Page 1 RSV 1000 R - RSV 1000 R FACTORY 1137 3 00/2003-10 workshopmanual...
Page 2 INTRODUCTION RSV 1000 R - RSV 1000 R FACTORY INTRODUCTION 0 - 1...
Page 3 INTRODUCTION RSV 1000 R - RSV 1000 R FACTORY SUMMARY 0.1. INTRODUCTION ............................. 3 0.1.1. INTRODUCTION............................ 3 0.1.2. REFERENCE MANUALS........................4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................5 0 - 2...
Page 4 Aprilia S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.
Page 5 INTRODUCTION RSV 1000 R - RSV 1000 R FACTORY 0.1.2. REFERENCE MANUALS PARTS CATALOGUES Aprilia part# (description) 3974 SPECIAL TOOLS CATALOGUES Aprilia part# (description) 001A00 OWNER’S MANUALS Aprilia part# (description) 8104334 8104691 8104692 8104693 8104704 8104694 8104695 CYCLE PARTS TECHNICAL MANUAL...
Page 6 INTRODUCTION RSV 1000 R - RSV 1000 R FACTORY 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F...
Page 7 INTRODUCTION RSV 1000 R - RSV 1000 R FACTORY RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head = flat head screw = Twin Spark Ignition UPSIDE- DOWN...
Page 8 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY GENERAL INFORMATION 1 - 1...
Page 9: Table Of Contents
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ..................... 3 1.1.2. SAFETY WARNINGS..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES......................... 5 1.3. DANGEROUS ELEMENTS ..........................8 1.3.1.
Page 10: Structure Of The Manual
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting this manual.
Page 11: Safety Warnings
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard.
Page 12: General Rules
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well- aerated room.
Page 13 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY COOLANT The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send forth invisible flames causing severe burns. DANGER Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch fire and send forth invisible flames.
Page 14 Never clean a bearing with compressed air. NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL Aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.
Page 15: Dangerous Elements
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refueling and engine service should take place in a well-ventilated area with the engine turned off. Do not smoke when refueling or when near fuel vapors’...
Page 16 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that most ensure your safety and for this reason they must always be in perfectly working order.
Page 17 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY COOLANT DANGER Coolant is toxic when ingested; it is an irritant, contact with eyes or skin may cause irritation. In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice immediately.
Page 18 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY TIRES WARNING If tires are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at your ease. In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired. Flat tires (insufficient pressure) can slip on the rim and make you lose control of the vehicle.
Page 19: Running-In
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS Running-in the engine is essential to ensure its duration and correct functioning. If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un- dergo a more effective running-in.
Page 20: Vehicle Identification
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for the vehicle’s registration. IMPORTANT Do not alter the identification numbers if you do not want to incur severe penal and administrative sanc- tions;...
Page 21 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY DIGIT MEANING Manufacturer’s identification alphanumeric code. Vehicle type. Model. Country for which the vehicle is intended. #= Check digit number. Model year. Assembling factory designation (N = NOALE-VE- , S = SCORZÉ -VE- , 0 = NOT SPECIFIED).
Page 22: Position Of The Warning Adhesive Labels
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.6. POSITION OF THE WARNING ADHESIVE LABELS 1.6.1. POSITION OF THE WARNING ADHESIVE LA- BELS 1 - 15...
Page 23 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 16...
Page 24 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 17...
Page 25 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 18...
Page 26 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY Muffler stamping 1 - 19...
Page 27 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 20...
Page 28 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 21...
Page 29 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 22...
Page 30 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1 - 23...
Page 31 GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY Muffler stamping 1 - 24...
Page 32: California Evaporative Emission System
GENERAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM FOR STATE OF CALIFORNIA ONLY. The system consists of: Fuel tank Fuel tank breather line Breather line (to 2 way ventilation valve) 2 way ventilation valve Breather line (to carbon canister) Carbon canister Drain line (to norrow passage)
Page 33 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY GENERAL TECHNICAL INFORMATION 2 - 1...
Page 34 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY SUMMARY 2.1. GENERAL TECHNICAL INFORMATION ......................3 2.1.1. TECHNICAL DATA ..........................3 2.1.2. PERIODIC MAINTENANCE CHART...................... 7 2.1.3. TABLE OF LUBRICANTS ........................9 2.1.4. TIGHTENING TORQUES ........................10 2.1.5. SPECIAL TOOLS ..........................
Page 35: General Technical Information
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. length 79.724 in (2025 mm) Max. length 28.740 in (730 mm) Max. height (incl. windshield) 44.685 in (1135 mm) Rider’s seat height 32.283 in (820 mm) Wheelbase 55.512 in (1410 mm)
Page 36 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY FRAME Type Two-beam frame with light alloy cast elements and extruded elements Steering head angle 25° Trail 3.937 in (100 mm) (with 120/70 front tire) SUSPENSION Front Adjustable hydraulic upside-down fork, Ø 1.693 in (Ø 43 mm) Travel RSV R 4.999 in (127 mm) –...
Page 37 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY TIRES Pressure kPa (bar) Recom- Wheel Make Model Type Size Alternative mended Rider and Rider Rider passenger ** Front PIRELLI DIABLO CORSA 120/70– RSV R + R 230 (2,3) 250 (2,5) ZR 17"...
Page 38 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY SPARK PLUGS Standard NGK R DCPR9E Electrode gap 0.024– 0.028 in (0,6 – 0,7 mm) Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V – 10 Ah Main fuses 30 A Auxiliary fuses 5 A, 15 A, 20 A Generator (permanent-wound type)
Page 39: Periodic Maintenance Chart
RSV 1000 R - RSV 1000 R FACTORY 2.1.2. PERIODIC MAINTENANCE CHART OPERATIONS TO BE CARRIED OUT BY THE Aprilia Official Dealer (CAN BE CARRIED OUT BY THE USER AS WELL). check and clean, adjust, lubricate or replace, if necessary;...
Page 40 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY OPERATIONS TO BE CARRIED OUT BY THE Aprilia Official Dealer. check and clean, adjust, lubricate or replace, if necessary; clean; replace adjust. (*) = only for versions with magnesium wheels: check that rim paint is in good conditions.
Page 41: Table Of Lubricants
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.3. TABLE OF LUBRICANTS LUBRICANT PRODUCT RECOMMENDED: EXTRA RAID 4, SAE 15W - 50 or TEC 4T, SAE 15W - 50. Engine oil As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I.
Page 42: Tightening Torques
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.4. TIGHTENING TORQUES DESCRIPTION ENGINE Engine mounting to frame Front fitting 36,878 Left side upper and lower rear fitting 36,878 Adjuster bushing right side upper and lower rear fitting M20x1,5 8,851 Locknut right side upper and lower rear fitting...
Page 43 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY FRONT SUSPENSION Front fork Fork leg on top yoke 18,439 Fork leg on bottom yoke 18,439 tighten first Head stock nut (tighten first, then slacken) M35x1 29,502 and then slacken tighten 2nd Head stock nut (tighten down 2nd time)
Page 44 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY COOLING SYSTEM Fan support 4,425 Expansion reservoir to frame 3,688 Expansion reservoir cap M28x3 man. Hose clips (8104097) 2,213 BRAKE SYSTEM Front brakes Right and left brake calipers M10x1,25 36,878 Brake fluid reservoir to bracket 5,163...
Page 45 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY ENGINE OIL RESERVOIR Oil reservoir ( nuts ) 7,376 Oil filter shank M20x1,5 22,127 Oil drain cap 11,063 Oil level bracket M10x1 14,751 FRAME / FAIRING PANELS Front fairing to air scoop 2,213 Windshield to front fairing 0,738...
Page 46: Special Tools
Aprilia part# (tool description and function) 8140176 (complete support stand kit) 8146486 (front support stand) xxxxxxx N.A. [center stand] 8705021 (rear support stand) xxxxxxx N.A. = available only with the Aprilia kit part# 8140176 (complete support stand kit) 2 - 14...
Page 47 Pos. Aprilia part# (tool description and function) 8140203 (complete tool kit for frame included) 8140189 [oil seal fitting tool - Ø 43 hole. Kit accessory Aprilia part# 8140151 (complete tool kit for fork included)] 8140190 (steering tightening tool) 8140191 (rear fork pin and engine support tightening tool) FORK TOOLS Pos.
Page 48 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY ENGINE TOOLS 2 - 16...
Page 49 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY Pos. Aprilia part# (tool description and function) 8140175 (complete tool kit for engine included) 0277680 (gearshift secondary shaft oil seal assembly pad) 0277660 (upper countershaft oil seal assembly pad)
Page 50 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY MISCELLANEOUS TOOLS 2 - 18...
Page 51 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY Pos. Aprilia part# (tool description and function) 8140196 [Plurigas (Italian)] 8140578 [Plurigas (English)] 8140192 (chain installation kit) 8140180 (bearing extractors) 8140202 (exhaust gas analysis probes) 8140267 (intake flange for vacuometer)
Page 52 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY TOOLS USED FOR OTHER Aprilia Pos. Aprilia part# (tool description and function) 0877650 (handle for pads) 0277265 (extractor for balance shaft, gearbox input and output shaft) 8116050 (engine oil) –...
Page 53: Arrangement Of The Main Elements
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS KEY RSV R Left side fairing Adjustable steering damper RSV R OPT Headlight left lamp Front fairing Left rear-view mirror Clutch fluid’s reservoir Engine’s oil filter Left side panel Rider’s seat...
Page 54 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY KEY RSV R Rear shock absorber Passenger right footrest (snaps closed/open) Tail light Glove/tool kit compartment Passenger seat (glove/tool kit’s compartment cover) Passenger’s grab strap Engine’s Control Unit Right side panel Fuel tank 10.
Page 55 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY PRINCIPALI KEY RFACT Left side fairing Adjustable steering damper Headlight left lamp Front fairing Left rear-view mirror Clutch fluid’s reservoir Engine’s oil filter Left side panel Rider’s seat 10. Battery 11.
Page 56 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY KEY RFACT Rear shock absorber Passenger’s right footrest (snaps closed/open) Tail light Glove/tool kit’s compartment Passenger seat (Glove/tool kit’s compartment cover) Passenger’s grab strap Engine’s Control Unit Right side panel Fuel tank 10.
Page 57: Arrangement Of The Instruments/Controls
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.7. ARRANGEMENT OF THE INSTRU- MENTS/CONTROLS Key: Clutch lever Ignition/steering lock switch ( Instruments and indicators Front brake lever Throttle twistgrip High beam flasher ( )/LAP button (multifunction) Light dimmer switch ( Direction indicator switch ( Horn button ( 10.
Page 58: Dashboard Operation
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.8. DASHBOARD OPERATION When the ignition key is turned to “ ”, the following will light up on the dashboard for 3 seconds: all segments of the multifunction display all indicator leds display backlighting The revolution counter pointer (1) will move to the maximum...
Page 59 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY CURRENT/MAX/AVERAGE SPEED BATTERY VOLTAGE DISPLAY IMPORTANT The average/max speed and battery voltage are only displayed with the vehicle stationary. Only the cur- rent speed is displayed when the vehicle is being driven. When the ignition key is turned to “...
Page 60 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY To reset partial odometer 1 (TRIP 1), display the reading and hold down the TRIP/V key for at least 3 seconds. To reset partial odometer 2 (TRIP 2) display the reading and hold down the TRIP/V key for at least 3 seconds.
Page 61 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY SETTING THE DIGITAL CLOCK The digital clock is at the top of the display. The clock displays only when the ignition key is turned to “ ”. IMPORTANT The clock can be set only with the vehicle sta- tionary and the ignition key turned to “...
Page 62 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY To start the chronometer : • press and immediately release the LAP button. The first time the button is pressed, the stop clock starts. Pressing LAP again within the first 10 seconds will re- set the chronometer.
Page 63 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY RED LINE ADJUSTMENT (ONLY WITH ENGINE OFF) When the engine rpm exceeds the red line setting, the red line indicator (2) on the dashboard flashes. IMPORTANT The red line setting can only be adjusted with the engine off and the odometer displayed (adjustment range 2000 to 12000 rpm).
Page 64 XX is the last two digits of the code in question. If the CAN line does not respond or is disconnected in diagnostics mode, ERR will flash in place of the code digits. DIAGNOSTICS CODE TABLE Error Type Error type Aprilia Code NO error Cam Sensor No signal No signal Crank Sensor...
Page 65 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY SERVICE INTERVALS Display type : SERVICE icon Operating modes : the SERVICE icon displays after the first 1000 Km (620 mi) ± 5%; next after a total 10000 Km (6213 mi), i.e. 9000 Km (5592 mi) after the first time, every 10000 Km (6213 mi) ±...
Page 66: Systems Diagram
GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY 2.1.9. SYSTEMS DIAGRAM BRAKES 2 - 34...
Page 67 GENERAL TECHNICAL INFORMATION RSV 1000 R - RSV 1000 R FACTORY GAS RECOVERY FROM CRANKCASE 2 - 35...
Page 68 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY FUEL SYSTEM 3 - 1...
Page 69 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY SUMMARY 3.1. FUEL SYSTEM..............................3 3.1.1. DIAGRAM .............................. 3 3.1.2. INJECTION SYSTEM DIAGRAM ......................4 3.1.3. CYLINDER TIMING AND CO LEVEL ADJUSTMENT................6 3.1.4. AXONE..............................7 3.1.5. AIRBOX..............................11 3.2. FUEL PUMP ..............................
Page 70: Fuel System
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.1. FUEL SYSTEM 3.1.1. DIAGRAM 1) Fuel tank 2) Filler cap 3) Fuel supply pump unit 4) Fuel vapor breather pipe (for the vapors produced by excessive pressure inside the tank) 5) Fuel “overflow”...
Page 71: Injection System Diagram
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.1.2. INJECTION SYSTEM DIAGRAM 3 - 4...
Page 72 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY Legend : ECU location Ignition switch Battery Engine shaft position sensor Camshaft position sensor Engine temperature sensor Air temperature sensor Throttle position sensor Intake pressure sensor 10. Safety system: Side stand, idle sensor 11.
Page 73: Cylinder Timing And Co Level Adjustment
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.1.3. CYLINDER TIMING AND CO LEVEL ADJUST- MENT • With the vehicle switched off, connect the Axone 2000 to the diagnostics’ connector and the vehicle’s battery. • Switch on the instrument. •...
Page 74: Axone
ERRORS DISPLAY ADJUSTABLE PARAMETERS UNITS VALUES DISPLAY DESCRIPTION NOTES (APPROXIMATE) MEASURE- MENT Aprilia hardware Aprilia software Revision number Engine Manufactured Mapping Indicates the ECU mapping code Date programmed Most recent mapping date Last author ID of PC/Axone which loaded the most...
Page 75 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY Lambda sensor Value ranges from 300 to 3000 mV Type 1 carburetor adjust- Tells the ECU how much air is required ment in the type 1 engine load condition Type 2 carburetor adjust- Tells the ECU how much air is required ment in the type 2 engine load condition...
Page 76 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY sor status recognition / wait after recognition / de-activated due to driving / de-activated due to fault / wait after interruption / lambda sensor active / saturated Long term adjustment de- no / max tries / water temperature Reasons for de-activation of long term activation...
Page 77 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY lation (activates a set of parameters) FROZEN PA- Engine load Contrary to the engine parameters dis- RAMETERS play, here expressed as % Water temperature °C Air temperature °C Battery voltage Intake pressure approx.
Page 78: Airbox
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.1.5. AIRBOX Key: Throttle body Front air intake Check valve Membrane Solenoid valve Vacuum chamber Atmospheric pressure Air intake is controlled by a flap in the duct leading from the windshield to the airbox. This flap reduces engine noise at low engine speeds.
Page 79: Fuel Pump
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.2. FUEL PUMP 3.2.1. REMOVING THE FUEL PUMP ASSEMBLY • Completely remove the fuel tank. IMPORTANT Position the tank on a clean surface with the pump unit uppermost. • Loosen and remove the eight screws (1). IMPORTANT To refit, fasten all screws (1) by hand in their holes and tighten in a cross pattern.
Page 80: Removing The Fuel Level Sensor
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.2.2. REMOVING THE FUEL LEVEL SENSOR • Remove the entire fuel system. • Disconnect the connector. • Release and remove the 2 screws. • Remove the fuel level sensor. 3 - 13...
Page 81: Removing The Delivery Filter
• Remove the whole fuel supply pump unit. NOTE: Have the appropriate special tool OPT at hand: - Aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions.
Page 82: Removing The Fuel Supply Pump
• Remove the whole fuel supply pump unit. NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 0277295 (hose clamp installation pliers). CAUTION Upon installation, replace the hose clamp that has been removed with a new one having the same dimensions.
Page 83 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY • Loosen and remove the 3 screws. • Bend the fuel filter over sideways and keep it held down. If the filtering mesh shows traces of sediments, clean it using a compressed air jet pointing it so that the impuri- ties do not get inside.
Page 84: Throttle Body
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3. THROTTLE BODY 3.3.1. REMOVING THE THROTTLE BODY WARNING The throttle setting screws (1) are painted over and cannot be adjusted. Only if the entire cable fitting (2) is to be re- placed, the setting screws can be adjusted.
Page 85 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY IMPORTANT Make sure to use the special OPT tool: - Aprilia part# 0277295 (snap clip pliers). • Undo the snap clip (4). • Undo the snap clip (5). • Extract the hoses from the throttle body.
Page 86 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY • Undo the two clips WARNING When removing the throttle body proceed with care as it is still connected to the fuel tank via the fuel hose. • Grip the throttle body firmly and move it up and away from the intake flanges with small rocking movements.
Page 87: Disassembling The Throttle Body
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3.2. DISASSEMBLING THE THROTTLE BODY • Unscrew and remove the M8x1 nut (1) and remove the spring washer. • Turn the throttle valve control lever (2) slightly, un- screw and remove three T.E. M5x12 screws (3). •...
Page 88 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY • Loosen and remove the two M6x25 screws (14) and the right injector support (15), together with the rele- vant gasket (16), injector (17) and sealing ring (18). NOTE The injector’s sealing ring (18) may be kept inserted in the slot on the throttle body.
Page 89 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY • Unscrew and remove the M8x1 nut (19) and remove the spring washer (20), the pulley (21), the two bushes (22) and torsion spring (23). • Slide the fulcrum pin (24), together with the lock washer (25), out of the hole on the throttle cable sup- port bracket and remove the two shaft sealing rings (26) with the torsion spring (27) and cold-start lever...
Page 90: Inspecting The Throttle Body
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3.3. INSPECTING THE THROTTLE BODY TESTING THE INJECTOR NOTE The injectors can be controlled electrically. • Check the following components: wiring and connections; injector or injection’s signal of the engine control unit. THROTTLE BODY •...
Page 91: Refitting The Throttle Body
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3.4. REFITTING THE THROTTLE BODY CAUTION After disassembling the throttle body, replace all the gaskets, O-rings, torsion springs, bushes and seals. These components are sup- plied with the repair kit. •...
Page 92 FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY CAUTION Make sure that the ends of the torsion spring (20) are hooked onto the throttle cable support bracket and pulley (21). NOTE Spray a temporary lubricant on the spring (20), see 1.9.2 (USE OF CONSUMABLES).
Page 93: Replacing The Throttle Valve Control Lever
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3.5. REPLACING THE THROTTLE VALVE CON- TROL LEVER DISASSEMBLY • Partially remove the fuel tank. • Remove the air filter casing. • Unscrew and remove the M8x1 nut (1) and remove the spring washer.
Page 94: Checking Throttle Valve Control Shaft End Play
FUEL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 3.3.6. CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY • Partially remove the fuel tank. • Remove the air filter casing. NOTE Have an appropriate thickness gauge (1) with a 0.00197 in (0.05 mm) scale at hand. With throttle valves closed: •...
Page 95 ENGINE RSV 1000 R - RSV 1000 R FACTORY ENGINE 4 - 1...
Page 96 ENGINE RSV 1000 R - RSV 1000 R FACTORY SUMMARY 4.1. ENGINE ................................3 4.1.1. REMOVING THE ENGINE........................3 4.1.2. REINSTALLING THE ENGINE ......................26 4.1.3. TIGHTENING TORQUES ........................51 4 - 2...
Page 97: Engine
ENGINE RSV 1000 R - RSV 1000 R FACTORY 4.1. ENGINE 4.1.1. REMOVING THE ENGINE • Remove the airbox cover. • Loosen the screw securing the airbox to the frame. • Remove the six screws securing the throttle body to the airbox 4 - 3...
Page 98 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Detach the by pass lines to the throttle body and the stepper motor connector • Remove the oil vapor recovery line • Detach the manifold pressure sensor connection and the lines coming from the throttle body 4 - 4...
Page 99 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the airbox • Disconnect the cabling from the ignition coil 4 - 5...
Page 100 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Disengage the throttle cables • Detach the throttle potentiometer connector • Remove the vacuum lines from the throttle body 4 - 6...
Page 101 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Disconnect the injector connectors • Loosen the clamps on the intake manifolds 4 - 7...
Page 102 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the throttle body • Close the lines so that impurities are unable to enter the cylinders • Open the clamps on the lubrication circuit lines leading to the oil tank 4 - 8...
Page 103 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Detach the engine casing oil lines • Loosen the three screws securing the oil tank 4 - 9...
Page 104 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the oil tank and extract the line coming from the cooler. • Remove the fairing air dam by loosening its screws (2 central 4 side). 4 - 10...
Page 105 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Extract the bleed lines from their seat • Remove the oil line on the engine casing. • Undo the stud mounting the oil line clamp to the engine casing • Disconnect the oil hose from the right side.
Page 106 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Release and remove the four screws securing the oil cooler’s subframe. IMPORTANT To remove the left side screw, hold the inner nut steady with a wrench. • Remove the subframe and the oil cooler. •...
Page 107 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Loosen the screws securing the rear brake pump • Undo the clip securing the pump to the brake lever • Detach the line leading to the expansion tank • Loosen the screws securing the expansion tank and remove it 4 - 13...
Page 108 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Detach the engine oil pressure sensor connector • Detach the lambda sensor, stop light switch, speed sensor and rectifier connections. 4 - 14...
Page 109 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the lower cooler mounts and move it away while holding it in a vertical position. • Unscrew the starter motor connector • Release the silencer mounting clips • Loosen the screw securing the silencer clamp 4 - 15...
Page 110 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the silencers • Release the clip securing the front cylinder manifold to the exhaust • Undo the four nuts securing the manifold to the front cylinder • Remove the manifold 4 - 16...
Page 111 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Keep the gasket • Undo the clip securing the rear manifold to the exhaust • Extract the lambda sensor cable from the frame • Remove the entire exhaust assembly including the lambda sensor 4 - 17...
Page 112 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Undo the four nuts fixing the manifold to the rear cylin- • Remove the exhaust manifold and keep the gasket • Disconnect the temperature sensor, timing sensor, en- gine speed sensor, side stand safety switch and gen- erator connectors.
Page 113 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Detach the spark plug cap 4 - 19...
Page 114 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the gearshift lever • Remove the clutch lever and flange 4 - 20...
Page 115 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the pinion casing and guide plate on the en- gine casing • Undo the bolt securing the pinion and keep the wash- • Remove the pinion 4 - 21...
Page 116 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Open the clamps and remove the coolant lines on the radiator • Undo the engine casing ground connectors • Detach the neutral sensor connector 4 - 22...
Page 117 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Remove the rear brake lever • Remove the lever mount and rear brake pump • Remove the brake pump mount • Detach the vacuum line on the pneumatic clutch actua- •...
Page 118 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Loosen the screws mounting the engine to the frame at the rear • Loosen the four screws on the front engine mounts • Remove the screws and the spacers between the frame and the engine.
Page 119 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Slacken the adjuster bushings between the engine and the frame • Fully lower the engine 4 - 25...
Page 120: Reinstalling The Engine
ENGINE RSV 1000 R - RSV 1000 R FACTORY 4.1.2. REINSTALLING THE ENGINE • Place the engine on a suitable support • Partly raise the engine. • Position the engine so that the rear mounts are aligned with the frame •...
Page 121 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the two screws to the front left mount. • Locate the rear left spacer and tighten the screw to the prescribed torque. • Fit the rear left screw. • Locate the front right spacer 4 - 27...
Page 122 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the two screws to the front right mount. • Tighten down the four left side screws. • Tighten the upper right bush to the prescribed torque. • Tighten the upper right nut to the prescribed torque. •...
Page 123 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Tighten the lower right nut to the prescribed torque. • Fit the upper right screw. • Fit the lower right screw. • Tighten down the four right side screws. • Remove the engine support 4 - 29...
Page 124 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Refit the pneumatic clutch actuator vacuum line and secure it with a clamp • Fit the rear brake lever mount and pump and tighten the screws to the specified torque •...
Page 125 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the rear brake pump and connect it to the brake lever • Screw in the neutral sensor connector • Refit the engine casing ground connectors and tighten their screws to the specified torque 4 - 31...
Page 126 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the coolant lines to the radiator and secure them with clamps • Fit the pinion in the right orientation 4 - 32...
Page 127 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Mount the pinion, tightening it to the specified torque • Fit the pinion casing and guide plate and tighten the screws to the specified torque • Fit the clutch lever complete with flange 4 - 33...
Page 128 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Mount the gear shift lever • Fit the spark plug caps • Hook up the temperature sensor, timing sensor, engine speed sensor, side stand safety switch and generator connectors. 4 - 34...
Page 129 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Mount the rear cylinder exhaust manifold with its gas- 4 - 35...
Page 130 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Tighten the studbolt nuts to their specified torque • Fit the entire exhaust assembly complete with lambda sensor • Insert the clip securing the rear manifold and exhaust • Secure the lambda sensor cabling to the frame •...
Page 131 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the manifold to the cylinder studbolts and exhaust • Tighten the four nuts securing the manifold to the cyl- inder to the specified torque • Reconnect the clip securing the front cylinder manifold to the exhaust 4 - 37...
Page 132 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Refit the silencers • Screw on the silencer clamp screws • Clip on the silencer clips • Screw in the starter motor connector 4 - 38...
Page 133 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Move the cooler towards the engine and refit the lower mounts • Hook up the lambda sensor, stop light switch, speed sensor and rectifier connections. 4 - 39...
Page 134 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Connect up the engine oil pressure sensor connector • Fit the expansion tank and screw in the two mounting screws • Connect the line leading to the expansion tank 4 - 40...
Page 135 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Engage the brake lever pump clip • Tighten the screws securing the rear brake pump • Fit the rear brake fluid tank • Fit the subframe and the oil cooler. •...
Page 136 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Connect the oil hose from the right side. • Screw in the stud mounting the oil line clamp to the en- gine casing • Fit the oil line to the engine casing 4 - 42...
Page 137 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Insert the bleed lines in their seats. • Screw in the two screws securing the conveyor to the coolant radiator mount • Fit the coolant radiator conveyor • Fit the fairing air dam and tighten its screws (2 central 4 side).
Page 138 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the oil tank and the oil cooler line • Tighten down the three screws securing the oil tank • Mount the oil lines to the engine casing 4 - 44...
Page 139 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Tighten the clamps on the lubrication circuit lines lead- ing to the oil tank • Remove the protectors inserted into the lines • Fit the throttle body • Tighten down the clamps on the intake manifolds 4 - 45...
Page 140 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Hook the connectors to the injectors • Fit the vacuum lines to the throttle body 4 - 46...
Page 141 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Refit the throttle potentiometer connector • Fit the throttle control cables and adjust their play • Connect the cabling to the ignition coil 4 - 47...
Page 142 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Fit the airbox • Tighten the six screws securing the airbox to the throt- tle body to the specified torque 4 - 48...
Page 143 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Tighten the screw mounting the airbox to the frame at the front to the specified torque • Hook up the throttle body hoses to the stepper motor. • Refit the manifold pressure sensor connector •...
Page 144 ENGINE RSV 1000 R - RSV 1000 R FACTORY • Connect the stepper motor and bypass lines leading to the throttle body • Fit the airbox cover 4 - 50...
Page 145: Tightening Torques
ENGINE RSV 1000 R - RSV 1000 R FACTORY 4.1.3. TIGHTENING TORQUES DESCRIPTION ENGINE Engine mounting to frame Front fitting 36,878 - Left side upper and lower rear fitting 36,878 - Adjuster bushing right side upper and lower rear fitting M20x1,5 8,851 - Locknut right side upper and lower rear fitting...
Page 146 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY CYCLE PARTS 5 - 1...
Page 147 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY SUMMARY 5.1. BODY PANELS ............................... 4 5.1.1. REMOVING THE BODY PANELS ......................4 5.1.2. BODY PANEL REASSEMBLY ......................13 5.1.3. TIGHTENING TORQUES ........................21 5.2. FRONT FORK ............................... 22 5.2.1. DIAGRAM (RSV R) ..........................
Page 148 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.10. CLUTCH...............................132 5.10.1. BLEEDING THE CLUTCH CIRCUIT....................132 5.11. DRIVE CHAIN ..............................133 5.11.1. DRIVE CHAIN.............................133 5.11.2. INSPECTING THE DRIVING CHAIN SHOE..................135 5.11.3. REMOVING THE CHAIN SHOE ......................136 5.11.4. LOWER CHAIN SHOE ........................138 5 - 3...
Page 149: Body Panels
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.1. BODY PANELS 5.1.1. REMOVING THE BODY PANELS • Remove the screws securing the fairing to the sides. • With the aid of screwdriver, undo the clips securing the fairing to the front fairing •...
Page 150 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the upper front fairing panels by loosening the front fairing’s retaining screws • Detach the direction indicator connectors and detach the cabling from its mount • Remove the rear view mirrors •...
Page 151 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the clips using a pair of pliers. • Partially extract the front fairing. • Detach the six lamp connectors • Remove the front fairing 5 - 6...
Page 152 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Undo the two screws securing the rider’s seat and lift it • Unlock the passenger’s seat using the ignition key • Push the seat forwards so as to disengage it from its mount 5 - 7...
Page 153 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Extract the passenger’s seat from the belt and remove • Undo the screw securing the belt and keep the center- ing bushings • Remove the spacers between the tail and the seat’s subframe •...
Page 154 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Undo the screws securing the side panels • Extract the side panels • Undo the screws securing the tail light to the tail • Loosen the six screws securing the tail to the lower panel 5 - 9...
Page 155 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Separate the tail from the tail light • Detach the direction indicator connectors • Remove the tail • Undo the two screws securing the fuel tank 5 - 10...
Page 156 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the screws and turn the tank over • Detach the bleed tubes • Detach the fuel delivery and return lines • Lower the tank 5 - 11...
Page 157 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Disconnect the fuel pump connector • Remove the rear tank retaining screw • Remove the tank and slide the cabling out of the frame 5 - 12...
Page 158: Body Panel Reassembly
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.1.2. BODY PANEL REASSEMBLY • Place the tank and its cabling on the frame. • Fit the rear tank’s retaining screw. • Connect the fuel pump connector. • Raise the fuel tank 5 - 13...
Page 159 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the fuel delivery and return lines • Connect the bleed lines and secure them with their clamps • Lower the tank and fit the two front retaining screws 5 - 14...
Page 160 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the tail • Connect the direction indicator connectors • Tighten the six screws securing the tail to the lower panel • Install the screws securing the tail light to the tail •...
Page 161 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the side panels • Secure the side panels to the tank and the seat sub- frame • Connect the passenger seat unlock cable 5 - 16...
Page 162 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the spacers between the tail and the seat’s sub- frame • Fit the passenger’s belt and tighten the two retaining screws • Mount the passenger’s seat • Position the rider’s seat and secure it with its screws 5 - 17...
Page 163 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Hook up the six lamp connectors • Fit the front fairing • Secure the clips 5 - 18...
Page 164 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the rear view mirrors • Hook up the direction indicator connectors • Mount the front fairing upper panels and tighten the screws securing the front fairing • Insert the fairing from the side taking care not to dam- age it 5 - 19...
Page 165 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • With the aid of a screwdriver, secure the clips securing the fairing to the front fairing • Fit the screws securing the fairing to the side 5 - 20...
Page 166: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.1.3. TIGHTENING TORQUES DESCRIPTION FRAME / FAIRING PANELS Front fairing to air scoop 2,213 Windshield to front fairing 0,738 Fairings to rider's footrest and spacer 1,475 Side fairing panels internal fitting w/ air dam 2,213 Air dam to cooler's support(s) 2,213...
Page 167: Front Fork
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2. FRONT FORK 5.2.1. DIAGRAM (RSV R) 5 - 22...
Page 168 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY Key: Retainer ring Spring preload adjuster Spring preload pusher Slider upper plug Washer Slide bush Piston assembly Centering bush Spring-press tube 10. Spring 11. Spring rest washer 12. Lower collar 13.
Page 169: Removing The Fork Legs
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.2. REMOVING THE FORK LEGS • Support the front part of the motorcycle. • Undo the screws securing the front mudguard and re- move it • Undo the screws securing the front brake calipers and remove them from their seats •...
Page 170 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Keep the seal washer • Slacken the screws on the wheel axle clamps • Lightly knock the wheel axle with a rubber mallet so as to uncover the holes on the opposite side •...
Page 171 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • While removing the axle, support the wheel and then remove it • Slacken the screws securing the handlebar on the side in question to the fork • Support the fork leg and slacken the screws on the up- per and lower plates 5 - 26...
Page 172 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Extract the fork leg. 5 - 27...
Page 173: Fitting The Fork Legs
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.3. FITTING THE FORK LEGS • Insert the fork leg. • Adjust the slider resistance and tighten the screws on the fork plates to the specified torque • Tighten the handlebar screws to the specified torque •...
Page 174 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the wheel axle • Tighten down the clamp screws (nut side) to secure the wheel axle • Fit the seal washer and screw on the axle nut to the specified torque •...
Page 175 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the screws securing the wheel axle clamps to the specified torque • Tighten the screws securing it to the specified torque WARNING After fitting the brake calipers, repeatedly operate the front brake lever •...
Page 176: Changing The Fork Fluid (Rsv R)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.4. CHANGING THE FORK FLUID (RSV R) • Clamp the slider with the specified tool. • Set the spring preload to its minimum • Undo the upper slider cap • Clamp the fork end taking care not to damage it 5 - 31...
Page 177 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the special tool to the spring coupling • Push the tool downwards to compress the spring and install the tool spacer under the cartridge locknut • Slacken the cap using the locknut for leverage with a wrench fitted to the wrench seat •...
Page 178 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the spacer and the washer • Press downwards to compress the spring and extract the spacer • Extract the spring coupling • Drain the oil into a container and remove the spring 5 - 33...
Page 179: Topping Up The Fork Fluid (Rsv R)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.5. TOPPING UP THE FORK FLUID (RSV R) • Fill the fork so that any air inside it is vented • Fit the spring coupling • Fit the special tool to the spring coupling so as to lock the cartridge stem in position •...
Page 180 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Screw the top cap on the cartridge leg • Clamp the slider in a vice using the special tool 5 - 35...
Page 181 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the top cap to the specified torque 5 - 36...
Page 182: Replacing The Oil/Dust Seal (Rsv R)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.6. REPLACING THE OIL/DUST SEAL (RSV R) • Clamp the slider with the specified tool. • Set the spring preload to its minimum • Undo the upper slider cap • Clamp the fork end taking care not to damage it 5 - 37...
Page 183 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the special tool to the spring coupling • Push the tool downwards to compress the spring and install the tool spacer under the cartridge locknut • Slacken the cap using the locknut for leverage with a wrench fitted to the wrench seat •...
Page 184 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the spacer and the washer • Press downwards to compress the spring and extract the spacer • Extract the spring coupling • Drain the oil into a container and remove the spring 5 - 39...
Page 185 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Extract the washer and lower spacer • Undo the cartridge retainer screw on the fork end • Keep the centering bushing 5 - 40...
Page 186 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • With a screwdriver, extract the wiper seal from the slider • Take care not to damage the rim of the slider • Remove the stop ring • Extract the slider from the stanchion tube using the slider itself to exert leverage •...
Page 187 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the ring and wiper seal 5 - 42...
Page 188 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5 - 43...
Page 189: Refitting The Oil/Dust Seal (Rsv R)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.7. REFITTING THE OIL/DUST SEAL (RSV R) • Clamp the fork leg in such as way as not to damage it. • Protect the end of the stanchion tube with tape. •...
Page 190 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • The seal ring must be installed with the stamped side facing the wiper seal • Now fit the ring, mobile bushing and, after removing the tape, the fixed bushing 5 - 45...
Page 191 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit the slider to the stem and install the oil seal in its correct position with the special tool • Fit the stop ring in its seat • Fit the wiper seal with the prescribed tool •...
Page 192 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the cartridge retainer screw on the fork end to the specified torque • Fit the lower spacer and washer • Install the fork spring 5 - 47...
Page 193 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fill the fork so that any air inside it is vented • Fit the spring coupling • Fit the special tool to the spring coupling so as to lock the cartridge stem in position •...
Page 194 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Screw the top cap on the cartridge leg • Clamp the slider in a vice using the special tool 5 - 49...
Page 195 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the top cap to the specified torque 5 - 50...
Page 196: Checking The Components
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.8. CHECKING THE COMPONENTS WHEEL-HOLDER TUBE Check the sliding surface, which must be neither lined, nor scratched. Slight lines can be eliminated by sanding the surface with wet sandpaper (grain 1). If the lines are deep, change the tube.
Page 197 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY pumping element. If excessive wear or any damage is noticed, change the component in question. CAUTION Remove any accumulation of impurities from the bushings, taking care not to scratch their surfaces.
Page 198 4 - 5 notches are in view Fork height (A) (***) over top yoke (not 4 notches in view 5 notches in view including top cap) (*) clockwise (**) counterclockwise (***) Have this adjustment carried out exclusively by an Aprilia Official Dealer 5 - 53...
Page 199 6 - 9 turns Fork height (A) (***) over top yoke (not 4 notches in view 5 notches in view including top cap) (*) clockwise (**) counterclockwise (***) Have this adjustment carried out exclusively by an Aprilia Official Dealer 5 - 54...
Page 200: Front Fork Diagram
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.9. FRONT FORK DIAGRAM (RSV FACT) Key: 1. Complete RH fork leg 2. Complete LH fork leg 3. Top cap 4. Spring 5. Fork overhaul kit 5 - 55...
Page 201: Changing The Fork Fluid (Rsv Fact)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.10. CHANGING THE FORK FLUID (RSV FACT) NOTE The same internal components are used in both fork legs. The procedures described below apply to both fork legs. • Remove the stanchion tube-slider assembly. •...
Page 202 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the stanchion and slider assembly (5) from the vice. • Turn stanchion and slider over (5) to drain oil into the container. NOTE Make sure the damping cylinder rod does not come out while draining the oil.
Page 203: Topping Up The Fork Fluid (Rsv Fact)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.11. TOPPING UP THE FORK FLUID (RSV FACT) NOTE Make sure to have the special tools A (no.8140424) and B (no.8140149) ready at hand before proceeding. • Keep the stanchion and slider assembly upright and fit the two shells of the special tool (B).
Page 204 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Grasp the damping cylinder assembly (1) and pump it up and down a dozen of times to expel any air inside. • Allow several minutes and measure oil level again. If necessary, top up or remove oil until oil is at the correct level (editor’s note: 3.35 in).
Page 205: Replacing The Oil/Dust Seal (Rsv Fact)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.12. REPLACING THE OIL/DUST SEAL (RSV FACT) REMOVAL NOTE Make sure to have the special tools B (no. 8140149), C (no. 8140189), and D (no. 8140146) ready at hand before proceeding.
Page 206 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY NOTE Protect the slider edge with a rubber strip to avoid denting during the oil seal’s removal (5). • Pry off the oil seal (5) using a flat-blade screwdriver. REFITTING WARNING Be careful to prevent dirt from entering slider or stanchion.
Page 207 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Insert the retaining ring (4) into its groove in the slider (2). • Push the dust seal (3) into its seat in the slider (2) and ensure it becomes properly seated. •...
Page 208: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.2.13. TIGHTENING TORQUES DESCRIPTION FRONT SUSPENSION Front fork Fork leg on top yoke 18,439 Fork leg on bottom yoke 18,439 tighten first Head stock nut (tighten first, then slacken) M35x1 29,502 and then slacken...
Page 209: Steering Bearing
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.3. STEERING BEARING 5.3.1. DIAGRAM 5 - 64...
Page 210 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY Key: Upper bush Washer Upper plate Lock ring Lock washer Adjuster ring Anti dust gasket Anti dust gasket Bearings 10. Lower plate 11. Steering damper 5 - 65...
Page 211: Checking The Bearing Slack Steering
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.3.2. CHECKING THE BEARING SLACK STEERING Steering bearings and steering clearance: • Position the vehicle on the special center stand. • Shake the fork in the direction of travel. • In the event any slack is encountered, adjust the steer- ing.
Page 212: Steering Bearing Adjustment
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.3.3. STEERING BEARING ADJUSTMENT • Undo the upper steering column bolt. • Slacken the screws securing the fork legs to the top yoke. • Loosen and remove the screws uniting the handlebar halves and fork yoke.
Page 213 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Settle the safety washer on the steering column • Unscrew the upper ring nut and remove the safety washer • Adjust the steering bearing preload by tightening the lower ring nut to the specified torque. 5 - 68...
Page 214 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Position the safety washer • Install the upper ring nut and tighten it so that the grooves fit over the safety washer keys • Settle the lugs on the upper ring nut •...
Page 215 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Fit and tighten the upper steering column bolt to the specified torque • Tighten the screws uniting the handlebar halves and fork yoke to the specified torque • Tighten the screws securing the fork stems to the top yoke to the specified torque 5 - 70...
Page 216: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.3.4. TIGHTENING TORQUES DESCRIPTION FRONT SUSPENSION Front fork Fork leg on top yoke 18,439 Fork leg on bottom yoke 18,439 tighten first Head stock nut (tighten first, then slacken) M35x1 29,502 and then slacken...
Page 217: Rear Suspension
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4. REAR SUSPENSION 5.4.1. DIAGRAM Key: Shock absorber Double conrod Needle bearing Oil seal Piston pin Screw T bush Self-locking nut Single conrod comp. 10. Hex socket screw 11. Screw w/ flange 5 - 72...
Page 218: Removing The Rear Suspension
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4.2. REMOVING THE REAR SUSPENSION • Support the rear end of the motorcycle • Undo the clips uniting the lower seat’s subframe pan- els. • Move the fuel lines away from the area over the rear suspension assembly •...
Page 219 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Remove the panel and extract the cable bundles • Undo the nuts on the double connecting rods 5 - 74...
Page 220 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Undo the screws and remove the double connecting rods • Undo the screw on the rear suspension upper mount • Undo the screw and extract the rear suspension from its seat by rotating it 5 - 75...
Page 221 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5 - 76...
Page 222: Checking The Components
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4.3. CHECKING THE COMPONENTS CAUTION Make sure that none of the components ap- pear to be visibly distorted, broken, cracked and/or dented. Replace any damaged com- ponents BEARINGS Rotate the rollers by hand. Each should rotate smoothly without jamming and/or noise.
Page 223 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY CAUTION Racing settings may only be used during of- ficial competitions or sports events author- ized by the competent authorities and taking place in closed circuits or, anyway, away from public roads. The law forbids riding a vehicle with racing settings on public roads and highways.
Page 224: Refitting The Rear Suspension
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4.4. REFITTING THE REAR SUSPENSION • Fit the rear suspension into its seat • Fit the upper suspension mounting screw • Tighten the screw to the specified torque • Fit the right hand double connecting rod together with the screw on the rear suspension mount 5 - 79...
Page 225 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Install the remaining screws to the double connecting • Fit the left hand double connecting rod • Tighten all screws to their specified torque • Fit the panel onto the frame over the cable bundles 5 - 80...
Page 226 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the two screws securing the panel to the frame to the specified torque • Fit the clips uniting the lower seat subframe panels 5 - 81...
Page 227: Disassembling The Rear Suspension Linkage
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4.5. DISASSEMBLING THE REAR SUSPENSION LINKAGE • Working from the right-hand side of the vehicle, loosen and remove the nut (1). • Pull the screw (2) out from the opposite side. •...
Page 228: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.4.6. TIGHTENING TORQUES DESCRIPTION REAR SUSPENSION Shock absorber Shock absorber to frame 36,878 Linkages Single conrod to frame 36,878 Single / double conrod 36,878 Double conrod swinging arm 36,878 Double conrod / shock absorber 36,878 5 - 83...
Page 229: Swinging Arm
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.5. SWINGING ARM 5.5.1. REMOVING THE SWINGING ARM • Position the vehicle on its center stand (OPT). • Remove the rear wheel. IMPORTANT Although not required for removing the rear wheel, the rear stand (OPT) is necessary for supporting the swinging arm without the wheel mounted.
Page 230 Extract the screw from the other side. • Release and remove the nut and collect its washer. IMPORTANT Make sure to use the special tool (OPT): Aprilia part# 8140191 (swinging arm spindle / engine stand tool). • Using the provided socket wrench, slacken and remove the locknut (1) from the right hand side of the vehicle.
Page 231 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Place a support beneath the front of the swinging arm. • Support the front of the swinging arm. • Extract the swinging arm spindle (2) from the right- hand side. WARNING Make sure the transmission chain does not get entangled when removing the swinging arm.
Page 232: Checking The Components
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.5.2. CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particularly the following. REAR FORK BEARINGS Carry out the check with the bearings mounted on the rear fork.
Page 233: Disassembling The Rear Fork Gaskets
Remove the seal (3). • Remove the snap ring (4). NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Use a special extractor to extract the two bearings (5) and roller bearing (6).
Page 234: Refitting The Swinging Arm
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.5.4. REFITTING THE SWINGING ARM • Grease the entire length of the swinging arm spindle. • Fit the adjuster bush (3) and tighten it by hand. IMPORTANT The adjuster bush (3) must not thrust beyond the frame’s inner edge.
Page 235 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY IMPORTANT Make sure to use the special tool (OPT): Aprilia part# 8140191 (swinging arm spindle / engine stand tool). • Use the provided socket wrench to tighten the lock nut (1).
Page 236 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Working from the right side, fit the lower shock ab- sorber screw. • Tighten down the nut from the opposite side. • Working from the right side, fit the double connecting link / swinging arm screw.
Page 237: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.5.5. TIGHTENING TORQUES DESCRIPTION SWINGING ARM Swinging arm spindle nut M30x1,5 44,254 Swinging arm spindle adjuster bushing M30x1,5 8,851 Swinging arm spindle nut M20x1,5 66,38 Caliper support pin 36,878 Loctite 243 Chain tensioner screw and nut man.
Page 238: Front Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.6. FRONT WHEEL 5.6.1. DIAGRAM Key: Wheel pin Seal Bearing Inner spacer Complete wheel Snap ring Right spacer Washer 5 - 93...
Page 239: Removing The Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.6.2. REMOVING THE WHEEL • Support the front part of the motorcycle. • Undo the screws securing the front mudguard and re- move it • Undo the screws securing the front brake calipers and remove them from their seats •...
Page 240 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Keep the seal washer • Slacken the screws on the wheel axle clamps • Lightly knock the wheel axle with a rubber mallet so as to uncover the holes on the opposite side •...
Page 241 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • While removing the axle, support the wheel and then remove it 5 - 96...
Page 242: Checking The Front Wheel Components
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.6.3. CHECKING THE FRONT WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particularly the following. FRONT WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel.
Page 243 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY FRONT WHEEL RIM • Using a comparator, make sure that the radial (A) and axial (B) eccentricity of the rim (2) do not exceed the limit value. Excessive eccentricity is usually caused by worn or damaged bearings.
Page 244: Disassembling The Front Wheel Bearings
The ends of the spacer (4) are provided with slots (A) to al- low the passage of the extractor teeth. NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Use a special extractor to extract the right bearing (5).
Page 245: Assembling The Front Wheel Bearings
• remove the front wheel bearings. Work on the right-hand side of the wheel: NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Using the appropriate pad, insert the right bearing (5) completely.
Page 246 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5 - 101...
Page 247: Refitting The Front Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.6.6. REFITTING THE FRONT WHEEL • Fit the front wheel • Fit the wheel axle • Tighten down the clamp screws (nut side) to secure the wheel axle • Fit the seal washer and screw on the axle nut to the specified torque •...
Page 248 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the screws securing the wheel axle clamps to the specified torque • Tighten the screws securing it to the specified torque WARNING After fitting the brake calipers, repeatedly oper- ate the front brake lever 5 - 103...
Page 249: Rear Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7. REAR WHEEL 5.7.1. DIAGRAM Key: Washer Side spacers Left chain tightener shoe Bearings Central spacer Complete wheel Snap ring Seal 10. Right chain tightener shoe 11. Wheel pin 5 - 104...
Page 250: Removing The Rear Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.2. REMOVING THE REAR WHEEL • Support the motorcycle on the rear stand • Slacken and remove the wheel axle nut • Keep the thrust washer and left hand chain tightener shoe 5 - 105...
Page 251 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Lightly knock on the wheel axle so that its head thrusts forth from its seat • Move the wheel forwards and disengage the chain from the sprocket • Extract the wheel axle together with the right hand chain guide shoe •...
Page 252: Removing The Final Drive Unit
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.3. REMOVING THE FINAL DRIVE UNIT • Remove the rear wheel. CAUTION Proceed with care. If the final drive unit (1) is installed on the flexible coupling holder (2), do not overturn or rotate the rear wheel in hori- zontal position on the rear sprocket side (A), since the final drive unit would come off and...
Page 253 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5 - 108...
Page 254: Checking The Rear Wheel Components
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.4. CHECKING THE REAR WHEEL COMPONENTS CAUTION Make sure that all the components are intact, particularly the following. REAR WHEEL BEARINGS Carry out the check with the bearings mounted on the wheel. CHECKING THE ROTATION •...
Page 255 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY REAR WHEEL PIN • Using a comparator, check the eccentricity of the pin wheel (1). If the eccentricity exceeds the limit value, change the pin wheel (1). Maximum eccentricity: 0.0098 in (0.25 mm). REAR WHEEL RIM •...
Page 256 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY FINAL DRIVE UNIT BEARINGS • Carry out the check with the bearings mounted on the final drive unit. CHECKING THE ROTATION • Remove the left spacer (3). • Remove the right spacer (4). •...
Page 257 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY FLEXIBLE COUPLINGS • Make sure the rubber elements (5) of the flexible cou- plings are not damaged and/or do not show excessive wear. To carry out the check: • Fit the whole final drive unit (6) on the wheel. •...
Page 258: Disassembling The Rear Wheel Bearings
The ends of the spacer (4) are provided with slots (A) to al- low the passage of the extractor teeth. NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Use a special extractor to extract the right bearing (5).
Page 259: Assembling The Rear Wheel Bearings
• Remove the rear wheel bearings. Work on the right-hand side of the wheel: NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Using the appropriate pad, insert the right bearing (5) completely.
Page 260 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5 - 115...
Page 261: Disassembling The Final Drive Unit Bearings
NOTE The elastic ring (3) is provided only on the left side of the final drive unit. NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Use a special extractor to extract the left bearing (4).
Page 262: Assembling The Final Drive Unit Bearings
• Remove the final drive unit bearings. Work from the left-hand side: NOTE Have the appropriate special tool OPT at hand: - Aprilia part# 8140180 (bearing extractors). • Using the appropriate pad, insert the right bearing (6) completely. NOTE The right bearing must be inserted until its contact with the wheel hub shoulder is complete (Y).
Page 263: Removing The Flexible Couplings
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.9. REMOVING THE FLEXIBLE COUPLINGS • Remove the final drive unit. NOTE The flexible couplings remain installed on the flexible coupling holder. • Extract all the flexible coupling rubber elements. 5 - 118...
Page 264: Removing The Crown Gear
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.10. REMOVING THE CROWN GEAR • Working on the appropriate seat (1) with an hexagon wrench, lock the threaded pin (2), unscrew and remove the self-locking nut (3) and the threaded pin (2). CAUTION The self-locking nuts (3) must be replaced every three removals of the sprocket.
Page 265: Refitting The Rear Wheel
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.11. REFITTING THE REAR WHEEL • Fit the wheel axle together with right hand chain guide shoe to the swing arm. • Fit the rear wheel and insert the wheel axle into its seat •...
Page 266 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Tighten the nut hand tight • Check the chain tension • Tighten the nut to the specified torque 5 - 121...
Page 267: Tightening Torques
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.7.12. TIGHTENING TORQUES DESCRIPTION REAR WHEEL Sprocket / Sprocket carrier 36,878 Wheel axle nut M25x1,5 88,507 5 - 122...
Page 268: Front Brake
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.8. FRONT BRAKE 5.8.1. CHANGING THE FRONT BRAKE PADS (RSV R) WARNING This vehicle is equipped with a double-disc front braking system (right side and left side). Always replace all the pads of both the front brake calipers.
Page 269: Changing The Front Brake Pads (Rsv Fact)
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.8.2. CHANGING THE FRONT BRAKE PADS (RSV FACT) TORQUE WRENCH SETTINGS Brake caliper bolts (1) 36.87 ftlb (50 Nm) WARNING This vehicle is equipped with a twin-disc front brake (one disc either side...
Page 270 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY WARNING The four brake pads must always be replaced to- gether. Ensure they become properly seated in the brake caliper. • Position the retaining clip (2). • Press the retaining clip (2) and insert the pin (3) from the inside.
Page 271: Checking The Front Brake Discs
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.8.3. CHECKING THE FRONT BRAKE DISCS Brake discs: NOTE These operations must be performed with the brakes discs installed on the wheel; they refer to a single disc, though they are applicable to both. •...
Page 272: Removing The Front Brake Discs
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.8.4. REMOVING THE FRONT BRAKE DISCS • Remove the front wheel. NOTE The following procedure refers to a single disc, though it is applicable to both. To remove the screws (1), it is advisable to use an impact driver, thanks to which it will be possible to detach the ®...
Page 273: Bleeding The Brake Circuit
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.8.5. BLEEDING THE BRAKE CIRCUIT • Connect the hose to the brake pump bleed nipple. • Operate the brake lever and open the pump bleed nip- ple slightly to allow the air to escape. •...
Page 274: Rear Brake
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.9. REAR BRAKE 5.9.1. CHANGING THE REAR BRAKE PADS • Position the vehicle on the stand.· • Remove the rear brake caliper. CAUTION Once the pads have been removed do not pull the brake lever as the brake caliper pins are li- able to come out of their slot: brake fluid will spill out.
Page 275: Checking The Rear Brake Disc
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.9.2. CHECKING THE REAR BRAKE DISC NOTE These operations must be performed with the brake disc installed on the wheel. • Check the wear on the brake disc. Using a micrometer, measure the minimum thickness in several places.
Page 276: Removing The Rear Brake Disc
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.9.3. REMOVING THE REAR BRAKE DISC • Remove the rear wheel. NOTE To unscrew the screws (1), it is advisable to use an impact driver, thanks to which it will be possible to detach ®...
Page 277: Clutch
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.10. CLUTCH 5.10.1. BLEEDING THE CLUTCH CIRCUIT • Connect the hose to the clutch pump bleed nipple. • Operate the clutch lever and open the pump bleed nip- ple slightly to allow the air to escape. •...
Page 278: Drive Chain
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.11. DRIVE CHAIN 5.11.1. DRIVE CHAIN The vehicle is fitted with an endless chain that has no master link. NOTE Halve maintenance intervals if the vehicle is used in rainy or dusty conditions, on rough roads or for racing. CHAIN SLACK INSPECTION To check chain slack: •...
Page 279 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY CHECKING CHAIN AND SPROCKETS FOR WEAR Check the following parts every 10000 Km (6250 mi). Visually inspect chain, front and rear sprockets looking for: damaged chain rollers; loose chain link pins; dry, rusty, warped or seized links;...
Page 280: Inspecting The Driving Chain Shoe
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.11.2. INSPECTING THE DRIVING CHAIN SHOE • Position the vehicle on the stand. • Make sure the shoe (1) is not worn or damaged; if so, replace with a new one. •...
Page 281: Removing The Chain Shoe
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.11.3. REMOVING THE CHAIN SHOE • Position the vehicle on its rear stand (OPT). • Release and remove the three screws. • Remove the pinion cover. • Slacken the chain tension. •...
Page 282 CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY • Loosen and remove the lower chain shoe screw and collect its washer. • Pull the lower part of the chain shoe out from the front. • Remove the lower chain shoe from the rear. 5 - 137...
Page 283: Lower Chain Shoe
CYCLE PARTS RSV 1000 R - RSV 1000 R FACTORY 5.11.4. LOWER CHAIN SHOE IMPORTANT The shoe must be disassembled to check its wear. • Release and remove the two screws. • Remove the lower chain shoe. CHECKING WEAR Check the wear of the chain shoe. Minimum thickness : 2 mm (0.079 in).
Page 284 COOLING SYSTEM RSV 1000 R - RSV 1000 R FACTORY COOLING SYSTEM 6 - 1...
Page 285 COOLING SYSTEM RSV 1000 R - RSV 1000 R FACTORY SUMMARY 6.1. COOLING SYSTEM ............................3 6.1.1. DIAGRAM .............................. 3 6.1.2. FILLING THE COOLING SYSTEM ......................4 6 - 2...
Page 286 COOLING SYSTEM RSV 1000 R - RSV 1000 R FACTORY 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: Radiator Fans Expansion reservoir Filler cap Three-way thermostatic valve Three-way manifold 6 - 3...
Page 287 COOLING SYSTEM RSV 1000 R - RSV 1000 R FACTORY 6.1.2. FILLING THE COOLING SYSTEM • Filling the cooling system requires around 0.58 gal (2.2 liters) of coolant. • Place the vehicle on its rear stand. OPT. • Undo the radiator bleed screw. •...
Page 288 COOLING SYSTEM RSV 1000 R - RSV 1000 R FACTORY • Tighten down the filler cap and the expansion reservoir cap. • If fluid does not issue from the radiator bleed screw, before the circuit is completely filled (around 2 liters), use the expansion reservoir level as a reference.
Page 289 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY ELECTRICAL SYSTEM 7 - 1...
Page 290 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY SUMMARY 7.1. ELECTRICAL SYSTEM........................... 3 7.1.1. COMPONENT LOCATION........................3 7.1.2. ELECTRICAL EQUIPMENT CHECK TABLE ..................5 7.1.3. CAN LINE............................. 14 7.1.4. IMMOBILIZER............................16 7.1.5. WIRING DIAGRAM ..........................18 7 - 2...
Page 291: Electrical System
ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 7.1. ELECTRICAL SYSTEM 7.1.1. COMPONENT LOCATION 7 - 3...
Page 292 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY Key: Engine speed sensor Sensor Camshaft sensor Coolant temperature sensor Intake air temperature sensor Fall sensor Vehicle speed sensor Injector Ignition coil 10. Throttle potentiometer (TPS) 11. Immobilizer antenna 12. Starter motor 13.
Page 293: Electrical Equipment Check Table
ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 7.1.2. ELECTRICAL EQUIPMENT CHECK TABLE 7 - 5...
Page 294 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY ENGINE SPEED SENSOR inductive sensor winding resistance 1 KΩ (across pins 1 and 2) output voltage 3 V AC (under load) LAMBDA SENSOR oxygen sensor with heater sensor voltage 0 to 0.9 V (across pins 3 and 4) heater resistance 12.5 Ω...
Page 295 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY INTAKE AIR TEMPERATURE SENSOR NTC sensor resistance 1.9 KΩ (at 68°F) FALL SENSOR resistance 62 KΩ with sensor at installation position resistance 0 Ω when rotated 90° relative to installation posi- tion.
Page 296 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY IGNITION COIL primary resistance 0.4-0.5 Ω THROTTLE POTENTIOMETER (TPS) resistance 4.1 ± 1.23 Ω (across pins 1 and 4) output voltage 0.5-4 V (varies according to throttle position, across pins 2 and 4) IMMOBILIZER ANTENNA winding resistance 14 Ω...
Page 297 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY INTAKE FLAP winding resistance 30 Ω STEPPER phase resistance 50 Ω GENERATOR three-phase generator winding resistance 0.4 Ω output voltage 75 V AC (measure with generator discon- nected from electrical system and engine running at 4000 rpm) RECHARGE VOLTAGE voltage 13.8 V across battery terminals (with engine running...
Page 298 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY FUEL PUMP absorption 3.9 A FUEL RESERVE SENSOR The vehicle does not have a fuel gauge but rather a simple led which turns on when the fuel level is below 0.98 gal (3.7 liters): the sensor starts conducting (and the led turns on) 30 seconds after it is no longer wetted by fuel.
Page 299 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY ECU pinout Connector A Pin Description Signal type Rear cylinder coil control Power output n.c. Atmospheric pressure sensor power Power (5V) Atmospheric pressure sensor power Power (ground) Engine speed sensor signal Frequency in- n.c.
Page 300 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY Connector B Pin Description Signal type ECU power (ground) Power ECU power (ground) Power Power output n.c. Lambda sensor heater control Power output Vehicle speed sensor signal Frequency input n.c. n.c.
Page 301 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY TAIL LIGHT Number plate light 12 V – 5W SECONDARY FUSES A – From key to: lights relay, horn, parking lights (5A). A – From key to: direction indicators, dashboard (5A). C –...
Page 302: Can Line
ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 7.1.3. CAN LINE A CAN (Controller Area Network) line is a connection be- tween the vehicle’s various electronic components that oper- ates like a computer (Internet) network. The use of CAN lines greatly simplifies the electrical system and its overall weight.
Page 303 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY STARTING Before it starts the engine, the ECU waits for permission from the dashboard over the CAN which identifies the engine model V990 (this information resides in the dashboard). No sensor (apart from the fuel reserve sensor) is connected directly to the dashboard;...
Page 304: Immobilizer
ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 7.1.4. IMMOBILIZER IMMOBILIZER The vehicle is equipped with an immobilizer that stops the engine from being started if the correct code is not entered. The code is stored in the transponder in each of the two keys supplied with the vehicle.
Page 305 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY ADDITIONAL KEY STORE PROCEDURE The immobilizer system can recognize up to 4 keys. The storage procedure can only be done at the Dealer’s with a Master Key. The storage procedure cancels the existing codes, so that if the client wishes to store new keys he must come to the Dealer’s with all the keys he wishes to use.
Page 306: Wiring Diagram
ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY 7.1.5. WIRING DIAGRAM 7 - 18...
Page 307 ELECTRICAL SYSTEM RSV 1000 R - RSV 1000 R FACTORY Multiple connectors SECONDARY FUSES: Fall sensor A 5A LIGHT RELAY, STOP, HORN, PARKING High beam relay LIGHTS Low beam relay B 5A DIRECTION INDICATORS, DASHBOARD Horn C 5A KEY-ENABLED POSITIVE POLE, TO E.C.U. Clutch switch D 15A SPEED SENSOR, FUEL PUMP, STARTER...
Page 308 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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Rsv 1000 r 2003

APRILIA RSV 1000 R FACTORY 2003 Workshop Manual

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Cycle Parts 5

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