APRILIA RSV4 1100 Factory 2021 Manual Download

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Main transmission gear removal

In order to remove the primary gear, the clutch

cover, alternator cover and complete clutch must

be removed beforehand.

Then proceed as described:

•

Fit the special primary gear lock tool

Specific tooling

020850Y

Primary gear lock

•

Unscrew and remove the fastener nut

of the primary gear.

•

Remove the lock tool and remove the

primary gear.

Specific tooling

020850Y

Primary gear lock

Installing the primary drive gear

To install the primary gear, follow the procedure

described below:

•

Fit the primary shaft gear onto the

crankshaft, ensuring that it is aligned

correctly with the countershaft drive

gear. Align the markings on the respec-

tive teeth to align the gears correctly.

Engine

RSV4 1100 Factory

ENG - 298

Summary of Contents for RSV4 1100 Factory 2021

Page 1: ...MANUALE STAZIONE DI SERVIZIO 2Q000479 RSV4 1100 Factory ...

Page 2: ...hicle itself All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only While the basic features as described and illustrated in this manual remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication bef...

Page 3: ...so del veicolo Piaggio C s p a si impegna a migliorare continuamente i propri prodotti e la relativa documentazione Le principali modifiche tecniche e modifiche alle procedure per le riparazioni del veicolo vengono comunicate a tutti i Punti Vendita Aprilia e alle Filiali nel Mondo Tali modifiche verranno apportate nelle edizioni successive di questo manuale Nel caso di necessità o dubbi sulle pro...

Page 4: ...Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee ...

Page 5: ... CHARACTERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS BODYWORK BODYW ...

Page 6: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 7: ... lights low beam lights taillights front and rear and relevant warning lights Headlight adjustment according to regulations in force Rear brake light push button Turn indicators and their warning lights Instrument cluster Instrument cluster warning lights Horn Electric starter Engine stop via emergency stop switch and side stand Through the diagnostic tool check that the last mapping version is pr...

Page 8: ... necessary charge the battery CHARGE LEVEL ACTION NUMBER OF BARS Ready for use 5 6 Charging recommended 3 4 Charging necessary 1 2 Fault 0 RECHARGE Always use a specific charger for lithium batteries to recharge the battery To avoid damage to the battery the charging voltage must NEVER be higher than 15 volts Do not charge the battery with a charger with automatic DESULPHATION MODE using a voltage...

Page 9: ... step on it Do not perform welds on the battery terminals Do not use the battery in combination with primary batteries such as dry batteries or batteries of different capacity type and brand Do not use the battery if it emits a strange odour emits heat changes colour or deforms or if it presents any anomaly Stop use immediately if the battery is in use or under charge THE BATTERY DOES NOT CONTAIN ...

Page 10: ...sing the six cells This operation is extremely important in or der to have the best battery perform ance over time Recharge the battery following the specifications indicated on the battery see photo and using a suitable bat tery charger NOTE IN THE SHOWN EXAMPLE IT IS IMPORTANT TO USE A BATTERY CHARGER WITH 1 2 AMPERE CHARGING TIME 5 10 HOURS OR 5 AMPERE CHARGING TIME 1 HOUR Levels check Hydrauli...

Page 11: ...rect operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Check the frame and engine numbers Check included tools where applicable Licence plate fitting Locks checking Tyre pressure check Fitting of mirrors and possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES SINCE THE TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSUR...

Page 12: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 13: ... ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot parts The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Coolant Th...

Page 14: ...REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORT...

Page 15: ...ble material Lubricate the parts when possible before reassembling them When tightening screws and nuts begin with the larger diameter or internal ones proceeding diagonally Tighten with subsequent steps before applying the prescribed torque Always replace the locknuts gaskets seal rings snap rings O Rings OR cotter pins and screws if they have damaged thread with new ones When disassembling the b...

Page 16: ...CKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period Thi...

Page 17: ...his number consists of numbers and letters as in the example shown below ZD4KYA00YSXXXXXX KEY ZD4 WMI World Manufacturer Identifier code KY model A00 Europe UA0 USA RSV4 1100 B00 Europe UB0 USA RSV4 1100 Factory 0 digit free Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the RH side of the headstock ENGINE NUMBER The ...

Page 18: ...ft cam to cam gear bucket tap pets and valve clearance adjustments with calibrated pads Lubrication system Wet sump with oil radiator Oil pump Dual trochoidal pump lubrication cooling Oil filter With external cartridge filter Cooling Liquid Cooling system 3 way thermostatic valve cooling radiator with electric fan and expansion tank Coolant pump Centrifugal bearingless aspirating pump with integra...

Page 19: ...m ELECTRICAL SYSTEM Specification Desc Quantity Spark plugs NGK IR MR9DI 7 Electrode gap 0 6 0 7 mm 0 023 0 027 in Battery BS BATTERY BSLi 04 LITHIUM 12V 48Wh 280A Alternative solution YUASA YTZ10S 12V 8 6 Ah Coils Stick coil Recharging system Flywheel with rare earth magnets Alternator 360 W Main fuse 30A Secondary fuses 5A 4 7 5 A 3 15 A 20 A ABS fuses 10 A 25 A ASC fuse if supplied 7 5 A FUNCTI...

Page 20: ...k absorber with piggy back that can be electronically adjusted for hydraulic brake compression and extension and mechanically adjusted for spring pre loading Rear shock absorber RSV4 1100 Sachs NO ASC With progressive linkage with APS system Shock absorber with piggy back that can be adjusted for spring pre loading wheelbase length and hydraulic brake compression and ex tension Rear stroke 62 mm 2...

Page 21: ...R SUPPLY Specification Desc Quantity Fuel Unleaded gasoline E10 95 R O N FUEL SUPPLY SYSTEM Specification Desc Quantity Throttle body diameter 48 mm 1 89 in Type Electronic injection with 2 injectors per cylinder 4 motorised throttle bodies Ride by wire with fixed height air intakes dif ferentiated per main bearing front rear 2 dynamic air intakes Selectable multimap Tightening Torques If the foll...

Page 22: ...UST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED BEFORE FITTING THE NEW SCREWS CLEAN THE THREADED HOLES CAREFULLY MAKING SURE THAT ALL TRACES OF THE OLD THREAD LOCK SEALANT HAVE BEEN ELIMINATED Chassis Front side FRONT WHEEL Pos Description Type Quantity Torque Notes 1 Front wheel axle nut M25x1 5 1 80 Nm 59 00 lb ft 2 Front brake disc fastening screws M8 6 6 30 Nm 22 13 lb ft Loct 24...

Page 23: ...r fastening screws M10x1 25 2 2 50 Nm 36 88 lb ft FRONT FORK OHLINS ASC RSV4 1100 FACTORY Pos Description Type Quantity Torque Notes 1 Calliper mounting bracket fixing screws M6 2 2 10 Nm 7 37 lb ft 2 ABS sensor fixing screw M5 1 8 Nm 5 90 lb ft RSV4 1100 Factory Characteristics CHAR 23 ...

Page 24: ...ntity Torque Notes 1 Calliper bracket fixing screws Sachs M6 4 12 Nm 8 85 lbf ft 2 Speed sensor fastening screw M5 1 6 Nm 4 43 lbf ft 3 Upper cap 2 20 Nm 14 75 lbf ft 4 Upper cap locking nut 2 20 Nm 14 75 lbf ft Characteristics RSV4 1100 Factory CHAR 24 ...

Page 25: ...crews M6 2 8 Nm 5 90 lb ft 9 Screw used to fasten the front brake pipe to the steering lower plate M5 1 8 Nm 5 90 lb ft HANDLEBAR AND CONTROLS Pos Description Type Quantity Torque Notes 1 Screws for fastening the handlebar collar to the forks sleeves M8 1 1 25 Nm 18 44 lbf ft 2 Handlebar safety screw M6 1 1 10 Nm 7 38 lbf ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lbf ft 4 ...

Page 26: ... lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lbf ft 3 Front brake pump U bolt clamp M6 2 10 Nm 7 38 lbf ft 4 Front brake lever pin fixing screw M6 1 10 Nm 7 38 lbf ft Screw used to fasten the brake pipe cable gland to the lower yoke M5 1 8 Nm 5 90 lbf ft Characteristics RSV4 1100 Factory CHAR 26 ...

Page 27: ...tch lever collar fastening screws M6 1 10 Nm 7 38 lbf ft FAIRING FRONT Pos Description Type Quantity Torque Notes 1 Top fairing fixing screws M4 4 0 5 Nm 0 37 lb ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 38 lbf ft RSV4 1100 Factory Characteristics CHAR 27 ...

Page 28: ...for fastening the in take ducts M6 4 4 Nm 2 95 lb ft Loct 243 2 Intake duct fixing nuts M6 4 Manual FRONT MUDGUARD ENGINE FAIRING Pos Description Type Quantity Torque Notes 1 Front mudguard fixing screws M5 4 3 Nm 2 21 lbf ft Characteristics RSV4 1100 Factory CHAR 28 ...

Page 29: ... Quantity Torque Notes 1 Flanged hex head screws for fasten ing the water radiator support brack et to the frame M6x20 2 10 Nm 7 38 lbf ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lbf ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lbf ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm...

Page 30: ...ion Type Quantity Torque Notes 1 Screw fastening oil radiator to mounting bracket M6x25 1 7 Nm 5 16 lbf ft 2 Hex head flange screws fastening bracket to engine M6x12 2 8 Nm 5 90 lbf ft Characteristics RSV4 1100 Factory CHAR 30 ...

Page 31: ...Type Quantity Torque Notes 1 Pinion cover guard fastening screws M6 3 6 Nm 4 43 lbf ft 2 Threaded stand off 2 8 Nm 5 90 lbf ft 3 Countersunk flat head hex socket screw M6x35 1 10 Nm 7 38 lbf ft Loct 4 Self locking nut M8 1 25 Nm 18 44 lbf ft 5 Fastening between gearbox tie rod joint and gear lever 1 8 Nm 5 90 lbf ft Loct 6 Nut used to fasten the gearbox tie rod to the quick shift device 1 8 Nm 5 9...

Page 32: ...er s footrests to the frame M8 2 2 18 Nm 13 28 lbf ft Loctite 243 For use in countries where it is mandatory to fit the passenger s footrests or for the two seater configu ration 3 Rider s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 4 Passenger s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 5 Anti creep pin M6 1 8 Nm 5 90 lbf ft Characteristics RSV4 1100 Factory CHAR 32 ...

Page 33: ...ng screws M6 2 8 Nm 5 90 lbf ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lbf ft Loctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lbf ft 5 Brake lever ferrule fastening screw M6 1 8 Nm 5 90 lbf ft 6 Special oil pipe coupling retaining screw 1 23 26 Nm 16 96 19 18 lbf ft RSV4 1100 Factory Characteristics CHAR 33 ...

Page 34: ... Loct 243 2 Fastener nut of rotary switch M6 1 10 Nm 7 37 lbf ft 3 Stand fastening pin 1 Nm lbf ft 4 Fastener nut of side stand 1 Nm lbf ft SIDE FAIRINGS Pos Description Type Quantity Torque Notes 1 Screws fastening side fairing fins to interior of extractor vent 2 2 1 Nm 0 73 lbf ft Characteristics RSV4 1100 Factory CHAR 34 ...

Page 35: ...t to saddle carrier subframe M6 2 7 Nm 5 16 lbf ft 4 Tank breather connectors M7 2 3 Nm 2 21 lbf ft 5 Fastener screws of tilt sensor mount M6 2 7 Nm 5 16 lbf ft 6 Screws fastening tilt sensor to mounting bracket M6 2 6 Nm 4 42 lbf ft 7 Fastener screws of plastic mount for fuel pipe M5 1 2 5 Nm 1 84 lbf ft 8 Hex head flange screws for fastening fuel pump M5x16 6 8 Nm 5 90 lbf ft RSV4 1100 Factory C...

Page 36: ...5 lbf ft 2 Shear head screw to the left of the ignition lock M8x28 1 manual tighten until the head shears off 3 Right hand cylindrical head hex socket fastener screw of ignition switch block M8x35 1 20 Nm 14 75 lbf ft 4 Nut fastening saddle lock to tail fair ing M22x1 25 1 5 Nm 3 68 lbf ft Characteristics RSV4 1100 Factory CHAR 36 ...

Page 37: ...scription Type Quantity Torque Notes 1 Lower intake duct fastener screws 4 5 Nm 3 68 lbf ft 2 SWP self tapping screws for fasten ing temperature sensor 2 9x12 2 1 Nm 0 73 lbf ft RSV4 1100 Factory Characteristics CHAR 37 ...

Page 38: ... 1 Nm lbf ft 4 Torx button head silencer aesthetic protection fastening screw M6x10 3 8 Nm 5 90 lbf ft 5 Lambda probe fastener 2 25 Nm 18 43 lbf ft 6 Exhaust valve opening closing ca bles regulator lock nuts M6 2 5 Nm 3 69 lbf ft ABS CONTROL UNIT Pos Description Type Quantity Torque Notes 1 Oil tube screws M10x1 4 23 26 Nm 16 96 19 18 lbf ft 2 Control unit support screws M6 2 6 8 1 Nm 5 01 0 74 lb...

Page 39: ...Nm 47 94 lbf ft AGIP GREASE SM2 4 Chain guard fastening screws M5 3 2 Nm 1 47 lbf ft 5 Chain guard fastener screw M5 3 2 Nm 1 47 lbf ft 6 Rear stand bushing retaining screw M6 2 7 Nm 5 16 lbf ft 7 Chain tensioner shoe adjustment screws M8 2 Adjust the screw until the head is in contact with the tensioner shoe and then tighten the lock nut to the specified torque RSV4 1100 Factory Characteristics C...

Page 40: ...es 1 ABS sensor fixing screw M5x15 1 8 Nm 5 90 lbf ft 2 Screws fastening brake calliper to mount M8 2 25 Nm 18 43 lbf ft SADDLE Pos Description Type Quantity Torque Notes Rider saddle fastener screw M5 2 6 Nm 4 43 lbf ft Characteristics RSV4 1100 Factory CHAR 40 ...

Page 41: ...1 11 lbf ft REAR WHEEL Pos Description Type Quantity Torque Notes 1 Rear wheel axle nut M25x1 5 1 120 Nm 88 51 lbf ft 2 Nuts used to fasten the crown to the sprocket M10 5 50 Nm 36 88 lbf ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lbf ft Loct 243 RSV4 1100 Factory Characteristics CHAR 41 ...

Page 42: ...Type Quantity Torque Notes 1 Flanged hex cap screw M6x20 1 10 Nm 7 38 lbf ft 2 Flanged hex cap screw M6x35 2 12 Nm 8 85 lbf ft Tighten to torque unscrew and re tighten to torque 3 Flanged hex cap screw M6x22 14 12 Nm 8 85 lbf ft Tighten to torque unscrew and re tighten to torque 4 Engine timing inspection cap 1 20 Nm 14 75 lbf ft 5 Spacers for soundproof cover 5 6 Nm 4 43 lbf ft 6 Oil level dipsti...

Page 43: ...scription Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft 2 TE flanged coil fixing screw M6x12 4 8 Nm 5 90 lb ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lb ft RSV4 1100 Factory Characteristics CHAR 43 ...

Page 44: ...t cam tower fixing screws M6x45 20 11 Nm 8 11 lb ft 3 Reed valve covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head Characteri...

Page 45: ...stening the timing system gear on the intake shaft M8 4 30 Nm 22 13 lb ft Loct 243 2 Chain tensioner sliders fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Chain guide sliders fixing screws M6x18 2 10 Nm 7 38 lb ft Loct 243 RSV4 1100 Factory Characteristics CHAR 45 ...

Page 46: ...w M8x70 4 25 Nm 18 44 lbf ft Lubricate the head and under the head 3 Flanged hex cap screw M6x50 8 10 Nm 7 38 lbf ft Lubricate the head and under the head 4 Flanged hex cap screw M8x35 1 25 Nm 18 44 lbf ft Lubricate the head and under the head 5 Flanged hex cap screw M8x50 3 25 Nm 18 44 lbf ft Lubricate the head and under the head 6 Gearbox control rod support SHC fix ing screws M6x35 2 10 Nm 7 38...

Page 47: ... 60 2 Screw fastening ground cable to the engine M6 2 6 Nm 4 43 lbf ft GEARBOX Pos Description Type Quantity Torque Notes 1 Philips cylindrical head hex socket screw M6x20 1 10 Nm 7 38 lbf ft Pre coated screw if not pre coated apply 3M SCOTCH GRIP 2353 to thread 2 Pre coated countersunk flat head hex socket screws for fastening bearing retainer plates M6x16 3 10 Nm 7 38 lbf ft Pre coated screw if ...

Page 48: ...to secure the pre selec tor to the crankcase 1 25 Nm 18 44 lbf ft Pre coated screw if not pre coated apply 3M 2353 to thread CLUTCH Pos Description Type Quantity Torque Notes 1 Flanged nut fixing clutch M20x1 1 150 Nm 110 63 lbf ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lbf ft Characteristics RSV4 1100 Factory CHAR 48 ...

Page 49: ...e Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 2 Starter motor SHC fastener screw M6x40 2 10 Nm 7 38 lbf ft Screw fastening cables to the starter motor M6 1 6 Nm 4 43 lbf ft RSV4 1100 Factory Characteristics CHAR 49 ...

Page 50: ...rew M6x30 1 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 LUBRICATION Pos Description Type Quantity Torque Notes 1 Oil filter coupling fastening screw 1 30 Nm 22 13 lbf ft 2 Oil drainage plug 1 30 Nm 22 13 lbf ft 3 Oil sump fixing screws M6x30 12 12 Nm 8 85 lbf ft Tighten to torque unscrew and re tighten to torque 4 Oil pressure sensor 1 15 Nm 11 06 lbf ft 5 Flanged TE rose pip...

Page 51: ...SECONDARY AIR SYSTEM Pos Description Type Quantity Torque Notes 1 Cylindrical head hex socket secon dary air solenoid screws M6x16 2 10 Nm 7 38 lbf ft RSV4 1100 Factory Characteristics CHAR 51 ...

Page 52: ...WATER PUMP Pos Description Type Quantity Torque Notes 1 Cylindrical head hex socket screws for fastening the pump to the crank case M6x25 2 10 Nm 7 38 lbf ft Characteristics RSV4 1100 Factory CHAR 52 ...

Page 53: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 54: ...ode Description 020845Y Engine support 020846Y Containment tray plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch retainer tool 020850Y Primary gear lock Special tools RSV4 1100 Factory S TOOLS 54 ...

Page 55: ... timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension er of the timing chain 020980Y Piston assembly ring 020857Y Crankshaft support U bolt RSV4 1100 Factory Special tools S TOOLS 55 ...

Page 56: ... AP8140199 Tool storage panel 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear box control rod 020863Y Punch assembly cage with rollers des modromic drum 020864Y Engine support plate Special tools RSV4 1100 Factory S TOOLS 56 ...

Page 57: ...pport for camshaft gear on head 020883Y Fitting removing timing chain tensioner tool 020709Y Engine support AP8140187 U bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide RSV4 1100 Factory Special tools S TOOLS 57 ...

Page 58: ...64Y 25 mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft Special tools RSV4 1100 Factory S TOOLS 58 ...

Page 59: ...l for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140149 Guard for assembly operations AP8140190 Steering tightening tool 01761 04 Ohlins fork cap ring nut RSV4 1100 Factory Special tools S TOOLS 59 ...

Page 60: ...e clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles Special tools RSV4 1100 Factory S TOOLS 60 ...

Page 61: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 62: ...ts that in ex treme cases can cause a slight clearance to the handlebar Therefore it is recommended to perform the check and adjustment operations at an Authorised Aprilia Piaggio Workshop every 5 000 km 3 106 86 mi 8 Replace at whichever of the following occurs first 40 000 km 24 854 85 mi or 4 years SCHEDULED MAINTENANCE TABLE Km x 1 000 mi x 1 000 1 0 6 10 6 2 20 12 4 30 18 6 40 24 9 EVERY 12 M...

Page 63: ...and allows to plan eventual maintenance Therefore when the general warning light see figure steadily lights up for 2 seconds each 120 seconds it is necessary to contact an Au thorised Service Centre to plan the specific maintenance intervention which is recom mended by the manufacturer To carry out the correct verification Flexible coupling pin nuts tightening indicated in the scheduled maintenanc...

Page 64: ...els 5 I I I I I Diagnosis by tool I I I I I Brake discs 5 Pads wear 2 I I I I I Air filter 5 I R I R Engine oil filter 5 R R R R R Raked I I General vehicle operation 5 I I I I I Valve clearance 6 A A Cooling system 5 I I I I Brake systems 5 I I I I I Light circuit I I I I I Safety switches stand stop clutch extra negative stroke gas control I I I I I Brake Fluid I I I I I Coolant I I I I I Fork o...

Page 65: ...histicated system based on exchangeable conical bushes that allow the modification of the steering angle for track use In case of prolonged road use in conditions with uneven ground e g use on pave holes speed bumps can bring small adjustments that in ex treme cases can cause a slight clearance to the handlebar Therefore it is recommended to perform the check and adjustment operations at an Author...

Page 66: ...ve degree of technological stress of the mechanical components an electric device in tervenes that registers the engine perform ance and allows to plan eventual maintenance Therefore when the general warning light see figure steadily lights up for 2 seconds each 120 seconds it is necessary to contact an Au thorised Service Centre to plan the specific maintenance intervention which is recom mended ...

Page 67: ...me in hours 14 15 17 15 14 18 Use of the P A D S diagnostic tool update the instrument to the latest available version the new engine calibration dedicated to the model in ques tion will allow monitoring the actual technolog ical stress level of the mechanical parts for track use For this reason when the general warning lamp see the figure remains on in the steady state for more than 2 seconds eve...

Page 68: ...ased lubricant for high per formance four stroke engines SAE 10W 50 API SL JASO MA2 Lithium based grease Lithium calcium soap based grease colour black contains EP Extreme Pressure additives excellent water re pellent properties Anti freeze liquid ready to use colour red Ethylene glycol antifreeze liquid with or ganic inhibition additives Red ready to use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA N...

Page 69: ...hem REAR SPARK PLUGS Cylinder 1 To proceed with the removal of the cylinder 1 spark plug proceed as described After removing the fixing screw of main wiring harness support release it from the filter housing by lifting it as indica ted Release the connector from the sup port on the filter housing and discon nect it RSV4 1100 Factory Maintenance MAIN 69 ...

Page 70: ...ng harnesses on the filter housing Using a special spark plug wrench un screw and remove it Cylinder 3 To proceed with the removal of the cylinder 3 spark plug proceed as described Release the connector from the sup port on the filter housing and discon nect it Remove the air pressure sensor fixing screw to facilitate the coil removal Maintenance RSV4 1100 Factory MAIN 70 ...

Page 71: ...ST BE CHECKED WHEN THE ENGINE IS WARM CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL PREFERABLY CHECK THE OIL AFTER A JOURNEY OF AFTER TRAVELLING APPROXIMATELY 15 Km 10 miles IN EXTRA URBAN CONDITIONS ENOUGH TO WARM UP THE ENGINE OIL TO OPERATING TEMPERATURE Shut off the engine and wait a few sec onds Kee...

Page 72: ...THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED THE MAXIMUM MARKING AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with suitable capaci ty under the drainage plug Unscrew and remove the drainage plug Unscrew and remove the filler cap Mai...

Page 73: ...K gal 1 06 US gal engine oil of the specified type Screw on the filler cap Warm up the engine up by running it for a few minutes then switch it off After thirty seconds check the level with a oil level dipstick Top up if necessary CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED THE MAXIMUM MARKING AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ...

Page 74: ...new engine oil filter in the seat filling the filter to 1 3 of its capacity with engine oil before fitting See also Replacement Air filter To remove the air filter the fuel tank must be re moved to be able to reach the filter housing area Then proceed as described Disconnect the ENGINE connector from the control unit After having disconnected the VEHI CLE connector from the control unit release th...

Page 75: ...ove the three screws fixing the ECU support to the filter housing Remove the control unit complete with support After having removed the fixing screw of the engine wiring harness support release it from the filter housing by lift ing it as indicated RSV4 1100 Factory Maintenance MAIN 75 ...

Page 76: ...m its seat Remove the nine fixing screws of the filter housing cover Disconnect the fuel pipe from the upper injectors by lifting the filter housing cov er Remove the air filter retainer by lifting it Maintenance RSV4 1100 Factory MAIN 76 ...

Page 77: ...proceed as follows COVER REMOVAL Disconnect the ENGINE connector from the control unit After having disconnected the VEHI CLE connector from the control unit release the wiring harness from the two cable glands on the filter housing Remove the three screws fixing the ECU support to the filter housing RSV4 1100 Factory Maintenance MAIN 77 ...

Page 78: ...oved the fixing screw of the engine wiring harness support release it from the filter housing by lift ing it as indicated Remove the quick shift connector from its seat Remove the nine fixing screws of the filter housing cover Maintenance RSV4 1100 Factory MAIN 78 ...

Page 79: ... remove it by releasing it from the upper injectors Remove the four injectors from the fil ter box and disconnect the connectors Disconnect the intake air temperature sensor connector and the main wiring harness from the cable gland on the fil ter housing cover RSV4 1100 Factory Maintenance MAIN 79 ...

Page 80: ...ing harness to the engine wir ing harness Remove the filter housing cover To remove the upper intake ducts re move the four fixing screws on the filter housing cover BASE REMOVAL After having removed the filter housing cover proceed with removing the air filter retainer by lifting it Maintenance RSV4 1100 Factory MAIN 80 ...

Page 81: ...t side of the vehi cle remove the screw that fastens the front bank oil pressure sensor to the base of the filter housing removing al so the gear sensor connector support bracket Operating on the right side of the vehi cle remove the screw that fastens the rear bank oil pressure sensor to the base of the filter housing RSV4 1100 Factory Maintenance MAIN 81 ...

Page 82: ...ery pipe of the blow by valve on the left and the vapour recovery pipe of the sas valve on the right Operating on the left side of the vehi cle remove the clamp that fastens the engine wiring harness to the filter hous ing base Release from the supports the connec tors of the front bank coils located on the filter housing base Maintenance RSV4 1100 Factory MAIN 82 ...

Page 83: ...g particular at tention to the following operations CLAMP PRE FITTING Place a suitably sized clamp on the en gine wiring harness next to the grey taping and secure it to the filter housing base Do not tighten the clamp to facilitate the connection of the front bank coil con nectors and of the lower injector wiring harnesses Subsequently after having placed the filter housing base close the clamp c...

Page 84: ...r from the clutch side Remove the clutch cover Turn the crankshaft in the normal di rection of rotation of the engine with a wrench applied to the primary gear fas tener nut until the valves are under spring tension Use a feeler gauge to check the clear ance between the cam of the shaft and the relative tappet for both front head shafts Characteristic Acceptable values with control clearance be tw...

Page 85: ...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 Front cylinder head valves Check the front cylinder head valve clearance val ues and adjust if necessary to attain the correct values following the procedure described below Remove both cylinder head covers the soundproofing cov...

Page 86: ...n the engine rotation direction direction of travel Insert the pin from the flywheel side in to the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole in the bearing cap Specific tooling 020851Y Camshaft timing pin Loosen the second screw of the cam shaft drive sprocket Maintenance RSV4 1100 Factory MAIN 86 ...

Page 87: ...ll the specific camshaft gear sup port tool Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head Remove the second screw of the cam shaft drive sprocket Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool s spacer RSV4 1100 Factory Maintenance MAIN 87 ...

Page 88: ... the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Retrieve the buckets using a magnet Remove the calibrated pads with a magnet and replace with new calibra ted pads of the size necessary to attain the correct valve clearance value See the paragraph Calibrated pad thickness to determine the correct thickness CAUTION ...

Page 89: ...ent and fit and hand tighten the seven screws indicated Use new copper washers on the four screws near the spark plug holes Loosen the camshaft sprocket lock screw on the tool Slide the sprocket off the holder tool and onto the camshaft CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Apply Loctite 243 thread lock adhesive to the first screw of th...

Page 90: ...ankshaft in direction of engine rotation only as far as neces sary to reveal the second fastener hole for the sprocket Apply Loctite 243 thread lock adhesive to the thread of the second fastener screw of the camshaft sprocket this screw must be replaced with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation ...

Page 91: ...Remove both cylinder head covers the soundproofing covers the alternator side cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Start rotating the crankshaft in the di rection of rotation of the engine with a wrench applied to the primary gear fas tener nut As soon as the first fastener screw of the camshaft gear is visible remove the screw Continue rotating the cranksh...

Page 92: ...he cam shaft drive sprocket Remove the pin from the camshaft drive sprocket Unscrew and remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Remove the second screw of the cam shaft drive sprocket CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Maintenance RSV4 1100 Factory MAIN 92 ...

Page 93: ...w the seven screws in progres sive steps in a criss cross pattern and remove Retrieve the copper washers from the screws near the spark plug holes Remove the bearing caps complete with O rings and alignment pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gea...

Page 94: ...d thickness to determine the correct thickness CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE Refit the bucket tappets Refit the camshafts ensuring that they are aligned correctly If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Maintenance RSV4 1100 ...

Page 95: ...AUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Remove the tool for holding the cam shaft drive sprocket gear on the head Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand tighten the screw only Fit the bearing cap the oil pipe and the three fastener screws Tighten the ten fastener screws of the camshafts ...

Page 96: ...placed with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation of engine to bring it back to the previous position in which the holes in the camshaft and the bear ing cap were aligned insert the refer ence pin while checking with the crank shaft reference pin that the flywheel side hole and the hole on the cr...

Page 97: ...709 in 1 82 mm 0 0716 in 1 85 mm 0 0728 in 1 87 mm 0 0736 in 1 90 mm 0 0748 in 1 92 mm 0 0756 in 1 95 mm 0 0768 in 1 97 mm 0 0775 in 2 mm 0 0787 in 2 02 mm 0 0795 in 2 05 mm 0 0807 in 2 07 mm 0 0815 in 2 1 mm 0 0827 in 2 12 mm 0 0835 in 2 15 mm 0 0846 in 2 17 mm 0 0854 in 2 2 mm 0 0866 in RSV4 1100 Factory Maintenance MAIN 97 ...

Page 98: ...mm 0 1012 in 2 6 mm 0 1024 in 2 62 mm 0 1031 in 2 65 mm 0 1043 in 2 67 mm 0 1051 in 2 7 mm 0 1063 in 2 72 mm 0 1071 in 2 75 mm 0 1083 in 2 77 mm 0 1090 in 2 8 mm 0 1102 in 2 82 mm 0 1110 in 2 85 mm 0 1122 in 2 87 mm 0 1129 in 2 9 mm 0 1142 in 2 92 mm 0 1150 in 2 95 mm 0 1161 in 2 97 mm 0 1169 in 3 mm 0 1181 in 3 02 mm 0 1189 in 3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 i...

Page 99: ... FULL maximum and LOW minimum marks WARNING CARRY OUT THE CHECK AND TOP UP THE REFRIGER ANT LIQUID WITH THE ENGINE SWITCHED OFF AN COLD Top up To top up the cooling system it is necessary to first remove the right hand guard the lock of the upper right fairing and the right side fairing Then proceed as described Remove the expansion tank filler plug Top up the system by checking the lev el using t...

Page 100: ...ID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE TO AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE LEVEL OF THE FLUID IN THE RES ERVOIR PARALLEL WITH THE EDGE OF THE RESERVOI...

Page 101: ... THE DEAD ZONE OF THE BRAKE PEDAL OR BRAKE LEVER IS TOO LONG OR IN CASE OF FLUID LOSS IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM HAVE THIS PROCEDURE PERFORMED BY AN Authorised Aprilia Dealer Rear braking system Unscrew and remove the upper nut 5 from the rear brake pump Top up the reservoir with the recom mended brake fluid to reach the correct level on the sight glass 6 CAUTION ON...

Page 102: ...tand Partially undo the screw 4 Turn the cam 5 searching for the best position for the pedal Tighten the screw 4 and check the cam is stable in position Clutch system Adjusting the lever Adjust the clutch when the engine stops or the ve hicle tends to move forward even when clutch lever is operated and the gear engaged or if the clutch slides resulting in acceleration delay con sidering the engine...

Page 103: ...r Make sure that the engine does not stop or that the vehicle does not tend to move or that the clutch does not slip during acceleration or while rid ing Headlight adjustment NOTE IN COMPLIANCE WITH LOCAL LEGISLATION SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN ALIGNING THE LIGHTS To quickly check if the headlamp is aimed correct ly place the vehicle on a level surface 10 m 32 8 ft from a vertical wa...

Page 104: ... be used to adjust the vertical alignment of the low beam headlight beam NOTE CHECK THAT THE VERTICAL ALIGNMENT OF THE BEAM IS CORRECT HIGH BEAM HEADLIGHT Operating from underneath the head lamp unit turn the adjuster screw 3 TIGHTEN clockwise to lower the light beam LOOSEN anticlockwise to raise the beam This adjuster screw may be used to adjust the vertical alignment of the high beam headlight b...

Page 105: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 106: ...Components arrangement Key 1 Side stand sensor 2 Fuel pump 3 Instrument cluster Electrical system RSV4 1100 Factory ELE SYS 106 ...

Page 107: ...ed sensor 17 Rear speed sensor 18 Headlamp 19 Rear turn indicators 20 Licence plate light 21 Taillight 22 Horn 23 Voltage regulator 24 Battery 25 Secondary fuses 26 Main fuse 27 11SM control unit 28 Rear brake switch 29 Stator with timing sensor 30 Coils 31 Starter motor 32 Oil pressure sensor 33 Inertia platform 34 Accelerator control 35 Quick Shift 36 a PRC commands 37 Modulator ABS control unit...

Page 108: ...define the correct cable harness routing layout to ensure the reliability of the vehicle Materials used and corresponding quantities The electrical system consists of the following wiring harnesses and parts 1 x Main vehicle wiring harness 1 x Licence plate holder wiring harness 1 x Engine Battery Earth Cable Only for RSV 1100 Factory OHLINS ASC 1 x Main vehicle wiring harness 1 x Ohlins fork wiri...

Page 109: ...d Check the ground fastening on the starter motor starter motor positive and relative hood Check the taillight connection Check the connection between the number plate holder wiring harness and the main wiring harness Check the fuel pump connection Check the regulator connection Check fastening of the chassis engine ground cable Check the flywheel regulator connection Check the Lambda connection f...

Page 110: ...S THESE CONNECTORS HAVE BEEN LISTED AS THEY ARE MORE CRITICAL THAN OTH ERS AND THEIR DISCONNECTION MAY CAUSE VEHICLE BREAKDOWN OR MALFUNCTION NATURALLY IT IS ALSO NECESSARY THAT ALL OTHER CONNECTORS CONNECTED COR RECTLY TO ENSURE THAT THE VEHICLE FUNCTIONS CORRECTLY THE INSTRUCTIONS FOR ROUTING AND FASTENING THE WIRING HARNESS THROUGHOUT THE VEHICLE MUST BE FOLLOWED PRECISELY TO ENSURE THAT THE VE...

Page 111: ...TTING Place the cable gland as indicated TABLE A2 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA The wiring harnesses of the right light switch and ride by wire must pass out side the fork RSV4 1100 Factory Electrical system ELE SYS 111 ...

Page 112: ...d fit the right instru ment panel support TABLE A4 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA Place the main wiring harness as indi cated and use a clamp to secure it next to the grey taping together with the in strument panel horn and headlight wir ing harness Electrical system RSV4 1100 Factory ELE SYS 112 ...

Page 113: ...wer part of the instrument support TABLE A5 1 ROUTING THE CABLES IN THE INSTRUMENT PANEL SUPPORT AREA Group the wiring harnesses of the clutch switch left light switch and a PRC adjustment control by securing them with rubber cable gland and place them as indicated to be able to insert the left instrument panel support RSV4 1100 Factory Electrical system ELE SYS 113 ...

Page 114: ...e the instru ment support arch must be well con nected and placed inside it TABLE A7 ROUTING THE CABLES IN THE IN STRUMENT PANEL SUPPORT AREA Connect the connector for the USB port provision on the specific grommet on the instrument panel support Electrical system RSV4 1100 Factory ELE SYS 114 ...

Page 115: ...strument panel connec tor and then place it on the support TABLE B FRONT ABS SPEED SENSOR PRE FITTING OHLINS After having placed the front ABS speed sensor on the fork leg secure the wiring harness using a cable gland 1 and a clamp 2 RSV4 1100 Factory Electrical system ELE SYS 115 ...

Page 116: ... secured the sensor arrange its wiring harness 2 as indicated and secure it with two clamps 3 TABLE B1 FRONT ABS SPEED SENSOR Pass the front ABS speed sensor wir ing harness as shown and using a clamp secure it together with the main wiring harness on the radiator support Electrical system RSV4 1100 Factory ELE SYS 116 ...

Page 117: ...speed sensor wir ing as shown and secure it with two clamps to the main wiring harness TABLE B3 FRONT ABS SPEED SENSOR Use cable glands to secure the front ABS speed sensor wiring harness to the brake pipe RSV4 1100 Factory Electrical system ELE SYS 117 ...

Page 118: ...ru ment panel support at the indicated point The wiring harness must pass inside the cable gland together with the front light cluster wiring harness TABLE D ELECTRONIC FORKS IF PRESENT Pre install the wiring harness 1 of the electronic forks on the upper steering plate and after having secured it by means of special clamps 2 in the in dicated points tighten the screws 3 of the cover 4 Electrical ...

Page 119: ...upport TABLE D2 ELECTRONIC FORKS IF PRESENT The wiring harnesses that will be con nected to the stanchion cap must pass over the front of the steering plate as indicated After having checked the correct con nection place the rubber protection covers RSV4 1100 Factory Electrical system ELE SYS 119 ...

Page 120: ...TEERING DAMPER IF PRESENT Route the steering damper cable to ward the damper TABLE F CLUTCH SWITCH PRE FITTING Place the switch wiring harness as shown and insert it into its cover Electrical system RSV4 1100 Factory ELE SYS 120 ...

Page 121: ...ed the switch on the clutch control and after having inserted the nut screw it in until the thread pro trusion is 4 mm Central part TABLE A VEHICLE CABLE HARNESS Place the main wiring harness as indi cated RSV4 1100 Factory Electrical system ELE SYS 121 ...

Page 122: ... CABLE HARNESS Place the relays as indicated Injection relay with red reference tape on the right support Fan relay without taping on the sup port in central position Petrol pump relay with grey reference tape on the left support Then secure the main wiring harness next to the grey taping using cable glands Electrical system RSV4 1100 Factory ELE SYS 122 ...

Page 123: ...iring har ness on the chassis using a clamp next to with the grey taping TABLE B GEAR SENSOR Place the gear sensor wiring harness as indicated before proceeding with the installation of the engine on the ve hicle RSV4 1100 Factory Electrical system ELE SYS 123 ...

Page 124: ...two cable glands as indica ted on the filter housing cover in order to secure the ECU branch TABLE C1 VEHICLE ECU BRANCH Insert the ECU branch in the cable glands and arrange it as indicated Electrical system RSV4 1100 Factory ELE SYS 124 ...

Page 125: ...ng harness TABLE D1 MAIN WIRING HARNESS CON NECTION WITH THE ECU After having connected the VEHICLE ECU connector by pushing lightly with a finger check if the grey lever of both connectors moves to the inside If this happens the connector is not secured try to close it until a CLICK is heard Repeat the test to check if the connec tors and closed and secured RSV4 1100 Factory Electrical system ELE...

Page 126: ...connected and that the wiring harness of the coil and of the power supply connector are placed un der the guide as indicated TABLE F ENGINE OIL PRESSURE SENSOR CONNECTION Check that the terminal is connected and that the cover is inserted on the bulb correctly Electrical system RSV4 1100 Factory ELE SYS 126 ...

Page 127: ...rea indicated by the red triangle symbol TABLE G1 GROUND LEADS 1 Main wiring harness ground lead 2 Engine battery earth cable 3 Engine wiring harness ground lead The ground wiring harnesses must converge at the fixing point on the en gine All wiring harnesses on the left side of the vehicle must pass inside the cable gland on the chassis at the indicated point RSV4 1100 Factory Electrical system E...

Page 128: ...ck the tightening of the screw TABLE H WIRING HARNESS ON THE LOWER CHASSIS SHOULDERS Operating on the internal right side se cure the starter motor wiring harness to the cooling system pipe using a clamp Place the main wiring harness inside the cable gland on the internal side of the chassis Electrical system RSV4 1100 Factory ELE SYS 128 ...

Page 129: ...ace the wiring harnesses inside the cable gland on the internal part of the chassis TABLE H2 WIRING HARNESS ON THE LOW ER CHASSIS SHOULDERS Use a large clamp to secure all the wiring harnesses at the indicated point on the left side of the vehicle RSV4 1100 Factory Electrical system ELE SYS 129 ...

Page 130: ...LECTRIC WATER REPELLENT GREASE TABLE J RADIATOR FAN PRE FITTING The assembly is correct if the fan ca bles from the fan motor exits down ward as indicated TABLE K VOLTAGE REGULATOR Insert the pick up connector in the spe cific tab on the internal fairing and after having connected the voltage regulator connectors secure the voltage regula tor and pick up wiring harnesses using two clamps Leave the...

Page 131: ...ss the wiring harnesses of the volt age regulator and of the pick up inside the pre installed cable gland on the canister Fasten the electric fan connector to the canister support TABLE K2 VOLTAGE REGULATOR Secure the wiring harnesses with a clamp as indicated RSV4 1100 Factory Electrical system ELE SYS 131 ...

Page 132: ...e routed between the chassis and the exhaust valve motor cables TABLE L1 EXHAUST VALVE MOTOR AREA WIRING HARNESSES Connect the electric fan connector 3 and the ride by wire handle 4 to the counterpart and then fasten them to the exhaust valve motor support Electrical system RSV4 1100 Factory ELE SYS 132 ...

Page 133: ...lowered position TABLE M RIDE BY WIRE HANDLE CABLE ROUTING The ride by wire handle cable must pass over the main wiring harness branch that goes to the instrument pan el and under the radiator pipe that con nects the thermostatic valve with the radiator 1 Ride by wire handle wiring harness 2 Radiator pipe 3 Main wiring harness IF THIS CABLE IS NOT ROUTED CORRECTLY IT MAY DAMAGE THE RIDE BY WIRE HA...

Page 134: ...d to the fan wiring harness on the top and below it must pass through the in dicated cable gland TABLE N SIDE STAND After having placed the side stand sen sor wiring harness as indicated secure it with a clamp together with the lambda probe wiring and the quick shift to the crankcase cover fixing threaded pin Electrical system RSV4 1100 Factory ELE SYS 134 ...

Page 135: ...i cated to facilitate the positioning of the wiring harness on the vehicle during installation TABLE O1 QUICK SHIFT After having installed the quick shift place the wiring harness under the sprocket protective metal casing RSV4 1100 Factory Electrical system ELE SYS 135 ...

Page 136: ... SHIFT Pass the wiring harness between the chassis and the engine and then pass it behind the engine wiring harness at tached to the filter housing Connect the connector to its counter part and place it in the appropriate seat on the filter housing Electrical system RSV4 1100 Factory ELE SYS 136 ...

Page 137: ...e cable gland must be placed as in the figure completely upward and the lambda sensor cable must be routed through it TABLE P1 REAR LAMBDA Pass the wiring harness as indicated RSV4 1100 Factory Electrical system ELE SYS 137 ...

Page 138: ...protec tion cover Secure the wiring harness with a clamp at the indicated point TABLE Q FRONT LAMBDA After having correctly connected the rear lambda probe connector with its counterpart secure it using the special support to the side fairing metal sup port Insert the wiring harness in the tow in dicated cable glands Electrical system RSV4 1100 Factory ELE SYS 138 ...

Page 139: ...g system pipe TABLE R CONNECTIONS ON THE TANK After having inserted the main wiring harness branch to the two cable glands connect the connector of the inertial platform 1 and of the fuel pump 2 The connector 3 is not used RSV4 1100 Factory Electrical system ELE SYS 139 ...

Page 140: ...points TABLE X1 LICENCE PLACE HOLDER PRE FITTING The right arrow is identified with the RED taping and must be inserted on the licence plate holder as indicated in the picture The arrow with the red tape must be connected with the wiring har ness branch that includes the grey tape Electrical system RSV4 1100 Factory ELE SYS 140 ...

Page 141: ...ry using M5x8 screw 1 Starter relay 2 Battery positive cable pole identified by the let ter B 3 Vehicle wiring starter motor cable pole identi fied by the letter M TABLE A1 IGNITION RELAY PRE ASSEMBLY If the battery positive cable is not connected to the ignition relay correctly it may result in fires and in correct vehicle operation 1 Ignition relay 2 Battery positive cable RSV4 1100 Factory Elec...

Page 142: ... arrow and pull up the lever with your finger TABLE C PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION The initial position of the connector fastener lever must be as shown in the figure TABLE C1 PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION Place the connector on the opposite side of the control unit and lower the driving lever until the click that signals the end of the st...

Page 143: ...d the meas ured distance will be higher around 12 mm In this case repeat the operation as described in TABLE C1 C2 We recommend creating a template in order to en sure that the connector is inserted correctly FIGURE D MAIN WIRING HARNESS The main wiring harness must pass in side the motorcycle on the right side Next to the grey taping place the suit able cable clamp that must be inserted in the ho...

Page 144: ...indicated and secured with the two cable glands TABLE E ROUTING ON THE SADDLE COLUMN FOR THE STARTER RELAY The main wiring harness must be arranged as indicated and using a clamp secure it as indicated making sure not to fasten the wiring harness of the battery relay positive cable Secure the wiring harnesses on the two cable glands Electrical system RSV4 1100 Factory ELE SYS 144 ...

Page 145: ...ir seats secure the main wiring harness in the two cable glands located on the saddle column frame TABLE E2 ROUTING ON THE SADDLE COL UMN FOR THE STARTER RELAY Use a rubber cable gland at the indica ted point to secure the wiring harness es TABLE F REAR SPEED SENSOR Check that the rear ABS speed sensor connector is connected correctly and attached to its support RSV4 1100 Factory Electrical system...

Page 146: ...e TABLE F2 REAR SPEED SENSOR Insert the ABS rear speed sensor wir ing harness into the three cable glands on the swingarm TABLE F3 REAR SPEED SENSOR Place the ABS rear speed sensor wir ing harness as shown and secure it using the cable gland fastened to the rear brake calliper support Electrical system RSV4 1100 Factory ELE SYS 146 ...

Page 147: ... BRAKE SWITCH Check that the rear brake switch con nector is well connected to its counter part and then secure it to the main wiring harness with a clamp TABLE G1 REAR BRAKE SWITCH Pass the rear brake switch wiring har ness through the cable gland inside the chassis on the right side RSV4 1100 Factory Electrical system ELE SYS 147 ...

Page 148: ... connector in the support pass the wiring harness inside between the saddle column frame and the under tail fairing TABLE J AMP CONTROL UNIT IF PRESENT After having secured the control unit connect the connector with its counter part TABLE K ELECTRONIC SHOCK ABSORBER IF PRESENT Fasten the two wiring harnesses of the rear damper with a cable gland fixed under the saddle Electrical system RSV4 1100 ...

Page 149: ...pression using a clamp together with the rear stop switch wiring harness and rear ABS speed sensor TABLE K2 ELECTRONIC SHOCK ABSORBER IF PRESENT Connect the wiring harness connector with the reference C compression and place it as shown TABLE L FUSES Place the three fuse boxes as indica ted RSV4 1100 Factory Electrical system ELE SYS 149 ...

Page 150: ...General wiring diagram Key 1 Multiple connectors 2 Horn 3 Left light switch 4 Left light switch 2 lever Electrical system RSV4 1100 Factory ELE SYS 150 ...

Page 151: ...sensor 20 Rear wheel speed sensor 21 Fan control relay 22 Fan 23 Sensor box 24 Auxiliary fuses 1 FUSE 1 25 Ohlins suspension fuses FUSE 2 if applicable 26 Auxiliary fuses 3 FUSE 3 27 ABS fuses FUSE 4 28 Alternator 29 Voltage regulator 30 Starter Motor 31 Starter relay Main fuse 30A 32 Battery 33 Side stand switch 34 Main injection relay 35 Fuel pump relay 36 Engine ground 37 Fuel level sensor 38 F...

Page 152: ... Cylinder 2 coil REAR 59 Cylinder 1 coil REAR 60 Canister 61 Engine ground 62 Map sensor 2 63 Motorised throttle valve 2 64 Map sensor 1 65 Motorised throttle valve 1 66 air temperature sensor 67 Water temperature sensor 68 Engine speed sensor 69 Oil pressure sensor 70 11 MP control unit 71 Engine vehicle wiring harness connector 72 OBD connector 73 AMP control unit if present 74 Complete headlamp...

Page 153: ...GE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure includes the following checks 1 Observation and check of the connector correct position on the component or on the coupling con nector making sure that the locking catch is re leased 2 Observation of the terminals on the connector no rust marks or dirt should be present and it is important to check terminal correct positioning on the connecto...

Page 154: ...and place one of the tester probes on the vehicle ground point or on the battery negative pole and the other probe on the cable under inspection Normally the tester will sound an audible signal to confirm continuity in the section of circuit tested Continuity may also be tested by setting the tester selector to the Ohm symbol and checking that the resistance in the circuit is zero or of a few tent...

Page 155: ... IMMOBILIZER ANTENNA IS DISCONNECTED YOU WILL NOT BE ABLE TO START KEY PROGRAMMING Enter the USER CODE to continue If the code entered is correct the first key is stored At this point on the digital display of the motorcycle after the automatic restart of the dynamic presentation screen a message will appear with a countdown of 20 seconds to insert the second key to be programmed Set key to OFF in...

Page 156: ...ing the function Rpm indicator from the Devices Activation screen page injector icon Diagnosis In case of malfunction of certain or gans the digital display of the instru ment panel may display errors To check and diagnose the specific com ponent check the dedicated section Maintenance icon reset The system displays the function as follows After the maintenance interval thresh olds are exceeded ex...

Page 157: ...ary fuses CAUTION DO NOT ATTEMPT TO REPAIR FAULTY FUSES NEVER USE A FUSE THAT IS DIFFERENT THAN WHAT IS SPECIFIED TO PREVENT DAMAGES TO THE ELECTRICAL SYSTEM OR SHORT CIRCUITS AND THE RISK OF FIRE CAUTION A FUSE THAT BLOWS FREQUENTLY MAY INDICATE A SHORT CIRCUIT OR OVERLOAD To check To avoid an accidental short circuit place the power switch to OFF Remove the rider saddle Open the covers of the se...

Page 158: ...er for the instrument panel positive key on power for the right hand handlebar control set main start relay coil positive key on power for inertial sensor platform D 7 5A fuse ECU permanent positive lead E 5A fuse Positive key on power for AMP positive key on power for OBD positive key on power for USB positive key on power for the timer fitting F 5A fuse Positive key on power for headlamp load G ...

Page 159: ...TION OF THE MAIN FUSE Specification Desc Quantity O 30A fuse Battery charging all vehicle utilities P spare fuse 30 A The main fuse is located on the rear part of the motorcycle under the tail fairing passenger saddle CAUTION REMOVING THE 30A FUSE WILL RESET THE DIGITAL CLOCK TRIP INFORMATION AND CHRONOMETER TIMES Control unit ASC CONTROL UNIT ELECTRONIC SUSPENSION CONTROL UNIT IF AVAILABLE REMOVA...

Page 160: ...n BOOT version Software version Map identification DIAGNOSTIC TOOL ACTIVATIONS Suspension test Softest setting min damping Minimum damping preload check Suspension test Hardest setting max damping Maximum damping preload check DIAGNOSTIC TOOL ERRORS ASC ELECTRONIC SUSPENSION ECU ERROR Code Description Symptoms 504900 Internal electronic fault 504600 Calibration Checksum error 501600 Under voltage ...

Page 161: ...valid WZ angular value sensor signal D08606 Invalid front wheel speed sensor signal D08607 Invalid rear wheel speed sensor signal D08608 Invalid front brake pressure sensor signal D08609 Invalid rear brake pressure sensor signal D0860A Invalid accelerator sensor signal D0860B Invalid bank angle sensor signal D0860C Invalid suspension mode sensor signal D0860D Invalid front compression block HMI si...

Page 162: ... in which the main component involves the control unit Location on the vehicle above the filter box connector on control unit 80 PIN ENGINE connector 77 of which functional 66 PIN VE HICLE connector 53 of which functional Pin out See CONNECTORS paragraph screen page example values with key ON Drawing number identified inserted by the manufacturer HW number indicates the Hardware number Hardware ve...

Page 163: ...and 3 Front int est press 2 and 4 front cylinders intake estimated pressure 2 and 4 Timing implemented Current cylinder timing Battery voltage Rear lambda 1 volt indicates the rear bank lambda probe 1 voltage Front lambda 2 volt indicates the front bank lambda probe 2 voltage Rear lambda 1 corr rear bank lambda 1 correction Front lambda 2 corr front bank lambda 2 correction Rear bank lambda 1 bank...

Page 164: ...da 2 check front bank lambda 2 check Rear thrott auto self learning rear throttle automatic self learning Front thrott auto self learning front throttle automatic self learning Engine status Engine mode Hand grip Gearbox in neutral Gear selected indicates the gear selected Fan relay Immobilizer consent Tone wheel synchro tone wheel synchronisation status Side stand Fall sensor RUN STOP switch Clut...

Page 165: ...a probe 1 heater Rear cyl 1 low inj rear bank cylinder 1 lower injector Front cyl 2 low inj front bank cylinder 2 lower injector Rear cyl 3 low inj rear bank cylinder 3 lower injector Front cyl 4 low inj front bank cylinder 4 lower injector Rear cyl 1 upp inj rear bank cylinder 1 upper injector Front cyl 2 upp inj front bank cylinder 2 upper injector Rear cyl 3 upp inj rear bank cylinder 3 upper i...

Page 166: ...HUT DOWN P060B A D converter Electrical diagnostic Circuit not functioning Error cause Replace the injection control unit The instrument cluster indicates this error by lighting up in a fixed manner the MI warning light and by flashing the general warning light NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT DOWN P1301 Stop lights relay error Electrical diagnostic short circuit to po...

Page 167: ...fact that the level 2 safety system comparison between requested torque and calculated torque detected a fault the control unit reset the engine severity C The instrument cluster does not indicate the presence of this error even in the ATT status Troubleshooting Perform the troubleshooting for the other detected errors P060C Safety Engine Stop Error cause Due to the fact that the safety system det...

Page 168: ...e instrument cluster indicates the presence of this error with the MI warning light on fixed Troubleshooting Contact technical service NOTE THIS ERROR DISABLES THE TRACTION CONTROL P1650 Engine events configuration Checksum calculation error Error cause Corrupt Flash eeprom hardware problem Upload e g in service of an incompatible software version therefore missing the reference check sum The pres...

Page 169: ...lectrical power to vehicle the BS BAT TERY LITIO BSLi 04 lithium battery is already activated charged and sealed or alternatively the traditional YUASA YTZ10S battery which must be activated and charged Level in electrical circuit diagram Battery charge Location on the vehicle under the saddle connector on the battery Electrical specifications 12V 48Wh 280A Pin out 1 Positive pole red approx 12 6 ...

Page 170: ... connector and ECU connector check in particular for oxidation if not OK repair If OK check that resist ance of the Red White cable from the voltage regulator connector to the ECU connector is a few tenths of an Ohm if not OK repair the wiring harness if OK check that the electric generator is operating correctly if not OK repair If OK check that the voltage regulator is working correctly P1560 Lo...

Page 171: ...ermanently open in all gears except neutral With the motorcycle stationary and the gearbox in neutral the valve remains closed up to 7000 rpm Operation Operating principle The system consists of a throttle valve with return spring on the exhaust The valve is closed by 2 cables operated by an electric motor which is elec trically connected to the instrument cluster The logic and the motor control h...

Page 172: ...ration stopped due to detected faults zero searching NOTES If there is no problem the following is displayed in operation DIAGNOSTIC TOOL ELECTRICAL ERRORS P1501 Search exhaust butterfly valve stop positions Diagnosis potentiometer signal above maximum threshold potentiometer signal below minimum threshold time out search not executed or incorrect travel Error cause If the potentiometer signal is ...

Page 173: ...ical characteristics of the motor if not OK replace the motor if OK check the valve connector and the instrument cluster connector checking in particular for corrosion if not OK repair if OK replace the electrical motor Also check the condition of the cables If research not performed or incorrect stroke perform the procedure Exhaust butterfly valve self acquisition if the stop position acquisition...

Page 174: ...ground continuity if they do replace the motor If short circuit to positive or short circuit between the two cables disconnect the instrument panel connector and check with key ON if there is voltage on PIN 3 or PIN 2 of the connector if there is restore the wiring harness if there isn t with key OFF and disconnecting the exhaust connector as well check if the two cables are insulated one from the...

Page 175: ...ct operation of the return spring and the absence of foreign objects that might obstruct its rotation if not ok restore if ok perform the check procedure fro the valve connector and for the instrument panel connectors ay attention to oxidation signs and check the cable resistance if not ok restore if ok with the cables disconnected check at key ON the normal rotation of the electric motor and repl...

Page 176: ...CAUTION WORK ON THE MOTOR OF THE EXHAUST THROTTLE VALVE ONLY WITH THE KEY SET TO OFF OR ONLY AFTER DISCONNECTING THE NEGATIVE POLE OF THE BATTERY CAUTION NEVER REMOVE THE PULLEY FROM THE MOTOR CAUTION LOOSEN THE ADJUSTER SCREWS OF THE CONTROL CABLES BEFORE REMOVING THEM TO PREVENT FORCING THEM CAUTION BEFORE REMOVING THE CONTROL CABLES CHECK THAT THE MOTOR PULLEY IS IN THE ZERO POSITION NEVER WORK...

Page 177: ...ON BRING BOTH NUTS OF THE TWO ADJUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE WELDED TO THE SI LENCER Connect the PADS and carry out the valve zero actuator in the corresponding valve fully open position CAUTION CHECK THAT THE PULLEY HAS THE END STOP RESTING AGAINST THE END STOP OF THE SILENCER RSV4 1100 Factory Electrical system ELE SYS 177 ...

Page 178: ...IONING THE ADJUSTER SCREW KEEPING THE COUNTER NUT STILL DO NOT TURN CLOCKWISE FOR ANY CORRECTIONS SINCE THE AD JUSTMENT IS DISTORTED DUE TO THE PLAY IF IT GOES BEYOND THE REQUIRED VALUE FULLY TIGHTEN THE ADJUSTER SCREW AND REPEAT THE ADJUSTMENT CHECKING THAT THE PULLEY HAS THE END STOP RESTING AGAINST THE END STOP OF THE SILENCER Electrical system RSV4 1100 Factory ELE SYS 178 ...

Page 179: ...uire the end position with the PADS the actuator searches for the opening and closing travel limits Open and close with the key and check that the cables are taut on the pulley Visually check that the valve spring and the barrels are in their seats EXHAUST VALVE CLEARANCE Condition of use Closing cable Value X Opening cable Value Y New cables 4 0 2mm 0 16 0 0078 in 1 0 2mm 0 04 0 0078 in At 1 000 ...

Page 180: ...MP Tecnology Sincronizzazione To use the system V4 MP the synchronisation that differs depending on the operating system must be performed iOS OPERATING SYSTEM Turn the ignition switch of the motor cycle ON with the PMP ECU correctly connected Open the App settings clicking on the icon In the page settings click on the Blue Tooth menu Electrical system RSV4 1100 Factory ELE SYS 180 ...

Page 181: ...e to con nect When connected the PMP shows Connected Now the PMP is connected to the phone and in the V4 MP App you should note the motorcy cle data transmission After the first connection the system connects automatically to the instrument panel key ON ANDROID OPERATING SYSTEM Turn the ignition switch of the motor cycle ON with the PMP ECU correctly connected Open the App s settings by clicking o...

Page 182: ...t phone is connected Once connected the PMP is added to the Paired devi ces list and in the menu PMP appears the message Paired Now the PMP is connected to the phone and in the V4 MP App you should note the motorcy cle data transmission After the first connection the system connects automatically to the instrument panel key ON Once the connection is established you can start the application by sel...

Page 183: ...OR ABOUT 20 SECONDS TO EN SURE THAT THE WIRELESS CONNECTION IS CLOSED IN CASE OF CONNECTION FAILURE JUST EXIT THE APPLICATION USING THE APPROPRIATE BUTTON CLOSE IT FROM THE BACKGROUND MENU AND MANUALLY RESTART IT IF THE PREVIOUS DEVICE IS NOT IN THE AREA AFTER 20 SECONDS THE SYSTEM WILL BE AVAILABLE TO CONNECT WITH A NEW SMARTPHONE RSV4 1100 Factory Electrical system ELE SYS 183 ...

Page 184: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 185: ...weight of the vehicle to the semi handlebars and to a hoist Place the rear stand Removing the engine from the vehicle To proceed with the removal of the engine from the vehicle proceed as described Unscrew and remove the filler plug of the coolant radiator Use a container with a suitable capaci ty and operating from the left side of the vehicle remove the discharge screw of the cooling system Use ...

Page 186: ...side electric fan and remove the safety clamp applied on the connector Remove the clamp that fastens the generator s alternator s wiring har nesses the oil pressure bulb the front bank lambda probe and the left side electric fan Temporarily move away the canister by blocking it using circlips to facilitate the subsequent operations Engine from vehicle RSV4 1100 Factory ENG VE 186 ...

Page 187: ...sconnect it Release the connector of the demand sensor from the exhaust valve motor support and disconnect it Detach the expansion tank water drain pipe from the pipe guide connected to the mounting bracket of the radiators and remove the pipe retainer clip se curing the drain pipe to the cable of the demand sensor RSV4 1100 Factory Engine from vehicle ENG VE 187 ...

Page 188: ...pansion tank Remove the metal clamp and discon nect the oil pipe from the sump Remove the two fixing screws of the radiators support bracket Disconnect the connector of the front cylinder bank lambda probe and de tach it from the relative mount Engine from vehicle RSV4 1100 Factory ENG VE 188 ...

Page 189: ... to the thermostat valve Remove the metal clamp and discon nect the oil pipe from the coupling Move the metal clip along the pipe and disconnect the cooling system pipe from the radiator Remove the cable tie indicated and free the wiring harnesses from the ra diator mount RSV4 1100 Factory Engine from vehicle ENG VE 189 ...

Page 190: ...rt on the left side and remove both radiators by extracting them at the same time from the right side Loosen the metal clamp that fastens the front manifolds to the central ex haust manifold Unscrew the four fastener screws of the front cylinder bank headers and re move the headers Engine from vehicle RSV4 1100 Factory ENG VE 190 ...

Page 191: ... leads fixing screw and release the wiring harnesses Move the wiring harness to the outside and fasten them using a circlip Remove the internal cable gland on the left side of the vehicle to facilitate the engine removal RSV4 1100 Factory Engine from vehicle ENG VE 191 ...

Page 192: ...ap and removed the fixing nut of the start er motor power cable release the wir ing harness Loosen the clutch cable tensioning by using the adjuster nuts and disconnect it from the transmission lever and from the cover Remove the fastener screw of the gearbox lever and extract it from the primary shaft Engine from vehicle RSV4 1100 Factory ENG VE 192 ...

Page 193: ... Disconnect the rear bank lambda probe connector and release it from its support Detach the springs and remove the centre exhaust manifold easing it out from underneath Remove the rubber cable ties and ex tract the tank s breather pipe RSV4 1100 Factory Engine from vehicle ENG VE 193 ...

Page 194: ...ies and after hav ing removed the quick shift connector extract its wiring harness and the wir ing harness of the side stand s switch Unscrew the two fixing screws and re move the rider s footboard support from the left side Loosen the final drive chain tension to facilitate the sprocket removal Remove the fixing screw and retrieve the spring washer the T bushing and extract the sprocket from the ...

Page 195: ...nt Unscrew the nuts fastening the rear headers and remove the headers eas ing out towards the rear Unscrew the two side stand fixing screws and remove it Remove the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support RSV4 1100 Factory Engine from vehicle ENG VE 195 ...

Page 196: ...BS modulator with the sup port extract the metal plate at the rear Disconnect the wiring harnesses from the cable gland inside the chassis on the right front side and after having moved them to the outside fasten them using a circlip together with the exhaust valve motor to facilitate the engine removal Engine from vehicle RSV4 1100 Factory ENG VE 196 ...

Page 197: ... to the chassis and re trieve the internal plate Completely unscrew the adjuster screw Unscrew the nut of the lower pin and extract it from the left side of the vehi cle Operating from the right side of the ve hicle completely unscrew the adjuster screw Operating from both sides remove the four screws that fasten the engine to the chassis and make sure to retrieve the spacer on the right side of t...

Page 198: ...stalling the engine to the vehicle To install the engine on the vehicle perform the operations below Before aligning the engine retainers place on the frame the internal and external right and left inserts with the precautions described below Adjustment of engine height relative to the chassis is determined by properly inserts placed on the chassis front position and on the engine matching the fix...

Page 199: ...LOWER LEFT REAR INSERT 5mm 0 19 in ARE EQUAL Check that the adjuster bushings on the right side of the chassis are com pletely unscrewed Lift the engine and align it with the fix ing holes on the chassis RSV4 1100 Factory Engine from vehicle ENG VE 199 ...

Page 200: ...only for the right side and the lower pin inserting it from the left side together with the washer to align the engine Tighten to the specified torque only the two front screws on the left side Extract the pin until it allows screwing at the specified torque the two adjuster screws on the right side of the chassis Refit the pin and after having inserted the upper rear screw together with the washe...

Page 201: ...system Fit the central manifold by connecting the rear manifolds making sure to pass the rear bank lambda probe wir ing harness inside the metal cable gland Connect the springs that hold the rear manifolds joined with the central mani fold Place the engine spacer on the left side of the vehicle and secure it by tighten ing the four screws to the specified torque RSV4 1100 Factory Engine from vehic...

Page 202: ...sher on the fix ing screw tighten the screw to the specified torque Place the left rider footrest support on the chassis insert the two fixing screws and tighten them to the speci fied torque Refit the wiring harness of the quick shift and of the side stand switch con necting the connectors with their coun terparts Secure the wiring harnesses with the cable tie Engine from vehicle RSV4 1100 Factor...

Page 203: ...the correct chain play Connect the rear bank lambda probe connector engaging in it the specific support and this in turn to the chain guide Restore the fuel tank breather pipe and fasten it using the rubber cable tie to gether with the quick shift wiring har ness the side stand switch wiring harness and the rear bank lambda probe wiring harness Fit the sprocket cover and secure it us ing the three...

Page 204: ...able and using the adjuster nuts adjust the tension and check the play on the handlebar lever Restore the front right internal cable gland on the chassis Insert the main wiring harness branch in the right side cable gland and place the discharge valve support in its seat Engine from vehicle RSV4 1100 Factory ENG VE 204 ...

Page 205: ...he clamp that fastens the cooling system s pipe to the starter motor s wir ing harness and the ground lead Insert the front left internal cable gland on the chassis and refit the wiring har nesses Connect the engine oil pressure bulb connector and refit the clamp that fas tens the wiring harness to it RSV4 1100 Factory Engine from vehicle ENG VE 205 ...

Page 206: ...crew them partially to facilitate the subsequent op erations for the assembly of the ex haust system Connect the front bank lambda probe connector and engage it in its support Insert the radiators from the right side and engage the water radiator in the support on the left side CAUTION BEFORE FITTING THE RADIATORS MAKE SURE THEY ARE COMPLETELY EMPTY Engine from vehicle RSV4 1100 Factory ENG VE 206...

Page 207: ... Refit the wiring harnesses on the radi ator support and secure them with a new clamp Connect the coolant radiator pipe on the right side and secure it using the specific metal clamp Connect the oil pipe to the fitting and secure it using a new metal clamp RSV4 1100 Factory Engine from vehicle ENG VE 207 ...

Page 208: ... radi ators support bracket and tighten them to the specified torque Secure the demand sensor wiring har ness to the expansion tank breather pipe using a new clamp Connect the breather pipe to the de mand sensor wiring harness using a cable gland and then place the pipe on the cable gland connected to the radi ator support bracket Engine from vehicle RSV4 1100 Factory ENG VE 208 ...

Page 209: ...e motor support Insert the two exhaust valve motor sup port fixing screws and tighten them to the specified torque Operating from the left side of the ve hicle secure the generator alternator wiring harnesses the oil pressure bulb the front bank lambda probe and the left electric fan using a new clamp RSV4 1100 Factory Engine from vehicle ENG VE 209 ...

Page 210: ... connector of the left side electric fan on the canister support Insert the two canister support fixing screws and tighten them to the speci fied torque Connect the oil pipe on the sump and secure it using a new metal clamp Insert the oil discharge plug fitted with a new sealing gasket and tighten it to the specified torque Engine from vehicle RSV4 1100 Factory ENG VE 210 ...

Page 211: ...and insert it under the ABS modulator sup port as shown Insert the ABS modulator support at the back into the rubber ring Insert the screw that fastens the ABS modulator support to the chassis and the screw that fastens the metal plate to the support and then tighten them to the specified torque RSV4 1100 Factory Engine from vehicle ENG VE 211 ...

Page 212: ...rform the valve ad justment procedure Insert 2 7 l 0 59 Uk gal and check the level in the expansion tank Insert 4 1 l 0 90 Uk gal of engine oil and check the level with the dipstick Connect the fuel tank the voltage regulator and battery Subsequently with the vehicle on the central stand start the engine and wait for the activation of the cooling fans Stop the engine check the oil and coolant leve...

Page 213: ...INDEX OF TOPICS ENGINE ENG ...

Page 214: ... 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 cyl 4 605 Engine RSV4 1100 Factory ENG 214 ...

Page 215: ... 38 lbf ft Pre coated screw if not pre coated apply 3M SCOTCH GRIP 2353 to thread 3 Flanged hex head flange retaining screws M8x25 6 25 Nm 18 44 lbf ft Lubricate with oil 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lbf ft Loct 243 5 Hex head flange screw for fastening sprocket M10x35 1 50 Nm 36 88 lbf ft Loct 243 6 Screw used to secure the pre selec tor to the crankcase 1 25...

Page 216: ...d gear on primary shaft 7 Ring 8 Shoulder washer 9 Roller bearing cage for sixth speed gear on primary shaft 10 Sixth speed gear on primary shaft 11 Second speed gear on primary shaft 12 Ring 13 Bearing 14 Selector fork for primary shaft 15 Fork shaft 16 Springs for selector fork shaft 17 Transmission shaft 18 Ball bearing 19 Sprocket Engine RSV4 1100 Factory ENG 216 ...

Page 217: ...ller bearing cage for fourth speed gear on secondary shaft 33 Shoulder washer 34 Seeger ring 35 Fifth speed gear on secondary shaft 36 Washer 37 First speed gear on secondary shaft 38 Roller bearing cage 39 Washer 40 Selector forks for secondary shaft 41 Fork shaft 42 Springs for selector fork shaft 43 Pin for selector 44 Gearbox shaft 45 Roller bearing cage 46 Index cam plate 47 Ball bearing 48 B...

Page 218: ...housing Remove the gear sensor from the flywheel side 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 Engine RSV4 1100 Factory ENG 218 ...

Page 219: ...tap on the sec ondary shaft from the alternator side to detach the gearbox cover from the crankcase Remove the complete gearbox unit Gearbox shafts Disassembling the gearbox Select neutral and check that the sec ondary shaft does not move when the primary shaft is rotated Remove the gearbox unit Slide off the gearbox primary shaft con trol rod 1 RSV4 1100 Factory Engine ENG 219 ...

Page 220: ...fork 2 of the gearbox pri mary shaft Slide off the gearbox secondary shaft control rod 3 Remove the forks 4 of the gearbox secondary shaft Remove both gearbox shafts from the cover Engine RSV4 1100 Factory ENG 220 ...

Page 221: ...the shim washer 5 that is lo cated on the secondary shaft between the shaft and the cover Loosen and remove the screw 6 Remove the desmodromic shaft 7 Remove the selector drum 8 RSV4 1100 Factory Engine ENG 221 ...

Page 222: ...dromic gearbox control rod drum roller cage Lubricate the seat and insert the new roller cage Specific tooling 020863Y Punch assembly cage with rollers desmodromic drum Checking the primary shaft Characteristic Maximum wear limit for selector gear splines 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 secon...

Page 223: ... and wear and replace it if necessary Check the desmodromic bearing 2 for damage and pitting and replace it if necessary Characteristic Maximum selector shaft eccentricity 0 2 mm 0 0079 in 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 endfloat of selector forks 0 05 mm 0 0020...

Page 224: ...place the gearbox forks if it is irregular Assembling the gearbox Place the drum 1 of the gear selector on the support and insert the desmo dromic shaft 2 paying attention to correspond the operations on both components Position and tighten the screw 3 fixing the drum to the desmodromic shaft CAUTION SECURE THE SHIM WASHER 4 TO THE SECONDARY SHAFT WITH GREASE Engine RSV4 1100 Factory ENG 224 ...

Page 225: ... into the support Grease the sliding bushes of the forks Insert the forks 5 in the specific seats of the gearbox secondary shaft Insert the gearbox secondary shaft control rod 6 checking the presence of the springs RSV4 1100 Factory Engine ENG 225 ...

Page 226: ...e gearbox primary shaft con trol rod 8 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 gearbox secondary shaft Engine RSV4 1100 Factory ENG 226 ...

Page 227: ...l 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 Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Working from the clutch side remove the selector control shaft Remove the gear locking pawl and re trieve the washer and the spring RSV4 1100 Fa...

Page 228: ...Punch assembly cage with rollers gearbox control rod GEARBOX CONTROL ROD OIL SEAL AND ROLLER CAGE SPACER Remove the gearbox control rod spacer Remove the oil seal and the roller cage Install a new gearbox control rod roller cage on the spacer using the specific tool without an adaptor Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod Position a new oil seal on the space...

Page 229: ...rt Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Reassembling the gear selector To refit lubricate and carry out the removal operations but in reverse order Starter motor Removing the starter motor Undo the fixing screws 1 of the starter motor collecting the spacers 2 RSV4 1100 Facto...

Page 230: ...E DOUBLE STARTING GEAR TOOTHING IS DEFORMED IT IS NECESSARY TO ALSO CHECK THE TOOTHING OF THE STARTING MOTOR Check the dual starter gear toothing 1 and the freewheel gear 2 to see if the material is dam aged or deformed For instructions on removing the freewheel gear see the procedure Removing balancer coun tershaft Engine RSV4 1100 Factory ENG 230 ...

Page 231: ... Remove the needle cage 3 and the roller cage 4 from their housings on the freewheel 2 and check the rollers needles for wear Check for wear on the freewheel sliding surface 2 Fitting the idle gear The ratios between the gears of the starter system are 1 Starter motor 9 teeth 2 External transmission gear 64 teeth 3 Internal transmission gear 12 teeth 4 Freewheel 49 teeth RSV4 1100 Factory Engine E...

Page 232: ...rews M6x40 3 12 Nm 8 85 lbf ft Tighten to torque unscrew and re tighten to torque 3 Blow by coupling SHC fastening screws M5x16 3 5 Nm 3 69 lbf ft 4 Spacers for soundproof cover 3 6 Nm 4 43 lbf ft 5 Soundproof cover fastening screws M6 3 6 Nm 4 43 lbf ft 6 Fastener screws for timing sensor re tainer plate 1 Nm lbf ft Stator SHC fixing screw M6x30 1 10 Nm 7 38 lbf ft Pre impregnated screw and in ab...

Page 233: ...he fitting on the cover and the relative metal clamp is removed use a new clamp when re assembling Unscrew and remove the five screws 3 and the three special screws 4 retrieving the relative seal washers Mark the screws 3 appropriately as their lengths are different Remove the cover 5 together with the stator and retrieve the two centring dowels Remove the ThreeBond sealant from the mating surface...

Page 234: ...onents Unscrew and remove the three screws of the blow by system connector Remove the Blow by system fitting Remove the O ring USE A NEW O RING WHEN REASSEMBLING Remove the seeger ring Remove the shim Engine RSV4 1100 Factory ENG 234 ...

Page 235: ...HE FLYWHEEL FASTEN USING THE THREE SCREWS INDICA TED Unscrew and remove the screw Specific tooling 020914Y Flywheel stop Remove the tool for blocking flywheel rotation Insert a SHC M10x20 screw into the crankshaft hole which will act as a mounting base for flywheel extraction Remove the flywheel using the specific extractor Collect the SHC M10x20 screw Specific tooling 020913Y Flywheel extractor W...

Page 236: ...roceed as described Remove the three fastener screws of the stator Remove the two fastener screws of the pickup Remove the stator cable retainer plate Remove the stator complete with pick up Disconnect the wiring harness from the cover to complete the removal Engine RSV4 1100 Factory ENG 236 ...

Page 237: ...w the fastener nut of the pri mary gear and the fastener nut of the countershaft drive gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Remove the washer and remove the countershaft drive gear freewheel gear taking care not to let the key drop into the engine Separate the freewheel gear from the countershaft drive gear to allow access to the roller b...

Page 238: ...DING SURFACE Installing the flywheel Before installing the magneto flywheel cover the apertures of the crankcase with a cloth to prevent the retainer key from dropping into the interior of the engine Fit the retainer key on the crankshaft and fit the magneto flywheel aligning the slot with the key Block flywheel rotation using the spe cific tool THE SPECIFIC TOOL MUST BE MODIFIED FOR USE ON THIS E...

Page 239: ...e a suitable punch tool to install Lubricate the inner part of the oil seal and fit onto the cover oriented correct ly as shown Drive the oil seal fully into its seat using the specific punch tool Specific tooling 020376Y Adaptor handle 020483Y 30 mm guide Fit the shim Fit the circlip RSV4 1100 Factory Engine ENG 239 ...

Page 240: ...heck that the two centring pins are correctly in place on the casing 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 Fit and hand tighten the five screws 1 and the three special screws 2 fitting a washer 3 on every screw Tighten the screws working in stages and diagonally Engine RSV4 1100 F...

Page 241: ... by pipe and se cure the pipe with a new retainer clip Use a new metal clamp if the blow by pipe was disconnected from the fitting on the cover dur ing disassembly Check the seal tightness of the system Clutch side CLUTCH COVER Pos Description Type Quantity Torque Notes 1 Flanged hex cap screw M6x20 1 10 Nm 7 38 lbf ft RSV4 1100 Factory Engine ENG 241 ...

Page 242: ...cap 1 20 Nm 14 75 lbf ft 5 Spacers for soundproof cover 5 6 Nm 4 43 lbf ft 6 Oil level dipstick 1 3 Nm 2 21 lbf ft 7 Oil load cap 1 5 Nm 3 69 lbf ft CLUTCH Pos Description Type Quantity Torque Notes 1 Flanged nut fixing clutch M20x1 1 150 Nm 110 63 lbf ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lbf ft Removing the clutch cover Drain the engine oil Unscrew and remove the five ...

Page 243: ...ive washers Remove the clutch crankcase Remove the gasket the two alignment pins and the starter idler gear Disassembling the clutch Remove the clutch cover Unscrew and remove the six screws loosening them by a quarter of a turn at a time by stages and working in a diagonal fashion while recovering the washers and the clutch springs RSV4 1100 Factory Engine ENG 243 ...

Page 244: ... rod Remove the discs Block clutch bell rotation using the spe cific tools Unscrew and remove the clutch hous ing fixing nut Specific tooling 020849Y Clutch retainer tool Remove the two washers and the cup spring washer Engine RSV4 1100 Factory ENG 244 ...

Page 245: ... Remove the clutch hub Remove the clutch hub cam tower Remove the washer Remove the clutch bell RSV4 1100 Factory Engine ENG 245 ...

Page 246: ... Remove the clutch gear that controls the oil water pumps Remove the needle cage Remove the spacer Remove the thrust bearing Engine RSV4 1100 Factory ENG 246 ...

Page 247: ...clutch irregular operation If necessary replace the bell Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness Check the primary driven gear for damage and wear and if necessary replace the primary driven gear and the clutch bell all together Make sure there is not excessive noise during op eration if necessary replace the primary drive ...

Page 248: ... result in clutch irregular operation If neces sary replace the hub Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS Check the springs for signs of damage and replace them if necessary Measure the free length of the clutch springs and replace them if necessa ry Characteristic Minimum wear limit with individual clutch springs in release position 46 8 mm 1 84 in Engi...

Page 249: ...ring with the collar facing the gearbox Insert the spacer Insert the roller cage Install the clutch gear making it mesh with the oil water pump control gear TURN THE CLUTCH GEAR COLLAR TO FACE THE CLUTCH HOUSING RSV4 1100 Factory Engine ENG 249 ...

Page 250: ... making it engage with the engine pinion Insert the washer Install the clutch hub cam tower Position the clutch hub INSTALL THE THREE CLUTCH HUB CAMS IN THE RE SPECTIVE CLUTCH BASKET INCLINES Engine RSV4 1100 Factory ENG 250 ...

Page 251: ...rotation using the appropriate tool Tighten the clutch housing fixing nut Specific tooling 020849Y Clutch retainer tool Insert the disc with friction material and the black tooth into the bell Insert one of the metal discs into the bell RSV4 1100 Factory Engine ENG 251 ...

Page 252: ...washer Insert the spring washer with the con cave side facing out Insert the disc covered with friction ma terial into the housing Insert the nitrided metal disc into the clutch housing Engine RSV4 1100 Factory ENG 252 ...

Page 253: ...g a metal disc with one with friction material end ing with a friction material disc with a black tooth Place the control rod together with the thrust bearing and the shim washer Fit the thrust plate RSV4 1100 Factory Engine ENG 253 ...

Page 254: ...Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING Before carrying out the removal of the bushing it is necessary to thread the inside to allow the extractor to tighten sufficiently Warm up the cover Using a generic extractor it is then possible to remove the bushing from the cover Engine RSV4 1100 Factory ENG 254 ...

Page 255: ...ng clutch bushing Then insert the tool to push the bushing into the seat until it stops Position the starting transmission gear on the crankcase Position the gasket and the two dowel pins in the clutch cover Insert the clutch cover making sure to have correctly engaged the clutch con trol lever and the rack shaft Insert the five special screws 5 and the eleven fastening screws 6 around the perimet...

Page 256: ... 7 fit the five fastener screws 8 and then tight en the screws to the specified torque Fill with engine oil to the correct level Heads VALVES COVER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft Engine RSV4 1100 Factory ENG 256 ...

Page 257: ... Cam shaft cam tower fixing screws M6x45 20 11 Nm 8 11 lb ft 3 Reed valve covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head R...

Page 258: ...hain tensioner sliders fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Chain guide sliders fixing screws M6x18 2 10 Nm 7 38 lb ft Loct 243 Head cover removal The procedure described as follows is for a single cylinder head but is valid for both heads Unscrew and remove the three screws with the relative rubber washers Engine RSV4 1100 Factory ENG 258 ...

Page 259: ... the area indicated in the figure Recommended products Three bond Sealing paste Smear the head surface with suitable sealant in the area indicated in the fig ure Recommended products Three bond Sealing paste Fit the head cover Tighten the three screws with rubber washers to the prescribed tightening torque Front head RSV4 1100 Factory Engine ENG 259 ...

Page 260: ...d to the primary gear fas tener nut Position cylinder 1 piston LH rear pis ton so that it is at the point where it crosses TDC Unscrew and remove the first screw of the camshaft drive sprocket rotate the crankshaft 150 in the engine rotation direction direction of travel Insert the pin from the flywheel side in to the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pi...

Page 261: ... and remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Install the specific camshaft gear sup port tool Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head Remove the second screw of the cam shaft drive sprocket RSV4 1100 Factory Engine ENG 261 ...

Page 262: ...take and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots 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 ...

Page 263: ...the timing chain guide sliders for damage If necessary replace the parts Installing camshafts NOTE THE INTAKE AND EXHAUST CAMSHAFTS ARE BOTH DEDICATED FOR THE FRONT AND REAR CYLINDER BANKS NOTE THE INTAKE AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Refit the camshafts ensuring that they are aligned correctly If the two camshafts are timed...

Page 264: ...the holder tool and onto the camshaft CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM SHAFT Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand tighten the screw only Fit the bearing cap the oil pipe and the three fastener screws Tighten the ten fastener screws of the camshafts tightening in progressive steps in ...

Page 265: ... replaced with a new component at each reassembly and tighten the screw to the specified tor que Continue rotating the crankshaft in di rection of rotation of engine to bring it back to the previous position in which the holes in the camshaft and the bear ing cap were aligned insert the refer ence pin while checking with the crank shaft reference pin that the flywheel side hole and the hole on the...

Page 266: ...ve the chain sliders screws Remove the chain sliders Unscrew and remove the two head fas tener screws a b from the flywheel side Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Remove the front head slipping it off the stud bolts Collect the gasket and the two dowel pins Engine RSV4 1100 Factory ENG 2...

Page 267: ...n ten sioner tool See also Removing camshafts Front head check Check that The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal Check the status of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air Front head fitting Follow the procedure described below to install...

Page 268: ... correctly This washer is available as a spare part Fit the washer onto the front chain ten sioner then install the chain tensioner in the relative seat in the crankcase ensuring that it is oriented correctly Take particular care during this step to ensure that the washer fits correctly in place if the washer is bent or not seat ed in the correct position the operation of the timing system will be...

Page 269: ... 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 NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY RSV4 1100 Factory Engine ENG 269 ...

Page 270: ...AKE AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with nine O rings ...

Page 271: ...iston to TDC in the valve overlap position rotate the crankshaft 150 in the engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft Specific tooling 020852Y Crankshaft timing pin Reposition the sprocket on the cam shaft with timing hole and the hole for the fastener screw of the sprocket aligned with the slot in the sprocket...

Page 272: ...sely tighten the gear fix ing screw on the camshaft Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the second screw of the sprocket is revealed Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix in...

Page 273: ... Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Rear head Removing camshafts To remove the camshafts of the rear head follow the procedure described below Remove both cylinder head covers the soundproofing covers the alternator side cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Start rotating the crankshaft in the di rection of rotation o...

Page 274: ...the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole in the bearing cap Specific tooling 020851Y Camshaft timing pin Loosen the second screw of the cam shaft drive sprocket Remove the pin from the camshaft drive sprocket Unscrew and remove the three screws 1 and remove the bearing cap 2 and the oil pipe 3 Engine RSV4 ...

Page 275: ...the two screws Specific tooling 020956Y Support for camshaft gear on head Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool s spacer Unscrew the seven screws in progres sive steps in a criss cross pattern and remove Retrieve the copper washers from the screws near the spark plug holes Remove the bearing caps complete with O rings and alignment pins R...

Page 276: ...CAMSHAFT LOBES Check that they do not show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Fasten the camshaft horizontally 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 outlet 0 3 0 1 mm 0 012 0 004 in Check the timing chain for damage or stif...

Page 277: ... haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Fit the bearing caps complete with O rings and alignment and fit and hand tighten the seven screws indicated Use new copper washers on the four screws near the spark plug holes Loosen the camshaft sprocket lock screw on the tool Slide the sprocket off the holder tool and on...

Page 278: ...le on the bearing cap and fit the pin Tighten the first fastener screw of the camshaft sprocket to the specified tor que Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Rotate the crankshaft in direction of engine rotation only as far as neces sary to reveal the second fastener hole for the sprocket Apply Loctite 243 thread lock adhesive to the t...

Page 279: ...ng operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Check if the clearance between the cam on the shaft and the tappet is correct If not repeat the valve clearance adjustment procedure Rear head removal In order to remove the rear head the procedures described in the paragraph Removing the cam shafts rear head must be performed beforehand Then proceed as descri...

Page 280: ...e 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 REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Fitting removing timing chain ten sioner tool Rear head check Check that Engine RSV4 1100 Factory ENG 280 ...

Page 281: ...by blowing a jet of compressed air Rear head fitting Follow the procedure described below to install the rear cylinder head 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 Insert the chain tensioner into the crankcase being careful to position it correctly RSV4 ...

Page 282: ... 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 NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Engine RSV4 1100 Factory ENG 282 ...

Page 283: ...AKE AND EXHAUST CAMSHAFTS OF THE FRONT CYLINDER BANK ARE IDENTIFIED BY TWO LINES IN THE POSITIONS INDICATED Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with nine O rings ...

Page 284: ...d rear piston to TDC in the valve overlap position rotate the crankshaft 450 in the engine rotation direction direction of travel Insert the pin from the clutch side into the hole in the crankshaft Specific tooling 020852Y Crankshaft timing pin Reposition the sprocket on the cam shaft with timing hole and the hole for the fastener screw of the sprocket aligned with the slot in the sprocket Insert ...

Page 285: ...sely tighten the gear fix ing screw on the camshaft Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the second screw of the sprocket is revealed Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix in...

Page 286: ...the clutch side hole and the hole in the crankshaft are perfectly aligned If this is not the case repeat the timing operations Specific tooling 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 Extract the bucket tappets Ext...

Page 287: ...53Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal Remove the cotters using a magnet 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 RSV4 1100 Factory Engine ENG 287 ...

Page 288: ...wo perpen dicular directions and position the dial gauge as shown in the figure 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 Recheck the clearance after replacing the valve Characteristic Intake valve stem diameter 4 985 4 965 mm 0 1963 0 1954 in Exhaus...

Page 289: ...sure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve head eccentricity 0 03 mm 0 0012 in Coating may get slightly damaged in the indicated area Valve installation The intake valves are fitted with dual springs while he exhaust valves only have a single spring The intake springs are marked in orange 1 ex ternal and blue 2 internal whereas the...

Page 290: ...AVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Fit the caps Compress the valve springs with the specific wrench and with the spring compressing tool Insert the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs Engine RSV4 1100 Factory ENG 290 ...

Page 291: ... Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjusting shims Position the bucket tappets RSV4 1100 Factory Engine ENG 291 ...

Page 292: ...ad 7 Flanged TE screw fixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of the con necting rods lubrication nozzles 4x12 4 5 Nm 3 69 lbf ft Pre impregnated screw in absence Loct 2045 9 TSPEI screw fixing bearing stop plates M6x16 2 10 Nm 7 38 lbf ft Loct 243 10 Stud bolt M6 1 Bring to 33mm from the surface Loct 648...

Page 293: ... 2 6 Nm 4 43 lbf ft IGNITION UNIT Pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 2 Starter motor SHC fastener screw M6x40 2 10 Nm 7 38 lbf ft Screw fastening cables to the starter motor M6 1 6 Nm 4 43 lbf ft RSV4 1100 Factory Engine ENG 293 ...

Page 294: ... SHC fixing screw M6x30 3 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 5 Fastener screws for pick up retainer plate 2 6 Nm 4 43 lbf ft Pre impregnated screw and in ab sence Loct 2045 Balancing countershaft removal In order to remove the balancer countershaft the clutch cover alternator cover and complete clutch must be removed beforehand Then proceed as described Fit the speci...

Page 295: ...ve gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Remove the washer and remove the countershaft drive gear freewheel gear taking care not to let the key drop into the engine Remove the key from the countershaft RSV4 1100 Factory Engine ENG 295 ...

Page 296: ...nstall the balancer countershaft follow the pro cedure described below Fit the balancer countershaft into the casing from the flywheel side Working from the clutch side fit the spacer onto the countershaft ensuring that the spacer is installed the right way around as shown Engine RSV4 1100 Factory ENG 296 ...

Page 297: ...UTION MAKE SURE THAT THE KEY IS INSTALLED AND SEATED CORRECTLY AS SHOWN Fit the washer and the fastener nut of the countershaft drive gear CAUTION MAKE SURE THAT THE KEY IS INSTALLED AND SEATED CORRECTLY AS SHOWN Fit the special primary gear lock tool Fit the primary gear fastener nut and then tighten both nuts of the gears to the specified torque Specific tooling 020850Y Primary gear lock RSV4 11...

Page 298: ...w and remove the fastener nut of the primary gear Remove the lock tool and remove the primary gear Specific tooling 020850Y Primary gear lock Installing the primary drive gear To install the primary gear follow the procedure described below Fit the primary shaft gear onto the crankshaft ensuring that it is aligned correctly with the countershaft drive gear Align the markings on the respec tive tee...

Page 299: ...rnator water pump gearbox unit primary drive shaft gear both timing chains the chain sliders oil sump the gear selector pin spacer starter motor and intermediate gear countershaft See also Magneto flywheel removal Water pump Disassembling the gearbox Main transmission gear removal Front head removal Rear head removal Removing the oil sump Balancing countershaft removal RSV4 1100 Factory Engine ENG...

Page 300: ...wnward 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 After loosening all screws remove them in order indicated above Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Engine RSV4 1100 Factory ENG 300 ...

Page 301: ...th heads Open the crankcases Install the tool that keeps the crank shaft in position Specific tooling 020857Y Crankshaft support U bolt Unscrew and remove the two connect ing rod screws Remove the connecting rod cap NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the piston connected to the connecting rod from the cylinder side Take out the Seeger ring RSV4 1100 Factory Engine ENG ...

Page 302: ... heads were removed position the specific special tool to keep the pis tons from coming out Specific tooling 020858Y Maintenance of the pistons in the cyl inders Unscrew and remove the eight con necting rod screws Remove the four connecting rod caps NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Engine RSV4 1100 Factory ENG 302 ...

Page 303: ...emove the countershaft FLYWHEEL SIDE Unscrew and remove the bearing re tainer screw Remove the lock Heat up the crankcase to 150 C 302 F Position the general tool to pull out bearings Remove the bearing CLUTCH SIDE Unscrew and remove the bearing re tainer screw Remove the lock RSV4 1100 Factory Engine ENG 303 ...

Page 304: ...eck Characteristic Maximum crankshaft axial clearance after closing the crankcase 0 40 0 10 mm 0 0157 0 0039 in Maximum radial play between main bushings and crankpins 0 07 mm 0 00275 in Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0 1 mm 0 0039 in Engine RSV4 1100 Factory ENG 304 ...

Page 305: ...e 0 027 0 045 mm 0 025 0 043 mm CAUTION THE MEASUREMENT OF THE PISTON DIAMETER IS PER FORMED AT 6 mm 0 24 in FROM ITS BASE Characteristic Coupling clearance between the pin and the hole on the piston 0 016 0 005 mm 0 0006 0 0002 in Aperture tolerance of the first piston ring mounted on the cylinder 0 10 0 25 mm 0 0039 0 0098 in Aperture tolerance of the second piston ring mounted on the cylinder 0...

Page 306: ...LASSES Crankshaft balancing classes Combinations of weight classes for connecting rod pair on alternator side Combinations of weight classes for connecting rod pair on primary drive side LL AA AA NOT PERMITTED AA AA NOT PERMITTED mm BB BB AA CC BB BB CC AA NN CC CC BB DD CC CC DD BB OO DD DD CC EE DD DD EE CC PP EE EE NOT PERMITTED EE EE NOT PERMITTED Key Paired selections of mountable weight as a...

Page 307: ...asses 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 gearbox Different classes of bearings can be used e g A B C or B B C or A B A A number that indicates the position of the main journal is stamped on the crankcase 1 flywheel side 2 central 3 clutch side RSV4 1100 Factory Engine EN...

Page 308: ... diameter 46 023 46 018 mm 1 8119 1 8117 in Class E Main journals diameter 46 018 46 013 mm 1 8117 1 8115 in Once the categories below are checked 1 crankcase 2 flywheel side main journal 3 centre main journal 4 clutch side main journal Choose the bushings used for assembly from the following table CRANKSHAFT BUSHINGS Crankshaft main journal Class A crankcase Class B crankcase Class C crankcase Cl...

Page 309: ...pes of semi bushing are available for the connecting rods Blue Yellow Green For the coupling of the connecting rod with the crankshaft according to the engraving on the counter weights observe the following table RSV4 1100 Factory Engine ENG 309 ...

Page 310: ... 054 0 026 mm 0 054 0 027 mm Z 35 874 35 869 mm Yellow Green 1 Green Green 0 054 0 027 mm 0 054 0 028 mm Key 1 If using bushing of different thickness install the thickest on the side of the connecting rod shank BIG END BUSHING REPLACEMENT PROCEDURE 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 s...

Page 311: ... install the bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw CLUTCH SIDE Heat up the crankcase to 150 C 302 F Prepare the following tools Specific tooling 020363Y 20 mm diam punch for crankshaft oil seal 020359Y 42 x 47 mm punch 020376Y Adaptor handle RSV4 1100 Factor...

Page 312: ...o install the bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw Install the balancing countershaft Crankshaft fitting Lubricate the crankshaft pins and in sert them into their positions Engine RSV4 1100 Factory ENG 312 ...

Page 313: ... is aligned correctly with the countershaft drive gear Align the markings on the respec tive teeth to align the gears correctly NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR Fit the retainer tool fit the nut and then tighten the nut to the specified torque Specific tooling 020850Y Primary gear lock Installing conne...

Page 314: ...embly procedure is identical for all four pistons and must be done as follows with the piston crown parallel to the workbench and the arrow 1 posi tioned from the side opposite of the operator fit the connecting rod shank with the bevelling 2 on the hole of the rod head on the right side Position the special tool on the crank case Partially insert the connecting rod shank piston assembly in the co...

Page 315: ...crews lubri cating the thread and under the head Proceed with tightening according to the procedure described in the tighten ing torque table using the torque wrench and angular tightening with a goniometer Crankcase closing Insert the crankshaft together with con necting rods and pistons in the upper crankcase Position the three centring dowels in the crankcase Insert a new oil seal O ring in the...

Page 316: ...e 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 6 Then tighten them fully following the same order Pre tighten the screws in the following order 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Engine RSV4 1100 Factory ENG 316 ...

Page 317: ... Then tighten them fully following the same order Turn the engine with the heads facing upward Tighten the screw 24 RSV4 1100 Factory Engine ENG 317 ...

Page 318: ...hten to torque unscrew and re tighten to torque 4 Oil pressure sensor 1 15 Nm 11 06 lbf ft 5 Flanged TE rose pipe fastening screw M6x16 1 10 Nm 7 38 lbf ft Pre impregnated screw in absence Loct 2045 6 SHC screw fixing pump to the casing M6x16 5 10 Nm 7 38 lbf ft 7 SHC screw fixing pump to the casing M6x50 1 10 Nm 7 38 lbf ft 8 SHC screw fixing oil pipe connection M6x20 1 10 Nm 7 38 lbf ft Engine R...

Page 319: ...screw fixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lbf ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of the con necting rods lubrication nozzles 4x12 4 5 Nm 3 69 lbf ft Pre impregnated screw in absence Loct 2045 9 TSPEI screw fixing bearing stop plates M6x16 2 10 Nm 7 38 lbf ft Loct 243 10 Stud bolt M6 1 Bring to 33mm from the surface Loct 648 11 SHC screw M6...

Page 320: ...the gear wheels inside the gearbox via the lubrication pipe CAUTION IN ORDER TO ENSURE THAT THE LUBRICATION JETS CONTINUE TO FUNCTION IT IS IMPOR TANT TO CHECK THAT THE OIL DELIVERY HOLES ARE NOT BLOCKED To remove the lubrication jets simply remove the retaining screw and then extract them from their housings tak ing care not to lose the rubber O ring To remove the lubrication pipe simply remove t...

Page 321: ...six screws fastening the oil pump to the crank case Remove the oil pumps OIL PUMP REMOVAL Place the oil pumps on a work table Remove the gasket See also Removing the gearbox Water pump Unscrew and remove the four cooling oil pump cover screws RSV4 1100 Factory Engine ENG 321 ...

Page 322: ...or from the cover Remove the internal oil cooling rotor Collect the hitch pin Unscrew and remove the four lubrica tion oil pump cover screws Remove the lubrication oil pump cover and the intermediate pump casing from the shaft Collect the two dowel pins Engine RSV4 1100 Factory ENG 322 ...

Page 323: ...or on the oil pump control shaft The lubrication pump components are larger than the cooling pump components The lubrication pump must be fit onto the shaft from the side with the Seeger ring seat for fasten ing the gear Install the drive spindle on the shaft Position the external rotor on the lubri cation pump s internal rotor RSV4 1100 Factory Engine ENG 323 ...

Page 324: ...ica tion pump s external rotor To check that the intermediate casing is oriented correctly check the gasket seat Tighten the four lubrication oil pump cover screws Position the hitch pin on the oil pump control shaft Position the oil cooling pump s internal rotor Engine RSV4 1100 Factory ENG 324 ...

Page 325: ...the cooling oil pump cover Fit the pump cover on the internal rotor Tighten the four cooling oil pump cover screws Fit a new gasket Removing the oil sump Drain the engine oil Unscrew and remove the twelve oil sump screws RSV4 1100 Factory Engine ENG 325 ...

Page 326: ...E PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE Remove the metal gasket central fixing screw Engine RSV4 1100 Factory ENG 326 ...

Page 327: ...asket Blow by 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 RSV4 1100 Factory Engine ENG 327 ...

Page 328: ...iagram Valve controlled by control unit which delivers as pirated air from the filter box to the exhaust mani folds The advantages of this function are twofold the catalytic converter reaches the op erating temperature more quickly it permits the use of richer mixtures in some critical conditions e g at idle or low engine speeds Engine RSV4 1100 Factory ENG 328 ...

Page 329: ...Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves RSV4 1100 Factory Engine ENG 329 ...

Page 330: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 331: ...y 2 Lower injectors on the front throttle body 3 Connection 4 Upper injector on the rear of the filter casing 5 Upper injector on the front of the filter casing 6 Fuel tank 7 Fuel pump 8 Filter box 9 Front throttle body 10 Rear throttle body RSV4 1100 Factory Power supply P SUPP 331 ...

Page 332: ...UT Key 1 Connection 2 Purge valve 3 ECU 4 T connection 5 Lower injectors on the rear throttle body 6 Lower injectors on the front throttle body 7 Fuel tank 8 Canister 9 Front throttle body 10 Rear throttle body Power supply RSV4 1100 Factory P SUPP 332 ...

Page 333: ...To facilitate removal of the fuel pump remove the mount by unscrewing the fastener screw Remove the safety plate Press the release buttons on both sides of the connector and disconnect the connector from the fitting on the fuel pump Unscrew and remove the six fastener screws of the fuel pump RSV4 1100 Factory Power supply P SUPP 333 ...

Page 334: ... Ease out the pump taking particular care not to damage the pump Injection Power supply RSV4 1100 Factory P SUPP 334 ...

Page 335: ...Diagram Key 1 Electronic suspension control unit where applicable 2 Demand sensor 3 Exhaust valve motor 4 ECU RSV4 1100 Factory Power supply P SUPP 335 ...

Page 336: ...om their engines but actually a specific torque The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit The control unit refers to specific handle maps to determine by how much and how quickly the throttle valves are opened The...

Page 337: ...nd as a re sult have a high fuel flow rate The electrical connectors are colour coded as fol lows to prevent accidentally swapping the injector connectors Cylinder 1 Black Cylinder 2 Brown Cylinder 3 Green Cylinder 4 Grey UPPER INJECTORS To permit removal of the upper injectors remove the fuel tank and the ECU complete with mount Then proceed as described Remove the four screws fastening the fuel ...

Page 338: ... throttle body Remove the fuel pipe Checking the injector Checking the wiring harness and the connections The injectors may be activated to check that they are working correctly from the menu SELF DIAGNOSIS ACTIVATION FUNCTIONS ACTIVATE INJECTOR of the diagnostic tool Removing the throttle body Completely remove the air filter box Disconnect the injector fuel pipe Release the snap fit clamp on the...

Page 339: ...ction As all the internal components of the throttle body assembly potentiometers and electrical motor are contactless no electrical diagnosis is possible Functional tests are performed on the throttle body assembly by the control unit during vehicle oper ation with the results visible on the diagnostic instrument The only action possible before replacing the com ponent is checking the connectors ...

Page 340: ...nnect the control unit connector en suring that the security lock is in the locked position Stepper motor The control unit regulates the idle speed by controlling the throttle body motors directly As a result idle speed adjustment and maintenance of the components involved in idle speed regulation stepper mo tors thermoactuators etc are not necessary Power supply RSV4 1100 Factory P SUPP 340 ...

Page 341: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 342: ... 1 20 Nm 14 75 lbf ft 4 Right hand handlebar control set outer shell 2 1 2 1 4 Nm 0 88 1 03 lbf ft 5 Right hand handlebar control set int clamp M5 1 3 Nm 2 21 lbf ft 6 LH light switch outer shell 2 1 2 1 4 Nm 0 88 1 03 lbf ft 7 LH light switch int clamp M5 1 4 Nm 2 95 lbf ft 8 Traction control command fastening screw M4 1 2 5 Nm 1 84 lbf ft 9 Screw for fastening the Ride By Wire control to the sem...

Page 343: ...es 1 Clutch lever collar fastening screws M6 1 10 Nm 7 38 lbf ft FRONT BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lbf ft RSV4 1100 Factory Suspensions SUSP 343 ...

Page 344: ... Front brake lever pin fixing screw M6 1 10 Nm 7 38 lbf ft Screw used to fasten the brake pipe cable gland to the lower yoke M5 1 8 Nm 5 90 lbf ft Front fork FRONT FORK OHLINS ASC RSV4 1100 FACTORY Pos Description Type Quantity Torque Notes 1 Calliper mounting bracket fixing screws M6 2 2 10 Nm 7 37 lb ft 2 ABS sensor fixing screw M5 1 8 Nm 5 90 lb ft Suspensions RSV4 1100 Factory SUSP 344 ...

Page 345: ...ng is adjusted to suit most high and low speed riding conditions whether the vehicle is partially or fully loaded However the setting can be modified for specific needs according to vehicle use RACING TRACK SETTINGS MUST BE DONE ONLY FOR OFFICIAL COMPETITIONS OR SPORTS EVENTS WHICH ARE IN ALL CASES AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES IT IS STRICTLY ...

Page 346: ... adjustment screw 1 unscrew 10 clicks from fully tightened Hydraulic compression adjustment adjuster screw 3 unscrew 6 clicks from fully tightened Spring pre loading nut 2 tighten 5 turns from fully loosened Stanchion protrusion A from top yoke excluding cover 2 notches 8 mm 2 notches 0 31 in RACING ADJUSTMENT TRACK USE ONLY Specification Desc Quantity Rebound damping adjustment screw 1 unscrew 8 ...

Page 347: ...E FRONT FORK ACCORD ING TO THE VEHICLE USE CONDITIONS BY INCREASING THE SPRING PRE LOAD THE CONTROL PARAMETERS OF THE FRONT FORK MUST BE ADJUS TED BY INCREASING THEIR VALUES TO AVOID UNEX PECTED JOLTS WHILE DRIVING Rear compression and rebound damp ing and the cornering acceleration as sistance function are adjusted elec tronically The forks can be adjusted as follows Standard adjustment Spring pr...

Page 348: ...s disconnect the front brake callipers and remove the mudguard the front wheel the side fairings and the air ducts THE FOLLOWING OPERATIONS REFER TO A STANCHION BUT APPLY TO BOTH FOR VERSION WITH ELECTRONIC SUSPEN SION ONLY WORKING WITH PARTICULAR CARE DISCONNECT THE CONNECTOR FROM THE FORK CAP Loosen the screws on the lower plate Disconnect the clutch cable Loosen the screws on the handlebars Sus...

Page 349: ... attention to the adjustment of the stanchion protrusion referring to the Adjustment paragraph in the Suspensions chapter Draining oil RSV4 1100 FACTORY OHLINS ASC NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS ELECTRONIC FORKS Set the pre loading spring to the mini mum position RSV4 1100 Factory Suspensions SUSP 349 ...

Page 350: ...sing a wrench in order to release the upper nut on the spring retaining ring Unscrew the upper adjustment cap us ing the special Ohlins tool Specific tooling 01761 04 Ohlins fork cap ring nut Remove the complete cap Unscrew the nut and remove it exert ing slight pressure on the pre loading spring Suspensions RSV4 1100 Factory SUSP 350 ...

Page 351: ...l con tainer taking care not to let the pre loading tube come out RSV4 1100 SACHS NO ASC NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS Using the appropriate tool fasten the fork in the vice Specific tooling AP8140149 Guard for assembly operations RSV4 1100 Factory Suspensions SUSP 351 ...

Page 352: ...cking it in a vice by the specific tool Completely unscrew the plug Specific tooling AP8140149 Guard for assembly operations Using the specific tool fixed to the pre loading pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Pre load tube clamp Suspensions RSV4 1100 Factory SUSP 352 ...

Page 353: ... Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Remove the spring paying attention to drain the oil correctly RSV4 1100 Factory Suspensions SUSP 353 ...

Page 354: ...E NEAREST USED OIL COLLECTION CENTRE Disassembling the fork RSV4 1100 FACTORY OHLINS ASC NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS ELECTRONIC FORKS Remove the pre loading tube Remove the wheel holder shaft 1 and the sleeve 2 Clamp the sleeve in a vice and by lev ering it alternately at various points remove the anti dust seal 3 from the sleeve 2 Suspensions RSV4 1100 Factory SUSP 354 ...

Page 355: ... PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT DO NOT REUSE THE OIL THAT WAS DRAINED EARLIER RSV4 1100 SACHS NO ASC NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS Discharge the fork remove the internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so...

Page 356: ... damage the sleeve rim Remove the retainer ring Take out the sleeve from the stem using the stem as a hammer puller Remove the fixed bushing 1 the movable bushing 2 the ring 3 and the oil seal 4 from the stem Remove the lock seeger ring of the spring guide Remove the spring guide Suspensions RSV4 1100 Factory SUSP 356 ...

Page 357: ...f the scratches are deep replace the stanchion Using a dial gauge check than any bending of the stanchion is below the limit value If it is over the limit replace the stanchion CAUTION A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAKENED MAKING THE VEHICLE DANGEROUS TO USE Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check for damage and or cracks if it is d...

Page 358: ...ION A BENT STANCHION SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAKENED MAKING THE VEHICLE DANGEROUS TO USE Characteristic Bending limit 0 00787 in 0 2 mm Sleeve Check for damage and or cracks if it is damaged replace it Spring Check the condition of the spring making sure that the length is within the acceptable limits If not replace the spring MINIMUM LENGTH OF FREE SPRING 265 mm...

Page 359: ...st gaiter 3 retainer ring 4 and oil seal 5 Fix the sleeve in a vice taking care not to damage the sleeve Insert the stanchion 1 into the sleeve 2 Position the two halves of the special tool on the shaft 1 behind shaft seal 5 together with the respective buffer Grip the special tool and push the shaft seal 5 into its housing on the sleeve 2 Remove the tool Specific tooling AP8140189 Tool for fittin...

Page 360: ...TION THE SHAFT MUST SLIDE FREELY WITHIN THE SLEEVE WITHOUT OBSTRUCTIONS Specific tooling AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight RSV4 1100 SACHS NO ASC NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges ...

Page 361: ...ing Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Insert the retainer ring in its position RSV4 1100 Factory Suspensions SUSP 361 ...

Page 362: ...rescribed torque Specific tooling 020889Y Wrench for locking pumping unit ring nut Filling oil RSV4 1100 FACTORY OHLINS ASC NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS ELECTRONIC FORKS Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stanchion Place a support under the stanchion in order to leave it compressed Pour part of the fork oil into the sleev...

Page 363: ...e edge of the sleeve without spring or pre loading tube THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Characteristic Fork oil 408 cm 24 90 cu in for each stanchion Insert the pre load tube in the stanchion making sure that it is aligned correctly Insert the spring CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRI...

Page 364: ...ntil it stops Using the special Ohlins tool tighten the cap to the prescribed torque RSV4 1100 SACHS NO ASC NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR SACHS MECHANICAL FORKS Clamp the forks in a vice using the special tool Fill the forks with oil according to the indicated quantities Wait a few minutes until the oil fills all the ducts Suspensions RSV4 1100 Factory SUSP 364 ...

Page 365: ...pipe THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Characteristic Fork oil 427 5 cc 26 06 0 30 cu in for each shaft Insert the spring CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRING AND ENSURE THAT THE PART WHERE THE SPI RAL IS MORE COMPRESSED IS FACING DOWNWARDS Insert the spring guide and lock it in place u...

Page 366: ...r to the USE AND MAINTENANCE BOOKLET paragraph ADVANCED FUNCTIONS in the VEHICLE chapter The type of adjustment that can be performed is described in detail at paragraph a PRC SYSTEM under the ASC section 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 CARRY OUT THE ADJUSTMENT...

Page 367: ...EERING DAMPER Unscrew the screw fastening the damper to the frame working from above via the hole Unscrew the fixing screw at the bottom yoke Remove the steering damper Disconnect the connector from the steering damper and remove it RSV4 1100 SACHS NO ASC NOTE THE FOLLOWING OPERATIONS ARE APPLICABLE FOR THE SACHS MECHANICAL STEERING DAMPER Unscrew the chassis fixing screw Unscrew the fixing screw ...

Page 368: ...M35x1 1 60 9 Nm 44 25 6 64 lb ft 4 Headstock counter lock ring M35x1 1 Manual 35 or 10 Bend the tabs into the notches in the lock ring 5 Upper yoke fixing cap M29x1 1 100 Nm 73 76 lb ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 38 lbf ft Loctite 243 7 Screw fastening shock absorber to lower yoke M6 1 14 Nm 10 32 lbf ft 8 Lower cover fixing screws M6 2 8 Nm 5 90 lb ft 9 Screw used to f...

Page 369: ...directions Adjust if clearance is detected NOTE THE STEERING COLUMN RESISTANCE TO ROTATION MUST BE PERFORMED IN THE TWO OPPOSITE ROTATION DIRECTIONS THE STEERING DAMPER MUST BE DISCONNECTED DURING MEASUREMENT Disconnect the connectors of the elec tronic forks where required Unscrew and remove the top bolt on the headstock and retrieve the washer Loosen the screws fixing the fork stan chions to the...

Page 370: ...ar ness fixed in the part below in order to remove the steering plate where re quired 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 Suspensions RSV4 1100 Factory SUSP 370 ...

Page 371: ...ssive resistance If any problems are noted repeat the procedures described above NOTE DISCONNECT THE STEERING DAMPER WHEN ADJUST ING THE STEERING FREE PLAY Specific tooling AP8140190 Steering tightening tool Fit the safety washer and bend the two opposing tabs into the notches on the lock ring Fit the counter lock ring hand tighten ing only To allow the tabs to be bent into the notches of the coun...

Page 372: ...er fork plate Disassembling Remove the steering assembly com pletely Unscrew and remove the lower dowel fastening the collar Remove the lower collar Unscrew and remove the upper dowel fastening the collar Remove the upper collar CAUTION ALWAYS CHANGE BOTH COLLARS UPPER AND LOW ER Upper and lower collars are not interchangeable To identify them check the number printed on them lower collar 0 49 mm ...

Page 373: ...conical surface Fit the bushing in its seat ensuring that the seal in the groove in the bushing remains in place Press the bushing into place with a rub ber mallet Tighten the dowel to the specified tor que Repeat the procedure for the lower bushing Fit the steering assembly and restore the correct steering bearing free play See also Adjusting play Rear RSV4 1100 Factory Suspensions SUSP 373 ...

Page 374: ...od fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lbf ft Adjusting The rear suspension consists of a spring shock absorber unit linked to the frame via uniball joints and to the swingarm via a linkage system To adjust the rear shock absorbers proceed as follows Suspensions RSV4 1100 Factory SUSP 374 ...

Page 375: ...CREW 1 AND DO NOT TAMPER WITH THE SEAL UNDERNEATH AS NITROGEN MAY COME OUT RESULTING IN RISK OF ACCIDENTS NOTE THE VEHICLE HAS A HEIGHT ADJUSTABLE SUSPEN SION A TO CHANGE THE HEIGHT YOU MUST CONTACT AN Au thorised Aprilia Dealer 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 ...

Page 376: ... RIDING IN ANY CASE IT IS POSSIBLE TO INSERT PERSONAL SETTINGS DEPENDING ON VEHICLE UTILIZATION RACING TRACK SETTINGS MUST BE DONE ONLY FOR OFFICIAL COMPETITIONS OR SPORTS EVENTS WHICH ARE IN ALL CASES AWAY FROM NORMAL ROAD TRAF FIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES IT IS STRICTLY FORBIDDEN TO RIDE A VEHICLE SET FOR RACING ON ROADS AND MOTORWAYS TO COUNT THE NUMBER OF CLICKS A...

Page 377: ...justment ring nut 1 open 8 clicks from fully closed Compression adjustment adjuster screw 2 open 1 2 turns from fully closed clockwise anticlockwise Removing Remove the side covers and tail fairings Secure the front of the vehicle with straps and then support the rear of the vehicle with a workshop crane lift Then proceed as described The following operations are applicable for the RSV4 1100 FACTO...

Page 378: ...iring harness of the damper Disconnect the connector for the elec tronic rebound control Disconnect the connector for the elec tronic compression control Remove the screw fastening the shock absorber to the dual link Suspensions RSV4 1100 Factory SUSP 378 ...

Page 379: ...d removal Remove the shock absorber from the right side Linkages Removing In order to remove the linkages the lower fairings and the exhaust silencer must be removed before hand After securing the front of the vehicle with straps use a stand to support the centre of the vehicle and keep the rear shock absorber unloa ded Then proceed as described SINGLE LINKAGE RSV4 1100 Factory Suspensions SUSP 37...

Page 380: ...d side of the vehicle unscrew the nut 2 fastening the single linkage to the frame pulling the screw out from the right hand side to remove it Remove the single linkage Remove the T bush installed on the right hand side of the frame Follow the procedure described below to remove the components of the single linkage Remove the pins Remove the oil seals Suspensions RSV4 1100 Factory SUSP 380 ...

Page 381: ...O THE DUAL LINKAGE POINTS TOWARDS THE FRONT OF THE VEHICLE AS SHOWN CAUTION 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 Checking CAUTION CHECK THAT NO COMPONENT IS NOTICEABLY DISTORTED DAMAGED CRACKED AND OR DENTED REPLACE ALL DAMAGED COMPONENTS ROLLER BEARIN...

Page 382: ... condition of the oil seals replace if damaged or excessively worn ALWAYS REPLACE THE OIL SEALS WITH NEW COMPONENTS AFTER DISASSEMBLING THE COMPONENTS OF THE SINGLE LINKAGE Suspensions RSV4 1100 Factory SUSP 382 ...

Page 383: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 384: ...t 4 RH lower rear regulator bushing M18x1 5 1 12 Nm 8 85 lbf ft 5 RH upper rear regulator bushing M18x1 5 1 12 Nm 8 85 lbf ft 6 RH upper rear coupling M10 1 50 Nm 36 88 lbf ft 7 Upper rear mount M10 1 50 Nm 36 88 lbf ft 8 LH upper rear engine coupling fas tening screws M8 3 25 Nm 18 43 lbf ft 9 Saddle mounting fixing screws M10 4 50 Nm 36 88 lbf ft Wheels Chassis RSV4 1100 Factory CHAS 384 ...

Page 385: ...80 Nm 59 00 lb ft 2 Front brake disc fastening screws M8 6 6 30 Nm 22 13 lb ft Loct 243 Removal Support the front part of the motorcycle Remove the front mudguard Unscrew the front calliper fixing screws and slide them off the disk taking care to retrieve the spacers RSV4 1100 Factory Chassis CHAS 385 ...

Page 386: ...upport the wheel while extracting the pin and then remove it Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or both bearings do not fall within the con...

Page 387: ...TOGETHER ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity Replace the wheel axle if the eccentricity exceeds the limit value Characteristic Maximum eccentricity 0 25 mm 0 0098 in 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 us...

Page 388: ... fasten the crown to the sprocket M10 5 50 Nm 36 88 lbf ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lbf ft Loct 243 Rimozione To proceed with the removal of the rear wheel lift the motorcycle using an appropriate rear stand and proceed as described Undo the fastening nut 1 of the wheel Chassis RSV4 1100 Factory CHAS 388 ...

Page 389: ...e chain ten sioner Supporting the wheel and working from the right hand side of the vehicle re move the wheel axle 5 complete with both chain tensioners 6 retrieving the spacers 7 installed on both sides be tween the wheel and the swingarm Remove the chain 8 from the sprock et and remove the rear wheel 9 REAR SPROCKET SUPPORT RSV4 1100 Factory Chassis CHAS 389 ...

Page 390: ...N THE JAWS OF THE VICE IN WOOD OR ALUMI NIUM SECURE ONLY THE CROWN GEAR IN THE VICE DO NOT BLOCK ANY OTHER COMPONENT OF THE FINAL DRIVE ASSEMBLY Act on the threaded pin 1 with a hex agonal wrench blocking rotation Un screw the DAX nut 2 and remove it Repeat the operation to remove all the nuts and related pins Remove the crown gear support 3 and the flange 4 Chassis RSV4 1100 Factory CHAS 390 ...

Page 391: ...CKING SCREWS OF THE FLEXIBLE COUPLING HOLDER OR CHECK THE TIGHTENING TORQUE ANY MAINTENANCE INTERVENTION ON THESE COMPONENTS MAY CAUSE A VEHICLE MAL FUNCTION FITTING Fit the sprocket 3 and the flange 4 on the crown gear Place the pins 1 with the corresponding DAX nuts 2 paying attention so the pins are directed towards the inside the machining on the flange CAUTION WITH EVERY REMOVAL REPLACE THE P...

Page 392: ...OTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both be...

Page 393: ...s Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm 0 031 in FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit ROTATION CHECK Remove the left spacer 3 Remove the right spacer 4 Manually rotate the inside ring of each bearing Rotation must be constant ...

Page 394: ...uplings 5 ALWAYS REPLACE ALL THE FLEXIBLE COUPLINGS WITH OTHERS OF THE SAME TYPE SPROCKET Check the sprocket 7 toothing for proper conditions If there is excessive wear Replace the sprocket TO PREVENT NEW COMPONENTS FROM WEARING PREMATURELY THE REAR SPROCKET FRONT SPROCKET AND DRIVE CHAIN MUST ALWAYS BE REPLACED TOGETHER AS A SET REAR WHEEL BEARINGS Remove the rear wheel Clean both sides of the hu...

Page 395: ...move the left hand bearing 16 Specific tooling AP8140180 Bearing extractor Clean the interior of the hub thoroughly CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION FINAL DRIVE UNIT BEARING REMOVAL Remove the final drive unit Clean the two sides of the hub with a cloth Remove the left spacer 15 Remove the sealing gasket 16 Remove the circlip 17 CAUTION RSV4 1100 Factory Chassis CHAS 395 ...

Page 396: ...ic 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 CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION Specific tooling AP8140180 Bearing extractor Chassis RSV4 1100 Factory CHAS 396 ...

Page 397: ... 16 lbf ft 7 Chain tensioner shoe adjustment screws M8 2 Adjust the screw until the head is in contact with the tensioner shoe and then tighten the lock nut to the specified torque Removing In order to remove the swingarm remove the side fairings radiators exhaust silencers centre mani fold shock absorber rear wheel and rear mud guard and the chain guard beforehand secure the front of the vehicle ...

Page 398: ... the three fastener screws of the front sprocket cover and remove the cover Unscrew and remove the fastener screw of the front sprocket complete with the T bush and the cup spring washer Detach the front sprocket from the sec ondary shaft freeing if from the final drive chain Remove the nut with the screw fasten ing the dual linkage to the swingarm Chassis RSV4 1100 Factory CHAS 398 ...

Page 399: ...wingarm pin As the pin rotates it also turns the adjustment bush loosening it completely Support the front end of the swingarm and drive the swingarm pin complete with adjuster bush out from the right hand side Using the rear mounting stand remove the swingarm completely from the ve hicle from the rear UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN RSV4 1100 Factory Ch...

Page 400: ... BEARINGS AFTER EVERY BEARING REMOVAL Specific tooling AP8140180 Bearing extractor Remove the inner spacer 7 and collect the two OR seals 8 Carefully clean inside the bearing seat CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION UPON REFITTING USE A BUFFER WITH A DIAMETER EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO INSERT THE BEARINGS DO NOT HIT THE BALLS AND OR THE INTERNAL RING CHECK ...

Page 401: ...t fall within the control parameters Replace both swingarm bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE SWINGARM SEALS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear ALWAYS REPLACE BOTH SEALS TOGETHER ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE SWINGARM PIN Use a dial gaug...

Page 402: ...ARNING PAY PARTICULAR ATTENTION TO THE DIRECTION OF THE INSERTS WHEN REFITTING IN CORRECT ASSEMBLY MAY CAUSE SEVERE DAMAGE TO THE VEHICLE THE ARROW MUST FACE DOWNWARD Spread a light coating of lubricating grease along the entire length of the swingarm pin Fit the adjustment bush into its seat and tighten by hand CAUTION THE ADJUSTMENT BUSH MUST NOT PROTRUDE BEYOND THE INNER EDGE OF THE FRAME Suppo...

Page 403: ...djustment bush driving the swingarm in until it is fully seated Tighten to the specified torque Tighten the locking ring nut Put some grease on the swingarm pin nut as indicated Fit the washer on the pin fit the nut and then tighten the nut to the specified tor que RSV4 1100 Factory Chassis CHAS 403 ...

Page 404: ...fit the rear brake calliper complete with mount onto the swingarm Refit the cable guides onto the swing arm Pinion Removing In order to remove the front sprocket first slacken the tension of the final drive chain Then proceed as described Remove the three fastener screws 1 of the front sprocket cover 2 retriev ing the spacer 3 Chassis RSV4 1100 Factory CHAS 404 ...

Page 405: ...n To check the state of wear of the front sprocket simply check that the teeth of the sprocket are not worn or damaged In this case replace the rear sprocket and the final drive chain also Installing To proceed with the installation of the front sprock et proceed as described Assemble the front sprocket 1 with the drive chain 2 and fit onto the transmission shaft RSV4 1100 Factory Chassis CHAS 405...

Page 406: ... specified tor que Restore the drive chain to the correct tension following the specific procedure described in the Adjustment paragraph Drive chain Removing The transmission chain although closed has a different coloured hammerlock where provided which should be used to perform opening disas sembling procedures NOTE WHERE PRESENT THE HAMMERLOCK 1 MAY ALSO BE IDENTIFIED BY A SIGN 2 APPLIED IN THE ...

Page 407: ...and remove the chain proceed as follows Partially remove the pins 3 using a generic chain breaker Remove the outer plate 4 Remove the outer O ring rings 5 Remove the inner plate 6 RSV4 1100 Factory Chassis CHAS 407 ...

Page 408: ...nt These in dicate from right to left the correct measurements for 1 New chain with length near nominal value 2 Chain with chain stretch of 1 5 3 Chain with chain stretch of 3 which must therefore be replaced in accordance with ap plicable legislation Perform the procedure described as follows to check chain wear Tauten the chain Place the jaws of the tool on the rollers at the opposite ends of a ...

Page 409: ...gs 3 on the pins Compress the outer plate 4 using the appropriate generic tool CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN Check that the links in the transmission chain are not seized and that it can move in both directions Use a generic clincher to re tighten the pins of the link checking riveting at points A RSV4 1100 Factory Chassis CHAS 409 ...

Page 410: ...ED IN PARTICULARLY RAINY OR DUSTY CONDITIONS ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING To check the clearance Shut off the engine Rest the vehicle on its stand Select neutral Check that the vertical oscillation at a point between the pinion and the sprocket on the lower branch of the chain is about 20 mm 0 78 in Move the vehicle forwards to check the vertical deflection of the chain in other po...

Page 411: ...f erences 2 3 match on both sides of the vehicle Tighten the two lock nuts 4 Tighten the nut 1 Check the chain clearance CAUTION THERE ARE TWO FIXED REFERENCES 2 3 FOR WHEEL CENTRING THAT CAN BE FOUND ON THE SWINGARM CHECKING WEAR OF CHAIN PINION AND SPROCKET Also regularly check the following parts and make sure that the chain the pinion and the sprocket do not show damaged rollers loosened pins ...

Page 412: ...ickly carry out the mainte nance operations more frequently Lubricate the chain at the intervals shown in the routine maintenance table and whenever necessary After washing and drying the chain lubricate it with spray grease for sealed chains Chain sliders Place the vehicle on its OPTIONAL rear service stand Remove the front sprocket cover and check the front shoe 1 and the chain slider shoe 2 for...

Page 413: ...he chain slider shoe the swingarm must be removed beforehand Then proceed as described Remove the inner screw Remove the lateral screw Remove the upper screw Remove the chain slider shoe RSV4 1100 Factory Chassis CHAS 413 ...

Page 414: ... Loctite 243 For use in countries where it is mandatory to fit the passenger s footrests or for the two seater configu ration 3 Rider s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 4 Passenger s heel guard fastening screws M6 2 2 8 Nm 5 90 lbf ft 5 Anti creep pin M6 1 8 Nm 5 90 lbf ft Rimozione LEFT RIDER FOOTREST REMOVAL GEAR BOX LEVER Remove the fuel tank Loosen the screw 1 and ease off t...

Page 415: ...he fixing screw 4 of the ca ble grommet 5 Cut the two clamps 6 that connect the wiring of the quick shift to the wiring of the side stand and of the lambda probe Disconnect the connector 7 of the quick shift and release the wiring RSV4 1100 Factory Chassis CHAS 415 ...

Page 416: ...rew to change the O rings NOTE NOTE THE WIRING HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION REMOVING THE RIGHT HAND RIDER FOOT PEG REAR BRAKE PEDAL Remove the two screws fastening the rear brake master cylinder and fasten ing the guard to the footpeg Disconnect the brake master cylinder Chassis RSV4 1100 Factory CHAS 416 ...

Page 417: ...ER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE FER TO A SINGLE PASSENGER FOOTREST BUT ARE VALID FOR BOTH Remove the seeger ring 1 Extract the pin 2 While pressing the side plates remove the complete pedal 3 Check that the plates 4 are aligned correctly before dismantling the pedal taking care not to lose the spring 5 and the ball 6 RSV4 1100 Factory Chassis CHAS 417 ...

Page 418: ...Remove the footrest support 8 Stand SIDE STAND Pos Description Type Quantity Torque Notes 1 Screws for fastening the stand to the frame M10 2 45 Nm 33 19 lbf ft Loct 243 2 Fastener nut of rotary switch M6 1 10 Nm 7 37 lbf ft Chassis RSV4 1100 Factory CHAS 418 ...

Page 419: ...s described Disconnect the connector 1 of the side stand sensor and remove the ca ble tie 2 to free the wiring harness from the subframe Remove the rubber cable retainer clip 3 and the spiral cable protector 4 to free the wiring harnesses Remove the fastener screw of the met al cable retainer 5 and the cable tie 6 securing the wiring harnesses to the chain guide Free the wiring harness of the side...

Page 420: ...ifold flange fastening nuts M7 8 13 Nm 9 59 lbf ft 2 Silencer central manifold clamp fas tening screw M8 1 20 Nm 14 75 lbf ft 3 Screw fastening front header clamp centre manifold M6 1 Nm lbf ft 4 Torx button head silencer aesthetic protection fastening screw M6x10 3 8 Nm 5 90 lbf ft 5 Lambda probe fastener 2 25 Nm 18 43 lbf ft 6 Exhaust valve opening closing ca bles regulator lock nuts M6 2 5 Nm 3...

Page 421: ...stand Remove the three fixing screws of the heat guard Remove the heat guard making sure to recover the washers Loosen the clamp between the ex haust terminal and the central mani fold Loosen the adjustment nuts of the ex haust valve RSV4 1100 Factory Chassis CHAS 421 ...

Page 422: ...and the spacer Disconnect the actuator cables of the exhaust valve Remove the exhaust terminal com pletely INSTALLATION CAUTION IN CASE OF DISCOLOURATION OF THE SILENCER APPLY FINISHING POLISH WITH A SOFT CLOTH Fit the exhaust silencer onto the centre manifold Chassis RSV4 1100 Factory CHAS 422 ...

Page 423: ... cable free play adjust ment procedure described in the para graph EXHAUST BUTTERFLY VALVE in the chapter ELECTRICAL SYSTEM Carry out the exhaust valve actuator cable free play adjustment procedure and then tighten the lock nuts of the adjuster screws to the specified torque Tighten the screw of the clamp con necting the exhaust silencer and the centre manifold to the specified torque RSV4 1100 Fa...

Page 424: ...ect the connector of the rear cylinder bank lambda probe and de tach it from the chain guide Detach the springs and remove the centre exhaust manifold easing it out from underneath Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFOLD In order to remove the exhaust manifolds the side fairings lower fairings and the radiators must be removed beforehand Then proceed as described Loosen the met...

Page 425: ...linder bank exhaust head ers in addition to the components described pre viously for removal of the front cylinder bank exhaust headers it is also necessary to remove the centre catalytic converter Then follow the steps for removal described below Remove the left hand rider footpeg mount Remove the screw fastening the en gine mount to the frame and the three screws fastening the mount to the en gi...

Page 426: ...ated correctly see the paragraph EX HAUST VALVE in the chapter ELECTRICAL SYSTEM See also Butterfly valve in exhaust Engine oil cooler OIL RADIATOR Pos Description Type Quantity Torque Notes 1 Screw fastening oil radiator to mounting bracket M6x25 1 7 Nm 5 16 lbf ft 2 Hex head flange screws fastening bracket to engine M6x12 2 8 Nm 5 90 lbf ft Chassis RSV4 1100 Factory CHAS 426 ...

Page 427: ...adiator pipe Release the clamp and disconnect the left hand radiator pipe See also Replacement Remove the split pin From the opposite site remove the coolant radiator oil radiator connector pin Unscrew and remove the lower radia tor retainer Remove the radiator draining com pletely of oil RSV4 1100 Factory Chassis CHAS 427 ...

Page 428: ...Chassis RSV4 1100 Factory CHAS 428 ...

Page 429: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 430: ... 18 lbf ft 2 Control unit support screws M6 2 6 8 1 Nm 5 01 0 74 lbf ft Modulator REMOVING THE ABS MODULATOR To remove the ABS modulator first drain the brake system and then follow the procedure described below Disconnect the connector from the ABS control unit Braking system RSV4 1100 Factory BRAK SYS 430 ...

Page 431: ... metal plate Unscrew and remove the screws fas tening the ABS pipes to the modulator Remove the screw fastening the ABS modulator mount to the frame Partially free the ABS modulator mount from the rubber bush RSV4 1100 Factory Braking system BRAK SYS 431 ...

Page 432: ... modulator follow the procedure for removal in reverse order Before fitting the ABS modulator complete with mount and metal plate pre fit a cable tie onto the plate This cable tie will be used later to fasten the brake pipes to the metal plate it self ABS CONTROL UNIT CONNECTOR INSERTION PROCEDURE Check the initial position of the connection clip lever Braking system RSV4 1100 Factory BRAK SYS 432...

Page 433: ... the driving lever is not that shown in fig 1 the connector will not be prop erly coupled and the distance meas ured will be greater 12 mm approx 0 47 in In this case repeat the oper ation as described in the two previous points WE RECOMMEND CREATING A TEMPLATE IN ORDER TO ENSURE THAT THE CONNECTOR IS INSERTED CORRECTLY RSV4 1100 Factory Braking system BRAK SYS 433 ...

Page 434: ...ance between tone wheel and front sensor 0 5 2 00 mm 0 020 0 079 in Distance between tone wheel and rear sensor 0 5 2 00 mm 0 020 0 079 in TONE WHEELS 2 CLEANING It is important to check that all the tone wheels 2 are always clean Otherwise delicately remove any dirt residues using a cloth or wire brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 REPLACING THE...

Page 435: ... fixing screw M5x15 1 8 Nm 5 90 lbf ft 2 Screws fastening brake calliper to mount M8 2 25 Nm 18 43 lbf ft Removal To remove the rear brake calliper it is necessary to previously drain the braking system Remove the protective cap from the bleed nipple RSV4 1100 Factory Braking system BRAK SYS 435 ...

Page 436: ...the bleed nipple and unscrew the nipple to drain the system Protect the brake calliper adequately remove the fastener screws of the pipe and plug the pipe Remove the two fastener screws of the brake calliper Remove the brake calliper Braking system RSV4 1100 Factory BRAK SYS 436 ...

Page 437: ...crews of the brake calliper and tighten to the specified tor que Protect the brake calliper adequately connect the brake pipe fit the special screw and then tighten the screw to the specified torque Fill with oil and bleed the system Check the correct functioning of the braking system RSV4 1100 Factory Braking system BRAK SYS 437 ...

Page 438: ...8 lb ft Removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH To remove the front brake calliper it is necessary to previously drain the braking system Remove the protective cap of the bleed nipple and free the wiring harness of the front ABS sensor if applicable Braking system RSV4 1100 Factory BRAK SYS 438 ...

Page 439: ... unscrew the nipple to drain the system Remove the fastener screw of the pipe and plug the pipe Remove the two fastener screws of the brake calliper Remove the brake calliper retrieving the two spacers Installing NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH RSV4 1100 Factory Braking system BRAK SYS 439 ...

Page 440: ...two fastener screws of the brake calliper and tighten to the specified tor que Protect the brake calliper adequately connect the brake pipe fit the special screw and then tighten the screw to the specified torque Fill with oil and bleed the system Rear brake disc Braking system RSV4 1100 Factory BRAK SYS 440 ...

Page 441: ...ing the rear wheel Disc Inspection The operations must be carried out with the brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the minimum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Using a dial gauge check that the max im...

Page 442: ... THE SCREWS 1 MAN UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE A B C D E F See also Removing the front wheel Disc Inspection The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum ...

Page 443: ...OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY POSING SERIOUS DANGER FOR PEOPLE OBJECTS AND THE VE HICLE ITSELF CAUTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER BUT APPLY TO BOTH Unscrew and remove the two screws 1 Slide off the disc from the front brake calliper Separate the brake calliper pistons Remove the pads from the brake cal liper Retrieve the clip DO...

Page 444: ...iper on the disc Hand tighten the two screws 1 fully Pull the front brake lever to seat the brake calliper correctly Tighten the two screws 1 Check the front brake fluid level Rear brake pads Removal To remove the rear brake pads follow the proce dure described below Remove the two screws 1 fastening the brake calliper to the mount CAUTION DO NOT OPERATE THE REAR BRAKE PEDAL ONCE THE CALLIPER HAS ...

Page 445: ...THE BRAKE LEVER ONCE THE BRAKE PADS HAVE BEEN REMOVED AS THIS MAY FORCE THE PISTONS OUT FROM THEIR SEATS AND ALLOW BRAKE FLUID TO ESCAPE If worn replace the anti vibration plates Installing Insert two new pads and the vibration damping plates placing them so that the holes are aligned with the calliper holes UPON REFITTING MAKE SURE THE ARROWS ON THE VI BRATION DAMPING PLATES FACE THE DIRECTION OF...

Page 446: ...ORRECTLY POSITIONED INSIDE THE CALLIPER Fit the safety retainer clip 4 as shown While pressing the centre of the safety retainer clip 4 fit the pin 3 so that it passes over the clip Fit the retainer ring 2 Braking system RSV4 1100 Factory BRAK SYS 446 ...

Page 447: ... CIRCUIT IS AIR PURGED NOTE THE FOLLOWING OPERATIONS REFER TO ONE FRONT BRAKE CALLIPER ONLY BUT ARE VALID FOR BOTH THE VEHICLE MUST BE ON LEVEL GROUND TO BE BLED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover of the bleed valve Insert the...

Page 448: ...ver still feels spongy after completing all checks it is necessary to bleed the brakes using this type of procedure With the diagnostic tool properly connected select the function FRONT BLEEDING in the section SETTINGS The pump starts running While the pump is performing a rotation cycle operate and release the front brake lever until the message diagnostic tool cycle completion is received This p...

Page 449: ...y and quickly press and re lease the rear brake pedal then keep it fully pressed Loosen the bleed valve by a 1 4 turn so that the brake fluid flows into the con tainer this will release the tension on the brake pedal and it will make it arrive at the end stop Close the bleed valve before arriving at the end of the stroke with the pedal Repeat the operation until the are no air bubbles in the fluid...

Page 450: ...and accumulate Once the procedure with diagnostic tool is finished perform again the REGULAR PURGING to remove the air from the system completely Front brake pump FRONT BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 l...

Page 451: ...astening screws M6 2 8 Nm 5 90 lbf ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lbf ft Loctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lbf ft 5 Brake lever ferrule fastening screw M6 1 8 Nm 5 90 lbf ft 6 Special oil pipe coupling retaining screw 1 23 26 Nm 16 96 19 18 lbf ft RSV4 1100 Factory Braking system BRAK SYS 451 ...

Page 452: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 453: ... 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 RSV4 1100 Factory Cooling system COOL SYS 453 ...

Page 454: ... fasten ing the water radiator support brack et to the frame M6x20 2 10 Nm 7 38 lbf ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lbf ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lbf ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm 0 37 lbf ft 5 Screw for fastening the expansion tan...

Page 455: ...l head hex socket screws for fastening the pump to the crank case M6x25 2 10 Nm 7 38 lbf ft Electric fan Remove the front underfairings and the hand grip position sensor Disconnect the cooling fan connector to be replaced RSV4 1100 Factory Cooling system COOL SYS 455 ...

Page 456: ...ric fan are not the same as the hole 2 com pared to the holes 1 has a different thickness and is therefore fixed from the internal side using a threaded T bushing Now it is possible to remove the electric fan Coolant replacement Remove both fairings Place a container with a suitable ca pacity under the coolant pump Remove the radiator cap valve to help the fluid drain out Cooling system RSV4 1100 ...

Page 457: ...essary to reach the edge Fit the cap valve 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 101 C 213 F then turn off the engine and wait for it to cool With the vehicle standing vertically check the liquid level both in the radi...

Page 458: ... the two screws fastening the pipe to the engine Retrieve the gasket and replace with a new component when refitting See also Coolant replacement Unscrew and remove the two screws fastening the pump to the engine Remove the coolant pump Cooling system RSV4 1100 Factory COOL SYS 458 ...

Page 459: ... 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 In order to carry out the procedure described below the side fairings the inner side fairings the lower fairings and the chin fairing must be removed beforehand Then proceed as described RSV4 1100 Factory C...

Page 460: ... mount Remove the cable tie indicated and free the wiring harnesses from the ra diator mount Remove the screw fastening the radi ator to the mount on the right hand side of the vehicle Remove the two chassis bracket fixing screws Then remove the radiator retainer bracket Cooling system RSV4 1100 Factory COOL SYS 460 ...

Page 461: ...TOR REMOVAL To remove the radiator first drain the cooling sys tem Then proceed as described Disconnect the canister from the frame and remove the clamp fastening the wiring harnesses of the alternator the oil pressure bulb the front cylinder bank lambda probe and the left hand electric fan Disconnect the connector of the left hand electric fan Disconnect the mount of the exhaust valve actuator mo...

Page 462: ...emand sensor Remove the cable tie fastening the ca ble of the demand sensor to the drain pipe of the expansion tank Move the metal clips along the pipe and disconnect the cooling system pipe from the pump and the connector pipe leading to the thermostat valve Move the metal clip along the pipe and disconnect the cooling system pipe from the radiator Cooling system RSV4 1100 Factory COOL SYS 462 ...

Page 463: ...astening the coolant radiator to the oil radiator On both sides of the vehicle remove the two screws fastening the radiator to the mount Separate the water radiator from the mount on the left hand side and re move the radiator while simultaneously removing the expansion tank on the right hand side RSV4 1100 Factory Cooling system COOL SYS 463 ...

Page 464: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 465: ...supplied hex key unscrew and remove the two saddle fixing screws in order to remove it from the vehicle RIDER SADDLE INSTALLATION Perform the above described steps in reverse order After refitting and fixing the saddle place the hexagonal wrench in the cor responding seat of the tail fairing pas senger seat RSV4 1100 Factory Bodywork BODYW 465 ...

Page 466: ...with its seat C on the vehicle Press the saddle downward with one hand and with the other push it back ward until it is completely coupled CAUTION BEFORE RIDING MAKE SURE THAT THE SADDLE IS PROPERLY FIXED IF THE PASSENGER SEAT IS FITTED ON THE VEHICLE MAKE SURE IT IS PROPERLY FIXED BEFORE ALLOWING THE PASSENGER TO SIT ON IT THE TAIL FAIRING CAN BE USED INSTEAD OF THE PASSENGER SEAT HOWEVER WITH TH...

Page 467: ...mirror but is applicable to both mirrors where applicable Disconnect the turn indicator connector from the relative fixed connector on the instrument clus ter Unscrew and remove the two nuts supporting the rear view mirror Guiding the turn indicator cable where applicable through the relative hole on the top fairing remove the rear view mirror RSV4 1100 Factory Bodywork BODYW 467 ...

Page 468: ...w the two fastener screws of the instrument panel brow and remove the brow Lift the instrument panel by just enough to allow access to and removal of the rubber blocks from the slotted holes Disconnect the connector from the in strument panel Unscrew the three screws Remove the washers and the rubber blocks Bodywork RSV4 1100 Factory BODYW 468 ...

Page 469: ...d Remove the two inner screws fasten ing the headlight unit to the instrument panel mount Move the top fairing complete with headlight unit out of the way by just enough to reach and disconnect the connector Remove the eight screws fastening the headlight unit to the front fairing Separate the front fairing from the headlight unit After reassembling check that the headlight beams are aimed correct...

Page 470: ... lock In order to remove the lock the left hand side cover and the left hand tail fairing section must be re moved previously Then proceed as described Detach the cable 1 from the lock bar rel 2 Remove the left hand tail fairing sec tion completely Unscrew and remove fastener the screw 3 of the actuator arm complete with special washer 4 Bodywork RSV4 1100 Factory BODYW 470 ...

Page 471: ... Remove the actuator arm 5 Remove the spring 6 Unscrew and remove the fastener nut 7 of the lock barrel Remove the plate 8 from the lock bar rel RSV4 1100 Factory Bodywork BODYW 471 ...

Page 472: ...er plate Remove the lock striker plate 11 com plete with cable INSTALLATION To install the lock follow the procedure for removal in reverse order ensuring that the return spring and actuator arm are oriented correctly Then fit the clip into the indicated hole and fasten the actuator arm as shown Bodywork RSV4 1100 Factory BODYW 472 ...

Page 473: ...eral fastener screws and the relative T bushes Detach the rubber pipe grommet of the brake pipe from the lower trim piece of the steering yoke Remove the lower trim piece of the steering yoke Taillight assy Carry out the tail fairing removal pro cedure Unscrew and remove the two lateral screws RSV4 1100 Factory Bodywork BODYW 473 ...

Page 474: ...nd remove the tail light unit License plate light To remove the license plate light proceed as fol lows Unscrew the screw 1 and remove the closure 2 of the license plate holder Disconnect the license plate light con nector 3 Bodywork RSV4 1100 Factory BODYW 474 ...

Page 475: ... the rider sad dle and then follow the procedure described be low THE PROCEDURE DESCRIBED AS FOLLOWS IS FOR ONE SIDE FAIRING BUT APPLIES TO BOTH Unscrew and remove the lateral screws Unscrew and remove the lower screw Pull the front edge of the side fairing outwards and then move the fairing to wards the rear of the vehicle to detach and remove it RSV4 1100 Factory Bodywork BODYW 475 ...

Page 476: ...er fairings must be removed before hand Then start disassembly of the inner part of the dashboard removing the two fastener screws 1 of the hand guard Remove the hand guard 2 Remove the outer fastener screw of the upper fairing trim piece 3 Remove the two inner fastener screws of the upper fairing trim piece 4 Bodywork RSV4 1100 Factory BODYW 476 ...

Page 477: ... the upper fairing trim piece 5 Working from underneath the head light unit remove the screw 6 Remove the four screws 7 on the in ner fairing Remove the four outer screws 8 RSV4 1100 Factory Bodywork BODYW 477 ...

Page 478: ...ht screws 10 to sep arate the components of the side fair ing Detach the outer part 11 of the side fairing from the inner part 12 to sep arate them To separate the winglet from the outer part of the side fairing remove the five screws 13 Bodywork RSV4 1100 Factory BODYW 478 ...

Page 479: ...the winglet from the outer part 18 to separate the two parts Fairing mounting panels In order to remove the under fairings the lower fairings chin fairing and side fairings must be re moved beforehand Then proceed as described LEFT HAND UNDER FAIRING Remove the cable tie 1 fastening the wiring harnesses of the voltage regu lator and the pickup RSV4 1100 Factory Bodywork BODYW 479 ...

Page 480: ...er screw 3 fastening the under fairing to the coolant radiator mount Remove the screw 4 fastening the under fairing to the centre under fair ing Unscrew and remove the two fastener nuts of the voltage regulator retrieving the washers and bushes Bodywork RSV4 1100 Factory BODYW 480 ...

Page 481: ...r 6 Remove the left hand under fairing 7 RIGHT HAND UNDER FAIRING Remove the screw 1 fastening the expansion tank to the radiator Without draining the cooling system hold the expansion tank to one side of the vehicle with suitable measures RSV4 1100 Factory Bodywork BODYW 481 ...

Page 482: ...ove the cable tie 3 fastening the main wiring harness to the under fair ing Remove the screw 4 fastening the under fairing to the centre under fair ing Remove the inner screw 5 fastening the under fairing to the coolant radiator mount Bodywork RSV4 1100 Factory BODYW 482 ...

Page 483: ...astening the lateral under fairing to the centre un der fairing Remove the centre under fairing 2 To refit the under fairings carry out the procedure described previously for removal in re verse order License plate holder To remove the license plate holder follow the pro cedure described below Undo and remove the screw inside of the point indicated in the figure RSV4 1100 Factory Bodywork BODYW 48...

Page 484: ...rd To remove the rear mudguard follow the proce dure described below Unscrew and remove the two screws 1 fastening the rear mudguard to the chain guard and the two screws 2 fastening the mudguard to the swing arm Remove the mudguard easing it out towards the rear of the motorcycle Bodywork RSV4 1100 Factory BODYW 484 ...

Page 485: ...screws on both sides Slowly lower the lower fairings pulling out the breather pipe at both the front and the rear Remove the three screws fastening the left hand half of the lower fairings to the right hand half to separate the halves To remove the chin fairing follow the procedure described below Remove the screws fastening the chin fairing to the inner lateral fairings on both sides RSV4 1100 Fa...

Page 486: ...ust be removed beforehand Then proceed as described Remove the front screw 1 fastening the tank to the frame Remove the two rear screws 2 fas tening the tank to the saddle carrier subframe Uncouple from its support the connec tor 3 of the fuel pump and disconnect it Bodywork RSV4 1100 Factory BODYW 486 ...

Page 487: ...Disconnect the connector 4 of the in ertia platform Disconnect the two breather pipes 5 Lift the tank partially and disconnect the fuel pipe 6 Remove the fuel tank 7 RSV4 1100 Factory Bodywork BODYW 487 ...

Page 488: ...elhouse To remove the rear wheel splash guard first re move the battery the fuel tank the saddles the grab handle the bodywork parts constituting the tail fairing the license plate holder the side covers and the passenger footpeg mounts Then proceed as described Disconnect the main injection relay holder from the mount 1 Bodywork RSV4 1100 Factory BODYW 488 ...

Page 489: ...ing har ness 3 from the cable retainer clips on the splash guard Detach the connector 4 for connect ing the diagnostic tool from the mount on the splash guard Detach the connector 5 of the side stand sensor from the mount on the splash guard RSV4 1100 Factory Bodywork BODYW 489 ...

Page 490: ... the metal plate to the mount Partially free the ABS modulator mount from the rubber bush Remove the two screws 9 fastening the rear wheel splash guard to the sad dle carrier subframe Ease out the splash guard 10 towards the rear of the vehicle to remove it Bodywork RSV4 1100 Factory BODYW 490 ...

Page 491: ...the mudguard Detach the rubber clip fastening the brake pipe On both sides of the vehicle remove the fastener screws of the mudguard Unscrew the nuts situated on the inner side of the mudguard to remove the re flectors CAUTION WHEN REASSEMBLING MAKE SURE THAT THE PIN ON THE LEFT HAND REFLECTOR IS INSERTED CORRECTLY INTO THE RESPECTIVE HOLE IN THE MUDGUARD RSV4 1100 Factory Bodywork BODYW 491 ...

Page 492: ...e the instrument panel cover Instrument cluster support In order to remove the instrument panel mount first remove the front fairing complete with head light unit the side fairings outer and inner the instrument panel cover the ASC control unit if applicable and the instrument panel Then pro ceed as described Disconnect the USB port connector 1 Bodywork RSV4 1100 Factory BODYW 492 ...

Page 493: ...ing harness to the mount and the six screws 4 joining the two parts of the instrument panel mount Working on the left hand side of the vehicle remove the two screws 5 fas tening the left hand part of the instru ment panel mount Remove the left hand part 6 of the in strument panel mount RSV4 1100 Factory Bodywork BODYW 493 ...

Page 494: ...mount 9 Battery Ensure that the ignition switch is turned to OFF Remove the rider saddle Remove the two screws 1 Turn the battery so that its poles are accessible Unscrew and remove the screw 2 of the negative terminal Move the negative lead 3 aside Move the positive terminal protec tive rubber cap Unscrew and remove the screw 4 of the positive terminal Move the positive lead 5 aside Bodywork RSV4...

Page 495: ... TO THE POSITIVE TERMINAL FIRST AND AFTER WARDS THE LEAD TO THE NEGATIVE TERMINAL If the saddle had been refitted remove it Install the battery 6 in its seat Position the positive cable 5 correct ly and fasten it to the positive terminal tightening the screw 4 The positive cable 5 must be positioned to the side of the battery 6 Position the rubber protective cap on the positive terminal Position t...

Page 496: ...HOLDER MUST BE REMOVED ACT ON THE LOCKING TABS 8 TO REMOVE THE SPACER 7 Tail guard In order to remove the tail fairing the saddles and the side covers must be removed beforehand Then proceed as described RIGHT HAND TAIL FAIRING Unscrew and remove the screw 1 and then remove the rear seat trim 2 On both sides of the vehicle remove the upper fastener screws 3 Remove the lateral fastener screw 4 Body...

Page 497: ... de tach the front part of the right hand tail fairing section and remove the tail fair ing section completely LEFT HAND TAIL FAIRING To remove the right hand tail fairing follow the procedure described for the left hand side but also disconnecting the passenger seat release cable RSV4 1100 Factory Bodywork BODYW 497 ...

Page 498: ...ecting rods 301 305 313 coolant 456 458 Coolant 456 458 Countershaft 294 296 299 304 Crankcase 292 300 304 315 Crankshaft 302 304 312 Cylinder 85 91 D Desmodromic drum 223 Drive chain 19 406 E ECU Electric fan 455 Electrical system 7 19 106 108 Engine oil 71 426 Exhaust 171 420 424 426 Exhaust manifold 424 F Fairings 476 Filter box Fork 344 348 354 359 Forks 223 Front cylinder head valves 85 Front...

Page 499: ...lter 74 Oil sump 299 325 One way valve 329 P Pistons 301 305 313 Primary shaft 222 R Radiator 459 Rear cylinder head valves 91 Rear head 273 279 281 287 299 302 Rear wheel 388 441 Recommended products 68 Ride by wire 336 S Saddle Scheduled maintenance 62 Secondary air system Secondary shaft 223 Shock absorber Shock absorbers 374 Side fairings 476 Side stand 419 Spark plug 68 Stand 418 419 Start up...

Page 500: ...T Tank 486 Throttle body 338 340 Track 66 Transmission 18 298 299 Tyres 21 U Use 66 W Water pump 299 321 458 Wiring diagram 150 ...

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