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APRILIA RSV4 R Service Station Manual

APRILIA RSV4 R Service Station Manual

895777

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RSV4 R

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Page 1 SERVICE STATION MANUAL 895777 RSV4 R...
Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
RSV4 R Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 RSV4 R Characteristics KEEP OUT OF THE REACH OF CHILDREN DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-...
Page 11: Vehicle Identification
RSV4 R Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Page 12: Cylinder
RSV4 R Characteristics Specification Desc./Quantity Kerb weight 194 kg (428 lb) Kerb weight 205 kg (452 lb) Full loaded weight (rider only) 280 kg (617 lb) Engine ENGINE Specification Desc./Quantity Model Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double overhead camshafts.
Page 13 RSV4 R Characteristics Specification Desc./Quantity Seats 1 + 1 Two seat configuration: if vehicle is fitted with footrests and saddle for passenger Maximum weight capacity 201 kg (443 lb) Drive chain RIVE CHAIN Specification Desc./Quantity Type With sealed master link...
Page 14: Wheels And Tyres
RSV4 R Characteristics USPENSION Specification Desc./Quantity Front fork Showa upside-down stanchions with adjustable hydraulic damping and 43 mm (1.69 in) diam. stanchions Front wheel travel 120 mm (4.72 in) Rear shock absorber Sachs piggyback shock absorber with progressive APS system...
Page 15 RSV4 R Characteristics Specification Desc./Quantity 190/50 ZR17 (73W) Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI) 2 passengers: 2.8 bar (280 kPa) (40.61 PSI) Supply UEL SYSTEM Specification Desc./Quantity Fuel Premium unleaded petrol, minimum octane rating of 95...
Page 16 RSV4 R Characteristics RONT FORK pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 22 Nm (16.23 lbf ft) screws Pumping member fixing screw 30 - 39 Nm (22.13 - 28.76 lbf ft) Sleeve top cap 30 - 39 Nm (22.13 - 28.76 lbf ft)
Page 17 RSV4 R Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lbf ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lbf ft) chions Headstock lock ring M35x1 40 Nm (29.50 lbf ft)
Page 18 RSV4 R Characteristics RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft)
Page 19 RSV4 R Characteristics pos. Description Type Quantity Torque Notes Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft) to the lower yoke Front brake pump U bolt clamp 10 Nm (7.37 lbf ft)
Page 20 RSV4 R Characteristics EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) CHAR - 20...
Page 21 RSV4 R Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 22 RSV4 R Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft)
Page 23 RSV4 R Characteristics OOLING pos. Description Type Quantity Torque Notes Screws fastening water radiator 10 Nm (7.37 lbf ft) mounting bracket to chassis Screws fastening water radiator to 7 Nm (5.16 lbf ft) mounting bracket Screw fastening pipe grommet for 6 Nm (4.42 lbf ft)
Page 24 RSV4 R Characteristics Central part IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft)
Page 25 RSV4 R Characteristics ADDLE pos. Description Type Quantity Torque Notes Rider saddle fixing screw 6 Nm (4.42 lbf ft) UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft)
Page 26 RSV4 R Characteristics OOTPEGS pos. Description Type Quantity Torques Notes Screws fastening rider footpegs to 2 + 2 25 Nm (18.44 lbf ft) chassis Screws fastening passenger foot- 2 + 2 18 Nm (13.28 lbf ft) For countries in pegs to chassis...
Page 27 RSV4 R Characteristics RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 28 RSV4 R Characteristics EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft)
Page 29 RSV4 R Characteristics LOCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lbf ft) Lock lever self-tapping screw 2 Nm (1.47 lbf ft) RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque...
Page 30 RSV4 R Characteristics ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate CHAR - 30...
Page 31 RSV4 R Characteristics ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft) AIRING pos.
Page 32 RSV4 R Characteristics Back side XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft)
Page 33 RSV4 R Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount CHAR - 33...
Page 34 RSV4 R Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) EAR BRAKE CALLIPER pos.
Page 35 RSV4 R Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 36 RSV4 R Characteristics EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual linkage fixing screw 50 Nm (36.88 lbf ft) Screw fastening single linkage to 50 Nm (36.88 lbf ft)
Page 37 RSV4 R Characteristics AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9...
Page 38 RSV4 R Characteristics TAIL pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft)
Page 39 RSV4 R Characteristics ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft)
Page 40 RSV4 R Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) TE flanged screws M6x35 12 Nm (8.85 lbf ft) TE flanged screws M6x22 12 Nm (8.85 lbf ft)
Page 41 RSV4 R Characteristics ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) CHAR - 41...
Page 42 RSV4 R Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft)
Page 43: Timing System
RSV4 R Characteristics TIMING SYSTEM pos. Description Type Quantity Torque Notes Screws fastening the timing system 30 Nm (22.13 lbf ft) Loct. 243 gear on the intake shaft Skid fastener screws 20 Nm (14.75 lbf ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.37 lbf ft)
Page 44 RSV4 R Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 45 RSV4 R Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 46 RSV4 R Characteristics EARBOX pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw 10 Nm (7.37 lbf ft)
Page 47 RSV4 R Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch nut 150 Nm (110.63 lbf ft) Loct. 243 IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct.
Page 48 RSV4 R Characteristics LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft) side Blow-by union fastener screws M5x16 7 Nm (5.16 lbf ft) Stator fixing screw UNI 5931 CL8.8...
Page 49 RSV4 R Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft)
Page 50 RSV4 R Characteristics ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Recommended products chart ECOMMENDED PRODUCTS Product Description Specifications AGIP TEC 4T, SAE 15W-50 Engine oil Use branded oils with performances equal to or exceeding CCMC G-4 A.P.I.
Page 51 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 52 RSV4 R Special tools TTREZZI SPECIALI Stores code Description 020845Y Engine support 020846Y Retaining tray + plastic caps 020847Y Flywheel extractor 020848Y Flywheel retainer 020849Y Clutch retainer 020850Y Primary gear lock S-TOOLS - 52...
Page 53 RSV4 R Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring 020857Y Crankshaft bearing U bolt...
Page 54 RSV4 R Special tools Stores code Description 020858Y Device for holding the pistons in the cyl- inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020861Y Countershaft bushing punch 020862Y Gearbox control rod roller cage fitting...
Page 55 RSV4 R Special tools Stores code Description 020863Y Desmodromic drum roller cage fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020709Y Engine support AP8140187 Engine support stand 020376Y Adapter handle 020363Y 20-mm Oil seal guide...
Page 56 RSV4 R Special tools Stores code Description 020364Y 25-mm Guide 020359Y 42 x 47 mm punch 020360Y 52x55 mm Adaptor 020655Y 62x68 mm Adaptor 020408Y 72x75-mm (2.83x2.95 in) adaptor 020306Y Punch for fitting the valve seal rings S-TOOLS - 56...
Page 57 RSV4 R Special tools Stores code Description 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor 0277308 Guide bushing for secondary gearbox shaft AP8140146 Weight AP8140145 fitting tool for Ø 41 mm sealing rings S-TOOLS - 57...
Page 58 RSV4 R Special tools Stores code Description AP8140147 Spacer tool AP8140148 Spacer-pumping element separating plate AP8140149 Protection for fitting operations AP8140150 Perforated rod for pumping member air bleed AP8140151 Complete tool kit for fork AP8140190 Tool for steering tightening AP8140181...
Page 59 RSV4 R Special tools Stores code Description 020481Y Control unit interface wiring 020680Y TXB Navigator S-TOOLS - 59...
Page 60 INDEX OF TOPICS MAIN AINTENANCE...
Page 61: Maintenance Chart
Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it.
Page 62: Spark Plug
RSV4 R Maintenance Km x 1000 Brake systems (6) Light circuit Stand switch Safety switches Stop switches Brake fluid (4) Coolant (4) Fork oil (7) Engine oil (6) Light aiming Fork oil seals (6) Flexible coupling Tyres - pressure/wear (2)
Page 63: Engine Oil
RSV4 R Maintenance • Remove the fuel tank. • Unscrew and remove the rear coil fixing screw. • Slide off the rear coil. • Unscrew and slide off the rear spark plug. Engine oil Check NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Page 64 RSV4 R Maintenance • Place a container with a larger capacity than the circuit under the drainage plug. • Unscrew and remove the drainage plug. • Unscrew and remove the filler cap. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.
Page 65: Engine Oil Filter
RSV4 R Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.
Page 66: Checking The Valve Clearance
RSV4 R Maintenance • Disconnect the variable geometry in- take system connector. (If connected) • Fit a suitably sized shim behind the fil- ter box cover. • Lift the filter box cover on which the control unit is installed. •...
Page 67 RSV4 R Maintenance • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 68 RSV4 R Maintenance • Use a feeler gauge to check the clear- ance between the cam on the shaft and the relative tappet for both rear head shafts. Characteristic Acceptable values with control clearance be- tween cam and valve intake: 0.10 - 0.15 mm (0.0039 - 0.0059 in) ex- haust: 0.20 - 0.25 mm (0.0079 - 0.0098 in)
Page 69 RSV4 R Maintenance • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 70: Cylinder Bank
RSV4 R Maintenance Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft 150° in the direction of engine rotation (direction of travel) in...
Page 71 RSV4 R Maintenance • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 72 RSV4 R Maintenance Calibrated pad thickness NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 73 RSV4 R Maintenance • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 74 RSV4 R Maintenance • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 75 RSV4 R Maintenance • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel). • Insert the pin from the clutch side into the hole in the crankshaft. NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION.
Page 76 RSV4 R Maintenance Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en- gine rotation (direction of travel) to align the hole on the intake camshaft with the specific hole on the U bolt.
Page 77 RSV4 R Maintenance • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 78 RSV4 R Maintenance Calibrated pad thickness NOTE Engines up to engine No. V4 2470 are equipped with conventional exhaust camshaft gears, while engines from engine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 79 RSV4 R Maintenance • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 80 RSV4 R Maintenance • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 81 RSV4 R Maintenance Calibrated pad thickness Pad thicknesses for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.80 mm (0.0709 in) 1.85 mm (0.0728 in) 1.90 mm (0.0748 in) 1.95 mm (0.0768 in) 2 mm (0.0787 in) 2.05 mm (0.0807 in) 2.1 mm (0.0827 in)
Page 82 RSV4 R Maintenance 2.75 mm (0.1083 in) 2.8 mm (0.1102 in) 2.85 mm (0.1122 in) 2.9 mm (0.1142 in) 2.95 mm (0.1161 in) 3 mm (0.1181 in) 3.05 mm (0.1201 in) 3.10 mm (0.1220 in) 3.15 mm (0.1240 in) MAIN - 82...
Page 83 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 84 SHOWN or ONE OF THE TWO SITUATIONS TAKES PLACE AND IS SUDDENLY OUT or THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE DIAGNOSIS INSTRUMENT THROUGH CONTROL UNIT BY SE- LECTING "SELF-ACQUISITION, APRILIA, RSV4" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 85 RSV4 R Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 86 RSV4 R Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION AXONE SHOULD BE WORKING PROPERLY AND UPGRADED AT LEAST TO THE 7.0.0 VERSION OR THE PGDS UPDATED AT LEAST TO THE 3.0.0 VERSION...
Page 87 RSV4 R Troubleshooting • 8. WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS ON THE DIAGNOSIS INSTRUMENT, DEVICES STATUS SCREEN PAGE, ICON 0/1 MEAN? If "RUN" is shown, go to 9; if "STOP" is shown, go to 15 •...
Page 88 RSV4 R Troubleshooting PIN 42, "URGENT SERVICE" TURNS ON IN THE INSTRUMENT PANEL AND THE CON- TROL UNIT INDICATES ERRORS RELATED TO THE FRONT AND REAR THROTTLE BODY) YES, go to 3; NO, go to 6 • 3. CHECK CONTINUITY WITH GROUND CONNECTION AT PIN 5 and 16 If there is continuity, go to 4;...
Page 89 RSV4 R Troubleshooting • 1. CHECK CONTINUITY OF WHITE/BLUE CABLE FROM PIN 14 OF THE CONTROL UNIT ON CABLE HARNESS SIDE TO PIN 3 OF THE BLACK CONNECTOR OF THE DIAGNO- YES, go to 2; NO, go to 4 •...
Page 90 RSV4 R Troubleshooting • 7. CHECK CONTINUITY OF THE CABLE FROM THE INJECTION RELAY 33 TO THE PROTECTION RELAY 19: ORANGE (BETWEEN RELAY 33 AND FUSE F) and RED/ BROWN (BETWEEN FUSE RELAY F AND RELAY 19) If there is continuity, go to PROTECTION RELAY 19 CHECK; if there is not continuity, restore...
Page 91 RSV4 R Troubleshooting • 2. WITH CONNECTOR DISCONNECTED (4-ways black, inside the bow) CHECK IF THERE IS GROUND CONNECTION ON PIN 3, ON THE CABLE HARNESS SIDE YES, go to 3; NO, go to 6 • 3. CHECK WITH CONNECTOR DISCONNECTED (4-ways black, inside the bow) ON THE...
Page 92 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 93 RSV4 R Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft) Screw fastening the voltage regula- 6 Nm (4.42 lbf ft)
Page 94 RSV4 R Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate...
Page 95 RSV4 R Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Starter motor 11.Lower injectors 12.Air pressure sensor...
Page 96 RSV4 R Electrical system Component position Component name Location on the vehicle in the electrical circuit diagram Recovery logic relay (urgent service) In the niche of the headstock, on the right Electrical system installation INTRODUCTION Scope and applicability The purpose of this document is to define the position of the engine cable harness, its rounting and how it is fixed on the engine and the filter box, any potential problems and particular checks to be carried out on the connections and routings in order to reach the objectives of vehicle reliability.
Page 97 RSV4 R Electrical system • 1 Regulator • 1 Hand grip position sensor • 1 Variable geometry control unit • 1 Engine cable harness • 1 Engine revolution sensor • 1 Control unit 7SM • 1 Air temperature sensor •...
Page 98 RSV4 R Electrical system • 5 Relay socket rubber rings • 2 Rubber rings • 3 Rubber rings • 2 Rubber rings • 1 Rubber ring for the protection relay • 1 Rubber ring for the fall sensor • 1 AMP Superseal connector mounting •...
Page 99 RSV4 R Electrical system • 4 Clic clamps Motorcycle division The wiring distribution is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section Special checks for the correct connection and laying of cables It is extremely important that any security-locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Page 100 RSV4 R Electrical system • Key switch connector • Immobilizer aerial connector • Oxygen sensor connector • Output "30" engine revolution sensor connector • Outputs "25" and"26" 7SM control unit connectors • Outputs "29", "8", "7" and "28" coil connectors •...
Page 101 RSV4 R Electrical system 11. TBEI M6x30 screw (x2) 12. Washer (x2) TABLE C1 - HEADLAMP PRE-FITTING The headlamp cable harness (23) and the two relays with a relay socket rubber ring (17) must be fit on the headlamp (13) as shown in the photos below.
Page 102 RSV4 R Electrical system TABLE C2 - HEADLAMP PRE-FITTING 16. Cable grommet 17. Relay with relay socket rubber ring 25. Cable harness routing behind the relay TABLE D - HANDLEBAR CONTROLS 26. Left handlebar control 27. Clutch connector 28. Right handlebar control...
Page 103 RSV4 R Electrical system TABLE F - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Pass all the cable harnesses arriving from the right semi-handlebar (right handlebar control + front stop switch) and from the left semi-handlebar (left handlebar control + key switch) inside of the right arch brace, as shown in the figure;...
Page 104 RSV4 R Electrical system 42. Front stop switch connector 43. Right handlebar control connector TABLE I - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Make the connections for all connectors. The key switch connector has a longer cable harness in comparison to the 6 pin connectors for the left light switch.
Page 105 RSV4 R Electrical system TABLE L - INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Right side Check that the cable grommets are not ten- sioned on the right and left cable grommet during steering rotation. 53. Cable harness routing to right handlebar con- trol 54.
Page 106 RSV4 R Electrical system TABLE N - COMPLETION OF THE FRONT 65. Headlamp connectors 66. Headlamp connector positioning (as shown in the figure) TABLE O - COMPLETION OF THE FRONT Check that the turn indicator connectors are inserted correctly and do not return inside the instrument holder arch brace.
Page 107 RSV4 R Electrical system Central part TABLE A - RADIATOR AREA Right side 1. Cable grommet 2. Vehicle cable harness TABLE B - RADIATOR AREA Right side 3. Starter motor 4. Clamp 5. Exhaust valve actuator cable harness routing 6. Oil pressure sensor and cable harness routing...
Page 108 RSV4 R Electrical system TABLE C - RADIATOR AREA The ground cable harness routing is behind the water pipe and behind the starter motor, as indi- cated by the arrow. 3. Starter motor 4. Clamp 5. Exhaust valve actuator cable harness routing 6.
Page 109 RSV4 R Electrical system TABLE F - DEMAND SENSOR FITTING 18. Slave Demand cable harness routing (creating a "U-bend" in the cable harness) 19. Master Demand cable harness routing (creat- ing a "U-bend" in the cable harness) TABLE G - DEMAND SENSOR FITTING Clamp where indicated.
Page 110 RSV4 R Electrical system 27. Flywheel connector 28. Regulator connector 29. Regulator connector on the vehicle cable harness TABLE I Right side 30. Instrument panel branch vehicle cable harness 31. Fan connector 32. Clamp TABLE J1 - EXHAUST VALVE ACTUATOR Positioning and calibration 33.
Page 111 RSV4 R Electrical system 41. T-shaped bushing 42. TE M6x30 screw TABLE J2 - EXHAUST VALVE ACTUATOR Positioning and calibration Actuator - valve Bowden cable (45) fitting procedure • Insert the cables with the set screws closed in the following sequence: 1.
Page 112 RSV4 R Electrical system TABLE K1 - PINION CASING AREA 46. Gear sensor cable harness routing 47. Oxygen sensor connector on the vehicle cable harness 48. Gear sensor 49. Oxygen sensor connector 50. Stand switch cable harness routing 51. Oxygen sensor cable harness routing 52.
Page 113 RSV4 R Electrical system TABLE M 62. Gear sensor cable harness routing 63. Oxygen sensor cable harness routing 64. Stand switch cable harness routing TABLE N 65. Stand switch connector TABLE O 66. Position the gear sensor and stand switch con-...
Page 114 RSV4 R Electrical system TABLE P2 - ENGINE - BATTERY GROUND CABLE ROUTING Clamp the engine- battery ground cable harness to the Demand sensor cable harness as far up as possible. 74. Clamp 75. Battery - engine ground lead 76. Engine - battery ground cable harness routing The engine - battery ground cable harness must not be visible within the area indicated with a red triangle.
Page 115: Table Of Contents
RSV4 R Electrical system CENTRAL Q1 - NOTES FOR ENGINE CABLE HARNESS FITTING Definition of component numbering: Upper view 77. Cylinder 1 78. Cylinder 2 79. Cylinder 3 80. Cylinder 4 81. Cylinder bank 1 82. Cylinder bank 2 83. Throttle body 1 (FARF 1) 84.
Page 116 RSV4 R Electrical system TABLE S1 - FILTER BOX COVER AND LOWER FILTER BOX PREPARATION Fit four mountings for the "coil" connectors and the mounting for the "vehicle" connector as shown in figures S1, S2 and S3. Lower filter box 90.
Page 117 RSV4 R Electrical system TABLE U - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING Before fitting the motorised throttle bodies (98 and 99), the respective engine cable harness connec- tors must be connected: on branch "2" of the cable...
Page 118 RSV4 R Electrical system TABLE Y - MOTORISED THROTTLE BODY FIT- TING First fasten the "Motorised Throttle Body 2 (front)" to the rubber manifolds with the specific clip-on clamps. Then fasten the "motorised throttle body 1 (rear)" to the rubber manifolds with the clip-on clamps us- ing the specific tool.
Page 119 RSV4 R Electrical system TABLE ZB - H2O TEMPERATURE SENSOR 114. Cable harness routing (branch "4") under the 3-way fitting 115. Engine speed sensor cable routing between the front motorised throttle body and the 3-way fit- ting 116. Rubber clamp TABLE ZC At this point, the injectors 2 (output "5") and 4 (out-...
Page 120 RSV4 R Electrical system 124. Lower injector 3 cable harness connector (output "17") - green connector 125. Coil 3 - long cable harness 126. Coil 1 - short cable harness TABLE ZE - COIL AND MAP SENSOR CON- NECTION Once the filter box is assembled, the coil and map sensor connections must be made.
Page 121 RSV4 R Electrical system TABLE ZH Once the Engine Speed Sensor (output "30") con- nector (142) has been connected to its counter- part, it must be clamped, using the indicated clamp (143), to the Blow-by pipe in the position shown in the figure.
Page 122 RSV4 R Electrical system 154. Air temperature sensor 155. Upper injector 1 cable harness connector (output "23") - black connector 156. Self-tapping screw Connect the upper injectors as shown in the figure and according to the following sequence: Injector 1 (output "23"): BLACK connector Injector 2 (output "20"): BROWN connector...
Page 123 RSV4 R Electrical system TABLE ZM 159. Clamp 160. Self-tapping 5x20 screw TABLE ZN The connectors (161) "ECU 1" (output "26") and (162) "ECU 2" (output "25") must be connected to their respective connectors on the 7SM control unit, being very careful when inserting them. The...
Page 124 RSV4 R Electrical system TABLE ZO It is advisable to create a jig in order to check the correct insertion of both connectors. TABLE ZP - VEHICLE CONNECTOR FASTEN- The "VEHICLE" (output "1") connector (165) must be fastened to the mounting with the white slide pre-fit on the connector itself, in the position indi- cated in the figure.
Page 125 RSV4 R Electrical system TABLE ZS - NOTES FOR FITTING THE GROUND CABLE There are two ground lug terminals on the cable harness: the "ENGINE GND" (output "9") and the "CHASSIS GND" (output "10"). The lug terminal "ENGINE GND" (172) (output "9")
Page 126 RSV4 R Electrical system 7. Breather pipe TABLE B - SPEED SENSOR PRE-FITTING 8. Speed sensor 9. TE M6x20 screw 10. Sensor cable harness routing in the cable grommet TABLE C - START-UP RELAY PRE-FITTING 11. Starter motor cable on the vehicle cable harness 12.
Page 127 RSV4 R Electrical system TABLES D1 and D2 - VEHICLE CABLE HAR- NESSES The Vehicle Cable Harness (16) and the "Relay and Fall Sensor" mounting (18) must be fit on the chassis before fitting the engine. Check that the fan relay (20), safety relay (23) and fall sensor (19) are connected correctly (fit on the relative mounting).
Page 128 RSV4 R Electrical system TABLE E2 - REAR STOP SWITCH AND SPEED SENSOR CABLE HARNESS ROUTING ON THE RIGHT SIDE 28. Cable grommet 29. Speed sensor cable harness 30. Rear brake switch cable harness TABLE F1 - REAR SADDLE MOUNTING AREA 31.
Page 129 RSV4 R Electrical system TABLE F3 43. ECU diagnosis connector 44. Instrument panel diagnosis connector 45. Insert the instrument panel diagnosis and the ECU diagnosis connectors in their specific seats 46. License plate frame and taillight cable harness routing 47. Taillight connector 48.
Page 130 RSV4 R Electrical system Outer 58. Fuel pump connector 59. Insert the tape clamp on the cable harness in the hole on the right side of the saddle mounting 60. variable length intake duct control unit connector 61. Clamp Inner 62.
Page 131 RSV4 R Electrical system TABLE H1 67. Intake duct control unit 68. Intake duct control unit connector 69. Rubber ring TABLE H2 70. Clamp 71. Intake duct control unit cable harness routing ELE SYS - 131...
Page 132 RSV4 R Electrical system General wiring diagram KEY: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. HEAD LIGHT ASSEMBLY 4. FRONT LEFT TURN INDICATOR ELE SYS - 132...
Page 133 RSV4 R Electrical system 5. RIGHT LOW-BEAM LIGHT BULB 6. HIGH-BEAM BULB 7. TAIL LIGHT BULB 8. LEFT LOW-BEAM LIGHT BULB 9. HIGH-BEAM LIGHT RELAY 10.LOW-BEAM LIGHT RELAY 11.LEFT LIGHT SWITCH 12.INSTRUMENT PANEL DIAGNOSIS 13.MATRIX II INSTRUMENT PANEL 14.OUTLET VALVE MOTOR 15.FRONT STOP SWITCH...
Page 134 RSV4 R Electrical system 43.SPEED SENSOR 44.SIDE STAND SWITCH 45.GEAR SENSOR 46.FRONT CYLINDERS PRESSURE SENSOR 47.REAR CYLINDERS PRESSURE SENSOR 48.FRONT CYLINDERS THROTTLE VALVES 49.REAR CYLINDER THROTTLE VALVES 50.AIR TEMPERATURE SENSOR 51.WATER TEMPERATURE SENSOR 52.TOP INJECTORS 53.75M CONTROL UNIT 54.EFG 1X THROTTLE CONTROL UNIT 55.REVOLUTION SENSOR...
Page 135 RSV4 R Electrical system the connector (i.e., all terminals aligned at the same depth) and terminal integrity (i.e., that termi- nals are not loose, open/bent, etc.). For connec- tors whose terminals are not visible (e.g. Marelli control unit) use a metal cable of suitable diameter...
Page 136: System Components
RSV4 R Electrical system Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level in wiring diagram: Immobilizer Location: • on the vehicle: in the key lock • connector: two-way, black, inside the Electrical specifications •...
Page 137 RSV4 R Electrical system • Immobilizer fault: aerial not working (open or short-circuited) Error cause • An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting • Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore;...
Page 138 RSV4 R Electrical system NOTE DELETE THE ERROR CAUSED BY THE LACK OF MEMORY OF KEY CODES. 3. Connect to the vehicle with the diagnosis tool and select the adjustable Parameters in the screen page: "Exhaust butterfly valve self-acquisition" NOTE SEARCH FOR MINIMUM AND MAXIMUM MECHANICAL STOPS STORED IN THE INSTRUMENT PANEL.
Page 139 RSV4 R Electrical system In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it. DSB 01 - Immobilizer fault: key code read but not recognised. DSB 02 - Immobilizer fault: key code not read (key not present or transponder not working)
Page 140 RSV4 R Electrical system Modify Keys With this function the instrument panel can update the keys. Up to 4 keys can be stored. The user code is first requested to be entered: • ENTER THE CODE After entering the correct code, the following message should be shown on the display: •...
Page 141 RSV4 R Electrical system Start-up system check Function Communicates to the control unit the will to start- up the engine. Operation / operating principle Press the start-up button to close the specific cir- cuit taking the PIN 58 of the control unit to a voltage equal to zero (ground closing).
Page 142 RSV4 R Electrical system • Check the locking cause and restore. level indicators See also Fuel pump Fuses SECONDARY FUSES DISTRIBUTION Specification Desc./Quantity A) 5A fuse Stop and running lights relay B) 5A fuse Instrument panel, turn indicators, speed and instrument panel diagnostics.
Page 143: Control Unit
RSV4 R Electrical system Control unit Removal • Remove the fuel tank. • Disconnect both control unit connec- tors • Unscrew and remove the three screws. • Remove the control unit. NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 144 RSV4 R Electrical system (screen/example value with key set to ON) • Drawing number / - • Marelli spare part code / IAW7SMHW430 • Hardware number / 00 • Mapping / - • Software version number / 0000 • Type-approval Code / - •...
Page 145 RSV4 R Electrical system • Indefinite_Start-up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal • yes/no • Indicates whether the control unit has received the consent by the instrument panel regard- ing the immobilizer: coded key or user code entered manually. Potential errors will be shown...
Page 146 RSV4 R Electrical system • circuit not operational Error cause • Replace injection ECU. The instrument panel does not indicate the presence of this error even in the ATT status RAM Error P0604 • circuit not operational Error cause •...
Page 147 RSV4 R Electrical system Level 2 safety reset P0608 Error cause • As the level 2 safety system (comparison between requested torque and calculated torque) has detected a fault, the control unit has reset engine (C gravity). The instrument panel does not indicate the presence of this error even in the ATT status.
Page 148 RSV4 R Electrical system garding the control unit serial number and the serial number of the Axone or Navigator that has carried out the download is also included in the file Saved data file deletion Error cause • Deletion enabled only if the file is downloaded after setting KEY ON...
Page 149 RSV4 R Electrical system Battery voltage • Example value with key ON: 12.0 V • Example value with engine on: 14.2 V In case of recovery, this value is set by the control unit Battery voltage pre Recovery • Example value with key ON: 12.0 V •...
Page 150: Speed Sensor
RSV4 R Electrical system Speed sensor Function to indicate the vehicle speed by reading the rear wheel turning speed Operation / operating principle Hall-effect sensor: a square-wave pulse is gener- ated with voltage between 10 V and 0 V with metal...
Page 151 RSV4 R Electrical system Variable geometry intake (IF AVAILABLE) Function Extend or shorten the engine inlet ducts to in- crease the inlet air quantity according to the engine revs. Operation / operating principle The system consists of: • two inlet ducts for each manifold, which may be joined (long ducts) or separa- ted (short ducts);...
Page 152 RSV4 R Electrical system • connector of the electrical motor cable to the engine cable harness: outside the filter box next to the rear upper in- jectors. Electrical characteristics: Electrical motor resistance. 4.5 +/- 0.5 Ω; PIN 1: 0V normal, Vbatt fault PIN 2: 0V ducts control down, 5V ducts control up.
Page 153 RSV4 R Electrical system to indicate error detection. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • If shorted to positive: if a voltage higher than 5V is detected, disconnect the variable geom- etry control unit connector and check with key ON the voltage to PIN 2: if it is higher than 5 V, restore cable harness;...
Page 154 RSV4 R Electrical system Engine rpm sensor Function informs crankshaft position and speed to the Mar- elli control unit Operation / operating principle inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the reference position...
Page 155 RSV4 R Electrical system Engine speed sensor P0336 • signal not valid Error cause • Probable bad contact in the electric circuit detected at PIN 20 - 35 of the ENGINE connector Troubleshooting • Check the electric circuit is in good conditions and the flywheel teeth cleaning and correct positioning of the sensor in its own housing: if it is not, replace it.
Page 156 RSV4 R Electrical system Function The throttle grip is the part to which the throttle control cables arrive; its task is to translate the rid- er's power request (Demand) into an electrical signal to be sent to the electronic control unit.
Page 157 RSV4 R Electrical system • C: Track C signal • D: Track D supply • E: Track D ground • F: Track D signal DIAGNOSIS INSTRUMENT: PARAMETERS Blue lower connector throttle grip position sensor - track A • Example value with key ON: 1107 mV •...
Page 158 RSV4 R Electrical system BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Blue lower connector throttle grip position sensor - track A P0150 •...
Page 159 RSV4 R Electrical system throttle grip sensor connector or the control unit connector): if the cable is not ground insu- lated, restore the wiring. If it is ground insulated, and with the switch key set to ON, check that there is power supply for the potentiometer PIN D and that PIN F is connected to ground.
Page 160 RSV4 R Electrical system cated by the diagnosis instrument: if the voltage does not vary, there is a short circuit in the cable wiring; replace the throttle grip sensor if the voltage drops to zero. • if the circuit is open, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector.
Page 161 RSV4 R Electrical system • incongruent signal Error cause • The value of the lower side sensor (tracks A-B) does not coincide with the value of the upper side sensor (tracks C-D) Troubleshooting • Replace the throttle grip sensor DIAGNOSIS INSTRUMENT: ADJUSTABLE PARAMETERS...
Page 162 RSV4 R Electrical system Electrical specifications: - Pin out: 1. Power supply 5V 2. Ground connection 3. Output signal DIAGNOSIS INSTRUMENT: PARAMETERS Front Cylinder Intake Pressure (2 and 4) • Example value with key ON: 1003 mbar • Example value with engine on: 720 mbar •...
Page 163 RSV4 R Electrical system • If shorted to positive: see that the parameter of the rear cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 164 RSV4 R Electrical system • signal not valid. Error cause • According to the engine operation data (rpm, throttle, etc.) an average value for the intake pressure is estimated: if the value read deviates by a given percentage, this error is activa- ted.
Page 165 RSV4 R Electrical system • A small difference between the estimated pressure and the measured pressure has been detected: the measured pressure is higher than the estimated one (for example, the pipe between sensor and throttle body is squashed or there is a hole in the intake manifold).
Page 166 RSV4 R Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean. Pressure too low at front cylinder manifold error P0218 •...
Page 167 RSV4 R Electrical system 2. B2 green/black: Ground connection DIAGNOSIS INSTRUMENT: PARAMETERS Engine temperature: • Example value with key ON: 25° C • Example value with engine on: 75° C • In case of recovery, this value is set by the control unit: if there is a malfunction after engine start-up, temperature decreases up to approximately 75°.
Page 168 RSV4 R Electrical system between the ENGINE connector PIN 6 or 17 and the sensor connector PIN 2: restore the cable harness if there is not continuity. If there is, it means that the control unit does not supply the ground connection and therefore should be replaced.
Page 169 RSV4 R Electrical system Air temperature sensor Function it tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion Operation / operating principle...
Page 170 RSV4 R Electrical system • open circuit, shorted to positive / shorted to negative Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 37 of the ENGINE connector. If shorted to negative: voltage equal to zero has been detected. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 171 RSV4 R Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 172 RSV4 R Electrical system • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time;...
Page 173 RSV4 R Electrical system covery value is displayed instead. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 174 RSV4 R Electrical system cable (PIN 3): if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable harness.
Page 175 RSV4 R Electrical system LOWER INJECTOR Function To supply the correct amount of petrol at the right timing. The lower injectors work in the field of low engine revs, the upper injectors in the field of high engine revs. Operation / operating principle...
Page 176 RSV4 R Electrical system onds and the injector cable connected to control unit is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications...
Page 177 RSV4 R Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the orange/red cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector.
Page 178 RSV4 R Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector.
Page 179 RSV4 R Electrical system Upper injectors key: • 5. Upper injector 1 • 6. Upper injector 3 • 7. Upper injector 2 • 8. Upper injector 4 UPPER INJECTOR Function To supply the correct amount of petrol at the right timing.
Page 180 RSV4 R Electrical system Cylinder injection time 2 • Example value with engine on: 1.9 ms Cylinder injection time 3 • Example value with engine on: 1.9 ms Cylinder injection time 4 • Example value with engine on: 1.9 ms...
Page 181 RSV4 R Electrical system activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Upper injector cylinder 1 P0205 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 182 RSV4 R Electrical system and the Marelli control unit connector: if not OK, restore. If OK, check cable continuity be- tween PIN 67 and component PIN - and restore the cable harness Upper injector cylinder 3 P0207 • short circuit to positive/ short circuit to negative / open circuit Error cause •...
Page 183 RSV4 R Electrical system Fuel pump Function Fuel pump: keeps pressure of the injectors supply duct. Low fuel: tells to the instrument panel about low fuel Operation / operating principle Low fuel: it is a resistance that if correctly supplied varies its electrical resistance if it is damped or not by petrol.
Page 184 RSV4 R Electrical system continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS fuel pump relay control P0230 • shorted to positive / open circuit, shorted to negative.
Page 185 RSV4 R Electrical system strap on engine cable harness); coil 4 with short cable: on the right of the front side of the filter box. Electrical characteristics: 0.7 - 0.9 Ω at ambient temperature Pin out: 1. Power supply + Vbatt 2.
Page 186 RSV4 R Electrical system The injection relay (No. 33 in the wiring diagram, placed under the right side of the saddle; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the brown/purple cable of the coil is closed to ground for 2 ms per second.
Page 187 RSV4 R Electrical system the ground insulation of the cable (from coil connector or control unit connector), if not OK, restore cable harness. Coil 3 P0353 • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector.
Page 188: Throttle Body
RSV4 R Electrical system Throttle body Function Sends to the injection control unit the throttle position and activates the throttle according to the control unit Operation / Operating principle All the unit internal components (potentiometer and electric motor) are contactless; therefore, no elec- trical diagnosis is possible for the throttle body, but for the circuits connected to it only.
Page 189 RSV4 R Electrical system is not engaged, at approx. 6000 rpm, throttles open very little because the requested torque is too low (around 5-7°) Rear throttle Potentiometer 1 (degrees) • Example value with key ON: 8° • Example value with engine on: 1.5°...
Page 190 RSV4 R Electrical system Front cylinders throttle Limp Home position • Example value with key ON: 878 mV Voltage stored in the control unit corresponding to the Limp home position Rear cylinders throttle Limp Home position • Example value with key ON: 888 mV...
Page 191 RSV4 R Electrical system • carried out/not carried out Indicates whether the self-acquisition process through the diagnosis instrument has/has not been car- ried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero...
Page 192 RSV4 R Electrical system (from throttle sensor connector or control unit connector). If it is ground insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 193 RSV4 R Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature. Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 194 RSV4 R Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 195 RSV4 R Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 196 RSV4 R Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 197 RSV4 R Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 198 RSV4 R Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 199 RSV4 R Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 200 RSV4 R Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 201 RSV4 R Electrical system • connector: between head cover and fil- ter box on left side (3-ways white con- nector). Electrical characteristics: PIN 64: gear indication: closed circuit (continuity); gear engaged: open circuit (infinite resistance). Gear engaged circuit resistance: 1st gear: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th...
Page 202 RSV4 R Electrical system replace the sensor (there is short circuit to ground of the pink cable in the section from the sensor connector to the sensor or inside the sensor). Clutch lever sensor Function It tells the clutch lever position to the control unit.
Page 203 RSV4 R Electrical system • Indication on Axone always Pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace sensor; if the circuit is open, it means that there is short circuit to ground of black cable from sensor PIN 1 to engine-vehicle cable harness connector PIN C3 or of the white/purple cable from PIN C3 to VEHICLE connector PIN 56: restore the cable harness.
Page 204: Bank Angle Sensor
RSV4 R Electrical system • Indication on Axone always down: check the connector: if not OK, restore; if it is OK, dis- connect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor •...
Page 205 RSV4 R Electrical system • Indication on Axone always Normal, even when the sensor is inverted: disconnect the con- nector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor; if there is continuity, check the con- nector: if not OK, restore cable harness;...
Page 206 RSV4 R Electrical system DIAGNOSIS INSTRUMENT: ACTIVATION • The fan relay (No. 36 in the wiring dia- gram, placed in the headstock niche, left side; CHECK, however, the identi- fication of the relay with the colour of the cables) is energised for 10 sec- onds.
Page 207 RSV4 R Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / operating principle The valve coil is excited to open the air passage of the filter box to the exhaust manifold...
Page 208 RSV4 R Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
Page 209 RSV4 R Electrical system RUN / STOP switch • Run/Stop NOTES • Indication on Axone always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - blue/green and yellow/red: If there is not continuity, replace the sensor;...
Page 210 RSV4 R Electrical system Level in wiring diagram: Exhaust valve Location: • on the vehicle: The motor is placed in the front lower part of the engine. The valve in the exhaust duct. • connector: on the motor. Electrical characteristics: •...
Page 211 RSV4 R Electrical system • If potentiometer signal is above maximum threshold: voltage of the maximum end of stroke position (open valve) outside the foreseen field has been detected. If potentiometer signal is below maximum threshold: voltage of the minimum end of stroke position (closed valve) outside the foreseen field has been detected.
Page 212 RSV4 R Electrical system connector: if not OK, restore; if OK, check continuity of brown and black cables: if not OK, restore cable harness; if OK, check motor electrical characteristics and replace it. • If thermal overload protection: replace the instrument panel.
Page 213 RSV4 R Electrical system • position error. Error cause • Position indicated by potentiometer does not correspond with position set by control unit. Troubleshooting • Mechanically check the valve, its normal rotation (with cables disconnected from motor, manually activate the cables and see movement regularity and check valve complete stroke with correct operation of the return spring) and absence of foreign bodies which do not allow its rotation: if not OK, restore;...
Page 214 RSV4 R Electrical system EXHAUST THROTTLE VALVE CALIBRATION • Slacken the exhaust throttle valve ca- ble tension. • From the Adjustable parameters screen, use the diagnostic instrument to select: Acquire exhaust valve zero position • After pressing the send button for zero research, stop the vehicle and leave the key in OFF.
Page 215 RSV4 R Electrical system Engine pinout key: Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output (+) PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5...
Page 216 RSV4 R Electrical system Front throttle motor output (-) PIN 15 Power ground connection 2 PIN 16 Engine speed sensor input (-) PIN 20 Input for front throttle potentiometer 2 signal PIN 21 Lambda sensor input (-) PIN 22 Track C throttle grip input PIN 23...
Page 217 RSV4 R Electrical system Vehicle pinout key: Upper cylinder 1 injector control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Variable geometry control unit control output PIN 62 (If available)
Page 218 RSV4 R Electrical system Side stand input PIN 70 Gear input PIN 72 Injection relay control output PIN 73 Upper cylinder 3 injector control output PIN 74 Variable geometry control unit failure input PIN 76 (If available) "engine stop" input PIN 78...
Page 219 RSV4 R Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 219...
Page 220 RSV4 R Electrical system 4 High-beam lights input 5 Crono input 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control...
Page 221 RSV4 R Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1...
Page 222 RSV4 R Electrical system In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense). If during this period there is no activity on BUS, every nod has the same chance to send a message (Multiple Access).
Page 223 RSV4 R Electrical system • No communication on CAN line (PIN 66 and/or PIN 80): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground). Troubleshooting • check the Marelli control unit VEHICLE connector and the engine-vehicle cable harness connector: if not OK, restore;...
Page 224 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 225 RSV4 R Engine from vehicle ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft)
Page 226 RSV4 R Engine from vehicle See also Fairing mounting panels Lower cowl Radiator cover Fuel tank Exhaust Twistgrip position sensor Air box Removing the radiator Removing Side stand Removing the engine from the vehicle • Detach the clutch cable. •...
Page 227 RSV4 R Engine from vehicle • Remove the engine oil pressure sen- sor. • Remove the rubber cap. • Unscrew and remove the nut, retrieve the washer and disconnect the starter motor. • Unscrew and remove the screw, re- move the cable grommet and detach the three ground cables.
Page 228 RSV4 R Engine from vehicle • Working on the right hand side of the vehicle, detach the exhaust valve con- trol unit connector. • Disconnect the vehicle cable harness/ engine cable harness connector • Unscrew and remove the three screws and remove the pinion cover.
Page 229 RSV4 R Engine from vehicle • Loosen the drive chain adjuster screws. • Loosen the rear wheel fixing nut. • Remove the pinion, releasing it from the drive chain. • Remove the side stand. • Remove the two fuel breather pipes •...
Page 230 RSV4 R Engine from vehicle • Remove the hand grip position sensor from the chassis. • Disconnect the voltage regulator con- nector. See also Twistgrip position sensor • Disconnect the alternator connector. • Working from the left hand side of the vehicle, unscrew and remove the screw and retrieve the washer.
Page 231 RSV4 R Engine from vehicle • Unscrew and remove the three plate fixing screws and remove the plate. • Loosen the screw and ease off the gear lever. • Unscrew and remove the subframe fix- ing screw and retrieve the washer, re- move the radiator subframe.
Page 232 RSV4 R Engine from vehicle • Working on the left side of the vehicle, undo and remove the two screws. • Working on the right side of the vehicle, undo and remove the two screws and the washers. • Also retrieve the shims on the inner side of the frame.
Page 233 RSV4 R Engine from vehicle • Unscrew and remove the screw and retrieve the nut. • Unscrew the upper adjuster screw bushing until it turns no more. • Working on the right side of the vehicle, unscrew and remove the nut and re- trieve the washer.
Page 234 RSV4 R Engine from vehicle • Remove the clamps on the saddle mounting. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SECOND OPERATOR. • Lower the engine • Lift the front part of the vehicle. • Remove the front stand.
Page 235 RSV4 R Engine from vehicle • Working from the vehicle left side, in- stall the left upper engine attachment, tightening the three screws. • With the help of a second operator, secure the vehicle chassis with a hoist and onto a front and rear stand and lift the engine to place it in position.
Page 236 RSV4 R Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: •...
Page 237 RSV4 R Engine from vehicle • Refit the clamps on the saddle mount- ing. • Place the radiator frame, the washer and tighten the screw, fastening the frame to the engine. • Place the gear lever and tighten the screw.
Page 238 RSV4 R Engine from vehicle • Connect the voltage regulator connec- tor. • Position and fix the hand grip position sensor to the chassis. WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS. • Connect the neutral sensor.
Page 239 RSV4 R Engine from vehicle • Place the pinion and insert the trans- mission chain in the seat. • Tighten the rear wheel fixing nut. • Adjust the drive chain adjuster screws. • Place the two washers and tighten the pinion fixing screw.
Page 240 RSV4 R Engine from vehicle • Connect the vehicle cable harness / engine cable harness connector. • Working on the right side of the vehicle, connect the exhaust valve control unit connector. • Place the ground on the frame. •...
Page 241 RSV4 R Engine from vehicle • Connect the starter motor, place the washer and tighten the nut. • Place the rubber cap. • Tighten the engine oil pressure sensor. • Connect the timing sensor. • Connect the clutch cable. ENG VE - 241...
Page 242 RSV4 R Engine from vehicle • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in). ENG VE - 242...
Page 243 INDEX OF TOPICS NGINE...
Page 244 RSV4 R Engine key: 1. rear left cylinder; 2. front left cylinder; 3. rear right cylinder; 4. front right cylinder. Combustion sequence: 1 - 3 - 2 - 4 Combustion angle: cyl 1: 0° cyl 2: 180° cyl 3: 425°...
Page 245 RSV4 R Engine Gearbox Diagram EARBOX pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft)
Page 246 RSV4 R Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw. • Unscrew and remove the six screws.
Page 247 RSV4 R Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 248 RSV4 R Engine • Remove both gearbox shafts from the cover. • Collect the shim washer that is located on the secondary shaft between the shaft and the cover. • Unscrew and remove the screw. • Remove the selector drum.
Page 249 RSV4 R Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in)
Page 250 RSV4 R Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.5 mm (0.020 in) Minimum wear limit of the selection fork guide pins 6.8 mm (0.27 in)
Page 251 RSV4 R Engine • Grease the bushings. • Introduce the forks in their respective seats. • Insert the desmodromic gearbox con- trol rod on the cover. • Position the selector drum. • Turn the screw without tightening it. • Position the fork bushings into the grooves on the desmodromic control rod.
Page 252 RSV4 R Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for secondary gearbox shaft •...
Page 253 RSV4 R Engine • Tighten the selector drum screw. • Insert the driving pin on the oil pump shaft. • Install the water/oil pump control gear. • Insert the Seeger ring. • Install the gear sensor, making the pin coincide with the slot on the desmo- dromic control rod.
Page 254 RSV4 R Engine GEARBOX CONTROL ROD ROLLER CAGE, CLUTCH SIDE • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side. Specific tooling 020862Y Gearbox control rod roller cage fitting punch •...
Page 255: Starter Motor
RSV4 R Engine Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely. If necessary, replace the parts. Check the gear selector spring for damage and wear. If necessary, replace the part.
Page 256 RSV4 R Engine Removing the idle gear • Remove the clutch cover. • Remove the intermediate gear. Start-up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER ENGINE TOOTHING MUST BE CHECKED AS WELL. Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed.
Page 257 RSV4 R Engine If deformations or broken material are found on the sliding surface, replace the freewheel gear (2). Check the freewheel sliding surface (2) for wear. Make sure that the woodruff key slot is in perfect condition. Remove the needle cage (3) and the roller cage (4) from their housings on the freewheel (2) and check the rollers/needles for wear.
Page 258 RSV4 R Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 259 RSV4 R Engine Inspecting the cover components • Unscrew and remove the three Blow- by system fitting screws. • Remove the Blow-by system fitting. • Replace the O-ring with a new one of the same type • Remove the flywheel cover.
Page 260 RSV4 R Engine Flywheel cover installation • Insert the centring dowels in the cover. • Apply a layer of sealing paste along the external edge of the cover. • Insert the cover together with the sta- tor. Recommended products Three bond Sealing paste •...
Page 261 RSV4 R Engine Clutch side LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) TE flanged screws M6x35 12 Nm (8.85 lbf ft)
Page 262 RSV4 R Engine Removing the clutch cover • Drain the engine oil. • Unscrew and remove the sixteen peri- metric fixing screws and retrieve the washers • Remove the clutch casing, retrieving the gasket, the two locator pins and the starter motor transmission gear.
Page 263 RSV4 R Engine • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch retainer • Remove the slipper unit. • Remove the clutch hub. • Remove the clutch hub cam tower.
Page 264 RSV4 R Engine • Collect the shim washer. • Collect the clutch bell. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 264...
Page 265: Checking The Clutch Plates
RSV4 R Engine • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch disc deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch disc sliding teeth 13.5 mm (0.53 in)
Page 266 RSV4 R Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch bell and the primary drive sprocket for correct sealing and evenness.
Page 267 RSV4 R Engine Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded; if necessary, replace the springs all together.
Page 268 RSV4 R Engine • Fit the needle cage. • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion •...
Page 269 RSV4 R Engine • Install the clutch hub cam tower. • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • Fit the three slipper unit clips, offsetting them by 120°.
Page 270 RSV4 R Engine • Insert the disc with friction material and the black tooth into the bell. • Insert one of the metal discs into the bell. • Insert the flat washer. • Insert the belleville spring with the con- cave side facing outward.
Page 271 RSV4 R Engine • Insert the disc covered with the friction material into the bell. • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 272: Installing The Clutch Cover
RSV4 R Engine • Place the thrust plate. • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally. Installing the clutch cover • Position the starting transmission gear on the crankcase.
Page 273 RSV4 R Engine Heads ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) ENG - 273...
Page 274 RSV4 R Engine HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve cover fixing screws 6 Nm (4.42 lbf ft) Water outlet union fixing screw 12 Nm (8.85 lbf ft)
Page 275 RSV4 R Engine Head cover removal • Unscrew and remove the three screws with rubber washers. • Remove the head cover together with the sealing gasket. When refitting: spread a layer of sealing paste on the external corners of the head DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE.
Page 276 RSV4 R Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 277 RSV4 R Engine Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft 150° in the direction of engine rotation (direction of travel) in...
Page 278 RSV4 R Engine • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020865Y Support for camshaft gear on head •...
Page 279 RSV4 R Engine • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge; if necessary, replace the part. Characteristic Maximum camshaft axial clearance (intake/ex- haust) 0.4 mm (0.0016 in)
Page 280 RSV4 R Engine • Install the intake and exhaust cam- shafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake cam- shaft gear (indicated with two dots).
Page 281 RSV4 R Engine • Align the intake camshaft with the spe- cific hole on the U bolt. • Insert the specified pin. Specific tooling 020851Y Camshaft timing pin • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 282 RSV4 R Engine screw. This screw must be replaced at each reassembly. • Tighten the second camshaft gear fix- ing screw to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock...
Page 283 RSV4 R Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the engine rotation direction (direction of travel), in...
Page 284 RSV4 R Engine • Unscrew and remove the second in- take camshaft gear screw. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer • Slide the gear off the intake camshaft. • Block the gear to the timing chain with a clamp.
Page 285 RSV4 R Engine • Unscrew and remove the mobile chain slider screw. • Remove the mobile chain slider. • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side.
Page 286 RSV4 R Engine • Remove the front head, slipping it off the stud bolts. • Collect the gasket and the two dowel pins. • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat.
Page 287 RSV4 R Engine Front head fitting • Install a new O ring on the chain ten- sioner REPLACE THE O RING UPON EACH REMOVAL. • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in).
Page 288 RSV4 R Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order.
Page 289 RSV4 R Engine • Install both chain sliders and fasten them with the specific screws. • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the overlap TDC; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 290 RSV4 R Engine NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 291 RSV4 R Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin.
Page 292 RSV4 R Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 293 RSV4 R Engine 020852Y Crankshaft timing pin Rear head Removing camshafts • Remove the rear head cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC; • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel).
Page 294 RSV4 R Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 295 RSV4 R Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling...
Page 296 RSV4 R Engine Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES • Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
Page 297 RSV4 R Engine Installing camshafts NOTE Engines up to engine No. V4 2470 are equipped with con- ventional exhaust camshaft gears, while engines from en- gine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam-...
Page 298 RSV4 R Engine • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt.
Page 299 RSV4 R Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 300 RSV4 R Engine • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. • Block crankshaft rotation using one of the specific tools.
Page 301 RSV4 R Engine • Slide the gear off the intake camshaft. • Block the gear to the timing chain with a clamp. • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes.
Page 302 RSV4 R Engine • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fas- tener screws (a - b) from the clutch side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1.
Page 303 RSV4 R Engine • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat. REPLACE THE O RING UPON EACH REMOVAL.
Page 304 RSV4 R Engine • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in). • Insert the chain tensioner into the crankcase, being careful to position it correctly. •...
Page 305 RSV4 R Engine • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order. • Tighten the two screws according to the sequence (a - b) •...
Page 306 RSV4 R Engine NOTE Engines up to engine No. V4 2470 are equipped with conventional exhaust camshaft gears, while engines from engine No. V4 2471, are equipped with self-adjusting exhaust camshaft gears. • Install the intake and exhaust cam- shafts on the rear head, remembering...
Page 307 RSV4 R Engine • Fit the U bolts with the nine O rings and locator pins. • Install the oil pipe. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the ten screws (1 - 2) working in stages and diagonally.
Page 308 RSV4 R Engine 020855Y Lever for engaging the chain tensioner • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool.
Page 309: Valve Removal
RSV4 R Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them correctly upon refitting.
Page 310 RSV4 R Engine • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING. • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME.
Page 311 RSV4 R Engine If the measured deviation exceeds the specified limit, determine if the valve or the guide must be replaced. Characteristic Valve stem distortion 0.25 mm (0.0098 in) If the valve stem, when measured with a micro- meter, is worn to its limit and the clearance ex- ceeds the specified limit, replace the valve.
Page 312: Valve Installation
RSV4 R Engine A slight amount of material may be extracted in the area shown. Valve installation • Lubricate the valve stem and insert the valves on the valve guide. • Position the springs with the closest turns facing the head of the valve...
Page 313 RSV4 R Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor •...
Page 314 RSV4 R Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft)
Page 315 RSV4 R Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct. 243 8674 ENG - 315...
Page 316 RSV4 R Engine RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 317 RSV4 R Engine • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. • Remove the spacer. Balancing countershaft fitting • Install the spacer. ENG - 317...
Page 318 RSV4 R Engine • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR.
Page 319 RSV4 R Engine • Unscrew and remove the tone wheel fixing screw. • Remove the tone wheel. See also Disassembling the clutch • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock •...
Page 320 RSV4 R Engine Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide.
Page 321 RSV4 R Engine • alternator; • water pump; • gearbox unit; • primary transmission shaft gear • both timing chains; • the chain sliders; • oil sump; • the gear selector pin spacer; • starter motor and intermediate gear; •...
Page 322 RSV4 R Engine • Turn the engine with the heads facing downward and loosen the screws in the following order: 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7.
Page 323 RSV4 R Engine Removing connecting rods - pistons • Remove both heads. • Open the crankcases. • Install the tool that keeps the crank- shaft in position. Specific tooling 020857Y Crankshaft bearing U bolt See also Front head removal Rear head removal •...
Page 324: Crankshaft Removal
RSV4 R Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Crankshaft removal • Separate the crankcases, removing the lower part • If the heads were removed, position the specific special tool to keep the pis- tons from coming out.
Page 325 RSV4 R Engine Bushing removal COUNTERSHAFT BUSHINGS • Remove the countershaft. • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the bushings; positioning the buffer, which is sup- plied with the special tool, on the op- posite side of the crankcase.
Page 326 RSV4 R Engine Connecting rod check Characteristic Maximum wear limit of the rod small end 17.05 mm (0.671 in) Maximum rod small end radial clearance 0.055 mm (0.0022 in) Maximum axial clearance between the con- necting rod and the crank pin 0.55 mm (0.022 in)
Page 327 RSV4 R Engine Selecting connecting rods If a selection class of connecting rods is fit on the crankshaft that is not class D - D, it is not a problem. It is essential, for proper crankshaft balance, that if one connecting rod is replaced the other one fit on the same crank pin must also be replaced: •...
Page 328 RSV4 R Engine Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings. The category is marked on the crankcase, on the right side, in the area below the crankshaft.
Page 329 RSV4 R Engine RANKSHAFT CATEGORIES WITH REMOVABLE REELS Specification Desc./Quantity Class A Main journals - diameter: 46.005 - 46.000 mm (1.8112 - 1.8110 Class B Main journals - diameter: 46.000 - 45.995 mm (1.8110 - 1.8108 RANKSHAFT CATEGORIES WITH REMOVABLE REELS Specification Desc./Quantity...
Page 330 RSV4 R Engine COUNTERSHAFT BUSHINGS There are no selection classes for the countershaft bushings, there is only one type. CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available: • Blue • • Yellow There are no dimension classes for the crank pins or the connecting rods. As a result, only the two semi-bushing combinations are possible: 1.
Page 331 RSV4 R Engine When replacing the big end bushings, make sure that the tang of the semi-bushing is correctly housed in the corresponding notch in the connecting rod shank or cap Bushing fitting COUNTERSHAFT BUSHINGS • Place the lower crankcase in a press, resting it on the buffer supplied with the special tool.
Page 332 RSV4 R Engine • Spread grease on the sliding surfaces of the bushing on the special tool. • Install the new bushing, aligning the hole with the slot on the ring of the spe- cial tool. • Place the ring on which the bushing is installed onto the special tool's punch.
Page 333 RSV4 R Engine Crankshaft fitting If the two timing chain control sprockets (1 - 2) on the crankshaft were removed, check their exact positioning carefully because the two components cannot be interchanged. Remember that the thicker sprocket (1) must be positioned from the clutch side of the crankshaft.
Page 334 RSV4 R Engine • Install the connecting rod shank piston assembly in the relative cylinders. • Join the crankcases. • If the special tool was used, remove it to keep the pistons from coming out. Specific tooling 020858Y Device for holding the pistons in the cylinders •...
Page 335 RSV4 R Engine • Tighten the tone wheel fixing screw. • Remove the special tool. Specific tooling 020850Y Primary gear lock Installing connecting rods - pistons The piston rings are different and must be fit with the markings "R" and "RN" facing upward.
Page 336 RSV4 R Engine There are no dimension classes for the pistons. Preassemble the pistons on the workbench with the connecting rod shank and the relative semi- bushing. The pre-assembly procedure is identical for all four pistons and must be done as follows: •...
Page 337 RSV4 R Engine • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces. • Use new connecting rod screws, lubri- cating the thread and under the head.. • Proceed with tightening according to...
Page 338 RSV4 R Engine • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - •...
Page 339 RSV4 R Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 339...
Page 340 RSV4 R Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase Lubrication ENG - 340...
Page 341: Oil Pump
RSV4 R Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft)
Page 342 RSV4 R Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor.
Page 343 RSV4 R Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle.
Page 344 RSV4 R Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat.
Page 345 RSV4 R Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor.
Page 346 RSV4 R Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket.
Page 347 RSV4 R Engine The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 348 RSV4 R Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 348...
Page 349 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 350 RSV4 R Power supply Fuel pump Removing • Remove and empty the fuel tank. • Loosen the pipe grommet screw. • Detach the fuel pipe. • Unscrew and remove the screws. • Remove the fuel pump. Injection P SUPP - 350...
Page 351 RSV4 R Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor 4. Outlet valve P SUPP - 351...
Page 352 RSV4 R Power supply 5. Clutch position sensor 6. Fuel pump (inside the tank) 7. Air temperature sensor 8. Air pressure sensor (MAP) 9. Lower injectors 10.Upper injectors 11.Coils (spark plug cover) 12.Engine throttle valves 13.Throttle valve position sensor 14.Electric fan 15.Starter motor...
Page 353 RSV4 R Power supply Removing the injector To optimise engine performance, there are four lower injectors on the throttle bodies and four up- per injectors on the filter box. Except during tran- sition stages, only the lower or the upper injectors are working at any given time.
Page 354 RSV4 R Power supply Air box UPPER INJECTORS • Remove the control unit. • Disconnect the injector connectors. • Unscrew and remove the injector fixing screws. • Remove the upper injectors, identified by green collars. See also Control unit Removing the throttle body •...
Page 355 RSV4 R Power supply • Disconnect the lower injector connec- tors. See also Air box • Disconnect the connector. • Remove the complete throttle body. Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction.
Page 356 RSV4 R Power supply Installing the throttle body • When installing the throttle body, refer to the electrical system section for the correct cable routing. • Ensure that the injector connectors are correctly fastened. • Connect the control unit connector, en- suring that the security lock is in the locked position.
Page 357 RSV4 R Power supply a variable geometry control unit for managing the system, interfaced with the engine injection control unit Operation At key-ON, the variable geometry control unit low- ers the ducts (if still in the raised position). Subsequently, depending on the control voltage...
Page 358 RSV4 R Power supply Variable geometry intake Cylinders synchronisation The control unit receives information on the intake pressure in the four ducts from the two pressure sensors: as the control unit knows the timing phase of the cylinders, it can calculate the individ- ual pressure of the four cylinders.
Page 359 RSV4 R Power supply After making any adjustment, wait for confirmation that the position of the adjusted screw position is now correct. The procedure then continues with screws 2 and 4. To ensure correct engine operation, one of the two screws of each throttle body must always be closed.
Page 360 INDEX OF TOPICS SUSP USPENSIONS...
Page 361: Removing The Front Wheel
RSV4 R Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lbf ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lbf ft) Loct. 243 Removing the front wheel •...
Page 362 RSV4 R Suspensions • Remove the wheel spindle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel spin- dle clamps. • Tap the wheel spindle slightly with a rubber mallet so that the hole on the opposite side is exposed.
Page 363 RSV4 R Suspensions CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: •...
Page 364 RSV4 R Suspensions • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim if, after replacing the bearings, the value is not within the specified limit.
Page 365: Front Fork
RSV4 R Suspensions LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) Front fork Diagram SUSP - 365...
Page 366 RSV4 R Suspensions RONT FORK pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 22 Nm (16.23 lbf ft) screws Pumping member fixing screw 30 - 39 Nm (22.13 - 28.76 lbf ft) Sleeve top cap 30 - 39 Nm (22.13 - 28.76 lbf ft)
Page 367: Removing The Fork Legs
RSV4 R Suspensions (*) = clockwise (**) = anticlockwise NOTE TO CHECK FOR FRONT FORK FAILURE, MEASURE THE DIFFERENCE BETWEEN THE BEGIN- NING OF THE WHEEL HUB AND THE END OF THE FORK SLEEVE Removing the fork legs • Remove the front wheel.
Page 368 RSV4 R Suspensions Removing the front wheel Draining oil • Lock the clamp sleeve using the speci- fied tool. • Reduce spring load to the minimum. Specific tooling 8140149 Cover removal operations • Unscrew the sleeve top cap. • Lock the fork end on a vice paying at- tention not to damage it.
Page 369 RSV4 R Suspensions • Push down the tool to compress the spring and then fit the tool spacer be- low the cartridge lock nut. • Loosen the cap by the key grip and by making the lock nut turn. •...
Page 370 RSV4 R Suspensions • Remove the spring coupling. • Drain off oil into a collecting container and remove the spring. Disassembling the fork • After emptying the oil, fasten the fork stem end in a vice. • Take out the washer and the lower spacer.
Page 371 RSV4 R Suspensions • Undo the screw fixing the cartridge on the fork end. • Collect the centring bushing. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • Do not damage the sleeve edge while doing this.
Page 372 RSV4 R Suspensions • Take out the sleeve from the stem us- ing the stem as a hammer puller. • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. SUSP - 372...
Page 373 RSV4 R Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
Page 374 RSV4 R Suspensions Check that the following components are in good conditions: • sliding bushing; • guide bushing; • pumping member pin. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SUR- FACE.
Page 375 RSV4 R Suspensions 520.0 +/- 2.5 cm³ (31.73 +/- 1.15 cu.in) (for each stem) Reassembling the fork • Lock the stem in a vice without dam- aging the surface. • Protect the bearing tube end with ad- hesive tape. •...
Page 376 RSV4 R Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
Page 377 RSV4 R Suspensions • Insert the retainer ring in its position. • Fit the oil seal with the specific tool. Specific tooling 8140145 Fitting tool for Ø 41 mm (1.61 in) seal- ing ring 8140146 Weight to be applied to the tool: 8140145 •...
Page 378 RSV4 R Suspensions • Position the lower spacer and the washer. • Fit the fork spring. • Perform the fork oil filling. Filling oil • Keep the sleeve in vertical position. • Fill up the fork so that air bubbles trap- ped inside are freed.
Page 379 RSV4 R Suspensions • Fit the specified tool on the spring cou- pling so that the cartridge stem is locked in position. Specific tooling 8140147 Spacer tool 8140148 Spacer / pumping member separating plate • Position the spacer and the washer.
Page 380: Steering Damper
RSV4 R Suspensions • Place the sleeve in the vice using the specified tool. • Screw the upper cover, tightening it to the prescribed torque. Specific tooling AP8140149 Protection for fitting operations Steering damper Adjusting • It is not possible to make any adjust- ment on the steering damper.
Page 381 RSV4 R Suspensions Removing The steering damper steering more precise and stable, improving motorcycle handling in all con- ditions. The damper is fastened at the front of the motorcycle between the base of the headstock and the frame Removal: •...
Page 382 RSV4 R Suspensions TEERING pos. Description Type Quantity Torque Notes Screws fastening upper yoke to stan- 25 Nm (18.44 lbf ft) chions Screws fastening lower yoke to stan- 25 Nm (18.44 lbf ft) chions Headstock lock ring M35x1 40 Nm (29.50 lbf ft)
Page 383 RSV4 R Suspensions • Remove the upper yoke • Rivet the safety washer on the head- stock. • Undo the counter-lock ring, remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly.
Page 384 RSV4 R Suspensions • Adjust the preloading of the steering bearings by tightening the lower ring nut to the prescribed torque. • Turn the steering 3-4 times completely from right to left and then check correct tightening torque of such ring nut.
Page 385: Removing The Rear Wheel
RSV4 R Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount Removing the rear wheel • Place the vehicle on its rear service stand.
Page 386 RSV4 R Suspensions • Tap the wheel spindle slightly to extract the head from its seat. • Make the wheel move forward and re- lease the gearing chain from the sprocket. • Remove the wheel spindle together with the right hand chain tensioner skid.
Page 387 RSV4 R Suspensions • Using an Allen spanner on the related seat (1), lock the rotation of the threa- ded pin (2), unscrew and remove the self-locking nut (3) and the threaded pin (2). THE SELF-LOCKING NUTS (3) MUST BE REPLACED EV- ERY THREE SPROCKET REMOVALS.
Page 388: Checking The Rear Wheel
RSV4 R Suspensions Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless.
Page 389 RSV4 R Suspensions REAR WHEEL RIM • Using a dial gauge, check that the ra- dial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit val- An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim (2) if after replacing the bearings, the value is not within the specified limit.
Page 390 RSV4 R Suspensions FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn. To check: • Fit the entire final transmission unit (6) to the wheel. • Manually rotate the sprocket (7) to right and left, and check the clearance be- tween the flexible couplings (5) and their holder (8).
Page 391 RSV4 R Suspensions • Collect the inside spacer (12). Working from the wheel left side: • Take out the left bearing (16) with the specific extractor. Specific tooling AP8140180 Extractor for bushings • Clean the inside of the hub thoroughly.
Page 392 RSV4 R Suspensions • Remove the left bearing (18) with the specific extractor. • Collect the inside spacer (19). • Remove the right bearing (20) with the specific extractor. • Retrieve the right hand spacer (21). • Clean the inside of the hub thoroughly.
Page 393: Shock Absorbers
RSV4 R Suspensions Shock absorbers EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual linkage fixing screw 50 Nm (36.88 lbf ft) Screw fastening single linkage to 50 Nm (36.88 lbf ft)
Page 394 RSV4 R Suspensions Adjusting SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD ADJUSTMENT FOR ROAD USE ONLY Specification Desc./Quantity...
Page 395 RSV4 R Suspensions NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: • CENTRE OF THE FRONT SCREW FASTEN- ING THE LICENSE PLATE HOLDER TO UN- DERTAIL SECTION AND • UPPER CORNER OF THE SCREW FASTEN-...
Page 396 RSV4 R Suspensions Linkages Removing • Working from the left side of the vehicle, loosen and remove the nut (1). • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3). • Slide off the screw (4) from the opposite side.
Page 397 RSV4 R Suspensions UPON REFITTING, GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY. PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV- ERAL TIMES THAT JOINTS MOVE SMOOTHLY. SUSP - 397...
Page 398 INDEX OF TOPICS CHAS HASSIS...
Page 399 RSV4 R Chassis RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2...
Page 400 RSV4 R Chassis EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft)
Page 401 RSV4 R Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 402 RSV4 R Chassis • Working from the right side, loosen and remove the locking ring nut. • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.
Page 403 RSV4 R Chassis • Remove the adjustment bushing from the swingarm pin (2). UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. • If necessary, use a specific tool to re- move a pin from the drive chain.
Page 404 RSV4 R Chassis DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm. ROTATION CHECK •...
Page 405 RSV4 R Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the adjustment bushing (3) to its seat and tighten it manually. CAUTION THE ADJUSTMENT BUSHING (3) MUST NOT PROTRUDE BEYOND THE CHASSIS INTERNAL EDGE.
Page 406 RSV4 R Chassis • Working from the right hand side of the vehicle, turn the swingarm pin (2) clockwise. This turns the adjustment bushing (3), driving the swingarm in until fully seated. • Tighten the locking ring nut (1). •...
Page 407 RSV4 R Chassis • Fit the washer on the screw • Tighten the screw. • Install the rear shock absorber and the linkages. • Fit the rear brake calliper plate. • Fasten the two pipe grommets on the swingarm •...
Page 408 RSV4 R Chassis • Move the vehicle forward so as to check vertical oscillation in other posi- tions too. clearance should remain constant at all wheel rotation phases. ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN.
Page 409 RSV4 R Chassis FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED. THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE. ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION.
Page 410 RSV4 R Chassis • Unscrew and remove the upper screw fixing the chain pad and retrieve the washer. • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand...
Page 411: Side Stand
RSV4 R Chassis IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) Side stand •...
Page 412 RSV4 R Chassis • Remove the side stand. Exhaust XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft)
Page 413 RSV4 R Chassis Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold. • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis;...
Page 414 RSV4 R Chassis Removing the catalytic converter • Remove the exhaust end. • Remove the front exhaust manifold. • Remove the pinion crankcase • Disconnect the oxygen sensor connec- tor. • Release the oxygen sensor cable har- ness from the clamps.
Page 415 RSV4 R Chassis • Remove the front underfairings. • Remove the hand grip position sensor control unit. • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front...
Page 416 RSV4 R Chassis • Remove the front exhaust manifold. REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers.
Page 417 RSV4 R Chassis Lower cowl • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler...
Page 418 RSV4 R Chassis IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe.
Page 419 RSV4 R Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 419...
Page 420 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 421 RSV4 R Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake disc fixing screws 30 Nm (22.13 lbf ft) Loct. 243 Screw fastening odometer sensor 12 Nm (8.85 lbf ft) onto rear brake calliper mounting Rear brake calliper mounting plate 50 Nm (36.88 lbf ft)
Page 422 RSV4 R Braking system Front brake calliper RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) Rear brake disc Removal • Remove the rear wheel. CAUTION...
Page 423 RSV4 R Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 424 RSV4 R Braking system Removal • Remove the front wheel. The following operations refers to a single disc but apply to both. To unscrew the screws (1), use an air screwer gun to give a clean blow, which will detach the screws stuck with LOCTITE 243.
Page 425: Front Brake Pads
RSV4 R Braking system Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS.
Page 426: Rear Brake Pads
RSV4 R Braking system • Fit the two new pads in the correct po- sition. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CAL- LIPER. • Fit the front brake calliper on the disc.
Page 427 RSV4 R Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 428 RSV4 R Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. Air in the system causes a "spongy" feeling in the brake control and poor braking efficiency.
Page 429 RSV4 R Braking system • Screw the bleed valve and remove the pipe. • Top-up the reservoir until the right brake fluid level is obtained. • Refit and block the front brake fluid res- ervoir cap. • Refit the protective rubber cap.
Page 430 RSV4 R Braking system • Refit and lock the rear brake fluid reservoir cap. • Refit the protective rubber cap. Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft)
Page 431 RSV4 R Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft)
Page 432 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 433: Circuit Diagram
RSV4 R Cooling system Circuit diagram SYSTEM TYPE Self bleeding cooling circuit with aspirating centrifugal pump (1), three-way thermostat valve (2), cooling radiator (3) with electric fans (4) and expansion tank (5). key: COOL SYS - 433...
Page 434 RSV4 R Cooling system 1. Centrifugal pump 2. Thermostatic valve 3. Radiator 4. Electric fans 5. Expansion tank 6. With the thermostat open 7. With the thermostat closed 8. From front head 9. From rear head 10.To upper crankcase OOLING pos.
Page 435 RSV4 R Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Electric fan • Remove the front underfairings and the hand grip position sensor • Disconnect the cooling fan connector to be replaced.
Page 436: Coolant Replacement
RSV4 R Cooling system Fairing mounting panels Twistgrip position sensor • Move the radiator forward. • Unscrew and remove the three fan re- tainers and retrieve the washers. Coolant replacement • Remove both fairings. • Place a container with a suitable ca- pacity under the coolant pump.
Page 437: Water Pump
RSV4 R Cooling system • Via the filler orifice on the expansion tank, fill with the quantity of coolant necessary to reach the FULL marking, then refit the cap. • Start the engine, run at idle speed and wait for the electric fans to activate (ap- prox.
Page 438 RSV4 R Cooling system • Unscrew and remove the two screws fastening the pump to the engine. • Remove the coolant pump. • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw.
Page 439 RSV4 R Cooling system • At each removal, replace the inner gas- ket between the pump casing and the cover and the O ring on the pump cas- ing. ENSURE THAT THE LIQUID PASSAGE ORIFICES ARE NOT OBSTRUCTED. Removing the radiator •...
Page 440 RSV4 R Cooling system Twistgrip position sensor • Unscrew and remove both radiator up- per fixing screws. • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return...
Page 441 RSV4 R Cooling system • Remove the split pin. • From the opposite site, remove the coolant radiator-oil radiator connector pin. • Remove the radiator. COOL SYS - 441...
Page 442 INDEX OF TOPICS BODYW ODYWORK...
Page 443 RSV4 R Bodywork EADLAMP pos. Description Type Quantity Torque Notes Screw fastening headlamp to front SWP 4.9 2 Nm (1.47 lbf ft) fairing Headlamp fixing screw 2 + 1 2 Nm (1.47 lbf ft) BODYW - 443...
Page 444 RSV4 R Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 445 RSV4 R Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 3 Nm (2.21 lbf ft) Lug fixing screws 4 Nm (2.95 lbf ft) AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft)
Page 446 RSV4 R Bodywork pos. Description Type Quantity Torque Notes Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER pos.
Page 447 RSV4 R Bodywork TAIL pos. Description Type Quantity Torque Notes Rear screws fastening tail fairing to 3 Nm (2.21 lbf ft) taillight bracket Screws fastening the saddle cover SWP 2.9 1 Nm (0.74 lbf ft) base to the saddle cover Saddle cover pin fixing screws 1.5 Nm (1.11 lbf ft)
Page 448 RSV4 R Bodywork ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft)
Page 449 RSV4 R Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to 3 Nm (2.21 lbf ft)
Page 450 RSV4 R Bodywork AIRING pos. Description Type Quantity Torque Notes Centre screws fastening lower fairing 10 Nm (7.37 lbf ft) Right hand lower fairing mounting 10 Nm (7.37 lbf ft) bracket Left hand lower fairing mounting 10 Nm (7.37 lbf ft)
Page 451 RSV4 R Bodywork Driving mirrors • The following procedure is for a single rear view mirror, but is applicable to both mirrors. • Unscrew and remove the two nuts, supporting the rear view mirror. • Disconnect the turn indicator connec- tor from the relative fixed connector on the instrument panel.
Page 452: Instrument Panel
RSV4 R Bodywork Instrument panel • Remove the windshield. • Unscrew and remove the two screws. • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the arch brace.
Page 453 RSV4 R Bodywork Headlight fairing • Remove the side fairings. • Disconnect the turn indicator connec- tors from the fixed connector on the instrument panel mounting. • Remove the two rear view mirrors if necessary. • Remove the three lower inserts.
Page 454 RSV4 R Bodywork • Supporting the windshield, move it for- ward to the create the minimum space necessary to work on the front bulb connectors. • Disconnect the front bulb connectors. • Remove the windshield in a forward motion. Side fairings...
Page 455 RSV4 R Bodywork • Ease off the side fairing, taking partic- ular care not to damage the fitting with the lower side fairing and the tabs fas- tening the side fairing to the lug. • Release the insert on the retainer with the duct.
Page 456 RSV4 R Bodywork LOWER SIDE FAIRINGS • The operations described below are valid for both lower side fairings. • Remove the side fairing. • Unscrew and remove the screw and remove the lower side fairing. Fairing mounting panels CENTRAL UNDERFAIRING •...
Page 457 RSV4 R Bodywork LATERAL UNDERFAIRINGS • The following procedure is relative to a single lateral underfairing, but is appli- cable to both, except where specified otherwise. • Unscrew and remove the central un- derfairing fixing screw. • Remove the respective side fairing.
Page 458 RSV4 R Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit. • Disconnect the air temperature sensor connector. • Move the two rear coil connectors See also Control unit • Unscrew and remove the four upper injector screws.
Page 459 RSV4 R Bodywork • Unscrew and remove the eight air filter box cover screws. • Remove the air filter box cover. FILTER BOX BASE • Open the air filter box cover. • Unscrew and remove the air intake duct fixing screws.
Page 460 RSV4 R Bodywork • Working from both sides, disconnect the Blow-by system intake pipes. • Release the cable harness from the cable grommet on the filter box. • Remove the air filter box base. Rear mudguard • Unscrew and remove the two screws.
Page 461: Fuel Tank
RSV4 R Bodywork • Unscrew and remove the front screw. See also Side fairings • Unscrew and remove the lower screw. • Supporting the right fairing lug, un- screw and remove the right lug fixing screw and remove the lug.
Page 462 RSV4 R Bodywork • Remove the rider saddle. • Unscrew and remove the two rear screws. • Release the clamps. • Remove the two tank breather pipes. • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank.
Page 463: Front Mudguard
RSV4 R Bodywork Front mudguard • Working from both sides, unscrew and remove the two screws. • Remove the front mudguard. Instrument cluster support REMOVAL • Remove the instrument panel. • Working on both sides, unscrew and remove the two screws fastening the arch brace to the headstock.
Page 464 RSV4 R Bodywork • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws. • Connect the Immobilizer aerial cables. • Fasten the main cable harness to the semi-arch brace with a clamp.
Page 465 RSV4 R Bodywork • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws. Do not strain the connection between the two semi- arch braces, as this would prevent the removal of the clamp.
Page 466 RSV4 R Bodywork NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 467 RSV4 R Bodywork Side air deflectors The following procedure is for a single lateral duct but is applicable to both. • Remove the windshield. • Unscrew and remove the two fixing nuts. • Remove the duct from its seat on the frame.
Page 468 INDEX OF TOPICS PRE DE DELIVERY...
Page 469 RSV4 R Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit...
Page 470: Road Test
RSV4 R Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 471 RSV4 R Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 472 RSV4 R Pre-delivery OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP- PROVAL. • Remove the screw (2). • Remove the plastic cover (1). • Fit the rear pedal in its seat. • Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm (13.27 lbf ft)
Page 473 RSV4 R Pre-delivery • Fit the two-seater saddle. PRE DE - 473...
Page 474 Air filter: 65 Battery: 148 Brake: 421–423, 425, 426, 430, 431 Bulbs: Chain: 13, 407, 409 Clutch: 75, 202, 246, 261, 262, 265–267, 272, 293, 300, 316, 319 Clutch lever: 202 Coolant: 436, 437, 439 Engine oil: 63, 199, 417 Fork: 365, 367, 370, 375 Forks: 250 Fuel: 65, 142, 183, 226, 350, 461...
Page 475 Spark plug: 62, 67 Stand: 87, 203, 226, 229, 410, 411 Start-up: 141, 256 Tank: 65, 226, 461 Transmission: 12, 318, 321 Tyres: 14 Warning lights: Windshield:...

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