APRILIA RSV4 1100 Factory 2021 Manual

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MANUALE STAZIONE DI SERVIZIO

2Q000479

RSV4 1100 Factory

Summary of Contents for APRILIA RSV4 1100 Factory 2021

Page 1 MANUALE STAZIONE DI SERVIZIO 2Q000479 RSV4 1100 Factory...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
Page 3 Le principali modifiche tecniche e modifiche alle procedure per le riparazioni del veicolo vengono comunicate a tutti i Punti Vendita Aprilia e alle Filiali nel Mondo. Tali modifiche verranno apportate nelle edizioni successive di questo manuale. Nel caso di necessità o dubbi sulle procedure di riparazione e di controllo, interpellare il REPARTO ASSISTENZA Aprilia, il quale sarà...
Page 4 Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee...
Page 5 INDEX OF TOPICS PRE DE DELIVERY CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 RSV4 1100 Factory Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
Page 8 RSV4 1100 Factory Pre-delivery TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. THE LACK OF AN ADEQUATE BATTERY CHARGE BEFORE THE FIRST USE WILL CAUSE A PREMATURE FAILURE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
Page 9 RSV4 1100 Factory Pre-delivery Quick charge - Electric current: 8 A - Time: 0,5 hours WARNING THE CHARGE VOLTAGE MUST NEVER EXCEED 15V. WARNINGS - Do not knock, throw or subject the battery to violent shocks. - Do not carry the battery together with flammable, explosive or sharp objects. - NEVER attempt to open the battery.
Page 10 RSV4 1100 Factory Pre-delivery • Check that air bubbles come out of the cells; let the liquid flow into the cells for at least 20 minutes. • If no air bubbles escape and the liquid does not flow, tap lightly on the bottom of the container until the liquid begins to flow into the cells.
Page 11 RSV4 1100 Factory Pre-delivery - Abnormal noise Static test Static control after the test drive: - Restarting when warmed up - Idling - Uniform turning of the steering - Possible leaks - Radiator electric fans operation Functional inspection - Hydraulic braking system - Brake and clutch lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and absence of abnormal noise...
Page 12 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 13 RSV4 1100 Factory Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 14 RSV4 1100 Factory Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
Page 15 CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only aprilia ORIGINAL SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
Page 16 Preferably do not exceed 7500 rpm during the first 1000 km (621 mi) and 9500 rpm from 1000 to 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "RECOMMENDED PRODUCTS" TABLE IN THE SCHEDULED MAIN-...
Page 17 RSV4 1100 Factory Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Page 18 LECTRONIC CONTROL SYSTEMS Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control) which includes: ALC (con- trolled launch), AEM (engine map management system), AEB (engine brake map management system), ASC (suspen- sion electronic control) (if available), ABS (anti-lock braking CHAR - 18...
Page 19 RSV4 1100 Factory Characteristics Specification Desc./Quantity system), ATC (traction control), AWC (wheelie control), AQS (Assisted upshift and downshift without using the clutch), PIT (pit lane speed control). Capacities APACITY Specification Desc./Quantity Fuel tank capacity (including reserve) 17.9 l (3.93 UK gal; 4.72 US gal) Fuel tank reserve capacity 4 l (0.88 UK gal;...
Page 20 RSV4 1100 Factory Characteristics Specification Desc./Quantity Fuel reserve Immobilizer Neutral Frame and suspensions RAME Specification Desc./Quantity Type Adjustable aluminium, dual beam chassis with pressed and cast sheet elements. Steering rake angle 26.5° (measurements with reference to bare chassis) USPENSIONS Specification Desc./Quantity Front fork - RSV4 1100 Factory (Ohlins - ASC) With upside-down stanchions, electronic adjustment and hy-...
Page 21 RSV4 1100 Factory Characteristics Specification Desc./Quantity (1.18 inches) and 2 pads - radial pump and brake pipe in metal braid. Rear disc brake -220 mm diam. (8.66 inches), 2-piston callipers - 32 mm diam. (1.25 inches) - pump with built-in tank and metal braid pipe.
Page 22 RSV4 1100 Factory Characteristics ETRIC SCREW TIGHTENING TORQUES ON FASTENERS WITH PLASTIC COMPRESSION WITHOUT INSERTED COL- LAR OR BUSH Tightening torque: 1.5 Nm (1.10 lb ft) 2 Nm (1.47 lb ft) 3 Nm (2.21 lbf ft) CAUTION THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED.
Page 23 RSV4 1100 Factory Characteristics RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) ASC (RSV4 1100 FACTORY) RONT FORK HLINS Pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 2 + 2 10 Nm (7.37 lb ft)
Page 24 RSV4 1100 Factory Characteristics (RSV4 1100) RONT FORK ACHS Pos. Description Type Quantity Torque Notes Calliper bracket fixing screws 12 Nm (8.85 lbf ft) (Sachs) Speed sensor fastening screw 6 Nm (4.43 lbf ft) Upper cap 20 Nm (14.75 lbf ft) Upper cap locking nut 20 Nm (14.75 lbf ft) CHAR - 24...
Page 25 RSV4 1100 Factory Characteristics TEERING Pos. Description Type Quantity Torque Notes Upper plate stem fastening screws 25 Nm (18.44 lbf ft) Lower plate stem fastening screws 25 Nm (18.44 lbf ft) Headstock ring nut - pre-tightening M35x1 70 Nm (51.63 lb ft) Unscrew after pre- tightening Headstock ring nut - tightening...
Page 26 RSV4 1100 Factory Characteristics RONT BRAKE MASTER CYLINDER 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 Front brake pump U bolt clamp 10 Nm (7.38 lbf ft) Front brake lever pin fixing screw...
Page 27 RSV4 1100 Factory Characteristics LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lbf ft) AIRING FRONT Pos. Description Type Quantity Torque Notes Top fairing fixing screws 0.5 Nm (0.37 lb ft) Rear-view mirror fixing nuts 2 + 2 10 Nm (7.38 lbf ft) CHAR - 27...
Page 28 RSV4 1100 Factory Characteristics UCTS Pos. Description Type Quantity Torque Notes Threaded pins for fastening the in- 4 Nm (2.95 lb ft) Loct. 243 take ducts Intake duct fixing nuts Manual RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft)
Page 29 RSV4 1100 Factory Characteristics RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Inertial platform fixing screws 6 Nm (4.42 lb ft) Voltage regulator fastening screws 6 Nm (4.42 lb ft) Horn fixing screw 15 Nm (11.06 lbf ft) Starter relay cables fastening screws 4 Nm (2.95 lb ft) Central part OOLING...
Page 30 RSV4 1100 Factory Characteristics IL RADIATOR Pos. Description Type Quantity Torque Notes Screw fastening oil radiator to M6x25 7 Nm (5.16 lbf ft) mounting bracket Hex head flange screws fastening M6x12 8 Nm (5.90 lbf ft) bracket to engine CHAR - 30...
Page 31 RSV4 1100 Factory Characteristics RAME Pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Front couplings 2 + 2 50 Nm (36.88 lbf ft) Lower rear coupling 50 Nm (36.88 lbf ft) RH lower rear regulator bushing M18x1.5 12 Nm (8.85 lbf ft) RH upper rear regulator bushing...
Page 32 RSV4 1100 Factory Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Screws used to fasten the rider's 2 + 2 25 Nm (18.44 lbf ft) Loctite 243 footrest to the chassis Screws for fastening the passenger's 2 + 2 18 Nm (13.28 lbf ft) Loctite 243 - For use footrests to the frame in countries where it...
Page 33 RSV4 1100 Factory Characteristics EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 Nm (4.42 lbf ft) Rear brake pump fastening screws 8 Nm (5.90 lbf ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lbf ft) Loctite 243 Tank filler cap...
Page 34 RSV4 1100 Factory Characteristics IDE STAND Pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 frame Fastener nut of rotary switch 10 Nm (7.37 lbf ft) Stand fastening pin ...
Page 35 RSV4 1100 Factory Characteristics UEL TANK Pos. Description Type Quantity Torque Notes Fastener screw of left hand side cov- 3 Nm (2.21 lbf ft) er mounting bracket Screw fastening front part to frame 8 Nm (5.90 lbf ft) Screws fastening rear part to saddle 7 Nm (5.16 lbf ft) carrier subframe Tank breather connectors...
Page 36 RSV4 1100 Factory Characteristics OCKS Pos. Description Type Quantity Torque Notes Cylindrical head hex. socket screws M5x14 4 Nm (2.95 lbf ft) for fastening filler to tank Shear head screw (to the left of the M8x28 manual tighten until the ignition lock) head shears off Right hand cylindrical head hex.
Page 37 RSV4 1100 Factory Characteristics ILTER BOX Pos. Description Type Quantity Torque Notes Lower intake duct fastener screws 5 Nm (3.68 lbf ft) SWP self-tapping screws for fasten- 2.9x12 1 Nm (0.73 lbf ft) ing temperature sensor CHAR - 37...
Page 38 RSV4 1100 Factory Characteristics XHAUST Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lbf ft) nuts Silencer - central manifold clamp fas- 20 Nm (14.75 lbf ft) tening screw Screw fastening front header clamp - ...
Page 39 RSV4 1100 Factory Characteristics Back side EAR SWINGARMS Pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain guard fastening screws 2 Nm (1.47 lbf ft)
Page 40 RSV4 1100 Factory Characteristics EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes ABS sensor fixing screw M5x15 8 Nm (5.90 lbf ft) Screws fastening brake calliper to 25 Nm (18.43 lbf ft) mount ADDLE Pos. Description Type Quantity Torque Notes Rider saddle fastener screw 6 Nm (4.43 lbf ft)
Page 41 RSV4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Fastener screw for passenger seat 1.5 Nm (1.11 lbf ft) latch pin EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lbf ft) Nuts used to fasten the crown to the 50 Nm (36.88 lbf ft) sprocket...
Page 42 RSV4 1100 Factory Characteristics EAR SHOCK ABSORBER Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual connecting rod fixing screw 50 Nm (36.88 lbf ft) Screw fastening single connecting 50 Nm (36.88 lbf ft) rod to chassis Engine LUTCH COVER...
Page 43 RSV4 1100 Factory Characteristics ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.38 lb ft) TE flanged coil fixing screw M6x12 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft) CHAR - 43...
Page 44 RSV4 1100 Factory Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft) Reed valve covers fixing screws...
Page 45 RSV4 1100 Factory Characteristics IMING SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Chain tensioner sliders fastening 20 Nm (14.75 lb ft) Loct. 243 screws Chain guide sliders fixing screws M6x18...
Page 46 RSV4 1100 Factory Characteristics RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lbf ft) + 130° and under head with PANKL Lubricant 01 (PLB01) Primary fixing ring nut 200 Nm (147.51 lbf ft) Loct.
Page 47 RSV4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Stud bolt Bring to 33mm from the Loct. 648 surface SHC screw M6x40 10 Nm (7.38 lbf ft) Lubricate the head and under the head. Special nut 10 Nm (7.38 lbf ft) Flanged nut 15 + 20 Nm (11.06 + Lubricate the head...
Page 48 RSV4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Hex head flange screw for fastening M10x35 50 Nm (36.88 lbf ft) Loct. 243 sprocket Screw used to secure the pre-selec- 25 Nm (18.44 lbf ft) Pre-coated screw - tor to the crankcase if not pre-coated, apply 3M 2353 to thread...
Page 49 RSV4 1100 Factory Characteristics GNITION UNIT Pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lbf ft) Loct. 243 Starter motor SHC fastener screw M6x40 10 Nm (7.38 lbf ft) Screw fastening cables to the starter 6 Nm (4.43 lbf ft) motor CHAR - 49...
Page 50 RSV4 1100 Factory Characteristics ENERATOR COVER Pos. Description Type Quantity Torque Notes Cover fastening screws M6x25 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque. Cover fastening screws M6x40 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque.
Page 51 RSV4 1100 Factory Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket secon- M6x16 10 Nm (7.38 lbf ft) dary air solenoid screws CHAR - 51...
Page 52 RSV4 1100 Factory Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lbf ft) for fastening the pump to the crank- case CHAR - 52...
Page 53 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 54 RSV4 1100 Factory Special tools PECIAL TOOLS Stores code Description 020845Y Engine support 020846Y Containment tray + plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch retainer tool 020850Y Primary gear lock S-TOOLS - 54...
Page 55 RSV4 1100 Factory Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension- er of the timing chain 020980Y Piston assembly ring 020857Y Crankshaft support U-bolt S-TOOLS - 55...
Page 56 RSV4 1100 Factory Special tools Stores code Description 020858Y Maintenance of the pistons in the cylin- ders AP8140199 Tool storage panel 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear- box control rod 020863Y Punch assembly cage with rollers des- modromic drum 020864Y...
Page 57 RSV4 1100 Factory Special tools Stores code Description 020956Y Support for camshaft gear on head 020883Y Fitting/removing timing chain tensioner tool 020709Y Engine support AP8140187 U-bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide S-TOOLS - 57...
Page 58 RSV4 1100 Factory Special tools Stores code Description 020364Y 25-mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft S-TOOLS - 58...
Page 59 RSV4 1100 Factory Special tools Stores code Description 020877Y Calliper for clamps 020926Y Tool for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140149 Guard for assembly operations AP8140190 Steering tightening tool 01761-04 Ohlins fork cap ring nut S-TOOLS - 59...
Page 60 RSV4 1100 Factory Special tools Stores code Description 020888Y Pre-load tube clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles S-TOOLS - 60...
Page 61 INDEX OF TOPICS MAIN AINTENANCE...
Page 62 (e.g. use on pave, holes, speed bumps) can bring small adjustments that, in ex- treme cases, can cause a slight clearance to the handlebar. Therefore it is recommended to perform the check and adjustment operations at an Authorised Aprilia-Piaggio Workshop every 5,000 km (3,106.86 mi).
Page 63 RSV4 1100 Factory Maintenance Km x 1,000 (mi x 1,000) 1 (0.6) EVERY EVERY (6.2) (12.4) (18.6) (24.9) MONTH MONTH Coolant Fork oil (6) (8) Engine oil (5) Headlight aiming Fork oil seals (5) Tyres - pressure / wear (2) Nut/bolt tightness (5) Flexible coupling pin nuts tightening Clutch cover, flywheel and sump screw tightness...
Page 64 (e.g. use on pave, holes, speed bumps) can bring small adjustments that, in ex- treme cases, can cause a slight clearance to the handlebar. Therefore it is recommended to perform the check and adjustment operations at an Authorised Aprilia-Piaggio Workshop every 3,106.86 mi (5,000 km).
Page 65 (e.g. use on pave, holes, speed bumps) can bring small adjustments that, in ex- treme cases, can cause a slight clearance to the handlebar. Therefore it is recommended to perform the check and adjustment operations at an Authorised Aprilia-Piaggio Workshop every 5,000 km (3,106.86 mi).
Page 66 RSV4 1100 Factory Maintenance Km x 1.000 or (months) maximum 1 (1) 10 (10) 20 (20) 30 (30) 40 (40) Brake systems (5) Light circuit Safety switches (stand, stop, clutch, extra negative stroke, gas con- trol) Brake Fluid Coolant Fork oil (6) (8) Engine oil (5) Headlight aiming Fork oil seals (5)
Page 67 (see the figure) remains on in the steady state for more than 2 seconds, every 120 sec- onds, users should contact their local Authorised Aprilia Service Centre in order to arrange for the specific maintenance procedure to be carried out, as indicated in the table.
Page 68 RSV4 1100 Factory Maintenance Upon completing the specific track maintenance procedure, access the "adjustments" section of the diagnostic tool and reset the equivalent kil- ometres, so that it is possible to extinguish the "warning lamp" and carry out the calculation for the next service.
Page 69 RSV4 1100 Factory Maintenance • After removing the screws holding the coils, disconnect them from the spark plugs and remove them. • Using a special spark plug wrench, un- screw and remove them. REAR SPARK PLUGS Cylinder 1 To proceed with the removal of the cylinder 1 spark plug, proceed as described: •...
Page 70 RSV4 1100 Factory Maintenance • After having removed the fixing screw of the coil, disconnect it from the spark plug and remove it. While refitting, make sure you pass the coil wiring harness behind the wiring harnesses on the filter housing. •...
Page 71 RSV4 1100 Factory Maintenance • After having removed the fixing screw of the coil, disconnect it from the spark plug and remove it. While refitting, place the wiring harness under the air pressure sensor pipes. • Using a special spark plug wrench, un- screw and remove it.
Page 72 RSV4 1100 Factory Maintenance • Clean the engine oil level dipstick (1) and put it back in without screwing it in • Remove it again and check the engine oil level • The level is correct if it reaches the ''MAX'' level approximately.
Page 73 RSV4 1100 Factory Maintenance • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and, if necessary, replace the drainage plug sealing washers. • Remove the oil filter. • Spread a thin layer of oil on the sealing ring of the new engine oil filter.
Page 74 RSV4 1100 Factory Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER. •...
Page 75 RSV4 1100 Factory Maintenance • From the support on the filter housing disconnect the cylinder 3 coil connec- tor. • Remove the three screws fixing the ECU support to the filter housing. • Remove the control unit complete with support. •...
Page 76 RSV4 1100 Factory Maintenance • Remove the quick shift connector from its seat. • Remove the nine fixing screws of the filter housing cover. • Disconnect the fuel pipe from the upper injectors by lifting the filter housing cov- • Remove the air filter retainer by lifting MAIN - 76...
Page 77 RSV4 1100 Factory Maintenance • Remove the air filter. Air filter housing Air filter housing removal Remove the fuel tank to be able to reach the filter housing area and proceed as follows: COVER REMOVAL • - Disconnect the "ENGINE" connector from the control unit.
Page 78 RSV4 1100 Factory Maintenance • Remove the control unit complete with support. • After having removed the fixing screw of the engine wiring harness support, release it from the filter housing by lift- ing it as indicated. • Remove the quick shift connector from its seat.
Page 79 RSV4 1100 Factory Maintenance • Remove the four fixing screws of the upper injectors petrol circuit. • Disconnect the fuel pipe and remove it by releasing it from the upper injectors. • Remove the four injectors from the fil- ter box and disconnect the connectors. •...
Page 80 RSV4 1100 Factory Maintenance • Disconnect from the supports on the filter housing the coil connectors and the power supply connector from the main wiring harness to the engine wir- ing harness. • Remove the filter housing cover. • To remove the upper intake ducts, re- move the four fixing screws on the filter housing cover.
Page 81 RSV4 1100 Factory Maintenance • Remove the air filter. • Disconnect the main wiring harness and the canister system valve from the cable gland on the filter housing base. • Operating on the left side of the vehi- cle, remove the screw that fastens the front bank oil pressure sensor to the base of the filter housing, removing al- so the gear sensor connector support...
Page 82 RSV4 1100 Factory Maintenance • Unscrew the eight screws to remove the lower intake ducts. • Partially lifting the filter housing base, after having removed the pipe clamps, disconnect the vapour recovery pipe of the blow by valve on the left and the vapour recovery pipe of the sas valve on the right.
Page 83 RSV4 1100 Factory Maintenance • Disconnect the lower injector wiring harness from the bracket located on the filter housing base. • Remove the filter housing base. Air filter housing installation To install the filter housing, carry out the removal procedure in reverse order, paying particular at- tention to the following operations: CLAMP PRE-FITTING •...
Page 84 RSV4 1100 Factory Maintenance FITTING THE LOWER INTAKE DUCTS • The lower intake ducts have two differ- ent lengths. The shorter ducts (A) are placed on the front bank and the longer ones (B) on the rear bank. Checking the valve clearance FRONT HEAD •...
Page 85 RSV4 1100 Factory Maintenance REAR CYLINDER HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover and the spark plugs. • Remove the sound-proofing cover from the clutch side. • Remove the clutch cover. •...
Page 86 RSV4 1100 Factory Maintenance • Position cylinder 1 piston (LH, rear pis- ton) so that it is at the point where it crosses TDC. • Unscrew and remove the first screw of the camshaft drive sprocket. • rotate the crankshaft 150° in the engine rotation direction (direction of travel).
Page 87 RSV4 1100 Factory Maintenance • Remove the pin from the camshaft drive sprocket. • Unscrew and remove the three screws (1) and remove the bearing cap (2) and the oil pipe (3). • Install the specific camshaft gear sup- port tool. •...
Page 88 RSV4 1100 Factory Maintenance • Unscrew the seven screws in progres- sive steps in a criss-cross pattern and remove. • Retrieve the copper washers from the screws near the spark plug holes. • Remove the bearing caps complete with O-rings and alignment pins. •...
Page 89 RSV4 1100 Factory Maintenance • Refit the camshafts, ensuring that they are aligned correctly. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 90 RSV4 1100 Factory Maintenance • Fit the bearing cap, the oil pipe and the three fastener screws. • Tighten the ten fastener screws of the camshafts, tightening in progressive steps in a criss-cross pattern. • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin.
Page 91 RSV4 1100 Factory Maintenance side hole and the hole on the crank- shaft are perfectly aligned. • If this is not the case, repeat the timing operations. Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Check if the clearance between the cam on the shaft and the tappet is correct. •...
Page 92 RSV4 1100 Factory Maintenance • Fit the pin for aligning the intake cam- shaft with the hole in the bearing cap. Specific tooling 020851Y Camshaft timing pin • Loosen the second screw of the cam- shaft drive sprocket. • Remove the pin from the camshaft drive sprocket.
Page 93 RSV4 1100 Factory Maintenance • Install the specific camshaft gear sup- port tool. • Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer.
Page 94 RSV4 1100 Factory Maintenance • Retrieve the buckets using a magnet. • Remove the calibrated pads with a magnet and replace with new calibra- ted pads of the size necessary to attain the correct valve clearance value. See the paragraph "Calibrated pad thickness" to determine the correct thickness.
Page 95 RSV4 1100 Factory Maintenance • Fit the bearing caps complete with O- rings and alignment, and fit and hand- tighten the seven screws indicated. Use new copper washers on the four screws near the spark plug holes. • Loosen the camshaft sprocket lock screw on the tool.
Page 96 RSV4 1100 Factory Maintenance • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin. • Tighten the first fastener screw of the camshaft sprocket to the specified tor- que. Specific tooling 020851Y Camshaft timing pin •...
Page 97 RSV4 1100 Factory Maintenance Calibrated pad thickness Pad thickness for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.77 mm (0.0697 in) 1.80 mm (0.0709 in) 1.82 mm (0.0716 in) 1.85 mm (0.0728 in) 1.87 mm (0.0736 in) 1.90 mm (0.0748 in) 1.92 mm (0.0756 in) 1.95 mm (0.0768 in) 1.97 mm (0.0775 in)
Page 98 RSV4 1100 Factory Maintenance 2.22 mm (0.0874 in) 2.25 mm (0.0886 in) 2.27 mm (0.0894 in) 2.3 mm (0.0905 in) 2.32 mm (0.0913 in) 2.35 mm (0.0925 in) 2.37 mm (0.0933 in) 2.4 mm (0.0945 in) 2.42 mm (0.0953 in) 2.45 mm (0.0964 in) 2.47 mm (0.0972 in) 2.50 mm (0.0984 in)
Page 99 RSV4 1100 Factory Maintenance Cooling system Level check • Shut off the engine and wait until it cools off. • Keep the vehicle upright with both wheels on a flat surface. • Looking from the left side of the vehicle through the specific opening on the in- ternal right fairing, ensure that the liq- uid level in the expansion tank is...
Page 100 RSV4 1100 Factory Maintenance Level check Checking brake fluid • Rest the vehicle on its stand. • For the front brake, turn the handlebar all the way to the right. • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level as the plug.
Page 101 LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM. HAVE THIS PROCEDURE PERFORMED BY AN Authorised Aprilia Dealer. Rear braking system • Unscrew and remove the upper nut (5) from the rear brake pump.
Page 102 RSV4 1100 Factory Maintenance Adjusting the levers FRONT BRAKE LEVER It is possible to adjust the distance between the end of the lever (1) and the grip (2), turning the adjuster (3). • Push the control lever (1) forwards and turn the adjuster (3) until the lever (1) is at the desired distance.
Page 103 RSV4 1100 Factory Maintenance • Ensure that the play is between 1 and 3 mm (0.039 and 0.12 in). In the event that the adjustment of the adjuster on the lever is not sufficient, act on the register loca- ted on the right side of the vehicle: •...
Page 104 RSV4 1100 Factory Maintenance To carry out vertical adjustment of the light beam: (LOW BEAM HEADLIGHTS) • Operating from the rear side of the fair- ing, under the internal bodywork, act on the adjuster ("1" left side / "2" right side).
Page 105 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 106 RSV4 1100 Factory Electrical system Components arrangement Key: 1. Side stand sensor 2. Fuel pump 3. Instrument cluster ELE SYS - 106...
Page 107 RSV4 1100 Factory Electrical system 4. Left hand switch 5. Right hand switch 6. Water temperature sensor 7. Cooling fans 8. Upper injectors 9. Lower injectors 10.air temperature sensor 11.Intake ducts 12.Air pressure sensor 13.Exhaust valve control motor 14.Front bank lambda probe 15.Rear bank lambda probe 16.Front speed sensor 17.Rear speed sensor...
Page 108 RSV4 1100 Factory Electrical system THE IDENTIFICATION OF THE RELAY CANNOT BE CARRIED OUT JUST ON THE BASIS OF THE INDICATIONS BELOW: IN ANY EVENT IT SHOULD OCCUR WITH THE IDENTIFICATION OF THE COLOUR OF THE RELAY CABLES. ELAY LAYOUT Location of the Component name Position on the vehicle...
Page 109 RSV4 1100 Factory Electrical system • 2 x Spring clips • 2 x spring clips (regulator connector) • 2 x chassis gaskets • 1 x Cable glands Motorcycle division The wiring harnesses on the vehicle are subdivi- ded into three main sections, as indicated in the figure.
Page 110 RSV4 1100 Factory Electrical system • Check that the R&W connector is connected and routed correctly. • Check the RH and LH rear indicator connections. • Check the gear connector connection. • Check the quick shift connector connection. • Check that all the connectors inside the instrument support arch have been connected cor- rectly.
Page 111 RSV4 1100 Factory Electrical system TABLE A1 - LH INSTRUMENT PANEL SUP- PORT PRE-FITTING • Place the cable gland as indicated. TABLE A2 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • The wiring harnesses of the right light switch and ride by wire must pass out- side the fork.
Page 112 RSV4 1100 Factory Electrical system TABLE A3 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • Place the right light switch wiring har- ness as shown and fit the right instru- ment panel support. TABLE A4 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA •...
Page 113 RSV4 1100 Factory Electrical system TABLE A5 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • Place the wiring harnesses as indica- ted; the front ABS speed sensor con- nector must remain in the lower part of the instrument support.
Page 114 RSV4 1100 Factory Electrical system TABLE A6 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • All other connectors inside the instru- ment support arch must be well con- nected and placed inside it. TABLE A7 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA •...
Page 115 RSV4 1100 Factory Electrical system TABLE A8 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • Connect the instrument panel connec- tor and then place it on the support. TABLE B - FRONT ABS SPEED SENSOR PRE- FITTING (OHLINS) •...
Page 116 RSV4 1100 Factory Electrical system TABLE B - FRONT ABS SPEED SENSOR PRE- FITTING (SACHS) • After having pre-fitted the cable gland (1) on the fork foot and having secured the sensor, arrange its wiring harness (2) as indicated and secure it with two clamps (3).
Page 117 RSV4 1100 Factory Electrical system TABLE B2 - FRONT ABS SPEED SENSOR • Pass the front ABS speed sensor wir- ing as shown and secure it with two clamps to the main wiring harness. TABLE B3 - FRONT ABS SPEED SENSOR •...
Page 118 RSV4 1100 Factory Electrical system TABLE C - ELECTRONIC SUSPENSION ECU (IF PRESENT) • After having installed the control unit on the specific support behind the in- strument panel, make sure that the connector is correctly connected to its counterpart and secure it to the instru- ment panel support at the indicated point.
Page 119 RSV4 1100 Factory Electrical system TABLE D1 - ELECTRONIC FORKS (IF PRESENT) • The wiring harness must pass inside the instrument panel support. TABLE D2 - ELECTRONIC FORKS (IF PRESENT) • The wiring harnesses that will be con- nected to the stanchion cap must pass over the front of the steering plate, as indicated.
Page 120 RSV4 1100 Factory Electrical system WIRING TABLE I - ELECTRONIC STEERING DAMPER (IF PRESENT) • Route the steering damper cable to- ward the damper. TABLE F - CLUTCH SWITCH PRE-FITTING • Place the switch wiring harness as shown and insert it into its cover. ELE SYS - 120...
Page 121 RSV4 1100 Factory Electrical system TABLE F1 - CLUTCH SWITCH PRE-FITTING • After having placed the switch on the clutch control and after having inserted the nut, screw it in until the thread pro- trusion is 4 mm. Central part TABLE A - VEHICLE CABLE HARNESS •...
Page 122 RSV4 1100 Factory Electrical system TABLE A1 - VEHICLE CABLE HARNESS • Check that the wiring harness with the VEHICLE connector is facing up and secure the conduit to the chassis. TABLE A2 - VEHICLE CABLE HARNESS Place the relays as indicated: •...
Page 123 RSV4 1100 Factory Electrical system TABLE A3 - VEHICLE CABLE HARNESS • Completely secure the main wiring har- ness on the chassis using a clamp next to with the grey taping. TABLE B - GEAR SENSOR • Place the gear sensor wiring harness as indicated before proceeding with the installation of the engine on the ve- hicle.
Page 124 RSV4 1100 Factory Electrical system TABLE C - VEHICLE ECU BRANCH • Place the two cable glands as indica- ted on the filter housing cover in order to secure the ECU branch. TABLE C1 - VEHICLE ECU BRANCH • Insert the ECU branch in the cable glands and arrange it as indicated.
Page 125 RSV4 1100 Factory Electrical system TABLE D - MAIN WIRING HARNESS CONNEC- TION WITH THE ECU • Connect the VEHICLE connector to the ECU, and make sure that a " CLICK" is heard. This noise confirms that the control unit is correctly con- nected to the wiring harness.
Page 126 RSV4 1100 Factory Electrical system TABLE E - COILS AND INJECTORS POWER SUPPLY CONNECTION • Make sure that the engine wiring har- ness connector is connected and that the wiring harness of the coil and of the power supply connector are placed un- der the guide, as indicated.
Page 127 RSV4 1100 Factory Electrical system TABLE F1 - ENGINE OIL PRESSURE SENSOR CONNECTION • After bending the cap stem by 180 de- grees, place a clamp as indicated. TABLE G - GROUND LEADS • The battery-engine ground wiring har- ness must not be visible in the area indicated by the red triangle symbol.
Page 128 RSV4 1100 Factory Electrical system TABLE G2 - GROUND LEADS • After having secured the screw, grab the terminal with two fingers and try to gently move it. If the terminal moves, check the tightening of the screw. TABLE H - WIRING HARNESS ON THE LOWER CHASSIS SHOULDERS •...
Page 129 RSV4 1100 Factory Electrical system TABLE H1 - WIRING HARNESS ON THE LOW- ER CHASSIS SHOULDERS • Operating on the internal left side, place the wiring harnesses inside the cable gland on the internal part of the chassis. TABLE H2 - WIRING HARNESS ON THE LOW- ER CHASSIS SHOULDERS •...
Page 130 RSV4 1100 Factory Electrical system TABLE I - STARTER MOTOR WIRING HAR- NESS • IF THE RELAY-STARTER MOTOR IS NOT ROUTED OR SECURED COR- RECTLY IT MAY CAUSE THE VEHI- CLE CATCH FIRE. CHECK THAT THE CABLE ON THE STARTER MO- TOR IS PLACED AS INDICATED.
Page 131 RSV4 1100 Factory Electrical system TABLE K1 - VOLTAGE REGULATOR • Connect the left electric fan connector and lock it with a clamp, as indicated. • Pass the wiring harnesses of the volt- age regulator and of the pick-up inside the pre-installed cable gland on the canister.
Page 132 RSV4 1100 Factory Electrical system TABLE L - EXHAUST VALVE MOTOR AREA WIRING HARNESSES • The fan (1) and ride by wire (2) wiring harnesses must be routed between the chassis and the exhaust valve motor cables. TABLE L1 - EXHAUST VALVE MOTOR AREA WIRING HARNESSES •...
Page 133 RSV4 1100 Factory Electrical system TABLE L2 - EXHAUST VALVE MOTOR AREA WIRING HARNESSES • The electric fan wiring harness must be secured to the ride by wire wiring har- ness with a clamp, at the indicated point. • Check that the grey safety lock on the ride by wire connector is secured in the lowered position.
Page 134 RSV4 1100 Factory Electrical system TABLE M1 - RIDE BY WIRE HANDLE CABLE ROUTING • The wiring harness of the ride by wire handle must be secured with a clamp to the expansion tank breather pipe and to the fan wiring harness on the top and below it must pass through the in- dicated cable gland.
Page 135 RSV4 1100 Factory Electrical system TABLE O - QUICK SHIFT PRE-FITTING • The quick shift must be placed as indi- cated to facilitate the positioning of the wiring harness on the vehicle during installation. TABLE O1 - QUICK SHIFT • After having installed the quick shift, place the wiring harness under the sprocket protective metal casing.
Page 136 RSV4 1100 Factory Electrical system TABLE O2 - QUICK SHIFT • The quick shift wiring harness must be placed as indicated. TABLE O3 - QUICK SHIFT • Pass the wiring harness between the chassis and the engine, and then pass it behind the engine wiring harness at- tached to the filter housing.
Page 137 RSV4 1100 Factory Electrical system TABLE P - REAR LAMBDA • The cable gland must be placed as in the figure (completely upward) and the lambda sensor cable must be routed through it. TABLE P1 - REAR LAMBDA • Pass the wiring harness as indicated. ELE SYS - 137...
Page 138 RSV4 1100 Factory Electrical system TABLE P2 - REAR LAMBDA • After having correctly connected the rear lambda probe connector with its counterpart, secure it using the special support to the sprocket metal protec- tion cover. • Secure the wiring harness with a clamp, at the indicated point.
Page 139 RSV4 1100 Factory Electrical system TABLE Q1 - FRONT LAMBDA • The wiring harness must pass behind the cooling system pipe. TABLE R - CONNECTIONS ON THE TANK • After having inserted the main wiring harness branch to the two cable glands, connect the connector of the inertial platform (1) and of the fuel pump (2).
Page 140 RSV4 1100 Factory Electrical system Back side TABLE X - LICENCE PLACE HOLDER PRE-FIT- TING • Place the three cable glands on the li- cence plate holder in the indicated points. TABLE X1 - LICENCE PLACE HOLDER PRE- FITTING • The right arrow is identified with the RED taping and must be inserted on the licence plate holder as indicated in...
Page 141 RSV4 1100 Factory Electrical system TABLE X2 - LICENCE PLACE HOLDER PRE- FITTING • Fit the clip on the wiring harness on the indicated area. TABLE A - IGNITION RELAY PRE-ASSEMBLY The positive battery cable must be connected to the hole identified by the letter B (Battery) using M5x8 screw 1.
Page 142 RSV4 1100 Factory Electrical system TABLE A2 - IGNITION RELAY PRE-ASSEMBLY After having correctly placed the cables, tighten the two screws to the specified torque. TABLE B - PROCEDURE FOR THE CORRECT OPENING OF THE ABS CONTROL UNIT CON- NECTOR •...
Page 143 RSV4 1100 Factory Electrical system TABLE C2 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION When the connector is fully inserted, the measured distance between the connector and the ABS con- trol unit must be 7.5 mm TABLE C3 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION If the initial position of the connector and the pull- ing level is not as the one shown in "TABLE C", the...
Page 144 RSV4 1100 Factory Electrical system FIGURE D2 - MAIN WIRING HARNESS • The main wiring harness must be ar- ranged as indicated. FIGURE D3 - MAIN WIRING HARNESS • The central branch of the main wiring harness must be arranged as indicated and secured with the two cable glands.
Page 145 RSV4 1100 Factory Electrical system TABLE E1 - ROUTING ON THE SADDLE COL- UMN FOR THE STARTER RELAY • After having correctly connected the starter relay (1), the taillight (2) and the turn indicators / licence plate light (3) and after having placed them in their seats, secure the main wiring harness in the two cable glands located on the saddle column frame.
Page 146 RSV4 1100 Factory Electrical system TABLE F1 - REAR SPEED SENSOR • Pass the ABS rear speed sensor wiring harness through the cable gland inside the chassis on the right side. TABLE F2 - REAR SPEED SENSOR • Insert the ABS rear speed sensor wir- ing harness into the three cable glands on the swingarm.
Page 147 RSV4 1100 Factory Electrical system TABLE F4 - REAR SPEED SENSOR • Place a cable gland that fastens the ABS rear speed sensor wiring harness to the brake pipe. TABLE G - REAR BRAKE SWITCH • Check that the rear brake switch con- nector is well connected to its counter- part and then secure it to the main wiring harness with a clamp.
Page 148 RSV4 1100 Factory Electrical system TABLE H - OBD2 CONNECTOR • The OBD2 wiring harness connector must pass from the inside of the vehicle to the outside and must be inserted in the specific support, as indicated. TABLE I - AMP CONNECTOR •...
Page 149 RSV4 1100 Factory Electrical system TABLE K1 - ELECTRONIC SHOCK ABSORBER (IF PRESENT) • Place the wiring harnesses as indica- ted. • Secure the wiring harness with the ref- erence (C) (compression) using a clamp together with the rear stop switch wiring harness and rear ABS speed sensor.
Page 150 RSV4 1100 Factory Electrical system General wiring diagram Key: 1. Multiple connectors 2. Horn 3. Left light switch 4. Left light switch 2 (lever) ELE SYS - 150...
Page 151 RSV4 1100 Factory Electrical system 5. Exhaust valve motor 6. Instrument cluster 7. Chronometer pre-installation 8. Right light switch 9. Brake light switch 10.Clutch switch 11.Ignition switch 12.Immobilizer antenna 13.RH rear turn indicator (LED) 14.Licence plate light (LED) 15.LH rear turn indicator (LED) 16.Taillight (LED) 17.USB socket (where applicable) 18.ABS control unit...
Page 152 RSV4 1100 Factory Electrical system 43.Gear sensor 44.Lambda probe cylinder 2 (FRONT) 45.Lambda probe cylinder 1 (REAR) 46.- 47.- 48.Upper injector cylinder 4 (FRONT) 49.Upper injector cylinder 3 (REAR) 50.Upper injector cylinder 2 (FRONT) 51.Upper injector cylinder 1 (REAR) 52.Lower injector cylinder 4 (FRONT) 53.Lower injector cylinder 3 (REAR) 54.Lower injector cylinder 2 (FRONT) 55.Lower injector cylinder 1 (REAR)
Page 153 RSV4 1100 Factory Electrical system 81.OHLINS suspensions ECU (if present) 82.Steering shock absorber (if present) 83.OHLINS left fork stanchion (compression) (if present) 84.OHLINS right fork stanchion (rebound) (if present) 85.OHLINS rear shock absorber (rebound) (if present) 86.OHLINS rear shock absorber (compression) (if present) 87.CAN 2 Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS...
Page 154 RSV4 1100 Factory Electrical system 3. Pull cables gently from the back of the connector to check that the terminals are fitted correctly on the connector and that the wires are fastened correctly to the terminals. Checking electrical CONTINUITY Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re- sistance (due to corroded terminals, for example) in the circuit under inspection.
Page 155 RSV4 1100 Factory Electrical system • To carry out the one or more key pro- gramming procedures, up to a maxi- mum of four, you must connect the motorcycle to the diagnostic tool. • Turn key to "ON" and insert the USER CODE where required.
Page 156 RSV4 1100 Factory Electrical system • The second key is stored and you will be asked to enter the third key (if you have one). The same operation will be repeated to store the fourth key. • To complete AND end the memorisa- tion procedure, set key to "OFF".
Page 157 RSV4 1100 Factory Electrical system • Select "SELF-DIAGNOSIS"; • Select "ACTIVATIONS"; • Enable the command "SERVICE RE- SET". Fuses It is necessary to check the fuses whenever an electrical component fails to operate or malfunctions or when the engine does not start. Check the secondary fuses first, and then the primary fuses.
Page 158 RSV4 1100 Factory Electrical system • Take out one fuse at a time and check whether the filament (2) is broken. • Before replacing the fuse, find and solve, if possible, the reason that caused the problem. • If the fuse is damaged, replace it with one of the same current rating.
Page 159 RSV4 1100 Factory Electrical system Auxiliary fuses are placed on the rear part of the motorcycle, under the rider saddle. • To check and replace the main fuse, remove the screw (3) that fastens the cover (4). • Disconnect the main relay holder from the supports and remove the protec- tion cover to gain access to the main fuse (O).
Page 160 RSV4 1100 Factory Electrical system • Disconnect the ASC control unit (2) from the mount (3) fastened to the in- strument cluster mount. Alternatively, the mount may be removed complete with control unit by unscrewing the two fastener screws (4). ASC CONTROL UNIT - Diagnosis Function It manages the ASC system, the system safety checks and the self-diagnosis function.
Page 161 RSV4 1100 Factory Electrical system Code Description / Symptoms 541300 Rear rebound sensor - open circuit 541900 Rear rebound sensor - short circuit D08700 Communication interrupted with instrument cluster ECU (DSB1) D08701 Communication interrupted with instrument cluster ECU (DSB2) D08702 Communication interrupted with inertia measurement ECU (IMU1) D08703 Communication interrupted with inertia measurement ECU (IMU2)
Page 162 RSV4 1100 Factory Electrical system • Disconnect the 11MP control unit (2) from the mount (3) fastened to the filter box cover. Alternatively, the mount may be removed complete with control unit by unscrewing the three fastener screws (4). NOTE WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION: THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED.
Page 163 RSV4 1100 Factory Electrical system PARAMETERS: • Engine rpm / - • Air temperature / - • Engine temperature / - • Engine temp. on start-up / - (motor temperatures on start-up) • Track A position sensor / - (track A hand grip position sensor) •...
Page 164 RSV4 1100 Factory Electrical system • exhaust valve targ. pos. / - (exhaust valve target position) • Front wheel speed / - • Rear wheel circ. / - (rear wheel circumference) • Final drive ratio / - (final drive ratio) •...
Page 165 RSV4 1100 Factory Electrical system • Cruise control / - (indicates the cruise control status) • Front brake lev. qual. swit. / - (front brake lever qualified switch) • Rear brake lev. qual. swit. / - (rear brake lever qualified switch) •...
Page 166 RSV4 1100 Factory Electrical system NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. P0604 RAM Error Electrical diagnostic: • Circuit not functioning Error cause: • Replace the injection control unit. The instrument cluster indicates the presence of this error with the MI warning light on fixed. NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN.
Page 167 RSV4 1100 Factory Electrical system • Short-circuit to positive: check the correct electrical characteristics of the relay by discon- necting it from the wiring harness, if not ok replace the relay, if ok restore the wiring harness (blue/pink cable) • If short circuit to negative: check the correct electrical characteristics of the relay by discon- necting it from the wiring harness, if not ok replace the relay, if ok restore the wiring harness (blue/pink cable)
Page 168 The instrument cluster does not indicate the presence of this error even in the ATT status Troubleshooting • Perform the troubleshooting for the other detected errors. P1608 a-PRC (Aprilia Performance Ride Control) operating error Electrical diagnostic: • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit...
Page 169 RSV4 1100 Factory Electrical system • Exhaust valve self-learn. / - (exhaust valve self-learning) • Equiv. km reset / - (equivalent km partial counter reset) • Ign. switch count reset / - (ignition switch assembly errors counter reset) • Download stored files / - (download of stored data files CAUTION AFTER CANCELLING ALL THE DATA STORED DURING THE VEHICLE PRODUCTION PHASE (INCLUDING THE SELF-ADAPTIVE PARAMETERS), THE FOLLOWING MUST BE SELECTED:...
Page 170 RSV4 1100 Factory Electrical system Value determined from signal read without taking considering whether recovery mode is implemen- CAUTION PAY ATTENTION TO THE POSITIVE BATTERY CABLE, WHICH MUST PASS BELOW THE UPPER PART OF THE FRAME. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE...
Page 171 RSV4 1100 Factory Electrical system control unit is a few tenths of Ohm: if not OK, repair the wiring harness; if OK, check that the electric generator is operating correctly: Restore if not OK. NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON- TROL AND THE CRUISE CONTROL.
Page 172 RSV4 1100 Factory Electrical system • Electric motor resistance (PIN 4-5): 2-4 • Potentiometer resistance (PIN 1-3): 10.1 kOhm +/- 10% Pin out: 1. 5V supply voltage 2. Output signal (0- 5 V) 3. Ground 4. A motor power supply 5.
Page 173 RSV4 1100 Factory Electrical system • Search not executed: this symptom may occur if the stop position self-acquisition procedure is not performed after installing a new instrument cluster, or if the travel between the mini- mum and maximum stop positions is too short or too long. The presence of this error is signalled by the fixed lighting of the general warning light.
Page 174 RSV4 1100 Factory Electrical system This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light. Troubleshooting: • If open circuit: may be due to loose cables, in which case make sure that the cables are stretched: if they are not, stretch them;...
Page 175 RSV4 1100 Factory Electrical system • If short circuit to negative, open circuit: check the valve connector and the instrument panel connector: if they are not ok, restore; if they are ok, check continuity on the Brown/White: if not ok, restore; if ok, with the two connector disconnected, check the ground insulation: if there is ground continuity, disconnect the instrument panel connector as well, and if there is ground, restore the wiring harness and if there is no ground, replace the instrument panel;...
Page 176 RSV4 1100 Factory Electrical system The motor consists of a potentiometer for controlling the position and a DC electric motor. With the key set to ON, the valve self-cleaning is carried. In the event of a malfunction (electric or mechanical) the valve could stay stuck in the closed position. In the event of a CAN line malfunction the valve returns to the open position.
Page 177 RSV4 1100 Factory Electrical system • Check that the valve spring on the si- lencer is in its seat • Bring the two adjuster screws of the cables to zero, fully tightening them. CAUTION BRING BOTH NUTS OF THE TWO ADJUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE, WELDED TO THE SI- LENCER;...
Page 178 RSV4 1100 Factory Electrical system • Use the closing cable adjuster screw up to the value corresponding to the value "X" (see values in the table); CAUTION TURN THE ADJUSTER SCREW FULLY ANTI-CLOCKWISE (DIRECTION FOR TENSIONING THE ADJUSTER SCREW), KEEPING THE COUNTER-NUT STILL. DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS, SINCE THE AD- JUSTMENT IS DISTORTED DUE TO THE PLAY.
Page 179 RSV4 1100 Factory Electrical system • Use the opening cable adjuster screw up to the value corresponding to the value "Y" (see values in the table); CAUTION TURN THE ADJUSTER SCREW FULLY ANTI-CLOCKWISE (DIRECTION FOR TENSIONING THE ADJUSTER SCREW), KEEPING THE COUNTER-NUT STILL. DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS, SINCE THE AD- JUSTMENT IS DISTORTED DUE TO THE PLAY.
Page 180 Remove the front bodywork to access the connec- tor. Aprilia V4-MP Tecnology Sincronizzazione To use the system V4-MP the synchronisation that differs depending on the operating system must be performed: iOS OPERATING SYSTEM •...
Page 181 RSV4 1100 Factory Electrical system • Inside the "BlueTooth" page if Blue- Tooth is not active, to activate it press the button shown • BlueTooth active = Green button • Once BlueTooth is enabled, the smart- phone automatically searches devi- ces.
Page 182 RSV4 1100 Factory Electrical system • In the page settings click on the "Blue- Tooth" menu. • Inside the "BlueTooth" page if Blue- Tooth is not active, proceed to activate it by pressing the button indicated by the arrow BlueTooth active -> green button.
Page 183 RSV4 1100 Factory Electrical system TO MAINTAIN A SUCCESSFUL CONNECTION IT IS ESSENTIAL THAT THE KEY SWITCH IS IN THE "ON" POSITION BEFORE THE APP IS LAUNCHED CAUTION AFTER THE KEY IS OFF IT WILL BE NECESSARY TO WAIT FOR ABOUT 20 SECONDS TO EN- SURE THAT THE WIRELESS CONNECTION IS CLOSED.
Page 184 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 185 RSV4 1100 Factory Engine from vehicle Vehicle preparation To remove the engine from the chassis, previously perform the following operations: • Remove the fuel tank and the battery. • Remove the fairings, the side fairings, the internal fairings, the fairing lug and the oil radiator guard.
Page 186 RSV4 1100 Factory Engine from vehicle • Remove the spacer and the canister fixing screw. • Release the wiring harnesses from the cable gland connected on the rear part of the canister, disconnect the connec- tor of the right side electric fan and remove the safety clamp applied on the connector.
Page 187 RSV4 1100 Factory Engine from vehicle • Remove the spacer and the fixing screw of the exhaust valve motor. • Release the connector of the right side electric fan from the exhaust valve mo- tor support and disconnect it. • Release the connector of the demand sensor from the exhaust valve motor support and disconnect it.
Page 188 RSV4 1100 Factory Engine from vehicle • Remove the cable tie fastening the ca- ble of the demand sensor to the drain pipe of the expansion tank. • Remove the metal clamp and discon- nect the oil pipe from the sump. •...
Page 189 RSV4 1100 Factory Engine from vehicle • Move the metal clips along the pipe and disconnect the cooling system pipe from the pump and the connector pipe leading to the thermostat valve. • Remove the metal clamp and discon- nect the oil pipe from the coupling. •...
Page 190 RSV4 1100 Factory Engine from vehicle • On both sides of the vehicle, remove the two screws fastening the radiator to the mount. • Release the water radiator from the support on the left side and remove both radiators, by extracting them at the same time from the right side.
Page 191 RSV4 1100 Factory Engine from vehicle • Disconnect the engine oil pressure bulb connector. • Remove the ground leads fixing screw and release the wiring harnesses. • Move the wiring harness to the outside and fasten them using a circlip. •...
Page 192 RSV4 1100 Factory Engine from vehicle • Remove the clamp that fastens the cooling system's pipe to the starter mo- tor's wiring harness and the ground lead. • After having moved the protective cap and removed the fixing nut of the start- er motor power cable, release the wir- ing harness.
Page 193 RSV4 1100 Factory Engine from vehicle • Unscrew the three fastener screws of the front sprocket cover and remove the cover. • Disconnect the rear bank lambda probe connector and release it from its support. • Detach the springs and remove the centre exhaust manifold, easing it out from underneath.
Page 194 RSV4 1100 Factory Engine from vehicle • Unscrew the three screws of the chain guide and remove it together with the chain guide slider. • Remove the clamp that fastens the rear bank lambda probe wiring harness to the quick shift wiring harness and to the side stand switch wiring harness.
Page 195 RSV4 1100 Factory Engine from vehicle • Remove the screw fastening the en- gine mount to the frame and the three screws fastening the mount to the en- gine. • Remove the mount. • Unscrew the nuts fastening the rear headers and remove the headers, eas- ing out towards the rear.
Page 196 RSV4 1100 Factory Engine from vehicle • Partially free the ABS modulator mount from the rubber bush. • Remove the clamp that fastens the pipes of the ABS system to the metal plate. • Lifting the ABS modulator with the sup- port, extract the metal plate at the rear.
Page 197 RSV4 1100 Factory Engine from vehicle • Remove the internal cable gland on the right side of the vehicle to facilitate the engine removal. • Install the engine support and place a centre stand under it. Specific tooling 020864Y Engine support plate •...
Page 198 RSV4 1100 Factory Engine from vehicle • Disconnect the VEHICLE connector from the control unit and release the wiring harness from the cable glands. • Release the connector from the sup- port on the filter housing and discon- nect it. •...
Page 199 RSV4 1100 Factory Engine from vehicle CAUTION THE RIGHT REAR INSERTS (-5mm (-0.19 in)) AND THE LOWER LEFT REAR INSERT (-5mm (-0.19 in)), ARE EQUAL. • Check that the adjuster bushings on the right side of the chassis are com- pletely unscrewed.
Page 200 RSV4 1100 Factory Engine from vehicle • Place the ground lead that goes to the battery and lock it together with the wir- ing harnesses on the right side using a new clamp. • Insert the four front fixing screws together with the washers and the relative supports for mounting the side fairings, making sure to insert the special spacers only for the right side, and the lower pin, inserting it from the left side, together with the washer to align the engine.
Page 201 RSV4 1100 Factory Engine from vehicle • Remove the engine support and insert the rear bank manifolds equipped with new gaskets. • Insert the locking nuts and screw them partially to facilitate the subsequent op- erations for the assembly of the ex- haust system.
Page 202 RSV4 1100 Factory Engine from vehicle • Place the stand with the support and secure it with two screws with washers. • Place the drive chain on the sprocket. • Insert the sprocket on the secondary shaft and after having placed the "T" bush and the spring washer on the fix- ing screw, tighten the screw to the specified torque.
Page 203 RSV4 1100 Factory Engine from vehicle • Insert the chain guide slider together with the chain guide and fasten it with the three screws. • Refit the clamp that fastens the rear bank lambda probe wiring harness to the quick shift wiring harness and to the side stand switch wiring harness.
Page 204 RSV4 1100 Factory Engine from vehicle • Insert the gearbox lever on the primary shaft and tighten the stop screw to the specified torque. • Connect the clutch cable and, using the adjuster nuts, adjust the tension and check the play on the handlebar lever.
Page 205 RSV4 1100 Factory Engine from vehicle • Place the starter motor power cable, insert the washer and the nut and tight- en them to the specified torque. • Refit the rubber protection cover. • Refit the clamp that fastens the cooling system's pipe to the starter motor's wir- ing harness and the ground lead.
Page 206 RSV4 1100 Factory Engine from vehicle • Connect the ground leads and tighten the fixing screw to the specified torque. • Insert the front bank manifolds with new gaskets and connect them to the central manifold. • Insert the locking nuts and screw them partially to facilitate the subsequent op- erations for the assembly of the ex- haust system.
Page 207 RSV4 1100 Factory Engine from vehicle • Operating from both sides, insert and tighten the two screws used to fasten the radiator to the support. • Refit the wiring harnesses on the radi- ator support and secure them with a new clamp.
Page 208 RSV4 1100 Factory Engine from vehicle • Connect the cooling system pipe to the pump, the cross member that goes to the thermostatic valve and secure both of them using the metal clamps. • Insert the two fixing screws of the radi- ators support bracket and tighten them to the specified torque.
Page 209 RSV4 1100 Factory Engine from vehicle • Engage the connector of the demand sensor on the exhaust valve motor support. • Engage the connector of the right side electric fan on the exhaust valve motor support. • Insert the two exhaust valve motor sup- port fixing screws and tighten them to the specified torque.
Page 210 RSV4 1100 Factory Engine from vehicle • Insert the wiring harnesses in the cable gland connected on the rear side of the canister, connect the left electric fan connector and secure it with a new clamp. • Connect the connector of the left side electric fan on the canister support.
Page 211 RSV4 1100 Factory Engine from vehicle • Insert the coolant discharge screw fit- ted with a new seal gasket and tighten it to the specified torque. • First fit a clamp on the metal plate and insert it under the ABS modulator sup- port as shown.
Page 212 RSV4 1100 Factory Engine from vehicle • Tighten the clamp that fastens the pipes of the ABS system. • Connect the chassis architecture/en- gine power supply connector and en- gage it in the support on the filter housing. • Insert the main wiring harness in the cable glands and connect the VEHI- CLE connector to the control unit.
Page 213 INDEX OF TOPICS NGINE...
Page 214 RSV4 1100 Factory Engine key: 1. rear left cylinder; 2. front left cylinder; 3. rear right cylinder; 4. front right cylinder. Combustion sequence: 1 - 3 - 2 - 4 Combustion angle: cyl 1: 0° cyl 2: 180° cyl 3: 425° cyl 4: 605°...
Page 215 RSV4 1100 Factory Engine Gearbox EARBOX Pos. Description Type Quantity Torque Notes "Philips" cylindrical head hex. socket M6x20 10 Nm (7.38 lbf ft) Pre-coated screw - screw if not pre-coated, apply 3M SCOTCH GRIP 2353 to thread Pre-coated countersunk flat head M6x16 10 Nm (7.38 lbf ft) Pre-coated screw -...
Page 216 RSV4 1100 Factory Engine Diagram Key: 1. Primary shaft 2. Fifth speed gear on primary shaft 3. Roller bearing cage for fifth speed gear on primary shaft 4. Shoulder washer 5. Ring 6. Third-fourth speed gear on primary shaft 7. Ring 8.
Page 217 RSV4 1100 Factory Engine 20.Spring washer 21.T-shaped bushing 22.Second speed gear on secondary shaft 23.Roller bearing cage for second speed gear on secondary shaft 24.Washer 25.Seeger ring 26.Sixth speed gear on secondary shaft 27.Seeger ring 28.Shoulder washer 29.Roller bearing cage for third speed gear on secondary shaft 30.Third speed gear on secondary shaft 31.Fourth speed gear on secondary shaft 32.Roller bearing cage for fourth speed gear on secondary shaft...
Page 218 RSV4 1100 Factory Engine Gearbox Removing the gearbox • Remove the gearbox selector. • Remove the clutch housing. • Remove the gear sensor from the flywheel side. • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch...
Page 219 RSV4 1100 Factory Engine • Unscrew and remove the six screws. • 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 220 RSV4 1100 Factory Engine • Remove the fork (2) of the gearbox pri- mary shaft • Slide off the gearbox secondary shaft control rod (3) • Remove the forks (4) of the gearbox secondary shaft • Remove both gearbox shafts from the cover ENG - 220...
Page 221 RSV4 1100 Factory Engine • Remove the shim washer (5) that is lo- cated on the secondary shaft between the shaft and the cover • Loosen and remove the screw (6) • Remove the desmodromic shaft (7) • Remove the selector drum (8) ENG - 221...
Page 222 RSV4 1100 Factory Engine DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE, ALTERNATOR SIDE • Remove the lower crankcase. • A suitable extractor must be used to remove the desmodromic gearbox control rod drum roller cage from the alternator side. • A specific punch is required to install the desmodromic gearbox control rod drum roller cage.
Page 223 RSV4 1100 Factory Engine Checking the secondary shaft Characteristic Maximum wear limit for selector gear splines 5.3 mm (0.21 in) Minimum wear limit of the pinion side secon- dary shaft seat 29.97 mm (1.18 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in) Checking the desmodromic drum...
Page 224 RSV4 1100 Factory Engine • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary. • Check the gearbox fork's movement, and replace the gearbox forks if it is irregular. Assembling the gearbox •...
Page 225 RSV4 1100 Factory Engine • Move the gearbox shafts together and fit them into the support • Grease the sliding bushes of the forks • Insert the forks (5) in the specific seats of the gearbox secondary shaft • Insert the gearbox secondary shaft control rod (6) checking the presence of the springs ENG - 225...
Page 226 RSV4 1100 Factory Engine • Insert the fork (7) in the specific seat of the gearbox primary shaft • Insert the gearbox primary shaft con- trol rod (8) • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal.
Page 227 RSV4 1100 Factory Engine • Remove the special tool from the alter- nator side. • Tighten the six screws that fasten the gearbox unit to the crankcase. Specific tooling 0277308 Guide bushing for gearbox secondary shaft • Insert the driving pin on the oil pump shaft.
Page 228 RSV4 1100 Factory Engine GEARBOX CONTROL ROD ROLLER CAGE, CLUTCH SIDE • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side. Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod •...
Page 229 RSV4 1100 Factory Engine Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely. If necessary, replace the parts. Check the gear selector spring for damage and wear. If necessary, replace the part. Check the selector shaft and its teeth for damage and wear.
Page 230 RSV4 1100 Factory Engine • Remove the starter motor (3) from its housing. Removing the idle gear • Remove the clutch cover. • Remove the intermediate gear. Start-up system check IF THE DOUBLE STARTING GEAR TOOTHING IS DEFORMED, IT IS NECESSARY TO ALSO CHECK THE TOOTHING OF THE STARTING MOTOR.
Page 231 RSV4 1100 Factory Engine If deformations or broken material are found on the sliding surface, replace the freewheel gear (2). Check the freewheel sliding surface (2) for wear. Make sure that the woodruff key slot is in perfect condition. Remove the needle cage (3) and the roller cage (4) from their housings on the freewheel (2) and check the rollers/needles for wear.
Page 232 RSV4 1100 Factory Engine • Fit the intermediate gear. • Install the clutch cover. Generator side ENERATOR COVER Pos. Description Type Quantity Torque Notes Cover fastening screws M6x25 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque. Cover fastening screws M6x40 12 Nm (8.85 lbf ft)
Page 233 RSV4 1100 Factory Engine Removing the flywheel cover • Unscrew and remove the three fasten- ing screws (1) from the soundproofing cover (2). • Remove the soundproofing cover (2). • Working from the underside of the filter box, release the retainer clip and dis- connect the blow-by pipe.
Page 234 RSV4 1100 Factory Engine Removing the flywheel cover components • Unscrew and remove the three screws of the blow-by system connector. • Remove the Blow-by system fitting. • Remove the O-ring. USE A NEW O-RING WHEN REASSEMBLING • Remove the seeger ring. •...
Page 235 RSV4 1100 Factory Engine • Remove the oil seal. CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE. FIT THE NEW OIL SEAL AS INDICATED. Magneto flywheel removal • Remove the flywheel cover. • Block flywheel rotation using the spe- cific tool.
Page 236 RSV4 1100 Factory Engine Removing the flywheel cover Removing the stator To proceed with the removal of the stator, proceed as described: • Remove the three fastener screws of the stator • Remove the two fastener screws of the pickup. •...
Page 237 RSV4 1100 Factory Engine Rimozione ingranaggio ruota libera In order to remove the countershaft drive gear, complete with freewheel, the complete clutch must be removed beforehand. Then proceed as described: • Fit the special primary gear lock tool Specific tooling 020850Y Primary gear lock •...
Page 238 RSV4 1100 Factory Engine Flywheel components check - Check that the magnets are in good conditions. - Check that the magnet support cage is not deformed or broken. Checking the starter clutch Remove the free wheel from its housing and check the rollers for signs of wear. Check if the outer spring is sufficiently preloaded to hold the rollers in place.
Page 239 RSV4 1100 Factory Engine Flywheel cover components installation Fit a new oil seal if the original oil seal was re- moved during disassembly. Use a suitable punch tool to install. • Lubricate the inner part of the oil seal and fit onto the cover, oriented correct- ly as shown.
Page 240 RSV4 1100 Factory Engine • Replace the O-ring with a new one of the same type. • Fit the connector of the blow-by sys- tem. • Fit the three screws of the blow-by sys- tem connector and tighten to the speci- fied torque.
Page 241 RSV4 1100 Factory Engine • Position the soundproofing cover and lock it in place using the three appro- priate screws • Working from the underside of the filter box, connect the blow-by pipe and se- cure the pipe with a new retainer clip. Use a new metal clamp if the blow-by pipe was disconnected from the fitting on the cover dur- ing disassembly.
Page 242 RSV4 1100 Factory Engine Pos. Description Type Quantity Torque Notes Flanged hex cap screw M6x35 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque. Flanged hex cap screw M6x22 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque.
Page 243 RSV4 1100 Factory Engine • Unscrew and remove the engine oil dipstick. • Unscrew and remove the five special screws (3) and the eleven fastening screws (4) around the perimeter, and retrieve the relative washers. • Remove the clutch crankcase. •...
Page 244 RSV4 1100 Factory Engine • Remove the thrust plate and the com- plete control rod. • Remove the discs. • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch hous- ing fixing nut. Specific tooling 020849Y Clutch retainer tool •...
Page 245 RSV4 1100 Factory Engine • Remove the clutch hub. • Remove the clutch hub cam tower. • Remove the washer. • Remove the clutch bell. ENG - 245...
Page 246 RSV4 1100 Factory Engine • Remove the clutch gear that controls the oil/water pumps. • Remove the needle cage. • Remove the spacer. • Remove the thrust bearing. ENG - 246...
Page 247 RSV4 1100 Factory Engine Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in) Minimum wear limit of the complete clutch pack thickness (friction discs + steel discs) 47.6 mm (1.87 in) Checking the clutch housing...
Page 248 RSV4 1100 Factory Engine Characteristic Maximum deformation permitted on the thrust plate compression surface 0.15 mm (0.0059 in) Maximum depth of the thrust plate 27.3 mm (1.07 in) Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation.
Page 249 RSV4 1100 Factory Engine Assembling the clutch • Insert the thrust bearing with the collar facing the gearbox. • Insert the spacer. • Insert the roller cage. • Install the clutch gear, making it mesh with the oil/water pump control gear. TURN THE CLUTCH GEAR COLLAR TO FACE THE CLUTCH HOUSING.
Page 250 RSV4 1100 Factory Engine • Insert the clutch bell, making it engage with the engine pinion. • Insert the washer. • Install the clutch hub cam tower. • Position the clutch hub. INSTALL THE THREE CLUTCH HUB CAMS IN THE RE- SPECTIVE CLUTCH BASKET INCLINES.
Page 251 RSV4 1100 Factory Engine • Fit the cup spring washer and the two washers. • Block clutch housing rotation using the appropriate tool. • Tighten the clutch housing fixing nut. Specific tooling 020849Y Clutch retainer tool • Insert the disc with friction material and the black tooth into the bell.
Page 252 RSV4 1100 Factory Engine • Insert the flat washer. • Insert the spring washer with the con- cave side facing out. • Insert the disc covered with friction ma- terial into the housing. • Insert the nitrided metal disc into the clutch housing.
Page 253 RSV4 1100 Factory Engine • Continue inserting, alternating a metal disc with one with friction material, end- ing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer. •...
Page 254 RSV4 1100 Factory Engine • Fit the clutch springs (3). • Insert the spring holder cap (2) onto the screws (1). • Tighten the six screws working in stages and diagonally. Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING •...
Page 255 RSV4 1100 Factory Engine INSTALLING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the installation of the bushing, it is necessary to warm up the cover. • Position the guide (1) to insert the bushing (2) as indicated in the figure. •...
Page 256 RSV4 1100 Factory Engine • Fit and tighten the engine oil dipstick. • Fit the soundproofing cover (7), fit the five fastener screws (8) and then tight- en the screws to the specified torque. • Fill with engine oil to the correct level. Heads ALVES COVER Pos.
Page 257 RSV4 1100 Factory Engine Pos. Description Type Quantity Torque Notes TE flanged coil fixing screw M6x12 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft) EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Cam shaft cam tower fixing screws M6x45...
Page 258 RSV4 1100 Factory Engine IMING SYSTEM Pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Chain tensioner sliders fastening 20 Nm (14.75 lb ft) Loct. 243 screws Chain guide sliders fixing screws M6x18...
Page 259 RSV4 1100 Factory Engine • Remove the head cover together with the sealing gasket INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure. Recommended products Three bond Sealing paste •...
Page 260 RSV4 1100 Factory Engine Removing camshafts To remove the camshafts of the front head, follow the procedure described below: • Remove both cylinder head covers, the soundproofing covers, the alternator side cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC.
Page 261 RSV4 1100 Factory Engine • Loosen the second screw of the cam- shaft drive sprocket. • Remove the pin from the camshaft drive sprocket. • Unscrew and remove the three screws (1) and remove the bearing cap (2) and the oil pipe (3). •...
Page 262 RSV4 1100 Factory Engine • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer. • Unscrew the seven screws in progres- sive steps in a criss-cross pattern and remove.
Page 263 RSV4 1100 Factory Engine • Fasten the camshaft horizontally, 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/ outlet) 0.3-0.1 mm (0.012-0.004 in) Check the timing chain for damage or stiffness while moving.
Page 264 RSV4 1100 Factory Engine • Fit the bearing caps complete with O- rings and alignment, and fit and hand- tighten the seven screws indicated. Use new copper washers on the four screws near the spark plug holes. • Loosen the camshaft sprocket lock screw on the tool.
Page 265 RSV4 1100 Factory Engine • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin. • Tighten the first fastener screw of the camshaft sprocket to the specified tor- que. Specific tooling 020851Y Camshaft timing pin •...
Page 266 RSV4 1100 Factory Engine Front head removal In order to remove the front head, the procedures described in the paragraph "Removing the cam- shafts " (front head) must be performed beforehand. Then proceed as described: • Unscrew and remove the chain sliders' screws.
Page 267 RSV4 1100 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. Specific tooling 020883Y Fitting/removing timing chain ten- sioner tool...
Page 268 RSV4 1100 Factory Engine • 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 269 RSV4 1100 Factory Engine • Place a new gasket between the crank- case and the head. • Position the two centring pins. • Fit the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6.
Page 270 RSV4 1100 Factory Engine • Install the intake and exhaust cam- shafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake cam- shaft gear (indicated with two dots). CLEAN THOROUGHLY THE SEATS OF THE GEAR RE- TAINER SCREWS, ON THE INTAKE CAMSHAFT.
Page 271 RSV4 1100 Factory Engine • Install the chain shoe and the chain guide shoe, fastening with the relative screws. • Install the chain complete with timing sprocket, fitting the chain and sprocket onto the camshaft. • Turn the crankshaft in the direction of rotation of the engine (towards front) to bring the piston of cylinder 1 (left hand rear piston) to TDC in the valve overlap...
Page 272 RSV4 1100 Factory Engine • Load the chain tensioner with special tool. Specific tooling 020981Y Lever for disarming the hydraulic ten- sioner of the timing chain • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 273 RSV4 1100 Factory Engine Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; insert the reference pin while checking with the crankshaft reference pin, that the flywheel side hole and the hole on the crankshaft are perfectly aligned.
Page 274 RSV4 1100 Factory Engine • Continue rotating the crankshaft in the direction of rotation of the engine to complete one full turn + 90° (450° in total) relative to the starting position in the previous step. • Insert the pin from the flywheel side in- to the hole in the crankshaft.
Page 275 RSV4 1100 Factory Engine • Remove the second screw of the cam- shaft drive sprocket. CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM- SHAFT. • Install the specific camshaft gear sup- port tool. •...
Page 276 RSV4 1100 Factory Engine • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots). Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK •...
Page 277 RSV4 1100 Factory Engine Installing camshafts NOTE THE INTAKE AND EXHAUST CAMSHAFTS ARE BOTH DEDICATED FOR THE FRONT AND REAR CYLINDER BANKS. NOTE THE INTAKE AND EXHAUST CAMSHAFTS OF THE REAR CYLINDER BANK ARE IDENTIFIED BY A SINGLE LINE IN THE POSITIONS INDICATED.
Page 278 RSV4 1100 Factory Engine • Remove the tool for holding the cam- shaft drive sprocket gear on the head. • Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand-tighten the screw only. • Fit the bearing cap, the oil pipe and the three fastener screws.
Page 279 RSV4 1100 Factory Engine • Continue rotating the crankshaft (in di- rection of rotation of engine) to bring it back to the previous position in which the holes in the camshaft and the bear- ing cap were aligned; insert the refer- ence pin while checking with the crank- shaft reference pin, that the flywheel side hole and the hole on the crank-...
Page 280 RSV4 1100 Factory Engine • Loosen the six nuts on the stud bolts, proceeding in the following order: 6 - 5 - 4 - 3 - 2 - 1. • After loosening all nuts, remove them in order indicated above. •...
Page 281 RSV4 1100 Factory Engine • The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal. • Check the status of the valve seats. • Check that the routing of the oil pipes is free and if required, clean them by blowing a jet of compressed air.
Page 282 RSV4 1100 Factory Engine • Place a new gasket between the crank- case and the head. • Position the two centring pins. • Fit the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6.
Page 283 RSV4 1100 Factory Engine • Install the intake and exhaust cam- shafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake cam- shaft gear (indicated with two dots). CLEAN THOROUGHLY THE SEATS OF THE GEAR RE- TAINER SCREWS, ON THE INTAKE CAMSHAFT.
Page 284 RSV4 1100 Factory Engine • Install the chain shoe and the chain guide shoe, fastening with the relative screws. • Install the chain complete with timing sprocket, fitting the chain and sprocket onto the camshaft. • Turn the crankshaft in the direction of rotation of the engine (towards front) to bring the piston of cylinder 1 (left hand rear piston) to TDC in the valve overlap...
Page 285 RSV4 1100 Factory Engine • Load the chain tensioner with special tool. Specific tooling 020981Y Lever for disarming the hydraulic ten- sioner of the timing chain • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 286 RSV4 1100 Factory Engine Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; Refit the reference pin while checking, using the crankshaft reference pin, that the clutch side hole and the hole in the crankshaft are perfectly aligned.
Page 287 RSV4 1100 Factory Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal •...
Page 288 RSV4 1100 Factory Engine • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL. VALVE STEM DEVIATION Lift up the valve approx.
Page 289 RSV4 1100 Factory Engine Support the valve with two "V" blocks as shown and check the run-out with a dial gauge. If the run-out exceeds the specified limit, replace the valve. Characteristic Valve stem run-out 0.05 mm (0.0020 in) Position the dial gauge at a right angle to the valve head face and measure the eccentricity.
Page 290 RSV4 1100 Factory Engine • 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 CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING.
Page 291 RSV4 1100 Factory Engine • Release the wrench, checking that the cotters are positioned correctly in the valve grooves. • Position the adjusting shims • Position the bucket tappets. ENG - 291...
Page 292 RSV4 1100 Factory Engine Crankcase RANKCASE Pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lbf ft) Loct. 270 Flanged hex cap screw M8x70 25 Nm (18.44 lbf ft) Lubricate the head and under the head. Flanged hex cap screw M6x50 10 Nm (7.38 lbf ft) Lubricate the head...
Page 293 RSV4 1100 Factory Engine Pos. Description Type Quantity Torque Notes tion for another 60° +/- 2 Screw fastening ground cable to the 6 Nm (4.43 lbf ft) engine GNITION UNIT Pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lbf ft) Loct.
Page 294 RSV4 1100 Factory Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lbf ft) + 130° and under head with PANKL Lubricant 01 (PLB01) Primary fixing ring nut 200 Nm (147.51 lbf ft) Loct.
Page 295 RSV4 1100 Factory Engine • Unscrew the fastener nut of the pri- mary gear and the fastener nut of the countershaft drive gear. • Remove the lock tool and remove the primary gear. Specific tooling 020850Y Primary gear lock • Remove the washer and remove the countershaft drive gear/freewheel gear, taking care not to let the key drop...
Page 296 RSV4 1100 Factory Engine • Remove the countershaft from the al- ternator side. • Collect the spacer. Balancing countershaft fitting To install the balancer countershaft, follow the pro- cedure described below: • Fit the balancer countershaft into the casing from the flywheel side. •...
Page 297 RSV4 1100 Factory Engine • Fit the primary gear, aligning the mark- ings on both gears correctly as shown. • Rotate the countershaft to align the slot on the shaft itself with the slot in the countershaft drive gear and permit in- stallation of the key.
Page 298 RSV4 1100 Factory Engine Main transmission gear removal In order to remove the primary gear, the clutch cover, alternator cover and complete clutch must be removed beforehand. Then proceed as described: • Fit the special primary gear lock tool Specific tooling 020850Y Primary gear lock •...
Page 299 RSV4 1100 Factory Engine • Fit the retainer tool, fit the nut and then tighten the nut to the specified torque. Specific tooling 020850Y Primary gear lock Preparation To open the crankcase, first remove the following components: • alternator; • water pump;...
Page 300 RSV4 1100 Factory Engine Crankcase opening • Position the engine with the heads fac- ing upward, unscrew and remove the screw (24). • 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 301 RSV4 1100 Factory Engine • Separate the crankcases, removing the lower part • Collect the three dowel pins. • The crankshaft, the pistons and the connecting rods remain in the upper crankcase. Removing connecting rods - pistons • Remove both heads. •...
Page 302 RSV4 1100 Factory Engine • Slide off the pin See also Front head removal Rear head removal 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 303 RSV4 1100 Factory Engine • Take out the crankshaft. Bearing removal BALANCING COUNTERSHAFT BEARING RE- MOVAL • Remove the lower crankcase. • Remove the countershaft. FLYWHEEL-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302°...
Page 304 RSV4 1100 Factory Engine • Heat up the crankcase to 150°C (302° • Position the general tool to pull out bearings. • Remove the bearing. See also Crankcase opening Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0.40 - 0.10 mm (0.0157 - 0.0039 in) Maximum radial play between main bushings and crankpins...
Page 305 RSV4 1100 Factory Engine Connecting rod check Characteristic Maximum wear limit of the connecting rod small end 17.03 mm (0.6705 in) Maximum connecting rod small end radial clearance 0.045 mm (0.0018 in) Maximum radial play between connecting rod and crankpin 0.55 mm (0.022 in) Maximum radial play of crankpin 0.08 mm (0.0031 in)
Page 306 RSV4 1100 Factory Engine crankshafts and connecting rods have been intro- duced which are matched with each other in rela- tion to their balancing class. The class is easily identifiable as it is marked on the component itself. The permitted crankshaft-connecting rod balancing class combinations are listed in the following table: CRANKSHAFT - CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Combinations of weight classes for...
Page 307 RSV4 1100 Factory Engine The connecting rod class is stamped on its left side, viewed from the front, from the side with the bevelling on the big end hole. Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings.
Page 308 RSV4 1100 Factory Engine RANKCASE CATEGORY Specification Desc./Quantity Class A Bushing seat diameter 52.023 - 52.018 mm (2.0481 - 2.0479 Class B Bushing seat diameter 52.018 - 52.013 mm (2.0479 - 2.0477 Class C Bushing seat diameter 52.013 - 52.008 mm (2.0477 - 2.0475 SHAFT CATEGORY The category of the three crankshaft main journals is stamped on the flat face of the counterweight,...
Page 309 RSV4 1100 Factory Engine CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available for the connecting rods: • Blue • Yellow • Green For the coupling of the connecting rod with the crankshaft, according to the engraving on the counter- weights, observe the following table: ENG - 309...
Page 310 RSV4 1100 Factory Engine USHINGS THICKNESS Bushing colours Thickness BLUE 1.547 - 1.552 mm YELLOW 1.552 - 1.557 mm GREEN 1.557 - 1.562 mm ONNECTING RODS COUPLING RANKSHAFT Selection connecting Big end class 1 Big end class 2 Required clearances Required clearances rod pin dimension class 1...
Page 311 RSV4 1100 Factory Engine 020364Y 25 mm adapter 020359Y 42 x 47 mm punch 020376Y Adaptor handle • Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase. In this way it will be possible to install the bearing retainer in the groove.
Page 312 RSV4 1100 Factory Engine • Position the new bearings with their groove on the outside diameter facing outward with respect to the crankcase. In this way it will be possible to install the bearing retainer in the groove. • Using the suitable tools, fit the bearing in the crankcase until tool stops.
Page 313 RSV4 1100 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 Maintenance of the pistons in the cyl- inders •...
Page 314 RSV4 1100 Factory Engine The five ring gaps (two piston rings, two oil scraper rings, one oil scraper spring) are fitted displaced 90º to each other, starting from the exhaust-side stud bolt opposite the chain and continuing clock- wise. The fitted pistons have two selections A and B. Therefore they are coupled with the cylinder ac- cording to the selection of the latter, which is marked on the upper crankcase halves.
Page 315 RSV4 1100 Factory Engine ling on the connecting rod head must face outward of its crank pin. Specific tooling 020980Y Piston assembly ring • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces.
Page 316 RSV4 1100 Factory Engine • Insert the maximum pressure valve in the crankcase, composed of two sep- arate parts • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste •...
Page 317 RSV4 1100 Factory Engine • Then tighten them fully following the same order. • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 317...
Page 318 RSV4 1100 Factory Engine Lubrication UBRICATION Pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.13 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque.
Page 319 RSV4 1100 Factory Engine RANKCASE Pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lbf ft) Loct. 270 Flanged hex cap screw M8x70 25 Nm (18.44 lbf ft) Lubricate the head and under the head. Flanged hex cap screw M6x50 10 Nm (7.38 lbf ft) Lubricate the head...
Page 320 RSV4 1100 Factory Engine Pos. Description Type Quantity Torque Notes Screw fastening ground cable to the 6 Nm (4.43 lbf ft) engine COOLING JETS The motor is fitted with lubrication jets whose function is to increase the efficacy of the oil cooling circuit at two specific points: 1.
Page 321 RSV4 1100 Factory Engine Removing • Remove the gearbox. • Remove the water pump. • Unscrew and remove the six screws fastening the oil pump to the crank- case. • Remove the oil pumps. OIL PUMP REMOVAL • Place the oil pumps on a work table. •...
Page 322 RSV4 1100 Factory Engine • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor. • Collect the hitch pin. • Unscrew and remove the four lubrica- tion oil pump cover screws.
Page 323 RSV4 1100 Factory Engine • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle. Installing • Position the lubrication pump internal rotor on the oil pump control shaft The lubrication pump components are larger than the cooling pump components.
Page 324 RSV4 1100 Factory Engine • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat. •...
Page 325 RSV4 1100 Factory Engine • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor. • Tighten the four cooling oil pump cover screws. • Fit a new gasket. Removing the oil sump •...
Page 326 RSV4 1100 Factory Engine • Remove the oil sump • Remove the upper gasket • Remove the rose pipe together with the gasket CAUTION THE ROSE PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER- HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL.
Page 327 RSV4 1100 Factory Engine • Remove the metal gasket • Remove the lower gasket • Remove the overpressure valve together with gasket Blow-by The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid.
Page 328 RSV4 1100 Factory Engine SAS valve ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket secon- M6x16 10 Nm (7.38 lbf ft) dary air solenoid screws Diagram Valve controlled by control unit which delivers as- pirated air from the filter box to the exhaust mani- folds.
Page 329 RSV4 1100 Factory Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 329...
Page 330 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 331 RSV4 1100 Factory Power supply Circuit diagram FUEL SYSTEM LAYOUT Key: 1. Lower injectors on the rear throttle body 2. Lower injectors on the front throttle body 3. Connection 4. Upper injector on the rear of the filter casing 5. Upper injector on the front of the filter casing 6.
Page 332 RSV4 1100 Factory Power supply 11.Engine EVAPORATIVE EMISSIONS CONTROL SYSTEM LAYOUT Key: 1. Connection 2. Purge valve 3. ECU 4. "T" connection 5. Lower injectors on the rear throttle body 6. Lower injectors on the front throttle body 7. Fuel tank 8.
Page 333 RSV4 1100 Factory Power supply Fuel pump Removing In order to remove the fuel pump, the tank must be removed from the vehicle beforehand. Then pro- ceed as described: • To facilitate removal of the fuel pump, remove the mount by unscrewing the fastener screw.
Page 334 RSV4 1100 Factory Power supply • Ease out the pump, taking particular care not to damage the pump. Injection P SUPP - 334...
Page 335 RSV4 1100 Factory Power supply Diagram Key: 1. Electronic suspension control unit (where applicable) 2. Demand sensor 3. Exhaust valve motor 4. ECU P SUPP - 335...
Page 336 RSV4 1100 Factory Power supply 5. Inertia platform 6. ABS control unit 7. Diagnostic connector (OBD II) 8. Clutch position sensor 9. Fuel pump (inside the tank) 10.air temperature sensor 11.Air pressure sensors (MAP) 12.Lower injectors 13.Coils (spark plug cover) 14.Engine throttle valve / Throttle valve position sensor 15.Electric fan 16.Starter motor...
Page 337 RSV4 1100 Factory Power supply Removing the injector To optimise engine performance, there are four lower injectors on the throttle bodies and four up- per injectors on the filter box. Except during tran- sition stages, only the lower or the upper injectors are working at any given time.
Page 338 RSV4 1100 Factory Power supply • Remove the four injectors from the fil- ter box and disconnect the connectors. LOWER INJECTORS DO NOT REMOVE THE LOWER INJECTORS Only the fuel pipe of the lower injectors may be removed; in order to remove the pipe, the com- plete filter box must be removed beforehand.
Page 339 RSV4 1100 Factory Power supply • Disconnect the lower injector connec- tors. • Disconnect the connector. • Remove the complete throttle body. See also Air box Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction.
Page 340 RSV4 1100 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 341 INDEX OF TOPICS SUSP USPENSIONS...
Page 342 RSV4 1100 Factory Suspensions Front Handlebar ANDLEBAR AND CONTROLS Pos. Description Type Quantity Torque Notes Screws for fastening the handlebar 1 + 1 25 Nm (18.44 lbf ft) collar to the forks sleeves Handlebar safety screw 10 Nm (7.38 lbf ft) Anti-vibration counterweight fastener M18x1.5 20 Nm (14.75 lbf ft)
Page 343 RSV4 1100 Factory Suspensions LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lbf ft) RONT BRAKE MASTER CYLINDER Pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket SUSP - 343...
Page 344 RSV4 1100 Factory Suspensions Pos. Description Type Quantity Torque Notes Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Front brake pump U bolt clamp 10 Nm (7.38 lbf ft) Front brake lever pin fixing screw 10 Nm (7.38 lbf ft) Screw used to fasten the brake pipe 8 Nm (5.90 lbf ft)
Page 345 RSV4 1100 Factory Suspensions (RSV4 1100) RONT FORK ACHS Pos. Description Type Quantity Torque Notes Calliper bracket fixing screws 12 Nm (8.85 lbf ft) (Sachs) Speed sensor fastening screw 6 Nm (4.43 lbf ft) Upper cap 20 Nm (14.75 lbf ft) Upper cap locking nut 20 Nm (14.75 lbf ft) Adjustment...
Page 346 2 notches/ 8 mm (2 notches/0.31 in) (*) - Clockwise (**) - Anticlockwise (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. RSV4 1100 Factory (Ohlins fork - ASC) • Refer to the USE AND MAINTENANCE BOOKLET, paragraph "ADVANCED FUNCTIONS"...
Page 347 RSV4 1100 Factory Suspensions • To adjust the spring pre-load, discon- nect the connector (1) from the elec- tronic forks to be able to reach the adjustment nut (2) located on the cap. TO AVOID DAMAGING THE CONNECTOR, PRESS THE TAB (3) ON THE INDICATED POINT AND THEN CAREFUL- LY REMOVE THE CONNECTOR.
Page 348 • Stems (A) (***) protrusion from top plate: 3 notches (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. Removing the fork legs To remove the stanchions, place the motorcycle on suitable support stands, disconnect the front brake callipers and remove the mudguard, the front wheel, the side fairings and the air ducts.
Page 349 RSV4 1100 Factory Suspensions • While supporting the stanchion, loosen the screw on the top plate. • Extract and remove the stanchion. • During reassembly, pay attention to the adjustment of the stanchion protrusion, referring to the "Adjustment" paragraph in the "Suspensions" chapter. Draining oil RSV4 1100 FACTORY (OHLINS - ASC) NOTE...
Page 350 RSV4 1100 Factory Suspensions • Unscrew the upper cap from the sleeve using a specific Öhlins tool. Specific tooling 01761-04 Ohlins fork cap ring nut • Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring.
Page 351 RSV4 1100 Factory Suspensions • Remove the pre-loading spring retain- ing ring. • Remove the pre-loading spring. • Empty the fork oil into a special con- tainer, taking care not to let the pre- loading tube come out. RSV4 1100 (SACHS - NO ASC) NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS.
Page 352 RSV4 1100 Factory Suspensions • Operating on the upper screw, unload the spring. • Loosen the cover without unscrewing it completely. • Place the fork vertically locking it in a vice by the specific tool. • Completely unscrew the plug. Specific tooling AP8140149 Guard for assembly operations •...
Page 353 RSV4 1100 Factory Suspensions • Unscrew the cap and remove it. • Remove the spring preload pipe. • Remove the lock nut and the washer. • Remove the spring paying attention to drain the oil correctly. SUSP - 353...
Page 354 RSV4 1100 Factory Suspensions • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 355 RSV4 1100 Factory Suspensions • Remove the retaining ring (4). • Remove the shaft seal (5) by levering it alternately at various points. CAUTION PROTECT THE EDGE OF THE SLEEVE IN ORDER TO AVOID RUINING IT WHILE REMOVING THE SHAFT SEAL (5).
Page 356 RSV4 1100 Factory Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim. • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. •...
Page 357 RSV4 1100 Factory Suspensions • Using a hook spanner lock the pump- ing member pin. • Remove the stem bottom screw. Specific tooling 020889Y Wrench for locking pumping unit ring • Remove the pumping member pin. Checking the components RSV4 1100 FACTORY (OHLINS - ASC) NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS ELECTRONIC FORKS.
Page 358 RSV4 1100 Factory Suspensions RSV4 1100 (SACHS - NO ASC) NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS. stanchion Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1). If the scratches are deep, replace the stanchion .
Page 359 RSV4 1100 Factory Suspensions CAUTION REMOVE ANY IMPURITIES FROM THE BUSHINGS, BEING CAREFUL NOT TO SCRATCH THEIR SURFACES. Reassembling the fork RSV4 1100 FACTORY (OHLINS - ASC) NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS ELECTRONIC FORKS. • Install the following components on the wheel holder stanchion (1) in the order given: dust gaiter (3), retainer ring (4) and oil seal (5).
Page 360 RSV4 1100 Factory Suspensions • Insert the retaining ring (4) into its housing on the sleeve (2). • Position the two halves of the special tool on the shaft behind anti-dust seal (3), together with the respective buffer. • Grip the special tool and push the anti- dust seal (3) into its housing on the sleeve (2).
Page 361 RSV4 1100 Factory Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole...
Page 362 RSV4 1100 Factory Suspensions • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight • Insert the pumping member pin in the stem. • Using a hook spanner lock the pump- ing member pin and tighten the fixing screw on the fork end to the prescribed...
Page 363 RSV4 1100 Factory Suspensions • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS.
Page 364 RSV4 1100 Factory Suspensions • Position the ring nut on the preload spring and keeping it compressed, screw the lock nut on the pumping el- ement • Tighten the nut as much as possible. • Insert the cover and tighten until it stops.
Page 365 RSV4 1100 Factory Suspensions • Pour the remaining oil. • Pump out oil a few times. • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
Page 366 RSV4 1100 Factory Suspensions • Insert the nut on the plunger and hand tighten it • Position the pre-loading tube. • Screw the special tool onto the plunger shaft and maintain it in the raised po- sition as long as possible, in order to insert a wrench on the nut, while com- pressing the spring.
Page 367 RSV4 1100 Factory Suspensions THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS. The RSV4 1100 version is fitted with a non-adjustable steering damper. No adjustments can be carried out. Removing RSV4 1100 FACTORY (OHLINS - ASC) NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR THE OHLINS ELECTRONIC STEERING DAMPER.
Page 368 RSV4 1100 Factory Suspensions Steering bearing TEERING Pos. Description Type Quantity Torque Notes Upper plate stem fastening screws 25 Nm (18.44 lbf ft) Lower plate stem fastening screws 25 Nm (18.44 lbf ft) Headstock ring nut - pre-tightening M35x1 70 Nm (51.63 lb ft) Unscrew after pre- tightening Headstock ring nut - tightening...
Page 369 RSV4 1100 Factory Suspensions Adjusting play • Place the vehicle so that the front wheel is off the ground. • Carry out a handlebar rotation test, using a dynamometer at the hand grip external end. • The handlebar resistance to rotation must be of 450 (+250 / -100 g) (0.88 +0.55 / -0.22 lb) in both directions.
Page 370 RSV4 1100 Factory Suspensions • Working from both sides, unscrew and remove the semi-handlebar screws. • If necessary, remove the wiring har- ness fixed in the part below in order to remove the steering plate. (where re- quired). • Rivet the safety washer on the head- stock.
Page 371 RSV4 1100 Factory Suspensions • Tighten the lower lock ring to a torque of 70 Nm (51.63 lb ft). • Steer repeatedly completely left and completely right to allow the bearings to settle. • Loosen the ring nut. • Retighten the lock ring to the prescri- bed torque of 60 Nm +/- 9 Nm (44.25 lb ft +/- 6.64 lb ft).
Page 372 RSV4 1100 Factory Suspensions • When tightening the counter-lock ring, hold the lock ring still with an appropri- ate hook spanner. • Lock the counter-lock ring by bending the tabs of the retainer washer into the notches in the counter-lock ring itself. •...
Page 373 RSV4 1100 Factory Suspensions • upper collar 0.49 mm + 1.5 mm (0.30 in / + 0.93 in) Assembling • Fit the upper collar. • Partially tighten the dowel in the rela- tive threaded hole, so that it protrudes by no more than 2 or 3 mm into the conical surface.
Page 374 RSV4 1100 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 connecting rod fixing screw 50 Nm (36.88 lbf ft) Screw fastening single connecting 50 Nm (36.88 lbf ft) rod to chassis Adjusting The rear suspension consists of a spring-shock absorber unit linked to the frame via uniball joints and...
Page 375 SION (A). TO CHANGE THE HEIGHT, YOU MUST CONTACT AN Au- thorised Aprilia Dealer. SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES.
Page 376 SION. FOR USE ON THE TRACK PLEASE OBSERVE THE VALUES RECOMMENDED FOR USE ON THE ROAD. TO CHANGE THE HEIGHT, YOU MUST CONTACT AN Au- thorised Aprilia Dealer. CAUTION CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PAR- TICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Page 377 RSV4 1100 Factory Suspensions STANDARD ADJUSTMENT FOR ROAD USE Specification Desc./Quantity Shock absorber centre-to-centre distance (A) 312 mm (12.28 in) (preloaded) Spring (B) length 148 mm (5.83 in) Rebound adjustment, ring nut (1) open (**) 20 clicks from fully closed (*) Compression adjustment, adjuster screw (2) open (**) 2 turns from fully closed (*) RACING...
Page 378 RSV4 1100 Factory Suspensions • Remove the cable clamp fastening screw and free the wiring harness of the damper. • Disconnect the connector for the elec- tronic rebound control. • Disconnect the connector for the elec- tronic compression control. • Remove the screw fastening the shock absorber to the dual link.
Page 379 RSV4 1100 Factory Suspensions The following operations are valid for all ver- sions: • Remove the upper fixing screw of the shock absorber to the frame. • Slightly lower the shock absorber and rotate it anti-clockwise by approx 90° to aid removal.
Page 380 RSV4 1100 Factory Suspensions • Working on the right hand side of the vehicle, unscrew the nut (1) fastening the single linkage to the frame, pulling the screw out from the left hand side to remove it. • Working on the left hand side of the vehicle, unscrew the nut (2) fastening the single linkage to the frame, pulling the screw out from the right hand side...
Page 381 RSV4 1100 Factory Suspensions • Use a press and the specific punch to remove the two roller bearing cages (one on each side). Specific tooling 020456Y Ø 24 mm adaptor 020376Y Adaptor handle DUAL LINKAGE • Working on the left hand side of the vehicle, unscrew the two nuts (3) fas- tening the dual linkage to the frame and to the shock absorber, pulling the re-...
Page 382 RSV4 1100 Factory Suspensions Check the condition of the oil seals; replace if damaged or excessively worn. ALWAYS REPLACE THE OIL SEALS WITH NEW COMPONENTS AFTER DISASSEMBLING THE COMPONENTS OF THE SINGLE LINKAGE SUSP - 382...
Page 383 INDEX OF TOPICS CHAS HASSIS...
Page 384 RSV4 1100 Factory Chassis RAME Pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Front couplings 2 + 2 50 Nm (36.88 lbf ft) Lower rear coupling 50 Nm (36.88 lbf ft) RH lower rear regulator bushing M18x1.5 12 Nm (8.85 lbf ft) RH upper rear regulator bushing...
Page 385 RSV4 1100 Factory Chassis Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel axle nut M25x1.5 80 Nm (59.00 lb ft) Front brake disc fastening screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 Removal •...
Page 386 RSV4 1100 Factory Chassis • Remove the wheel hub fastening nut. • Retrieve the sealing washer. • Loosen the screws on the shaft clamps. • Strike the wheel pin gently using a rub- ber mallet in order to extract it more easily.
Page 387 RSV4 1100 Factory Chassis • Replace both wheel bearings. CHECKING RADIAL AND AXIAL PLAY • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: •...
Page 388 RSV4 1100 Factory Chassis Rear wheel EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lbf ft) Nuts used to fasten the crown to the 50 Nm (36.88 lbf ft) sprocket Rear brake disc fastening screws 30 Nm (22.13 lbf ft) Loct.
Page 389 RSV4 1100 Factory Chassis • Remove the washer (2). • On both sides of the vehicle, loosen the lock nut (3) of the adjuster screw (4) and then tighten the adjuster screw to release the tension of the chain ten- sioner.
Page 390 RSV4 1100 Factory Chassis REMOVAL • Remove the final drive assembly NOTE THE FLEXIBLE COUPLING REMAIN INSTALLED ON THE WHEEL REMOVAL • Place the final drive assembly in a vice TO PROTECT THE CROWN GEAR, INSTALL PROTEC- TIONS ON THE JAWS OF THE VICE (IN WOOD OR ALUMI- NIUM).
Page 391 RSV4 1100 Factory Chassis • After the disassembly of the rear wheel, pay particular attention to the locking screws of the flexible coupling holder, which must be perfectly seated. If anomalies are noted it is necessary to proceed with the REPLACEMENT of the complete rim.
Page 392 RSV4 1100 Factory Chassis • Block the rotation of the pins with a hex wrench (1) (EVEN IF THE FLANGE IT- SELF DOES NOT ALLOW THE RO- TATION) and tighten to the prescribed torque, the nuts (2) diametrically op- posed in the order: (A) (B) (C) (D) (E). CAUTION IN THIS WAY THE PRESSURE EXERTED BY THE FIXING ELEMENTS WILL BE EVENLY DISTRIBUTED ON THE...
Page 393 RSV4 1100 Factory Chassis REAR WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity (1). Replace the wheel axle if the eccentricity exceeds the limit value (1). Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM •...
Page 394 RSV4 1100 Factory Chassis • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: • Replace both bearings of the final drive unit. FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn.
Page 395 RSV4 1100 Factory Chassis • Use the extractor tool to remove the right hand bearing (13). Specific tooling AP8140180 Bearing extractor • Retrieve the inner spacer (12). On the left hand side of the wheel: • Use the extractor tool to remove the left hand bearing (16).
Page 396 RSV4 1100 Factory Chassis THE CIRCLIP (17) IS FITTED ONLY ON THE FINAL DRIVE UNIT, LEFT SIDE. • Remove the left bearing (18) with the specific extractor. • Collect the inside spacer (19). • Remove the right bearing (20) with the specific extractor.
Page 397 RSV4 1100 Factory Chassis Swinging arm EAR SWINGARMS Pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain guard fastening screws 2 Nm (1.47 lbf ft)
Page 398 RSV4 1100 Factory Chassis • Detach the rear brake calliper com- plete with mount from the pin on the inner side of the swingarm, and move it out of the way laterally to facilitate re- moval of the swingarm. • Unscrew the three fastener screws of the front sprocket cover and remove the cover.
Page 399 RSV4 1100 Factory Chassis • Working on the left hand side of the vehicle, unscrew and remove the fas- tener nut of the swingarm pin, retriev- ing the washer. • Working on the right hand side of the vehicle, loosen the locking ring nut. •...
Page 400 RSV4 1100 Factory Chassis • If necessary, use a specific tool to re- move a pin from the drive chain. • Open and remove the chain. Checking • Remove the swingarm. • Clean the two sides of the bearing seats with a cloth. •...
Page 401 RSV4 1100 Factory Chassis ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: • Replace both swingarm bearings. RADIAL AND AXIAL CLEARANCE CHECK •...
Page 402 RSV4 1100 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 -5 mm (-0.197 in) relative to the centreline of the insert, as a result the swingarm is in the low position.
Page 403 RSV4 1100 Factory Chassis • Working from the right hand side of the vehicle, turn the swingarm pin clock- wise. This turns the adjustment bush, driving the swingarm in until it is fully seated. • Tighten to the specified torque. •...
Page 404 RSV4 1100 Factory Chassis • Refit the chain onto the drive sprocket and fit the front sprocket, complete with chain, onto the shaft. • Fit the screw complete with cup spring washer and "T" bush. • Refit the rear brake calliper complete with mount onto the swingarm.
Page 405 RSV4 1100 Factory Chassis • Remove the fastener screw (4) of the sprocket complete with the "T" bush (5) and the cup spring washer (6). • Remove the front sprocket (7) from the transmission shaft and free it from the drive chain.
Page 406 RSV4 1100 Factory Chassis • Fit the fastener screw (3) of the front sprocket complete with "T" bush (4) and cup spring washer (5), and tighten to the specified torque. • Fit the front sprocket cover (6), fit the three screws (7), ensuring that the bush (8) is fitted correctly in place, and tighten the screws to the specified tor- que.
Page 407 RSV4 1100 Factory Chassis To dismantle and remove the chain, proceed as follows: • Partially remove the pins (3) using a generic chain breaker. • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6). CHAS - 407...
Page 408 RSV4 1100 Factory Chassis • Collect the inner O-ring rings (7) and completely remove the transmission chain. inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001. The different chain pitches which may be checked with the instrument are indicated on the instrument itself.
Page 409 RSV4 1100 Factory Chassis Installing • After fitting the chain on the pinion and on the crown, put the inner O-rings (1) back onto the hammerlock pins (2) and connect the two ends of the transmis- sion chain. • Place the outer O-rings (3) on the pins. •...
Page 410 RSV4 1100 Factory Chassis • Turn the pin of the specific tool 90° and re-engage the link pin again (checking riveting at points "B"). • Grease the chain and record the clearance. Adjusting The vehicle has an endless chain, without master link. NOTE HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING.
Page 411 RSV4 1100 Factory Chassis constant throughout the entire rotation of the wheel. if the clearance is uniform, but greater or less than 20 mm (0.78 in), carry out the adjustment. CAUTION IF THE CLEARANCE IS GREATER IN SOME POSITIONS IT MEANS THAT SOME ELEMENTS OF THE CHAIN ARE CRUSHED OR HAVE SEIZED UP.
Page 412 RSV4 1100 Factory Chassis CRUSHED OR SEIZED LINKS MUST BE LUBRICATED AND RESTORED TO PROPER WORKING ORDER. THE DRIVE CHAIN HAS SEAL RINGS BETWEEN THE LINKS, WHICH KEEP THE GREASE INSIDE. BE EXTREMELY CAREFUL WHEN ADJUSTING, LUBRICATING, WASHING AND REPLACING THE CHAIN.
Page 413 RSV4 1100 Factory Chassis In order to remove the chain slider shoe, the swingarm must be removed beforehand. Then proceed as described: • Remove the inner screw. • Remove the lateral screw. • Remove the upper screw. • Remove the chain slider shoe. CHAS - 413...
Page 414 RSV4 1100 Factory Chassis Pedaline OOTRESTS Pos. Description Type Quantity Torque Notes Screws used to fasten the rider's 2 + 2 25 Nm (18.44 lbf ft) Loctite 243 footrest to the chassis Screws for fastening the passenger's 2 + 2 18 Nm (13.28 lbf ft) Loctite 243 - For use footrests to the frame...
Page 415 RSV4 1100 Factory Chassis • Remove the three fixing screws (2) of the pinion cover (3) • Remove the fixing screw (4) of the ca- ble grommet (5) • Cut the two clamps (6) that connect the wiring of the quick-shift to the wiring of the side stand and of the lambda probe •...
Page 416 RSV4 1100 Factory Chassis • Remove the two fixing screws (8) of the footrest complete with leverage • If necessary, you can loosen and re- move the quick-shift fixing screw to change the O-rings. NOTE NOTE THE WIRING HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION REMOVING THE RIGHT HAND RIDER FOOT- PEG - REAR BRAKE PEDAL...
Page 417 RSV4 1100 Factory Chassis • Remove the two fastener screws of the right hand rider footpeg mount, com- plete with brake pedal. • Complete removal of the plate, remov- ing the rear brake switch. PASSENGER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE- FER TO A SINGLE PASSENGER FOOTREST, BUT ARE VALID FOR BOTH.
Page 418 RSV4 1100 Factory Chassis • To remove the footrest support, re- move the two screws (7). • Remove the footrest support (8). Stand IDE STAND Pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lbf ft) Loct.
Page 419 RSV4 1100 Factory Chassis Pos. Description Type Quantity Torque Notes Stand fastening pin ... Nm (... lbf ft) Fastener nut of side stand ... Nm (... lbf ft) Side stand In order to remove the side stand, the side fairings, fuel tank and front sprocket cover must be re- moved beforehand.
Page 420 RSV4 1100 Factory Chassis • Working outwards from the interior of the vehicle, remove the two screws fastening the mounting plate of the side stand. • Remove the side stand complete with mounting plate. Exhaust XHAUST Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening...
Page 421 RSV4 1100 Factory Chassis Removing the tail pipe REMOVAL • Rest the vehicle on the rear centre stand. • Remove the three fixing screws of the heat guard. • Remove the heat guard making sure to recover the washers. • Loosen the clamp between the ex- haust terminal and the central mani- fold.
Page 422 RSV4 1100 Factory Chassis • Remove the screw and relative nut fas- tening the exhaust to the frame, re- trieving the collar and the spacer. • Disconnect the actuator cables of the exhaust valve. • Remove the exhaust terminal com- pletely.
Page 423 RSV4 1100 Factory Chassis • Tighten the screw and relative nut fas- tening the exhaust to the passenger footpeg mount, fitting the collar and spacer correctly. • Connect the actuator cables of the ex- haust valve and carry out the exhaust valve actuator cable free play adjust- ment procedure described in the para- graph "EXHAUST BUTTERFLY...
Page 424 RSV4 1100 Factory Chassis • Position the protection plate and fix it to the exhaust terminal using the three screws. Removing the catalytic converter In order to remove the catalytic converter, the side fairings, front exhaust headers, front sprocket cov- er and silencer must be removed beforehand.
Page 425 RSV4 1100 Factory Chassis • Disconnect the connector of the front cylinder bank lambda probe and de- tach it from the relative mount. • Unscrew the four fastener screws of the front cylinder bank headers and re- move the headers. REAR CYLINDER BANK EXHAUST HEADERS To remove the rear cylinder bank exhaust head- ers, in addition to the components described pre-...
Page 426 RSV4 1100 Factory Chassis • Unscrew the nuts fastening the rear headers and remove the headers, eas- ing out towards the rear. Butterfly valve in exhaust • To check that the exhaust valve is working and calibrated correctly, see the paragraph "EX- HAUST VALVE"...
Page 427 RSV4 1100 Factory Chassis Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe. • Release the clamp and disconnect the left hand radiator pipe. See also Replacement •...
Page 428 RSV4 1100 Factory Chassis CHAS - 428...
Page 429 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 430 RSV4 1100 Factory Braking system CONTROL UNIT Pos. Description Type Quantity Torque Notes Oil tube screws M10x1 23-26 Nm (16.96-19.18 lbf ft) Control unit support screws 6.8+/-1 Nm (5.01 +/-0.74 lbf ft) Modulator REMOVING THE ABS MODULATOR To remove the ABS modulator, first drain the brake system and then follow the procedure described below: •...
Page 431 RSV4 1100 Factory Braking system • Remove the cable tie fastening the ABS pipes to the metal plate. • Unscrew and remove the screws fas- tening the ABS pipes to the modulator. • Remove the screw fastening the ABS modulator mount to the frame. •...
Page 432 RSV4 1100 Factory Braking system • Remove the ABS modulator, complete with mount, from the vehicle. • Remove the two screws fastening the ABS modulator to the mount. • Remove the ABS modulator. INSTALLING THE ABS MODULATOR To install the ABS modulator, follow the procedure for removal in reverse order.
Page 433 RSV4 1100 Factory Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
Page 434 RSV4 1100 Factory Braking system Component maintenance The vehicle is equipped with two-channel ABS. In other words, it works on both the front and rear wheel. Check periodically and each time the wheels are refitted, the tone wheel (2) or the sensor (1) re- placed, that the wheel distance is constant at each 360°.
Page 435 RSV4 1100 Factory Braking system Rear brake calliper EAR BRAKE CALLIPER Pos. Description Type Quantity Torque Notes ABS sensor fixing screw M5x15 8 Nm (5.90 lbf ft) Screws fastening brake calliper to 25 Nm (18.43 lbf ft) mount Removal To remove the rear brake calliper, it is necessary to previously drain the braking system.
Page 436 RSV4 1100 Factory Braking system • Using a container of suitable capacity to collect the oil, connect a tube to the bleed nipple and unscrew the nipple to drain the system. • Protect the brake calliper adequately, remove the fastener screws of the pipe and plug the pipe.
Page 437 RSV4 1100 Factory Braking system Installing To install the rear brake calliper, proceed as de- scribed: • Fit the rear brake calliper on the disc. • Fit the two fastener screws of the brake calliper and tighten to the specified tor- que.
Page 438 RSV4 1100 Factory Braking system Front brake calliper RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) Removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH.
Page 439 RSV4 1100 Factory Braking system • Using a container of suitable capacity to collect the oil and protecting the brake calliper adequately, connect a tube to the bleed nipple and unscrew the nipple to drain the system. • Remove the fastener screw of the pipe and plug the pipe.
Page 440 RSV4 1100 Factory Braking system To install the front brake calliper, proceed as de- scribed: • Fit the front brake calliper on the disc. • Fit the two fastener screws of the brake calliper and tighten to the specified tor- que.
Page 441 RSV4 1100 Factory Braking system Removal • Remove the rear wheel. • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION DURING REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY...
Page 442 RSV4 1100 Factory Braking system Disc oscillation tolerance: 0.1 mm (0.0039 in) Front brake disc Removal • Remove the front wheel The following operations refers to a single disc but apply to both. • Unscrew and remove the six brake disc screws (1).
Page 443 RSV4 1100 Factory Braking system Disc thickness minimum value: 4 mm (0.16 in) • Using a dial gauge, check that the max- imum oscillation of the disc does not exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT...
Page 444 RSV4 1100 Factory Braking system Installing • An arrow is stamped on the brake calliper and on the clip, which must always point in the direction of rotation of the front wheel. • Fit the clip in the brake calliper. •...
Page 445 RSV4 1100 Factory Braking system • Remove the stop ring (2). BEFORE DISCONNECTING THE PIN (3), CHECK THE PO- SITION OF THE SAFETY SPRING (4); IT MUST BE POSI- TIONED IN THE SAME WAY ON REASSEMBLY. • Remove the pin (3) and recover the safety spring (4).
Page 446 RSV4 1100 Factory Braking system ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Fit the safety retainer clip (4) as shown. • While pressing the centre of the safety retainer clip (4), fit the pin (3) so that it passes over the clip.
Page 447 RSV4 1100 Factory Braking system • Refit the rear brake calliper and fasten by tightening the two screws (1) to the specified torque. Bleeding the braking system Front TRADITIONAL BLEEDING SYSTEM 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.
Page 448 RSV4 1100 Factory Braking system tainer, this will release the tension on the brake lever and it which will make it arrive at the end stop. • Close the bleed valve before arriving at the end of the stroke with the lever. •...
Page 449 RSV4 1100 Factory Braking system CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING THE BRAKE CALLIPER TO RESTORE THE BRAKING SYSTEM TO ITS REGULAR USE CONDITIONS, SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED. NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED.
Page 450 RSV4 1100 Factory Braking system If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure. • With the diagnostic tool properly connected, select the function "REAR BLEEDING" in the section "SETTINGS".
Page 451 RSV4 1100 Factory Braking system Rear brake pump EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 Nm (4.42 lbf ft) Rear brake pump fastening screws 8 Nm (5.90 lbf ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lbf ft) Loctite 243 Tank filler cap...
Page 452 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 453 RSV4 1100 Factory Cooling system Circuit diagram SYSTEM TYPE Self bleeding cooling circuit with aspirating centrifugal pump (1), three-way thermostat valve (2), cooling radiator (3) with electric fans (4) and expansion tank (5). key: COOL SYS - 453...
Page 454 RSV4 1100 Factory Cooling system 1. Centrifugal pump 2. Thermostatic valve 3. Radiator 4. Electric fans 5. Expansion tank 6. With the thermostat open 7. With the thermostat closed 8. From front head 9. From rear head 10.To upper crankcase OOLING Pos.
Page 455 RSV4 1100 Factory Cooling system ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lbf ft) for fastening the pump to the crank- case Electric fan • Remove the front underfairings and the hand grip position sensor •...
Page 456 RSV4 1100 Factory Cooling system • Internally blocking the nuts, unscrew the fixing screw from the internal part. • Make sure that the nuts and washers are retrieved. See also Fairing mounting panels Twistgrip position sensor • The retainer points of the electric fan are not the same as the hole (2), com- pared to the holes (1), has a different thickness and is therefore fixed from...
Page 457 RSV4 1100 Factory Cooling system • Unscrew and remove the system drain screw and retrieve the sealing washer. • Wait for the entire circuit to drain (en- gine+pipes+radiator). • Refit the system drain screw complete with a new washer. REFILL •...
Page 458 RSV4 1100 Factory Cooling system Water pump • Drain the coolant. • Remove the pipe from the radiator. • Unscrew and remove the two screws fastening the pipe to the engine. • Retrieve the gasket and replace with a new component when refitting. See also Coolant replacement •...
Page 459 RSV4 1100 Factory Cooling system • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw. • Remove the pump cover. TO PREVENT IRREPARABLE DAMAGE TO THE PUMP, UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER.
Page 460 RSV4 1100 Factory Cooling system RADIATOR BRACKET REMOVAL • Working on the left hand side of the vehicle, remove the screw fastening the radiator to the mount. • Remove the cable tie indicated and free the wiring harnesses from the ra- diator mount.
Page 461 RSV4 1100 Factory Cooling system • Moving the bracket outwards, it is then possible to remove it by sliding it out. CAUTION DURING THE REFIT PHASE, MAKE SURE THAT THE MAIN CABLE HARNESS IS CORRECTLY POSITIONED ON THE CAVITY OF THE RADIATOR RETAINER BRACKET, IN ORDER TO PRE- VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF.
Page 462 RSV4 1100 Factory Cooling system • Detach the expansion tank water drain pipe from the pipe guide connected to the mounting bracket of the radiators and remove the pipe retainer clip se- curing the drain pipe to the cable of the demand sensor.
Page 463 RSV4 1100 Factory Cooling system • Remove the cable tie indicated and free the wiring harnesses from the ra- diator mount. • Remove the safety retainer circlip and remove the pin fastening the coolant radiator to the oil radiator. • On both sides of the vehicle, remove the two screws fastening the radiator to the mount.
Page 464 INDEX OF TOPICS BODYW ODYWORK...
Page 465 RSV4 1100 Factory Bodywork Seat REMOVAL TAIL FAIRING / PASSENGER SEAT • Turn the key clockwise. • Lift and remove the tail fairing / pas- senger seat. RIDER SADDLE REMOVAL • Using the supplied hex key, unscrew and remove the two saddle fixing screws in order to remove it from the vehicle.
Page 466 RSV4 1100 Factory Bodywork TAIL FAIRING INSTALLATION • Place the tail fairing by aligning the two hooks (A) and (B) with their seats (A) and (B) on the vehicle. • Press the tail fairing downward with one hand and with the other push it backward until it is completely coupled.
Page 467 RSV4 1100 Factory Bodywork TRANSPORT ON THE TAIL FAIRING IS ILLEGAL, AND IT IS EXTREMELY LIKELY THAT THE PASSENGER WILL FALL FROM THE VEHICLE. Driving mirrors The following procedure is for a single rear view mirror, but is applicable to both mirrors. •...
Page 468 RSV4 1100 Factory Bodywork Instrument panel To remove the instrument panel, first the fairing complete with light assembly must be removed. Then proceed as described: • Unscrew the two fastener screws of the instrument panel brow and remove the brow. •...
Page 469 RSV4 1100 Factory Bodywork Headlight assy. In order to remove the headlight unit, first remove the side fairings, the inner covers, the hand guards, the upper fairing trim pieces, the front trim piece, the rear view mirrors and the inner fairings. Then proceed as described: •...
Page 470 RSV4 1100 Factory Bodywork Headlight fairing • To remove the top fairing, remove the four fixing screws (1) paying attention to collect the washers. • Slide off the top fairing (2) and remove Disassembling the lock In order to remove the lock, the left hand side cover and the left hand tail fairing section must be re- moved previously.
Page 471 RSV4 1100 Factory Bodywork • Remove the actuator arm (5). • Remove the spring (6). • Unscrew and remove the fastener nut (7) of the lock barrel. • Remove the plate (8) from the lock bar- rel. BODYW - 471...
Page 472 RSV4 1100 Factory Bodywork • Remove the lock barrel (9), working from outside the lateral tail fairing sec- tion. • Remove the two fastener screws (10) of the lock striker plate. • Remove the lock striker plate (11) com- plete with cable. INSTALLATION •...
Page 473 RSV4 1100 Factory Bodywork Front wheelhouse REMOVING LOWER STEERING YOKE TRIM ELEMENT • To remove the lower trim piece of the steering yoke, remove the two lateral fastener screws and the relative "T" bushes. • Detach the rubber pipe grommet of the brake pipe from the lower trim piece of the steering yoke.
Page 474 RSV4 1100 Factory Bodywork • Undo and remove the upper screw. • Disconnect the connector and remove the tail light unit. License plate light To remove the license plate light, proceed as fol- lows: • Unscrew the screw (1) and remove the closure (2) of the license plate holder.
Page 475 RSV4 1100 Factory Bodywork • Remove the two fixing screws (4) and extract the license plate light (5) by re- moving the wiring harness from the li- cense plate holder. Side body panels To remove the side fairings, remove the rider sad- dle and then follow the procedure described be- low: THE PROCEDURE DESCRIBED AS FOLLOWS...
Page 476 RSV4 1100 Factory Bodywork Side fairings The procedure described below is for one side of the vehicle but is valid for both sides. • In order to remove the side fairings, the lower fairings must be removed before- hand. Then start disassembly of the inner part of the dashboard, removing the two fastener screws (1) of the hand guard.
Page 477 RSV4 1100 Factory Bodywork • Remove the upper fairing trim piece (5). • Working from underneath the head- light unit, remove the screw (6). • Remove the four screws (7) on the in- ner fairing. • Remove the four outer screws (8). BODYW - 477...
Page 478 RSV4 1100 Factory Bodywork • Remove the side fairing (9). DISASSEMBLING THE SIDE FAIRING • Remove the eight screws (10) to sep- arate the components of the side fair- ing. • Detach the outer part (11) of the side fairing from the inner part (12) to sep- arate them.
Page 479 RSV4 1100 Factory Bodywork • Separate the winglet (14) from the out- er part (15) of the side fairing. • To separate the inner part of the wing- let from the outer part, remove the screw (16). • Detach the inner part (17) of the winglet from the outer part (18) to separate the two parts.
Page 480 RSV4 1100 Factory Bodywork • Remove the outer screw (2) fastening the under-fairing to the duct. • Remove the inner screw (3) fastening the under-fairing to the coolant radiator mount. • Remove the screw (4) fastening the under-fairing to the centre under-fair- ing.
Page 481 RSV4 1100 Factory Bodywork • Disconnect the connectors (5) of the voltage regulator and the pickup sen- sor (6). • Remove the left hand under-fairing (7). RIGHT HAND UNDER-FAIRING • Remove the screw (1) fastening the expansion tank to the radiator. •...
Page 482 RSV4 1100 Factory Bodywork • Remove the outer screw (2) fastening the under-fairing to the duct. • Remove the cable tie (3) fastening the main wiring harness to the under-fair- ing. • Remove the screw (4) fastening the under-fairing to the centre under-fair- ing.
Page 483 RSV4 1100 Factory Bodywork • Remove the left hand under-fairing (6). CENTRAL UNDERFAIRING To remove the centre under-fairing, first remove at least one of the two lateral under-fairings. Then proceed as described: • Remove the screw (1) fastening the lateral under-fairing to the centre un- der-fairing.
Page 484 RSV4 1100 Factory Bodywork • Unscrew the nuts (1) and remove the screws (2). • Disconnect the connector (3). • Remove the license plate holder (4). Rear mudguard To remove the rear mudguard, follow the proce- dure described below: • Unscrew and remove the two screws (1) fastening the rear mudguard to the chain guard, and the two screws (2)
Page 485 RSV4 1100 Factory Bodywork Lower cowl To remove the lower fairings, follow the procedure described below: • Remove the lower screw fastening the fairings to the metal bracket. • While supporting the weight of the low- er fairings, remove the lateral fastener screws on both sides.
Page 486 RSV4 1100 Factory Bodywork • Remove the fairing lug. Fuel tank In order to remove the fuel tank, the rider saddle and side covers must be removed beforehand. Then proceed as described: • Remove the front screw (1) fastening the tank to the frame. •...
Page 487 RSV4 1100 Factory Bodywork • Disconnect the connector (4) of the in- ertia platform. • Disconnect the two breather pipes (5). • Lift the tank partially and disconnect the fuel pipe (6). • Remove the fuel tank (7). BODYW - 487...
Page 488 RSV4 1100 Factory Bodywork To remove the fuel filler, follow the procedure de- scribed below: • Remove the four fastener screws (8) of the filler. • Remove the cap (9). • Remove the gasket (10). Rear wheelhouse To remove the rear wheel splash guard, first re- move the battery, the fuel tank, the saddles, the grab handle, the bodywork parts constituting the tail fairing, the license plate holder, the side covers...
Page 489 RSV4 1100 Factory Bodywork • Disconnect the fuse boxes from the mounts (2). • Free the branch of the main wiring har- ness (3) from the cable retainer clips on the splash guard. • Detach the connector (4) for connect- ing the diagnostic tool from the mount on the splash guard.
Page 490 RSV4 1100 Factory Bodywork • Remove the screw (7) fastening the ABS modulator mount to the frame and the screw (8) fastening the metal plate to the mount. • Partially free the ABS modulator mount from the rubber bush. • Remove the two screws (9) fastening the rear wheel splash guard to the sad- dle carrier subframe.
Page 491 RSV4 1100 Factory Bodywork Front mudguard To remove the front mudguard, follow the proce- dure described below: • Working from the right hand side of the vehicle, remove the cable guide secur- ing the front ABS sensor cable to the mudguard.
Page 492 RSV4 1100 Factory Bodywork • Remove the front mudguard. Instrument cluster cover • To remove the instrument panel cover, after removing the top ring, remove the two fixing screws of the instrument panel cover. • Remove the instrument panel cover. Instrument cluster support In order to remove the instrument panel mount, first remove the front fairing complete with head-...
Page 493 RSV4 1100 Factory Bodywork • Disconnect the connector (2) of the ASC control unit wiring harness (if ap- plicable). • Remove the cable tie (3) fastening the wiring harness to the mount and the six screws (4) joining the two parts of the instrument panel mount.
Page 494 RSV4 1100 Factory Bodywork • Working on the right hand side of the vehicle, remove the two screws (7) fas- tening the right hand part of the instru- ment panel mount. • Remove the cable tie (8) to free the wiring harnesses and permit removal of the right hand mount (9).
Page 495 RSV4 1100 Factory Bodywork TAKE UTMOST CAR AND DO NOT MAKE CONTACT BE- TWEEN THE BATTERY TERMINALS AND ANY METALLIC OBJECT IN ORDER TO PREVENT THE RISK OF SHORT CIRCUIT. • Grip the battery (6) firmly and remove it from its seat, lifting it. •...
Page 496 RSV4 1100 Factory Bodywork THIS MOTORCYCLE IS EQUIPPED WITH A BATTERY THAT REQUIRES NO MAINTENANCE OTHER THAN PERIODICALLY CHECKING STATE OF CHARGE. NOTE IN ORDER TO INSTALL AND USE A NEW CONVENTIONAL LEAD BATTERY, THE SPACER (7) INSTALLED ON THE SECONDARY FUSE HOLDER MUST BE REMOVED.
Page 497 RSV4 1100 Factory Bodywork • Unscrew the two rear fastener screws of the tank by just enough to allow the tank to be lifted slightly in order to de- tach the front part of the right hand tail fairing section and remove the tail fair- ing section completely.
Page 498 ABS: 430 Air filter: 74, 77, 83 Aprilia V4-MP Tecnology: 180 Battery: 169, 494 Brake: 435, 438, 440, 442–444, 450, 451 Brake calliper: 435, 438 Brake disc: 440, 442 Brake pads: 443, 444 Brake pump: 450, 451 Bushings: Catalytic converter: 424 Chain: 19, 406, 412 Clutch: 102, 218, 238, 241–243, 247–249, 254...
Page 499 Handlebar: 342 Head cover: 258 Headlight: 103, 469, 470 Identification: 17 Instrument panel: 468 Keys: 154 License plate holder: 483 Linkages: 379 Magneto flywheel: 235, 299 Maintenance: 14, 62, 66, 156, 434 Maintenance Table: 66 Mirrors: 467 Mudguard: 484, 491 Oil filter: 74 Oil sump: 299, 325 One-way valve: 329...
Page 500 Tank: 486 Throttle body: 338–340 Track: 66 Transmission: 18, 298, 299 Tyres: 21 Use: 66 Water pump: 299, 321, 458 Wiring diagram: 150...

APRILIA RSV4 1100 Factory 2021 Manual

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