Page 1 SERVICE STATION MANUAL 894159 RSV4 Factory...
Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 RSV4 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 Factory Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-...
Page 11 RSV4 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 RSV4 Factory Characteristics Specification Desc./Quantity Kerb weight 189 kg (417 lb) Kerb weight 200 kg (441 lb) Full loaded weight (rider only) 275 kg (441 lb) Engine ENGINE Specification Desc./Quantity Model Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double overhead camshafts.
Page 13 RSV4 Factory Characteristics Specification Desc./Quantity Seats 1 + 1 Two seat configuration: if vehicle is fitted with footrests and saddle for passenger Maximum weight capacity 201 kg (443 lb) Drive chain RIVE CHAIN Specification Desc./Quantity Type With sealed master link...
Page 14 RSV4 Factory Characteristics USPENSION Specification Desc./Quantity Front fork Ohlins upside down units with adjustable hydraulic damping and 43 mm (1.69 in) diam. stanchions with Tin surface coating) Front wheel travel 120 mm (4.72 in) Rear shock absorber Lateral mounted hydraulic shock absorber with progressive APS system.
Page 15 RSV4 Factory Characteristics Specification Desc./Quantity Rear tyre 190/55 ZR17 (75W) 190/50 ZR17 (73W) Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI) 2 passengers: 2.8 bar (280 kPa) (40.61 PSI) Supply UEL SYSTEM Specification Desc./Quantity Fuel Premium unleaded petrol, minimum octane rating of 95...
Page 16 RSV4 Factory Characteristics IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket RONT FORK pos. Description Type Quantity Torque Notes Fastener screws for calliper mount- 2 + 2 12 Nm (8.85 lbf ft) ing bracket (Öhlins)
Page 17 RSV4 Factory Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lbf ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lbf ft) chions Headstock lock ring M35x1 60 Nm (44.25 lbf ft)
Page 18 RSV4 Factory Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lbf ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lbf ft) Loct. 243 RONT BRAKE CALLIPER pos.
Page 19 RSV4 Factory Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft)
Page 20 RSV4 Factory Characteristics ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screw fastening the semi-handlebar 1 + 1 25 Nm (18.44 lbf ft) collar to the fork sleeves Semi-handlebar safety screw 10 Nm (7.37 lbf ft) Anti-vibration counterweight fastener M18x1.5...
Page 21 RSV4 Factory Characteristics EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) NSTRUMENT PANEL pos. Description Type Quantity...
Page 22 RSV4 Factory Characteristics INDSHIELD pos. Description Type Quantity Torque Notes Windshield fixing screws 0.5 Nm (0.37 lbf ft) Rear-view mirror fixing nuts 2 + 2 10 Nm (7.37 lbf ft) - Screws fastening the side fairings 1 Nm (0.74 lbf ft)
Page 23 RSV4 Factory Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft)
Page 24 RSV4 Factory Characteristics OOLING pos. Description Type Quantity Torque Notes Screws fastening water radiator 10 Nm (7.37 lbf ft) mounting bracket to chassis Screws fastening water radiator to 7 Nm (5.16 lbf ft) mounting bracket Screw fastening pipe grommet for 6 Nm (4.42 lbf ft)
Page 25 RSV4 Factory Characteristics Central part IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft)
Page 26 RSV4 Factory Characteristics ADDLE pos. Description Type Quantity Torque Notes Rider saddle fixing screw 6 Nm (4.42 lbf ft) UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft)
Page 27 RSV4 Factory Characteristics OOTPEGS pos. Description Type Quantity Torques Notes Screws fastening rider footpegs to 2 + 2 25 Nm (18.44 lbf ft) chassis Screws fastening passenger foot- 2 + 2 18 Nm (13.28 lbf ft) For countries in pegs to chassis...
Page 28 RSV4 Factory Characteristics RONT CHASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 29 RSV4 Factory Characteristics EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft)
Page 30 RSV4 Factory Characteristics LOCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lbf ft) Lock lever self-tapping screw 2 Nm (1.47 lbf ft) RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque...
Page 31 RSV4 Factory Characteristics ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate CHAR - 31...
Page 32 RSV4 Factory Characteristics ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft) AIRING pos.
Page 33 RSV4 Factory Characteristics Back side XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft)
Page 34 RSV4 Factory Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount CHAR - 34...
Page 35 RSV4 Factory Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) EAR BRAKE CALLIPER pos.
Page 36 RSV4 Factory Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 37 RSV4 Factory Characteristics EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual linkage fixing screw 50 Nm (36.88 lbf ft) Screw fastening single linkage to 50 Nm (36.88 lbf ft)
Page 38 RSV4 Factory Characteristics AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9...
Page 39 RSV4 Factory Characteristics TAIL pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft)
Page 40 RSV4 Factory Characteristics ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft)
Page 41 RSV4 Factory Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) TE flanged screws M6x35 12 Nm (8.85 lbf ft) TE flanged screws M6x22 12 Nm (8.85 lbf ft)
Page 42 RSV4 Factory Characteristics ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) CHAR - 42...
Page 43 RSV4 Factory Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft)
Page 44 RSV4 Factory Characteristics TIMING SYSTEM pos. Description Type Quantity Torque Notes Screws fastening the timing system 30 Nm (22.13 lbf ft) Loct. 243 gear on the intake shaft Skid fastener screws 20 Nm (14.75 lbf ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.37 lbf ft)
Page 45 RSV4 Factory Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 46 RSV4 Factory Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 47 RSV4 Factory Characteristics EARBOX pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw 10 Nm (7.37 lbf ft)
Page 48 RSV4 Factory Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch nut 150 Nm (110.63 lbf ft) Loct. 243 IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct.
Page 49 RSV4 Factory Characteristics LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft) side Blow-by union fastener screws M5x16 7 Nm (5.16 lbf ft) Stator fixing screw UNI 5931 CL8.8...
Page 50 RSV4 Factory Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft)
Page 51 RSV4 Factory Characteristics ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Recommended products chart ECOMMENDED PRODUCTS Product Description Specifications AGIP TEC 4T, SAE 15W-50 Engine oil Use branded oils with performances equal to or exceeding CCMC G-4 A.P.I.
Page 52 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 53 RSV4 Factory Special tools PECIAL TOOLS Stores code Description 020845Y Engine support 020846Y Retaining tray + plastic caps 020847Y Flywheel extractor 020848Y Flywheel retainer 020849Y Clutch retainer 020850Y Primary gear lock S-TOOLS - 53...
Page 54 RSV4 Factory Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring 020857Y Crankshaft bearing U bolt...
Page 55 RSV4 Factory Special tools Stores code Description 020858Y Device for holding the pistons in the cyl- inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020861Y Countershaft bushing punch 020862Y Gearbox control rod roller cage fitting...
Page 56 RSV4 Factory Special tools Stores code Description 020863Y Desmodromic drum roller cage fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020883Y Timing chain tensioner installation/re- moval tool 020709Y Engine support AP8140187 Engine support stand 020376Y...
Page 57 RSV4 Factory Special tools Stores code Description 020363Y 20-mm Oil seal guide 020364Y 25-mm Guide 020359Y 42 x 47 mm punch 020360Y 52x55 mm Adaptor 020655Y 62x68 mm Adaptor 020408Y 72x75-mm (2.83x2.95 in) adaptor S-TOOLS - 57...
Page 58 RSV4 Factory Special tools Stores code Description 020306Y Punch for fitting the valve seal rings 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor 0277308 Guide bushing for secondary gearbox shaft AP8140146 Weight S-TOOLS - 58...
Page 59 RSV4 Factory Special tools Stores code Description AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140190 Tool for steering tightening 020877Y Pliers for clamps AP8140181 Fuel pressure checking tool 020481Y Control unit interface wiring 020680Y TXB Navigator...
Page 60 INDEX OF TOPICS MAIN AINTENANCE...
Page 61 Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it.
Page 62 RSV4 Factory Maintenance Km x 1000 Brake systems (6) Light circuit Stand switch Safety switches Stop switches Brake fluid (4) Coolant (4) Fork oil (7) Engine oil (6) Light aiming Fork oil seals (6) Flexible coupling Tyres - pressure/wear (2)
Page 63 RSV4 Factory Maintenance • Remove the fuel tank. • Unscrew and remove the rear coil fixing screw. • Slide off the rear coil. • Unscrew and slide off the rear spark plug. Engine oil Check NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Page 64 RSV4 Factory Maintenance ALLOWING THE LEVEL TO DROP BELOW THE MINIMUM LEVEL OR OVERFILLING BEYOND THE MAXIMUM LEVEL MAY CAUSE SEVERE ENGINE DAMAGE. Replacement NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Place a container with a larger capacity than the circuit under the drainage plug.
Page 65 RSV4 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 66 RSV4 Factory Maintenance • Disconnect the variable geometry in- take system connector. • Fit a suitably sized shim behind the fil- ter box cover. • 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 67 RSV4 Factory Maintenance • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 68 RSV4 Factory Maintenance • Use a feeler gauge to check the clear- ance between the cam on the shaft and the relative tappet for both rear head shafts. Characteristic Acceptable values with control clearance be- tween cam and valve intake: 0.10 - 0.15 mm (0.0039 - 0.0059 in) ex- haust: 0.20 - 0.25 mm (0.0079 - 0.0098 in)
Page 69 RSV4 Factory Maintenance • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 70 RSV4 Factory Maintenance Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer 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...
Page 71 RSV4 Factory Maintenance • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 72 RSV4 Factory Maintenance Calibrated pad thickness NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 73 RSV4 Factory Maintenance • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 74 RSV4 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 75 RSV4 Factory Maintenance • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel). • Insert the pin from the clutch side into the hole in the crankshaft. NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION.
Page 76 RSV4 Factory Maintenance Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en- gine rotation (direction of travel) to align the hole on the intake camshaft with the specific hole on the U bolt.
Page 77 RSV4 Factory Maintenance • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 78 RSV4 Factory Maintenance Calibrated pad thickness NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 79 RSV4 Factory Maintenance • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 80 RSV4 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 81 RSV4 Factory Maintenance Calibrated pad thickness Pad thicknesses for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.80 mm (0.0709 in) 1.85 mm (0.0728 in) 1.90 mm (0.0748 in) 1.95 mm (0.0768 in) 2 mm (0.0787 in) 2.05 mm (0.0807 in) 2.1 mm (0.0827 in)
Page 82 RSV4 Factory Maintenance 2.75 mm (0.1083 in) 2.8 mm (0.1102 in) 2.85 mm (0.1122 in) 2.9 mm (0.1142 in) 2.95 mm (0.1161 in) 3 mm (0.1181 in) 3.05 mm (0.1201 in) 3.10 mm (0.1220 in) 3.15 mm (0.1240 in) MAIN - 82...
Page 83 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 84 SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE DIAGNOSIS INSTRUMENT THROUGH CONTROL UNIT BY SE- LECTING "SELF-ACQUISITION, APRILIA, RSV4" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 85 RSV4 Factory Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 86 RSV4 Factory Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION AXONE SHOULD BE WORKING PROPERLY AND UPGRADED AT LEAST TO THE 7.0.0 VERSION OR THE PGDS UPDATED AT LEAST TO THE 3.0.0 VERSION...
Page 87 RSV4 Factory Troubleshooting • 8. WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS ON THE DIAGNOSIS INSTRUMENT, DEVICES STATUS SCREEN PAGE, ICON 0/1 MEAN? If "RUN" is shown, go to 9; if "STOP" is shown, go to 15 •...
Page 88 RSV4 Factory Troubleshooting PIN 42, "URGENT SERVICE" TURNS ON IN THE INSTRUMENT PANEL AND THE CON- TROL UNIT INDICATES ERRORS RELATED TO THE FRONT AND REAR THROTTLE BODY) YES, go to 3; NO, go to 6 • 3. CHECK CONTINUITY WITH GROUND CONNECTION AT PIN 5 and 16 If there is continuity, go to 4;...
Page 89 RSV4 Factory Troubleshooting • 1. CHECK CONTINUITY OF WHITE/BLUE CABLE FROM PIN 14 OF THE CONTROL UNIT ON CABLE HARNESS SIDE TO PIN 3 OF THE BLACK CONNECTOR OF THE DIAGNO- YES, go to 2; NO, go to 4 •...
Page 90 RSV4 Factory Troubleshooting • 7. CHECK CONTINUITY OF THE CABLE FROM THE INJECTION RELAY 33 TO THE PROTECTION RELAY 19: ORANGE (BETWEEN RELAY 33 AND FUSE F) and RED/ BROWN (BETWEEN FUSE RELAY F AND RELAY 19) If there is continuity, go to PROTECTION RELAY 19 CHECK; if there is not continuity, restore...
Page 91 RSV4 Factory Troubleshooting • 2. WITH CONNECTOR DISCONNECTED (4-ways black, inside the bow) CHECK IF THERE IS GROUND CONNECTION ON PIN 3, ON THE CABLE HARNESS SIDE YES, go to 3; NO, go to 6 • 3. CHECK WITH CONNECTOR DISCONNECTED (4-ways black, inside the bow) ON THE...
Page 92 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 93 RSV4 Factory Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft) Screw fastening the voltage regula- 6 Nm (4.42 lbf ft)
Page 94 RSV4 Factory Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate...
Page 95 RSV4 Factory Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Intake connectors 11.Lower injectors 12.Air pressure sensor...
Page 96 RSV4 Factory Electrical system Component position Component name Location on the vehicle in the electrical circuit diagram Protection relay Under the saddle next to the battery, left side Injection relay Under the saddle next to the battery, right side Fan control relay...
Page 97 RSV4 Factory Electrical system • 1 Right handlebar control • 1 Left handlebar control • 1 Regulator • 1 Hand grip position sensor • 1 Variable geometry control unit • 1 Engine cable harness • 1 Engine revolution sensor •...
Page 98 RSV4 Factory Electrical system • 2 Cable grommets • 3 Cable guides • 5 Relay socket rubber rings • 2 Rubber rings • 3 Rubber rings • 2 Rubber rings • 1 Rubber ring for the protection relay • 1 Rubber ring for the fall sensor •...
Page 99 RSV4 Factory Electrical system • 1 Secondary air pipe • 4 Rubber manifolds • 4 Clic clamps Motorcycle division The wiring distribution is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section...
Page 100 RSV4 Factory Electrical system • Left handlebar control connector • Clutch connector • Key switch connector • Immobilizer aerial connector • Oxygen sensor connector • Output "30" engine revolution sensor connector • Outputs "25" and"26" 7SM control unit connectors •...
Page 101 RSV4 Factory Electrical system 9. Self-locking nut (x2) 10. T-shaped bushing (x2) 11. TBEI M6x30 screw (x2) 12. Washer (x2) TABLE C1 - HEADLAMP PRE-FITTING The headlamp cable harness (23) and the two relays with a relay socket rubber ring (17) must be fit on the headlamp (13) as shown in the photos below.
Page 102 RSV4 Factory Electrical system TABLE C2 - HEADLAMP PRE-FITTING 16. Cable grommet 17. Relay with relay socket rubber ring 25. Cable harness routing behind the relay TABLE D - HANDLEBAR CONTROLS 26. Left handlebar control 27. Clutch connector 28. Right handlebar control...
Page 103 RSV4 Factory Electrical system TABLE F - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Pass all the cable harnesses arriving from the right semi-handlebar (right handlebar control + front stop switch) and from the left semi-handlebar (left handlebar control + key switch) inside of the right arch brace, as shown in the figure;...
Page 104 RSV4 Factory Electrical system 42. Front stop switch connector 43. Right handlebar control connector TABLE I - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Make the connections for all connectors. The key switch connector has a longer cable harness in comparison to the 6 pin connectors for the left light switch.
Page 105 RSV4 Factory Electrical system TABLE L - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Right side Check that the cable grommets are not ten- sioned on the right and left cable grommet during steering rotation. 53. Cable harness routing to right handlebar con- trol 54.
Page 106 RSV4 Factory Electrical system TABLE N - COMPLETION OF THE FRONT 65. Headlamp connectors 66. Headlamp connector positioning (as shown in the figure) TABLE O - COMPLETION OF THE FRONT Check that the turn indicator connectors are inserted correctly and do not return inside the instrument holder arch brace.
Page 107 RSV4 Factory Electrical system Central part TABLE A - RADIATOR AREA Right side 1. Cable grommet 2. Vehicle cable harness TABLE B - RADIATOR AREA Right side 3. Starter motor 4. Clamp 5. Exhaust valve actuator cable harness routing 6. Oil pressure sensor and cable harness routing...
Page 108 RSV4 Factory Electrical system TABLE C - RADIATOR AREA The ground cable harness routing is behind the water pipe and behind the starter motor, as indi- cated by the arrow. 3. Starter motor 4. Clamp 5. Exhaust valve actuator cable harness routing 6.
Page 109 RSV4 Factory Electrical system TABLE F - DEMAND SENSOR FITTING 18. Slave Demand cable harness routing (creating a "U-bend" in the cable harness) 19. Master Demand cable harness routing (creat- ing a "U-bend" in the cable harness) TABLE G - DEMAND SENSOR FITTING Clamp where indicated.
Page 110 RSV4 Factory Electrical system 27. Flywheel connector 28. Regulator connector 29. Regulator connector on the vehicle cable harness TABLE I Right side 30. Instrument panel branch vehicle cable harness 31. Fan connector 32. Clamp TABLE J1 - EXHAUST VALVE ACTUATOR Positioning and calibration 33.
Page 111 RSV4 Factory Electrical system 41. T-shaped bushing 42. TE M6x30 screw TABLE J2 - EXHAUST VALVE ACTUATOR Positioning and calibration Actuator - valve Bowden cable (45) fitting procedure • Insert the cables with the set screws closed in the following sequence: 1.
Page 112 RSV4 Factory Electrical system TABLE K1 - PINION CASING AREA 46. Gear sensor cable harness routing 47. Oxygen sensor connector on the vehicle cable harness 48. Gear sensor 49. Oxygen sensor connector 50. Stand switch cable harness routing 51. Oxygen sensor cable harness routing 52.
Page 113 RSV4 Factory Electrical system TABLE M 62. Gear sensor cable harness routing 63. Oxygen sensor cable harness routing 64. Stand switch cable harness routing TABLE N 65. Stand switch connector TABLE O 66. Position the gear sensor and stand switch con-...
Page 114 RSV4 Factory Electrical system TABLE P2 - ENGINE - BATTERY GROUND CABLE ROUTING Clamp the engine- battery ground cable harness to the Demand sensor cable harness as far up as possible. 74. Clamp 75. Battery - engine ground lead 76. Engine - battery ground cable harness routing The engine - battery ground cable harness must not be visible within the area indicated with a red triangle.
Page 115 RSV4 Factory Electrical system CENTRAL Q1 - NOTES FOR ENGINE CABLE HARNESS FITTING Definition of component numbering: Upper view 77. Cylinder 1 78. Cylinder 2 79. Cylinder 3 80. Cylinder 4 81. Cylinder bank 1 82. Cylinder bank 2 83. Throttle body 1 (FARF 1) 84.
Page 116 RSV4 Factory Electrical system TABLE S1 - FILTER BOX COVER AND LOWER FILTER BOX PREPARATION Fit four mountings for the "coil" connectors and the mounting for the "vehicle" connector as shown in figures S1, S2 and S3. Lower filter box 90.
Page 117 RSV4 Factory Electrical system TABLE U - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING Before fitting the motorised throttle bodies (98 and 99), the respective engine cable harness connec- tors must be connected: on branch "2" of the cable...
Page 118 RSV4 Factory Electrical system TABLE Y - MOTORISED THROTTLE BODY FIT- TING First fasten the "Motorised Throttle Body 2 (front)" to the rubber manifolds with the specific clip-on clamps. Then fasten the "motorised throttle body 1 (rear)" to the rubber manifolds with the clip-on clamps us- ing the specific tool.
Page 119 RSV4 Factory Electrical system TABLE ZB - H2O TEMPERATURE SENSOR 114. Cable harness routing (branch "4") under the 3-way fitting 115. Engine speed sensor cable routing between the front motorised throttle body and the 3-way fit- ting 116. Rubber clamp TABLE ZC At this point, the injectors 2 (output "5") and 4 (out-...
Page 120 RSV4 Factory Electrical system 124. Lower injector 3 cable harness connector (output "17") - green connector 125. Coil 3 - long cable harness 126. Coil 1 - short cable harness TABLE ZE - COIL AND MAP SENSOR CON- NECTION Once the filter box is assembled, the coil and map sensor connections must be made.
Page 121 RSV4 Factory Electrical system TABLE ZH Once the Engine Speed Sensor (output "30") con- nector (142) has been connected to its counter- part, it must be clamped, using the indicated clamp (143), to the Blow-by pipe in the position shown in the figure.
Page 122 RSV4 Factory Electrical system 154. Air temperature sensor 155. Upper injector 1 cable harness connector (output "23") - black connector 156. Self-tapping screw Connect the upper injectors as shown in the figure and according to the following sequence: Injector 1 (output "23"): BLACK connector Injector 2 (output "20"): BROWN connector...
Page 123 RSV4 Factory Electrical system TABLE ZM 159. Clamp 160. Self-tapping 5x20 screw TABLE ZN The connectors (161) "ECU 1" (output "26") and (162) "ECU 2" (output "25") must be connected to their respective connectors on the 7SM control unit, being very careful when inserting them. The...
Page 124 RSV4 Factory Electrical system TABLE ZO It is advisable to create a jig in order to check the correct insertion of both connectors. TABLE ZP - VEHICLE CONNECTOR FASTEN- The "VEHICLE" (output "1") connector (165) must be fastened to the mounting with the white slide pre-fit on the connector itself, in the position indi- cated in the figure.
Page 125 RSV4 Factory Electrical system TABLE ZS - NOTES FOR FITTING THE GROUND CABLE There are two ground lug terminals on the cable harness: the "ENGINE GND" (output "9") and the "CHASSIS GND" (output "10"). The lug terminal "ENGINE GND" (172) (output "9")
Page 126 RSV4 Factory Electrical system TABLE B - SPEED SENSOR PRE-FITTING 8. Speed sensor 9. TE M6x20 screw 10. Sensor cable harness routing in the cable grommet TABLE C - START-UP RELAY PRE-FITTING 11. Starter motor cable on the vehicle cable harness 12.
Page 127 RSV4 Factory Electrical system TABLES D1 and D2 - VEHICLE CABLE HAR- NESSES The Vehicle Cable Harness (16) and the "Relay and Fall Sensor" mounting (18) must be fit on the chassis before fitting the engine. Check that the fan relay (20), safety relay (23) and fall sensor (19) are connected correctly (fit on the relative mounting).
Page 128 RSV4 Factory Electrical system TABLE E2 - REAR STOP SWITCH AND SPEED SENSOR CABLE HARNESS ROUTING ON THE RIGHT SIDE 28. Cable grommet 29. Speed sensor cable harness 30. Rear brake switch cable harness TABLE F1 - REAR SADDLE MOUNTING AREA 31.
Page 129 RSV4 Factory Electrical system TABLE F3 43. ECU diagnosis connector 44. Instrument panel diagnosis connector 45. Insert the instrument panel diagnosis and the ECU diagnosis connectors in their specific seats 46. License plate frame and taillight cable harness routing 47. Taillight connector 48.
Page 130 RSV4 Factory Electrical system Outer 58. Fuel pump connector 59. Insert the tape clamp on the cable harness in the hole on the right side of the saddle mounting 60. variable length intake duct control unit connector 61. Clamp Inner 62.
Page 131 RSV4 Factory Electrical system TABLE H1 67. Intake duct control unit 68. Intake duct control unit connector 69. Rubber ring TABLE H2 70. Clamp 71. Intake duct control unit cable harness routing ELE SYS - 131...
Page 132 RSV4 Factory Electrical system General wiring diagram key: 1. MULTIPLE CONNECTORS 2. Front right turn indicator 3. COMPLETE HEADLAMP 4. Front left turn indicator ELE SYS - 132...
Page 133 RSV4 Factory Electrical system 5. RIGHT LOW BEAM LIGHT BULB 6. HIGH-BEAM BULB 7. TAIL LIGHT BULB 8. LEFT LOW BEAM LIGHT BULB 9. High-beam light relay 10.LOW-BEAM LIGHT RELAY 11.LEFT LIGHT SWITCH 12.INSTRUMENT PANEL DIAGNOSIS 13.Instrument panel 14.EXHAUST VALVE MOTOR 15.FRONT STOP SWITCH...
Page 134 RSV4 Factory Electrical system 43.SPEED SENSOR 44.SIDE STAND SWITCH 45.GEAR SENSOR 46.FRONT CYLINDER PRESSURE SENSOR 47.REAR CYLINDER PRESSURE SENSOR 48.FRONT CYLINDER THROTTLE 49.REAR CYLINDER THROTTLE 50.AIR TEMPERATURE SENSOR 51.Water Temperature Sensor 52.UPPER INJECTORS 53.75M CONTROL UNIT 54.HAND GRIP POSITION SENSOR 55.REVOLUTION SENSOR...
Page 135 RSV4 Factory Electrical system the connector (i.e., all terminals aligned at the same depth) and terminal integrity (i.e., that termi- nals are not loose, open/bent, etc.). For connec- tors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter...
Page 136 RSV4 Factory Electrical system Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level in wiring diagram: Immobilizer Location: • on the vehicle: in the key lock • connector: two-way, black, inside the Electrical specifications •...
Page 137 RSV4 Factory Electrical system • Immobilizer fault: aerial not working (open or short-circuited) Error cause • An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting • Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore;...
Page 138 RSV4 Factory Electrical system NOTE DELETE THE ERROR CAUSED BY THE LACK OF MEMORY OF KEY CODES. 3. Connect to the vehicle with the diagnosis tool and select the adjustable Parameters in the screen page: "Exhaust butterfly valve self-acquisition" NOTE SEARCH FOR MINIMUM AND MAXIMUM MECHANICAL STOPS STORED IN THE INSTRUMENT PANEL.
Page 139 RSV4 Factory Electrical system In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it. DSB 01 - Immobilizer fault: key code read but not recognised. DSB 02 - Immobilizer fault: key code not read (key not present or transponder not working)
Page 140 RSV4 Factory Electrical system Modify Keys With this function the instrument panel can update the keys. Up to 4 keys can be stored. The user code is first requested to be entered: • ENTER THE CODE After entering the correct code, the following message should be shown on the display: •...
Page 141 RSV4 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 142 RSV4 Factory Electrical system • Check the locking cause and restore. level indicators See also Fuel pump Fuses SECONDARY FUSES DISTRIBUTION Specification Desc./Quantity A) 5A fuse Stop and running lights relay B) 5A fuse Instrument panel, turn indicators, speed and instrument panel diagnostics.
Page 143 RSV4 Factory Electrical system 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 REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 144 RSV4 Factory Electrical system (screen/example value with key set to ON) • Drawing number / - • Marelli spare part code / IAW7SMHW430 • Hardware number / 00 • Mapping / - • Software version number / 0000 • Type-approval Code / - •...
Page 145 RSV4 Factory Electrical system • Indefinite_Start-up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal • yes/no • Indicates whether the control unit has received the consent by the instrument panel regard- ing the immobilizer: coded key or user code entered manually. Potential errors will be shown...
Page 146 RSV4 Factory Electrical system • circuit not operational Error cause • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status RAM Error P0604 • circuit not operational Error cause •...
Page 147 RSV4 Factory Electrical system Level 2 safety reset P0608 Error cause • As the level 2 safety system (comparison between requested torque and calculated torque) has detected a fault, the control unit has reset engine (C gravity). The instrument panel does not indicate the presence of this error even in the ATT status.
Page 148 RSV4 Factory Electrical system garding the control unit serial number and the serial number of the Axone or Navigator that has carried out the download is also included in the file Saved data file deletion Error cause • Deletion enabled only if the file is downloaded after setting KEY ON...
Page 149 RSV4 Factory Electrical system Battery voltage • Example value with key ON: 12.0 V • Example value with engine on: 14.2 V In case of recovery, this value is set by the control unit Battery voltage pre Recovery • Example value with key ON: 12.0 V •...
Page 150 RSV4 Factory Electrical system Speed sensor Function to indicate the vehicle speed by reading the rear wheel turning speed Operation / operating principle Hall-effect sensor: a square-wave pulse is gener- ated with voltage between 10 V and 0 V with metal...
Page 151 RSV4 Factory Electrical system Variable geometry intake Function Extend or shorten the engine inlet ducts to in- crease the inlet air quantity according to the engine revs. Operation / operating principle The system consists of: • two inlet ducts for each manifold, which may be joined (long ducts) or separa- ted (short ducts);...
Page 152 RSV4 Factory Electrical system the filter box next to the rear upper in- jectors. Electrical characteristics: Electrical motor resistance. 4.5 +/- 0.5 Ω; PIN 1: 0V normal, Vbatt fault PIN 2: 0V ducts control down, 5V ducts control up. Pin out: 1.
Page 153 RSV4 Factory Electrical system • If shorted to positive: if a voltage higher than 5V is detected, disconnect the variable geom- etry control unit connector and check with key ON the voltage to PIN 2: if it is higher than 5 V, restore cable harness;...
Page 154 RSV4 Factory Electrical system 1. negative signal 2. positive signal 3. shielding with ground connection DIAGNOSIS INSTRUMENT: PARAMETERS Engine rpm: rpm CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 155 RSV4 Factory Electrical system Twistgrip position sensor Removal • Remove the left fairing. • Loosen the two throttle cable nuts. • Unscrew and remove the three plate fixing screws. • Remove the throttle cables. • Unscrew and remove the nut and the stud bolt.
Page 156 RSV4 Factory Electrical system Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit.
Page 157 RSV4 Factory Electrical system • C: Track C signal • D: Track D supply • E: Track D ground • F: Track D signal DIAGNOSIS INSTRUMENT: PARAMETERS Blue lower connector throttle grip position sensor - track A • Example value with key ON: 1107 mV •...
Page 158 RSV4 Factory Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Blue lower connector throttle grip position sensor - track A P0150 •...
Page 159 RSV4 Factory Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
Page 160 RSV4 Factory Electrical system cated by the diagnosis instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 161 RSV4 Factory Electrical system • incongruent signal Error cause • The value of the lower side sensor (tracks A-B) does not coincide with the value of the upper side sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor DIAGNOSIS INSTRUMENT: ADJUSTABLE PARAMETERS...
Page 162 RSV4 Factory Electrical system Electrical specifications: - Pin out: 1. Power supply 5V 2. Ground connection 3. Output signal DIAGNOSIS INSTRUMENT: PARAMETERS Front Cylinder Intake Pressure (2 and 4) • Example value with key ON: 1003 mbar • Example value with engine on: 720 mbar •...
Page 163 RSV4 Factory Electrical system • If shorted to positive: see that the parameter of the rear cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 164 RSV4 Factory Electrical system • signal not valid. Error cause • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted.
Page 165 RSV4 Factory Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, the pipe between sensor and throttle body is squashed or there is a hole in the intake manifold).
Page 166 RSV4 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. Pressure too low at front cylinder manifold error P0218 •...
Page 167 RSV4 Factory Electrical system 2. B2 green/black: Ground connection DIAGNOSIS INSTRUMENT: PARAMETERS Engine temperature: • Example value with key ON: 25° C • Example value with engine on: 75° C • In case of recovery, this value is set by the control unit: if there is a malfunction after engine start-up, temperature decreases up to approximately 75°.
Page 168 RSV4 Factory Electrical system between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced.
Page 169 RSV4 Factory Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion Operation / operating principle...
Page 170 RSV4 Factory Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 171 RSV4 Factory Electrical system Lambda sensor 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 172 RSV4 Factory Electrical system • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time;...
Page 173 RSV4 Factory Electrical system covery value is displayed instead. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 174 RSV4 Factory Electrical system cable (PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable harness.
Page 175 RSV4 Factory Electrical system LOWER INJECTOR Function To supply the correct amount of petrol at the right timing. 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 176 RSV4 Factory Electrical system onds and the injector cable connected to control unit is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications...
Page 177 RSV4 Factory Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the orange/red cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector.
Page 178 RSV4 Factory Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector.
Page 179 RSV4 Factory Electrical system Upper injectors key: • 5. Upper injector 1 • 6. Upper injector 3 • 7. Upper injector 2 • 8. Upper injector 4 UPPER INJECTOR Function To supply the correct amount of petrol at the right timing.
Page 180 RSV4 Factory Electrical system Cylinder injection time 2 • Example value with engine on: 1.9 ms Cylinder injection time 3 • Example value with engine on: 1.9 ms Cylinder injection time 4 • Example value with engine on: 1.9 ms...
Page 181 RSV4 Factory Electrical system activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Upper injector cylinder 1 P0205 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 182 RSV4 Factory Electrical system and the Marelli control unit connector: if not OK, restore. If OK, check cable continuity be- tween PIN 67 and component PIN - and restore the cable harness Upper injector cylinder 3 P0207 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 183 RSV4 Factory Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Low fuel: tells to the instrument panel about low fuel Operation / operating principle Low fuel: it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol.
Page 184 RSV4 Factory Electrical system continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS fuel pump relay control P0230 • shorted to positive / open circuit, shorted to negative.
Page 185 RSV4 Factory Electrical system strap on engine cable harness); coil 4 with short cable: on the right of the front side of the filter box. Electrical characteristics: 0.7 - 0.9 Ω at ambient temperature Pin out: 1. Power supply + Vbatt 2.
Page 186 RSV4 Factory Electrical system The injection relay (No. 33 in the wiring diagram, placed under the right side of the saddle; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the brown/purple cable of the coil is closed to ground for 2 ms per second.
Page 187 RSV4 Factory Electrical system the ground insulation of the cable (from coil connector or control unit connector), if not OK, restore cable harness. Coil 3 P0353 • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector.
Page 188 RSV4 Factory Electrical system Throttle body Function Sends to the injection control unit the throttle position and activates the throttle according to the control unit Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no elec- trical diagnosis is possible for the throttle body, but for the circuits connected to it only.
Page 189 RSV4 Factory Electrical system is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low (around 5-7°) Rear throttle Potentiometer 1 (degrees) • Example value with key ON: 8° • Example value with engine on: 1.5°...
Page 190 RSV4 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 191 RSV4 Factory Electrical system • carried out/not carried out Indicates whether the self-acquisition process through the diagnosis instrument has/has not been car- ried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero...
Page 192 RSV4 Factory Electrical system (from throttle sensor connector or control unit connector). If it is ground insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 193 RSV4 Factory Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature. Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 194 RSV4 Factory Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 195 RSV4 Factory Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 196 RSV4 Factory Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 197 RSV4 Factory Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 198 RSV4 Factory Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 199 RSV4 Factory Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 200 RSV4 Factory Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 201 RSV4 Factory Electrical system • connector: between head cover and fil- ter box on left side (3-ways white con- nector). Electrical characteristics: PIN 64: gear indication: closed circuit (continuity); gear engaged: open circuit (infinite resistance). Gear engaged circuit resistance: 1st gear: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th...
Page 202 RSV4 Factory Electrical system replace the sensor (there is short circuit to ground of the pink cable in the section from the sensor connector to the sensor or inside the sensor). Clutch lever sensor Function It tells the clutch lever position to the control unit.
Page 203 RSV4 Factory Electrical system • Indication on Axone always Pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace sensor; if the circuit is open, it means that there is short circuit to ground of black cable from sensor PIN 1 to engine-vehicle cable harness connector PIN C3 or of the white/purple cable from PIN C3 to VEHICLE connector PIN 56: restore the cable harness.
Page 204 RSV4 Factory Electrical system • Indication on Axone always down: check the connector: if not OK, restore; if it is OK, dis- connect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor •...
Page 205 RSV4 Factory Electrical system • Indication on Axone always Normal, even when the sensor is inverted: disconnect the con- nector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor; if there is continuity, check the con- nector: if not OK, restore cable harness;...
Page 206 RSV4 Factory Electrical system DIAGNOSIS INSTRUMENT: ACTIVATION • The fan relay (No. 36 in the wiring dia- gram, placed in the headstock niche, left side; CHECK, however, the identi- fication of the relay with the colour of the cables) is energised for 10 sec- onds.
Page 207 RSV4 Factory Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / operating principle The valve coil is excited to open the air passage of the filter box to the exhaust manifold...
Page 208 RSV4 Factory Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
Page 209 RSV4 Factory Electrical system RUN / STOP switch • Run/Stop NOTES • Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - blue/green and yellow/red: If there is not continuity, replace the sensor;...
Page 210 RSV4 Factory Electrical system Level in wiring diagram: Exhaust valve Location: • on the vehicle: The motor is placed in the front lower part of the engine. The valve in the exhaust duct. • connector: on the motor. Electrical characteristics: •...
Page 211 RSV4 Factory Electrical system • If potentiometer signal is above maximum threshold: voltage of the maximum end of stroke position (open valve) outside the foreseen field has been detected. If potentiometer signal is below maximum threshold: voltage of the minimum end of stroke position (closed valve) outside the foreseen field has been detected.
Page 212 RSV4 Factory Electrical system connector: if not OK, restore; if OK, check continuity of brown and black cables: if not OK, restore cable harness; if OK, check motor electrical characteristics and replace it. • If thermal overload protection: replace the instrument panel.
Page 213 RSV4 Factory Electrical system • position error. Error cause • Position indicated by potentiometer does not correspond with position set by control unit. Troubleshooting • Mechanically check the valve, its normal rotation (with cables disconnected from motor, manually activate the cables and see movement regularity and check valve complete stroke with correct operation of the return spring) and absence of foreign bodies which do not allow its rotation: if not OK, restore;...
Page 214 RSV4 Factory Electrical system EXHAUST THROTTLE VALVE CALIBRATION • Slacken the exhaust throttle valve ca- ble tension. • From the Adjustable parameters screen, use the diagnostic instrument to select: Acquire exhaust valve zero position • After pressing the send button for zero research, stop the vehicle and leave the key in OFF.
Page 215 RSV4 Factory Electrical system Engine pinout key: Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output (+) PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5...
Page 216 RSV4 Factory Electrical system Front throttle motor output (-) PIN 15 Power ground connection 2 PIN 16 Engine speed sensor input (-) PIN 20 Input for front throttle potentiometer 2 signal PIN 21 Lambda sensor input (-) PIN 22 Track C throttle grip input PIN 23...
Page 217 RSV4 Factory Electrical system Vehicle pinout key: Upper cylinder 1 injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Variable geometry control unit control output PIN 62...
Page 218 RSV4 Factory Electrical system Side stand input PIN 70 Gear input PIN 72 Injection relay control output PIN 73 Upper cylinder 3 injector control output PIN 74 Variable geometry control unit fault input PIN 76 "engine stop" input PIN 78...
Page 219 RSV4 Factory Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 219...
Page 220 RSV4 Factory Electrical system 4 High-beam lights input 5 Crono input 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control...
Page 221 RSV4 Factory Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1...
Page 222 RSV4 Factory Electrical system In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense). If during this period there is no activity on BUS, every nod has the same chance to send a message (Multiple Access).
Page 223 RSV4 Factory Electrical system • No communication on CAN line (PIN 66 and/or PIN 80): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground). Troubleshooting • check the Marelli control unit VEHICLE connector and the engine-vehicle cable harness connector: if not OK, restore;...
Page 224 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 225 RSV4 Factory Engine from vehicle ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft)
Page 226 RSV4 Factory Engine from vehicle See also Fairing mounting panels Lower cowl Radiator cover Fuel tank Exhaust Twistgrip position sensor Air box Removing the radiator Removing Side stand Removing the engine from the vehicle • Detach the clutch cable. •...
Page 227 RSV4 Factory Engine from vehicle • Remove the engine oil pressure sen- sor. • Remove the rubber cap. • Unscrew and remove the nut, retrieve the washer and disconnect the starter motor. • Unscrew and remove the screw, re- move the cable grommet and detach the three ground cables.
Page 228 RSV4 Factory Engine from vehicle • Working on the right hand side of the vehicle, detach the exhaust valve con- trol unit connector. • Disconnect the vehicle cable harness/ engine cable harness connector • Unscrew and remove the three screws and remove the pinion cover.
Page 229 RSV4 Factory Engine from vehicle • Loosen the drive chain adjuster screws. • Loosen the rear wheel fixing nut. • Remove the pinion, releasing it from the drive chain. • Remove the side stand. • Remove the two fuel breather pipes •...
Page 230 RSV4 Factory Engine from vehicle • Remove the hand grip position sensor from the chassis. • Disconnect the voltage regulator con- nector. See also Twistgrip position sensor • Disconnect the alternator connector. • Working from the left hand side of the vehicle, unscrew and remove the screw and retrieve the washer.
Page 231 RSV4 Factory Engine from vehicle • Unscrew and remove the three plate fixing screws and remove the plate. • Loosen the screw and ease off the gear lever. • Unscrew and remove the subframe fix- ing screw and retrieve the washer, re- move the radiator subframe.
Page 232 RSV4 Factory Engine from vehicle • Working on the left hand side of the vehicle, unscrew and remove the two screws and retrieve the respective plates. • Working on the right hand side of the vehicle, unscrew and remove the two screws and retrieve the respective plates and washers.
Page 233 RSV4 Factory Engine from vehicle • Unscrew and remove the screw and retrieve the nut. • Unscrew the upper adjuster screw bushing until it turns no more. • Working on the right side of the vehicle, unscrew and remove the nut and re- trieve the washer.
Page 234 RSV4 Factory Engine from vehicle • Remove the clamps on the saddle mounting. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SECOND OPERATOR. • Lower the engine • Lift the front part of the vehicle. • Remove the front stand.
Page 235 RSV4 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 centre- line of the insert, as a result the swingarm is in the high position.
Page 236 RSV4 Factory Engine from vehicle • 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. Specific tooling 020864Y Engine mounting plate...
Page 237 RSV4 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 238 RSV4 Factory Engine from vehicle • Place the radiator frame, the washer and tighten the screw, fastening the frame to the engine. • Place the gear lever and tighten the screw. • Connect the alternator connector. • Connect the voltage regulator connec- tor.
Page 239 RSV4 Factory Engine from vehicle • 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. • Connect the neutral sensor. • Place the two fuel breather pipes.
Page 240 RSV4 Factory Engine from vehicle • Adjust the drive chain adjuster screws. • 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.
Page 241 RSV4 Factory Engine from vehicle • Working on the right side of the vehicle, connect the exhaust valve control unit connector. • Place the ground on the frame. • Fit the washer and tighten the nut. • Place the cable grommet and the three cable leads as shown.
Page 242 RSV4 Factory Engine from vehicle • Tighten the engine oil pressure sensor. • Connect the timing sensor. • Connect the clutch cable. ENG VE - 242...
Page 243 RSV4 Factory Engine from vehicle • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in). ENG VE - 243...
Page 244 INDEX OF TOPICS NGINE...
Page 245 RSV4 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 246 RSV4 Factory Engine Gearbox Diagram EARBOX pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft)
Page 247 RSV4 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 248 RSV4 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 249 RSV4 Factory Engine • Remove both gearbox shafts from the cover. • Collect the shim washer that is located on the secondary shaft between the shaft and the cover. • Unscrew and remove the screw. • Remove the selector drum.
Page 250 RSV4 Factory Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in)
Page 251 RSV4 Factory Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.5 mm (0.020 in) Minimum wear limit of the selection fork guide pins 6.8 mm (0.27 in)
Page 252 RSV4 Factory Engine • Grease the bushings. • Introduce the forks in their respective seats. • Insert the desmodromic gearbox con- trol rod on the cover. • Position the selector drum. • Turn the screw without tightening it. • Position the fork bushings into the grooves on the desmodromic control rod.
Page 253 RSV4 Factory Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for secondary gearbox shaft •...
Page 254 RSV4 Factory Engine • Tighten the selector drum screw. • Insert the driving pin on the oil pump shaft. • Install the water/oil pump control gear. • Insert the Seeger ring. • Install the gear sensor, making the pin coincide with the slot on the desmo- dromic control rod.
Page 255 RSV4 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 Gearbox control rod roller cage fitting punch •...
Page 256 RSV4 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 257 RSV4 Factory Engine 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 ENGINE TOOTHING MUST BE CHECKED AS WELL. Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed.
Page 258 RSV4 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 259 RSV4 Factory Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 260 RSV4 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 261 RSV4 Factory Engine Flywheel cover installation • Insert the centring dowels in the cover. • Apply a layer of sealing paste along the external edge of the cover. • Insert the cover together with the sta- tor. Recommended products Three bond Sealing paste •...
Page 262 RSV4 Factory Engine Clutch side LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) TE flanged screws M6x35 12 Nm (8.85 lbf ft)
Page 263 RSV4 Factory Engine Removing the clutch cover • Drain the engine oil. • Unscrew and remove the sixteen peri- metric fixing screws and retrieve the washers • Remove the clutch casing, retrieving the gasket, the two locator pins and the starter motor transmission gear.
Page 264 RSV4 Factory Engine • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch retainer • Remove the slipper unit. • Remove the clutch hub. • Remove the clutch hub cam tower.
Page 265 RSV4 Factory Engine • Collect the shim washer. • Collect the clutch bell. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 265...
Page 266 RSV4 Factory Engine • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch disc deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch disc sliding teeth 13.5 mm (0.53 in)
Page 267 RSV4 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 bell and the primary drive sprocket for correct sealing and evenness.
Page 268 RSV4 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 269 RSV4 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 270 RSV4 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 by 120°.
Page 271 RSV4 Factory Engine • Insert the disc with friction material and the black tooth into the bell. • Insert one of the metal discs into the bell. • Insert the flat washer. • Insert the belleville spring with the con- cave side facing outward.
Page 272 RSV4 Factory Engine • Insert the disc covered with the friction material into the bell. • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 273 RSV4 Factory Engine • Place the thrust plate. • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally. Installing the clutch cover • Position the starting transmission gear on the crankcase.
Page 274 RSV4 Factory Engine Heads ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) ENG - 274...
Page 275 RSV4 Factory Engine HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve cover fixing screws 6 Nm (4.42 lbf ft) Water outlet union fixing screw 12 Nm (8.85 lbf ft)
Page 276 RSV4 Factory Engine Head cover removal • Unscrew and remove the three screws with rubber washers. • Remove the head cover together with the sealing gasket. When refitting: spread a layer of sealing paste on the external corners of the head DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE.
Page 277 RSV4 Factory Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 278 RSV4 Factory Engine Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer 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...
Page 279 RSV4 Factory Engine • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 280 RSV4 Factory Engine • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge; if necessary, replace the part. Characteristic Maximum camshaft axial clearance (intake/ex- haust) 0.4 mm (0.0016 in)
Page 281 RSV4 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 282 RSV4 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 283 RSV4 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. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock...
Page 284 RSV4 Factory Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the engine rotation direction (direction of travel), in...
Page 285 RSV4 Factory Engine • Unscrew and remove the second in- take camshaft gear screw. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer • Slide the gear off the intake camshaft. • Block the gear to the timing chain with a clamp.
Page 286 RSV4 Factory Engine • Unscrew and remove the mobile chain slider screw. • Remove the mobile chain slider. • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side.
Page 287 RSV4 Factory Engine • Remove the front head, slipping it off the stud bolts. • Collect the gasket and the two dowel pins. • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat.
Page 288 RSV4 Factory Engine Front head fitting • Install a new O ring on the chain ten- sioner REPLACE THE O RING UPON EACH REMOVAL. • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in).
Page 289 RSV4 Factory Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order.
Page 290 RSV4 Factory Engine • Install both chain sliders and fasten them with the specific screws. • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 291 RSV4 Factory Engine NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 292 RSV4 Factory Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin.
Page 293 RSV4 Factory Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 294 RSV4 Factory Engine 020852Y Crankshaft timing pin Rear head 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 295 RSV4 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 296 RSV4 Factory Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling...
Page 297 RSV4 Factory Engine Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK • 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 298 RSV4 Factory Engine Installing camshafts NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 299 RSV4 Factory Engine • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 300 RSV4 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 301 RSV4 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 302 RSV4 Factory Engine • Slide the gear off the intake camshaft. • Block the gear to the timing chain with a clamp. • 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 303 RSV4 Factory Engine • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fas- tener screws (a - b) from the clutch side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1.
Page 304 RSV4 Factory Engine • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat. REPLACE THE O RING UPON EACH REMOVAL.
Page 305 RSV4 Factory Engine • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in). • Insert the chain tensioner into the crankcase, being careful to position it correctly. •...
Page 306 RSV4 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 307 RSV4 Factory Engine NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 308 RSV4 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 309 RSV4 Factory Engine 020855Y Lever for engaging the chain tensioner • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool.
Page 310 RSV4 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 311 RSV4 Factory Engine • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING. • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME.
Page 312 RSV4 Factory Engine If the measured deviation exceeds the specified limit, determine if the valve or the guide must be replaced. Characteristic Valve stem distortion 0.25 mm (0.0098 in) If the valve stem, when measured with a micro- meter, is worn to its limit and the clearance ex- ceeds the specified limit, replace the valve.
Page 313 RSV4 Factory Engine A slight amount of material may be extracted in the area shown. Valve installation • Lubricate the valve stem and insert the valves on the valve guide. • Position the springs with the closest turns facing the head of the valve...
Page 314 RSV4 Factory Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor •...
Page 315 RSV4 Factory Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft)
Page 316 RSV4 Factory Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct. 243 8674 ENG - 316...
Page 317 RSV4 Factory Engine RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 318 RSV4 Factory Engine • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. • Remove the spacer. Balancing countershaft fitting • Install the spacer. ENG - 318...
Page 319 RSV4 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 320 RSV4 Factory Engine • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. See also Disassembling the clutch • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock •...
Page 321 RSV4 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 322 RSV4 Factory Engine • alternator; • water pump; • gearbox unit; • primary transmission shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear; •...
Page 323 RSV4 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 324 RSV4 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 bearing U bolt See also Front head removal Rear head removal •...
Page 325 RSV4 Factory Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Crankshaft removal • Separate the crankcases, removing the lower part • If the heads were removed, position the specific special tool to keep the pis- tons from coming out.
Page 326 RSV4 Factory Engine Bushing removal COUNTERSHAFT BUSHINGS • Remove the countershaft. • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the bushings; positioning the buffer, which is sup- plied with the special tool, on the op- posite side of the crankcase.
Page 327 RSV4 Factory Engine Connecting rod check Characteristic Maximum wear limit of the rod small end 17.05 mm (0.671 in) Maximum rod small end radial clearance 0.055 mm (0.0022 in) Maximum axial clearance between the con- necting rod and the crank pin 0.55 mm (0.022 in)
Page 328 RSV4 Factory Engine Selecting connecting rods If a selection class of connecting rods is fit on the crankshaft that is not class D - D, it is not a problem. It is essential, for proper crankshaft balance, that if one connecting rod is replaced the other one fit on the same crank pin must also be replaced: •...
Page 329 RSV4 Factory Engine Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings. The category is marked on the crankcase, on the right side, in the area below the crankshaft.
Page 330 RSV4 Factory Engine RANKSHAFT CATEGORIES WITH REMOVABLE REELS Specification Desc./Quantity Class A Main journals - diameter: 46.005 - 46.000 mm (1.8112 - 1.8110 Class B Main journals - diameter: 46.000 - 45.995 mm (1.8110 - 1.8108 RANKSHAFT CATEGORIES WITH REMOVABLE REELS Specification Desc./Quantity...
Page 331 RSV4 Factory Engine COUNTERSHAFT BUSHINGS There are no selection classes for the countershaft bushings, there is only one type. CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available: • Blue • • Yellow There are no dimension classes for the crank pins or the connecting rods. As a result, only the two semi-bushing combinations are possible: 1.
Page 332 RSV4 Factory Engine When replacing the big end bushings, make sure that the tang of the semi-bushing is correctly housed in the corresponding notch in the connecting rod shank or cap Bushing fitting COUNTERSHAFT BUSHINGS • Place the lower crankcase in a press, resting it on the buffer supplied with the special tool.
Page 333 RSV4 Factory Engine • Spread grease on the sliding surfaces of the bushing on the special tool. • Install the new bushing, aligning the hole with the slot on the ring of the spe- cial tool. • Place the ring on which the bushing is installed onto the special tool's punch.
Page 334 RSV4 Factory Engine Crankshaft fitting If the two timing chain control sprockets (1 - 2) on the crankshaft were removed, check their exact positioning carefully because the two components cannot be interchanged. Remember that the thicker sprocket (1) must be positioned from the clutch side of the crankshaft.
Page 335 RSV4 Factory Engine • Install the connecting rod shank piston assembly in the relative cylinders. • Join the crankcases. • If the special tool was used, remove it to keep the pistons from coming out. Specific tooling 020858Y Device for holding the pistons in the cylinders •...
Page 336 RSV4 Factory Engine • Tighten the tone wheel fixing screw. • Remove the special tool. Specific tooling 020850Y Primary gear lock Installing connecting rods - pistons The piston rings are different and must be fit with the markings "R" and "RN" facing upward.
Page 337 RSV4 Factory Engine There are no dimension classes for the pistons. Preassemble the pistons on the workbench with the connecting rod shank and the relative semi- bushing. The pre-assembly procedure is identical for all four pistons and must be done as follows: •...
Page 338 RSV4 Factory Engine • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces. • Use new connecting rod screws, lubri- cating the thread and under the head.. • Proceed with tightening according to...
Page 339 RSV4 Factory Engine • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - •...
Page 340 RSV4 Factory Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 340...
Page 341 RSV4 Factory Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase Lubrication ENG - 341...
Page 342 RSV4 Factory Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft)
Page 343 RSV4 Factory Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor.
Page 344 RSV4 Factory Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle.
Page 345 RSV4 Factory Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat.
Page 346 RSV4 Factory Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor.
Page 347 RSV4 Factory Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket.
Page 348 RSV4 Factory Engine The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 349 RSV4 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 - 349...
Page 350 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 351 RSV4 Factory Power supply Fuel pump Removing • Remove and empty the fuel tank. • Loosen the pipe grommet screw. • Detach the fuel pipe. • Unscrew and remove the screws. • Remove the fuel pump. Injection P SUPP - 351...
Page 352 RSV4 Factory Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor 4. Outlet valve P SUPP - 352...
Page 353 RSV4 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 15.Starter motor...
Page 354 RSV4 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 355 RSV4 Factory Power supply Air box UPPER INJECTORS • Remove the control unit. • Disconnect the injector connectors. • Unscrew and remove the injector fixing screws. • Remove the upper injectors, identified by green collars. See also Control unit Removing the throttle body •...
Page 356 RSV4 Factory Power supply • Disconnect the lower injector connec- tors. See also Air box • Disconnect the connector. • Remove the complete throttle body. Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction.
Page 357 RSV4 Factory Power supply Installing the throttle body • When installing the throttle body, refer to the electrical system section for the correct cable routing. • Ensure that the injector connectors are correctly fastened. • Connect the control unit connector, en- suring that the security lock is in the locked position.
Page 358 RSV4 Factory Power supply a variable geometry control unit for managing the system, interfaced with the engine injection control unit Operation At key-ON, the variable geometry control unit low- ers the ducts (if still in the raised position). Subsequently, depending on the control voltage...
Page 359 RSV4 Factory Power supply Variable geometry intake Cylinders synchronisation The control unit receives information on the intake pressure in the four ducts from the two pressure sensors: as the control unit knows the timing phase of the cylinders, it can calculate the individ- ual pressure of the four cylinders.
Page 360 RSV4 Factory Power supply After making any adjustment, wait for confirmation that the position of the adjusted screw position is now correct. The procedure then continues with screws 2 and 4. To ensure correct engine operation, one of the two screws of each throttle body must always be closed.
Page 361 INDEX OF TOPICS SUSP USPENSIONS...
Page 362 RSV4 Factory Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lbf ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lbf ft) Loct. 243 Removing the front wheel •...
Page 363 RSV4 Factory Suspensions • Remove the wheel spindle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel spin- dle clamps. • Tap the wheel spindle slightly with a rubber mallet so that the hole on the opposite side is exposed.
Page 364 RSV4 Factory Suspensions • Replace both wheel bearings. RADIAL AND AXIAL CLEARANCE CHECK • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: •...
Page 365 RSV4 Factory Suspensions Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screw fastening the semi-handlebar 1 + 1 25 Nm (18.44 lbf ft) collar to the fork sleeves Semi-handlebar safety screw 10 Nm (7.37 lbf ft) Anti-vibration counterweight fastener M18x1.5...
Page 366 RSV4 Factory Suspensions LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) Front fork Diagram SUSP - 366...
Page 367 RSV4 Factory Suspensions RONT FORK pos. Description Type Quantity Torque Notes Fastener screws for calliper mount- 2 + 2 12 Nm (8.85 lbf ft) ing bracket (Öhlins) Adjustment Standard front fork setting is adjusted to suit most high and low speed riding conditions, whether the vehicle is partially or fully loaded.
Page 368 RSV4 Factory Suspensions NOTE TO CHECK FOR FRONT FORK FAILURE, MEASURE THE DIFFERENCE BETWEEN THE BEGIN- NING OF THE WHEEL HUB AND THE END OF THE FORK SLEEVE Removing the fork legs • Remove the front wheel. • Support the fork stanchion and loosen the screws on the upper yoke.
Page 369 RSV4 Factory Suspensions Removing the front wheel Draining oil • Fix the fork in a vice, taking care not to damage the fork. • Set the minimum spring preloading. • Unscrew the upper cap from the sleeve using a specific Öhlins tool.
Page 370 RSV4 Factory Suspensions • Loosen and remove the nut, keeping the preload spring slightly com- pressed. • Remove the lock nut for the preload spring • Remove the preload spring • Drain the fork oil into a specific con- tainer, taking care not to allow the pre-...
Page 371 RSV4 Factory Suspensions Disassembling the fork • Fix the fork again in a vice, taking care not to damage the fork. • Remove the preload pipe. • Remove the sleeve (2) from the wheel holder stanchion (1). • Use a plain slot screwdriver to lift up the dust gaiter (3) in multiple points and re- move from the sleeve (2).
Page 372 RSV4 Factory Suspensions • Use a plain slot screwdriver to remove the oil seal (5). CAUTION PLACE A STRIP OF RUBBER ON THE EDGE OF THE SLEEVE TO PROTECT IT FROM DAMAGE WHEN REMOV- ING THE OIL SEAL (5). Replace the following components with new ones:...
Page 373 RSV4 Factory Suspensions • Remove the spring guide (3), noting its direction of installation to ensure cor- rect reassembly. • Remove the other spring guide snap ring (4). • Remove the ring (5) and extract the rubber buffer (6) •...
Page 374 RSV4 Factory Suspensions If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value. If over the value, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Page 375 RSV4 Factory Suspensions Oil level: 110 mm (4.33 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Page 376 RSV4 Factory Suspensions • Insert the ring nut, on which the threa- ded pipe is attached, on the pumping member pin. • Insert the rubber buffer (6). • Insert the spring guide support ring (5), noting the internal milling allowing the spring guide retainer ring to be instal- led against the support ring.
Page 377 RSV4 Factory Suspensions • Install the following components on the wheel holder stanchion (1) in the order given: dust gaiter (3), retainer ring (4) and oil seal (5). • Fix the sleeve in a vice, taking care not to damage the sleeve.
Page 378 RSV4 Factory Suspensions • Push the dust gaiter (3) into its seat on the sleeve (2), ensuring that it is loca- ted correctly. • Grip the stanchion and move it repeat- edly and slowly in opposite directions. CAUTION THE STANCHION MUST SLIDE FREELY IN THE SLEEVE WITHOUT RESISTANCE.
Page 379 RSV4 Factory Suspensions • Holding up the pin, insert the preload spring. • Fit the lock nut for the preload spring (1). • Fit the nut (2). • Keeping the spring compressed, tight- en the nut completely. • Screw the complete cap onto the pumping member pin.
Page 380 RSV4 Factory Suspensions Adjusting The steering damper may be adjusted by turning the knob (1). • Turn the knob (1) clockwise to stiffen the steering. • Turn the knob anticlockwise to loosen the steering. SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL...
Page 381 RSV4 Factory Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lbf ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lbf ft) chions Headstock lock ring M35x1 60 Nm (44.25 lbf ft)
Page 382 RSV4 Factory Suspensions • Loosen the screws fixing the fork stan- chions to the upper yoke. • Working from both sides, unscrew and remove the semi-handlebar screws. • Remove the upper yoke • Rivet the safety washer on the head- stock.
Page 383 RSV4 Factory Suspensions • Undo the counter-lock ring, remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly. • Tighten the lower lock ring to a torque of 70 Nm (51.63 lbf ft).
Page 384 RSV4 Factory Suspensions • Fit the safety washer and bend the two opposing tabs into the notches on the lock ring. • Fit the counter-lock ring, hand tighten- ing only. • To allow the tabs to be bent into the...
Page 385 RSV4 Factory Suspensions Disassembling • Remove the steering assembly com- pletely. • Unscrew and remove the lower dowel fastening the collar. • Remove the lower collar. • Unscrew and remove the upper dowel fastening the collar. • Remove the upper collar.
Page 386 RSV4 Factory Suspensions • Fit the steering assembly and restore the correct steering bearing free play. See also Adjusting play Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft)
Page 387 RSV4 Factory Suspensions Removing the rear wheel • Place the vehicle on its rear service stand. • Loosen and remove the nut on the wheel spindle. • Retrieve the thrust washer and the left hand chain tensioner skid. • Tap the wheel spindle slightly to extract the head from its seat.
Page 388 RSV4 Factory Suspensions • Remove the final transmission unit. CAUTION THE FLEXIBLE COUPLINGS REMAIN FITTED ON THEIR HOLDER. • Remove all the flexible couplings. • Using an Allen spanner on the related seat (1), lock the rotation of the threa-...
Page 389 RSV4 Factory Suspensions • Lock sprocket in a vice. CAUTION TO AVOID POTENTIAL DISTORTIONS AND/OR INCORRECT COUPLING, TIGHTEN AS FOL- LOWS: • Using an Allen key on the specific seat (1), lock the rotation of the threaded pin (2), and applying half the specified torque, tighten the diametrically opposed elements in this se- quence: (A) (B) (C) (D) (E).
Page 390 RSV4 Factory Suspensions REAR wheel spindle • Use a dial gauge to check the wheel spindle eccentricity (1). Replace the wheel spindle if the eccentricity ex- ceeds the limit value (1). Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM •...
Page 391 RSV4 Factory Suspensions • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: • Replace both bearings of the final transmission unit.
Page 392 RSV4 Factory Suspensions The spacer end (12) is fitted with slots (A) for the extractor teeth to pass through. • Take out the right bearing (13) with the specific extractor. Specific tooling AP8140180 Extractor for bushings • Collect the inside spacer (12).
Page 393 RSV4 Factory Suspensions FINAL TRANSMISSION UNIT - BEARING RE- MOVAL • Remove the final transmission unit. • Clean the two sides of the hub with a cloth. • Remove the left spacer (15). • Remove the sealing gasket (16). •...
Page 394 RSV4 Factory Suspensions Shock absorbers EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual linkage fixing screw 50 Nm (36.88 lbf ft) Screw fastening single linkage to 50 Nm (36.88 lbf ft)
Page 395 RSV4 Factory Suspensions Adjusting SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD ADJUSTMENT FOR ROAD USE ONLY Specification Desc./Quantity...
Page 396 RSV4 Factory Suspensions NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: • CENTRE OF THE FRONT SCREW FASTEN- ING THE LICENSE PLATE HOLDER TO UN- DERTAIL SECTION AND • UPPER CORNER OF THE SCREW FASTEN-...
Page 397 RSV4 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 398 RSV4 Factory Suspensions UPON REFITTING, GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY. PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV- ERAL TIMES THAT JOINTS MOVE SMOOTHLY. SUSP - 398...
Page 399 INDEX OF TOPICS CHAS HASSIS...
Page 400 RSV4 Factory Chassis RONT CHASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 401 RSV4 Factory Chassis EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft)
Page 402 RSV4 Factory Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 403 RSV4 Factory Chassis • 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. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.
Page 404 RSV4 Factory Chassis • Remove the adjustment bushing from the swingarm pin (2). UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. • If necessary, use a specific tool to re- move a pin from the drive chain.
Page 405 RSV4 Factory Chassis DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm. ROTATION CHECK •...
Page 406 RSV4 Factory Chassis Installing 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 centreline of the insert, as a result the swingarm is in the high position.
Page 407 RSV4 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 408 RSV4 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 409 RSV4 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 410 RSV4 Factory Chassis • Move the vehicle forward so as to check vertical oscillation in other posi- tions too. clearance should remain constant at all wheel rotation phases. ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN.
Page 411 RSV4 Factory Chassis FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED. THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE. ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION.
Page 412 RSV4 Factory Chassis • Unscrew and remove the upper screw fixing the chain pad and retrieve the washer. • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand...
Page 413 RSV4 Factory Chassis IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) Side stand •...
Page 414 RSV4 Factory Chassis • Remove the side stand. Exhaust XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft)
Page 415 RSV4 Factory Chassis Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold. • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis;...
Page 416 RSV4 Factory Chassis Removing the catalytic converter • Remove the exhaust end. • Remove the front exhaust manifold. • Remove the pinion crankcase • Disconnect the oxygen sensor connec- tor. • Release the oxygen sensor cable har- ness from the clamps.
Page 417 RSV4 Factory Chassis • Remove the front underfairings. • Remove the hand grip position sensor control unit. • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front...
Page 418 RSV4 Factory Chassis • Remove the front exhaust manifold. REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers.
Page 419 RSV4 Factory Chassis Lower cowl • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler...
Page 420 RSV4 Factory Chassis IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe.
Page 421 RSV4 Factory Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 421...
Page 422 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 423 RSV4 Factory Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake disc fixing screws 30 Nm (22.13 lbf ft) Loct. 243 Screw fastening odometer sensor 12 Nm (8.85 lbf ft) onto rear brake calliper mounting Rear brake calliper mounting plate 50 Nm (36.88 lbf ft)
Page 424 RSV4 Factory Braking system Front brake calliper RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) Rear brake disc Removal • Remove the rear wheel. CAUTION...
Page 425 RSV4 Factory Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 426 RSV4 Factory Braking system Removal • Remove the front wheel. The following operations refers to a single disc but apply to both. To unscrew the screws (1), use an air screwer gun to give a clean blow, which will detach the screws stuck with LOCTITE 243.
Page 427 RSV4 Factory Braking system 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 428 RSV4 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 429 RSV4 Factory Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 430 RSV4 Factory Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. Air in the system causes a "spongy" feeling in the brake control and poor braking efficiency.
Page 431 RSV4 Factory Braking system • Screw the bleed valve and remove the pipe. • Top-up the reservoir until the right brake fluid level is obtained. • Refit and block the front brake fluid res- ervoir cap. • Refit the protective rubber cap.
Page 432 RSV4 Factory Braking system • Refit and lock the rear brake fluid reservoir cap. • Refit the protective rubber cap. Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft)
Page 433 RSV4 Factory Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft)
Page 434 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 435 RSV4 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 - 435...
Page 436 RSV4 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 OOLING pos.
Page 437 RSV4 Factory Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Electric fan • Remove the front underfairings and the hand grip position sensor • Disconnect the cooling fan connector to be replaced.
Page 438 RSV4 Factory Cooling system Fairing mounting panels Twistgrip position sensor • Move the radiator forward. • Unscrew and remove the three fan re- tainers and retrieve the washers. Coolant replacement • Remove both fairings. • Place a container with a suitable ca- pacity under the coolant pump.
Page 439 RSV4 Factory Cooling system • Via the filler orifice on the expansion tank, fill with the quantity of coolant necessary to reach the FULL marking, then refit the cap. • Start the engine, run at idle speed and wait for the electric fans to activate (ap- prox.
Page 440 RSV4 Factory Cooling system • Unscrew and remove the two screws fastening the pump to the engine. • Remove the coolant pump. • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw.
Page 441 RSV4 Factory Cooling system • At each removal, replace the inner gas- ket between the pump casing and the cover and the O ring on the pump cas- ing. ENSURE THAT THE LIQUID PASSAGE ORIFICES ARE NOT OBSTRUCTED. Removing the radiator •...
Page 442 RSV4 Factory Cooling system Twistgrip position sensor • Unscrew and remove both radiator up- per fixing screws. • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return...
Page 443 RSV4 Factory Cooling system • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Remove the radiator. COOL SYS - 443...
Page 444 INDEX OF TOPICS BODYW ODYWORK...
Page 445 RSV4 Factory Bodywork EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) BODYW - 445...
Page 446 RSV4 Factory Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 447 RSV4 Factory Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft)
Page 448 RSV4 Factory Bodywork pos. Description Type Quantity Torque Notes Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER pos.
Page 449 RSV4 Factory Bodywork TAIL pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft)
Page 450 RSV4 Factory Bodywork ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft)
Page 451 RSV4 Factory Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to 3 Nm (2.21 lbf ft)
Page 452 RSV4 Factory Bodywork AIRING pos. Description Type Quantity Torque Notes Centre screws fastening lower fairing 10 Nm (7.37 lbf ft) Right hand lower fairing mounting 10 Nm (7.37 lbf ft) bracket Left hand lower fairing mounting 10 Nm (7.37 lbf ft)
Page 453 RSV4 Factory Bodywork Driving mirrors • The following procedure is for a single rear view mirror, but is applicable to both mirrors. • Unscrew and remove the two nuts, supporting the rear view mirror. • Disconnect the turn indicator connec- tor from the relative fixed connector on the instrument panel.
Page 454 RSV4 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 arch brace.
Page 455 RSV4 Factory Bodywork Headlight fairing • Working from both sides, unscrew and remove the four screws. BODYW - 455...
Page 456 RSV4 Factory Bodywork • Remove the side fairings. • Disconnect the turn indicator connec- tors from the fixed connector on the instrument panel mounting. • Remove the two rear view mirrors if necessary. • Remove the three lower inserts. See also Side fairings •...
Page 457 RSV4 Factory Bodywork • Ease off the side fairing, taking partic- ular care not to damage the fitting with the lower side fairing and the tabs fas- tening the side fairing to the lug. • Release the insert on the retainer with the duct.
Page 458 RSV4 Factory Bodywork LOWER SIDE FAIRINGS • The operations described below are valid for both lower side fairings. • Remove the side fairing. • Unscrew and remove the screw and remove the lower side fairing. Fairing mounting panels CENTRAL UNDERFAIRING •...
Page 459 RSV4 Factory Bodywork LATERAL UNDERFAIRINGS • The following procedure is relative to a single lateral underfairing, but is appli- cable to both, except where specified otherwise. • Unscrew and remove the central un- derfairing fixing screw. • Remove the respective side fairing.
Page 460 RSV4 Factory Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit. • Disconnect the air temperature sensor connector. • Move the two rear coil connectors See also Control unit • Unscrew and remove the four upper injector screws.
Page 461 RSV4 Factory Bodywork • Unscrew and remove the eight air filter box cover screws. • Remove the air filter box cover. FILTER BOX BASE • Open the air filter box cover. • Unscrew and remove the air intake duct fixing screws.
Page 462 RSV4 Factory Bodywork • Working from both sides, disconnect the Blow-by system intake pipes. • Release the cable harness from the cable grommet on the filter box. • Remove the air filter box base. Rear mudguard • Unscrew and remove the two screws.
Page 463 RSV4 Factory Bodywork • Unscrew and remove the front screw. See also Side fairings • Unscrew and remove the lower screw. • Supporting the right fairing lug, un- screw and remove the right lug fixing screw and remove the lug.
Page 464 RSV4 Factory Bodywork • Remove the rider saddle. • Unscrew and remove the two rear screws. • Release the clamps. • Remove the two tank breather pipes. • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank.
Page 465 RSV4 Factory Bodywork Front mudguard • Working from both sides, unscrew and remove the two screws. • Remove the front mudguard. Instrument cluster support REMOVAL • Remove the instrument panel. • Working on both sides, unscrew and remove the two screws fastening the arch brace to the headstock.
Page 466 RSV4 Factory Bodywork • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws. • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp.
Page 467 RSV4 Factory Bodywork • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws. Do not strain the connection between the two semi- arch braces, as this would prevent the removal of the clamp.
Page 468 RSV4 Factory Bodywork NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 469 RSV4 Factory Bodywork Side air deflectors The following procedure is for a single lateral duct but is applicable to both. • Remove the windshield. • Unscrew and remove the two fixing nuts. • Remove the duct from its seat on the frame.
Page 470 INDEX OF TOPICS PRE DE DELIVERY...
Page 471 RSV4 Factory Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit...
Page 472 RSV4 Factory Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 473 RSV4 Factory Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 474 RSV4 Factory Pre-delivery Specific operations for the vehicle • Remove the screw (2). • Remove the plastic cover (1). • Fit the rear pedal in its seat. • Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm (13.27 lbf ft)
Page 475 RSV4 Factory Pre-delivery • Fit the two-seater saddle. PRE DE - 475...
Page 476 Air filter: 65 Battery: 148 Brake: 423–425, 427, 428, 432, 433 Bulbs: Chain: 13, 409, 411 Clutch: 75, 202, 247, 262, 263, 266–268, 273, 294, 301, 317, 320 Clutch lever: 202 Coolant: 438, 439, 441 Engine oil: 63, 199, 419 Fork: 366, 368, 371, 375 Forks: 251 Fuel: 65, 142, 183, 226, 351, 463...
Page 477 Spark plug: 62, 67 Stand: 87, 203, 226, 229, 412, 413 Start-up: 141, 257 Tank: 65, 226, 463 Transmission: 12, 319, 322 Tyres: 14 Warning lights: Windshield:...

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