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Table Of Contents - APRILIA RSV4 Factory Service Station Manual

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Use and maintenance manual (239 pages)

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Manual (181 pages)

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Brochure (12 pages)

Table Of Contents

Table of Contents

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Table of Contents

Index Of Topics5

Characteristics6

Carbon Monoxide7

Hot Components7

Used Engine Oil And Transmission Oil8

Battery Electrolyte And Hydrogen Gas8

Maintenance Rules8

Before Disassembling Components9

Components Removal9

Reassembling Components9

Electric Connectors9

Tightening Torques10

Vehicle Identification11

Serial Number Location11

Engine Number11

Dimensions And Mass11

Table Of Contents22

Type Quantity23

Nm (0.37 Lbf Ft)38

Nm (7.37 Lbf Ft)42

Special Tools52

Maintenance Chart61

Routine Maintenance Table61

Front Spark Plugs62

Engine Oil Filter65

Checking The Valve Clearance66

Front Cylinder Head Valves68

020850Y Primary Gear Lock70

020848Y Flywheel Retainer70

020851Y Camshaft Timing Pin70

020852Y Crankshaft Timing Pin70

020865Y Support For Camshaft Gear On Head71

Calibrated Pad Thickness81

Troubleshooting83

Check Control Unit Power Supply87

Check Fuel Pump88

Diagnosis Instrument Connection Check88

Injection Relay 33 Check89

Protection Relay 19 Check90

Starter Button Check90

Electrical System92

Components Arrangement94

Electrical System Installation96

Scope And Applicability96

Motorcycle Division99

C1 - Headlamp Pre-Fitting101

Headlamp Pre-Fitting102

Handlebar Controls102

Front Stop Switch Connector104

Right Handlebar Control Connector104

Instrument Holder Arch Brace And Front Part104

Completion Of The Front106

Central Part107

Radiator Area107

Demand Sensor Fitting109

Exhaust Valve Actuator110

Pinion Casing Area112

Notes For Fitting The Ground Cables113

Engine - Battery Ground Cable Routing114

Notes For Engine Cable Harness Fitting115

Engine Cable Harness Layout115

Filter Box Cover And Lower116

Filter Box Preparation116

Fitting The Pipes On The Secondary Air Solenoid117

Motorised Throttle Body Fitting118

H2O Temperature Sensor119

Rear Saddle Mounting Area128

Left Side Saddle Mounting130

General Wiring Diagram132

Checks And Inspections134

Connector Check Procedure134

Instrument Panel: Errors136

Dsb 04 Internal Controller Fault137

Installing A New Instrument Panel137

Instrument Panel Errors138

Service Warning Light Reset140

Vehicle Servicing Reset140

Start-Up System Check141

Diagnosis Instrument: Electrical Errors141

Diagnosis Instrument: Logic Errors141

Level Indicators142

Secondary Fuses Distribution142

Main Fuses Distribution142

Control Unit143

Control Unit - Diagnosis143

Diagnosis Instrument: Parameters144

Diagnosis Instrument: Statuses144

Immobilizer Signal145

Start-Up Enabling145

Error Clearing145

Ambient Parameter Reading145

Ram Error P0604146

Rom Error P0605146

A/D Converter P0607146

Stop Lights Relay Error P0610146

Level 2 Safety Reset P0608147

Safety Engine Stop P0609147

Diagnosis Instrument: Adjustable Parameters147

Battery Recharge148

Battery Voltage149

Battery Voltage Pre Recovery149

Battery Voltage P0560149

Speed Sensor150

Variable Geometry Intake151

Diagnosis Instrument: Errors152

Variable Geometry Intake P0447152

Engine Rpm Sensor153

Twistgrip Position Sensor155

Intake Pressure Sensor161

Engine Temperature Sensor166

Air Temperature Sensor169

Lambda Sensor171

Lower Injector175

Upper Injector Function179

Dsb 08: Oil Pressure200

Neutral Sensor200

Clutch Lever Sensor202

Side Stand Sensor203

Bank Angle Sensor204

Electric Fan Circuit205

Sas Valve Actuator207

Run/Stop Switch208

Run / Stop Switch209

Butterfly Valve In Exhaust209

Exhaust Valve Engine P0192211

Exhaust Throttle Valve Calibration214

Side Stand Input Pin 70218

Engine From Vehicle224

Vehicle Preparation225

Removing The Engine From The Vehicle226

Removing The Gearbox246

Gearbox Shafts248

Disassembling The Gearbox248

Checking The Primary Shaft250

Checking The Secondary Shaft250

Checking The Desmodromic Drum250

Checking The Forks251

Assembling The Gearbox251

Gearbox Control Rod Oil Seal And Roller Cage, Spacer255

Checking The Gear Selector256

Reassembling The Gear Selector256

Removing The Starter Motor256

Removing The Idle Gear257

Generator Side258

Removing The Flywheel Cover259

Magneto Flywheel Removal259

Inspecting The Cover Components260

Installing The Flywheel260

Flywheel Cover Installation261

Removing The Clutch Cover263

Disassembling The Clutch263

Checking The Clutch Housing267

Checking The Pusher Plate267

Checking The Springs268

Assembling The Clutch268

Head Cover Removal276

Removing Camshafts276

Front Head Check287

Front Head Fitting288

Inspecting Camshafts297

Camshaft Toothed Wheel Check297

Camshaft Lobes297

Installing Camshafts298

Rear Head Removal300

Valve Removal310

Ignition Unit316

Balancing Countershaft Removal317

Balancing Countershaft Fitting318

Main Transmission Gear Removal319

Installing The Primary Drive Gear321

Crankcase Opening322

Removing Connecting Rods - Pistons324

Crankshaft Removal325

Bushing Removal326

Crankshaft Check326

Balancing Countershaft Check326

Countershaft Bushings326

Connecting Rod Check327

Inspecting Pistons327

Minimum Piston Diameter327

Selecting Connecting Rods328

Bushing Selection329

Shaft Category329

Crankshaft Bushings329

Bushing Fitting332

Crankshaft Fitting334

Thermal Group341

Removing The Oil Sump347

Inspecting The One-Way Valve349

Power Supply350

Removing The Injector354

Lower Injectors354

Upper Injectors355

Removing The Throttle Body355

Checking The Throttle Body356

Installing The Throttle Body357

Stepper Motor357

Cylinders Synchronisation359

Removing The Front Wheel362

Checking The Front Wheel363

Front Wheel Bearings363

Radial And Axial Clearance Check364

Wheel Spindle364

Front Fork - Standard367

Front Fork - Racing367

Removing The Fork Legs368

Draining Oil369

Disassembling The Fork371

Reassembling The Fork375

Steering Bearing381

Adjusting Play381

Removing The Rear Wheel387

Checking The Rear Wheel389

Rear Wheel Spindle390

Rear Wheel Rim390

Final Transmission Unit Bearings390

Flexible Coupling391

Rear Wheel Bearings391

Shock Absorbers394

Front Chassis400

Swinging Arm401

Swingarm Bearings405

Swingarm Pin405

Chain Sliders411

Removing The Tail Pipe415

Removing The Catalytic Converter416

Removing The Exhaust Manifold416

Rear Exhaust Manifolds418

Removing The Exhaust Throttle Valve418

Engine Oil Cooler419

Oil Radiator420

Braking System422

Rear Brake Calliper423

Front Brake Calliper424

Rear Brake Disc424

Disc Inspection425

Front Brake Disc425

Front Brake Pads427

Rear Brake Pads428

Bleeding The Braking System430

Front Brake Pump432

Rear Brake Pump433

Cooling System434

Circuit Diagram435

Coolant Replacement438

Driving Mirrors453

Instrument Panel454

Headlight Fairing455

Side Fairings456

Fairing Mounting Panels458

Lower Side Fairings458

Central Underfairing458

Lateral Underfairings459

Filter Box Cover Removal460

Filter Box Base461

Rear Mudguard462

Front Mudguard465

Instrument Cluster Support465

Radiator Cover468

Side Air Deflectors469

Pre-Delivery470

Aesthetic Inspection471

Tightening Torques Inspection471

Functional Inspection473

Specific Operations For The Vehicle474

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