Page 1 SERVICE STATION MANUAL 2Q000401 RSV4 1100 Factory...
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 1100 Factory 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 1100 Factory 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 1100 Factory Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Page 12 LECTRONIC CONTROL SYSTEMS Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control), which includes: ALC (con- trolled launch), ABS (Anti-lock braking system), ATC (traction control), AWC (wheelie control), AQS (Assisted gear up-shift or down-shift system without clutch aid), PIT (pit lane speed control).
Page 13 RSV4 1100 Factory 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)
Page 14 RSV4 1100 Factory Characteristics Specification Desc./Quantity Side stand a-PRC 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 Öhlins upside down units with adjustable hydraulic damping...
Page 15 RSV4 1100 Factory Characteristics Wheels and tyres HEEL RIMS Specification Desc./Quantity Front wheel rim 3.50 x 17" forged Rear wheel rim 6.00 x 17" forged YRES Specification Desc./Quantity Front tyre 120/70 ZR17 (58W) Inflation pressure 1 passenger: 2.3 bar (230 KPa) (33.36 PSI) 2 passengers: 2.5 bar (250 KPa) (36.26 PSI)
Page 16 RSV4 1100 Factory 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)
Page 17 RSV4 1100 Factory 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 1100 Factory 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)
Page 19 RSV4 1100 Factory Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lb ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lb ft) chions Headstock ring nut - pre-tightening M35x1 70 Nm (51.63 lb ft)
Page 20 RSV4 1100 Factory Characteristics RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel pin nut M25x1.5 80 Nm (59.00 lb ft) Front brake disk fastening screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 RONT BRAKE CALLIPER Pos.
Page 21 RSV4 1100 Factory Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lb ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lb ft) mounting bracket to handlebar Front brake pump U bolt clamp 10 Nm (7.38 lb ft)
Page 22 RSV4 1100 Factory Characteristics ANDLEBAR AND CONTROLS Pos. Description Type Quantity Torque Notes Screws for fastening the handlebar 1 + 1 25 Nm (18.44 lb ft) collar to the forks sleeves Handlebar safety screw 10 Nm (7.38 lb ft) Anti-vibration counterweight fastener M18x1.5...
Page 23 RSV4 1100 Factory 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)
Page 24 RSV4 1100 Factory Characteristics NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 25 RSV4 1100 Factory Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lb ft) Lug fixing screws 4 Nm (2.95 lb ft) Screws fixing the side fairings to the 1.5 Nm (1.11 lb ft)
Page 26 RSV4 1100 Factory 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)
Page 27 RSV4 1100 Factory 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)
Page 28 RSV4 1100 Factory 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 1100 Factory Characteristics UEL TANK Pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft) er's saddle to the fuel tank Filler to tank retaining screws 4 Nm (2.95 lb ft) Screws fastening fuel pump flange to 5 Nm (3.69 lb ft)
Page 30 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory Characteristics HASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 33: Manual
RSV4 1100 Factory Characteristics OCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lb ft) Lock lever self-tapping screw 2 Nm (1.48 lb ft) Shear head screw (to the left of the...
Page 34: Nm (8.85 Lb Ft)
RSV4 1100 Factory Characteristics EARBOX LEVER pos. Description Type Quantity Torque Notes Pinion cover guard fastening screws 6 Nm (4.43 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk flat head hex socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 35: Nm (36.88 Lb Ft)
RSV4 1100 Factory Characteristics pos. Description Type Quantity Torque Notes Screws for securing the upper fairing self-tapping 1 Nm (0.74 lb ft) closure to the intake duct Screws for securing the upper fairing self-tapping 1 Nm (0.74 lb ft) closure to the front headlight...
Page 36: Nm (2.95 Lb Ft)
RSV4 1100 Factory 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 1100 Factory 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)
Page 38 RSV4 1100 Factory 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)
Page 39 RSV4 1100 Factory 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)
Page 40 RSV4 1100 Factory 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)
Page 41 RSV4 1100 Factory Characteristics EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lb ft) Dual connecting rod fixing screw 50 Nm (36.88 lb ft) Screw fastening single connecting 50 Nm (36.88 lb ft)
Page 42 RSV4 1100 Factory 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...
Page 43 RSV4 1100 Factory 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...
Page 44 RSV4 1100 Factory 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)
Page 45 RSV4 1100 Factory 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)
Page 46 RSV4 1100 Factory Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft)
Page 47 RSV4 1100 Factory 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...
Page 48 RSV4 1100 Factory 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)
Page 49 RSV4 1100 Factory 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 1100 Factory 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...
Page 51 RSV4 1100 Factory 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...
Page 52 RSV4 1100 Factory Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque.
Page 53 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory Special tools PECIAL TOOLS Stores code Description 020845Y Engine support 020846Y Containment tray + plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch lock 020850Y Primary gear lock S-TOOLS - 56...
Page 57 RSV4 1100 Factory Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension- er of the timing chain 020856Y Piston assembly ring...
Page 58 RSV4 1100 Factory Special tools Stores code Description 020858Y Maintenance of the pistons in the cylin- ders AP8140199 Tool storage panel 020859Y Graphics for panels 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear- box control rod....
Page 59 RSV4 1100 Factory 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...
Page 60 RSV4 1100 Factory 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 1100 Factory 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 AP8140149 Guard for assembly operations AP8140190 Tool for steering tightening...
Page 62 RSV4 1100 Factory Special tools Stores code Description 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 1100 Factory 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) Flexible coupling holder fastening screws (5)
Page 66 (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 3,106.86 mi (5,000 km).
Page 67 (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 68 RSV4 1100 Factory 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.
Page 69 RSV4 1100 Factory Maintenance • Undo and remove the screw. • 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.
Page 70 RSV4 1100 Factory Maintenance PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km (10 miles) IN EXTRA-URBAN CONDITIONS (ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE). • Shut off the engine and wait a few sec- onds.
Page 71 RSV4 1100 Factory 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. •...
Page 72 RSV4 1100 Factory 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 73 RSV4 1100 Factory 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.
Page 74 RSV4 1100 Factory 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 75 RSV4 1100 Factory 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 76 RSV4 1100 Factory 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 77 RSV4 1100 Factory 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 78 RSV4 1100 Factory 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 79 RSV4 1100 Factory Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 80 RSV4 1100 Factory 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 81 RSV4 1100 Factory 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 82 RSV4 1100 Factory 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.
Page 83 RSV4 1100 Factory 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 84 RSV4 1100 Factory 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 85 RSV4 1100 Factory Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 86 RSV4 1100 Factory 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)
Page 87 RSV4 1100 Factory 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)
Page 88 RSV4 1100 Factory 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 - 88...
Page 89 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 90 RSV4 1100 Factory 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 91 RSV4 1100 Factory Electrical system ENTRAL ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Starter relay cables fastening screws 4 Nm (2.95 lb ft) ELE SYS - 91...
Page 92 RSV4 1100 Factory Electrical system Components arrangement Key: 1. Side stand sensor. 2. Fuel pump 3. Instrument panel 4. Left hand switch ELE SYS - 92...
Page 93 RSV4 1100 Factory 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...
Page 94 RSV4 1100 Factory 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...
Page 95 RSV4 1100 Factory 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 •...
Page 96 RSV4 1100 Factory 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 97 RSV4 1100 Factory 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 98 RSV4 1100 Factory 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...
Page 99 RSV4 1100 Factory 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...
Page 100 RSV4 1100 Factory 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-...
Page 101 RSV4 1100 Factory 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.
Page 102 RSV4 1100 Factory 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...
Page 103 RSV4 1100 Factory 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...
Page 104 RSV4 1100 Factory 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 105 RSV4 1100 Factory 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...
Page 106 RSV4 1100 Factory 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 107 RSV4 1100 Factory 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 108 RSV4 1100 Factory 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.
Page 109 RSV4 1100 Factory 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...
Page 110 RSV4 1100 Factory 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 111 RSV4 1100 Factory 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 112 RSV4 1100 Factory 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...
Page 113 RSV4 1100 Factory 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 114 RSV4 1100 Factory 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 115 RSV4 1100 Factory 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 116 RSV4 1100 Factory 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 117 RSV4 1100 Factory Electrical system TABLE C1 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard...
Page 118 RSV4 1100 Factory 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-...
Page 119 RSV4 1100 Factory Electrical system WIRING TABLE E - REAR SADDLE MOUNTING ZONE Preparing the battery support bracket with fuses 1. Battery support bracket 2. Vehicle wiring harness TABLE E1 - REAR SEAT POST AREA Fit the (individual) fan fuse on battery mounting...
Page 120 RSV4 1100 Factory Electrical system TABLE E4 - REAR SEAT POST AREA 1. Taillight 2. Taillight connector 3. License plate frame wiring harness connector WIRING TABLE E5 - REAR SADDLE MOUNT- ING ZONE Insert the ECU diagnostic and the instrument clus-...
Page 121 RSV4 1100 Factory 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 122 RSV4 1100 Factory 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 123 RSV4 1100 Factory 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 - 123...
Page 124 RSV4 1100 Factory 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 - 124...
Page 125 RSV4 1100 Factory Electrical system 5. Right low beam light bulb 6. High beam bulb 7. Tail light bulb (LED) 8. Left low beam light bulb 9. High beam light relay 10.Low beam light relay 11.Left light switch 1 12.Instrument panel diagnosis 13.Instrument panel matrix II...
Page 126 RSV4 1100 Factory Electrical system 43.Electronic transmission 44.Side stand switch 45.Gear sensor 46.Front cylinder pressure sensor 47.Rear cylinder pressure sensor 48.Front cylinder throttles 49.Rear cylinder throttles 50.Air temperature sensor 51.Water temperature sensor 52.Upper injectors 53.7SM control unit 54.Throttle grip position sensor 55.Engine speed sensor...
Page 127 RSV4 1100 Factory 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 128 RSV4 1100 Factory Electrical system mally, the tester will sound an audible signal to confirm continuity in the section of circuit tested. Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the resistance in the circuit is zero or of a few tenths of an Ohm.
Page 129 RSV4 1100 Factory 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 130 RSV4 1100 Factory 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 131 RSV4 1100 Factory 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 132 RSV4 1100 Factory 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"...
Page 133 RSV4 1100 Factory 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 134 RSV4 1100 Factory 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-...
Page 135 RSV4 1100 Factory 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 136 RSV4 1100 Factory 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.
Page 137 RSV4 1100 Factory 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 138 RSV4 1100 Factory Electrical system CONTROL UNIT - Diagnosis Function It manages the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves...
Page 139 RSV4 1100 Factory 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) •...
Page 140 RSV4 1100 Factory 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/ - •...
Page 141 RSV4 1100 Factory 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 142 RSV4 1100 Factory 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.
Page 143 RSV4 1100 Factory 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 144 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 145 RSV4 1100 Factory 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 146 RSV4 1100 Factory Electrical system PAY ATTENTION TO THE POSITIVE BATTERY CABLE, WHICH MUST PASS BELOW THE UPPER PART OF THE FRAME. 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 147 RSV4 1100 Factory Electrical system THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON- TROL AND THE CRUISE CONTROL. Speed sensor FRONT VEHICLE ABS SENSOR Function: Generates a signal used by the ABS control unit to determine the speed value of the wheel.
Page 148 RSV4 1100 Factory Electrical 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 149 RSV4 1100 Factory Electrical system • ABS system malfunction Troubleshooting: • 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.
Page 150 RSV4 1100 Factory Electrical system C1031 Rear wheel speed sensor Electrical diagnosis: Open circuit, short circuit to negative or short circuit to positive. Error cause: • Open circuit: circuit interruption detected. • Short-circuit to negative: null voltage detected on PIN 14 of the ABS control unit.
Page 151 RSV4 1100 Factory Electrical system • ABS system malfunction Troubleshooting: • 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;...
Page 152 RSV4 1100 Factory Electrical system NECESSARY, IF THEY ARE OK CHECK THE SENSOR CONFORMS TO THE ELECTRICAL SPEC- IFICATIONS: IF NECESSARY, REPLACE THE SENSOR, IF IT IS OK, CHECK THE CONTINUITY ON THE TWO CABLES, VERIFYING THAT THEY ISOLATED FROM THE POWER SUPPLY AND EARTH.
Page 153 RSV4 1100 Factory Electrical system 3. A track signal (yellow cable) 4. B track power supply (orange/black cable) 5. Sensors 2 ground (pink/black cable) 6. B track signal (light blue cable) DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0225 Track A handle position sensor Electrical diagnosis: •...
Page 154 RSV4 1100 Factory Electrical system This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light Troubleshooting • short circuit to positive:check the value indicated by the parameter handle position sensor...
Page 155 RSV4 1100 Factory 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...
Page 156 RSV4 1100 Factory 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 157 RSV4 1100 Factory 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 158 RSV4 1100 Factory 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 159 RSV4 1100 Factory 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 160 RSV4 1100 Factory 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.
Page 161 RSV4 1100 Factory 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...
Page 162 RSV4 1100 Factory 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 163 RSV4 1100 Factory 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 164 RSV4 1100 Factory 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 165 RSV4 1100 Factory 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 166 RSV4 1100 Factory 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 167 RSV4 1100 Factory 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 168 RSV4 1100 Factory 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 169 RSV4 1100 Factory 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 170 RSV4 1100 Factory 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 171 RSV4 1100 Factory 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 172 RSV4 1100 Factory 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 173 RSV4 1100 Factory 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 174 RSV4 1100 Factory 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;...
Page 175 RSV4 1100 Factory 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...
Page 176 RSV4 1100 Factory 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...
Page 177 RSV4 1100 Factory 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...
Page 178 RSV4 1100 Factory 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 179 RSV4 1100 Factory 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 180 RSV4 1100 Factory 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 181 RSV4 1100 Factory 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.
Page 182 RSV4 1100 Factory 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 183 RSV4 1100 Factory 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 184 RSV4 1100 Factory 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 185 RSV4 1100 Factory 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 186 RSV4 1100 Factory 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 187 RSV4 1100 Factory 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 188 RSV4 1100 Factory Electrical system Front cylinders throttle Limp Home position • Example value with key ON: 878 mV Voltage stored in the control unit corresponding to the Limp home position Rear cylinders throttle Limp Home position • Example value with key ON: 888 mV...
Page 189 RSV4 1100 Factory Electrical system • Performed/Not performed Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed one time, it will always remain performed unless a control unit EEPROM reset is carried out DIAGNOSTIC TOOL: ELECTRICAL ERRORS...
Page 190 RSV4 1100 Factory 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 191 RSV4 1100 Factory 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.
Page 192 RSV4 1100 Factory 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 193 RSV4 1100 Factory 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 194 RSV4 1100 Factory 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 195 RSV4 1100 Factory 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...
Page 196 RSV4 1100 Factory 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 197 RSV4 1100 Factory 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 198 RSV4 1100 Factory 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 199 RSV4 1100 Factory 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.
Page 200 RSV4 1100 Factory 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.
Page 201 RSV4 1100 Factory 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...
Page 202 RSV4 1100 Factory 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 203 RSV4 1100 Factory 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) •...
Page 204 RSV4 1100 Factory 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...
Page 205 RSV4 1100 Factory 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 206 RSV4 1100 Factory 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 % •...
Page 207 RSV4 1100 Factory 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...
Page 208 RSV4 1100 Factory 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 209 RSV4 1100 Factory 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 210 RSV4 1100 Factory 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 211 RSV4 1100 Factory 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 212 RSV4 1100 Factory 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 213 RSV4 1100 Factory 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 214 RSV4 1100 Factory 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 215 RSV4 1100 Factory 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 216 RSV4 1100 Factory 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 217 RSV4 1100 Factory 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)
Page 218 RSV4 1100 Factory 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 219 RSV4 1100 Factory 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 220 RSV4 1100 Factory 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 221 RSV4 1100 Factory 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.
Page 222 RSV4 1100 Factory 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;...
Page 223 RSV4 1100 Factory 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 224 RSV4 1100 Factory 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.
Page 225 RSV4 1100 Factory 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...
Page 226 RSV4 1100 Factory 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 227 RSV4 1100 Factory 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 •...
Page 228 RSV4 1100 Factory Electrical system • PIN 54 - • PIN 55 - • PIN 56 - Clutch sensor input • PIN 57 - Sensor ground 2 • PIN 58 - Engine start button input • PIN 59 - •...
Page 229 RSV4 1100 Factory 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 •...
Page 230 RSV4 1100 Factory 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 231 RSV4 1100 Factory Electrical system • PIN 20 - Normally closed "+" DC switch • PIN 21 - • PIN 22 - Normally open "-" TC switch • PIN 23 - Rear stop switch • PIN 24 - Ground •...
Page 232 RSV4 1100 Factory 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 233 RSV4 1100 Factory 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).
Page 234 RSV4 1100 Factory 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,...
Page 235 RSV4 1100 Factory Electrical system Electrical diagnosis: • 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 236 RSV4 1100 Factory 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.
Page 237 (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 238 RSV4 1100 Factory Electrical system • If the signal is not plausible, there was a transcription error of the value of the rear wheel radius from the non volatile memory (EEPROM) to the volatile memory (RAM) at key ON. In this case the default value is used.
Page 239 RSV4 1100 Factory Electrical system Rimozione • 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 240 RSV4 1100 Factory Electrical system • Remove the fixing screw (6) of the sup- port bracket (7) paying attention to re- cover the elastic washer (8) • Remove the USB port Installazione • Unscrew and remove the screws (1) Remove the top fairing glass from the seats of the motorcycle •...
Page 241 RSV4 1100 Factory 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 242 RSV4 1100 Factory 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 243 RSV4 1100 Factory 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 244 RSV4 1100 Factory 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 245 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 246 RSV4 1100 Factory Engine from vehicle EARBOX LEVER pos. Description Type Quantity Torque Notes Pinion cover guard fastening screws 6 Nm (4.43 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk flat head hex socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 247 RSV4 1100 Factory 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 248 RSV4 1100 Factory 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 249 RSV4 1100 Factory 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 250 RSV4 1100 Factory 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...
Page 251 RSV4 1100 Factory 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 252 RSV4 1100 Factory 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 •...
Page 253 RSV4 1100 Factory 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 •...
Page 254 RSV4 1100 Factory Engine from vehicle • Remove the guard. • Loosen the adjustment nuts of the ex- haust valve. • Remove the screw (33) and the locking nut of the silencer to the foot board • Remove the exhaust terminal from the...
Page 255 RSV4 1100 Factory Engine from vehicle • Remove the exhaust terminal com- pletely. • Remove the clamp (34) securing the exhaust valve wiring harness. • Disconnect the connector (35) of the exhaust valve. • Disconnect the connector (35) of the exhaust valve.
Page 256 RSV4 1100 Factory 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...
Page 257 RSV4 1100 Factory 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 •...
Page 258 RSV4 1100 Factory 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...
Page 259 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: •...
Page 264 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory Engine from vehicle • Place the ground on the frame. • Fit the washer and tighten the nut. • Place the cable grommet and the three cable leads as shown. • Tighten the cable grommet fixing screw.
Page 269 RSV4 1100 Factory Engine from vehicle • Connect the timing sensor. • Connect the clutch cable. • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in).
Page 270 INDEX OF TOPICS NGINE...
Page 271 RSV4 1100 Factory Engine key: 1. rear left cylinder; 2. front left cylinder; 3. rear right cylinder; 4. front right cylinder. Combustion sequence: 1 - 3 - 2 - 4 Combustion angle: cyl 1: 0° cyl 2: 180° cyl 3: 425°...
Page 272 RSV4 1100 Factory 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...
Page 273 RSV4 1100 Factory Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw. • Unscrew and remove the six screws.
Page 274 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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) •...
Page 277 RSV4 1100 Factory 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 1100 Factory 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)
Page 279 RSV4 1100 Factory 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.
Page 280 RSV4 1100 Factory 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...
Page 281 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 285 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 288 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 stop Flywheel cover installation • Insert the centring dowels in the cover.
Page 291 RSV4 1100 Factory Engine Clutch side LUTCH COVER Pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.90 lb ft) TE Flanged screw M6x20 10 Nm (7.38 lb ft) TE Flanged screw M6x35 12 Nm (8.85 lb ft)
Page 292 RSV4 1100 Factory 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 1100 Factory 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. •...
Page 294 RSV4 1100 Factory 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.
Page 295 RSV4 1100 Factory 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 1100 Factory 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)
Page 297 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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. •...
Page 302 RSV4 1100 Factory 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 1100 Factory 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).
Page 304 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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)
Page 307 RSV4 1100 Factory Engine EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft) Reed valve covers fixing screws 6 Nm (4.43 lb ft) Water outlet coupling fixing screw 10 Nm (7.38 lb ft)
Page 308 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 312 RSV4 1100 Factory Engine • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 313 RSV4 1100 Factory 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).
Page 314 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory Engine • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. • After loosening all nuts, remove them in order indicated above.
Page 319 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 325 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory Engine • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. • After loosening all nuts, remove them in order indicated above.
Page 335 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 340 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory 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.
Page 346 RSV4 1100 Factory 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 1100 Factory 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)
Page 348 RSV4 1100 Factory 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 •...
Page 349 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory 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 1100 Factory Engine Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide.
Page 353 RSV4 1100 Factory Engine • alternator; • water pump; • gearbox unit; • primary drive shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear;...
Page 354 RSV4 1100 Factory 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 1100 Factory 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 1100 Factory Engine • Slide off the pin 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. Specific tooling...
Page 357 RSV4 1100 Factory Engine 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 1100 Factory Engine Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0.40 - 0.10 mm (0.0157 - 0.0039 in) Maximum radial play between main bushings and crankpins 0.07 mm (0.00275 in) Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0.1 mm (0.0039 in)
Page 359 RSV4 1100 Factory Engine CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PER- FORMED AT 6 mm (0.24 in) FROM ITS BASE Characteristic Coupling clearance between the pin and the hole on the piston 0.016 - 0.005 mm (0.0006 - 0.0002 in)
Page 360 RSV4 1100 Factory Engine Crankshaft balancing classes Combinations of weight classes for Combinations of weight classes for connecting rod pair on alternator side connecting rod pair on primary drive side BB+BB / AA+CC* BB+BB / CC+AA* CC+CC / BB+DD* CC+CC / DD+BB*...
Page 361 RSV4 1100 Factory Engine A number that indicates the position of the main journal is stamped on the crankcase: 1. flywheel side; 2. central; 3. clutch side. 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...
Page 362 RSV4 1100 Factory Engine Crankshaft main journal Class A crankcase Class B crankcase Class C crankcase Class D main journal Bushing (black) Bushing (green) Bushing (green) Class E main journal Bushing (black) Bushing (black) Bushing (green) The flywheel side and clutch side main bearings are different from the central ones and therefore, so are the respective replacement part numbers.
Page 363 RSV4 1100 Factory Engine • 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: USHINGS THICKNESS Bushing colours Thickness BLUE 1.547 - 1.552 mm YELLOW 1.552 - 1.557 mm...
Page 364 RSV4 1100 Factory Engine Bearing fitting BALANCING COUNTERSHAFT BEARING INSTALLATION FLYWHEEL-SIDE • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020364Y 25 mm adapter 020359Y 42 x 47 mm punch 020376Y Sleeve for adaptors •...
Page 365 RSV4 1100 Factory Engine • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020363Y 20 mm diam. punch for crankshaft oil seal 020359Y 42 x 47 mm punch 020376Y Sleeve for adaptors • Position the new bearings with their groove on the outside diameter facing outward with respect to the crankcase.
Page 366 RSV4 1100 Factory Engine Crankshaft fitting When refitting the primary gear, remember to first place the lining as shown in the figure. The greater diameter side is facing outwards the engine. • Lubricate the crankshaft pins and in- sert them into their positions.
Page 367 RSV4 1100 Factory Engine • Install the crankshaft blocking tool. • Tighten the primary shaft fixing nut. Specific tooling 020850Y Primary gear lock • Insert the tone wheel on the crank- shaft. The crankshaft and the tone wheel have a bevel that identifies the fitting direction.
Page 368 RSV4 1100 Factory Engine The five ring gaps (two piston rings, two oil scraper rings, one oil scraper spring) are fitted displaced 90º to each other, starting from the exhaust-side stud bolt opposite the chain and continuing clock- wise. The fitted pistons have two selections A and B.
Page 369 RSV4 1100 Factory Engine ling on the connecting rod head must face outward of its crank pin. Specific tooling 020856Y Piston assembly ring • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces.
Page 370 RSV4 1100 Factory Engine • Insert the maximum pressure valve in the crankcase, composed of two sep- arate parts • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste •...
Page 371 RSV4 1100 Factory Engine • Pre-tighten the screws in the following order: 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 - 22 - 23.
Page 372 RSV4 1100 Factory 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 - 372...
Page 373 RSV4 1100 Factory Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft) Tighten to torque, unscrew and re- tighten to torque.
Page 374 RSV4 1100 Factory Engine pos. Description Type Quantity Torque Notes 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. Special nut 10 Nm (7.38 lb ft) Flanged nut 15 + 20 Nm (11.06 +...
Page 375 RSV4 1100 Factory Engine Removing • Remove the gearbox. • Remove the water pump. • Unscrew and remove the six screws fastening the oil pump to the crank- case. • Remove the oil pumps. OIL PUMP REMOVAL • Place the oil pumps on a work table.
Page 376 RSV4 1100 Factory Engine • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor. • Collect the hitch pin. • Unscrew and remove the four lubrica- tion oil pump cover screws.
Page 377 RSV4 1100 Factory Engine • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle. Installing • Position the lubrication pump internal rotor on the oil pump control shaft The lubrication pump components are larger than the cooling pump components.
Page 378 RSV4 1100 Factory Engine • 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 379 RSV4 1100 Factory Engine • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor. • Tighten the four cooling oil pump cover screws. • Fit a new gasket.
Page 380 RSV4 1100 Factory Engine • 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- HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL.
Page 381 RSV4 1100 Factory Engine • 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 382 RSV4 1100 Factory Engine SAS valve 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 Diagram Valve controlled by control unit which delivers as- pirated air from the filter box to the exhaust mani- folds.
Page 383 RSV4 1100 Factory Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 383...
Page 384 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 385 RSV4 1100 Factory Power supply Circuit diagram Key: 1. Pressure check valve 2. Valve 3. "T" connection 4. Connection 5. Lower injectors on the front throttle body 6. Lower injectors on the rear throttle body 7. Upper injector on the front of the filter casing 8.
Page 386 RSV4 1100 Factory Power supply 12.Filter box 13.Front throttle body 14.Rear throttle body 15.Engine 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...
Page 387 RSV4 1100 Factory Power supply • Remove the fuel pump Injection P SUPP - 387...
Page 388 RSV4 1100 Factory Power supply Diagram key: 1. Control unit position 2. Throttle grip position sensor 3. Fall sensor 4. Exhaust valve P SUPP - 388...
Page 389 RSV4 1100 Factory Power supply 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...
Page 390 RSV4 1100 Factory 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 391 RSV4 1100 Factory 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 392 RSV4 1100 Factory 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 393 INDEX OF TOPICS SUSP USPENSIONS...
Page 394 RSV4 1100 Factory Suspensions Handlebar ANDLEBAR AND CONTROLS Pos. Description Type Quantity Torque Notes Screws for fastening the handlebar 1 + 1 25 Nm (18.44 lb ft) collar to the forks sleeves Handlebar safety screw 10 Nm (7.38 lb ft) Anti-vibration counterweight fastener M18x1.5...
Page 395 RSV4 1100 Factory Suspensions LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lb ft) Front fork SUSP - 395...
Page 396 RSV4 1100 Factory 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)
Page 397 RSV4 1100 Factory Suspensions STANDARD ADJUSTMENT FOR ROAD USE Specification Desc./Quantity Rebound damping adjustment, screw (1) Unscrew (**) 12 clicks from fully closed (*) Compression damping adjustment, screw (2) Unscrew (**) 12 clicks from fully closed (*) Spring pre-loading, nut (3)
Page 398 RSV4 1100 Factory Suspensions • Loosen the screws on the lower plate. • Slide out the fork stanchion. Draining oil • Clamp the forks in a vice, taking care not to damage them. • Set the pre-loading spring to the mini- mum position.
Page 399 RSV4 1100 Factory Suspensions • Unscrew the nut and remove it, exert- ing slight pressure on the pre-loading spring. • Remove the pre-loading spring retain- ing ring. • Remove the pre-loading spring. • Drain the oil from the forks into a suit-...
Page 400 RSV4 1100 Factory Suspensions Disassembling the fork • 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 401 RSV4 1100 Factory 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:...
Page 402 RSV4 1100 Factory Suspensions Reassembling the fork • 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 403 RSV4 1100 Factory 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 404 RSV4 1100 Factory Suspensions • Insert the pre-loading spring while maintaining the pin in the raised posi- tion. • 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 •...
Page 405 RSV4 1100 Factory Suspensions • Using the special Öhlins tool, tighten the upper cap, applying the pre-de- fined torque. Steering damper Adjusting 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 406 RSV4 1100 Factory 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 407 RSV4 1100 Factory 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)
Page 408 RSV4 1100 Factory 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 409 RSV4 1100 Factory 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...
Page 410 RSV4 1100 Factory 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 411 RSV4 1100 Factory 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 412 RSV4 1100 Factory Suspensions Adjusting play 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)
Page 413 RSV4 1100 Factory Suspensions The rear suspension consists of a spring-shock absorber unit linked to the frame via uniball joints and to the swingarm via a linkage system. The following operations can be performed to ad- just the rear shock absorber: •...
Page 414 RANGE. CAUTION FOR THE CORRECT SETTING PARAMETERS, READ THE PARAGRAPH "SETTING THE REAR SHOCK ABSORBER" CAREFULLY. TAKE YOUR VEHICLE TO AN Authorised Aprilia Dealer, IF NECESSARY. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED. Adjusting...
Page 415 RSV4 1100 Factory Suspensions (*) = clockwise (**) = anticlockwise 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.
Page 416 RSV4 1100 Factory Suspensions Linkages 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 417 INDEX OF TOPICS CHAS HASSIS...
Page 418 RSV4 1100 Factory Chassis HASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 419 RSV4 1100 Factory Chassis Front wheel 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 Removal •...
Page 420 RSV4 1100 Factory Chassis • 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 421 RSV4 1100 Factory Chassis • Replace both wheel bearings. CHECKING RADIAL AND AXIAL PLAY • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings are not conformant: • Replace both wheel bearings.
Page 422 RSV4 1100 Factory Chassis Rear wheel 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)
Page 423 RSV4 1100 Factory Chassis • Tap lightly on the wheel pin to extract the head of the housing. • Rotate the wheel forwards and disen- gage the drive chain from the sprocket. • Remove the wheel pin together with the right chain guide pad.
Page 424 RSV4 1100 Factory Chassis • Act on the threaded pin (1) with a hex- agonal wrench, blocking rotation Un- screw the DAX nut (2) and remove it. • Repeat the operation to remove all the nuts and related pins. •...
Page 425 RSV4 1100 Factory Chassis • Place the pins (1) with the corresponding DAX nuts (2) paying attention so the pins are directed towards the inside the machining on the flange CAUTION WITH EVERY REMOVAL, REPLACE THE PINS AND NUTS WITH THE NEW COMPONENTS •...
Page 426 RSV4 1100 Factory Chassis • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: • Replace both wheel bearings. REAR WHEEL GASKETS •...
Page 427 RSV4 1100 Factory Chassis FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit. ROTATION CHECK • Remove the left spacer (3). • Remove the right spacer (4). • Manually rotate the inside ring of each bearing.
Page 428 RSV4 1100 Factory Chassis • Check the sprocket (7) toothing for proper conditions. If there is excessive wear: • Replace the sprocket. TO PREVENT NEW COMPONENTS FROM WEARING PREMATURELY, THE REAR SPROCKET, FRONT SPROCKET AND DRIVE CHAIN MUST ALWAYS BE REPLACED TOGETHER AS A SET.
Page 429 RSV4 1100 Factory Chassis 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). •...
Page 430 RSV4 1100 Factory 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)
Page 431 RSV4 1100 Factory Chassis pos. Description Type Quantity Torque Notes Chain guard fastening screws 4 Nm (2.95 lb ft) Front chain guide fixing screw 4 Nm (2.95 lb ft) Chain guide rear fastening nut 7 Nm (5.16 lb ft) Chain feeder shoe fastening screws 2 Nm (1.48 lb ft)
Page 432 RSV4 1100 Factory Chassis • Unscrew and remove the nut and re- trieve the washer. • Working from the right side, loosen and remove the locking ring nut. • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely.
Page 433 RSV4 1100 Factory Chassis • Place a mounting under the front part of the swingarm. • Support the swingarm from the front. • Remove the swingarm pin (2) from the right hand side. • Support the front part of the swingarm and be ready to accompany it.
Page 434 RSV4 1100 Factory Chassis CHECK AND, IF REQUIRED, REPLACE THE BEARINGS AFTER EVERY BEARING REMOVAL. Specific tooling AP8140180 Bearing extractor • Remove the inner spacer (7) and collect the two OR seals (8). • Carefully clean inside the bearing seat.
Page 435 RSV4 1100 Factory Chassis • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. ALWAYS REPLACE BOTH SEALS TOGETHER. ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE. SWINGARM PIN •...
Page 436 RSV4 1100 Factory Chassis • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the adjustment bushing (3) to its seat and tighten it manually. CAUTION THE ADJUSTMENT BUSHING (3) MUST NOT PROTRUDE BEYOND THE CHASSIS INTERNAL EDGE.
Page 437 RSV4 1100 Factory Chassis • Working from the right hand side of the vehicle, turn the swingarm pin (2) clockwise. This turns the adjustment bushing (3), driving the swingarm in until fully seated. • Tighten the locking ring nut (1).
Page 438 RSV4 1100 Factory Chassis • Fit the washer on the screw • Tighten the screw. • Install the rear shock absorber and the linkages. • Fit the rear brake calliper plate. • Fasten the two pipe grommets on the swingarm •...
Page 439 RSV4 1100 Factory Chassis To dismantle and remove the chain, proceed as follows: • Partially remove the pins (3) using a generic chain breaker. • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6).
Page 440 RSV4 1100 Factory Chassis • 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. The different chain pitches which may be checked with the instrument are indicated on the instrument itself.
Page 441 RSV4 1100 Factory Chassis Installing • After fitting the chain on the pinion and on the crown, put the inner O-rings (1) back onto the hammerlock pins (2) and connect the two ends of the transmis- sion chain. • Place the outer O-rings (3) on the pins.
Page 442 RSV4 1100 Factory Chassis • Turn the pin of the specific tool 90° and re-engage the link pin again (checking riveting at points "B"). • Grease the chain and record the clearance. Adjusting The vehicle has an endless chain, without master link.
Page 443 RSV4 1100 Factory Chassis deflection must be constant throughout the entire rotation of the wheel. ADJUSTMENT CAUTION TO ADJUST THE CHAIN GET A SPECIFIC REAR SERVICE STAND. If you need to adjust the chain tension after the check: • Place the vehicle on its rear service stand.
Page 444 RSV4 1100 Factory Chassis BE EXTREMELY CAREFUL WHEN ADJUSTING, LUBRICATING, WASHING AND REPLACING THE CHAIN. CLEANING AND LUBRICATION Do not wash the chain with water jets, vapour jets, high-pressure water jets and highly flammable sol- vents. • Wash the chain with naphtha or kerosene. If it tends to rust quickly, carry out the mainte- nance operations more frequently.
Page 445 RSV4 1100 Factory Chassis See also Removing the rear wheel • 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)
Page 446 RSV4 1100 Factory 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 - 446...
Page 447 RSV4 1100 Factory 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)
Page 448 RSV4 1100 Factory Chassis • Remove the heat guard making sure to recover the washers. • Loosen the clamp between the ex- haust terminal and the central mani- fold. • Loosen the adjustment nuts of the ex- haust valve. •...
Page 449 RSV4 1100 Factory Chassis • Remove the exhaust terminal from the central manifold and support it to dis- connect the exhaust valve control ca- bles. • Remove the exhaust terminal com- pletely. Installation • Connect the cables of the exhaust valve.
Page 450 RSV4 1100 Factory Chassis • Tighten the screw with the relevant ex- haust fixing nut on the frame, making sure to insert the collar and the washer. • Tighten the clamp between the ex- haust terminal and the central mani- fold.
Page 451 RSV4 1100 Factory Chassis • Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables. CAUTION ON REASSEMBLY, POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET. • Release the springs between the rear...
Page 452 RSV4 1100 Factory Chassis • Release the springs between the front exhaust manifolds and the catalytic converter • Move the radiator forward. • Unscrew and remove the four nuts fas- tening the front exhaust manifold and retrieve the washers. •...
Page 453 RSV4 1100 Factory Chassis Butterfly valve in exhaust To check correct operation and calibration of the exhaust valve, see electrical system section. 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.
Page 454 RSV4 1100 Factory Chassis Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe. • Release the clamp and disconnect the left hand radiator pipe.
Page 455 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 456 RSV4 1100 Factory 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 - 456...
Page 457 RSV4 1100 Factory Braking system Operating diagram ABS functional diagram key BRAK SYS - 457...
Page 458 RSV4 1100 Factory 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)
Page 459 RSV4 1100 Factory 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 460 RSV4 1100 Factory 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 461 RSV4 1100 Factory Braking system REPLACING THE ABS CONTROL UNIT • Before replacing the ABS control unit, mark the hoses so that they can be refit correctly on the new control unit. • Remove the ABS support (1), the heat shield plate (2) and finally the ABS con- trol unit.
Page 462 RSV4 1100 Factory Braking system • Take care of hose position on the sup- port. 1. Goes to the pump. 2. Goes to the caliper. • After replacing hoses or the control unit the entire ABS system must be bled.
Page 463 RSV4 1100 Factory Braking system ABS PIPES ROUTING TABLE A - ABS PIPES ROUTING 1. Small clamps TABLE B - ABS PIPES ROUTING 1. Rear speed sensor cable. 2. Cable guide. 3. Cable grommet. 4. Cable grommet. TABLE C - ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure.
Page 464 RSV4 1100 Factory Braking system Guide to diagnosis PREMISE Each time the key is ON, if, at least one current or stored* error is detected, the ABS warning light turns on permanently. The ABS system is deactivated automatically The system operates perfectly just as any other...
Page 465 RSV4 1100 Factory Braking system 8. PERFORM THESE CHECKS: • A. CAN line integrity from the ABS modulator (PIN 2, PIN 11) to the instrument panel (PIN 26, PIN 27). • B. Check connectors - refer to the operations described in the chapter If the above checks are OK, the causes can be: •...
Page 466 RSV4 1100 Factory Braking system PARAMETERS screen page This screen shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec- tion time, ignition advance, etc.) PARAMETERS AND STATUSES P.A.D.S.
Page 467 RSV4 1100 Factory Braking system ERRORS screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS Description Code Symptom Front wheel speed sensor: electrical diagnosis...
Page 468 RSV4 1100 Factory Braking system PADS report mode In the following are described the procedure to be performed through the diagnostic tool in order to generate an errors report: • When started the program, select the brand. • Select the vehicle and the component.
Page 469 RSV4 1100 Factory Braking system • 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 470 RSV4 1100 Factory Braking system SETTINGS screen page This screen is used to adjust some control unit pa- rameters. ADJUSTMENTS P.A.D.S. characteristic. Value/example Units of Notes measure ment Encoding reset Resets the vehicle code and obtains it automati- cally from the CAN line at the next key ON...
Page 471 RSV4 1100 Factory Braking system • between PIN 14 of the ABS control unit and PIN 1 of the sensor (yellow cable) • between PIN 13 of the ABS control unit and PIN 2 of the sensor (yellow/brown cable) Short-circuit to negative: - Disconnect the sensor connector.
Page 472 RSV4 1100 Factory Braking system - If there is no insulation, restore the wiring harness or replace the sensor. Short-circuit to positive: - Disconnect the sensor connector. - Check the battery supply insulation of the two PINS. - If there is no insulation, restore the wiring harness or replace the sensor.
Page 473 RSV4 1100 Factory Braking system U2921 Controller error U2922 Line failure (busoff) Error cause: Communication problem on CAN line: possible contact. Troubleshooting: Check the integrity and continuity of the wiring harness: • between ABS control unit PIN 2, instrument panel PIN 33 and injection control unit PIN 80 (Orange cable) •...
Page 474 RSV4 1100 Factory Braking system 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 475 RSV4 1100 Factory Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
Page 476 RSV4 1100 Factory Braking system Component maintenance The vehicle is fitted with a two-channel ABS sys- tem, i.e. it works on both the front and the rear wheel. Check periodically and each time the wheels are refitted, the tone wheel (2) or the sensor (1) re- placed, that the wheel distance is constant at each 360°.
Page 477 RSV4 1100 Factory 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)
Page 478 RSV4 1100 Factory 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.
Page 479 RSV4 1100 Factory 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 480 RSV4 1100 Factory 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 481 RSV4 1100 Factory Braking system exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS.
Page 482 RSV4 1100 Factory 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 483 RSV4 1100 Factory Braking system • Remove the pin (3) and recover the safety spring (4). • Remove the two pads (5) and recover the soundproofing plates. • If worn, replace the anti-vibration plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 484 RSV4 1100 Factory Braking system • Place the safety spring (3). • Hold the centre of the safety spring (3) depressed and insert the pin (2) so it passes above the spring. • Fit the retainer ring (1). • Check the brake fluid.
Page 485 RSV4 1100 Factory Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid.
Page 486 RSV4 1100 Factory Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
Page 487 RSV4 1100 Factory Braking system RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lb ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lb ft) mounting bracket to handlebar Front brake pump U bolt clamp 10 Nm (7.38 lb ft)
Page 488 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 489 RSV4 1100 Factory 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 - 489...
Page 490 RSV4 1100 Factory 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 491 RSV4 1100 Factory 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 492 RSV4 1100 Factory 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...
Page 493 RSV4 1100 Factory 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 •...
Page 494 RSV4 1100 Factory 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 495 RSV4 1100 Factory 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-...
Page 496 RSV4 1100 Factory 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...
Page 497 RSV4 1100 Factory 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 498 RSV4 1100 Factory 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.
Page 499 INDEX OF TOPICS BODYW ODYWORK...
Page 500 RSV4 1100 Factory 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)
Page 501 RSV4 1100 Factory Bodywork NSTRUMENT PANEL Pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 502 RSV4 1100 Factory Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lb ft) Lug fixing screws 4 Nm (2.95 lb ft) Screws fixing the side fairings to the 1.5 Nm (1.11 lb ft)
Page 503 RSV4 1100 Factory Bodywork UEL TANK Pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft) er's saddle to the fuel tank Filler to tank retaining screws 4 Nm (2.95 lb ft) Screws fastening fuel pump flange to 5 Nm (3.69 lb ft)
Page 504 RSV4 1100 Factory 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 - 504...
Page 505 RSV4 1100 Factory 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) AIRINGS pos. Description Type...
Page 506 RSV4 1100 Factory Bodywork ICENSE PLATE HOLDER pos. Description Type Quantity Torque Notes License plate light fixing screws 1 Nm (0.74 lb ft) Rear turn indicator fixing screws 2.5 Nm (1.84 lb ft) Taillight fixing screws 3 Nm (2.21 lb ft) Taillight cover self-tapping fixing SWP 3.9...
Page 507 RSV4 1100 Factory Bodywork EAR BODYWORK Pos. Description Type Quantity Torque Notes Rear screws used to fasten the tail 3 Nm (2.21 lb ft) fairing to the rear headlight bracket Screws used to fasten the saddle SWP 2.9 1 Nm (0.74 lb ft)
Page 508 RSV4 1100 Factory Bodywork OCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lb ft) Lock lever self-tapping screw 2 Nm (1.48 lb ft) Shear head screw (to the left of the...
Page 509 RSV4 1100 Factory Bodywork ODYWORK UNDER SADDLE Pos. Description Type Quantity Torque Notes Flanged button head hex. socket M5x12 3 Nm (2.21 lb ft) screws for fastening the saddle mounting Screws and nuts for fastening the 4 Nm (2.95 lb ft)
Page 510 RSV4 1100 Factory Bodywork OOTRESTS Pos. Description Type Quantity Torque Notes Screws for fastening the rider's footr- 2 + 2 25 Nm (18.44 lb ft) Loctite 243 ests to the frame Screws for fastening the passenger's 2 + 2 18 Nm (13.28 lb ft)
Page 511 RSV4 1100 Factory Bodywork EAR MUDGUARD pos. Description Type Quantity Torque Notes Rear mudguard fixing screws 5 Nm (3.69 lb ft) For plastic mud- guard Rear mudguard fixing screws 3 Nm (2.21 lb ft) For carbon mud- guard Seat •...
Page 512 RSV4 1100 Factory Bodywork • 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. • Disconnect the turn indicator connector from the relative fixed connector on the instrument panel •...
Page 513 RSV4 1100 Factory Bodywork Instrument panel • Remove the windshield. • Unscrew and remove the two screws. • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the support.
Page 514 RSV4 1100 Factory Bodywork Headlight assy. • Remove the top fairing complete • Remove the side air deflectors from the top fairing • Remove the four fixing screws (1) • Remove the lower fixing screw (2) pay- ing attention to collect the bush (3) •...
Page 515 RSV4 1100 Factory 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 516 RSV4 1100 Factory 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 517 RSV4 1100 Factory 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 518 RSV4 1100 Factory 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 519 RSV4 1100 Factory 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 520 RSV4 1100 Factory 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 521 RSV4 1100 Factory Bodywork Side fairings • Working from the left side of the mo- torcycle, unhook the three clips (1) positioned on the inner fairing. • Remove the four screws (2) • Unhook the internal fixing clip (3) with the duct •...
Page 522 RSV4 1100 Factory Bodywork • Remove the four internal fixing screws of the aerodynamic fin. • Remove the aerodynamic fin. DUCTS • The following operations are valid for both deflectors • Remove the fixing screw (1) of the de- flector to the lower fairing •...
Page 523 RSV4 1100 Factory Bodywork • Disconnect the connectors (2) of the alternator to the radiator • Remove the lower fixing screw (3) of the left inner fairing • Remove the upper fixing screw (4) of the left inner fairing •...
Page 524 RSV4 1100 Factory Bodywork CENTRAL UNDERFAIRING • Remove the three clips (1) and the two screws (2) fixing the central underfair- ing to the top fairing. • In case the side underfairing are not removed, remove the internal screws (3) from both sides.
Page 525 RSV4 1100 Factory Bodywork • Working from both sides of the motor- cycle, undo and remove the two screws (3). • Remove the two auxiliary fuse boxes (4) from the corresponding supports in- dicated in the figure. • Unscrew and remove the screw (5).
Page 526 RSV4 1100 Factory Bodywork • Remove the underfairing (6). License plate holder • Remove the plastic cover (1). • Undo and remove the screw inside of the point indicated in the figure. • Unscrew the fixing screws (2) together with the nuts (3).
Page 527 RSV4 1100 Factory Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit complete with support. • Undo the four screws fixing the injec- tors unit to the filter box • Remove the injectors from the filter box •...
Page 528 RSV4 1100 Factory Bodywork • Move the two rear coil connectors. • Remove the two clamps blocking the wiring harness to the filter box cover BODYW - 528...
Page 529 RSV4 1100 Factory Bodywork • Remove the four screws fixing the var- iable geometry intake system and re- move it • Remove the fixing screws of the intake duct/supports • Remove the intake ducts complete with support • Operating from both sides, unscrew and remove the air pressure sensors fixing screws •...
Page 530 RSV4 1100 Factory Bodywork • Operating from the left side of the mo- torcycle, remove the clamp blocking the main wiring harness to the filter box • Disconnect the engine wiring connec- tor, previously placed on the filter box •...
Page 531 RSV4 1100 Factory Bodywork • Remove the filter box Rear mudguard • Unscrew and remove the two screws. • Remove the rear mudguard. Lower cowl • Remove the side fairings • Working from both sides, remove the front fixing screws (1) •...
Page 532 RSV4 1100 Factory Bodywork • Remove the clamp that holds the vent pipe to the fairing stanchion. • Remove the clip (3) and the two screws (4) to divide the stanchion Fuel tank • Remove the saddle. • Unscrew and remove the front screw fixing the tank.
Page 533 RSV4 1100 Factory Bodywork • 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 534 RSV4 1100 Factory Bodywork Front mudguard • Working on both sides of the vehicle, undo and remove the two screws. • Remove the cable clamp fixing screw (if fitted) • Release the brake pipe by detaching the cable clamp from the mudguard •...
Page 535 RSV4 1100 Factory Bodywork 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. • Unscrew and remove the five semi- arch brace fixing screws.
Page 536 RSV4 1100 Factory Bodywork • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp. • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp.
Page 537 RSV4 1100 Factory Bodywork • Fit the turn indicator connectors in the relative housings, noting the colours of the wires identifying the correct side. • Join the remaining connectors and ar- range the cable carefully in the space available within the arch brace. Note that there are two pairs of connectors which may be connected incorrectly.
Page 538 RSV4 1100 Factory Bodywork • Remove the radiator cover Tail guard • Carry out the saddle removal proce- dure. • Carry out the side fairing removal pro- cedure. • Undo and remove the six fixing screws (1). • Remove the two plastic inserts (2) from both sides of the motorcycle.
Page 539 RSV4 1100 Factory Bodywork • Unhook the saddle opening cable (4) from its seat. • Remove the left (5) and right (6) tail fairing. Side air deflectors The following procedure is for a single lateral duct but is applicable to both.
Page 540 INDEX OF TOPICS PRE DE DELIVERY...
Page 541 RSV4 1100 Factory Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 542 RSV4 1100 Factory Pre-delivery TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. THE LACK OF AN ADEQUATE BATTERY CHARGE BEFORE THE FIRST USE WILL CAUSE A PREMATURE FAILURE 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 543 RSV4 1100 Factory Pre-delivery - Do not carry the battery together with flammable, explosive or sharp objects. - NEVER attempt to open the battery. - Keep the connecting poles clean and firmly secured at all times. - Do not immerse the battery in water, or leave it exposed to moisture.
Page 544 RSV4 1100 Factory Pre-delivery - 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 545 RSV4 1100 Factory Pre-delivery • 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 546 RSV4 1100 Factory Pre-delivery • Fit the two-seater saddle. PRE DE - 546...
Page 547 219 ABS: 231, 456, 465 Air filter: 72 Air temperature sensor: 162 Aprilia V4-MP Tecnology: 242 Battery: 132, 145 Brake: 477–479, 481, 482, 486, 487 Brake calliper: 477, 478 Brake disc: 478, 479 Brake pads: 481, 482...
Page 548 Front cylinder head valves: 74 Front head: 309, 315, 318, 319, 340, 353, 355 Front wheel: 419, 480 Fuel: 180, 386, 532 Fuel pump: 180, 386 Fuses: 136 Handlebar: 394 Head cover: 308 Headlight: 514, 515, 539 Identification: 11 Instrument panel: 513, 535 Intake pressure sensor: 155 Keys: 129 License plate holder: 526...
Page 549 Secondary shaft: 278 Shock absorber: Shock absorbers: 412 Side fairings: 521 Side stand: 202, 446 Side stand sensor: 202 Spark plug: 68 Speed sensor: 147 Stand: 202, 445, 446 Start-up: 135, 285 Starter motor: 284 Steering damper: 405 Stepper motor: 392 Tank: 532 Throttle body: 185, 391, 392 Top fairing:...

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Summary of Contents for APRILIA RSV4 1100 Factory

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