF Engine Main transmission gear removal • Remove the clutch. • Turn the crankshaft and align the ref- erences on the countershaft gear and the primary shaft gear. • Block crankshaft rotation using the specific tool. Specific tooling 020850Y Primary gear lock •...
Page 352 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. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO...
Page 353 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; • countershaft.
Page 354 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 355 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 356 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 • If the heads were removed, position the specific special tool to keep the pis- tons from coming out.
Page 357 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 358 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 Characteristic Maximum crankshaft axial clearance after closing the crankcase...
Page 359 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) Inspecting pistons...
Page 360 RSV4 RR-RF Engine crankshafts and connecting rods have been intro- duced which are matched with each other in rela- tion to their balancing class. The class is easily identifiable as it is marked on the component itself. The permitted crankshaft-connecting rod balancing class combinations are listed in the following table: CRANKSHAFT - CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Combinations of weight classes for...
Page 361 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 362 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 SHAFT CATEGORY The category of the three crankshaft main journals is stamped on the flat face of the counterweight,...
Page 363 RSV4 RR-RF Engine CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available for the connecting rods: • Blue • Yellow • Green For the coupling of the connecting rod with the crankshaft, according to the engraving on the counter- weights, observe the following table: ENG - 363...
Page 364 RSV4 RR-RF Engine USHINGS THICKNESS Bushing colours Thickness BLUE 1.547 - 1.552 mm YELLOW 1.552 - 1.557 mm GREEN 1.557 - 1.562 mm ONNECTING RODS COUPLING RANKSHAFT Selection connecting Big end class 1 Big end class 2 Required clearances Required clearances rod pin dimension class 1 class 2...
Page 365 RSV4 RR-RF Engine 020364Y 25 mm adapter 020359Y 42 x 47 mm punch 020376Y Sleeve for adaptors • Position the new bearing with its 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 366 RSV4 RR-RF Engine • 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. • Using the suitable tools, fit the bearing in the crankcase until tool stops.
Page 367 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 368 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 020850Y Primary gear lock Installing connecting rods - pistons The piston rings are different and must be fitted...
Page 369 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 workbench and the arrow (1) posi- tioned from the side opposite of the operator, fit the connecting rod shank...
Page 370 RSV4 RR-RF Engine • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces. • Use new connecting rod screws, lubri- cating the thread and under the head.. • Proceed with tightening according to the procedure described in the tighten- ing torque table using the torque wrench and angular tightening with a...
Page 371 RSV4 RR-RF Engine • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - •...
Page 372 RSV4 RR-RF Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 372...
Page 373 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 - 373...
Page 374 RSV4 RR-RF Engine UBRICATION SYSTEM 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 375 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 376 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. Installing •...
Page 377 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 378 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 379 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 CAUTION THE ROSE PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER-...
Page 380 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 381 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 Cylindrical head, hex.
Page 382 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 - 382...
Page 383 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 384 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 385 RSV4 RR-RF Power supply Injection Diagram key: 1. Control unit position 2. Throttle grip position sensor P SUPP - 385...
Page 386 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 14.Electric fan 15.Starter motor...
Page 387 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 388 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 389 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 390 INDEX OF TOPICS SUSP USPENSIONS...
Page 391 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 392 RSV4 RR-RF Suspensions • Remove the wheel hub fastening nut. • Retrieve the sealing washer. • Loosen the screws on the shaft clamps. • Strike the wheel pin gently using a rub- ber mallet in order to extract it more easily.
Page 393 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. ALWAYS REPLACE BOTH BEARINGS.
Page 394 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 20 Nm (14.75 lb ft) RH light switch...
Page 395 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 - 395...
Page 396 RSV4 RR-RF Suspensions RONT FORKS HLINS Pos. Description Type Quantity Torque Notes Calliper bracket fixing screws (Oh- 2 + 2 12 Nm (8.85 lb ft) lins) Speed sensor fastening screw 6 Nm (4.43 lb ft) Cable gland fastening screw 8 Nm (5.90 lb ft) (SACHS FORKS) RONT FORKS ACHS...
Page 397 RSV4 RR-RF Suspensions The right stem is also equipped with an upper ad- juster screw (1) for adjusting hydraulic rebound damping. RSV 1000 RR Each fork has a top adjustment screw (1) to set the rebound damping; an upper nut (3) to adjust the spring pre-loading and a lower adjustment screw (2) to modify the compression damping.
Page 398: Notches/ 8 Mm (2 Notches/0.31 In)
RSV4 RR-RF Suspensions FRONT FORK - RSV4 1000 RF - RACING ADJUSTMENT RANGE HLINS TRACK USE ONLY Specification Desc./Quantity Rebound damping adjustment, screw (1) Unscrew (**) 10 clicks from fully closed (*) Compression damping adjustment, screw (2) Unscrew (**) 7 clicks from fully closed (*) Spring pre-loading, nut (3) screw (*) 10 turns from fully open (**) Stems (A) protrusion from top plate (excluding cover)
Page 399 RSV4 RR-RF Suspensions Removing the fork legs • Remove the front wheel. • Support the fork shaft and loosen the screws on the upper plate. • Disconnect the clutch cable. • Loosen the screws on the handlebars. • Loosen the screws on the lower plate. •...
Page 400 RSV4 RR-RF Suspensions • Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring. • Unscrew the upper adjustment cap. • Remove the complete cap. • Unscrew the nut and remove it, exert- ing slight pressure on the pre-loading spring.
Page 401 RSV4 RR-RF Suspensions • Remove the pre-loading spring. • Drain the oil from the forks into a suit- able receptacle, taking care not to ex- tract the pre-loading pipe and the hydraulic rebound damping adjust- ment rod. (PROCEDURE FOR SACHS FORKS) NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STANCHIONS.
Page 402 RSV4 RR-RF Suspensions • Loosen the cover without unscrewing it completely. • Place the fork vertically locking it in a vice by the specific tool. • Completely unscrew the plug. Specific tooling AP8140149 Guard for assembly operations • Using the specific tool, fixed to the pre- loading pipe, compress the spring.
Page 403 RSV4 RR-RF Suspensions • Remove the spring preload pipe. • Remove the lock nut and the washer. • 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.
Page 404 RSV4 RR-RF Suspensions • Remove the pre-loading tube. • Remove the wheel holder shaft (1) and the sleeve (2). • Clamp the sleeve in a vice and, by lev- ering it alternately at various points, remove the anti-dust seal (3) from the sleeve (2).
Page 405 RSV4 RR-RF Suspensions • Remove the shaft seal (5) by levering it alternately at various points. CAUTION PROTECT THE EDGE OF THE SLEEVE IN ORDER TO AVOID RUINING IT WHILE REMOVING THE SHAFT SEAL (5). Replace the following components with new ones: - shaft seal (5) - anti-dust seal (3) CAUTION...
Page 406 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 407 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. Using a dial gauge, check than any bending of the stem is below the limit value.
Page 408 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. Spring Check that the spring is in good conditions.
Page 409 RSV4 RR-RF Suspensions • Install the following components on the wheel holder stanchion (1) in the order given: dust gaiter (3), retainer ring (4) and oil seal (5). • Fix the sleeve in a vice, taking care not to damage the sleeve. •...
Page 410 RSV4 RR-RF Suspensions • Position the two halves of the special tool on the shaft behind anti-dust seal (3), together with the respective buffer. • Grip the special tool and push the anti- dust seal (3) into its housing on the sleeve (2).
Page 411 RSV4 RR-RF Suspensions • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight •...
Page 412 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 Filling oil (PROCEDURE FOR OHLINS FORKS) •...
Page 413 RSV4 RR-RF Suspensions • Insert the pre-loading spring retaining ring (1). • Insert the nut (2). • While maintaining the spring com- pressed, tighten the nut as far as it will • Screw the complete cap into place on the plunger pin. •...
Page 414 RSV4 RR-RF Suspensions • Fill the forks with oil, according to the indicated quantities. • Wait a few minutes until the oil fills all the ducts. • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
Page 415 RSV4 RR-RF Suspensions • Position the forks vertically. • Insert the base washer. • Insert the nut on the plunger and hand tighten it • Position the pre-loading tube. • Screw the special tool onto the plunger shaft and maintain it in the raised po- sition as long as possible, in order to insert a wrench on the nut, while com- pressing the spring.
Page 416: Specification
RSV4 RR-RF Suspensions Steering damper Adjusting ONLY FOR VERSION RSV4 1000 RF: the steering damper can be adjusted by turning the knob (1). • Turning the knob (1) clockwise will cause the steering to take on a more rigid behaviour. •...
Page 417 RSV4 RR-RF Suspensions Removing The steering damper steering more precise and stable, improving motorcycle handling in all con- ditions The damper is fastened at the front of the motorcycle between the bottom yoke and the frame Removal: • Unscrew the chassis fixing screw. •...
Page 418 RSV4 RR-RF Suspensions pos. Description Type Quantity Torque Notes Upper yoke fixing cap M29x1 100 Nm (73.76 lb ft) Screw fastening shock absorber to 10 Nm (7.38 lb ft) Loctite 243 frame Screw fastening shock absorber to 10 Nm (7.38 lb ft) Loctite 243 lower yoke Lower cover fixing screws...
Page 419 RSV4 RR-RF Suspensions • Working from both sides, unscrew and remove the semi-handlebar screws. • Remove the upper yoke • 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.
Page 420 RSV4 RR-RF Suspensions • Tighten the lower lock ring to a torque of 70 Nm (51.63 lb ft). • Steer repeatedly completely left and completely right to allow the bearings to settle. • Loosen the ring nut. • Retighten the lock ring to the prescri- bed torque of 60 Nm +/- 9 Nm (44.25 lb ft +/- 6.64 lb ft).
Page 421 RSV4 RR-RF Suspensions • Fit the counter-lock ring, hand tighten- ing only. • To allow the tabs to be bent into the notches of the counter-lock ring in or- der to lock the ring, the counter-lock ring may be tightened further by up to 35°...
Page 422 RSV4 RR-RF Suspensions • Unscrew and remove the upper dowel fastening the collar. • Remove the upper collar. CAUTION ALWAYS CHANGE BOTH COLLARS (UPPER AND LOW- ER). Upper and lower collars are not interchangeable. To identify them, check the number printed on them: •...
Page 423 RSV4 RR-RF Suspensions Adjusting play Rear EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lb ft) Nuts for fastening crown to sprocket 50 Nm (36.88 lb ft) Rear brake disc fastening screws 30 Nm (22.13 lb ft) Loct.
Page 424 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 425 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 flange (4) FITTING •...
Page 426 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). CAUTION IN THIS WAY THE PRESSURE EXERTED BY THE FIXING ELEMENTS WILL BE EVENLY DISTRIBUTED ON THE...
Page 427 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 428 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. FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn.
Page 429 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 430 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). CAUTION THE CIRCLIP (17) IS FITTED ONLY ON THE FINAL DRIVE UNIT, LEFT SIDE.
Page 431 RSV4 RR-RF Suspensions Shock absorbers 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) rod to chassis The rear suspension consists of a spring-shock absorber unit linked to the frame via uniball joints...
Page 432: Rsv4 1000 Rr (Sachs Forks)
RSV4 RR-RF Suspensions TO AVOID COMPROMISING SHOCK ABSORBER OPERA- TION, DO NOT LOOSEN THE SCREW (5) AND DO NOT TAMPER WITH THE SEAL UNDERNEATH, AS NITROGEN MAY COME OUT RESULTING IN RISK OF ACCIDENTS. RSV4 1000 RR • To adjust the rebound damping, turn the ring nut (1);...
Page 433: Specification
RSV4 RR-RF Suspensions ALWAYS OBSERVE THE RECOMMENDED ADJUSTMENT RANGE. CAUTION CONSULT THE "SETTING UP" PARAGRAPH FOR THE PA- RAMETER SETTINGS. Adjusting (PROCEDURE FOR OHLINS FORKS) 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.
Page 434: Adjustment Range (Ohlins )
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 ADJUSTMENT ACHS FOR ROAD...
Page 435 RSV4 RR-RF Suspensions Removing • Secure the vehicle using a belt and hoist. • Remove the silencer and the right hand rider footpeg. • Unscrew and remove the lower screw and retrieve the nut. • Unscrew and remove the screw fixing the dual linkage rod to the single link- age.
Page 436 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 437 INDEX OF TOPICS CHAS HASSIS...
Page 438 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 Manual Front couplings 2 + 2...
Page 439 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) Front chain guide fixing screw...
Page 440 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 441 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 442 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 443 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 444 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 445 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). • Put some grease on the swingarm pin nut as indicated •...
Page 446 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 447 RSV4 RR-RF Chassis • Install the rear wheel and the exhaust system. • Fit the pinion casing. • Adjust the chain tension Drive chain Removing The transmission chain, although "closed", has a different coloured hammerlock (where provided), which should be used to perform opening / disas- sembling procedures.
Page 448 RSV4 RR-RF Chassis • Remove the outer O-ring rings (5). • Remove the inner plate (6). • Collect the inner O-ring rings (7) and completely remove the transmission chain. inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001.
Page 449 RSV4 RR-RF Chassis 2. Chain with chain stretch of 1.5%; 3. Chain with chain stretch of 3%, which must therefore be replaced in accordance with ap- plicable legislation. Perform the procedure described as follows to check chain wear: • Tauten the chain. •...
Page 450 RSV4 RR-RF Chassis • Compress the outer plate (4) using the appropriate generic tool. CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN. • Check that the links in the transmission chain are not seized and that it can move in both directions.
Page 451 RSV4 RR-RF Chassis Adjusting The vehicle has an endless chain, without master link. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Page 452 RSV4 RR-RF Chassis THERE ARE TWO FIXED REFERENCES (2-3) FOR WHEEL CENTRING THAT CAN BE FOUND ON THE SWINGARM. CHECKING WEAR OF CHAIN, PINION AND SPROCKET Also regularly check the following parts and make sure that the chain, the pinion and the sprocket do not show: •...
Page 453 RSV4 RR-RF Chassis Chain sliders • Place the vehicle on its OPTIONAL rear service stand. • Check that the pad (1) is not worn or damaged. Replace it with a new one if it is. • Check the chain guide (2) for wear. •...
Page 454 RSV4 RR-RF Chassis • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand IDE STAND Pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lb ft) Loct.
Page 455 RSV4 RR-RF Chassis Side stand • Remove the fuel tank. • Remove the pinion cover. • Remove the clamps. • Disconnect the stand connector. • Unscrew and remove the two screws. • Remove the side stand. CHAS - 455...
Page 456 RSV4 RR-RF Chassis Exhaust XHAUST Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lb ft) nuts Silencer clamp fastening screw - 20 Nm (14.75 lb ft) central manifold Screw used to secure the silencer to 25 Nm (18.44 lb ft) the RH footrest support Torx button head silencer aesthetic...
Page 457 RSV4 RR-RF Chassis • Remove the heat shield, taking care not to lose the washers. • Loosen the clamp between the ex- haust terminal and the central mani- fold. • Remove the screw together with the nut that fastens the exhaust to the frame, taking care not to lose the collar and washer.
Page 458 RSV4 RR-RF Chassis • Remove the exhaust terminal. INSTALLATION • Fit the exhaust terminal on the central manifold. • Connect the exhaust valve cables. • Tighten the screw together with the nut that fastens the exhaust to the frame (taking care to insert the collar and washer).
Page 459 RSV4 RR-RF Chassis • Tighten the clamp between the ex- haust terminal and the central mani- fold. • Carry out the "ADJUST PLAY ON EX- HAUST VALVE CABLES" procedure in the "EXHAUST VALVE" section of the chapter "ELECTRICAL SYSTEM". • Position the protection plate and fasten it to the exhaust terminal using the three screws.
Page 460 RSV4 RR-RF Chassis • Release the springs between the rear exhaust manifolds and the catalytic converter • Remove the catalytic converter. Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFOLD • Remove the front underfairings. • Remove the hand grip position sensor control unit. •...
Page 461 RSV4 RR-RF Chassis • Move the radiator forward. • Unscrew and remove the four nuts fas- tening the front exhaust manifold and retrieve the washers. • Remove the front exhaust manifold. REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg.
Page 462 RSV4 RR-RF Chassis Engine oil cooler ADIATORE OLIO Pos. Descrizione Tipo Quantità Coppia Note Screws fastening oil radiator to 7 Nm (5.16 lb ft) mounting bracket Viti TE fl. per fissaggio staffa a telaio M6x20 10 Nm (7.38 lbf ft) Removing •...
Page 463 RSV4 RR-RF Chassis • Release the clamp and disconnect the left hand radiator pipe. See also Replacement • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Unscrew and remove the lower radia- tor retainer.
Page 464 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 465 RSV4 RR-RF Braking system CONTROL UNIT Pos. Description Type Quantity Torque Notes Oil tube screws M10x1 23-26 Nm (16.96-19.18 lb ft) Control unit support screws 6.8+/-1 Nm (5.01 +/-0.74 lb ft) BRAK SYS - 465...
Page 466 RSV4 RR-RF Braking system Operating diagram ABS functional diagram key BRAK SYS - 466...
Page 467 RSV4 RR-RF Braking system 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. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Rear brake circuit intake solenoid valve (normally open) 12.Rear brake exhaust circuit solenoid valve (normally closed)
Page 468 RSV4 RR-RF Braking system B - Pressure reduction: coincides with the recognition of the dangerous situation (wheel slippage exceeds the threshold): the system closes the inlet valve (10-11) and opens the outlet valve (12-13) temporarily. At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the pressure on the callipers partially.
Page 469 RSV4 RR-RF Braking system When sensors (3) detect a significant speed difference between the rear and the front wheels (for example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation. In this case, 2 things may occur: - the ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel;...
Page 470 RSV4 RR-RF Braking system This function allows you to disable the ABS system that is normally active "On". By briefly pressing in the middle or shifting the MODE selector switch to the right, the "ABS" func- tion is highlighted in red. Shifting briefly upwards or downwards the function is deactivated "Off".
Page 471 RSV4 RR-RF Braking system • Use clamps to secure any axial move- ments of the hoses. • Reposition the front brake steel pipes in the conduit, secure the pipes using clamps and observing the tolerances indicated in the figure. Characteristic Pipe axial clearance 0 - 0.10 mm (0 - 0.39 in) •...
Page 472 RSV4 RR-RF Braking system REPLACING/ACTIVATING NEW ABS CONTROL UNIT In case of replacement of the ABS control unit, ensure that the new one has caps on all four hydraulic connections and then proceed as follows: • Before disconnecting the electrical connections, switch the key "OFF". •...
Page 473 RSV4 RR-RF Braking system TABLE D - ABS PIPES ROUTING 1. Delivery rear calliper. 2. Input from the rear pump. 3. Delivery front calliper. 4. Input from the front pump. 5. Medium clamp. 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.
Page 474 RSV4 RR-RF Braking system If during this given time one of the conditions is missing but then it comes back, the timer is reset and the system is no longer able to diagnose the error. The ABS system continues to be inactive. GUIDE TO ABS FAULT DIAGNOSIS 1.
Page 475 RSV4 RR-RF Braking system ECU INFO screen page This screen shows general data regarding the con- trol unit, for example software type, mapping, con- trol unit programming date CONTROL UNIT DATA P.A.D.S. characteristic. Value/example Units of Notes measure ment Spare part code CM281701 SW version Vehicle manuf.
Page 476 RSV4 RR-RF Braking system ACTIVATION screen page On this screen, you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit. ACTIVATIONS P.A.D.S. characteristic. Value/example Units of Notes measure ment ABS Warning Light ERRORS screen page...
Page 477 RSV4 RR-RF Braking system Description Code Symptom + button (connect to the injection control unit diagnosis) U2926 connect to the 7SM control unit diagnosis - button (connect to the injection control unit diagnosis) U2927 connect to the 7SM control unit diagnosis Internal error: fault at the pressure sensor C1331 fault at the pressure sensor...
Page 478 RSV4 RR-RF Braking system • 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). • Go to the page Report and then on Print and select the virtual PDF printer.
Page 479 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 480 RSV4 RR-RF Braking system • Open circuit: circuit interruption detected. • Short-circuit to negative: null voltage detected on PIN 14 of the ABS control unit. • Short-circuit to positive: excessive voltage detected on PIN 14 of the ABS control unit. Troubleshooting: Open circuit: - Check the connectors on the component and on the ABS control unit.
Page 481 RSV4 RR-RF Braking system - Check the connectors on the component and on the ABS control unit. - Check the integrity and continuity of the wiring harnesses: • between PIN 3 of the ABS control unit and PIN 1 of the sensor (white cable) •...
Page 482 RSV4 RR-RF Braking system Error cause: The configuration stored in the ABS control unit does not correspond to the configuration in the vehicle it is installed on. Troubleshooting: Check the control unit mapping and reset the vehicle configuration. NOTE THIS ERROR DISABLES THE ABS SYSTEM. CAN LINE ERRORS U2921 Controller error U2922 Line failure (busoff)
Page 483 RSV4 RR-RF Braking system +/- BUTTON ERRORS Key: A. Button "+" open B. Button "+" closed C. Button "-" open D. Button "-" closed U2926 + button U2927 - button Error cause Switch malfunction. Troubleshooting - Connect to the injection control unit diagnosis - Check according to the indication in the figure whether there is or not continuity between the contact of the switches and in the various opening/closing states: •...
Page 484 RSV4 RR-RF Braking system • Disconnect the ABS control unit from its rear inserts. • Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR • Check the initial position of the lever that couples the connector. • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5...
Page 485 RSV4 RR-RF Braking system IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN- SERTION. • Fit the protection casing. 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.
Page 486 RSV4 RR-RF Braking system Rear brake calliper EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes ABS sensor fixing screw 6 Nm (4.43 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) Brake pipe bracket fastening screw...
Page 487 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 - 487...
Page 488 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 489 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 490 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. REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE- HICLE ITSELF.
Page 491 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 492 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 BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
Page 493 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. CAUTION IN VIEW OF THE DANGER THIS POSES FOR VEHICLE AND RIDER, THE HYDRAULIC CIRCUIT MUST BE BLED AFTER REFITTING THE BRAKES AND RESTORING THE BRAKING SYSTEM TO...
Page 494 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 495 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 496 RSV4 RR-RF Braking system Rear brake pump EAR BRAKE MASTER CYLINDER 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) Loctite 243 Tank filler cap...
Page 497 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 498 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 - 498...
Page 499 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 IQUID Pos.
Page 500 RSV4 RR-RF Cooling system ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lb ft) for fastening the pump to the crank- case Electric fan • Remove the front underfairings and the hand grip position sensor •...
Page 501 RSV4 RR-RF Cooling system • Internally blocking the nuts, unscrew the fixing screw from the internal part. • Make sure that the nuts and washers are retrieved. See also 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...
Page 502 RSV4 RR-RF Cooling system • Unscrew and remove the system drain screw and retrieve the sealing washer. • Wait for the entire circuit to drain (en- gine+pipes+radiator) • Refit the system drain screw complete with a new washer. FILLING • Via the filler orifice on the radiator, fill with the quantity of coolant (approx.
Page 503 RSV4 RR-RF Cooling system • Unscrew and remove the two screws fastening the pipe to the engine. • Retrieve the gasket and replace with a new component when refitting. See also Coolant replacement • Unscrew and remove the two screws fastening the pump to the engine.
Page 504 RSV4 RR-RF Cooling system • Unscrew and remove the inner screw. • Remove the pump cover. TO PREVENT IRREPARABLE DAMAGE TO THE PUMP, UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER. • At each removal, replace the inner gas- ket between the pump casing and the cover and the O ring on the pump cas- ing.
Page 505 RSV4 RR-RF Cooling system • Remove the two chassis bracket fixing screws. • Then remove the radiator retainer bracket. • 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 506 RSV4 RR-RF Cooling system • Disconnect the expansion tank breath- er pipe from the pipe grommet. See also Coolant replacement Fairing mounting panels Twistgrip position sensor • 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.
Page 507 RSV4 RR-RF Cooling system • Release the clamp fastening the return pipe to the radiator pipe UPON REFITTING, REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE. DO NOT REFIT THE CLIP-ON CLAMP REMOVED PREVI- OUSLY AS IT IS NO LONGER USABLE. DO NOT REPLACE THE CLIP-ON CLAMP REMOVED PRE- VIOUSLY WITH A SCREW CLAMP OR ANY OTHER TYPE OF CLAMP.
Page 508 INDEX OF TOPICS BODYW ODYWORK...
Page 509 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 - 509...
Page 510 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) tening screws Screws used to fasten the instrument 8 Nm (5.90 lb ft)
Page 511 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) side spacers Screws fastening the lower fairing to 2 Nm (1.48 lb ft)
Page 512 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) fuel tank Screws fastening the rear fuel tank to...
Page 513 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 - 513...
Page 514 RSV4 RR-RF Bodywork ENTRAL BODYWORK Pos. Description Type Quantity Torque Notes Screws fastening fairing to tail fairing 1 Nm (0.74 lb ft) Screws fastening fairing to tank 2 + 2 2 Nm (1.48 lb ft) AIRING Pos. Description Type Quantity Torque Notes Fairing retaining spacer...
Page 515 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 0.5 Nm (0.37 lb ft)
Page 516 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) cover base to the saddle cover Saddle cover stud fastening screws 1.5 Nm (1.11 lb ft)
Page 517 RSV4 RR-RF Bodywork pos. Description Type Quantity Torque Notes Shear head screw (to the left of the Manual Tighten until the ignition lock) head shears off Right hand ignition lock screw 20 Nm (14.75 lb ft) Passenger saddle fixing screws 8 Nm (5.90 lb ft) ODYWORK UNDER SADDLE Pos.
Page 518 RSV4 RR-RF Bodywork ILTER BOX Pos. Description Type Quantity Torque Notes Flanged SWP petrol/injectors circuit M5x20 ... Nm (... lb ft) fastening screws Flanged SWP upper intake ducts re- M5x20 ... Nm (... lb ft) taining screws Flanged SWP lower intake ducts re- ...
Page 519 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) Loctite 243 - For use footrests to the frame in countries where it...
Page 520 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 521 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 522 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 523 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 524 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 525 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 526 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 527 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 528 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 529 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 530 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 531 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 532 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 533 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 - 533...
Page 534 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 535 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 - 535...
Page 536 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 537 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 • Operating from the left side of the mo- torcycle, remove the clamp blocking the main wiring harness to the filter box...
Page 538 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 539 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 (4) to divide the lug Fuel tank •...
Page 540 RSV4 RR-RF Bodywork • Unscrew and remove the two rear screws. • Uncouple from its support the connec- tor (1) of the fuel pump and disconnect • Disconnect the connector (2) of the in- ertia platform. • Working on the left side, disconnect the tank's two vent pipes.
Page 541 RSV4 RR-RF Bodywork • Slightly lift the fuel tank and working on the right side of the motorcycle, dis- connect the fuel pipe at the coupling point. • Remove the tank. Front mudguard • Working on both sides of the vehicle, undo and remove the two screws.
Page 542 RSV4 RR-RF Bodywork • Remove the front mudguard. Instrument cluster support REMOVAL • Remove the instrument panel. • Working on both sides, unscrew and remove the two screws fastening the arch brace to the headstock. • Retrieve the cable grommet. •...
Page 543 RSV4 RR-RF Bodywork • 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 544 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 545 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 546 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 547 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. CAUTION DURING REASSEMBLY, THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN- SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS.
Page 548 INDEX OF TOPICS PRE DE DELIVERY...
Page 549 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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 550 RSV4 RR-RF Pre-delivery TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
Page 551 RSV4 RR-RF Pre-delivery - Abnormal noise Static test Static control after the test drive: - Restarting when warmed up - Idling - Uniform turning of the steering - Possible leaks - Radiator electric fans operation Functional inspection - Hydraulic braking system - Brake and clutch lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and absence of abnormal noise...
Page 552 RSV4 RR-RF Pre-delivery Specific operations for the vehicle • Remove the screw (2). • Remove the plastic cover (1). • Fit the rear pedal in its seat. • Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm (13.27 lbf ft) NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE.
Page 553 RSV4 RR-RF Pre-delivery • Insert the key in the lock and turn it clockwise. • Remove the tail fairing. • Fit the two-seater saddle. Regolazione snodo degli specchietti retrovisori • With the mirror closed (base turned 90° in relation to the mirror) check that the nut is closed properly, as indicated by the arrow, (you should be able to see about 0.5 mm - 1 mm (0.02 in - 0.04 in)
Page 554 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 555 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. PRE DE - 555...
Page 556 220 ABS: 232, 465, 474 Air filter: 73 Air temperature sensor: 163 Aprilia V4-MP Tecnology: 243 Battery: 133, 146 Brake: 486–488, 490, 491, 495, 496 Brake calliper: 486, 487 Brake disc: 487, 488 Brake pads: 490, 491...
Page 557 Front cylinder head valves: 75 Front head: 309, 315, 318, 319, 340, 353, 355 Front wheel: 391, 392, 489 Fuel: 181, 384, 539 Fuel pump: 181, 384 Fuses: 137 Handlebar: 394 Head cover: 308 Headlight: 522, 523, 547 Identification: 11 Instrument panel: 521, 542 Intake pressure sensor: 156 Keys: 130...
Page 558 Secondary shaft: 278 Shock absorber: Shock absorbers: 431 Side fairings: 529 Side stand: 203, 455 Side stand sensor: 203 Spark plug: 69 Speed sensor: 148 Stand: 203, 454, 455 Start-up: 136, 285 Starter motor: 284 Steering damper: 416 Stepper motor: 389 Tank: 539 Throttle body: 186, 388, 389 Top fairing:...

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Page 32: Table Of Contents

Page 34: Nm (8.85 Lb Ft)

Page 35: Nm (36.88 Lb Ft)

Page 36: Nm (2.95 Lb Ft)

Page 398: Notches/ 8 Mm (2 Notches/0.31 In)

Page 416: Specification

Page 432: Rsv4 1000 Rr (Sachs Forks)

Page 433: Specification

Page 434: Adjustment Range (Ohlins )

This manual is also suitable for:

APRILIA RSV4 RR 2017 Service Station Manual

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Summary of Contents for APRILIA RSV4 RR 2017

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Table of Contents