APRILIA RS 457 2023 Workshop Manual

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WORKSHOP MANUAL

2Q000572

RS 457

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Summary of Contents for APRILIA RS 457 2023

Page 1 WORKSHOP MANUAL 2Q000572 RS 457...
Page 2 RS 457 The descriptions and images in this technical publication are given for illustrative purposes only. Piaggio & C. S.p.A. reserves the right to modify the components and accessories of its products, without altering the essential characteristics of the product described and illustrated herein, to make any changes to organs, details or supplies, deemed appropriate for the purpose of improvement, or for any other requirement of a technical or commercial nature, at any time, without undertaking to promptly update this publication.
Page 3 WORKSHOP MANUAL RS 457 This workshop manual has been produced for consultation by the technical staff of Dealerships, Service Centres, Authorised Service Network Workshops. This manual is addressed to service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle mounting techniques and procedures.
Page 4 LIST OF TOPICS Pre-delivery..................Appearance check..........................10 Safety locks check..........................10 Electrical system.............................10 Level check.............................14 Test drive..............................14 Static check............................14 Functional checks........................... 14 Specifications..................Regulations............................. 17 Safety rules............................17 maintenance instructions........................20 Running-in...............................23 vehicle identification..........................24 Dimensions and mass..........................25 Engine..............................25 Transmission............................
Page 5 Braking system............................82 Level check............................82 Top-up..............................83 Replacing front brake pads........................85 Replacing rear brake pads........................88 Clutch lever adjustment..........................90 Gear pedal adjustment........................... 91 Headlight adjustment..........................91 Anti-evaporating system......................... 92 System components removal....................... 92 Electrical system................Fuses..............................98 Relay..............................101 Starter motor............................104 Electronic..............................
Page 6 Fuel pump.............................148 Throttle body............................150 Throttle body removal.........................150 Injectors..............................151 Suspension..................Front..............................154 Semi-handlebar........................... 154 Front fork.............................159 Adjustment............................160 Fork removal............................. 161 Checking components........................166 Fork refitting............................167 Steering upper plate........................... 174 Removal............................174 Steering lower plate..........................180 Removal............................180 Installation............................182 Steering bearings..........................184 Clearance adjustment........................184 Removal............................
Page 7 Driver footrests............................242 Footpegs............................. 248 Passenger footrests..........................250 Stand..............................250 Side stand............................250 Exhaust..............................252 Exhaust............................... 253 Braking system.................. ABS............................... 257 Foreword............................. 257 Functional diagram..........................260 Modulator............................264 Rear brake calliper..........................271 Removal.............................. 271 Installation............................273 Front brake calliper..........................275 Removal.............................. 275 Installation............................276 Rear brake disc............................
Page 8 Instrument panel........................... 321 Instrument panel support........................322 Light switch............................326 Side fairings............................330 under fairings............................332 fairing lug.............................. 335 Front mudguard............................ 337 Saddle..............................338 Battery..............................338 Side fairings............................340 Lock...............................342 Fuel tank............................... 343 Rear handle............................349 Rear wheel arch........................... 351 Rear mudguard.............................357 Rear light assembly..........................359 Number plate light..........................
Page 9 LIST OF TOPICS Pre-delivery...
Page 10 Pre-delivery RS 457 1.1 Appearance check - Paintwork - Fitting of plastics - Scratches - Dirt 1.2 Safety locks check - Safety fasteners: • front and rear suspension unit • front and rear brake calliper retainer unit • front and rear wheel unit •...
Page 11 Pre-delivery RS 457 TO ENSURE MAXIMUM PERFORMANCE, BATTERY MUST CHARGED BEFORE USE. LACK ADEQUATE BATTERY CHARGE BEFORE FIRST WILL CAUSE PREMATURE FAILURE OF THE BATTERY. ATTENTION WHEN INSTALLING BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
Page 12 Pre-delivery RS 457 the indicator is between 1 and 4 notches, the battery should be further charged. CHARGE MODES Normal recharge - Electric current: 2,0 A - Time: 2 hours Quick charge - Electric current: 8 A - Time: 0,5 hours WARNING THE CHARGE VOLTAGE MUST NEVER EXCEED 15V.
Page 13 Pre-delivery RS 457 immediately if the battery is in use or under charge. BATTERY DOES CONTAIN HARMFUL POLLUTANTS, CORROSIVE ACIDS OR TOXIC HEAVY METALS TRADITIONAL BATTERY ACTIVATION PROCEDURE • Place the battery on a flat surface. • Remove the cell's protective sticker. •...
Page 14 Pre-delivery RS 457 1.4 Level check - Hydraulic brake system liquid level - Engine coolant level - Engine oil level 1.5 Test drive - Cold start - Instrument operations - Response to throttle control - Stability on acceleration and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise...
Page 15 Pre-delivery RS 457 ATTENTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST. ATTENTION CHECK ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 16 LIST OF TOPICS Specifications...
Page 17 Specifications RS 457 2.1 Regulations 2.1.1 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 18 Specifications RS 457 engine exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
Page 19 Specifications RS 457 THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER.
Page 20 Specifications RS 457 WELL WITH PLENTY OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS BATTERY ACID CAUSE BLINDNESS. FLUID GETS INTO CONTACT WITH THE EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT SPECIALIST IMMEDIATELY.
Page 21 WARNING THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only aprilia ORIGINAL SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
Page 22 Specifications RS 457 • Tighten all the engine screws scrupulously observing the tightening torques given in the "TIGHTENING TORQUES" chapter.. WARNING IN THE EVENT THAT A SELF-BRAKING NUT IS UNSCREWED, IT IS NECESSARY TO REPLACE IT WITH A NEW ONE. COOLANT •...
Page 23 Preferably do not exceed 7500 rpm during the first 1,000 km (621 mi) and 9,500 rpm up to 2,000 km (1,243 mi). ATTENTION AFTER SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer CHECKS INDICATED "SCHEDULED MAINTENANCE TABLE" SCHEDULED MAINTENANCE SECTION, TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Page 24 Specifications RS 457 2.3 vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. WARNING ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PARTICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY. This number consists of numbers and letters, as in the example shown below.
Page 25 Specifications RS 457 ENGINE NUMBER The engine number is stamped on the rear side of the engine block, opposite the rear shock absorber. Engine No..... 2.4 Dimensions and mass Dimensions and mass Max. length 1960 mm (77.17 in) Max. width (at handlebar) 795 mm (31.30 in) Max.
Page 26 31 / 32 (secondary) Final drive ratio 15 / 43 Electronic control systems a-PRC system (Aprilia Performance Ride Control) which includes: AEM (engine map management system), ABS (Anti-lock Braking System), ATC (traction control), AQS (where fitted) (Clutchless Assisted Shifting System both up...
Page 27 Specifications RS 457 2.7 Capacity Capacity Fuel tank capacity (including reserve) 13 l (2.86 UK gal; 3.43 US gal) Fuel tank reserve capacity 3 l (0.66 UK gal; 0.79 US gal) Engine oil oil change and oil filter replacement: 2200 cc in (134.25 cu in) Coolant 1.5 l (0.33 UK gal;...
Page 28 Specifications RS 457 Indicator lamps Turn indicators 2.10 Frame and suspension Chassis Type Composite structure aluminium frame with cast elements. Steering rake angle 24.1° (measurements with respect to bare chassis) Suspension Front fork Adjustable upside-down hydraulic fork with 41 mm (1.61 in) stanchions Travel 120 mm (4.72 in) Rear shock absorber...
Page 29 Specifications RS 457 2.11 Brakes Brakes Front Ø 320 mm (12.60 in) disc, four-piston caliper - Ø 28 mm (1.10 in) and 2 pads - axial master cylinder and metal braided brake hose. Rear Disc - Ø 220 mm (8.66 in), single-piston floating caliper - Ø...
Page 30 Specifications RS 457 Tightening torque: 1.5 Nm (1.10 lbf ft) 2 Nm (1.47 lbf ft) 3 Nm (2.21 lbf ft) WARNING THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED. BEFORE FITTING THE NEW SCREWS, CLEAN THE THREADED HOLES CAREFULLY, MAKING SURE THAT ALL TRACES OF THE OLD THREAD-LOCK SEALANT HAVE BEEN ELIMINATED.
Page 31 Specifications RS 457 POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Top fairing 0.5 Nm ± fastener 0.08 (0.36 ± screw 0.06 lbf ft) FRONT WHEEL POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 80 ± 12 Nm Front wheel M25 x 1.5 (59.01 ± axle nut 8.85 lbf ft) Pre-...
Page 32 Specifications RS 457 FRONT FORK POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Pumping unit 25 ÷ 30 Nm fastening (18.44 ÷ screw 22.13 lbf ft) 20 ÷ 25 Nm Cap locknut (14.75 ÷ 18.44 lbf ft) 30 Nm Fork cap (22.13 lbf ft) Calliper 12 ±...
Page 33 Specifications RS 457 FRONT BRAKE CALLIPER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Front brake 30 ± 3 Nm calliper M8 x 1 (22.13 ± fixing screw 2.21 lbf ft) 25 ± 3.75 Nm Banjo fitting M10 x 1 (18.44 ± 2.77 lb ft) 7 ±...
Page 34 Specifications RS 457 STEERING POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screw fastening 25 ± 2.5 Nm top steering (18.44 ± yoke to fork 1.84 lb ft) stanchion Screw fastening 25 ± 2.5 Nm bottom (18.44 ± steering 1.84 lb ft) yoke to fork stanchion 100 ±...
Page 35 Specifications RS 457 POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Steering headstock 60 Nm M30 x 1 Pre-tightening tightening (44.25 lbf ft) ring nut Steering 25 ± 2.5 Nm headstock M30 x 1 (18.44 ± Tightening tightening 1.84 lb ft) ring nut Steering 25 ±...
Page 36 Specifications RS 457 POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Semi- 46 ± 7 Nm handlebar (33.92 ± fixing screw 5.16 lbf ft) Right hand 4 ± 0.8 Nm light switches (2.95 ± fixing screw 0.59 lb ft) Left hand 4 ± 0.8 Nm light switches (2.95 ±...
Page 37 Specifications RS 457 FRONT BRAKE MASTER CYLINDER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screw fastening 10 ± 1.5 front brake Nm (7.37 master ± 1.11 lb ft) cylinder 25 ± 3.75 Nm Banjo fitting M10 x 1 (18.44 ± 2.77 lb ft)
Page 38 Specifications RS 457 INSTRUMENTS POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screw fixing 6.5 ± 1 Nm instrument (4.79 ± cluster 0.74 lb ft) to frame...
Page 39 Specifications RS 457 2.12.2 Centre of vehicle CHASSIS POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Saddle 50 ± 7.5 mounting Nm (36.88 fixing screw ± 5.53 lb ft) Saddle 50 ± 7.5 mounting Nm (36.88 Self-locking fixing nut ± 5.53 lb ft) Screw fixing 50 ±...
Page 40 Specifications RS 457 SIDE FAIRINGS POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screw fixing 3 ± 0.5 Nm inner fairing (2.21 ± to radiator 0.37 lb ft)
Page 41 Specifications RS 457 FRONT MUDGUARD - ENGINE FAIRING POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Front 7 ± 1 Nm mudguard (2.21 ± fixing screw 0.74 lbf ft)
Page 42 Specifications RS 457 FUEL TANK POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Fuel pump 20 ± 3 Nm fastener (14.75 ± ring nut 2.21 lb ft) Apply Screws 10 ± 2 Nm medium- fastening (7.38 ± strength tank to frame 1.48 lb ft) threadlocking...
Page 43 Specifications RS 457 LOCKS POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screws 4 ± 0.6 Nm fastening cap (2.95 ± and petrol 0.44 lb ft) tank tray Ignition switch assembly Bring to break fixing shear head screw Ignition switch 20 ± 4 Nm assembly lock (14.75 ±...
Page 44 Specifications RS 457 AIR FILTER BOX POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Temperature 0.8 ± 0.16 sensor x pl. 2.9 Nm (0.59 ± fastener 0.12 lb ft) screw Filter casing 1 ± 0.2 Nm cover x pl. 4.9 (0.74 ± fastening 0.15 lb ft) screw...
Page 45 Specifications RS 457 COOLING SYSTEM POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Upper screw 6 ± 1.2 Nm fixing radiator (4.42 ± to support 0.89 lb ft) Screw fixing 7.5 ± 1.5 Nm the electric (5.53 ± fan to the 1.11 lb ft) radiator...
Page 46 Specifications RS 457 EXHAUST POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 25 ± 5 Nm Lambda (18.43 ± 3.69 probe lbf ft) Exhaust 13 ± 2 Nm manifold (9.58 ± flange 1.48 lbf ft) fastening nuts...
Page 47 Specifications RS 457 FOOTRESTS POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Screws 45 ± 9 Nm fastening (33.19 ± footplates to 6.64 lbf ft) crankcase Screws fixing 22 ± 3 Nm passenger (16.23 ± footpegs 2.21 lbf ft)
Page 48 Specifications RS 457 GEARBOX LEVER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 20 ± 3 Nm Gearbox lever Self- (14.75 pin fixing nut locking nut ± 2.21 lbf ft) Spherical pin 8.5 ± 1.27 Self- fixing tie rod Nm (6.26 ± locking nut to gear lever 0.94 lb ft)
Page 49 Specifications RS 457 REAR BRAKE MASTER CYLINDER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Apply Rear brake 25 ± 3.75 medium- lever Nm (18.43 strength fixing pin ± 2.77 lb ft) threadlocking Rear brake Apply 8 ± 1.2 Nm pump medium- (5.90 ±...
Page 50 Specifications RS 457 SIDE STAND Pos. Description Type Quantity Torque Notes Screws 45 ± 9 Nm fastening (33.19 ± footplates to 6.64 lbf ft) crankcase Apply Nut fixing 30 ± 6 Nm medium- stand pin M10 x 1.25 (22.12 ± strength to bracket 4.43 lbf ft)
Page 51 Specifications RS 457 2.12.3 Rear section REAR BODYWORK POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Apply 30 ± 4.5 Nm Handle medium- (22.13 ± 3.32 fixing screws strength lbf ft) threadlocking 4 ± 0.6 Nm Front screws (2.95 ± fixing handle 0.44 lb ft)
Page 52 Specifications RS 457 REAR WHEEL POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 50 ± 7.5 Sprocket M10 x 1.25 Nm (36.88 fixing nuts ± 5.53 lb ft) Apply Rear brake 25 ± 3.75 Nm medium- disc fastening (18.43 ± strength screws 2.77 lb ft) threadlocking 120 ±...
Page 53 Specifications RS 457 SWINGARM POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 110 ± 16.5 Nm Swingarm pin M16 x 1.25 Self-locking (81.13 ± 12.17 lb ft) Chain 4 ± 0.6 Nm feeder shoe (1.47 ± fastening 0.44 lb ft) screws Rear 4 ±...
Page 54 Specifications RS 457 REAR SHOCK ABSORBER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Shock 50 ± 7.5 Nm absorber (36.87 ± Self-locking upper 5.53 lb ft) fixing nut Lower shock 50 ± 7.5 Nm absorber (36.87 ± Self-locking fixing nut 5.53 lb ft)
Page 55 Specifications RS 457 REAR BRAKE CALLIPER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Rear ABS 6 ± 1 Nm sensor (4.42 ± fastening 0.74 lbf ft) screw 7 ± 1 Nm Brake calliper (5.16 ± bleeding 0.74 lbf ft)
Page 56 LIST OF TOPICS Special tools...
Page 57 Special tools RS 457 CODE DESCRIPTION IMAGE Intake camshaft 021044Y disarming lever 021043Y Camshaft stopper pin 020851Y Camshaft timing pin Special tools 021044Y Intake camshaft disarming lever 021043Y Camshaft timing pin (2 pieces) 020851Y Camshaft timing pin 669N/5 (BETA) Ratchet torque wrench, rectangular...
Page 58 Special tools RS 457 Special tools 020431Y Valve oil seal extractor 021039Y Pick-up distance template 021040Y Transmission shaft oil seal press-fit punch on front sprocket side 021041Y Engine fixing bracket to mount 021042Y Oil seal and clutch shaft bearing and gear shaft punch 020980Y Piston assembly ring...
Page 59 LIST OF TOPICS Maintenance...
Page 60 Maintenance RS 457 4.1 Scheduled maintenance table ATTENTION CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS RECOMMENDED IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.
Page 61 Maintenance RS 457 Km x 1,000 MONTHS MONTHS Front sprocket - rear sprocket - Chain slider Steering bearings and steering play Wheel bearings - Wheels Diagnosis by tool Brake discs - Brake pads wear Air filter Engine oil filter Vehicle general operation Valve clearance Head cover...
Page 62 Maintenance RS 457 Km x 1,000 MONTHS MONTHS Headlight aiming Fork oil seals Tyres - pressure / wear Nut/bolt tightness Head cover fastening screws dampers Labour time (minutes) NOTE AT EACH SCHEDULED SERVICE, USE THE DIAGNOSTIC TOOL TO CHECK FOR ERRORS AND CHECK THAT ALL PARAMETERS ARE CORRECT.
Page 63 Maintenance RS 457 Product Description Specifications colour - black, contains Lithium-calcium EP (Extreme Pressure) Lithium-based grease soap based grease. additives, excellent water- repellent properties. Glycol ethylene based antifreeze liquid with ASTM D 3306 - ASTM Anti-freeze liquid, ready organic additive technology D 4656 - ASTM D 4985 to use, colour red corrosion inhibitor.
Page 64 Maintenance RS 457 • Using a spark plug spanner, unscrew and remove the spark plug (3). • Repeat for the second candle. • Check the wear condition of each spark plug and measure the distance between the electrodes with a feeler gauge. •...
Page 65 Maintenance RS 457 TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE). • Shut off the engine and wait a few seconds • Keep the vehicle upright with both wheels on the earth • Ensure that you are on a flat surface •...
Page 66 Maintenance RS 457 • Place a container with suitable capacity under the drainage plug. • Unscrew and remove the drainage plug. • Drain the oil into the container; allow several minutes for oil to drain out completely. • Replace sealing washer discharge plug with a new one.
Page 67 Maintenance RS 457 AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE. 4.5 Engine oil filter Replace the engine oil filter each time you change the engine oil. • Remove the bottom fairing before starting the procedure. • Place a container of suitable capacity under the drain plug and the engine oil filter.
Page 68 Maintenance RS 457 • Remove the eleven filter housing lid fastening screws. • Remove the filter housing cover. • Remove the filter retainer.. • Remove the filter.
Page 69 Maintenance RS 457 4.7 Valve clearance check To proceed with the valve clearance check, it is necessary to remove the valve clearance beforehand: • the fuel tank, • the side fairings; • The air filter housing, • the throttle bodies; •...
Page 70 Maintenance RS 457 • Remove the inspection cap (3) from the flywheel casing. • Turn the crankshaft, through the inspection hole, so that the cam of the valve to be measured is brought upwards. • Using a feeler gauge, measure the distance between the camshaft and the valve cup: repeat the operation for each valve.
Page 71 Maintenance RS 457 • The holes on the flanges of the intake and exhaust camshafts match the holes on the head and the corresponding timing pins (2) and (3) can be inserted. 021047Y Intake timing spanner and centring 021043Y Exhaust camshaft timing pin •...
Page 72 Maintenance RS 457 • Gradually unscrew the two fixing screws (6) of the chain tensioner. • Remove the timing chain tensioner (7) and its gasket (8) from the cylinder head. • Unscrew the two fixing screws (9) and (10) of the upper skid (11). •...
Page 73 Maintenance RS 457 • Remove the upper skid (11) and the rear screw (10). • Remove timing pin (2) from the intake camshaft. • Remove the two fixing screws and remove the crown (13) of the intake camshaft. • Install the specific tool (14) on the flange of the intake camshaft, using a sprocket gear fastening screw.
Page 74 Maintenance RS 457 • Turn the intake camshaft clockwise to release it from the valve thrust. • Once the camshaft is free, turn it in the opposite direction, just enough to unscrew the screw and remove the tool from the flange.
Page 75 Maintenance RS 457 • Depending on the valve to be adjusted, remove the relevant camshaft, making sure not to drop the timing chain inside the engine. • If the exhaust camshaft is to be removed, remove the chain from the chainring and attach it to the frame.
Page 76 Maintenance RS 457 • The correct positioning of the camshafts is determined by the holes for inserting the timing pins. • The holes on the camshaft flange must face upward and diverge from each other, as shown in the figure. •...
Page 77 Maintenance RS 457 • Fit the special tool (14) on the flange of the intake camshaft, using a sprocket fixing screw. 021047Y Intake timing spanner and centring • Rotate the shaft until the timing pin (2) can be inserted into the flange hole and the corresponding cylinder head hole.
Page 78 Maintenance RS 457 • Using a flat screwdriver, screw in the chain tensioner so that it "retracts", so that the chain tensioner flange is flush with the mating surface of the head. • Hold the screwdriver in position and simultaneously press the chain tensioner (7) against the head, then insert the two chain tensioner fixing screws (6) and bring them to a stop.
Page 79 Maintenance RS 457 • Re-insert the timing pin (2) on the intake camshaft, making sure to intercept the sprocket with its hole on the cylinder head. • Tighten the fixing screws of the intake camshaft sprocket to the specified torque. DESCRIPTION TORQUE Timing system gear...
Page 80 Maintenance RS 457 • Tighten all fixing screws of the upper casing to the specified torque, following the sequence shown in the figure. DESCRIPTION TORQUE Upper tower 10 - 12 Nm (7.38 - fastener screw 8.85 lb ft) • Remove timing pins (1), (2) and (3) and manually run the engine through 2 revolutions, there must NOT be any sticking and/or difficulty in rotation.
Page 81 Maintenance RS 457 • Install and torque the valve cover fixing screws. 4.9 Cooling system 4.9.1 Level check WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGERANT LIQUID WITH THE ENGINE SWITCHED OFF AND COLD. • Shut off the engine and wait until it cools off. •...
Page 82 Maintenance RS 457 CARRY OUT THE CHECK AND TOP UP THE REFRIGERANT LIQUID WITH THE ENGINE SWITCHED OFF AND COLD. 4.10 Braking system 4.10.1 Level check Checking brake fluid Front brake • Rest the vehicle on its stand. • Turn the handlebar completely to the right, so that the liquid contained in the tank is parallel to the cap.
Page 83 Maintenance RS 457 4.10.2 Top-up WARNING RISK OF BRAKE FLUID SPILLING. DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED. WARNING AVOID PROLONGED EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID HYGROSCOPIC ABSORBS MOISTURE WHEN IN CONTACT WITH AIR.
Page 84 Maintenance RS 457 OF THE RESERVOIR WITH ABSORBENT MATERIAL. Front braking system DOT 4 brake fluid SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 • Using a Phillips screwdriver, loosen the screws (1) securing the front brake reservoir cover (2).
Page 85 Maintenance RS 457 Rear braking system DOT 4 brake fluid SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 • Unscrew and remove the cap (1) of the rear brake reservoir. • Remove the gasket (2) from the tank. •...
Page 86 Maintenance RS 457 • Unscrew and remove the pin (2) from the brake calliper. • Recover the spring (3) of the pads. • Remove the outer pad (4) from the brake calliper. • Remove the inner pad (5) from the brake calliper.
Page 87 Maintenance RS 457 Installation • Insert the inner pad (5) into the brake calliper. • Insert the external pad (4) in the brake calliper • Position the spring (3) in the orientation shown in the figure. • Insert the pin (2) into the hole on the brake calliper, ensuring that it fits correctly into the brake pad holes and spring seat (3).
Page 88 Maintenance RS 457 • Screw the pin (2) in as far as it will go and finally insert the safety cotter pin (1). 4.10.4 Replacing rear brake pads Removal • Remove the cotter pin (1) from the pin of the pads.
Page 89 Maintenance RS 457 Installation • Insert the inner pad (4) into the brake calliper. • Ensure that the front of the pad is correctly inserted into the brake calliper holder seat. • Insert the pin (2) into the brake calliper, intercepting the fixing hole of the inner calliper (4).
Page 90 Maintenance RS 457 4.11 Clutch lever adjustment Adjust the clutch when the engine stops or the vehicle tends to move forward even when clutch lever is operated and the gear engaged, or if the clutch ”slides”, resulting in acceleration delay considering the engine revs. Minor adjustments can be realized by acting on the clutch lever adjuster operating as follows: •...
Page 91 Maintenance RS 457 4.12 Gear pedal adjustment To adjust the height of the gearbox pedal, proceed as follows: • Rest the vehicle on its stand. • Loosen the locknuts (1) and (2). (The nut (2) has left-hand thread and has a superficial machining to be able to recognize) •...
Page 92 Maintenance RS 457 NOTE CHECK THAT THE HORIZONTAL ALIGNMENT OF THE BEAM IS CORRECT. • Repeat, if necessary, the adjustment operation for the right headlamp using the adjuster (2). NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT. (HIGH BEAM HEADLIGHT) •...
Page 93 Maintenance RS 457 • Disconnect the connectors (1). • Disconnect the right-hand coil connectors (2) from their holder. • Disconnect the connectors (2). • Cut the plastic clamp (3).
Page 94 Maintenance RS 457 • Remove the two spring clamps (4). • Remove the return tubes (5) from the injectors. • Remove the two instrument cannister support fastening screws (6). • Cut the clamps securing the canister (7) to the bracket.
Page 95 Maintenance RS 457 • Remove the canister holder (8) from the work area. It will NOT yet be possible to remove the holder from the vehicle because it is still attached to the canister • Disconnect the connector (9). • Remove the spring clamp (10) and disconnect the vent pipe from the canister.
Page 96 Maintenance RS 457 • If it is necessary to replace the safety valve (11), remove the two spring clamps (12) and disconnect the pipes. When reassembling, be sure to point the coloured part of the valve (11) towards the canister.
Page 97 LIST OF TOPICS Electrical system...
Page 98 Electrical system RS 457 5.1 Fuses WARNING DO NOT ATTEMPT TO REPAIR FAULTY FUSES. NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS, AND THE RISK OF FIRE. To check: •...
Page 99 Electrical system RS 457 AUXILIARY FUSES DISTRIBUTION C) 5A fuse ECU positive switched live, ABS positive switched live, instrument panel positive switched live, Positive key-on power for engine starter relay D) empty E) 5A fuse Positive key-on power for AMP (optional), positive key-on power for OBD2, positive key- on power for anti-theft (optional), positive key- on power for TPMS (optional)
Page 100 Electrical system RS 457 • Remove the fastening screw located under the rider saddle (2). • Remove the three central fixing screws (3). • Remove the front fixing screw (4). • Release the retaining clip (5) of the side panel.
Page 101 Electrical system RS 457 • Remove the left fairing from the vehicle. • Disconnect the connector (6) to access the main fuse (R). • Remove the fuse and check whether the filament is broken. • Before replacing the fuse, find and solve, if possible, the reason that caused the problem.
Page 102 Electrical system RS 457 • Whenever relays need to be serviced, to avoid an accidental short-circuit, place the power switch to "OFF". The engine start relay is located near the rider's seat, under the left side panel, to access it operate as described: •...
Page 103 Electrical system RS 457 • Remove the front fixing screw (4). • Release the retaining clip (5) of the side panel. • Remove the left fairing from the vehicle. • The engine start relay (6) is attached to the seat post frame.
Page 104 Electrical system RS 457 • The fuel pump (7) and radiator fan (8) relays are located on the opposite side of the vehicle; to access them, the right side panel must be removed, following the same procedure as for the left. •...
Page 105 Electrical system RS 457 • Remove the cable (3) from the starter motor. • Remove the two fixing screws (4) and pull the starter motor (5) out of the crankcase. 5.4 Electronic 5.4.1 Ignition coils Key:...
Page 106 Electrical system RS 457 1 . Electronic control unit 11MP 2 . Left cylinder coil 3 . Right cylinder coil 4 . Battery 5 . Injection relay Pin out: 1 . Power supply +Vbatt 2 . Secondary circuit ground connection 3 .
Page 107 Electrical system RS 457 Key: 1 . Electronic control unit 11MP 2 . Left injector 3 . Right injector 4 . Battery 5 . Injection relay 12-hole injector ɑ = 15° ± 4° β ≤ 12° # = 8.9° ± 4° DESCRIPTION / FUNCTION VALUE...
Page 108 Electrical system RS 457 Key: 1 . Electronic control unit 11MP 2 . Probe before catalyst 3 . Probe after catalyst 4 . Battery 5 . Injection relay Pin out: DESCRIPTION / FUNCTION VALUE 1 . Sensor signal (black wire) 2 .
Page 109 Electrical system RS 457 DESCRIPTION / FUNCTION VALUE Calibration 0.3 – 0,6 bar 5.4.5 Engine temperature sensor Key: 1 . Electronic control unit 11MP 2 . Engine temperature sensor Pin out: 1 Ground lead 3 Signal It is an NTC sensor, so the electrical resistance decreases as the temperature increases.
Page 110 Electrical system RS 457 TEMPERATURE MINIMUM NOMINAL MAXIMUM RESISTANCE (Ohm) RESISTANCE (Ohm) RESISTANCE (Ohm) 0°C 5689 5975 6261 20°C 2406 2502 2598 60°C 562,5 575,8 589,1 90°C 231,2 234,4 NTC 2 TEMPERATURE MINIMUM NOMINAL MAXIMUM RESISTANCE (Ohm) RESISTANCE (Ohm) RESISTANCE (Ohm) 0°C 7487 8039...
Page 111 Electrical system RS 457 The positive half-wave must precede the negative half-wave. Pin out: 1 . Signal 2 . Ground DESCRIPTION / FUNCTION VALUE Electrical resistance at 100 - 150 Ohm 20 °C Nominal gap 0.6 mm 5.4.7 Throttle bodies Key: 1 .
Page 112 Electrical system RS 457 Pin out throttle bodies from 36 mm: 1 . TPS ground 2 . TPS 1 signal 3 . TPS 2 signal 4 . TPS power supply 5 . Throttle body engine positive 6 . Throttle body engine ground 5.4.8 MAP sensor Key: 1 .
Page 113 Electrical system RS 457 5.4.9 Fall sensor Key: 1 . Electronic control unit 11MP 2 . Fall sensor Pin out: 1 . Signal 2 . Ground 3 . Positive OUTPUT SIGNAL DESCRIPTION / FUNCTION VALUE DESCRIPTION / FUNCTION VALUE Electrical resistance 1080 Ohm between pin 1 and pin...
Page 114 Electrical system RS 457 DESCRIPTION / FUNCTION VALUE Electrical resistance 3880 Ohm between pin 3 and pin 5.4.10 Purge Valve - Secondary Air Valve Key: 1 . Electronic control unit 11MP 2 . Purge valve 3 . Secondary air system 4 .
Page 115 Electrical system RS 457 SECONDARY AIR VALVE DESCRIPTION / FUNCTION VALUE Purge valve electrical 30 ohm ± 10 % resistance at 20 °C Secondary air valve 24 ohm ± 10 % electrical resistance at 20 °C 5.4.11 Gear sensor Key: 1 .
Page 116 Electrical system RS 457 DESCRIPTION / FUNCTION VALUE First gear 0.625 V ± 0.1 V Neutral 1 V ± 0.09 V Second gear 1.375 V ± 0.1 V Third gear 2.125 V ± 0.1 V Fourth gear 2,875 ± 0.1 V Fifth gear 3.625 V ±...
Page 117 Electrical system RS 457 Pin out Quick Shift sensor: 1 . Power feed: 5 Volt 2 . Signal 3 . Ground N.B.: Quick shift is non standard. 5.4.13 Stand sensor Key: 1 . Electronic control unit 11MP 2 . Stand sensor Pin out stand sensor (Hall-effect sensor): 1 .
Page 118 Electrical system RS 457 5.4.14 Demand sensor Key: 1 . Electronic control unit 11MP 2 . Demand sensor Pin out Demand Sensor: 1 . Track power supply 1 2 . Track 1 ground 3 . Track 1 signal 4 . Track power supply 2 5 .
Page 119 Electrical system RS 457 5.4.15 Fuel pump Key: 1 . Electronic control unit 11MP 2 . Fuel pump relay 3 . Fuel pump 4 . Battery 5 . Injection relay Pin out fuel pump: 1 . Not connected 2 . Pump ground 3 .
Page 120 Electrical system RS 457 DESCRIPTION / FUNCTION VALUE Sensor resistance with 300 ± 7 Ohm empty tank Full tank sensor 20 ± 5 Ohm resistance 5.4.16 Recharging system Key: 1 . Voltage regulator 2 . Three-phase stator with delta winding ZERO LOAD VOLTAGE TEST Disconnect the stator from the AVR and carry out the corresponding measurement on the...
Page 121 Electrical system RS 457 2000 rpm 6000 rpm 8000 rpm 26.4 volt 79.2 volt 106 volt SHORT-CIRCUIT CURRENT TEST Disconnect the stator from the regulator and short-circuit the three stator phases as shown. Measure the alternating short-circuit current on the three phases using a current clamp. This measurement must be carried out at 2000, 6000 and 8000 rpm.
Page 122 Electrical system RS 457 MEASUREMENT ABSORPTION CURRENT 5.4.17 Ignition Key: 1 . Battery 2 . Key switch 3 . Electronic control unit 11MP 4 . Start-up relay...
Page 123 Electrical system RS 457 5.4.18 Cooling fan Key: 1 . Electronic control unit 11MP 2 . Fan relay 3 . Fan 4 . Battery 5 . Injection relay 5.4.19 TPMS ECU...
Page 124 Electrical system RS 457 Key: 1 . Battery 2 . Main fuse 3 . Key switch 4 . TPMS ECU NOTE: The TPMS control unit is not standard. 5.4.20 ABS Key: 1 . Battery 2 . Key switch 3 . ABS control unit Pin out ABS control unit: (s) Rear speed sensor (+) Front speed sensor...
Page 125 Electrical system RS 457 Not connected Line K (nc) Warning light ABS (nc) (+) Valve battery Ground 10 . (+) Rear speed sensor 11 . (s) Front speed sensor 12 . BLS 13 . WSO_R 14 . + KEY (ECU) 15 .
Page 126 Electrical system RS 457 MODE RIGHT 10 . INDICATOR LEFT 11 . RIDING MODE 12 . AIR TEMPERATURE 13 . CAN L 14 . GLD 15 . INDICATOR RFSFT 16 . MODE SET 17 . Not connected 18 . HIGH BEAM warning light 19 .
Page 127 Electrical system RS 457 5.4.23 Rear light Key: 1 . Battery 2 . Main fuse 3 . Key switch 4 . Instrument cluster 5 . Electronic control unit 11MP 6 . Right turn indicator 7 . Rear light 8 . Left turn indicator 9 .
Page 128 Electrical system RS 457 5.4.24 Headlamp Key: 1 . Headlamp 2 . Key switch 3 . Main fuse 4 . Battery 5 . Instrument cluster 6 . Left light switch Pin out: 1 . + KEY 2 . TURN LEFT 3 .
Page 129 Electrical system RS 457 5.4.25 OBD socket Key: 1 . OBD socket 2 . Key switch 3 . Main fuse 4 . Battery Pin out: 1 . + KEY 2 . CAN H 3 . GROUND 4 . + BATT. 5 .
Page 130 Electrical system RS 457 5.4.26 CAN network Key: 1 . Electronic control unit 11MP 2 . Instrument cluster 3 . OBD 4 . ABS With all ECUs connected, the electrical resistance value measured by the multimeter between pins 2 and 5 of the OBD socket must be 60 ohms (±10%).
Page 131 LIST OF TOPICS Engine from the vehicle...
Page 132 Engine from the vehicle RS 457 6.1 Preparation of the vehicle To remove the engine from the chassis, previously perform the following operations: • Disconnect the battery. • Remove: • the fairings, • the side fairings; • the fairing lug, •...
Page 133 Engine from the vehicle RS 457 • Detach the rubber protection (1) from the starter motor cable. • Unscrew the nut (2). • Remove the cable (3) from the starter motor. • Unscrew the nut (4) and tighten the adjuster (5) in order to loosen the clutch cable tensioning.
Page 134 Engine from the vehicle RS 457 • Disconnect the clutch cable from the actuator lever. • Undo the fixing screws (6) and remove the bracket (7), complete with the clutch cable, from the engine. • Disconnect the coolant temperature sensor connector (8).
Page 135 Engine from the vehicle RS 457 • Remove the cam gearshift control (10) from the gear selector shaft. • Remove the screw (11) securing the ground cables to the engine. • Release the gear sensor wiring harness from the ABS modulator support. •...
Page 136 Engine from the vehicle RS 457 • Pull the wiring harness out of the frame, running it through as shown. • Remove the screw (13) securing the ABS modulator bracket to the motor. • Remove the lock nut (14) and the lower fixing screw (15) of the radiator.
Page 137 Engine from the vehicle RS 457 • Open the metal clamp (17) and remove the hose from the radiator connection. • Remove the metal clamp (18) and remove the hose from the radiator connection. • Cut the plastic cable tie of the oil sensor harness.
Page 138 Engine from the vehicle RS 457 • Remove the fixing screw (20). • Remove the bracket (21) fastening the wiring harnesses from the engine. • Remove the fixing screw (22). • Remove the bracket (23) fastening the wiring harnesses from the engine.
Page 139 Engine from the vehicle RS 457 • Remove the piping from the expansion tank support bracket. • Release the pipe from the support shown in the figure. • Remove the metal clamp (24) and remove the blow-by pipe from the cylinder head •...
Page 140 Engine from the vehicle RS 457 • Unscrew the two fixing screws (27) of the left pilot footrest. • Remove the footrest/shift pedal assembly from the vehicle, including screws (27), washers (28) and spacer bushings (29). • Unscrew the two fixing screws (30) of the right-hand pilot footrest and retrieve the corresponding washers.
Page 141 Engine from the vehicle RS 457 • Remove the nut (31) of the rear pin of the engine. • Collect the washer (32). • Remove the rear pin (33) of the engine. • Remove the front fastener screw of the left lambda probe (34) of the engine and recover the elastic washer (35) and the spacer bushing (36).
Page 142 Engine from the vehicle RS 457 • Remove the right front fastening screw (37) of the engine and retrieve the washer (38). ATTENTION WHEN REMOVING ENGINE FASTENING SCREWS, ENSURE STABILITY OF THE ENGINE AND VEHICLE. • BEING VERY CAREFUL, lower the engine from the vehicle chassis, ensuring that no wiring / tubing remains attached to the engine during the operation.
Page 143 LIST OF TOPICS Power feed...
Page 144 Power feed RS 457 7.1 Air filter box 7.1.1 Air filter box removal To remove the filter housing, firstly remove the fuel tank and then proceed as described: • Disconnect the intake air temperature sensor connector (1). • Remove the eleven fixing screws (2) of the filter housing cover.
Page 145 Power feed RS 457 • Remove the filter (5). • If it needs cleaning, remove the blow-by filter (6). • Remove the two screws (7) securing the filter housing to the cable support of the main wiring harness. • Remove the two fixing screws (8) of the ECU support to the filter housing.
Page 146 Power feed RS 457 • Remove the fixing screw (9) and relative bush (10) of the sensor (11). • After removing the two springs (12) from the breather pipes (13), disconnect them. • Remove the central screw (14) inside the filter housing which is fixed on the canister support below.
Page 147 Power feed RS 457 • Remove the 2 intake ducts (16). • Disconnect the two connectors (17) of the ignition switch assembly from the filter housing. • Disconnect the vacuum valve (18) from the support. • Remove the complete filter housing (19). •...
Page 148 Power feed RS 457 7.2 Fuel pump Removal • Remove the tank cover beforehand. • Release the fuel hose from its holder on the air filter housing. • Press the quick-release coupling (1) of the fuel hose to the side. •...
Page 149 Power feed RS 457 • Remove the safety plate (3) from the fuel pipe. • Press the outer ring (4) down and pull the fuel hose (5) out of the fuel pump. • Using a ring spanner, unscrew and remove the ring nut (6) on the petrol pump.
Page 150 Power feed RS 457 • When reassembling, check the integrity of the gasket (8) and align the petrol pump connector as shown. 7.3 Throttle body 7.3.1 Throttle body removal • Remove the fuel tank and complete air filter case beforehand. •...
Page 151 Power feed RS 457 7.4 Injectors Removal • Remove the petrol tank and air filter case beforehand. • Pull out the safety tab (1) and disconnect the connector (2) from the injector. • Repeat for the second injector. • Remove the two fastening screws (3). •...
Page 152 Power feed RS 457 • Working on the workbench, remove the injectors (5) from the fuel line (6). WARNING SEAL RINGS DURING REASSEMBLY.
Page 153 LIST OF TOPICS Suspension...
Page 154 Suspension RS 457 8.1 Front 8.1.1 Semi-handlebar RIGHT SEMI-HANDLEBAR Removal • Unscrew the fixing screw (1) of the right handlebar counterweight. • Remove the right counterweight (2) from the handlebar and retrieve its washer. • Remove the electrical cables (3) and (4) of the front stop switch.
Page 155 Suspension RS 457 • Remove the upper U-bolt (6), remove the front brake master cylinder (7) from the right-hand half of the handlebar and tie it to the fairing, so that the oil inside the filler tank remains horizontal. • Loosen, but DO NOT remove, the front screw of the right-hand light switch.
Page 156 Suspension RS 457 • Remove the right-hand light switch (8), complete with throttle grip, from the semi- handlebar. • Lock the rotation of the semi-handlebar (9) and unscrew the fixing screw (10). During refitting, tighten the screw (10) to the prescribed torque: DESCRIPTION TORQUE...
Page 157 Suspension RS 457 LEFT SEMI-HANDLEBAR Removal • Unscrew the fixing screw (1) of the left handlebar counterweight. • Remove the left counterweight (2) from the handlebar and retrieve its washer. • Remove left hand handle from the semi-handlebar. To facilitate removal, blow compressed air between the semi- handlebar and the handlebar during the operation.
Page 158 Suspension RS 457 • Loosen the fixing screw (3) of the clutch lever holder. • Lock the rotation of the semi-handlebar (4) and unscrew the fixing screw (5). During refitting, tighten the screw (5) to the prescribed torque: DESCRIPTION TORQUE Semi-handlebar 46 ±...
Page 159 Suspension RS 457 8.1.2 Front fork FRONT FORK POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Pumping unit 25 ÷ 30 Nm fastening (18.44 ÷ screw 22.13 lbf ft) 20 ÷ 25 Nm Cap locknut (14.75 ÷ 18.44 lbf ft) 30 Nm Fork cap (22.13 lbf ft) Calliper...
Page 160 Suspension RS 457 8.1.2.1 Adjustment • The standard front fork setting is adjusted to suit most high and low speed riding conditions, whether the vehicle is partially or fully loaded. • However, it is possible to make a customised adjustment, depending on the use of the vehicle;...
Page 161 (A) (***) from top yoke (excluding cover) (*) - Clockwise (**) - Anticlockwise (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. 8.1.2.2 Fork removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE STANCHION BUT APPLY TO BOTH.
Page 162 Suspension RS 457 • Position the rod on the spring compressor tool RACETECH TFSC 01, previously clamped firmly in the vice. • Position the slider (2) of the spring compressor at the two holes of the pre-fill pipe (3). • Tighten the screw (4) so that the slider (2) is secured to the pre-fill pipe (3).
Page 163 Suspension RS 457 • Unscrew the adjuster (5) in order to release the tension on the pre-fill pipe (3). • Loosen the screw (4) of the slider and remove the rod from the spring compressor tool. • Remove the pre-fill pipe (3) from the sleeve. •...
Page 164 Suspension RS 457 • Clamp the fork in a vice, using special protective jaws, taking care not to damage the foot.. • Insert the special tool 021084Y (8) into the sleeve and make sure it engages correctly on the pump. •...
Page 165 Suspension RS 457 • Remove the special tool (8) from the sleeve. • Remove the pumper (11) from the sleeve. • Pull the sleeve repeatedly towards yourself in order to remove it from the stanchion. • Open the sliding bushing (12) and remove it from its stanchion seat.
Page 166 Suspension RS 457 • When working on the bench, remove the dust cover (13) from the sleeve. • Remove the spring (14). • Remove the oil seal (15). • Remove the shim washer (16). 8.1.2.3 Checking components stanchion...
Page 167 Suspension RS 457 • Check that the sliding surface is not scratched or scored. • Any scoring can be removed by sanding with damp sandpaper (grain 1). • If the scratches are deep, replace the stanchion . • Using a dial gauge, check than any bending of the stanchion is below the limit value.
Page 168 Suspension RS 457 • Place the dust cover (13), spring (14), oil seal (15) and washer (16) on the stanchion and slide them towards the foot. • Remove the special tool (17) from the stanchion. • Install the sliding bushing (12) in its seat on the stanchion.
Page 169 Suspension RS 457 • Insert the oil seal (15) inside the sleeve, observing the orientation shown in the figure. • Assemble special tool 021083Y (18) on the stanchion. • Using the special tool (18), tap the oil seal (15) until it comes to rest in its seat in the sleeve.
Page 170 Suspension RS 457 • Insert the dust cover (13) until it is flush with the upper edge of the sleeve, respecting the orientation shown in the figure. • Insert the pumping element (11) into the sleeve until it comes into contact with the foot, observing the orientation shown in the figure.
Page 171 Suspension RS 457 • Using a 18 mm spanner stop the rotation of the tool (8), then tighten the fixing screw (9) to the specified torque. • Once the fixing screw is tightened, remove the special tool from the pump. DESCRIPTION TORQUE Pumping...
Page 172 Suspension RS 457 • Insert the spring (7) in the sleeve. WARNING INSTALL THE SPRING WITH THE MOST CLOSED COILS FACING THE FOOT. • Insert the pre-load tube (3) in the sleeve. • If necessary, press the pre-fill pipe (3) downwards so that the special tool AP8140150 (19) can be screwed back onto the pump rod.
Page 173 Suspension RS 457 • Screw in the adjuster (5) until the slider (2) is close to the upper edge of the sleeve. • Remove the tool (19) from the pump rod. • Tighten the lock nut (6) on the pump rod. •...
Page 174 Suspension RS 457 • Clamp the complete stanchion in a vice, using special protective jaws, taking care not to damage the foot. • Screw the cap (1) onto the sleeve and tighten it to the specified torque DESCRIPTION TORQUE Fork cap fixing to 30 Nm (22.13 lbf ft) sleeve •...
Page 175 Suspension RS 457 • Loosen, but DO NOT remove, the front screw of the right-hand light switch. • Loosen, but DO NOT remove, the rear screw of the right-hand light switch. • Remove the electrical cables (3) and (4) of the front stop switch.
Page 176 Suspension RS 457 • Remove the upper U-bolt (6), remove the front brake master cylinder (7) from the right-hand half of the handlebar and tie it to the fairing, so that the oil inside the filler tank remains horizontal. • Working from the underside of the steering plate, loosen the screw shown in the figure.
Page 177 Suspension RS 457 • Remove the left counterweight (9) from the handlebar and retrieve its washer. • Remove left hand handle from the semi-handlebar. To facilitate removal, blow compressed air between the semi- handlebar and the handlebar during the operation. •...
Page 178 Suspension RS 457 • Remove the two rubber clamps from the wiring harness of the left-hand light switch. • Remove the bushing (11) securing the top plate. • During refitting, tighten the bushing (11) to the prescribed torque. DESCRIPTION TORQUE Upper steering plate 100 ±...
Page 179 Suspension RS 457 • Supporting upper steering plate, complete with half handlebars, release the right-hand steering wheel (13) from its hole on the right-hand semi-handlebar. • Remove the right-hand light switch (13), complete with throttle grip, from the semi- handlebar. •...
Page 180 Suspension RS 457 8.1.4 Steering lower plate 8.1.4.1 Removal • Remove the side fairings and exhaust beforehand. • Place a pantograph jack under the oil pan and lift the front wheel off the support surface. • Then remove the front mudguard and wheel, fork stanchions and upper steering plate.
Page 181 Suspension RS 457 • Remove the lower flap (3) and horn (4) from the vehicle. • Remove the lock washer (5) from the steering lock washer. • Using the specific tool, unscrew and remove the steering counter-ring (6). AP8140190 Steering tightening tool •...
Page 182 Suspension RS 457 • Support the lower steering plate and unscrew the steering ring nut (8) using the specific tool. AP8140190 Steering tightening tool • Remove the lower steering plate (9), complete with pin and lower bearing, from the vehicle by sliding it downwards. 8.1.4.2 Installation •...
Page 183 Suspension RS 457 AP8140190 Steering tightening tool • Insert the rubber shim (7). • Screw on the counter ring (6) until aligning the grooves in order to be able to insert the safety plate. • Position the lower flap (3) and horn (4) on the lower part of the steering plate.
Page 184 Suspension RS 457 • Tighten the central fixing screw (1) of the lower flap. • Reconnect the electric cables of the horn. 8.1.5 Steering bearings 8.1.5.1 Clearance adjustment • Place the vehicle so that the front wheel is off the ground. •...
Page 185 Suspension RS 457 • Loosen the screws (1) fixing the stanchions to the upper plate. • Unscrew and remove the fixing bush (2) of the upper clamp. • Collect the washer (3). • After adequately protecting the tank, remove the upper plate (4) complete with semi-handlebars and place it on the tank.
Page 186 Suspension RS 457 • Remove the safety plate, unscrew the counter ring and remove the rubber shim. • Supporting the steering plate, unscrew the ring nut, using the special tool, in order to loosen it completely and repeat the correct tightening procedure for the steering block.
Page 187 Suspension RS 457 • Tighten the screws fixing the stanchion (1) to the specified torque. DESCRIPTION TORQUE Stanchion-to-plate 25 ± 2.5 Nm (18.44 ± fixing screw 1.84 lb ft) 8.1.5.2 Removal • Remove the lower steering plate, as described above. •...
Page 188 Suspension RS 457 • Using a generic bearing puller, remove the outer sliding track (4) from the frame. • Remove the inner dust ring (5) from the frame. To remove the lower steering bearing: • After removing the inner bearing ring (6) complete with balls from the bearing tube, heat the inner sliding track (7) with a hair dryer to remove it and then remove the dust...
Page 189 Suspension RS 457 • Remove the internal dust gaiter ring (10) from the chassis. 8.1.5.3 Fitting To assemble the steering assembly, proceed as described: • Insert the dust cover (1) into the pin of the lower steering plate. • Insert the inner seat of the lower bearing (2) and the inner ring of the bearing (3) complete with balls, sprinkling them with grease...
Page 190 Suspension RS 457 • Insert the complete triple clamp (6) into the headstock. • Supporting the lower triple clamp, insert the ring of the bearing (7) complete with balls on the headstock and lubricate it. • Supporting lower steering plate, lubricate the inner bearing seat (8) and insert it into the steering head.
Page 191 Suspension RS 457 • Supporting the lower triple clamp, insert the ring nut (10) on the headstock and tighten it fully by hand. • Using the special tool, pre-tighten the ring nut (10) to 60 Nm (44.25 lbf ft). • Turn the steering plate left and right, as far as it will go, to settle the bearings.
Page 192 Suspension RS 457 8.2 Rear 8.2.1 Shock absorbers REAR SHOCK ABSORBER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Shock 50 ± 7.5 Nm absorber (36.87 ± Self-locking upper 5.53 lb ft) fixing nut Lower shock 50 ± 7.5 Nm absorber (36.87 ± Self-locking fixing nut 5.53 lb ft)
Page 193 Suspension RS 457 8.2.1.1 Adjustment The rear suspension consists of a spring-shock absorber unit connected to the frame by uniball joints. The suspension has a ring nut (1) for adjusting the spring preload (A) and a locking counter ring nut (2). HALVE SERVICE INTERVALS...
Page 194 Suspension RS 457 • Turn the adjustment ring (1) clockwise or anti-clockwise to adjust the spring preload (A). • Once the adjustment is done, screw the counter ring nut (2). ATTENTION 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...
Page 195 Suspension RS 457 • While holding the lower pin (2), unscrew and remove the nut (3). • Remove the lower pin (2) from the swingarm. • Working from the right side of the vehicle, remove the nut (4) on the upper shock absorber pin, holding the pin in place from the opposite side.
Page 196 Suspension RS 457 • Remove the rear shock absorber (6) from the vehicle. 8.2.1.3 Installation To install the shock absorber, proceed as described: • Reposition the shock absorber (6), taking care not to damage any components during the operation. • Align the upper hole of the shock absorber with the corresponding hole in the frame •...
Page 197 Suspension RS 457 • Lift the rear swingarm, then align the lower hole of the shock absorber with its fixing hole on the swingarm. • Then insert the lower pin (2). • While holding the lower pin in place, tighten the nut (3) to the specified torque.
Page 198 LIST OF TOPICS Chassis architecture...
Page 199 Chassis architecture RS 457 9.1 Wheels 9.1.1 Front wheel FRONT WHEEL POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 80 ± 12 Nm Front wheel M25 x 1.5 (59.01 ± axle nut 8.85 lbf ft) Pre- Front brake 25 ± 3.75 Nm impregnated disc fixing (18.44 ±...
Page 200 Chassis architecture RS 457 9.1.1.1 Removal • Remove the exhaust beforehand. • Install a workshop stand at the rear of the vehicle. • Place a pantograph jack under the oil pan and lift the front wheel off the support surface. WARNING CARRY MAINTENANCE...
Page 201 Chassis architecture RS 457 • Remove the two fixing screws (1) of the front brake calliper. • Remove the brake calliper from the fork and position it so as not to stress the pipework. • Unscrew and remove the nut (2) of the wheel axle.
Page 202 Chassis architecture RS 457 • Loosen the two screws of the right-hand stanchion foot. • Loosen the two screws of the left-hand stanchion foot. • Support the wheel and remove the wheel axle from the front fork. • Remove the wheel from the vehicle.
Page 203 Chassis architecture RS 457 REMOVAL EXTERNAL WHEEL COMPONENTS • Remove the six fixing screws (1) of the tone wheel/brake disc. • Remove the tone wheel (2). • Remove the front brake disc (3). REMOVAL INTERNAL WHEEL COMPONENTS • Remove the spacer (4) on the side of the brake disc.
Page 204 Chassis architecture RS 457 • Remove the dust guard (5). • Repeat the operation for the dust seal on the opposite side. • Working from the side of the brake disc again, remove the seeger (6) using a special pliers. •...
Page 205 Chassis architecture RS 457 • Using the special tool, remove the second wheel bearing by knocking it out of the hub. 020376Y Handle for adaptors 020358Y Adaptor 37 x 40 mm 9.1.1.2 Installation INSTALLATION INTERNAL COMPONENTS • Working from the side opposite the brake disc, insert the bearing (9) into the wheel hub and drive it in as far as it will go using the special tool.
Page 206 Chassis architecture RS 457 • Insert the seeger (6) into the wheel hub, ensuring that it is properly seated. • Place the dust cover (5) on the wheel hub. • Using the appropriate punch, bring the oil seal (5) flush with the upper edge of its seat •...
Page 207 Chassis architecture RS 457 • Apply medium-strength threadlock to the phonic wheel/brake disc screws and tighten them to the specified torque, following the sequence shown in the figure. DESCRIPTION TORQUE Brake disc fixing 25 ± 3.75 Nm (18.44 ± screw 2.77 lb ft) •...
Page 208 Chassis architecture RS 457 • Tighten the nut (2) loosely, but sufficiently to bring the wheel axle to a stop. • Temporarily tighten the screws of the left foot. • Tighten the wheel axle nut (2) to the specified torque. DESCRIPTION TORQUE Wheel axle nut...
Page 209 Chassis architecture RS 457 • Loosen the screws of the left foot again. • Remove the stand from under the vehicle. • Apply the front brake and compress the front suspension repeatedly. This centres the wheel/wheel axle assembly with the fork stanchions.
Page 210 Chassis architecture RS 457 9.1.2 Rear wheel REAR WHEEL POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 50 ± 7.5 Sprocket M10 x 1.25 Nm (36.88 fixing nuts ± 5.53 lb ft) Apply Rear brake 25 ± 3.75 Nm medium- disc fastening (18.43 ±...
Page 211 Chassis architecture RS 457 9.1.2.1 Removal • Place the vehicle on a workshop stand for the rear wheel. • Remove the nut (1) of the rear wheel axle. • Collect the washer (2). • Remove the pin (3) of the rear wheel and its washer (4).
Page 212 Chassis architecture RS 457 • Lifting the drive chain from the rear sprocket. NOTE IT IS NOT NECESSARY TO REMOVE THE UPPER CHAIN GUARD WHEN REMOVING/ MOUNTING THE REAR WHEEL. • Remove the rear wheel from the vehicle. REAR SPROCKET SUPPORT / FLEXIBLE COUPLING DISASSEMBLY •...
Page 213 Chassis architecture RS 457 • Remove the chain guard (7). • Remove the sprocket (8). • Remove the oil seal (9). • Remove the cir-clip (10).
Page 214 Chassis architecture RS 457 • Working from the inner side of the crown support, remove the bushing with shoulder (11) from the bearing. • Using a suitable punch, tap the bearing (12) out of the sprocket carrier. 020376Y Handle for adaptors 020359Y Adaptor 42 x 47 mm 9.1.2.2 Installation WHEEL BEARINGS INSTALLATION...
Page 215 Chassis architecture RS 457 • Insert the oil seal (17) into the wheel hub. • Using the appropriate punch, insert the oil seal until it is flush with the upper edge of its seat. 020360Y Adaptor 52 x 55 mm •...
Page 216 Chassis architecture RS 457 • Turn the wheel 180° to intervene on the side of the brake disc. • Insert the spacer (16). • Place the brake disc (15). • Place the phonic wheel (14). • Apply medium-strength threadlocker to the threads of the screws (13).
Page 217 Chassis architecture RS 457 REAR SPROCKET SUPPORT / FLEXIBLE COUPLING ASSEMBLY • Working on the outer side, place the bearing on the sprocket support. • Using the appropriate punch, insert the bearing as far as it will go. 020376Y Handle for adaptors 020655Y Adaptor 62 x 68 mm •...
Page 218 Chassis architecture RS 457 • Working from the inner side of the sprocket support, insert the bushing with shoulder (11) into the bearing, observing the orientation shown in the figure. • Install the sprocket (8) on the sprocket carrier. • Place the chain guard (7) on the sprocket.
Page 219 Chassis architecture RS 457 • Tighten the five nuts (5) securing the sprocket to the specified torque. DESCRIPTION TORQUE Sprocket fixing nut 50 ± 7.5 Nm (36.88 ± 5.53 lb ft) • Insert the wheel hub's rubber inserts into the flexbile coupling, as shown.
Page 220 Chassis architecture RS 457 INSTALLING THE REAR WHEEL • Ensure that the brake calliper support is correctly inserted in the swingarm. The pin on the inside of the swingarm must be inserted into the relevant raceway of the caliper bracket. •...
Page 221 Chassis architecture RS 457 • Install the washer (2). • Install the nut (1) and bring it into contact with the swingarm. • Check that the vertical deflection of the bottom section of the chain, measured at a distance of 302.5 mm (11.91 in) from the centre of the rear wheel axle (along imaginary line between centres of front and rear sprockets), is within 25 ÷...
Page 222 Chassis architecture RS 457 • Move the vehicle forwards to check the vertical deflection of the chain in other positions; the chain deflection must be constant throughout the entire rotation of the wheel. If the clearance is uniform, but not between 25 - 30 mm (0.98 - 1.18 in), adjust it.
Page 223 Chassis architecture RS 457 SWINGARM POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 110 ± 16.5 Nm Swingarm pin M16 x 1.25 Self-locking (81.13 ± 12.17 lb ft) Chain 4 ± 0.6 Nm feeder shoe (1.47 ± fastening 0.44 lb ft) screws Rear 4 ±...
Page 224 Chassis architecture RS 457 • Unscrew the three fixing screws (1) of the left swingarm cover. • Remove left cover (2) from swingarm. • Disconnect the brake hose and ABS sensor cable from the fastenings on the swingarm. • Remove the brake calliper and its support from the swingarm.
Page 225 Chassis architecture RS 457 WHEN REASSEMBLING, MAKE SURE TO INSERT THE PIN, WHICH IS ON THE INSIDE OF THE SWINGARM, INTO THE SLIDING TRACK OF THE BRAKE CALLIPER SUPPORT. • Unscrew the lock nut (3) of the rear shock absorber lower pin. •...
Page 226 Chassis architecture RS 457 • Remove the swingarm pin locknut (5). • Support the swingarm and remove the pin (6). • Remove the swingarm from the vehicle, ensuring that it does not get caught in the drive chain during removal. •...
Page 227 Chassis architecture RS 457 • Remove the dust cover rings (9) from both sides. • Using a suitable punch, remove the roller bearings. 020376Y Handle for adaptors 020441Y Adaptor 26 x 28 mm 9.2.2 Control ATTENTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED, DAMAGED, CRACKED AND/OR DENTED.
Page 228 Chassis architecture RS 457 SWINGARM PIN With a dial gauge check if the pin eccentricity exceeds the limit value. Otherwise, replace the pin. Maximum pin eccentricity: 0.2 mm (0.0078 in). The axial play of the swingarm, in the transverse direction, is intrinsic in the assembly system.
Page 229 Chassis architecture RS 457 9.2.3 Installation To proceed with the installation of the swingarm, proceed as described: • If the roller bearings have been removed during the disassembly phase for a check or replacement, proceed with the insertion by means of a special punch, respecting the following measurements, after having greased the contact parts: LEFT SIDE:...
Page 230 Chassis architecture RS 457 9.3 Sprocket 9.3.1 Removal To proceed with the removal of the front sprocket, after having loosened the tension of the final drive chain, it is necessary to first remove the left footrest support complete with linkages. Then proceed as described: •...
Page 231 Chassis architecture RS 457 • Remove the front sprocket (8) from the transmission shaft and free it from the drive chain. • Remove spacer from transmission shaft. 9.3.2 Check To check the state of wear of the front sprocket, simply check that the teeth of the sprocket are not worn or damaged.
Page 232 Chassis architecture RS 457 • Fit the drive chain onto the sprocket (8) and insert it onto the transmission shaft. • Place the cup spring (7) on the pinion, with the concave part facing outwards, and the bushing with shoulder (6). •...
Page 233 Chassis architecture RS 457 • After positioning the sprocket cover (2), insert the three screws (1) complete with "T" bushes (3) and tighten them to the prescribed torque. • Restore the drive chain to the correct tension, following the specific procedure described in the "Adjustment"...
Page 234 Chassis architecture RS 457 • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6). • Collect the inner O-ring rings (7) and completely remove the transmission chain.
Page 235 Chassis architecture RS 457 9.4.2 Check To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001. The different chain pitches which may be checked with the instrument are indicated on the instrument itself. There are three reference markings for each chain pitch indicated on the instrument.
Page 236 Chassis architecture RS 457 • Place the outer O-rings (3) on the pins. • Compress the outer plate (4) using the appropriate generic tool. WARNING BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN. •...
Page 237 Chassis architecture RS 457 9.4.4 Adjustment To check the clearance: • Shut off the engine. • Rest the vehicle on the side stand. • Select neutral. • Check that the vertical oscillation of the lower chain strand, measured on the sprocket axle at 302.5 mm (11.91 in) from the centre of the rear wheel axle, is between 25 - 30 mm (0.98 - 1.18 in).
Page 238 Chassis architecture RS 457 For the adjustment of the chain tension: • Place the vehicle on its rear service stand. • Loosen, but DO NOT remove, the nut (1) of the rear wheel axle. • Loosen the locknut (2) of the chain tensioner adjuster.
Page 239 Chassis architecture RS 457 • Using a gauge, check that the protrusion of the registers is the same on both sides. • Insert a screwdriver, or similar tool, between two teeth of the sprocket and rotate the wheel until it stops rotating, WITHOUT INSPECTING THE ROTATION ONCE RESISTANCE IS FOUND.
Page 240 Chassis architecture RS 457 • Check the chain play again, if it is not within the specified values, repeat the adjustment operations. 9.4.5 Chain guide pads • Place the vehicle on the specific rear support stand (optional). • Check the wear condition of the chain guide skid, if excessively worn proceed with replacement.
Page 241 Chassis architecture RS 457 • Remove the upper fastener screw (3). • Remove the lower fastener screw (4). • Remove the front fixing screw (5). • Remove the fixing screw (6) of the rear mudguard.
Page 242 Chassis architecture RS 457 • Release the rear mudguard (7) from the chain skid (8). • Slide the chain skid (8) off the swingarm. 9.5 Footrests 9.5.1 Driver footrests LEFT FOOTREST PLATE Removal • Remove the screw (1) used to fasten the stand sensor.
Page 243 Chassis architecture RS 457 • Remove the sensor (2) from the stand. • Loosen the screw (3). • Pull the lever (4) out of the gear selector shaft. • While keeping the pin (5) rotating, unscrew and remove the nut (6) of the swingarm pin. During refitting, tighten the nut (6) to the prescribed torque: DESCRIPTION...
Page 244 Chassis architecture RS 457 • Unscrew the fixing screw (7), with its washer (8), and remove the spacer bushing (9) located between the engine base and the stand support bracket. During refitting, tighten the screw (7) to the prescribed torque: DESCRIPTION TORQUE Screws fastening...
Page 245 Chassis architecture RS 457 • Recover the washer (15) from the swingarm pin. REMOVING THE GEAR SHIFT LEVER After removing the footplate from the vehicle, place it on the workbench and work as described below: • Lock the rotation of the ball joint (1) and unscrew the fixing nut (2).
Page 246 Chassis architecture RS 457 • Remove the pin (5) of the gear lever (4), taking care to recover the washer (8) and O-rings (9). When reassembling, apply bearing grease to the pin seat (5). RIGHT FOOTREST PLATE Removal • While keeping the pin (1) rotating, unscrew and remove the nut (2) of the swingarm pin.
Page 247 Chassis architecture RS 457 • Rotate the pin (4) to release the brake pump control rod and then slide it out in order to remove it from the pump. • Remove the two rear brake pump fastener screws (5). When reassembling, apply medium-strength threadlocking to the threads of the screws (6) and tighten them to the specified torque: DESCRIPTION...
Page 248 Chassis architecture RS 457 • Pull the right footplate (8) out of the vehicle. BRAKE PEDAL REMOVAL After removing the footplate from the vehicle, place it on the workbench and work as described below: • Using a lever puller, unhook and remove the return spring (1) from the brake lever.
Page 249 Chassis architecture RS 457 Removal The following operations refer to a single rider pedal, but apply to both. • "Open" the cotter pin (1) and pull it out of the pin. • Remove the washer (2). • Support the footplate (3) and remove the pin (4) from the footplate.
Page 250 Chassis architecture RS 457 9.5.3 Passenger footrests • Support the passenger footrest and remove the two fixing screws. During refitting, tighten the fixing screws to the prescribed torque. DESCRIPTION TORQUE Fixing screw for the 22 ± 3 Nm (16.23 ± passenger footrest 2.21 lbf ft) •...
Page 251 Chassis architecture RS 457 • Remove the sensor (2) from the stand. • Unscrew the fixing screw (3), with its washer (4), and remove the spacer bushing (5) located between the engine base and the stand support bracket. During refitting, tighten the screw (3) to the prescribed torque: DESCRIPTION TORQUE...
Page 252 Chassis architecture RS 457 NOTES FOR THE REFIT PHASE: • Check the correct positioning of the side stand sensor, in particular that the sensor pin is engaged in the hole on the stand. NOTE INCORRECT POSITIONING OF THE SIDE STAND SENSOR CAN GENERATE THE "STAND OPEN"...
Page 253 Chassis architecture RS 457 POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES Exhaust 13 ± 2 Nm manifold (9.58 ± flange 1.48 lbf ft) fastening nuts 9.7.1 Exhaust • Remove the side fairings, lower toe cap and terminal cover beforehand. • Remove the nuts (1) on the exhaust flanges and remove the flanges (2) from their studs.
Page 254 Chassis architecture RS 457 • Disconnect rear lambda probe connector (5). • Remove the wiring from the cable gland shown in the figure. • Remove the connector (6) of the rear lambda sensor harness from its bracket.
Page 255 Chassis architecture RS 457 • Hold the lock nut (7) in place and remove the lower fixing screw (8) of the drain with its washers. • Remove the complete exhaust from the vehicle. • Recover the sealing rings (9) from the cylinder head.
Page 256 LIST OF TOPICS Braking system...
Page 257 Braking system RS 457 10.1 ABS 10.1.1 Foreword The ABS system consists of the following elements: 1 . ABS Modulator. 2 . Front brake calliper. 3 . Rear brake calliper. 4 . Front brake master cylinder. 5 . Rear brake master cylinder. The ABS system improves vehicle control provided that the physical limits of vehicle grip on the road are not exceeded.
Page 258 Braking system RS 457 ATTENTION THE ANTI-LOCK BRAKING SYSTEM OF THE WHEEL DOES NOT PREVENT FALLS WHILE CORNERING. AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLEBAR TURNED, ON UNEVEN OR SLIPPERY ROADS, OR WITH POOR GRIP, CREATES A LACK OF STABILITY DIFFICULT TO HANDLE.
Page 259 Braking system RS 457 ATTENTION THE ABS SYSTEM ACTS ON BOTH THE FRONT AND REAR WHEELS BY OBTAINING INFORMATION FROM THE ROTATION/ LOCKING TONE WHEELS. ALWAYS CHECK THAT THE TONE WHEEL IS CLEAN, AND REGULARLY CHECK THAT THE DISTANCE FROM THE SENSOR IS CONSTANT ON ALL 360 DEGREES. SHOULD THE WHEELS BE REMOVED AND REFITTED, IT IS VERY IMPORTANT TO CHECK THAT THE DISTANCE BETWEEN TONE WHEEL AND SENSOR IS THE ONE SPECIFIED.
Page 260 Braking system RS 457 10.1.2 Functional diagram...
Page 261 Braking system RS 457 ABS functional diagram key Front system circuit Rear system circuit Front brake calliper Rear brake calliper Front brake master cylinder Rear brake master cylinder Front brake control lever Rear brake pedal Front brake circuit inlet solenoid valve (normally open) 10 .
Page 262 Braking system RS 457 General specifications: The front circuit is the same as the rear one. • The ABS intake valve (9 - 10) is normally open and is closed only when the system intervenes to prevent locking. • The exhaust valve (11 - 12) is normally closed and it is opened only when the system intervenes to avoid wheel locking.
Page 263 Braking system RS 457 Position sensors (1) 'read' on the tone wheels (2), which are attached to the vehicle's wheels, the status of the wheels and detect whether they are locked. The signal is controlled by a control unit / modulator (3), which adjusts the pressure within the brake circuit accordingly to prevent the wheels from locking under braking.
Page 264 Braking system RS 457 the callipers (3-4) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider. E - In the event that the wheel does not regain full grip, the system continues to operate as before until it is restored or until the vehicle stops.
Page 265 Braking system RS 457 Removal • Remove the fuel tank and side fairings beforehand. • Disconnect the connector (1). • Remove the other half of the connector (1) from the ABS control unit holder. • Disconnect the connector (2) of the rear stop.
Page 266 Braking system RS 457 • Route the drop sensor wiring inside the frame, as shown. • Unscrew the fixing screw (3). • Remove the protection (4) of the connector. • Disconnect the connector (5) of the modulator.
Page 267 Braking system RS 457 • Remove the connection screw / hydraulic switch (6) and retrieve the corresponding sealing washers (7). WARNING DURING REFITTING, USE NEW SEALING WASHERS. • Remove the union screw (8) and retrieve the corresponding sealing washers (9). WARNING DURING REFITTING, USE NEW SEALING WASHERS.
Page 268 Braking system RS 457 • Remove the wiring from the grommets on the left side of the modulator holder. • Remove the fixing screw (14) ground cable and retrieve the 'T' bushing (15). • Remove the wiring from the cable inlet on the rear side of the modulator holder.
Page 269 Braking system RS 457 • Release the relay (17), complete with rubber support, from the modulator bracket. • Remove the front fixing screw (18). • Remove the left fixing screw (19). • Remove the right fixing screw (20).
Page 270 Braking system RS 457 • Remove the modulator (21), complete with holder and drop sensor, from the vehicle. • Working on the underside of the bracket, unscrew the fixing screw (22) and recover the 'T' bushing (23). • Remove the modulator (21) from the bracket (24).
Page 271 Braking system RS 457 MORE OIL IS REQUIRED TO BLEED THE ABS SYSTEM THAN A CONVENTIONAL SYSTEM. FOR THIS REASON, CAREFULLY CHECK THE OIL LEVEL IN THE BRAKE TANK. • If even after bleeding, the front brake lever feels "spongy", the secondary circuit in the ABS modulator must be bled.
Page 272 Braking system RS 457 • Place the vehicle on the specific rear support stand (optional). • Remove the brake pads beforehand. • Connect the bleed bottle to the calliper bleeder screw and open it. • Fully depress the rear brake lever and secure it in place with a locking device to prevent brake fluid from flowing out of the open circuit.
Page 273 Braking system RS 457 • Remove the rear wheel of the vehicle, referring to the procedure described in chapter "chassis architecture" • Remove the brake calliper support (3) complete with calliper from swingarm. • Slide the brake calliper (4) out of its support guides (3).
Page 274 Braking system RS 457 • Install the brake calliper support (3) complete with the callipers (4) in the swingarm, making sure to insert the peg of the swingarm in its sliding track of the calliper support. • Install the rear wheel in the vehicle, referring to the procedure described in chapter "chassis architecture"...
Page 275 Braking system RS 457 • Insert the screw and the associated seal washers in the brake pipe fitting, in the order shown in the figure. WARNING DURING REFITTING, USE NEW SEALING WASHERS. • Install the brake pipe on calliper and tighten the special screw of the fitting to the prescribed torque.
Page 276 Braking system RS 457 • Connect the bleed bottle to the calliper bleeder screw and open it. • Fully depress the front brake lever and secure it in place with a locking device to prevent brake fluid from flowing out of the open circuit.
Page 277 Braking system RS 457 • Insert the piston completely into the clamp. • Install the brake calliper (2) on the vehicle. • Install the two fixing screws (1) and tighten them to the specified torque. DESCRIPTION TORQUE Front brake calliper 30 ±...
Page 278 Braking system RS 457 PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED CHAPTER. • Top up the oil tank and refit the cap. • Check the stroke and sensitivity of the brake lever. • If, after bleeding, the lever travel is too long, check that there are no leaks in the brake system and, if everything is in order, proceed with bleeding using a diagnostic...
Page 279 Braking system RS 457 • Remove the brake disc (3). 10.4.2 Disc check This procedure must be performed with the brake disc installed on the wheel. • Check the disc for wear by measuring the minimum thickness with a micrometer in different points.
Page 280 Braking system RS 457 MILLED SURFACE MUST BE FACING OUTWARDS. • Position the tone wheel (2) on the rim, making sure it is in the correct direction of installation. WARNING THE CURVED SURFACE ON THE INSIDE MUST BE FACED OUTSIDE AS INDICATED. •...
Page 281 Braking system RS 457 • Remove the tone wheel (2). • Remove the brake disc (3). 10.5.2 Disc check • The following operations must be carried out with the brake discs fitted on the wheel; they refer to a single disc, but are valid for both.
Page 282 Braking system RS 457 10.5.3 Installation After checking the integrity and state of wear of the brake disc, proceed as described for fitting: • Position the brake disc (3) on the rim, making sure it is in the correct direction of installation.
Page 283 Braking system RS 457 10.7 Rear pads • For removal and fitting of the rear pads, please refer to the section "Braking system" in the "Maintenance" chapter. 10.8 Front brake master cylinder Removal To remove the front brake pump it is necessary to previously empty the oil from the system.
Page 284 Braking system RS 457 • Unscrew the two fixing screws (4) of the front brake master cylinder. During refitting, tighten the screws (4) to the prescribed torque: DESCRIPTION TORQUE Screw fastening front 10 ± 1.5 Nm brake master cylinder (7.37 ± 1.11 lb ft) •...
Page 285 Braking system RS 457 10.9 Rear brake master cylinder Removal To remove the rear brake pump it is necessary to previously empty the oil from the system. Then proceed as described: • Remove the safety O-ring (1) from the pin that blocks the brake pump control rod.
Page 286 Braking system RS 457 DURING REFITTING, USE NEW SEALING WASHERS. • Remove the two rear brake pump fastener screws (7) at the rider footrest support. When reassembling, apply medium-strength threadlocking to the threads and tighten the two fixing screws to the specified torque: DESCRIPTION TORQUE Rear brake pump...
Page 287 Braking system RS 457 • Remove the reservoir (9), complete with tubing, from the brake master cylinder (8). Installation • Follow the removal in reverse order. WARNING PERFORM THE STANDARD BRAKING SYSTEM BLEEDING PROCEDURE, AS DESCRIBED CHAPTER. After bleeding the brake system: •...
Page 288 Braking system RS 457 FRONT PUMP - MODULATOR (Pipe with GREEN colour reference) Removal • Remove the fuel tank and air filter case beforehand. • Completely drain the hydraulic circuit of the brake system of oil. • Remove the right upper fixing screw (1) of the radiator.
Page 289 Braking system RS 457 • Remove the plastic bracket (4) retaining the front brake hoses. • Remove the connection screw (5) from the front brake master cylinder and retrieve the two sealing washers (6).. During refitting, tighten the screw (5) to the prescribed torque: DESCRIPTION TORQUE...
Page 290 Braking system RS 457 • Remove the connection screw (7) from the ABS modulator and retrieve the two sealing washers (8). During refitting, tighten the screw (7) to the prescribed torque: DESCRIPTION TORQUE Banjo fitting 25 ± 3.75 Nm (18.44 ± 2.77 lb ft) WARNING DURING REFITTING, USE NEW SEALING WASHERS.
Page 291 Braking system RS 457 MODULATOR - FRONT CLAMP (Pipe with RED colour reference) Removal • Remove the fuel tank and air filter case beforehand. • Completely drain the hydraulic circuit of the brake system of oil. • Remove the right upper fixing screw (1) of the radiator.
Page 292 Braking system RS 457 • Remove the plastic bracket (4) retaining the front brake hoses. • Remove the connection screw (5) from the front brake calliper and retrieve the two sealing washers (6).. During refitting, tighten the screw (5) to the prescribed torque: DESCRIPTION TORQUE...
Page 293 Braking system RS 457 • Remove the connection screw (7) from the ABS modulator and retrieve the two sealing washers (8). During refitting, tighten the screw (7) to the prescribed torque: DESCRIPTION TORQUE Banjo fitting 25 ± 3.75 Nm (18.44 ± 2.77 lb ft) WARNING DURING REFITTING, USE NEW SEALING WASHERS.
Page 294 Braking system RS 457 REAR PUMP - MODULATOR Removal • First remove the fuel tank. • Completely drain the hydraulic circuit of the brake system of oil. • Disconnect the connector (2) of the rear stop. • Release the other half of the connector (2) from its fixing.
Page 295 Braking system RS 457 DURING REFITTING, USE NEW SEALING WASHERS. • Remove the connection screw (5) from the rear brake master cylinder and retrieve the two sealing washers (6).. During refitting, tighten the screw (5) to the prescribed torque: DESCRIPTION TORQUE Banjo fitting 25 ±...
Page 296 Braking system RS 457 WARNING DURING REFITTING, USE NEW SEALING WASHERS. • Remove the connection screw (3) from the rear brake calliper and retrieve the two sealing washers (4).. During refitting, tighten the screw (3) to the prescribed torque: DESCRIPTION TORQUE Banjo fitting 25 ±...
Page 297 Braking system RS 457 AFTER REPLACING THE MODULATOR/ CONTROL UNIT OR THE PIPES, THE ABS SYSTEM MUST BE BLED. MORE OIL IS REQUIRED TO BLEED THE ABS SYSTEM THAN A CONVENTIONAL SYSTEM. FOR THIS REASON, CAREFULLY CHECK THE OIL LEVEL IN THE BRAKE TANK.
Page 298 Braking system RS 457 CONSIDERING DANGER VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKE CALLIPERS TO RESTORE THE BREAKING SYSTEM TO ITS REGULAR CONDITIONS, THAT HYDRAULIC CIRCUIT IS AIR PURGED. TRADITIONAL BLEEDING SYSTEM WARNING THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED.
Page 299 Braking system RS 457 • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. • Refit and block the front brake oil reservoir cap. • Refit the rubber protection cover. BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT If the brake lever still feels "spongy"...
Page 300 Braking system RS 457 BRAKE CALLIPERS TO RESTORE THE BREAKING SYSTEM TO ITS REGULAR CONDITIONS, THAT HYDRAULIC CIRCUIT IS AIR PURGED. TRADITIONAL BLEEDING SYSTEM WARNING THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED. WHILE PURGING HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.
Page 301 Braking system RS 457 BLEEDING SYSTEM WITH DIAGNOSTIC INSTRUMENT If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure. • With the diagnostic tool properly connected, select the function "REAR BLEEDING" in the section "SETTINGS".
Page 302 LIST OF TOPICS Cooling system...
Page 303 Cooling system RS 457 11.1 Water pump POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 6 ± 0.6 Nm Water pump (4.43 ± impeller 0.44 lb ft) Flywheel 12 ± 1.2 cover Nm (8.85 ± fastening 0.86 lb ft) screw 10 ± 1 Nm Flywheel M36 x 1,5 (7.38 ±...
Page 304 Cooling system RS 457 11.1.1 Removal To proceed with the removal of the water pump, proceed as described: • Remove the five fixing screws (1) of the water pump cover. • Remove the water pump cover (2) complete with gasket (3). •...
Page 305 Cooling system RS 457 • Using a rubber hammer, remove the gear of the water pump (7) complete with washer (8). • From the outside of the cover, using a punch remove the sealing ring (9). • Remove the oil seal (10). 11.1.2 Installation To proceed with the installation of the water pump, proceed as described:...
Page 306 Cooling system RS 457 • Using the special punch, fully seat the oil seal on the cover. 020376Y Handle for adaptors 020414Y 28 mm punch • Apply a light coat of grease to the sliding surface of the oil pump gear (2). •...
Page 307 Cooling system RS 457 • Screw the first component of the seal ring installation tool (A) onto the gear of the water pump. 021037Y Water pump seal insertion tool • Insert the gear complete with tool on the cover. • Insert the sealing ring (4).
Page 308 Cooling system RS 457 • Ensure that the pin (A) cannot rotate, and then tighten the nut until the sealing ring is fully seated. • Insert the impeller (5) and tighten it to the prescribed torque. 11.2 Radiator removal • First remove the side fairings and the fairing lug.
Page 309 Cooling system RS 457 • Remove the lock nut (3) and the lower fixing screw (4) of the radiator. • Open the metal clamp (5) and move it away from the radiator connection. • Remove the pipework from the radiator connection.
Page 310 Cooling system RS 457 • Remove the pipework from the radiator connection. • Remove the metal clamp (7). • Remove the pipework from the radiator connection. • Open the clip (8) and move it away from the radiator connection.
Page 311 Cooling system RS 457 • Remove the pipework from the radiator connection. • Disconnect the fan harness from its bracket. • Disconnect the connector of the electric fan (9). • Remove the upper fixing screw (10) on the left side. During refitting, tighten the screw (10) to the prescribed torque.
Page 312 Cooling system RS 457 • Support the radiator and remove the upper fixing screw (11) on the right side. During refitting, tighten the screw (11) to the prescribed torque. DESCRIPTION TORQUE Screw fastening 6 ± 1 Nm (4.43 ± 0.74 radiator to frame lbf ft) •...
Page 313 Cooling system RS 457 • Remove the plastic fixing clamp (2) of the radiator wiring harness. • Remove the electric fan, complete with support, from the radiator. 11.5 Thermostatic valve 11.5.1 Removal • First remove the side fairings and the fairing lug.
Page 314 Cooling system RS 457 SEAL RINGS DURING REASSEMBLY. • Open the metal clamp (3) and remove the hose from the cylinder head connection. • Remove the two fixing screws (4) of the thermostatic valve cover. • Remove the cover (5) from the cylinder head.
Page 315 Cooling system RS 457 11.5.2 Installation • Verified integrity effective functioning of the thermostatic valve. • Insert the thermostatic valve (6) into place, orientating it as shown. • Position the thermostatic valve cover (5). • Insert the two screws (4) and tighten them to the specified torque.
Page 316 Cooling system RS 457 • Tighten the drainage screw (2) of the water pump. • Fill the radiator up to the lower edge of the filling hole, then tighten the filler cap (1). • Start the engine and check that there are no leaks at the coupling points of the pipes.
Page 317 LIST OF TOPICS Bodywork...
Page 318 Bodywork RS 457 12.1 Rear-view mirrors NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE REAR-VIEW MIRROR, BUT APPLY TO BOTH. • Remove the two upper fastening screws (1) of the inner top fairing cover (2). • Remove the two lower fixing screws (3). •...
Page 319 Bodywork RS 457 • Remove the rear-view mirror (6) from the vehicle. • Repeat for the mirror on the opposite side of the vehicle. 12.2 Top fairing • First remove the rear-view mirrors. • Remove the two left-hand fixing screws (1). •...
Page 320 Bodywork RS 457 • Remove the expansion plug (3) from the front headlamp. • Repeat for the second expansion plug (4). • Slightly move the top fairing away from the vehicle, taking care not to damage the front headlamp wiring. •...
Page 321 Bodywork RS 457 • Pull the connector (6) out of the front headlamp. • Remove the top fairing, complete with front headlamp, from the vehicle. 12.3 Front light cluster • Remove the top fairing, complete with light assembly, from the vehicle beforehand. •...
Page 322 Bodywork RS 457 • Remove the upper cover (2) from the vehicle. NOTE WHEN REASSEMBLING, ENSURE THAT THE TAB IS INSERTED CORRECTLY INTO THE CORRECT SEAT OF THE BRACKET. • Disconnect the connector (3) from the instrument cluster. • Slide the instrument cluster upwards just enough to centre the grommets with the holes in the instrument cluster holder.
Page 323 Bodywork RS 457 • Remove the left fastening screw (3) of the lower fastener (2). • Remove the lower lock (2) of the instrument support. • Remove the two locking screws shown in the figure. • Remove the two locking screws shown in the figure.
Page 324 Bodywork RS 457 • Remove the locking screw shown in the figure. • Remove the two fixing screws (4) of the left half shell (5). • Remove the left half shell (5) from the vehicle. • Disconnect the cable harness from the cable clamp shown in the figure.
Page 325 Bodywork RS 457 • Cut the plastic clamp of the horn cables. • Remove the clamp screw securing the harness to the instrument bracket. • Disconnect the cable harness from the cable clamp shown in the figure. • Remove the clamp and its holder from the right half shell.
Page 326 Bodywork RS 457 • Remove the two fixing screws (6) of the right half shell (7). • Remove the right half shell (7) from the vehicle. 12.6 Light switch To remove the light switches it is necessary to first remove the entire front part of the motorcycle, in order to allow the instrument cluster support to be opened in order to access the various connectors.
Page 327 Bodywork RS 457 • Remove the two rubber clamps (3). • Route the right-hand light switch harness between the right fork stanchion and the frame, as shown. • Unscrew the fixing screw of the handlebar counterweight. • Remove the counterweight (4) from the handlebar.
Page 328 Bodywork RS 457 • Loosen, BUT DO NOT REMOVE, the front screw (5) of the right-hand light switch. • Loosen, BUT DO NOT REMOVE, the rear screw (6) of the right-hand light switch. • Open the two half-shells so as to free the light switch from the positioning hole on the semi-handlebar.
Page 329 Bodywork RS 457 LEFT LIGHT SWITCH • Cut the two cable ties (1) from the cable harness. • Disconnect the connectors (1) and (2) on the left-hand light switch. • Route the left-hand light switch harness between the left fork stanchion and the frame, as shown.
Page 330 Bodywork RS 457 • Blow compressed air between the left handlebar grip and the semi-handlebar to inflate the grip and facilitate removal. • Loosen, BUT DO NOT REMOVE, the screw (4) on the left-hand light switch. • Pull the left-hand light switch (5) off the semi-handlebar.
Page 331 Bodywork RS 457 TO REMOVE THE SIDE FAIRINGS, IT IS NOT NECESSARY TO REMOVE THE TOP FAIRING FROM THE VEHICLE. • Working from the inside of the front wheel arch, remove the two screws shown in the figure. • Working from the inside of the front wheel arch, remove the three screws shown in the figure.
Page 332 Bodywork RS 457 • Remove the side fairing from the vehicle. 12.8 under fairings To remove the under fairings, the side fairings must first be removed. Then proceed as described: LEFT SIDE • Cut the two clamps shown in the figure. WARNING WHEN REASSEMBLING, SECURE THE WIRING HARNESS WITH NEW PLASTIC...
Page 333 Bodywork RS 457 • Remove the connector (1) from the voltage regulator. • Remove the connector (2) from the voltage regulator. • Remove the rubber clamp (3), complete with connector (4) from the left fairing. • Unscrew the lock nut (5) and remove the fixing screw (6) of the voltage regulator.
Page 334 Bodywork RS 457 • Unscrew the lock nut (7) and remove the second fixing screw (8) of the voltage regulator. • Remove the voltage regulator (9) from the vehicle. • Recover the two adjuster bushings (10) from the left fairing. •...
Page 335 Bodywork RS 457 • Remove the left under-fairing from the vehicle. RIGHT SIDE • Remove the three fixing screws (1). • Remove the right under-fairing from the vehicle. 12.9 fairing lug • First remove the side fairings. • Remove the four fixing screws (1).
Page 336 Bodywork RS 457 • Remove the right-hand tip (2) from the vehicle. • Working from the left side of the vehicle, remove the two front fixing screws (3). • Remove the front tip (4). • Remove the two fastening screws (5).
Page 337 Bodywork RS 457 • Remove the left-hand tip (6) from the vehicle. 12.10 Front mudguard • To avoid damaging the mudguard during removal, first remove the front wheel Remove the three side fixing screws (1). • Remove the three side fixing screws (2). •...
Page 338 Bodywork RS 457 12.11 Saddle To remove the saddles, proceed as described: • After inserting the key into the lock located under the tail fairing on the left side of the motorcycle, turn it clockwise and release the passenger seat from the lock. •...
Page 339 Bodywork RS 457 • Ensure that the ignition switch is turned to "OFF". • Remove the passenger and rider saddles. • Unscrew the two fastening screws (1). • Remove the battery cover (2). • Unscrew and remove the screw (3) from the negative terminal (-).
Page 340 Bodywork RS 457 • Move the positive lead (6) aside. • Grip the battery (7) firmly, slide it upwards and remove it from its housing. • Put the battery away on a level surface, in a cool and dry place. •...
Page 341 Bodywork RS 457 • Remove the two central fastening screws (2). • Remove the three front fixing screws (3). • Remove the complete side panel (4) from the vehicle. • Place the side panel on a suitable work surface, making sure not to damage the paintwork.
Page 342 Bodywork RS 457 • Separate the front side (6) from the rear side (7). REFITTING • For reassembly, follow the disassembly procedure in reverse, making sure to insert the retaining clip, shown in the figure, into its seat on the tail fairing. 12.14 Lock Removal •...
Page 343 Bodywork RS 457 • Slide the latch (5) downwards and retrieve the retaining plate (2). • Working on the bench, unscrew the fixing screw and remove the lever (3) and return spring (6). • When reassembling, make sure to insert the spring (6) into the latch seat (5) and the hole in the lever.
Page 344 Bodywork RS 457 • Remove the left side screw (2). • Remove the right side screw (3). • Remove the airbox cover (4) from the vehicle. • Remove the two fixing screws (5) indicated in the figure.
Page 345 Bodywork RS 457 • Remove the two fixing screws (6) indicated in the figure. • Remove the rear fixing screw of the tank (7). • Retrieve the bushing (8) from the tank. • Open the tank cap and remove the screw (9) shown in the figure.
Page 346 Bodywork RS 457 • Remove the three fixing screws (10) of the cap to the tank. • Remove the cap (11), and its gasket (12), from the tank. • Remove the tank cover from the vehicle. • Release the fuel hose and the breather hose from their holders on the filter housing.
Page 347 Bodywork RS 457 • Press the quick-release coupling (13) of the fuel hose to the side. • Pull the fuel tank quick coupling (13) out of the vehicle's fuel line. • Remove the spring clip (14). • Remove the vent tube (15) from the tank.
Page 348 Bodywork RS 457 • Disconnect the connector (16) of the fuel pump wiring harness. • Remove the spring clip (17). • Disconnect the breather pipe (18). • Remove the side screw fastening the tank to the frame (19).
Page 349 Bodywork RS 457 • Remove the side screw fastening the tank to the frame (20). • Remove the fuel tank (21) from the vehicle by pulling it upwards. REFITTING • For reassembly, follow the disassembly procedures in reverse order, taking care to torque the screws securing the tank to the frame.
Page 350 Bodywork RS 457 • Remove the rear fixing screw (2). • Remove the five upper fixing screws (3). • Recover the five bushes (4) from the handle. • Remove the rear handle (5) from the vehicle.
Page 351 Bodywork RS 457 12.17 Rear wheel arch In order to remove the rear wheel arch, the battery, fuel tank, side panels, passenger grab rail, rear light, number plate holder and passenger footrests must first be removed. Then proceed as described: •...
Page 352 Bodywork RS 457 • Press the safety tab on the E.C.U. connector. • Turn the E.C.U. control unit connector lever outwards. • Pull the connector (3) out of the E.C.U. unit. Repeat for the second connector. • Remove the E.C.U. control unit. (4) from the vehicle by pulling it upwards.
Page 353 Bodywork RS 457 • Remove the OBD2 connector (5) from the rear wheel arch. • Release both fuse holders (6) from the rear wheel arch. • Disconnect the connector (7) of the rear ABS sensor. • Release the other part of the rear ABS sensor connector (8) from the slide and pull the cable harness out of the wheel arch.
Page 354 Bodywork RS 457 • Release the relay holders (9), complete with relays, from the wheel arch. • Cut the plastic clamp (10) as shown in the figure. • Release the connector (11) from its holder by pulling it upwards. • Cut the plastic clamp (12).
Page 355 Bodywork RS 457 • Remove the connector (13) from the wheel arch. • Cut the fixing clamp (14) of the starter relay. • Remove the starter relay (15) from the wheel arch by pulling it outwards. • Release the connector (16) from the wheel arch and disconnect it.
Page 356 Bodywork RS 457 • Anchor the rear of the vehicle to a suitable lifting device and lift the rear wheel a few centimetres to remove the rear shock absorber, following the procedure described in the "SUSPENSION" chapter. NOTE ENSURE NOT TO 'LOCK' THE REAR WHEEL ARCH WITH THE DEVICES USED TO LIFT THE REAR WHEEL ARCH.
Page 357 Bodywork RS 457 • Release the wheel arch from the rear frame and remove it from the vehicle. WARNING TAKE CARE NOT TO DAMAGE WIRING AND ELECTRICAL COMPONENTS WHEN REMOVING THE WHEEL ARCH. 12.18 Rear mudguard Removal • Anchor the rear of the vehicle to a suitable lifting device, protecting the body parts that come into contact with the anchoring systems.
Page 358 Bodywork RS 457 • Remove the fixing screw (4). • While holding the lower pin (5) of the rear shock absorber, unscrew and remove the nut (6). • Remove the lower pin (5) from the swingarm. • Disconnect the brake hose and rear ABS sensor cable from its attachment to the rear mudguard.
Page 359 Bodywork RS 457 • Raise the rear of the vehicle so that the rear mudguard (7) can pass through, then remove the mudguard (7) from the vehicle. 12.19 Rear light assembly • Remove the side panels and passenger handle beforehand. •...
Page 360 Bodywork RS 457 • Remove the rear light assembly (4) from the vehicle. 12.20 Number plate light Removal • Remove the six fixing screws (1) of the lower fastening of the number plate holder (2). • Remove the lower fastener of the number plate holder (2).
Page 361 Bodywork RS 457 • Remove the fixing screw (4) of the licence plate light. • Remove the licence plate light (5) from the licence plate holder. 12.21 Licence plate mount • Remove both saddles and the passenger handle beforehand. • Undo the six lower cover fixing screws (1).
Page 362 Bodywork RS 457 • Disconnect the turn indicator connector (3). • Unscrew the lock nut and remove the indicator fixing screw (4). • Remove the turn indicator (5) from the licence plate holder. • Repeat the above steps for the turn indicator on the opposite side.
Page 363 Bodywork RS 457 • Unscrew the fixing screw (7) of the licence plate light. • Remove the licence plate light (8) from the licence plate holder. • Disconnect the wiring harness from its mounts on the inside of the licence plate holder.
Page 364 Bodywork RS 457 • Remove the license plate holder (10) from the vehicle. 12.22 Terminal cover • Remove the right side fairing and the right tip cap beforehand. • Remove the front fixing screw (1) and retrieve the corresponding washer. •...
Page 365 WORKSHOP MANUAL 2Q000571 Engine 457 E5...
Page 366 Engine 457 E5 The descriptions and images in this technical publication are given for illustrative purposes only. Piaggio & C. S.p.A. reserves the right to modify the components and accessories of its products, without altering the essential characteristics of the product described and illustrated herein, to make any changes to organs, details or supplies, deemed appropriate for the purpose of improvement, or for any other requirement of a technical or commercial nature, at any time, without undertaking to promptly update this publication.
Page 367 WORKSHOP MANUAL Engine 457 E5 This workshop manual has been produced for consultation by the technical staff of Dealerships, Service Centres, Authorised Service Network Workshops. This manual is addressed to service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle mounting techniques and procedures.
Page 368 LIST OF TOPICS Specifications..................Regulations............................... 6 maintenance instructions........................6 Dimensions and mass..........................8 Engine............................... 8 Transmission............................. 9 Tightening torques..........................10 Engine..............................11 Special tools..................Engine....................REMOVING THE HEAD AND TIMING CHAIN..................18 CYLINDER HEAD AND VALVE TIMING SYSTEM COMPONENTS CHECK........29 VALVE CLEARANCE CHECK AND ADJUSTMENT................31 FITTING OF CYLINDER HEAD AND TIMING..................
Page 369 LIST OF TOPICS Specifications...
Page 370 WARNING THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only aprilia ORIGINAL SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
Page 371 Specifications Engine 457 E5 ELECTRICAL CONNECTORS The electrical connectors should be disconnected as follows. Failure to observe these procedures will cause irreparable damage to the connector and the wiring: If present, press on the specific safety catches. • Grip the two connectors and unplug them, pulling them apart in opposite directions. •...
Page 372 Specifications Engine 457 E5 WEAR LATEX GLOVES. WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY APPEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE REACHED AND DRUNK BY AN ANIMAL. KEEP OUT OF THE REACH OF CHILDREN. DO NOT REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT - THE COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS.
Page 373 Specifications Engine 457 E5 Engine Bore / stroke 69 mm / 61.11 mm (2.72 in / 2.41 in) Compression ratio 10.5 +/- 0.5: 1 Intake valve clearance 0.10 - 0.15 mm (0.0039 - 0.0059 in) Exhaust valve clearance 0.15 - 0.20 mm (0.0059 - 0.0078 in) Idle engine speed 1,550 +/- 100 rpm Engine revs at maximum speed...
Page 374 31 / 32 (secondary) Final drive ratio 15 / 43 Electronic control systems a-PRC system (Aprilia Performance Ride Control) which includes: AEM (engine map management system), ABS (anti-lock braking system), ATC (traction control), AQS (where applicable) (Clutchless Assisted Shifting System both up and downshifting).
Page 375 Specifications Engine 457 E5 1.5.1 Engine FLYWHEEL - WATER PUMP COVER POSITION DESCRIPTION TYPE QUANTITY TORQUE NOTES 6 ± 0.6 Nm Water pump (4.43 ± impeller 0.44 lb ft) Flywheel 12 ± 1.2 cover Nm (8.85 ± fastening 0.86 lb ft) screw 10 ±...
Page 376 LIST OF TOPICS Special tools...
Page 377 Special tools Engine 457 E5 CODE DESCRIPTION IMAGE 021036Y Flywheel removal tool Tappets for removing / 020854Y fitting exhaust valves Tappets for removing / 020853Y fitting intake valves 020382Y Valve-removing bow 020851Y Camshaft timing pin...
Page 378 Special tools Engine 457 E5 CODE DESCRIPTION IMAGE 021047Y Tuareg 600 timing wrench Tool for removing 020712Y flywheel cover 020713Y Flywheel puller tool 020431Y Valve oil seal extractor 021043Y Camshaft stopper pin...
Page 379 Special tools Engine 457 E5 CODE DESCRIPTION IMAGE 021042Y Bearing/O-ring fitting punch Engine fixing bracket 021041Y to support (engine fixing - beta carriage) Transmission shaft oil 021040Y seal press-fit punch on front sprocket side 021039Y Pick-up distance template 020376Y Adaptor handle Beta 014400010 Piston mounting ring (commercial)
Page 380 Special tools Engine 457 E5 CODE DESCRIPTION IMAGE 021077Y Crankshaft support U-bolt 021078Y Clutch lock wrench Water pump seal 021079Y installation punch Bearing / flywheel 021080Y cover shaft fitting punch Tool kit for engine 457 containing: 021081Y 021077Y-021078Y-021079Y-021080Y...
Page 381 LIST OF TOPICS Engine...
Page 382 Engine Engine 457 E5 3.1 REMOVING THE HEAD AND TIMING CHAIN REMOVAL OF COILS / SPARK PLUGS • Remove the two fixing screws of the coils. • Remove both coils / spark plugs from the cylinder head. REMOVAL OF SPARK PLUGS •...
Page 383 Engine Engine 457 E5 • Remove the five fixing screws (1) on the valve cover (2) and retrieve the rubber sealing washers. • Remove the valve cover (2) from the head. • Remove the spark plug hole gaskets (3) and the outer gasket (4) from the valve cover.
Page 384 Engine Engine 457 E5 • Using a socket spanner, turn the crankshaft using the flywheel fixing screw so that the outer lobes of the camshafts of the left cylinder are in the position shown in the figure. In this position, the camshafts have the least possible thrust from the valve springs.
Page 385 Engine Engine 457 E5 • Recover the plate (1). • Recover the upper chain guide pad (2). • Remove the upper cam tower (3) from the cylinder head. WARNING TAKE CARE THAT CENTRING BUSHES DO NOT FALL INSIDE THE ENGINE.
Page 386 Engine Engine 457 E5 • Lift the timing chain from the sprocket and remove the exhaust camshaft (4) from the cylinder head. • Lift the timing chain from the sprocket and remove the intake camshaft (5) from the cylinder head. NOTE CAMSHAFTS DIFFERENT,...
Page 387 Engine Engine 457 E5 • Slide the timing chain (1) upwards and remove it from the engine. • Unscrew the screw (3) of the rear chain tensioner pad. • Remove the bushing (4) from the chain tensioner pad. • Remove the rear chain tensioner pad (5) by pulling it upwards.
Page 388 Engine Engine 457 E5 • Unscrew the screw (6) of the front chain tensioner pad. • Remove the bushing (7) from the chain tensioner pad. • Remove the front chain tensioner pad (8) by pulling it upwards. REMOVING THE CYLINDER HEAD •...
Page 389 Engine Engine 457 E5 • Working on the left side of the engine, remove the two external side screws from the cylinder head. • Remove the rear external screw from the cylinder head, located between the two intake manifolds. • Remove the cylinder head fixing nuts, loosening them gradually in two/three steps following the sequence (A-B-C-D-E-F).
Page 390 Engine Engine 457 E5 • Remove the gasket from the cylinders. WARNING TAKE CARE THAT CENTRING BUSHES DO NOT FALL INSIDE THE ENGINE. REMOVING VALVES NOTE OPERATIONS SHOWN BELOW REFER TO A SINGLE VALVE BUT ARE VALID FOR ALL OF THEM. THE INTAKE VALVES HAVE A LARGER MUSHROOM AND SHORTER STEM THAN THE EXHAUST VALVES.
Page 391 Engine Engine 457 E5 SAME VALVE FROM WHICH THEY WERE REMOVED. THIS WILL DEPEND ON THE VALVE CLEARANCE VALUE THAT WILL BE MEASURED DURING REASSEMBLY. • Position the valve-removing bow 020382Y (1) , and its spring compressor 020382Y012 (2) on the valve to be removed, as shown in the figure.
Page 392 Engine Engine 457 E5 • Remove the spring (5). • Remove the valve (6) by pulling it out of the combustion chamber. Use special tool 020431Y to remove the valve stem seal, working as described below: • Place the inner part (7) of the tool on the oil seal.
Page 393 Engine Engine 457 E5 • Position the nut (9) on the thread and bring it into contact with the outer part of the tool. • Tighten the nut until good resistance to rotation can be felt. • Remove the special tool from the cylinder head and check that the oil seal has been removed.
Page 394 Engine Engine 457 E5 of the mating surfaces of the cylinder head and cylinder must be checked. CHECKING THE CAMSHAFT • Check that the surfaces of rotation (1) of the camshafts are free of signs of seizing and/ or pitting. •...
Page 395 Engine Engine 457 E5 xxxx mm (xxxx in) Valve stem distortion (MEASURED ON 45°) xxxx mm (xxxx in) Valve stem diameter (MINIMUM WEAR VALUE) xxxx mm (xxxx in) Valve head eccentricity (MAXIMUM ALLOWED VALUE) xxxx mm (xxxx in) CHECK TIMING CHAIN TENSIONER Check that the chain tensioner retracts freely when screwed in and that it comes out without locking when released.
Page 396 Engine Engine 457 E5 • Remove the valve cover and the inspection plug from the flywheel cover beforehand. • Rotate the crankshaft, using the flywheel fixing screw, so that the valve lobe to be measured is brought upwards. • Using a feeler gauge, measure the valve clearance value.
Page 397 Engine Engine 457 E5 NOTE OPERATIONS SHOWN BELOW REFER TO A SINGLE VALVE BUT ARE VALID FOR ALL OF THEM. THE INTAKE VALVES HAVE A LARGER MUSHROOM AND SHORTER STEM THAN THE EXHAUST VALVES. • Place the lower cup (1) in the affected valve guide.
Page 398 Engine Engine 457 E5 • Position the upper cup (5) on the valve spring. • Position the valve-removing bow 020382Y (6) , and its spring compressor 020382Y012 (7) on the affected valve, as shown in the figure. • Rotate the handle of the special tool clockwise to compress the valve spring.
Page 399 Engine Engine 457 E5 • Lubricate the cup (9) with MOLYKOTE G- RAPID PLUS and position it on the valve. WARNING BUCKET TAPPETS ALSO AS CALIBRATED PADS AND CANNOT ALWAYS BE REASSEMBLED ON THE SAME VALVE FROM WHICH THEY WERE REMOVED.
Page 400 Engine Engine 457 E5 • Install the cylinder head (2) on the cylinders. • Lubricate the threads of the stud bolts and the bearing surfaces of the nuts with MOLYKOTE G-RAPID PLUS. • Tighten the fixing nuts to the specified torque in two/three steps following the sequence (A-B-C-D-E-F).
Page 401 Engine Engine 457 E5 • Operating on the left-hand side, insert and torque the two external side screws. • Insert and tighten to torque the rear external screw, located between the intake manifolds. FITTING OF TIMING CHAIN PADS • Take care not to invert the pads during reassembly.
Page 402 Engine Engine 457 E5 • Insert the bushing (1) into the pad (B). • Insert and tighten the fixing screw (2) to the prescribed torque. • Position the rear pad (A) by inserting it from the head. • Insert the bushing (3) in the pad (A).
Page 403 Engine Engine 457 E5 • Insert and tighten the fixing screw (4) to the prescribed torque. CAMSHAFTS FITTING • Check the presence of the centring bushings of the upper cam tower. WARNING TAKE CARE THAT CENTRING BUSHES DO NOT FALL INSIDE THE ENGINE.
Page 404 Engine Engine 457 E5 • Install the intake (3) and exhaust (4) camshafts in their seats in the cylinder head and position them as shown in the figure. INTAKE SHAFT (3): Hole for timing pin facing the exhaust. EXHAUST SHAFT (4): Hole for timing pin facing upwards.
Page 405 Engine Engine 457 E5 (Bucket tappet thickness fitted + clearance measured) - clearance specified = NEW bucket tappet thickness • In the case of replacing one or more bucket tappets, repeat the procedure CAMSHAFT FITTING. TIMING • Rotate the crankshaft until the hole in the right shoulder of the crankshaft corresponds with the hole in the lower crankcase.
Page 406 Engine Engine 457 E5 • Insert the timing chain into the engine and fit it onto the crankshaft sprocket. • Fit the sprocket (2) into the timing chain and then install it on the exhaust camshaft. • Position the ring gear (2) by centring its slots with the camshaft fixing holes.
Page 407 Engine Engine 457 E5 • Install the tool 021047Y (4) on the intake camshaft, as shown in the figure, and secure it using a sprocket screw. • Rotate the camshaft anti-clockwise until the hole in the flange corresponds to the corresponding hole in the cam tower.
Page 408 Engine Engine 457 E5 • Insert a fixing screw and tighten it provisionally. • Position the upper chain-guide pad on the cam tower. • Position the plate as shown in the figure, turning the fold DOWN. • Install and tighten the two fixing screws of the upper chain guide pad to the specified torque.
Page 409 Engine Engine 457 E5 • Remove the cap (7) from the chain tensioner (8). • Insert the chain tensioner (8) and a new gasket (9) into its seat on the cylinder head. • Using a flat screwdriver, screw in the chain tensioner so that it "retracts", so that the chain tensioner flange is flush with the mating surface of the head.
Page 410 Engine Engine 457 E5 • Torque tighten the two chain tensioner fixing screws. • Screw on the chain tensioner cap (7). • Insert the second fixing screws on the camshaft sprockets. • Tighten the fixing screws on the camshaft sprockets to the specified torque. DESCRIPTION TORQUE Timing system gear...
Page 411 Engine Engine 457 E5 • Remove the centring pins (3) and (5) from the camshafts. • Remove the centring pin (1) from the crankshaft. • Check that the timing operation has been carried out correctly by manually turning the crankshaft two complete revolutions. •...
Page 412 Engine Engine 457 E5 • Position the valve cover (3) on the cylinder head. • Insert new rubber washers in the holes of the cover, then tighten the five fixing screws (4) of the valve cover (3) to a torque. SPARK PLUGS FITTING •...
Page 413 Engine Engine 457 E5 • Insert both coils/spark plugs into their respective seats in the cylinder head. • Torque tighten the two coils fixing screws. 3.5 REMOVAL OF HEAD-ENGINE BLOCK-PISTON ASSEMBLY REMOVAL OF PISTON-CONNECTING RODS • Preventively remove: the cylinder head and timing components, the oil pan from the lower crankcase.
Page 414 Engine Engine 457 E5 • Remove the connecting rod cap (3) from the crankshaft. WARNING NOTE THE CONNECTING ROD FROM WHICH THE CONNECTING ROD CAP HAS BEEN REMOVED; THEY MUST NOT BE REVERSED. • Push the connecting rod head in the direction of the cylinder head, taking care not to drop the connecting rod-piston assembly from the cylinder.
Page 415 Engine Engine 457 E5 • Pull out the piston pin (7) from the side of the piston (6) on which the snap ring has been removed and remove the piston from the connecting rod. • Remove the two rings (8) and the oil scraper ring (9) from the piston.
Page 416 Engine Engine 457 E5 • Remove the base gasket (3) from the upper crankcase. • Check that the centring bushings have remained inserted in their seats in the upper crankcase. CHECK HEAD-ENGINE BLOCK-PISTON ASSEMBLY COMPONENTS PISTON CHECK • Clean off combustion residues from the piston crown and from the area above the top ring.
Page 417 Engine Engine 457 E5 PIN CHECK • Measure the outside diameter (1) of the piston pin. • If it is out of specification, replace the piston pin. Piston pin external diameter (MINIMUM PERMITTED) xxx mm (xxxx in) VERIFICATION OF PISTON RINGS •...
Page 418 Engine Engine 457 E5 • Measure the internal diameter of the cylinders (1) at the dimension (2) shown in the figure; set the dial gauge graduated in hundredths of a millimetre to zero using a ring gauge before measuring. (2) = 51 mm (2.008 in) CYLINDER DIAMETER (1) 68.998...
Page 419 Engine Engine 457 E5 • Clean the mating surface of the upper crankcase of any gasket residue. • Check the presence of the two centring bushings. • Position a new base gasket (1) on the upper crankcase. • Install the cylinders (2) on the upper crankcase.
Page 420 Engine Engine 457 E5 • Insert the spacers rings (2) and the oil scraper ring (3) in the third slot of the piston. • Lubricate the second slot and the second piston ring (4) with engine oil. • Insert the piston ring into its slot, taking care to point the "TOP 2"...
Page 421 Engine Engine 457 E5 • Insert a NEW snap ring (8) in its seating of the piston pin hole. WARNING TURN SNAP RING OPENING DOWNWARDS, TAKING CARE THAT IT IS NOT CLOSE TO THE PISTON RECESS (A). • Using the piston tightening tool Beta (9), insert piston-rod...
Page 422 Engine Engine 457 E5 • Position the connecting rod head on the relevant crank pin. • Install the connecting rod cap (10), complete with bushing (11), onto the connecting rod head. NOTE ENSURE THAT APPROPRIATE BUSHINGS HAVE BEEN INSTALLED ON THE CONNECTING ROD HEAD AND ITS CAP.
Page 423 Engine Engine 457 E5 • Tighten the connecting rods (12) according to the specified torque and sequence: 1. PRE-TIGHTENING: 15 ± 1 Nm (11.06 ± 0.74 lbf ft) 2. PRE-TIGHTENING: 20 ± 1 Nm (14.75 ± 0.74 lbf ft) FINAL TIGHTENING: 110° ± 1° RESIDUAL (CONTROL) TORQUE:46 ÷...
Page 424 Engine Engine 457 E5 • Remove the inspection cap (3). • Screw the special tool 020712Y (3) into the flywheel cover inspection hole. • Remove the screws (4) used to fasten the flywheel cover. • Remove the flywheel cover (5) using the special tool.
Page 425 Engine Engine 457 E5 • Remove the gasket (6). REMOVAL FLYWHEEL/ROTOR 3.9 CHECKING THE FLYWHEEL COMPONENTS CHECKING FLYWHEEL / ROTOR • Check the integrity of the magnets. • Check the magnet retaining cage for deformations and/or fractures. FREEWHEEL CHECK • Remove the free wheel (1) from the relative fixing flange (2) and check that the rollers do not show signs of wear and / or damage.
Page 426 Engine Engine 457 E5 • Insert the oil pump (1) into its seat in the lower crankcase. • Make sure to align the pump fixing holes with the relevant threaded holes in the crankcase • Rotate the sprocket so that two holes in the sprocket coincide with the two pump fixing holes.
Page 427 Engine Engine 457 E5 • Insert the starter sprocket (2) on the crankshaft as far as it will go. • Position the plate (3) as shown in the figure. • Tighten the fixing screw (4) of the plate to a torque. WARNING APPLY MEDIUM-STRENGTH...
Page 428 Engine Engine 457 E5 • Position the flange/free wheel assembly in its seat on the rear side of the flywheel. • Insert the six fixing screws (3) of the free wheel and tighten them to the specified torque. Tightening torque for the freewheel fixing screws: DESCRIPTION TORQUE...
Page 429 Engine Engine 457 E5 • Position the washer (3) and fixing screw (4) in the cylinder head hole of the crankshaft. • Install the special tool 021036Y (5) as shown in the figure, using only the two fasteners shown. • Tighten the fastening screw (4) of the flywheel to the specified torque.
Page 430 Engine Engine 457 E5 • Screw and tighten to the prescribed torque the three stator fixing screws (3). WARNING APPLY HIGH-STRENGTH THREAD- LOCKING TO THE THREADS. • Insert the wiring harness rubber cable clamp in its seat on the flywheel cover. •...
Page 431 Engine Engine 457 E5 • Check the presence of the two centring bushings. • Place the gasket (1) on the mating surface of the engine. • Place the flywheel cover (2) using the special tool 020721 Y (3). • Screw and tighten to the prescribed torque the fixing screws (4) of the flywheel cover.
Page 432 Engine Engine 457 E5 • Remove the special tool 020721Y (3) from the flywheel cover inspection hole. • Screw the inspection plug (5) in the specific hole on the flywheel cover. • Place the water pump cover (6) with the gasket in its housing.
Page 433 Engine Engine 457 E5 • Install a NEW O-ring (1) into the seat of the sensor (2) and lubricate it with bearing grease. • Insert the sensor (2) in the specific seat of the upper crankcase. • Tighten the two fixing screws (3) to the specified torque.
Page 434 Engine Engine 457 E5 • Insert the starter motor (2) in its seat. • Tighten the two fixing screws (3) to the specified torque. 3.11 REMOVAL OF CLUTCH SIDE REMOVAL OF CLUTCH COVER • Remove the screws (1) used to fasten the clutch cover (2).
Page 435 Engine Engine 457 E5 • Remove the gasket (3) of the clutch cover. REMOVING THE CLUTCH ACTUATOR SHAFT REMOVING THE CLUTCH • Remove the three fixing screws (1) of the springs. WARNING CAREFUL ATTENTION WHILE LOOSENING TIGHTENING THREE SCREWS. ALWAYS PROCEED GRADUALLY AND PROGRESSIVELY ON EACH SCREW.
Page 436 Engine Engine 457 E5 • Remove the springs (3) from the clutch. • Remove the thrust plate (4) complete with actuator (5) from the clutch. • Extract the actuator (5) from the thrust plate (4). • Remove the spring stop rings (6) from the thrust plate (4).
Page 437 Engine Engine 457 E5 • Pull the first driving disc with reduced friction material (7) out of the clutch. • Pull out the driven disc with reduced friction surface (8). • Pull out the second drive disc with reduced friction material (9). •...
Page 438 Engine Engine 457 E5 • Pull out the four driving discs with standard friction surface (11). • After removing the fifth and last driven disc (10), pull out the third driving disc with reduced friction material (12). • Remove the spring washer (13). WARNING THE CONCAVE PART OF THE SPRING MUST FACE UPWARDS.
Page 439 Engine Engine 457 E5 • Use the special tool to 021078 Y (15), lock the rotation of the clutch hub and unscrew the fixing nut (16). • Remove the washer (17). • Remove the clutch hub (18) from the primary shaft gear. •...
Page 440 Engine Engine 457 E5 • Remove the roller bearing (20) from the primary shaft gear. • Remove the shoulder bushing (21) from the gearbox output shaft. 3.12 CHECK CLUTCH COMPONENTS CHECK CLUTCH DISCS • Check that the thickness of the driving discs is within the specified values: 2.85 - 2.95 mm (0.112 - 0.116 in) •...
Page 441 Engine Engine 457 E5 CHECK THRUST PLATE • Check the thrust plate and the bearing for damage and wear. If necessary, replace the parts. Maximum permissible deformation thrust plate pressure face 0.15mm (0.0059 in) Maximum depth of thrust plate: 27.3 mm (1.07 in) SPRING CHECK •...
Page 442 Engine Engine 457 E5 CHECK CLUTCH HUB • Check the clutch housing for any damage or signs of wear that could lead to clutch malfunctioning. Replace the hub if necessary. 3.13 FITTING OF CLUTCH SIDE FITTING THE CLUTCH • Insert the bushing with shoulder (1) into the gearbox output shaft.
Page 443 Engine Engine 457 E5 • Insert the clutch hub (4) in the gearbox output shaft. • Insert the washer (5) in the gearbox output shaft. • Tighten the retaining nut (6) and bring it into contact with the clutch hub (4). •...
Page 444 Engine Engine 457 E5 • Insert the thrust washer (8) in the clutch housing. • Insert the spring washer (9) in the clutch housing. WARNING THE CONCAVE PART OF THE SPRING MUST FACE UPWARDS. • Insert the first driving disc with reduced friction material (10) into the clutch housing.
Page 445 Engine Engine 457 E5 • Insert the four driving discs with standard friction material (12), alternating each driving disc (12) with a driven disc (11). • The sequence of the standard discs must end with the insertion of the fifth (and last) driven disc (11).
Page 446 Engine Engine 457 E5 • Insert the second driving disc with reduced friction material (16) into the thrust plate (14). • Insert the driven disc with reduced friction surface (17) into the thrust plate (14). • Insert the third driving disc with reduced friction material (18) into the thrust plate (14).
Page 447 Engine Engine 457 E5 • Ensure that the slots of the thrust plate (14) are centred in relation to the hub studs. WARNING INCORRECT POSITIONING THRUST PLATE ON THE HUB CAN CAUSE THE CLUTCH TO BREAK. • Insert the three springs (19). •...
Page 448 Engine Engine 457 E5 • Insert the three fixing screws (21) in the relevant holes of the plate (20). • Tighten the three fixing screws (21) torque, proceeding gradually progressively. WARNING CAREFUL ATTENTION WHILE LOOSENING TIGHTENING THREE SCREWS. ALWAYS PROCEED GRADUALLY AND PROGRESSIVELY ON EACH SCREW.
Page 449 Engine Engine 457 E5 • Insert and tighten the clutch cover (2) fixing screws (3) to the prescribed torque. 3.14 LUBRICATION OIL FILTER • To remove the oil filter (1) use a dedicated tool and unscrew it from the front side of the crankcase.
Page 450 Engine Engine 457 E5 • During reassembly ALWAYS replace the aluminium sealing washer (2) with a new one. 3.15 CRANKCASE CRANKCASE OPENING NOTE THE OPERATIONS DESCRIBED BELOW REFER TO THE COMPLETE REMOVAL OF THE ENGINE. IT IS POSSIBLE TO SEPARATE THE CRANKCASES WITHOUT REMOVING THE HEAD-ENGINE BLOCK- PISTON ASSEMBLY (CYLINDER HEADS, CYLINDERS, CONNECTING RODS AND...
Page 451 Engine Engine 457 E5 • Working on the flywheel side, insert an aluminium shim (3) between the toothed wheels of the crankshaft (4) and countershaft (5), to prevent the rotation. • Unscrew the fixing screw (6) of the countershaft toothed wheel (5) and recover the respective washer.
Page 452 Engine Engine 457 E5 • Remove the flange (9) from the crankcase. • Remove the five M6 screws (10). • Remove the thirteen M8 screws (11) and recover the copper washer where present. WARNING WHEN REFITTING REPLACE THE COPPER SEALING WASHERS. •...
Page 453 Engine Engine 457 E5 • Remove the six M10 screws (13). • Separate the crankcases and then remove the lower crankcase (14) from the upper one (15). NOTE IN CASE IT IS DIFFICULT TO SEPARATE THE CRANKCASE, TAP THE LOWER CRANKCASE WITH A RUBBER HAMMER FACILITATE DETACHMENT.
Page 454 Engine Engine 457 E5 • Remove the crankshaft (2) by pulling it out of the upper crankcase. NOTE FOR REMOVING / FITTING OPERATIONS, CONNECTING RODS MUST NOT BE INSTALLED ON THE CRANKSHAFT. • Remove the three upper half-bushings (3) from the upper crankcase. •...
Page 455 Engine Engine 457 E5 NOTE IT IS NOT NECESSARY TO REMOVE THE CRANKSHAFT FROM THE UPPER CRANKCASE WHEN REMOVING AND FITTING THE GEARBOX. IN CASE IT IS NOT NECESSARY TO REMOVE THE CRANKSHAFT, IT IS INDISPENSABLE TO INSTALL THE CRANKSHAFT SUPPORT U-BOLTS 021077Y UPPER...
Page 456 Engine Engine 457 E5 • Unscrew the fixing screw (4) of the index lever (5). • Remove the fixing screw (4) along with the spring (6) and index lever (5). • Remove the fixing screw (7) and extract the selector drum (8) from the seat of the desmodromic shaft.
Page 457 Engine Engine 457 E5 • Remove the guide shaft (10) from the crankcase and remove both forks (11) of the transmission shaft command. • Pull the guide shaft (12) of the primary shaft control fork out of the crankcase. • Release the fork of the primary shaft (13) from its desmodromic track (14).
Page 458 Engine Engine 457 E5 • Remove the fork (13) from the primary shaft of the gear (16). • Remove the two screws (17) and respective retaining washers (18) of the bearing (19) of the primary shaft. • Partially extract the primary shaft (16) and remove the bearing (19) from the shaft itself.
Page 459 Engine Engine 457 E5 GEAR SELECTOR REMOVAL Once the gear selector shaft has been removed, it can be dismantled as shown below: • Remove the seeger ring (1). • Remove the shim washer (2). • Release the retaining plate (3) and pull it off the selector shaft.
Page 460 Engine Engine 457 E5 • Remove the return spring (4). WARNING WHEN REFITTING, ENSURE THAT THE SPRING IS CORRECTLY POSITIONED IN ITS SEAT. • Remove the bushing (5). NOTE TO REFIT THE GEAR SELECTOR, FOLLOW THE REMOVAL PROCEDURE IN REVERSE ORDER.
Page 461 Engine Engine 457 E5 • Remove the second speed gear (2). • Remove the sixth speed gear (3). • Remove the roller bearing cage (4) of the sixth gear. NOTE IT IS POSSIBLE TO SPREAD OUT THE ROLLER CAGES OF THE GEARBOX GEARS TO ALLOW THEM TO BE FITTED AND REMOVED.
Page 462 Engine Engine 457 E5 • Remove the toothed thrust washer (5). • Remove the snap ring (6). WARNING DURING REFITTING, USE A NEW SEEGER RING. • Remove the third-fourth speed gear (7). • Remove the cir-clip (8). WARNING DURING REFITTING, USE A NEW SEEGER RING.
Page 463 Engine Engine 457 E5 • Remove the toothed thrust washer (9). • Remove the fifth speed gear (10). • Remove the roller bearing cage (11) of the fifth gear. • The first gear (12) is integrated with the primary shaft of the gearbox, it is NOT possible to remove/replace it from the shaft.
Page 464 Engine Engine 457 E5 • After removing the gearbox shafts from the upper crankcase, proceed as described below to dismantle the secondary shaft: • Remove the bearing (1). • Remove the cir-clip (2). WARNING DURING REFITTING, USE A NEW SEEGER RING.
Page 465 Engine Engine 457 E5 • Remove the first speed gear (4). • Remove the roller bearing cage (5). • Remove the thrust washer (6). • Remove the fifth speed gear (7)
Page 466 Engine Engine 457 E5 • Remove the cir-clip (8). WARNING DURING REFITTING, USE A NEW SEEGER RING. • Remove the toothed thrust washer (9). • Remove the fourth speed gear (10). • Remove the roller bearing cage of the fourth gear (11).
Page 467 Engine Engine 457 E5 NOTE IT IS POSSIBLE TO SPREAD OUT THE ROLLER CAGES OF THE GEARBOX GEARS TO ALLOW THEM TO BE FITTED AND REMOVED. • Remove the third speed gear (12). • Remove the roller bearing cage of the third gear (13).
Page 468 Engine Engine 457 E5 • Remove the cir-clip (15). WARNING DURING REFITTING, USE A NEW SEEGER RING. • Remove the sixth speed gear (16). • Remove the cir-clip (17). WARNING DURING REFITTING, USE A NEW SEEGER RING. • Remove the toothed thrust washer (18).
Page 469 Engine Engine 457 E5 • Remove the second speed gear (19). • Remove the roller bearing cage of the second gear (20). • Remove the spacer (21), pulling it out from the side shown in the figure. • Remove the oil seal (22). WARNING WHEN REFITTING, USE A NEW OIL SEAL.
Page 470 Engine Engine 457 E5 • Remove the O-ring (23). WARNING REPLACE THE O RING UPON EACH REMOVAL. • Remove the bearing (24). NOTE TO REFIT THE SECONDARY SHAFT, FOLLOW THE REMOVAL PROCEDURE IN REVERSE ORDER. GEARBOX FITTING NOTE IT IS NOT NECESSARY TO REMOVE THE CRANKSHAFT FROM THE UPPER CRANKCASE WHEN REMOVING AND FITTING THE GEARBOX.
Page 471 Engine Engine 457 E5 NOTE FOR THE EXTRACTION AND INSERTION OF THE GEARBOX OUTPUT SHAFT, PASS THE END THROUGH THE MILLING OF THE UPPER CRANKCASE SHOWN IN THE FIGURE. • Insert the primary shaft (1) in the bearing in the crankcase until it stops. •...
Page 472 Engine Engine 457 E5 • Insert the desmodromic shaft (6) through the hole in the crankcase and until it stops on the bearing. • Once inserted the desmodromic shaft (6), position the fork (5) in the relevant sliding track of the desmodromic shaft. •...
Page 473 Engine Engine 457 E5 • Insert the shaft (10) in the crankcase until the stop and make sure to intercept the forks (9). • Torque-tighten the two screws (11) securing the gearbox fork shafts. WARNING APPLY MEDIUM-STRENGTH THREAD LOCKER TO THE THREADS. •...
Page 474 Engine Engine 457 E5 • Rotate the drum (12) so that the chamfered part is at the shaft (10) of the secondary shaft forks, as shown. • In this way, the gearbox is in neutral and the installation of the index lever is facilitated. •...
Page 475 Engine Engine 457 E5 • Torque-tighten the two fixing screws (18) of the selector shaft retaining plate. • Insert the output shaft (19) complete with oil seal (20) and spacer (21) into the upper crankcase, making sure to insert the forks into their seats.
Page 476 Engine Engine 457 E5 the reference of the bushing into its seat of the crankcase. • Apply grease Jota 3 to the bushings (1). • Install the three upper main bushings (2) in the upper crankcase, making sure to insert the reference of the bushing into its seat of the crankcase.
Page 477 Engine Engine 457 E5 NOTE INSTALLED, REMOVE CRANKSHAFT SUPPORT U-BOLTS 021077Y FROM THE UPPER CRANKCASE BEFORE STARTING THE CRANKCASE CLOSING PROCEDURES. • Ensure the integrity of the crankcases and that the coupling surfaces are free of damage. • Apply a coat of THREEBOND 1027B to the lower crankcase (1) at the points indicated in the figure, taking care not to block the oil passages.
Page 478 Engine Engine 457 E5 • Tighten the M10 screws to the specified torque, following the sequence shown in the figure and acting gradually and progressively. Tightening torque for M10 crankcase screws: DESCRIPTION TORQUE 1. pre-tightening M10 15 Nm (11.06 lbf ft) screws crankcase 2.
Page 479 Engine Engine 457 E5 • Lubricate the threads and bearing surfaces of the M8 crankcase screws with engine oil. • Tighten the M8 screws to the specified torque, following the sequence shown in the figure and acting gradually and progressively Tightening torque crankcase...
Page 480 Engine Engine 457 E5 • Insert the timing pin (7) on the countershaft. • Place the toothed wheel (8) on the countershaft, making sure to intercept the timing pin (7) and align the punching on the wheel with that on the crankshaft toothed wheel (9).
Page 481 Engine Engine 457 E5 3.16 CHECKING CRANKCASE AND COMPONENTS OF THE GEAR CHECKING CRANKCASE • Check that the mating surfaces are intact, free of dents and/or scoring. Remove any liquid sealant from all mating surfaces. • Check various threads crankcases for damage and stripping. •...
Page 482 Engine Engine 457 E5 • Using a generic indoor bearing puller, remove the bearing (4) from the upper crankcase. • Using a generic indoor bearing puller, remove the bearing (5) from the upper crankcase. • Using a generic indoor bearing puller, remove the bearing (6) from the upper crankcase.
Page 483 Engine Engine 457 E5 • Heat the bearing seat (5) with a workshop hair dryer, insert the bearing and press it into place using the punch 020483Y and the adapter handle 020376Y. • Heat the bearing seat (6) with a workshop hair dryer, insert the bearing and press it into place using the punch 020439Y and the adapter handle 020376Y.
Page 484 Engine Engine 457 E5 CHECKING GEAR SHAFTS • Check transmission gears for any signs of pitting or wear, and replace the defective gears if necessary. • Check the gears' engagement teeth for any signs of cracks, damage or wear, and replace the defective ones if necessary.
Page 485 Engine Engine 457 E5 CHECK FORKS • Check that the forks work area are well levelled and are not worn, so as to have lost the toughening characteristics and that the nose-pieces operating in the drum splines are not excessively worn. Otherwise, replace the affected forks.
Page 486 Engine Engine 457 E5 • Remove the thermostatic valve (3) from the cylinder head. FITTING • Position the thermostatic valve (3) in its seat on the cylinder head. • Place the cover (2) on the cylinder head. • Tighten the fixing screws (1) to the torque. WATER PUMP...
Page 487 COLOUR KEY DIAGRAM COLOURS - KEY Ar Orange POWER SUPPLY Az Sky blue GROUND B Blue ENABLING/ SIGNAL Bi White ENABLING/ SIGNAL G Yellow Gr Grey M Brown N Black R Red GEN11 CONTROL UNIT PINOUT Ro Pink V Green MULTIPLE CONNECTORS VEHICLE CONNECTOR Vi Purple...

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