APRILIA RSV 1000 R Workshop Manual Download Page 272

Page: 272 / 308

CYCLE PARTS

5 - 127

RSV

1000

R - RSV

1000

R FACTORY

5.8.4.

REMOVING THE FRONT BRAKE DISCS

•

Remove the front wheel.

NOTE

The following procedure refers to a single disc,

though it is applicable to both.

To remove the screws (1), it is advisable to use an impact
driver, thanks to which it will be possible to detach the
screws from the LOCTITE

243.

•

Loosen and remove the six brake disc screws (1).

CAUTION
When reassembling, apply LOCTITE

243 on

the thread of the brake disc screws (1).

NOTE

When reassembling, insert all the screws (1) by hand

and tighten them in a crisscross pattern in the following or-
der: A-B-C-D-E-F.

•

Remove the brake disc (2).

Summary of Contents for RSV 1000 R

Page 1: ...www serviceaprilia com workshopmanual RSV 1000 R RSV 1000 R FACTORY 1137 3 00 2003 10 8140742 USA ...

Page 2: ...INTRODUCTION 0 1 RSV 1000 R RSV 1000 R FACTORY INTRODUCTION 0 ...

Page 3: ...INTRODUCTION 0 2 RSV 1000 R RSV 1000 R FACTORY SUMMARY 0 1 INTRODUCTION 3 0 1 1 INTRODUCTION 3 0 1 2 REFERENCE MANUALS 4 0 1 3 ABBREVIATIONS SYMBOLS CONVENTIONS 5 ...

Page 4: ...encies worldwide Such modifications will be supplied in subse quent editions of the manual In case of doubt regarding specific repairs or checks contact the Aprilia SERVICE DEPARTMENT we will be pleased to provide all necessary information and assistance as well as keeping you up dated on changes and modifications to the vehicle Aprilia S p A reserves the right to make changes to its products at a...

Page 5: ...TALOGUES Aprilia part description 001A00 OWNER S MANUALS Aprilia part description 8104334 8104691 8104692 8104693 8104704 8104694 8104695 CYCLE PARTS TECHNICAL MANUAL Aprilia part description 8140737 8140738 8140739 8140740 8140741 8140742 ENGINE TECHNICAL MANUAL Aprilia part description 8140743 8140744 8140745 8140746 8140747 8140748 ...

Page 6: ...le Overhead Camshaft ECU Electronic Control Unit rpm revolutions per minute HC unburnt hydrocarbons ISC Idle Speed Control ISO International Standardization Organization Kg kilograms Kgm kilogram meter 1 kgm 10 Nm km kilometers kph kilometers per hour kΩ kilo Ohm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungseite kW kiloWatt l liters LAP racetrack lap LED Light Emitting Dio...

Page 7: ...HT SIDE right side SAE Society of Automotive Engineers TEST diagnostic check T B E I crown head Allen screw T C E I cheese head Allen screw T E hexagonal head TP flat head screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V Volt W Watt Ø Diameter ...

Page 8: ...GENERAL INFORMATION 1 1 RSV 1000 R RSV 1000 R FACTORY GENERAL INFORMATION 1 ...

Page 9: ...1 2 GENERAL RULES 5 1 2 1 BASIC SAFETY RULES 5 1 3 DANGEROUS ELEMENTS 8 1 3 1 WARNINGS 8 1 4 RUNNING IN 12 1 4 1 RUNNING IN RECOMMENDATIONS 12 1 5 VEHICLE IDENTIFICATION 13 1 5 1 POSITION OF THE SERIAL NUMBERS 13 1 6 POSITION OF THE WARNING ADHESIVE LABELS 15 1 6 1 POSITION OF THE WARNING ADHESIVE LABELS 15 1 6 2 CALIFORNIA EVAPORATIVE EMISSION SYSTEM 25 ...

Page 10: ...right and left are referred to the rider seated on the vehicle in the normal riding position Motorcycle s operation and basic maintenance are covered in the OWNER S MANUAL In this manual any variants are identified with these symbols optional catalytic version all versions MP national certification SF European certification EURO 1 limits VERSION Italy Greece Malaysia United Kingdom Holland Chile A...

Page 11: ...ate a personal injury hazard Non compliance with the indications given in the messages preceded by this symbol may result in very serious risks for your and other people s safety and for the vehicle WARNING Indicates a potential hazard which may result in serious injury or even death CAUTION Indicates a potential hazard which may result in minor personal injury or damage to the vehicle IMPORTANT T...

Page 12: ...ue to be hot even for some time after the engine has been stopped Before handling these parts wear insulating gloves or wait for the engine and the exhaust system to cool completely down USED GEARBOX AND FORK OILS DANGER In case any maintenance operation should be required it is advisable to use latex gloves Gear oil may cause serious damage to the skin if handled daily and for long periods Wash y...

Page 13: ... KEEP IT AWAY FROM CHILDREN The battery fluid is corrosive Do not pour it on the plastic parts Make sure that the electrolyte acid is suitable for the type of battery used GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Using bare flames is strictly forbidden when working on the motorcycle Be...

Page 14: ...crews which have a damaged thread Lubricate the bearings abundantly before assembly Make a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform the preliminary checks and then drive the motorcycle in a private estate area or in a safe area away from traffic Clean all joint surfaces oil seal edges and gaske...

Page 15: ...new and clean type of lubricant can lead to the engine s or gearbox s seizure thus leading to serious accidents personal in jury or even death Gear oil may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use Do not dispose of oil into the environment Take it to the filling station where you usually buy it or to an oil salvage center WARNING Wh...

Page 16: ...ye specialist or seek medical advice DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT KEEP IT AWAY FROM CHILDREN When handling brake fluid take care not to spill it onto plastic or paint finished parts or they will damage DANGER Do not use any brake fluids other than the specified type Never mix different types of fluids to top up level as this will damage the braking system Do not use brake fluid ...

Page 17: ...ore anti freeze up to 60 maximum to the solution Use distilled water in the coolant mixture Tap water will damage the engine Refer to the chart given below and add water with the quantity of anti freeze to obtain a solution with the desired freezing point Freezing point F C Coolant of volume 4 20 35 22 30 45 40 40 55 NOTE Coolants have different specifications The protection degree is written on t...

Page 18: ...es Never use rubber treating substances on tires In particular avoid contact with fluid fuels leading to a rapid wear In case of contact with oil or fuel do not clean but change tires DANGER Some of the factory assembled tires of this vehicle are provided with wear indicators There are several kinds of wear indicators For more information on how to check the wear contact your Dealer Visually check...

Page 19: ...he speed is low both during and after the running in During the first 62 mi 100 km pull the brakes with caution avoiding sharp and prolonged braking This ensures a correct bedding in of the pads on the brake disc During the first 621 mi 1000 km never exceed 6000 rpm see table WARNING After the first 621 mi 1000 km Dealers carry out the checks indicated in the column After running in see REGULAR SE...

Page 20: ... penal and administrative sanc tions in particular altering the frame number voids the war ranty FRAME NUMBER The frame number 1 is stamped on the right hand side of the headstock ENGINE NUMBER The engine number 2 is stamped on the rear part of the engine near the pinion INFORMATION CONTAINED IN THE VEHICLE IDENTIFI CATION NUMBER Description of the vehicle identification number V I N stamped on th...

Page 21: ...IT MEANING 1 Manufacturer s identification alphanumeric code 2 Vehicle type 3 Model 4 Country for which the vehicle is intended 5 Check digit number 6 Model year 7 Assembling factory designation N NOALE VE S SCORZÉ VE 0 NOT SPECIFIED 8 Sequential serial number ...

Page 22: ...GENERAL INFORMATION 1 15 RSV 1000 R RSV 1000 R FACTORY 1 6 POSITION OF THE WARNING ADHESIVE LABELS 1 6 1 POSITION OF THE WARNING ADHESIVE LA BELS 1 2 ...

Page 23: ...GENERAL INFORMATION 1 16 RSV 1000 R RSV 1000 R FACTORY 3 4 5 6 ...

Page 24: ...GENERAL INFORMATION 1 17 RSV 1000 R RSV 1000 R FACTORY 7 8 9 10 ...

Page 25: ...GENERAL INFORMATION 1 18 RSV 1000 R RSV 1000 R FACTORY 11 12 13 14 ...

Page 26: ...GENERAL INFORMATION 1 19 RSV 1000 R RSV 1000 R FACTORY 14a 15 Muffler stamping ...

Page 27: ...GENERAL INFORMATION 1 20 RSV 1000 R RSV 1000 R FACTORY 1 2 3 4 ...

Page 28: ...GENERAL INFORMATION 1 21 RSV 1000 R RSV 1000 R FACTORY 5 6 7 8 ...

Page 29: ...GENERAL INFORMATION 1 22 RSV 1000 R RSV 1000 R FACTORY 9 10 11 12 ...

Page 30: ...GENERAL INFORMATION 1 23 RSV 1000 R RSV 1000 R FACTORY 13 14 15 15a ...

Page 31: ...GENERAL INFORMATION 1 24 RSV 1000 R RSV 1000 R FACTORY 16 Muffler stamping ...

Page 32: ...l tank breather line 4 Breather line to 2 way ventilation valve 5 2 way ventilation valve 6 Breather line to carbon canister 7 Carbon canister 8 Drain line to norrow passage 9 Restrictor Ø 0 06 in Ø 1 5 mm 10 Drain line to tee 11 Tee 12 Drain line to manifold vacum port 13 Manifold vacum port right front part of throttle body 14 Warm air inlet from armosphere to canister ...

Page 33: ...GENERAL TECHNICAL INFORMATION 2 1 RSV 1000 R RSV 1000 R FACTORY GENERAL TECHNICAL INFORMATION 2 ...

Page 34: ...INFORMATION 3 2 1 1 TECHNICAL DATA 3 2 1 2 PERIODIC MAINTENANCE CHART 7 2 1 3 TABLE OF LUBRICANTS 9 2 1 4 TIGHTENING TORQUES 10 2 1 5 SPECIAL TOOLS 14 2 1 6 ARRANGEMENT OF THE MAIN ELEMENTS 21 2 1 7 ARRANGEMENT OF THE INSTRUMENTS CONTROLS 25 2 1 8 DASHBOARD OPERATION 26 2 1 9 SYSTEMS DIAGRAM 34 ...

Page 35: ...ng system Liquid coolant GEARBOX Type Mechanical 6 gears with foot control on engine s left side CAPACITIES Fuel including reserve 4 755 gal 18 l Fuel reserve 1 189 0 264 gal 4 5 1 l Engine oil Oil change 225 788 in 3 3700 cm 3 oil and oil filter change 237 993 in 3 3900 cm3 Front fork oil RSV R 31 732 0 152 in 3 520 2 5 cm 3 each leg Front fork R FACTORY RFACT RSV R OPT oil 30 512 0 152 in3 500 2...

Page 36: ...3 in Ø 43 mm Travel RSV R 4 999 in 127 mm RFACT RSV R OPT 4 724 in 120 mm Rear Light alloy swinging arm with differentiated profiles on both sides and adjustable air oil sprung mono shock absorber Wheel travel 5 31 in 135 mm BRAKES Front Twin floating disk Ø 12 598 in Ø 320 mm four piston calipers Ø 1 338 in Ø 34 mm Rear Disk brake Ø 8 661 in Ø 220 mm twin piston caliper Ø 1 260 in Ø 32 mm WHEEL R...

Page 37: ...ER SPORT TEC M1 190 50 ZR 17 RSV R R FACT 250 2 5 280 2 8 200 2 0 Front METZELER RENNSPO RT 120 70 ZR 17 RSV R R FACT 210 2 1 Rear METZELER RENNSPO RT 180 55 ZR 17 RSV R R FACT 200 2 0 Front MICHELIN PILOT SPORT E 120 70 ZR 17 TL RSV R 230 2 3 250 2 5 Rear MICHELIN PILOT SPORT E 190 50 ZR 17 TL RSV R 250 2 5 280 2 8 Front MICHELIN PILOT SPORT CUP 120 70 ZR 17 RFACT 210 2 1 Front MICHELIN PILOT SPO...

Page 38: ... Generator permanent wound type 12 V 500 W BULBS Low beam halogen 12 V 55 W H7U x 2 High beam halogen 12 V 55 W H7U x 2 Front parking light 12 V 5 W Direction indicators 12 V 10 W Number plate light 12 V 5 W Stop rear parking lights LED Rev counter light LED Left multifunction display LED WARNING LIGHTS Neutral LED Direction indicators LED Fuel reserve LED High beam LED Stand down LED General warn...

Page 39: ... roads or for racing Component Post running in 625 mi 1000 Km Every 3125 mi 5000 Km only for inten sive racing use Every 6250 mi 10000 Km or 12 months Every 12500 mi 20000 Km or 24 months Spark plug 3 1 3 Air cleaner 3 1 3 Engine oil filter 3 3 3 Engine oil filter on oil tank 2 2 2 Light operation beam setting 1 Light system 1 1 Safety switches 1 1 Clutch fluid 1 1 1 Brake fluid 1 1 1 Coolant 1 1 ...

Page 40: ... mi 1000 Km 1 Bowden cables and con trols 1 1 1 Rear suspension linkage bearings 1 Steering bearings and steering play 1 1 1 Wheel bearings 1 1 Brake discs 1 1 1 Vehicle operation 1 1 1 Valve clearance 4 4 Braking systems 1 1 1 Cooling system 1 1 Clutch fluid every 12 months 3 every 24 months 3 Brake fluid every 12 months 3 every 24 months 3 Coolant every 24 months 3 Fork oil RSV R After the first...

Page 41: ...ther lubrication points RECOMMENDED BIMOL GREASE 481 AUTOGREASE MP or GREASE 30 As an alternative to recommended grease use top brand rolling bearing grease that will resist a temperature range of 30 C 140 C with dropping point 150 C 230 C high corrosion protection good resistance to water and oxidation Battery lead protection Use neutral grease or Vaseline Chains Spray grease RECOMMENDED CHAIN SP...

Page 42: ...on 1 M10 36 878 Loctite 243 Clutch control cylinder 3 M6 7 376 Pinion cover 3 M6 7 376 Fuel delivery hose to throttle body 1 M12x1 5 16 226 72 78 Kw reduction bushing 1 M5 2 213 10 Loctite 243 Swinging arm spindle nut 1 M30x1 5 44 254 Swinging arm spindle adjuster bushing 1 M30x1 5 8 851 Swinging arm spindle nut 1 M20x1 5 66 38 Caliper support pin 1 M12 36 878 Loctite 243 Chain tensioner screw and...

Page 43: ... Single double conrod 1 M10 36 878 Double conrod swinging arm 1 M10 36 878 Double conrod shock absorber 1 M10 36 878 Battery cover bracket 2 M5 1 475 Horn mount bracket 1 M8 18 439 Odometer sensor on rear brake caliper support 1 M6 8 851 Rear direction indicators 2 M4 0 738 Front direction indicators rear view mirrors 2 2 M6 3 688 Voltage regulator 2 M6 3 688 Coil to bracket support 1 M6 7 376 Tai...

Page 44: ...t 1 M6 man Brake disc 5 M8 22 127 Loctite 243 Front brake hose three way bracket 1 M5 2 213 Front exhaust hose to engine 4 M6 8 851 Rear exhaust hose to engine upper screws 2 M6 Fasten by hand Rear exhaust hose to engine lower screws 2 M6 8 851 Lambda sensor 1 M18x1 5 28 027 Fuel return fitting 1 M6 4 425 Loctite 243 Pump support to flange 3 M5 1 475 Electrical terminals on flange 2 M5 3 688 Fuel ...

Page 45: ...uard 4 M5 2 213 Front mudguard 4 M5 1 475 Rectangular reflector to license plate holder 2 M4 0 738 Stand bushing lower panel to seat subframe 2 M6 8 851 Left right side fairing 4 M5 2 213 Rear fairing passenger s belt to seat subframe 2 M6 8 851 Vibration damping weights 2 M6 7 376 Vibration damping weights terminals 2 M18x1 25 815 Handlebars to fork legs 2 M8 36 878 Handlebar safety screws 2 M6 7...

Page 46: ... improvised methods Below is a list of the special tools designed especially for this specific vehicle If necessary request the multi purpose special tools CAUTION Before using the special tools consult any documents attached SUPPORT STANDS Pos Aprilia part tool description and function A 8140176 complete support stand kit 1 8146486 front support stand 2 xxxxxxx N A center stand 3 8705021 rear sup...

Page 47: ... tool FORK TOOLS Pos Aprilia part tool description and function A 8140151 complete tool kit for fork included 1 8140145 Ø 41 mm sealing ring fitting tool 2 8140146 weight to be applied to the tool Aprilia part 8140145 Ø 1 61 in sealing ring fitting tool and Aprilia part 8140189 oil seal fitting tool Ø 1 69 in hole Kit accessory Aprilia part 8140151 complete tool kit for fork included 3 8140147 spa...

Page 48: ...GENERAL TECHNICAL INFORMATION 2 16 RSV 1000 R RSV 1000 R FACTORY ENGINE TOOLS ...

Page 49: ...er pad 13 0277729 insertion pad for lower balance shaft clutch cover bushes 14 8140177 plug socket spanner 15 0277252 flywheel magneto cover removal tool 16 0277730 flywheel removal hexagonal bolt 17 0240880 threaded bolt to lock the drive shaft at the TDC 18 0277308 gearshift secondary shaft guide bush 19 8140178 pin installation and removal pad 20 8140181 fuel oil pressure gauge compression 21 8...

Page 50: ...GENERAL TECHNICAL INFORMATION 2 18 RSV 1000 R RSV 1000 R FACTORY MISCELLANEOUS TOOLS ...

Page 51: ...8140199 tool panel 9 8140426 panel hooks 10 8140432 pushing extractor 11 8140187 engine support stand 12 8124838 battery charger M F 13 0897651 LOCTITE 243 blue 3 94 in 14 0899788 LOCTITE 648 green 0 176 oz 15 0899784 LOCTITE 574 orange 16 0297434 LOCTITE 767 Anti Seize 15378 17 0297433 MOLYKOTE G N 1 76 oz 18 0897330 multi purpose grease bp lz 19 0297386 SILASTIC 732 RTV 3 53 oz 20 8116067 LOCTIT...

Page 52: ...gine oil 8116053 grease BIMOL GREASE 481 AUTOGREASE MP or GREASE 30 8116038 grease LUBERING ST xxxxxxx N A AP LUBE temporary lubricant xxxxxxx N A grease DID CHAIN LUBE 8116031 Fluid Biosolvent frame detergent 8116945 ACRILICON 28 cyanoacrylic glue xxxxxxx N A MOTUL MOTOWASH degreaser 8116043 ANTI SEIZE MOTAGEPASTE AS 1800 antiscuff paste xxxxxxx N A alcohol 0898011 fluorescent green LOCTITE 275 x...

Page 53: ...ring 5 Left rear view mirror 6 Clutch fluid s reservoir 7 Engine s oil filter 8 Left side panel 9 Rider s seat 10 Battery 11 Main fuse carrier 30 A 12 Passenger seat s lock glove tool kit compartment 13 Passenger left footrest snaps closed open 14 Drive chain 15 Rear swinging arm 16 Rider s left footrest 17 Side stand 18 Gear shift lever 19 Engine s oil tank 20 Engine s oil level 21 Engine oil tan...

Page 54: ...compartment cover 6 Passenger s grab strap 7 Engine s Control Unit 8 Right side panel 9 Fuel tank 10 Coolant expansion tank s cap 11 Fuel tank s filler cap 12 Air cleaner 13 Right rear view mirror 14 Front brake fluid s reservoir 15 Secondary fuse carrier 15 A 16 Horn 17 Right side fairing 18 Expansion tank 19 Rear brake fluid s reservoir 20 Rear brake master s cylinder 21 Rear brake s lever 22 Ri...

Page 55: ...t rear view mirror 6 Clutch fluid s reservoir 7 Engine s oil filter 8 Left side panel 9 Rider s seat 10 Battery 11 Main fuse carrier 30A 12 Passenger seat Glove tool kit s compartment lock 13 Passenger s left footrest 14 Drive chain 15 Rear swinging arm 16 Rider s left footrest 17 Side stand 18 Gear shift lever 19 Engine s oil tank 20 Engine s oil level 21 Engine oil tank s cap ...

Page 56: ...mpartment cover 6 Passenger s grab strap 7 Engine s Control Unit 8 Right side panel 9 Fuel tank 10 Coolant expansion tank s cap 11 Fuel tank filler s cap 12 Air cleaner 13 Right rear view mirror 14 Front brake fluid s reservoir 15 Secondary fuse carrier 15A 16 Horn 17 Right side fairing 18 Coolant expansion tank 19 Rear brake fluid s reservoir 20 Rear brake s master cylinder 21 Rear brake s lever ...

Page 57: ... Direction indicator switch 9 Horn button 10 Starter button 11 Engine kill switch Key 1 Rev counter 2 Red line light 3 Green direction indicator light 4 Blue high beam light 5 Amber stand down light 6 Amber low fuel light 7 Red immobilizer light where immobilizer system is fitted 8 Green neutral light N 9 Multifunction digital display coolant temperature clock battery voltage lap timer engine oil ...

Page 58: ...hes on the dashboard instead of the water temperature reading and if the stand and red line leds turn on then there is a communi cations problem on the can line between the dashboard and the ECU After the first 1000 Km the SERVICE icon will be displayed on the multifunction display It will be displayed for a second time after 10 000 Km and every 10 000 Km thereafter To reset the SERVICE message ho...

Page 59: ...g displayed IMPORTANT The max and average speed readings refer to the period since they were last reset The battery voltage reading V is not modifiable and gives information on the operating condition of the battery The recharger circuit is operating correctly if the battery volt age reads 13 to 15 V with the headlamp set to low beam and the engine running at 4000 rpm Instruments lighting adjustme...

Page 60: ...COOLANT TEMPERATURE The coolant temperature display reads when the sensor reads a temperature below 34 C 93 F The current temperature reading is displayed without flashing when the sensor reads a temperature between 35 C 95 F and 114 C 237 F The display flashes when the reading is between 115 C 239 F and 135 C 275 F The warning led also lights up to indicate that the temperature is in the danger z...

Page 61: ...ing mode MINUTES SETTING Press the or key to increase decrease the minute setting If one of the keys is held down the setting runs through the minutes one a second Hold down the TRIP V key for at least 3 seconds at which point the minute digits will stop flashing to indi cate that the new setting is confirmed The clock setting is lost when the battery is discon nected from the vehicle CHRONOMETER ...

Page 62: ...ay will read Ø1 LAP ØØ ØØ ØØ to indi cate that all 40 stored laps have been set to zero Stored lap times are zeroed when the battery is dis connected from the vehicle To display the stored lap times Enable the chronometer function and hold down TRIP V for more than 3 seconds To scroll through the laps press the keys forwards back respectively To return to the chronometer function press TRIP V agai...

Page 63: ...essing it briefly will increase the setting by 100 rpm holding it down will increase it by 1000 rpm If the pointer reaches the full scale value 12000 rpm it is automatically reset to zero 3 seconds after the last adjustment key the new red line setting is stored and confirmed by the red line indi cator 2 turning on for 3 seconds The pointer 1 re turns to zero If the engine is started during the ad...

Page 64: ...nsor Signal V 13 Sensor voltage V Sensor voltage V Sensor fault TPS Sensor not adapted 15 Sensor fault Sensor voltage V Engine temperature Sensor voltage V 21 Sensor fault Sensor voltage V Air temperature Sensor voltage V 22 Sensor voltage V Barometric pressure Sensor voltage V 23 Ignition 1 Ignition signal 1 not present 33 Ignition 2 Ignition signal 2 not present 35 Tip Over Switch Sensor fault d...

Page 65: ...odes the SERVICE icon displays after the first 1000 Km 620 mi 5 next after a total 10000 Km 6213 mi i e 9000 Km 5592 mi after the first time every 10000 Km 6213 mi 5 thereafter hence at 20000 Km 12427 mi 30000 Km 18641 mi etc To reset the SERVICE function hold down the and keys together for at least 15 seconds at key ON ...

Page 66: ...GENERAL TECHNICAL INFORMATION 2 34 RSV 1000 R RSV 1000 R FACTORY 2 1 9 SYSTEMS DIAGRAM BRAKES ...

Page 67: ...GENERAL TECHNICAL INFORMATION 2 35 RSV 1000 R RSV 1000 R FACTORY GAS RECOVERY FROM CRANKCASE ...

Page 68: ...FUEL SYSTEM 3 1 RSV 1000 R RSV 1000 R FACTORY FUEL SYSTEM 3 ...

Page 69: ...VING THE FUEL PUMP ASSEMBLY 12 3 2 2 REMOVING THE FUEL LEVEL SENSOR 13 3 2 3 REMOVING THE DELIVERY FILTER 14 3 2 4 REMOVING THE FUEL SUPPLY PUMP 15 3 3 THROTTLE BODY 17 3 3 1 REMOVING THE THROTTLE BODY 17 3 3 2 DISASSEMBLING THE THROTTLE BODY 20 3 3 3 INSPECTING THE THROTTLE BODY 23 3 3 4 REFITTING THE THROTTLE BODY 24 3 3 5 REPLACING THE THROTTLE VALVE CONTROL LEVER 26 3 3 6 CHECKING THROTTLE VAL...

Page 70: ...M Key 1 Fuel tank 2 Filler cap 3 Fuel supply pump unit 4 Fuel vapor breather pipe for the vapors produced by excessive pressure inside the tank 5 Fuel overflow drainage pipe 6 Fuel level sensor 7 Fuel delivery filter 8 Fuel supply pump 9 Fuel delivery pipe 10 Fuel return pipe ...

Page 71: ...FUEL SYSTEM 3 4 RSV 1000 R RSV 1000 R FACTORY 3 1 2 INJECTION SYSTEM DIAGRAM ...

Page 72: ...emperature sensor 7 Air temperature sensor 8 Throttle position sensor 9 Intake pressure sensor 10 Safety system Side stand idle sensor 11 Test switch 12 Fall sensor 13 Atmospheric pressure sensor 14 Oil pressure sensor 15 Fan 16 Automatic air 17 Intake flap 18 Lambda sensor 19 Diagnostics connector 20 Starter relay 21 Fuel pump 22 Injector 1 23 Injector 2 24 Coil ...

Page 73: ... the exhaust gas analyzer s lines to their fit tings Start with both throttle body bypass screws fully closed Open a single screw to balance the exhaust gas CO level as read off the analyzer s display Read the front and rear cylinder pressure values off the Axone and check that they are as follows front cylinder pressure rear cylinder pressure 30 10 mbar IMPORTANT Incorrect pressure value s readin...

Page 74: ...ctivated at 101 C Air temperature C Engine speed rpm Target minimum engine speed rpm ECU target engine speed for current operating conditions Engine load Intake pressure hPa Value read by sensor connected to the two intake ducts Effective throttle aperture 2 7 80 Parameter which accounts for the throt tle aperture and stepper motor position Spark advance Throttle 0 78 Reads the throttle aperture i...

Page 75: ...r switch circuit is inter rupted although the ignition button is pressed the condition of this parameter does not change it stays OFF Purge valve on off Lambda sensor active on off Lambda sensor operational Cut off on off Activates at certain engine speed throttle position etc combinations Throttle self teaching com pleted on off If throttle position self teaching does not end successfully the par...

Page 76: ...isplay ECU initialized yes Indicates that the ECU initialized parameter has been enabled If the ECU is replaced this parameter must be enabled DEVICE AC TIVATION Errors reset Fuel pump Intake distribution Lambda sensor heating Fan Purge valve Activation only for USA version Front injector Rear injector Front coil Rear coil ADJUSTABLE PARAME TERS Initialization To reset adaptive parameters when cha...

Page 77: ...d The counter does not reset when the Initialization parameter is en abled The following options are available from the adjustable pa rameters display throttle position sensor alignment ECU initialization including throttle alignment mini mum stepper motor reset and lambda sensor adaptive parameters reset ECU initialization required when a new ECU is in stalled Throttle position alignment must be ...

Page 78: ...e windshield to the airbox This flap reduces engine noise at low engine speeds The flap assembly is composed of hatch tie rod membrane solenoid valve The flap is normally closed and opens in the following circumstances minimum 6500 rpm minimum 30 throttle opening The vacuum chamber acts to prevent pressure pulses If the check valve is to be replaced take care to fit it in the correct position the ...

Page 79: ...ORTANT Position the tank on a clean surface with the pump unit uppermost Loosen and remove the eight screws 1 IMPORTANT To refit fasten all screws 1 by hand in their holes and tighten in a cross pattern WARNING When removing the pump assembly make sure not to damage the fuel hoses and level sensor Remove the entire fuel pump assembly ...

Page 80: ...FUEL SYSTEM 3 13 RSV 1000 R RSV 1000 R FACTORY 3 2 2 REMOVING THE FUEL LEVEL SENSOR Remove the entire fuel system Disconnect the connector Release and remove the 2 screws Remove the fuel level sensor ...

Page 81: ...lace the hose clamp that has been removed with a new one having the same dimensions Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp or with other types of clamp Release the hose clamp 1 Slip the pipe off the filter Release the hose clamp 2 Slip the filter off the pipe CAUTION Do not use filters that have already been ...

Page 82: ...allation pliers CAUTION Upon installation replace the hose clamp that has been removed with a new one having the same dimensions Do not attempt to reinstall the removed hose clamp since it is unusable Do not replace the removed hose clamp with a screw clamp or with other types of clamp Release the hose clamp 1 Pull the fuel pipe off the pump Disconnect the electric connector Disconnect the electri...

Page 83: ...0 R FACTORY Loosen and remove the 3 screws Bend the fuel filter over sideways and keep it held down If the filtering mesh shows traces of sediments clean it using a compressed air jet pointing it so that the impuri ties do not get inside ...

Page 84: ...d Only if the entire cable fitting 2 is to be re placed the setting screws can be adjusted The two M4x12 3 screws securing the throttle valve potentiometer are painted over and can only be extracted if the sensor itself is being removed Partially remove the fuel tank Remove the airbox Detach the electrical connectors right injector left injector throttle valve potentiometer ...

Page 85: ...lip pliers Undo the snap clip 4 Undo the snap clip 5 Extract the hoses from the throttle body Undo the two throttle control cables WARNING During rebody make sure the two throttle con trol cable adjusters are correctly mounted to their fittings and check adjust their play Extract the airbox flap hose from the throttle body ...

Page 86: ...entire throttle body and fuel tank which are connected to each other on a clean surface When reassembling the fuel delivery hose must not be twisted or squeezed by other components if it is damaged or degraded in any way it must be replaced the fuel delivery hose must be positioned in such a way as to reach the right hand side of the throttle body from below passing between the two intake flanges ...

Page 87: ...E M5x12 screws 3 Slip the whole support bracket 4 securing the throttle cables with the two bushes 5 and the torsion spring 6 off the throttle body Loosen and remove the two M6x16 screws 7 and re move the fuel pressure regulator 8 complete with O ring Loosen and remove the three M6x25 screws 9 and remove the left injector support 10 together with the relevant gasket 11 injector 12 and sealing ring...

Page 88: ...ACTORY Loosen and remove the two M6x25 screws 14 and the right injector support 15 together with the rele vant gasket 16 injector 17 and sealing ring 18 NOTE The injector s sealing ring 18 may be kept inserted in the slot on the throttle body ...

Page 89: ...remove the spring washer 20 the pulley 21 the two bushes 22 and torsion spring 23 Slide the fulcrum pin 24 together with the lock washer 25 out of the hole on the throttle cable sup port bracket and remove the two shaft sealing rings 26 with the torsion spring 27 and cold start lever 28 ...

Page 90: ...pes of the intake pressure sensor 2 watching out for any clogging Check the throttle valves unit and the cable fastening mechanism 3 watching out for any signs of mechani cal damage NOTE In the event the synchronization screws 4 or O rings 5 are replaced synchronize the cylinders Loosen the two cylinder synchronization screws 4 only in case of air escapes When replacing the tie rod of the ball joi...

Page 91: ...g screws 11 and respective O rings 12 have been replaced tighten the screws 11 until they touch the stop and then unscrew them a single turn Presetting of synchronizing screws 11 1 turn CAUTION The precise adjustment of the screws 11 must be performed using a vacuum gauge Fasten the fuel pressure regulator 13 using the two M6x16 screws 14 NOTE Smear a film of grease over the surfaces of the ful cr...

Page 92: ...pray a temporary lubricant on the spring 20 see 1 9 2 USE OF CONSUMABLES Fit the spring washer 22 NOTE Apply LOCTITE 243 on the thread of the nut 23 Screw the M8x1 nut 23 and tighten it NOTE Apply LOCTITE 243 on the thread of the screws 25 Fasten the anchoring bracket of the accelerator cables 24 with the three hex head screws M5x12 25 Fit the throttle valve control lever 26 ...

Page 93: ...on spring 4 on the throttle body Fit the throttle valve control lever 2 on the throttle valve spindle NOTE Spray a temporary lubricant on the spring 4 CAUTION Make sure the ends of the torsion spring 4 are hooked on the throttle body and throttle valve control lever 2 Fit the spring washer NOTE Apply LOCTITE 243 on the thread of the nut 1 Screw the M8x1 nut 1 and tighten it NOTE Once assembly is c...

Page 94: ...ed Use the thickness gauge 1 to measure the minimum play between the lever 2 and the contact surface 3 on the throttle body in a number of points End play min 0 00394 in 0 1 mm CAUTION If the minimum value measured is lower than 0 00394 in 0 1 mm the throttle body must be replaced With throttle valves open Repeat the above procedure End play min 0 0059 in 0 15 mm CAUTION If the minimum value measu...

Page 95: ...ENGINE 4 1 RSV 1000 R RSV 1000 R FACTORY ENGINE 4 ...

Page 96: ...ENGINE 4 2 RSV 1000 R RSV 1000 R FACTORY SUMMARY 4 1 ENGINE 3 4 1 1 REMOVING THE ENGINE 3 4 1 2 REINSTALLING THE ENGINE 26 4 1 3 TIGHTENING TORQUES 51 ...

Page 97: ... 4 3 RSV 1000 R RSV 1000 R FACTORY 4 1 ENGINE 4 1 1 REMOVING THE ENGINE Remove the airbox cover Loosen the screw securing the airbox to the frame Remove the six screws securing the throttle body to the airbox ...

Page 98: ... RSV 1000 R FACTORY Detach the by pass lines to the throttle body and the stepper motor connector Remove the oil vapor recovery line Detach the manifold pressure sensor connection and the lines coming from the throttle body ...

Page 99: ...ENGINE 4 5 RSV 1000 R RSV 1000 R FACTORY Remove the airbox Disconnect the cabling from the ignition coil ...

Page 100: ...ENGINE 4 6 RSV 1000 R RSV 1000 R FACTORY Disengage the throttle cables Detach the throttle potentiometer connector Remove the vacuum lines from the throttle body ...

Page 101: ...ENGINE 4 7 RSV 1000 R RSV 1000 R FACTORY Disconnect the injector connectors Loosen the clamps on the intake manifolds ...

Page 102: ...INE 4 8 RSV 1000 R RSV 1000 R FACTORY Remove the throttle body Close the lines so that impurities are unable to enter the cylinders Open the clamps on the lubrication circuit lines leading to the oil tank ...

Page 103: ...ENGINE 4 9 RSV 1000 R RSV 1000 R FACTORY Detach the engine casing oil lines Loosen the three screws securing the oil tank ...

Page 104: ...ENGINE 4 10 RSV 1000 R RSV 1000 R FACTORY Remove the oil tank and extract the line coming from the cooler Remove the fairing air dam by loosening its screws 2 central 4 side ...

Page 105: ...V 1000 R RSV 1000 R FACTORY Extract the bleed lines from their seat Remove the oil line on the engine casing Undo the stud mounting the oil line clamp to the engine casing Disconnect the oil hose from the right side ...

Page 106: ... R FACTORY Release and remove the four screws securing the oil cooler s subframe IMPORTANT To remove the left side screw hold the inner nut steady with a wrench Remove the subframe and the oil cooler Remove the rear brake fluid tank ...

Page 107: ... RSV 1000 R FACTORY Loosen the screws securing the rear brake pump Undo the clip securing the pump to the brake lever Detach the line leading to the expansion tank Loosen the screws securing the expansion tank and remove it ...

Page 108: ...ENGINE 4 14 RSV 1000 R RSV 1000 R FACTORY Detach the engine oil pressure sensor connector Detach the lambda sensor stop light switch speed sensor and rectifier connections ...

Page 109: ... RSV 1000 R FACTORY Remove the lower cooler mounts and move it away while holding it in a vertical position Unscrew the starter motor connector Release the silencer mounting clips Loosen the screw securing the silencer clamp ...

Page 110: ... 4 16 RSV 1000 R RSV 1000 R FACTORY Remove the silencers Release the clip securing the front cylinder manifold to the exhaust Undo the four nuts securing the manifold to the front cylinder Remove the manifold ...

Page 111: ... RSV 1000 R RSV 1000 R FACTORY Keep the gasket Undo the clip securing the rear manifold to the exhaust Extract the lambda sensor cable from the frame Remove the entire exhaust assembly including the lambda sensor ...

Page 112: ...FACTORY Undo the four nuts fixing the manifold to the rear cylin der Remove the exhaust manifold and keep the gasket Disconnect the temperature sensor timing sensor en gine speed sensor side stand safety switch and gen erator connectors ...

Page 113: ...ENGINE 4 19 RSV 1000 R RSV 1000 R FACTORY Detach the spark plug cap ...

Page 114: ...ENGINE 4 20 RSV 1000 R RSV 1000 R FACTORY Remove the gearshift lever Remove the clutch lever and flange ...

Page 115: ...ENGINE 4 21 RSV 1000 R RSV 1000 R FACTORY Remove the pinion casing and guide plate on the en gine casing Undo the bolt securing the pinion and keep the wash ers Remove the pinion ...

Page 116: ...ENGINE 4 22 RSV 1000 R RSV 1000 R FACTORY Open the clamps and remove the coolant lines on the radiator Undo the engine casing ground connectors Detach the neutral sensor connector ...

Page 117: ...0 R RSV 1000 R FACTORY Remove the rear brake lever Remove the lever mount and rear brake pump Remove the brake pump mount Detach the vacuum line on the pneumatic clutch actua tor Support the engine with a suitable support ...

Page 118: ...4 RSV 1000 R RSV 1000 R FACTORY Loosen the screws mounting the engine to the frame at the rear Loosen the four screws on the front engine mounts Remove the screws and the spacers between the frame and the engine ...

Page 119: ...ENGINE 4 25 RSV 1000 R RSV 1000 R FACTORY Slacken the adjuster bushings between the engine and the frame Fully lower the engine ...

Page 120: ...1000 R RSV 1000 R FACTORY 4 1 2 REINSTALLING THE ENGINE Place the engine on a suitable support Partly raise the engine Position the engine so that the rear mounts are aligned with the frame Locate the front left spacer ...

Page 121: ... 4 27 RSV 1000 R RSV 1000 R FACTORY Fit the two screws to the front left mount Locate the rear left spacer and tighten the screw to the prescribed torque Fit the rear left screw Locate the front right spacer ...

Page 122: ...Fit the two screws to the front right mount Tighten down the four left side screws Tighten the upper right bush to the prescribed torque Tighten the upper right nut to the prescribed torque Tighten the lower right bush to the prescribed torque ...

Page 123: ...E 4 29 RSV 1000 R RSV 1000 R FACTORY Tighten the lower right nut to the prescribed torque Fit the upper right screw Fit the lower right screw Tighten down the four right side screws Remove the engine support ...

Page 124: ...TORY Refit the pneumatic clutch actuator vacuum line and secure it with a clamp Fit the rear brake lever mount and pump and tighten the screws to the specified torque Fit the rear brake lever and tighten the screws to the specified torque ...

Page 125: ...SV 1000 R RSV 1000 R FACTORY Fit the rear brake pump and connect it to the brake lever Screw in the neutral sensor connector Refit the engine casing ground connectors and tighten their screws to the specified torque ...

Page 126: ...ENGINE 4 32 RSV 1000 R RSV 1000 R FACTORY Fit the coolant lines to the radiator and secure them with clamps Fit the pinion in the right orientation ...

Page 127: ... RSV 1000 R RSV 1000 R FACTORY Mount the pinion tightening it to the specified torque Fit the pinion casing and guide plate and tighten the screws to the specified torque Fit the clutch lever complete with flange ...

Page 128: ...INE 4 34 RSV 1000 R RSV 1000 R FACTORY Mount the gear shift lever Fit the spark plug caps Hook up the temperature sensor timing sensor engine speed sensor side stand safety switch and generator connectors ...

Page 129: ...ENGINE 4 35 RSV 1000 R RSV 1000 R FACTORY Mount the rear cylinder exhaust manifold with its gas ket ...

Page 130: ... the studbolt nuts to their specified torque Fit the entire exhaust assembly complete with lambda sensor Insert the clip securing the rear manifold and exhaust Secure the lambda sensor cabling to the frame Fit the exhaust gasket to the front cylinder ...

Page 131: ...V 1000 R FACTORY Fit the manifold to the cylinder studbolts and exhaust Tighten the four nuts securing the manifold to the cyl inder to the specified torque Reconnect the clip securing the front cylinder manifold to the exhaust ...

Page 132: ...ENGINE 4 38 RSV 1000 R RSV 1000 R FACTORY Refit the silencers Screw on the silencer clamp screws Clip on the silencer clips Screw in the starter motor connector ...

Page 133: ...ENGINE 4 39 RSV 1000 R RSV 1000 R FACTORY Move the cooler towards the engine and refit the lower mounts Hook up the lambda sensor stop light switch speed sensor and rectifier connections ...

Page 134: ...ENGINE 4 40 RSV 1000 R RSV 1000 R FACTORY Connect up the engine oil pressure sensor connector Fit the expansion tank and screw in the two mounting screws Connect the line leading to the expansion tank ...

Page 135: ... R RSV 1000 R FACTORY Engage the brake lever pump clip Tighten the screws securing the rear brake pump Fit the rear brake fluid tank Fit the subframe and the oil cooler Tighten down the four screws to the prescribed torque ...

Page 136: ...ENGINE 4 42 RSV 1000 R RSV 1000 R FACTORY Connect the oil hose from the right side Screw in the stud mounting the oil line clamp to the en gine casing Fit the oil line to the engine casing ...

Page 137: ... 1000 R FACTORY Insert the bleed lines in their seats Screw in the two screws securing the conveyor to the coolant radiator mount Fit the coolant radiator conveyor Fit the fairing air dam and tighten its screws 2 central 4 side ...

Page 138: ...ENGINE 4 44 RSV 1000 R RSV 1000 R FACTORY Fit the oil tank and the oil cooler line Tighten down the three screws securing the oil tank Mount the oil lines to the engine casing ...

Page 139: ...1000 R RSV 1000 R FACTORY Tighten the clamps on the lubrication circuit lines lead ing to the oil tank Remove the protectors inserted into the lines Fit the throttle body Tighten down the clamps on the intake manifolds ...

Page 140: ...ENGINE 4 46 RSV 1000 R RSV 1000 R FACTORY Hook the connectors to the injectors Fit the vacuum lines to the throttle body ...

Page 141: ...ENGINE 4 47 RSV 1000 R RSV 1000 R FACTORY Refit the throttle potentiometer connector Fit the throttle control cables and adjust their play Connect the cabling to the ignition coil ...

Page 142: ...ENGINE 4 48 RSV 1000 R RSV 1000 R FACTORY Fit the airbox Tighten the six screws securing the airbox to the throt tle body to the specified torque ...

Page 143: ...hten the screw mounting the airbox to the frame at the front to the specified torque Hook up the throttle body hoses to the stepper motor Refit the manifold pressure sensor connector Hook up the oil vapor recovery line and secure it with its clamp ...

Page 144: ...ENGINE 4 50 RSV 1000 R RSV 1000 R FACTORY Connect the stepper motor and bypass lines leading to the throttle body Fit the airbox cover ...

Page 145: ...ng 2 M20x1 5 36 878 Screw right side upper and lower rear fitting 2 M10 36 878 Engine oil intake flange 2 M6 7 376 Engine oil outlet flange 2 M6 7 376 Rear brake lever support 1 M6 7 376 Rear brake lever support 1 M8 18 439 Rear brake pump support 2 M8 18 439 Pinion 1 M10 36 878 Loctite 243 Clutch control cylinder 3 M6 7 376 Pinion cover 3 M6 7 376 Fuel delivery hose to throttle body 1 M12x1 5 16 ...

Page 146: ...CYCLE PARTS 5 1 RSV 1000 R RSV 1000 R FACTORY CYCLE PARTS 5 ...

Page 147: ...ING THE SWINGING ARM 84 5 5 2 CHECKING THE COMPONENTS 87 5 5 3 DISASSEMBLING THE REAR FORK GASKETS 88 5 5 4 REFITTING THE SWINGING ARM 89 5 5 5 TIGHTENING TORQUES 92 5 6 FRONT WHEEL 93 5 6 1 DIAGRAM 93 5 6 2 REMOVING THE WHEEL 94 5 6 3 CHECKING THE FRONT WHEEL COMPONENTS 97 5 6 4 DISASSEMBLING THE FRONT WHEEL BEARINGS 99 5 6 5 ASSEMBLING THE FRONT WHEEL BEARINGS 100 5 6 6 REFITTING THE FRONT WHEEL...

Page 148: ...R RSV 1000 R FACTORY 5 10 CLUTCH 132 5 10 1 BLEEDING THE CLUTCH CIRCUIT 132 5 11 DRIVE CHAIN 133 5 11 1 DRIVE CHAIN 133 5 11 2 INSPECTING THE DRIVING CHAIN SHOE 135 5 11 3 REMOVING THE CHAIN SHOE 136 5 11 4 LOWER CHAIN SHOE 138 ...

Page 149: ...VING THE BODY PANELS Remove the screws securing the fairing to the sides With the aid of screwdriver undo the clips securing the fairing to the front fairing Remove the clips from their seats with a pair of pliers Slide out the fairing sideways taking care not to dam age it ...

Page 150: ...front fairing panels by loosening the front fairing s retaining screws Detach the direction indicator connectors and detach the cabling from its mount Remove the rear view mirrors With the aid of a screwdriver undo the clips securing the front fairing to its mount ...

Page 151: ...CYCLE PARTS 5 6 RSV 1000 R RSV 1000 R FACTORY Remove the clips using a pair of pliers Partially extract the front fairing Detach the six lamp connectors Remove the front fairing ...

Page 152: ...RTS 5 7 RSV 1000 R RSV 1000 R FACTORY Undo the two screws securing the rider s seat and lift it off Unlock the passenger s seat using the ignition key Push the seat forwards so as to disengage it from its mount ...

Page 153: ... R FACTORY Extract the passenger s seat from the belt and remove it Undo the screw securing the belt and keep the center ing bushings Remove the spacers between the tail and the seat s subframe Disconnect the passenger seat unlock cable ...

Page 154: ...S 5 9 RSV 1000 R RSV 1000 R FACTORY Undo the screws securing the side panels Extract the side panels Undo the screws securing the tail light to the tail Loosen the six screws securing the tail to the lower panel ...

Page 155: ...CYCLE PARTS 5 10 RSV 1000 R RSV 1000 R FACTORY Separate the tail from the tail light Detach the direction indicator connectors Remove the tail Undo the two screws securing the fuel tank ...

Page 156: ...CYCLE PARTS 5 11 RSV 1000 R RSV 1000 R FACTORY Remove the screws and turn the tank over Detach the bleed tubes Detach the fuel delivery and return lines Lower the tank ...

Page 157: ...CYCLE PARTS 5 12 RSV 1000 R RSV 1000 R FACTORY Disconnect the fuel pump connector Remove the rear tank retaining screw Remove the tank and slide the cabling out of the frame ...

Page 158: ...CLE PARTS 5 13 RSV 1000 R RSV 1000 R FACTORY 5 1 2 BODY PANEL REASSEMBLY Place the tank and its cabling on the frame Fit the rear tank s retaining screw Connect the fuel pump connector Raise the fuel tank ...

Page 159: ...CYCLE PARTS 5 14 RSV 1000 R RSV 1000 R FACTORY Fit the fuel delivery and return lines Connect the bleed lines and secure them with their clamps Lower the tank and fit the two front retaining screws ...

Page 160: ...R FACTORY Fit the tail Connect the direction indicator connectors Tighten the six screws securing the tail to the lower panel Install the screws securing the tail light to the tail Install the screws securing the tail to the seat subframe ...

Page 161: ...CYCLE PARTS 5 16 RSV 1000 R RSV 1000 R FACTORY Fit the side panels Secure the side panels to the tank and the seat sub frame Connect the passenger seat unlock cable ...

Page 162: ...0 R RSV 1000 R FACTORY Fit the spacers between the tail and the seat s sub frame Fit the passenger s belt and tighten the two retaining screws Mount the passenger s seat Position the rider s seat and secure it with its screws ...

Page 163: ...CYCLE PARTS 5 18 RSV 1000 R RSV 1000 R FACTORY Hook up the six lamp connectors Fit the front fairing Secure the clips ...

Page 164: ...1000 R FACTORY Fit the rear view mirrors Hook up the direction indicator connectors Mount the front fairing upper panels and tighten the screws securing the front fairing Insert the fairing from the side taking care not to dam age it ...

Page 165: ...CYCLE PARTS 5 20 RSV 1000 R RSV 1000 R FACTORY With the aid of a screwdriver secure the clips securing the fairing to the front fairing Fit the screws securing the fairing to the side ...

Page 166: ...t fairing panel to bottom yoke 3 M6 5 163 License plate holder to lower seat subframe cover 4 M6 2 213 Lower panel to seat subframe 3 M6 3 688 Front lower seat subframe panel to frame 2 M5 1 475 Side body panels to tank 1 1 M5 3 688 Side body panels to seat subframe 2 2 M5 2 213 Rear mudguard 4 M5 2 213 Front mudguard 4 M5 1 475 Rectangular reflector to license plate holder 2 M4 0 738 Stand bushin...

Page 167: ...CYCLE PARTS 5 22 RSV 1000 R RSV 1000 R FACTORY 5 2 FRONT FORK 5 2 1 DIAGRAM RSV R ...

Page 168: ... 4 Slider upper plug 5 Washer 6 Slide bush 7 Piston assembly 8 Centering bush 9 Spring press tube 10 Spring 11 Spring rest washer 12 Lower collar 13 Slider 14 Slide bush 15 Guide bush 16 Stop ring 17 Gasket 18 Retainer ring 19 Anti dust gasket 20 Wheel holder tube 21 Copper washer 22 Center screw 23 O ring 24 O ring ...

Page 169: ...5 2 2 REMOVING THE FORK LEGS Support the front part of the motorcycle Undo the screws securing the front mudguard and re move it Undo the screws securing the front brake calipers and remove them from their seats Undo the nut securing the wheel axle ...

Page 170: ...000 R FACTORY Keep the seal washer Slacken the screws on the wheel axle clamps Lightly knock the wheel axle with a rubber mallet so as to uncover the holes on the opposite side Pull out the hollow axle using a screwdriver in the holes ...

Page 171: ...SV 1000 R FACTORY While removing the axle support the wheel and then remove it Slacken the screws securing the handlebar on the side in question to the fork Support the fork leg and slacken the screws on the up per and lower plates ...

Page 172: ...CYCLE PARTS 5 27 RSV 1000 R RSV 1000 R FACTORY Extract the fork leg ...

Page 173: ...V 1000 R FACTORY 5 2 3 FITTING THE FORK LEGS Insert the fork leg Adjust the slider resistance and tighten the screws on the fork plates to the specified torque Tighten the handlebar screws to the specified torque Fit the front wheel ...

Page 174: ...000 R FACTORY Fit the wheel axle Tighten down the clamp screws nut side to secure the wheel axle Fit the seal washer and screw on the axle nut to the specified torque Make sure the fork legs are aligned by pumping the fork up and down ...

Page 175: ... axle clamps to the specified torque Tighten the screws securing it to the specified torque WARNING After fitting the brake calipers repeatedly operate the front brake lever Fit the front mudguard Install the brake calipers and tighten the screws secur ing them to the specified torque ...

Page 176: ...RSV 1000 R RSV 1000 R FACTORY 5 2 4 CHANGING THE FORK FLUID RSV R Clamp the slider with the specified tool Set the spring preload to its minimum Undo the upper slider cap Clamp the fork end taking care not to damage it ...

Page 177: ...special tool to the spring coupling Push the tool downwards to compress the spring and install the tool spacer under the cartridge locknut Slacken the cap using the locknut for leverage with a wrench fitted to the wrench seat Remove the entire cap assembly ...

Page 178: ...S 5 33 RSV 1000 R RSV 1000 R FACTORY Remove the spacer and the washer Press downwards to compress the spring and extract the spacer Extract the spring coupling Drain the oil into a container and remove the spring ...

Page 179: ... R FACTORY 5 2 5 TOPPING UP THE FORK FLUID RSV R Fill the fork so that any air inside it is vented Fit the spring coupling Fit the special tool to the spring coupling so as to lock the cartridge stem in position Fit the spacer and washer ...

Page 180: ...CYCLE PARTS 5 35 RSV 1000 R RSV 1000 R FACTORY Screw the top cap on the cartridge leg Clamp the slider in a vice using the special tool ...

Page 181: ...CYCLE PARTS 5 36 RSV 1000 R RSV 1000 R FACTORY Tighten the top cap to the specified torque ...

Page 182: ...V 1000 R RSV 1000 R FACTORY 5 2 6 REPLACING THE OIL DUST SEAL RSV R Clamp the slider with the specified tool Set the spring preload to its minimum Undo the upper slider cap Clamp the fork end taking care not to damage it ...

Page 183: ...special tool to the spring coupling Push the tool downwards to compress the spring and install the tool spacer under the cartridge locknut Slacken the cap using the locknut for leverage with a wrench fitted to the wrench seat Remove the entire cap assembly ...

Page 184: ...S 5 39 RSV 1000 R RSV 1000 R FACTORY Remove the spacer and the washer Press downwards to compress the spring and extract the spacer Extract the spring coupling Drain the oil into a container and remove the spring ...

Page 185: ...CYCLE PARTS 5 40 RSV 1000 R RSV 1000 R FACTORY Extract the washer and lower spacer Undo the cartridge retainer screw on the fork end Keep the centering bushing ...

Page 186: ...tract the wiper seal from the slider Take care not to damage the rim of the slider Remove the stop ring Extract the slider from the stanchion tube using the slider itself to exert leverage Remove the fixed bushing mobile bushing ring and oil seal from the stanchion tube ...

Page 187: ...CYCLE PARTS 5 42 RSV 1000 R RSV 1000 R FACTORY Remove the ring and wiper seal ...

Page 188: ...CYCLE PARTS 5 43 RSV 1000 R RSV 1000 R FACTORY ...

Page 189: ...ITTING THE OIL DUST SEAL RSV R Clamp the fork leg in such as way as not to damage it Protect the end of the stanchion tube with tape Lubricate the sliding surfaces with fork oil or seal grease Fit the wiper seal stop ring and seal ring to the stan chion tube ...

Page 190: ...CYCLE PARTS 5 45 RSV 1000 R RSV 1000 R FACTORY The seal ring must be installed with the stamped side facing the wiper seal Now fit the ring mobile bushing and after removing the tape the fixed bushing ...

Page 191: ...he slider to the stem and install the oil seal in its correct position with the special tool Fit the stop ring in its seat Fit the wiper seal with the prescribed tool Fit the centering bushing to the cartridge and install the entire assembly to the fork ...

Page 192: ...CYCLE PARTS 5 47 RSV 1000 R RSV 1000 R FACTORY Tighten the cartridge retainer screw on the fork end to the specified torque Fit the lower spacer and washer Install the fork spring ...

Page 193: ...RSV 1000 R RSV 1000 R FACTORY Fill the fork so that any air inside it is vented Fit the spring coupling Fit the special tool to the spring coupling so as to lock the cartridge stem in position Fit the spacer and washer ...

Page 194: ...CYCLE PARTS 5 49 RSV 1000 R RSV 1000 R FACTORY Screw the top cap on the cartridge leg Clamp the slider in a vice using the special tool ...

Page 195: ...CYCLE PARTS 5 50 RSV 1000 R RSV 1000 R FACTORY Tighten the top cap to the specified torque ...

Page 196: ...ds the limit value change the tube Curving limit 0 0079 in 0 2 mm WARNING NEVER straighten a curved tube since its structure would be weakened thus making the use of the vehicle quite dangerous SLIDER Make sure that there are neither damages nor cracks Otherwise change it SPRING Check the integrity of the spring making sure that its length does not exceed the limit value If the length does not cor...

Page 197: ...hings taking care not to scratch their surfaces Replace the following components with new ones gasket anti dust gasket the two O rings on the adjusting element Oil quantity 204 7 0 98 in 520 2 5 cm Oil level 4 646 0 079 in 118 2 mm from the slider edge NOTE In order to obtain a correct measurement of the oil level the slider must be perfectly vertical The oil level must be the same for both tubes ...

Page 198: ... during offi cial competitions or sports events authorized by the competent authorities and taking place in closed circuits or anyway away from pub lic roads The law forbids riding a vehicle with racing settings on public roads and highways Front suspension Standard setting Racing setting Hydraulic rebound damping screw 1 Tighten fully and then slacken by 1 25 turn Tighten fully and then slacken b...

Page 199: ...during offi cial competitions or sports events authorized by the competent authorities and taking place in closed circuits or anyway away from pub lic roads The law forbids riding a vehicle with racing settings on public roads and highways Front suspension Standard setting Racing setting Hydraulic rebound damping screw 1 Hydraulic compression damping screw 2 Tighten fully and then slacken by 12 cl...

Page 200: ...CYCLE PARTS 5 55 RSV 1000 R RSV 1000 R FACTORY 5 2 9 FRONT FORK DIAGRAM RSV FACT Key 1 Complete RH fork leg 2 Complete LH fork leg 3 Top cap 4 Spring 5 Fork overhaul kit ...

Page 201: ...n3 550 cm 3 ready at hand before proceeding Place the stanchion and slider assembly in a vice Position the two shells of the special tool B to the vice jaws to protect the stanchion and slider assembly Turn the top adjuster screw 1 fully counterclockwise to reduce rebound damping force Turn the spring preload top nut 2 fully counterclockwise Release the top cap 3 from the slider using the special ...

Page 202: ...0 R RSV 1000 R FACTORY Remove the stanchion and slider assembly 5 from the vice Turn stanchion and slider over 5 to drain oil into the container NOTE Make sure the damping cylinder rod does not come out while draining the oil ...

Page 203: ...mbly upright and fit the two shells of the special tool B Raise the washer and the damping cylinder assembly Fill the fork with the specified fluid up to correct level Use a dipstick to determine correct level Oil quantity 30 51 in3 500 cm 3 Oil level 3 35 in 85 mm from slider rim Accurate oil level s measurement is only ensured when the slider is perfectly vertical and fully down Oil level must b...

Page 204: ...easure oil level again If necessary top up or remove oil until oil is at the correct level editor s note 3 35 in Insert the spacer tube 2 Tighten the top cap 3 on the damping cylinder assembly until finger tight Hold the damping cylinder steady with a wrench and tighten the top cap 3 Use the special tool A to tighten the top cap 3 on the slider Adjust to obtain correct setting ...

Page 205: ...ceeding Perform the first nine steps of the procedure described at paragraph FRONT FORK OIL CHANGE Place the fork leg in a vice Position the two shells of the special tool B to the vice to avoid damage Separate the slider 2 from the stanchion tube 1 Pry the dust seal 3 off the slider 2 levering with a flat blade screwdriver at various positions Use the flat blade screwdriver to remove the retainin...

Page 206: ...seal 5 dust seal 3 NOTE Smear the oil seal 5 lightly with fork fluid before installation Fit the following components to the stanchion 1 in the order dust seal 3 retaining ring 4 and oil seal 5 Place the slider in a vice and protect it with the two shells of the special tool B Insert the stanchion 1 into the slider 2 Position the two shells of the special tool B C to the stanchion 1 just below the...

Page 207: ...e slider 2 Push the dust seal 3 into its seat in the slider 2 and ensure it becomes properly seated Grasp the stanchion and pump it up and down slowly several times WARNING The stanchion must slide freely in the slider in a smooth motion Pour front fork fluid into the fork leg up to correct level ...

Page 208: ... first then slacken 1 M35x1 29 502 tighten first and then slacken Head stock nut tighten down 2nd time 1 M35x1 14 751 tighten 2nd time Head stock locknut 1 M35x1 man 90 grade Top yoke cap 1 M29x1 73 756 SHOWA fork hub clamps 2 2 M8 18 226 OHLINS fork hub clamps 2 2 M6 8 851 Steering damper collar to frame 1 M6 7 376 Loctite 243 Steering damper rod on bottom yoke 1 M6 7 376 Steering damper FRONT SU...

Page 209: ...CYCLE PARTS 5 64 RSV 1000 R RSV 1000 R FACTORY 5 3 STEERING BEARING 5 3 1 DIAGRAM ...

Page 210: ... PARTS 5 65 RSV 1000 R RSV 1000 R FACTORY Key 1 Upper bush 2 Washer 3 Upper plate 4 Lock ring 5 Lock washer 6 Adjuster ring 7 Anti dust gasket 8 Anti dust gasket 9 Bearings 10 Lower plate 11 Steering damper ...

Page 211: ...FACTORY 5 3 2 CHECKING THE BEARING SLACK STEERING Steering bearings and steering clearance Position the vehicle on the special center stand Shake the fork in the direction of travel In the event any slack is encountered adjust the steer ing ...

Page 212: ... 3 STEERING BEARING ADJUSTMENT Undo the upper steering column bolt Slacken the screws securing the fork legs to the top yoke Loosen and remove the screws uniting the handlebar halves and fork yoke Extract the top yoke and move it towards the dashboard ...

Page 213: ...1000 R RSV 1000 R FACTORY Settle the safety washer on the steering column Unscrew the upper ring nut and remove the safety washer Adjust the steering bearing preload by tightening the lower ring nut to the specified torque ...

Page 214: ...S 5 69 RSV 1000 R RSV 1000 R FACTORY Position the safety washer Install the upper ring nut and tighten it so that the grooves fit over the safety washer keys Settle the lugs on the upper ring nut Fit the top yoke ...

Page 215: ...TORY Fit and tighten the upper steering column bolt to the specified torque Tighten the screws uniting the handlebar halves and fork yoke to the specified torque Tighten the screws securing the fork stems to the top yoke to the specified torque ...

Page 216: ...first then slacken 1 M35x1 29 502 tighten first and then slacken Head stock nut tighten down 2nd time 1 M35x1 14 751 tighten 2nd time Head stock locknut 1 M35x1 man 90 grade Top yoke cap 1 M29x1 73 756 SHOWA fork hub clamps 2 2 M8 18 226 OHLINS fork hub clamps 2 2 M6 8 851 Steering damper collar to frame 1 M6 7 376 Loctite 243 Steering damper rod on bottom yoke 1 M6 7 376 Steering damper FRONT SUS...

Page 217: ...R RSV 1000 R FACTORY 5 4 REAR SUSPENSION 5 4 1 DIAGRAM Key 1 Shock absorber 2 Double conrod 3 Needle bearing 4 Oil seal 5 Piston pin 6 Screw 7 T bush 8 Self locking nut 9 Single conrod comp 10 Hex socket screw 11 Screw w flange ...

Page 218: ... 2 REMOVING THE REAR SUSPENSION Support the rear end of the motorcycle Undo the clips uniting the lower seat s subframe pan els Move the fuel lines away from the area over the rear suspension assembly Undo the two screws securing the panel to the frame ...

Page 219: ...CYCLE PARTS 5 74 RSV 1000 R RSV 1000 R FACTORY Remove the panel and extract the cable bundles Undo the nuts on the double connecting rods ...

Page 220: ...5 75 RSV 1000 R RSV 1000 R FACTORY Undo the screws and remove the double connecting rods Undo the screw on the rear suspension upper mount Undo the screw and extract the rear suspension from its seat by rotating it ...

Page 221: ...CYCLE PARTS 5 76 RSV 1000 R RSV 1000 R FACTORY ...

Page 222: ...ontains pressurized ni trogen To prevent the risk of an explosion keep it away from flames and or sources of heat In the event the shock absorber is to be replaced discharge the nitrogen by pressing the central core of the valve under the cap or under the screw Rear suspension Standard setting Racing setting Shock absorber distance between centers A 12 3 0 06 in 313 1 5 mm 12 2 to 12 5 in 310 to 3...

Page 223: ...ettings may only be used during of ficial competitions or sports events author ized by the competent authorities and taking place in closed circuits or anyway away from public roads The law forbids riding a vehicle with racing settings on public roads and highways ...

Page 224: ...5 4 4 REFITTING THE REAR SUSPENSION Fit the rear suspension into its seat Fit the upper suspension mounting screw Tighten the screw to the specified torque Fit the right hand double connecting rod together with the screw on the rear suspension mount ...

Page 225: ... 1000 R RSV 1000 R FACTORY Install the remaining screws to the double connecting rod Fit the left hand double connecting rod Tighten all screws to their specified torque Fit the panel onto the frame over the cable bundles ...

Page 226: ...CYCLE PARTS 5 81 RSV 1000 R RSV 1000 R FACTORY Tighten the two screws securing the panel to the frame to the specified torque Fit the clips uniting the lower seat subframe panels ...

Page 227: ... screw 2 out from the opposite side Loosen and remove the nut 3 Pull the screw 4 out from the opposite side Loosen and remove the nut 5 Pull the screw 6 out from the opposite side Remove the whole suspension linkage unit 7 NOTE When reassembling grease the linkage fulcrum points and be extremely careful to refit the components cor rectly making sure that the joints move smoothly ...

Page 228: ...SCRIPTION QUANTITY SCREW NUT TORQUE ftlb NOTES Shock absorber to frame 1 M10 36 878 Single conrod to frame 1 M10 36 878 Single double conrod 1 M10 36 878 Double conrod swinging arm 1 M10 36 878 Double conrod shock absorber 1 M10 36 878 REAR SUSPENSION Shock absorber Linkages ...

Page 229: ...with the two pawls on the swinging arm itself Remove the exhaust assembly Loosen and remove the three screws securing the cover and collect the washers Move the mount plate complete with brake caliper and speed sensor connected to their hose and cable re spectively carefully to one side and rest it on the ground WARNING Do not operate the rear brake lever with the brake caliper removed or the brak...

Page 230: ...part 8140191 swinging arm spindle engine stand tool Using the provided socket wrench slacken and remove the locknut 1 from the right hand side of the vehicle Turn the swinging arm spindle 2 counterclockwise to rotate the adjuster bush 3 and thus loosen it WARNING Take great care when removing the swinging arm Support it at the front to prevent it from drop ping Place a wooden support beneath the f...

Page 231: ...he swinging arm spindle 2 from the right hand side WARNING Make sure the transmission chain does not get entangled when removing the swinging arm Support the front of the swinging arm and prepare to hold it as it moves Using the rear stand slide the swinging arm out from the rear of the vehicle Extract the swinging arm spindle 2 and adjuster bush 3 ...

Page 232: ...arings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check criteria Change both rear fork bearings WARNING Always change both bearings Always replace the bearings with bearings of the same type REAR FORK GASKETS Make sure the seals are intact ...

Page 233: ...AUTION The bearings must be checked and if neces sary changed every time they are disassem bled Remove the inner spacer 7 and retrieve the two O rings 8 Remove the inner spacer 9 Remove the seals 10 Use a special extractor to extract the two roller bear ings 11 CAUTION The bearings must be checked and if neces sary changed every time they are disassem bled Thoroughly clean the inside of the bearin...

Page 234: ...f the swinging arm with its special rear stand OPT IMPORTANT Shim out the rear stand base OPT to bring it into position engaged with the two pawls on the swinging arm itself Support the swinging arm at the front align the holes and fully insert the spindle 2 IMPORTANT Make sure that the hexagonal section of the spindle head 2 is correctly seated into the hexagonal cavity in the adjuster bush 3 Fit...

Page 235: ...rovided socket wrench to tighten the lock nut 1 Tighten the nut 4 Remove the tape holding the chain in place Refit the chain to the pinion IMPORTANT When refitting apply LOCTITE Anti Seize to the inner pinion toothing Fit the pinion with chain mounted to the shaft IMPORTANT Apply LOCTITE 243 to the screw thread Fit the washer onto the screw Tighten down the screw ...

Page 236: ...t side fit the double connecting link swinging arm screw Tighten down the nut from the opposite side Fit the mount plate complete with brake caliper and speed sensor Tighten down the three screws securing the cover complete with washers Fit the pinion cover and tighten down its three screws Refit the rear wheel and exhaust assembly Adjust the tension of the transmission chain ...

Page 237: ...6 878 REAR SUSPENSION Shock absorber Linkages DESCRIPTION QUANTITY SCREW NUT TORQUE ftlb NOTES Swinging arm spindle nut 1 M30x1 5 44 254 Swinging arm spindle adjuster bushing 1 M30x1 5 8 851 Swinging arm spindle nut 1 M20x1 5 66 38 Caliper support pin 1 M12 36 878 Loctite 243 Chain tensioner screw and nut 1 1 M8 man Rear brake hose bracket 3 M5 2 95 Chain guard cover 2 M5 2 95 Chain shoe 2 M5 2 21...

Page 238: ...CYCLE PARTS 5 93 RSV 1000 R RSV 1000 R FACTORY 5 6 FRONT WHEEL 5 6 1 DIAGRAM Key 1 Wheel pin 2 Nut 3 Seal 4 Bearing 5 Inner spacer 6 Complete wheel 7 Snap ring 8 Right spacer 9 Washer ...

Page 239: ...Y 5 6 2 REMOVING THE WHEEL Support the front part of the motorcycle Undo the screws securing the front mudguard and re move it Undo the screws securing the front brake calipers and remove them from their seats Undo the nut securing the wheel axle ...

Page 240: ...000 R FACTORY Keep the seal washer Slacken the screws on the wheel axle clamps Lightly knock the wheel axle with a rubber mallet so as to uncover the holes on the opposite side Pull out the hollow axle using a screwdriver in the holes ...

Page 241: ...CYCLE PARTS 5 96 RSV 1000 R RSV 1000 R FACTORY While removing the axle support the wheel and then remove it ...

Page 242: ...h bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check criteria Change both wheel bearings WARNING Always change both bearings Always replace the bearings with bearings of the same type FRONT WHEEL GASKETS Make sure the seals are intac...

Page 243: ...he radial A and axial B eccentricity of the rim 2 do not exceed the limit value Excessive eccentricity is usually caused by worn or damaged bearings If after changing the bearings the value does not fall within the indicated limit change the rim 2 Maximum radial and axial eccentricity 0 079 in 2 mm ...

Page 244: ...the spacer 4 are provided with slots A to al low the passage of the extractor teeth NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors Use a special extractor to extract the right bearing 5 Retrieve the inner spacer 4 Work from the left hand side of the wheel Remove the seal 2 NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing ex...

Page 245: ...he left hand side of the wheel Insert the spacer 4 NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors Use a special pad to insert the left bearing 6 NOTE The complete insertion of the left bearing 6 will bring the following components into contact right bearing 5 spacer 4 left bearing 6 CAUTION After the contact with the right bearing 5 do not push further i...

Page 246: ...CYCLE PARTS 5 101 RSV 1000 R RSV 1000 R FACTORY ...

Page 247: ...TING THE FRONT WHEEL Fit the front wheel Fit the wheel axle Tighten down the clamp screws nut side to secure the wheel axle Fit the seal washer and screw on the axle nut to the specified torque Make sure the fork legs are aligned by pumping the fork up and down ...

Page 248: ...RSV 1000 R FACTORY Tighten the screws securing the wheel axle clamps to the specified torque Tighten the screws securing it to the specified torque WARNING After fitting the brake calipers repeatedly oper ate the front brake lever ...

Page 249: ...1000 R RSV 1000 R FACTORY 5 7 REAR WHEEL 5 7 1 DIAGRAM Key 1 Nut 2 Washer 3 Side spacers 4 Left chain tightener shoe 5 Bearings 6 Central spacer 7 Complete wheel 8 Snap ring 9 Seal 10 Right chain tightener shoe 11 Wheel pin ...

Page 250: ...PARTS 5 105 RSV 1000 R RSV 1000 R FACTORY 5 7 2 REMOVING THE REAR WHEEL Support the motorcycle on the rear stand Slacken and remove the wheel axle nut Keep the thrust washer and left hand chain tightener shoe ...

Page 251: ...n the wheel axle so that its head thrusts forth from its seat Move the wheel forwards and disengage the chain from the sprocket Extract the wheel axle together with the right hand chain guide shoe Remove the entire wheel sliding the disc out from the brake caliper ...

Page 252: ...ng holder Working B with both hands on the outer diameter of the sprocket 3 extract the final drive unit keeping it parallel to the wheel axis REASSEMBLY NOTE Keep the final drive unit parallel to the wheel axis To introduce the unit insert the flexible couplings 5 in the cor responding seats on the flexible coupling holder 2 Working C with both hands on the outer diameter of the sprocket 3 insert...

Page 253: ...CYCLE PARTS 5 108 RSV 1000 R RSV 1000 R FACTORY ...

Page 254: ...ange both wheel bearings WARNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check criteria Change both wheel bearings WARNING Always change both bearings Always replace t...

Page 255: ...1 Maximum eccentricity 0 0098 in 0 25 mm REAR WHEEL RIM Using a comparator make sure that the radial A and axial B eccentricity of the rim 2 do not exceed the limit value Excessive eccentricity is usually caused by worn or damaged bearings If after changing the bearings the value does not fall within the indicated limit change the rim 2 Maximum radial and axial eccentricity 0 079 in 2 mm ...

Page 256: ... both bearings is are not in compliance with the check criteria Change both final drive unit bearings WARNING Always change both bearings Always replace the bearings with bearings of the same type CHECKING THE END AND RADIAL PLAY Check the radial play and the end play End play a minimum end play is allowed Radial play none If one or both bearings is are not in compliance with the check criteria Ch...

Page 257: ...the slack between the flexible coupling rub ber elements 5 and the flexible coupling holder 8 If slack is excessive Change all the flexible coupling rubber elements 5 WARNING Always replace the flexible couplings with ones of the same type SPROCKET Check the conditions of the sprocket teeth 7 If there are signs of excessive wear Change the crown gear the drive pinion and the drive chain CAUTION To...

Page 258: ...ends of the spacer 4 are provided with slots A to al low the passage of the extractor teeth NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors Use a special extractor to extract the right bearing 5 Retrieve the inner spacer 4 Work from the left hand side of the wheel NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors U...

Page 259: ...l Work from the left hand side of the wheel Insert the spacer 4 NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors Use a special pad to insert the left bearing 6 NOTE The complete insertion of the left bearing 6 will bring the following components into contact right bearing 5 spacer 4 left bearing 6 CAUTION After the contact with the right bearing 5 do not p...

Page 260: ...CYCLE PARTS 5 115 RSV 1000 R RSV 1000 R FACTORY ...

Page 261: ...g 3 NOTE The elastic ring 3 is provided only on the left side of the final drive unit NOTE Have the appropriate special tool OPT at hand Aprilia part 8140180 bearing extractors Use a special extractor to extract the left bearing 4 Retrieve the inner spacer 5 Use a special extractor to extract the right bearing 6 Take the right spacer ring 7 Thoroughly clean the inside of the hub NOTE Wash all the ...

Page 262: ...ith the wheel hub shoulder is complete Y Insert the inner spacer 5 Use a special pad to insert the left bearing 4 NOTE The complete insertion of the left bearing 4 will bring the following components into contact right bearing 6 inner spacer 5 left bearing 4 Insert the elastic ring 3 NOTE The elastic ring 3 is provided only on the left side of the final drive unit Install a new seal 2 Insert the l...

Page 263: ...SV 1000 R RSV 1000 R FACTORY 5 7 9 REMOVING THE FLEXIBLE COUPLINGS Remove the final drive unit NOTE The flexible couplings remain installed on the flexible coupling holder Extract all the flexible coupling rubber elements ...

Page 264: ...by hand CAUTION It is forbidden to install the final drive unit 6 on the wheel to tighten the self locking nuts CAUTION To protect the crown gear install guards in wood or aluminum on the vice jaws Lock only the crown gear in the vice be careful not to lock any other component of the final drive unit Lock the crown gear in the vice NOTE To prevent any deformation and or incorrect coupling carry ou...

Page 265: ...HEEL Fit the wheel axle together with right hand chain guide shoe to the swing arm Fit the rear wheel and insert the wheel axle into its seat Move the wheel forwards to hook the drive chain over the sprocket Fit the left hand chain tightener shoe and thrust washer to the axle ...

Page 266: ...CYCLE PARTS 5 121 RSV 1000 R RSV 1000 R FACTORY Tighten the nut hand tight Check the chain tension Tighten the nut to the specified torque ...

Page 267: ...YCLE PARTS 5 122 RSV 1000 R RSV 1000 R FACTORY 5 7 12 TIGHTENING TORQUES DESCRIPTION QUANTITY SCREW NUT TORQUE ftlb NOTES Sprocket Sprocket carrier 5 M10 36 878 Wheel axle nut 1 M25x1 5 88 507 REAR WHEEL ...

Page 268: ...Using pliers clamp one pad and then the other shak ing them slightly crosswise so as to eliminate any pressure exerted by the caliper pins making it easier to extract the pads Extract the two pads 3 CAUTION Once the pads have been removed do not pull the brake lever as the caliper pins are liable to come out of their slot brake fluid will spill out Insert two new pads positioning them correctly CA...

Page 269: ...bility and safety of the vehicle putting the safety of persons or property at risk or leading to vehicle damage NOTE The following procedure applies to both brake calipers Release and remove the two caliper mounting bolts 1 Extract the front brake caliper from the disc Press the retaining clip 2 and extract the pin 3 from the inside Remove the retaining clip 2 Extract both pads 4 WARNING Do not op...

Page 270: ...the pin 3 DANGER When released the retaining clip 2 should become correctly located into its seats to lock the pin 3 in place When the clip is positioned correctly the pin 3 will not come off Try to extract the pin to ensure clip and pin are securely in place Position the front brake caliper on the brake disc Tighten the two bolts 1 fully until finger tight Operate the front brake lever This will ...

Page 271: ...ugh they are applicable to both Check the wear on the brake disc Using a micrometer measure the minimum thickness in several places If the minimum thickness is below the minimum value even in a single point change the disc Brake disc min thickness 2 95 in 4 mm Using a comparator make sure that the disc s maxi mum wobbling does not exceed the limit value other wise change it Brake disc max wobbling...

Page 272: ...rews 1 it is advisable to use an impact driver thanks to which it will be possible to detach the screws from the LOCTITE 243 Loosen and remove the six brake disc screws 1 CAUTION When reassembling apply LOCTITE 243 on the thread of the brake disc screws 1 NOTE When reassembling insert all the screws 1 by hand and tighten them in a crisscross pattern in the following or der A B C D E F Remove the b...

Page 273: ... before reaching the lever s full stroke and repeat the operation until no more air issues from the nipple Connect the tubes to the brake caliper bleed nipples Operate the brake lever and open the caliper bleed nipple slightly to allow the air to escape Close the nipple before reaching the lever s full stroke and repeat the operation until no more air issues from the nipple To be quite sure of the...

Page 274: ...re assembling it must be refitted in the same way Pull out the pin 2 and retrieve the safety spring 3 Extract the two pads 4 CAUTION Once the pads have been removed do not pull the brake lever as the caliper pins are liable to come out of their slot brake fluid will spill out Insert two new pads positioning them so that the holes are lined up with those in the caliper CAUTION Always change both pa...

Page 275: ...e wear on the brake disc Using a micrometer measure the minimum thickness in several places If the minimum thickness is below the minimum value even in a single point change the disc Brake disc min thickness 2 95 in 4 mm Using a comparator make sure that the disc s maxi mum wobbling does not exceed the limit value other wise change it Brake disc max wobbling 0 22 in 0 3 mm ...

Page 276: ...driver thanks to which it will be possible to detach the screws from the LOCTITE 243 Loosen and remove the five brake disc screws 1 CAUTION When reassembling apply LOCTITE 243 on the thread of the brake disc screws 1 NOTE When reassembling insert all the screws by hand and tighten them in a crisscross pattern in the following or der A B C D E Remove the brake disc 2 ...

Page 277: ...ple before reaching the lever s full stroke and repeat the operation until no more air issues from the nipple Connect the hose to the clutch control cylinder bleed nipple Operate the clutch lever and open the cylinder bleed nipple slightly to allow the air to escape Close the nipple before reaching the lever s full stroke and repeat the operation until no more air issues from the nipple To be quit...

Page 278: ... check slack at various sections of the chain Slack should be the same throughout one full turn of the wheel CHAIN SLACK ADJUSTMENT NOTE To adjust the chain slack you will need the rear wheel stand OPT Make sure to have it ready at hand If the chain needs adjusting after the inspection proceed as follows Place the vehicle on the rear wheel stand Loosen the nut 1 completely NOTE Fixed reference mar...

Page 279: ...s as a set Lubricate the chain frequently especially if you find any dry or rusty parts Warped or seized links must be lubricated and repaired CLEANING AND LUBRICATION CAUTION The drive chain links are fitted with O rings that retain the grease inside Use the utmost care when adjusting lubricating washing or replacing the chain Never wash the drive chain using steam cleaners high pressure water no...

Page 280: ...SV 1000 R RSV 1000 R FACTORY 5 11 2 INSPECTING THE DRIVING CHAIN SHOE Position the vehicle on the stand Make sure the shoe 1 is not worn or damaged if so replace with a new one Check the wear of the chain plastic guide 2 ...

Page 281: ...ews Remove the pinion cover Slacken the chain tension Release and remove the pinion screw and collect the washers IMPORTANT When refitting apply LOCTITE Anti Seize to the inner pinion toothing and LOCTITE 243 to the screw threads Loosen and remove the two left rider foot peg cover screws Loosen and remove the upper chain shoe screw and collect its washer ...

Page 282: ...PARTS 5 137 RSV 1000 R RSV 1000 R FACTORY Loosen and remove the lower chain shoe screw and collect its washer Pull the lower part of the chain shoe out from the front Remove the lower chain shoe from the rear ...

Page 283: ...000 R FACTORY 5 11 4 LOWER CHAIN SHOE IMPORTANT The shoe must be disassembled to check its wear Release and remove the two screws Remove the lower chain shoe CHECKING WEAR Check the wear of the chain shoe Minimum thickness 2 mm 0 079 in ...

Page 284: ...COOLING SYSTEM 6 1 RSV 1000 R RSV 1000 R FACTORY COOLING SYSTEM 6 ...

Page 285: ...COOLING SYSTEM 6 2 RSV 1000 R RSV 1000 R FACTORY SUMMARY 6 1 COOLING SYSTEM 3 6 1 1 DIAGRAM 3 6 1 2 FILLING THE COOLING SYSTEM 4 ...

Page 286: ...COOLING SYSTEM 6 3 RSV 1000 R RSV 1000 R FACTORY 6 1 COOLING SYSTEM 6 1 1 DIAGRAM Key 1 Radiator 2 Fans 3 Expansion reservoir 4 Filler cap 5 Three way thermostatic valve 6 Three way manifold ...

Page 287: ...Unscrew the filler cap Pour around 0 53 gal 2 liters of coolant into the radia tor via the filler cap When the coolant starts to issue from the radiator bleed screw tighten the screw down to its prescribed torque Complete filling the circuit up to the upper rim of the filler cap Unscrew the expansion reservoir cap and pour in the remaining 0 05 gal 0 2 liters of coolant until it reaches a level be...

Page 288: ...on reservoir level as a reference Run the engine for about 30 seconds with the filler cap open Switch off the engine and pour coolant into the filler cap Complete filling the circuit up to the upper rim of the filler cap Run the engine up to its normal running temperature the fans must cut in at least twice switch it off and wait for it to cool down around 12 hours Check that the coolant level is ...

Page 289: ...ELECTRICAL SYSTEM 7 1 RSV 1000 R RSV 1000 R FACTORY ELECTRICAL SYSTEM 7 ...

Page 290: ...ICAL SYSTEM 7 2 RSV 1000 R RSV 1000 R FACTORY SUMMARY 7 1 ELECTRICAL SYSTEM 3 7 1 1 COMPONENT LOCATION 3 7 1 2 ELECTRICAL EQUIPMENT CHECK TABLE 5 7 1 3 CAN LINE 14 7 1 4 IMMOBILIZER 16 7 1 5 WIRING DIAGRAM 18 ...

Page 291: ...ELECTRICAL SYSTEM 7 3 RSV 1000 R RSV 1000 R FACTORY 7 1 ELECTRICAL SYSTEM 7 1 1 COMPONENT LOCATION ...

Page 292: ...sor 5 Intake air temperature sensor 6 Fall sensor 7 Vehicle speed sensor 8 Injector 9 Ignition coil 10 Throttle potentiometer TPS 11 Immobilizer antenna 12 Starter motor 13 Intake flap 14 Stepper 15 Generator 16 Recharge voltage 17 Fuel pump 18 Fuel reserve sensor 19 ECU 20 Head lamp 21 Tail light 22 Secondary fuses 23 Main fuses ...

Page 293: ...ELECTRICAL SYSTEM 7 5 RSV 1000 R RSV 1000 R FACTORY 7 1 2 ELECTRICAL EQUIPMENT CHECK TABLE ...

Page 294: ...3 V AC under load 2 LAMBDA SENSOR oxygen sensor with heater sensor voltage 0 to 0 9 V across pins 3 and 4 heater resistance 12 5 Ω across pins 1 and 2 at 68 F 3 CAMSHAFT SENSOR hall effect sensor power 12 V square wave output 1 pulse every 2 engine revolutions 4 COOLANT TEMPERATURE SENSOR NTC sensor resistance 2 5 KΩ at 68 F resistance 220 Ω at 212 F ...

Page 295: ...ce 62 KΩ with sensor at installation position resistance 0 Ω when rotated 90 relative to installation posi tion 7 VEHICLE SPEED SENSOR hall effect sensor with square wave output 5 pulses every revolution power 11 12V across pins 1 and 3 sensor signal is low when the sensor is facing the screw head across pins 2 and 3 8 INJECTOR resistance 15 Ω ...

Page 296: ... primary resistance 0 4 0 5 Ω 10 THROTTLE POTENTIOMETER TPS resistance 4 1 1 23 Ω across pins 1 and 4 output voltage 0 5 4 V varies according to throttle position across pins 2 and 4 11 IMMOBILIZER ANTENNA winding resistance 14 Ω 12 STARTING MOTOR peak absorption 120 A ...

Page 297: ...STEPPER phase resistance 50 Ω 15 GENERATOR three phase generator winding resistance 0 4 Ω output voltage 75 V AC measure with generator discon nected from electrical system and engine running at 4000 rpm 16 RECHARGE VOLTAGE voltage 13 8 V across battery terminals with engine running at 4000 rpm ...

Page 298: ...P absorption 3 9 A 18 FUEL RESERVE SENSOR The vehicle does not have a fuel gauge but rather a simple led which turns on when the fuel level is below 0 98 gal 3 7 liters the sensor starts conducting and the led turns on 30 seconds after it is no longer wetted by fuel ...

Page 299: ...or 2 control Power output 16 n c 17 n c 18 Atmospheric pressure sensor signal Analogue input 19 Engine speed sensor signal ground Power 20 Timing sensor ground Power 21 Air temperature sensor signal Power 22 n c 23 n c 24 Throttle potentiometer signal Analogue input 25 Throttle potentiometer power ground Power 26 n c 27 Water temperature sensor signal ground Power 28 Manifold pressure sensor power...

Page 300: ...l Digital output 18 n c 19 n c 20 Vehicle speed sensor power ground Power 21 Ignition request Digital input 22 n c 23 Side stand switch Digital input 24 Diagnostics line K Comms line 25 Clutch switch Digital input 26 Stop switch Digital input 27 CAN Line L Comms line 28 CAN Line H Comms line 29 Fuel pump control Power output 30 n c 31 Starter relay control Digital output 32 ECU power ground Power ...

Page 301: ... under key at ECU 5 A D From battery to speed sensor fuel pump relay starter lambda sensor 15 A E From battery to fan relay coils injectors intake flap camshaft sensor 15 A F From ignition switch to high beam low beam 20 A IMPORTANT There are three spare fuses G 23 MAIN FUSES H battery recharge and vehicle loads red and red white cables immobilizer 30 A I injection loads red and red black cables 3...

Page 302: ...ound 250 kbps data is transmitted to the nodes every 20 ms 50 times a second THE CAN CONTROLLER AREA NETWORK PROTOCOL The CAN comms protocol is a CSMA CD Carrier Sense Multiple Access w Collision Detection protocol In order to transmit each node must first check that the BUS connecting it to all the other nodes is free Carrier Sense only then can it transmit on the BUS If there is no activity on t...

Page 303: ...ndicator LED Activation Neutral SMD green Side stand SMD am ber EFI Oil pressure SMD red ECU via CAN CAN BUS LINE SIGNALS Transmitted signal Frequency Hz Engine speed Speed Diagnostics Neutral indicator Stand indicator Oil pressure indicator Water temperature 50 Signal sent Frequency Hz Odometer stored in injec tion controller memory for future applications Model ID 50 If data is not received CAN ...

Page 304: ...W KEY CODES VIRGIN MEMORY When the immobilizer ECU is first powered up its memory is virgin and the led stays on without flashing To store the first two key codes run a key ON cycle with the first key the led will switch off for 0 5 sec and turn on again When it turns on turn the key to OFF turn the second key supplied to ON within 20 seconds The led will switch off and immediately flash 4 times N...

Page 305: ... to use The storage pro cedure is as follows 1 with a customer key already stored turn from key ON to OFF 2 fit the Master Key within 20 seconds thus enabling the storing procedure The led will stay on continuously 3 insert and run key ON s in sequence with all the keys to be stored The led will switch off for 0 5 seconds after each key has been successfully stored 4 After each key has been stored...

Page 306: ...ELECTRICAL SYSTEM 7 18 RSV 1000 R RSV 1000 R FACTORY 7 1 5 WIRING DIAGRAM ...

Page 307: ...e sensor 41 Atmospheric pressure sensor 42 Throttle sensor 43 Twin coil 44 Front cylinder spark plug 45 Rear cylinder spark plug 46 Front cylinder injector 47 Rear cylinder injector 48 Camshaft sensor 49 Pick up 50 Engine Control Unit ECU 51 Front left direction indicator 52 Left headlamp 53 Right headlamp 54 Left beam parking light 55 Left low beam bulb 56 Left high beam bulb 57 Right high beam b...

Page 308: ...aprilia s p a via G Galilei 1 30033 Noale VE Italy tel 39 041 5829111 fax 39 041 5829190 www serviceaprilia com www aprilia com ...

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APRILIA RSV 1000 R, Workshop Manual

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