BODY PANELS ............................................................................................................................................... 4

5.1.1.

REMOVING THE BODY PANELS ......................................................................................................... 4

5.1.2.

BODY PANEL REASSEMBLY ............................................................................................................. 13

5.1.3.

TIGHTENING TORQUES .................................................................................................................... 21

5.2.

FRONT FORK ............................................................................................................................................... 22

5.2.1.

DIAGRAM (RSV R) .............................................................................................................................. 22

5.2.2.

REMOVING THE FORK LEGS ............................................................................................................ 24

5.2.3.

FITTING THE FORK LEGS.................................................................................................................. 28

5.2.4.

CHANGING THE FORK FLUID (RSV R) ............................................................................................. 31

5.2.5.

TOPPING UP THE FORK FLUID (RSV R) .......................................................................................... 34

5.2.6.

REPLACING THE OIL/DUST SEAL (RSV R) ...................................................................................... 37

5.2.7.

REFITTING THE OIL/DUST SEAL (RSV R) ........................................................................................ 44

5.2.8.

CHECKING THE COMPONENTS ....................................................................................................... 51

5.2.9.

FRONT FORK DIAGRAM .................................................................................................................... 55

5.2.10.

CHANGING THE FORK FLUID (RSV FACT) ...................................................................................... 56

5.2.11.

TOPPING UP THE FORK FLUID (RSV FACT).................................................................................... 58

5.2.12.

REPLACING THE OIL/DUST SEAL (RSV FACT)................................................................................ 60

5.2.13.

TIGHTENING TORQUES .................................................................................................................... 63

5.3.

STEERING BEARING ................................................................................................................................... 64

5.3.1.

DIAGRAM ............................................................................................................................................ 64

5.3.2.

CHECKING THE BEARING SLACK STEERING ................................................................................. 66

5.3.3.

STEERING BEARING ADJUSTMENT................................................................................................. 67

5.3.4.

TIGHTENING TORQUES .................................................................................................................... 71

5.4.

REAR SUSPENSION .................................................................................................................................... 72

5.4.1.

DIAGRAM ............................................................................................................................................ 72

5.4.2.

REMOVING THE REAR SUSPENSION .............................................................................................. 73

5.4.3.

CHECKING THE COMPONENTS ....................................................................................................... 77

5.4.4.

REFITTING THE REAR SUSPENSION............................................................................................... 79

5.4.5.

DISASSEMBLING THE REAR SUSPENSION LINKAGE .................................................................... 82

5.4.6.

TIGHTENING TORQUES .................................................................................................................... 83

5.5.

SWINGING ARM ........................................................................................................................................... 84

5.5.1.

REMOVING THE SWINGING ARM ..................................................................................................... 84

5.5.2.

CHECKING THE COMPONENTS ....................................................................................................... 87

5.5.3.

DISASSEMBLING THE REAR FORK GASKETS ................................................................................ 88

5.5.4.

REFITTING THE SWINGING ARM...................................................................................................... 89

5.5.5.

TIGHTENING TORQUES .................................................................................................................... 92

5.6.

FRONT WHEEL............................................................................................................................................. 93

5.6.1.

DIAGRAM ............................................................................................................................................ 93

5.6.2.

REMOVING THE WHEEL.................................................................................................................... 94

5.6.3.

CHECKING THE FRONT WHEEL COMPONENTS............................................................................ 97

5.6.4.

DISASSEMBLING THE FRONT WHEEL BEARINGS ......................................................................... 99

5.6.5.

ASSEMBLING THE FRONT WHEEL BEARINGS ............................................................................. 100

5.6.6.

REFITTING THE FRONT WHEEL ..................................................................................................... 102

5.7.

REAR WHEEL ............................................................................................................................................. 104

5.7.1.

DIAGRAM .......................................................................................................................................... 104

5.7.2.

REMOVING THE REAR WHEEL ....................................................................................................... 105

5.7.3.

REMOVING THE FINAL DRIVE UNIT ............................................................................................... 107

5.7.4.

CHECKING THE REAR WHEEL COMPONENTS............................................................................. 109

5.7.5.

DISASSEMBLING THE REAR WHEEL BEARINGS.......................................................................... 113

5.7.6.

ASSEMBLING THE REAR WHEEL BEARINGS................................................................................ 114

5.7.7.

DISASSEMBLING THE FINAL DRIVE UNIT BEARINGS .................................................................. 116

5.7.8.

ASSEMBLING THE FINAL DRIVE UNIT BEARINGS ........................................................................ 117

5.7.9.

REMOVING THE FLEXIBLE COUPLINGS........................................................................................ 118

5.7.10.

REMOVING THE CROWN GEAR ..................................................................................................... 119

5.7.11.

REFITTING THE REAR WHEEL ....................................................................................................... 120

5.7.12.

TIGHTENING TORQUES .................................................................................................................. 122

5.8.

FRONT BRAKE ........................................................................................................................................... 123

5.8.1.

CHANGING THE FRONT BRAKE PADS (RSV R) ........................................................................... 123

5.8.2.

CHANGING THE FRONT BRAKE PADS (RSV FACT)..................................................................... 124

5.8.3.

CHECKING THE FRONT BRAKE DISCS.......................................................................................... 126

5.8.4.

REMOVING THE FRONT BRAKE DISCS ......................................................................................... 127

5.8.5.

BLEEDING THE BRAKE CIRCUIT .................................................................................................... 128

5.9.

REAR BRAKE.............................................................................................................................................. 129

5.9.1.

CHANGING THE REAR BRAKE PADS ............................................................................................. 129

5.9.2.

CHECKING THE REAR BRAKE DISC............................................................................................... 130

5.9.3.

REMOVING THE REAR BRAKE DISC .............................................................................................. 131

5 - 2

RSV 1000 R - RSV 1000 R FACTORY

SUMMARY

Table of Contents