APRILIA RSV4 ABS 2009 Manual Download Page 1

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MANUALE STAZIONE DI SERVIZIO

2Q000013

RSV4 ABS

Summary of Contents for RSV4 ABS 2009

Page 1: ...MANUALE STAZIONE DI SERVIZIO 2Q000013 RSV4 ABS ...

Page 2: ...estato già durante la fase di progettazione del veicolo I Ricambi Originali Aprilia sono sistematicamente sottoposti a procedure di controllo della qualità per garantirne la piena affidabilità e durata nel tempo Le descrizioni ed illustrazioni fornite nella presente pubblicazione s intendono non impegnative Aprilia perciò si riserva il diritto ferme restando le caratteristiche essenziali del tipo ...

Page 3: ...ly improve its products and the relative documentation The main technical modifications 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...

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

Page 5: ...OLS S TOOLS MAINTENANCE MAIN TROUBLESHOOTING TROUBL 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: ... CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant contains e...

Page 8: ...E 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...

Page 9: ...ing 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 pins and screws with new parts if the thread is damaged When assembling the bear...

Page 10: ... RISK OF SERIOUS INJURY OR DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period This ensures that components operate in loaded conditions and then unloaded conditions allowing the engine compone...

Page 11: ... 0 digit free Y anno di fabbricazione S stabilimento di produzione S Scorzè XXXXXX numero progressivo 6 cifre NUMERO DI TELAIO Il numero di telaio è stampigliato sul cannotto dello sterzo lato destro ENGINE NUMBER The engine number is printed on the base of the engine crankcase left hand side Engine No Dimensions and mass DIMENSIONS Specification Desc Quantity Max length 2040 mm 80 31 in Max width...

Page 12: ... in Lubrication Wet sump with oil radiator Oil pump Dual trochoidal pump lubrication cooling Oil filter With external cartridge filter Cooling Fluid 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 In cotton Alternatively Air filter Paper Transmission GEAR RA...

Page 13: ... R CR9EB NGK R CR10E for competition use Electrode gap 0 7 0 8 mm 0 027 0 031 in Battery YUASA YT12A BS 12 V 9 5 Ah or YUASA YTZ10S 12 V 8 6 Ah Coils Stick coil Recharging system Flywheel with rare earth magnets Generator 450 W Main fuses 30 A Auxiliary fuses 5A 7 5A 15A ABS fuses 15 A 30 A BULBS Specification Desc Quantity Low high beam headlight 12V 55W H11 Front daylight running light 12V 5W Tu...

Page 14: ...inkage and APS system ÖHLINS piggy back shock absorber with adjustable spring preloading wheelbase and hydraulic compression and rebound damping Rear shock absorber R version With progressive linkage with APS system Sachs shock ab sorber with adjustable spring preload piggy back wheel base compression damping and rebound damping Rear wheel travel 130 mm 5 12 in SIZES A AND B Specification Desc Qua...

Page 15: ...ar tyre 200 55 ZR17 78W 190 55 ZR17 75W 190 50 ZR17 73W With these dimensions use only Pirelli Diablo Super corsa SP and Diablo Supercorsa SP V2 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 SYSTEM Specification Desc Quantity Fuel Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM FUEL SYSTEM Specification Desc Quan...

Page 16: ...Front side OIL RADIATOR pos Description Type Quantity Torque Notes 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lbf ft OHLINS FORK Characteristics RSV4 ABS CHAR 16 ...

Page 17: ...d sensor bracket screws 1 SACHS FORK FRONT FORK SACHS pos Description Type Quantity Torque Notes 1 TEFL screw fasten onto Fork Hubs M6x40 4 10 Nm 7 37 lb ft 2 Screw Pumping member pin fixing to the stem base 2 30 Nm 22 13 lb ft 3 Upper cover 2 20 Nm 14 75 lb ft 4 Upper cover locking nut 2 20 Nm 14 75 lb ft Speed sensor bracket screw M5x12 1 0 6 Nm 0 44 lb ft RSV4 ABS Characteristics CHAR 17 ...

Page 18: ...m 18 44 lb ft 3 Headstock lock ring M35x1 1 60 Nm 44 25 lbf 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 1 100 Nm 73 76 lb ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 37 lb ft 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 37 lb ft Characteristics RSV4 ABS CHAR 18 ...

Page 19: ... spindle nut M25x1 5 1 80 Nm 59 lb ft 2 Front brake disc fixing 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 fixing screws M10x1 25 2 2 50 Nm 36 88 lb ft RSV4 ABS Characteristics CHAR 19 ...

Page 20: ... 5 16 lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lbf ft 3 Screw fastening brake pipe grommet to the lower yoke M5 1 8 Nm 5 9 lbf ft 4 Front brake pump U bolt clamp M6 2 10 Nm 7 37 lbf ft 5 Front brake lever pin fixing screw M6 1 10 Nm 7 37 lbf ft Characteristics RSV4 ABS CHAR 20 ...

Page 21: ... handlebar safety screw M6 1 1 10 Nm 7 37 lbf ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lbf ft 4 Right light switch M4 2 1 5 Nm 1 11 lbf ft 5 Left light switch M5 2 1 5 Nm 1 11 lbf ft 6 Throttle control fixing screws M5 2 2 Nm 1 47 lbf ft 7 Traction control control unit fixing screw M4 1 2 Nm 1 47 lbf ft RSV4 ABS Characteristics CHAR 21 ...

Page 22: ...EADLAMP pos Description Type Quantity Torque Notes 1 Screw fastening headlamp to front fairing SWP 4 9 4 2 Nm 1 47 lbf ft 2 Headlamp fixing screw M5 2 1 2 Nm 1 47 lbf ft Characteristics RSV4 ABS CHAR 22 ...

Page 23: ... ing screws SWP 4 9 5 2 Nm 1 47 lbf ft 3 Screws fastening instrument panel mounting to chassis M6 4 8 Nm 5 9 lbf ft WINDSHIELD pos Description Type Quantity Torque Notes 1 Windshield fixing screws M4 4 0 5 Nm 0 37 lbf ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 37 lbf ft 3 Screws fastening the side fairings to front fairing M5 4 1 Nm 0 74 lbf ft RSV4 ABS Characteristics CHAR 23 ...

Page 24: ...ue Notes 1 Front mudguard fixing screws M5 4 3 Nm 2 21 lbf ft 2 Lug fixing screws M5 2 4 Nm 2 95 lbf ft CLUTCH LEVER pos Description Type Quantity Torque Notes 1 Clutch lever collar fixing screws M6 1 10 Nm 7 37 lbf ft Characteristics RSV4 ABS CHAR 24 ...

Page 25: ...ng screw for fastening the water radiator to the mounting brack et 1 2 Nm 1 47 lbf ft 3 Screw fastening pipe grommet for By pass water hose M5 1 6 Nm 4 42 lbf ft 4 Screws fastening electric fan to wa ter radiator M4 6 2 Nm 1 47 lbf ft 5 Flanged TE screw for fastening the water radiator to the mounting brack et M6x20 1 7 Nm 5 16 lbf ft RSV4 ABS Characteristics CHAR 25 ...

Page 26: ...Type Quantity Torque Notes 1 Screws fastening the stand to the chassis M10 2 45 Nm 33 19 lbf ft Loct 243 2 Linear switch retainer M5 2 4 Nm 2 95 lbf ft Rear stand bushing fastening screws M6 2 7 Nm 5 16 lbf ft Characteristics RSV4 ABS CHAR 26 ...

Page 27: ...ening the tank to the chassis M6 1 8 Nm 5 9 lbf ft 5 Rear screws fastening the tank to the rear chassis M6 2 7 Nm 5 16 lbf ft 6 Screws fastening plastic fuel pipe mounting M5 1 2 5 Nm 1 84 lbf ft 7 Left fairing mounting bracket fixing screws M5 1 3 Nm 2 21 lbf ft 8 Screws fastening structural tank mounting to tank M6 4 3 Nm 2 21 lbf ft 9 Flanged TBEI screw fixing the sen sor box M6x16 stainless st...

Page 28: ... fastening passenger foot pegs to chassis M8 2 2 18 Nm 13 28 lbf ft For countries in which passenger footpegs are man datory or for two seat configuration 3 Rider heelrest fixing screws M6 2 2 8 Nm 5 9 lbf ft 4 Passenger heelrest fixing screws M6 2 2 8 Nm 5 9 lbf ft Anti slip pin M6 1 8 Nm 5 9 lbf ft Characteristics RSV4 ABS CHAR 28 ...

Page 29: ...bf ft 6 Lower rear right hand adjuster screw bushing M18x1 5 1 12 Nm 8 85 lbf ft 7 Upper rear right hand adjuster screw bushing M18x1 5 1 12 Nm 8 85 lbf ft 8 Upper rear right hand mount M10 1 50 Nm 36 88 lbf ft 9 Right fairing spacer M6 1 10 Nm 7 37 lbf ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lbf ft 11 Upper rear mount M10 1 50 Nm 36 88 lbf ft Screw fasten...

Page 30: ...s 1 Saddle mounting fixing screws M10 4 50 Nm 36 88 lbf ft 2 Screws fastening oil radiator mount ing bracket to engine M6 2 8 Nm 5 9 lbf ft 3 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lbf ft Characteristics RSV4 ABS CHAR 30 ...

Page 31: ...cription Type Quantity Torque Notes 1 Fall sensor mounting fixing screw M6 1 8 Nm 5 9 lbf ft 2 Horn fixing screw M8 1 15 Nm 11 06 lbf ft 3 Screw fastening the voltage regula tor to the inner fairing M6 2 6 Nm 4 42 lbf ft 4 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 5 Right hand ignition lock screw M8 1 20 Nm 14 75 lbf ft RSV4 ABS Characteristics...

Page 32: ...os Description Type Quantity Torque Notes 1 Upper Silentblock nut demand sen sor mounting bracket M6 1 5 Nm 3 69 lbf ft 2 Demand sensor fixing screw to mounting plate SWP 4 9 4 1 2 Nm 0 88 lbf ft Characteristics RSV4 ABS CHAR 32 ...

Page 33: ...NT MUST BE APPROX 180mm 7 09in FAIRING pos Description Type Quantity Torque Notes Centre screws fastening lower fairing M6 2 10 Nm 7 37 lb ft Right hand lower fairing mounting bracket M6 2 10 Nm 7 37 lb ft Left hand lower fairing mounting bracket M6 2 10 Nm 7 37 lb ft Screws fixing the side fairings to the side spacers M5 2 1 5 Nm 1 11 lb ft Screws fixing upper fairing fastener to intake duct M5 2...

Page 34: ... fixing lower front fairing fas tener to intake ducts SWP 3 9 2 1 Nm 0 74 lb ft Inner screws fixing fairing to the low er front fairing fastener M4 2 0 5 Nm 0 37 lb ft Inner screws fastening the fairing to the lug M5 2 2 Nm 1 47 lb ft ABS CONTROL UNIT pos Description Type Quantity Torque Notes 1 Oil hose screws M10x1 4 23 26 Nm 16 96 19 18 lb ft 2 ECU support screws M6 2 6 8 1 Nm 5 01 0 74 lb ft C...

Page 35: ...nting M8 1 25 Nm 18 44 lbf ft 4 Screw fastening silencer to central lower fairing bracket M8 1 20 Nm 14 75 lbf ft 5 Cosmetic silencer shield fixing screw M5 2 5 Nm 3 69 lbf ft 6 Oxygen sensor fastener M18x1 5 1 38 Nm 28 03 lbf ft 7 Fastener screw for cable grommet for exhaust butterfly valve cables M6 1 10 Nm 7 37 lbf ft 8 Exhaust butterfly valve actuator fix ing screws M6 2 10 Nm 7 37 lbf ft RSV4...

Page 36: ...WHEEL pos Description Type Quantity Torque Notes 1 Rear wheel spindle nut M25x1 5 1 120 Nm 88 5 lbf ft 2 Screws fastening sprocket on sprocket mount M10 5 50 Nm 36 88 lbf ft Characteristics RSV4 ABS CHAR 36 ...

Page 37: ...R pos Description Type Quantity Torque Notes 1 Rear brake disc fixing screws M8 5 30 Nm 22 13 lbf ft Loct 243 2 Odometer sensor fixing screw M6 1 10 Nm 7 38 lb ft 3 Rear brake calliper mounting plate lock pin M12 1 50 Nm 36 88 lbf ft Loct 243 4 Rear calliper fixing screw M5 2 25 Nm 18 44 lbf ft 5 Brake pipe clamp fixing screw M5 2 4 Nm 2 95 lbf ft Brake pipe bracket fixing screw M5 2 4 Nm 2 95 lbf...

Page 38: ... M20x1 5 1 65 Nm 47 94 lbf ft AGIP GREASE SM2 4 Chain casing fixing screws M5 2 4 Nm 2 95 lbf ft 5 Front chain guide fixing screw M5 1 4 Nm 2 95 lbf ft 6 Rear chain guide fixing nut M6 1 7 Nm 5 16 lbf ft 7 Chain skid fixing screws M5 2 2 Nm 1 47 lbf ft Lower chain slider fixing screws M6 2 10 Nm 7 37 lbf ft Chain guide fixing screw M6 1 8 Nm 5 90 lbf ft Characteristics RSV4 ABS CHAR 38 ...

Page 39: ...tity Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lbf ft 2 Dual connecting rod fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lbf ft RSV4 ABS Characteristics CHAR 39 ...

Page 40: ...on Type Quantity Torque Notes 1 Rear mudguard fixing screws M6 2 3 Nm 2 21 lbf ft 2 License plate light fixing screws M4 1 1 Nm 0 74 lbf ft 3 Reflector fixing nuts M4 2 1 Nm 0 74 lbf ft 4 Screws fastening rear license plate holder to front license plate holder SWP 3 9 4 1 Nm 0 74 lbf ft 5 Self tapping screws fastening rear li cense plate holder to front license plate holder 5x20 2 2 Nm 1 47 lbf ft...

Page 41: ...f ft 4 Screws fastening grilles to tail fairing M5 2 0 5 Nm 0 37 lbf ft 5 Screws fastening side fairings to tail fairing M5 2 1 Nm 0 74 lbf ft 6 Screws fixing side fairings to tank M5 2 2 2 Nm 1 47 lbf ft 7 Screws fastening tail fairing to saddle mounting M5 2 3 Nm 2 21 lbf ft 8 Screws fastening tail fairing to saddle mounting bracket M5 2 2 Nm 1 47 lbf ft 9 Screws fixing tail fairing to lower sad...

Page 42: ...es 1 Screws and nuts for fastening li cense plate holder to saddle mount ing plate M6 2 4 Nm 2 95 lbf ft 2 Lower saddle mounting fastener fix ing screws M5 5 3 Nm 2 21 lbf ft 3 Battery bracket fixing screws M5 2 2 Nm 1 47 lbf ft Characteristics RSV4 ABS CHAR 42 ...

Page 43: ...ine speed sensor fixing screw 1 8 Nm 5 9 lbf ft 2 TE flanged screw M6x20 1 12 Nm 8 85 lbf ft 3 Flanged TE screws M6x35 2 12 Nm 8 85 lbf ft 4 Flanged TE screws M6x22 16 12 Nm 8 85 lbf ft 5 Engine timing inspection cap 1 25 Nm 18 44 lbf ft RSV4 ABS Characteristics CHAR 43 ...

Page 44: ...OVER pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 37 lbf ft 2 Coil fixing screws 4 8 Nm 5 9 lbf ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lbf ft Characteristics RSV4 ABS CHAR 44 ...

Page 45: ...t stud bolts 8 10 Nm 7 37 lbf ft 2 Camshaft cam tower fixing screws M6x45 20 12 Nm 8 85 lbf ft 3 Reed valve cover fixing screws 6 6 Nm 4 42 lbf ft 4 Water outlet union fixing screw 2 12 Nm 8 85 lbf ft Loct 243 5 Flanged head nut 12 30 55 Nm 22 13 40 56 lbf ft Molykote spray on thread and under head 6 Head fastener screw chain side M6x55 4 12 Nm 8 85 lbf ft RSV4 ABS Characteristics CHAR 45 ...

Page 46: ...ue Notes 1 Screws fastening the timing system gear on the intake shaft M8 4 30 Nm 22 13 lbf ft Loct 243 2 Skid fastener screws M8 2 20 Nm 14 75 lbf ft Loct 243 3 Skid fastener screws M6x18 2 10 Nm 7 37 lbf ft Loct 243 Characteristics RSV4 ABS CHAR 46 ...

Page 47: ... the head with Molykote 2 Fastener ring nut for alternator side timing sprocket 1 100 Nm 73 76 lbf ft Loct 243 3 Primary sprocket fixing ring nut 1 200 Nm 147 51 lbf ft Loct 243 4 Alternator fixing screw M12x1 25 1 120 Nm 88 51 lbf ft 5 Tone wheel fixing screw M8x1 25 1 50 Nm 36 88 lbf ft Loct 3M or 270 RSV4 ABS Characteristics CHAR 47 ...

Page 48: ...he thread and un der the head 5 Crankcase fixing screw M8x70 4 25 Nm 18 44 lbf ft Lubricate the thread and under the head 6 Crankcase fixing screw M8x35 3 25 Nm 18 44 lbf ft Lubricate the thread and under the head 7 Crankcase fixing screw M6x45 2 10 Nm 7 37 lbf ft Lubricate the thread and under the head 8 Crankcase fixing screw M6x20 5 10 Nm 7 37 lbf ft Lubricate the thread and under the head 9 Cr...

Page 49: ...w M6x16 3 10 Nm 7 37 lbf ft Loct 243 3 Flange fixing screws M8x25 6 25 Nm 18 44 lbf ft 4 Index lever fixing screw M6 1 10 Nm 7 37 lbf ft Loct 243 5 Pinion retainer 1 50 Nm 36 88 lbf ft Loct 243 6 Screw retaining pre selector on crankcase 1 25 Nm 18 44 lbf ft Loct 270 Gear indicator fixing screw M5x15 2 6 Nm 4 42 lbf ft RSV4 ABS Characteristics CHAR 49 ...

Page 50: ...ut 1 150 Nm 110 63 lbf ft Loct 243 2 Clutch spring fastener screw M6 6 10 12 Nm 7 38 8 85 lbf ft IGNITION UNIT pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 ISO 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 Characteristics RSV4 ABS CHAR 50 ...

Page 51: ...s M6x25 6 12 Nm 8 85 lbf ft 2 Cover fastener screws alternator side M6x40 2 12 Nm 8 85 lbf ft 3 Blow by union fastener screws M5x16 3 7 Nm 5 16 lbf ft Stator fixing screw UNI 5931 CL8 8 M6x25 3 10 Nm 7 37 lbf ft Loct 243 Flanged screw M5x12 1 6 Nm 4 42 lbf ft Loct 243 RSV4 ABS Characteristics CHAR 51 ...

Page 52: ...6x22 4 12 Nm 8 85 lbf ft 5 Oil sump fixing screws M6x25 1 12 Nm 8 85 lbf ft 6 Screws fastening the pump to the crankcase M6 5 1 10 Nm 7 37 lbf ft 7 Oil pipe union fixing screw M6 1 8 Nm 5 90 lbf ft Loct 243 Screw fastening the diffuser in the oil sump 1 10 Nm 7 37 lbf ft SECONDARY AIR SYSTEM pos Description Type Quantity Torque Notes 1 Secondary air system solenoid screws 2 10 Nm 7 37 lbf ft Chara...

Page 53: ... JASO MA JASO MA2 specifi cations AGIP MP GREASE Black smooth textured lithium calcium soap based grease containing EP ex treme pressure additives with optimal water repellent properties ISO L X BCHB 2 DIN 51 825 KP2K 20 AGIP PERMANENT SPEZIAL Ethylene glycol based antifreeze fluid with organic inhibition additives Red ready for use ASTM D 3306 ASTM D 4656 ASTM D 4985 CUNA NC 956 16 AGIP BRAKE 4 B...

Page 54: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 55: ...code Description 020845Y Engine support 020846Y Retaining tray plastic caps 020847Y Flywheel extractor 020848Y Flywheel retainer Mitsubishi 020914Y Flywheel retainer 020849Y Clutch retainer RSV4 ABS Special tools S TOOLS 55 ...

Page 56: ... 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring Special tools RSV4 ABS S TOOLS 56 ...

Page 57: ...U bolt 020858Y Device for holding the pistons in the cyl inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020862Y Gearbox control rod roller cage fitting punch RSV4 ABS Special tools S TOOLS 57 ...

Page 58: ...ge fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020883Y Tool for fitting removing the timing chain tensioner 020709Y Engine support AP8140187 Engine support stand 020376Y Adapter handle Special tools RSV4 ABS S TOOLS 58 ...

Page 59: ...cription 020363Y 20 mm Oil seal guide 020364Y 25 mm Guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor RSV4 ABS Special tools S TOOLS 59 ...

Page 60: ...arbox shaft 020877Y Pliers for clamps 020926Y Tool for fitting the clutch control bushing AP8140146 Weight AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140147 Spacer tool AP8140148 Spacer piston separating plate Special tools RSV4 ABS S TOOLS 60 ...

Page 61: ...149 Protection for fitting operations AP8140150 Perforated rod for piston air bleed AP8140190 Tool for steering tightening AP8140181 Fuel pressure checking tool 020680Y TXB Navigator 020922Y P A D S RSV4 ABS Special tools S TOOLS 61 ...

Page 62: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 63: ... LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Check at each engine start 2 Check and clean and adjust or replace if necessary before every journey 3 Check and clean and adjust or replace if necessary every 1000 Km 621 mi 4 Replace every 2 years 5 Replac...

Page 64: ...I I I Fork oil 7 9 R Engine oil 6 R R R R R Light aiming I I I I Fork oil seals 6 I I Flexible coupling I I Tyres pressure wear 2 I I I I I Wheels 6 I I I I I Tightening torques 6 I I I I I Tightening of clutch cover flywheel and oil sump screws I I I I I Fault warning light on instrument panel 1 Fuel lines 5 I I I I Clutch wear 7 I I Brake pad wear 2 I I I I I Tempo manodopera minuti 90 140 550 1...

Page 65: ...e rear spark plug Engine oil Check NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Shut off the engine and wait for a few seconds Keep the vehicle upright with both wheels on the ground Ensure that the vehicle is on a level surface Check via the inspection glass in the crankcase that the oil level is near the upper marking Upper marking Max level RSV4 ABS Maintenance MAIN ...

Page 66: ... NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with suitable capaci ty under the drainage plug Unscrew and remove the drainage plug Unscrew and remove the filler cap Drain the oil into the container allow several minutes for oil to drain out com pletely Check and if necessary replace the drainage plug sealing washers Screw and tighten the drainage plug ...

Page 67: ...D Engine oil filter Replace the engine oil filter each time you change the engine oil Drain the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTER 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...

Page 68: ...ind the fil ter box cover Lift the filter box cover on which the control unit is installed Do not rotate the cover excessively to avoid straining the pipes and cables Plug the intake duct opening with clean paper Unscrew and remove the three air filter screws Remove the filter and replace it with a new component of the same type Maintenance RSV4 ABS MAIN 68 ...

Page 69: ...kshaft taking care not to lose the O ring See also Removing the throttle body Spark plug Head cover removal Use a feeler gauge to check the clear ance between the cam of the shaft and the relative tappet for both front head shafts Characteristic Acceptable values with control clearance be 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 RSV4 ABS Maint...

Page 70: ...plug Head cover removal Use a feeler gauge to check the clear ance between the cam on the shaft and the relative tappet for both rear head shafts Characteristic Acceptable values with control clearance be tween cam and valve Intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Maintenance RSV4 ABS MAIN 70 ...

Page 71: ... cover removal Removing the flywheel cover Turn the crankshaft from the hole on the clutch cover Move cylinder piston 1 left rear piston to the TDC overlap Turn the crankshaft 150 in the direc tion of engine rotation direction of trav el Insert the pin from the flywheel side in the hole in the crankshaft NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION DO NOT USE ...

Page 72: ...nscrew and remove the camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the direction of engine rotation direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ens...

Page 73: ...w and remove the second in take camshaft gear screw Leave the gear on the camshaft Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020865Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in st...

Page 74: ...onent to achieve the cor rect valve clearance Refer to the table Calibrated pad thickness es to identify the suitable thickness Fit the tappet See also Calibrated pad thickness NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Install the intake and exhaust camshafts on the front head bearing in mind that the exhaust camshaft gear tooth indicated with a dot is meshed wit...

Page 75: ...yet Move the gear from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Specific tooling 020865Y Support for camshaft gear on head Fit the U bolt and the oil pipe Tighten the two U bolt screws 1 and the screw 2 that was not fitted previ ously Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camsha...

Page 76: ...lock 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 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...

Page 77: ... the valve clearance adjustment procedure Rear cylinder head valves Check the rear valve head clearance and restore the correct clearance values if necessary proceeding as described below Remove the rear head cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Turn the crankshaft 450 one complete turn 90 in the direction of motor rotation direction of travel Insert the pi...

Page 78: ...and remove the camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 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 bol...

Page 79: ...and remove the second in take camshaft gear screw Leave the gear on the camshaft Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020865Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in stag...

Page 80: ...omponent to achieve the cor rect valve clearance Refer to the table Calibrated pad thickness es to identify the suitable thickness Fit the tappet See also Calibrated pad thickness 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 t...

Page 81: ...yet Move the gear from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Specific tooling 020865Y Support for camshaft gear on head Fit the U bolt and the oil pipe Tighten the two U bolt screws 1 and the screw 2 that was not fitted previ ously Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camsha...

Page 82: ...lock 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 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...

Page 83: ... repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Check if the clearance between the cam on the shaft and the tappet is correct If not repeat the valve clearance adjustment procedure 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...

Page 84: ... mm 0 0913 in 2 35 mm 0 0925 in 2 37 mm 0 0933 in 2 4 mm 0 0945 in 2 42 mm 0 0953 in 2 45 mm 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 11...

Page 85: ...92 mm 0 1150 in 2 95 mm 0 1161 in 2 97 mm 0 1169 in 3 mm 0 1181 in 3 02 mm 0 1189 in 3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 in 3 15 mm 0 1240 in RSV4 ABS Maintenance MAIN 85 ...

Page 86: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 87: ...W IS SELECTED AND IS DISPLAYED PRESS THE KEY TO OBTAIN FURTHER INFORMATION ABOUT THE ERROR THEN GO TO THE ELECTRICAL SYSTEM CHECKS AND CONTROLS CHAPTER AND READ THE INFORMATION CONCERNING THE DEFECTIVE COMPONENT 5 ACCORDING TO WHAT IS INDICATED ABOUT THE ERROR S PROCEED AS SUG GESTED AND SOLVE THE PROBLEM 6 WAS THE PROBLEM SOLVED BY REPLACING THE MARELLI CONTROL UNIT YES go to 7 NO go to 8 7 READ ...

Page 88: ... C 15 IN THE ENGINE PARAMETER READING WITH ENGINE AT IDLE AND ENGINE TEMPERATURE 65 c FRONT THROTTLE CORRECTION OR REAR THROTTLE CORRECTION WITH ENGINE AT IDLE ARE THE PARAMETERS INCLUDED WITHIN 0 8 0 8 INTERVAL AND IN THE SAME SCREEN PAGE ARE THE FRONT THROT POT 1 DEGREES AND REAR THROT POT 1 DEGREES WITH EN GINE AT IDLE OR A 0 5 CAUTION THE DIFFERENCE OF THE THROTTLE CORRECTION VALUES BETWEEN TH...

Page 89: ... go to 3 NO go to FUEL PUMP CHECK 3 THE DIAGNOSIS INSTRUMENT COMMUNICATES WITH THE CONTROL UNIT THAT IS AFTER SELECTING FUEL INJECTION AND FOLLOWING THE INSTRUCTION WITH KEY SET TO ON THE PARAMETERS STATUSES ETC ARE READ YES go to 4 NO go to DIAGNOSIS INSTRUMENT CONNECTION CHECK 4 WITH DIAGNOSIS INSTRUMENT DEVICES ACTIVATION SCREEN PAGE INJEC TOR ICON CARRY OUT ACTIVATION OF A LOWER INJECTOR IT IS...

Page 90: ...FRAME INTERNAL FRONT NICHE IN VERTICAL POSI TION YES go to 13 NO go to 14 13 REFER TO THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS FALL SENSOR INDICATION ON DIAGNOSIS INSTRUMENT ALWAYS TIP OVER END 14 SET THE SENSOR TO THE CORRECT POSITION END 15 REFER TO THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS RUN STOP SWITCH INDICATION ON DIAGNOSIS INSTRUMENT ALWAYS TIP OVER END 16 CHECK OPERATION...

Page 91: ...NECTOR ON THE RIGHT IS THE INJECTOR ACTIVATED YES go to 5 NO go to INJECTION RELAY 33 CHECK 5 DOES THE MOTOR TURN WHEN THE STARTER SWITCH IS PRESSED YES SEE CHAPTER ELECTRICAL SYSTEM CHECK AND CONTROLS ENGINE SPEED SEN SOR and if engine speed sensor works correctly go to 16 NO go to 6 6 WHAT DOES THE START UP ENABLING SWITCH STATUS IN THE DIAGNOSIS INSTRUMENT DEVICE STATUS SCREEN PAGE ICON 0 1 MEA...

Page 92: ...INE MECHANICAL OPERATION END See also Engine rpm sensor Neutral sensor CHECK CONTROL UNIT POWER SUPPLY 1 WITH THE KEY TURNED TO OFF CHECK IF THERE IS BATTERY VOLTAGE AT PIN 52 OF THE CONTROL UNIT CABLE HARNESS SIDE YES go to 2 NO go to 5 2 WITH THE KEY TURNED TO ON THERE IS BATTERY VOLTAGE AT PIN 40 OF THE CONTROL UNIT CABLE HARNESS SIDE IN CASE OF LACK OF POWER SUPPLY ON PIN 42 URGENT SERVICE TUR...

Page 93: ...5 3 CHECK ON CONNECTOR ON THE PUMP SIDE THE ELECTRICAL CHARACTERIS TICS between PIN 1 and PIN 2 there should be a resistance of 0 5 1 ohm END 4 CHECK CONTINUITY OF ORANGE GREEN CABLE FROM PUMP CONNECTOR TO INJECTION RELAY 33 AND RESTORE CABLE HARNESS END 5 RESTORE GROUND CONNECTION END DIAGNOSIS INSTRUMENT CONNECTION CHECK 1 CHECK CONTINUITY OF WHITE BLUE CABLE FROM PIN 14 OF THE CONTROL UNIT ON C...

Page 94: ...REPLACE THE CONTROL UNIT END 6 CHECK CONTINUITY OF RED BROWN CABLE FROM THE INJECTION RELAY 33 TO THE PROTECTION RELAY 19 If there is continuity go to PROTECTION RELAY 19 CHECK if there is not continuity restore cable harness END 7 CHECK CONTINUITY OF THE CABLE FROM THE INJECTION RELAY 33 TO THE PROTECTION RELAY 19 ORANGE BETWEEN RELAY 33 AND FUSE F and RED BROWN BETWEEN FUSE RELAY F AND RELAY 19 ...

Page 95: ... ON DISCONNECT THE SWITCH CONNECTOR 4 ways black inside the bow AND CHECK IF THERE IS VOLTAGE 5V ON PIN 2 ON THE CABLE HARNESS SIDE YES go to 2 NO go to 5 2 WITH CONNECTOR DISCONNECTED 4 ways black inside the bow CHECK IF THERE IS GROUND CONNECTION ON PIN 3 ON THE CABLE HARNESS SIDE YES go to 3 NO go to 6 3 CHECK WITH CONNECTOR DISCONNECTED 4 ways black inside the bow ON THE SWITCH SIDE PUSHING TH...

Page 96: ... 7 REPLACE THE STARTER BUTTON COMPONENT END Troubleshooting RSV4 ABS TROUBL 96 ...

Page 97: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 98: ...ft 2 Horn fixing screw M8 1 15 Nm 11 06 lbf ft 3 Screw fastening the voltage regula tor to the inner fairing M6 2 6 Nm 4 42 lbf ft 4 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 5 Right hand ignition lock screw M8 1 20 Nm 14 75 lbf ft Electrical system RSV4 ABS ELE SYS 98 ...

Page 99: ...ype Quantity Torque Notes 1 Upper Silentblock nut demand sen sor mounting bracket M6 1 5 Nm 3 69 lbf ft 2 Demand sensor fixing screw to mounting plate SWP 4 9 4 1 2 Nm 0 88 lbf ft Components arrangement key RSV4 ABS Electrical system ELE SYS 99 ...

Page 100: ...rs 18 Fall sensor 19 Horn 20 Voltage regulator 21 Battery 22 Auxiliary fuses 23 Control unit 24 Throttle grip position sensor 25 Intake duct control unit WHERE PROVIDED 26 Alternator 27 Coils 28 Timing sensor 29 Starter motor 30 Oil pressure sensor 31 Inertia sensor platform 32 Quick Shift 33 Front tone wheel sensor 34 a PRC controls 35 ABS control unit A RELAY CANNOT BE IDENTIFIED BASED ON THE FO...

Page 101: ...ION Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets CHASSIS Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Vehicle cable harness 1 Headlamp cable harness 1 License plate frame cable harness 1 Positive battery cable 1 Battery engine ground cab...

Page 102: ...6 screw 2 M5x8 screws 2 TBEI M5x16 screws 1 TE M6x30 screw 3 Self tapping 5x14 screws 2 flanged TBEI M5x9 screws 1 M6 nut 2 Flanged self locking M6 nuts 10 Cable grommet there are various types of cable grommets 3 Cable guides 5 Relay socket rubber rings 11 Rubber block there are various types of rubber blocks 1 Rubber ring for the protection relay 1 Rubber ring for the fall sensor 1 AMP Superseal...

Page 103: ...peed sensor 1 Control unit 7SM 1 Air temperature sensor 1 H2O temperature sensor 2 Coil with short cable Cylinder 1 and Cylinder 4 2 Coil with long cable Cylinder 2 and Cylinder 3 1 Gear sensor 1 Secondary air solenoid 1 Front motorised throttle body where provided 1 Rear motorised throttle body where provided 2 MAP sensor 1 Alternator 1 Starter motor 4 Upper injectors 4 Lower injectors Small part...

Page 104: ...ecks for the correct connection and laying of cables It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine and therefore proper vehicle operation CHASSIS Instrument panel connector Demand sensor connectors Start up relay connector Front speed sensor connector Rear speed sensor connector Fall sensor conn...

Page 105: ...r motorised throttle body connector Output 14 where provided MAP sensor connector Outputs 11 and 27 Upper injector connectors Outputs 20 21 22 and 23 Lower injector connectors Outputs 5 6 16 and 17 The connectors in the list are circled in the different pictures The listed connectors are con sidered more critical than the others because their disconnection could cause the vehicle to stop or malfun...

Page 106: ...dication UP PER facing upward 1 fall sensor 2 Fall sensor rubber ring 3 Relay 4 Fall sensor connector 5 Mounting TABLE B REGULATOR PRE FITTING 6 Regulator 7 Regulator connector 8 Flywheel connector 9 Self locking nut x2 10 T shaped bushing x2 11 TBEI M6x30 screw x2 12 Washer x2 TABLE C1 HEADLAMP PRE FITTING Electrical system RSV4 ABS ELE SYS 106 ...

Page 107: ...he cable grommet 19 Right position light connector 20 Right low beam light connector 21 Vehicle cable harness interface connectors 22 High beam light connector 23 Headlamp cable harness 24 Left low beam light connector TABLE C2 HEADLAMP PRE FITTING 16 Cable grommet 17 Relay with relay socket rubber ring 25 Cable harness routing behind the relay TABLE D HANDLEBAR CONTROLS 26 Left handlebar control ...

Page 108: ...TABLE F INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Pass all the cable harnesses arriving from the right semi handlebar right handlebar control front stop switch and from the left semi handlebar left handlebar control key switch inside of the right arch brace as shown in the figure also pass the cable with the clutch connector on the vehicle ca ble harness together with the left switch cable harne...

Page 109: ...k Shift control connector 37 Left handlebar control connectors 38 Antenna connector 39 Left turn indicator connector cable colours light blue and blue 40 Instrument panel connector 41 Right turn indicator connector cable colours red and blue 42 Front stop switch connector 43 Right handlebar control connector TABLE I INSTRUMENT HOLDER SUPPORT AND FRONT PART Make the connections for all connectors T...

Page 110: ...strument panel mounting cover 52 Screw TABLE L INSTRUMENT HOLDER SUPPORT AND FRONT PART Right side Check that the cable grommets are not tensioned on the right and left cable grommet during steering rotation 53 Cable harness routing to right handlebar control 54 Front stop switch cable harness routing 55 Rubber clamp 56 Cable grommet 57 Red reference tape on the right handlebar control cable harne...

Page 111: ...tenna cable harness routing 59 Ignition switch cable harness routing 60 Rubber clamp 61 Cable harness routing to left handlebar control 61A Quick Shift control cable harness routing 62 Clutch cable harness routing 63 Cable grommet 64 Red tape on the clutch and left handlebar control cable harness in correspondence of the cable grommet RSV4 ABS Electrical system ELE SYS 111 ...

Page 112: ... shown in the figure TABLE O COMPLETION OF THE FRONT Check that the turn indicator connectors are inserted correctly and do not return inside the instrument holder arch brace 67 Front right turn indicator connectors 68 Front left turn indicator connector Electrical system RSV4 ABS ELE SYS 112 ...

Page 113: ...TABLE P FRONT SPEED SENSOR 69 Cable grommet 70 Front speed sensor 71 Clamp 72 Front speed sensor cable harness routing RSV4 ABS Electrical system ELE SYS 113 ...

Page 114: ...sor cable harness 77 Clamp Route cable harness on clutch cable grommet and tie it together with the front speed sensor 78 Front speed sensor connector 79 Clamps Central part TABLE A RADIATOR AREA Right side 1 Cable grommet 2 Vehicle cable harness Electrical system RSV4 ABS ELE SYS 114 ...

Page 115: ...RIV ER TO RELEASE TANG AND DISCONNECT THE FASTON TABLE C RADIATOR AREA 7 Ground cable harness routing behind water pipe and behind the starter motor 8 Starter motor cable harness routing behind wa ter pipe 9 Starter motor eyelet Cover motor nut and square terminal with wa terproof dielectric grease Quantity 0 5 g 0 18 oz 10 Oil pressure sensor cable harness routing be hind water pipe 10A Clamp 11 ...

Page 116: ...ly and that the purple slide is at the end of stroke as shown in the figure TABLE E RADIATOR AREA Left side Check that the connectors are inserted correctly and that the security locks are in the locked position 16 Master Demand connector blue 17 Slave Demand connector white Electrical system RSV4 ABS ELE SYS 116 ...

Page 117: ...Flywheel connector 21 Flywheel connector to the regulator 22 Flywheel cable harness routing 23 Fan connector TABLE H DEMAND SENSOR FITTING 24 Clamp flywheel cable harness and regulator cable harness routing 25 Flywheel cable harness routing The flywheel connectors must be positioned between the two demand connectors so that they remain away from the exhaust pipes 26 Flywheel connector to the regul...

Page 118: ...le harness TABLE I Right side 30 Instrument panel branch vehicle cable harness 31 Fan connector 32 Clamp TABLE J 32A Tie 32B Fan connector 32C Instrument panel branch vehicle cable har ness TABLE J1 EXHAUST VALVE ACTUATOR Positioning and calibration Electrical system RSV4 ABS ELE SYS 118 ...

Page 119: ...e Bowden cable 45 fitting procedure Insert the cables with the set screws closed in the following sequence 1 Valve side closing cable 44 univocal fit ting 2 Actuator side closing cable 44 3 Valve side opening cable 43 univocal fit ting 4 Actuator side opening cable 43 Turn the closing cable set screw until there is a distance of 1 9 2 mm 0 0748 0 0787 in between the me chanical endstop and the pul...

Page 120: ... 47 Oxygen sensor connector on the vehicle cable harness 48 Gear sensor 49 Oxygen sensor connector 50 Stand switch cable harness routing 51 Oxygen sensor cable harness routing 52 Clamp 53 Stand switch 54 Lambda probe 55 Mounting TABLE K2 Pass the cable harnesses behind the cable grommet that closes the two fuel breather pipes 56 Quick shift cable harness routing 57 Oxygen sensor cable harness rout...

Page 121: ...or cable harness routing 61 Stand switch cable harness routing TABLE M 62 Quick Shift cable harness routing 63 Gear sensor cable harness routing 64 Stand switch cable harness routing 64A Oxygen sensor cable harness routing TABLE M1 64B Quick Shift connector RSV4 ABS Electrical system ELE SYS 121 ...

Page 122: ...m the vehicle cable harness 70 Engine battery ground cable engine Gnd lug terminal 71 Cable grommet 72 Flanged M6x16 screw 73 Chassis GND lug terminal from the engine cable harness To avoid inverting the ground connections unscrew the screw 67 from the engine to connect the other ground connections the chassis ground cable 73 can be connected with the screw 72 as shown in the figure CAUTION BE CAR...

Page 123: ...s as far up as possible 74 Clamp 75 Battery engine ground lead 76 Engine battery ground cable harness routing The engine battery ground cable harness must not be visible within the area indicated with a red triangle CAUTION BE CAREFUL NOT TO INVERT THE TWO GROUND LUG TERMINALS 68 AND 73 RSV4 ABS Electrical system ELE SYS 123 ...

Page 124: ...2 79 Cylinder 3 80 Cylinder 4 81 Cylinder bank 1 82 Cylinder bank 2 83 Throttle body 1 FARF 1 84 Throttle body 2 FARF 2 CENTRAL Q2 Right side view 86 Engine speed sensor 87 Starter motor Left side view 87 Starter motor 88 Alternator 89 Gear sensor TABLE R ENGINE CABLE HARNESS LAYOUT Electrical system RSV4 ABS ELE SYS 124 ...

Page 125: ...5x20 screw 91 Connector mounting 92 Connector mounting TABLE S2 Lower filter box 93 Connector mounting TABLE S3 Filter box cover 94 Connector mounting TABLE T CONTROL UNIT MOUNTING PREP ARATION Fit the three silent blocks 96 onto the seats on the mounting then fit the 7SM control unit 95 using the specific links 95 7SM control unit 96 Silent block 97 Control unit mounting RSV4 ABS Electrical syste...

Page 126: ...8 rear shorter branch and motorised throttle body 2 99 front longer branch 98 Rear motorised throttle body 99 Front motorised throttle body TABLE V Check that the connectors are inserted correctly and that the security locks are in the locked posi tion CENTRAL W FITTING THE PIPES ON THE SECONDARY AIR SOLENOID 100 Pipe 101 Pipe 102 Pipe 103 Secondary air solenoid mounting TABLE X FITTING AND CONNEC...

Page 127: ...he rubber manifolds with the clip on clamps us ing the specific tool 106 Cable harness routing branch 4 under the fuel pipe Pay attention when positioning the Map Sensor 2 connector Specific tooling 020877Y Pliers for clamps TABLE ZA H2O TEMPERATURE SENSOR AND LOWER INJECTORS CONNECTION Cable harness routing on the right side of the en gine branch 4 of the cable harness must pass behind the Front ...

Page 128: ...wiring together with the injector cable harnesses 117 Lower injector 4 cable harness connector output 6 grey connector 118 Coil 4 short cable harness 119 Lower injector 2 cable harness connector output 5 brown connector 120 Coil 2 cable harness routing output 7 121 Coil 2 long cable harness TABLE ZD Connect the injectors 1 output 16 and 3 output 17 which are on branch 3 the connector 123 for injec...

Page 129: ...d under the connector in the plastic tooth of the mounting Passage of coil 3 and coil 1 cables between the Fuel Rail and the filter box 127 Coil 1 connector 128 Coil 1 cable harness connector output 29 129 Coil 3 connector 130 Coil 3 cable harness connector output 28 TABLE ZF 131 Coil 4 cable harness connector output 8 132 Coil 4 connector TABLE ZG 133 Coil 2 connector 134 Coil 2 cable harness con...

Page 130: ...own in the figure 145 144 Gear sensor cable harness connector 145 Cable harness routing and connector position behind the corrugated pipes CENTRAL ZJ The Oxygen sensor output 19 cable harness 147 must go down along the left side of the en gine together with the Gear Sensor cable harness 146 Oxygen sensor cable harness routing 147 Oxygen sensor cable harness connector output 19 TABLE ZK AIR TEMPERA...

Page 131: ...23 BLACK connector Injector 2 output 20 BROWN connector Injector 3 output 22 GREEN connector Injector 4 output 21 GREY connector TABLE ZL 7SM CONTROL UNIT FITTING AND CONNECTION After connecting the upper injector connections and the air temperature sensor connector the 7SM control unit can be fastened which was pre viously fastened to its relative mounting 157 Washer 158 Self tapping screw RSV4 A...

Page 132: ...serting them The slides must move freely until the end of the stroke which helps with connector insertion you must hear the release of the retaining tang at the end of the stroke 161 ECU 1 cable harness connector output 26 162 ECU 2 cable harness connector output 25 163 Cable harness routing output 25 under the mounting 164 Cable harness routing output 25 above the mounting Electrical system RSV4 ...

Page 133: ...ing TABLE ZQ CONNECTORS FOR INTAKE DUCT CONTROL UNIT AND INTAKE DUCT MOTOR WHERE PROVIDED The Intake duct mot output 32 connector 167 must be fastened with a small black clamp 170 as shown in the figure 167 Intake duct motor connector output 32 168 Cable harness routing 169 Intake duct motor cable harness connection output 32 170 Clamp TABLE ZR Clamp 170 the connector 171 together with the main ca...

Page 134: ...rminal 174 output 10 must be left free CAUTION TAKE CARE NOT TO SWAP THE TWO GROUND LUG TER MINALS Back side TABLE A LICENSE PLATE FRAME PRE FITTING Check that the drainage hole 7 for the water of both turn indicators is positioned downward 1 License plate frame cable harness 2 Right rear turn indicator cable harness routing 3 2 8 mm 0 11 in Faston cable colours red and blue 4 License plate light ...

Page 135: ...t 10A Control unit connector TABLE C START UP RELAY PRE FITTING 11 Starter motor cable on the vehicle cable harness 12 Positive battery cable 13 Start up relay 14 Positive battery cable 15 M5x8 screw The positive battery cable 14 must be connected with a screw 15 on the hole marked with the letter B battery M starter motor RSV4 ABS Electrical system ELE SYS 135 ...

Page 136: ...the engine Check that the fan relay 19 safety relay 22 and fall sensor 18 are connected correctly fit on the relative mounting 16 Vehicle cable harness 17 Fall sensor and relay mounting 18 Fall sensor connector 19 Fan relay connector 20 TE M6x20 screw 21 T shaped bushing 22 Safety relay connector 23 Fasten the fall sensor connector on the mounting link 24 Vehicle cable harness Electrical system RS...

Page 137: ...ING ON THE RIGHT SIDE 28 Cable grommet 29 Speed sensor cable harness 30 Rear brake switch cable harness TABLE F0 REAR SADDLE MOUNTING AREA 30C Fit the individual fan fuse on battery mounting bracket tongue 30D Fuse box positioning on battery mounting bracket 30E Insert the fuse box in the two tongues on the battery mounting bracket RSV4 ABS Electrical system ELE SYS 137 ...

Page 138: ...ket with fuses 30A Battery mounting bracket 30B Vehicle cable harness TABLE F1 REAR SADDLE MOUNTING AREA 31 License plate frame cable harness connector 32 License plate frame cable harness routing 33 Taillight connector 34 Taillight Electrical system RSV4 ABS ELE SYS 138 ...

Page 139: ...CU diagnosis connector 44 Instrument panel diagnosis connector 45 Insert the instrument panel diagnosis and the ECU diagnosis connectors in their specific seats 46 License plate frame and taillight cable harness routing 47 Taillight connector 48 License plate frame cable harness connector TABLE F4 49 Cable grommet 50 Rubber clamp 51 Vehicle cable harness 52 Insert the tape clamp on the cable harne...

Page 140: ...ter 58 Fuel pump connector 59 Insert the tape clamp on the cable harness in the hole on the right side of the saddle mounting 60 variable length intake duct control unit connector 61 Clamp Inner 62 Speed sensor connector 63 Rear brake switch connector Electrical system RSV4 ABS ELE SYS 140 ...

Page 141: ...line push fitting the fuel pump connector 66 can be connected and positioned as shown in the figure No clamps are necessary 66 Fuel pump connector TABLE G1 SENSOR BOX 66A Sensor Box 66B Sensor Box cable harness routing 66C Sensor Box connector TABLE H1 67 Intake duct control unit 68 Intake duct control unit connector 69 Rubber ring RSV4 ABS Electrical system ELE SYS 141 ...

Page 142: ...TABLE H2 70 Clamp 71 Intake duct control unit cable harness routing Electrical system RSV4 ABS ELE SYS 142 ...

Page 143: ...General wiring diagram key 1 MULTIPLE CONNECTORS 2 FRONT RIGHT TURN INDICATOR 3 COMPLETE HEADLAMP 4 FRONT LEFT TURN INDICATOR 5 RIGHT LOW BEAM LIGHT BULB RSV4 ABS Electrical system ELE SYS 143 ...

Page 144: ... RELAY 20 IMMOBILIZER AERIAL 21 REAR RIGHT TURN INDICATOR 22 TAILLIGHT ASSEMBLY 23 LICENSE PLATE LIGHT BULB 24 REAR LEFT TURN INDICATOR 25 RECOVERY LOGIC RELAY 26 MAIN FUSES 27 28 Voltage regulator 29 ALTERNATOR 30 STARTER MOTOR 31 START UP RELAY 32 BATTERY 33 INJECTION LOAD RELAY 34 OIL PRESSURE SENSOR 35 FAN 36 FAN CONTROL RELAY 37 FUEL RESERVE SENSOR 38 FUEL PUMP 39 ECU DIAGNOSIS 40 RIGHT LIGHT...

Page 145: ... GEOMETRY ENGINE 63 ABS CONTROL UNIT 64 FRONT WHEEL SPEED SENSOR 65 REAR WHEEL SPEED SENSOR 66 INERTIA SENSOR PLATFORM 67 aPRC CONTROLS 68 FAN FUSE Checks and inspections GENERAL CONCEPTS OF ELECTRICAL TROUBLESHOOTING THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKI...

Page 146: ...ect position of terminals on the connector and of the cable on the terminal CONTINUITY check Check goal this control is to check that there are not any circuit interruptions nor excessive resistance for instance caused by rust on the two terminals being inspected Tester set the tester on the continuity symbol and place the tester probes on the two circuit ends the tester emits a sound signal only ...

Page 147: ...ALL DUE CHECKS LOOKING FOR FAULT BY MOVING SLIGHTLY THE CABLE HARNESS BEING INSPECTED Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical circuit diagram Immobilizer Location on the vehicle in the ignition switch as sembly connector two way black inside the bow Electrical specifications 14 Ohm Pin out not significa...

Page 148: ...ness 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 circuit ends if there is voltage restore the cable harness DSB 04 Internal controller fault Error cause There is a fault in the instrument panel Troubleshooting Replace the instrument panel Dashboard In...

Page 149: ... Connect to the vehicle with the diagnosis tool and select the adjustable Parameters in the screen page Exhaust butterfly valve self acquisition NOTE SEARCH FOR MINIMUM AND MAXIMUM MECHANICAL STOPS STORED IN THE INSTRUMENT PANEL In case of a correct self acquisition the procedure is finished If the self acquisition is not performed correctly follow the procedure Exhaust butterfly valve calibra tio...

Page 150: ...n it is detected that the sensor circuit is open or shorted to positive DSB 07 Oil pressure sensor Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open Troubleshooting The test is performed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well DSB 08 Oil pressure sensor...

Page 151: ...is function the instrument panel can update the keys Up to 4 keys can be stored The user code is first requested to be entered ENTER THE CODE After entering the correct code the following message should be shown on the display INSERT THE X KEY INSERT THE X 1 KEY At least one key must be programmed for the next start ups If no other key is inserted within 20 seconds or if there is no power or after...

Page 152: ...INE SIDE IS IDENTIFIED WITH THE LETTER A Measurement of resistance with engine off For a correct detection of the alternator resistance 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 det...

Page 153: ... 15 0 20 0 25 0 30 Stage 2 0 15 0 20 0 25 0 30 Stage 3 0 15 0 20 0 25 0 30 RESISTANCE MEASURE MITSUBISHI FLYWHEEL Winding stage Ambient temperature ohm Afterwards heat stabilisation ohm Stage 1 2 0 10 0 15 0 15 0 20 Stage 1 3 0 10 0 15 0 15 0 20 Stage 2 3 0 10 0 15 0 15 0 20 Empty voltage Disconnect the three way connector 1 For a correct detection of the alternator voltage a measurement must be c...

Page 154: ... Start the engine and with an ammeter clamp measure each single cable If there is a significant difference be tween the measure of the single cables other than 10 A this means that the alternator is defective and must be re placed CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 2 3 A LESS THAN THOSE DETECTED WITH THE ENGINE COLD WARNING NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ON...

Page 155: ...principle Press the start up button to close the specific cir cuit taking the PIN 58 of the control unit to a voltage equal to zero ground closing Level in wiring diagram Start up signal Location on the vehicle right light switch connector inside the bow 4 ways black Electrical characteristics key released the circuit is open key pressed the circuit is closed Pin out 2 voltage 5V 3 ground CAUTION ...

Page 156: ...se Lights relay stop light daylight running lights variable geom etry intake ducts factory A fuse of 5A ABS version Stop and running lights relay B 5A fuse Instrument panel turn indicators speed instrument panel di agnosis tone wheel ECU a PRC B fuse of 5A ABS version Instrument panel turn indicators C 15A fuse Control unit D 7 5A fuse Control unit E 15A fuse High beam low beam horn F 15A fuse Coi...

Page 157: ...esc Quantity L 30A fuse Battery recharge and vehicle current consumers injection cur rent consumers red and red white cables CAUTION THERE IS ONE SPARE FUSE I Control unit Removal Remove the fuel tank Disconnect both control unit connec tors RSV4 ABS Electrical system ELE SYS 157 ...

Page 158: ...ks and the self di agnosis function Level in electrical circuit diagram Each level in which the main component involves the control unit Location on the vehicle above the filter box connector on connector control unit of ENGINE PIN 52 figure A connector of ENGINE PIN 28 figure B Pin out See the CONNECTORS section DIAGNOSIS INSTRUMENT PARAMETERS ISO Screen page screen example value with key set to ...

Page 159: ...ngine_Stopped_Power latch_Power latch 2_Power latch fin ished Engine mode Indefinite_Start up_Stable_Idle_Acceleration_Deceleration_Enters Cut Off_Cut Off_Exits Cut Off Immobilizer signal yes no Indicates whether the control unit has received the consent by the instrument panel regard ing the immobilizer coded key or user code entered manually Potential errors will be shown on the Instrument Panel...

Page 160: ...Indefinite_Key ON_Running engine_Stopped_Power latch_Power latch 2_Power latch finished Odometer Mapping selection Indefinite Track Sport Road DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS EEPROM Error P0601 circuit not operational Error cause Replace injection ECU The instrument panel does not indicate the presence of this error even in the ATT status RAM Error P0604 circuit not operational Error caus...

Page 161: ... is open check the relay electrical characteristics are correct by disconnecting it from the cable harness if not OK replace the relay if OK check relay connector engine vehicle cable harness connector and ENGINE connector of the Marelli control unit if not OK restore if OK check continuity of cable harness Blue Pink cable DIAGNOSIS INSTRUMENT LOGIC ERRORS Level 2 safety reset P0608 Error cause As...

Page 162: ...safety system has detected a serious security failure the control unit has disabled the a PRC system Troubleshooting Contact technical service See also Cylinders synchronisation Saved data file download Error cause The BUFRSVXX BIN file is saved in the diagnostics instrument memory card or in your hard disk PC if you are using Piaggio Software data regarding the control unit serial number and the ...

Page 163: ...been probably detected by the control unit solve these malfunctions and repeat the procedure Battery Function Electrically supply the vehicle battery YTZ 10 S MF is already activated loaded and sealed or al ternatively battery YT 12A BS which must be activated and loaded Level in electrical circuit diagram Battery recharge Location on the vehicle under the saddle connector on the battery Electrica...

Page 164: ...e vehicle cable harness connector and the control unit connector paying special attention to possible oxidation if not OK restore if OK check that red white cable resistance from the voltage regulator connector to the control unit connector is a few tenths of Ohm if not OK restore cable harness if OK check correct operation of the electrical alternator if not OK restore if OK check operation of th...

Page 165: ...ck continuity of the white brown cable between PIN 2 of the sensor on the cable harness side and PIN 3 if NOT OK restore cable harness if OK check continuity of the white cable between PIN 1 of the sensor on the cable harness side and PIN 6 of the ABS control unit connector If NOT OK restore cable harness if OK check the white brown cable ground insulation If NOT OK restore cable harness if OK che...

Page 166: ...speed sensor missing signal or different speed measured at the two wheels Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1108 Front speed sensor the signal works irregularly Faulty sensor or signal interference C1110 Front speed sensor the signal decreases periodically Possible tone wheel fault due to deform...

Page 167: ...rs if it is OK check continuity of the yellow brown cable across wiring side sensor PIN 2 and PIN 4 If NOT OK restore cable harness if OK check the continuity of the yellow cable across wiring side sensor PIN 1 and ABS control unit connector PIN 5 If NOT OK restore cable harness if OK check the yellow brown cable ground insulation If NOT OK restore cable harness if OK check the yellow cable ground...

Page 168: ...wheels Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1107 Rear speed sensor missing signal or different speed measured at the two wheels Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1109 Rear speed sensor the signal...

Page 169: ...ntly depending on the control voltage on PIN 2 from the injection control unit 0V down 5V up the control unit drives the electric motor with the relative polarity for raising or lowering the ducts The drive voltage delivered to the motor is deter mined in relation to battery voltage and the motor is stopped once a given current limit is reached or if the time out period of 500 ms has elapsed Level...

Page 170: ...NOSTICS INSTRUMENT ACTIVATION Variable geometry intake control NOTE The injection ECU sends the command to the variable geometry control unit to lift the ducts In the version PGDS 3 0 0 for Navigator the command works once only then it is used to take the key to OFF and wait if communication with the control unit is lost DIAGNOSIS INSTRUMENT ERRORS Variable geometry intake P0447 shorted to positiv...

Page 171: ... connector check the PINS of the connector installed directly on the motor if not OK restore if OK check electrical characteristics of the motor if not OK replace if OK check with connector of the variable geometry control unit and connector of the motor disconnected and intermediate connector connected if the red and black cables are in continuity insulated from ground and without voltage and ins...

Page 172: ...K RESTORE IF OK CHECK THE CORRECT ELECTRIC CHAR ACTERISTICS OF THE SENSOR IF NOT OK REPLACE THE SENSOR IF OK CHECK THAT THERE IS CONTINUITY ON BOTH CABLES SUPPLY INSULATION AND GROUND INSULATION CARRY OUT THE TESTS FROM THE SENSOR CONNECTOR TO THE SENSOR IF NOT OK RE STORE THE CABLE HARNESS REPLACE THE SENSOR IF OK PERFORM THE TEST FROM PIN 20 AND 35 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR DI...

Page 173: ...e cables Unscrew and remove the nut and the stud bolt Retrieve the washers Move the hand grip position sensor disconnect the two connectors Remove the hand grip position sensor NOTE WHEN REFITTING REMEMBER NOT TO INVERT THE CONNECTORS THE LIGHT BLUE CONNECTOR HAS THE BLUE CABLE AND THE WHITE CONNECTOR HAS THE WHITE CABLE RSV4 ABS Electrical system ELE SYS 173 ...

Page 174: ... means of which the torque demand is read and checked The 4 potentiometers are tinned and magnetically con trolled contactless they cannot be overhauled nor replaced Level in wiring diagram Hand grip position sensor Location on the vehicle front left part next to the cooling liquid radiator connector on the sensor Electrical specifications Not detected by a multimeter as they are contactless read ...

Page 175: ...on Voltage value of the upper potentiometer track C White upper connector throttle grip position sensor track D Example value with key ON 3555 mV Example value with engine on Voltage value times 2 of the upper potentiometer track D Throttle grip position sensor Example value with key ON 1107 mV Example value with engine on Voltage corresponding to the potentiometer track A Throttle grip opening pe...

Page 176: ...control unit connector if the cable is not ground insu lated restore the wiring If it is ground insulated and with the key set to ON check that there is power supply for the potentiometer PIN A and that PIN C is connected to ground If both are correct replace the throttle grip sensor if not check the continuity of the cable that is not functioning properly if there is continuity replace the contro...

Page 177: ...r if the voltage drops to zero if the circuit is open shorted to negative carry out the open circuit shorted to negative check the throttle grip sensor connector and the Marelli control unit connector If not OK restore If OK check circuit continuity between the two cable terminals If not OK restore if OK check the cable ground insulation from the throttle grip sensor connector or the control unit ...

Page 178: ...tracks A B Troubleshooting Check the parameters of the blue lower connector Throttle Grip Position Sensor tracks A and B if one of the two values clearly deviates from 600 1400 mV it means that this po tentiometer is defective Check the throttle grip sensor connector and the control unit connector if not OK restore If OK check that cable resistance between the throttle grip sensor connector and th...

Page 179: ...T TO THE THROTTLE GRIP SENSOR ARE ALIKE BUT THEY SHOULD NEVER BE INVERTED MARK OR CHECK THE CONNECTOR MARKING BEFORE RE MOVING THEM BLUE STAMP BLUE BAND THE BLUE CONNECTOR AND COLLAR ARE PLACED DOWNWARDS AND THE WHITE CONNECTOR AND COLLAR ARE PLACED UPWARDS Intake pressure sensor Function The pressure sensors one per bank are funda mental for calculation of generated torque for cal culation of amb...

Page 180: ...ing to the throttle position Rear Cylinder estimated Intake Pressure 1 and 3 Example value with key ON 1004 mbar Example value with engine on 735 mbar NOTE pressure estimated by the control unit according to the throttle position CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECT...

Page 181: ...or cause If shorted to positive excessive voltage has been detected at PIN 49 If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 49 Troubleshooting If shorted to positive see that the parameter of the front cylinders air Pressure Sensor on the diagnosis instrument reads approx 1200 mbar disconnect the sensor connector if the value does not vary it means that ...

Page 182: ...ormal resistance in the sensor circuit for example rusted terminals or sensor with poor performance Troubleshooting Check the filter box large connector the Marelli control unit connector and the sensor con nector if not OK restore If everything is OK check that resistance between VEHICLE connector PIN 49 and sensor connector PIN 3 is a few tenths of an Ohm If it is above that value restore cable ...

Page 183: ...the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean there is an evident defect in the intake and pressure reading systems Estimation error for front cylinder intake manifold pressure P0216 too high pressure too low pressure Error cause A substantial difference between the estimated pressure and the measured pressure has been detected for ex...

Page 184: ...t to read pressure on the throttle body check that the intake manifold is in good conditions and the pressure reading hole is clean Engine temperature sensor Function It tells the engine temperature to the control unit to improve its performance and to calculate the en gine friction for a better estimation of the generated torque Operation operating principle NTC type sensor resistance sensor inve...

Page 185: ...ircuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 12 of the ENGINE connector If shorted to negative voltage equal to zero has been detected The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting If the circuit is open shorted to positive check the sensor ...

Page 186: ...sive temperature variation has been detected for example the cause may be a contact resistance between the terminals The instrument panel does not indicate the pres ence of this error even in the ATT status Troubleshooting Check the sensor connector and the ENGINE connector of the Marelli control unit NOTES No error is detected if the sensor does not work correctly or the control unit connector or...

Page 187: ... Pin out 1 0 5 V signal 2 Ground connection DIAGNOSIS INSTRUMENT PARAMETERS Air temperature Example value with key ON 26 C 78 8 F In case of recovery this value is set by the control unit Air temperature pre Recovery Example value with key ON 40 C 40 0 F Value drawn from the signal read without taking into account any recovery the value in the exam ple refers to an open circuit CAUTION BEFORE CARR...

Page 188: ...nit connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if OK it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 37 and sensor PIN 1 check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If...

Page 189: ...en sensor Location on the vehicle left side of the vehicle 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 DIAGNOSIS INSTRUMENT PARAMETERS Oxygen sensor Example value with key ON 0 mV Ex...

Page 190: ...ctor is removed voltage almost equal to zero the status is Fault due to lean value 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 oxygen sensor signal to keep the combustion as close as possible to the stoichiometric value DIAGNOSIS INSTRUMENT ACTIVATION Oxygen sensor heating The injection relay No 33 in ...

Page 191: ...voltage at PIN 4 if it is not OK check the orange green cable continuity between the probe connector and the injection relay No 33 in the wiring diagram placed under the saddle next to the battery positive CHECK however the identification of the relay with the colour of the cables If there are also coil lower and upper injector and secondary air errors check the relay and its excitation and power ...

Page 192: ...n variable volt age In case of fault indication carry out the following troubleshooting Troubleshooting Check circuit continuity from probe connector PIN 1 and PIN 2 toward 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 continuity between the ENGINE connector PIN 22 ...

Page 193: ...njection time 1 Example value with engine on 1 9 ms Cylinder injection time 2 Example value with engine on 1 9 ms Cylinder injection time 3 Example value with engine on 1 9 ms Cylinder injection time 4 Example value with engine on 1 9 ms CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONT...

Page 194: ...be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation Lower injector cylinder 4 The injection relay No 33 in the wiring diagram placed under saddle right side CHECK however the identification of the relay with the colour of the cables is energised for 5 sec onds and the inj...

Page 195: ...the filter box cable harness If there is no voltage replace the sensor If shorted to negative disconnect the injector connector set the key to ON and check if there is a ground connection on the white green cable if there connection restore the cable har ness If there is no connection replace the injector If the circuit is open check the component correct electrical characteristic if it is not the...

Page 196: ...ted If the circuit is open an interruption has been detected Troubleshooting If shorted to positive disconnect the injector connector set key to ON activate the compo nent with the diagnosis instrument and check the voltage on the white blue cable on the injector connector if there is voltage if there is voltage restore the filter box cable harness If there is no voltage replace the sensor If shor...

Page 197: ...tors in the field of high engine revs Operation Operating principle Injector coil is excited for the petrol passage to open Level in electrical circuit diagram Coils and injectors Location on the vehicle on filter box cover connector on injectors Electrical characteristics 14 8Ω 5 at ambient temp Pin out supply ground DIAGNOSIS INSTRUMENT PARAMETERS Cylinder injection time 1 Example value with eng...

Page 198: ...ur of the cables is energised for 5 sec onds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation Upper injector cylinder 3 The injec...

Page 199: ... 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 be tween PIN 53 and component PIN and restore the cable harness Upper injector cylinder 2 P0206 short circuit to positive short circuit to negative open circuit Error cause If shorted to positive excessive vo...

Page 200: ...omponent and the Marelli control unit connector if not OK restore If OK check cable continuity be tween PIN 74 and component PIN and restore the cable harness Upper injector cylinder 4 P0208 short circuit to positive short circuit to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 68 If shorted to negative no voltage has been detected If the circ...

Page 201: ...th suitable supply from the instrument panel only Check correct operation as follows connect in series a bulb of approxi mately 2 W it should turn on if the tank is in reserve otherwise it remains off Pin out 1 12 V 2 ground connection 3 ground connection 4 12 V signal CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE ...

Page 202: ...f the circuit is open shorted to negative 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 continuity of cable harness Brown Black cable Coil Function Spark generat...

Page 203: ...y and injector activation The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation Coil 2 The injection relay No 33 in the wiring diagram placed under the saddle next 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 red cable of the co...

Page 204: ...tics of the coil if not OK replace the coil if OK check the coil connector and the Marelli control unit connector if not OK restore if OK check cable continuity between the two cable terminals if there is not continuity restore the cable harness if there is cable continuity with key set to ON check the ground insulation of the cable from coil connector or control unit connector if not OK restore c...

Page 205: ...ity with key set to ON check the ground insulation of the cable from coil connector or control unit connector if not OK restore cable harness Coil 4 P0354 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 1 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at P...

Page 206: ...rrection Example value with key ON 0 0 Example value with engine on 0 4 The system reading the intake pressure tries to balance the intake pressures between the cylinders of the rear 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 Rear cylinder throttle correction Example value with key ON 0 0 Example value with engine on 0 2 Th...

Page 207: ...Example value with engine on 4426 mV Rear throttle Potentiometer 2 voltage Example value with key ON 4113 mV Example value with engine on 4455 mV Front throttle Potentiometer 2 degrees Example value with key ON 8 0 Example value with engine on 1 5 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 mecha...

Page 208: ...BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT STATUSES Front throttle automatic self learning ice interrupted carried out limp home closed throttle stop springs check limp home self ac quisition initialise Indicates if self acquisition carried out by control unit has has not been carried out it...

Page 209: ...or If not OK restore if everything is OK check circuit continuity between the two terminals If not OK restore the cable harness if OK check the circuit ground insulation from throttle sensor connector or control unit connector If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle b...

Page 210: ...tor If it is ground insulated check that there is power 5 V at the throttle body connector PIN 2 and that PIN 6 is connected to ground If both are correct replace the throttle body potentiometer 2 sensor front throttle position P0127 short circuit to positive open circuit short circuit to negative Error cause If shorted to positive excessive voltage has been detected at PIN 21 If the circuit is op...

Page 211: ...onnected check that the resistance from the throttle control unit connector between PIN 29 and 41 is within 1 and 2 5 Ohm if it is not replace the throttle body if it is check that the throttle body is not mechanically blocked if blocked solve the problem and replace the body if it is not replace the control unit Front throttle control circuit P0186 short circuit to positive short circuit to negat...

Page 212: ...ottle voltage Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor rear throttle position P0123 signal not valid Error cause S...

Page 213: ...s and to compare it to the Potentiometer 1 front throttle voltage Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN 36 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor front ...

Page 214: ...ach key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If OK replace the throttle body Rear throttle mechanical springs self acquisition P0161 failed test Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a dete...

Page 215: ...indering throttle self learning Rear throttle position error P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Front throttle Limp Home self acquisition P0180 failed test Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not ind...

Page 216: ...k that the throttle body is clean and that there is no ice or condensation in the intake duct If OK replace the throttle body Front throttle power supply voltage during self learning P0184 low supply voltage Error cause The throttle power supply voltage is too low to carry out the self acquisition test correctly at each key ON The instrument panel does not indicate the presence of this error even ...

Page 217: ...rocess on the adjustable parameters screen page screwdriver and hammer and check again that the Throttle self learning with diagnostics instrument status indicates Carried out and that the Front throttle automatic self learning or Rear throttle automatic self learning indicate carried out Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure 0 5 0 2 bar...

Page 218: ...rcuit is closed There is an error when the general warning light turns on Troubleshooting Check if oil pressure is low with the specific gauge Neutral sensor Function It tells the gear position to the control unit from the 1st gear to the 6th gear and if the gear is neutral or riding Operation Operating principle The sensor has 2 circuits one to indicate the en gaged gear whose resistance varies a...

Page 219: ...r open circuit shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 72 If shorted to negative voltage equal to zero has been detected at PIN 72 Troubleshooting If the circuit is open shorted to positive the error is detected with gear engaged only Check the sensor connector and the VEHICLE connector of the control unit if not OK rest...

Page 220: ...icle on the handlebar connector on the sensor Electrical specifications Clutch pulled closed circuit continui ty Clutch released open circuit infinite resistance Pin out 1 voltage 5V 2 ground connection 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 SYSTE...

Page 221: ...e side stand position to the control unit Operation Operating principle If the gear is engaged and the side stand is unfol ded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in electrical circuit diagram Start up enabling switches Location on the vehicle on the stand connector between head cover and fil ter box on...

Page 222: ...tore the cable harness Bank angle sensor if applicable Function It tells the vehicle position to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground When the Marelli control unit detects this ground connection it does not enable start up or shuts off the engine Level in electrical circuit diagram Start up enabling switches Location on the vehi...

Page 223: ...stics instrument always Tip over disconnect the connector and check if there is continuity between the two PINS when the sensor is in vertical position if there is continuity replace the sensor if there is not it means that with key set to ON there is no 5V voltage at PIN 2 restore the cable harness whose pink white cable will be shorted to ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CA...

Page 224: ...detected at PIN 61 of the VEHICLE con nector If shorted to negative no voltage has been detected If the circuit is open 5V voltage has been detected Error recognition carries out only when the fan relay is activated Troubleshooting If shorted to positive check the relay electrical specifications are correct by disconnecting it from the cable harness If not OK replace the relay if OK restore the ca...

Page 225: ...IAGNOSIS INSTRUMENT PARAMETERS Secondary air valve duty cycle Example value with key ON 0 Example value with engine on Used only at 0 or 100 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 DIAGNOSIS INSTRUMENT LOGIC ERRORS Secondary air valv...

Page 226: ... characteristics and replace the component RUN STOP switch Function It tells the control unit if the rider wishes to enable engine start up or to keep the engine running Operation Operating principle If the rider wants to shut off the engine or to disable engine start up the switch should be open i e VEHICLE connector PIN 78 of the Marelli control unit must not be connected to ground Level in elec...

Page 227: ...or PIN 78 if not OK restore the cable harness if OK replace the Marelli control unit indication on the diagnostics instrument always RUN disconnect the connector and with the switch set to STOP check if there is continuity between the two cables of the switch if there is continuity replace the switch if there is not continuity it means that with key set to ON the Pink cable between switch and the ...

Page 228: ...he exhaust duct connector on the motor Electrical characteristics Electrical motor resistance PIN 4 5 2 4 Ohm Potentiometer resistance PIN 1 3 10 1 kOhm 10 Pin out 1 Power supply voltage 5V 2 Output signal 0 5V 3 Ground connection 4 Motor A supply 5 Motor B supply DIAGNOSIS INSTRUMENT PARAMETERS Exhaust butterfly valve target position 7 93 NOTE Value that control unit sends to the instru ment pane...

Page 229: ...g adjustment Exhaust butterfly valve self acquisition voltage of maximum opening end of stroke outside the foreseen field is detected Check correct tensioning of the two valve cables If potentiometer signal is below maximum threshold during adjustment Exhaust butterfly valve self acquisition voltage of minimum opening end of stroke outside the foreseen field is detected Check correct tensioning of...

Page 230: ... ground connection at PIN 5 of the con nector if there is ground connection disconnect also the instrument panel connector and if it is still present restore the black cable if there is not ground connection replace the in strument panel if there is not ground connection check if PIN 4 or PIN 5 on the motor are in continuity with ground connection if it is in continuity replace the motor If shorte...

Page 231: ...l connectors special attention to oxidation and check cables resistance if not OK restore if OK always with cables disconnected and key set to ON check normal rotation of the electric motor and replace motor potentiometer does not work correctly DIAGNOSIS INSTRUMENT ADJUSTABLE PARAMETERS Acquire exhaust valve zero position NOTE Motor is placed in a reference position to correctly search mechanical...

Page 232: ...POSITION NEVER OPERATE ON THE CONTROL CABLES IF THE MOTOR PULLEY IS NOT IN THE ZERO POSITION EXHAUST THROTTLE VALVE CALIBRATION From the Adjustable parameters screen page use the diagnostic instru ment to select Acquire exhaust valve zero position After having pressed the enter button for the zero position search shut off the vehicle and leave the keys in OFF even in the event that the instruments...

Page 233: ...is obtained Turn the key to ON CAUTION THE ZERO SEARCH OF THE DISCHARGE VALVE MO TOR PROCEDURE ENTAILS RESETTING THE EXISTING MECHANICAL STOPS AN ERROR FOR STOP SEARCH NOT CARRIED OUT IS THEN INDICATED WHICH RE MAINS UNTIL THE SELF TEACHING OF THE DISCHARGE VALVE PROCEDURE IS PERFORMED DO NOT CARRY OUT THIS OPERATION WHEN USING A NON ORIGINAL EXHAUST SYSTEM WHERE ANY CABLES CONSIDERED NOT NECESSAR...

Page 234: ...ft Present Not present DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS Quick Shift sensor electronic transmission P0462 Shorted to negative upon key ON Signal not valid Error cause If shorted to negative on key ON a voltage equal to zero has been detected at PIN 47 If signal is not valid it means that the control unit has detected activation of the lever but not its release within the set time limit Trou...

Page 235: ...time the instrument panel sends the requested command to the Marelli ECU via CAN line Electrical circuit diagram Level in wiring dia gram Traction control Location on the vehicle On the left side semi handlebar Connector location if available Inside the top fairing and instrument panel mount ing support Electrical specifications button 0 Ohm across PIN 2 and PIN 1 Infinite resistance across PIN 2 ...

Page 236: ... at PIN 13 of the instrument panel disconnect the gearshift control connector and read voltage at PIN 13 of the instru ment panel if voltage is below 1 V it means that on the brown cable there is a short circuit to ground if voltage is above 1 V approximately battery voltage replace the button sensor Indication on diagnostics instrument Invalid data due to open circuit error CASE 1 if this status ...

Page 237: ...eans that on the blue cable there is a short circuit to ground if voltage is above 1 V approximately battery voltage replace the button sensor Indication on diagnostics instrument Invalid data due to open circuit error CASE 1 if this status is displayed only with control not activated it means that circuit from PIN 19 to PIN 30 of the instrument panel is inter rupted or that PIN 30 is not grounded...

Page 238: ...ignal 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 Sensor box error inertia sensor platform P0711 Faulty sensor Signal not valid 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 gener...

Page 239: ...ommended 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 Connectors ECU Engine pinout key Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 RSV4 ABS Electrical system ELE S...

Page 240: ... 26 Cylinder 2 coil control output PIN 27 Cylinder 1 coil control output PIN 28 Rear throttle motor output PIN 29 STOP lights relay control output PIN 31 Lambda heating control output PIN 32 Lower cylinder 3 injector control output PIN 34 Engine speed sensor input PIN 35 Input for front throttle potentiometer 1 signal PIN 36 Air temperature sensor input PIN 37 Track A hand grip input PIN 39 Key in...

Page 241: ...y control output PIN 61 Variable geometry control unit control output PIN 62 Reference voltage output 5V tracks B D and front throttle PIN 63 Neutral input PIN 64 Fall sensor input PIN 65 CAN L line high speed PIN 66 Upper cylinder 2 injector control output PIN 67 Upper cylinder 4 injector control output PIN 68 Start up control output PIN 69 RSV4 ABS Electrical system ELE SYS 241 ...

Page 242: ...ol output PIN 3A PIN 4A PIN 5A PIN 6A Analogue ground connection 2 PIN 7A Direct power supply to control unit PIN 8A Injection supply PIN 1B CAN H PIN 2B CAN L PIN 3B Key PIN 4A Electric fan relay control PIN 5B Fall sensor PIN 6B Variable geometry power supply PIN 7B Power ground connection 2 PIN 8B Injection power supply PIN 1C Serial line K for diagnosis PIN 2C Clutch sensor PIN 3C Start engine...

Page 243: ...Dashboard Grey bodied instrument panel pinout key 1 Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply RSV4 ABS Electrical system ELE SYS 243 ...

Page 244: ... 11 Battery 12 Left turn indicator control 13 Normally closed button 14 15 16 Indicator reset 17 Oil sensor input 18 Normally open button 19 Normally closed button 20 K line Black bodied instrument panel pinout key 21 Battery 22 Front left turn indicator activation 23 Front right turn indicator activation 24 Aerial 2 Electrical system RSV4 ABS ELE SYS 244 ...

Page 245: ...ust valve B control output 38 Ground connection 39 Ground connection 40 Ground connection ABS Modulator ABS control unit pin out key Valve ground and ECU PIN 1 CAN H line high speed PIN 2 Front speed sensor input PIN 3 Key positive ECU PIN 4 Serial line K for diagnosis PIN 5 Battery for valve positive PIN 9 Pump engine ground PIN 10 CAN L line high speed PIN 11 Front speed sensor positive PIN 12 R...

Page 246: ...ins unaltered Communication speed messages travel at a speed of 250 kbps data arrive at nodes every 20 ms i e 50 times second CAN PROTOCOL CONT NETWORK AREA The communication protocol is CSMA CD Carrier Sense Multiple Access w Collision Detection In order to transmit every nod must first check that the BUS the connection among all devices is free before attempting to send a message with BUS Carrie...

Page 247: ...g Replace the Marelli control unit CAN line without signals U1602 Bus Off Error cause No communication on CAN line PIN 66 and or PIN 80 problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting check the Marelli control unit VEHICLE connector and the engine vehicle cable harness connector if not OK restore if OK check the ground insulation of ...

Page 248: ...y fault CAN line toward Sensor Box U1722 Intermittent signal or communication error Error cause Probable bad contact in the CAN line Troubleshooting Check the Vehicle connector pins 66 and 80 and the vehicle engine cable harness pins B2 and B3 If not OK restore If OK check pins 2 and 3 and the inertia sensor platform Sensor box connector If not OK restore If OK check overall operation of the Marel...

Page 249: ...ly 12V at pins 1 and 2 and ground at pin 4 of the ABS control unit connector If NOT OK restore the cable harness if OK change the instrument panel DIAGNOSTICS INSTRUMENT LOGIC ERRORS CAN line to ABS control unit U1711 No signal Configuration error Error cause If there is no signal no signal is received from the ABS control unit In case of configuration error some devices are present e g ABS that w...

Page 250: ...ehicle connector pins 66 and 80 If NOT OK restore If OK with key OFF disconnect the following a ABS control unit connector b inertia sensor platform Sensor box connector and check the continuity across inertia sensor platform Sensor box pin 3 and ABS control unit pin 11 If NOT OK change the vehicle cable harness if OK check the continuity across inertia sensor platform Sensor box pin 2 and ABS con...

Page 251: ... not be com pleted due to a communication problem on the CAN line In case of invalid value it means that on key ON an error of transcription occurred from the non volatile memory EEPROM to the volatile one RAM of the value concerning the rear wheel radius In this case the default value is used RSV4 ABS Electrical system ELE SYS 251 ...

Page 252: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 253: ...between the O rings and the Quick Shift uniball NOTE ONCE REASSEMBLY IS COMPLETED CENTRE TO CENTRE DISTANCE BETWEEN UNIBALL AND JOINT MUST BE APPROX 180mm 7 09in Vehicle preparation Proceed as follows to remove from the chassis Remove the underfairings the fairing lug and the radiator cowl Remove the fuel tank and the battery Disconnect and remove the hand grip position sensor Remove the throttle ...

Page 254: ...nds Fit the specific under sump engine support plate Specific tooling 020864Y Engine mounting plate See also Fairing mounting panels Lower cowl Radiator cover Fuel tank Exhaust Twistgrip position sensor Air box Removing Side stand Removing the engine from the vehicle Detach the clutch cable Engine from vehicle RSV4 ABS ENG VE 254 ...

Page 255: ... pressure sen sor Remove the rubber cap Unscrew and remove the nut retrieve the washer and disconnect the starter motor Unscrew and remove the screw re move the cable grommet and detach the three ground cables RSV4 ABS Engine from vehicle ENG VE 255 ...

Page 256: ...the chassis Working on the right hand side of the vehicle detach the exhaust valve con trol unit connector Disconnect the vehicle cable harness engine cable harness connector Unscrew and remove the three screws and remove the pinion cover Engine from vehicle RSV4 ABS ENG VE 256 ...

Page 257: ...d retrieve the two washers Loosen the drive chain adjuster screws Loosen the rear wheel fixing nut Remove the pinion releasing it from the drive chain Remove the side stand Remove the two fuel breather pipes RSV4 ABS Engine from vehicle ENG VE 257 ...

Page 258: ...he neutral sensor See also Side stand Remove the hand grip position sensor from the chassis Disconnect the voltage regulator con nector See also Twistgrip position sensor Engine from vehicle RSV4 ABS ENG VE 258 ...

Page 259: ...the vehicle unscrew and remove the screw and retrieve the washer Unscrew and remove the three plate fixing screws and remove the plate Unscrew and remove the subframe fix ing screw and retrieve the washer re move the radiator subframe RSV4 ABS Engine from vehicle ENG VE 259 ...

Page 260: ...ct the quick shift connector Cut the ties fastening the cable har ness to the engine Loosen the screw and slide off the gear shift lever and cable harness from the engine Engine from vehicle RSV4 ABS ENG VE 260 ...

Page 261: ...e two screws and retrieve the respective plates Working on the right hand side of the vehicle unscrew and remove the two screws and retrieve the respective plates and washers Also retrieve the shims on the inner side of the frame RSV4 ABS Engine from vehicle ENG VE 261 ...

Page 262: ...juster screw bushing until it turns no more Working on the right side of the vehicle unscrew and remove the nut and re trieve the washer Ease off the pin from the left hand side of the vehicle Unscrew the lower adjuster screw bushing Engine from vehicle RSV4 ABS ENG VE 262 ...

Page 263: ...ACTO RY MODEL Before aligning the engine retainers place on the frame the internal and external right and left inserts with the precautions described below Adjustment of engine height relative to the chassis is assured by properly inserts placed on the chassis front position and on the engine matching the fixing points of the engine to the chassis The hole position relative to the centreline of th...

Page 264: ...ed 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 Working from the vehicle left side in stall the le...

Page 265: ...SIS 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 tighten the two front fixing screws 2 and from the ch...

Page 266: ...he 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 side of the chassis...

Page 267: ...er 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 Connect the quick shift connector RSV4 ABS Engine from vehicle ENG VE 267 ...

Page 268: ... voltage regulator connec tor Position and fix the hand grip position sensor to the chassis WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS Connect the neutral sensor Engine from vehicle RSV4 ABS ENG VE 268 ...

Page 269: ...e 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 Place the two washers and tighten the pinion fixing screw RSV4 ABS Engine from vehicle ENG VE 269 ...

Page 270: ...nnect the vehicle cable harness engine cable harness connector Working on the right side of the vehicle connect the exhaust valve control unit connector Place the ground on the frame Fit the washer and tighten the nut Engine from vehicle RSV4 ABS ENG VE 270 ...

Page 271: ...e 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 Connect the timing sensor RSV4 ABS Engine from vehicle ENG VE 271 ...

Page 272: ... 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 Engine from vehicle RSV4 ABS ENG VE 272 ...

Page 273: ...INDEX OF TOPICS ENGINE ENG ...

Page 274: ...key 1 rear left cylinder 2 front left cylinder 3 rear right cylinder 4 front right cylinder Combustion sequence 1 3 2 4 Combustion angle cyl 1 0 cyl 2 180 cyl 3 425 cyl 4 605 Engine RSV4 ABS ENG 274 ...

Page 275: ...xing screws M8x25 6 25 Nm 18 44 lbf ft 4 Index lever fixing screw M6 1 10 Nm 7 37 lbf ft Loct 243 5 Pinion retainer 1 50 Nm 36 88 lbf ft Loct 243 6 Screw retaining pre selector on crankcase 1 25 Nm 18 44 lbf ft Loct 270 Gear indicator fixing screw M5x15 2 6 Nm 4 42 lbf ft Removing the gearbox Remove the gearbox selector Remove the clutch housing Remove the gear sensor from the flywheel side RSV4 A...

Page 276: ...Remove the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Unscrew and remove the six screws Engine RSV4 ABS ENG 276 ...

Page 277: ...he gearbox cover from the crankcase Remove the complete gearbox unit Gearbox shafts Disassembling the gearbox Position the gear in neutral checking that when the primary shaft rotates the secondary shaft does not move Remove the gearbox unit Slide off the gearbox primary shaft con trol rod together with the fork Slide off the gearbox secondary shaft control rod together with the forks RSV4 ABS Eng...

Page 278: ...r drum DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE ALTERNATOR SIDE Remove the lower crankcase A suitable extractor must be used to remove the desmodromic gearbox control rod drum roller cage from the alternator side A specific punch is required to install the desmodromic gearbox control rod drum roller cage Lubricate the seat and insert the new roller cage Engine RSV4 ABS ENG 278 ...

Page 279: ...rooves 5 3 mm 0 21 in Minimum wear limit of the pinion side secon dary shaft seat 29 97 mm 1 18 in Minimum wear limit of the clutch side primary and secondary shaft seat 19 97 mm 0 79 in Checking the desmodromic drum Check gear drum for damage scratches and wear and replace the desmodromic if necessary Check the desmodromic segment 1 for damage and wear and replace it if necessary Check the desmod...

Page 280: ... FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS Check the transmission fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary Check the transmission fork movement and if it is not regular replace the transmission forks Assembling the gearbox Move the gearbox primary and secon dary shafts together and fit them into the cov...

Page 281: ...t the desmodromic gearbox con trol rod on the cover Position the selector drum Turn the screw without tightening it Position the fork bushings into the grooves on the desmodromic control rod Insert the fork shafts making sure the springs are present RSV4 ABS Engine ENG 281 ...

Page 282: ...he gearbox unit in the crank case Specific tooling 0277308 Guide bushing for secondary gearbox shaft Remove the special tool from the alter nator side Tighten the six screws that fasten the gearbox unit to the crankcase Specific tooling 0277308 Guide bushing for secondary gearbox shaft Engine RSV4 ABS ENG 282 ...

Page 283: ...ing Install the gear sensor making the pin coincide with the slot on the desmo dromic control rod Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Working from the clutch side remove the selector control shaft Remove the gear locking pawl and re trieve the washer and the spring RSV4 ABS Engine ENG 283 ...

Page 284: ...ing 020862Y Gearbox control rod roller cage fitting punch 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 Gearbox control rod roller cage fitting punch Position a new oil seal on the spacer ...

Page 285: ...amage 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 NOTE ON THE MOTORCYCLE THERE MAY BE TWO DIFFERENT TYPES OF STARTER MOTOR DENSO OPT 1 OR MITSUBA OPT 2 Unscrew the starter motor fixin...

Page 286: ...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 Engine RSV4 ABS ENG 286 ...

Page 287: ... on the freewheel sliding surface 2 Fitting the idle gear NOTE BE CAREFUL IN MAINTAINING THE CORRECT GEAR RATIO FOLLOWING THAT INDICATED IN THE TABLE MOTOR AND GEAR Model Engine No Starter motor Transmission Freewheel gear MY 2009 2010 V4 marking From the beginning of production at No 7419 Denso Z 12 64 Z 49 MY 2010 V4 marking From No 7420 to No 8922 Mitsuba Z 12 64 Z 49 MY 2011 V4 A mark ing From...

Page 288: ...rews fastening cover onto centre pins M6x25 6 12 Nm 8 85 lbf ft 2 Cover fastener screws alternator side M6x40 2 12 Nm 8 85 lbf ft 3 Blow by union fastener screws M5x16 3 7 Nm 5 16 lbf ft Stator fixing screw UNI 5931 CL8 8 M6x25 3 10 Nm 7 37 lbf ft Loct 243 Flanged screw M5x12 1 6 Nm 4 42 lbf ft Loct 243 Engine RSV4 ABS ENG 288 ...

Page 289: ...ES OF FLY WHEEL MITSUBISHI OR KOKUSAN IN THIS ENGINE THE TWO FLYWHEELS CANNOT BE INTERCHANGED AS WELL AS THE TOOLS USED FOR THEIR LOCKING AND REMOVAL TOOLS FOR KOKUSAN FLYWHEEL Flywheel extractor cod 020913Y Flywheel lock cod 020914Y TOOLS FOR MITSUBISHI FLYWHEEL Flywheel extractor cod 020847Y Flywheel lock cod 020848Y FIND BELOW THE REMOVING AND REFIT TING PROCEDURE OF THE MITSUBISHI FLY WHEEL TH...

Page 290: ...shaft hole which will act as a mounting base for flywheel extraction Remove the flywheel using the specific extractor Collect the TCEI M10x20 screw Specific tooling 020847Y Flywheel extractor Mitsubishi 020913Y Flywheel extractor Kokusan See also Removing the flywheel cover Inspecting the cover components Unscrew and remove the three Blow by system fitting screws Remove the Blow by system fitting ...

Page 291: ... OF THE SAME TYPE SET THE NEW OIL SEAL WITH THE MARKING ON THE EDGE FACING OUTWARD See also Removing the flywheel cover Installing the flywheel Position the flywheel on the crankshaft Block flywheel rotation using the spe cific tool Tighten the screw Specific tooling 020848Y Flywheel retainer Mitsubishi 020914Y Flywheel retainer RSV4 ABS Engine ENG 291 ...

Page 292: ...ng the external edge of the cover Insert the cover together with the sta tor Recommended products Three bond Sealing paste Turn the five screws 1 and the two screws 2 Tighten the screws working in stages and diagonally Insert the Blow by system pipe and fasten it with a new clamp Engine RSV4 ABS ENG 292 ...

Page 293: ...s 1 Engine speed sensor fixing screw 1 8 Nm 5 9 lbf ft 2 TE flanged screw M6x20 1 12 Nm 8 85 lbf ft 3 Flanged TE screws M6x35 2 12 Nm 8 85 lbf ft 4 Flanged TE screws M6x22 16 12 Nm 8 85 lbf ft 5 Engine timing inspection cap 1 25 Nm 18 44 lbf ft RSV4 ABS Engine ENG 293 ...

Page 294: ...ransmission gear Disassembling the clutch Unscrew and 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 See also Removing the clutch cover En...

Page 295: ...otation using the spe cific tools Unscrew and remove the clutch bell fixing nut Specific tooling 020849Y Clutch retainer Remove the slipper unit Remove the clutch hub Remove the clutch hub cam tower RSV4 ABS Engine ENG 295 ...

Page 296: ... Collect the shim washer Collect the clutch housing Remove the clutch gear that controls the oil water pumps Remove the needle cage Engine RSV4 ABS ENG 296 ...

Page 297: ...istic 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 RSV4 ABS Engine ENG 297 ...

Page 298: ... all 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...

Page 299: ... 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 ORANGE 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 RSV4 ABS Engine ENG 299 ...

Page 300: ...ll the clutch gear making it mesh with the oil water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL Insert the clutch bell making it engage with the engine pinion Fit the shim washer Engine RSV4 ABS ENG 300 ...

Page 301: ...PPER SPRINGS First assembly solution Specific assistance Model Engine No Spring No Thickness Washer Thickness Spring No Thickness Washer Thickness My2009 2010 All engines 3 0 8 mm NO 3 0 8 mm NO Alternatively Alternatively My2011 up to No 3637 3 0 8 mm NO 2 0 9 mm YES 0 9 mm My2011 from No 3638 2 0 9 mm YES 0 9 mm 2 0 9 mm YES 0 9 mm CAUTION ONCE THE SPRINGS HAVE BEEN RECEIVED BY THE SPARE PARTS V...

Page 302: ...correctly Where specified in the table insert the washer 1 Block clutch bell rotation using the spe cific tool Tighten the clutch bell fixing nut Specific tooling 020849Y Clutch retainer Insert the disc with friction material and the black tooth into the bell Engine RSV4 ABS ENG 302 ...

Page 303: ... of the metal discs into the bell Insert the flat washer Insert the belleville spring with the con cave side facing outward Insert the disc covered with the friction material into the bell RSV4 ABS Engine ENG 303 ...

Page 304: ...bearing and the shim washer Place the thrust plate CAUTION IN THE EVENT OF AN ORANGE SPRING IF YOU WANT TO LIGHTEN THE LOAD ON THE CLUTCH LEVER INSERT THE SHIMMING WASHER IF NOT ALREADY PRESENT IN THE EVENT OF A BLUE SPRING THE SHIMMING WASHER MUST NOT BE INSERTED THE SOLUTIONS ORANGE SPRING SHIMMING WASHER AND BLUE WASHER ARE EQUAL AND CANNOT BE INTERCHANGED Engine RSV4 ABS ENG 304 ...

Page 305: ...Fit the clutch springs 4 Insert the spring holder cap 2 and the shimming washers 3 onto the screws 1 BLUE SPRING CAUTION PAY ATTENTION WHEN REFITTING RESPECT THE SEQUENCE OF SCREW CAP AND SPRING Fit the clutch springs 3 Insert the spring holder cap 2 onto the screws 1 Tighten the six screws operating in stages and diagonally RSV4 ABS Engine ENG 305 ...

Page 306: ...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 the guide 4 Specific tooling 020926Y Tool for fitting the cl...

Page 307: ...Diam 20 mm 0 79 in Ø 12 mm 0 47 in Diam 12x20 mm 0 47x0 79 in MY 2011 V4 A mark ing From No 1002 to No 1440 From No 8785 to No 8922 Seat Diam 20 mm 0 79 in Ø 12 mm 0 47 in Diam 12x20 mm 0 47x0 79 in MY 2011 V4 A mark ing From No 1441 onwards Seat Diam 22 mm 0 87 in Ø 12 mm 0 47 in Diam 12x20 mm 0 47x0 79 in Position the starting transmission gear on the crankcase Position the gasket and the two do...

Page 308: ...VALVE COVER pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 37 lbf ft 2 Coil fixing screws 4 8 Nm 5 9 lbf ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lbf ft Engine RSV4 ABS ENG 308 ...

Page 309: ...bf ft Loct 243 5 Flanged head nut 12 30 55 Nm 22 13 40 56 lbf ft Molykote spray on thread and under head 6 Head fastener screw chain side M6x55 4 12 Nm 8 85 lbf ft TIMING SYSTEM pos Description Type Quantity Torque Notes 1 Screws fastening the timing system gear on the intake shaft M8 4 30 Nm 22 13 lbf ft Loct 243 2 Skid fastener screws M8 2 20 Nm 14 75 lbf ft Loct 243 3 Skid fastener screws M6x18...

Page 310: ...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 Front head Engine RSV4 ABS ENG 310 ...

Page 311: ... from the hole on the clutch cover Move cylinder piston 1 left rear piston to the TDC overlap Turn the crankshaft 150 in the direc tion of engine rotation direction of trav el Insert the pin from the flywheel side in the hole in the crankshaft NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION DO NOT USE IT FOR TIGHTENING OPERATIONS Specific tooling 020852Y Cranksha...

Page 312: ...s Unscrew and remove the camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the direction of engine rotation direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ...

Page 313: ...rew and remove the second in take camshaft gear screw Leave the gear on the camshaft Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020865Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in ...

Page 314: ...ot show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the part Characteristic Maximum camshaft axial clearance intake ex haust 0 4 mm 0 0016 in WARNING THE EXHAUST CAMSHAFTS OF THE FRONT AND REAR CYLINDER BANKS MUST ...

Page 315: ...xhaust camshafts 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 camshaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RETAINER SCREWS ON THE INTAKE CAM SHAFT Fit the U bolts with the nine O rings and locator pins Fit the new washers under the screws 2 near the spark plug holes only Tighten t...

Page 316: ...o U bolt screws 1 and the screw 2 that was not fitted previ ously Align the intake camshaft with the spe cific hole on the U bolt Insert the specified 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 Engine RSV...

Page 317: ...ead 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 020848Y Flywheel retainer 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Turn the crankshaft back to the previous position in w...

Page 318: ...urn 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 Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible Block cranksh...

Page 319: ...mshaft 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 in take camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Slide the gear off the intake camshaft Block the gear to t...

Page 320: ...d 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 fixed chain slider screw Remove the fixed chain slider Unscrew and remove the mobile chain slider screw Remove the mobile chain slider Remove the camshaft control gear connected with a clamp to the timing chain Engine RSV4 ABS ENG 320 ...

Page 321: ...cated above Remove the front head slipping it off the stud bolts Collect the gasket and the two dowel pins Remove the chain tensioner complete with O ring using the specific tool If the O ring is not on the chain ten sioner make sure it was not left in the crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Tool for fitting removing the timing chain tensioner RSV4 ABS Engi...

Page 322: ...s of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air Front head fitting 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 Engine RSV4 ABS ENG 322 ...

Page 323: ...hain 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 THIS WASHER CANNOT BE INSTALLED ON THE CHAIN TENSIONER OF ONE CYLINDER BANK ALONE ALWAYS INSTALL WASHERS ON BOTH CHAIN TENSIONERS Place a new ...

Page 324: ... following the same order Tighten the two screws according to the sequence a b Install the camshaft control gear con nected with a clamp to the timing chain 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 Engine RSV4 ABS ENG 324 ...

Page 325: ... to the TDC overlap Turn the crankshaft 150 in the direc tion of engine rotation direction of trav el Insert the pin from the flywheel side in the hole in the crankshaft NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION DO NOT USE IT FOR TIGHTENING OPERATIONS Specific tooling 020852Y Crankshaft timing pin RSV4 ABS Engine ENG 325 ...

Page 326: ... RETAINER SCREWS ON THE INTAKE CAM SHAFT Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with the nine O rings and locator pins Install the oil pipe Fit the new washers under...

Page 327: ...cific 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 the chain tensioner with special tool Specific tooling 020855Y Lever for engaging the chain tensioner RSV4 ABS Engine ENG ...

Page 328: ... 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 020848Y Flywheel retainer 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Turn the crankshaft back to the previous position in which the camsha...

Page 329: ...he hole in the crankshaft NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION DO NOT USE IT FOR TIGHTENING OPERATIONS Specific tooling 020852Y Crankshaft timing pin See also Head cover removal Removing the clutch cover 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 tim...

Page 330: ...C 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 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 ...

Page 331: ...the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020865Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in stages and diago nally 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 int...

Page 332: ...uge if necessary replace the part Characteristic Maximum camshaft axial clearance intake ex haust 0 4 mm 0 0016 in WARNING THE EXHAUST CAMSHAFTS OF THE FRONT AND REAR CYLINDER BANKS MUST BOTH BE OF THE SAME TYPE EITHER WITH A CONVENTIONAL GEAR OR WITH A SELF ADJUSTING CAM SHAFT GEAR THE TWO TYPES OF CAMSHAFT ARE INTERCHANGEABLE ON ALL ENGINES IRRESPECTIVE OF THE CAMSHAFT TYPE ORIGINALLY INSTALLED ...

Page 333: ...ith the nine O rings and locator pins Fit the new washers under the screws 2 near the spark plug holes only Tighten the seven screws 2 operating in stages and diagonally Do not fit the eighth screw 2 fastening the oil pipe yet Move the gear from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Specific tooling 020865Y Support for camshaft gear on head Fit the U...

Page 334: ...e of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock 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 ...

Page 335: ...ns Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Rear head removal Remove the rear head cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Turn the crankshaft 450 one complete turn 90 in the direction of motor rotation direction of travel in order to align the hole on the intake camshaft gear with the hole on the U bolt This ensures that all ...

Page 336: ...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 second in take camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Slide the gear off the intake camsh...

Page 337: ...nd locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust camshafts from the rear head Unscrew and remove the mobile chain slider screw Remove the mobile chain slider Unscrew and remove the fixed chain slider screw Remove the fixed chain slider Remove the camshaft control gear connected with a clamp to the timing chain RSV4 ABS Engine ENG 337 ...

Page 338: ...icated above Remove the rear head slipping it off the stud bolts Collect the gasket and the two dowel pins Remove the chain tensioner complete with O ring using the specific tool If the O ring is not on the chain ten sioner make sure it was not left in the crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Tool for fitting removing the timing chain tensioner Engine RSV4 A...

Page 339: ...s of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air 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 RSV4 ABS Engine ENG 339 ...

Page 340: ...hain 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 THIS WASHER CANNOT BE INSTALLED ON THE CHAIN TENSIONER OF ONE CYLINDER BANK ALONE ALWAYS INSTALL WASHERS ON BOTH CHAIN TENSIONERS Place a new ...

Page 341: ... following the same order Tighten the two screws according to the sequence a b Install the camshaft control gear con nected with a clamp to the timing chain 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 RSV4 ABS Engine ENG 341 ...

Page 342: ... 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 exhaust camshaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RETAINER SCREWS ON THE INTAKE CAM SHAFT Engine RSV4 ABS ENG 342 ...

Page 343: ... the screws 2 near the spark plug holes only Tighten the ten screws 1 2 working in stages and diagonally Cut the clamp that binds the chain to the gear Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot Insert the specific timing pin Specific tooling 020851Y Camshaft timing pin Apply Loctite 243 thread lock on the thread of the t...

Page 344: ...020848Y Flywheel retainer 020850Y Primary gear lock 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 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 ...

Page 345: ...aligned If this is not the case repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal Remove the head Place the head on supporting surface Number the valves and their bucket tappets in order to position them correctly upon refitting Remove the bucket tappets and the adjustment shims using a magnet Compress the valve springs wit...

Page 346: ...emoval Remove the cotters using a magnet Release the valve springs Remove the upper cap and the springs CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Remove the valves Engine RSV4 ABS ENG 346 ...

Page 347: ... Valve stem distortion 0 25 mm 0 0098 in If the valve stem when measured with a micro meter is worn to its limit and the clearance ex ceeds the specified limit replace the valve If the valve stem lies within the specific limit re place the valve guide Recheck the clearance after replacing the valve or the guide Characteristic Intake valve stem diameter 4 985 4 965 mm 0 1963 0 1954 in Exhaust valve...

Page 348: ... Valve head eccentricity 0 03 mm 0 0012 in Coating may get slightly damaged in the indicated area Valve installation Lubricate the valve stem and insert the valves on the valve guide Position the springs with the closest turns facing the head of the valve CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE AS THE EXHAUST VALVES HAVE A SINGLE SPRING Engine RSV4 ABS ENG 348 ...

Page 349: ... Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjustment shims and then the bucket tappets NEW SPRING KIT From engine number V4 A 4215 onwards and on the following engine numbers RSV4 ABS Engine ENG 349 ...

Page 350: ...alve springs are marked blue and the new exhaust springs are marked red The old intake valve springs are marked blue and the old exhaust springs are marked yellow The new springs are identifiable as they are marked differently than the old springs on the new springs the first turn is coloured completely whereas the old springs are marked with lines on the side CAUTION WHEN REPLACING ALL THE SPRING...

Page 351: ...bricate the thread and un der the head 5 Crankcase fixing screw M8x70 4 25 Nm 18 44 lbf ft Lubricate the thread and under the head 6 Crankcase fixing screw M8x35 3 25 Nm 18 44 lbf ft Lubricate the thread and under the head 7 Crankcase fixing screw M6x45 2 10 Nm 7 37 lbf ft Lubricate the thread and under the head 8 Crankcase fixing screw M6x20 5 10 Nm 7 37 lbf ft Lubricate the thread and under the ...

Page 352: ...IGNITION UNIT pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 ISO 8674 M10x1 1 50 Nm 36 88 lbf ft Loct 243 Engine RSV4 ABS ENG 352 ...

Page 353: ... 88 51 lbf ft 5 Tone wheel fixing screw M8x1 25 1 50 Nm 36 88 lbf ft Loct 3M or 270 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 head Block crankshaft rotation using the specific tool Specific tooling 02085...

Page 354: ... Remove the countershaft from the al ternator side Remove the countershaft gear Remove the key on countershaft Engine RSV4 ABS ENG 354 ...

Page 355: ... THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR RSV4 ABS Engine ENG 355 ...

Page 356: ...ntershaft Block crankshaft rotation using the specific tool Tighten the nut on the countershaft Specific tooling 020849Y Clutch retainer Main transmission gear removal Remove the clutch Turn the crankshaft and align the ref erences on the countershaft gear and the primary shaft gear Block crankshaft rotation using the specific tool Specific tooling 020850Y Primary gear lock Engine RSV4 ABS ENG 356...

Page 357: ... screw Remove the tone wheel See also Disassembling the clutch Unscrew and remove the primary shaft fixing nut Remove the crankshaft blocking tool Specific tooling 020850Y Primary gear lock Remove the primary shaft gear RSV4 ABS Engine ENG 357 ...

Page 358: ...ENTIFIED 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 Prep...

Page 359: ... and intermediate gear countershaft See also Magneto flywheel removal Water pump Disassembling the gearbox Main transmission gear removal Front head removal Rear head removal Removing the oil sump Balancing countershaft removal Crankcase opening Position the engine with the heads fac ing upward unscrew and remove the screw 24 RSV4 ABS Engine ENG 359 ...

Page 360: ...ws remove them in order indicated above Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above 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 ABS ENG 360 ...

Page 361: ...57Y Crankshaft bearing 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 Extract the snap ring slide off the pin RSV4 ABS Engine ENG 361 ...

Page 362: ...art If the heads were removed position the specific special tool to keep the pis tons from coming out Specific tooling 020858Y Device for holding the pistons in the cylinders 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 ABS ENG 362 ...

Page 363: ...iner 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 ABS Engine ENG 363 ...

Page 364: ...aracteristic Maximum wear limit of the rod small end 17 05 mm 0 671 in Maximum rod small end radial clearance 0 055 mm 0 0022 in Maximum axial clearance between the con necting rod and the crank pin 0 55 mm 0 022 in Maximum connection rod pin clearance 0 08 mm 0 0031 in Inspecting pistons WITHOUT CLASS SELECTION Characteristic Minimum piston diameter 77 914 mm 3 067 in Maximum clearance between th...

Page 365: ...A 0 027 0 045 mm 0 0010 0 0017 in With piston class B 0 025 0 043 mm 0 0009 0 0016 in Maximum wear limit of the clearance between pin and pin hole on the piston 0 040 mm 0 0016 in Maximum permitted clearance between piston ring 1 starting from the bottom and the cor responding slot on the piston 0 1 mm 0 0039 in Maximum permitted clearance between piston ring 2 starting from the bottom and the cor...

Page 366: ...g class combinations for primary drive side connecting rod pair AA AA AA ZZ BB AA AA ZZ BB BB BB BB AA CC BB BB AA CC CC CC CC BB DD CC CC BB DD DD DD DD CC EE DD DD CC EE EE EE EE DD FF EE EE DD FF FF FF FF GG EE FF FF GG EE balancing class pairing usable as an alternative to the first choice CAUTION WHEN REPLACING A CRANKSHAFT WITH NO IDENTIFIABLE BALANCING CLASS ON EN GINES PRIOR TO THE INTRODU...

Page 367: ...on 1 connecting rod is re placed the one relative to piston 2 must also be replaced and vice versa if the piston 3 connecting rod is re placed the one relative to piston 4 must also be replaced and vice versa 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 ONLY ONE CONNECTING ROD SELECTION CLASS IS SPECIFIED FOR REPLAC...

Page 368: ...lutch side CRANKCASE CATEGORY Specification Desc Quantity Class A Bushing seat diameter 52 023 52 018 mm 2 0481 2 0479 in Class B Bushing seat diameter 52 018 52 013 mm 2 0479 2 0477 in Class C Bushing seat diameter 52 013 52 008 mm 2 0477 2 0475 in SHAFT CATEGORY The three crankshaft main journals 1 flywheel side 2 central 3 clutch side they are each selectable in two pairs of classes A B up to e...

Page 369: ...entre main journal 4 clutch side main journal Choose the bushings used for assembly from the following table CRANKSHAFT BUSHINGS UP TO NO 3990 Crankshaft main journal Class A crankcase Class B crankcase Class C crankcase Class A main journal Bushing blue Bushing blue Bushing red Class B main journal Bushing yellow Bushing blue Bushing blue CRANKSHAFT BUSHINGS FROM NO 3991 Crankshaft main journal C...

Page 370: ...BLUE recommended solution 2 YELLOW RED if combination 1 is not possible In combination 2 the YELLOW semi bushing must be installed on the connecting rod shank and the RED semi bushing must be installed on the cap CRANKSHAFT BUSHING REPLACEMENT PROCEDURE When replacing the big end bushings make sure that the tang of the semi bushing is correctly housed in the corresponding notch in the connecting r...

Page 371: ... 020364Y 25 mm Adaptor 020359Y 42 x 47 mm punch 020376Y Adapter handle 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 RSV4 ABS Engine ENG 371 ...

Page 372: ...63Y Crankshaft oil seal punch D 20 mm 020359Y 42 x 47 mm punch 020376Y Adapter handle Position the 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 Engine RSV4 ABS ENG 372 ...

Page 373: ...N 1 Crankshaft with removable gear If the two timing chain control sprockets 1 2 on the crankshaft were removed check their exact positioning carefully because the two components cannot be interchanged Remember that the thicker sprocket 1 must be positioned from the clutch side of the crankshaft Position the sprocket 1 with the smooth side fac ing outward of the crankshaft Move the sprocket 1 up a...

Page 374: ... place the lining as shown in the figure The greater diameter side is facing outwards the engine Lubricate the crankshaft pins and in sert them into their positions Install the connecting rod shank piston assembly in the relative cylinders Join the crankcases If the special tool was used remove it to keep the pistons from coming out Specific tooling 020858Y Device for holding the pistons in the cy...

Page 375: ... 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 Installing connecting rods pistons CAUTION REPLACE PISTONS THUS M...

Page 376: ...ing can be of a different type according to the type of piston used The pistons with the letter W on the crown next to the selection marking A or B fit an upper ring cast iron different from the pistons that do not have this marking chrome steel This ring can be identified with the code KDN 5 which when fit ting must be placed upwards CAUTION THE TWO RINGS R AND KDN5 CANNOT BE INTER CHANGED THE PI...

Page 377: ... 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 big end on the right side Position the special tool on the crank case Partially insert the connecting rod shank piston assembly in the corre sponding cylinder with the arrow on the piston twisted 45 towards the ex haust ...

Page 378: ...connecting rod shank and cap correctly combin ing the respective numerical referen ces Use new connecting rod screws lubri cating the thread and under the head Proceed with tightening according to the procedure described in the tighten ing torque table using the torque wrench and angular tightening with a goniometer Engine RSV4 ABS ENG 378 ...

Page 379: ...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 Pre tighten the screws in the following order 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Then tighten them fully following the same o...

Page 380: ... Turn the engine with the heads facing upward Tighten the screw 24 Engine RSV4 ABS ENG 380 ...

Page 381: ...Thermal group CYLINDERS PISTON pos Description Type Quantity Torque Notes 1 Screws fastening water union onto crankcase M6x40 2 10 Nm 7 37 lbf ft Lubrication RSV4 ABS Engine ENG 381 ...

Page 382: ...5 lbf ft 6 Screws fastening the pump to the crankcase M6 5 1 10 Nm 7 37 lbf ft 7 Oil pipe union fixing screw M6 1 8 Nm 5 90 lbf ft Loct 243 Screw fastening the diffuser in the oil sump 1 10 Nm 7 37 lbf ft Oil pump Removing Remove the gearbox Remove the water pump Unscrew and remove the six screws fastening the oil pump to the crank case Remove the oil pumps OIL PUMP REMOVAL Place the oil pumps on ...

Page 383: ...crews Remove the cooling oil pump cover Collect the two dowel pins Remove the external rotor from the cover Remove the internal oil cooling rotor Collect the hitch pin Unscrew and remove the four lubrica tion oil pump cover screws RSV4 ABS Engine ENG 383 ...

Page 384: ...brication ro tor Collect the drive spindle Installing Position the lubrication pump internal rotor 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 Engine RSV4 ABS ENG 384 ...

Page 385: ...tion the dowel pins Position the pump cover and the inter mediate pump casing on the lubrica tion pump s external rotor To check that the intermediate casing is oriented correctly check the gasket seat Tighten the four lubrication oil pump cover screws RSV4 ABS Engine ENG 385 ...

Page 386: ... Position the oil cooling pump s internal rotor Position the dowel pins and the exter nal rotor on the cooling oil pump cover Fit the pump cover on the internal rotor Tighten the four cooling oil pump cover screws Fit a new gasket Engine RSV4 ABS ENG 386 ...

Page 387: ...N THE ROSE 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 pressure relief valve to gether with gasket DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE RSV4 ABS Engine ENG 387 ...

Page 388: ...our 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 SAS valve SECONDARY AIR SYSTEM pos Description Type Quantity Torque Notes 1 Secondary air system solenoid screws 2 10 Nm 7 37 lbf ft Engine RSV4 ABS ENG 388 ...

Page 389: ...ction 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 Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves RSV4 ABS Engine ENG 389 ...

Page 390: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 391: ...Fuel pump Removing Remove and empty the fuel tank Loosen the pipe grommet screw Detach the fuel pipe Unscrew and remove the screws Remove the fuel pump Injection RSV4 ABS Power supply P SUPP 391 ...

Page 392: ...Diagram key 1 Control unit position 2 Hand grip position sensor 3 Fall sensor 4 Outlet valve Power supply RSV4 ABS P SUPP 392 ...

Page 393: ...ir engines but actually a specific torque The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit The control unit refers to specific handle maps to determine by how much and how quickly the throttle valves are opened The param...

Page 394: ...d fuel con sumption The upper injectors are designed for maximum power 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 LOWER INJECTORS Remove the air filter box Disconnect the injector connectors Unscrew and remove the...

Page 395: ...njectors identified by green collars See also Control unit Removing the throttle body Completely remove the air filter box Disconnect the injector fuel pipe Release the 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 RSV4 ABS Power supply P SUPP 395 ...

Page 396: ...alfunction As all the internal components of the throttle body assembly potentiometers and electrical motor are contactless no electrical diagnosis is possible Functional tests are performed on the throttle body assembly by the control unit during vehicle oper ation with the results visible on the diagnostic instrument The only action possible before replacing the com ponent is checking the connec...

Page 397: ...gulation stepper mo tors thermoactuators etc are not necessary Variable geometry intake IF APPLICABLE To access the variable geometry intake system remove the air filter box cover The system consists of two intake ducts for each manifold which may be joined long ducts or sep arated short ducts CAUTION TAKE PARTICULAR CARE DURING REASSEMBLY THE SCREW SEAT WITH THE CHAMFER IS ASSEMBLED IN THE FRONT ...

Page 398: ... for raising or lowering the ducts The drive voltage delivered to the motor is deter mined in relation to battery voltage and the motor is stopped once a given current limit is reached or if the time out period of 500 ms has elapsed There is no feedback relative to duct position If in doubt use the diagnostic instrument to actuate the ducts In the case of a defect in the variable geometry control ...

Page 399: ...ed and adjusted if necessary to ensure correct equalisation between cylinders 1 3 and 2 4 On the diagnostic instrument select Cylinder pressure equalisation from the Adjustable parameters screen In order for the procedure to start the engine must have a water temperature above 80 C 176 F be at the idling speed there may not be any control unit errors As soon as the fans are activated approx 101 C ...

Page 400: ...ight 1 IF FIT TED Remove the remaining cones by un screwing the eight screws 2 Remove the two caps 3 CAUTION WHEN REFITTING THE COVERS PAY ATTENTION TO NOT DAMAGE THEM To ensure correct engine operation one of the two screws of each throttle body must always be closed Motorcycles are factory set with screws 1 and 2 turned by half a turn and screws 3 and 4 closed Power supply RSV4 ABS P SUPP 400 ...

Page 401: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 402: ...1 5 1 80 Nm 59 lb ft 2 Front brake disc fixing screws M8 6 6 30 Nm 22 13 lb ft Loct 243 Removing the front wheel Hold the vehicle front part Remove the front mudguard Unscrew the screws fixing the front pli ers and slide them off the disc See also Front mudguard Suspensions RSV4 ABS SUSP 402 ...

Page 403: ... holes on the pin During extraction support the wheel and then remove it Checking the front wheel FRONT WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fal...

Page 404: ...ssive wear ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS 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 ...

Page 405: ... 2 Semi handlebar safety screw M6 1 1 10 Nm 7 37 lbf ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lbf ft 4 Right light switch M4 2 1 5 Nm 1 11 lbf ft 5 Left light switch M5 2 1 5 Nm 1 11 lbf ft 6 Throttle control fixing screws M5 2 2 Nm 1 47 lbf ft 7 Traction control control unit fixing screw M4 1 2 Nm 1 47 lbf ft RSV4 ABS Suspensions SUSP 405 ...

Page 406: ...CLUTCH LEVER pos Description Type Quantity Torque Notes 1 Clutch lever collar fixing screws M6 1 10 Nm 7 37 lbf ft Front fork Diagram Suspensions RSV4 ABS SUSP 406 ...

Page 407: ...THE NUMBER OF CLICKS AND OR TURNS OF ADJUST MENT SCREW 3 ALWAYS START FROM THE SOFTEST SETTING ADJUSTER SCREW TURNED FULLY ANTI CLOCKWISE FRONT FORK STANDARD SETTING FOR ROAD USE ONLY Specification Desc Quantity Rebound damping adjustment screw 1 Unscrew 12 clicks from fully closed Compression damping adjustment screw 2 Unscrew 14 clicks from fully closed Spring preloading nut 3 screw 8 turns from...

Page 408: ... AND THE END OF THE FORK SLEEVE Removing the fork legs Remove the front wheel Support the fork stanchion and loosen the screws on the upper yoke Loosen the screws on the semi han dlebars Loosen the lower yoke screws Remove the stanchion See also Removing the front wheel Suspensions RSV4 ABS SUSP 408 ...

Page 409: ...ot to damage the fork Set the minimum spring preloading Unscrew the upper cap from the sleeve using a specific Öhlins tool Loosen the cap holding the upper spring ring nut still with a wrench Unscrew the upper adjustment cap Remove the complete cap RSV4 ABS Suspensions SUSP 409 ...

Page 410: ...oad spring Remove the preload spring Drain the fork oil into a specific con tainer taking care not to allow the pre load pipe and the hydraulic rebound damping brake adjustment pipe to es cape PROCEDURE FOR SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Suspensions RSV4 ABS SUSP 410 ...

Page 411: ...itting operations Operating on the upper screw unload the spring Loosen the cover without unscrewing it completely Place the fork vertically locking it in a vice by the specific tool Completely unscrew the plug Specific tooling AP8140149 Protection for fitting operations RSV4 ABS Suspensions SUSP 411 ...

Page 412: ...ng pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Pliers for pre fill pipe Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Suspensions RSV4 ABS SUSP 412 ...

Page 413: ...TO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Disassembling the fork PROCEDURE FOR OHLINS FORKS Fix the fork again in a vice taking care not to damage the fork Remove the preload pipe Remove the sleeve 2 from the wheel holder stanchion 1 RSV4 ABS Suspensions SUSP 413 ...

Page 414: ...lot screwdriver to remove the oil seal 5 CAUTION PLACE A STRIP OF RUBBER ON THE EDGE OF THE SLEEVE TO PROTECT IT FROM DAMAGE WHEN REMOV ING THE OIL SEAL 5 Replace the following components with new ones oil seal 5 dust gaiter 3 CAUTION BE EXTREMELY CAREFUL IN ORDER THAT NO FOREIGN BODIES GET INTO THE SLEEVE OR THE WHEEL HOLDER STEM NEVER REUSE OIL Suspensions RSV4 ABS SUSP 414 ...

Page 415: ...1 Remove the spring guide support ring 2 Remove the spring guide 3 noting its direction of installation to ensure cor rect reassembly Remove the other spring guide snap ring 4 Remove the ring 5 and extract the rubber buffer 6 Remove the ring nut on which the threaded pipe is attached from the pumping member pin RSV4 ABS Suspensions SUSP 415 ...

Page 416: ...he internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Suspensions RSV4 ABS SUSP 416 ...

Page 417: ...ing 1 the movable bushing 2 the ring 3 and the oil seal 4 from the stem Remove the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Pumping member ring nut locking spanner RSV4 ABS Suspensions SUSP 417 ...

Page 418: ... A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Springs Check that the springs are in good condition Check that the length of the springs is within the specified tolerance range Replace the springs if t...

Page 419: ... SUR FACE Replace the following components with new ones seal dust gaiter the two OR on the regulator PROCEDURE FOR SACHS FORKS Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value re...

Page 420: ... good conditions Check that the spring length is within the limit value Replace the spring if its length does not fall within the limit values SPRING MINIMUM LENGTH WHEN UNLOADED 265 mm 10 4 in Check that the following components are in good conditions upper bushing lower bushing piston If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE...

Page 421: ...e the following components with new ones seal ring dust gaiter O Ring on the cap Reassembling the fork PROCEDURE FOR OHLINS FORKS Insert the guide bushing and the coun terspring RSV4 ABS Suspensions SUSP 421 ...

Page 422: ...the internal milling allowing the spring guide retainer ring to be instal led against the support ring Insert the spring guide retainer ring 4 Insert the spring guide 3 Insert the spring guide retainer ring 1 Insert the spring guide support ring 2 noting the internal milling allowing the spring guide retainer ring to be instal led against the support ring Suspensions RSV4 ABS SUSP 422 ...

Page 423: ...n 1 in the order given dust gaiter 3 retainer ring 4 and oil seal 5 Fix the sleeve in a vice taking care not to damage the sleeve Insert the stanchion 1 into the sleeve 2 Fit the two half shells of the special tool on the wheel holder stanchion 1 be hind the oil seal 5 Grip the special tool and push the oil seal 5 into its seat on the sleeve 2 Remove the tool RSV4 ABS Suspensions SUSP 423 ...

Page 424: ... WITHOUT RESISTANCE Insert the pumping member pin unit CAUTION THE STANCHION MUST SLIDE FREELY IN THE SLEEVE WITHOUT RESISTANCE PROCEDURE FOR SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit the dust gaiter th...

Page 425: ...xed bushing Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Insert the retainer ring in its position RSV4 ABS Suspensions SUSP 425 ...

Page 426: ...ERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN WARDS See also Filling oil Fit the dust gaiter with the specific tool Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm 1 69 in orifices AP8140146 Weight Insert the pumping member pin in the stem Suspensions RSV4 ABS SUSP 426 ...

Page 427: ...seeger Place the fork vertically Insert the washer Insert the washer that will be supported on the spring Insert and hand tighten the nut on the pumping member pin Place the preload pipe Tighten the appropriate tool on the pumping member pin rod and keep it raised to allow inserting a wrench in the nut by compressing the spring Specific tooling 020890Y Pumping member stanchion support rod AP814014...

Page 428: ... the sleeve to the prescribed torque Filling oil PROCEDURE FOR OHLINS FORKS Place the sleeve in a vertical position Insert the pumping member pin unit and tighten to the specified torque with the Öhlins tool Insert the preload pipe Fill the fork so that any air bubbles trapped within are expelled Suspensions RSV4 ABS SUSP 428 ...

Page 429: ... LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Characteristic Fork oil 530 cc 0 12 Uk gal for each stanchion Holding up the pin insert the preload spring Fit the lock nut for the preload spring 1 Fit the nut 2 Keeping the spring compressed tight en the nut completely Screw the complete cap onto the pumping member pin RSV4 ABS Suspensions SUSP 429 ...

Page 430: ...Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Specific tooling AP8140149 Protection for fitting operations Oil level 110 2 mm 4 33 0 08 in from the sleeve edge wit...

Page 431: ...ELY IN BOTH DIRECTIONS STEERING DAMPER STANDARD SETTING FOR ROAD USE Specification Desc Quantity Hydraulic setting From all open tighten 5 8 clicks STEERING DAMPER RACING SETTING RANGE FOR TRACK ONLY Specification Desc Quantity Hydraulic setting From all open tighten 10 13 clicks clockwise anticlockwise Removing The steering damper steering more precise and stable improving motorcycle handling in ...

Page 432: ...g M35x1 1 60 Nm 44 25 lbf 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 1 100 Nm 73 76 lb ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 37 lb ft 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 37 lb ft Adjusting play Unscrew and remove the top bolt on the headstock and retrieve the washer Sus...

Page 433: ...crews fixing the fork stan chions to the upper yoke Working from both sides unscrew and remove the semi handlebar screws Remove the upper yoke Rivet the safety washer on the head stock RSV4 ABS Suspensions SUSP 433 ...

Page 434: ...w the bearings to settle Loosen the ring nut Retighten the lock ring to the prescri bed torque of 60 Nm 44 25 lbf 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 AP814...

Page 435: ...n or der to lock the ring the counter lock ring may be tightened further by up to 35 or loosened by up to 10 When tightening 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 RSV4 ABS Suspensions...

Page 436: ...lars are not interchangeable To identify them check the number printed on them lower collar 0 3 5 5 upper collar 0 3 4 5 Assembling 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 i...

Page 437: ...ore the correct steering bearing free play See also Adjusting play Rear REAR WHEEL pos Description Type Quantity Torque Notes 1 Rear wheel spindle nut M25x1 5 1 120 Nm 88 5 lbf ft 2 Screws fastening sprocket on sprocket mount M10 5 50 Nm 36 88 lbf ft RSV4 ABS Suspensions SUSP 437 ...

Page 438: ...le together with the right hand chain tensioner skid Remove the wheel by freeing the disc from the brake calliper Holding the outer rim of the sprocket with both hands slide off the final transmission unit by pulling it parallel to the wheel axis OPERATE WITH CAUTION IF THE FINAL TRANSMISSION UNIT IS INSTALLED ON THE ANTI VIBRATION BUFFER HOLDER DO NOT TURN OVER O ROTATE THE REAR WHEEL SPROCKET SI...

Page 439: ... locking nut 3 and the threaded pin 2 THE SELF LOCKING NUTS 3 MUST BE REPLACED EV ERY THREE SPROCKET REMOVALS REPLACE THE SELF LOCKING NUTS 3 WITH NUTS OF THE SAME TYPE Remove the sprocket mounting 4 Clean the sprocket 5 and the sprock et mounting 4 with fresh detergent Reassembly Fit the five threaded pins 2 on the sprocket 5 Install the sprocket mounting on the sprocket mounting threaded pin as ...

Page 440: ... COUPLING SURFACE Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION ESPECIALLY THOSE LISTED AS FOL LOWS REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel ROTATION CHECK Manually rotate the inside ring of each bearing Rotation must be constant smooth and noiseless If one or both bearings do not fall within the control parameters Replace both wheel bearin...

Page 441: ...ic 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 bearings Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm ...

Page 442: ... Axial 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 cl...

Page 443: ...ing gasket 10 Remove the circlip 11 CAUTION THE CIRCLIP 11 IS FITTED ONLY ON THE WHEEL RIGHT SIDE The spacer end 12 is fitted with slots A for the extractor teeth to pass through Take out the right bearing 13 with the specific extractor Specific tooling AP8140180 Extractor for bushings Collect the inside spacer 12 Working from the wheel left side Take out the left bearing 16 with the specific extr...

Page 444: ...RCLIP 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 THE PARTS WITH CLEAN DETERGENT Specific tooling AP8140180 Extractor for bushings Suspensions RSV4 ABS SUSP 444 ...

Page 445: ...Type Quantity Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lbf ft 2 Dual connecting rod fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single connecting rod to chassis M10 1 50 Nm 36 88 lbf ft RSV4 ABS Suspensions SUSP 445 ...

Page 446: ... from fully closed Compression adjustment knob 2 open 15 2 clicks from fully closed Theoretical shock absorber failure motorcycle rider 70kg 154lb C 25 1 mm 0 98 0 039 in REAR SHOCK ABSORBER RACING ADJUSTMENT RANGE ONLY ON THE RACING TRACK Specification Desc Quantity Shock absorber centre to centre distance A 311 1 mm 12 24 0 039 in preloaded Spring B length 145 5 mm 1 5 mm 5 73 0 059 in Rebound a...

Page 447: ... A 310 1 5 mm 12 20 0 059 in preloaded Spring B length 148 1 5 mm 5 83 0 059 in Rebound adjustment ring nut 1 open 20 1 clicks from fully closed Compression adjustment knob 2 open 1 5 click from fully closed Theoretical shock absorber failure motorcycle rider 70kg 154lb C 25 1 mm 0 98 0 039 in REAR SHOCK ABSORBER RACING ADJUSTMENT RANGE ONLY ON THE RACING TRACK Specification Desc Quantity Shock ab...

Page 448: ...F THE FRONT SCREW FASTEN ING THE LICENSE PLATE HOLDER TO UN DERTAIL SECTION AND UPPER CORNER OF THE SCREW FASTEN ING THE REAR STAND PIN ON THE SWING ARM Removing Secure the vehicle using a belt and hoist Remove the silencer and the right 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 Retriev...

Page 449: ...and remove the upper screw and retrieve the nut Remove the shock absorber from the right side Linkages Removing Working from the left side of the vehicle loosen and remove the nut 1 RSV4 ABS Suspensions SUSP 449 ...

Page 450: ... 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 ABS SUSP 450 ...

Page 451: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 452: ...8 lbf ft 6 Lower rear right hand adjuster screw bushing M18x1 5 1 12 Nm 8 85 lbf ft 7 Upper rear right hand adjuster screw bushing M18x1 5 1 12 Nm 8 85 lbf ft 8 Upper rear right hand mount M10 1 50 Nm 36 88 lbf ft 9 Right fairing spacer M6 1 10 Nm 7 37 lbf ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lbf ft 11 Upper rear mount M10 1 50 Nm 36 88 lbf ft Screw fas...

Page 453: ... Saddle mounting fixing screws M10 4 50 Nm 36 88 lbf ft 2 Screws fastening oil radiator mount ing bracket to engine M6 2 8 Nm 5 9 lbf ft 3 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lbf ft Swinging arm RSV4 ABS Chassis CHAS 453 ...

Page 454: ...kid fixing screws M5 2 2 Nm 1 47 lbf ft Lower chain slider fixing screws M6 2 10 Nm 7 37 lbf ft Chain guide fixing screw M6 1 8 Nm 5 90 lbf 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 th...

Page 455: ...m pin 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 RSV4 ABS Chassis CHAS 455 ...

Page 456: ...e adjustment bushing from the swingarm pin 2 UPON REMOVING THE REAR SWINGARM PAY ATTEN TION NOT TO JAM THE GEARING CHAIN If necessary use a specific tool to re move a pin from the drive chain 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 ...

Page 457: ...HOSE LISTED AS FOL LOWS 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 a mi...

Page 458: ...ative to the chassis is adjusted with special inserts installed in the respective seats in the chassis The hole is offset by 2 5 mm 0 098 in relative to the cen treline 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 F...

Page 459: ...nd hold 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 ...

Page 460: ...riving 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 Chassis RSV4 ABS CHAS 460 ...

Page 461: ...he vehicle is fitted with an endless chain without master link NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE CLEARANCE CHECK To check clearance Shut off the engine Rest the vehicle on its stand Engage neutral gear Check that the vertical oscillation at a point between the pinion and th...

Page 462: ...learance CAUTION WHEEL CENTRING IS CARRIED OUT USING THE IDENTI FIABLE FIXED REFERENCES 2 3 INSIDE THE CHAIN TENSIONER PAD MOUNTS ON THE SWINGARMS IN FRONT OF THE WHEEL AXLE CHECKING THE CHAIN THE PINION AND THE SPROCKET FOR WEAR Furthermore check the following parts and make sure the chain the pinion and the sprocket do not show damaged rollers loosened pins dry rusty flattened or jammed chain li...

Page 463: ...fuel oil or kerosene Maintenance operations should be more frequent if there are signs of quick rust Lubricate the chain at the intervals specified on 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 R...

Page 464: ...per screw fixing the chain slider and retrieve the washer See also Removing the rear wheel Unscrew and remove the lower screw fixing the chain pad and retrieve the washers Remove the chain skid 1 Stand Chassis RSV4 ABS CHAS 464 ...

Page 465: ...to the chassis M10 2 45 Nm 33 19 lbf ft Loct 243 2 Linear switch retainer M5 2 4 Nm 2 95 lbf ft Rear stand bushing fastening screws M6 2 7 Nm 5 16 lbf ft Side stand Remove the fuel tank Remove the pinion cover Remove the clamps Disconnect the stand connector RSV4 ABS Chassis CHAS 465 ...

Page 466: ...encer to right hand footpeg mounting M8 1 25 Nm 18 44 lbf ft 4 Screw fastening silencer to central lower fairing bracket M8 1 20 Nm 14 75 lbf ft 5 Cosmetic silencer shield fixing screw M5 2 5 Nm 3 69 lbf ft 6 Oxygen sensor fastener M18x1 5 1 38 Nm 28 03 lbf ft 7 Fastener screw for cable grommet for exhaust butterfly valve cables M6 1 10 Nm 7 37 lbf ft 8 Exhaust butterfly valve actuator fix ing scr...

Page 467: ...emove the front screw fastening the exhaust to the chassis Unscrew and remove the upper attach ment screw fixing the exhaust pipe to the chassis retrieve the collar the washer and the nut DURING THIS OPERATION SUPPORT THE EXHAUST PIPE SO THAT IT DOES NOT FALL Remove the exhaust end RSV4 ABS Chassis CHAS 467 ...

Page 468: ...the two exhaust butterfly valve control cables Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables CAUTION ON REASSEMBLY POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET Release the springs between the rear exhaust manifolds and the catalytic converter Remove the catalytic converter Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFO...

Page 469: ...or up per fixing screws See also Fairing mounting panels Twistgrip position sensor Release the springs between the front exhaust manifolds and the catalytic converter Move the radiator forward Unscrew and remove the four nuts fas tening the front exhaust manifold and retrieve the washers RSV4 ABS Chassis CHAS 469 ...

Page 470: ...ing the rear exhaust manifolds and retrieve the washers Remove both rear exhaust manifolds Butterfly valve in exhaust To check correct operation and calibration of the exhaust valve see electrical system section REMOVING THE EXHAUST THROTTLE VALVE Remove the fairing lug Disconnect the connector from the valve actuator motor See also Chassis RSV4 ABS CHAS 470 ...

Page 471: ...onnect the two exhaust butterfly valve control cables Unscrew and remove the two valve ac tuator motor screws Remove the valve actuator motor to gether with the heat shield Engine oil cooler RSV4 ABS Chassis CHAS 471 ...

Page 472: ...aio M6x20 2 10 Nm 7 38 lbf ft Removing Drain the engine oil Remove both fairings and the radiator cowl Release the clamp and disconnect the right hand radiator 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 Chassis RSV4 ABS CHAS 472 ...

Page 473: ... Unscrew and remove the lower radia tor retainer Remove the radiator draining com pletely of oil RSV4 ABS Chassis CHAS 473 ...

Page 474: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 475: ...9 Key 10 ABS control unit fuse ABS ECU control unit pin configuration Valve ground and ECU PIN 1 CAN H line high speed PIN 2 Front speed sensor input PIN 3 Key positive ECU PIN 4 Serial line K for diagnosis PIN 5 Battery for valve positive PIN 9 Pump engine ground PIN 10 CAN L line low speed PIN 11 RSV4 ABS Braking system BRAK SYS 475 ...

Page 476: ...d sensor positive PIN 12 Rear speed sensor positive PIN 13 Rear speed sensor input PIN 14 ABS warning light PIN 17 Battery for ABS pump engine positive PIN 18 Operating diagram Braking system RSV4 ABS BRAK SYS 476 ...

Page 477: ...alliper 2 callipers 10 Front brake circuit intake solenoid valve normally open 11 Rear brake circuit intake solenoid valve normally open 12 Rear brake exhaust circuit solenoid valve normally closed 13 Rear front brake circuit low pressure accumulator 14 Front brake exhaust circuit solenoid valve normally closed 15 DC electric motor 16 Double circuit hydraulic pump ABS RSV4 ABS Braking system BRAK ...

Page 478: ... the rider starts braking as he would usually do B Pressure reduction coincides with the recognition of the dangerous situation wheel slippage exceeds the threshold the system closes the inlet valve 10 11 and opens the outlet valve 12 13 temporarily At this stage the rider cannot increase the pressure on the callipers 8 9 and the system reduces the pressure on the callipers partially Excess fluid ...

Page 479: ...hicle A position sensor 3 on the tone wheel 2 forming an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly CAUTION WHEN THE ABS STARTS WORKING A PULSING IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND A...

Page 480: ...standstill with a long press of the mode button it is possible to access the menu a PRC Settings When ABS is selected shown in negative in ad dition to varying its level by short pressing it can be deactivated To do this position it to level one and press with a long pressure the button To reactivate it press with a short pressure the button CAUTION THE DISABLING OF THE ABS REMAINS EVEN AFTER A KE...

Page 481: ...lly the ABS con trol unit In case of replacement 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 a...

Page 482: ...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 and electrical connection of the new ABS control unit activation recognition must be carried out Connect t...

Page 483: ...ble 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 ABS Braking system BRAK SYS 483 ...

Page 484: ...s any 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...

Page 485: ...example software type map ping control unit programming date INFO ECU SCREEN PAGE P A D S Navigator characteristic Value example Unit of measure ment Notes Spare parts code Software version Vehicle manufacture date or code Frame number VIN or diagnostics instrument serial number Vehicle ID stored Vehicle ID read by ECU Date filled in PARAMETERS screen page This screen page shows the parameters mea...

Page 486: ...pressure bar ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit ACTIVATION P A D S Navigator characteristic Value example Unit of measure ment Notes ABS warning light Error clearing Freezes and saves the parameter and states values Braking system RSV4 ABS BRAK SYS 486 ...

Page 487: ...nlet solenoid valve failure Inside error C1049 Rear circuit output solenoid valve failure Inside error C1052 Rear circuit input solenoid valve failure Inside error C1048 Rear circuit output solenoid valve failure Inside error C1015 Recirculation pump failure Inside error C1014 Solenoid valve relay failure Inside error C1021 Control unit failure Low power supply voltage C1058 High power supply volt...

Page 488: ... unit parameters ADJUSTMENTS P A D S Navigator characteristic Value example Unit of measure ment Notes Coding Reset the vehicle code and it performs the self learning from CAN line to the key ON Modulator Disconnect the ABS connector Braking system RSV4 ABS BRAK SYS 488 ...

Page 489: ...S 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 that couples the connector When the connector is fully inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in RSV4 ABS Braking system BRAK SYS 489 ...

Page 490: ...works on both the front and the rear wheel Check periodically and each time the wheels are refitted the tone wheel 2 or the sensor 1 re placed that the wheel distance is constant at each 360 Use a thickness gauge to check the distance between sensor 1 and tone wheel 2 at three points at a 120 span The values should be be tween 0 3 2 00 mm 0 012 0 079 in for the front one 0 3 2 00 mm 0 012 0 079 in...

Page 491: ...ACES BETWEEN THE SENSOR 1 AND THE SEAT ITSELF DO NOT SHOW SIGNS OF DAMAGE AND ARE COMPLETELY CLEAN ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR 1 AND THE TONE WHEEL 2 Rear brake calliper REAR BRAKE CALLIPER pos Description Type Quantity Torque Notes 1 Rear brake disc fixing screws M8 5 30 Nm 22 13 lbf ft Loct 243 2 Odometer sensor fixing screw M6 1 10 Nm 7 38 lb ft 3 Rear brake calliper mounting p...

Page 492: ...tes 1 Front brake calliper fixing screws M10x1 25 2 2 50 Nm 36 88 lb ft Rear brake disc Removal Remove the rear wheel CAUTION TO UNSCREW THE SCREWS 1 USE AN AIR SCREWER GUN TO GIVE A CLEAN BLOW WHICH WILL DETACH THE SCREWS STUCK WITH LOCTITE 243 Braking system RSV4 ABS BRAK SYS 492 ...

Page 493: ...ations 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 ...

Page 494: ...LY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE A B C D E F See also Removing the front wheel Disc Inspection The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a s...

Page 495: ...AUTION 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 CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LE...

Page 496: ...n the two screws 1 Check the front brake fluid level Rear brake pads Removal Rest the vehicle on its stand Remove the rear brake calliper CAUTION DO NOT ACTUATE ON THE REAR BRAKE LEVER AFTER REMOVING THE WHEEL OTHERWISE THE CALLIPER PLUNGER COULD GO OUT OF ITS SEAT RESULTING IN BRAKE FLUID LEAK AGE Remove the snap ring 1 BEFORE REMOVING THE PIN 2 CHECK THAT THE SAFETY SPRING 3 IS CORRECTLY POSITIO...

Page 497: ... 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 Place the safety spring 3 Hold the centre of the safety spring 3 depressed and i...

Page 498: ...AYS 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 impianto nell ordine che segue Pompa freno Pinza destra Pinza sinistra Pompa freno rifinitura Sotto è riportata la procedura di spurgo tradizionale CAUTION IN CASO DI SOSTITUZIONE DEL LIQUIDO FRENI PR...

Page 499: ...er The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAUL IC SYSTE...

Page 500: ...k the rear brake oil reservoir cap Refit the rubber protection cover Front brake pump FRONT BRAKE PUMP pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lbf ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lbf ft 3 Screw fastening brake pipe grommet to the lower yoke M5 1 8 Nm 5 9 lbf ft 4 Fron...

Page 501: ...s Description Type Quantity Torque Notes 1 Rear brake rod lock nut M6 1 12 Nm 8 85 lbf ft 2 Rear brake pump fixing screws M6 2 8 Nm 5 9 lbf ft 3 Rear brake lever fixing screw M8 1 25 Nm 18 44 lbf ft RSV4 ABS Braking system BRAK SYS 501 ...

Page 502: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 503: ...gram 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 ABS Cooling system COOL SYS 503 ...

Page 504: ...for fastening the water radiator mounting bracket to frame M6x20 2 10 Nm 7 37 lbf ft 2 Self tapping screw for fastening the water radiator to the mounting brack et 1 2 Nm 1 47 lbf ft 3 Screw fastening pipe grommet for By pass water hose M5 1 6 Nm 4 42 lbf ft 4 Screws fastening electric fan to wa ter radiator M4 6 2 Nm 1 47 lbf ft 5 Flanged TE screw for fastening the water radiator to the mounting ...

Page 505: ...7 37 lbf ft Electric fan Remove the front underfairings and the hand grip position sensor Disconnect the cooling fan connector to be replaced Internally blocking the nuts unscrew the fixing screw from the internal part Make sure that the nuts and washers are retrieved See also RSV4 ABS Cooling system COOL SYS 505 ...

Page 506: ... 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 Unscrew and remove the system drain screw and retrieve the sealing washer Wait for the entire circuit to drain en gine pipes radiator Refit the system drain screw complete with a new washer FILLING Via the filler orifice on the radiator fill with the quantity ...

Page 507: ...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 and top up if necessary Water pump Drain the coolant Remove the pipe from the radiator Unscrew and remove the two screws fastening the pipe to the engine Retrieve the gasket and replace with a new component when refitting See also Coolant replaceme...

Page 508: ... the coolant pump Unscrew and remove the two external pump cover fixing screws Unscrew and remove the inner screw Remove the pump cover TO PREVENT IRREPARABLE DAMAGE TO THE PUMP UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER Cooling system RSV4 ABS COOL SYS 508 ...

Page 509: ...AGE 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 Remove the two chassis bracket fixing screws Then remove the radiator retainer bracket RSV4 ABS Cooling system COOL SYS 509 ...

Page 510: ...ENT 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 Disconnect the expansion tank breath er pipe from the pipe grommet See also Coolant replacement Fairing mounting panels Twistgrip position senso...

Page 511: ... 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 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 CL...

Page 512: ... Remove the split pin From the opposite site remove the coolant radiator oil radiator connector pin Remove the radiator Cooling system RSV4 ABS COOL SYS 512 ...

Page 513: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 514: ...HEADLAMP pos Description Type Quantity Torque Notes 1 Screw fastening headlamp to front fairing SWP 4 9 4 2 Nm 1 47 lbf ft 2 Headlamp fixing screw M5 2 1 2 Nm 1 47 lbf ft Bodywork RSV4 ABS BODYW 514 ...

Page 515: ...fix ing screws SWP 4 9 5 2 Nm 1 47 lbf ft 3 Screws fastening instrument panel mounting to chassis M6 4 8 Nm 5 9 lbf ft WINDSHIELD pos Description Type Quantity Torque Notes 1 Windshield fixing screws M4 4 0 5 Nm 0 37 lbf ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 37 lbf ft 3 Screws fastening the side fairings to front fairing M5 4 1 Nm 0 74 lbf ft RSV4 ABS Bodywork BODYW 515 ...

Page 516: ...tity Torque Notes 1 Front mudguard fixing screws M5 4 3 Nm 2 21 lbf ft 2 Lug fixing screws M5 2 4 Nm 2 95 lbf ft TAILLIGHT pos Description Type Quantity Torque Notes 1 Taillight fixing screws M5 2 3 Nm 2 21 lbf ft Bodywork RSV4 ABS BODYW 516 ...

Page 517: ...tes 1 Rear mudguard fixing screws M6 2 3 Nm 2 21 lbf ft 2 License plate light fixing screws M4 1 1 Nm 0 74 lbf ft 3 Reflector fixing nuts M4 2 1 Nm 0 74 lbf ft 4 Screws fastening rear license plate holder to front license plate holder SWP 3 9 4 1 Nm 0 74 lbf ft 5 Self tapping screws fastening rear li cense plate holder to front license plate holder 5x20 2 2 Nm 1 47 lbf ft Screws fastening license ...

Page 518: ... lbf ft 4 Screws fastening grilles to tail fairing M5 2 0 5 Nm 0 37 lbf ft 5 Screws fastening side fairings to tail fairing M5 2 1 Nm 0 74 lbf ft 6 Screws fixing side fairings to tank M5 2 2 2 Nm 1 47 lbf ft 7 Screws fastening tail fairing to saddle mounting M5 2 3 Nm 2 21 lbf ft 8 Screws fastening tail fairing to saddle mounting bracket M5 2 2 Nm 1 47 lbf ft 9 Screws fixing tail fairing to lower ...

Page 519: ...otes 1 Screws and nuts for fastening li cense plate holder to saddle mount ing plate M6 2 4 Nm 2 95 lbf ft 2 Lower saddle mounting fastener fix ing screws M5 5 3 Nm 2 21 lbf ft 3 Battery bracket fixing screws M5 2 2 Nm 1 47 lbf ft RSV4 ABS Bodywork BODYW 519 ...

Page 520: ... Screws fastening structural tank mounting to tank M6 4 3 Nm 2 21 lbf ft 9 Flanged TBEI screw fixing the sen sor box M6x16 stainless steel 2 6 Nm 4 42 lbf ft Central screw fastening the cover to the tank M4 1 0 5 Nm 0 37 lbf ft Fuel tank breather pipe unions M7 2 3 Nm 2 21 lbf ft FOOTRESTS pos Description Type Quantity Torques Notes 1 Screws fastening rider footpegs to chassis M8 2 2 25 Nm 18 44 l...

Page 521: ...xing upper fairing fastener to intake duct self tapping 2 1 Nm 0 74 lb ft Screws fixing upper fairing fastener to headlamp self tapping 2 1 Nm 0 74 lb ft Screws fastening the lower fairing to the bracket M5 2 2 1 Nm 0 74 lb ft Screws fastening the lower fairing to the lug M5 2 2 Nm 1 47 lb ft Lower fairing lower fastening screws M5 2 2 Nm 1 47 lb ft Lower fork fastener fixing screws M6 2 8 Nm 5 90...

Page 522: ...irrors Unscrew and remove the two nuts supporting the rear view mirror Disconnect the turn indicator connec tor from the relative fixed connector on the instrument panel Guiding the turn indicator cable through the relative hole on the windshield remove the rear view mirror Bodywork RSV4 ABS BODYW 522 ...

Page 523: ...ings from the seats on the support Rotate the instrument panel connector retainer lever Remove the connector Remove the instrument panel NOTE WHEN REFITTING THE CONNECTORS THE SLIDES MUST MOVE FREELY TO THE END OF STROKE WHICH HELPS WITH THE INSERTION OF THE CONNECTOR YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE RSV4 ABS Bodywork BODYW 523 ...

Page 524: ...Headlight fairing Working from both sides unscrew and remove the four screws Bodywork RSV4 ABS BODYW 524 ...

Page 525: ...Remove the two rear view mirrors if necessary Remove the three lower inserts See also Side fairings Supporting the windshield move it for ward to the create the minimum space necessary to work on the front bulb connectors Disconnect the front bulb connectors Remove the windshield in a forward motion RSV4 ABS Bodywork BODYW 525 ...

Page 526: ...el tank Unscrew and remove the three screws and remove the pinion cover Disconnect the quick shift connector Cut the ties fastening the cable har ness to the engine Loosen the screw and slide off the gear shift lever and cable harness from the engine Bodywork RSV4 ABS BODYW 526 ...

Page 527: ...g screw to change the O rings NOTE NOTE THE CABLE HARNESS DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION Side fairings The following procedure is relative to a single fair ing but is applicable to both Remove the lower side fairing Unscrew and remove the three screws Release the insert on the retainer with the duct RSV4 ABS Bodywork BODYW 527 ...

Page 528: ...o damage the fitting with the lower side fairing and the tabs fas tening the side fairing to the lug LOWER SIDE FAIRINGS The operations described below are valid for both lower side fairings Remove the side fairing Unscrew and remove the screw and remove the lower side fairing Bodywork RSV4 ABS BODYW 528 ...

Page 529: ...fittings with the lateral underfairings and the wind shield Working from both sides unscrew and remove the lower screw LATERAL UNDERFAIRINGS The following procedure is relative to a single lateral underfairing but is appli cable to both except where specified otherwise Unscrew and remove the central un derfairing fixing screw Remove the respective side fairing RSV4 ABS Bodywork BODYW 529 ...

Page 530: ...ntral underfair ing When working on the left hand side of the vehicle support the left hand un derfairing unscrew and remove the two nuts retrieve the screws and lower the regulator Remove the underfairing Air box FILTER BOX COVER REMOVAL Remove the control unit Disconnect the air temperature sensor connector Move the two rear coil connectors Bodywork RSV4 ABS BODYW 530 ...

Page 531: ...he variable geometry in take system connector Unscrew and remove the eight air filter box cover screws Remove the air filter box cover FILTER BOX BASE Open the air filter box cover Unscrew and remove the air intake duct fixing screws Disconnect the variable geometry intake system connector RSV4 ABS Bodywork BODYW 531 ...

Page 532: ...sor fixing screw Disconnect both front coil connectors cylinders 2 and 4 Working from both sides disconnect the Blow by system intake pipes Release the cable harness from the cable grommet on the filter box Remove the air filter box base Bodywork RSV4 ABS BODYW 532 ...

Page 533: ...ve the rear mudguard Lower cowl The following procedure is applicable to both parts of the fairing lug Remove the lower side fairing Unscrew and remove the front screw See also Side fairings Unscrew and remove the lower screw RSV4 ABS Bodywork BODYW 533 ...

Page 534: ...screw and remove the lug Remove the left fairing lug in the same manner Fuel tank Unscrew and remove the front screw fixing the tank Remove the rider saddle Unscrew and remove the two rear screws Release the clamps Remove the two tank breather pipes Bodywork RSV4 ABS BODYW 534 ...

Page 535: ...ipe Disconnect the fuel pump connector Remove the tank Front mudguard Working from both sides undo and re move the two screws Release the brake pipe eliminating the clamp Remove the front mudguard RSV4 ABS Bodywork BODYW 535 ...

Page 536: ...screws 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 Bodywork RSV4 ABS BODYW 536 ...

Page 537: ...ith 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 RSV4 ABS Bodywork BODYW 537 ...

Page 538: ...ctly The 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 REFITTING THE CONNECTORS THE SLIDES MUST MOVE FREELY TO THE END OF STROKE WHICH HELPS WITH THE INSERTION OF THE CONNECTOR YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE Radiator cover Remove the side fairings...

Page 539: ...ide air deflectors The following procedure is for a single lateral duct but is applicable to both Remove the windshield Unscrew and remove the two fixing nuts Remove the duct from its seat on the frame 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 ABS Bodywork BODYW 539 ...

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

Page 541: ...s fixing screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning ligh...

Page 542: ...E OF CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WO...

Page 543: ... present Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories N...

Page 544: ...the screw 2 Remove the plastic cover 1 Fit the rear pedal in its seat Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm 13 27 lbf ft NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL Sostituzione sella Pre delivery RSV4 ABS PRE DE 544 ...

Page 545: ...tion to the mirror check that the nut is closed properly as indicated by the arrow you should be able to see about 0 5 mm 1mm 0 02 in 0 04 in of the threaded pin projecting from the nut and the Loctite 270 If the nut is not closed correctly proceed as fol lows Close the mirror base turned 90 in re lation to the mirror Remove the glass from the indicator light RSV4 ABS Pre delivery PRE DE 545 ...

Page 546: ...n the nut so its upper surface is about 0 5 mm 0 02 in above the end of the threaded pin Put some Loctite 270 inside the nut Screw the nut back down until its upper surface is about 0 5 mm 1 mm 0 02 in 0 04 in away from the end of the pin Wait 24 hours for the Loctite to dry well before moving the mirror Pre delivery RSV4 ABS PRE DE 546 ...

Page 547: ...rear view mirror Pass the cable harness through the specific hole and place the rear view mirror in its seat Tighten the two fixing nuts of the rear view mirror Connect the connector RSV4 ABS Pre delivery PRE DE 547 ...

Page 548: ...29 336 353 357 Coil 202 Connecting rods 361 365 375 Connectors 239 coolant 506 507 510 Coolant 506 507 510 Countershaft 353 355 359 364 Crankcase 351 359 363 379 Crankshaft 362 364 373 Cylinder 71 77 D Desmodromic drum 279 Drive chain 13 461 E ECU 239 485 Electric fan 223 505 Electrical system 13 98 101 541 Engine oil 65 471 Engine temperature sensor 184 Exhaust 149 227 254 466 468 470 Exhaust man...

Page 549: ...ntenance 8 63 490 Maintenance Table Mirrors 522 Mudguard 402 533 535 O Oil filter 67 Oil pressure sensor 217 Oil sump 359 387 One way valve 389 P Pistons 361 364 375 Primary shaft 279 R Radiator 254 509 538 Rear cylinder head valves 77 Rear head 329 335 339 346 359 361 Rear wheel 438 440 464 493 Recommended products 53 Ride by wire 393 Run Stop switch 226 S Saddle SAS valve actuator 225 Secondary ...

Page 550: ...Start up 155 286 Starter motor 285 Steering damper 430 Stepper motor 397 T Tank 68 254 534 Throttle body 69 70 206 395 397 Transmission 12 356 359 Tyres 15 V Variable geometry intake 168 397 399 W Warning lights Water pump 359 382 507 Windshield Wiring diagram 143 ...

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Summary of Contents for RSV4 ABS 2009

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APRILIA RSV4 ABS 2009, Manual, Page: 1 / 550

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Summary of Contents for RSV4 ABS 2009

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