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APRILIA RSV4 FACTORY, Service Station Manual

The Aprilia RSV4 Factory is a high-performance motorcycle designed for passionate riders. Discover the exhilaration of its precise handling and powerful engine. For a complete understanding of this exceptional machine, download the free manual from manualshive.com to unlock all the information you need for an unforgettable riding experience.

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1 Right handlebar control

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1 Left handlebar control

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1 Regulator

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1 Hand grip position sensor

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1 Variable geometry control unit

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1 Engine cable harness

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1 Engine revolution sensor

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1 Control unit 7SM

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1 Air temperature sensor

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1 Water temperature sensor

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2 Coil with short cable (Cylinder 1 and Cylinder 4)

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2 Coil with long cable (Cylinder 2 and Cylinder 3)

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1 Gear sensor

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1 Secondary air solenoid

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1 Front motorised throttle body

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1 Rear motorised throttle body

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2 MAP sensor

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1 Alternator

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1 Starter motor

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4 Upper injectors

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4 Lower injectors (including the motorised throttle body)

Small parts and mountings

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6 Large black clamps 178x4

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6 Small black clamps 160x2.5

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5 Rubber clamps

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2 TBEI M6x30N screws

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2 TE M6x20

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1 flanged TE 6x16 screw

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2 M5x8 screws

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2 TBEI M5x16 screws

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1 TE M6x30 screw

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3 Self-tapping 5x14 screws

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2 flanged TBEI M5x9 screws

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1 M6 nut

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2 Flanged self-locking M6 nuts

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4 Cable grommets

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1 Cable grommet

RSV4 Factory

Electrical system

ELE SYS - 97

Summary of Contents for RSV4 FACTORY

Page 1: ...SERVICE STATION MANUAL 894159 RSV4 Factory ...

Page 2: ...and tested together with the actual vehicle itself All aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability The descriptions and illustrations given in this publication are not binding While the basic characteristics as described and illustrated in this booklet remain unchanged aprilia reserves the right at any time and without being required to u...

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

Page 4: ......

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 IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO 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 con...

Page 8: ...ry electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYE...

Page 9: ... SPARE PARTS Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start either from the components with the largest diameter or from the innermost components proceeding diagonally Tighten nuts and screws in suc cessive steps before applying the tightening torque Always replace self locking nuts washers seali...

Page 10: ...OR EVEN DETACH CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed during the run in This ensures that components operate under both...

Page 11: ...facturer identifier code RK model 000 version variation 0 free digit Y year of manufacture S production plant S Scorzè XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock 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...

Page 12: ...m 0 0079 0 0098 in Lubrication system 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 Cotton Alternatively Air filter Paper T...

Page 13: ...ging system Flywheel with rare earth magnets Generator 450 W Main fuses 30 A Auxiliary fuses 5A 7 5A 15A BULBS Specification Desc Quantity Low high beam light 12V 55W H11 Front daylight running light 12V 5W Turn indicators 12V 10W White light License plate light 12V 5W WARNING LIGHTS Specification Desc Quantity High beam light LED Right turn indicator LED Left turn indicator LED General warning LE...

Page 14: ...sis Brakes BRAKES Specification Desc Quantity Front With dual floating disc 320 mm diam 12 59 inches monobloc calipers with radial fixing and four pistons 34 mm diam 1 34 inches and 4 pads radial pump and brake pipe in metal braid Rear disc type 220 mm diam 8 66 inches 2 piston calipers 32 mm diam 1 25 inches pump with built in tank and metal braid pipe Wheels and tyres WHEEL RIMS Specification De...

Page 15: ...Quantity Fuel Premium unleaded petrol minimum octane rating of 95 NORM and 85 NOMM FUEL SYSTEM Specification Desc Quantity Throttle body diameter 48 mm 1 89 in Type Electronic injection with 2 injectors per cylinder 4 throttle bod ies motorised Ride by wire Intake cones at variable height 2 dynamic air intakes Selectable multimap Tightening Torques Chassis Front side RSV4 Factory Characteristics C...

Page 16: ...Notes 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lbf ft FRONT FORK pos Description Type Quantity Torque Notes 1 Fastener screws for calliper mount ing bracket Öhlins M6 2 2 12 Nm 8 85 lbf ft Characteristics RSV4 Factory CHAR 16 ...

Page 17: ...8 44 lbf 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 lbf ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 37 lbf ft 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 37 lbf ft RSV4 Factory Characteristics CHAR 17 ...

Page 18: ...indle nut M25x1 5 1 80 Nm 59 lbf ft 2 Front brake disc fixing screws M8 6 6 30 Nm 22 13 lbf 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 lbf ft Characteristics RSV4 Factory CHAR 18 ...

Page 19: ... 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 RSV4 Factory Characteristics CHAR 19 ...

Page 20: ...M8 1 1 25 Nm 18 44 lbf ft 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 Characteristics RSV4 Factory CHAR 20 ...

Page 21: ... 2 Nm 1 47 lbf ft INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Screws fastening the rubber rings to the instrument panel SWP 4 9 3 3 Nm 2 21 lbf ft 2 Instrument panel mounting shell 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 RSV4 Factory Characteristics CHAR 21 ...

Page 22: ...tity 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 Characteristics RSV4 Factory CHAR 22 ...

Page 23: ... 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 RSV4 Factory Characteristics CHAR 23 ...

Page 24: ...ket to chassis M6 2 10 Nm 7 37 lbf ft 2 Screws fastening water radiator to mounting bracket M6 2 7 Nm 5 16 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 Characteristics RSV4 Factory CHAR 24 ...

Page 25: ...pe 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 RSV4 Factory Characteristics CHAR 25 ...

Page 26: ...M5 8 3 Nm 2 21 lbf ft 4 Front screws fastening 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 Central screw fasteni...

Page 27: ...astening 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 RSV4 Factory Characteristics CHAR 27 ...

Page 28: ... 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 fastenin...

Page 29: ...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 RSV4 Factory Characteristics CHAR 29 ...

Page 30: ...iption 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 Characteristics RSV4 Facto...

Page 31: ... 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 RSV4 Factory Characteristics CHAR 31 ...

Page 32: ... 5 Nm 1 11 lbf ft Screws fixing upper fairing fastener to front fairing M5 2 1 5 Nm 1 11 lbf ft Screws fixing upper fairing fastener to inlet duct self tapping 2 1 Nm 0 74 lbf ft Screws fixing upper fairing fastener to headlamp self tapping 2 1 Nm 0 74 lbf ft Screws fastening the lower fairing to the bracket M5 2 2 1 Nm 0 74 lbf ft Screws fastening the lower fairing to the lug M5 2 2 Nm 1 47 lbf f...

Page 33: ...ing 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 F...

Page 34: ...EEL 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 Factory CHAR 34 ...

Page 35: ...e Quantity Torque Notes 1 Rear brake disc fixing screws M8 5 30 Nm 22 13 lbf ft Loct 243 2 Screw fastening odometer sensor onto rear brake calliper mounting M6 1 12 Nm 8 85 lbf 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 M...

Page 36: ...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 skid fixing screws M6 2 10 Nm 7 37 lbf ft Chain guide fixing screw M6 1 8 Nm 5 90 lbf ft Characteristics RSV4 Factory CHAR 36 ...

Page 37: ... Quantity Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lbf ft 2 Dual linkage fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single linkage to chassis M10 1 50 Nm 36 88 lbf ft RSV4 Factory Characteristics CHAR 37 ...

Page 38: ...iption 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 Screws fastening rear license plate holder to front license plate holder SWP 4 9 2 2 Nm 1 47 lbf ft Screws...

Page 39: ... 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 dle m...

Page 40: ... 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 Factory CHAR 40 ...

Page 41: ...pm sensor fixing screw 1 8 Nm 5 9 lbf ft 2 TE flanged screw M6x20 1 12 Nm 8 85 lbf ft 3 TE flanged screws M6x35 2 12 Nm 8 85 lbf ft 4 TE flanged screws M6x22 16 12 Nm 8 85 lbf ft 5 Engine timing inspection cap 1 25 Nm 18 44 lbf ft RSV4 Factory Characteristics CHAR 41 ...

Page 42: ...ER 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 Factory CHAR 42 ...

Page 43: ...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 Factory Characteristics CHAR 43 ...

Page 44: ... 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 Factory CHAR 44 ...

Page 45: ...he 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 30 Nm 22 13 lbf ft Loct 3M or 270 RSV4 Factory Characteristics CHAR 45 ...

Page 46: ... 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 Cran...

Page 47: ... 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 Factory Characteristics CHAR 47 ...

Page 48: ...ntity Torque Notes 1 Clutch nut 1 150 Nm 110 63 lbf ft Loct 243 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 Factory CHAR 48 ...

Page 49: ...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 Factory Characteristics CHAR 49 ...

Page 50: ...22 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 Charact...

Page 51: ...anded grease for roller bearings with an operating temperature range of 30 C to 140 C 22 F to 284 F a drop point between 150 C and 230 C 302 F and 446 F high corrosion pro tection qualities and good water and rust resistance AGIP PERMANENT SPEZIAL Coolant Ready for use mixed biodegradable cool ant with long life technology and char acteristics red Freezing protection up to 40 C Compliant with CUNA...

Page 52: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 53: ...es code Description 020845Y Engine support 020846Y Retaining tray plastic caps 020847Y Flywheel extractor 020848Y Flywheel retainer 020849Y Clutch retainer 020850Y Primary gear lock RSV4 Factory Special tools S TOOLS 53 ...

Page 54: ...852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring 020857Y Crankshaft bearing U bolt Special tools RSV4 Factory S TOOLS 54 ...

Page 55: ...e pistons in the cyl inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020861Y Countershaft bushing punch 020862Y Gearbox control rod roller cage fitting punch RSV4 Factory Special tools S TOOLS 55 ...

Page 56: ...e fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020883Y Timing chain tensioner installation re moval tool 020709Y Engine support AP8140187 Engine support stand 020376Y Adapter handle Special tools RSV4 Factory S TOOLS 56 ...

Page 57: ... Description 020363Y 20 mm Oil seal guide 020364Y 25 mm Guide 020359Y 42 x 47 mm punch 020360Y 52x55 mm Adaptor 020655Y 62x68 mm Adaptor 020408Y 72x75 mm 2 83x2 95 in adaptor RSV4 Factory Special tools S TOOLS 57 ...

Page 58: ... for fitting the valve seal rings 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor 0277308 Guide bushing for secondary gearbox shaft AP8140146 Weight Special tools RSV4 Factory S TOOLS 58 ...

Page 59: ... fitting tool for Ø 43 mm 1 69 in orifices AP8140190 Tool for steering tightening 020877Y Pliers for clamps AP8140181 Fuel pressure checking tool 020481Y Control unit interface wiring 020680Y TXB Navigator RSV4 Factory Special tools S TOOLS 59 ...

Page 60: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 61: ...AD OR FOR TRACK USE 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 Replace every 4 years 6 Every 5000 Km 3107 mi if the vehicle is used for raci...

Page 62: ...ble 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 Clutch cover flywheel and oil sump screws tight ening 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 Spark plug FRONT SPARK PLUGS Remove the base of the air filter box Undo and remove the screw Slide off the front coil Unscrew and...

Page 63: ...il level is near the upper marking Upper marking Max level Lower marking Min level If this is not the case top up the oil im mediately through the filler plug CAUTION NEVER ALLOW THE OIL LEVEL TO DROP BELOW THE MINIMUM LEVEL OR FILL ABOVE THE MAXIMUM LEVEL IF YOU DO NOT COMPLY WITH THE MINIMUM AND MAX IMUM OIL LEVELS THE ENGINE COULD BE SERIOUSLY DAMAGED NOTE ON ENGINES PRODUCED BEFORE SERIAL NUMB...

Page 64: ...f the specified type Screw on the filler cap Warm up the engine up by running it for a few minutes then switch it off After thirty seconds check the level in the sight glass Top up if necessary CAUTION NEVER ALLOW THE OIL LEVEL TO DROP BELOW THE MINIMUM LEVEL OR FILL ABOVE THE MAXIMUM LEVEL IF YOU DO NOT COMPLY WITH THE MINIMUM AND MAX IMUM OIL LEVELS THE ENGINE COULD BE SERIOUSLY DAMAGED NOTE ON ...

Page 65: ... a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the new engine oil filter in the seat filling the filter to 1 3 of its capacity with engine oil before fitting See also Replacement Air filter Remove the fuel tank Unscrew and remove the eight air filter box cover screws Disconnect the upper injector fuel de livery union See also Fuel tank RSV4 Factory Maintenan...

Page 66: ...trol 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 Remove the air filter Checking the valve clearance FRONT HEAD Maintenance RSV4 Factory MAIN 66 ...

Page 67: ...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 REAR HEAD Remove both throttle bodies and the spark plugs Remove the rear head cover See also Removing the throttle body S...

Page 68: ...9 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Front cylinder head valves Check the front valve head clearance and restore the correct clearance values if necessary proceeding as described below Remove both head covers the alter nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft Remove the O ring See also Head cover removal Removing the flywheel cover Mai...

Page 69: ...ing 020852Y Crankshaft timing pin Fit the pin aligning the intake camshaft with the hole in the U bolt If it was not possible before adjusting the valve clearance check the engine timing Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with t...

Page 70: ... bolt on the front head and refit the crankshaft timing pin from the flywheel side to check that the tim ing setting was not altered while the engine was turned with only one cam shaft drive gear fastener screw in place Remove the camshaft timing pin Unscrew and remove the two U bolt screws 1 Remove the U bolt and the oil pipe Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing ...

Page 71: ...and locator pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Use a magnet to remove the tappet CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE Retrieve the pad and replace with a suitable component to achie...

Page 72: ...of the intake cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT 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 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 m...

Page 73: ...octite 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 Block crankshaft rotation using one of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020848Y Flywheel retainer 02...

Page 74: ...shaft timing pin Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned insert the reference pin while checking with the crankshaft reference pin that the flywheel side hole and the hole on the crankshaft are perfectly aligned If this is not the case repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pi...

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

Page 76: ...d refit the crankshaft timing pin from the clutch side to check that the timing setting was not altered while the en gine was turned with only one cam shaft drive gear fastener screw in place Remove the camshaft timing pin Unscrew and remove the two U bolt screws 1 Remove the U bolt and the oil pipe Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Block crankshaft rotatio...

Page 77: ...and locator pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the intake camshaft gear tooth indicated with one dot is meshed with the trough of the exhaust camshaft gear indicated with two dots Use a magnet to remove the tappet CAUTION REMOVE THE TAPPET CAREFULLY AS THE PAD MAY FALL INTO THE ENGINE Retrieve the pad and replace with a suitable component to achi...

Page 78: ...the exhaust cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT 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 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 mou...

Page 79: ...octite 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 Block crankshaft rotation using one of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020848Y Flywheel retainer 02...

Page 80: ...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 camshaft and U bolt holes were aligned Refit the reference pin while checking using the crankshaft reference pin that the clutch side hole and the hole in the crankshaft are perfectly aligned If th...

Page 81: ... in 1 90 mm 0 0748 in 1 95 mm 0 0768 in 2 mm 0 0787 in 2 05 mm 0 0807 in 2 1 mm 0 0827 in 2 15 mm 0 0846 in 2 2 mm 0 0866 in 2 25 mm 0 0886 in 2 3 mm 0 0905 in 2 35 mm 0 0925 in 2 4 mm 0 0945 in 2 45 mm 0 0964 in 2 50 mm 0 0984 in 2 55 mm 0 1004 in 2 6 mm 0 1024 in 2 65 mm 0 1043 in 2 7 mm 0 1063 in RSV4 Factory Maintenance MAIN 81 ...

Page 82: ...2 75 mm 0 1083 in 2 8 mm 0 1102 in 2 85 mm 0 1122 in 2 9 mm 0 1142 in 2 95 mm 0 1161 in 3 mm 0 1181 in 3 05 mm 0 1201 in 3 10 mm 0 1220 in 3 15 mm 0 1240 in Maintenance RSV4 Factory MAIN 82 ...

Page 83: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 84: ...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 TH...

Page 85: ...te 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 ...

Page 86: ...o 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 ADVISED TO D...

Page 87: ...ND 12 IS THE SENSOR IN THE 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 ...

Page 88: ...CTOR END 6 CHECK CONTINUITY OF RED BROWN CABLE FROM PIN 40 TO PROTECTION RE LAY 19 CHECKING ENGINE VEHICLE ELECTRICAL SYSTEM CONNECTOR If there is continuity go to PROTECTION RELAY 19 CHECK if there is not continuity restore cable harness END See also Control unit CHECK FUEL PUMP 1 WITH KEY SET TO ON DISCONNECT THE CONNECTOR AND CHECK THAT THERE IS BATTERY VOLTAGE ON PIN 1 YES go to 2 NO go to 4 2...

Page 89: ... RELAY CONNECTOR If there is continuity go to 2 if there is not continuity restore cable harness END 2 WITH KEY SET TO ON IS THERE VOLTAGE ON RED BROWN CABLE OF THE IN JECTION RELAY CONNECTOR ON THE CABLE HARNESS SIDE YES go to 3 NO go to 6 3 WITH KEY SET TO ON IS THERE VOLTAGE ON ORANGE CABLE OF THE INJEC TION RELAY CONNECTOR ON THE CABLE HARNESS SIDE YES go to 4 NO go to 7 4 CHECK CORRECT OPERAT...

Page 90: ...AND GROUND ON SPECIFIC PIN TO THE BLUE CABLE IS THERE CONTINUITY BETWEEN THE OTHER TWO RELAY PINS YES go to 4 NO replace the relay END 4 CHECK CONTINUITY OF THE GREEN BLUE CABLE FROM THE KEY CONNECTOR AT PIN 3 OF THE RELAY CHECKING ALSO THE KEY SWITCH CONNECTOR AND RE LAY CONNECTOR If there is continuity go to 5 if there is not continuity restore cable harness END 5 WITH KEY SET TO OFF CHECK IF TH...

Page 91: ...4 NO go to 7 4 REPLACE THE CONTROL UNIT END 5 CHECK CONTINUITY OF PINK CABLE BETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT CHECKING ALSO THE ENGINE VEHICLE CABLE HAR NESS CONNECTOR YES go to 4 NO restore the cable harness END 6 CHECK CONTINUITY OF PINK BLACK CABLE BETWEEN SWITCH CONNECTOR AND PIN 4 OF THE CONTROL UNIT CHECKING ALSO THE ENGINE VEHICLE CABLE HARNESS CONNECTOR YES go to 4 N...

Page 92: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 93: ... 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 Factory Electrical system ELE SYS 93 ...

Page 94: ...e 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 Electrical system RSV4 Factory ELE SYS 94 ...

Page 95: ...liary fuses 23 Control unit 24 Hand grip position sensor 25 Intake ducts connector control unit 26 Alternator 27 Coils 28 Timing sensor 29 Starter motor 30 Oil pressure sensor A RELAY CANNOT BE IDENTIFIED BASED ON THE FOLLOWING INDICATIONS ONLY THIS HAS TO BE DONE ALSO IDENTIFYING THE COLOUR OF THE RELAY CABLES RELAY LAYOUT Component position in the electrical circuit diagram Component name Locati...

Page 96: ...l problems and particular checks to be carried out on the connections and routings in order to reach the objectives of vehicle reliability Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Vehicle cable harness 1 Front light cable harness 1 License plate frame cable harness 1 Positive battery cable 1 Battery engine ground cable ...

Page 97: ...ary air solenoid 1 Front motorised throttle body 1 Rear motorised throttle body 2 MAP sensor 1 Alternator 1 Starter motor 4 Upper injectors 4 Lower injectors including the motorised throttle body Small parts and mountings 6 Large black clamps 178x4 6 Small black clamps 160x2 5 5 Rubber clamps 2 TBEI M6x30N screws 2 TE M6x20 1 flanged TE 6x16 screw 2 M5x8 screws 2 TBEI M5x16 screws 1 TE M6x30 screw...

Page 98: ...sher 1 5x20x1 5 washer 1 Spacer 1 Spacer 1 Exhaust valve opening cable 1 Exhaust valve closing cable 1 Instrument panel mounting cover 1 Heat protecting cover 1 Control unit mounting 3 Large black 178x4 clamps 4 Self tapping 5x20 screws 3 Self tapping screws 3 Washers 3 Silentblocks 2 Self tapping screws 4 AMP Superseal connector mountings 1 Mounting for the Framatome connector 2 Small black 98x2 ...

Page 99: ...onnected and correctly tightened to ensure proper engine and therefore proper vehicle operation Instrument panel connector Demand sensor connectors Start up relay connector Speed sensor connector Fall sensor connector Safety relay connector Protection relay connector Injection relay connector Taillight connector Fuel pump connector Exhaust valve actuator connector Engine vehicle interface connecto...

Page 100: ...nnectors are con sidered more critical than the others because their disconnection could cause the vehicle to stop or malfunction Obviously the correct connection of the other connectors is also important and essential for proper vehicle operation It is also important and essential that the instructions regarding the routing and fixing of the cable har ness in the various areas are followed meticu...

Page 101: ...tos below 13 Headlamp 14 Left position light connector 15 Cable harness routing in the cable grommet 16 Cable grommet 17 Relay with relay socket rubber ring 18 Cable harness routing in the 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 conne...

Page 102: ...Right handlebar control TABLE E INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Use a clamp 31 to fasten the vehicle cable har ness in correspondence of the grey taping on the specific seat located on the instrument holder arch brace Connect the Immobilizer antenna connector 30 to the corresponding cable harness connector 29 Antenna connector 30 Key switch 31 Clamp Electrical system RSV4 Factory ELE S...

Page 103: ...CE AND FRONT PART The left arch brace can now be fit After fitting the left arch brace the clamp used for holding the cable harnesses inside the arch brace itself must be cut and removed 33 Left turn indicator connector cable colours light blue and blue 34 Right turn indicator connector cable colours red and blue 35 Insert the connectors into their seats on the arch brace TABLE H INSTRUMENT HOLDER...

Page 104: ...switch con nector is distinguished with red taping on its branch 44 Insert the connectors inside the two arch brace compartments left and right TABLE J INSTRUMENT HOLDER ARCH BRACE AND FRONT PART 45 Rubber ring x3 46 Screw x3 47 Washer x3 48 Instrument panel TABLE K INSTRUMENT HOLDER ARCH BRACE AND FRONT PART 49 Insert the instrument panel rubber rings in their seats on the arch brace 50 Instrumen...

Page 105: ...able harness in correspondence of the cable grommet TABLE M INSTRUMENT HOLDER ARCH BRACE AND FRONT PART Left side Check that the cable grommets are not ten sioned on the right and left cable grommet during steering rotation 58 Antenna cable harness routing 59 Key switch cable harness routing 60 Rubber clamp 61 Cable harness routing to left handlebar control 62 Clutch cable harness routing 63 Cable...

Page 106: ...hown 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 Factory ELE SYS 106 ...

Page 107: ...t side 1 Cable grommet 2 Vehicle cable harness TABLE B RADIATOR AREA Right side 3 Starter motor 4 Clamp 5 Exhaust valve actuator cable harness routing 6 Oil pressure sensor and cable harness routing RSV4 Factory Electrical system ELE SYS 107 ...

Page 108: ...ness routing TABLE D RADIATOR AREA 13 Vehicle connector 14 Engine connector 15 Check that the connectors are inserted cor rectly 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 whit...

Page 109: ...ed 20 Flywheel connector 21 Flywheel connector to the regulator 22 Flywheel cable harness routing 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 regulator RSV4 F...

Page 110: ... branch vehicle cable harness 31 Fan connector 32 Clamp TABLE J1 EXHAUST VALVE ACTUATOR Positioning and calibration 33 Exhaust valve actuator 34 Exhaust valve actuator cable harness routing 35 Exhaust valve actuator connector 36 Clamp 37 Spacer 38 Heat protecting cover 39 Spacer 40 Rubber ring Electrical system RSV4 Factory ELE SYS 110 ...

Page 111: ...5 univocal fit ting 4 Actuator side opening cable 45 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 pulley Finally tighten the lock nut on the set screw TABLE J3 EXHAUST VALVE ACTUATOR Positioning and calibration Actuator valve Bowden cable 45 fitting procedure Turn the opening cable 43 set screw until the cable tensi...

Page 112: ...harness routing 52 Clamp 53 Stand switch 54 Oxygen sensor 55 Mounting TABLE K2 Pass the cable harnesses behind the cable grommet that closes the two fuel breather pipes 56 Oxygen sensor cable harness routing 57 Gear sensor cable harness routing 58 Stand switch cable harness routing TABLE L 59 Cable guide 60 Oxygen sensor cable harness routing 61 Stand switch cable harness routing Electrical system...

Page 113: ...minal from the engine cable harness 69 Engine GND lug terminal from 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...

Page 114: ...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 Electrical system RSV4 Factory ELE SYS 114 ...

Page 115: ...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 RSV4 Factory Electrical system ELE SYS 115 ...

Page 116: ...20 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 Electrical system RSV4 Fact...

Page 117: ...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 CONNECTI...

Page 118: ... 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 Mo...

Page 119: ...ring 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 injecto...

Page 120: ... 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 conn...

Page 121: ...n 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 TEMPERATU...

Page 122: ... 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 Electric...

Page 123: ...rting 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 RSV4 Factory Electrical s...

Page 124: ...RS FOR INTAKE DUCT CONTROL UNIT AND INTAKE DUCT MOTOR 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 cable harness and rear brake switch co...

Page 125: ...0 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 Cable harness routing 3 2 8 mm 0 11 in Faston cable colours red and blue 4 License plate light grey rubber ring 5 2 8 mm 0 11 in Faston cabl...

Page 126: ...rter 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 B battery Be careful not to bend the positive battery cable 14 Electrical system RSV4 Factory ELE SYS 126 ...

Page 127: ...ehicle cable harness 17 Insert two tape clamps on the rigid section of the cable harness in the two holes on the right chassis beam 18 Fall sensor and relay mounting 19 Fall sensor connector 20 Fan relay connector 21 TE M6x20 screw 22 T shaped bushing 23 Safety relay connector 24 Fasten the fall sensor connector on the mount ing link TABLE E1 REAR SWINGARM AREA 25 Rubber clamp 26 Rear brake switch...

Page 128: ... Taillight connector 34 Taillight TABLE F2 35 Insert the fuse box in the two tongues on the battery mounting bracket 36 Protection relay and relay socket rubber ring 37 Insert the relay in the plastic tongue on the left 38 TBEI M5x16 screw 39 Battery mounting bracket 40 TBEI M5x16 screw 41 Insert the relay in the plastic tongue on the right 42 Relay and relay socket rubber ring TABLE F2 BIS Pass t...

Page 129: ...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 harness in the hole on the right side of the saddle mounting 53 Starter motor cable 54 M5x8 screw 55 Start up relay connector 56 Start up relay 57 Insert the start up relay in the two plastic tongues Pay attention not to bend the starter motor cable TABLE F5 ...

Page 130: ...sensor connector 63 Rear brake switch connector TABLE F6 LEFT SIDE SADDLE MOUNTING 64 Battery engine ground lead 65 Cable grommet TABLE G INTAKE DUCT CONTROL UNIT AND TANK After fitting the tank and connecting the fuel 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 Electrical system RSV4 Factory ELE...

Page 131: ...TABLE H1 67 Intake duct control unit 68 Intake duct control unit connector 69 Rubber ring TABLE H2 70 Clamp 71 Intake duct control unit cable harness routing RSV4 Factory Electrical system ELE SYS 131 ...

Page 132: ...General wiring diagram key 1 MULTIPLE CONNECTORS 2 Front right turn indicator 3 COMPLETE HEADLAMP 4 Front left turn indicator Electrical system RSV4 Factory ELE SYS 132 ...

Page 133: ...ITCH 19 PROTECTION RELAY 20 IMMOBILIZER AERIAL 21 REAR RIGHT TURN INDICATOR 22 Taillight assembly 23 REAR LEFT TURN INDICATOR 24 LICENSE PLATE LIGHT BULB 25 RECOVERY LOGIC RELAY 26 AUXILIARY FUSES 27 28 Voltage regulator 29 ALTERNATOR 30 STARTER MOTOR 31 START UP RELAY 32 BATTERY 33 MAIN INJECTION RELAY 34 OIL PRESSURE SENSOR 35 FAN 36 FAN CONTROL RELAY 37 FUEL RESERVE SENSOR PIC 38 FUEL PUMP 39 E...

Page 134: ...HE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING PROCEDURE ON THE VEHICLE CHECK THAT THE BATTERY VOLTAGE IS ABOVE 12V CONNECTOR CHECK PROCEDURE The procedure in...

Page 135: ...tance is null or a few tenths of an Ohm CAUTION THE CIRCUIT SHOULD NOT BE ENERGISED OTHERWISE THE TEST IS IRRELE VANT GROUND CONNECTION check Check goal this control is to check if a cable or a circuit is in contact with the vehicle ground connection Tester set the tester on the continuity symbol and place one tester probe on the vehicle ground connection or on the battery terminal and the other p...

Page 136: ...NG CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER INSTRUMENT PANEL ERRORS DSB 01 Immobilizer fault key code read but not recognised Error cause The read code is not stored in the instrument panel memory Troubleshooting Carry out key data storage procedure DSB 02 Immobilizer fault read key code not read key not present or transpon...

Page 137: ...d activate the engine revs indication choosing the function Rpm indicator from the Devices Activation screen page injector icon Installing a new instrument panel In case the instrument panel is replaced by a new one follow the procedure shown below so that the immobilizer system key storage and the exhaust butterfly valve controlled by the ECU through the instrument panel operate correctly 1 Reque...

Page 138: ...ols Exhaust butterfly valve See also Butterfly valve in exhaust Diagnosis An access code is required to enter this menu which controls the diagnosis function ENTER SERVICE CODE This is a 5 digit code fixed for each vehicle For these vehicles the code is 12412 If the code is incorrect the following message is displayed INCORRECT CODE and the instrument panel goes back to the main menu Otherwise the...

Page 139: ... oil sensor fault is signalled when with engine running it is detected that the sensor circuit is closed There is an error when the general warning light turns on Troubleshooting This error is signalled by the bulb icon and the general warning light turns on as well The instrument panel must keep all previous errors stored in its memory DELETE ERRORS This option deletes all instrument panel errors...

Page 140: ...icle and the instrument panel must be enabled even if only one key has been programmed Km miles This menu selects the unit of measurement either for the speed or the total or partial odometers KM MILES LANGUAGES Select the user interface language from this menu ITALIANO ENGLISH FRANCAIS DEUTSCH ESPAÑOL Service warning light reset VEHICLE SERVICING RESET This function is used to reset vehicle servi...

Page 141: ... 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 ELECTRICAL ERRORS Starter switch P0170 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 58 if the circuit is open sho...

Page 142: ... C 15A fuse Control unit D 7 5A fuse Control unit E 15A fuse High beam light low beam light horn and fans F 15A fuse Coils injectors fuel pump oxygen sensor and secondary air valve CAUTION THERE ARE THREE SPARE FUSES G CAUTION THERE IS ONE SPARE FUSE H MAIN FUSES DISTRIBUTION Specification Desc Quantity I 30A fuse Battery recharge and vehicle current consumers injection cur rent consumers red and ...

Page 143: ...T THE END OF STROKE CONTROL UNIT Diagnosis Function it controls the Ride by wire system the injection ignition the system safety checks and the self di agnosis function Level in wiring 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...

Page 144: ...s car ried out the last control unit remapping DIAGNOSIS INSTRUMENT PARAMETERS Nominal idle speed Example value with key ON 1600 rpm Adjustable fuel supply Adjustable fuel correction 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 ...

Page 145: ...he start up consent to the control unit the status is NO DIAGNOSIS INSTRUMENT ACTIVATION Stop light The stop light logic relay No 25 in the wiring diagram position in the front niche of the frame right side CHECK however the identification of the relay with the colour of the cables is energised Error clearing Ambient parameter reading Rear throttle target position angle Front throttle target posit...

Page 146: ...egative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting If shorted to positive check the relay electrical specifications are correct by disconnecting it from the cable harness If they are not correct replace the relay if OK restore the cable harness blue pink cable If shorted to negative check the relay electrical specifications are correct by ...

Page 147: ...es not indicate the presence of this error even in the ATT status Troubleshooting Continue fault search for the other errors detected DIAGNOSIS INSTRUMENT ADJUSTABLE PARAMETERS Cylinders pressure balance It allows balancing the cylinders 1 3 and then the cylinders 2 4 by the by pass screws Control unit EEPROM zero setting CAUTION DELETING ALL THE SAVED DATA WHEN THE VEHICLE IS BEING MANUFACTURED I...

Page 148: ...o to phase 1 if indicate Carried out go to phase 2 Phase 1 current errors have probably been detected by the control unit solve these malfunctions and check the two statuses Throttle Self learning can also be checked from the Parameter adjustment screwdriver and hammer screen page Stage 2 Carry out the Throttle Self learning from the Parameter adjustment screwdriver and hammer screen page and chec...

Page 149: ... Battery voltage P0560 too high too low Error cause If too high too high a voltage has been detected at PIN 42 If too low too low a voltage has been detected at PIN 42 The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting If too high check correct operation of the voltage regulator If too low check voltage regulator connectors engine vehicle cable...

Page 150: ...he control unit In case of incorrect or missing speed indication on the instrument panel carry out troubleshooting indicated below Troubleshooting Check the speed sensor connector the engine vehicle cable harness and the VEHICLE connector of the Marelli control unit specially at PIN 79 if not OK restore if OK check with sensor connector disconnected that there is continuity between PIN 3 and groun...

Page 151: ...ition Subse quently 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 ha...

Page 152: ...OSIS 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 positive s...

Page 153: ...tor 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 ...

Page 154: ...STORE 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 9 AND 23 OF THE MARELLI CONTROL UNIT ENGINE CONNECTOR DIAGNOS...

Page 155: ...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 Factory Electrical system ELE SYS 155 ...

Page 156: ...eans 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 th...

Page 157: ... 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 perc...

Page 158: ...ntrol 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 control ...

Page 159: ...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 co...

Page 160: ...acks 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 the ...

Page 161: ...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 ambie...

Page 162: ...g 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 SECTIO...

Page 163: ... 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 th...

Page 164: ...mal 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 ha...

Page 165: ...e 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 exam...

Page 166: ...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 invers...

Page 167: ...uit 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 con...

Page 168: ...ssive 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 o...

Page 169: ...in 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 CARRYI...

Page 170: ...t 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 O...

Page 171: ...be 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 Lambda probe Example value with key ON 0 mV Example va...

Page 172: ...or 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 lambda probe signal to keep the combustion as close as possible to the stoichiometric value DIAGNOSIS INSTRUMENT ACTIVATION Lambda probe heating The injection relay No 33 in the ...

Page 173: ...ge 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 right side 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 lin...

Page 174: ...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 an...

Page 175: ... 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 CONTROL SECT...

Page 176: ... 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 injec...

Page 177: ...e 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 c...

Page 178: ...d 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 shorte...

Page 179: ...njectors in the field of high engine revs Operation operating principle Injector coil is excited for the petrol passage to open Level in wiring 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 engine on 1...

Page 180: ... 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 injecti...

Page 181: ...f 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 volt...

Page 182: ...ponent 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 circui...

Page 183: ...table 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 BEGIN ...

Page 184: ...e 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 generation ...

Page 185: ...lay 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 right side of the saddle CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the brown red cable of the coil is clo...

Page 186: ...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 cable har...

Page 187: ...y 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 PIN...

Page 188: ...n 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 The syste...

Page 189: ...ample 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 mechani...

Page 190: ...HOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Front throttle automatic self acquisition 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 is...

Page 191: ...f 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 body ...

Page 192: ...r 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 open...

Page 193: ...nected 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 negativ...

Page 194: ...otentiometer 1 rear Throttle voltage Check the throttle body connector as well as the control unit connector Check that the resistance of the cable between the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm If different restore cable harness if OK replace the entire throttle body potentiometer 2 sensor rear throttle position P0123 signal not valid Error cause Si...

Page 195: ...l unit receives 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 the resistance of the cable between the throttle body connector PIN 1 and the control unit PIN 36 is a few tenths of an Ohm If different restore cable harness if OK replace the entire throttle body potentiometer 2 sensor front throttle p...

Page 196: ... 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 deterioration of t...

Page 197: ...dering 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 field at each key ON The instrument panel does not indic...

Page 198: ...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 in...

Page 199: ...cess on the adjustable parameters screen page screwdriver and hammer and check again that the Throttle self acquisition with diagnosis instrument status indicates Carried out and that the Front throttle automatic self acquisition or Rear throttle automatic self acquisition indi cate carried out Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure 0 5 0...

Page 200: ...r circuit 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 vari...

Page 201: ...e 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 restore if they are OK check the continuity of the grey black cable between the two connecto...

Page 202: ...tage 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 SYSTEM CHAPTER DIAGNOSIS INSTRUMENT STATUSES Clutch Indefinite_Released_Pulled WARNING The statuses regularly viewed are Released and Pulled Indication on Axone always Released che...

Page 203: ...e 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 wiring diagram Start up enabling switches Location on the vehicle on the stand connector between head cover and fil ter box on left side 2 ways white con nector Pin out 1 Ground connection 2 Voltage 12V Electrical characteristics Side Stand Up ...

Page 204: ...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 wiring diagram Start up enabling switches Location on the vehicle sensor placed in the frame front niche connector next to the sensor 2 ways grey connector Electrical characte...

Page 205: ...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 CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK...

Page 206: ...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 cable harness brown cable If...

Page 207: ... 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 valve contro...

Page 208: ...al characteristics and replace the component RUN STOP switch Function It tells the control unit if the driver wishes to enable engine start up or to keep the engine running Operation operating principle If the driver wants to shut off the engine or to dis able engine start up the switch should be open i e VEHICLE connector PIN 78 of the Marelli con trol unit must not be connected to ground Level i...

Page 209: ...unit Indication on Axone 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 yellow red cable between switch and the PIN C7 of the engine vehicle cable harness connector or from the latter to the PIN 78 of the co...

Page 210: ...te the valve 7 closed valve 93 open valve 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 STATUSES Exhaust valve Indefinite in research activation with key ON in operation stopped for detected malfunction research of zer...

Page 211: ...ck that mechanical rotation of the exhaust valve is without friction or deceleration if they are not OK restore normal valve rotation if they are OK check motor electrical characteristics if they are not OK replace the motor if they are OK check valve connector and instrument panel connector with special attention to possible oxidation if they are not OK restore if they are OK replace the electric...

Page 212: ... also the valve connector if both cables are insulated between them if they are not insulated restore cable harness if insulated between them it is possible that there is a shorted to positive inside the motor or instrument panel it is necessary to replace one of the two components to identify which of them is faulty Exhaust valve potentiometer P0193 shorted to positive shorted to negative open ci...

Page 213: ...a reference position to correctly search mechanical stop later Exhaust valve self acquisition NOTE Search minimum and maximum mechanical stop The system consists of a throttle valve 1 with a return spring placed in the exhaust pipe The valve is closed via two cables actuated by an electric motor 2 which in turn is connected electrically to the instrument panel The operating logic and motor control...

Page 214: ...on the lower cable so it has the same tension as the upper cable Tightening the lower cable will proba bly have caused the travel limit to shift repeat the procedure until the correct position is obtained Using the diagnostic tool from the Adjustable parameters screen select Exhaust exhaust valve self acquisition which acquires the opening travel limit 4 valve open and the closing travel limit 3 v...

Page 215: ...nd connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6 17 Lower cylinder 1 injector control output PIN 8 Lambda sensor input PIN 10 Track D throttle grip input PIN 11 Water temp sensor input PIN 12 Track B throttle grip input PIN 13 Serial line K for diagnosis PIN 14 RSV4 Factory Electrical system ELE SYS 215 ...

Page 216: ... 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 throttle grip input PIN 39 Key input PIN 40 42 Rear throttle motor output PIN 41 Secondary air valve control output PIN 43 Lower cylinder 4...

Page 217: ...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 Factory Electrical system ELE SYS 217 ...

Page 218: ... 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 s...

Page 219: ...Dashboard Grey bodied instrument panel pinout key 1 Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply RSV4 Factory Electrical system ELE SYS 219 ...

Page 220: ... signal input 11 Battery 12 Left turn indicator control 13 14 15 16 Indicator reset 17 Oil sensor input 18 Tuono V4 RSV V4 selection 19 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 Factory ELE SYS 220 ...

Page 221: ... its complexity With this communication line needless duplication of several sensors present on the motorbike has been obviated The sensor signals are shared by the two electronic elaboration units instrument panel and control unit Cable number reduction The CAN line travels through a twisted cable to several nodes These nodes can also isolate the errors without causing a system breakdown FaultsCo...

Page 222: ...ed or rejected Besides every nod can request information from the other nodes RTR Remote Transmit Request Level in wiring diagram CAN line Electrical characteristics between PIN 66 and 80 of the control unit approximately 130 Ohm between PIN 26 and 27 of the instrument panel approximately 120 Ohm Pin out Line L white black cable between Marelli control unit PIN 66 and the black bodied connector PI...

Page 223: ...he cable harness if OK check that the two lines are not shorted to positive testing each of the 3 connectors Marelli control unit engine vehicle cable harness connector and instrument panel connector with 1 connector discon nected at a time and by setting the key to ON If not OK restore if OK replace the Marelli control unit CAN line towards instrument panel U1701 no signal Error cause No signal i...

Page 224: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 225: ...uel tank and the battery Disconnect and remove the hand grip position sensor Remove the throttle body and the filter box Remove the complete exhaust Remove the lubrication and cooling system radiators Remove the side stand Remove the left hand rider footpeg Position the vehicle as described Fasten an appropriately sized belt for the weight of the vehicle to the semi handlebars and to a hoist Fit t...

Page 226: ...owl Radiator cover Fuel tank Exhaust Twistgrip position sensor Air box Removing the radiator Removing Side stand Removing the engine from the vehicle Detach the clutch cable Remove the timing sensor Engine from vehicle RSV4 Factory ENG VE 226 ...

Page 227: ... 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 Unscrew and remove the nut and re trieve the washer Detach the ground from the chassis RSV4 Factory Engine from vehicle ENG VE 227 ...

Page 228: ... con trol unit connector Disconnect the vehicle cable harness engine cable harness connector Unscrew and remove the three screws and remove the pinion cover Unscrew and remove the pinion fixing screw and retrieve the two washers Engine from vehicle RSV4 Factory ENG VE 228 ...

Page 229: ...rews 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 Detach the neutral sensor See also Side stand RSV4 Factory Engine from vehicle ENG VE 229 ...

Page 230: ...isconnect the voltage regulator con nector See also Twistgrip position sensor Disconnect the alternator connector Working from the left hand side of the vehicle unscrew and remove the screw and retrieve the washer Engine from vehicle RSV4 Factory ENG VE 230 ...

Page 231: ... plate fixing screws and remove the plate Loosen the screw and ease off the gear lever Unscrew and remove the subframe fix ing screw and retrieve the washer re move the radiator subframe RSV4 Factory Engine from vehicle ENG VE 231 ...

Page 232: ...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 Engine from vehicle RSV4 Factory ENG VE 232 ...

Page 233: ...ster 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 RSV4 Factory Engine from vehicle ENG VE 233 ...

Page 234: ...ers 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 the insert is e 5 mm e 0 197 in therefore the eng...

Page 235: ...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 UPWARDS 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 left...

Page 236: ...S 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 center the engine position Working on the right side place and screw without tighten the two front fixing screws 2 and from the chas...

Page 237: ... 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 t...

Page 238: ...the washer and tighten the screw fastening the frame to the engine Place the gear lever and tighten the screw Connect the alternator connector Connect the voltage regulator connec tor Engine from vehicle RSV4 Factory ENG VE 238 ...

Page 239: ...G THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS Connect the neutral sensor Place the two fuel breather pipes Install the side stand Place the pinion and insert the trans mission chain in the seat Tighten the rear wheel fixing nut RSV4 Factory Engine from vehicle ENG VE 239 ...

Page 240: ...ster screws Place the two washers and tighten the pinion fixing screw Place the pinion cover and tighten the three screws Connect the vehicle cable harness engine cable harness connector Engine from vehicle RSV4 Factory ENG VE 240 ...

Page 241: ... Place the ground on the frame Fit the washer and tighten the nut Place the cable grommet and the three cable leads as shown Tighten the cable grommet fixing screw Connect the starter motor place the washer and tighten the nut Place the rubber cap RSV4 Factory Engine from vehicle ENG VE 241 ...

Page 242: ... Tighten the engine oil pressure sensor Connect the timing sensor Connect the clutch cable Engine from vehicle RSV4 Factory ENG VE 242 ...

Page 243: ... Check and adjust the clutch lever clearance with the adjuster screw The clutch lever clearance should be between 1 3 mm 0 039 0 12 in RSV4 Factory Engine from vehicle ENG VE 243 ...

Page 244: ...INDEX OF TOPICS ENGINE ENG ...

Page 245: ...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 RSV4 Factory Engine ENG 245 ...

Page 246: ...ixing 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 bell Remove the gear sensor from the flywheel side Engine R...

Page 247: ...move the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Unscrew and remove the six screws RSV4 Factory Engine ENG 247 ...

Page 248: ... 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 Engine RSV4 Fa...

Page 249: ...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 RSV4 Factory Engine ENG 249 ...

Page 250: ...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 control rod if nec essary Check the desmodromic segment 1 for damage and wear and replace it if necessary Check the de...

Page 251: ...OLLOWING 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 cover...

Page 252: ...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 Engine RSV4 Factory ENG 252 ...

Page 253: ... 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 RSV4 Factory Engine ENG 253 ...

Page 254: ...g Install the gear sensor making the pin coincide with the slot on the desmo dromic control rod Gear selector Removing the gear selector Drain the engine oil Remove the clutch cover Working from the clutch side remove the selector control shaft Remove the gear locking pawl and re trieve the washer and the spring Engine RSV4 Factory ENG 254 ...

Page 255: ...g 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 wi...

Page 256: ...part Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Reassembling the gear selector To refit lubricate and carry out the removal operations but in reverse order Starter motor Removing the starter motor Unscrew the starter motor fixing screws and pull it out of its housing Engine RSV4 F...

Page 257: ...r Start up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING THE STARTER ENGINE TOOTHING MUST BE CHECKED AS WELL Check the dual starter gear toothing 1 and the freewheel gear 2 to see if the material is dam aged or deformed RSV4 Factory Engine ENG 257 ...

Page 258: ...check the rollers needles for wear Check for wear on the freewheel sliding surface 2 Generator side ALTERNATOR COVER pos Description Type Quantity Torque Notes 1 Screws 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 ...

Page 259: ...oval Remove the flywheel cover Block flywheel rotation using the spe cific tool Unscrew and remove the screw Specific tooling 020848Y Flywheel retainer Remove the tool for blocking flywheel rotation Insert a TCEI M10x20 screw into the crankshaft hole which will act as a mounting base for flywheel extraction Remove the flywheel using the specific extractor Collect the TCEI M10x20 screw Specific too...

Page 260: ... Remove the flywheel cover Remove the circlip thrust washer and inner sealing ring or replace if they are spoiled or in case of oil leaks 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 Engine RSV4 Factory ENG 260 ...

Page 261: ... 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 RSV4 Factory Engine ENG 261 ...

Page 262: ...tes 1 Rpm sensor fixing screw 1 8 Nm 5 9 lbf ft 2 TE flanged screw M6x20 1 12 Nm 8 85 lbf ft 3 TE flanged screws M6x35 2 12 Nm 8 85 lbf ft 4 TE flanged screws M6x22 16 12 Nm 8 85 lbf ft 5 Engine timing inspection cap 1 25 Nm 18 44 lbf ft Engine RSV4 Factory ENG 262 ...

Page 263: ...nsmission 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 pressure plate and the complete control rod Remove the discs See also Removing the clutch cover RSV...

Page 264: ...ation 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 Engine RSV4 Factory ENG 264 ...

Page 265: ... Collect the shim washer Collect the clutch bell Remove the clutch gear that controls the oil water pumps Remove the needle cage RSV4 Factory Engine ENG 265 ...

Page 266: ...stic Maximum clutch disc deformation in compar ison to a flat surface 0 15 mm 0 0059 in Minimum wear limit of the clutch disc sliding teeth 13 5 mm 0 53 in Minimum wear limit of the complete clutch pack thickness friction discs steel discs 47 6 mm 1 87 in Engine RSV4 Factory ENG 266 ...

Page 267: ...r 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 spring holder plate compression surface 0 15 mm 0 0059 in Maximum depth of the spring holder pla...

Page 268: ...m all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Characteristic Minimum wear limit in the release position of the individual clutch springs 46 8 mm 1 84 in Assembling the clutch Insert the thrust bearing with the collar facing the gearbox Insert the spacer Engine RSV4 Factory ENG 268 ...

Page 269: ... 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 RSV4 Factory Engine ENG 269 ...

Page 270: ...IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES Fit the three slipper unit clips offsetting them by 120 Install the slipper unit correctly Block clutch bell rotation using the spe cific tool Tighten the clutch bell fixing nut Specific tooling 020849Y Clutch retainer Engine RSV4 Factory ENG 270 ...

Page 271: ...with friction material and the black tooth into the bell Insert one of the metal discs into the bell Insert the flat washer Insert the belleville spring with the con cave side facing outward RSV4 Factory Engine ENG 271 ...

Page 272: ... into the bell Continue inserting alternating a metal disc with one with friction material fin ishing with a friction material disc with a black tooth Place the control rod together with the thrust bearing and the shim washer Engine RSV4 Factory ENG 272 ...

Page 273: ...ansmission gear on the crankcase Position the gasket and the two dowel pins in the clutch cover Insert the clutch cover making sure to have correctly engaged the clutch con trol lever and the rack shaft Screw the sixteen perimetric fixing screws with the washers Tighten the screws working in stages and diagonally Add engine oil up to the correct level RSV4 Factory Engine ENG 273 ...

Page 274: ...LVE 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 Factory ENG 274 ...

Page 275: ... 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 2...

Page 276: ...al corners of the head DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE Recommended products Three bond Sealing paste Front head Removing camshafts Remove both head covers the alter nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft Remove the O ring See also Head cover removal Removing the flywheel cover Engine RSV4 Factory ENG 276 ...

Page 277: ...ooling 020852Y Crankshaft timing pin Fit the pin aligning the intake camshaft with the hole in the U bolt If it was not possible before adjusting the valve clearance check the engine timing Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned wit...

Page 278: ...e U bolt on the front head and refit the crankshaft timing pin from the flywheel side to check that the tim ing setting was not altered while the engine was turned with only one cam shaft drive gear fastener screw in place Remove the camshaft timing pin Unscrew and remove the two U bolt screws 1 Remove the U bolt and the oil pipe Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timi...

Page 279: ...s and locator pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the ex haust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK Check that the camshaft gear works properly if it is damaged or does not move smoothly replace the timing chain and t...

Page 280: ...ADJUSTING CAM SHAFT GEAR THE TWO TYPES OF CAMSHAFT ARE INTERCHANGEABLE ON ALL ENGINES IRRESPECTIVE OF THE CAMSHAFT TYPE ORIGINALLY INSTALLED Check the timing chain for damage or stiffness while moving If necessary replace the timing chain together with the camshaft gears Check the timing chain guide sliders for damage If necessary replace the parts Installing camshafts NOTE Engines up to engine No...

Page 281: ...ine 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 bolt and...

Page 282: ...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 vi...

Page 283: ...shaft and U bolt holes were aligned insert the reference pin while checking with the crankshaft reference pin that the flywheel side hole and the hole on the crankshaft are perfectly aligned If this is not the case repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Front head removal Remove both head covers the alter nator side cover and remove ...

Page 284: ...ligned with the hole on the U bolt is visible Block crankshaft rotation using one of the specific tools 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 engine rotation direction direction of ...

Page 285: ...with a clamp Unscrew and remove the ten screws 1 2 proceeding in stages and in a crossed pattern Retrieve the washers from the screws 2 near the spark plug holes Remove the U bolts with the O rings and locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust cam shafts from the front head Unscrew and remove the fixed chain slider screw Remove the fixed ch...

Page 286: ...control gear connected with a clamp to the timing chain Unscrew and remove the two head fix ing screws a b from the flywheel side Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Engine RSV4 Factory ENG 286 ...

Page 287: ...he crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Timing chain tensioner installation removal tool Front head check Check that The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal Check the status of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet o...

Page 288: ...AL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly Place a new gasket between the crank case and the head Place the two dowel pins Engine RSV4 Factory ENG 288 ...

Page 289: ...ollowing 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 Factory Engine ENG 289 ...

Page 290: ...o the overlap TDC 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 Engine RSV4 Factory ENG 290 ...

Page 291: ... with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are 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 locato...

Page 292: ...fic 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 Engine RSV4 Factory EN...

Page 293: ...d 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 whi...

Page 294: ...h side into 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 See also Head cover removal Removing the clutch cover Fit the pin aligning the intake camshaft with the hole in the U bolt If it was not possible before adjusting the valve clearance check th...

Page 295: ...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 to...

Page 296: ...e 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 intak...

Page 297: ...e 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 Ch...

Page 298: ...the exhaust cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT 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 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 mou...

Page 299: ... 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 Block crankshaft rotation using one of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020848Y Flywheel retainer ...

Page 300: ...rankshaft timing pin Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned Refit the reference pin while checking using the crankshaft reference pin that the clutch side hole and the hole in the crankshaft are perfectly aligned If this is not the case repeat the timing operations Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing ...

Page 301: ...utch cover Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft by 450 one com plete turn 90 in the direction of en gine rotation direction of travel to align the hole on the intake camshaft with the specific hole on the U bolt This ensures that all the rear cylinder bank valve springs are decompressed Block crankshaft rotation using one of the specifi...

Page 302: ...om the screws 2 near the spark plug holes Remove the U bolts with the O rings and locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust 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 Engine RSV4 Factory ENG 302 ...

Page 303: ... fas tener screws a b from the clutch side Loosen the six nuts on the stud bolts proceeding in the following order 6 5 4 3 2 1 After loosening all nuts remove them in order indicated above Remove the rear head slipping it off the stud bolts Collect the gasket and the two dowel pins RSV4 Factory Engine ENG 303 ...

Page 304: ...ioner installation removal tool Rear head check Check that The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal Check the status of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air Rear head fitting Install a new O ring on the chain ten sioner REPLACE THE O RING...

Page 305: ...at the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly Place a new gasket between the crank case and the head Place the two dowel pins Install the head RSV4 Factory Engine ENG 305 ...

Page 306: ...ews 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 Install both chain sliders and fasten them with the specific screws Engine RSV4 Factory ENG 306 ...

Page 307: ...aft gear tooth indicated with a dot is inserted in the groove of the exhaust cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ...

Page 308: ...haft so that the timing hole and the gear fixing screw hole are centred with the gear slot Insert the specific timing pin Specific tooling 020851Y Camshaft timing pin Apply Loctite 243 thread lock on the thread of the timing gear fastener screw This screw must be replaced at each reassembly Apply and loosely tighten the gear fix ing screw on the camshaft Protect the edge of the head with rubber Lo...

Page 309: ...specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing screw to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Turn the crankshaf...

Page 310: ...ly upon refitting Remove the bowl tappets and the ad justment shims using a magnet Compress the valve springs with the specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor See also Front head removal Rear head removal Remove the cotters using a magnet Engine RSV4 Factor...

Page 311: ...ves Valve check CAUTION REPLACE THE VALVES ONE AT A TIME DO NOT MIX THE COMPONENTS EACH VALVE MUST BE INSERTED INTO ITS SEAT WHICH IS MARKED PRIOR TO REMOVAL VALVE STEM DEVIATION Lift up the valve approx 10 mm 0 39 in from its seat Measure the valve stem deviation in two perpen dicular directions and position the dial gauge as shown in the figure RSV4 Factory Engine ENG 311 ...

Page 312: ...lacing the valve or the guide Characteristic Intake valve stem diameter 4 985 4 965 mm 0 1963 0 1954 in Exhaust valve stem diameter 4 975 4 955 mm 0 1959 0 1951 in Support the valve with two V blocks as shown and check the run out with a dial gauge If the run out exceeds the specified limit replace the valve Characteristic Valve stem run out 0 05 mm 0 0020 in Position the dial gauge at a right ang...

Page 313: ...ion 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 Fit the caps RSV4 Factory Engine ENG 313 ...

Page 314: ...the seat Specific tooling AP8140179 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 Engine RSV4 Factory ENG 314 ...

Page 315: ...icate 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 he...

Page 316: ...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 Factory ENG 316 ...

Page 317: ...Nm 88 51 lbf ft 5 Tone wheel fixing screw M8x1 25 1 30 Nm 22 13 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 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...

Page 318: ... Remove the countershaft from the al ternator side Remove the countershaft gear Remove the spacer Balancing countershaft fitting Install the spacer Engine RSV4 Factory ENG 318 ...

Page 319: ...til aligning the key seat on the countershaft and on the gear Insert the drive key Turn the nut on the countershaft Block crankshaft rotation using the specific tool Tighten the nut on the countershaft Specific tooling 020850Y Primary gear lock 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 cr...

Page 320: ...crew 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 Engine RSV4 Factory ENG 320 ...

Page 321: ...TIFIED 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 Prepar...

Page 322: ...diate 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 Removing the starter motor Balancing countershaft removal Crankcase opening Position the engine with the heads fac ing upward unscrew and remove the screw 24 Engine RSV4 Factory ENG 322 ...

Page 323: ... 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 RSV4 Factory Engine ENG 323 ...

Page 324: ...Y 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 Engine RSV4 Factory ENG 324 ...

Page 325: ...t 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 RSV4 Factory Engine ENG 325 ...

Page 326: ...al Crankcase opening Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0 5 mm 0 0197 in Maximum radial clearance between the main bearings and the crankshaft pins 0 05 mm 0 00197 in Balancing countershaft check Characteristic Wear limit maximum inner diameter of the countershaft bushings 20 06 mm 0 790 in Maximum radial clearance between the countershaf...

Page 327: ...39 in Maximum wear limit of the pin hole on the pis ton 0 055 mm 0 0022 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 responding slot on the piston 0 1 mm 0 0039 in Maximum opening of the piston ring fit on the piston 0 3 ...

Page 328: ...if the piston 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...

Page 329: ...rankcase 1 flywheel side 2 central 3 clutch 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 each are available in ...

Page 330: ...ain journal Choose the bushings used for assembly from the following table CRANKSHAFT BUSHINGS WITH REMOVABLE REELS 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 WITH NON REMOVABLE REELS Crankshaft main journal Class A crankcas...

Page 331: ... dimension classes for the crank pins or the connecting rods As a result only the two semi bushing combinations are possible 1 BLUE 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 RSV4 Factory E...

Page 332: ...s already installed on the side oppo site to which you want to install the new bushing use only the buffer 1 If instead a bushing is not installed use the adaptor 2 in addition to the buf fer 1 Specific tooling 020861Y Countershaft bushing punch Shim the crankcase sufficiently in the gearbox area in order to keep it parallel to the work table Heat the crankcase to a temperature of 150 C 302 F On t...

Page 333: ...l tool s punch Place the adaptor 3 on the ring for centring the bushing Place the punch in the crankcase aligning the slot on the ring of the spe cial tool with the reference marked on the crankcase exterior Use the press to install the new bush ing Remove the special tool Use a thin screwdriver to check that the countershaft lubrication oil passage is aligned with the hole on the installed bushin...

Page 334: ...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 against the crankshaft shoulder Position the sprocket 2 with the smooth side fac ing the inside of the crankshaft Move the sprocket 2 up against the crankshaft shoulder Lubricate the crankshaft pins and in sert them into their positions Eng...

Page 335: ...shaft from the clutch side Make the references on the gears of the primary shaft and the countershaft coincide NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED 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 T...

Page 336: ...s pistons The piston rings are different and must be fit with the markings R and RN facing upward The five ring gaps two piston rings two oil scraper rings one oil scraper spring are fitted displaced 90º to each other starting from the exhaust side stud bolt opposite the chain and continuing clock wise Engine RSV4 Factory ENG 336 ...

Page 337: ... the bevelling 2 on the hole of the rod head on the right side Position the special tool on the crank case Partially insert the connecting rod shank piston assembly in the corre sponding cylinder with the arrow on the piston twisted 45 towards the ex haust When the connecting rod head is low and has exceed its lubricating jet ro tate the connecting rod shank piston assembly with the arrow on the p...

Page 338: ...eed with tightening according to the procedure described in the tighten ing torque table using the torque wrench and angular tightening with a goniometer Crankcase closing Insert the crankshaft together with con necting rods and pistons in the upper crankcase Position the three centring dowels in the crankcase Insert a new oil seal O ring in the spe cific seat Engine RSV4 Factory ENG 338 ...

Page 339: ...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 order RSV4 Factory Engine ENG 339 ...

Page 340: ... Turn the engine with the heads facing upward Tighten the screw 24 Engine RSV4 Factory ENG 340 ...

Page 341: ...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 Factory Engine ENG 341 ...

Page 342: ...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 a ...

Page 343: ...ews 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 Factory Engine ENG 343 ...

Page 344: ...ication 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 Factory ENG 344 ...

Page 345: ...on 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 Factory Engine ENG 345 ...

Page 346: ...osition 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 Factory ENG 346 ...

Page 347: ...il Unscrew and remove the twelve oil sump screws Remove the oil sump Remove the metal gasket Remove the rose pipe together with the gasket DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE Blow by RSV4 Factory Engine ENG 347 ...

Page 348: ...IR SYSTEM pos Description Type Quantity Torque Notes 1 Secondary air system solenoid screws 2 10 Nm 7 37 lbf ft Diagram Valve controlled by control unit which delivers as pirated air from the filter box to the exhaust mani folds The advantages of this function are twofold the catalytic converter reaches the op erating temperature more quickly it permits the use of richer mixtures in some critical ...

Page 349: ...Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves RSV4 Factory Engine ENG 349 ...

Page 350: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 351: ...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 Factory Power supply P SUPP 351 ...

Page 352: ...Diagram key 1 Control unit position 2 Hand grip position sensor 3 Fall sensor 4 Outlet valve Power supply RSV4 Factory P SUPP 352 ...

Page 353: ... 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 paramet...

Page 354: ...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 i...

Page 355: ...ectors 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 Factory Power supply P SUPP 355 ...

Page 356: ...function 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 connecto...

Page 357: ...ed regulation stepper mo tors thermoactuators etc are not necessary Variable geometry intake 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 PART Elec...

Page 358: ...r 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 unit an error ...

Page 359: ...trument 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 214 F the procedure is aborted and cannot be carried out During the procedure the position of the hand grip pos...

Page 360: ...n is now correct The procedure then continues with screws 2 and 4 To ensure correct engine operation one of the two screws of each throttle body must always be closed Motorcycles are factory set with screws 1 and 2 turned by half a turn and screws 3 and 4 closed Power supply RSV4 Factory P SUPP 360 ...

Page 361: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 362: ... 1 80 Nm 59 lbf ft 2 Front brake disc fixing screws M8 6 6 30 Nm 22 13 lbf 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 Factory SUSP 362 ...

Page 363: ... the 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...

Page 364: ...ear ALWAYS REPLACE BOTH GASKETS ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE wheel spindle Use a dial gauge to check the wheel spindle eccentricity Replace the wheel spindle 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 A...

Page 365: ...eeves M8 1 1 25 Nm 18 44 lbf ft 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 RSV4 Factory Suspensions SUSP 365 ...

Page 366: ...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 Factory SUSP 366 ...

Page 367: ... 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 from fully closed 12 click Spring preloading nut 3 screw 8 turns from fully open Stems A protrusion from top plat...

Page 368: ...E WHEEL HUB 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 fork stem See also Suspensions RSV4 Factory SUSP 368 ...

Page 369: ... 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 whole cap RSV4 Factory Suspensions SUSP 369 ...

Page 370: ... pressed Remove the lock nut for the preload 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 Suspensions RSV4 Factory SUSP 370 ...

Page 371: ...he fork Remove the preload pipe Remove the sleeve 2 from the wheel holder stanchion 1 Use a plain slot screwdriver to lift up the dust gaiter 3 in multiple points and re move from the sleeve 2 Use a plain slot screwdriver to remove the snap ring 4 RSV4 Factory Suspensions SUSP 371 ...

Page 372: ...ing 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 Use the Öhlins tool to unscrew the pumping member pin fixing ring nut Remove the pumping member pin unit Remove the spring guide snap ring 1 Remove the spring guide support ring 2 Suspensions RSV4 Factory SUSP 372 ...

Page 373: ... rubber buffer 6 Remove the ring nut on which the threaded pipe is attached from the pumping member pin Remove the rubber O ring Remove the guide bushing and the counterspring Checking the components Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 1 RSV4 Factory Suspensions SUSP 373 ...

Page 374: ...ition Check that the length of the springs is within the specified tolerance range Replace the springs if the length is not within the specified tolerance range SPRING MINIMUM LENGTH WHEN UNLOADED 254 mm 9 99 in MINIMUM COUNTERSPRING LENGTH 35 mm 1 38 in Check that the following components are in good conditions sliding bushing guide bushing pumping member pin If there are signs of excessive wear ...

Page 375: ...T BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Fork oil 530 cc 0 12 Uk gal for each stanchion Reassembling the fork Insert the guide bushing and the coun terspring Insert the rubber O ring RSV4 Factory Suspensions SUSP 375 ...

Page 376: ...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 Insert the pumping member pin unit Use the Öhlins tool to tighten the pumping member pin fixing ring nut to 40 Nm 29 50 ...

Page 377: ...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 Fit the retainer ring 4 into its seat on the sleeve 2 RSV4 Factory Suspensions SUSP 377 ...

Page 378: ...Y IN THE SLEEVE WITHOUT RESISTANCE Insert the pumping member pin unit CAUTION THE STANCHION MUST SLIDE FREELY IN THE SLEEVE WITHOUT RESISTANCE Filling oil 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 Factor...

Page 379: ...mpletely Screw the complete cap onto the pumping member pin Tighten the cap using a wrench to block the lower spring ring nut Tighten the upper adjustment cap to bring it into contact with the lower nut on the cap Use the specific Öhlins tool to tighten the upper cap on the sleeve to 20 Nm 14 75 lbf ft Steering damper RSV4 Factory Suspensions SUSP 379 ...

Page 380: ...Y 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 al...

Page 381: ...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 lbf ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 37 lbf ft 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 37 lbf ft Adjusting play Unscrew and remove the top bolt on the headstock and retrieve the washer RS...

Page 382: ...ews 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 Suspensions RSV4 Factory SUSP 382 ...

Page 383: ...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 AP81401...

Page 384: ...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 Suspensions RSV4 Facto...

Page 385: ...ing Fit the upper collar Partially tighten the dowel in the rela tive threaded hole so that it protrudes by no more than 2 or 3 mm into the conical surface Fit the bushing in its seat ensuring that the seal in the groove in the bushing remains in place Press the bushing into place with a rub ber mallet Tighten the dowel to the specified tor que Repeat the procedure for the lower bushing RSV4 Facto...

Page 386: ... 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 Suspensions RSV4 Factory SUSP 386 ...

Page 387: ...he 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 SIDE HORIZONTALLY OR THE FINAL TRANSMISSION UNIT COULD SLIDE OU...

Page 388: ...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 sembly Hand tighten the five self locking nuts 3 NEVER INSTALL THE FINAL TRANSMISSION UNIT 6 ON THE WHEEL TO TIGHTEN THE SELF LOCKING NUTS TO PROTECT TH...

Page 389: ...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 bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE Check the radial and axial clearance Axial ...

Page 390: ...ace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm 0 031 in FINAL TRANSMISSION UNIT BEARINGS Carry out the check with the bearings fitted on the final transmission unit ROTATION CHECK Remove the left spacer 3 Remove the right spacer 4 Manually rotate the inside ring of each bearing Rotation must be c...

Page 391: ... couplings 5 and their holder 8 If there is excessive clearance Replace all the flexible couplings 5 ALWAYS REPLACE ALL THE FLEXIBLE COUPLINGS WITH OTHERS OF THE SAME TYPE SPROCKET Check the sprocket 7 toothing for proper conditions If there is excessive wear Replace the sprocket TO PREVENT EARLY WEAR OF NEW COMPONENTS REPLACE THE SPROCKET PINION AND TRANSMISSION CHAIN AT THE SAME TIME REAR WHEEL ...

Page 392: ... 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 extractor Specific tooling AP8140180 Extractor for bushings Clean the inside of the hub thoroughly CAUTION WASH ALL THE PARTS WITH CLEAN DETERGENT Suspensions RSV4 Factory SUSP 392 ...

Page 393: ...IRCLIP 17 IS FITTED ONLY ON THE FINAL TRANS MISSION 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 RSV4 Factory Suspensio...

Page 394: ...tion Type Quantity Torque Notes 1 Upper shock absorber fixing screw M10 1 50 Nm 36 88 lbf ft 2 Dual linkage fixing screw M10 3 50 Nm 36 88 lbf ft 3 Screw fastening single linkage to chassis M10 1 50 Nm 36 88 lbf ft Suspensions RSV4 Factory SUSP 394 ...

Page 395: ... closed Compression adjustment knob 2 open 12 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 TRACK USE ONLY Specification Desc Quantity Shock absorber wheelbase A 313 1 5 mm 12 33 0 059 in preloaded Spring B length 145 5 mm 1 5 mm 5 73 0 059 in Rebound adjustment ring nut 1 open 16 18 cli...

Page 396: ...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 Retrieve the nut Unscrew and remove the upper screw and retrieve the nut Remove the shock absorber from the right side Suspensio...

Page 397: ...lide off the screw 2 from the opposite side Loosen and remove the nut 3 Slide off the screw 4 from the opposite side Loosen and remove the nut 5 Slide off the screw 6 from the opposite side Remove the complete suspension connecting rod assembly unit CAUTION RSV4 Factory Suspensions SUSP 397 ...

Page 398: ...ITTING 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 Factory SUSP 398 ...

Page 399: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 400: ...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 faste...

Page 401: ...addle 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 Factory Chassis CHAS 401 ...

Page 402: ...ain skid fixing screws M5 2 2 Nm 1 47 lbf ft Lower chain skid 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...

Page 403: ...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 Place a mounting under the front part of the swingarm Support the swingarm from the front Remove the swingarm pin 2 from the right hand side Support the front part of the swingarm and be ready to accompany it Using the rear mounting stand remove the swingarm complet...

Page 404: ...ng gasket 2 Remove the sealing gasket 3 Remove the circlip 4 Use the specific special tool to extract the two bearings 5 and the roller bear ing 6 CHECK AND IF REQUIRED REPLACE THE BEARINGS AFTER EVERY BEARING REMOVAL Specific tooling AP8140180 Extractor for bushings Remove the inner spacer 7 and collect the two OR seals 8 Carefully clean inside the bearing seat CAUTION WASH ALL THE PARTS WITH CLE...

Page 405: ...arance 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 swingarm bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE SWINGARM SEALS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear ALWAYS REPLACE...

Page 406: ...ion 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 DIFFERENT Refit the fork height adjustment inserts if removed bearing in mind that the arrow must face upward WARNING PAY PARTICULAR ATTENTION TO THE DIRECTION OF THE INSERTS WHEN REFITTING IN CORRECT ASSEMBLY MAY CAUSE SEVERE DAMAG...

Page 407: ...and 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 ring nut by a few turns 1 Put some grease on the swingarm pin nut as indicated Fit and the ...

Page 408: ...ving 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 Factory CHAS 408 ...

Page 409: ... 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 the ...

Page 410: ...AUTION TO ENSURE THAT THE WHEEL IS CORRECTLY CEN TRED THERE ARE FIXED REFERENCE MARKINGS 2 3 INSIDE THE CHAIN TENSIONER SKID SEATS ON THE SWING ARMS IN FRONT OF THE WHEEL SPINDLE 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 cha...

Page 411: ... 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 Wash the chain allow to dry and lubricate 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 Replac...

Page 412: ...nd remove the upper screw fixing the chain pad and retrieve the washer Unscrew and remove the lower screw fixing the chain pad and retrieve the washers Remove the chain skid 1 Stand Chassis RSV4 Factory CHAS 412 ...

Page 413: ...and 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 clamp Disconnect the stand connector Unscrew and remove the two screws RSV4 Factory Chassis CHAS 413 ...

Page 414: ... 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 screws M6 2 10 Nm 7 37...

Page 415: ...ove 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 Factory Chassis CHAS 415 ...

Page 416: ... har ness from the clamps Disconnect the two exhaust butterfly valve control cables Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables 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 MANIFOLD Chassis RSV4 Factory CHAS 416 ...

Page 417: ... 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 Factory Chassis CHAS 417 ...

Page 418: ...haust 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 Butterfly valve in exhaust Chassis RSV4 Factory CHAS 418 ...

Page 419: ...nect 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 Factory Chassis CHAS 419 ...

Page 420: ...g 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 Factory CHAS 420 ...

Page 421: ... Unscrew and remove the lower radia tor retainer Remove the radiator draining com pletely of oil RSV4 Factory Chassis CHAS 421 ...

Page 422: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 423: ...tening odometer sensor onto rear brake calliper mounting M6 1 12 Nm 8 85 lbf 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 ft RSV4 Factory Braking system BRAK SYS 423 ...

Page 424: ...s 1 Front brake calliper fixing screws M10x1 25 2 2 50 Nm 36 88 lbf 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 Factory BRAK SYS 424 ...

Page 425: ...ions must be carried out with the brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the minimum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Using a dial gauge check that the max imum oscillation of the disc does not exceed th...

Page 426: ...G 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 single point of the disc is l...

Page 427: ...RATIONS 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 LEAKAGE Installing An arro...

Page 428: ...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 POSITIONE...

Page 429: ...ew 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 ins...

Page 430: ...RS THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a ...

Page 431: ...NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAUL IC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe i...

Page 432: ...nt 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 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 Braking system RSV4 Factory BRAK SYS 432 ...

Page 433: ...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 Factory Braking system BRAK SYS 433 ...

Page 434: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 435: ...am 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 Factory Cooling system COOL SYS 435 ...

Page 436: ...OOLING pos Description Type Quantity Torque Notes 1 Screws fastening water radiator mounting bracket to chassis M6 2 10 Nm 7 37 lbf ft 2 Screws fastening water radiator to mounting bracket M6 2 7 Nm 5 16 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 Cooling system RSV4 Factory COOL SYS 436...

Page 437: ...ump to the crankcase M6x25 2 10 Nm 7 37 lbf ft Electric fan Remove the front underfairings and the hand grip position sensor Disconnect the cooling fan connector to be replaced Unscrew and remove both radiator up per fixing screws See also RSV4 Factory Cooling system COOL SYS 437 ...

Page 438: ...ant pump Remove the radiator cap valve to help the fluid drain out Unscrew and remove the system drain screw and retrieve the seal 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 of coolant approx 2 2 l 0 48 UK gal necessary to reach the edge Fit the cap ...

Page 439: ...rn 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 replacement...

Page 440: ...he 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 Factory COOL SYS 440 ...

Page 441: ...E ORIFICES ARE NOT OBSTRUCTED Removing the radiator 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 RSV4 Factory Cooling system COOL SYS 441 ...

Page 442: ...IT THE CLIP ON CLAMP REMOVED PREVI OUSLY AS IT IS NO LONGER USABLE DO NOT REPLACE THE CLIP ON CLAMP REMOVED PRE VIOUSLY WITH A SCREW CLAMP OR ANY OTHER TYPE OF CLAMP 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...

Page 443: ... Remove the split pin From the opposite site remove the coolant radiator oil radiator connector pin Remove the radiator RSV4 Factory Cooling system COOL SYS 443 ...

Page 444: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 445: ...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 RSV4 Factory Bodywork BODYW 445 ...

Page 446: ...x 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 Bodywork RSV4 Factory BODYW 446 ...

Page 447: ...ty 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 RSV4 Factory Bodywork BODYW 447 ...

Page 448: ... 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 Screws fastening rear license plate holder to front license plate holder SWP 4 9 2 2 Nm 1 47 lbf ft Screws fastening license plate mo...

Page 449: ...t 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 dl...

Page 450: ...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 Bodywork RSV4 Factory BODYW 450 ...

Page 451: ...ket 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 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 FOOTPEGS pos Description Type Quantity Torques Notes 1 Screws fastening rider footpegs to chassis M8 2 2 25 Nm 18 44 lbf ft 2 Screws fastening passenger foot pegs ...

Page 452: ...g upper fairing fastener to inlet duct self tapping 2 1 Nm 0 74 lbf ft Screws fixing upper fairing fastener to headlamp self tapping 2 1 Nm 0 74 lbf ft Screws fastening the lower fairing to the bracket M5 2 2 1 Nm 0 74 lbf ft Screws fastening the lower fairing to the lug M5 2 2 Nm 1 47 lbf ft Lower fairing lower fastening screws M5 2 2 Nm 1 47 lbf ft Lower fork fastener fixing screws M6 2 8 Nm 5 9...

Page 453: ...rors 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 RSV4 Factory Bodywork BODYW 453 ...

Page 454: ...s from the seats on the arch brace 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 Bodywork RSV4 Factory BODYW 454 ...

Page 455: ...Headlight fairing Working from both sides unscrew and remove the four screws RSV4 Factory Bodywork BODYW 455 ...

Page 456: ...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 Side fairings 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 Bodywork RSV4...

Page 457: ... to the lug Release the insert on the retainer with the duct Release the three inserts on the inner fairing To refit repeat the above procedure in reverse order taking particular care not to damage the components involved NOTE HANDLE PAINTED AND PLASTIC COMPONENTS WITH CARE BE CAREFUL NOT TO SCRATCH OR DAMAGE THEM RSV4 Factory Bodywork BODYW 457 ...

Page 458: ... lower side fairing Fairing mounting panels CENTRAL UNDERFAIRING Remove the three windshield fixing in serts Unscrew and remove the two screws Ease off the central underfairing tak ing care not to damage the fittings with the lateral underfairings and the wind shield Working from both sides unscrew and remove the lower screw Bodywork RSV4 Factory BODYW 458 ...

Page 459: ...ctive side fairing Unscrew and remove the lower screw When working on the left hand side of the vehicle remove the underfairing taking particular care not to damage the fittings with the central 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 RSV4 ...

Page 460: ...t the air temperature sensor connector Move the two rear coil connectors See also Control unit Unscrew and remove the four upper injector screws Move the upper injector mounting Disconnect the variable geometry in take system connector Bodywork RSV4 Factory BODYW 460 ...

Page 461: ...Open the air filter box cover Unscrew and remove the air intake duct fixing screws Disconnect the variable geometry intake system connector Working from both sides unscrew and remove the air pressure sensor fixing screw Disconnect both front coil connectors cylinders 2 and 4 RSV4 Factory Bodywork BODYW 461 ...

Page 462: ...ess from the cable grommet on the filter box Remove the air filter box base Rear mudguard Unscrew and remove the two screws Remove the rear mudguard Lower cowl The following procedure is applicable to both parts of the fairing lug Remove the lower side fairing Bodywork RSV4 Factory BODYW 462 ...

Page 463: ...w and remove the lower screw Supporting the right fairing lug un screw and remove the right lug fixing 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 RSV4 Factory Bodywork BODYW 463 ...

Page 464: ...rider saddle Unscrew and remove the two rear screws Release the clamps Remove the two tank breather pipes Disconnect the fuel pipe Disconnect the fuel pump connector Remove the tank Bodywork RSV4 Factory BODYW 464 ...

Page 465: ...nstrument cluster support REMOVAL Remove the instrument panel Working on both sides unscrew and remove the two 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 RSV4 Factory Bodywork BODYW 465 ...

Page 466: ...emi arch braces FITTING Fit the right semi arch brace fixing it to the headstock with two screws Connect the Immobilizer aerial cables Fasten the main cable harness to the semi arch brace with a clamp Bodywork RSV4 Factory BODYW 466 ...

Page 467: ...tighten the two screws on the headstock Tighten the five coupling screws Fit the turn indicator connectors in the relative housings noting the colours of the wires identifying the correct side Join the remaining connectors and ar range the cable carefully in the space available within the arch brace Note that there are two pairs of connectors which may be connected incorrectly The male connector o...

Page 468: ...HE RETAINING TANG AT THE END OF STROKE Radiator cover Remove the side fairings Remove the fairing lug Working from both sides unscrew and remove the screw Supporting the radiator cover and working from the right side of the vehi cle unscrew and remove the screw and retrieve the washer and the nut See also Lower cowl Side fairings Bodywork RSV4 Factory BODYW 468 ...

Page 469: ...o 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 Factory Bodywork BODYW 469 ...

Page 470: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 471: ...parts 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 ...

Page 472: ...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 WORK...

Page 473: ...resent 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 NEV...

Page 474: ...tighten with a torque wrench to a torque of 18 Nm 13 27 lbf ft NOTE REPEAT THE STEPS TO FIT THE PASSENGER PEDAL ON THE OPPOSITE SIDE WARNING OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL Saddle replacement Insert the key in the lock and turn it clockwise Remove the tail fairing Pre delivery RSV4 Factory PRE DE 474 ...

Page 475: ... Fit the two seater saddle RSV4 Factory Pre delivery PRE DE 475 ...

Page 476: ... lever 202 Coolant 438 439 441 E Engine oil 63 199 419 F Fork 366 368 371 375 Forks 251 Fuel 65 142 183 226 351 463 Fuses 142 H Headlight 455 469 Helmet compartment I Identification 11 Instrument panel 137 454 465 M Maintenance 8 61 Mirrors 453 O Oil filter 65 R Recommended products 51 Ride by wire 353 S Saddle Shock absorber Shock absorbers 394 ...

Page 477: ...Spark plug 62 67 Stand 87 203 226 229 412 413 Start up 141 257 T Tank 65 226 463 Transmission 12 319 322 Tyres 14 W Warning lights Windshield ...

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