APRILIA RSV4 Factory a-PRC 2009 Service Station Manual

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SERVICE STATION MANUAL

898952

RSV4 Factory a-PRC

Summary of Contents for APRILIA RSV4 Factory a-PRC 2009

Page 1 SERVICE STATION MANUAL 898952 RSV4 Factory a-PRC...
Page 2 THE VALUE OF SERVICE As a result of continuous updates and specific technical training programmes for Aprilia products, only Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out maintenance and repair operations correctly.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 RSV4 Factory a-PRC Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 RSV4 Factory a-PRC 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 Factory a-PRC 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. This number consists of numbers and letters, as in the example shown below.
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 Factory a-PRC Characteristics Specification Desc./Quantity Seats 1 + 1 Two seat configuration: if vehicle is fitted with footrests and saddle for passenger Maximum weight capacity 201 kg (443 lb) Fork oil 530 cc (0.12 Uk gal) (for each stanchion) Drive chain RIVE CHAIN Specification...
Page 14 RSV4 Factory a-PRC Characteristics Specification Desc./Quantity Steering rake 26.5° (measurements with reference to bare frame). For the Factory versions the adjustments allow for variations of "+" or "-" 1° Trail 110 mm (4.33 in) (with adjustable inserts, headstock as a standard feature) USPENSION Specification Desc./Quantity...
Page 15 RSV4 Factory a-PRC Characteristics Specification Desc./Quantity Dunlop SPORTMAX GP Racer (Mixture "M" Front) Dunlop SPORTMAX GP Racer (Mixture "E" Rear) Front tyre 120/70 ZR17 (58W) Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI) 2 passengers: 2.5 bar (250 kPa) (36.26 PSI) Rear tyre 200/55 ZR17 (78W) (*) 190/55 ZR17 (75W)
Page 16 RSV4 Factory a-PRC Characteristics IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket RONT FORK pos. Description Type Quantity Torque Notes Fastener screws for calliper mount- 2 + 2 12 Nm (8.85 lb ft) ing bracket (Öhlins) Odometer sensor fixing screw...
Page 17 RSV4 Factory a-PRC 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 18 RSV4 Factory a-PRC 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.
Page 19 RSV4 Factory a-PRC 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 20 RSV4 Factory a-PRC 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 21 RSV4 Factory a-PRC 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 - 21...
Page 22 RSV4 Factory a-PRC 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)
Page 23 RSV4 Factory a-PRC 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 - 23...
Page 24 RSV4 Factory a-PRC 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 25 RSV4 Factory a-PRC 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 - 25...
Page 26 RSV4 Factory a-PRC 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 27 RSV4 Factory a-PRC 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-...
Page 28 RSV4 Factory a-PRC 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...
Page 29 RSV4 Factory a-PRC 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 - 29...
Page 30 RSV4 Factory a-PRC 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...
Page 31 RSV4 Factory a-PRC Characteristics ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate CHAR - 31...
Page 32 RSV4 Factory a-PRC 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 33 RSV4 Factory a-PRC 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 34 RSV4 Factory a-PRC Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount CHAR - 34...
Page 35 RSV4 Factory a-PRC Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) EAR BRAKE CALLIPER pos.
Page 36 RSV4 Factory a-PRC Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 37 RSV4 Factory a-PRC 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 - 37...
Page 38 RSV4 Factory a-PRC 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 39 RSV4 Factory a-PRC 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 40 RSV4 Factory a-PRC 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 41 RSV4 Factory a-PRC 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 42 RSV4 Factory a-PRC Characteristics ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) CHAR - 42...
Page 43 RSV4 Factory a-PRC 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 44 RSV4 Factory a-PRC 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 45 RSV4 Factory a-PRC Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 46 RSV4 Factory a-PRC Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 47 RSV4 Factory a-PRC 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 48 RSV4 Factory a-PRC 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...
Page 49 RSV4 Factory a-PRC 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...
Page 50 RSV4 Factory a-PRC 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 51 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 52 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 53 RSV4 Factory a-PRC Special tools PECIAL 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 - 53...
Page 54 RSV4 Factory a-PRC 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 - 54...
Page 55 RSV4 Factory a-PRC 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 - 55...
Page 56 RSV4 Factory a-PRC 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 - 56...
Page 57 RSV4 Factory a-PRC 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 - 57...
Page 58 RSV4 Factory a-PRC 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...
Page 59 RSV4 Factory a-PRC 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 S-TOOLS - 59...
Page 60 INDEX OF TOPICS MAIN AINTENANCE...
Page 61 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 62 RSV4 Factory a-PRC 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 63 RSV4 Factory a-PRC 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 64 RSV4 Factory a-PRC 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 65 RSV4 Factory a-PRC 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 66 RSV4 Factory a-PRC 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 67 RSV4 Factory a-PRC 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 68 RSV4 Factory a-PRC 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 69 RSV4 Factory a-PRC 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 70 RSV4 Factory a-PRC 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 •...
Page 71 RSV4 Factory a-PRC 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 72 RSV4 Factory a-PRC 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 73 RSV4 Factory a-PRC 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 74 RSV4 Factory a-PRC Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 75 RSV4 Factory a-PRC 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 76 RSV4 Factory a-PRC 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 •...
Page 77 RSV4 Factory a-PRC 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 78 RSV4 Factory a-PRC 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 79 RSV4 Factory a-PRC 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 80 RSV4 Factory a-PRC Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 81 RSV4 Factory a-PRC 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 82 RSV4 Factory a-PRC 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)
Page 83 RSV4 Factory a-PRC 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 - 83...
Page 84 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 85 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 86 RSV4 Factory a-PRC 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 87 RSV4 Factory a-PRC Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION NAVIGATOR 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 88 RSV4 Factory a-PRC 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 89 RSV4 Factory a-PRC 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 90 RSV4 Factory a-PRC 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 91 RSV4 Factory a-PRC 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 92 RSV4 Factory a-PRC 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 93 RSV4 Factory a-PRC 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 94 RSV4 Factory a-PRC Troubleshooting • 7. REPLACE THE STARTER BUTTON COMPONENT - END TROUBL - 94...
Page 95 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 96 RSV4 Factory a-PRC 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 97 RSV4 Factory a-PRC 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 - 97...
Page 98 RSV4 Factory a-PRC Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Intake connectors 11.Lower injectors 12.Air pressure sensor 13.Exhaust valve 14.Lambda probe...
Page 99 RSV4 Factory a-PRC 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 100 RSV4 Factory a-PRC 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 101 RSV4 Factory a-PRC 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 102 RSV4 Factory a-PRC 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 103 RSV4 Factory a-PRC 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 104 RSV4 Factory a-PRC 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 105 RSV4 Factory a-PRC 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 106 RSV4 Factory a-PRC 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 107 RSV4 Factory a-PRC 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 108 RSV4 Factory a-PRC 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 109 RSV4 Factory a-PRC 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 110 RSV4 Factory a-PRC 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 111 RSV4 Factory a-PRC Electrical system TABLE P - FRONT SPEED SENSOR 69. Cable grommet 70. Front speed sensor 71. Clamp 72. Front speed sensor cable harness routing 73. Speed sensor cable harness routing inside the cable grommet, between throttle cables and frame 74.
Page 112 RSV4 Factory a-PRC 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.
Page 113 RSV4 Factory a-PRC 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 114 RSV4 Factory a-PRC 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 115 RSV4 Factory a-PRC 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 116 RSV4 Factory a-PRC 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 117 RSV4 Factory a-PRC 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 118 RSV4 Factory a-PRC 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 119 RSV4 Factory a-PRC 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 120 RSV4 Factory a-PRC 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 121 RSV4 Factory a-PRC 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.
Page 122 RSV4 Factory a-PRC 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.
Page 123 RSV4 Factory a-PRC 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 124 RSV4 Factory a-PRC 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 125 RSV4 Factory a-PRC 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 126 RSV4 Factory a-PRC 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 127 RSV4 Factory a-PRC 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 128 RSV4 Factory a-PRC 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 129 RSV4 Factory a-PRC 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 130 RSV4 Factory a-PRC 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 131 RSV4 Factory a-PRC 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 132 RSV4 Factory a-PRC Electrical system TABLE ZS - NOTES FOR FITTING THE GROUND CABLE There are two ground lug terminals on the cable harness: the "ENGINE GND" (output "9") and the "CHASSIS GND" (output "10"). The "ENGINE GND" lug terminal (172) (output "9") must be connected to the M6 hole on the upper engine crankcase with a flanged M6x16 screw (173).
Page 133 RSV4 Factory a-PRC 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 - CLF CONTROL UNIT PRE-FITTING 10A. CLF control unit 10B. Left fairing 10C.
Page 134 RSV4 Factory a-PRC Electrical system B=battery Be careful not to bend the positive battery cable (14). TABLES D1 and D2 - VEHICLE CABLE HAR- NESSES The Vehicle Cable Harness (16) and the "Relay and Fall Sensor" mounting (18) must be fit on the chassis before fitting the engine.
Page 135 RSV4 Factory a-PRC 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 136 RSV4 Factory a-PRC 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 137 RSV4 Factory a-PRC Electrical system TABLE F3 43. ECU diagnosis connector 44. Instrument panel diagnosis connector 45. Insert the instrument panel diagnosis and the ECU diagnosis connectors in their specific seats 46. License plate frame and taillight cable harness routing 47.
Page 138 RSV4 Factory a-PRC Electrical system Outer 58. Fuel pump connector 59. Insert the tape clamp on the cable harness in the hole on the right side of the saddle mounting 60. variable length intake duct control unit connector 61. Clamp Inner 62.
Page 139 RSV4 Factory a-PRC Electrical system TABLE G1 - SENSOR BOX 66A. Sensor Box 66B. Sensor Box cable harness routing 66C. Sensor Box connector TABLE H1 67. Intake duct control unit 68. Intake duct control unit connector 69. Rubber ring TABLE H2 70.
Page 140 RSV4 Factory a-PRC 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 6. HIGH BEAM BULB 7. TAIL LIGHT BULB 8. LEFT LOW BEAM LIGHT BULB 9.
Page 141 RSV4 Factory a-PRC Electrical system 13.INSTRUMENT PANEL 14.EXHAUST VALVE MOTOR 15.FRONT STOP SWITCH 16.REAR STOP SWITCH 17.CLUTCH SWITCH 18.IGNITION SWITCH 19.PROTECTION RELAY 20.IMMOBILIZER AERIAL 21.Rear right turn indicator 22.TAILLIGHT ASSEMBLY 23.LICENSE PLATE LIGHT BULB 24.REAR LEFT TURN INDICATOR 25.RECOVERY LOGIC RELAY 26.MAIN FUSES 27.- 28.Voltage regulator...
Page 142 RSV4 Factory a-PRC Electrical system 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 59.SECONDARY AIR SYSTEM 60.LAMBDA PROBE 61.VARIABLE GEOMETRY CONTROL UNIT 62.VARIABLE GEOMETRY ENGINE 63.TONE WHEEL READING CONTROL UNIT 64.FRONT WHEEL SPEED SENSOR 65.REAR WHEEL SPEED SENSOR 66.INERTIA SENSOR PLATFORM...
Page 143 RSV4 Factory a-PRC Electrical system same depth) and terminal integrity (i.e., that termi- nals are not loose, open/bent, etc.). For connec- tors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter and introduce it carefully in the connector slot at the same depth as for the other terminals of the connector.
Page 144 RSV4 Factory a-PRC Electrical system Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical circuit diagram: Immobilizer Location: • on the vehicle: in the ignition switch as- sembly •...
Page 145 RSV4 Factory a-PRC Electrical system • Immobilizer fault: aerial not working (open or short-circuited) Error cause • An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting • Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore;...
Page 146 RSV4 Factory a-PRC Electrical system NOTE DELETE THE ERROR CAUSED BY THE LACK OF MEMORY OF KEY CODES. 3. Connect to the vehicle with the diagnosis tool and select the adjustable Parameters in the screen page: "Exhaust butterfly valve self-acquisition" NOTE SEARCH FOR MINIMUM AND MAXIMUM MECHANICAL STOPS STORED IN THE INSTRUMENT PANEL.
Page 147 RSV4 Factory a-PRC Electrical system In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it. DSB 01 - Immobilizer fault: key code read but not recognised. DSB 02 - Immobilizer fault: key code not read (key not present or transponder not working) DSB 03 - Immobilizer fault: aerial not working (open or short-circuited) DSB 04 - Internal controller fault DSB 05 - -...
Page 148 RSV4 Factory a-PRC Electrical system Modify Keys With this function the instrument panel can update the keys. Up to 4 keys can be stored. The user code is first requested to be entered: • ENTER THE CODE After entering the correct code, the following message should be shown on the display: •...
Page 149 RSV4 Factory a-PRC Electrical system Battery recharge circuit RECHARGE SYSTEM (Mitsubishi - Kokusan) • Remove the left side fairing; • Disconnect the three-way connector (1) (white). NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER "A" Measurement of resistance (with engine off) •...
Page 150 RSV4 Factory a-PRC 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 151 RSV4 Factory a-PRC 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 152 RSV4 Factory a-PRC 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 153 RSV4 Factory a-PRC 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 •...
Page 154 RSV4 Factory a-PRC Electrical system CAUTION THERE IS ONE SPARE FUSE (I). Control unit Removal • Remove the fuel tank. • Disconnect both control unit connec- tors • Unscrew and remove the three screws. • Remove the control unit. NOTE WHEN 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 155 RSV4 Factory a-PRC Electrical system CONTROL UNIT - Diagnosis Function it controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves the control unit Location: •...
Page 156 RSV4 Factory a-PRC Electrical system Adjustable fuel supply Adjustable fuel correction 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. DIAGNOSIS INSTRUMENT: STATUSES Engine status •...
Page 157 RSV4 Factory a-PRC Electrical system • 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 158 RSV4 Factory a-PRC 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 159 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 160 RSV4 Factory a-PRC Electrical system "Handle self-learning" is "Not carried out" (this last status entails Urgent service being displayed on the instrument panel). If front and rear throttle automatic self-acquisition indicate "Not carried out" go to phase 1, if indicate "Carried out" go to phase 2. Phase 1: current errors have probably been detected by the control unit: solve these malfunctions and check the two statuses.
Page 161 RSV4 Factory a-PRC Electrical system CAUTION 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 162 RSV4 Factory a-PRC Electrical system Connector location (if available): 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 DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS C1002 Front speed sensor: short circuit.
Page 163 RSV4 Factory a-PRC Electrical system P0501 Front wheel speed signal/sensor. Connect to CLF control unit diagnosis (Tone Wheel Reading control unit) DIAGNOSTICS INSTRUMENT: LOGIC ERRORS C1100 Front speed sensor: missing signal or speed measured too low in relation to the rear wheel.
Page 164 RSV4 Factory a-PRC Electrical system Connector location (if available): 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 DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS C1004 Rear speed sensor: short circuit.
Page 165 RSV4 Factory a-PRC Electrical system DIAGNOSTICS INSTRUMENT: LOGIC ERRORS 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.
Page 166 RSV4 Factory a-PRC Electrical system At key-ON, the variable geometry control unit low- ers the ducts (if still in the raised position). Subse- quently, depending on the control voltage on PIN 2 from the injection control unit (0V down, 5V up), the control unit drives the electric motor with the relative polarity for raising or lowering the ducts.
Page 167 RSV4 Factory a-PRC Electrical system DIAGNOSTICS INSTRUMENT: STATUSES Variable geometry intake • not active/active NOTE: It indicates whether the control unit has sent the command to the variable geometry control unit to lift the ducts. DIAGNOSTICS INSTRUMENT: ACTIVATION Variable geometry intake control NOTE: The injection ECU sends the command to the variable geometry control unit to lift the ducts.
Page 168 RSV4 Factory a-PRC Electrical system the endless screw (however it must turn a bit): if not OK, place it correctly; if OK, replace the variable geometry control unit. Engine rpm sensor Function informs crankshaft position and speed to the Mar- elli control unit Operation / Operating principle inductive sensor: sinusoidal-type generated volt-...
Page 169 RSV4 Factory a-PRC Electrical system CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR. IF NOT OK, RE- STORE THE CABLE HARNESS/REPLACE THE SENSOR. IF OK, PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR. DIAGNOSTICS INSTRUMENT: LOGIC ERRORS Engine speed sensor P0336 •...
Page 170 RSV4 Factory a-PRC Electrical system • Move the hand grip position sensor, disconnect the two connectors. • Remove the hand grip position sensor. NOTE WHEN REFITTING, REMEMBER NOT TO INVERT THE CONNECTORS. THE LIGHT BLUE CONNECTOR HAS THE BLUE CABLE AND THE WHITE CONNECTOR HAS THE WHITE CABLE.
Page 171 RSV4 Factory a-PRC Electrical system • B: Track A ground • C: Track A signal • D: Track B supply • E: Track B ground • F: Track B signal WHITE connector • A: Track C supply • B: Track C ground •...
Page 172 RSV4 Factory a-PRC Electrical system • Example value with engine on: - With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle grip fully twisted. DIAGNOSIS INSTRUMENT: STATUSES Throttle grip • Slightly twisted_choked_fully twisted Throttle grip self-acquisition •...
Page 173 RSV4 Factory a-PRC Electrical system • If shorted to positive: excessive voltage has been detected at PIN 13 of the VEHICLE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 13 of the VEHICLE connector Troubleshooting •...
Page 174 RSV4 Factory a-PRC Electrical system if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring White upper connector throttle grip position sensor - track D P0153 •...
Page 175 RSV4 Factory a-PRC Electrical system • incongruent signal Error cause • Two illogical voltage signals have been detected at PIN 23 and 11 of the ENGINE connector (tracks A-B) Troubleshooting • Check the parameters of the white upper connector Throttle Grip Position Sensor - tracks C and D: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective.
Page 176 RSV4 Factory a-PRC Electrical system Intake pressure sensor Function The pressure sensors (one per bank), are funda- mental for calculation of generated torque, for cal- culation of ambient pressure and for correct ignition timing during start-up. Operation / operating principle Diaphragm sensor which translates the diaphragm position into electrical voltage when in contact with the intake air.
Page 177 RSV4 Factory a-PRC Electrical system • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure (1 and 3) • Example value with key ON: 1004 mbar • Example value with engine on: 735 mbar •...
Page 178 RSV4 Factory a-PRC Electrical system • If shorted to positive: see that the parameter of the front 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 179 RSV4 Factory a-PRC Electrical system connector PIN 49 and sensor connector PIN 3 is a few tenths of an Ohm; If it is above that value, restore cable harness. Replace the sensor if it is correct. Error for unexpected air intake in the rear cylinder manifold P0210 •...
Page 180 RSV4 Factory a-PRC Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). Troubleshooting • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body;...
Page 181 RSV4 Factory a-PRC Electrical system Engine temperature sensor Function It tells the engine temperature to the control unit to improve its performance and to calculate the en- gine friction for a better estimation of the generated torque. Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
Page 182 RSV4 Factory a-PRC Electrical system • Example value with engine on: 25° C • The temperature value is stored during engine start-up. With key ON, value -40°C is read. CAUTION 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.
Page 183 RSV4 Factory a-PRC Electrical system • Check the sensor connector and the ENGINE connector of the Marelli control unit. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Navigator if the temperature indicated is the same as the engine tem- perature.
Page 184 RSV4 Factory a-PRC Electrical system Value drawn from the signal read without taking into account any recovery: the value in the exam- ple refers to an open circuit CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 185 RSV4 Factory a-PRC 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 186 RSV4 Factory a-PRC 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 187 RSV4 Factory a-PRC 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 188 RSV4 Factory a-PRC Electrical system cable (PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable harness.
Page 189 RSV4 Factory a-PRC 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...
Page 190 RSV4 Factory a-PRC 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.
Page 191 RSV4 Factory a-PRC 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 192 RSV4 Factory a-PRC 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 193 RSV4 Factory a-PRC 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 194 RSV4 Factory a-PRC 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 195 RSV4 Factory a-PRC 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 196 RSV4 Factory a-PRC 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 197 RSV4 Factory a-PRC 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 198 RSV4 Factory a-PRC 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 199 RSV4 Factory a-PRC 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 200 RSV4 Factory a-PRC 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 201 RSV4 Factory a-PRC 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 202 RSV4 Factory a-PRC 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 203 RSV4 Factory a-PRC 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 204 RSV4 Factory a-PRC 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 205 RSV4 Factory a-PRC 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 206 RSV4 Factory a-PRC 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 207 RSV4 Factory a-PRC 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 208 RSV4 Factory a-PRC 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 209 RSV4 Factory a-PRC 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 210 RSV4 Factory a-PRC 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 211 RSV4 Factory a-PRC 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 212 RSV4 Factory a-PRC 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 213 RSV4 Factory a-PRC 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 214 RSV4 Factory a-PRC 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 215 RSV4 Factory a-PRC 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 216 RSV4 Factory a-PRC 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 217 RSV4 Factory a-PRC Electrical system the sensor and check, with key set to ON, continuity to ground of PIN 2: if there is no con- tinuity, restore the cable harness; if there is, replace the sensor. • Indication on Navigator 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 218 RSV4 Factory a-PRC Electrical system • Indication on Navigator always down: check the connector: if not OK, restore; 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; if there is, replace the sensor •...
Page 219 RSV4 Factory a-PRC Electrical system Fall sensor: Normal / Tip over • Indication on Navigator always Normal, even when the sensor is inverted: disconnect 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 220 RSV4 Factory a-PRC Electrical system • 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 221 RSV4 Factory a-PRC 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 222 RSV4 Factory a-PRC 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 223 RSV4 Factory a-PRC Electrical system RUN / STOP switch • Run/Stop NOTES • Indication on Navigator 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 224 RSV4 Factory a-PRC 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 225 RSV4 Factory a-PRC 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 226 RSV4 Factory a-PRC 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 227 RSV4 Factory a-PRC 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 228 RSV4 Factory a-PRC 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 229 RSV4 Factory a-PRC 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 230 PIN1 - Signal • PIN2 - Ground DIAGNOSTICS INSTRUMENT: STATUSES Quick shift (electronic transmission) control status: Activated released. Aprilia Quick Shift: Present/Not present DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Quick Shift sensor (electronic transmission) P0462. • Shorted to negative (upon key-ON)/Signal not valid.
Page 231 RSV4 Factory a-PRC Electrical system 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. NOTE: The control unit can not detect faults due to failed cable continuity.
Page 232 RSV4 Factory a-PRC Electrical system 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 DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS "+" button sensor P0720: •...
Page 233 RSV4 Factory a-PRC 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 234 RSV4 Factory a-PRC Electrical system Tone wheel reading ECU Function: Receives the signals coming from the wheel speed sensors and calculates the wheel speed accord- ingly. Electrical circuit diagram - Level in wiring dia- gram: Traction control. Location on the vehicle: Inside the left fairing.
Page 235 RSV4 Factory a-PRC Electrical system • Possible control unit fault. Troubleshooting: Replace the control unit. DIAGNOSIS INSTRUMENT: LOGIC ERRORS 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.
Page 236 RSV4 Factory a-PRC Electrical system Sensor box error (inertia sensor platform) P0712 • 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 237 RSV4 Factory a-PRC Electrical system Engine pinout key: Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output (+) PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6/17 Lower cylinder 1 injector control output PIN 8 Lambda sensor input (+) PIN 10...
Page 238 RSV4 Factory a-PRC Electrical system Input for rear throttle potentiometer 1 signal PIN 48 Front cylinder intake pressure sensor input PIN 49 Input for rear throttle potentiometer 2 signal PIN 50 Direct power supply to control unit PIN 52 Vehicle pinout key: Upper cylinder 1 injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57...
Page 239 RSV4 Factory a-PRC Electrical system CAN L line (high speed) PIN 66 Upper cylinder 2 injector control output PIN 67 Upper cylinder 4 injector control output PIN 68 Start-up control output PIN 69 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...
Page 240 RSV4 Factory a-PRC Electrical system Tone wheels ecu reading key: 1. 12 V Key-on power supply 2. 12V power from battery 3. Front tone wheel signal (+) 4. Rear tone wheel signal (+) 5. Rear tone wheel signal (-) 6. Front tone wheel signal (-) 7.
Page 241 RSV4 Factory a-PRC Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply 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...
Page 242 RSV4 Factory a-PRC Electrical system Black-bodied instrument panel pinout key: 21 +Battery 22 Front left turn indicator activation 23 Front right turn indicator activation 24 Aerial 2 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery...
Page 243 RSV4 Factory a-PRC Electrical system 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 244 RSV4 Factory a-PRC Electrical system • 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 245 RSV4 Factory a-PRC Electrical system • 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 246 RSV4 Factory a-PRC Electrical system Error cause • No signal is received from the injection ECU. Troubleshooting • Check the pins 66 and 80 of the Vehicle connector of the Marelli control unit, vehicle-engine connector pins B2 and B3 and CLF control unit connector pins 8 and 9. If not OK, restore. If OK, with key OFF disconnect the following: a) CLF control unit connector, b) vehicle- engine connector and check the continuity across vehicle-engine connector pin B2 and CLF control unit connector pin 9.
Page 247 CLF control unit, the correct status we should find on the Navigator devices status page will be: Aprilia Traction Control PRESENT. While on a bike equipped with CLF control unit and Navigator indication: Aprilia Traction Control NOT PRESENT update the control unit.
Page 248 (Sensor box), the correct status we should find on the Navigator devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a bike equipped with inertia sensor platform (Sensor box) and Navigator indication: Aprilia Traction Control Performance (in a bend) NOT PRESENT update the control unit.
Page 249 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 250 RSV4 Factory a-PRC 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 251 RSV4 Factory a-PRC 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...
Page 252 RSV4 Factory a-PRC 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 253 RSV4 Factory a-PRC 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 254 RSV4 Factory a-PRC 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 255 RSV4 Factory a-PRC 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 - 255...
Page 256 RSV4 Factory a-PRC 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 257 RSV4 Factory a-PRC 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 - 257...
Page 258 RSV4 Factory a-PRC 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 259 RSV4 Factory a-PRC 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 260 RSV4 Factory a-PRC 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 261 RSV4 Factory a-PRC Engine from vehicle The height of the swingarm pin relative to the chassis is adjusted with special inserts installed in the respective seats in the chassis. The hole is offset by +2.5 mm (0.098 in) relative to the centre- line of the insert, as a result the swingarm is in the high position.
Page 262 RSV4 Factory a-PRC 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 263 RSV4 Factory a-PRC Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: •...
Page 264 RSV4 Factory a-PRC 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 265 RSV4 Factory a-PRC 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 266 RSV4 Factory a-PRC 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 267 RSV4 Factory a-PRC 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 268 RSV4 Factory a-PRC 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 269 RSV4 Factory a-PRC 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 - 269...
Page 270 INDEX OF TOPICS NGINE...
Page 271 RSV4 Factory a-PRC 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 272 RSV4 Factory a-PRC 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...
Page 273 RSV4 Factory a-PRC 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 - 273...
Page 274 RSV4 Factory a-PRC Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 275 RSV4 Factory a-PRC 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 276 RSV4 Factory a-PRC 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 277 RSV4 Factory a-PRC 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 278 RSV4 Factory a-PRC 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 279 RSV4 Factory a-PRC 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 280 RSV4 Factory a-PRC 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 281 RSV4 Factory a-PRC 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 282 RSV4 Factory a-PRC 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 283 RSV4 Factory a-PRC 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 284 RSV4 Factory a-PRC 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 285 RSV4 Factory a-PRC 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...
Page 286 RSV4 Factory a-PRC 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 287 RSV4 Factory a-PRC 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 288 RSV4 Factory a-PRC 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 289 RSV4 Factory a-PRC 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 290 RSV4 Factory a-PRC 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 291 RSV4 Factory a-PRC 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 292 RSV4 Factory a-PRC 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 - 292...
Page 293 RSV4 Factory a-PRC Engine • Collect the shim washer. • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 293...
Page 294 RSV4 Factory a-PRC 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 295 RSV4 Factory a-PRC 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 296 RSV4 Factory a-PRC 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 297 RSV4 Factory a-PRC 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 298 RSV4 Factory a-PRC 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 299 RSV4 Factory a-PRC 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 300 RSV4 Factory a-PRC 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 - 300...
Page 301 RSV4 Factory a-PRC 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 302 RSV4 Factory a-PRC 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 303 RSV4 Factory a-PRC 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 304 RSV4 Factory a-PRC 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 305 RSV4 Factory a-PRC 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 - 305...
Page 306 RSV4 Factory a-PRC 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 307 RSV4 Factory a-PRC 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 308 RSV4 Factory a-PRC 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 309 RSV4 Factory a-PRC 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 •...
Page 310 RSV4 Factory a-PRC 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 311 RSV4 Factory a-PRC 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 312 RSV4 Factory a-PRC 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 313 RSV4 Factory a-PRC 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 314 RSV4 Factory a-PRC 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 315 RSV4 Factory a-PRC 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 316 RSV4 Factory a-PRC 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 317 RSV4 Factory a-PRC 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 318 RSV4 Factory a-PRC 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 319 RSV4 Factory a-PRC 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 320 RSV4 Factory a-PRC 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 321 RSV4 Factory a-PRC 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 322 RSV4 Factory a-PRC 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°...
Page 323 RSV4 Factory a-PRC 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 324 RSV4 Factory a-PRC Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin.
Page 325 RSV4 Factory a-PRC 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 326 RSV4 Factory a-PRC 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 327 RSV4 Factory a-PRC 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 328 RSV4 Factory a-PRC 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 329 RSV4 Factory a-PRC 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 330 RSV4 Factory a-PRC 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 331 RSV4 Factory a-PRC 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 332 RSV4 Factory a-PRC 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 333 RSV4 Factory a-PRC 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 334 RSV4 Factory a-PRC 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 335 RSV4 Factory a-PRC 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 336 RSV4 Factory a-PRC 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 337 RSV4 Factory a-PRC 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 338 RSV4 Factory a-PRC 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 339 RSV4 Factory a-PRC 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 340 RSV4 Factory a-PRC 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 341 RSV4 Factory a-PRC 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. •...
Page 342 RSV4 Factory a-PRC 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 343 RSV4 Factory a-PRC 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 344 RSV4 Factory a-PRC 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 345 RSV4 Factory a-PRC 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 346 RSV4 Factory a-PRC 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 347 RSV4 Factory a-PRC 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 348 RSV4 Factory a-PRC 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 349 RSV4 Factory a-PRC 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 - 349...
Page 350 RSV4 Factory a-PRC 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 351 RSV4 Factory a-PRC Engine • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. • Remove the key on countershaft ENG - 351...
Page 352 RSV4 Factory a-PRC 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 353 RSV4 Factory a-PRC 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 354 RSV4 Factory a-PRC 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 355 RSV4 Factory a-PRC Engine Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide.
Page 356 RSV4 Factory a-PRC Engine • alternator; • water pump; • gearbox unit; • primary drive shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear; •...
Page 357 RSV4 Factory a-PRC 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 358 RSV4 Factory a-PRC 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 359 RSV4 Factory a-PRC 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 360 RSV4 Factory a-PRC 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 361 RSV4 Factory a-PRC 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 362 RSV4 Factory a-PRC 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 363 RSV4 Factory a-PRC 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 364 RSV4 Factory a-PRC 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 365 RSV4 Factory a-PRC 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 366 RSV4 Factory a-PRC 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...
Page 367 RSV4 Factory a-PRC 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 368 RSV4 Factory a-PRC 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 369 RSV4 Factory a-PRC 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 370 RSV4 Factory a-PRC 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 371 RSV4 Factory a-PRC 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 372 RSV4 Factory a-PRC 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 373 RSV4 Factory a-PRC 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 374 RSV4 Factory a-PRC 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 375 RSV4 Factory a-PRC 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 376 RSV4 Factory a-PRC 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 377 RSV4 Factory a-PRC Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 377...
Page 378 RSV4 Factory a-PRC 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 - 378...
Page 379 RSV4 Factory a-PRC 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 380 RSV4 Factory a-PRC 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 381 RSV4 Factory a-PRC 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 382 RSV4 Factory a-PRC 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 383 RSV4 Factory a-PRC 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 384 RSV4 Factory a-PRC Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket.
Page 385 RSV4 Factory a-PRC Engine The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 386 RSV4 Factory a-PRC Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 386...
Page 387 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 388 RSV4 Factory a-PRC 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 - 388...
Page 389 RSV4 Factory a-PRC Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor 4. Outlet valve P SUPP - 389...
Page 390 RSV4 Factory a-PRC 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...
Page 391 RSV4 Factory a-PRC 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 392 RSV4 Factory a-PRC 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 393 RSV4 Factory a-PRC 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 394 RSV4 Factory a-PRC 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 395 RSV4 Factory a-PRC 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 396 RSV4 Factory a-PRC 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 397 RSV4 Factory a-PRC 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 398 INDEX OF TOPICS SUSP USPENSIONS...
Page 399 RSV4 Factory a-PRC 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 400 RSV4 Factory a-PRC 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 401 RSV4 Factory a-PRC 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 402 RSV4 Factory a-PRC 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 403 RSV4 Factory a-PRC Suspensions LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) Front fork Diagram SUSP - 403...
Page 404 RSV4 Factory a-PRC 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 405 RSV4 Factory a-PRC 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 406 RSV4 Factory a-PRC Suspensions Draining oil • Fix the fork in a vice, taking care not to damage the fork. • Set the minimum spring preloading. • Unscrew the upper cap from the sleeve using a specific Öhlins tool. • Loosen the cap, holding the upper spring ring nut still with a wrench.
Page 407 RSV4 Factory a-PRC 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-...
Page 408 RSV4 Factory a-PRC Suspensions Disassembling the fork • Fix the fork again in a vice, taking care not to damage the fork. • Remove the preload pipe. • Remove the sleeve (2) from the wheel holder stanchion (1). • Use a plain slot screwdriver to lift up the dust gaiter (3) in multiple points and re- move from the sleeve (2).
Page 409 RSV4 Factory a-PRC Suspensions • Use a plain slot screwdriver to remove the oil seal (5). CAUTION PLACE A STRIP OF RUBBER ON THE EDGE OF THE SLEEVE TO PROTECT IT FROM DAMAGE WHEN REMOV- ING THE OIL SEAL (5). Replace the following components with new ones: - oil seal (5) - dust gaiter (3)
Page 410 RSV4 Factory a-PRC Suspensions • Remove the spring guide (3), noting its direction of installation to ensure cor- rect reassembly. • Remove the other spring guide snap ring (4). • Remove the ring (5) and extract the rubber buffer (6) •...
Page 411 RSV4 Factory a-PRC Suspensions If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value. If over the value, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Page 412 RSV4 Factory a-PRC Suspensions Reassembling the fork • Insert the guide bushing and the coun- terspring. • Insert the rubber O ring. • Insert the ring nut, on which the threa- ded pipe is attached, on the pumping member pin. SUSP - 412...
Page 413 RSV4 Factory a-PRC Suspensions • 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. • Insert the spring guide retainer ring (4). •...
Page 414 RSV4 Factory a-PRC Suspensions • Fix the sleeve in a vice, taking care not to damage the sleeve. • Insert the stanchion (1) into the sleeve (2). • Fit the two half-shells of the special tool on the wheel holder stanchion (1), be- hind the oil seal (5).
Page 415 RSV4 Factory a-PRC Suspensions • Insert the pumping member pin unit. CAUTION THE STANCHION MUST SLIDE FREELY IN THE SLEEVE WITHOUT RESISTANCE. Filling oil • Place the sleeve in a vertical position. • Insert the pumping member pin unit and tighten to the specified torque with the Öhlins tool.
Page 416 RSV4 Factory a-PRC Suspensions • Holding up the pin, insert the preload spring. • Fit the lock nut for the preload spring (1). • Fit the nut (2). • Keeping the spring compressed, tight- en the nut completely. • Screw the complete cap onto the pumping member pin.
Page 417 RSV4 Factory a-PRC 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 418 RSV4 Factory a-PRC 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...
Page 419 RSV4 Factory a-PRC 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 420 RSV4 Factory a-PRC 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 421 RSV4 Factory a-PRC 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 422 RSV4 Factory a-PRC 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 423 RSV4 Factory a-PRC 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 424 RSV4 Factory a-PRC 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 425 RSV4 Factory a-PRC 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. •...
Page 426 RSV4 Factory a-PRC 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 427 RSV4 Factory a-PRC 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 428 RSV4 Factory a-PRC 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 429 RSV4 Factory a-PRC 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 430 RSV4 Factory a-PRC 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).
Page 431 RSV4 Factory a-PRC 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 - 431...
Page 432 RSV4 Factory a-PRC Suspensions Adjusting SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD ADJUSTMENT FOR USE ON ROAD Specification Desc./Quantity Shock absorber centre-to-centre distance (A)
Page 433 RSV4 Factory a-PRC 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- Removing •...
Page 434 RSV4 Factory a-PRC Suspensions Linkages Removing • Working from the left side of the vehicle, loosen and remove the nut (1). • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3). • Slide off the screw (4) from the opposite side. •...
Page 435 RSV4 Factory a-PRC Suspensions UPON REFITTING, GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY. PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV- ERAL TIMES THAT JOINTS MOVE SMOOTHLY. SUSP - 435...
Page 436 INDEX OF TOPICS CHAS HASSIS...
Page 437 RSV4 Factory a-PRC 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...
Page 438 RSV4 Factory a-PRC 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...
Page 439 RSV4 Factory a-PRC Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 440 RSV4 Factory a-PRC 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 441 RSV4 Factory a-PRC 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 442 RSV4 Factory a-PRC 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 443 RSV4 Factory a-PRC 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 •...
Page 444 RSV4 Factory a-PRC Chassis • Refit the swingarm height adjustment inserts if removed, bearing in mind that the arrow must face upward. WARNING PAY PARTICULAR ATTENTION TO THE DIRECTION OF THE INSERTS WHEN REFITTING. IN- CORRECT ASSEMBLY MAY CAUSE SEVERE DAMAGE TO THE VEHICLE. THE ARROW MUST FACE UPWARD.
Page 445 RSV4 Factory a-PRC Chassis • Ensure that the hexagonal area on the pin head (2) is inserted correctly in the hexagonal seat inside the adjustment bushing (3). • Fit and hand-tighten the counter-lock ring nut by a few turns (1). •...
Page 446 RSV4 Factory a-PRC Chassis • Screw the nut. • Refit the chain on the drive pinion CAUTION APPLY LOCTITE ANTI-SEIZE ON THE INTERNAL TOOTH- ING OF THE TRANSMISSION PINION. • Fit the pinion and the chain on the shaft. CAUTION APPLY LOCTITE 243 ON THE SCREW THREAD.
Page 447 RSV4 Factory a-PRC Chassis • Install the rear wheel and the exhaust system. • Fit the pinion casing. • Adjust the chain tension Drive chain Adjusting The vehicle is fitted with an endless chain, without master link. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Page 448 RSV4 Factory a-PRC Chassis • Tighten both lock nuts (4). • Tighten the nut (1). • Check chain clearance. CAUTION WHEEL CENTRING IS CARRIED OUT USING THE IDENTI- FIABLE FIXED REFERENCES (2-3) INSIDE THE CHAIN TENSIONER PAD MOUNTS ON THE SWINGARMS, IN FRONT OF THE WHEEL AXLE.
Page 449 RSV4 Factory a-PRC Chassis Chain sliders • Place the vehicle on its OPTIONAL rear service stand. • Check that the pad (1) is not worn or damaged. Replace it with a new one if it is. • Check the chain guide (2) for wear. •...
Page 450 RSV4 Factory a-PRC Chassis • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct.
Page 451 RSV4 Factory a-PRC Chassis Side stand • Remove the fuel tank. • Remove the pinion cover. • Remove the clamps. • Disconnect the stand connector. • Unscrew and remove the two screws. • Remove the side stand. CHAS - 451...
Page 452 RSV4 Factory a-PRC Chassis 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 Screw fastening silencer to central 20 Nm (14.75 lbf ft)
Page 453 RSV4 Factory a-PRC Chassis • 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; retrieve the collar, the washer and the nut. DURING THIS OPERATION SUPPORT THE EXHAUST PIPE SO THAT IT DOES NOT FALL.
Page 454 RSV4 Factory a-PRC Chassis • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables. CAUTION ON REASSEMBLY, POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET. •...
Page 455 RSV4 Factory a-PRC Chassis • 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 • Move the radiator forward. •...
Page 456 RSV4 Factory a-PRC Chassis 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. • Remove both rear exhaust manifolds. Butterfly valve in exhaust To check correct operation and calibration of the exhaust valve, see electrical system section.
Page 457 RSV4 Factory a-PRC Chassis • 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 ADIATORE OLIO Pos.
Page 458 RSV4 Factory a-PRC Chassis Pos. Descrizione Tipo Quantità Coppia Note Viti TE fl. per fissaggio staffa a telaio M6x20 10 Nm (7.38 lbf ft) Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe.
Page 459 RSV4 Factory a-PRC Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 459...
Page 460 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 461 RSV4 Factory a-PRC Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake disc fixing screws 30 Nm (22.13 lbf ft) Loct. 243 Odometer sensor fixing screw 10 Nm (7.38 lb ft) Rear brake calliper mounting plate 50 Nm (36.88 lbf ft) Loct.
Page 462 RSV4 Factory a-PRC 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...
Page 463 RSV4 Factory a-PRC 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 464 RSV4 Factory a-PRC 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 465 RSV4 Factory a-PRC 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 466 RSV4 Factory a-PRC 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 467 RSV4 Factory a-PRC 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 468 RSV4 Factory a-PRC 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 469 RSV4 Factory a-PRC Braking system Rear 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 470 RSV4 Factory a-PRC Braking system Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft)
Page 471 RSV4 Factory a-PRC 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 - 471...
Page 472 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 473 RSV4 Factory a-PRC 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 - 473...
Page 474 RSV4 Factory a-PRC 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 475 RSV4 Factory a-PRC 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 476 RSV4 Factory a-PRC 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 477 RSV4 Factory a-PRC 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 478 RSV4 Factory a-PRC 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 479 RSV4 Factory a-PRC 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 480 RSV4 Factory a-PRC 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 481 RSV4 Factory a-PRC 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 482 RSV4 Factory a-PRC Cooling system • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Remove the radiator. COOL SYS - 482...
Page 483 INDEX OF TOPICS BODYW ODYWORK...
Page 484 RSV4 Factory a-PRC 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 - 484...
Page 485 RSV4 Factory a-PRC Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 486 RSV4 Factory a-PRC 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 - 486...
Page 487 RSV4 Factory a-PRC 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 488 RSV4 Factory a-PRC 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 489 RSV4 Factory a-PRC 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 490 RSV4 Factory a-PRC 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 491 RSV4 Factory a-PRC 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 492 RSV4 Factory a-PRC 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 493 RSV4 Factory a-PRC Bodywork Instrument panel • Remove the windshield. • Unscrew and remove the two screws. • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the support. •...
Page 494 RSV4 Factory a-PRC Bodywork Headlight fairing • Working from both sides, unscrew and remove the four screws. BODYW - 494...
Page 495 RSV4 Factory a-PRC 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 496 RSV4 Factory a-PRC 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 497 RSV4 Factory a-PRC 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 498 RSV4 Factory a-PRC 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. FOR LEFT FAIRING ONLY •...
Page 499 RSV4 Factory a-PRC Bodywork HANDLE PAINTED AND PLASTIC COMPONENTS WITH CARE; BE CAREFUL NOT TO SCRATCH OR DAMAGE THEM. LOWER SIDE FAIRINGS • The operations described below are valid for both lower side fairings. • Remove the side fairing. • Unscrew and remove the screw and remove the lower side fairing.
Page 500 RSV4 Factory a-PRC Bodywork LATERAL UNDERFAIRINGS • The following procedure is relative to a single lateral underfairing, but is appli- cable to both, except where specified otherwise. • Unscrew and remove the central un- derfairing fixing screw. • Remove the respective side fairing. •...
Page 501 RSV4 Factory a-PRC Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit. • Disconnect the air temperature sensor connector. • Move the two rear coil connectors See also Control unit • Unscrew and remove the four upper injector screws.
Page 502 RSV4 Factory a-PRC Bodywork • Unscrew and remove the eight air filter box cover screws. • Remove the air filter box cover. FILTER BOX BASE • Open the air filter box cover. • Unscrew and remove the air intake duct fixing screws. •...
Page 503 RSV4 Factory a-PRC Bodywork • Working from both sides, disconnect the Blow-by system intake pipes. • Release the cable harness from the cable grommet on the filter box. • Remove the air filter box base. Rear mudguard • Unscrew and remove the two screws. •...
Page 504 RSV4 Factory a-PRC Bodywork • Unscrew and remove the front screw. See also Side fairings • Unscrew and remove the lower screw. • Supporting the right fairing lug, un- screw and remove the right lug fixing screw and remove the lug. •...
Page 505 RSV4 Factory a-PRC Bodywork Fuel tank • Unscrew and remove the front screw fixing the tank. • Remove the rider saddle. • Unscrew and remove the two rear screws. • Release the clamps. • Remove the two tank breather pipes. •...
Page 506 RSV4 Factory a-PRC Bodywork • Disconnect the fuel pump connector. • Remove the tank. Front mudguard • Working from both sides, unscrew and remove the two screws. • Remove the front mudguard. Instrument cluster support REMOVAL • Remove the instrument panel. •...
Page 507 RSV4 Factory a-PRC Bodywork Instrument panel • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws. • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp.
Page 508 RSV4 Factory a-PRC Bodywork • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws. Do not strain the connection between the two semi- arch braces, as this would prevent the removal of the clamp.
Page 509 RSV4 Factory a-PRC Bodywork NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE. Radiator cover •...
Page 510 RSV4 Factory a-PRC Bodywork Side air deflectors The following procedure is for a single lateral duct but is applicable to both. • Remove the windshield. • Unscrew and remove the two fixing nuts. • Remove the duct from its seat on the frame. CAUTION DURING REASSEMBLY, THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN- SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS.
Page 511 INDEX OF TOPICS PRE DE DELIVERY...
Page 512 RSV4 Factory a-PRC 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 513 RSV4 Factory a-PRC 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 514 RSV4 Factory a-PRC 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 515 RSV4 Factory a-PRC 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 516 RSV4 Factory a-PRC Pre-delivery • Insert the key in the lock and turn it clockwise. • Remove the tail fairing. • Fit the two-seater saddle. Adjusting the rear-view window joint. • 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 517 RSV4 Factory a-PRC 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 518 RSV4 Factory a-PRC 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 - 518...
Page 519 a-PRC setting buttons: 231 Air filter: 65 Air temperature sensor: 183 Alternator: Battery: 149, 160 Brake: 461–463, 465, 466, 470, 471 Brake calliper: 461, 462 Brake disc: 462, 463 Brake pads: 465, 466 Brake pump: 470, 471 Bulbs: Bushings: CAN line: 243 Catalytic converter: 453 Chain: 13, 447, 449 Clutch: 75, 216, 273, 290, 291, 294–296, 303, 326, 333, 350, 354...
Page 520 Fuel: 66, 153, 197, 251, 388, 505 Fuel pump: 153, 197, 388 Fuses: 153 Handlebar: 402 Head cover: 67–69, 75, 307, 308, 315, 326, 333 Headlight: 494, 510 Helmet compartment: Identification: 11 Instrument panel: 145, 493, 507 Intake pressure sensor: 176 License plate holder: Linkages: 434 Magneto flywheel: 286, 356...
Page 521 Speed sensor: 161 Stand: 217, 251, 255, 450, 451 Start-up: 152, 283 Starter motor: 282 Steering damper: 416 Stepper motor: 394 Tank: 66, 251, 505 Throttle body: 67, 68, 202, 392–394 Transmission: 12, 353, 356 Tyres: 14 Variable geometry intake: 165, 394, 396 Warning lights: Water pump: 356, 379, 477 Windshield:...

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