APRILIA RSV4 ABS 2009 Manual

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MANUALE STAZIONE DI SERVIZIO

2Q000013

RSV4 ABS

Summary of Contents for APRILIA RSV4 ABS 2009

Page 1 MANUALE STAZIONE DI SERVIZIO 2Q000013 RSV4 ABS...
Page 2 Pagine Gialle o cercare direttamente sulla cartina geografica presente nel nostro Sito Internet Ufficiale: www.aprilia.com Solo se si richiedono Ricambi Originali Aprilia si avrà un prodotto studiato e testato già durante la fase di progettazione del veicolo. I Ricambi Originali Aprilia sono sistematicamente sottoposti a procedure di controllo della qualità, per garantirne la piena affidabilità...
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 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 CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 RSV4 ABS Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 RSV4 ABS Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN- TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Page 11 RSV4 ABS Characteristics 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 FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY. Questo numero è composto da cifre e lettere come nell'esempio sotto riportato.
Page 12 27 /33 (secondary) Final drive gear ratio 16 / 42 RACTION CONTROL Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control), which includes traction control, wheelie control, launch control and clutchless gear shift functions. Capacities APACITY Specification Desc./Quantity Fuel capacity (reserve included) 17 l (3.74 UK gal)
Page 13 RSV4 ABS Characteristics Specification Desc./Quantity Fuel tank reserve 3.6 l (0.79 UK gal) Engine oil oil and filter change 4 l (0.88 UK gal) Coolant 2.7 l (0.59 UK gal) Seats 1 + 1 Two seat configuration: if vehicle is fitted with footrests and saddle for passenger Maximum weight capacity 201 kg (443 lb)
Page 14 RSV4 ABS Characteristics Frame and suspensions HASSIS Specification Desc./Quantity Type Adjustable aluminium, dual beam chassis with pressed and cast sheet elements. Steering rake 26.5° (measurements with reference to bare frame). For the Factory versions the adjustments allow for variations of "+" or "-"...
Page 15 RSV4 ABS Characteristics Wheels and tyres HEEL RIMS Specification Desc./Quantity Front wheel rim 3.50 x 17" Forged Rear wheel rim 6.00 x 17" Forged YRES Specification Desc./Quantity Tyre model Pirelli DIABLO Supercorsa SP V2 Pirelli DIABLO Supercorsa SP Metzeler RACETEC K3 Michelin Power One Dunlop SPORTMAX GP Racer (Mixture "M"...
Page 16 RSV4 ABS Characteristics Front side IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket (OHLINS FORK) CHAR - 16...
Page 17 RSV4 ABS Characteristics RONT FORK pos. Description Type Quantity Torque Notes Fastener screws for calliper mount- 2 + 2 12 Nm (8.85 lb ft) ing bracket (Öhlins) Odometer sensor fixing screw 10 Nm (7.38 lb ft) Speed sensor bracket screws (SACHS FORK) RONT FORK ACHS...
Page 18 RSV4 ABS Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lb ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lb ft) chions Headstock lock ring M35x1 60 Nm (44.25 lbf ft) Headstock counter-lock ring M35x1 Manual +35°...
Page 19 RSV4 ABS Characteristics RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lb ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 RONT BRAKE CALLIPER pos. Description Type Quantity...
Page 20 RSV4 ABS Characteristics RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft) to the lower yoke...
Page 21 RSV4 ABS Characteristics ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screw fastening the semi-handlebar 1 + 1 25 Nm (18.44 lbf ft) collar to the fork sleeves Semi-handlebar safety screw 10 Nm (7.37 lbf ft) Anti-vibration counterweight fastener M18x1.5 20 Nm (14.75 lbf ft) Right light switch...
Page 22 RSV4 ABS Characteristics EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) CHAR - 22...
Page 23 RSV4 ABS Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft) mounting to chassis...
Page 24 RSV4 ABS Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) CHAR - 24...
Page 25 RSV4 ABS Characteristics OOLING pos. Description Type Quantity Torque Notes Flanged TE screws for fastening the M6x20 10 Nm (7.37 lbf ft) water radiator mounting bracket to frame Self-tapping screw for fastening the 2 Nm (1.47 lbf ft) water radiator to the mounting brack- Screw fastening pipe grommet for 6 Nm (4.42 lbf ft) By-pass water hose...
Page 26 RSV4 ABS Characteristics Central part IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) CHAR - 26...
Page 27 RSV4 ABS Characteristics ADDLE pos. Description Type Quantity Torque Notes Rider saddle fixing screw 6 Nm (4.42 lbf ft) UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to...
Page 28 RSV4 ABS Characteristics OOTRESTS pos. Description Type Quantity Torques Notes Screws fastening rider footpegs to 2 + 2 25 Nm (18.44 lbf ft) chassis Screws fastening passenger foot- 2 + 2 18 Nm (13.28 lbf ft) For countries in pegs to chassis which passenger footpegs are man- datory or for two...
Page 29 RSV4 ABS Characteristics RONT CHASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2 Manual Front mounts 2 + 2...
Page 30 RSV4 ABS Characteristics EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft) catch plate fixing screws CHAR - 30...
Page 31 RSV4 ABS Characteristics LOCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lbf ft) Lock lever self-tapping screw 2 Nm (1.47 lbf ft) RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft)
Page 32 RSV4 ABS Characteristics ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate CHAR - 32...
Page 33 RSV4 ABS Characteristics ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lb ft) Threaded spacer 8 Nm (5.9 lb ft) TSPEI screw M6x35 10 Nm (7.38 lb ft) Loct. Self-locking nut 25 Nm (18.44 lb ft) Gearbox linkage joint to gearbox lev- 8 Nm (5.90 lb ft) Loct.
Page 34 RSV4 ABS Characteristics pos. Description Type Quantity Torque Notes Screws fastening the lower fairing to 2 Nm (1.47 lb ft) the lug Lower fairing lower fastening screws 2 Nm (1.47 lb ft) Lower fork fastener fixing screws 8 Nm (5.90 lb ft) Screws fixing lower front fairing fas- SWP 3.9 1 Nm (0.74 lb ft)
Page 35 RSV4 ABS Characteristics Back side XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft) hand footpeg mounting Screw fastening silencer to central 20 Nm (14.75 lbf ft)
Page 36 RSV4 ABS Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount CHAR - 36...
Page 37 RSV4 ABS Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) EAR BRAKE CALLIPER pos.
Page 38: Nm (2.95 Lbf Ft)
RSV4 ABS Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft) Front chain guide fixing screw...
Page 39 RSV4 ABS 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 CHAR - 39...
Page 40: Nm (2.21 Lbf Ft)
RSV4 ABS Characteristics AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER...
Page 41 RSV4 ABS Characteristics AIL FAIRING pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft) Screws fastening grilles to tail fairing...
Page 42 RSV4 ABS Characteristics ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft) ing screws Battery bracket fixing screws 2 Nm (1.47 lbf ft)
Page 43 RSV4 ABS Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Engine speed sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) Flanged TE screws M6x35 12 Nm (8.85 lbf ft) Flanged TE screws M6x22 12 Nm (8.85 lbf ft)
Page 44 RSV4 ABS Characteristics ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) CHAR - 44...
Page 45 RSV4 ABS Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve cover fixing screws...
Page 46 RSV4 ABS Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Screws fastening the timing system 30 Nm (22.13 lbf ft) Loct. 243 gear on the intake shaft Skid fastener screws 20 Nm (14.75 lbf ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.37 lbf ft) Loct.
Page 47 RSV4 ABS Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 48 RSV4 ABS Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 49 RSV4 ABS Characteristics pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw 10 Nm (7.37 lbf ft) Loct.
Page 50 RSV4 ABS Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch nut 150 Nm (110.63 lbf ft) Loct. 243 Clutch spring fastener screw 10 - 12 Nm (7.38 - 8.85 lbf ft) IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft)
Page 51 RSV4 ABS Characteristics LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft) side Blow-by union fastener screws M5x16 7 Nm (5.16 lbf ft) Stator fixing screw UNI 5931 CL8.8 M6x25 10 Nm (7.37 lbf ft)
Page 52 RSV4 ABS Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft) Oil sump fixing screws...
Page 53 Recommended products chart ECOMMENDED PRODUCTS TABLE Product Description Specifications ENI i-RIDE APRILIA RACING 5W-40 Engine oil Use branded oils with performance equivalent to or exceeding ACEA A3 - API SL - JASO MA - JASO MA2 specifi- cations AGIP MP GREASE...
Page 54 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 55 RSV4 ABS Special tools PECIFIC TOOLS Stores code Description 020845Y Engine support 020846Y Retaining tray + plastic caps 020847Y Flywheel extractor 020848Y Flywheel retainer (Mitsubishi) 020914Y Flywheel retainer 020849Y Clutch retainer S-TOOLS - 55...
Page 56 RSV4 ABS Special tools Stores code Description 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring S-TOOLS - 56...
Page 57 RSV4 ABS Special tools Stores code Description 020857Y Crankshaft bearing U bolt 020858Y Device for holding the pistons in the cyl- inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020862Y Gearbox control rod roller cage fitting punch S-TOOLS - 57...
Page 58 RSV4 ABS Special tools Stores code Description 020863Y Desmodromic drum roller cage fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020883Y Tool for fitting/removing the timing chain tensioner 020709Y Engine support AP8140187 Engine support stand 020376Y Adapter handle S-TOOLS - 58...
Page 59 RSV4 ABS Special tools Stores code Description 020363Y 20-mm Oil seal guide 020364Y 25-mm Guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor S-TOOLS - 59...
Page 60 RSV4 ABS Special tools Stores code Description 0277308 Guide bushing for secondary gearbox shaft 020877Y Pliers for clamps 020926Y Tool for fitting the clutch control bushing AP8140146 Weight AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140147 Spacer tool AP8140148...
Page 61 RSV4 ABS Special tools Stores code Description AP8140149 Protection for fitting operations AP8140150 Perforated rod for piston air bleed AP8140190 Tool for steering tightening AP8140181 Fuel pressure checking tool 020680Y TXB Navigator 020922Y P.A.D.S. S-TOOLS - 61...
Page 62 INDEX OF TOPICS MAIN AINTENANCE...
Page 63 Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it.
Page 64 RSV4 ABS Maintenance km x 1000 Air filter (6) Engine oil filter (6) Fork General vehicle operation (6) Valve clearance (7) Cooling system (6) Brake systems (6) Light circuit Stand switch Safety switches Stop switches Brake fluid (4) Coolant (4) Fork oil (7)(9) Engine oil (6) Light aiming...
Page 65 RSV4 ABS Maintenance • Slide off the front coil. • Unscrew and remove the front spark plug. REAR SPARK PLUGS • Remove the fuel tank. • Unscrew and remove the rear coil fastener screw. • Slide off the rear coil. •...
Page 66 RSV4 ABS Maintenance - Lower marking = Min. level • If this is not the case, top-up the oil im- mediately through the filler plug. CAUTION NEVER ALLOW THE OIL LEVEL TO DROP BELOW THE MINIMUM LEVEL OR FILL ABOVE THE MAXIMUM LEVEL; IF YOU DO NOT COMPLY WITH THE MINIMUM AND MAX- IMUM OIL LEVELS THE ENGINE COULD BE SERIOUSLY DAMAGED...
Page 67 RSV4 ABS Maintenance • Warm up the engine up by running it for a few minutes, then switch it off. After thirty seconds, check the level in the sight glass. Top up if necessary. CAUTION NEVER ALLOW THE OIL LEVEL TO DROP BELOW THE MINIMUM LEVEL OR FILL ABOVE THE MAXIMUM LEVEL;...
Page 68 RSV4 ABS Maintenance • Disconnect the upper injector fuel de- livery union. See also Fuel tank • Disconnect the variable geometry in- take system connector. • Fit a suitably sized shim behind the fil- ter box cover. • Lift the filter box cover on which the control unit is installed.
Page 69 RSV4 ABS Maintenance • Remove the air filter. Checking the valve clearance FRONT HEAD • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 70 RSV4 ABS Maintenance REAR HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover. See also Removing the throttle body Spark plug Head cover removal • Use a feeler gauge to check the clear- ance between the cam on the shaft and the relative tappet for both rear head shafts.
Page 71 RSV4 ABS Maintenance Front cylinder head valves • Check the front valve head clearance and restore the correct clearance values if necessary, proceeding as described below. • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft.
Page 72 RSV4 ABS Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin • Remove the two crankshaft and cam- shaft reference pins.
Page 73 RSV4 ABS Maintenance ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1). •...
Page 74 RSV4 ABS Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots). •...
Page 75 RSV4 ABS Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally. •...
Page 76 RSV4 ABS Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. • Block crankshaft rotation using one of the specific tools.
Page 77 RSV4 ABS Maintenance 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 78 RSV4 ABS Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin • Remove the two crankshaft and cam- shaft reference pins.
Page 79 RSV4 ABS Maintenance setting was not altered while the en- gine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1). •...
Page 80 RSV4 ABS Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the intake camshaft gear tooth (indicated with one dot) is meshed with the trough of the exhaust camshaft gear (indicated with two dots). •...
Page 81 RSV4 ABS Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally. •...
Page 82 RSV4 ABS Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. • Block crankshaft rotation using one of the specific tools.
Page 83 RSV4 ABS Maintenance 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 84 RSV4 ABS Maintenance 1.97 mm (0.0775 in) 2 mm (0.0787 in) 2.02 mm (0.0795 in) 2.05 mm (0.0807 in) 2.07 mm (0.0815 in) 2.1 mm (0.0827 in) 2.12 mm (0.0835 in) 2.15 mm (0.0846 in) 2.17 mm (0.0854 in) 2.2 mm (0.0866 in) 2.22 mm (0.0874 in) 2.25 mm (0.0886 in) 2.27 mm (0.0894 in)
Page 85 RSV4 ABS Maintenance 2.92 mm (0.1150 in) 2.95 mm (0.1161 in) 2.97 mm (0.1169 in) 3 mm (0.1181 in) 3.02 mm (0.1189 in) 3.05 mm (0.1201 in) 3.07 mm (0.1209 in) 3.10 mm (0.1220 in) 3.12 mm (0.1228 in) 3.15 mm (0.1240 in) MAIN - 85...
Page 86 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 87 SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE DIAGNOSIS INSTRUMENT THROUGH CONTROL UNIT BY SE- LECTING "SELF-ACQUISITION, APRILIA, RSV4" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 88 RSV4 ABS Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 89 RSV4 ABS Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION DIAGNOSTICS INSTRUMENT SHOULD BE WORKING PROPERLY AND UPGRADED AT LEAST TO THE 7.0.0 VERSION OR THE PGDS UPDATED AT LEAST TO THE 3.0.0 VERSION CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V;...
Page 90 RSV4 ABS Troubleshooting • 8. WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS ON THE DIAGNOSIS INSTRUMENT, DEVICE STATUS SCREEN PAGE, ICON 0/1 MEAN? If "RUN" is shown, go to 9; if "STOP" is shown, go to 15 •...
Page 91 RSV4 ABS Troubleshooting THE RELAY NUMBER SPECIFIED REFERS TO THE WIRING DIAGRAM. THE POSITION OF THE RELAY ON THE VEHICLE IS INDICATED IN THE "ELECTRICAL SYSTEM/COMPONENT LAYOUT/ RELAY LAYOUT" CHAPTER. • 1- WITH THE KEY TURNED TO "ON", THE INSTRUMENT PANEL LIGHTS UP BUT NO FAULT INDICATION IS SHOWN WITH INDICATION "SERVICE"...
Page 92 RSV4 ABS Troubleshooting • 10. ACCORDING TO THE FAULT, SEE CHAPTER "ELECTRICAL SYSTEM/CHECK AND CONTROLS/NEUTRAL GEAR SENSOR" or "ELECTRICAL SYSTEM/CHECK AND CON- TROLS/GEAR SENSOR" or "ELECTRICAL SYSTEM/CHECK AND CONTROLS/SIDE STAND SENSOR" - END • 11. REPLACE THE CONTROL UNIT - END •...
Page 93 RSV4 ABS Troubleshooting • 5. CHECK CONTINUITY red/blue CABLE up to secondary fuse D and red/white cable from secondary fuse to 30 A main fuse CHECKING ALSO THE ENGINE - VEHICLE CABLE HARNESS CONNECTOR - END • 6. CHECK CONTINUITY OF RED/BROWN CABLE FROM PIN 40 TO PROTECTION RE- LAY 19 CHECKING ENGINE - VEHICLE ELECTRICAL SYSTEM CONNECTOR If there is continuity, go to PROTECTION RELAY 19 CHECK;...
Page 94 RSV4 ABS Troubleshooting • 1. CHECK CONTINUITY OF THE ORANGE/GREEN CABLE FROM THE LOWER INJEC- TOR AT PIN 3 OF THE INJECTION RELAY 33, ALSO CHECKING THE ENGINE CABLE HARNESS - VEHICLE CABLE HARNESS CONNECTOR AND THE INJECTION RELAY CONNECTOR If there is continuity, go to 2;...
Page 95 RSV4 ABS Troubleshooting PIN TO THE BLUE CABLE IS THERE CONTINUITY BETWEEN THE OTHER TWO RELAY PINS? YES, go to 4; NO, replace the relay - END • 4. CHECK CONTINUITY OF THE GREEN/BLUE CABLE FROM THE KEY CONNECTOR AT PIN 3 OF THE RELAY CHECKING ALSO THE KEY SWITCH CONNECTOR AND RE- LAY CONNECTOR If there is continuity, go to 5;...
Page 96 RSV4 ABS Troubleshooting • 7. REPLACE THE STARTER BUTTON COMPONENT - END TROUBL - 96...
Page 97 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 98 RSV4 ABS Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft) Screw fastening the voltage regula- 6 Nm (4.42 lbf ft) tor to the inner fairing Shear head screw (to the left of the Manual...
Page 99 RSV4 ABS Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate Components arrangement key: ELE SYS - 99...
Page 100 RSV4 ABS Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Intake duct (WHERE PROVIDED) 11.Lower injectors 12.Air pressure sensor 13.Exhaust valve...
Page 101 RSV4 ABS Electrical system ELAY LAYOUT Component position Component name Location on the vehicle in the electrical circuit diagram Low beam light relay Windshield front part High beam light relay Windshield front part Start-up relay Rear undertail section Protection relay Under the saddle next to the battery, left side Injection relay Under the saddle next to the battery, right side...
Page 102 RSV4 ABS Electrical system • 1 Exhaust valve actuator • 1 Oxygen sensor • 2 Fans • 1 Right handlebar control • 1 Left handlebar control • 1 Shift control • 1 Regulator • 1 Demand sensor • 1 Variable geometry control unit •...
Page 103 RSV4 ABS Electrical system • 2 6.6x18x1.6 washers • 2 Washer • 1 Spring washer • 3 5x20x1.5 washer • 1 Spacer • 1 Spacer • 1 Exhaust valve opening cable • 1 Exhaust valve closing cable • 1 Instrument panel mounting cover •...
Page 104 RSV4 ABS Electrical system • 2 Self-tapping screws • 4 AMP Superseal connector mountings • 1 Mounting for the Framatome connector • 2 Small black clamps • 1 Rubber clamp • 1 Flanged M6x16 screw • 1 Secondary air solenoid mounting •...
Page 105 RSV4 ABS Electrical system • Regulator connector • Fan connectors • Starter motor eyelet • Stand switch connector • Right handlebar control connector • Left handlebar control connector • Clutch connector • Relay connectors • Ignition switch connector • Immobilizer aerial connector •...
Page 106 RSV4 ABS Electrical system Front side TABLE A - RELAY AND FALL SENSOR MOUNTING PRE-FITTING Check that the fall sensor has been positioned correctly, with the arrow above the indication UP- PER facing upward. 1. fall sensor 2. Fall sensor rubber ring 3.
Page 107 RSV4 ABS Electrical system The headlamp cable harness (23) and the two relays with a relay socket rubber ring (17) must be fit on the headlamp (13) as shown in the photos below. 13. Headlamp 14. Left position light connector 15.
Page 108 RSV4 ABS Electrical system TABLE E - INSTRUMENT HOLDER SUPPORT AND FRONT PART Use a clamp (31) to fasten the vehicle cable har- ness, in correspondence of the grey taping, on the specific seat located on the instrument holder sup- port.
Page 109 RSV4 ABS Electrical system TABLE G - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART The left arch brace can now be fit. After fitting the left arch brace, the clamp used for holding the cable harnesses inside the arch brace itself must be cut and removed.
Page 110 RSV4 ABS Electrical system TABLE J - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART 45. Rubber ring (x3) 46. Screw (x3) 47. Washer (x3) 48. Instrument panel TABLE K - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART 49. Insert the instrument panel rubber rings in their seats on the arch brace. 50.
Page 111 RSV4 ABS Electrical system TABLE M - INSTRUMENT HOLDER SUPPORT AND FRONT PART Left side Check that the cable grommets are not tensioned on the right and left cable grommet during steering rotation. 58. Antenna cable harness routing 59. Ignition switch cable harness routing 60.
Page 112 RSV4 ABS Electrical system TABLE N - COMPLETION OF THE FRONT 65. Headlamp connectors 66. Headlamp connector positioning (as shown in the figure) TABLE O - COMPLETION OF THE FRONT Check that the turn indicator connectors are inserted correctly and do not return inside the instrument holder arch brace.
Page 113 RSV4 ABS Electrical system TABLE P - FRONT SPEED SENSOR 69. Cable grommet 70. Front speed sensor 71. Clamp 72. Front speed sensor cable harness routing ELE SYS - 113...
Page 114 RSV4 ABS Electrical system TABLE Q - FRONT SPEED SENSOR CONNECTOR POSITION 75. Radiator support 76. Front speed sensor cable harness 77. Clamp Route cable harness on clutch cable grommet and tie it together with the front speed sensor 78. Front speed sensor connector 79 Clamps Central part TABLE A - RADIATOR AREA...
Page 115 RSV4 ABS Electrical system TABLE B - RADIATOR AREA 3. Starter motor 4. Clamp 5. Exhaust valve actuator cable harness routing 6. Oil pressure sensor cable harness routing 6A. Oil pressure sensor. CAUTION THE FEMALE FASTON OF OIL PRESSURE SENSOR FEA- TURES A RETAINING TANG.
Page 116 RSV4 ABS Electrical system TABLE D - RADIATOR AREA 13. Vehicle connector 14. Engine connector 15. Check that the connectors are inserted cor- rectly and that the purple slide is at the end of stroke (as shown in the figure). TABLE E - RADIATOR AREA Left side Check that the connectors are inserted correctly and that the security locks are in the locked...
Page 117 RSV4 ABS Electrical system TABLE F - DEMAND SENSOR FITTING 18. Slave Demand cable harness routing (creating a "U-bend" in the cable harness) 19. Master Demand cable harness routing (creat- ing a "U-bend" in the cable harness) TABLE G - DEMAND SENSOR FITTING Clamp where indicated.
Page 118 RSV4 ABS Electrical system 27. Flywheel connector 28. Regulator connector 29. Regulator connector on the vehicle cable harness TABLE I Right side 30. Instrument panel branch vehicle cable harness 31. Fan connector 32. Clamp TABLE J 32A. Tie 32B. Fan connector 32C.
Page 119 RSV4 ABS Electrical system 33 Exhaust valve actuator 34. Exhaust valve actuator cable harness routing 35 Exhaust valve actuator connector 36. Clamp 37. Spacer 38 Heat-protecting cover 39. Spacer 40. Rubber ring 41. T-shaped bushing 42. M6x30 screw TABLE J2 - EXHAUST VALVE ACTUATOR Positioning and calibration Actuator - valve Bowden cable (45) fitting procedure •...
Page 120 RSV4 ABS Electrical system TABLE J3 - EXHAUST VALVE ACTUATOR Positioning and calibration Actuator - valve Bowden cable (45) fitting procedure • Turn the opening cable (43) set screw until the cable tension is identical to the closing cable (44). •...
Page 121 RSV4 ABS Electrical system TABLE K3 - QUICK SHIFT 56. Quick shift cable harness routing TABLE L 59. Cable guide 60. Oxygen sensor cable harness routing 61. Stand switch cable harness routing TABLE M 62. Quick Shift cable harness routing 63.
Page 122 RSV4 ABS Electrical system TABLE N 65. Stand switch connector TABLE O 66. Set the connectors for stand switch, Quick Shift and gear sensor under the two corrugated pipes. TABLE P1 - NOTES FOR FITTING THE GROUND CABLES 67. Flanged M6x15 screw 68.
Page 123 RSV4 ABS Electrical system TABLE P2 - ENGINE - BATTERY GROUND CABLE ROUTING Clamp the engine- battery ground cable harness to the Demand sensor cable harness as far up as possible. 74. Clamp 75. Battery - engine ground lead 76. Engine - battery ground cable harness routing The engine - battery ground cable harness must not be visible within the area indicated with a red triangle.
Page 124 RSV4 ABS Electrical system CENTRAL Q1 - NOTES FOR ENGINE CABLE HARNESS FITTING Definition of component numbering: Upper view 77. Cylinder 1 78. Cylinder 2 79. Cylinder 3 80. Cylinder 4 81. Cylinder bank 1 82. Cylinder bank 2 83. Throttle body 1 (FARF 1) 84.
Page 125 RSV4 ABS Electrical system TABLE S1 - FILTER BOX COVER AND LOWER FILTER BOX PREPARATION Fit four mountings for the "coil" connectors and the mounting for the "vehicle" connector as shown in figures S1, S2 and S3. Lower filter box 90.
Page 126 RSV4 ABS Electrical system TABLE U - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING Before fitting the motorised throttle bodies (98 and 99), the respective engine cable harness connec- tors must be connected: on branch "2" of the cable harness (corrugated pipe marked with RED tape), there are outputs 13 and 14, which are respec- tively motorised throttle body 1 (98 - rear) (shorter...
Page 127 RSV4 ABS Electrical system TABLE Y - MOTORISED THROTTLE BODY FIT- TING First fasten the "Motorised Throttle Body 2 (front)" to the rubber manifolds with the specific clip-on clamps. Then fasten the "motorised throttle body 1 (rear)" to the rubber manifolds with the clip-on clamps us- ing the specific tool.
Page 128 RSV4 ABS Electrical system TABLE ZB - H2O TEMPERATURE SENSOR 114. Cable harness routing (branch "4") under the 3-way fitting 115. Engine speed sensor cable routing between the front motorised throttle body and the 3-way fit- ting 116. Rubber clamp TABLE ZC At this point, the injectors 2 (output "5") and 4 (out- put "6") can be connected: the connector (117) for...
Page 129 RSV4 ABS Electrical system 124. Lower injector 3 cable harness connector (output "17") - green connector 125. Coil 3 - long cable harness 126. Coil 1 - short cable harness TABLE ZE - COIL AND MAP SENSOR CON- NECTION Once the filter box is assembled, the coil and map sensor connections must be made.
Page 130 RSV4 ABS Electrical system TABLE ZH Once the Engine Speed Sensor (output "30") con- nector (142) has been connected to its counter- part, it must be clamped, using the indicated clamp (143), to the Blow-by pipe in the position shown in the figure.
Page 131 RSV4 ABS Electrical system 154. Air temperature sensor 155. Upper injector 1 cable harness connector (output "23") - black connector 156. Self-tapping screw Connect the upper injectors as shown in the figure and according to the following sequence: Injector 1 (output "23"): BLACK connector Injector 2 (output "20"): BROWN connector Injector 3 (output "22"): GREEN connector Injector 4 (output "21"): GREY connector...
Page 132 RSV4 ABS Electrical system TABLE ZM 159. Clamp 160. Self-tapping 5x20 screw TABLE ZN The connectors (161) "ECU 1" (output "26") and (162) "ECU 2" (output "25") must be connected to their respective connectors on the 7SM control unit, being very careful when inserting them. The slides must move freely until the end of the stroke, which helps with connector insertion: you must hear the release of the retaining tang at the end of...
Page 133 RSV4 ABS Electrical system TABLE ZO It is advisable to create a jig in order to check the correct insertion of both connectors. TABLE ZP - VEHICLE CONNECTOR FASTEN- The "VEHICLE" (output "1") connector (165) must be fastened to the mounting with the white slide pre-fit on the connector itself, in the position indi- cated in the figure.
Page 134 RSV4 ABS Electrical system 171. Intake duct "ECU" cable harness connector (output "31") TABLE ZS - NOTES FOR FITTING THE GROUND CABLE There are two ground lug terminals on the cable harness: the "ENGINE GND" (output "9") and the "CHASSIS GND" (output "10"). The "ENGINE GND"...
Page 135 RSV4 ABS Electrical system TABLE B - SPEED SENSOR PRE-FITTING 8. Speed sensor 9. TE M6x20 screw 10. Sensor cable harness routing in the cable grommet TABLE B1 - ABS CONTROL UNIT 10. ABS control unit 10A. Control unit connector TABLE C - START-UP RELAY PRE-FITTING 11.
Page 136 RSV4 ABS Electrical system B=battery Be careful not to bend the positive battery cable (14). TABLES D1 and D2 - VEHICLE CABLE HARNESSES The Vehicle Cable Harness (16) and the "Relay and Fall Sensor" mounting (17) must be fit on the chassis before fitting the engine.
Page 137 RSV4 ABS Electrical system TABLE E1 - REAR SWINGARM AREA 25. Rubber clamp 26. Rear brake switch cable harness 27. Speed sensor cable harness TABLE E2 - REAR STOP SWITCH AND SPEED SENSOR CABLE HARNESS ROUTING ON THE RIGHT SIDE 28.
Page 138 RSV4 ABS Electrical system TABLE F - REAR SADDLE MOUNTING AREA Preparing the battery mounting bracket with fuses. 30A. Battery mounting bracket 30B. Vehicle cable harness TABLE F1 - REAR SADDLE MOUNTING AREA 31. License plate frame cable harness connector 32.
Page 139 RSV4 ABS Electrical system TABLE F2 35. Insert the fuse-box in the two tongues on the battery mounting bracket 36. Protection relay and relay socket rubber ring 37. Insert the relay in the plastic tongue on the left 38. TBEI M5x16 screw 39.
Page 140 RSV4 ABS Electrical system Pay attention not to bend the starter motor cable TABLE F5 - RIGHT SIDE SADDLE MOUNTING Outer 58. Fuel pump connector 59. Insert the tape clamp on the cable harness in the hole on the right side of the saddle mounting 60.
Page 141 RSV4 ABS Electrical system TABLE F6 - LEFT SIDE SADDLE MOUNTING 64. Battery - engine ground lead 65. Cable grommet TABLE G - INTAKE DUCT CONTROL UNIT AND TANK After fitting the tank and connecting the fuel line push fitting, the fuel pump connector (66) can be connected and positioned as shown in the figure.
Page 142 RSV4 ABS Electrical system TABLE H2 70. Clamp 71. Intake duct control unit cable harness routing ELE SYS - 142...
Page 143 RSV4 ABS Electrical system General wiring diagram key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. COMPLETE HEADLAMP 4. FRONT LEFT TURN INDICATOR 5. RIGHT LOW BEAM LIGHT BULB ELE SYS - 143...
Page 144 RSV4 ABS Electrical system 6. HIGH BEAM BULB 7. TAIL LIGHT BULB 8. LEFT LOW BEAM LIGHT BULB 9. HIGH BEAM LIGHT RELAY 10.LOW BEAM LIGHT RELAY 11.LEFT LIGHT SWITCH 12.INSTRUMENT PANEL DIAGNOSIS 13.INSTRUMENT PANEL 14.EXHAUST VALVE MOTOR 15.FRONT STOP SWITCH 16.REAR STOP SWITCH 17.CLUTCH SWITCH 18.IGNITION SWITCH...
Page 145 RSV4 ABS Electrical system 44.SIDE STAND SWITCH 45.GEAR SENSOR 46.FRONT CYLINDER PRESSURE SENSOR 47.REAR CYLINDER PRESSURE SENSOR 48.FRONT CYLINDER THROTTLES 49.REAR CYLINDER THROTTLES 50.AIR TEMPERATURE SENSOR 51.Water Temperature Sensor 52.UPPER INJECTORS 53.7SM CONTROL UNIT 54.HAND GRIP POSITION SENSOR 55.ENGINE SPEED SENSOR 56.COIL 57.SPARK PLUG 58.LOWER INJECTORS...
Page 146 RSV4 ABS Electrical system CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector correct position on the component or on the coupling con- nector, making sure that the locking catch is re- leased. 2.
Page 147 RSV4 ABS Electrical system CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR- CUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit.
Page 148 RSV4 ABS Electrical system • The read code is not stored in the instrument panel memory Troubleshooting • Carry out key data storage procedure DSB 02 Immobilizer fault • read key code not read (key not present or transponder not working) Error cause •...
Page 149 RSV4 ABS Electrical system 1. Request all the keys of the vehicle in the customer possession. Once the instrument panel is electrically connected to the vehicle and a key is set to ON, the key is stored and the instrument panel waits for 20 seconds for a possible second key. If there is a second key, remove the first key and wait for the storage of the second key.
Page 150 RSV4 ABS Electrical system • Update • CHANGE KEYS • KM / MILES INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connec- ted to it. Instrument panel errors In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it.
Page 151 RSV4 ABS Electrical system This option deletes all instrument panel errors; a further confirmation is requested. Use the diagnosis instrument to reset ECU errors. VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check.
Page 152 RSV4 ABS Electrical system This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check. In order to activate this function follow the instructions in the DIAGNOSIS section.
Page 153 RSV4 ABS Electrical system • Resistance of the wires read on the display = 0.47 Ohm • Effective resistance stage 1 = 0.62-0.47 = 0.15 Ohm • If there is a significant difference between one stage and another (other than 0.15 Ohm), this means that the alternator is defective and must be replaced.
Page 154 RSV4 ABS Electrical system • If there is a significant difference between one stage and another (other than 15 V), this means that the alternator is defective and must be replaced. CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 4-5 V LESS THAN THOSE DETECTED WITH THE ENGINE COLD.
Page 155 RSV4 ABS Electrical system • Start the engine, after about one minute of operating bring the speed to 3000-5000 RPM, then measure with a tester the voltage at the battery poles that must always be between 13V and 15V. Otherwise, if the correct operation of the alternator has already been checked, replace the regulator.
Page 156 RSV4 ABS Electrical system • If shorted to positive: excessive voltage has been detected at PIN 58; if the circuit is open, shorted to negative: voltage equal to zero has been detected. DIAGNOSTICS INSTRUMENT: LOGIC ERRORS Starter switch P0169 • signal not valid.
Page 157 RSV4 ABS Electrical system CAUTION THREE OF THE FUSES ARE SPARES (H). MAIN FUSES DISTRIBUTION Specification Desc./Quantity L) 30A fuse Battery recharge and vehicle current consumers, injection cur- rent consumers (red and red/white cables). CAUTION THERE IS ONE SPARE FUSE (I). Control unit Removal •...
Page 158 RSV4 ABS Electrical system • Unscrew and remove the three screws. • Remove the control unit. NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 159 RSV4 ABS Electrical system • Marelli software code / - • Control unit series number (NIP) / 7SMPRA119 - Identifies the single control unit • Person in charge for last program- ming / - Indicates the series number of the diagnosis instrument that has car- ried out the last control unit remapping DIAGNOSIS INSTRUMENT: PARAMETERS Nominal idle speed...
Page 160 RSV4 ABS Electrical system Stop light • The stop light logic relay (No 25 in the wiring diagram, position in the front niche of the frame, right side, CHECK, however, the identification of the relay with the colour of the cables) is energised Error clearing Ambient parameter reading...
Page 161 RSV4 ABS Electrical system • circuit not operational Error cause • Replace injection ECU Stop lights relay error P0610 • short circuit to positive/ short circuit to negative / open circuit Error cause • If shorted to positive: excessive voltage has been detected at PIN 31. If shorted to negative: no voltage has been detected.
Page 162 LEARNING AND CHECK THE TWO "AUTOMATIC FRONT HANDLE SELF-LEARNING" AND "AUTOMATIC REAR HANDLE SELF-LEARNING" STATUSES ARE "PERFORMED". a-PRC (Aprilia Performance Ride Control) P0700 functional error • Wrong a-PRC scheduling / Wrong CheckSum of the software on Flash / Power supply volt-...
Page 163 RSV4 ABS Electrical system out" (the latter status entails Urgent service being displayed on the instrument panel). If Throttle Self- learning shows "Not carried out", go to stage 1. If it shows "Carried out", go to stage 2. Phase 1: current errors have probably been detected by the control unit: solve these malfunctions and check the two statuses.
Page 164 RSV4 ABS Electrical system BE CAREFUL WITH THE POSITIVE BATTERY CABLE - IT HAS TO GO UNDER THE TOP OF THE FRAME. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 165 RSV4 ABS Electrical system Under the right dynamic air intake. Pin-out: • PIN 1 - Power negative/Signal nega- tive (white) • PIN 2 - Power positive/Signal positive (white/brown) DIAGNOSIS INSTRUMENT Parameters: Speed (km/h) - Front wheel speed DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS C1002 Front speed sensor: short circuit.
Page 166 RSV4 ABS Electrical system Connect to the ABS control unit diagnostics DIAGNOSTICS INSTRUMENT: LOGIC ERRORS C1100 Front speed sensor: missing signal or speed measured too low in relation to the rear wheel. Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth.
Page 167 RSV4 ABS Electrical system Under the right side fairing. Pin-out: • PIN 1 - Power negative/Signal nega- tive (yellow) • PIN 2 - Power positive/Signal positive (yellow/brown) DIAGNOSIS INSTRUMENT Parameters: Speed (km/h) - Rear wheel speed DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS C1004 Rear speed sensor: short circuit.
Page 168 RSV4 ABS Electrical system C1101 Rear speed sensor: missing signal or speed measured too low in relation to the front wheel. Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth. C1103 Rear speed sensor: missing signal or speed measured too low in relation to the front wheel.
Page 169 RSV4 ABS Electrical system Function Extend or shorten the engine intake ducts to in- crease the intake air quantity according to the engine revs. Operation / Operating principle The system consists of: • two intake ducts for each manifold, which may be joined (long ducts) or separated (short ducts);...
Page 170 RSV4 ABS Electrical system the filter box next to the rear upper in- jectors. Electrical specifications: Electrical motor resistance. 4.5 +/- 0.5 Ω; PIN 1: 0V normal, Vbatt fault PIN 2: 0V ducts control down, 5V ducts control up. Pin out: 1.
Page 171 RSV4 ABS Electrical system • If shorted to positive: if a voltage higher than 5V is detected, disconnect the variable geom- etry control unit connector and check with key ON the voltage to PIN 2: if it is higher than 5 V, restore cable harness;...
Page 172 RSV4 ABS Electrical system 1. negative signal 2. positive signal 3. shielding with ground connection DIAGNOSTICS INSTRUMENT: PARAMETERS Engine rpm: rpm CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 173 RSV4 ABS Electrical system Twistgrip position sensor REMOVAL • Remove the left fairing. • Loosen the two throttle cable nuts. • Unscrew and remove the three plate fixing screws. • Remove the throttle cables. • Unscrew and remove the nut and the stud bolt.
Page 174 RSV4 ABS Electrical system Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit. Operation / operating principle The two throttle cables (opening and closing) ac- tuate on a scroll mounted on a shaft and which is...
Page 175 RSV4 ABS Electrical system • C: Track C signal • D: Track D supply • E: Track D ground • F: Track D signal DIAGNOSIS INSTRUMENT: PARAMETERS Blue lower connector throttle grip position sensor - track A • Example value with key ON: 1107 mV •...
Page 176 RSV4 ABS Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Blue lower connector throttle grip position sensor - track A P0150 •...
Page 177 RSV4 ABS Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground. If both are correct, replace the throttle grip sensor;...
Page 178 RSV4 ABS Electrical system cated by the diagnosis instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 179 RSV4 ABS Electrical system • incongruent signal Error cause • The value of the lower side sensor (tracks A-B) does not coincide with the value of the upper side sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor DIAGNOSIS INSTRUMENT: ADJUSTABLE PARAMETERS Throttle grip self-acquisition: - RESET PROCEDURE •...
Page 180 RSV4 ABS Electrical system Electrical specifications: - Pin out: 1. Power supply 5V 2. Ground connection 3. Output signal DIAGNOSIS INSTRUMENT: PARAMETERS Front Cylinder Intake Pressure (2 and 4) • Example value with key ON: 1003 mbar • Example value with engine on: 720 mbar •...
Page 181 RSV4 ABS Electrical system • If shorted to positive: see that the parameter of the rear cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 182 RSV4 ABS Electrical system • signal not valid. Error cause • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted.
Page 183 RSV4 ABS Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, the pipe between sensor and throttle body is squashed or there is a hole in the intake manifold). Troubleshooting •...
Page 184 RSV4 ABS Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Pressure too low at front cylinder manifold error P0218 •...
Page 185 RSV4 ABS Electrical system 2. B2 green/black: Ground connection DIAGNOSIS INSTRUMENT: PARAMETERS Engine temperature: • Example value with key ON: 25° C • Example value with engine on: 75° C • In case of recovery, this value is set by the control unit: if there is a malfunction after engine start-up, temperature decreases up to approximately 75°.
Page 186 RSV4 ABS Electrical system between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced. •...
Page 187 RSV4 ABS Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature) Level in wiring diagram:...
Page 188 RSV4 ABS Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 189 RSV4 ABS Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 190 RSV4 ABS Electrical system • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time;...
Page 191 RSV4 ABS Electrical system covery value is displayed instead. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 192 RSV4 ABS Electrical system cable (PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable harness. WARNING The control unit does not detects the following malfunctions of the lambda probe circuit according to the signal: interrupted circuit, shorted to ground or sensor malfunction (for example non variable volt-...
Page 193 RSV4 ABS Electrical system LOWER INJECTOR Function To supply the correct amount of petrol at the right timing. The lower injectors work in the field of low engine revs, the upper injectors in the field of high engine revs. Operation / Operating principle Injector coil is excited for the petrol passage to open Level in electrical circuit diagram:...
Page 194 RSV4 ABS Electrical system onds and the injector cable connected to control unit is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation Lower injector cylinder 2 •...
Page 195 RSV4 ABS Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the orange/red cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector. •...
Page 196 RSV4 ABS Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector. •...
Page 197 RSV4 ABS Electrical system Upper injectors key: • 5. Upper injector 1 • 6. Upper injector 3 • 7. Upper injector 2 • 8. Upper injector 4 UPPER INJECTOR Function To supply the correct amount of petrol at the right timing.
Page 198 RSV4 ABS Electrical system Cylinder injection time 2 • Example value with engine on: 1.9 ms Cylinder injection time 3 • Example value with engine on: 1.9 ms Cylinder injection time 4 • Example value with engine on: 1.9 ms CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 199 RSV4 ABS Electrical system activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Upper injector cylinder 1 P0205 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 200 RSV4 ABS Electrical system and the Marelli control unit connector: if not OK, restore. If OK, check cable continuity be- tween PIN 67 and component PIN - and restore the cable harness Upper injector cylinder 3 P0207 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 201 RSV4 ABS Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Low fuel: tells to the instrument panel about low fuel Operation / Operating principle Low fuel: it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol.
Page 202 RSV4 ABS Electrical system 30 seconds. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS fuel pump relay control P0230 • shorted to positive / open circuit, shorted to negative. Error cause •...
Page 203 RSV4 ABS Electrical system strap on engine cable harness); coil 4 with short cable: on the right of the front side of the filter box. Electrical specifications: 0.7 - 0.9 Ω at ambient temperature Pin out: 1. Power supply + Vbatt 2.
Page 204 RSV4 ABS Electrical system The injection relay (No. 33 in the wiring diagram, placed under the saddle, next to the battery positive CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the brown/purple cable of the coil is closed to ground for 2 ms per second.
Page 205 RSV4 ABS Electrical system the ground insulation of the cable (from coil connector or control unit connector), if not OK, restore cable harness. Coil 3 P0353 • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector.
Page 206 RSV4 ABS Electrical system Throttle body Function Sends to the injection control unit the throttle position and activates the throttle according to the control unit Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no elec- trical diagnosis is possible for the throttle body, but for the circuits connected to it only.
Page 207 RSV4 ABS Electrical system is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low (around 5-7°) Rear throttle Potentiometer 1 (degrees) • Example value with key ON: 8° • Example value with engine on: 1.5° With key set to ON, the throttle is kept in position by the springs (around 5 -7°).
Page 208 RSV4 ABS Electrical system Front cylinders throttle Limp Home position • Example value with key ON: 878 mV Voltage stored in the control unit corresponding to the Limp home position Rear cylinders throttle Limp Home position • Example value with key ON: 888 mV Voltage stored in the control unit corresponding to the Limp home position Front throttle lower position...
Page 209 RSV4 ABS Electrical system • carried out/not carried out Indicates whether the self-acquisition process through the diagnostics instrument has/has not been carried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero setting is carried out DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS CAUTION...
Page 210 RSV4 ABS Electrical system (from throttle sensor connector or control unit connector). If it is ground insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 211 RSV4 ABS Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 212 RSV4 ABS Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 213 RSV4 ABS Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 214 RSV4 ABS Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 215 RSV4 ABS Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 216 RSV4 ABS Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 217 RSV4 ABS Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 218 RSV4 ABS Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 219 RSV4 ABS Electrical system • connector: between head cover and fil- ter box on left side (3-ways white con- nector). Electrical specifications: PIN 64: gear indication: closed circuit (continuity); gear engaged: open circuit (infinite resistance). Gear engaged circuit resistance: 1st gear: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th gear 6.9 kohm, 5th gear 2.8 kohm, 6th gear 1.5 kohm.
Page 220 RSV4 ABS Electrical system • If shorted to negative: disconnect the sensor connector and with key set to ON, check Grey/ Black cable voltage: if equal to zero, restore the cable harness; if equal to approx. 5 V, replace the sensor (there is short circuit to ground of the Pink/Black cable in the section from the sensor connector to the sensor or inside the sensor).
Page 221 RSV4 ABS Electrical system both terminals from the sensor and check, with key set to ON, continuity to ground of PIN 2: if there is no continuity, restore the cable harness; if there is, replace the sensor. • indication on the diagnostics instrument always Pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace sensor;...
Page 222 RSV4 ABS Electrical system Side stand sensor: up/down • indication on the diagnostics instrument always down: check the connector: if not OK, re- store; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness;...
Page 223 RSV4 ABS Electrical system NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTICS INSTRUMENT: STATUSES Fall sensor: Normal / Tip over • Indication on diagnostics instrument always Normal, even when the sensor is inverted: dis- connect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor;...
Page 224 RSV4 ABS Electrical system DIAGNOSIS INSTRUMENT: STATUSES Fan relay • on/off DIAGNOSIS INSTRUMENT: ACTIVATIONS • The fan relay (No. 36 in the wiring dia- gram, placed in the headstock niche, left side; CHECK, however, the identi- fication of the relay with the colour of the cables) is energised for 10 sec- onds.
Page 225 RSV4 ABS Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / Operating principle The valve coil is excited to open the air passage of the filter box to the exhaust manifold Level in electrical circuit diagram: Secondary air valve and lambda probe Location:...
Page 226 RSV4 ABS Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
Page 227 RSV4 ABS Electrical system RUN / STOP switch • Run/Stop NOTES • indication on the diagnostics instrument always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - Blue/Green and Yellow/Red: If there is not continuity, replace the sensor;...
Page 228 RSV4 ABS Electrical system The system consists of a throttle valve with a re- turn spring placed on the exhaust pipe. The valve is closed via two cables actuated by an electric motor, which, in turn, is connected electrically to the instrument panel.
Page 229 RSV4 ABS Electrical system Exhaust butterfly valve • Indefinite/in research/activation with key ON/ in operation/stopped for detected malfunction/ research of zero position. NOTE: If there is no problem, it appears: in operation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Exhaust butterfly valve stop research P0191 •...
Page 230 RSV4 ABS Electrical system • open circuit, thermal overload protection, shorted to negative, shorted to positive or short circuit between both cables. Error cause • If the circuit is open: too low current has been detected at PIN 36 - 37 of the instrument panel connector.
Page 231 RSV4 ABS Electrical system connector and if there is voltage, restore cable harness; if there is not voltage, replace in- strument panel, if there is not voltage, replace motor. • If shorted to negative, the circuit is open: check the valve connector and instrument panel connector: if not OK, restore;...
Page 232 RSV4 ABS Electrical system CAUTION BEFORE CARRYING OUT THIS OPERATION, CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12.5 V CAUTION OPERATE ON THE CONTROL MOTOR OF THE EXHAUST VALVE ONLY WITH THE KEY "OFF" OR ONLY AFTER DISCONNECTING THE NEGATIVE POLE OF THE BATTERY. CAUTION NEVER REMOVE THE PULLEY FROM THE CONTROL MOTOR CAUTION...
Page 233 RSV4 ABS Electrical system • After having pressed the enter button for the zero position search, shut off the vehicle and leave the keys in OFF, even in the event that the instruments indicate the opposite. • With the appropriate adjuster screw, tension the upper cable to leave ap- proximately 1.8 mm (0.07 in) between the lock and opening travel limit (4) of...
Page 234 PIN1 - Signal • PIN2 - Ground DIAGNOSTICS INSTRUMENT: STATUSES Quick shift (electronic transmission) control status: Activated released. Aprilia Quick Shift: Present/Not present DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS Quick Shift sensor (electronic transmission) P0462. • Shorted to negative (upon key-ON)/Signal not valid.
Page 235 RSV4 ABS Electrical system PIN 1 - Marelli ECU PIN 47): if OK, check pink cable and black cable insulation; if NOT OK, restore cable harness; if pink/black cable insulation is OK, replace the Marelli control unit; if NOT OK, restore cable harness.
Page 236 RSV4 ABS Electrical system "+" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error. "-" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error DIAGNOSTICS INSTRUMENT: ELECTRICAL ERRORS "+" button sensor P0720: •...
Page 237 RSV4 ABS Electrical system • Open contacts/Closed contacts Error cause: With open contacts, a voltage over zero is detected at the same time at PIN 18 and PIN 19 of the instrument panel. With closed contacts, zero voltage is detected at the same time at PIN 18 and PIN 19 of the instrument panel.
Page 238 RSV4 ABS Electrical system Inertial sensor platform (sensor box) Function: To transmit information about the motorcycle dy- namics to the Marelli control unit (e.g.: yaw rate). Electrical circuit diagram - Level in wiring dia- gram: Traction control. Location on the vehicle: Fastened to the fuel tank, under the seat.
Page 239 RSV4 ABS Electrical system Sensor box error (inertia sensor platform) P0713 • Faulty sensor/Signal not valid Troubleshooting: With faulty sensor, the component inside the control unit is damaged and replacement of the control unit is recommended. With signal not valid, the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error.
Page 240 RSV4 ABS Electrical system Analogue ground connection 1 PIN 6/17 Lower cylinder 1 injector control output PIN 8 Lambda sensor input (+) PIN 10 Track D hand grip input PIN 11 Water temp. sensor input PIN 12 Track B hand grip input PIN 13 Serial line K for diagnosis PIN 14 Front throttle motor output (-) PIN 15 Power ground connection 2 PIN 16...
Page 241 RSV4 ABS Electrical system Vehicle pinout key: Upper cylinder 1 injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Variable geometry control unit control output PIN 62 Reference voltage output + 5V: tracks B-D and front throttle PIN 63 Neutral input PIN 64 Fall sensor input PIN 65...
Page 242 RSV4 ABS Electrical system Side stand input PIN 70 Gear input PIN 72 Injection relay control output PIN 73 Upper cylinder 3 injector control output PIN 74 Variable geometry control unit fault input PIN 76 "engine stop" input PIN 78 Vehicle speed input PIN 79 CAN H line (high speed) PIN 80 Engine - vehicle connector pinout key:...
Page 243 RSV4 ABS Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 243...
Page 244 RSV4 ABS Electrical system 4 High beam lights input 5 Normally open button "1" 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control 13 Normally closed button "+"...
Page 245 RSV4 ABS Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1 35 Low beam light relay activation 36 Exhaust valve A control output 37 Exhaust valve B control output...
Page 246 RSV4 ABS Electrical system Rear speed sensor input PIN 14 ABS warning light PIN 17 Battery for pump engine positive PIN 18 Can line Function It allows communication between the Marelli injection ECU and the instrument panel. Operation / operating principle CAN SYSTEM ADVANTAGES A CAN (controller Area network) line is a connection among the vehicle several electronic devices, organised as a computer network (Internet).
Page 247 RSV4 ABS Electrical system CAN line Electrical characteristics: • between PIN 66 and 80 of the control unit: approximately 130 Ohm • between PIN 26 and 27 of the instrument panel: approximately 120 Ohm Pin out: • Line L: white/black cable between Marelli control unit PIN 66 and the black-bodied connector PIN 27 of the instrument panel.
Page 248 RSV4 ABS Electrical system • no signal. Error cause • No signal is received from the instrument panel. Troubleshooting • Check the connector of the instrument panel: if not OK, restore; if OK, check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness;...
Page 249 RSV4 ABS Electrical system the vehicle cable harness; if OK, check the continuity across instrument panel pin 27 and ABS control unit connector pin 11. If NOT OK, replace the cable harness; if OK, check for the correct power supply (12V) at pins 1 and 11 and ground at pins 38,39, 40 of the instru- ment panel connector.
Page 250 (Sensor box), the correct status we should find on the diagnostics instrument devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a vehicle equipped with inertia sensor platform (Sensor...
Page 251 RSV4 ABS Electrical system • CAN error during acquisition/Invalid value. Error cause • In case of CAN error during acquisition, system warns that the procedure can not be com- pleted due to a communication problem on the CAN line. In case of invalid value, it means that on key-ON an error of transcription occurred - from the non-volatile memory (EEPROM) to the volatile one (RAM) - of the value concerning the rear wheel radius.
Page 252 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 253 RSV4 ABS Engine from vehicle ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lb ft) Threaded spacer 8 Nm (5.9 lb ft) TSPEI screw M6x35 10 Nm (7.38 lb ft) Loct. Self-locking nut 25 Nm (18.44 lb ft) Gearbox linkage joint to gearbox lev- 8 Nm (5.90 lb ft)
Page 254 RSV4 ABS Engine from vehicle • Fasten an appropriately sized belt for the weight of the vehicle to the semi-handlebars and to a hoist. • Fit the rear and front stands. • Fit the specific under-sump engine support plate. Specific tooling 020864Y Engine mounting plate See also Fairing mounting panels...
Page 255 RSV4 ABS Engine from vehicle • Remove the timing sensor. • Remove the engine oil pressure sen- sor. • Remove the rubber cap. • Unscrew and remove the nut, retrieve the washer and disconnect the starter motor. • Unscrew and remove the screw, re- move the cable grommet and detach the three ground cables.
Page 256 RSV4 ABS Engine from vehicle • Unscrew and remove the nut and re- trieve the washer. • Detach the ground from the chassis. • Working on the right hand side of the vehicle, detach the exhaust valve con- trol unit connector. •...
Page 257 RSV4 ABS Engine from vehicle • Unscrew and remove the pinion fixing screw and retrieve the two washers. • Loosen the drive chain adjuster screws. • Loosen the rear wheel fixing nut. • Remove the pinion, releasing it from the drive chain. •...
Page 258 RSV4 ABS Engine from vehicle • Detach the neutral sensor. See also Side stand • Remove the hand grip position sensor from the chassis. • Disconnect the voltage regulator con- nector. See also Twistgrip position sensor ENG VE - 258...
Page 259 RSV4 ABS Engine from vehicle • Disconnect the alternator connector. • Working from the left hand side of the vehicle, unscrew and remove the screw and retrieve the washer. • Unscrew and remove the three plate fixing screws and remove the plate. •...
Page 260 RSV4 ABS Engine from vehicle • Disconnect the quick-shift connector. • Cut the ties fastening the cable har- ness to the engine. • Loosen the screw and slide off the gear shift lever and cable harness from the engine. ENG VE - 260...
Page 261 RSV4 ABS Engine from vehicle • Working on the left hand side of the vehicle, unscrew and remove the two screws and retrieve the respective plates. • Working on the right hand side of the vehicle, unscrew and remove the two screws and retrieve the respective plates and washers.
Page 262 RSV4 ABS Engine from vehicle • Unscrew and remove the screw and retrieve the nut. • Unscrew the upper adjuster screw bushing until it turns no more. • Working on the right side of the vehicle, unscrew and remove the nut and re- trieve the washer.
Page 263 RSV4 ABS Engine from vehicle • Remove the clamps on the saddle mounting. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SECOND OPERATOR. • Lower the engine • Lift the front part of the vehicle. • Remove the front stand. •...
Page 264 RSV4 ABS Engine from vehicle The height of the swingarm pin relative to the chassis is adjusted with special inserts installed in the respective seats in the chassis. The hole is offset by -2.5 mm (- 0.098 in) relative to the cen- treline of the insert, as a result the swingarm is in the low position.
Page 265 RSV4 ABS Engine from vehicle • With the help of a second operator, secure the vehicle chassis with a hoist and onto a front and rear stand and lift the engine to place it in position. Specific tooling 020864Y Engine mounting plate Centring the engine on the chassis CAUTION PAY SPECIAL ATTENTION DURING CENTRING PHASE OF THE ENGINE ON THE CHASSIS.
Page 266 RSV4 ABS Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: • tighten the two front screws (1) to the prescribed torque.
Page 267 RSV4 ABS Engine from vehicle • Place the radiator frame, the washer and tighten the screw, fastening the frame to the engine. • Place the gear lever and tighten the screw. • Position the quick-shift cable harness and fasten using ties. •...
Page 268 RSV4 ABS Engine from vehicle • Connect the alternator connector. • Connect the voltage regulator connec- tor. • Position and fix the hand grip position sensor to the chassis. WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS. •...
Page 269 RSV4 ABS Engine from vehicle • Place the two fuel breather pipes. • Install the side stand. • Place the pinion and insert the trans- mission chain in the seat. • Tighten the rear wheel fixing nut. • Adjust the drive chain adjuster screws. •...
Page 270 RSV4 ABS Engine from vehicle • Place the pinion cover and tighten the three screws. • Connect the vehicle cable harness / engine cable harness connector. • Working on the right side of the vehicle, connect the exhaust valve control unit connector.
Page 271 RSV4 ABS Engine from vehicle • Place the cable grommet and the three cable leads as shown. • Tighten the cable grommet fixing screw. • Connect the starter motor, place the washer and tighten the nut. • Place the rubber cap. •...
Page 272 RSV4 ABS Engine from vehicle • Connect the clutch cable. • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in). ENG VE - 272...
Page 273 INDEX OF TOPICS NGINE...
Page 274 RSV4 ABS 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 275 RSV4 ABS Engine Gearbox Diagram pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw 10 Nm (7.37 lbf ft)
Page 276 RSV4 ABS Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw. • Unscrew and remove the six screws. ENG - 276...
Page 277 RSV4 ABS Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 278 RSV4 ABS Engine • Remove both gearbox shafts from the cover. • Collect the shim washer that is located on the secondary shaft between the shaft and the cover. • Unscrew and remove the screw. • Remove the selector drum. DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE, ALTERNATOR SIDE •...
Page 279 RSV4 ABS Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in) Checking the secondary shaft...
Page 280 RSV4 ABS Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.5 mm (0.020 in) Minimum wear limit of the selection fork guide pins 6.8 mm (0.27 in) Maximum eccentricity of the two fork guide shafts...
Page 281 RSV4 ABS Engine • Grease the bushings. • Introduce the forks in their respective seats. • Insert the desmodromic gearbox con- trol rod on the cover. • Position the selector drum. • Turn the screw without tightening it. • Position the fork bushings into the grooves on the desmodromic control rod.
Page 282 RSV4 ABS Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for secondary gearbox shaft •...
Page 283 RSV4 ABS Engine • Tighten the selector drum screw. • Insert the driving pin on the oil pump shaft. • Install the water/oil pump control gear. • Insert the Seeger ring. • Install the gear sensor, making the pin coincide with the slot on the desmo- dromic control rod.
Page 284 RSV4 ABS Engine GEARBOX CONTROL ROD ROLLER CAGE, CLUTCH SIDE • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side. Specific tooling 020862Y Gearbox control rod roller cage fitting punch •...
Page 285 RSV4 ABS 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 286 RSV4 ABS Engine Removing the idle gear • Remove the clutch cover. • Remove the intermediate gear. Start-up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL. Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed.
Page 287 RSV4 ABS 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 288 RSV4 ABS Engine • Fit the intermediate gear. • Fit the clutch cover. Generator side LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft) side Blow-by union fastener screws...
Page 289 RSV4 ABS Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 290 RSV4 ABS Engine • Remove the flywheel cover. • Block flywheel rotation using the spe- cific tool. • Unscrew and remove the screw. Specific tooling 020848Y Flywheel retainer (Mitsubishi) 020914Y Flywheel retainer • Remove the tool for blocking flywheel rotation. •...
Page 291 RSV4 ABS Engine • Remove the flywheel cover. • Remove the Seeger ring. • Remove the shim washer. • Remove the oil seal. CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE. SET THE NEW OIL SEAL WITH THE MARKING ON THE EDGE FACING OUTWARD.
Page 292 RSV4 ABS Engine Flywheel cover installation • Insert the centring dowels in the cover. • Apply a layer of sealing paste along the external edge of the cover. • Insert the cover together with the sta- tor. Recommended products Three bond Sealing paste •...
Page 293 RSV4 ABS Engine Clutch side LUTCH COVER pos. Description Type Quantity Torque Notes Engine speed sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) Flanged TE screws M6x35 12 Nm (8.85 lbf ft) Flanged TE screws M6x22 12 Nm (8.85 lbf ft)
Page 294 RSV4 ABS Engine Removing the clutch cover • Drain the engine oil. • Unscrew and remove the sixteen peri- metric fixing screws and retrieve the washers • Remove the clutch casing, retrieving the gasket, the two locator pins and the starter motor transmission gear.
Page 295 RSV4 ABS Engine • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch retainer • Remove the slipper unit. • Remove the clutch hub. • Remove the clutch hub cam tower. ENG - 295...
Page 296 RSV4 ABS Engine • Collect the shim washer. • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 296...
Page 297 RSV4 ABS Engine • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in) Minimum wear limit of the complete clutch...
Page 298 RSV4 ABS Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness.
Page 299 RSV4 ABS Engine Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded; if necessary, replace the springs all together.
Page 300 RSV4 ABS Engine • Fit the needle cage. • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion •...
Page 301 RSV4 ABS Engine • Install the clutch hub cam tower. • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • The slipper springs are distinguishable by the cleats. In the 0.8mm spring (1) there is only one notch, while in the 0.9mm spring (2) there are two notch- LIPPER SPRINGS...
Page 302 RSV4 ABS Engine • Fit the three slipper unit clips, offsetting them by 120°. • Install the slipper unit correctly. • Where specified in the table, insert the washer (1) • Block clutch bell rotation using the spe- cific tool. •...
Page 303 RSV4 ABS Engine • Insert one of the metal discs into the bell. • Insert the flat washer. • Insert the belleville spring with the con- cave side facing outward. • Insert the disc covered with the friction material into the bell. ENG - 303...
Page 304 RSV4 ABS Engine • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer. •...
Page 305 RSV4 ABS Engine USE THE SAME SOLUTION FOR ALL THE STUD BOLTS. ORANGE SPRING CAUTION PAY ATTENTION WHEN REFITTING, RESPECT THE SEQUENCE OF SCREW, CAP, LINING AND SPRING. • Fit the clutch springs (4). • Insert the spring holder cap (2) and the shimming washers (3) onto the screws (1).
Page 306 RSV4 ABS Engine Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the removal of the bushing, it is necessary to thread the inside to allow the extractor to tighten sufficiently. • Warm up the cover. •...
Page 307 RSV4 ABS Engine • Then insert the tool to push the bushing into the seat until it stops. NOTE IN THE EVENT OF SHAFT OR OIL SEAL REPLACEMENT, REFER TO THE TABLE AND ALWAYS VERIFY THE CORRECT SIZING. CLUTCH COVER AND COMPONENTS Model Engine No.
Page 308 RSV4 ABS Engine Heads ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) ENG - 308...
Page 309 RSV4 ABS Engine HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve cover fixing screws 6 Nm (4.42 lbf ft) Water outlet union fixing screw 12 Nm (8.85 lbf ft) Loct.
Page 310 RSV4 ABS Engine Head cover removal • Unscrew and remove the three screws with rubber washers. • Remove the head cover together with the sealing gasket. INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure.
Page 311 RSV4 ABS Engine Removing camshafts • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft. • Remove the O ring. See also Head cover removal Removing the flywheel cover •...
Page 312 RSV4 ABS Engine • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin • Remove the two crankshaft and cam- shaft reference pins.
Page 313 RSV4 ABS Engine ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1). •...
Page 314 RSV4 ABS 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 315 RSV4 ABS Engine Check the timing chain for damage or stiffness while moving. If necessary, replace the timing chain together with the camshaft gears. Check the timing chain guide sliders for damage. If necessary, replace the parts. Installing camshafts NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY.
Page 316 RSV4 ABS Engine • Move the gear from the mounting tool to the camshaft. • Unscrew and remove the two screws (1). • Remove the tool. Specific tooling 020865Y Support for camshaft gear on head • Fit the U bolt and the oil pipe. •...
Page 317 RSV4 ABS Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 318 RSV4 ABS Engine 020852Y Crankshaft timing pin Front head removal • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft. • Remove the O ring. See also Head cover removal Removing the flywheel cover •...
Page 319 RSV4 ABS Engine 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft 150° in the engine rotation direction (direction of travel), in order to align the hole on the intake camshaft with the specific hole on the U bolt;...
Page 320 RSV4 ABS Engine • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes. • Remove the U bolts with the O rings and locator pins.
Page 321 RSV4 ABS Engine • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. •...
Page 322 RSV4 ABS Engine Front head check Check that: • 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 323 RSV4 ABS Engine • Insert the chain tensioner into the crankcase, being careful to position it correctly. WASHER We recommend installing a washer between the crankcase and the chain tensioner to optimise the functionality of the timing system. This washer is available as a spare part. •...
Page 324 RSV4 ABS Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order. •...
Page 325 RSV4 ABS Engine • Install both chain sliders and fasten them with the specific screws. • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 326 RSV4 ABS Engine NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts 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 camshaft gear (indicated with two dots).
Page 327 RSV4 ABS Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin. Specific tooling 020851Y Camshaft timing pin •...
Page 328 RSV4 ABS Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 329 RSV4 ABS Engine Rear head Removing camshafts • Remove the rear head cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC; • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel).
Page 330 RSV4 ABS Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. •...
Page 331 RSV4 ABS Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 332 RSV4 ABS Engine Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES • Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
Page 333 RSV4 ABS Engine Installing camshafts • Install the intake and exhaust cam- shafts on the rear head, remembering that: the intake camshaft gear tooth (indicated with a dot) is inserted in the groove of the exhaust cam- shaft gear (indicated with two dots). CLEAN THOROUGHLY THE SEATS OF THE GEAR RE- TAINER SCREWS, ON THE INTAKE CAMSHAFT.
Page 334 RSV4 ABS Engine • Align the intake camshaft with the spe- cific hole on the U bolt. • Insert the specified pin. Specific tooling 020851Y Camshaft timing pin • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 335 RSV4 ABS Engine screw. This screw must be replaced at each reassembly. • Tighten the second camshaft gear fix- ing screw to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin •...
Page 336 RSV4 ABS Engine 020848Y Flywheel retainer See also Head cover removal Removing the clutch cover Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en- gine rotation (direction of travel) to align the hole on the intake camshaft with the specific hole on the U bolt.
Page 337 RSV4 ABS Engine • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes. • Remove the U bolts with the O rings and locator pins.
Page 338 RSV4 ABS Engine • Unscrew and remove the two head fas- tener screws (a - b) from the clutch side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. •...
Page 339 RSV4 ABS Engine Rear head check Check that: • 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 340 RSV4 ABS Engine • Insert the chain tensioner into the crankcase, being careful to position it correctly. WASHER We recommend installing a washer between the crankcase and the chain tensioner to optimise the functionality of the timing system. This washer is available as a spare part. •...
Page 341 RSV4 ABS Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order. •...
Page 342 RSV4 ABS Engine • Install both chain sliders and fasten them with the specific screws. NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the rear head, remembering that: the intake camshaft gear tooth (indicated with a dot) is inserted in the groove of the exhaust camshaft gear (indicated with two dots).
Page 343 RSV4 ABS Engine • Check the number engraved on the U bolts, which must correspond with the one engraved on the head. • If the U bolts between the two heads are inverted, camshaft seizure may oc- IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT, IF NECESSARY: REPLACE THE ENTIRE HEAD.
Page 344 RSV4 ABS Engine • Protect the edge of the head with rubber. • Load the chain tensioner with special tool. Specific tooling 020855Y Lever for engaging the chain tensioner • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied.
Page 345 RSV4 ABS Engine • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock 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;...
Page 346 RSV4 ABS Engine See also Front head removal Rear head removal • Remove the cotters using a magnet. • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING.
Page 347 RSV4 ABS Engine 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. 10 mm (0.39 in) from its seat.
Page 348 RSV4 ABS Engine Position the dial gauge at a right angle to the valve head face and measure the eccentricity. If the eccentricity exceeds the specified limit, re- place the valve. Characteristic Valve head eccentricity 0.03 mm (0.0012 in) Coating may get slightly damaged in the indicated area.
Page 349 RSV4 ABS Engine • Fit the caps. • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor •...
Page 350 RSV4 ABS Engine - V4-A 3017 - V4-A 3635 - V4-A 4153 - V4-A 4180 - V4-A 4205 the engine has been equipped with a new valve timing system spring kit. The procedure for installing the new springs is the same as the procedure described for the previous springs.
Page 351 RSV4 ABS Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 352 RSV4 ABS Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct. 243 8674 ENG - 352...
Page 353 RSV4 ABS Engine RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 354 RSV4 ABS Engine • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. • Remove the key on countershaft ENG - 354...
Page 355 RSV4 ABS Engine • Remove the spacer. • Remove the countershaft on the oppo- site side. Balancing countershaft fitting • Install the spacer. THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE. • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear.
Page 356 RSV4 ABS Engine • Insert the countershaft from the alter- nator side. • Turn the countershaft until aligning the key seat on the countershaft and on the gear. • Insert the drive key. • Place the washer. • Turn the nut on the countershaft. •...
Page 357 RSV4 ABS Engine • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. See also Disassembling the clutch • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock •...
Page 358 RSV4 ABS Engine Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO...
Page 359 RSV4 ABS Engine • alternator; • water pump; • gearbox unit; • primary drive shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear; • countershaft.
Page 360 RSV4 ABS Engine • Turn the engine with the heads facing downward and loosen the screws in the following order: 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7. •...
Page 361 RSV4 ABS Engine Removing connecting rods - pistons • Remove both heads. • Open the crankcases. • Install the tool that keeps the crank- shaft in position. Specific tooling 020857Y Crankshaft bearing U bolt See also Front head removal Rear head removal •...
Page 362 RSV4 ABS Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Crankshaft removal • Separate the crankcases, removing the lower part • If the heads were removed, position the specific special tool to keep the pis- tons from coming out.
Page 363 RSV4 ABS Engine Bearing removal BALANCING COUNTERSHAFT BEARING RE- MOVAL • Remove the lower crankcase. • Remove the countershaft. FLYWHEEL-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302° •...
Page 364 RSV4 ABS Engine Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0.5 mm (0.0197 in) Maximum radial clearance between the main bearings and the crankshaft pins 0.05 mm (0.00197 in) Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0.1 mm (0.0039 in) Connecting rod check Characteristic...
Page 365 RSV4 ABS Engine Maximum permitted clearance between piston ring 1 (starting from the bottom) and the corre- sponding slot on the piston 0.1 mm (0.0039 in) Maximum permitted clearance between piston ring 2 (starting from the bottom) and the corre- sponding slot on the piston 0.1 mm (0.0039 in) Maximum opening of the piston ring fit on the pin Piston ring 1 (from the bottom)
Page 366 RSV4 ABS 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 Balancing class combinations for...
Page 367 RSV4 ABS Engine If a selection class of connecting rods is fit on the crankshaft that is not class D - D, it is not a problem. It is essential, for proper crankshaft balance, that if one connecting rod is replaced the other one fit on the same crank pin must also be replaced: •...
Page 368 RSV4 ABS Engine Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings. The category is marked on the crankcase, on the right side, in the area below the crankshaft. Different classes of bearings can be used (e.g.: A - B - C or B - B - C or A - B - A ..).
Page 369 RSV4 ABS Engine pling (e.g. A - B - A or B - B - A etc.) o (e.g.: C - D - E or D - C - C etc.) . 3990 RANKSHAFT CATEGORY UP TO ENGINE Specification Desc./Quantity Class A Main journals - diameter: 46,005 - 46,000 mm (1,8112 - 1,8110 Class B...
Page 370 RSV4 ABS Engine CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available: • Blue • • Yellow There are no dimension classes for the crank pins or the connecting rods. As a result, only the two semi-bushing combinations are possible: 1.
Page 371 RSV4 ABS Engine Bearing fitting BALANCING COUNTERSHAFT BEARING INSTALLATION FLYWHEEL-SIDE • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020364Y 25 mm Adaptor 020359Y 42 x 47 mm punch 020376Y Adapter handle • Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase.
Page 372 RSV4 ABS Engine • Fit the retainer in the bearing groove. • Tighten the bearing retainer screw. CLUTCH-SIDE • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020363Y Crankshaft oil seal punch D 20 mm 020359Y 42 x 47 mm punch 020376Y Adapter handle •...
Page 373 RSV4 ABS Engine • Fit the retainer in the bearing groove. • Tighten the bearing retainer screw. • Install the balancing countershaft. Crankshaft fitting NOTE ACCORDING TO THE TYPE OF CRANKSHAFT, ITS INSTALLATION WILL FOLLOW TWO DIF- FERENT PROCEDURES ("OPTION 1" AND "OPTION 2"). OPTION 1 Crankshaft with removable gear.
Page 374 RSV4 ABS Engine Position the sprocket (2) with the smooth side fac- ing the inside of the crankshaft. Move the sprocket (2) up against the crankshaft shoulder. OPTION 2 Crankshaft with non removable gear. When refitting the primary gear, remember to first place the lining as shown in the figure.
Page 375 RSV4 ABS Engine • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR.
Page 376 RSV4 ABS Engine ISTONS AND PISTON RINGS COUPLING Model Engine No. Crankcase selections Piston type Piston ring MY 2009/2010 - "V4" Marking from 1006 to 9269 without marking Chrome steel (all engines) band EUROPE MY2011 - "V4" from 7999 to 8784 with "A"or"B"...
Page 377 RSV4 ABS Engine NOTE THERE ARE THREE TYPES OF PISTON MARKINGS ON THE ENGINE: • PISTON WITHOUT MARKING. • PISTON WITH MARKING "A" OR "B". • PISTON WITH MARKING "AW" OR "BW". ACCORDING TO THE TYPE OF PISTON MARKING, SE- LECT THE CORRESPONDING RING.
Page 378 RSV4 ABS Engine ling on the connecting rod head must face outward of its crank pin. Specific tooling 020856Y Piston installation ring • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces. •...
Page 379 RSV4 ABS Engine Crankcase closing • Insert the crankshaft together with con- necting rods and pistons in the upper crankcase. • Position the three centring dowels in the crankcase. • Insert a new oil seal O ring in the spe- cific seat.
Page 380 RSV4 ABS Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 380...
Page 381 RSV4 ABS Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase Lubrication ENG - 381...
Page 382 RSV4 ABS Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft) Oil sump fixing screws...
Page 383 RSV4 ABS Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor. •...
Page 384 RSV4 ABS Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle. Installing •...
Page 385 RSV4 ABS Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat.
Page 386 RSV4 ABS Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor. •...
Page 387 RSV4 ABS Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket. CAUTION THE ROSE PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER-...
Page 388 RSV4 ABS Engine Blow-by The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 389 RSV4 ABS Engine Diagram Valve controlled by control unit which delivers as- pirated air from the filter box to the exhaust mani- folds. The advantages of this function are twofold: • the catalytic converter reaches the op- erating temperature more quickly; •...
Page 390 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 391 RSV4 ABS Power supply Fuel pump Removing • Remove and empty the fuel tank. • Loosen the pipe grommet screw. • Detach the fuel pipe. • Unscrew and remove the screws. • Remove the fuel pump. Injection P SUPP - 391...
Page 392 RSV4 ABS Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor 4. Outlet valve P SUPP - 392...
Page 393 RSV4 ABS Power supply 5. Clutch position sensor 6. Fuel pump (inside the tank) 7. Air temperature sensor 8. Air pressure sensor (MAP) 9. Lower injectors 10.Upper injectors 11.Coils (spark plug cover) 12.Engine throttle valves 13.Throttle valve position sensor 14.Electric fan 15.Starter motor 16.Gear position sensor 17.Secondary air injection valve...
Page 394 RSV4 ABS 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 395 RSV4 ABS Power supply Air box UPPER INJECTORS • Remove the control unit. • Disconnect the injector connectors. • Unscrew and remove the injector fixing screws. • Remove the upper injectors, identified by green collars. See also Control unit Removing the throttle body •...
Page 396 RSV4 ABS Power supply • Disconnect the lower injector connec- tors. See also Air box • Disconnect the connector. • Remove the complete throttle body. Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction.
Page 397 RSV4 ABS 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 398 RSV4 ABS Power supply a variable geometry control unit for managing the system, interfaced with the engine injection control unit Operation At key-ON, the variable geometry control unit low- ers the ducts (if still in the raised position). Subsequently, depending on the control voltage on PIN 2 from the injection ECU (0V down, 5V up), the ECU drives the electric motor with the relative polarity for raising or lowering the ducts.
Page 399 RSV4 ABS Power supply Variable geometry intake Variable geometry intake Cylinders synchronisation The control unit receives information on the intake pressure in the four ducts from the two pressure sensors: as the control unit knows the timing phase of the cylinders, it can calculate the individ- ual pressure of the four cylinders.
Page 400 RSV4 ABS Power supply The procedure then continues with screws 1 and If necessary, operate on the Master screws (1-4) as follows: • Remove the filter casing cover. • Remove the four fixing screws of the cones with variable height (1) (IF FIT- TED).
Page 401 INDEX OF TOPICS SUSP USPENSIONS...
Page 402 RSV4 ABS Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lb ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 Removing the front wheel •...
Page 403 RSV4 ABS Suspensions • Remove the wheel axle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps. • Tap the wheel axle slightly with a rub- ber mallet so that the hole on the op- posite side is exposed.
Page 404 RSV4 ABS Suspensions • Replace both wheel bearings. RADIAL AND AXIAL CLEARANCE CHECK • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: •...
Page 405 RSV4 ABS Suspensions Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes Screw fastening the semi-handlebar 1 + 1 25 Nm (18.44 lbf ft) collar to the fork sleeves Semi-handlebar safety screw 10 Nm (7.37 lbf ft) Anti-vibration counterweight fastener M18x1.5 20 Nm (14.75 lbf ft) Right light switch...
Page 406 RSV4 ABS Suspensions LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) Front fork Diagram SUSP - 406...
Page 407 RSV4 ABS Suspensions RONT FORK pos. Description Type Quantity Torque Notes Fastener screws for calliper mount- 2 + 2 12 Nm (8.85 lb ft) ing bracket (Öhlins) Odometer sensor fixing screw 10 Nm (7.38 lb ft) Speed sensor bracket screws Adjustment Standard front fork setting is adjusted to suit most high and low speed riding conditions, whether the...
Page 408 RSV4 ABS Suspensions NOTE TO CHECK FOR FRONT FORK FAILURE, MEASURE THE DIFFERENCE BETWEEN THE BEGINNING OF THE WHEEL HUB AND THE END OF THE FORK SLEEVE Removing the fork legs • Remove the front wheel. • Support the fork stanchion and loosen the screws on the upper yoke.
Page 409 RSV4 ABS Suspensions Draining oil (PROCEDURE FOR OHLINS FORKS) • Fix the fork in a vice, taking care not to damage the fork. • Set the minimum spring preloading. • Unscrew the upper cap from the sleeve using a specific Öhlins tool. •...
Page 410 RSV4 ABS Suspensions • Loosen and remove the nut, keeping the preload spring slightly com- pressed. • Remove the lock nut for the preload spring • Remove the preload spring • Drain the fork oil into a specific con- tainer, taking care not to allow the pre- load pipe and the hydraulic rebound damping brake adjustment pipe to es- cape.
Page 411 RSV4 ABS Suspensions • Using the appropriate tool fasten the fork in the vice. Specific tooling AP8140149 Protection for fitting operations • 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.
Page 412 RSV4 ABS Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring. • Insert a spanner in the lock nut of the cover. Specific tooling 020888Y Pliers for pre-fill pipe • Unscrew the cap and remove it. •...
Page 413 RSV4 ABS Suspensions • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 414 RSV4 ABS Suspensions • Use a plain slot screwdriver to lift up the dust gaiter (3) in multiple points and re- move from the sleeve (2). • Use a plain slot screwdriver to remove the snap ring (4). • Use a plain slot screwdriver to remove the oil seal (5).
Page 415 RSV4 ABS Suspensions • Use the Öhlins tool to unscrew the pumping member pin fixing ring nut. • Remove the pumping member pin unit. • Remove the spring guide snap ring (1) • Remove the spring guide support ring • Remove the spring guide (3), noting its direction of installation to ensure cor- rect reassembly.
Page 416 RSV4 ABS Suspensions • Remove the rubber O ring. • Remove the guide bushing and the counterspring. (PROCEDURE FOR SACHS FORKS) • Discharge the fork, remove the internal dipstick of the pumping member pin (1) and the washer (2). • Operate repeatedly on the pumping member pin (3) so as to drain com- pletely the oil from inside.
Page 417 RSV4 ABS Suspensions • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem. •...
Page 418 RSV4 ABS Suspensions • Remove the pumping member pin. Checking the components (PROCEDURE FOR OHLINS FORKS) Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
Page 419 RSV4 ABS Suspensions Check that the following components are in good conditions: • sliding bushing; • guide bushing; • piston. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE.
Page 420 RSV4 ABS Suspensions A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS. Characteristic Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check that the spring is in good conditions.
Page 421 RSV4 ABS Suspensions Replace the following components with new ones: • seal ring; • dust gaiter; • O-Ring on the cap. Reassembling the fork (PROCEDURE FOR OHLINS FORKS) • Insert the guide bushing and the coun- terspring. SUSP - 421...
Page 422 RSV4 ABS Suspensions • Insert the rubber O ring. • Insert the ring nut, on which the threa- ded pipe is attached, on the pumping member pin. • Insert the rubber buffer (6). • Insert the spring guide support ring (5), noting the internal milling allowing the spring guide retainer ring to be instal- led against the support ring.
Page 423 RSV4 ABS Suspensions • Insert the pumping member pin unit. • Use the Öhlins tool to tighten the pumping member pin fixing ring nut to 40 Nm (29.50 lbf ft). • 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 424 RSV4 ABS Suspensions • Fit the retainer ring (4) into its seat on the sleeve (2). • Push the dust gaiter (3) into its seat on the sleeve (2), ensuring that it is loca- ted correctly. • Grip the stanchion and move it repeat- edly and slowly in opposite directions.
Page 425 RSV4 ABS 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 Oil seal fitting tool for Ø...
Page 426 RSV4 ABS Suspensions • Refill the fork with oil according to the prescribed quantity. • Fit the spring. CAUTION BE CAREFUL WHEN INSERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN- WARDS. See also Filling oil • Fit the dust gaiter with the specific tool.
Page 427 RSV4 ABS Suspensions • Using a hook spanner lock the pump- ing member pin and tighten the fixing screw on the fork end to the prescribed torque. Specific tooling 020889Y Pumping member ring nut locking spanner • Insert the spring guide and lock it by the appropriate seeger. •...
Page 428 RSV4 ABS Suspensions • Tighten the nut as much as possible. • Insert the cover and tighten until it stops. • Remove the specific tools. • Screw the cover in the sleeve to the prescribed torque. Filling oil (PROCEDURE FOR OHLINS FORKS) •...
Page 429 RSV4 ABS Suspensions Oil level: 110 mm (4.33 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS. Characteristic Fork oil 530 cc (0.12 Uk gal) (for each stanchion)
Page 430 RSV4 ABS Suspensions • Tighten the cap using a wrench to block the lower spring ring nut. • Tighten the upper adjustment cap to bring it into contact with the lower nut on the cap. • Use the specific Öhlins tool to tighten the upper cap on the sleeve to 20 Nm (14.75 lbf ft). (PROCEDURE FOR SACHS FORKS) •...
Page 431 RSV4 ABS Suspensions Adjusting The steering damper may be adjusted by turning the knob (1). • Turn the knob (1) clockwise to stiffen the steering. • Turn the knob anticlockwise to loosen the steering. SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES.
Page 432 RSV4 ABS Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lb ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lb ft) chions Headstock lock ring M35x1 60 Nm (44.25 lbf ft) Headstock counter-lock ring M35x1...
Page 433 RSV4 ABS Suspensions • Loosen the screws fixing the fork stan- chions to the upper yoke. • Working from both sides, unscrew and remove the semi-handlebar screws. • Remove the upper yoke • Rivet the safety washer on the head- stock.
Page 434 RSV4 ABS Suspensions • Undo the counter-lock ring, remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly. • Tighten the lower lock ring to a torque of 70 Nm (51.63 lbf ft). •...
Page 435 RSV4 ABS Suspensions • Fit the safety washer and bend the two opposing tabs into the notches on the lock ring. • Fit the counter-lock ring, hand tighten- ing only. • To allow the tabs to be bent into the notches of the counter-lock ring in or- der to lock the ring, the counter-lock ring may be tightened further by up to...
Page 436 RSV4 ABS Suspensions Disassembling • Remove the steering assembly com- pletely. • Unscrew and remove the lower dowel fastening the collar. • Remove the lower collar. • Unscrew and remove the upper dowel fastening the collar. • Remove the upper collar. CAUTION ALWAYS CHANGE BOTH COLLARS (UPPER AND LOW- ER).
Page 437 RSV4 ABS Suspensions • Repeat the procedure for the lower bushing. • Fit the steering assembly and restore the correct steering bearing free play. See also Adjusting play Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on...
Page 438 RSV4 ABS Suspensions Removing the rear wheel • Place the vehicle on its rear service stand. • Loosen and remove the nut on the wheel axle. • Retrieve the thrust washer and the left hand chain tensioner slider. • Tap the wheel axle slightly to extract the head from its seat.
Page 439 RSV4 ABS Suspensions DO NOT UNSCREW THE FIVE NUTS. THE FINAL TRANS- MISSION UNIT CAN BE SLID OFF COMPLETELY FROM THE ANTI-VIBRATION BUFFER HOLDER. • Remove the final transmission unit. CAUTION THE FLEXIBLE COUPLINGS REMAIN FITTED ON THEIR HOLDER. • Remove all the flexible couplings.
Page 440 RSV4 ABS Suspensions TO PROTECT THE SPROCKET, INSTALL (WOODEN OR ALUMINIUM) PROTECTIONS ON THE VICE JAWS. LOCK THE SPROCKET ONLY IN A VICE. DO NOT LOCK ANY OTHER COMPONENT OF THE FINAL TRANSMISSION UNIT. • Lock sprocket in a vice. CAUTION TO AVOID POTENTIAL DISTORTIONS AND/OR INCORRECT COUPLING, TIGHTEN AS FOL- LOWS:...
Page 441 RSV4 ABS Suspensions ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. 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).
Page 442 RSV4 ABS Suspensions FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit. ROTATION CHECK • Remove the left spacer (3). • Remove the right spacer (4). • Manually rotate the inside ring of each bearing.
Page 443 RSV4 ABS Suspensions • Check the sprocket (7) toothing for proper conditions. If there is excessive wear: • Replace the sprocket. TO PREVENT EARLY WEAR OF NEW COMPONENTS, REPLACE THE SPROCKET, PINION AND TRANSMISSION CHAIN AT THE SAME TIME. REAR WHEEL BEARINGS •...
Page 444 RSV4 ABS Suspensions FINAL DRIVE UNIT - BEARING REMOVAL • Remove the final drive unit. • Clean the two sides of the hub with a cloth. • Remove the left spacer (15). • Remove the sealing gasket (16). • Remove the circlip (17). CAUTION THE CIRCLIP (17) IS FITTED ONLY ON THE FINAL DRIVE UNIT, LEFT SIDE.
Page 445 RSV4 ABS 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 SUSP - 445...
Page 446 RSV4 ABS Suspensions Adjusting (PROCEDURE FOR OHLINS FORKS) SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD ADJUSTMENT FOR USE ON ROAD Specification...
Page 447 RSV4 ABS Suspensions NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: • CENTRE OF THE FRONT SCREW FASTEN- ING THE LICENSE PLATE HOLDER TO UN- DERTAIL SECTION AND • UPPER CORNER OF THE SCREW FASTEN- ING THE REAR STAND PIN ON THE SWING- (PROCEDURE FOR SACHS FORKS) SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL...
Page 448 RSV4 ABS Suspensions (**) = anticlockwise DO NOT LOOSEN THE LOCK NUT (5) AND THE ADJUSTER SCREW (6) BEYOND THE GROOVE ON THE SHOCK ABSORBER NEAR THE LOWER CONNECTION. NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: •...
Page 449 RSV4 ABS Suspensions • Unscrew and remove the upper screw and retrieve the nut. • Remove the shock absorber from the right side. Linkages Removing • Working from the left side of the vehicle, loosen and remove the nut (1). SUSP - 449...
Page 450 RSV4 ABS Suspensions • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3). • Slide off the screw (4) from the opposite side. • Loosen and remove the nut (5). • Slide off the screw (6) from the opposite side. •...
Page 451 INDEX OF TOPICS CHAS HASSIS...
Page 452 RSV4 ABS Chassis RONT CHASSIS pos. Description Type Quantity Torque Notes Headstock locator dowel M8x1 10 Nm (7.37 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2 Manual Front mounts 2 + 2...
Page 453 RSV4 ABS Chassis EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft) catch plate fixing screws Swinging arm CHAS - 453...
Page 454 RSV4 ABS Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft) Front chain guide fixing screw...
Page 455 RSV4 ABS Chassis • Unscrew and remove the nut and re- trieve the washer. • Working from the right side, loosen and remove the locking ring nut. • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely.
Page 456 RSV4 ABS Chassis • Place a mounting under the front part of the swingarm. • Support the swingarm from the front. • Remove the swingarm pin (2) from the right hand side. • Support the front part of the swingarm and be ready to accompany it.
Page 457 RSV4 ABS Chassis CHECK AND, IF REQUIRED, REPLACE THE BEARINGS AFTER EVERY BEARING REMOVAL. Specific tooling AP8140180 Extractor for bushings • Remove the inner spacer (7) and collect the two OR seals (8). • Carefully clean inside the bearing seat. CAUTION WASH ALL THE PARTS WITH CLEAN DETERGENT.
Page 458 RSV4 ABS Chassis • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. SWINGARM PIN • Use a dial gauge to check the swing- arm pin eccentricity.
Page 459 RSV4 ABS Chassis • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the adjustment bushing (3) to its seat and tighten it manually. CAUTION THE ADJUSTMENT BUSHING (3) MUST NOT PROTRUDE BEYOND THE CHASSIS INTERNAL EDGE. •...
Page 460 RSV4 ABS Chassis • Working from the right hand side of the vehicle, turn the swingarm pin (2) clockwise. This turns the adjustment bushing (3), driving the swingarm in until fully seated. • Tighten the locking ring nut (1). • Screw the nut.
Page 461 RSV4 ABS Chassis • Fit the washer on the screw • Tighten the screw. • Install the rear shock absorber and the linkages. • Fit the rear brake calliper plate. • Fasten the two pipe grommets on the swingarm • Install the rear wheel and the exhaust system.
Page 462 RSV4 ABS Chassis • Move the vehicle forward so as to check vertical oscillation in other posi- tions too. clearance should remain constant at all wheel rotation phases. ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN. If you need to adjust chain tension after the check: •...
Page 463 RSV4 ABS Chassis FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED. THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE. ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION. CLEANING AND LUBRICATION Do not wash the chain with water jets, steam jets, high-pressure water jets and highly flammable sol- vents.
Page 464 RSV4 ABS Chassis • Unscrew and remove the upper screw fixing the chain slider and retrieve the washer. See also Removing the rear wheel • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1).
Page 465 RSV4 ABS Chassis IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) Side stand •...
Page 466 RSV4 ABS Chassis • Unscrew and remove the two screws. • Remove the side stand. Exhaust XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft) hand footpeg mounting...
Page 467 RSV4 ABS Chassis Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold. • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis;...
Page 468 RSV4 ABS Chassis Removing the catalytic converter • Remove the exhaust end. • Remove the front exhaust manifold. • Remove the pinion crankcase • Disconnect the lambda sensor con- nector. • Release the oxygen sensor cable har- ness from the clamps. •...
Page 469 RSV4 ABS Chassis • Remove the front underfairings. • Remove the hand grip position sensor control unit. • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front exhaust manifolds and the catalytic converter •...
Page 470 RSV4 ABS Chassis • Remove the front exhaust manifold. REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers. •...
Page 471 RSV4 ABS Chassis Lower cowl • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler CHAS - 471...
Page 472 RSV4 ABS Chassis ADIATORE OLIO Pos. Descrizione Tipo Quantità Coppia Note Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket Viti TE fl. per fissaggio staffa a telaio M6x20 10 Nm (7.38 lbf ft) Removing • Drain the engine oil. •...
Page 473 RSV4 ABS Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 473...
Page 474 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 475 RSV4 ABS Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main fuse 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.ABS control unit fuse ABS ECU control unit pin configuration •...
Page 476 RSV4 ABS Braking system • Front speed sensor positive PIN 12 • Rear speed sensor positive PIN 13 • Rear speed sensor input PIN 14 • ABS warning light PIN 17 • Battery for ABS pump engine positive PIN 18 Operating diagram BRAK SYS - 476...
Page 477 RSV4 ABS Braking system ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9.
Page 478 RSV4 ABS Braking system Intakes and supplies 1. Supply to the rear brake calliper. 2. Intake from the rear brake pump. 3. Intake from the front brake pump. 4. Supply to the front brake calliper. ABS OPERATION General specifications: The front circuit is similar to the rear circuit. •...
Page 479 RSV4 ABS Braking system E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure reduction phase exceeds the pre-set time limit.
Page 480 RSV4 ABS Braking system - if the speed difference lasts long, the system may detect an error and deactivates the ABS system. As a consequence, the system works as any regular braking system. Riding with an active ABS system • During the vehicle start-up, after the in- strument panel initial check, the ABS warning light stops flashing when the...
Page 481 RSV4 ABS Braking system The warning light (5) turns on permanently, the system was deactivated. REPLACING THE ABS CONTROL UNIT • Before replacing the ABS control unit, mark the hoses so that they can be refit correctly on the new control unit. •...
Page 482 RSV4 ABS Braking system • Take care of hose position on the sup- port. 1. Goes to the pump. 2. Goes to the caliper. • After replacing hoses or the control unit the entire ABS system must be bled. To bleed the ABS system optimally, it is advisable to use devices such as vacuum pumps or similar. CAUTION THE OIL QUANTITY NECESSARY FOR THE ABS SYSTEM BLEED IS ABOVE A TRADITIONAL DEVICE.
Page 483 RSV4 ABS Braking system ABS PIPES ROUTING TABLE A - ABS PIPES ROUTING 1. Small clamps TABLE B - ABS PIPES ROUTING 1. Rear speed sensor cable. 2. Cable guide. 3. Cable grommet. 4. Cable grommet. TABLE C - ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure.
Page 484 RSV4 ABS Braking system Guide to diagnosis PREMISE Each time the key is ON, if, at least one current or stored* error is detected, the ABS warning light turns on permanently. The ABS system is deactivated automatically The system operates perfectly just as any other braking system without ABS * The diagnosis requires exceeding the 5 km/h (3.1 mph).
Page 485 RSV4 ABS Braking system • A. Cable continuity between PIN17 of the ABS control unit connector and PIN28 of the instrument panel. • B. Check connectors - refer to the operations described in the chapter If the previous checks are OK, the causes might be: •...
Page 486 RSV4 ABS Braking system PARAMETERS P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Front wheel speed km/h Rear wheel speed km/h Battery voltage Front brake circuit pressure ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit.
Page 487 RSV4 ABS Braking system ERRORS screen page This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Front wheel speed sensor electrical...
Page 488 RSV4 ABS Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTMENTS P.A.D.S./Navigator characteristic Value/example Unit of Notes measure ment Coding Reset the vehicle code and it performs the self- learning from CAN line to the key ON Modulator •...
Page 489 RSV4 ABS Braking system • Disconnect and remove the brake pipes inserts from the ABS control unit. • Undo the fixing screw of the ABS con- trol unit • Disconnect the ABS control unit from its rear inserts. • Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR •...
Page 490 RSV4 ABS Braking system • If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be prop- erly coupled and the distance meas- ured will be greater (12 mm approx. (0.47 in)).
Page 491 RSV4 ABS Braking system It is important to check that all the tone wheels (2) are always clean. Otherwise,: gently remove any possible dirt deposits with a cloth or metal brush. Avoid using solvents, abrasives and air or water jets directly on the tone wheel (2).
Page 492 RSV4 ABS Braking system Front brake calliper RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) Rear brake disc Removal • Remove the rear wheel. CAUTION TO UNSCREW THE SCREWS (1), USE AN AIR SCREWER GUN TO GIVE A CLEAN BLOW, WHICH WILL DETACH THE SCREWS STUCK WITH LOCTITE 243.
Page 493 RSV4 ABS Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 494 RSV4 ABS Braking system Removal • Remove the front wheel The following operations refers to a single disc but apply to both. CAUTION TO UNSCREW THE SCREWS (1), USE AN AIR SCREWER GUN TO GIVE A CLEAN BLOW, WHICH WILL DETACH THE SCREWS STUCK WITH LOCTITE 243.
Page 495 RSV4 ABS Braking system exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS. REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE- HICLE ITSELF.
Page 496 RSV4 ABS Braking system • Fit the two new pads in the correct po- sition. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CAL- LIPER. • Fit the front brake calliper on the disc. •...
Page 497 RSV4 ABS Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
Page 498 RSV4 ABS Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency. CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON-...
Page 499 RSV4 ABS Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 500 RSV4 ABS Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 501 RSV4 ABS Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) BRAK SYS - 501...
Page 502 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 503 RSV4 ABS 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 - 503...
Page 504 RSV4 ABS 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 505 RSV4 ABS Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Electric fan • Remove the front underfairings and the hand grip position sensor • Disconnect the cooling fan connector to be replaced.
Page 506 RSV4 ABS Cooling system 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 the internal side using a threaded "T"...
Page 507 RSV4 ABS Cooling system • Via the filler orifice on the expansion tank, fill with the quantity of coolant necessary to reach the FULL marking, then refit the cap. • Start the engine, run at idle speed and wait for the electric fans to activate (ap- prox.
Page 508 RSV4 ABS Cooling system • Unscrew and remove the two screws fastening the pump to the engine. • Remove the coolant pump. • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw. •...
Page 509 RSV4 ABS Cooling system • At each removal, replace the inner gas- ket between the pump casing and the cover and the O ring on the pump cas- ing. ENSURE THAT THE LIQUID PASSAGE ORIFICES ARE NOT OBSTRUCTED. Removing the radiator RADIATOR BRACKET REMOVAL •...
Page 510 RSV4 ABS 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 511 RSV4 ABS Cooling system • Remove the two fixing screws of the radiator bracket. • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return pipe to the radiator pipe UPON REFITTING, REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE.
Page 512 RSV4 ABS Cooling system • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Remove the radiator. COOL SYS - 512...
Page 513 INDEX OF TOPICS BODYW ODYWORK...
Page 514 RSV4 ABS Bodywork EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) BODYW - 514...
Page 515 RSV4 ABS Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft) mounting to chassis...
Page 516 RSV4 ABS Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) BODYW - 516...
Page 517 RSV4 ABS Bodywork pos. Description Type Quantity Torque Notes Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER pos.
Page 518 RSV4 ABS Bodywork AIL FAIRING pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft) Screws fastening grilles to tail fairing...
Page 519 RSV4 ABS Bodywork ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft) ing screws Battery bracket fixing screws 2 Nm (1.47 lbf ft)
Page 520 RSV4 ABS Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to 3 Nm (2.21 lbf ft) the tank Front screws fastening the tank to...
Page 521 RSV4 ABS Bodywork AIRING pos. Description Type Quantity Torque Notes Centre screws fastening lower fairing 10 Nm (7.37 lb ft) Right hand lower fairing mounting 10 Nm (7.37 lb ft) bracket Left hand lower fairing mounting 10 Nm (7.37 lb ft) bracket Screws fixing the side fairings to the 1.5 Nm (1.11 lb ft)
Page 522 RSV4 ABS Bodywork Driving mirrors • The following procedure is for a single rear view mirror, but is applicable to both mirrors. • Unscrew and remove the two nuts, supporting the rear view mirror. • Disconnect the turn indicator connec- tor from the relative fixed connector on the instrument panel.
Page 523 RSV4 ABS Bodywork Instrument panel • Remove the windshield. • Unscrew and remove the two screws. • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the support. • Rotate the instrument panel connector retainer lever.
Page 524 RSV4 ABS Bodywork Headlight fairing • Working from both sides, unscrew and remove the four screws. BODYW - 524...
Page 525 RSV4 ABS Bodywork • Remove the side fairings. • Disconnect the turn indicator connec- tors from the fixed connector on the instrument panel mounting. • Remove the two rear view mirrors if necessary. • Remove the three lower inserts. See also Side fairings •...
Page 526 RSV4 ABS Bodywork Rider footrest plate LEFT RIDER FOOTREST REMOVAL - GEAR- BOX LEVER • Remove the fuel tank. • Unscrew and remove the three screws and remove the pinion cover. • Disconnect the quick-shift connector. • Cut the ties fastening the cable har- ness to the engine •...
Page 527 RSV4 ABS Bodywork • Unscrew and remove the two screws fixing the left rider footrest plate to the chassis. • If necessary, you can loosen and re- move the quick-shift fixing screw to change the O-rings. NOTE NOTE THE CABLE HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION Side fairings The following procedure is relative to a single fair-...
Page 528 RSV4 ABS Bodywork • Release the three inserts on the inner fairing. • Ease off the side fairing, taking partic- ular care not to damage the fitting with the lower side fairing and the tabs fas- tening the side fairing to the lug. LOWER SIDE FAIRINGS •...
Page 529 RSV4 ABS Bodywork Fairing mounting panels CENTRAL UNDERFAIRING • Remove the three windshield fixing in- serts. • Unscrew and remove the two screws. • Ease off the central underfairing, tak- ing care not to damage the fittings with the lateral underfairings and the wind- shield.
Page 530 RSV4 ABS Bodywork • Unscrew and remove the lower screw. • When working on the left hand side of the vehicle, remove the underfairing taking particular care not to damage the fittings with the central underfair- ing. • When working on the left hand side of the vehicle, support the left hand un- derfairing, unscrew and remove the two nuts, retrieve the screws and lower...
Page 531 RSV4 ABS Bodywork See also Control unit • Unscrew and remove the four upper injector screws. • Move the upper injector mounting. • Disconnect the variable geometry in- take system connector. • Unscrew and remove the eight air filter box cover screws. •...
Page 532 RSV4 ABS Bodywork • Working from both sides, unscrew and remove the air pressure sensor fixing screw. • Disconnect both front coil connectors (cylinders 2 and 4). • Working from both sides, disconnect the Blow-by system intake pipes. • Release the cable harness from the cable grommet on the filter box.
Page 533 RSV4 ABS Bodywork Rear mudguard • Unscrew and remove the two screws. • Remove the rear mudguard. Lower cowl • The following procedure is applicable to both parts of the fairing lug. • Remove the lower side fairing. • Unscrew and remove the front screw. See also Side fairings •...
Page 534 RSV4 ABS Bodywork • Supporting the right fairing lug, un- screw and remove the right lug fixing screw and remove the lug. • Remove the left fairing lug in the same manner. Fuel tank • Unscrew and remove the front screw fixing the tank.
Page 535 RSV4 ABS Bodywork • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank. Front mudguard • Working from both sides, undo and re- move the two screws. • Release the brake pipe eliminating the clamp. •...
Page 536 RSV4 ABS Bodywork Instrument cluster support REMOVAL • Remove the instrument panel. • Working on both sides, unscrew and remove the two screws fastening the arch brace to the headstock. • Retrieve the cable grommet. • Unscrew and remove the five semi- arch brace fixing screws.
Page 537 RSV4 ABS Bodywork • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp. • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. •...
Page 538 RSV4 ABS Bodywork • Fit the turn indicator connectors in the relative housings, noting the colours of the wires identifying the correct side. • Join the remaining connectors and ar- range the cable carefully in the space available within the arch brace. Note that there are two pairs of connectors which may be connected incorrectly.
Page 539 RSV4 ABS Bodywork • Supporting the radiator cover and working from the right side of the vehi- cle, unscrew and remove the screw and retrieve the washer and the nut. See also Lower cowl Side fairings Side air deflectors The following procedure is for a single lateral duct but is applicable to both.
Page 540 INDEX OF TOPICS PRE DE DELIVERY...
Page 541 RSV4 ABS 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 542 RSV4 ABS Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 543 RSV4 ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 544 RSV4 ABS Pre-delivery Specific operations for the vehicle LICENSE PLATE HOLDER • Set three washers of suitable diameter between license plate and its holder to avoid damaging the license plate. • Remove the screw (2). • Remove the plastic cover (1). •...
Page 545 RSV4 ABS Pre-delivery • Insert the key in the lock and turn it clockwise. • Remove the tail fairing. • Fit the two-seater saddle. Regolazione snodo degli specchietti retrovisori • With the mirror closed (base turned 90° in relation to the mirror) check that the nut is closed properly, as indicated by the arrow, (you should be able to see about 0.5 mm - 1mm (0.02 in - 0.04 in)
Page 546 RSV4 ABS Pre-delivery • Cut the cable harness clamp (if there is one), disconnect the cable harness connector and pull the cable harness away from the mirror. • Loosen the nut so its upper surface is about 0.5 mm (0.02 in) above the end of the threaded pin.
Page 547 RSV4 ABS Pre-delivery • Assemble the rear-view mirror. • Pass the cable harness through the specific hole and place the rear-view mirror in its seat. • Tighten the two fixing nuts of the rear- view mirror. • Connect the connector. PRE DE - 547...
Page 548 a-PRC setting buttons: 235 ABS: 245, 475 Air filter: 67 Air temperature sensor: 187 Alternator: Battery: 152, 163 Brake: 491–493, 495, 496, 500, 501 Brake calliper: 491, 492 Brake disc: 492, 493 Brake pads: 495, 496 Brake pump: 500, 501 Bulbs: Bushings: CAN line: 246...
Page 549 Front wheel: 402, 403, 408, 494 Fuel: 68, 156, 201, 254, 391, 534 Fuel pump: 156, 201, 391 Fuses: 156 Handlebar: 405 Head cover: 69–71, 77, 310, 311, 318, 329, 336 Headlight: 524, 539 Helmet compartment: Identification: 11 Instrument panel: 148, 523, 536 Intake pressure sensor: 179 License plate holder: Linkages: 449...
Page 550 Spark plug: 64, 69, 70 Speed sensor: 164 Stand: 221, 254, 258, 464, 465 Start-up: 155, 286 Starter motor: 285 Steering damper: 430 Stepper motor: 397 Tank: 68, 254, 534 Throttle body: 69, 70, 206, 395–397 Transmission: 12, 356, 359 Tyres: 15 Variable geometry intake: 168, 397, 399 Warning lights:...

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Summary of Contents for APRILIA RSV4 ABS 2009

Page 38: Nm (2.95 Lbf Ft)

Page 40: Nm (2.21 Lbf Ft)

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