APRILIA RSV4 1100 Factory Service Station Manual Download Page 8 | Manualshive

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KEEP OUT OF THE REACH OF CHILDREN.
NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER
PRESSURE AND MAY CAUSE BURNS.

Used engine oil and transmission oil

CAUTION

WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC-
TIVE IMPERMEABLE GLOVES.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN.

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS
WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID
IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH
THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK
MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.

Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN 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 IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-

mendations strictly.

BEFORE DISASSEMBLING COMPONENTS

Characteristics

RSV4 1100 Factory

CHAR - 8

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Summary of Contents for RSV4 1100 Factory

Page 1: ...SERVICE STATION MANUAL 2Q000401 RSV4 1100 Factory ...

Page 2: ...le 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 before...

Page 3: ...ns and changes in repair procedures are communicated to all Aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates ...

Page 4: ......

Page 5: ...R 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 PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ... 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 8: ...EACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN 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 IMPORTANT TO PR...

Page 9: ...consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR cotter pin...

Page 10: ...OME OFF BLOCKING 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...

Page 11: ...LY VOIDS THE WARRANTY This number consists of numbers and letters as in the example shown below ZD4RKEA00YSXXXXXX KEY ZD4 WMI World Manufacturer Identifier code KE model A00 Europe UA0 USA 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 engine number is printe...

Page 12: ...stments with calibrated pads Lubrication 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 integrated ce ramic gasket Air filter Polyester Transmission GEAR RATIOS ...

Page 13: ...for competition use Electrode gap 0 7 0 8 mm 0 027 0 031 in Battery BOSCH LITHIUM LTZ10S 12V 48Wh 240A alternatively YUASA YTZ10S 12V 8 6 Ah Coils Stick coil Recharging system Flywheel with rare earth magnets Alternator 450 W Main fuses 15A 30A Secondary fuses 5A 7 5A 10A 15A 3 ABS fuses 15 A 30 A BULBS Specification Desc Quantity High beam low beam light 12 V 55 W H7 Front daylight running lights...

Page 14: ...heelbase compres sion damping and rebound damping with TTX system Rear stroke 62 mm 2 44 in Steering damper Adjustable Ohlins shock absorber with hydraulic brake SIZES A AND B Specification Desc Quantity Size A 655 5 mm 25 81 in measurements refer to the bare chassis Size B 337 5 mm 13 29 in measurements refer to the bare chassis Angle C 26 5 measurements with reference to bare chassis Brakes BRAK...

Page 15: ...lli Diablo Super corsa SP tyres Inflation pressure 1 passenger 2 5 bar 250 KPa 36 26 PSI 2 passengers 2 8 bar 280 KPa 40 61 PSI Supply FUEL SUPPLY Specification Desc Quantity Fuel Unleaded petrol max E10 95 RON 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 fix...

Page 16: ...langed hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lb ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lb ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm 0 37 lb ft 5 Screw for fastening the expansion tank M6 1 5 Nm 3 69 lb ft Loct 243 Characteristics RSV4 1100 Factory CHAR 16 ...

Page 17: ...OIL RADIATOR pos Description Type Quantity Torque Notes 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lb ft OHLINS FORKS RSV4 1100 Factory Characteristics CHAR 17 ...

Page 18: ...m 4 43 lb ft 3 Cable gland fastening screw M5 1 8 Nm 5 90 lb ft SACHS FORKS FRONT FORKS SACHS Pos Description Type Quantity Torque Notes 1 Calliper bracket fixing screws Sachs M6 4 12 Nm 8 85 lb ft 2 Speed sensor fastening screw M5 1 6 Nm 4 43 lb ft 3 Upper cap 2 20 Nm 14 75 lb ft 4 Upper cap locking nut 2 20 Nm 14 75 lb ft Characteristics RSV4 1100 Factory CHAR 18 ...

Page 19: ...htening 3 Headstock ring nut tightening 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 lb ft Loctite 243 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 38 lb ft Loctite 243 8 Lower cover fix...

Page 20: ...t M25x1 5 1 80 Nm 59 00 lb ft 2 Front brake disk fastening screws M8 6 6 30 Nm 22 13 lb ft Loct 243 FRONT BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 Front brake calliper fastening screws M10x1 25 2 2 50 Nm 36 88 lb ft Characteristics RSV4 1100 Factory CHAR 20 ...

Page 21: ...5 16 lb ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lb ft 3 Front brake pump U bolt clamp M6 2 10 Nm 7 38 lb ft 4 Front brake lever pin fixing screw M6 1 10 Nm 7 38 lb ft Screw fastening brake pipe grommet to the lower yoke M5 1 8 Nm 5 90 lb ft RSV4 1100 Factory Characteristics CHAR 21 ...

Page 22: ...ti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lb ft 4 RH light switch M5 2 1 5 Nm 1 11 lb ft 5 LH light switch outer shell M4 2 1 5 Nm 1 11 lb ft 6 LH light switch int clamp M3 2 0 5 Nm 0 37 lb ft 7 Traction control command fastening screw M4 1 2 5 Nm 1 84 lb ft 8 Screw for fastening the Ride By Wire control to the semi handlebar M4 1 2 2 Nm 1 62 lb ft Characteristics RSV4 1100 Facto...

Page 23: ...ription Type Quantity Torque Notes 1 Screw for fastening the front head light to the front mudguard SWP 4 9 4 2 Nm 1 48 lb ft 2 Headlamp fastener screw M5 x 12 1 2 Nm 1 48 lb ft RSV4 1100 Factory Characteristics CHAR 23 ...

Page 24: ...ument panel support shell fas tening screws SWP 4 9 5 2 Nm 1 48 lb ft 3 Screws used to fasten the instrument panel support to the chassis M6 4 8 Nm 5 90 lb ft TOP FAIRING pos Description Type Quantity Torque Notes 1 Windshield fixing screws M4 4 0 5 Nm 0 37 lb ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 38 lb ft Characteristics RSV4 1100 Factory CHAR 24 ...

Page 25: ... M5 2 4 Nm 2 95 lb ft 3 Screws fixing the side fairings to the side spacers M5 2 1 5 Nm 1 11 lb ft 4 Screws fastening the lower fairing to the lug M5 2 2 Nm 1 48 lb ft 5 Lower fairing lower fastening screws M5 2 2 Nm 1 48 lb ft 6 Centre screws fastening lower fairing M6 2 10 Nm 7 38 lb ft RSV4 1100 Factory Characteristics CHAR 25 ...

Page 26: ... lever collar fastening screws M6 1 10 Nm 7 38 lb ft FRONT ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes 1 Flanged button head hex socket screws for fastening the sensor to the bracket M6x12 2 6 Nm 4 43 lb ft Characteristics RSV4 1100 Factory CHAR 26 ...

Page 27: ...r to the bracket M6x12 2 6 Nm 4 43 lb ft Central part SIDE STAND Pos Description Type Quantity Torque Notes 1 Screws for fastening the stand to the frame M10 2 45 Nm 33 19 lb ft Loct 243 2 Linear switch retaining screws and nuts M5 2 4 Nm 2 95 lb ft 3 Spring retaining pin on stand 1 10 Nm 7 38 lb ft Loct 243 4 Stand fastening pin 1 15 Nm 11 06 lb ft Loct 243 5 Pin for retaining springs on stand pi...

Page 28: ...s Description Type Quantity Torque Notes 1 Rider s saddle retaining screw M5 2 6 Nm 4 43 lb ft 2 Passenger s saddle retaining pin fas tening screw M4 1 1 5 Nm 1 11 lb ft Characteristics RSV4 1100 Factory CHAR 28 ...

Page 29: ...ead hex socket screws for fastening the sensor to the bracket M6x12 2 6 Nm 4 43 lb ft Central fuel tank cover retaining screw M4 1 0 5 Nm 0 37 lb ft Fuel tank breather couplings M7 2 3 Nm 2 21 lb ft Fuel return coupling M6 1 6 Nm 4 43 lb ft Loctite 243 Pump support to flange fastening M5 3 4 Nm 2 95 lb ft Lug to flange fastening M5 2 5 Nm 3 69 lb ft Petrol return closure M6 1 10 Nm 7 38 lb ft Loct...

Page 30: ...YWORK Pos Description Type Quantity Torque Notes 1 Screws fastening fairing to tail fairing M5 2 1 Nm 0 74 lb ft 2 Screws fastening fairing to tank M5 2 2 2 Nm 1 48 lb ft Characteristics RSV4 1100 Factory CHAR 30 ...

Page 31: ... Screws for fastening the rider s footr ests to the frame M8 2 2 25 Nm 18 44 lb ft Loctite 243 2 Screws for fastening the passenger s footrests to the frame M8 2 2 18 Nm 13 28 lb 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 retaining screws M6 2 2 8 Nm 5 90 lb ft 4 Passenger s heel guard retaini...

Page 32: ... RH upper rear coupling M10 1 50 Nm 36 88 lb ft 9 Right fairing spacer M6 1 10 Nm 7 37 lb ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lb ft 11 Upper rear mount M10 1 50 Nm 36 88 lb ft 12 Saddle mounting fixing screws M10 4 50 Nm 36 88 lb ft 13 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lb ft 14 Taillight mounting bracket fixing s...

Page 33: ... 69 lb ft 2 Lock lever self tapping screw M4 1 2 Nm 1 48 lb ft 3 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 4 Right hand ignition lock screw M8 1 20 Nm 14 75 lb ft 5 Passenger saddle fixing screws M6 2 8 Nm 5 90 lb ft RSV4 1100 Factory Characteristics CHAR 33 ...

Page 34: ...tween the O rings and the Quick Shift uniball NOTE ONCE ASSEMBLE THE DISTANCE BETWEEN THE UNIBALL AND THE JOINT MUST BE AP PROXIMATELY 180mm 7 09in FAIRINGS pos Description Type Quantity Torque Notes 1 Aerodynamic fins TBEI flanged fas tening screws M5x9 4 5 Nm 3 69 lb ft Fairing retaining spacer M6 2 8 Nm 5 90 lb ft Lower fairing central bracket fasten ing screws M6 2 10 Nm 7 38 lb ft RH lower fa...

Page 35: ...er fairing fastening screws M5 2 2 Nm 1 47 lb ft Lower forks closure fastening screws M6 2 8 Nm 5 90 lb ft Screws for fastening the lower frontal closure to the intake ducts SWP 3 9 2 1 Nm 0 74 lb ft Internal fastening screws between the fairing and the lower frontal clo sure M4 2 0 5 Nm 0 37 lb ft Internal fastening screws between the airing and the stanchion M5 2 2 Nm 1 48 lb ft ABS CONTROL UNIT...

Page 36: ...CENTRAL ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes Starter relay cables fastening screws M5 2 4 Nm 2 95 lb ft Back side Characteristics RSV4 1100 Factory CHAR 36 ...

Page 37: ...aesthetic protection fastening screw M6x10 3 8 Nm 5 90 lb ft 5 Lambda probe fastener 2 18 Nm 13 28 lb ft 6 RH fairing spacer M6 1 8 Nm 5 90 lb ft 7 Exhaust valve opening closing ca bles regulator lock nuts M6 2 5 Nm 3 69 lb ft REAR WHEEL Pos Description Type Quantity Torque Notes 1 Rear wheel axle nut M25x1 5 1 120 Nm 88 51 lb ft 2 Nuts for fastening crown to sprocket M10 5 50 Nm 36 88 lb ft 3 Rea...

Page 38: ... retaining screws M6 2 8 Nm 5 90 lb ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lb ft Loctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lb ft 5 Brake lever ferrule retaining screw M6 1 8 Nm 5 90 lb ft 6 Special oil pipe coupling retaining screw 1 23 26 Nm 16 96 19 18 lb ft Characteristics RSV4 1100 Factory CHAR 38 ...

Page 39: ... lb ft 2 Rear brake calliper support plate re taining pin M12 1 50 Nm 36 88 lb ft Loct 243 3 Rear brake calliper fastening screw M5 2 25 Nm 18 44 lb ft 4 Brake pipe bracket fastening screw M5 1 4 Nm 2 95 lb ft Screw fastening brake pipe clamp M5 2 4 Nm 2 95 lb ft RSV4 1100 Factory Characteristics CHAR 39 ...

Page 40: ...lb ft 6 Chain guide rear fastening nut M6 1 7 Nm 5 16 lb ft 7 Chain feeder shoe fastening screws M5 2 2 Nm 1 48 lb ft 8 Chain tensioner fastener screw M8 2 Manual 9 Rear stand bushing fastening screws M6 2 7 Nm 5 16 lb ft Lower chain shoe fastening screws M6 2 10 Nm 7 38 lb ft REAR MUDGUARD pos Description Type Quantity Torque Notes 1 Rear mudguard fixing screws M6 2 5 Nm 3 69 lb ft For plastic mu...

Page 41: ...y Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lb ft 2 Dual connecting rod fixing screw M10 3 50 Nm 36 88 lb ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lb ft RSV4 1100 Factory Characteristics CHAR 41 ...

Page 42: ...ver stud fastening screws M4 1 1 5 Nm 1 11 lb ft 4 Screws used to fasten the grilles to the tail fairing M5 2 0 5 Nm 0 37 lb ft 5 Screws for fastening the grilles to the saddle mounting M5 2 3 Nm 2 21 lb ft 6 Screws used to fasten the tail fairing to the saddle support bracket M5 2 2 Nm 1 48 lb ft 7 Lower saddle mounting closure fas tening screws M5 2 3 Nm 2 21 lb ft 8 Screws for fastening number ...

Page 43: ...crews if fitted Self tapping Di am 3 9 2 0 3 Nm 0 22 lb ft BODYWORK UNDER SADDLE Pos Description Type Quantity Torque Notes 1 Flanged button head hex socket screws for fastening the saddle mounting M5x12 5 3 Nm 2 21 lb ft 2 Screws and nuts for fastening the number plate holder to the saddle mounting plate M6 2 4 Nm 2 95 lb ft 3 Button head hex socket battery bracket fastening screws M5 5 2 Nm 1 48...

Page 44: ... 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 4 TE Flanged screw M6x22 14 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 5 Engine timing inspection cap 1 20 Nm 14 75 lb ft 6 Spacers for soundproof cover 5 6 Nm 4 43 lb ft 7 Oil level dipstick 1 3 Nm 2 21 lb ft 8 Oil load cap 1 5 Nm 3 69 lb ft Characteristics RSV4 1100 Factory CHAR 44 ...

Page 45: ...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 45 ...

Page 46: ...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 47: ...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 47 ...

Page 48: ...ged screw M6x50 8 10 Nm 7 38 lb ft Lubricate the head and under the head 4 TE Flanged screw M8x35 1 25 Nm 18 44 lb ft Lubricate the head and under the head 5 TE Flanged screw M8x50 3 25 Nm 18 44 lb ft Lubricate the head and under the head 6 Gearbox control rod support SHC fix ing screws M6x35 2 10 Nm 7 38 lb ft Lubricate the head and under the head 7 Flanged TE screw fixing fuel rail gearbox lubri...

Page 49: ...EARBOX Pos Description Type Quantity Torque Notes 1 Philips cylindrical head hex socket screw M6x20 1 10 Nm 7 38 lb ft Loct 243 2 Hex socket flat head counter sunk screw for fastening the bearing re taining plates M6x16 3 10 Nm 7 38 lb ft Loct 243 3 Flanged hex head flange retaining screws M8x25 6 25 Nm 18 44 lb ft 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lb ft Loct 243 5...

Page 50: ...lutch M20x1 1 150 Nm 110 63 lb ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lb 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 lb ft Loct 243 Characteristics RSV4 1100 Factory CHAR 50 ...

Page 51: ... 2 Cover fastening screws M6x40 3 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 3 Blow by coupling SHC fastening screws M5x16 3 5 Nm 3 69 lb ft 4 Spacers for soundproof cover 3 6 Nm 4 43 lb ft 5 Soundproof cover fastening screws M6 3 6 Nm 4 43 lb ft 6 TE flanged screw fixing the cable tie plate M5x12 1 6 Nm 4 43 lb ft Pre impregnated screw and in ab sence Loct 2045 Stator SHC...

Page 52: ...rque unscrew and re tighten to torque 4 Oil pressure sensor 1 15 Nm 11 06 lb ft 5 Flanged TE rose pipe fastening screw M6x16 1 10 Nm 7 38 lb ft Pre impregnated screw in absence Loct 2045 6 SHC screw fixing pump to the casing M6x16 5 10 Nm 7 38 lb ft 7 SHC screw fixing pump to the casing M6x50 1 10 Nm 7 38 lb ft 8 SHC screw fixing oil pipe connection M6x20 1 10 Nm 7 38 lb ft Characteristics RSV4 11...

Page 53: ...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 lb ft RSV4 1100 Factory Characteristics CHAR 53 ...

Page 54: ...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 lb ft Characteristics RSV4 1100 Factory CHAR 54 ...

Page 55: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 56: ...es code Description 020845Y Engine support 020846Y Containment tray plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch lock 020850Y Primary gear lock Special tools RSV4 1100 Factory S TOOLS 56 ...

Page 57: ... timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension er of the timing chain 020856Y Piston assembly ring 020857Y Crankshaft support U bolt RSV4 1100 Factory Special tools S TOOLS 57 ...

Page 58: ... AP8140199 Tool storage panel 020859Y Graphics for panels 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 Special tools RSV4 1100 Factory S TOOLS 58 ...

Page 59: ...e 020956Y Support for camshaft gear on head 020883Y Fitting removing timing chain tensioner tool 020709Y Engine support AP8140187 U bolt for motor support 020376Y Sleeve for adaptors 020363Y 20mm oil seal guide RSV4 1100 Factory Special tools S TOOLS 59 ...

Page 60: ...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 60 ...

Page 61: ...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 Tool for steering tightening AP8140181 Tool for checking fuel pressure RSV4 1100 Factory Special tools S TOOLS 61 ...

Page 62: ...Stores code Description 020922Y Diagnostic tool 021011Y PADS PMP Interface cable Special tools RSV4 1100 Factory S TOOLS 62 ...

Page 63: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 64: ...ng 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 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 ...

Page 65: ... 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 by the manufacturer To carry out the correct verification Flexible coupling pin nuts tighteni...

Page 66: ...bearings Wheels 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 Fork 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...

Page 67: ...n hours 14 15 17 15 14 18 By using the P A D S diagnostic tool which must be updated to the latest available version the new dedicated engine calibration designed spe cifically for the version in question may be used to monitor the effective technological stress level of the mechanical components for use on the racetrack For this reason when the general warning lamp see figure remains on in the st...

Page 68: ...ions also apply when topping up fluid levels TABLE OF RECOMMENDED PRODUCTS Product Description Specifications Engine oil 10W 50 Synthetic based 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 ...

Page 69: ...ve the rear coil fastener screw Slide off the rear coil Unscrew and slide off the rear spark plug Engine oil Check THE OIL LEVEL MUST 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 RSV4 1100 Factory Maintenance MAIN 69 ...

Page 70: ...nd put it back in without screwing it in Remove it again and check the engine oil level The level is correct if it reaches the MAX level approximately Otherwise top off the engine oil 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 ENGINE DAMAGE Replacement NOTE HOT OIL IS MORE ...

Page 71: ...nning 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 ENGINE DAMAGE Verifica parastrappi Operating from the left side of the mo torcycle using a torque wren...

Page 72: ... NEVER REUSE AN OLD FILTER Spread a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the 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 Remove the fuel tank Unscrew and remove the eight air filter box cover screws Maintenance RSV4 1100 Factory MAIN 72 ...

Page 73: ...ing the pipes and cables Remove the air filter Checking the valve clearance FRONT HEAD Remove both throttle bodies and the coils Remove the front head cover and the spark plugs Remove the sound proofing cover from the clutch side Remove the cap on the clutch cover in order to turn the crankshaft taking care not to lose the O ring RSV4 1100 Factory Maintenance MAIN 73 ...

Page 74: ...ler gauge to check the clear ance between the cam on the shaft and the relative tappet for both rear head shafts Characteristic Acceptable values with control clearance be tween cam and valve intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Front cylinder head valves Check the play on the front head valves and if it is necessary to restore the correct play values proceed...

Page 75: ... pin Fit the pin for aligning the intake cam shaft with the hole on U bolt If it was not possible before adjusting the valve clearance check the engine timing Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt is vis...

Page 76: ...the crankshaft timing pin from the flywheel side to check that the tim ing setting was not altered while the engine was turned with only one cam shaft drive gear fastener screw in place Remove the camshaft timing pin Unscrew and remove the three screws 1 Remove the U bolt 2 and the oil pipe 3 Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Block crankshaft rotation using...

Page 77: ...ding in stages and diagonally Retrieve the washers from the screws near the spark plug holes Remove the U bolts with the O rings and locator 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 gear indicated with two dots Use a magnet to remove the tappet CAUTIO...

Page 78: ...ribution gear s lock screw and move the gear itself from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Position the U bolt 2 and the oil pipe 3 Insert the two screws 1 Tighten all the U bolts screws working in stages and diagonally Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camshaft timin...

Page 79: ...he head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible Block crankshaft rotation using one of the specific tools 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 ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn the ...

Page 80: ... left rear piston to the TDC Turn the crankshaft 450 one complete turn 90 in the direction of motor rotation direction of travel Insert the pin from the clutch side into the hole in the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT DO NOT USE IT FOR TIGHTENING COMPONENTS Specific tooling 020852Y Crankshaft timing pin Fit the pi...

Page 81: ...crankshaft by 450 one com plete turn 90 in the direction of the engine s rotation direction of travel to align the hole on the intake camshaft with the specific hole on the U bolt This ensures that all the rear cylinder bank valve springs are decompressed Refit the camshaft timing setting pin in the hole in the U bolt on the rear head and refit the crankshaft timing pin from the clutch side to che...

Page 82: ...p Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 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 and remove the seven screws 4 proceeding in stages and diagonally Retrieve the washers from the screws near the spark plug holes Remo...

Page 83: ...a suitable component to achieve the cor rect valve clearance Refer to the table Calibrated pad thickness es to identify the suitable thickness Fit the tappet NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Install the intake and exhaust camshafts on the rear head remembering that the intake camshaft gear tooth indicated with a dot is inserted in the groove of the exhau...

Page 84: ... gear itself from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Position the U bolt 2 and the oil pipe 3 Insert the two screws 1 Tighten all the U bolts screws working in stages and diagonally Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camshaft timing pin Maintenance RSV4 1100 Factory MAI...

Page 85: ...the head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible Block crankshaft rotation using one of the specific tools 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 ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn the...

Page 86: ...adjustment procedure Calibrated pad thickness Pad thicknesses for adjusting valve clearance correctly 1 75 mm 0 0689 in 1 77 mm 0 0697 in 1 80 mm 0 0709 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 Maintenance RSV4 1100 Factory MAIN 86 ...

Page 87: ...m 0 0964 in 2 47 mm 0 0972 in 2 50 mm 0 0984 in 2 52 mm 0 0992 in 2 55 mm 0 1004 in 2 57 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...

Page 88: ...3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 in 3 15 mm 0 1240 in Maintenance RSV4 1100 Factory MAIN 88 ...

Page 89: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 90: ... 2 Horn fixing screw M8 1 15 Nm 11 06 lb ft 3 Button head hex socket voltage regulator fixing screws M6x30 2 6 Nm 4 43 lb ft 4 Button head hex socket screws for fastening the USB port bracket if fit ted 1 6 Nm 4 43 lb ft 5 Flanged button head hex socket screws for fastening the sensor to the bracket M6x12 2 6 Nm 4 43 lb ft Electrical system RSV4 1100 Factory ELE SYS 90 ...

Page 91: ...CENTRAL ELECTRICAL SYSTEM Pos Description Type Quantity Torque Notes Starter relay cables fastening screws M5 2 4 Nm 2 95 lb ft RSV4 1100 Factory Electrical system ELE SYS 91 ...

Page 92: ...Components arrangement Key 1 Side stand sensor 2 Fuel pump 3 Instrument panel 4 Left hand switch Electrical system RSV4 1100 Factory ELE SYS 92 ...

Page 93: ...m 29 Quick Shift 30 Front tone wheel sensor 31 a PRC commands 32 ABS control unit THE IDENTIFICATION OF THE RELAY CANNOT BE CARRIED OUT JUST ON THE BASIS OF THE INDICATIONS BELOW IN ANY EVENT IT SHOULD OCCUR WITH THE IDENTIFICATION OF THE COLOUR OF THE RELAY CABLES RELAY LAYOUT Location of the component in the electrical circuit diagram Component name Position on the vehicle 10 Low beam lights rel...

Page 94: ...sts of the following wiring harnesses and parts 1 x Vehicle wiring harness 1 x Headlamp wiring harness 1 x Number plate holder wiring harness 1 x Positive Battery Cable 1 x Engine Battery Earth Cable 1 x Ignition switch 2 x ABS speed sensors 1 x Starter relay 5 x Relays 1 x Safety relay 1 x Horn 1 x Front Headlight 1 x Rear Headlight 1 x Instrument Cluster 1 x RH Rear view Mirror with Dir Ind 1 x ...

Page 95: ...orcycle division The wiring harnesses on the vehicle are subdivi ded into three main sections as indicated in the figure 1 Front section 2 Central section 3 Rear section Special checks for the correct connection and routing of cables It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine and therefore pr...

Page 96: ... correctly and the torque cable fastening screws are tightened correctly Check the rear stop switch connection Check that the R W connector is connected and routed correctly Check the RH and LH rear indicator connections Check the gear connector connection Check the quick shift connector connection Check that all the connectors inside the instrument support arch have been connected cor rectly CAUT...

Page 97: ...g nut x2 5 T shaped bushing x2 6 M6x30 button head hex socket screws x2 7 Washer x2 WIRING TABLE C FRONT HEADLIGHT PRE ASSEMBLY The front headlight wiring must be pre assembled on the headlight by means of a clamp 1 Headlamp wiring harness 2 Small black clamp WIRING TABLE C1 FRONT HEADLIGHT PRE ASSEMBLY 1 Headlamp 2 Relay 3 Cable grommet 4 Small black clamp WIRING TABLE D PRE ASSEMBLING THE LIGHT ...

Page 98: ... INSTRUMENT SUPPORT ARCH AND FRONT PART Position the two clamps as indicated WIRING TABLE E1 INSTRUMENT SUPPORT ARCH AND FRONT PART Using the first edge clamp secure the light switch wiring harness making a note of its length taking into account the movement of the handlebar first 1 RH light switch wiring harness Electrical system RSV4 1100 Factory ELE SYS 98 ...

Page 99: ...es from the left hand side of the handlebar and fasten them together making a note of their re spective lengths first WIRING TABLE E4 INSTRUMENT SUPPORT ARCH AND FRONT PART Cable output on right hand side of the instrument support 1 RH light switch wiring harness WIRING TABLE E5 INSTRUMENT SUPPORT ARCH AND FRONT PART Cable output on left hand side of the instrument support 1 LH light switch wiring...

Page 100: ... FORKS 1 ABS sensor 2 Cable grommet WIRING TABLE F1 FRONT WHEEL ABS SEN SOR PASSAGE SACHS FORK 1 ABS sensor 2 Cable guide 3 Clamp 4 Cable grommet WIRING TABLE F2 FRONT ABS SENSOR WIRING Wherever possible maintain the ABS sensor wir ing as externally as possible Clamp the ABS sensor wiring to the main wiring loom Using a small clamp 1 secure the ABS sensor wiring to the radiator Electrical system R...

Page 101: ...WIRING TABLE G COMPLETING THE FRONT MUDGUARD ASSEMBLY Position the front headlight connectors under the instrument support arch WIRING TABLE G COMPLETING THE FRONT MUDGUARD ASSEMBLY Check that the indicator connectors are inserted correctly and that they do not protrude into the in strument holder arch 1 Right hand turn signal connector 2 Left turn indicator connector RSV4 1100 Factory Electrical ...

Page 102: ...he hole identified by the letter B Battery using M5x8 screw 1 Start up 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 Batt...

Page 103: ...ts support bracket 2 which is fixed to the fuel tank TABLE C PINION GUARD PRE ASSEMBLY Position the support 1 for the lambda probe connector and the quick shift wir ing cable guide 2 on the pinion pro tection guard RSV4 1100 Factory Electrical system ELE SYS 103 ...

Page 104: ...E D2 VEHICLE WIRING HAR NESS Secure the main wiring harness 1 using the cable glands 2 at the points indicated by the grey taping present on the harness itself Secure the relay support to the frame that the safety relay 3 injection relay 4 and fans relay 5 are attached to WIRING TABLE D3 VEHICLE WIRING HAR NESS Secure the main wiring harness 1 using the clamp 2 at the point indicated by the grey t...

Page 105: ...nd the water pipe 5 Oil pressure sensor WIRING TABLE E1 STARTER MOTOR AND OIL BULB ZONE IF THE RELAY STARTER MOTOR CABLE IS NOT ROUTED AND OR SECURED CORRECT LY IT MAY CAUSE THE VEHICLE TO CATCH FIRE CHECK THAT THE CABLE ON THE STARTER MOTOR IS POSITIONED AS INDICA TED IN THE FIGURE WIRING TABLE E2 STARTER MOTOR AND OIL BULB ZONE Check that the terminal is connected and that the hood is inserted i...

Page 106: ...ymbol 1 Large clamp clamp the battery engine earth wiring to the demand sensor wiring as high up as pos sible 2 Engine battery earth cable WIRING TABLE H ENGINE EARTH CABLE IF THE SCREWS 1 USED TO SECURE THE EARTH CABLES ARE NOT FASTENED COR RECTLY IT MAY CAUSE THE VEHICLE TO CATCH FIRE 2 ENGINE EARTH lug from vehicle wiring har ness 3 ENGINE EARTH lug from engine wiring harness 4 ENGINE EARTH lug...

Page 107: ...ltage regu lator 2 wiring to the water radiator WIRING TABLE H2 LH SIDE ZONE 1 Small clamp 2 Large clamp must be large enough to clamp the hand wheel cable the regulator cable and the front lambda probe cable together RSV4 1100 Factory Electrical system ELE SYS 107 ...

Page 108: ...nd attached to their respective supports on the canister WIRING TABLE I EXHAUST VALVE MOTOR ZONE 1 Ride by wire wiring harness 2 RH fan wiring harness 3 Exhaust valve motor wiring harness 4 Exhaust valve 5 Small clamp 6 Vehicle wiring harness 7 Cable grommet Electrical system RSV4 1100 Factory ELE SYS 108 ...

Page 109: ...esses must be routed between the frame and the exhaust valve cables WIRING TABLE I EXHAUST VALVE MOTOR ZONE The fan 1 and ride by wire 2 wiring harness connectors must be connected correctly and at tached to the exhaust valve support RSV4 1100 Factory Electrical system ELE SYS 109 ...

Page 110: ... control wiring harness 1 must be routed above the arm of the main wiring harness 2 that branches towards the instrument cluster and below the radiator hose 3 which connects the thermostatic valve to the radiator CAUTION IF THE RIDE BY WIRE CONTROL WIRING HARNESS IS NOT ROUTED CORRECTLY IT MAY DAMAGE THE CON TROL WIRING TABLE L1 RIDE BY WIRE CONTROL WIRING HARNESS The ride by wire control wiring 1...

Page 111: ...and switch 2 Cable grommet 3 Side stand switch wiring harness WIRING TABLE M2 PINION GUARD ZONE ROUTE THE WIRING BEHIND THE CABLE GLAND USED TO CLOSE THE TWO FUEL BREATHER TUBES 1 Quick Shift wiring harness routing 2 Rear lambda probe wiring harness routing 3 Gear sensor wiring harness routing 4 Side stand switch wiring harness routing RSV4 1100 Factory Electrical system ELE SYS 111 ...

Page 112: ...OBES 1 Rear lambda probe wiring harness routing WIRING TABLE N1 LAMBDA PROBES THE CABLE GLAND MUST BE POSITIONED TOWARDS THE TOP AND LAMBDA SENSOR CABLE MUST BE ROUTED THROUGH IT Electrical system RSV4 1100 Factory ELE SYS 112 ...

Page 113: ...ING TABLE N3 LAMBDA PROBES 1 Front lambda probe cable from main wiring har ness 2 Front lambda probe cable to probe Route the lambda probe cable through the cable gland 3 and attach the connector to the support 4 on the bracket WIRING TABLE N4 LAMBDA PROBES 1 Lambda probe cable in front of breather tubes RSV4 1100 Factory Electrical system ELE SYS 113 ...

Page 114: ...G ZONE Check that the clamp fastens all the cables espe cially the Quick Shift cable The cable must be secured so that it cannot slip down and come into contact with the exhaust system 1 Quick Shift wiring harness 2 Clamp WIRING TABLE O2 AIR FILTER HOUSING ZONE Check that the gear sensor connector has been connected correctly Electrical system RSV4 1100 Factory ELE SYS 114 ...

Page 115: ...orrectly Back side TABLE A LICENSE PLATE FRAME PRE FIT TING The right arrow is identified with the RED taping and must be inserted on the license plate holder as indicated in the picture The arrow with the red tape must be connected with the wiring harness branch that includes the grey tape 1 Left LED indicator 2 Right LED indicator 3 Grey tape 4 Red tape RSV4 1100 Factory Electrical system ELE SY...

Page 116: ...pinch the cables TABLE B REAR ABS SPEED SENSOR PRE FITTING 1 ABS speed sensor TABLE B1 REAR ABS SPEED SENSOR PRE FITTING 1 ABS speed sensor wiring harness 2 Cable grommets 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 Electrical system RSV4 1100 Factory ELE SYS 116 ...

Page 117: ...ust be 7 5 mm TABLE C3 PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION If the initial position of the connector and the pull ing level is not as the one shown in TABLE C the connector will not hook correctly and the meas ured distance will be higher around 12 mm In this case repeat the operation as described in TABLE C1 C2 It is advisable to create a jig in order to check the correct co...

Page 118: ... the tip of the clamp into the hole on the sad dle mounting and push it until it locks into place 1 Grey taping 2 Clamp 3 Saddle mounting hole WIRING TABLE D2 ABS ON SADDLE MOUNTING IF THIS WIRING ABS FUSES BATTERY IS NOT SECURED CORRECTLY IT MAY CAUSE THE VEHICLE TO CATCH FIRE Check that the connected is securely attached and that all the terminals are in place Position it as indicated 1 ABS spee...

Page 119: ...REA Fit the individual fan fuse on battery mounting bracket tongue TABLE E2 REAR SEAT POST AREA Fuse box positioning on battery mounting bracket Insert the fuse box in the two tongues on the bat tery mounting bracket TABLE E3 REAR SEAT POST AREA Check that the connector is correctly connected with the protection relay RSV4 1100 Factory Electrical system ELE SYS 119 ...

Page 120: ... connectors in their respective hous ings 1 ECU diagnostic connector 2 Diagnostic connector 3 Number plate holder wiring connector 4 Taillight connector WIRING TABLE E6 REAR SADDLE MOUNTING ZONE Insert the starter relay between the two plastic flaps 1 Start up relay 2 Starter motor cable on vehicle wiring harness 3 Starter relay connector 4 Rubber clamp 5 Cable grommet Electrical system RSV4 1100 ...

Page 121: ...RTH CABLE 1 Engine battery earth cable 2 Cable grommet WIRING TABLE F1 ENGINE BATTERY EARTH CABLE 1 Engine battery earth cable 2 Large clamp 3 V4 MP control unit if fitted 4 Large clamps RSV4 1100 Factory Electrical system ELE SYS 121 ...

Page 122: ...ke switch wiring 2 Speed sensor wiring 3 Cable fasteners WIRING TABLE H1 SWINGARM ZONE 1 Rear brake switch wiring 2 Speed sensor wiring 3 Cable grommet WIRING TABLE I REAR ABS SENSOR Check that the rear ABS connector is connected correctly and attached to its support Electrical system RSV4 1100 Factory ELE SYS 122 ...

Page 123: ...WIRING TABLE I REAR ABS SENSOR Route the rear brake switch 2 and rear ABS sen sor 3 wiring harness through the cable gland 1 RSV4 1100 Factory Electrical system ELE SYS 123 ...

Page 124: ...General wiring diagram key 1 Multiple connectors 2 Front right turn indicator LED 3 Complete headlamp 4 Front left turn indicator LED Electrical system RSV4 1100 Factory ELE SYS 124 ...

Page 125: ...on relay 20 Immobilizer antenna 21 Rear right turn indicator LED 22 Complete taillight LED 23 Rear left turn indicator LED 24 License plate light bulb 25 Recovery logic relay 26 Auxiliary fuses 27 BLUEDASH pre installation 28 Voltage regulator 29 Alternator 30 Starter motor 31 Start up relay 32 Battery 33 Main injection relay 34 Oil pressure sensor 35 Fan 36 Fan control relay 37 Fuel reserve senso...

Page 126: ...t 62 Variable geometry engine 63 ABS control unit 64 Front wheel speed sensor 65 Rear wheel speed sensor 66 SensorBox 67 Left light switch 2 68 Fan fuse 69 ABS fuses 70 Lambda probe 2 71 Left headlamp connector 72 Right headlamp connector Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC TORS NOTE ...

Page 127: ... that the terminals are fitted correctly on the connector and that the wires are fastened correctly to the terminals Checking electrical CONTINUITY Purpose of check the purpose of this check is ensure that there are no interruptions or excess re sistance due to corroded terminals for example in the circuit under inspection Tester set the tester selector to the continuity symbol and place the probe...

Page 128: ...e under inspection and the black tester probe on the vehicle ground point or on the battery negative pole CAUTION IN THE CASE OF SPORADIC FAULTS MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT ING Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical ...

Page 129: ...s and the instrument panel connector If not OK restore if OK check electrical characteristics and aerial circuit continuity from the instrument panel connector on PIN 2 and 3 if not OK restore cable harness if OK check circuit ground insulation if not ground insulated restore cable harness if insulated with key ON with instrument panel connector disconnected check that there is not voltage at the ...

Page 130: ... 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 131: ...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 Azzeramento icona manutenzione The system displays the function as follows After the maintenance interval thresh olds are exceede...

Page 132: ...istance an ambient temperature measurement must be carried out and afterwards a heat stabilisation after turning fan on by using a tester using alternatively the 3 connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurement The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted obtaine...

Page 133: ... Stage 3 0 15 0 20 0 25 0 30 Zero load voltage Disconnect the three way connector 1 For a correct detection of the alternator voltage a measurement must be carried out using alternatively the 3 engine side connector pins stage 1 pin 1 2 stage 2 pin 1 3 stage 3 pin 2 3 Take the measurements If there is a significant difference between one stage and another other than 15 V this means that the altern...

Page 134: ...D WARNING NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ONE MINUTE FAILURE TO DO SO COULD CAUSE SERI OUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS COLD SHORT CIRCUIT CURRENT RPM 2000 4000 6000 8000 RMS DC current Arms average of the 3 stage currents 22 27 22 27 22 27 22 27 Voltage on battery poles with engine speed always between 3000 5000 RPM Start the engine after about one minute of operatin...

Page 135: ...voltage 5V 3 ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL ELECTRICAL ERRORS P0615 Starter relay short circuit to positive open circuit short circuit to negative Error cause Short circuit to positive excessive voltag...

Page 136: ... 2 E 15A fuse High beam low beam horn F 15A fuse Coils injectors fuel pump secondary air injection relay Auxiliary fuses are placed in the central part of the motorcycle under the rider saddle ABS FUSE LAYOUT Specification Desc Quantity M fuse of 15A ABS solenoid valves N fuse of 30A ABS pump motor WHERE CONTEMPLATED CAUTION THREE OF THE FUSES ARE SPARES H MAIN FUSES DISTRIBUTION Specification Des...

Page 137: ...ec tors Unscrew and remove the three screws Remove the control unit NOTE WHEN REASSEMBLING THE CONNECTORS THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP THUS FACILITATING THE CONNECTOR S INSERTION THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED RSV4 1100 Factory Electrical system ELE SYS 137 ...

Page 138: ...en page example values with key ON Drawing number identified inserted by the manufacturer HW number indicates the Hardware number Hardware version Mapping indicates the mapping number Software version Type approval number ISO code Marelli SW code Serial number NIP Author of the latest progr author of the latest programming Internal code IDEEKE Internal code IDVAG1 Hardware code indicates the hardw...

Page 139: ...s the front bank lambda probe 2 voltage Rear lambda 1 correction rear bank lambda 1 correction Front lambda 2 correction front bank lambda 2 correction Rear bank lambda 1 lambda generated from bank 1 rear bank Front bank lambda 2 lambda generated from bank 2 front bank Air flow rate indicates the intake air quantity for each engine cycle Cylinders efficiency of the cylinders injection Rear cul thr...

Page 140: ...ilizer Tone wheel synch tone wheel synchronization status Side stand Fall sensor RUN STOP switch Clutch Clutch signal Start up enabl start up enabling Rear lambda 1 probe rear bank lambda 1 probe Front lambda 2 probe front bank lambda 2 probe Handle self cleaning handle self learning Thr self learn diag instrum throttle self learning with diagnostics instrument Exhaust valve Button Button Quick sh...

Page 141: ...ow inject front bank cylinder 4 lower injector Rear cul 1 upp inject rear bank cylinder 1 upper injector Front cul 2 upp inject front bank cylinder 2 upper injector Rear cul 3 upp inject rear bank cylinder 3 upper injector Front cul 4 upp inject front bank cylinder 4 upper injector Fan Front lambda 2 heater front bank lambda 2 probe heater Secondary air valve secondary air solenoid valve activatio...

Page 142: ...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 top lights relay error Electrical diagnosis short circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage has been detected on PIN 31 If short circuit to negativ...

Page 143: ...reset the engine severity C The instrument panel 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 detected a serious fault the control unit has stopped the engine The instrument panel indicates this error by lighting up in a fixed ...

Page 144: ...chnical 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 This error is indicated by lighting up in a fixed manner the general warning light Troubleshooting Call the Help Desk DIAGNOSTI...

Page 145: ... YTZ10S battery which must be activated and charged Level in electrical circuit diagram Battery charge Position on the vehicle under the saddle connector on the battery Electrical specifications 12V 48Wh 240A Pin out 1 Positive pole red approx 12 6 V 2 negative pole black ground lead DIAGNOSTIC TOOL PARAMETERS Battery voltage Example value with key ON 12 0 V Example value with engine on 14 2 V Thi...

Page 146: ...ite 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 alternator is working correctly if not OK repair If OK check that the voltage regulator is working correctly P1560 Low battery voltage error GCC error Functional diagnosis low voltage Error cause The error is enabled if after 5 seconds from the key ...

Page 147: ...hion of fork near the brake cal liper mounting bracket Position of connector if applicable Under the right dynamic air intake Pin out PIN1 Power feed negative Signal negative white PIN2 Power feed positive Signal pos itive white brown DIAGNOSTIC TOOL Parameters Speed km h Front wheel speed DIAGNOSTIC TOOL ELECTRICAL ERRORS C1033 Front wheel speed sensor Electrical diagnosis Open circuit short circ...

Page 148: ...sor signal Connect to the ABS control unit diagnosis DIAGNOSTIC TOOL LOGIC ERRORS C1024 Comparison between the front and rear wheel Electrical diagnosis Excessive difference Error cause Incorrect wheel or tone wheel dimensions Troubleshooting Check the type and dimensions of the installed tyres Check the type and dimensions of the installed tone wheels C1034 Front wheel speed sensor Functional dia...

Page 149: ...on vehicle Right hand side of swingarm on brake calliper mounting bracket Position of connector if applicable Under the right side fairing Pin out PIN1 Power feed negative Signal negative yellow PIN2 Power feed positive Signal pos itive yellow brown DIAGNOSTIC TOOL Parameters Speed km h Rear wheel speed DIAGNOSTIC TOOL ELECTRICAL ERRORS C1024 Comparison between the front and rear wheel Electrical ...

Page 150: ...he ground insulation of the two PINs If there is no insulation restore the wiring harness or replace the sensor Short circuit to positive Disconnect the sensor connector Check the battery supply insulation of the two PINS If there is no insulation restore the wiring harness or replace the sensor P2158 Rear wheel speed sensor signal Connect to the ABS control unit diagnosis DIAGNOSTIC TOOL LOGIC ER...

Page 151: ...hm at ambient temperature Pin out 1 positive signal 2 negative signal 3 shielding with earth connection DIAGNOSTIC TOOL PARAMETERS Engine rpm rpm CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Synchronised panel No_...

Page 152: ...of the electrical circuit the cleanliness of the flywheel teeth and the correct positioning of the sensor in its seat if not ok restore if ok replace the sensor NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT DOWN Twistgrip position sensor Function The handle command is used to convert the driver s power demand to an electrical signal to be sent to the electronic control unit Operati...

Page 153: ...e voltage goes to zero replace the handle sensor open circuit short circuit to negative check the handle sensor connector and engine control unit connector if not ok restore if ok check cable continuity between the two terminals if not ok restore if ok check the ground insulation of the cable from the handle sensor con nector or control unit connector if not ground insulated restore the wiring har...

Page 154: ...ntinuity of the malfunctioning cable if the continuity is present replace the control unit if not present replace the wiring harness DIAGNOSTIC TOOL LOGIC ERRORS P1227 Tracks A B handle position sensor Functional diagnosis Signal not congruent Error cause Detected two voltages signals at PIN 39 and 13 of the ENGINE connector tracks A B This error is indicated by flashing the general warning light ...

Page 155: ...er box sensor for front cylinders 2 and 4 on the left of the filter box connector on the sensor Electrical specifications Pin out 1 Power supply 5V 2 Ground connection 3 Output signal DIAGNOSIS INSTRUMENT PARAMETERS Front Cylinder Intake Pressure 2 and 4 Example value with key ON 1003 mbar Example value with engine on 720 mbar NOTE pressure read by the front sensor Rear Cylinder Intake Pressure 1 ...

Page 156: ...the cable between the control unit connector and the sensor connector restore the wiring harness if the value changes re place the sensor If open circuit short circuit to negative check the Marelli control unit connector and the sensor connector if not ok restore if everything is OK with key OFF check the continuity between Marelli control unit connector PIN 24 and sensor connector PIN 3 if there ...

Page 157: ...ity between ENGINE connector PIN 25 and PIN 1 on the sensor connector if not OK restore the wiring harness if OK replace the control unit if a voltage of 5 V is present at PIN 1 check with key in ON position for continuity between PIN 3 on the sensor connector and ground if not OK restore the wiring harness if OK replace the sensor DIAGNOSTIC TOOL LOGIC ERRORS Rear bank air pressure sensor P0106 s...

Page 158: ...the pressure sensor and the socket to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Error for unexpected air intake in the front cylinder manifold P1601 signal not plausible Error cause Small difference detected between the estimated pressure and the measured pressure the measured pressure is higher than the estimated...

Page 159: ... in the intake and pressure reading sys tem Rear bank manifold pressure too low error P1604 signal not plausible Error cause Small difference detected between the estimated pressure and the measured pressure the measured pressure is below the estimated one for example smeared throttle body Troubleshooting Check the pneumatic system between the pressure sensor and the socket to read pressure on the...

Page 160: ...sistance at 60 575 Ω 15 Ω Resistance at 90 230 Ω 5 Ω Pin out 1 Greek Black Ground 2 Black 3 Yellow Brown 0 5 V signal 4 Black DIAGNOSTIC TOOL PARAMETERS Engine temperature Example value with key ON 25 C Example value with engine on 75 C This is one of the values set by the ECU in the event of recovery mode if there is a mal function after the engine start up the temperature is raised up to approxi...

Page 161: ...if ok reconnect the control unit connector and with key ON check the continuity between PIN 1 of the sensor connector and vehicle ground if OK it means that the error is caused by the cable being shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 12 and sensor PIN 3 if there is no continuity to ground check the sensor connector and the Marelli control unit conn...

Page 162: ...unit the temperature of the intake air used to calculate the oxygen to opti mise the required fuel quantity for the correct com bustion Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in the electrical circuit diagram Temperature sensors Position sensor on the rear side of the filter housing connector on the sensor Electrical specifications...

Page 163: ...ity replace the sensor if not OK if OK check continuity between the ENGINE connector PIN 37 and the sensor PIN 1 If continuity is absent restore the wiring harness if ok reconnect the control unit connector and with key ON check the continuity between PIN 2 of the sensor connector and vehicle ground if OK it means that the error is caused by the cable being shorted to positive and it is necessary ...

Page 164: ...side Level in electrical circuit diagram Lambda probe Position on manifold left side of the vehicle connector left side of the vehicle fixed to the support bracket of the fairing lug 4 way connector black Electrical specifications Heater circuit 7 9Ω at ambient temp Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white cable 4 Heater power supply white cable...

Page 165: ...TUSES Lambda probe Start up_Lean_Rich_Fault due to rich titre_Fault due to lean air fuel mixture If the probe connector is disconnected voltage almost equal to zero it switches to the state of Fault due to lean air fuel mixture Lambda check Open loop Closed loop Rich in closed loop Lean in closed loop enriched Closed loop indicates that the control unit is using the lambda probe signal to keep the...

Page 166: ...f NOT OK replace the sensor if OK restore the wiring harness Black Violet cable If open circuit short circuit to negative check the continuity from the probe connector PIN 3 and 4 to the probe if NOT OK replace the probe if ok perform the check procedure for the sensor connector and for the Marelli control unit connector if NOT OK restore if OK with the key ON and the sensor connector disconnected...

Page 167: ...ing from the HIGH RATIO to LOW RATIO is missing for a certain adjusted number of dead points PMS or TDC If no switching from low is shown when the ratio control is in closed loop and when the secondary air valve is not operating The error is validated if during the ratio control stage the switching from HIGH RATIO to LOW RATIO is missing for a certain adjusted number of upper dead points PMS or TD...

Page 168: ... electrical circuit diagram Lambda probe Position on manifold on the rear part of the ve hicle in correspondence with the shock absorber connector on the right of the pinion cover 4 ways black connector Electrical specifications Heater circuit 7 9Ω at ambient temp Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white cable 4 Heater power supply white cable D...

Page 169: ...USES Lambda probe Start up_Lean_Rich_Fault due to rich titre_Fault due to lean air fuel mixture If the probe connector is disconnected voltage almost equal to zero it switches to the state of Fault due to lean air fuel mixture Lambda check Open loop Closed loop Rich in closed loop Lean in closed loop enriched Closed loop indicates that the control unit is using the lambda probe signal to keep the ...

Page 170: ...OK restore the wiring harness Green cable If open circuit short circuit to negative check the continuity from the probe connector PIN 3 and 4 to the probe if NOT OK replace the probe if ok perform the check procedure for the sensor connector and for the Marelli control unit connector if NOT OK restore if OK with the key ON and the sensor connector disconnected check if there is battery voltage at ...

Page 171: ...nnector PIN 1 and PIN 2 towards the probe replace the lambda probe if there is no continuity if there is continuity check the sensor connector and the Marelli control unit connector if NOT OK restore if OK check the continuity between the ENGINE connector PIN 10 and PIN 22 and restore the wiring harness DIAGNOSTIC TOOL LOGIC ERRORS P0134 Rear bank lambda probe Functional diagnosis no switching fro...

Page 172: ...type of probes this error may be caused also by a short circuit to the wiring harness ground NOTE THIS ERROR DISABLES THE RATIO CONTROL IN CLOSED LOOP Injector Lower injectors key 1 Lower Injector 1 2 Lower Injector 3 3 Lower Injector 2 4 Lower Injector 4 LOWER INJECTOR Function Provide the correct amount of fuel at the correct time The lower injectors work in the field of low engine revs the uppe...

Page 173: ...the electrical circuit diagram placed under saddle right side CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiri...

Page 174: ...correctly no errors are generated if the relay fails to activate DIAGNOSTIC TOOL ELECTRICAL ERRORS Rear bank lower injector cylinder 1P0201 short circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage has been detected on ENGINE PIN 8 If short circuit to negative no voltage has been detected If open circuit an interruption has been detect...

Page 175: ...PIN and restore the cable harness Rear bank lower injector cylinder 3 P0203 short circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage has been detected on ENGINE PIN 34 If short circuit to negative no voltage has been detected If open circuit an interruption has been detected Troubleshooting Short circuit to positive disconnect the inj...

Page 176: ...ltage replace the sensor If short circuit to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the white blue cable if the connection is present restore the cable harness If there is no connection replace the injector If open circuit check the component correct electrical characteristic if it is not the correct one replace the component if it...

Page 177: ... the identification of the relay with the colour of the cables is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiring for the relay to activate correctly no errors are generated if the relay...

Page 178: ... P0205 short circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage has been detected on VEHICLE PIN 53 If short circuit to negative no voltage has been detected If open circuit an interruption has been detected Troubleshooting Short circuit to positive disconnect the injector connector set key to ON activate the com ponent with the diagn...

Page 179: ...hort circuit to positive short circuit to negative open circuit Error cause Short circuit to positive excessive voltage has been detected on VEHICLE PIN 74 If short circuit to negative no voltage has been detected If open circuit an interruption has been detected Troubleshooting Short circuit to positive disconnect the injector connector set key to ON activate the com ponent with the diagnostic to...

Page 180: ...nent correct electrical characteristic if it is not the correct one replace the component if it is correct check the connector on the component and the Marelli control unit connector if not OK restore If OK check cable continuity between VE HICLE PIN 68 and component PIN and restore the cable harness Fuel pump Function Fuel pump keeps pressure of the injectors supply duct Low fuel tells to the ins...

Page 181: ...GNOSIS INSTRUMENT ELECTRICAL ERRORS fuel pump relay control P0230 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 73 of the VEHICLE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 73 of the VEHICLE connector Troubleshooting If shorted to positive check whether the...

Page 182: ...nnector with red strip on the engine wiring harness coil 4 with short cable to the right of the front part of the filter housing Electrical specifications 0 7 0 9 Ω at ambient temperature Pin out 1 Power supply Vbatt 2 Secondary circuit ground 3 Activation from the control unit DIAGNOSTIC TOOL PARAMETERS Example value with key ON Actual start up ad vance Example value with engine on Indicates the ...

Page 183: ... to the battery positive CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the Brown Green cable of the coil is closed to ground for 2 ms per each second Dis connect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiring for the relay to activate correctly no ...

Page 184: ...e equal to zero was detected at PIN 27 of the ENGINE connector Troubleshooting Short circuit to positive disconnect the coil connector turn the key to ON activate the coil with the diagnostic tool and check the voltage at PIN 27 of the connector if there is voltage restore the wiring harness if the voltage is 0 replace the coil If open circuit short circuit to negative check the electrical charact...

Page 185: ...or Troubleshooting Short circuit to positive disconnect the coil connector turn the key to ON activate the coil with the diagnostic tool and check the voltage at PIN 1 of the connector if there is voltage restore the wiring harness if the voltage is 0 replace the coil If open circuit short circuit to negative check the electrical characteristics of the coil if not ok replace the coil if ok perform...

Page 186: ...bank 1 3 and of the front bank 2 4 working on the throttle position an acceptable value should be between 0 5 and 0 5 Front throttle Potentiometer 1 degrees Example value with key ON 7 8 Example value with engine on 1 4 With key set to ON the throttle is kept in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal...

Page 187: ...t in position by the springs around 5 7 After the engine starts up at idle the throttle is kept close to the mechanical minimum above or equal to 0 5 When the gear is not engaged at approx 6000 rpm throttles open very little because the requested torque is too low around 5 7 Rear throttle Potentiometer 2 degrees Example value with key ON 8 2 Example value with engine on 1 6 With key set to ON the ...

Page 188: ...NCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Front throttle automatic self learning Ice Interrupted Performed Limp home Throttle valve stopper closed Spring check Limp home acquisition Initialization Indicates if the self learning performed by the control unit was performed not performed this is funda men...

Page 189: ...rminals if not ok restore the wiring harness if ok check the ground insulation of the circuit from the throttle valve sensor connector or control unit connector if ground insulated check that the power supply 5 V is present at PIN 2 of the throttle body con nector and that ground is present at PIN 6 if present correctly replace the throttle body Rear bank throttle valve position potentiometer sens...

Page 190: ...r supply 5 V is present at PIN 2 of the throttle body con nector and that ground is present at PIN 6 if present correctly replace the throttle body Front throttle valve position potentiometer sensor CF2 P2125 short circuit to positive open circuit short circuit to negative Error cause Short circuit to positive excessive voltage has been detected on PIN 21 If open circuit short circuit to negative ...

Page 191: ...ted check that the resistance from the throttle control unit connector between PIN 29 and 41 is within 1 and 2 5 Ohm if not ok replace the throttle body if ok check that the throttle body is not mechanically blocked if blocked remove the cause or replace the body if not blocked replace the control unit Front throttle valve control circuit P1119 short circuit to positive short circuit to negative o...

Page 192: ...le resistance be tween the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm Otherwise restore the wiring harness if ok replace the complete throttle body Rear throttle valve potentiometer CF2 P2121 Signal not plausible Error cause Signal outside the specified value determined based on the values of the intake pressure Troubleshooting Check the parameter of the Pot...

Page 193: ...le body Front throttle valve potentiometer CF2 P2126 Signal not plausible Error cause Signal outside the specified value determined based on the values of the intake pressure Troubleshooting Check the parameter of the Potentiometer 2 rear throttle voltage to get which signal the control unit receives and to compare it to the Potentiometer 2 front throttle voltage Check the throttle body connector ...

Page 194: ...each key ON Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the throttle body Rear throttle valve minimum mechanical position self learning P1402 Test failed Error cause Position of the throttle valve stopper outside of the specified range at each key ON Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the thr...

Page 195: ...e at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check the cleanliness of the throttle body and the intake duct If ok replace the throttle body Front throttle valve mechanical re closing springs self learning P1411 Test failed Error cause Throttle valve return time in the position maintained by the springs outside of the spec...

Page 196: ...ly perform the self learning test at each key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Remove the presence of errors that prevent throttle self learning Front throttle valve position error EPOS P0639 error Misalignment between control and activation Error cause The throttle valve mechanical control could be damaged Troubleshooting ...

Page 197: ...GNOSTIC TOOL ADJUSTABLE PARAMETERS Throttle self learning NOTE AT EVERY KEY ON THE CONTROL UNIT PERFORMS A TEST ON THE THROTTLE VALVES TO CHECK THEIR MOBILITY ASSESSING THE NECESSARY FORCE TO MOVE THEM AN THE POTENTIAL PRESENCE OF OBSTACLES AT EVERY 150 KEY ON THE SYSTEM PERFORMS A STOPPER LEARNING FOR EACH THROTTLE BODY IF START UP IS ATTEMPTED DURING THIS PROCEDURE THAT REQUIRES APPROXIMATELY 3 ...

Page 198: ...LECTRICAL SYSTEM CHAPTER Dashboard Oil sensor FAULT error B0001 Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open The test is performed only once when the key is set to ON There is an error when the general warning light turns on Troubleshooting Check the sensor connector and the instrument panel connector PIN 13 if they are not OK res...

Page 199: ...able Position on the vehicle under the chain pinion behind the pinion cover connector behind the filter housing 4 way transparent connector Electrical specifications VEHICLE connector PIN 64 neutral indication closed circuit continuity gear engaged open circuit infinite resistance Gear circuit voltage 1st gear 1 6 V 2nd gear 0 83 V 3rd gear 4 6 V 4th gear 3 9 V 5th gear 3 1 V 6th gear 2 4 V Pin ou...

Page 200: ...and check if the cable is energised if energised restore the wiring harness if not energised replace the sensor there is an interruption or a short circuit to positive of the Pink cable on the segment that goes from the sensor connector to the sensor or inside the sensor If short circuit to negative disconnect the sensor connector and with key ON check the voltage of the Grey Black cable if it is ...

Page 201: ...control unit connector paying attention to PIN 56 if not ok restore the wiring harness if ok disconnect the two ends from the sensor and with key ON check if there is continuity to ground at PIN 2 if there is no continuity restore cable harness if there is replace the sensor Indication on the diagnostic tool always Engaged disconnect the two ends from the sensor and check if with the clutch releas...

Page 202: ...s active only with the lever released the problem is generated by the released clutch contact of the which is interrupted or by the engaged clutch contact which is in short circuit to ground If the error is active only with the lever engaged the problem is generated by the engaged clutch contact of the which is interrupted or by the released clutch contact which is in short circuit to ground If th...

Page 203: ...nosis up down Troubleshooting Indication on the diagnostic tool always down perform the connector check procedure if not ok restore if ok disconnect the two ends from the sensor and check the PIN 1 continuity to ground if there is no continuity restore cable harness if there is replace the sensor Indication on the diagnostic tool always up disconnect the two ends from the sensor and check if with ...

Page 204: ...elay on off DIAGNOSTIC TOOL ACTIVATIONS Fan Energy is applied for 10 seconds to the fan relay 36 in the electrical circuit di agram position in the steering head stock recess to the right however CHECK the identification of the relay with the colour of the cables Electrical continuity is required in the wiring for the relay to activate correctly no errors are generated if the relay fails to acti v...

Page 205: ... the cable harness If not OK replace the relay if OK restore the cable harness Brown cable If open circuit check the relay electrical characteristics are correct by disconnecting it from the cable harness if it is not OK replace the relay if it is OK check relay connector engine vehicle cable harness connector and VEHICLE connector of the Marelli control unit if not OK restore if OK check continui...

Page 206: ...ent panel indicates this error by lighting up in a fixed manner the MI warning light Troubleshooting Short circuit to positive disconnect the component set the key to ON start the vehicle and check if the error symptom is still shorted to positive it means that short circuit is between black white cable and a cable in voltage therefore restore cable harness if the error symp tom is short circuit t...

Page 207: ... Brown colour 3 Ground Green Pink colour 4 5V signal Engine stop Pink Yellow colour CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES RUN STOP switch Run Stop NOTES Indication on the diagnostic tool always STOP disconn...

Page 208: ...he control unit connector is in short circuit to positive restore the wiring harness Butterfly valve in exhaust Function Used to reduce the noise at the exhaust The ex haust valve is controlled as follows With engine off completely closed 0 With engine on depending on the gear engaged the exhaust valve has differ ent opening values according to the engine speed and load Above 6 000 rpm the valve i...

Page 209: ... 100 valve open CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Exhaust valve Not determined searching activation at key ON in operation stopped due to detected faults zero searching NOTES If there is no problem the ...

Page 210: ...tside the established range Check the correct voltage of the two cables of the valve If excessive duration check if the valve cables are energised if they are not energised energise them if ok check if the mechanical rotation of the exhaust valve occur without friction or delays if not ok restore the normal valve rotation if ok check the electrical char acteristics of the motor if not ok replace t...

Page 211: ...e the instrument panel if there is no ground with key ON check if there is ground continuity at the connector PIN 2 if there is ground disconnect the instrument panel connector as well and if there is still ground restore the Black Red cable and if there is not replace the instrument panel if there is no ground check if PIN 3 or PIN 2 on the motor have ground continuity if they do replace the moto...

Page 212: ...meter does not correspond to the one set by the control unit This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light Troubleshooting Perform a mechanical check of the valve check its normal rotation with the cables discon nected from the motor manually operate the cables and notice the movement regularity checking the complete stroke ...

Page 213: ...cal the valve could stay stuck in the closed position In the event of a CAN line malfunction the valve returns to the open position In the event of a check removal or replacement of one or more system cables valve motor a cali bration procedure is required CAUTION BEFORE CARRYING OUT THIS OPERATION CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12 5 V CAUTION WORK ON THE MOTOR OF THE EXHAUST THROTT...

Page 214: ... battery voltage is NOT below 12V Check that the cylinders are in their seat and are NOT obstructed If the cylinders are obstructed put them in their seats straight Check that the valve spring on the si lencer is in its seat Electrical system RSV4 1100 Factory ELE SYS 214 ...

Page 215: ...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 215 ...

Page 216: ...he opening cable adjuster screw up to the value corresponding to the value Y see values in the table CAUTION TURN THE ADJUSTER SCREW FULLY ANTI CLOCKWISE DIRECTION FOR TENSIONING 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 REPEA...

Page 217: ...t for as sisted gear shift Operation Operating principle Two normally open switches that are closed to ground by operating the gearshift lever either in UP or DOWN gear Electrical circuit diagram Level in electrical circuit diagram Electronic gearbox Position on vehicle On the gearbox lever gear Connector position Under the fuel tank on the left side close to the rear big end Electrical specificat...

Page 218: ...osition if NOT OK replace the sensor Check if between PIN 2 and PIN 3 there is a 500 Ohm resistance by bringing the lever in DOWN position if NOT OK replace the sensor Check if between PIN 2 and PIN 3 there is a 1000 Ohm resistance with the lever released if NOT OK replace the sensor With disconnected sensor voltage check Check if between PIN 3 and PIN 2 there is a 3 3 V voltage by bringing the le...

Page 219: ... P1906 error a PRC setting buttons Function To signal to the control unit the request for modi fication of the a PRC system settings Operation Operating principle Either control or is made up of a deviator with both outputs electrically connected to the in strument panel at the same time the instrument panel sends the requested command to the Marelli ECU via CAN line Electrical circuit diagram Lev...

Page 220: ... either of the two PINs a voltage over approx 1 V and at the same time a voltage below 1 V at the other PIN if this does not occur the instrument panel outputs the information to the control unit that shows this error Indication on diagnostic tool Invalid data due to short circuit error CASE 1 if this status is displayed with control not activated only it means that a voltage below 1V instead of b...

Page 221: ...k continuity on the red cable if it is not OK restore if it is OK check with control activated that there is not continuity of the button from the button connector between brown cable and red cable and then replace the control NOTES The control unit can not detect faults due to failed cable continuity P0570 command plausibility Electrical diagnosis Open contacts Closed contacts Error cause With op...

Page 222: ...re if it is OK check continuity of the button from the button connector between black cable and green cable if it is not OK change the control if it is OK check with key to ON that the black cable is not grounded and then change the in strument panel CASE 2 if this status is displayed only with control activated it means that circuit from PIN 19 to PIN 34 of the instrument panel is interrupted che...

Page 223: ...lacement of the control unit is recommended With signal not valid the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error NOTE The instrument panel does not indicate the presence of this error even in the ATT status NOTE THIS ERROR DISABLES THE TRACTION CONTROL P1903 Yaw sensor plausibility Functional diagnosis Faulty sensor ...

Page 224: ...ional diagnosis Timeout error Error cause If this error is displayed it means that the wheel stand control software detected an abnormal behaviour of the motorcycle Troubleshooting With faulty sensor the component inside the control unit is damaged and replacement of the control unit is recommended With signal not valid the sensor has generated a signal out of range that is still sent to the injec...

Page 225: ...ne pinout key PIN 1 Cylinder 4 coil control output PIN 2 Cylinder 3 coil control output PIN 3 Output for front throttle valve engine command PIN 4 Sensor ground 2 RSV4 1100 Factory Electrical system ELE SYS 225 ...

Page 226: ...essure sensor input PIN 25 5 V reference voltage output A C tracks rear throttle valves and pressure sensor map PIN 26 5 V reference voltage output B D tracks front throttle valves PIN 27 Cylinder 2 coil command output PIN 28 Cylinder 1 coil command output PIN 29 Output for rear throttle valve engine command PIN 30 PIN 31 Recovery logic stop light relay command output PIN 32 Lambda 1 heater comman...

Page 227: ...48 Rear throttle valve potentiometer 1 signal input PIN 49 Front cylinders intake pressure sensor input PIN 50 Rear throttle valve potentiometer 2 signal input PIN 51 5 V reference voltage output A C tracks rear throttle valves and pressure sensor map PIN 52 Control unit direct power supply Vehicle pinout key PIN 53 Cylinder 1 upper injector command output RSV4 1100 Factory Electrical system ELE S...

Page 228: ...utput PIN 68 Cylinder 4 upper injector command output PIN 69 Start up relay command output PIN 70 Side stand input PIN 71 PIN 72 Gear sensor input PIN 73 Injection relay command output PIN 74 Cylinder 3 upper injector command output PIN 75 PIN 76 Clutch sensor input PIN 77 PIN 78 Engine stop input PIN 79 PIN 80 H CAN line high speed Engine vehicle connector pinout key PIN A1 Battery PIN A2 PIN A3 ...

Page 229: ...ic fan relay control PIN B6 PIN B7 PIN B8 Power ground 1 PIN C1 Injection power supply PIN C2 K serial line for diagnosis PIN C3 Clutch engaged PIN C4 Start engine button PIN C5 Start up PIN C6 Injection relay PIN C7 Engine stop PIN C8 Power ground 2 RSV4 1100 Factory Electrical system ELE SYS 229 ...

Page 230: ...lay PIN 8 5 V reference voltage output PIN 9 Battery positive PIN 10 Valve command at the exhaust B terminal PIN 11 Power signal PIN 12 Rear stop switch PIN 13 Oil pressure PIN 14 High beam lights IN PIN 15 Normally closed TC switch PIN 16 Key positive PIN 17 Battery positive PIN 18 PIN 19 Normally open TC switch Electrical system RSV4 1100 Factory ELE SYS 230 ...

Page 231: ...t arrow PIN 28 RH rear arrow PIN 29 LH front arrow PIN 30 LH rear arrow PIN 31 Fuel reserve PIN 32 L CAN line high speed PIN 33 H CAN line high speed PIN 34 Sensor ground ABS Modulator ABS control unit pinout key PIN 1 Valve ground and ECU PIN 2 H CAN line high speed PIN 3 Front speed sensor input RSV4 1100 Factory Electrical system ELE SYS 231 ...

Page 232: ...s With this communication line it was possible to avoid useless duplications of various sensors on the motorcycle since the signals coming from them are divided among the three electronic processing units instrument panel control unit and ABS mod ulator and the LG light switch Cable number reduction The CAN line travels through a twisted cable to several nodes These nodes can also isolate the erro...

Page 233: ...ry nod can request information from the other nodes RTR Remote Transmit Request Level in electrical circuit diagram CAN Line Electrical specifications between PIN 66 and 80 of the control unit approx 120 Ohm between PIN 32 and 33 of the instrument panel approx 120 Ohm Pin out Line L White Black cable between PIN 66 and the Marelli control unit PIN 32 of the instru ment panel PIN 3 of the LH lights...

Page 234: ... THE CRUISE CONTROL U0002 CAN Line Mute Node Electrical diagnosis Mute Node Error cause The injection ECU cannot send CAN signals it receives signals from the instrument panel the control unit may need replacing This error is indicated by lighting up in a fixed manner the general warning light Troubleshooting Replace the Marelli control unit NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATI...

Page 235: ...received from the LH light switch This error is indicated by lighting up in a fixed manner the general warning light Troubleshooting Check the connector of LH light switch if not ok restore if ok check the continuity of the two lines from the LH light switch connector to the VEHICLE connector of the Marelli control unit if not ok restore the wiring harness if ok replace the light switch NOTE THIS ...

Page 236: ...re if ok check that there is no continuity between the two cables of the CAN line L and H if not ok restore if ok check that there is no continuity between vehicle ground and the battery positive If not ok restore if ok replace the ABS control unit NOTE THE PRESENCE OF THIS ERROR DETERMINE THE DEACTIVATION OF THE TRACTION CON TROL AND THE CRUISE CONTROL U0125 CAN line sensor box diagnosis Function...

Page 237: ...ROR DISABLES THE TRACTION CONTROL U1121 Diagnosis of ABS control unit CAN line or CLF frame counter Functional diagnosis Signal absent Error cause If there is no signal no signal is received from the ABS control unit This error is indicated by lighting up in a fixed manner the MI warning light Troubleshooting Missing signal Perform the check procedure for pin 2 and 11 of the ABS control unit con n...

Page 238: ...ke switches that are physically connected to the instrument panel if OK check the stability of the connections if NOT ok check the proper state of maintenance of the rear brake connector if NOT OK restore if OK maintaining the switch fitted on the vehicle check with a tester that there is no continuity between PIN 1 and PIN 3 of the switch with the lever engaged released if NOT OK replace the rear...

Page 239: ...ion lid Move the instrument panel to the right so as to remove it from its seat Once released move the instrument panel without disconnecting the con nectors from it so as to be able to easy access the USB port connector Disconnect the USB wiring connector 3 from the connector of the wiring harness on the vehicle 4 RSV4 1100 Factory Electrical system ELE SYS 239 ...

Page 240: ...ng glass from the seats of the motorcycle Unscrew and remove the two screws 2 Remove the instrumentation lid Move the instrument panel to the right so as to remove it from its seat Once released move the instrument panel without disconnecting the con nectors from it so as to be able to easy access the wiring harness connector on the vehicle Electrical system RSV4 1100 Factory ELE SYS 240 ...

Page 241: ...rough the headlamp and the instru mentation support and recover the connector 7 so as it is inside the in strumentation support compartment Connect the vehicle wiring harness connector 7 to the USB wiring har ness connector 8 and place it care fully inside the instrumentation support compartment Fix the USB supporting clamp 3 to the headlamp with the screw 9 provided with the washer 10 Locking tor...

Page 242: ...ATING 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 Inside the BlueTooth page if Blue Tooth is not active to activate it press the button shown BlueTooth active Green button Electrical system RSV4 1100 Factory ELE SYS 242 ...

Page 243: ...hone 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 on the icon NOTE THE ICON CAN VARY FROM ONE TO ANOTHER ANDROID VERSION In the page sett...

Page 244: ...s automatically to the instrument panel key ON Once the connection is established you can start the application by selecting the corresponding icon By turning off the instrument panel key OFF the application automatically closes CAUTION TO MAINTAIN A SUCCESSFUL CONNECTION IT IS ESSENTIAL THAT THE KEY SWITCH IS IN THE ON POSITION BEFORE THE APP IS LAUNCHED CAUTION AFTER THE KEY IS OFF IT WILL BE NE...

Page 245: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 246: ...Pin for fastening the gear change lev er to the footrest support M8 1 25 Nm 18 44 lb ft Apply water repellent grease between the O rings and the Quick Shift uniball NOTE ONCE ASSEMBLE THE DISTANCE BETWEEN THE UNIBALL AND THE JOINT MUST BE AP PROXIMATELY 180mm 7 09in Vehicle preparation To remove the engine from the chassis previously perform the following operations Remove the fuel tank and the ba...

Page 247: ...isconnect the water pipe with the connector from the engine in order to empty the system Move the clamp 5 and disconnect the water pipe from the radiator fluid tank Disconnect the connectors 6 of the electric fans RSV4 1100 Factory Engine from vehicle ENG VE 247 ...

Page 248: ...e the clamp 8 fixing the oil pressure bulb wiring and exhaust valve to the water pipe Remove the fixing screws 9 of the ra diators support bracket Operating from both sides of the motorcycle remove the screws 10 fixing the radiator to the support bracket Engine from vehicle RSV4 1100 Factory ENG VE 248 ...

Page 249: ...from the right side of the motorcycle Loosen the screw 11 and ease off the gear lever Remove the three fixing screws 12 of the pinion cover 13 Remove the fixing screw 14 of the ca ble grommet 15 RSV4 1100 Factory Engine from vehicle ENG VE 249 ...

Page 250: ...ng screw 18 of the chain guide plate 19 Cut the two clamps 20 that connect the wiring of the quick shift to the wiring of the side stand and of the lambda probe Disconnect the connector 21 of the quick shift and release the wiring Engine from vehicle RSV4 1100 Factory ENG VE 250 ...

Page 251: ...complete with leverage Disconnect the connector 23 of the side stand sensor and release the wir ing Undo the two fixing screws and remove side stand 24 Disconnect the connectors of the lamb da probes 25 RSV4 1100 Factory Engine from vehicle ENG VE 251 ...

Page 252: ...or cycle loosen the locknuts 27 and act on the register screws 28 to loose the chain tension Loose the clamp 32 that blocks the silencer at the central manifold Detach and remove the springs 29 fixing the front exhaust manifolds Engine from vehicle RSV4 1100 Factory ENG VE 252 ...

Page 253: ...manifolds to the front heads Remove the two front manifolds 31 Loose the clamp 32 that blocks the silencer at the central manifold Remove the three fixing screws of the carbon heat protection RSV4 1100 Factory Engine from vehicle ENG VE 253 ...

Page 254: ...x haust valve Remove the screw 33 and the locking nut of the silencer to the foot board Remove the exhaust terminal from the central manifold and support it to dis connect the exhaust valve control ca bles Engine from vehicle RSV4 1100 Factory ENG VE 254 ...

Page 255: ...inal com pletely Remove the clamp 34 securing the exhaust valve wiring harness Disconnect the connector 35 of the exhaust valve Disconnect the connector 35 of the exhaust valve RSV4 1100 Factory Engine from vehicle ENG VE 255 ...

Page 256: ...he exhaust valve Detach and remove the springs 37 fixing the rear exhaust manifolds Remove the central exhaust manifold 38 Remove the four fixing screws 39 of the rear exhaust manifolds Engine from vehicle RSV4 1100 Factory ENG VE 256 ...

Page 257: ...e the cable com plete with sheath 43 off from the guide in the housing Remove the rubber cap 44 Unscrew and remove the nut 45 and collect the washer Remove the power supply cable from the starter motor Remove the engine oil pressure sen sor 46 RSV4 1100 Factory Engine from vehicle ENG VE 257 ...

Page 258: ...se the ground cables Detach the ground cable and unscrew and remove the nut 48 Disconnect the engine wiring connec tor 49 Remove the clamp 50 that locks the main wiring at the ABS system pipes Engine from vehicle RSV4 1100 Factory ENG VE 258 ...

Page 259: ...m Install the engine support and place a winch under it Specific tooling 020864Y Engine mounting plate Operating from the right side of the mo torcycle remove the upper screw 53 fixing the engine to the chassis Completely unscrew the internal upper bush 54 RSV4 1100 Factory Engine from vehicle ENG VE 259 ...

Page 260: ...n relative to the centreline of the insert is e 5 mm e 0 197 in therefore the engine is fixed at minimum height possible CAUTION THE LEFT AND RIGHT FRONT INSERTS ARE EQUAL AND MUST NOT BE PLACED IN THE IN VERTED POSITION Adjustment of engine height relative to the chassis is assured by properly inserts placed on the chassis front position and on the engine matching the fixing points of the engine ...

Page 261: ...in the low position There are 4 inserts subdivided as follows Inner outer Right Left The two right side swingarm pin inserts are differ ent The two left side swingarm pin inserts are the same CAUTION THE FOUR INSERTS MUST BE FITTED WITH THE ARROW FACING DOWNWARDS OTHERWISE THE VEHICLE WILL BE DAMAGED CAUTION THE RIGHT REAR INSERTS 5mm 0 19 in AND THE LOWER LEFT REAR INSERT 5mm 0 19 in ARE EQUAL RS...

Page 262: ... DURING CENTRING PHASE OF THE ENGINE ON THE CHASSIS OP ERATE WITH CAUTION SO AS NOT TO DAMAGE THE SCREWS AND THE CHASSIS INTERNAL AND EXTERNAL SPACERS Working on the left side place and screw without tighten the two front fixing screws 1 the engine attachment upper fixing screw 6 the lower rear fixing pin 3 so as to centre the engine position Working on the right side place and screw without tight...

Page 263: ... after placing the corresponding washer Slide the lower rear fixing pin 3 Working on the right side slide the upper rear fixing screw 5 Place and tighten internally the two set pack bushings 7 to the prescribed torque Place again on the left side the lower rear fixing pin 3 Tighten the rear pin fastening nut 8 Place again the upper rear fixing screw 5 and tighten the lock nut 9 on the internal sid...

Page 264: ...Place the radiator frame the washer and tighten the screw fastening the frame to the engine Place the gear lever and tighten the screw Position the quick shift cable harness and fasten using ties Engine from vehicle RSV4 1100 Factory ENG VE 264 ...

Page 265: ...ator connector Connect the voltage regulator connec tor Position and fix the hand grip position sensor to the chassis WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS RSV4 1100 Factory Engine from vehicle ENG VE 265 ...

Page 266: ...the two fuel breather pipes Install the side stand Place the pinion and insert the trans mission chain in the seat Tighten the rear wheel fixing nut Adjust the drive chain adjuster screws Engine from vehicle RSV4 1100 Factory ENG VE 266 ...

Page 267: ...ew Place the pinion cover and tighten the three screws Connect the vehicle cable harness engine cable harness connector Working on the right side of the vehicle connect the exhaust valve control unit connector RSV4 1100 Factory Engine from vehicle ENG VE 267 ...

Page 268: ...lace the cable grommet and the three cable leads as shown Tighten the cable grommet fixing screw Connect the starter motor place the washer and tighten the nut Place the rubber cap Tighten the engine oil pressure sensor Engine from vehicle RSV4 1100 Factory ENG VE 268 ...

Page 269: ...ing sensor Connect the clutch cable Check and adjust the clutch lever clearance with the adjuster screw The clutch lever clearance should be between 1 3 mm 0 039 0 12 in RSV4 1100 Factory Engine from vehicle ENG VE 269 ...

Page 270: ...INDEX OF TOPICS ENGINE ENG ...

Page 271: ... 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 RSV4 1100 Factory Engine ENG 271 ...

Page 272: ...rews M8x25 6 25 Nm 18 44 lb ft 4 Special screw with index lever fas tening collar M6 1 10 Nm 7 38 lb ft Loct 243 5 Pinion fastening 1 50 Nm 36 88 lb ft Loct 243 6 Pre selector retaining screw on crankcase 1 25 Nm 18 44 lb ft Pre impregnated screw in absence of 3M 2353 7 Flanged hex head gear indicator fastening screws M5x15 2 6 Nm 4 43 lb ft Removing the gearbox Remove the gearbox selector Remove ...

Page 273: ...ve the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Unscrew and remove the six screws RSV4 1100 Factory Engine ENG 273 ...

Page 274: ... of the gear can have a superficial cover in WC C This coating consists of a layer composed of tungsten carbide lamellae alternating with amorphous carbon lamellae The coating WC C has an elevated hardness and a good resistance to wear The main reason for using this coating is its extremely low friction coefficient making this an ideal treatment for preventing adhesion phenomena such as seizing an...

Page 275: ...he secondary shaft does not move Remove the gearbox unit Slide off the gearbox primary shaft con trol rod 1 Remove the 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 RSV4 1100 Factory Engine ENG 275 ...

Page 276: ...rbox shafts from the cover Remove 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 Engine RSV4 1100 Factory ENG 276 ...

Page 277: ...l the desmodromic 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 the selection gear grooves 5 3 mm 0 21 in Minimum wear limit of the pinion side primary shaft seat 24 97 mm 0 98 in Minimum wear limit of the clutch side p...

Page 278: ... 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 selection fork axial clearance 0 05 mm 0 ...

Page 279: ...t is not regular replace the transmission forks 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 RSV4 1100 Factory Engine ENG 279 ...

Page 280: ... 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 Engine RSV4 1100 Factory ENG 280 ...

Page 281: ...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 RSV4 1100 Factory Engine ENG 281 ...

Page 282: ...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 Engine RSV4 ...

Page 283: ...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 284: ...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 Engine RSV4 110...

Page 285: ... the intermediate gear Start up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL Check the dual starter gear toothing 1 and the freewheel gear 2 to see if the material is dam aged or deformed RSV4 1100 Factory Engine ENG 285 ...

Page 286: ... 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 Engine RSV4 1100 Factory E...

Page 287: ...ft Tighten to torque unscrew and re tighten to torque 3 Blow by coupling SHC fastening screws M5x16 3 5 Nm 3 69 lb ft 4 Spacers for soundproof cover 3 6 Nm 4 43 lb ft 5 Soundproof cover fastening screws M6 3 6 Nm 4 43 lb ft 6 TE flanged screw fixing the cable tie plate M5x12 1 6 Nm 4 43 lb ft Pre impregnated screw and in ab sence Loct 2045 Stator SHC fixing screw M6x30 1 10 Nm 7 38 lb ft Pre impre...

Page 288: ...ator and retrieve the two centring dowels Magneto flywheel removal Remove the flywheel cover Block flywheel rotation using the spe cific tool 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 spec...

Page 289: ...ing Replace the O ring with a new one of the same type Remove the flywheel cover Remove the Seeger ring Remove the shim washer Remove the oil seal CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE SET THE NEW OIL SEAL WITH THE MARKING ON THE EDGE FACING OUTWARD RSV4 1100 Factory Engine ENG 289 ...

Page 290: ... 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 Tighten the five screws 1 and the three special screws 2 Tighten the screws working in stages and diagonally Insert the Blow by system pipe and fasten it with a new clamp Position the soundproofing cover and lock it in place using the three appropr...

Page 291: ...M6x35 2 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 4 TE Flanged screw M6x22 14 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 5 Engine timing inspection cap 1 20 Nm 14 75 lb ft 6 Spacers for soundproof cover 5 6 Nm 4 43 lb ft 7 Oil level dipstick 1 3 Nm 2 21 lb ft 8 Oil load cap 1 5 Nm 3 69 lb ft RSV4 1100 Factory Engine ENG 291 ...

Page 292: ...SHC fixing screw M6x25 6 10 Nm 7 38 lb ft Removing the clutch cover Drain the engine oil Unscrew and remove the five special screws 1 to remove the soundproof cover 2 Unscrew and remove the five special screws 3 and the eleven fastening screws 4 around the perimeter and retrieve the relative washers Engine RSV4 1100 Factory ENG 292 ...

Page 293: ...nd remove the tone wheel fixing screw Remove the tone wheel Remove the clutch cover Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate and the com plete control rod Remove the discs RSV4 1100 Factory Engine ENG 293 ...

Page 294: ...tion using the spe cific tools Unscrew and remove the clutch bell fixing nut Specific tooling 020849Y Clutch lock Remove the slipper unit Remove the clutch hub Remove the clutch hub cam tower Engine RSV4 1100 Factory ENG 294 ...

Page 295: ... Retrieve the shim Collect the clutch housing Remove the clutch gear that controls the oil water pumps Remove the needle cage RSV4 1100 Factory Engine ENG 295 ...

Page 296: ...c Maximum clutch plate deformation in compar ison to a flat surface 0 15 mm 0 0059 in Minimum wear limit of the clutch plate sliding teeth 13 5 mm 0 53 in Minimum wear limit of the complete clutch pack thickness friction discs steel discs 47 6 mm 1 87 in Engine RSV4 1100 Factory ENG 296 ...

Page 297: ...together Make sure there is not excessive noise during op eration if necessary replace the primary drive gear and the clutch bell all together Checking the pusher plate Check the thrust plate and the bearing for damage and wear If necessary replace the parts Characteristic Maximum deformation permitted on the thrust plate compression surface 0 15 mm 0 0059 in Maximum depth of the thrust plate 27 3...

Page 298: ...all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Characteristic Minimum wear limit in the release position of the individual clutch springs 46 8 mm 1 84 in Assembling the clutch Insert the thrust bearing with the collar facing the gearbox Insert the spacer Engine RSV4 1100 Factory ENG 298 ...

Page 299: ...e clutch gear making it mesh with the oil water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL Insert the clutch bell making it engage with the engine pinion Fit the shim washer RSV4 1100 Factory Engine ENG 299 ...

Page 300: ...he clutch hub HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES Fit the three slipper unit clips offsetting them between each other Install the slipper unit correctly Insert the washer Engine RSV4 1100 Factory ENG 300 ...

Page 301: ...g fixing nut Specific tooling 020849Y Clutch lock Insert the disc with friction material and the black tooth into the bell Insert one of the metal discs into the bell Insert the flat washer Insert the spring washer with the con cave side facing out RSV4 1100 Factory Engine ENG 301 ...

Page 302: ...terial into the housing Insert the nitrided metal disc into the clutch housing Continue inserting alternating a metal disc with one with friction material end ing with a friction material disc with a black tooth Engine RSV4 1100 Factory ENG 302 ...

Page 303: ...lace the control rod together with the thrust bearing and the shim washer Place the thrust plate Fit the clutch springs 3 Insert the spring holder cap 2 onto the screws 1 RSV4 1100 Factory Engine ENG 303 ...

Page 304: ...en sufficiently Warm up the cover Using a generic extractor it is then possible to remove the bushing from the cover INSTALLING THE CLUTCH CONTROL PIN BUSHING Before carrying out the installation of the bushing it is necessary to warm up the cover Position the guide 1 to insert the bushing 2 as indicated in the figure Insert the bushing so that the process ing notch 3 is aligned with the notch on ...

Page 305: ...er 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 perimeter taking care to also insert the relative washers Tighten the screws working in stages and diagonally Position the soundproofing cover 7 with the appropriate fastening screws 8 and tighten them to the req...

Page 306: ... Pos Description 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 Engine RSV4 1100 Factory ENG 306 ...

Page 307: ...langed 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 TIMING SYSTEM Pos Description Type Quantity Torque Notes 1 Screw fastening 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 Lo...

Page 308: ... Smear the gasket with suitable seal ant in 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 Engine RSV4 1100 Factory ENG 308 ...

Page 309: ...engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT DO NOT USE IT FOR TIGHTENING COMPONENTS Specific tooling 020852Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole on U bolt If it w...

Page 310: ...on to TDC turn the crankshaft 150 in the direction of engine rotation direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ensures that all the front cylinder bank valve springs are decom pressed Refit the camshaft timing setting pin in the hole in the U bolt on the front head and refit the crankshaft timing pin from the flywheel side to c...

Page 311: ...fic camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 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 and remove the seven screws 4 proceeding in stages and diagonally Retrieve the washers from the screws near ...

Page 312: ...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 stiffness while moving If necessary replace the timing chain t...

Page 313: ...TAKE CAMSHAFT Fit the U bolts with nine O rings and lo cator pins Position the screws 4 taking care to insert new washers on the screws near the spark plug holes Loosen the distribution gear s lock screw and move the gear itself from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Position the U bolt 2 and the oil pipe 3 Insert the two screws 1 Tighten all the...

Page 314: ...f the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel stop Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible...

Page 315: ...repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Front head removal Remove both head covers the alter nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft Remove the O ring Turn the crankshaft from the hole on the clutch cover Move cylinder piston 1 left rear piston to the overlap TDC Turn the crankshaft 15...

Page 316: ... following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the engine rotation direction direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ensures that all the front cylinder bank valve springs are decom pressed Block crankshaft rotation using one of the specific tools Unscrew and remove the second i...

Page 317: ... 2 near the spark plug holes Remove the U bolts with the O rings and locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust cam shafts from the front head Unscrew and remove the chain sliders screws Remove the chain sliders Unscrew and remove the two head fix ing screws a b from the flywheel side RSV4 1100 Factory Engine ENG 317 ...

Page 318: ...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 Front head check Check that Engine RSV4 1100 Factory ENG 318 ...

Page 319: ...em by blowing a jet of compressed air Front head fitting Install a new O ring on the chain ten sioner REPLACE THE O RING UPON EACH REMOVAL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly THE WASHER SHALL ONLY BE INSTALLED ON THE FRONT CHAIN TENSIONER RSV4 110...

Page 320: ...onto the front chain tensioner then install the chain tensioner in the relative seat in the crankcase Take particular care to ensure that the washer seats correctly as the functionality of the timing system may be compromised if the washer is bent or incorrectly positioned Place a new gasket between the crank case and the head Place the two dowel pins Install the head Engine RSV4 1100 Factory ENG ...

Page 321: ...ft gear Keep the gear in position with the chain tightened THE SIDE WITH THE BEVELLED HOLE IN THE TIMING SYSTEM GEAR MUST ALWAYS FACE THE EXTERIOR OF THE HEAD Install both chain sliders and fasten them with the specific screws Rotate the crankshaft via the opening on the clutch cover Position cylinder 1 piston LH rear piston so that it is at the point where it crosses TDC RSV4 1100 Factory Engine ...

Page 322: ...ES WITH CLEARANCE RECOVERY Install the intake and exhaust cam shafts on the front head bearing in mind that the exhaust camshaft gear tooth indicated with a dot is meshed with the trough of the intake cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT Check the number engraved on the U bolts which must correspond with the one engra...

Page 323: ...t so that the timing hole and the gear fixing screw hole are centred with the gear slot Insert the specific timing pin Specific tooling 020851Y Camshaft timing pin Apply Loctite 243 thread lock on the thread of the timing gear fastener screw This screw must be replaced at each reassembly Apply and loosely tighten the gear fix ing screw on the camshaft Protect the edge of the head with rubber Load ...

Page 324: ...rankshaft 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 ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned insert ...

Page 325: ...Y Crankshaft timing pin Fit the pin for aligning the intake cam shaft with the hole on U bolt If it was not possible before adjusting the valve clearance check the engine timing Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole o...

Page 326: ...efit the crankshaft timing pin from the clutch side to check that the timing setting was not altered while the en gine was turned with only one cam shaft drive gear fastener screw in place Remove the camshaft timing pin Unscrew and remove the two screws 1 from the U bolt 2 Remove the U bolt 2 and the oil pipe 3 Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Block cranks...

Page 327: ...move the seven screws 4 proceeding in stages and diagonally Retrieve the washers from the screws near the spark plug holes Remove the U bolts with the O rings and locator pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the intake camshaft gear tooth indicated with one dot is meshed with the trough of the exhaust camshaft gear indicated with two dots Inspectin...

Page 328: ... 3 0 1 mm 0 012 0 004 in Check the timing chain for damage or stiffness while moving If necessary replace the timing chain together with the camshaft gears Check 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 Install the intake and exhaust cam shafts on the ...

Page 329: ...w and move the gear itself from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Position the U bolt 2 and the oil pipe 3 Insert the two screws 1 Tighten all the U bolts screws working in stages and diagonally Fit the U bolt and the oil pipe Tighten the two U bolt screws 1 and the screw 2 that was not fitted previ ously RSV4 1100 Factory Engine ENG 329 ...

Page 330: ...r fastener screw This screw must be replaced at each reassembly Apply and loosely tighten the gear fix ing screw on the camshaft Block crankshaft rotation using one of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel stop Engine RSV4 1100 Factory ENG 330 ...

Page 331: ...4Y Flywheel stop Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned Refit the reference pin while checking using the crankshaft reference pin that 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 ...

Page 332: ...ations move cylinder piston 1 left rear piston to TDC turn the crankshaft by 450 one com plete turn 90 in the direction of en gine rotation direction of travel to align the hole on the intake camshaft with the specific hole on the U bolt This ensures that all the rear cylinder bank valve springs are decompressed Block crankshaft rotation using one of the specific tools Unscrew and remove the secon...

Page 333: ...Remove the U bolts with the O rings and locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust camshafts from the rear head Remove the clutch the tone wheel and the primary drive gear Unscrew and remove the chain sliders screws Remove the chain sliders Unscrew and remove the two head fas tener screws a b from the clutch side RSV4 1100 Factory Engine ENG...

Page 334: ...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 334 ...

Page 335: ... is free and if required clean them by blowing a jet of compressed air Rear head fitting Install a new O ring on the chain ten sioner REPLACE THE O RING UPON EACH REMOVAL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly RSV4 1100 Factory Engine ENG 335 ...

Page 336: ...ce the two dowel pins Install the head Pretighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order Tighten the two screws according to the sequence a b Engine RSV4 1100 Factory ENG 336 ...

Page 337: ...st cam shafts on the rear head remembering that the intake camshaft gear tooth indicated with a dot is inserted in the groove of the exhaust cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT 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 inv...

Page 338: ...t so that the timing hole and the gear fixing screw hole are centred with the gear slot Insert the specific timing pin Specific tooling 020851Y Camshaft timing pin Apply Loctite 243 thread lock on the thread of the timing gear fastener screw This screw must be replaced at each reassembly Apply and loosely tighten the gear fix ing screw on the camshaft Protect the edge of the head with rubber Load ...

Page 339: ...ne 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 ing screw to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020914Y Flywheel stop Turn the cra...

Page 340: ...er to position them correctly upon refitting Extract the bucket tappets Extract the adjusting shims Compress the valve springs with the specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Engine RSV4 1100 Factory ENG 340 ...

Page 341: ...ng 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 Remove the valves Valve check CAUTION RSV4 1100 Factory Engine ENG 341 ...

Page 342: ... 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 Exhaust valve stem diameter 4 975 4 955 mm 0 1959 0 1951 in Support the valve with two V blocks as shown and check the run out with a dial gauge If the run out exceeds the specified limit replace the valve Characteristic Valve stem r...

Page 343: ...ke springs are marked in orange 1 ex ternal and blue 2 internal whereas the exhaust springs 3 are marked in white Lubricate the valve stem and insert the valves on the valve guide Position the springs with the closest turns facing the head of the valve CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING RSV4 1100 Factory Engine ENG 343 ...

Page 344: ...the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjusting shims Engine RSV4 1100 Factory ENG 344 ...

Page 345: ...18 44 lb ft Lubricate the head and under the head 5 TE Flanged screw M8x50 3 25 Nm 18 44 lb ft Lubricate the head and under the head 6 Gearbox control rod support SHC fix ing screws M6x35 2 10 Nm 7 38 lb ft Lubricate the head and under the head 7 Flanged TE screw fixing fuel rail gearbox lubrication M6x12 2 10 Nm 7 38 lb ft Pre impregnated screw and in ab sence Loct 2045 8 TB TORX fixing screw of ...

Page 346: ...icate the head and under the head Use the sequence 1 Pre tighten to 15 Nm 11 06 lb ft 2 Tighten to 20 Nm 14 75 lb ft 3 Tighten applying an angle of 60 2 4 Repeat the opera tion for another 60 2 Screw fastening ground cable to the engine M6 2 6 Nm 4 43 lb 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 lb ft Loct 243 2 Starter m...

Page 347: ...43 3 Tone wheel fastener screw M8x24 1 50 Nm 36 88 lb ft Pre impregnated in absence Loct 270 or Loct 648 4 Generator fixing screw M12x1 25 1 120 Nm 88 51 lb ft Balancing countershaft removal To extract the balancing countershaft first remove the clutch cover and the alternator cover Turn the crankshaft so as to position the thicker side of countershaft gear on the side opposite to crankcase bulk h...

Page 348: ... tooling 020850Y Primary gear lock See also Removing the clutch cover Removing the flywheel cover Unscrew and remove the nut and col lect the washer Remove the countershaft from the al ternator side Remove the countershaft gear Engine RSV4 1100 Factory ENG 348 ...

Page 349: ...on countershaft Remove the spacer Remove the countershaft on the oppo site side Balancing countershaft fitting Install the spacer THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE RSV4 1100 Factory Engine ENG 349 ...

Page 350: ...H TWO BURINS ON THE COUNTERSHAFT GEAR Insert the countershaft from the alter nator side Turn the countershaft until aligning the key seat on the countershaft and on the gear Insert the drive key Place the washer Turn the nut on the countershaft Block crankshaft rotation using the specific tool Tighten the nut on the countershaft Specific tooling 020849Y Clutch lock Engine RSV4 1100 Factory ENG 350...

Page 351: ...lock crankshaft rotation using the specific tool Specific tooling 020850Y Primary gear lock Unscrew and remove the tone wheel fixing screw Remove the tone wheel Unscrew and remove the primary shaft fixing nut Remove the crankshaft blocking tool Specific tooling 020850Y Primary gear lock Remove the primary shaft gear RSV4 1100 Factory Engine ENG 351 ...

Page 352: ...FIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR Install the crankshaft blocking tool Tighten the primary shaft fixing nut Specific tooling 020850Y Primary gear lock Insert the tone wheel on the crank shaft The crankshaft and the tone wheel have a bevel that identifies the fitting direction Tighten the tone wheel fixing screw Remove the special tool Specific tooling 020850Y Primary gear lock Preparat...

Page 353: ...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 Crankcase opening Position the engine with the heads fac ing upward unscrew and remove the screw 24 RSV4 1100 Factory Engine ENG 353 ...

Page 354: ...move 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 Separate the crankcases removing the lower part Collect the three dowel pins The crankshaft the pistons and the connecting rods remain in the upper crankcase Engine RSV4 1100 Factory ENG 354 ...

Page 355: ...20857Y Crankshaft support U bolt See also Front head removal Rear head removal 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 355 ...

Page 356: ...ecific 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 Take out the crankshaft Engine RSV4 1100 Factory ENG 356 ...

Page 357: ... screw Remove the lock Heat up the crankcase to 150 C 302 F Position the general tool to pull out bearings Remove the bearing See also Crankcase opening CLUTCH 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 RSV4 1100 Factory Engine ENG 357 ...

Page 358: ...nnecting rod check Characteristic Maximum wear limit of the connecting rod small end 17 03 mm 0 6705 in Maximum connecting rod small end radial clearance 0 045 mm 0 0018 in Maximum radial play between connecting rod and crankpin 0 55 mm 0 022 in Maximum radial play of crankpin 0 08 mm 0 0031 in Inspecting pistons PISTON CYLINDER COUPLING Selection A B Selection Cylinder 80 998 81 006 mm 81 006 81 ...

Page 359: ...6 in Selecting connecting rods SELECTING CRANKSHAFTS AND CONNECTING RODS ACCORDING TO BALANCING CLASS crankshafts and connecting rods have been intro duced which are matched with each other in rela tion to their balancing class The class is easily identifiable as it is marked on the component itself The permitted crankshaft connecting rod balancing class combinations are listed in the following ta...

Page 360: ...in selection WARNING THE CONNECTING RODS OF A HEAVIER CLASS ARE MOUNTED IN POSITION 2 3 The connecting rod class is stamped on its left side viewed from the front from the side with the bevelling on the big end hole Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available A B C which differentiate in the diameter of the hole in the bearings The category is mar...

Page 361: ... the image The thee main journals may be of different classes CRANKSHAFT CATEGORIES Specification Desc Quantity Class C Main journals diameter 46 028 46 023 mm 1 8121 1 8119 in Class D Main journals 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 ...

Page 362: ...Class E main journal Bushing black Bushing black Bushing green The flywheel side and clutch side main bearings are different from the central ones and therefore so are the respective replacement part numbers CRANKSHAFT BUSHINGS CONNECTING RODS Three types of semi bushing are available for the connecting rods Engine RSV4 1100 Factory ENG 362 ...

Page 363: ...1 Required clearances class 2 X 35 885 35 880 mm Blue Yellow 1 Yellow Yellow 0 053 0 026 mm 0 053 0 027 mm Y 35 880 35 874 mm Yellow Yellow Yellow Green 1 0 054 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 PROC...

Page 364: ...0376Y Sleeve for adaptors Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase In this way it will be possible to 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 Engine RSV4 1100 Factory ...

Page 365: ...he new bearings with their groove on the outside diameter facing outward with respect to the crankcase In this way it will be possible to 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 RSV4 1100 Factory Engine ENG 365 ...

Page 366: ...rs Join the crankcases If the special tool was used remove it to keep the pistons from coming out Specific tooling 020858Y Maintenance of the pistons in the cyl inders Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side Make the references on the gears of the primary shaft and the countershaft coincide NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE I...

Page 367: ...ne wheel have a bevel that identifies the fitting direction Tighten the tone wheel fixing screw Remove the special tool Specific tooling 020850Y Primary gear lock Installing connecting rods pistons The piston rings are different and must be fitted with the KDN5 markings for the upper one A and K TOP and KDN5 markings for the lower one B facing upward RSV4 1100 Factory Engine ENG 367 ...

Page 368: ...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 369: ...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 370: ... of sealing paste along the external edge of the crankcase Join the two crankcases Recommended products Three bond Sealing paste Pretighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order Engine RSV4 1100 Factory ENG 370 ...

Page 371: ...ews in the following order 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 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 371 ...

Page 372: ...Thermal group CYLINDERS PISTON pos Description Type Quantity Torque Notes 1 Screws fastening water union onto crankcase M6x40 2 10 Nm 7 38 lb ft Lubrication Engine RSV4 1100 Factory ENG 372 ...

Page 373: ...d bolts M10 18 20 Nm 14 75 lb ft Loct 270 2 TE Flanged screw M8x70 4 25 Nm 18 44 lb ft Lubricate the head and under the head 3 TE Flanged screw M6x50 8 10 Nm 7 38 lb ft Lubricate the head and under the head 4 TE Flanged screw M8x35 1 25 Nm 18 44 lb ft Lubricate the head and under the head 5 TE Flanged screw M8x50 3 25 Nm 18 44 lb ft Lubricate the head and under the head 6 Gearbox control rod suppo...

Page 374: ...S The engine is equipped with lubrication jets to increase the efficiency of the oil cooling circuit in two specific points 1 At the basis of each cylinder by means of jets for the lubrication of the connecting rods pistons 2 Inside the gearbox by means of a nozzle to lubricate the gears CAUTION FOR THE CORRECT FUNCTIONING OF THE LUBRICATION JETS IT IS IMPORTANT TO CHECK THAT THE OIL PASSAGE HOLES...

Page 375: ...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 375 ...

Page 376: ...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 376 ...

Page 377: ...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 377 ...

Page 378: ...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 378 ...

Page 379: ...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 379 ...

Page 380: ...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 380 ...

Page 381: ...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 381 ...

Page 382: ...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 382 ...

Page 383: ...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 383 ...

Page 384: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 385: ...ction 5 Lower injectors on the front throttle body 6 Lower injectors on the rear throttle body 7 Upper injector on the front of the filter casing 8 Upper injector on the rear of the filter casing 9 Fuel tank 10 Fuel pump 11 Canister RSV4 1100 Factory Power supply P SUPP 385 ...

Page 386: ...ar throttle body 15 Engine Fuel pump Removing Remove and empty the fuel tank Remove the pipe grommet Disconnect the fuel pipe from the fuel pump Unscrew and remove the six fixing screws of the fuel pump Power supply RSV4 1100 Factory P SUPP 386 ...

Page 387: ... Remove the fuel pump Injection RSV4 1100 Factory Power supply P SUPP 387 ...

Page 388: ...Diagram key 1 Control unit position 2 Throttle grip position sensor 3 Fall sensor 4 Exhaust valve Power supply RSV4 1100 Factory P SUPP 388 ...

Page 389: ...gines 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 parameters...

Page 390: ...r output and 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 To remove the complete injectors unit disconnect and remove the engine control unit complete with support Undo the four screws fixing the injec tors unit to the filter ...

Page 391: ...e snap fit clamp on the col lars from the engine NOTE DO NOT RELEASE THE CLAMPS COMPLETELY LEAVE IN AN INTERMEDIATE POSITION TO FACILITATE REFIT TING Disconnect the lower injector connec tors See also Air box Disconnect the connector Remove the complete throttle body RSV4 1100 Factory Power supply P SUPP 391 ...

Page 392: ...possible before replacing the com ponent is checking the connectors and cable har nesses Installing the throttle body When installing the throttle body refer to the electrical system section for the correct cable routing Ensure that the injector connectors are correctly fastened Connect the control unit connector en suring that the security lock is in the locked position Stepper motor The control ...

Page 393: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 394: ...ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lb ft 4 RH light switch M5 2 1 5 Nm 1 11 lb ft 5 LH light switch outer shell M4 2 1 5 Nm 1 11 lb ft 6 LH light switch int clamp M3 2 0 5 Nm 0 37 lb ft 7 Traction control command fastening screw M4 1 2 5 Nm 1 84 lb ft 8 Screw for fastening the Ride By Wire control to the semi handlebar M4 1 2 2 Nm 1 62 lb ft Suspensions RSV4 1100 Fa...

Page 395: ...CLUTCH LEVER Pos Description Type Quantity Torque Notes 1 Clutch lever collar fastening screws M6 1 10 Nm 7 38 lb ft Front fork RSV4 1100 Factory Suspensions SUSP 395 ...

Page 396: ... com pression damping The right stem is also equipped with an upper adjuster screw 1 for adjusting hydraulic rebound damping IN ORDER TO AVOID DAMAGES DO NOT FORCE THE SET SCREWS TO TURN BEYOND THE END OF THE STROKE ON BOTH SIDES SET THE SAME SPRING PRE LOAD AND HYDRAULIC DAMPING SETTING FOR BOTH STAN CHIONS RIDING THE VEHICLE WITH DIFFERENT SET TINGS FOR THE TWO STANCHIONS REDUCES STABILI TY WHEN...

Page 397: ... TRACK USE ONLY Specification Desc Quantity Rebound damping adjustment screw 1 Unscrew 12 clicks from fully closed Compression damping adjustment screw 2 Unscrew 12 clicks from fully closed Spring pre loading nut 3 screw 8 turns from fully open Stems A protrusion from top plate excluding cover 3 notches 12 mm 3 notches 0 47 in clockwise anticlockwise Removing the fork legs Remove the front wheel S...

Page 398: ...to damage them Set the pre loading spring to the mini mum position Unscrew the upper cap from the sleeve using the special Ohlins tool Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring Unscrew the upper adjustment cap Remove the complete cap Suspensions RSV4 1100 Factory SUSP 398 ...

Page 399: ...ng Drain the oil from the forks into a suit able receptacle taking care not to ex tract the pre loading pipe and the hydraulic rebound damping adjust ment rod DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE RSV4 1100 Factory Suspensions SUSP 399 ...

Page 400: ...g 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 Remove the retaining ring 4 Suspensions RSV4 1100 Factory SUSP 400 ...

Page 401: ...ed or scored Any scoring can be removed by sanding with damp sandpaper grain 1 If the scratches are deep replace the stem Using a dial gauge check than any bending of the stem is below the limit value If it is over the limit replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK ENED MAKING THE VEHICLE DANGEROUS TO USE Characteristic Bending limit 0 2 m...

Page 402: ... 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 Insert the retaining ring 4 into its housing on the sleeve 2 Suspensions RSV4 1100 Factory SUSP 402 ...

Page 403: ...E FREELY WITHIN THE SLEEVE WITHOUT OBSTRUCTIONS Filling oil Clamp the forks in a vice using the special tool Fill the forks with oil until the air bubbles trapped inside are forced out Oil level 220 mm 8 66 in from the 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 STANCHION...

Page 404: ...pring com pressed tighten the nut as far as it will go Screw the complete cap into place on the plunger pin Tighten the cap using a wrench to lock the lower spring retaining ring nut Screw the upper regulator cap into place until comes into contact with the lower nut on the cap and then tighten by applying the pre defined torque Suspensions RSV4 1100 Factory SUSP 404 ...

Page 405: ...BE CARRIED OUT ON TRACKS AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES CARRY OUT THE ADJUSTMENT ONLY WHEN THE VEHI CLE IS AT STANDSTILL AFTER CHANGING THE ADJUST MENTS ALWAYS ENSURE THAT THE STEERING IS FREE IN BOTH ROTATION DIRECTIONS STEERING DAMPER STANDARD ADJUSTMENT FOR ROAD USE Specification Desc Quantity Damping adjustment screw 8 clicks from fully ope...

Page 406: ... damper Steering bearing STEERING pos Description Type Quantity Torque Notes 1 Screws fastening upper yoke to stan chions M8 2 25 Nm 18 44 lb ft 2 Screws fastening lower yoke to stan chions M8 4 25 Nm 18 44 lb ft 3 Headstock ring nut pre tightening M35x1 1 70 Nm 51 63 lb ft Unscrew after pre tightening 3 Headstock ring nut tightening M35x1 1 60 9 Nm 44 25 6 64 lb ft 4 Headstock counter lock ring M...

Page 407: ...e ground Carry out a handlebar rotation test using a dynamometer at the hand grip external end The handlebar resistance to rotation must be of 450 250 100 g 0 88 0 55 0 22 lb in both 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 Unscrew ...

Page 408: ...andlebar screws Remove the upper yoke Rivet the safety washer on the head stock Undo the counter lock ring remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly Suspensions RSV4 1100 Factory SUSP 408 ...

Page 409: ... lb ft Steer completely left and completely right and check that the steering ro tates smoothly and without excessive 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 Tool for steering tightening Fit the safety washer and bend the two opposing tabs into the notches on the...

Page 410: ...ightening the counter lock ring hold the lock ring still with an appropri ate hook spanner Lock the counter lock ring by bending the tabs of the retainer washer into the notches in the counter lock ring itself Reconnect the steering damper Fit the upper fork plate Disassembling Remove the steering assembly com pletely Unscrew and remove the lower dowel fastening the collar Remove the lower collar ...

Page 411: ...ssembling Fit the upper collar Partially tighten the dowel in the rela tive threaded hole so that it protrudes by no more than 2 or 3 mm into the 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 ...

Page 412: ...tion Type Quantity Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lb ft 2 Dual connecting rod fixing screw M10 3 50 Nm 36 88 lb ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lb ft Suspensions RSV4 1100 Factory SUSP 412 ...

Page 413: ...OMMENDED FOR USE ON THE ROAD TO CHANGE THE HEIGHT YOU MUST CONTACT AN Au thorised Aprilia Dealer CAUTION CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PAR TICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE REAR SHOCK ABSORBER STANDARD SETTING IS AD JUSTED TO MEET SPORTING RIDING IN ANY CASE IT IS POSSIBLE TO INSERT PERSONAL SETTINGS DEPENDING O...

Page 414: ... 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 STANDARD ADJUSTMENT FOR ROAD USE Specification Desc Quantity Shock absorber centre to centre distance A 311 mm 12 24 in preloaded Spring B length 148 mm 5 83 in Rebound adjustment knob 1 open 12 clicks from fully closed Compression adjustment ...

Page 415: ...hand rider footpeg Unscrew and remove the lower screw and retrieve the nut Unscrew and remove the screw fixing the dual linkage rod to the single link age Retrieve the nut Unscrew and remove the upper screw and retrieve the nut Remove the shock absorber from the right side RSV4 1100 Factory Suspensions SUSP 415 ...

Page 416: ...rom the opposite side Loosen and remove the nut 5 Slide off the screw 6 from the opposite side Remove the complete suspension connecting rod assembly unit 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 Suspensions RSV4 1100 Factory SUSP 416 ...

Page 417: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 418: ...t 8 RH upper rear coupling M10 1 50 Nm 36 88 lb ft 9 Right fairing spacer M6 1 10 Nm 7 37 lb ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lb ft 11 Upper rear mount M10 1 50 Nm 36 88 lb ft 12 Saddle mounting fixing screws M10 4 50 Nm 36 88 lb ft 13 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lb ft 14 Taillight mounting bracket fixin...

Page 419: ...0 Nm 59 00 lb ft 2 Front brake disk 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 419 ...

Page 420: ...on the pin Support 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 are not confor...

Page 421: ...WAYS 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 usually cause...

Page 422: ... for fastening crown to sprocket M10 5 50 Nm 36 88 lb ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lb ft Loct 243 Rimozione Place the vehicle on the specific rear support stand Loosen and remove the nut on the wheel pin Recover the shoulder ring and the left chain tensioner pad Chassis RSV4 1100 Factory CHAS 422 ...

Page 423: ...ing the disc from the brake calliper REAR SPROCKET SUPPORT REMOVAL Remove the final drive assembly NOTE THE FLEXIBLE COUPLING REMAIN INSTALLED ON THE WHEEL REMOVAL Place the final drive assembly in a vice TO PROTECT THE CROWN GEAR INSTALL PROTEC TIONS ON 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 RS...

Page 424: ...ar attention to the locking screws of the flexible coupling holder which must be perfectly seated If anomalies are noted it is necessary to proceed with the REPLACEMENT of the complete rim WARNING DO NOT REMOVE THE LOCKING 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 ...

Page 425: ...CAUTION IN THIS WAY THE PRESSURE EXERTED BY THE FIXING ELEMENTS WILL BE EVENLY DISTRIBUTED ON THE COUPLING SURFACE Checking CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR REAR WHEEL BEARINGS Check the bearings installed on the wheel CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noi...

Page 426: ...PE REAR WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity 1 Replace the wheel axle if the eccentricity exceeds the limit value 1 Characteristic Maximum eccentricity 0 25 mm 0 0098 in REAR WHEEL RIM Using a dial gauge check that the ra dial A and the axial eccentricity B of the rim 2 do not exceed the limit val ue An excessive eccentricity is usually caused by worn or damaged bearing...

Page 427: ...ial clearance a minimum axial clearance is allowed Radial clearance none If one or both bearings do not fall within the control parameters Replace both bearings of the final drive unit FLEXIBLE COUPLING Check that the flexible couplings 5 are not dam aged or excessively worn To check Fit the entire final drive unit 6 to the wheel Manually rotate the sprocket 7 to right and left and check the clear...

Page 428: ...al 10 Remove the circlip 11 CAUTION THE CIRCLIP 11 IS ONLY INSTALLED ON THE RIGHT HAND SIDE OF THE WHEEL There are notches A for engaging with the teeth of the extractor tool at the ends of the spacer 12 Use the extractor tool to remove the right hand bearing 13 Specific tooling AP8140180 Bearing extractor Retrieve the inner spacer 12 On the left hand side of the wheel Use the extractor tool to re...

Page 429: ... 17 IS FITTED ONLY ON THE FINAL DRIVE UNIT LEFT SIDE Remove the left bearing 18 with the specific extractor Collect the inside spacer 19 Remove the right bearing 20 with the specific extractor Retrieve the right hand spacer 21 Clean the inside of the hub thoroughly CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION Specific tooling AP8140180 Bearing extractor RSV4 1100 Factory Chassis CHAS ...

Page 430: ...escription Type Quantity Torque Notes 1 Swingarm regulator bushing M30x1 5 1 12 Nm 8 85 lb ft 2 Swingarm ferrule M30x1 5 1 60 Nm 44 25 lb ft 3 Fork pin nut M20x1 5 1 65 Nm 47 94 lb ft AGIP GREASE SM2 Chassis RSV4 1100 Factory CHAS 430 ...

Page 431: ... M6 2 7 Nm 5 16 lb ft Lower chain shoe fastening screws M6 2 10 Nm 7 38 lb ft Removing Remove the exhaust system Remove the rear mudguard Remove the rear shock absorber Remove the rear wheel Secure the rear part of the vehicle with a belt and a hoist Unscrew and remove the two pipe grommet screws Remove the rear brake calliper off the swingarm Unscrew and remove the three screws and remove the pin...

Page 432: ... 2 anticlock wise which turns and loosens the ad justment bushing 3 completely REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION SUPPORT THE SWINGARM FROM THE FRONT TO AVOID ACCIDENTAL FALLS PLACE A WOODEN SUPPORT UNDER THE FRONT PART OF THE REAR SWINGARM TO PREVENT IT FROM LOW ERING AND TO KEEP IT UPRIGHT Chassis RSV4 1100 Factory CHAS 432 ...

Page 433: ...justment bushing from the swingarm pin 2 UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN If necessary use a specific tool to re move a pin from the drive chain Open and remove the chain Checking Remove the swingarm Clean the two sides of the bearing seats with a cloth Slide off the bushing 1 Remove the sealing gasket 2 Remove the sealing gasket 3 Remove the circlip 4 Us...

Page 434: ...ED AS FOLLOWS IN PARTICULAR SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both swingarm bearings RADIAL AND AXIAL CLEARANCE CHECK Check the radial and axial clearance Axial clearance ...

Page 435: ...l inserts installed in the respective seats in the chassis The hole is offset by 5 mm 0 197 in relative to the centreline of the insert as a result the swingarm is in the low position There are four inserts subdivided as follows Inner outer Right left THE TWO LEFT SIDE SWINGARM PIN INSERTS ARE THE SAME THE TWO RIGHT SIDE SWINGARM PIN INSERTS ARE DIF FERENT Refit the swingarm height adjustment inse...

Page 436: ...old in position Support the swingarm from the front move it into position so that the holes are aligned and simultaneously insert the pin 2 fully Ensure that the hexagonal area on the pin head 2 is inserted correctly in the hexagonal seat inside the adjustment bushing 3 Fit and hand tighten the counter lock ring nut by a few turns 1 Put some grease on the swingarm pin nut as indicated Fit and the ...

Page 437: ...g the swingarm in until fully seated Tighten the locking ring nut 1 Screw the nut Refit the chain on the drive pinion CAUTION APPLY LOCTITE ANTI SEIZE ON THE INTERNAL TOOTH ING OF THE TRANSMISSION PINION Fit the pinion and the chain on the shaft CAUTION APPLY LOCTITE 243 ON THE SCREW THREAD RSV4 1100 Factory Chassis CHAS 437 ...

Page 438: ...d the exhaust system Fit the pinion casing Adjust the chain tension 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 MOUNTING LINES DURING MANUFACTURING Chassis RSV4 1100 Factory CHAS 43...

Page 439: ...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 439 ...

Page 440: ...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 441: ...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 441 ...

Page 442: ... THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE CLEARANCE CHECK 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 30 mm 1 18 in Move the vehicle forward in order to check the vertical oscillation o...

Page 443: ...E 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 dry rusty flattened or jammed chain links excessive wear missing sealing rings excessively worn or damaged pinion or sprocket teeth IF THE CHAIN ROLLERS ARE DAMAGED THE PINS ARE LOOSE AND OR TH...

Page 444: ...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 Check that the pad 1 is not worn or damaged Replace it with a new one if it is Check the chain guide 2 for wear Unscrew and remove the two screws from the left rider foot...

Page 445: ...s for fastening the stand to the frame M10 2 45 Nm 33 19 lb ft Loct 243 2 Linear switch retaining screws and nuts M5 2 4 Nm 2 95 lb ft 3 Spring retaining pin on stand 1 10 Nm 7 38 lb ft Loct 243 4 Stand fastening pin 1 15 Nm 11 06 lb ft Loct 243 5 Pin for retaining springs on stand pin 1 22 Nm 16 23 lb ft Loct 243 Rear stand bushing retaining screw M6 2 7 Nm 5 16 lb ft RSV4 1100 Factory Chassis CH...

Page 446: ...Side stand Remove the fuel tank Remove the pinion cover Remove the clamps Disconnect the stand connector Unscrew and remove the two screws Remove the side stand Chassis RSV4 1100 Factory CHAS 446 ...

Page 447: ...rest support M8 1 25 Nm 18 44 lb ft 4 Torx button head silencer aesthetic protection fastening screw M6x10 3 8 Nm 5 90 lb ft 5 Lambda probe fastener 2 18 Nm 13 28 lb ft 6 RH fairing spacer M6 1 8 Nm 5 90 lb ft 7 Exhaust valve opening closing ca bles regulator lock nuts M6 2 5 Nm 3 69 lb ft Removing the tail pipe REMOVAL Rest the vehicle on the rear centre stand Remove the three fixing screws of th...

Page 448: ... Loosen the clamp between the ex haust terminal and the central mani fold Loosen the adjustment nuts of the ex haust valve Remove the screw with the relevant exhaust fixing nut on the frame recov ering the collar and washer Chassis RSV4 1100 Factory CHAS 448 ...

Page 449: ...ifold and support it to dis connect the exhaust valve control ca bles Remove the exhaust terminal com pletely Installation Connect the cables of the exhaust valve Insert the exhaust terminal on the cen tral manifold RSV4 1100 Factory Chassis CHAS 449 ...

Page 450: ...S PLAY ADJUSTMENT proce dure present in chapter ELECTRICAL SYSTEM in section EXHAUST VALVE Position the protection plate and fix it to the exhaust terminal using the three screws Removing the catalytic converter Remove the exhaust end Remove the front exhaust manifold Remove the pinion crankcase Disconnect the lambda sensor con nector Release the oxygen sensor cable har ness from the clamps Chassi...

Page 451: ...he springs between the rear exhaust manifolds and the catalytic converter Remove the catalytic converter Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFOLD Remove the front underfairings Remove the hand grip position sensor control unit Unscrew and remove both radiator up per fixing screws See also Fairing mounting panels Twistgrip position sensor RSV4 1100 Factory Chassis CHAS 451 ...

Page 452: ...fas tening the front exhaust manifold and retrieve the washers Remove the front exhaust manifold REAR EXHAUST MANIFOLDS Remove the catalytic converter Remove the left rider footpeg Unscrew and remove the four nuts fas tening the rear exhaust manifolds and retrieve the washers Remove both rear exhaust manifolds Chassis RSV4 1100 Factory CHAS 452 ...

Page 453: ...valve see electrical system section Engine oil cooler RADIATORE OLIO Pos Descrizione Tipo Quantità Coppia Note 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lb ft 2 Viti TE fl per fissaggio staffa a telaio M6x20 2 10 Nm 7 38 lbf ft RSV4 1100 Factory Chassis CHAS 453 ...

Page 454: ...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 Chassis RSV4 1100 Factory CHAS 454 ...

Page 455: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 456: ...NTROL UNIT Pos Description Type Quantity Torque Notes 1 Oil tube screws M10x1 4 23 26 Nm 16 96 19 18 lb ft 2 Control unit support screws M6 2 6 8 1 Nm 5 01 0 74 lb ft Braking system RSV4 1100 Factory BRAK SYS 456 ...

Page 457: ...Operating diagram ABS functional diagram key RSV4 1100 Factory Braking system BRAK SYS 457 ...

Page 458: ... the front brake pump 4 Supply to the front brake calliper ABS OPERATION General specifications The front circuit is similar to the rear circuit The ABS inlet valve 10 11 is normally open and it is closed only when the system inter venes to avoid wheel locking The exhaust valve 12 14 is normally closed and is only opened when the system inter venes to prevent locking With the system in stand by mo...

Page 459: ...PTION The ABS system is a device to avoid wheels locking in case of emergency braking increasing vehicle braking stability when compared to a traditional braking system The ABS system enhances control over the vehicle taking into consideration never to exceed the physical limits of vehicle grip on the road The rider is fully responsible for riding at a suitable speed based on weather and road cond...

Page 460: ... an active ABS system During the vehicle start up after the in strument panel initial check the ABS warning light stops flashing when the speed is under 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated IN CASE OF FAILURE OR WITH ABS DISCONNECTED THE VEHICLE OPERATES AS IF IT ...

Page 461: ...placement or refitting of the front brake lines take care that the steel ends are correctly lodged in the respective seats on the radiator sup port Use clamps to secure any axial move ments of the hoses Reposition the front brake steel pipes in the conduit secure the pipes using clamps and observing the tolerances indicated in the figure Characteristic Pipe axial clearance 0 0 10 mm 0 0 39 in RSV4...

Page 462: ... the diagnostics instrument on the ABS control unit and on the 7SM one Before returning the vehicle carry out a functional road test REPLACING ACTIVATING NEW ABS CONTROL UNIT In case of replacement of the ABS control unit ensure that the new one has caps on all four hydraulic connections and then proceed as follows Before disconnecting the electrical connections switch the key OFF After hydraulic ...

Page 463: ...guide 3 Cable grommet 4 Cable grommet TABLE C ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure TABLE D ABS PIPES ROUTING 1 Delivery rear calliper 2 Input from the rear pump 3 Delivery front calliper 4 Input from the front pump 5 Medium clamp RSV4 1100 Factory Braking system BRAK SYS 463 ...

Page 464: ...other braking system without ABS The detection of malfunctions may require more or less time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able to diagnose the e...

Page 465: ...l malfunction Use of diagnostics instrument for ABS system Abs screen pages ECU INFO screen page This screen shows general data regarding the con trol unit for example software type mapping con trol unit programming date CONTROL UNIT DATA P A D S characteristic Value example Units of measure ment Notes Spare part code CM281701 SW version Vehicle manuf or encoding Chassis or diagn tool no Saved veh...

Page 466: ...l km h Speed of the rear wheel km h Battery voltage D Front brake circuit pressure bar ABS Quality test of the sensors When turning the wheel or acting on the brake a variation of parameters must be detected ACTIVATION screen page On this screen you can delete the errors from the memory of the controller and you can enable some systems controlled by the control unit ACTIVATIONS P A D S characteris...

Page 467: ...he electric valve relay Internal error fault at the control unit C1021 fault at the control unit Low power supply voltage C1058 low voltage High power supply voltage C1059 high voltage Encoding error C1089 CAN error controller error U2921 controller error CAN error line failure busoff U2922 line failure busoff CAN error failed reception at the instrument panel U2924 failed reception at the instrum...

Page 468: ...agnostic tool in order to generate an errors report When started the program select the brand Select the vehicle and the component Select Self diagnosis Go to the page Error codes Select an error and show the Ambient parameter error where provided Braking system RSV4 1100 Factory BRAK SYS 468 ...

Page 469: ...d then on Print and select the virtual PDF printer If there is no PDF printer there are several free programs ask the infor mation systems to install it Name the file with a name that contains the main information of the vehicle and the analysed component e g CN1200 Chassis0465 Instrument panel RSV4 1100 Factory Braking system BRAK SYS 469 ...

Page 470: ...g Check the type and dimensions of the installed tyres Check the type and dimensions of the installed tone wheels C1031 Rear wheel speed sensor Electrical diagnosis Open circuit short circuit to negative or short circuit to positive Error cause Open circuit circuit interruption detected Short circuit to negative null voltage detected on PIN 14 of the ABS control unit Short circuit to positive exce...

Page 471: ...wheel is correct Check that the tone wheel and the sensor are correctly positioned Check that the tyre is the correct size If all these checks are positive replace the sensor C1033 Front wheel speed sensor Electrical diagnosis Open circuit short circuit to negative or short circuit to positive Error cause Open circuit circuit interruption detected Short circuit to negative null voltage detected on...

Page 472: ...all these checks are positive replace the sensor VOLTAGE ERRORS C1058 Low power supply voltage C1059 High power supply voltage Error cause Power supply voltage below minimum threshold or above maximum threshold detected on PIN 4 or on PIN 18 of the ABS control unit This error is indicated by lighting up in a fixed manner the ABS warning light Troubleshooting Check that the voltage regulator is wor...

Page 473: ...continuity of wiring harness between PIN 2 of the ABS control unit and PIN 33 of the instrument panel Orange cable between PIN 11 of the ABS control unit and PIN 32 of the instrument panel White Black cable U2925 Failed reception from injection control unit Error cause Communication problem with the injection control unit possible CAN line contact Troubleshooting Check continuity of wiring harness...

Page 474: ...button must be closed with the button closed the button must be open Modulator Disconnect the ABS connector Disconnect and remove the brake pipes inserts from the ABS control unit Undo the fixing screw of the ABS con trol unit Disconnect the ABS control unit from its rear inserts Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever t...

Page 475: ...riving 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 IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN SERTION Fit the protection casing RSV4 1100 Factory Braking system BRAK SYS 475 ...

Page 476: ...ND OR THE TONE WHEEL 2 AND REPEAT THE CHECKS MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIM ITS TONE WHEELS 2 CLEANING It is important to check that all the tone wheels 2 are always clean Otherwise gently remove any possible dirt deposits with a cloth or metal brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 TONE WHEEL SENSOR REPLACEMENT Disconnect th...

Page 477: ... Nm 4 43 lb ft 2 Rear brake calliper support plate re taining pin M12 1 50 Nm 36 88 lb ft Loct 243 3 Rear brake calliper fastening screw M5 2 25 Nm 18 44 lb ft 4 Brake pipe bracket fastening screw M5 1 4 Nm 2 95 lb ft Screw fastening brake pipe clamp M5 2 4 Nm 2 95 lb ft RSV4 1100 Factory Braking system BRAK SYS 477 ...

Page 478: ...ONT BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 Front brake calliper fastening screws M10x1 25 2 2 50 Nm 36 88 lb ft Rear brake disc Removal Remove the rear wheel Braking system RSV4 1100 Factory BRAK SYS 478 ...

Page 479: ...ions 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 imum oscillation of the disc does not exceed th...

Page 480: ...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 thickness even in a single point of the disc is less than the minimum value replace the di...

Page 481: ...UTION 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 AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE Ins...

Page 482: ...heck the front brake fluid level Rear brake pads Removal Rest the vehicle on its stand Remove the two fixing screws 1 and free the brake calliper CAUTION DO NOT OPERATE THE REAR BRAKE LEVER AFTER HAVING REMOVER THE WHEEL OTHERWISE THE PIS TON OF THE CALLIPER COULD EXIT THE SEAT CAUSING THE LOSS OF THE BRAKE FLUID Remove the stop ring 2 BEFORE DISCONNECTING THE PIN 3 CHECK THE PO SITION OF THE SAFE...

Page 483: ...O OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE 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 ROTATION OF THE WHEEL CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER RSV4 ...

Page 484: ... BOTH THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURG ING 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 La procedura di spurgo può essere eseguita in modo tradizionale o con l uso di attrezzi specifici quali pompe a vuoto o simili E importante però procedere spurgando l imp...

Page 485: ...Refit and block the front brake oil reservoir cap Refit the rubber protection cover Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency CAUTION IN VIEW OF THE DANGER THIS POSES FO...

Page 486: ... brake lever and then open the bleed valve on the calliper 1 4 of a turn to let the air out Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection cover...

Page 487: ...ening brake pipe grommet to the lower yoke M5 1 8 Nm 5 90 lb ft Rear brake pump REAR BRAKE MASTER CYLINDER Pos Description Type Quantity Torque Notes 1 Rear brake rod lock nut M6 1 12 Nm 8 85 lb ft 2 Rear brake pump retaining screws M6 2 8 Nm 5 90 lb ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lb ft Loctite 243 4 Tank filler cap 1 17 23 Nm 12 54 16 96 lb ft 5 Brake lever ferrule ...

Page 488: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 489: ... 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 489 ...

Page 490: ...or fasten ing the water radiator support brack et to the frame M6x20 2 10 Nm 7 38 lb ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lb ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lb ft 4 Screws for fastening the electric fans to the water radiator M4 6 0 5 Nm 0 37 lb ft 5 Screw for fastening the expansion tank ...

Page 491: ...al head hex socket screws for fastening the pump to the crank case M6x25 2 10 Nm 7 38 lb 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 491 ...

Page 492: ...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 493: ...e 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 radia tor and in the expansion tank...

Page 494: ... 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 Unscrew and remove the two external pump cover fixing screws Cooling system RSV4 1100 Factory COOL SYS 494 ...

Page 495: ... 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 RADIATOR BRACKET REMOVAL Operating from the right side of the mo torcycle move the main cable harness and remove the screw fixing the radia tor to the retainer bracket RSV4 1100 Factory Cooling system COOL SYS 495 ...

Page 496: ... THE MAIN CABLE HARNESS IS CORRECTLY POSITIONED ON THE CAVITY OF THE RADIATOR RETAINER BRACKET IN ORDER TO PRE VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF RADIATOR REMOVAL Drain off the cooling system Remove the front underfairings and the hand grip position sensor Disconnect both cooling fan connec tors Cooling system RSV4 1100 Factory...

Page 497: ...See also Coolant replacement Fairing mounting panels Twistgrip position sensor Remove the two fixing screws of the radiator bracket Cut the clamp fastening the cable har ness to the radiator return pipe on the left hand side RSV4 1100 Factory Cooling system COOL SYS 497 ...

Page 498: ...HER TYPE OF CLAMP Release the clamp fastening the deliv ery pipe to the radiator pipe UPON REFITTING REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE DO NOT REFIT THE CLIP ON CLAMP REMOVED PREVI OUSLY AS IT IS NO LONGER USABLE DO NOT REPLACE THE CLIP ON CLAMP REMOVED PRE VIOUSLY WITH A SCREW CLAMP OR ANY OTHER TYPE OF CLAMP Remove the split pin From the opposite site remove the coolant radi...

Page 499: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 500: ...scription Type Quantity Torque Notes 1 Screw for fastening the front head light to the front mudguard SWP 4 9 4 2 Nm 1 48 lb ft 2 Headlamp fastener screw M5 x 12 1 2 Nm 1 48 lb ft Bodywork RSV4 1100 Factory BODYW 500 ...

Page 501: ...strument panel support shell fas tening screws SWP 4 9 5 2 Nm 1 48 lb ft 3 Screws used to fasten the instrument panel support to the chassis M6 4 8 Nm 5 90 lb ft TOP FAIRING pos Description Type Quantity Torque Notes 1 Windshield fixing screws M4 4 0 5 Nm 0 37 lb ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 38 lb ft RSV4 1100 Factory Bodywork BODYW 501 ...

Page 502: ...ws M5 2 4 Nm 2 95 lb ft 3 Screws fixing the side fairings to the side spacers M5 2 1 5 Nm 1 11 lb ft 4 Screws fastening the lower fairing to the lug M5 2 2 Nm 1 48 lb ft 5 Lower fairing lower fastening screws M5 2 2 Nm 1 48 lb ft 6 Centre screws fastening lower fairing M6 2 10 Nm 7 38 lb ft Bodywork RSV4 1100 Factory BODYW 502 ...

Page 503: ...crews for fastening the sensor support to the fuel tank M6x20 2 6 Nm 4 43 lb ft 8 Flanged button head hex socket screws for fastening the sensor to the bracket M6x12 2 6 Nm 4 43 lb ft Central fuel tank cover retaining screw M4 1 0 5 Nm 0 37 lb ft Fuel tank breather couplings M7 2 3 Nm 2 21 lb ft Fuel return coupling M6 1 6 Nm 4 43 lb ft Loctite 243 Pump support to flange fastening M5 3 4 Nm 2 95 l...

Page 504: ...ER Pos Description Type Quantity Torque Notes 1 Screws fastening front tank to frame M6 1 8 Nm 5 90 lb ft 2 Screws fastening tank structural sup port to tank M6 4 3 Nm 2 21 lb ft Bodywork RSV4 1100 Factory BODYW 504 ...

Page 505: ...M5 2 1 5 Nm 1 11 lb ft Screws for securing the upper fairing closure to the front mudguard M5 2 1 5 Nm 1 11 lb ft Screws for securing the upper fairing closure to the intake duct self tapping 2 1 Nm 0 74 lb ft Screws for securing the upper fairing closure to the front headlight self tapping 2 1 Nm 0 74 lb ft Screws for fastening the lower fairing to the bracket M5 2 2 1 Nm 0 74 lb ft Screws for fa...

Page 506: ... 74 lb ft 2 Rear turn indicator fixing screws M6 2 2 5 Nm 1 84 lb ft 3 Taillight fixing screws M5 2 3 Nm 2 21 lb ft 4 Taillight cover self tapping fixing screw SWP 3 9 1 0 5 Nm 0 37 lb ft Screws fastening license plate mounting to saddle mounting casting M6 3 4 Nm 2 95 lb ft Bodywork RSV4 1100 Factory BODYW 506 ...

Page 507: ... closure fas tening screws M5 2 3 Nm 2 21 lb ft 8 Screws for fastening number plate holder to the saddle mounting plate M6 2 4 Nm 2 95 lb ft 9 Screws for fastening the rear number plate holder to the front number plate holder SWP 3 9 4 1 Nm 0 74 lb ft 10 Self tapping screws for fastening the rear number plate holder to the front number plate holder SWP 4 9 2 2 Nm 1 48 lb ft 11 Reflector retaining ...

Page 508: ... 3 69 lb ft 2 Lock lever self tapping screw M4 1 2 Nm 1 48 lb ft 3 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 4 Right hand ignition lock screw M8 1 20 Nm 14 75 lb ft 5 Passenger saddle fixing screws M6 2 8 Nm 5 90 lb ft Bodywork RSV4 1100 Factory BODYW 508 ...

Page 509: ...o the saddle mounting plate M6 2 4 Nm 2 95 lb ft 3 Button head hex socket battery bracket fastening screws M5 5 2 Nm 1 48 lb ft FILTER BOX Pos Description Type Quantity Torque Notes 1 Flanged SWP petrol injectors circuit fastening screws M5x20 4 Nm lb ft 2 Flanged SWP upper intake ducts re taining screws M5x20 4 Nm lb ft 3 Flanged SWP lower intake ducts re taining screws 4 Nm lb ft RSV4 1100 Facto...

Page 510: ...enger s footrests to the frame M8 2 2 18 Nm 13 28 lb 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 retaining screws M6 2 2 8 Nm 5 90 lb ft 4 Passenger s heel guard retaining screws M6 2 2 8 Nm 5 90 lb ft 5 Anti creep pin M6 1 8 Nm 5 90 lb ft Bodywork RSV4 1100 Factory BODYW 510 ...

Page 511: ...ear mudguard fixing screws M6 2 5 Nm 3 69 lb ft For plastic mud guard 1 Rear mudguard fixing screws M6 2 3 Nm 2 21 lb ft For carbon mud guard Seat Remove the saddle cover passenger saddle Remove the two rear fastening screws RSV4 1100 Factory Bodywork BODYW 511 ...

Page 512: ... is applicable to both mirrors Disconnect the turn indicator connector from the relative fixed connector on the instrument panel Unscrew and remove the two nuts supporting the rear view mirror Guiding the turn indicator cable through the relative hole on the top fair ing remove the rear view mirror Bodywork RSV4 1100 Factory BODYW 512 ...

Page 513: ...gs from the seats on the support Rotate the instrument panel connector retainer lever Remove the connector Remove the instrument panel NOTE WHEN REASSEMBLING THE CONNECTORS THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP THUS FACILITATING THE CONNECTOR S INSERTION THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED RSV4 1100 Factory Bodywork BODYW 513 ...

Page 514: ...ectors from the top fairing Remove the four fixing screws 1 Remove the lower fixing screw 2 pay ing attention to collect the bush 3 Remove the headlight assembly com plete 4 Slide off the support 5 of the headlight from the top fairing Bodywork RSV4 1100 Factory BODYW 514 ...

Page 515: ...deflector Remove the upper screw 2 fixing the top fairing to the air deflector Remove the central screw 3 fixing the top fairing to the support frame Remove the previously described screws also for the right side of the motorcycle Remove the three clips 4 under the top fairing which are fixing it to the central underfairing RSV4 1100 Factory Bodywork BODYW 515 ...

Page 516: ...ulb connectors Disconnect the front headlamp con nectors 5 Remove the top fairing complete SIDE AIR DEFLECTOR COVERS To disassemble the side air deflector covers connected to the top fairing the lower screw 1 must be removed Remove the inner screw 2 Bodywork RSV4 1100 Factory BODYW 516 ...

Page 517: ... of the top fairing to remove the side air deflector covers PLEXIGLAS Remove the four fixing screws paying attention to collect the Teflon washers Slide the plexiglas from the lower pins and remove it Taillight assy Carry out the tail fairing removal pro cedure Unscrew and remove the two screws 1 RSV4 1100 Factory Bodywork BODYW 517 ...

Page 518: ...ect the connector 4 Remove the taillight 5 Rider footrest plate LEFT RIDER FOOTREST REMOVAL GEAR BOX LEVER Remove the fuel tank Loosen the screw 1 and ease off the gear lever Remove the three fixing screws 2 of the pinion cover 3 Bodywork RSV4 1100 Factory BODYW 518 ...

Page 519: ...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 Remove the two fixing screws 8 of the footrest complete with leverage RSV4 1100 Factory Bodywork BODYW 519 ...

Page 520: ...ES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION Side body panels Remove the rider saddle Working from the left side of the mo torcycle remove the three fixing screws of the side fairing Remove the side fairing To remove the right side fairing perform the previously described operations Bodywork RSV4 1100 Factory BODYW 520 ...

Page 521: ... torcycle unhook the three clips 1 positioned on the inner fairing Remove the four screws 2 Unhook the internal fixing clip 3 with the duct Remove the side fairing paying atten tion to the joints with the stanchion RSV4 1100 Factory Bodywork BODYW 521 ...

Page 522: ...ors Remove the fixing screw 1 of the de flector to the lower fairing Remove the deflector 2 Fairing mounting panels Previously remove the side fairings LATERAL UNDERFAIRINGS Working from the left side of the mo torcycle remove the clamp 1 locking the wiring of the connectors 2 of the alternator to the radiator Bodywork RSV4 1100 Factory BODYW 522 ...

Page 523: ... to the radiator Remove the lower fixing screw 3 of the left inner fairing Remove the upper fixing screw 4 of the left inner fairing Detach the internal left fairing 5 from the central underfairing and remove it RSV4 1100 Factory Bodywork BODYW 523 ...

Page 524: ...ng care not to damage the fittings with the lateral un derfairings and the top fairing REAR UNDERFAIRING Carry out the tail fairing removal pro cedure Remove the starter relay box 1 from the point indicated in the figure Remove the rear light unit Carry out the licence plate support re moval procedure Remove the tank Remove the battery Working from both sides of the motor cycle undo and remove the...

Page 525: ...d remove the two screws 3 Remove the two auxiliary fuse boxes 4 from the corresponding supports in dicated in the figure Unscrew and remove the screw 5 Unhook the underfairing 6 from the point indicated in the figure RSV4 1100 Factory Bodywork BODYW 525 ...

Page 526: ... holder Remove the plastic cover 1 Undo and remove the screw inside of the point indicated in the figure Unscrew the fixing screws 2 together with the nuts 3 Disconnect the connector 4 Remove the support 5 Bodywork RSV4 1100 Factory BODYW 526 ...

Page 527: ...xing the injec tors unit to the filter box Remove the injectors from the filter box Disconnect the air temperature sensor connector Remove the screw fixing the wiring harness to the filter box and move it away Unscrew and remove the eight air filter box cover screws RSV4 1100 Factory Bodywork BODYW 527 ...

Page 528: ... Move the two rear coil connectors Remove the two clamps blocking the wiring harness to the filter box cover Bodywork RSV4 1100 Factory BODYW 528 ...

Page 529: ...e fixing screws of the intake duct supports Remove the intake ducts complete with support Operating from both sides unscrew and remove the air pressure sensors fixing screws Operating from both sides unscrew and remove the air pressure sensors fixing screws RSV4 1100 Factory Bodywork BODYW 529 ...

Page 530: ...e remove the clamp blocking the main wiring harness to the filter box Disconnect the engine wiring connec tor previously placed on the filter box Release the cable harness from the cable grommet on the filter box Bodywork RSV4 1100 Factory BODYW 530 ...

Page 531: ...rew and remove the two screws Remove the rear mudguard Lower cowl Remove the side fairings Working from both sides remove the front fixing screws 1 Remove the lower fixing screw 2 sup porting the stanchion RSV4 1100 Factory Bodywork BODYW 531 ...

Page 532: ... to the fairing stanchion Remove the clip 3 and the two screws 4 to divide the stanchion Fuel tank Remove the saddle Unscrew and remove the front screw fixing the tank Unscrew and remove the two rear screws Bodywork RSV4 1100 Factory BODYW 532 ...

Page 533: ...nnect the connector 2 of the in ertia platform Working on the left side disconnect the tank s two vent pipes Slightly lift the fuel tank and working on the right side of the motorcycle dis connect the fuel pipe at the coupling point Remove the tank RSV4 1100 Factory Bodywork BODYW 533 ...

Page 534: ... sides of the vehicle undo and remove the two screws Remove the cable clamp fixing screw if fitted Release the brake pipe by detaching the cable clamp from the mudguard Remove the front mudguard Bodywork RSV4 1100 Factory BODYW 534 ...

Page 535: ...ws fastening the arch brace to the headstock Retrieve the cable grommet Unscrew and remove the five semi arch brace fixing screws See also Instrument panel Separate and remove the two semi arch braces FITTING Fit the right semi arch brace fixing it to the headstock with two screws RSV4 1100 Factory Bodywork BODYW 535 ...

Page 536: ...a clamp Fit the left semi arch brace applying the five coupling screws Do not strain the connection between the two semi arch braces as this would prevent the removal of the clamp Cut and remove the provisional clamp Fit the cable grommet from the left hand side of the arch brace tighten the two screws on the headstock Tighten the five coupling screws Bodywork RSV4 1100 Factory BODYW 536 ...

Page 537: ...e male connector on the cable with the red strip must be connected to the female connector on the longer cable Reconnect the instrument panel con nector NOTE WHEN REASSEMBLING THE CONNECTORS THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP THUS FA CILITATING THE CONNECTOR S INSERTION THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED Radiator cover Remove the side fairings Remove the...

Page 538: ...the saddle removal proce dure Carry out the side fairing removal pro cedure Undo and remove the six fixing screws 1 Remove the two plastic inserts 2 from both sides of the motorcycle Unscrew and remove the screw 3 Bodywork RSV4 1100 Factory BODYW 538 ...

Page 539: ...r a single lateral duct but is applicable to both Remove the windshield Unscrew and remove the two fixing nuts Remove the duct from its seat on the frame CAUTION DURING REASSEMBLY THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS See also Headlight fairing RSV4 1100 Factory Bodywork BODYW 539 ...

Page 540: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 541: ...m lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Rear brake light push button Turn indicators and their warning lights Instrument cluster Instrument panel 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 prese...

Page 542: ...y 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 higher than 15 volts Always remove the battery from the vehicle before connecting it to the charger Stop charging if the battery feels w...

Page 543: ... 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 HARMFUL POLLUTANTS CORROSIVE ACIDS OR TOXIC HEAVY METALS Levels check Hydraulic braking system fluid...

Page 544: ...n 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 PRESSURE WITH TYRES AT AMBIENT TEMPERATURE Specific operations for the vehicle Remove the screw 2 Remove the plas...

Page 545: ...PEG ON THE OPPOSITE SIDE LICENSE PLATE HOLDER Set three washers of suitable diameter between license plate and its holder to avoid damaging the license plate WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL Sostituzione sella Insert the key in the lock and turn it clockwise Remove the tail fairing RSV4 1100 Factory Pre delivery PRE DE 545 ...

Page 546: ... Fit the two seater saddle Pre delivery RSV4 1100 Factory PRE DE 546 ...

Page 547: ...438 444 Clutch 200 273 291 293 296 298 304 348 Coil 182 Connecting rods 355 359 367 Connectors 224 coolant 492 494 497 Coolant 492 494 497 Countershaft 347 349 353 358 Crankcase 345 353 357 369 Crankshaft 356 358 366 Cylinder 74 80 D Desmodromic drum 278 Diagnostics 465 Drive chain 13 438 E ECU 225 465 Electric fan 204 491 Electrical system 13 90 94 541 Engine oil 69 453 Engine temperature sensor ...

Page 548: ...holder 526 Linkages 416 M Magneto flywheel 288 353 Maintenance 8 64 66 476 Maintenance Table 66 Mirrors 512 Mudguard 531 534 O Oil filter 72 Oil pressure sensor 198 Oil sump 353 379 One way valve 383 P Pistons 355 358 367 Primary shaft 277 R Radiator 495 537 Rear cylinder head valves 80 Rear head 324 331 334 335 341 353 355 Rear wheel 422 445 479 Recommended products 68 Ride by wire 389 Run Stop s...

Page 549: ... Side stand sensor 202 Spark plug 68 Speed sensor 147 Stand 202 445 446 Start up 135 285 Starter motor 284 Steering damper 405 Stepper motor 392 T Tank 532 Throttle body 185 391 392 Top fairing Track 66 Transmission 12 351 353 Tyres 15 U Use 66 465 W Water pump 353 375 493 Wiring diagram 124 ...

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