APRILIA RSV4 RF Service Station Manual Download Page 381

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•

Lubricate the crankshaft pins and in-

sert them into their positions.

•

Install the connecting rod shank piston

assembly in the relative cylinders.

•

Join the crankcases.

•

If the special tool was used, remove it

to keep the pistons from coming out.

Specific tooling

020858Y

Maintenance of the pistons in the cyl-

inders

•

Install the primary shaft gear correctly

in its seat on the crankshaft from the

clutch side.

•

Make the references on the gears of

the primary shaft and the countershaft

coincide.

NOTE

THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST
BE 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

RSV4 RR/RF

Engine

ENG - 381

Summary of Contents for RSV4 RF

Page 1: ...SERVICE STATION MANUAL 2Q000152 RSV4 RR RF ...

Page 2: ...undergo quality control procedures to guarantee reliability and durability The descriptions and images in this publication are given for illustrative purposes only and are not binding Piaggio C While the basic characteristics as described and illustrated in this booklet remain unchanged Piaggio C S p A reserves the right at any time and without being required to update this publication beforehand ...

Page 3: ...d 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 t...

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: ...SE 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 contain...

Page 8: ...H OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTE...

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

Page 10: ...OTHER PROBLEMS THAT WOULD COMPROMISE MA NOEUVRABILITY LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH Running in Running the engine in correctly is essential for ensuring engine longevity and functionality Twisty roads and gradients are ideal for running in the engine brakes and suspension effectively Vary your riding speed during the running in period This ensures that components...

Page 11: ...urer identifier code RK model L00 Race Pack RF or RR 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 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 WEIGHT AND DIMENSIONS Specification Desc Quantity ...

Page 12: ...nal cartridge filter Liquid Liquid Cooling system 3 way thermostatic valve cooling radiator with electric fan and expansion tank Coolant pump Centrifugal bearingless aspirating pump with integrated ce ramic gasket Air filter In cotton Transmission GEAR RATIOS Specification Desc Quantity Primary drive ratio 44 73 with gears Drive ratio 1st gear 15 39 secondary Drive ratio 2nd gear 16 33 secondary D...

Page 13: ...arth magnets Alternator 450 W Main fuses 30 A Secondary fuses 5A 7 5A 15A ABS fuses 15 A 30 A BULBS Specification Desc Quantity High beam low beam light 12 V 55 W H7 Front daylight running lights LED Turn indicator light LED Rear daylight running light stop light LED Licence plate light 12 V 5 W WARNING LIGHTS Specification Desc Quantity High beam light LED Turn indicators LED General warning LED ...

Page 14: ...gy back wheel base compression damping and rebound damping Rear wheel stroke RSV4 1000 RR Race Pack RF 137 mm 5 39 in Rear wheel stroke RSV4 1000 RR 138 5 mm 5 45 in SIZES A AND B Specification Desc Quantity Size A 639 5 mm 25 18 in measurements refer to the bare chassis Size B 329 5 mm 12 97 in measurements refer to the bare chassis Brakes BRAKES Specification Desc Quantity Front Dual 320 mm 12 5...

Page 15: ...a SP and Diablo Supercorsa SP V2 tyres Inflation pressure 1 passenger 2 5 bar 250 KPa 36 26 PSI 2 passengers 2 8 bar 280 KPa 40 61 PSI Supply FUEL SYSTEM Specification Desc Quantity Fuel Unleaded petrol max E10 95 RON 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 ...

Page 16: ...Nm 7 38 lb ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lb ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lb ft 4 Screws fastening electric fan to wa ter radiator M4 6 2 Nm 1 48 lb ft 5 Expansion tank support fixing screw M6 1 5 Nm 3 69 lb ft Characteristics RSV4 RR RF CHAR 16 ...

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

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

Page 19: ...tightening 3 Headstock ring nut tightening M35x1 1 60 9 Nm 44 25 6 64 lb ft 4 Headstock counter lock ring M35x1 1 Manual 35 or 10 Bend the tabs into the notches in the lock ring 5 Upper yoke fixing cap M29x1 1 100 Nm 73 76 lb ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 38 lb ft Loctite 243 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 38 lb ft Loctite 243 8 Lower cover ...

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

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

Page 22: ... Handlebar safety screw M6 1 1 10 Nm 7 38 lb ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lb ft 4 Right hand light switch M4 2 1 5 Nm 1 11 lb ft 5 Left light switch M5 2 1 5 Nm 1 11 lb ft 6 Throttle control fixing screws M5 2 2 Nm 1 48 lb ft 7 Traction control unit fixing screw M4 1 2 5 Nm 1 84 lb ft Characteristics RSV4 RR RF CHAR 22 ...

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

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

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

Page 26: ...CLUTCH LEVER Pos Description Type Quantity Torque Notes 1 Clutch lever collar fastening screws M6 1 10 Nm 7 38 lb ft Central part Characteristics RSV4 RR RF CHAR 26 ...

Page 27: ... ft Loct 243 2 Linear switch retaining screws and nuts M5 2 4 Nm 2 95 lb ft Rear stand bushing retaining screw M6 2 7 Nm 5 16 lb ft SADDLE pos Description Type Quantity Torque Notes 1 Rider s saddle retaining screw M5 2 6 Nm 4 43 lb ft Special screw saddle fastening M6 1 4 Nm 2 95 lb ft RSV4 RR RF Characteristics CHAR 27 ...

Page 28: ...cket retaining screws M5 1 3 Nm 2 21 lb ft 7 Fastening screws tilting sensor M6x16 stainless steel 2 6 Nm 4 43 lb ft Central fuel tank cover retaining screw M4 1 0 5 Nm 0 37 lb ft Fuel tank breather couplings M7 2 3 Nm 2 21 lb ft Fuel return coupling M6 1 6 Nm 4 43 lb ft Loctite 243 Pump support to flange fastening M5 3 4 Nm 2 95 lb ft Lug to flange fastening M5 2 5 Nm 3 69 lb ft Petrol return clo...

Page 29: ...ing front tank to frame M6 1 8 Nm 5 90 lb ft 2 Screws fastening tank structural sup port to tank M6 4 3 Nm 2 21 lb ft CENTRAL BODYWORK Pos Description Type Quantity Torque Notes 1 Screws fastening fairing to tail fairing M5 2 1 Nm 0 74 lb ft RSV4 RR RF Characteristics CHAR 29 ...

Page 30: ...44 lb ft Loctite 243 2 Screws for fastening the passenger s footrests to the frame M8 2 2 18 Nm 13 28 lb ft Loctite 243 For use in countries where it is mandatory to fit the passenger s footrests or for the two seater configu ration 3 Rider s heel guard retaining screws M6 2 2 8 Nm 5 90 lb ft 4 Passenger s heel guard retaining screws M6 2 2 8 Nm 5 90 lb ft 5 Anti creep pin M6 1 8 Nm 5 90 lb ft Cha...

Page 31: ...t 8 RH upper rear coupling M10 1 50 Nm 36 88 lb ft 9 Right fairing spacer M6 1 10 Nm 7 37 lb ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lb ft 11 Upper rear mount M10 1 50 Nm 36 88 lb ft 12 Saddle mounting fixing screws M10 4 50 Nm 36 88 lb ft 13 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lb ft 14 Taillight mounting bracket fixin...

Page 32: ...m 3 69 lb ft 2 Lock lever self tapping screw M4 1 2 Nm 1 48 lb ft 3 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 4 Right hand ignition lock screw M8 1 20 Nm 14 75 lb ft 5 Passenger saddle fixing screws M6 2 8 Nm 5 90 lb ft Characteristics RSV4 RR RF CHAR 32 ...

Page 33: ...tage regula tor to the inner fairing M6 2 6 Nm 4 43 lb ft CENTRAL ELECTRICAL SYSTEM pos Description Type Quantity Torque Notes 1 Upper Silentblock nut demand sen sor mounting bracket M6 1 5 Nm 3 69 lb ft 2 Demand sensor fixing screw to mounting plate SWP 4 9 4 1 5 Nm 1 11 lb ft 3 Silent block support bracket demand sensor M6 2 Manual Loctite 243 only to chassis RSV4 RR RF Characteristics CHAR 33 ...

Page 34: ...RICAL SYSTEM REAR pos Description Type Quantity Torque Notes Screw fixing the ground lead to chas sis M6 1 6 Nm 4 43 lb ft Battery bracket fixing screw M5 2 2 Nm 1 48 lb ft Characteristics RSV4 RR RF CHAR 34 ...

Page 35: ...uick Shift uniball NOTE ONCE ASSEMBLE THE DISTANCE BETWEEN THE UNIBALL AND THE JOINT MUST BE AP PROXIMATELY 180mm 7 09in FAIRING pos Description Type Quantity Torque Notes Lower fairing central bracket fasten ing screws M6 2 10 Nm 7 38 lb ft RH lower fairing support bracket M6 2 12 Nm 8 85 lb ft LH lower fairing support bracket M6 2 12 Nm 8 85 lb ft Screws for fastening the side fairings to the la...

Page 36: ... 5 90 lb ft Screws for fastening the lower frontal closure to the intake ducts SWP 3 9 2 1 Nm 0 74 lb ft Internal fastening screws between the fairing and the lower frontal clo sure M4 2 0 5 Nm 0 37 lb ft Internal fastening screws between the airing and the stanchion M5 2 2 Nm 1 48 lb ft ABS CONTROL UNIT Pos Description Type Quantity Torque Notes 1 Oil tube screws M10x1 4 23 26 Nm 16 96 19 18 lb f...

Page 37: ... 1 10 Nm 7 38 lb ft 3 Screw used to secure the silencer to the RH footrest support M8 1 25 Nm 18 44 lb ft 4 Cosmetic silencer shield fixing screw M5 3 5 Nm 3 69 lb ft 5 Lambda probe fastener M18x1 5 2 38 Nm 28 03 lb ft 6 Exhaust valve actuator fixing screws M6 2 10 Nm 7 38 lb ft Exhaust valve opening closure fixing nuts M6 2 5 Nm 3 69 lb ft RSV4 RR RF Characteristics CHAR 37 ...

Page 38: ...A Nuts fastening sprocket on sprocket mount M10 5 50 Nm 36 88 lb ft 2 B Nuts fastening sprocket on sprocket mount M10 5 55 Nm 40 57 lb ft 2 C Nuts fastening sprocket on sprocket mount M10 5 50 Nm 36 88 lb ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lb ft Loct 243 Characteristics RSV4 RR RF CHAR 38 ...

Page 39: ...r brake rod lock nut M6 1 12 Nm 8 85 lb ft 2 Rear brake pump retaining screws M6 2 8 Nm 5 90 lb ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lb ft Loctite 243 Brake lever push rod fixing screw M6 1 8 Nm 5 90 lb ft RSV4 RR RF Characteristics CHAR 39 ...

Page 40: ...m 8 85 lb ft REAR SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm regulator bushing M30x1 5 1 12 Nm 8 85 lb ft 2 Swingarm ferrule M30x1 5 1 60 Nm 44 25 lb ft 3 Fork pin nut M20x1 5 1 65 Nm 47 94 lb ft AGIP GREASE SM2 4 Chain guard fastening screws M5 2 4 Nm 2 95 lb ft 5 Front chain guide fixing screw M5 1 4 Nm 2 95 lb ft 6 Chain guide rear fastening nut M6 1 7 Nm 5 16 lb ft 7 Chain ...

Page 41: ... Description Type Quantity Torque Notes 1 Rear mudguard fixing screws M6 2 5 Nm 3 69 lb ft For plastic mud guard 1 Rear mudguard fixing screws M6 2 3 Nm 2 21 lb ft For carbon mud guard RSV4 RR RF Characteristics CHAR 41 ...

Page 42: ... 50 Nm 36 88 lb ft LICENSE PLATE HOLDER pos Description Type Quantity Torque Notes 1 License plate light fixing screws M4 1 1 Nm 0 74 lb ft 2 Rear turn indicator fixing screws M6 2 2 5 Nm 1 84 lb ft 3 Taillight fixing screws M5 2 3 Nm 2 21 lb ft 4 Taillight cover self tapping fixing screw SWP 3 9 1 0 5 Nm 0 37 lb ft Screws fastening license plate mounting to saddle mounting casting M6 3 4 Nm 2 95 ...

Page 43: ... 4 2 Nm 1 48 lb ft 7 Lower saddle mounting fastener fix ing screws M5 5 3 Nm 2 21 lb ft 8 Screws for fastening license plate holder to saddle mounting plate M6 3 4 Nm 2 95 lb ft 9 Screws for fastening the rear number plate holder to the front number plate holder SWP 3 9 4 1 Nm 0 74 lb ft 10 Self tapping screws for fastening the rear number plate holder to the front number plate holder SWP 4 9 2 2 ...

Page 44: ...langed screw M6x20 1 10 Nm 7 38 lb ft 3 TE Flanged screw M6x35 2 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 4 TE Flanged screw M6x22 14 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 5 Engine timing inspection cap 1 20 Nm 14 75 lb ft Characteristics RSV4 RR RF CHAR 44 ...

Page 45: ...VER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft 2 Coil fastening screws 4 8 Nm 5 90 lb ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lb ft RSV4 RR RF Characteristics CHAR 45 ...

Page 46: ...shaft cam tower fixing screws M6x45 20 11 Nm 8 11 lb ft 3 Reed valve covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head Charac...

Page 47: ...ue Notes 1 Screw fastening the timing system gear on the intake shaft M8 4 30 Nm 22 13 lb ft Loct 243 2 Shoe fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Skid fastener screws M6x18 2 10 Nm 7 38 lb ft Loct 243 RSV4 RR RF Characteristics CHAR 47 ...

Page 48: ...Loctite 648 or 270 2 TE Flanged screw 4 25 Nm 18 44 lb ft Lubricate the thread and under the head 3 TE Flanged screw 8 10 Nm 7 38 lb ft Lubricate the thread and under the head 4 TE Flanged screw 1 10 Nm 7 38 lb ft Lubricate the thread and under the head 5 TE Flanged screw 3 25 Nm 18 44 lb ft Lubricate the thread and under the head 6 SHC screw 2 10 Nm 7 38 lb ft Lubricate the thread and under the h...

Page 49: ...stening screw M6x20 1 10 Nm 7 38 lb ft Loct 243 2 Bearing retaining plate fastening screw M6x16 3 10 Nm 7 38 lb ft Loct 243 3 Flange fastening screws M8x25 6 25 Nm 18 44 lb ft 4 Index lever fixing screw M6 1 10 Nm 7 38 lb ft Loct 243 5 Pinion fastening 1 50 Nm 36 88 lb ft Loct 243 6 Screw retaining pre selector on crankcase 1 25 Nm 18 44 lb ft Loct 270 7 Gear selector fastening screw M5x15 2 6 Nm ...

Page 50: ...g clutch M20x1 1 150 Nm 110 63 lb ft Loct 243 2 Clutch springs SHC fixing screw M6x25 6 10 Nm 7 38 lb ft IGNITION UNIT pos Description Type Quantity Torque Notes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lb ft Loct 243 Characteristics RSV4 RR RF CHAR 50 ...

Page 51: ...crew bring back to torque 2 Cover fastening screws generator side M6x40 2 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 3 Blow by union fastener screws M5x16 3 7 Nm 5 16 lb ft Stator fixing screw UNI 5931 CL8 8 M6x25 3 10 Nm 7 38 lb ft Loct 2045 Flanged screw M5x12 1 6 Nm 4 43 lb ft Loct 2045 RSV4 RR RF Characteristics CHAR 51 ...

Page 52: ... fixing screws M6x30 12 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 4 Ergal conical cap 3 Move to 1mm un der the table 5 Oil pressure sensor 1 15 Nm 11 06 lb ft 6 TE Flanged screw 1 10 Nm 7 38 lb ft Loct 243 7 SHC screw 5 10 Nm 7 38 lb ft 8 SHC screw 1 10 Nm 7 38 lb ft 9 TE Flanged screw 1 6 Nm 4 43 lb ft Characteristics RSV4 RR RF CHAR 52 ...

Page 53: ...ype Quantity Torque Notes 1 Secondary air solenoid screws 2 10 Nm 7 38 lb ft WATER PUMP pos Description Type Quantity Torque Notes 1 Screws used to fasten the pump to the crankcase M6x25 2 10 Nm 7 38 lb ft RSV4 RR RF Characteristics CHAR 53 ...

Page 54: ...Characteristics RSV4 RR RF CHAR 54 ...

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

Page 56: ...ores code Description 020845Y Engine support 020846Y Containment tray plastic plugs 020847Y Flywheel extractor 020914Y Flywheel retainer 020849Y Clutch lock 020850Y Primary gear lock Special tools RSV4 RR RF S TOOLS 56 ...

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

Page 58: ...ders AP8140199 Tool storage panel 020859Y Graphics for panels 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear box control rod 020863Y Punch assembly cage with rollers des modromic drum Special tools RSV4 RR RF S TOOLS 58 ...

Page 59: ...g plate 020956Y Support for camshaft gear on head 020883Y Fitting removing timing chain tensioner tool 020709Y Engine support AP8140187 U bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide RSV4 RR RF Special tools S TOOLS 59 ...

Page 60: ...020364Y 25 mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft Special tools RSV4 RR RF S TOOLS 60 ...

Page 61: ...for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140147 Spacer retaining device AP8140148 Plunger spacer separator plate AP8140149 Protection for assembly operations RSV4 RR RF Special tools S TOOLS 61 ...

Page 62: ...s code Description AP8140150 Bored shaft for bleeding plunger air AP8140190 Tool for steering tightening AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool Special tools RSV4 RR RF S TOOLS 62 ...

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

Page 64: ...ME DEDICATED TO MANAGEMENT ACTIVITIES I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE 1 Check at each engine start 2 Check and clean adjust or replace if necessary before every journey 3 Check and clean and adjust or replace if necessary every 1 000 Km 621 37 mi 4 Replace every 2 years 5 Replace every 4 years 6 Every 5 000 Km 3 106 86 mi if the v...

Page 65: ...er mechanism pin nut tightness I I I I I Clutch cover flywheel and sump screw tightness I I I I I Fault indicator light on instrument cluster 1 Fuel lines 5 I I I I Clutch wear 7 I I Brake pads wear 2 I I I I I Labour times minutes Race Pack RF My2015 120 160 410 160 500 Labour time minutes RR My2015 150 190 440 190 530 Labour time minutes RF RR My2016 120 160 410 160 500 The scheduled maintenance...

Page 66: ... I I I Stand switch I I I I Safety switches I I I I I Stop switches I I I I Brake fluid 4 I I I I I Coolant 4 I I I I I Fork oil 7 9 R Engine oil 6 R R R R R Headlight aiming I I I I Fork oil seals 6 I I Slipper mechanism I I Tyres pressure wear 2 I I I I I Wheels 6 I I I I I Nut bolt tightness 6 I I I I I Slipper mechanism pin nut tightness I I I I I Clutch cover flywheel and sump screw tightness...

Page 67: ...R Pistons R R Gear selector fork R R R R R R Oil intake rose pipe R R Spark plugs R R R R R R Engine oil filter R R R R R R Air filter R R R R R R Valve clearance I I I I I I Engine oil R R R R R R Tightening nuts and bolts I I I I I I Clutch wear I R I R I R Labour in hours up to serial No 1319 14 5 14 5 18 14 5 14 5 18 Labour in hours up to serial No 1320 14 14 5 17 5 14 5 14 17 5 By using the P...

Page 68: ... specifications that are equivalent or superior to the recommen ded products These indications also apply when topping up fluid levels RECOMMENDED PRODUCTS TABLE Product Description Specifications Engine oil 5W 40 Synthetic based lubricant for four stroke engines SAE 5W 40 JASO MA MA2 API SL ACEA A3 Lithium based grease Lithium calcium soap based grease colour black contains EP Extreme Pressure ad...

Page 69: ...do and remove the screw Slide off the front coil Unscrew and remove the front spark plug REAR SPARK PLUGS Remove the fuel tank Unscrew and remove the rear coil fastener screw Slide off the rear coil Unscrew and slide off the rear spark plug RSV4 RR RF Maintenance MAIN 69 ...

Page 70: ...ds Keep the vehicle upright with both wheels on the ground Ensure that the vehicle is on a level surface Undo the oil level dipstick 1 Clean the oil dipstick 1 and insert it again without tighten it Pull it out again and check the oil level The oil level is correct when it is close to the MAX mark Otherwise top up with engine oil CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR ...

Page 71: ... level dipstick Top up if necessary CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI MUM MARKING OR EXCEED THE MAXIMUM MARKING AN OIL LEVEL NOT WITHIN THE MINIMUM AND MAXIMUM MARKINGS MAY CAUSE SEVERE ENGINE DAMAGE Verifica parastrappi The verification and tightening of the flexible coupling nuts differs according to the model Based on the type indicated in the table apply the correct tighteni...

Page 72: ... RSV4 1000 RR Remove the fixing nut 1 of the rear wheel pin recovering the washer 2 and the guide 3 Remove the rear wheel pin 4 pulling it from the right side of the motorcycle Maintenance RSV4 RR RF MAIN 72 ...

Page 73: ...SCREW THE FIVE NUTS THE FINAL TRANS MISSION UNIT CAN BE SLID OFF COMPLETELY FROM THE FLEXIBLE COUPLING SUPPORT Place the final transmission unit in a vice locking it on the crown gear Locking the pin rotation check and if necessary tighten the nut to the pre scribed torque indicated in the table using a torque wrench TO PROTECT THE CROWN GEAR INSTALL WOODEN OR ALUMINIUM PROTECTIONS ON THE VICE JAW...

Page 74: ... Replace the engine oil filter each time you change the engine oil Drain the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTER Spread a thin layer of oil on the sealing ring of the new engine oil filter Insert and screw the new engine oil filter in the seat filling the filter to 1 3 of its capacity with engine oil before fitting See also R...

Page 75: ... the upper injector fuel de livery union Lift the filter box cover on which the control unit is installed Do not rotate the cover excessively to avoid straining the pipes and cables RSV4 RR RF Maintenance MAIN 75 ...

Page 76: ...shaft taking care not to lose the O ring See also Removing the throttle body Spark plug Head cover removal Use a feeler gauge to check the clear ance between the cam of the shaft and the relative tappet for both front head shafts Characteristic Acceptable values with control clearance be tween cam and valve intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in Maintenance RSV...

Page 77: ...rk plug Head cover removal Use a feeler gauge to check the clear ance between the cam on the shaft and the relative tappet for both rear head shafts Characteristic Acceptable values with control clearance be tween cam and valve intake 0 10 0 15 mm 0 0039 0 0059 in ex haust 0 20 0 25 mm 0 0079 0 0098 in RSV4 RR RF Maintenance MAIN 77 ...

Page 78: ...ver Rotate the crankshaft via the opening on the clutch cover Position cylinder 1 piston LH rear pis ton so that it is at the point where it crosses TDC rotate the crankshaft 150 in the engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSIT...

Page 79: ...screw and remove the camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the direction of engine rotation direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ensu...

Page 80: ... and remove the second in take camshaft gear screw Leave the gear on the camshaft Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020956Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in sta...

Page 81: ...nent to achieve the cor rect valve clearance Refer to the table Calibrated pad thickness es to identify the suitable thickness Fit the tappet See also Calibrated pad thickness NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Install the intake and exhaust camshafts on the front head bearing in mind that the exhaust camshaft gear tooth indicated with a dot is meshed with...

Page 82: ...et Move the gear from the mounting tool to the camshaft Unscrew and remove the two screws 1 Remove the tool Specific tooling 020956Y Support for camshaft gear on head Fit the U bolt and the oil pipe Tighten the two U bolt screws 1 and the screw 2 that was not fitted previ ously Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camshaf...

Page 83: ... by the head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn...

Page 84: ... TDC Turn the crankshaft 450 one complete turn 90 in the direction of motor rotation direction of travel Insert the pin from the clutch side into the hole in the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT DO NOT USE IT FOR TIGHTENING COMPONENTS Specific tooling 020852Y Crankshaft timing pin See also Head cover removal Removi...

Page 85: ...rn 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 c...

Page 86: ... two screws 1 Move the gear from the camshaft to the tool Specific tooling 020956Y 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 intake...

Page 87: ...S WITH CLEARANCE RECOVERY Install the intake and exhaust camshafts on the rear head remembering that the intake camshaft gear tooth indicated with a dot is inserted in the groove of the exhaust camshaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RETAINER SCREWS ON THE INTAKE CAM SHAFT Fit the U bolts with the nine O rings and locator pins Fit the new washers under the scre...

Page 88: ...bolt screws 1 and the screw 2 that was not fitted previ ously Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camshaft timing pin Apply Loctite 243 thread lock on the thread of the timing gear fastener screw This screw must be replaced at each reassembly Apply and loosely tighten the gear fix ing screw on the camshaft Maintenance RS...

Page 89: ...d of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned Refit the reference pin while checking using the crankshaft reference pin that the clutch side hole ...

Page 90: ...in 1 82 mm 0 0716 in 1 85 mm 0 0728 in 1 87 mm 0 0736 in 1 90 mm 0 0748 in 1 92 mm 0 0756 in 1 95 mm 0 0768 in 1 97 mm 0 0775 in 2 mm 0 0787 in 2 02 mm 0 0795 in 2 05 mm 0 0807 in 2 07 mm 0 0815 in 2 1 mm 0 0827 in 2 12 mm 0 0835 in 2 15 mm 0 0846 in 2 17 mm 0 0854 in 2 2 mm 0 0866 in 2 22 mm 0 0874 in Maintenance RSV4 RR RF MAIN 90 ...

Page 91: ...012 in 2 6 mm 0 1024 in 2 62 mm 0 1031 in 2 65 mm 0 1043 in 2 67 mm 0 1051 in 2 7 mm 0 1063 in 2 72 mm 0 1071 in 2 75 mm 0 1083 in 2 77 mm 0 1090 in 2 8 mm 0 1102 in 2 82 mm 0 1110 in 2 85 mm 0 1122 in 2 87 mm 0 1129 in 2 9 mm 0 1142 in 2 92 mm 0 1150 in 2 95 mm 0 1161 in 2 97 mm 0 1169 in 3 mm 0 1181 in 3 02 mm 0 1189 in 3 05 mm 0 1201 in 3 07 mm 0 1209 in 3 10 mm 0 1220 in 3 12 mm 0 1228 in 3 15...

Page 92: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 93: ...TRAL WINDOW 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...

Page 94: ...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 THE REAR AND FRONT CYL...

Page 95: ... to the FUEL PUMP CHECK 3 DOES THE DIAGNOSTIC TOOL COMMUNICATE WITH THE CONTROL UNIT IN OTHER WORDS AFTER SELECTING FUEL IN INJECTION AND PERFORMING THE SUBSEQUENT INSTRUCTIONS ARE THE PARAMETERS STATES ETC DISPLAYED WHEN THE IGNITION KEY IS TURNED TO THE ON POSITION YES go to point 4 NO go to the DIAGNOSTIC TOOL CONNECTION CHECK 4 USING THE DIAGNOSTIC TOOL DEVICE ACTIVATION PAGE INJECTOR ICON ACT...

Page 96: ... INTERNAL RECESS ON THE FRAME POSITIONED VERTICALLY YES go to point 13 NO go to point 14 13 SEE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS TIP OVER SEN SOR INDICATION ON DIAGNOSTIC TOOL PERMANENTLY TIP OVER END 14 POSITION THE SENSOR CORRECTLY FINE 15 SEE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS RUN STOP SWITCH INDICATION ON DIAGNOSTIC TOOL PERMANENTLY TIP OVER END 16 CHECK THE FUEL SUPPLY...

Page 97: ...CTIVATE ONE OF THE LOWER INJECTORS WE RECOMMEND DISCONNECTING THE 4 PIN BLACK FUEL PUMP CONNECTOR ON THE LEFT HAND SIDE IS THE IN JECTOR ACTIVATED YES go to point 5 NO go to the INJECTION RELAY CHECK 33 5 DOES THE STARTER MOTOR STAR RUNNING WHEN THE STARTER BUTTON IS PRESSED YES SEE THE CHAPTER ELECTRICAL SYSTEM CHECKS AND CONTROLS ENGINE RPM SEN SOR and if the sensors function correctly go to poi...

Page 98: ...SYSTEM CHECKS AND CONTROLS RUN STOP SWITCH INDICATION ON DIAGNOSTIC TOOL PERMANENTLY TIP OVER END 16 CHECK THE FUEL SUPPLY CIRCUIT PRESSURE AND THE MECHANICAL OPER ATION OF THE ENGINE END See also Engine rpm sensor Neutral sensor CHECK CONTROL UNIT POWER SUPPLY 1 WITH THE KEY TURNED TO OFF CHECK IF THERE IS BATTERY VOLTAGE AT PIN 52 OF THE CONTROL UNIT CABLE HARNESS SIDE YES go to 2 NO go to 5 2 W...

Page 99: ... 2 NO go to 4 2 CHECK FUEL PUMP CONNECTOR AND CHECK THAT AT PIN 2 THERE IS GROUND CONTINUITY YES go to 3 NO go to 5 3 CHECK ON CONNECTOR ON THE PUMP SIDE THE ELECTRICAL CHARACTERIS TICS between PIN 1 and PIN 2 there should be a resistance of 0 5 1 ohm END 4 CHECK CONTINUITY OF ORANGE GREEN CABLE FROM PUMP CONNECTOR TO INJECTION RELAY 33 AND RESTORE CABLE HARNESS END 5 RESTORE GROUND CONNECTION END...

Page 100: ...RESPONDING PIN TO THE RED BROWN CABLE AND GROUND ON SPE CIFIC PIN TO THE BROWN BLACK CABLE IS THERE CONTINUITY BETWEEN THE OTHER TWO RELAY PINS YES go to 5 NO replace the relay END 5 REPLACE THE CONTROL UNIT END 6 CHECK CONTINUITY OF RED BROWN CABLE FROM THE INJECTION RELAY 33 TO THE PROTECTION RELAY 19 If there is continuity go to PROTECTION RELAY 19 CHECK if there is not continuity restore cable...

Page 101: ... WHITE CABLE ON THE KEY SWITCH CONNECTOR YES go to 6 NO restore the cable harness END 6 WITH KEY SET TO ON AND CONNECTOR DISCONNECTED CHECK ON THE SWITCH SIDE IF THERE IS LACK OF CONTINUITY BETWEEN THE TWO PINS COR RESPONDING TO THE RED WHITE CABLE AND GREEN BLUE AND REPLACE THE KEY SWITCH END STARTER BUTTON CHECK 1 WITH KEY SET TO ON DISCONNECT THE SWITCH CONNECTOR 4 ways black inside the bow AND...

Page 102: ...ESS 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 NO restore the cable harness END 7 REPLACE THE STARTER BUTTON COMPONENT END Troubleshooting RSV4 RR RF TROUBL 102 ...

Page 103: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 104: ...uantity Torque Notes 1 Fall sensor mounting fixing screws M6x16 2 8 Nm 5 90 lb ft 2 Horn fixing screw M8 1 15 Nm 11 06 lb ft 3 Screw fastening the voltage regula tor to the inner fairing M6 2 6 Nm 4 43 lb ft Electrical system RSV4 RR RF ELE SYS 104 ...

Page 105: ...lock nut demand sen sor mounting bracket M6 1 5 Nm 3 69 lb ft 2 Demand sensor fixing screw to mounting plate SWP 4 9 4 1 5 Nm 1 11 lb ft 3 Silent block support bracket demand sensor M6 2 Manual Loctite 243 only to chassis Components arrangement RSV4 RR RF Electrical system ELE SYS 105 ...

Page 106: ...4 Lambda probe 15 Speed sensor 16 Headlamp 17 Rear turn indicators 18 Fall sensor 19 Horn 20 Voltage regulator 21 Battery 22 Auxiliary fuses 23 Control unit 24 Throttle grip position sensor 25 Intake ducts connector control unit 26 Alternator 27 Coils 28 Timing sensor 29 Starter motor 30 Oil pressure sensor 31 Inertia sensor platform 32 Quick Shift 33 Front tone wheel sensor 34 a PRC controls 35 A...

Page 107: ...relay urgent service In the headstock niche on the right Electrical system installation Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Vehicle cable harness 1 Headlamp cable harness 1 License Pl...

Page 108: ...rew 1 M6x15 flanged screw 2 M5x8 screw 1 TE M6x30 screw 1 M6 nut 2 Flanged self locking M6 nuts 7 Cable grommets 4 W Cable grommets 3 Cable guide 5 Relay socket rubber ring 4 Rubber ring 1 AMP Superseal connector mounting 1 Relay fall sensor mounting 1 Battery mounting bracket YT12A BS 4 T shaped bushings 2 6 6x18x1 6 Washer 2 Washer 2 Spacer 1 Heat protecting cover 1 Clamp 2 Clamp for edges Elect...

Page 109: ...nnectors Start up relay connector Front speed sensor connector Rear speed sensor connector Check correct closure of ABS control unit connector Safety relay connector Protection relay connector Injection relay connector Taillight connector Fuel pump connector Exhaust valve actuator connector Engine vehicle interface connector Flywheel connector Regulator connector Fan connectors Starter motor eyele...

Page 110: ...nector and check if the ends came out Check if the cable grommet of the rear lambda probe is placed as in the picture and check if the cable of the lambda probe is inside the cable grommet Check that it is the clamp that is keeping the quick shift cable blocked Front side TABLE A RELAY SENSOR MOUNTING PRE FITTING Check that the fall sensor has been positioned correctly with the arrow above the ind...

Page 111: ... Headlamp wiring harness 2 Small black clamp WIRING TABLE C1 FRONT HEADLIGHT PRE ASSEMBLY 1 Headlamp 2 Relay 3 Cable grommet 4 Small black clamp TABLE D HANDLEBAR CONTROLS Check that the clutch connector is well hooked 1 Left light switch 2 Quick Shift control on handlebar 3 Clutch connector RSV4 RR RF Electrical system ELE SYS 111 ...

Page 112: ...for edges take and block the two cables first adjusting their length keeping in mind the handlebar movement 1 Front stop switch connector 2 Right handlebar control connector WIRING TABLE E2 INSTRUMENT SUPPORT ARCH AND FRONT PART Position the main wiring harness and secure it to the right hand instrument holder support using a grey reference clamp Electrical system RSV4 RR RF ELE SYS 112 ...

Page 113: ... of their re spective lengths first TABLE E4 INSTRUMENT HOLDER SUPPORT AND FRONT PART Instrument holder right side cables output TABLE E5 INSTRUMENT HOLDER SUPPORT AND FRONT PART Instrument holder left side cables output WIRING TABLE E6 INSTRUMENT SUPPORT ARCH AND FRONT PART Insert the connectors in their housings on the arch 1 Left turn indicator connector 2 Right hand turn signal connector RSV4 ...

Page 114: ...ors 4 Antenna connector 5 Left turn indicator connector cable colours light blue blue 6 Instrument panel connector 7 Right turn indicator connector cable colours red blue 8 Front stop switch connector 9 Right handlebar control connector TABLE E8 INSTRUMENT HOLDER SUPPORT AND FRONT PART The instrument panel connector must be engaged and the boot must be well inserted 1 Instrument panel connector 2 ...

Page 115: ...e brake pipe in the indicated point 1 ABS sensor 2 Cable grommets 3 Clamp TABLE F1 FRONT WHEEL ABS SENSOR PASSAGE SACHS FORK Pass the wiring harness of the speed sensor for ward to the brake pipe in the indicated point 1 ABS sensor 2 Cable guide 3 Cable grommets 4 Clamp RSV4 RR RF Electrical system ELE SYS 115 ...

Page 116: ...nnector Central part TABLE A IGNITION RELAY PRE ASSEMBLY The positive battery cable must be connected to the hole identified by the letter B Battery using M5x8 screw 1 Start up relay 2 Battery positive cable pole identified by the let ter B 3 Vehicle wiring starter motor cable pole identi fied by the letter M TABLE A1 IGNITION RELAY PRE ASSEMBLY If the battery positive cable is not connected to th...

Page 117: ...E B1 VEHICLE CABLE HARNESS Block the conduit to the chassis in the four indica ted points and fix it using the central screw 1 TABLE B2 VEHICLE CABLE HARNESS Place the relay unit behind the steering column and fix it by passing the main wiring harness through the cable grommet RSV4 RR RF Electrical system ELE SYS 117 ...

Page 118: ...insertion of the connectors on the relevant relays 1 Safety relay connector 2 Injection relay connector 3 Fan relay connector TABLE D RADIATOR AREA right side 1 Vehicle cable harness 2 Cable grommet Electrical system RSV4 RR RF ELE SYS 118 ...

Page 119: ... pressure sensor 4 Starter motor WIRING TABLE E STARTER MOTOR AND OIL BULB ZONE 1 Earth wiring routing behind the water pipe and starter motor 2 Starter motor wiring harness routing behind the water pipe 3 Starter motor lug COVER THE STARTER MOTOR NUT AND THE SQUARE TERMINAL WITH DI ELECTRIC WA TER REPELLENT GREASE 4 Oil pressure sensor wiring harness routing be hind the water pipe 5 Oil pressure ...

Page 120: ...MAIN WIRING HARNESS Check that the connectors have been connected correctly and that the purple slide is in the end stop position 1 Vehicle connector 2 Engine connector WIRING TABLE G VEHICLE EARTH CABLE Battery engine earth cable routing The battery engine earth cable must not be visible in the zone indicated by the red triangle symbol 1 Large clamp clamp the battery engine earth wiring to the de...

Page 121: ...ine wiring harness 3 Battery engine ground cable ENGINE GND eyelet PAY ATTENTION NOT TO INVERT THE FRAME GDN EYELET FROM THE ENGINE WIRING HARNESS WITH THE BATTERY EN GINE GROUND CABLE ENGINE GND EYELET TABLE H2 ENGINE GROUND CABLE 1 Check that the connector with BLUE tape is correctly hooked on demand with the BLUE label Ensure the grey security lock is closed 2 Check that the connector with WHIT...

Page 122: ... GROUND CABLE 1 Routing of the Demand Slave wiring harness 2 Routing of the Demand Master wiring harness TABLE H4 1 Big clamp 2 Fan connector 3 Regulator wiring harness routing Electrical system RSV4 RR RF ELE SYS 122 ...

Page 123: ...wiring harness is posi tioned so that it does not go near the discharge and the white connector is properly connected 1 Big clamp 2 Flywheel wiring harness routing TABLE I EXHAUST VALVE ACTUATOR PO SITIONING AND CALIBRATION CHECK THAT THE CONNECTOR OF THE EX HAUST VALVE ACTUATOR IS WELL CONNEC TED 1 Exhaust valve actuator 2 Exhaust valve actuator connector 3 Exhaust valve actuator wiring harness r...

Page 124: ...e wiring harness 6 Oxygen sensor connector 7 Gear sensor 8 Small clamp 9 Quick Shift TABLE L1 PINION CASING AREA 1 Stand switch 2 Cable grommet 3 Stand switch wiring harness TABLE L2 PINION CASING AREA PASS THE WIRING HARNESS BEHIND THE CA BLE GROMMET THAT CLOSES THE TWO FUEL BREATHER PIPES 1 Quick Shift wiring harness 2 Rear lambda probe wiring harness routing 3 Gear sensor wiring harness routing...

Page 125: ...M REAR LAMBDA 1 Rear lambda probe wiring harness routing TABLE M1 REAR LAMBDA THE CABLE GROMMET MUST BE POSITIONED UPWARD AND THE LAMBDA PROBE CABLE SHOULD PASS INSIDE RSV4 RR RF Electrical system ELE SYS 125 ...

Page 126: ...OBE CONNECTOR 1 Front lambda probe wiring harness routing TABLE M3 REAR LAMBDA 1 Front lambda probe cable of the main wiring harness 2 Front lambda probe cable to probe TABLE M4 REAR LAMBDA 1 Lambda probe cable in front of vent pipes Electrical system RSV4 RR RF ELE SYS 126 ...

Page 127: ...o contact with the exhaust 1 Quick Shift wiring harness 2 Clamp Back side TABLE A LICENSE PLATE FRAME PRE FIT TING The right arrow is identified with the RED taping and must be inserted on the license plate holder as indicated in the picture The arrow with the red tape must be connected with the wiring harness branch that includes the grey tape 1 Left LED indicator 2 Right LED indicator 3 Grey tap...

Page 128: ...to pinch the cables TABLE B REAR ABS SPEED SENSOR PRE FITTING 1 ABS speed sensor TABLE B1 REAR ABS SPEED SENSOR PRE FITTING 1 ABS speed sensor wiring harness 2 Cable grommets TABLE C PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION The initial position of the connector fastener lever must be as shown in the figure Electrical system RSV4 RR RF ELE SYS 128 ...

Page 129: ...t must be 7 5 mm TABLE C3 PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION If the initial position of the connector and the pull ing level is not as the one shown in TABLE C the connector will not hook correctly and the meas ured distance will be higher around 12 mm In this case repeat the operation as described in TABLE C1 C2 It is advisable to create a jig in order to check the correct...

Page 130: ...sert the tip of the clamp into the hole on the sad dle mounting and push it until it locks into place 1 Grey taping 2 Clamp 3 Saddle mounting hole WIRING TABLE D2 ABS ON SADDLE MOUNTING IF THIS WIRING ABS FUSES BATTERY IS NOT SECURED CORRECTLY IT MAY CAUSE THE VEHICLE TO CATCH FIRE Check that the connected is securely attached and that all the terminals are in place Position it as indicated 1 ABS ...

Page 131: ...ST AREA Fit the individual fan fuse on battery mounting bracket tongue TABLE E2 REAR SEAT POST AREA Fuse box positioning on battery mounting bracket Insert the fuse box in the two tongues on the bat tery mounting bracket TABLE E3 REAR SEAT POST AREA Check that the connector is correctly connected with the protection relay RSV4 RR RF Electrical system ELE SYS 131 ...

Page 132: ...tic connectors in their respective hous ings 1 ECU diagnostic connector 2 Diagnostic connector 3 Number plate holder wiring connector 4 Taillight connector WIRING TABLE E6 REAR SADDLE MOUNTING ZONE Insert the starter relay between the two plastic flaps 1 Start up relay 2 Starter motor cable on vehicle wiring harness 3 Starter relay connector 4 Rubber clamp 5 Cable grommet Electrical system RSV4 RR...

Page 133: ...RING TABLE F ENGINE BATTERY EARTH CABLE 1 Engine battery earth cable 2 Cable grommet TABLE F1 ENGINE BATTERY GROUND CA BLE 1 Battery engine ground lead 2 Big clamp RSV4 RR RF Electrical system ELE SYS 133 ...

Page 134: ...s TABLE G1 VARIABLE INTAKE DUCT CON TROL UNIT 1 Intake duct control unit wiring harness routing 2 Small clamp WIRING TABLE H SWINGARM ZONE 1 Rear brake switch wiring 2 Speed sensor wiring 3 Cable fasteners WIRING TABLE H1 SWINGARM ZONE 1 Rear brake switch wiring 2 Speed sensor wiring 3 Cable grommet Electrical system RSV4 RR RF ELE SYS 134 ...

Page 135: ...General wiring diagram key 1 Multiple connectors 2 Front right turn indicator LED 3 Complete headlamp 4 Front left turn indicator LED RSV4 RR RF Electrical system ELE SYS 135 ...

Page 136: ...ction relay 20 Immobilizer antenna 21 Rear right turn indicator LED 22 Complete taillight LED 23 Rear left turn indicator LED 24 License plate light bulb 25 Recovery logic relay 26 Auxiliary fuses 27 BLUEDASH pre installation 28 Voltage regulator 29 Alternator 30 Starter motor 31 Start up relay 32 Battery 33 Main injection relay 34 Oil pressure sensor 35 Fan 36 Fan control relay 37 Fuel reserve se...

Page 137: ...unit 62 Variable geometry engine 63 ABS control unit 64 Front wheel speed sensor 65 Rear wheel speed sensor 66 SensorBox 67 Left light switch 2 68 Fan fuse 69 ABS fuses 70 Lambda probe 2 71 Left headlamp connector 72 Right headlamp connector Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS THE SECTIONS RELATIVE TO THE ELECTRICAL SYSTEM CONTAIN DRAWINGS OF CONNEC TORS NO...

Page 138: ...heck that the terminals are fitted correctly on the connector and that the wires are fastened correctly to the terminals Checking electrical CONTINUITY Purpose of check the purpose of this check is ensure that there are no interruptions or excess re sistance due to corroded terminals for example in the circuit under inspection Tester set the tester selector to the continuity symbol and place the p...

Page 139: ...obe on the cable under inspection and the black tester probe on the vehicle ground point or on the battery negative pole CAUTION IN THE CASE OF SPORADIC FAULTS MOVE OR WIGGLE THE RELATIVE WIRING HARNESS SLIGHTLY WHILE PERFORMING EACH OF THE CHECKS INDICATED FOR TROUBLESHOOT ING Immobiliser System components Function detects the transponder code in the key and sends it to the instrument panel Level...

Page 140: ...f not OK restore if OK check electrical characteristics and aerial circuit continuity from the instrument panel connector on PIN 24 and 34 if not OK restore cable harness if OK check circuit ground insulation if not ground insulated restore cable harness if insulated with key ON with instrument panel connector disconnected check that there is not voltage at the circuit ends if there is voltage res...

Page 141: ...en Diagnosis An access code is required to enter this menu 12412 Then select the option Delete errors NOTE DELETE THE ERROR CAUSED BY THE LACK OF MEMORY OF KEY CODES 3 Connect to the vehicle with the diagnosis tool and select the adjustable Parameters in the screen page Exhaust butterfly valve self acquisition NOTE SEARCH FOR MINIMUM AND MAXIMUM MECHANICAL STOPS STORED IN THE INSTRUMENT PANEL In c...

Page 142: ... open or short circuited DSB 04 Internal controller fault DSB 05 DSB 06 Error cause An oil sensor fault is signalled when it is detected that the sensor circuit is open or shorted to positive DSB 07 Oil pressure sensor Error cause An oil sensor fault is signalled when with engine off it is detected that the sensor circuit is open Troubleshooting The test is performed only once when the key is set ...

Page 143: ...STRU MENT The instrument panel will restart to work normally after the key is inserted extracted MODIFY KEYS With this function the instrument panel can update the keys Up to 4 keys can be stored The user code is first requested to be entered ENTER THE CODE After entering the correct code the following message should be shown on the display INSERT THE X KEY INSERT THE X 1 KEY At least one key must...

Page 144: ...tion See also Diagnosis Battery recharge circuit RECHARGING SYSTEM Remove the left side fairing Disconnect the three way connector 1 white NOTE THE ENGINE SIDE IS IDENTIFIED WITH THE LETTER A Measurement of resistance with engine off For a correct detection of the alternator resistance an ambient temperature measurement must be carried out and afterwards a heat stabilisation after turning fan on b...

Page 145: ...nce between one stage and another other than 0 15 Ohm this means that the alternator is defective and must be replaced RESISTANCE MEASURE Winding stage Ambient temperature ohm Afterwards heat stabilisation ohm Stage 1 0 15 0 20 0 25 0 30 Stage 2 0 15 0 20 0 25 0 30 Stage 3 0 15 0 20 0 25 0 30 Zero load voltage Disconnect the three way connector 1 For a correct detection of the alternator voltage a...

Page 146: ...he single cables other than 10 A this means that the alternator is defective and must be re placed CAUTION WITH THE ENGINE HOT THE VALUES RECORDED ARE ON AVERAGE 2 3 A LESS THAN THOSE DETECTED WITH THE ENGINE COLD WARNING NEVER KEEP THE ENGINE RUNNING FOR MORE THAN ONE MINUTE FAILURE TO DO SO COULD CAUSE SERI OUS OVERHEATING DAMAGES TO THE MOTORCYCLE CIRCUITS COLD SHORT CIRCUIT CURRENT RPM 2000 40...

Page 147: ...ide the support 4 ways black Electrical specifications key released open circuit key pressed closed circuit Pin out 2 voltage 5V 3 ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL ELECTRICAL ERRORS Starter switch P0170 ...

Page 148: ... ECU 2 E 15A fuse High beam low beam horn F 15A fuse Coils injectors fuel pump secondary air injection relay G 15A fuse Fans Secondary fuses are placed in the central part of the motorcycle under the rider saddle ABS FUSE LAYOUT Specification Desc Quantity M fuse of 15A ABS solenoid valves N fuse of 30A ABS pump motor WHERE CONTEMPLATED CAUTION THREE OF THE FUSES ARE SPARES H MAIN FUSES DISTRIBUTI...

Page 149: ...onnec tors Unscrew and remove the three screws Remove the control unit NOTE WHEN REASSEMBLING THE CONNECTORS THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP THUS FACILITATING THE CONNECTOR S INSERTION THE CATCH SHOULD SNAP INTO PLACE ONCE THE LIMIT STOP IS REACHED RSV4 RR RF Electrical system ELE SYS 149 ...

Page 150: ...ee CONNECTORS paragraph DIAGNOSTIC TOOL PARAMETERS ISO screen page screen page example values with key ON Drawing number Marelli spare part number IAW7SMHW430 Hardware number 00 Mapping Software version number 0000 Type approval number ISO code Marelli software code Control unit serial number NIP 7SMPRA119 Identifies the individual control unit Author of the last programming In dicates the serial ...

Page 151: ...t from Cut Off Immobilizer consent yes no Indicates if the control unit received the consent from the instrument panel regarding the immobilizer coded key or user code entered manually Any errors can be read on the in strument panel error screen page in the DIAGNOSTICS section of the instrument panel Start up enabling yes no indicates if the control unit will make start up possible if requested if...

Page 152: ...ntermediate_Key ON_Engine running_Stopped_Power latch_Power latch 2_Power latch terminated Trip counter Mapping selection Intermediate Track Sport Road DIAGNOSTIC TOOL ELECTRICAL ERRORS Error EEPROM P0601 Circuit not functioning Error cause Replace the injection control unit The instrument panel does not indicate the presence of this error even in the ATT status Error RAM P0604 Circuit not functio...

Page 153: ...rical characteristics of the relay by disconnecting it from the wiring harness if not ok replace the relay if ok perform the check procedure for the relay connector the engine vehicle wiring harness connector and the ENGINE connec tor for the Marelli control unit if not ok restore if ok check the continuity of the wiring harness blue pink cable DIAGNOSTIC TOOL LOGIC ERRORS Level 2 safety reset P06...

Page 154: ...ED DURING THE VEHICLE PRODUCTION PHASE INCLUDING THE SELF ADAPTIVE PARAMETERS THE FOLLOWING MUST BE SELECTED HANDLE SELF LEARNING AND CHECK THE TWO AUTOMATIC SELF LEARNING OF THE FRONT THROTTLE VALVES AND AUTOMATIC SELF LEARNING OF THE REAR THROTTLE VALVES STATUSES ARE CARRIED OUT See also Cylinders synchronisation Download of stored data file Error cause The file BUFRSVXX BIN is saved in the memo...

Page 155: ...e self learning state is Performed If not ok either the voltage detected on the handle is out of scale check using the diagnostic tool or current errors were detected by the control unit resolve the malfunctions and repeat the pro cedure Battery Function Electrically supply the vehicle battery YTZ 10 S MF is already activated loaded and sealed or al ternatively battery YT 12A BS which must be acti...

Page 156: ... high check correct operation of the voltage regulator If too low check voltage regulator connectors engine vehicle cable harness connector and the control unit connector paying special attention to possible oxidation if not OK restore if OK check that red white cable resistance from the voltage regulator connector to the control unit connector is a few tenths of Ohm if not OK restore cable harnes...

Page 157: ...speed sensor electric malfunction Missing sensor or interrupted wire or short circuit to negative of one of the two wires Troubleshooting Check the sensor connector and the ABS control unit connector If they are NOT OK restore the con nectors If they are OK check continuity of the white brown cable between PIN 2 of the sensor on the cable harness side and PIN 3 if NOT OK restore cable harness if O...

Page 158: ...eel with wrong number of teeth C1104 Front speed sensor missing signal or different speed measured at the two wheels Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1106 Front speed sensor missing signal or different speed measured at the two wheels Faulty sensor or missing tone wheel or excessive distance be...

Page 159: ... ABS control unit C1005 Rear speed sensor electric malfunction Missing sensor or interrupted wire or short circuit to negative of one of the two wires Troubleshooting Check the sensor connector and the ABS control unit connector If it is not OK restore the connectors if it is OK check continuity of the yellow brown cable across wiring side sensor PIN 2 and PIN 4 If NOT OK restore cable harness if ...

Page 160: ...heel Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1105 Rear speed sensor missing signal or different speed measured at the two wheels Faulty sensor or missing tone wheel or excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth C1107 Rear speed sensor missing sign...

Page 161: ...d position Subse quently depending on the control voltage on PIN 2 from the injection ECU 0V down 5V up the ECU drives the electric motor with the relative po larity for raising or lowering the ducts The drive voltage delivered to the motor is determined in re lation 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 Le...

Page 162: ... lift the ducts DIAGNOSTIC TOOL ACTIVATION Variable geometry intake control NOTE The injection ECU sends the command to the variable geometry control unit to lift the ducts In PADS the command only works once then put the key to OFF and wait for the loss of communication with the control unit DIAGNOSIS INSTRUMENT ERRORS Variable geometry intake P0447 shorted to positive shorted to negative open ci...

Page 163: ...ctor 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 insulated...

Page 164: ...RE OK CHECK THE SENSOR CONFORMS TO THE ELECTRICAL SPEC IFICATIONS IF NECESSARY REPLACE THE SENSOR IF IT IS OK CHECK THE CONTINUITY ON THE TWO CABLES VERIFYING THAT THEY ISOLATED FROM THE POWER SUPPLY AND EARTH CARRY OUT THE TESTS ON THE CONNECTOR OF THE SENSOR TOWARDS THE SEN SOR IF IT IS NOT OK REPAIR THE WIRING REPLACE THE SENSOR IF IT IS OK CARRY OUT THE TEST ON PINS 20 TO 35 OF THE MARELLI CON...

Page 165: ... 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 RR RF Electrical system ELE SYS 165 ...

Page 166: ...means of which the torque demand is read and checked The 4 potentiometers are tinned and magnetically con trolled contactless they cannot be overhauled nor replaced Level in wiring diagram Hand grip position sensor Location on the vehicle front left part next to the cooling liquid radiator connector on the sensor Electrical specifications Not detected by a multimeter as they are contactless read t...

Page 167: ...n 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 per...

Page 168: ...ontrol 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 169: ... 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 c...

Page 170: ...racks 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 171: ... 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 ambi...

Page 172: ...ng 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 SECTI...

Page 173: ...r 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 t...

Page 174: ...rmal 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 h...

Page 175: ...he 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 exa...

Page 176: ... 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 inver...

Page 177: ...it 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 conn...

Page 178: ...cessive temperature variation was detected the cause could be a contact resistance between the terminals for example The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check the sensor connector and the ENGINE connector of the Marelli control unit NOTES No error is detected if the sensor does not work correctly or the control unit connector or ...

Page 179: ...Pin out 1 0 5 V signal 2 Ground connection DIAGNOSIS INSTRUMENT PARAMETERS Air temperature Example value with key ON 26 C 78 8 F In case of recovery this value is set by the control unit Air temperature pre Recovery Example value with key ON 40 C 40 0 F Value drawn from the signal read without taking into account any recovery the value in the exam ple refers to an open circuit CAUTION BEFORE CARRY...

Page 180: ...it connector and with key set to key ON check the continuity between the sensor connector PIN 2 and the vehicle ground connection if OK it means that the error cause is that the cable is shorted to positive and it is necessary to restore the cable harness between ENGINE PIN 37 and sensor PIN 1 check the sensor connector and the Marelli control unit connector If not OK restore the cable harness If ...

Page 181: ... inside Level in electrical circuit diagram Lambda probe Position on manifold left side of the vehicle connector left side of the vehicle fixed to the support bracket of the fairing lug 4 way connector black Electrical specifications Heater circuit 7 9Ω at ambient temp Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white cable 4 Heater power supply white ca...

Page 182: ...CTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Lambda probe Start up_Lean_Rich_Fault due to rich value_Fault due to lean value If the probe connector 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 th...

Page 183: ... from probe connector PIN 3 and 4 toward the probe if it is not OK replace the probe if it is OK check the sensor connector and the Marelli control unit connector if it is not OK restore if it is OK with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if it is not OK check the red brown cable continuity between the probe connector and the injection relay ...

Page 184: ...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 38 and PIN 9 and restore the cable harness REAR CYLINDER BANK Function In charge of telling...

Page 185: ...sed loop the value must be close to 1 00 values not within the 15 15 interval indi cate a fault In an open circuit the lambda probe signal is too low Therefore the control unit takes it as a lean mixture condition and will try to enrich it The value read will be 25 once this value is reached and remains unchanged for a certain time the lambda probe functional diagnosis is ac tivated resulting in i...

Page 186: ...cessive voltage battery voltage has been detected at PIN 10 and 22 of the ENGINE connector Caution the Lambda probe parameter is not the real value that is read a re covery value is displayed instead The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting shorted to positive with key set to ON disconnect the sensor connector and measure PIN 1 voltag...

Page 187: ...t OK restore if it is OK with key set to ON and sensor connector disconnected check if there is battery voltage at PIN 4 if it is not OK check the red brown cable continuity between the probe connector and the injection relay No 33 in the electrical circuit diagram placed under the saddle next to the battery positive CHECK however the identification of the relay with the colour of the ca bles If t...

Page 188: ...of low engine revs the upper injectors in the field of high engine revs Operation Operating principle Injector coil is energised for the petrol passage to open Level in electrical circuit diagram Coils and injectors Position on the vehicle on the throttle body connector on injectors Electrical specifications 14 8 Ω 5 at ambient temp Pin out supply ground DIAGNOSTIC TOOL PARAMETERS Electrical syste...

Page 189: ...the electrical circuit diagram placed under saddle right side CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiri...

Page 190: ...ce the injector If the circuit is open check the component correct electrical characteristic if it is not the correct one replace the component if it is correct check the connector on the component and the Marelli control unit connector if not OK restore If OK check cable continuity be tween the ENGINE PIN 8 and component PIN and restore the cable harness Lower injector cylinder 2 P0202 short circ...

Page 191: ...t and the Marelli control unit connector if not OK restore If OK check cable continuity be tween the ENGINE PIN 34 and component PIN and restore the cable harness Lower injector cylinder 4 P0204 short circuit to positive short circuit to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 45 If shorted to negative no voltage has been detected If the ...

Page 192: ...nciple Injector coil is energised for the petrol passage to open Level in electrical circuit diagram Coils and injectors Position on the vehicle on filter box cover connector on injectors Electrical specifications 12 0 6Ω 5 at ambient temp Pin out supply ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NI...

Page 193: ...uit diagram placed under saddle right side CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation Electrical continuity is required in the wiring for the relay to...

Page 194: ... shorted to positive disconnect the injector connector set key to ON activate the compo nent with the diagnostic tool and check the voltage on the white green cable on the injector connector if there is voltage restore the filter box cable harness If there is no voltage replace the sensor If shorted to negative disconnect the injector connector set the key to ON and check if there is a ground conn...

Page 195: ...rcuit 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 diagnostic tool 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 shorted to negative di...

Page 196: ... 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 NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSIS INSTRUMENT ACTIVATION Fuel pump NOTE The injection relay No 33 in the wiring diagram position under the saddle next to the battery...

Page 197: ...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 Operation Operating principle Inductive discharge system Level in electrical circuit diagram coils and injectors Location on the vehicle on the head covers connector For each 3 ways black coil connector Coil 1 with shor...

Page 198: ...conds and the brown red cable of the coil is closed to ground for 2 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 Coil 3 The injection relay No 33 in the wiring diagram placed under the saddle next to ...

Page 199: ...connector if not OK restore cable harness Coil 2 P0352 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 27 of the ENGINE con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 27 of the ENGINE connector Troubleshooting If shorted to positive disconnect the coil connector ...

Page 200: ...d 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 1 of the ENGINE connector Troubleshooting If shorted to positive disconnect the coil connector set the key to ON activate the coil with the diagnostics instrument and check voltage at connector PIN 1 if there is voltage restore the cable harness if voltage 0 replace the coi...

Page 201: ...ne on 0 2 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 Front throttle Potentiometer 1 degrees Example value with key ON 7 8 Example value with engine on 1 4 With key set to ON the throttle is kept in position by the ...

Page 202: ...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 mechanical minimum above or equal to 0 5 When the gear is not engaged at approx 6000 rpm throttles open very little because the requested torque is too low around 5 7 Rear throttle Potentiometer 2 degrees Example ...

Page 203: ...G CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTIC TOOL STATUSES Front throttle automatic self learning Ice Interrupted Performed Limp home Throttle valve stopper closed Spring check Limp home acquisition Initialization Indicates if the self learning performed by the control unit was performed not performed this is funda...

Page 204: ...ween 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 potentiometer 2 sensor rear throttle position P0122 short circuit...

Page 205: ...s 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 shorted to negative voltage equal to zero has...

Page 206: ...nnected 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 negati...

Page 207: ...ttle voltage Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN48 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor rear throttle position P0123 signal not valid Error cause Si...

Page 208: ... and to compare it to the Potentiometer 1 front throttle voltage Check the throttle body connector as well as the control unit connector Check that cable resistance between the throttle body connector PIN 1 and the control unit PIN 36 is a few tenths of an Ohm If this is not the case restore the cable harness If the value is correct replace the complete throttle body potentiometer 2 sensor front t...

Page 209: ...ch key ON The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting Check if the throttle body and the intake duct are clean If OK replace the throttle body Rear throttle mechanical springs self acquisition P0161 failed test Error cause Return time of the throttle kept in position by the springs not within the expected limits the causes can be a deter...

Page 210: ...ndering throttle self learning Rear throttle position error P0167 misalignment between control and activation Error cause The throttle mechanical control may be damaged Troubleshooting Replace the throttle body Front throttle Limp Home self acquisition P0180 failed test Error cause Throttle position kept by the springs not within the expected range at each key ON The instrument panel does not indi...

Page 211: ... 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 i...

Page 212: ...ess on the adjustable parameters screen page screwdriver and hammer and check again that the Throttle self learning with diagnostics instrument status indicates Carried out and that the Front throttle automatic self learning or Rear throttle automatic self learning indicate carried out Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure 0 5 0 2 bar in...

Page 213: ...s an error when the general warning light turns on Troubleshooting Check if oil pressure is low with the specific gauge Neutral sensor Function Indicates to the control unit the position of the gearbox from 1st gear to 6th gear and if the gear box is in neutral or drive Operation Operating principle The sensor is comprised of 2 circuits one to indi cate the gear engaged whose resistance varies dep...

Page 214: ... excessive voltage has been detected on PIN 72 If short circuit to negative voltage equal to zero detected at PIN 72 Troubleshooting If open circuit short circuit to positive the error is detected only with a gear engaged 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 connectors ...

Page 215: ...Pin out 1 voltage 5V 2 ground connection CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER DIAGNOSTICS INSTRUMENT STATUSES Clutch Indefinite_Released_Pulled WARNING The statuses regularly viewed are Released and Pulled indication on the diagno...

Page 216: ...he side stand is unfol ded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in electrical circuit diagram Start up enabling switches Location on the vehicle on the stand connector between head cover and fil ter box on left side 2 ways white con nector Pin out 1 Ground connection 2 Voltage 12V Electrical specificatio...

Page 217: ...t tells the vehicle position to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground When the Marelli control unit detects this ground connection it does not enable start up or shuts off the engine Level in electrical circuit diagram Start up enabling switches Location on the vehicle sensor placed in the frame front niche connector next to the ...

Page 218: ...ntinuity between the two PINS when the sensor is in vertical position if there is continuity replace the sensor if there is not it means that with key set to ON there is no 5V voltage at PIN 2 restore the cable harness whose pink white cable will be shorted to ground CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE B...

Page 219: ...IN 61 of the VEHICLE con nector If shorted to negative no voltage has been detected If the circuit is open 5V voltage has been detected Error recognition carries out only when the fan relay is activated Troubleshooting If shorted to positive check the relay electrical specifications are correct by disconnecting it from the cable harness If not OK replace the relay if OK restore the cable harness b...

Page 220: ...AGNOSIS 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...

Page 221: ...cteristics and replace the component RUN STOP switch Function It tells the control unit if the rider wishes to enable engine start up or to keep the engine running Operation Operating principle If the rider wants to shut off the engine or to disable engine start up the switch should be open i e VEHICLE connector PIN 78 of the Marelli control unit must not be connected to ground Level in electrical...

Page 222: ...r PIN 78 if not OK restore the cable harness if OK replace the Marelli control unit indication on the diagnostics instrument always RUN disconnect the connector and with the switch set to STOP check if there is continuity between the two cables of the switch if there is continuity replace the switch if there is not continuity it means that with key set to ON the Pink cable between switch and the P...

Page 223: ...e exhaust duct connector on the motor Electrical characteristics Electrical motor resistance PIN 4 5 2 4 Ohm Potentiometer resistance PIN 1 3 10 1 kOhm 10 Pin out 1 Power supply voltage 5V 2 Output signal 0 5V 3 Ground connection 4 Motor A supply 5 Motor B supply DIAGNOSIS INSTRUMENT PARAMETERS Exhaust butterfly valve target position 7 93 NOTE Value that control unit sends to the instru ment panel...

Page 224: ... adjustment Exhaust butterfly valve self acquisition voltage of maximum opening end of stroke outside the foreseen field is detected Check correct tensioning of the two valve cables If potentiometer signal is below maximum threshold during adjustment Exhaust butterfly valve self acquisition voltage of minimum opening end of stroke outside the foreseen field is detected Check correct tensioning of ...

Page 225: ...ground connection at PIN 5 of the con nector if there is ground connection disconnect also the instrument panel connector and if it is still present restore the black cable if there is not ground connection replace the in strument panel if there is not ground connection check if PIN 4 or PIN 5 on the motor are in continuity with ground connection if it is in continuity replace the motor If shorted...

Page 226: ...ectors special attention to oxidation and check cables resistance if not OK restore if OK always with cables disconnected and key set to ON check normal rotation of the electric motor and replace motor potentiometer does not work correctly DIAGNOSTICS INSTRUMENT ADJUSTABLE PARAMETERS Acquire exhaust butterfly valve zero position NOTE Motor is placed in a reference position to correctly search mech...

Page 227: ...OSITION NEVER WORK ON THE CONTROL CABLES IF THE MOTOR PULLEY IS NOT IN THE ZERO POSITION EXHAUST THROTTLE VALVE CALIBRATION From the Adjustable parameters screen page use the diagnostic instru ment to select Acquire exhaust valve zero position After having pressed the enter button for the zero position search shut off the vehicle and leave the keys in OFF even in the event that the instruments ind...

Page 228: ...s obtained Turn the key to ON CAUTION THE ZERO SEARCH OF THE DISCHARGE VALVE MO TOR PROCEDURE ENTAILS RESETTING THE EXISTING MECHANICAL STOPS AN ERROR FOR STOP SEARCH NOT CARRIED OUT IS THEN INDICATED WHICH RE MAINS UNTIL THE SELF TEACHING OF THE DISCHARGE VALVE PROCEDURE IS PERFORMED DO NOT CARRY OUT THIS OPERATION WHEN USING A NON ORIGINAL EXHAUST SYSTEM WHERE ANY CABLES CONSIDERED NOT NECESSARY...

Page 229: ...ift Present Not present DIAGNOSTICS INSTRUMENT ELECTRICAL ERRORS Quick Shift sensor electronic transmission P0462 Shorted to negative upon key ON Signal not valid Error cause If shorted to negative on key ON a voltage equal to zero has been detected at PIN 47 If signal is not valid it means that the control unit has detected activation of the lever but not its release within the set time limit Tro...

Page 230: ...e the instrument panel sends the requested command to the Marelli ECU via CAN line Electrical circuit diagram Level in electrical circuit diagram Traction control Position on vehicle On the left side semi handlebar Position of connector if applicable Inside the top fairing and instrument panel mount ing support Electrical specifications button 0 Ohm across PIN 2 and PIN 1 Infinite resistance acros...

Page 231: ...at PIN 13 of the instrument panel disconnect the gearshift control connector and read voltage at PIN 13 of the instru ment panel if voltage is below 1 V it means that on the brown cable there is a short circuit to ground if voltage is above 1 V approximately battery voltage replace the button sensor Indication on diagnostics instrument Invalid data due to open circuit error CASE 1 if this status i...

Page 232: ...ans that on the blue cable there is a short circuit to ground if voltage is above 1 V approximately battery voltage replace the button sensor Indication on diagnostics instrument Invalid data due to open circuit error CASE 1 if this status is displayed only with control not activated it means that circuit from PIN 19 to PIN 30 of the instrument panel is inter rupted or that PIN 30 is not grounded ...

Page 233: ...ith signal not valid the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error Sensor box error inertia sensor platform P0711 Faulty sensor Signal not valid Troubleshooting With faulty sensor the component inside the control unit is damaged and replacement of the control unit is recommended With signal not valid the sensor has ...

Page 234: ...ement of the control unit is recommended With signal not valid the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error Connectors ECU Engine pinout key Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output PIN 3 Electrical system RSV4 RR RF ELE SYS 234 ...

Page 235: ...e sensor PIN 25 51 Reference voltage output 5V tracks B D and front throttle PIN 26 Cylinder 2 coil control output PIN 27 Cylinder 1 coil control output PIN 28 Rear cylinder bank throttle motor output PIN 29 STOP lights relay control output PIN 31 Rear cylinder bank lambda heating control output 1 PIN 32 Lower cylinder 3 injector control output PIN 34 Engine speed sensor input PIN 35 Input for fro...

Page 236: ... control output PIN 53 Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 Start engine switch input PIN 58 Electric fan relay 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 Electrical system RSV4 RR RF ELE SYS 236 ...

Page 237: ...ut key Key PIN 1A Vehicle speed PIN 2A STOP lights relay control 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...

Page 238: ...Dashboard Grey bodied instrument panel pinout key 1 Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply Electrical system RSV4 RR RF ELE SYS 238 ...

Page 239: ...11 Battery 12 Left turn indicator control 13 Normally closed button 14 15 16 Indicator reset 17 Oil sensor input 18 Normally open button 19 Normally closed button 20 K line Black bodied instrument panel pinout key 21 Battery 22 Front left turn indicator activation 23 Front right turn indicator activation 24 Aerial 2 RSV4 RR RF Electrical system ELE SYS 239 ...

Page 240: ...st valve B control output 38 Ground connection 39 Ground connection 40 Ground connection ABS Modulator ABS control unit pin out key Valve ground and ECU PIN 1 CAN H line high speed PIN 2 Front speed sensor input PIN 3 Key positive ECU PIN 4 Serial line K for diagnosis PIN 5 Battery for valve positive PIN 9 Pump engine ground PIN 10 CAN L line high speed PIN 11 Front speed sensor positive PIN 12 Re...

Page 241: ...ltered Communication speed messages travel at a speed of 250 kbps data arrive at nodes every 20 ms i e 50 times second CAN PROTOCOL CONT NETWORK AREA The communication protocol is CSMA CD Carrier Sense Multiple Access w Collision Detection In order to transmit every nod must first check that the BUS the connection among all devices is free before attempting to send a message with BUS Carrier Sense...

Page 242: ...e the Marelli control unit CAN line without signals U1602 Bus Off Error cause No communication on CAN line PIN 66 and or PIN 80 problem on the whole network for example battery cut off or short circuited or shorted to ground Troubleshooting check the Marelli control unit VEHICLE connector and the engine vehicle cable harness connector if not OK restore if OK check the ground insulation of the two ...

Page 243: ... fault CAN line toward Sensor Box U1722 Intermittent signal or communication error Error cause Probable bad contact in the CAN line Troubleshooting Check the Vehicle connector pins 66 and 80 and the vehicle engine cable harness pins B2 and B3 If not OK restore If OK check pins 2 and 3 and the inertia sensor platform Sensor box connector If not OK restore If OK check overall operation of the Marell...

Page 244: ...ply 12V at pins 1 and 2 and ground at pin 4 of the ABS control unit connector If NOT OK restore the cable harness if OK change the instrument panel DIAGNOSTIC TOOL LOGIC ERRORS CAN line to ABS control unit U1711 No signal Configuration error Error cause If there is no signal no signal is received from the ABS control unit In case of configuration error some devices are present e g ABS that were no...

Page 245: ...tor pins 66 and 80 If NOT OK restore If OK with key OFF disconnect the following a ABS control unit connector b inertia sensor platform Sensor box connector and check the continuity across inertia sensor platform Sensor box pin 3 and ABS control unit pin 11 If NOT OK change the vehicle cable harness if OK check the continuity across inertia sensor platform Sensor box pin 2 and ABS control unit pin...

Page 246: ...ile one RAM of the value concerning the rear wheel radius In this case the default value is used Presa USB Rimozione Unscrew and remove the screws 1 Remove the top fairing glass from the seats of the motorcycle Unscrew and remove the two screws 2 Remove the instrumentation lid Move the instrument panel to the right so as to remove it from its seat Once released move the instrument panel without di...

Page 247: ...crew 6 of the sup port bracket 7 paying attention to re cover the elastic washer 8 Remove the USB port Installazione Unscrew and remove the screws 1 Remove the top fairing glass from the seats of the motorcycle Unscrew and remove the two screws 2 Remove the instrumentation lid RSV4 RR RF Electrical system ELE SYS 247 ...

Page 248: ...et housing the USB port 4 into the support bracket 3 Then insert the USB port 5 in the rub ber gasket 4 Operating from the left vehicle side in sert the nut in the corresponding hous ing on the headlamp Place the wiring harness of the USB cable 6 on the vehicle making it pass through the headlamp and the instru mentation support and recover the connector 7 so as it is inside the in strumentation s...

Page 249: ...e washer 10 Locking torques N m USB port support bracket fixing 6 Nm 4 43 lb ft Aprilia V4 MP Tecnology Rimozione CAUTION MAKE SURE THE ENGINE AND THERMAL PARTS OF THE MOTORCYCLE HAVE COOLED BE FORE PERFORMING THE REMOVAL Operating on the vehicle LHS remove the three expansion caps 1 located on the inside of the side fairing Remove the expansion cap 2 fixing the side fairing to the lower fairing R...

Page 250: ...3 and remove side fairing from the vehi cle Remove the nylon clamp 4 blocking the wiring harness of the control unit to the vehicle wiring harness Repeat the test using the resistance multimeter 5 Electrical system RSV4 RR RF ELE SYS 250 ...

Page 251: ...hers 10 Installazione CAUTION MAKE SURE THE ENGINE AND THERMAL PARTS OF THE MOTORCYCLE HAVE COOLED BE FORE PERFORMING THE REMOVAL Operating on the vehicle LHS remove the three expansion caps 1 located on the inside of the side fairing Remove the expansion cap 2 fixing the side fairing to the lower fairing Undo and remove the fixing screws 3 and remove side fairing from the vehi cle RSV4 RR RF Elec...

Page 252: ...f the side fairing Place the control unit V4 MP 5 on the fixing pins 7 insert the remaining two flat rubber washers 6 on the fixing pins 7 and fix the control unit V4 MP to the side fairing using the two elastic washers 8 Place the control unit wiring harness 9 paying attention to let it pass through the chassis and the accelera tor position sensor Electrical system RSV4 RR RF ELE SYS 252 ...

Page 253: ... the wiring harness of the vehicle using the nylon clamp 13 Place the left side fairing on the vehi cle first fix it to the top fairing and then fix it with the relative fixing screws 3 Fix the expansion cap fixing the side fairing 2 to the lower fairing Fix the three expansion caps 1 on the inside of the side fairing Sincronizzazione To use the system V4 MP the synchronisation that differs depend...

Page 254: ...BlueTooth is enabled the smart phone automatically searches devi ces When the PMP ECU has been recognized it appears in the MY DE VICES list as PMP Click on PMP and wait for the smartphone to con nect When connected the PMP shows Connected Now the PMP is connected to the phone and in the V4 MP App you should note the motorcy cle data transmission After the first connection the system connects auto...

Page 255: ...row BlueTooth active green button Wait for the smartphone to rec ognize the PMP ECU until you see PMP in Available devices list When the PMP is found click on the PMP line and make sure the smart phone is connected Once connected the PMP is added to the Paired devi ces list and in the menu PMP appears the message Paired Now the PMP is connected to the phone and in the V4 MP App you should note the...

Page 256: ... ON POSITION BEFORE THE APP IS LAUNCHED CAUTION AFTER THE KEY IS OFF IT WILL BE NECESSARY TO WAIT FOR ABOUT 20 SECONDS TO EN SURE THAT THE WIRELESS CONNECTION IS CLOSED IN CASE OF CONNECTION FAILURE JUST EXIT THE APPLICATION USING THE APPROPRIATE BUTTON CLOSE IT FROM THE BACKGROUND MENU AND MANUALLY RESTART IT IF THE PREVIOUS DEVICE IS NOT IN THE AREA AFTER 20 SECONDS THE SYSTEM WILL BE AVAILABLE ...

Page 257: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 258: ... lb ft 8 Pin for fastening the gear change lev er to the footrest support M8 1 25 Nm 18 44 lb ft Apply water repellent grease between the O rings and the Quick Shift uniball NOTE ONCE ASSEMBLE THE DISTANCE BETWEEN THE UNIBALL AND THE JOINT MUST BE AP PROXIMATELY 180mm 7 09in Vehicle preparation To remove the engine from the chassis previously perform the following operations Remove the fuel tank a...

Page 259: ... by wire support Disconnect the ride by wire connectors 3 Move the clamps 4 and disconnect the water pipe with the connector from the engine in order to empty the system Move the clamp 5 and disconnect the water pipe from the radiator fluid tank RSV4 RR RF Engine from vehicle ENG VE 259 ...

Page 260: ...he oil connection pipe Remove the clamp 8 fixing the oil pressure bulb wiring and exhaust valve to the water pipe Remove the fixing screws 9 of the ra diators support bracket Operating from both sides of the motorcycle remove the screws 10 fixing the radiator to the support bracket Engine from vehicle RSV4 RR RF ENG VE 260 ...

Page 261: ...radiators by sliding them off from the right side of the motorcycle Loosen the screw 11 and ease off the gear lever Remove the three fixing screws 12 of the pinion cover 13 RSV4 RR RF Engine from vehicle ENG VE 261 ...

Page 262: ...ixing screw 16 and slide off the chain slider 17 Remove the fixing screw 18 of the chain guide plate 19 Cut the two clamps 20 that connect the wiring of the quick shift to the wiring of the side stand and of the lambda probe Engine from vehicle RSV4 RR RF ENG VE 262 ...

Page 263: ...ease the wiring Remove the two fixing screws 22 of the footrest complete with leverage Disconnect the connector 23 of the side stand sensor and release the wir ing Undo the two fixing screws and remove side stand 24 RSV4 RR RF Engine from vehicle ENG VE 263 ...

Page 264: ...nut 26 of the rear wheel pin Working from both sides of the motor cycle loosen the locknuts 27 and act on the register screws 28 to loose the chain tension Loose the clamp 32 that blocks the silencer at the central manifold Engine from vehicle RSV4 RR RF ENG VE 264 ...

Page 265: ...ng the front exhaust manifolds Remove the four screws 30 fixing the manifolds to the front heads Remove the two front manifolds 31 Loose the clamp 32 that blocks the silencer at the central manifold RSV4 RR RF Engine from vehicle ENG VE 265 ...

Page 266: ...ng the silencer at the rider footrest Slide off the central manifold and re move the silencer Remove the fixing clamp 34 of the exhaust valve wiring Disconnect the connector 35 of the exhaust valve Engine from vehicle RSV4 RR RF ENG VE 266 ...

Page 267: ...tor 35 of the exhaust valve Remove the fixing screws 36 of the exhaust valve Detach and remove the springs 37 fixing the rear exhaust manifolds Remove the central exhaust manifold 38 RSV4 RR RF Engine from vehicle ENG VE 267 ...

Page 268: ... 40 Detach the clutch cable 41 remove the nut 42 and take the cable com plete with sheath 43 off from the guide in the housing Remove the rubber cap 44 Unscrew and remove the nut 45 and collect the washer Remove the power supply cable from the starter motor Engine from vehicle RSV4 RR RF ENG VE 268 ...

Page 269: ...l pressure sen sor 46 Undo and remove the screw 47 and release the ground cables Detach the ground cable and unscrew and remove the nut 48 Disconnect the engine wiring connec tor 49 RSV4 RR RF Engine from vehicle ENG VE 269 ...

Page 270: ...otection plate Remove the protection plate 52 of the ABS system Install the engine support and place a winch under it Specific tooling 020864Y Engine mounting plate Operating from the right side of the mo torcycle remove the upper screw 53 fixing the engine to the chassis Engine from vehicle RSV4 RR RF ENG VE 270 ...

Page 271: ... 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 engine is fixed at minimum height possible CAUTION THE LEFT AND RIGHT FRONT INSERTS ARE EQUAL AND MUST NOT BE PLACED IN THE IN VERTED POSITION Adjustment of engine height relati...

Page 272: ...n the chassis The hole is offset by 2 5 mm 0 098 in relative to the cen treline of the insert as a result the swingarm is in the low position There are 4 inserts subdivided as follows Inner outer Right Left The two right side swingarm pin inserts are differ ent The two left side swingarm pin inserts are the same CAUTION THE FOUR INSERTS MUST BE FITTED WITH THE ARROW FACING DOWNWARDS OTHERWISE THE ...

Page 273: ...ION DURING CENTRING PHASE OF THE ENGINE ON THE CHASSIS OP ERATE WITH CAUTION SO AS NOT TO DAMAGE THE SCREWS AND THE CHASSIS INTERNAL AND EXTERNAL SPACERS Working on the left side place and screw without tighten the two front fixing screws 1 the engine attachment upper fixing screw 6 the lower rear fixing pin 3 so as to centre the engine position Working on the right side place and screw without ti...

Page 274: ...rque after placing the corresponding washer Slide the lower rear fixing pin 3 Working on the right side slide the upper rear fixing screw 5 Place and tighten internally the two set pack bushings 7 to the prescribed torque Place again on the left side the lower rear fixing pin 3 Tighten the rear pin fastening nut 8 Place again the upper rear fixing screw 5 and tighten the lock nut 9 on the internal...

Page 275: ...ng Place the radiator frame the washer and tighten the screw fastening the frame to the engine Place the gear lever and tighten the screw Position the quick shift cable harness and fasten using ties RSV4 RR RF Engine from vehicle ENG VE 275 ...

Page 276: ...ernator connector Connect the voltage regulator connec tor Position and fix the hand grip position sensor to the chassis WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS Engine from vehicle RSV4 RR RF ENG VE 276 ...

Page 277: ...ce the two fuel breather pipes Install the side stand Place the pinion and insert the trans mission chain in the seat Tighten the rear wheel fixing nut Adjust the drive chain adjuster screws RSV4 RR RF Engine from vehicle ENG VE 277 ...

Page 278: ...screw Place the pinion cover and tighten the three screws Connect the vehicle cable harness engine cable harness connector Working on the right side of the vehicle connect the exhaust valve control unit connector Engine from vehicle RSV4 RR RF ENG VE 278 ...

Page 279: ...ut 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 Tighten the engine oil pressure sensor RSV4 RR RF Engine from vehicle ENG VE 279 ...

Page 280: ...timing sensor Connect the clutch cable Check and adjust the clutch lever clearance with the adjuster screw The clutch lever clearance should be between 1 3 mm 0 039 0 12 in Engine from vehicle RSV4 RR RF ENG VE 280 ...

Page 281: ...INDEX OF TOPICS ENGINE ENG ...

Page 282: ...key 1 rear left cylinder 2 front left cylinder 3 rear right cylinder 4 front right cylinder Combustion sequence 1 3 2 4 Combustion angle cyl 1 0 cyl 2 180 cyl 3 425 cyl 4 605 Engine RSV4 RR RF ENG 282 ...

Page 283: ...ng screws M8x25 6 25 Nm 18 44 lb ft 4 Index lever fixing screw M6 1 10 Nm 7 38 lb ft Loct 243 5 Pinion fastening 1 50 Nm 36 88 lb ft Loct 243 6 Screw retaining pre selector on crankcase 1 25 Nm 18 44 lb ft Loct 270 7 Gear selector fastening screw M5x15 2 6 Nm 4 43 lb ft Removing the gearbox Remove the gearbox selector Remove the clutch housing Remove the gear sensor from the flywheel side RSV4 RR ...

Page 284: ...emove the water oil pump control gear See also Removing the gear selector Disassembling the clutch Remove the water oil pump control gear driving pin Loosen the screw Unscrew and remove the six screws Engine RSV4 RR RF ENG 284 ...

Page 285: ... an elevated hardness and a good resistance to wear The main reason for using this coating is its extremely low friction coefficient making this an ideal treatment for preventing adhesion phenomena such as seizing and cold welding The treatment has a characteristic colouring darker than at a traditional operation OPTION 01 The components listed in the following are coated in WC C 1 Primary shaft 2...

Page 286: ... the primary shaft rotates the secondary shaft does not move Remove the gearbox unit Slide off the gearbox primary shaft con trol rod 1 Remove the fork 2 of the gearbox pri mary shaft Slide off the gearbox secondary shaft control rod 3 Engine RSV4 RR RF ENG 286 ...

Page 287: ... the gearbox secondary shaft Remove both gearbox shafts from the cover Remove the shim washer 5 that is lo cated on the secondary shaft between the shaft and the cover Loosen and remove the screw 6 RSV4 RR RF Engine ENG 287 ...

Page 288: ...able 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 Specific tooling 020863Y Punch assembly cage with rollers desmodromic drum Engine RSV4 RR RF ENG 288 ...

Page 289: ...ooves 5 3 mm 0 21 in Minimum wear limit of the pinion side secon dary shaft seat 29 97 mm 1 18 in Minimum wear limit of the clutch side primary and secondary shaft seat 19 97 mm 0 79 in Checking the desmodromic drum Check gear drum for damage scratches and wear and replace the desmodromic if necessary Check the desmodromic segment 1 for damage and wear and replace it if necessary Check the desmodr...

Page 290: ...shafts 0 05 mm 0 0020 in NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS Check the transmission fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary Check the transmission fork movement and if it is not regular replace the transmission forks Assembling the gearbox Place the drum 1 of the gear selector on the sup...

Page 291: ...fixing the drum to the desmodromic shaft CAUTION SECURE THE SHIM WASHER 4 TO THE SECONDARY SHAFT WITH GREASE Move the gearbox shafts together and fit them into the support Grease the sliding bushes of the forks RSV4 RR RF Engine ENG 291 ...

Page 292: ...gearbox secondary shaft Insert the gearbox secondary shaft control rod 6 checking the presence of the springs Insert the fork 7 in the specific seat of the gearbox primary shaft Insert the gearbox primary shaft con trol rod 8 Engine RSV4 RR RF ENG 292 ...

Page 293: ...he 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 gearbox secondary shaft Insert the driving pin on the oil pump shaft Install the water oil pump control gear Insert the Seeger ring Install the gear sensor making the pin coincide with the slot on the desmo dromic control rod Gear selector RSV4 R...

Page 294: ...l without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod Fit the adaptor on the specific tool to insert the roller cage at the controlled depth Lubricate the seat and insert the new roller cage from the clutch side Specific tooling 020862Y Punch assembly cage with rollers gearb...

Page 295: ...ool without an adaptor Specific tooling 020862Y Punch assembly cage with rollers gearbox control rod Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely If necessary replace the parts Check the gear selector spring for damage and wear If necessary replace the part Check the selector shaft and its teeth for damage and wear If necessary replace t...

Page 296: ...ng the spacers 2 Remove the starter motor 3 from its housing Removing the idle gear Remove the clutch cover Remove the intermediate gear Start up system check IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL Engine RSV4 RR RF ENG 296 ...

Page 297: ...Check the freewheel sliding surface 2 for wear Make sure that the woodruff key slot is in perfect condition Remove the needle cage 3 and the roller cage 4 from their housings on the freewheel 2 and check the rollers needles for wear Check for wear on the freewheel sliding surface 2 Fitting the idle gear The ratios between the gears of the starter system are 1 Starter motor 9 teeth RSV4 RR RF Engin...

Page 298: ...ews fastening cover onto centre pins M6x25 6 12 Nm 8 85 lb ft Move to the torque unscrew bring back to torque 2 Cover fastening screws generator side M6x40 2 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 3 Blow by union fastener screws M5x16 3 7 Nm 5 16 lb ft Stator fixing screw UNI 5931 CL8 8 M6x25 3 10 Nm 7 38 lb ft Loct 2045 Flanged screw M5x12 1 6 Nm 4 43 lb ft Loct 2045 ...

Page 299: ...emoval Remove the flywheel cover Block flywheel rotation using the spe cific tool Unscrew and remove the screw Specific tooling 020914Y Flywheel retainer Remove the tool for blocking flywheel rotation Insert a SHC M10x20 screw into the crankshaft hole which will act as a mounting base for flywheel extraction Remove the flywheel using the specific extractor Collect the SHC M10x20 screw Specific too...

Page 300: ...fitting Replace the O ring with a new one of the same type Remove the flywheel cover Remove the Seeger ring Remove the shim washer Remove the oil seal CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE SET THE NEW OIL SEAL WITH THE MARKING ON THE EDGE FACING OUTWARD Engine RSV4 RR RF ENG 300 ...

Page 301: ...nstallation Insert the centring dowels in the cover Apply a layer of sealing paste along the external edge of the cover Insert the cover together with the sta tor Recommended products Three bond Sealing paste 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 RR RF Engine ENG 301 ...

Page 302: ... re tighten to torque 4 TE Flanged screw M6x22 14 12 Nm 8 85 lb ft Tighten to torque unscrew and re tighten to torque 5 Engine timing inspection cap 1 20 Nm 14 75 lb ft Removing the clutch cover Drain the engine oil Unscrew and remove the sixteen peri metric fixing screws and retrieve the washers Remove the clutch casing retrieving the gasket the two locator pins and the starter motor transmission...

Page 303: ...y loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Remove the thrust plate and the com plete control rod Remove the discs Block clutch bell rotation using the spe cific tools Unscrew and remove the clutch bell fixing nut Specific tooling 020849Y Clutch lock RSV4 RR RF Engine ENG 303 ...

Page 304: ... Remove the slipper unit Remove the clutch hub Remove the clutch hub cam tower Retrieve the shim Engine RSV4 RR RF ENG 304 ...

Page 305: ... Collect the clutch housing Remove the clutch gear that controls the oil water pumps Remove the needle cage Remove the spacer RSV4 RR RF Engine ENG 305 ...

Page 306: ...th 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 Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation If necessary replace the bell Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness Engine RSV4 RR RF EN...

Page 307: ... Check the thrust plate and the bearing for damage and wear If necessary replace the parts Characteristic Maximum deformation permitted on the thrust plate compression surface 0 15 mm 0 0059 in Maximum depth of the thrust plate 27 3 mm 1 07 in Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation If neces sary replace the hub Checking the sp...

Page 308: ...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 Fit the needle cage Engine RSV4 RR RF ENG 308 ...

Page 309: ... 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 Install the clutch hub cam tower RSV4 RR RF Engine ENG 309 ...

Page 310: ...TOWER INCLINES Fit the three slipper unit clips offsetting them between each other Install the slipper unit correctly Insert the washer Block clutch housing rotation using the specific tool Tighten the clutch housing fixing nut Specific tooling 020849Y Clutch lock Engine RSV4 RR RF ENG 310 ...

Page 311: ... 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 RR RF Engine ENG 311 ...

Page 312: ...l 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 RR RF ENG 312 ...

Page 313: ...screws 1 Tighten the six screws operating in stages and diagonally Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING Before carrying out the removal of the bushing it is necessary to thread the inside to allow the extractor to tighten sufficiently RSV4 RR RF Engine ENG 313 ...

Page 314: ...ted in the figure Insert the bushing so that the process ing notch 3 is aligned with the notch on the guide 4 Specific tooling 020926Y Tool for fitting clutch bushing Then insert the tool to push the bushing into the seat until it stops Position the starting transmission gear on the crankcase Position the gasket and the two dowel pins in the clutch cover Insert the clutch cover making sure to have...

Page 315: ...ing in stages and diagonally Add engine oil up to the correct level Heads VALVES COVER Pos Description Type Quantity Torque Notes 1 Head cover fixing screws 6 10 Nm 7 38 lb ft 2 Coil fastening screws 4 8 Nm 5 90 lb ft Loct 243 3 Spark plugs 4 12 Nm 8 85 lb ft RSV4 RR RF Engine ENG 315 ...

Page 316: ...d valve covers fixing screws 6 6 Nm 4 43 lb ft 4 Water outlet coupling fixing screw 2 10 Nm 7 38 lb ft Pre impregnated or else Loct 270 or Loct 648 5 Flanged head nut 12 30 55 Nm 22 13 40 57 lb ft Lubricate the head and under the head 6 Head tightening screw chain side M6x55 4 12 Nm 8 85 lb ft Lubricate the head and under the head Engine RSV4 RR RF ENG 316 ...

Page 317: ...ming system gear on the intake shaft M8 4 30 Nm 22 13 lb ft Loct 243 2 Shoe fastening screws M8 2 20 Nm 14 75 lb ft Loct 243 3 Skid fastener screws M6x18 2 10 Nm 7 38 lb ft Loct 243 Head cover removal Unscrew and remove the three screws with rubber washers RSV4 RR RF Engine ENG 317 ...

Page 318: ...t in the area indicated in the figure Recommended products Three bond Sealing paste Smear the head surface with suitable sealant in the area indicated in the fig ure Recommended products Three bond Sealing paste Fit the head cover Tighten the three screws with rubber washers to the prescribed tightening torque Front head Engine RSV4 RR RF ENG 318 ...

Page 319: ...r Position cylinder 1 piston LH rear pis ton so that it is at the point where it crosses TDC rotate the crankshaft 150 in the engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT DO NOT USE IT FOR TIGHTENING COMPONENT...

Page 320: ... Unscrew and remove the camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Repeat the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the direction of engine rotation direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this e...

Page 321: ...ew and remove the second in take camshaft gear screw Leave the gear on the camshaft Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Install the specific camshaft gear sup port tool Fix it to the head using the two screws 1 Move the gear from the camshaft to the tool Specific tooling 020956Y Support for camshaft gear on head Unscrew and remove the eight screws 2 proceeding in s...

Page 322: ...t show blue colouring cracks or scratches otherwise replace the camshaft gear and chain Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the part Characteristic Maximum camshaft axial clearance intake ex haust 0 4 mm 0 0016 in WARNING THE EXHAUST CAMSHAFTS OF THE FRONT AND REAR CYLINDER BANKS MUST B...

Page 323: ...haust camshafts on the front head bearing in mind that the exhaust camshaft gear tooth indicated with a dot is meshed with the trough of the intake camshaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RETAINER SCREWS ON THE INTAKE CAM SHAFT Fit the U bolts with the nine O rings and locator pins Fit the new washers under the screws 2 near the spark plug holes only Tighten th...

Page 324: ...20956Y Support for camshaft gear on head Fit the U bolt and the oil pipe Tighten the two screws 1 of the U bolt Place and tighten the screw 2 not pre viously inserted Align the intake camshaft with the spe cific hole on the U bolt Insert the specified pin Specific tooling 020851Y Camshaft timing pin Engine RSV4 RR RF ENG 324 ...

Page 325: ... until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt is visible Block crankshaft rotation using one of the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing screw to exactly the torque speci fied Remove the...

Page 326: ...rankshaft Remove the O ring See also Head cover removal Removing the flywheel cover Turn the crankshaft from the hole on the clutch cover Move cylinder piston 1 left rear piston to the overlap TDC Turn the crankshaft 150 in the engine rotation direction direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ensures that all the front cylinde...

Page 327: ... the following operations move cylinder piston 1 left rear piston to TDC turn the crankshaft 150 in the engine rotation direction direction of travel in order to align the hole on the intake camshaft with the specific hole on the U bolt this ensures that all the front cylinder bank valve springs are decom pressed Block crankshaft rotation using one of the specific tools Unscrew and remove the seco...

Page 328: ...ear 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 chain slider Unscrew and remove the mobile chain slider screw Remove the mobile chain slider Engine RSV4 RR RF ENG 328 ...

Page 329: ...ndicated above Remove the front head slipping it off the stud bolts Collect the gasket and the two dowel pins Remove the chain tensioner complete with O ring using the specific tool If the O ring is not on the chain ten sioner make sure it was not left in the crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Fitting removing timing chain ten sioner tool RSV4 RR RF Engine...

Page 330: ... of the valve seats Check that the routing of the oil pipes is free and if required clean them by blowing a jet of compressed air Front head fitting Install a new O ring on the chain ten sioner REPLACE THE O RING UPON EACH REMOVAL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Engine RSV4 RR RF ENG 330 ...

Page 331: ...tionality of the timing system This washer is available as a spare part Fit the washer onto the front chain tensioner then install the chain tensioner in the relative seat in the crankcase Take particular care to ensure that the washer seats correctly as the functionality of the timing system may be compromised if the washer is bent or incorrectly positioned Place a new gasket between the crank ca...

Page 332: ...5 6 Then tighten them fully following the same order Tighten the two screws according to the sequence a b Fit the camshaft gear Keep the gear in position with the chain tightened THE SIDE WITH THE BEVELLED HOLE IN THE TIMING SYSTEM GEAR MUST ALWAYS FACE THE EXTERIOR OF THE HEAD Engine RSV4 RR RF ENG 332 ...

Page 333: ...ere it crosses TDC rotate the crankshaft 150 in the engine rotation direction direction of travel insert the respective pin from the fly wheel side into the groove on the crankshaft NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT DO NOT USE IT FOR TIGHTENING COMPONENTS Specific tooling 020852Y Crankshaft timing pin RSV4 RR RF Engine ENG 333...

Page 334: ...RETAINER SCREWS ON THE INTAKE CAM SHAFT Check the number engraved on the U bolts which must correspond with the one engraved on the head If the U bolts between the two heads are inverted camshaft seizure may oc cur IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT IF NECESSARY REPLACE THE ENTIRE HEAD Fit the U bolts with the nine O rings and locator pins Install the oil pipe Fit the new washers under ...

Page 335: ... 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 020981Y Lever for disarming the hydraulic tensioner of the timing chain RSV4 RR ...

Page 336: ...f the specific tools Apply Loctite 243 thread lock on the thread of the second gear fastener screw This screw must be replaced at each reassembly Tighten the second camshaft gear fix ing screw to exactly the torque speci fied Remove the crankshaft locking tool Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned insert the reference pin while checki...

Page 337: ...TS Specific tooling 020852Y Crankshaft timing pin See also Head cover removal Removing the clutch cover Fit the pin for aligning the intake cam shaft with the hole on U bolt If it was not possible before adjusting the valve clearance check the engine timing Specific tooling 020851Y Camshaft timing pin Remove the two crankshaft and cam shaft reference pins Turn the crankshaft until the gear screw c...

Page 338: ...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 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 r...

Page 339: ...e tool Specific tooling 020956Y Support for camshaft gear on head Unscrew and remove the seven screws 2 proceeding in stages and diagonally Retrieve the washers from the screws near the spark plug holes Remove the U bolts with the O rings and locator pins Remove the intake and exhaust cam shafts If the two camshafts are timed correctly the intake camshaft gear tooth indicated with one dot is meshe...

Page 340: ...KS 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 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 ...

Page 341: ... 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 020956Y Support for camshaft gear on head Fit the U bolt and the oil pipe Tighten the two U bolt screws 1 and the screw 2 that was not fitted previ ously RSV4 RR RF Engine ENG 341 ...

Page 342: ... of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer 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 v...

Page 343: ...s Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Rear head removal Remove the rear head cover and the clutch cover Move cylinder piston 1 left rear piston to the TDC Turn the crankshaft 450 one complete turn 90 in the direction of motor rotation direction of travel in order to align the hole on the intake camshaft gear with the hole on the U bolt This ensures that all t...

Page 344: ...vel to align the hole on the intake camshaft with the specific hole on the U bolt This ensures that all the rear cylinder bank valve springs are decompressed Block crankshaft rotation using one of the specific tools Unscrew and remove the second in take camshaft gear screw Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer Kokusan Slide and remo...

Page 345: ...nd locator pins NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the intake and exhaust camshafts from the rear head Unscrew and remove the mobile chain slider screw Remove the mobile chain slider Unscrew and remove the fixed chain slider screw Remove the fixed chain slider Unscrew and remove the two head fas tener screws a b from the clutch side RSV4 RR RF Engine ENG 345 ...

Page 346: ...f the stud bolts Collect the gasket and the two dowel pins Remove the chain tensioner complete with O ring using the specific tool If the O ring is not on the chain ten sioner make sure it was not left in the crankcase seat REPLACE THE O RING UPON EACH REMOVAL Specific tooling 020883Y Fitting removing timing chain ten sioner tool Rear head check Check that Engine RSV4 RR RF ENG 346 ...

Page 347: ...pes is free and if required clean them by blowing a jet of compressed air Rear head fitting Install a new O ring on the chain ten sioner REPLACE THE O RING UPON EACH REMOVAL Compress the chain tensioner com pletely making sure that the total length is 40 05 0 5 mm 1 58 0 02 in Insert the chain tensioner into the crankcase being careful to position it correctly RSV4 RR RF Engine ENG 347 ...

Page 348: ...Place the two dowel pins Install the head Pretighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order Tighten the two screws according to the sequence a b Engine RSV4 RR RF ENG 348 ...

Page 349: ...m with the specific screws NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY Install the intake and exhaust cam shafts on the rear head remembering that the intake camshaft gear tooth indicated with a dot is inserted in the groove of the exhaust cam shaft gear indicated with two dots CLEAN THOROUGHLY THE SEATS OF THE GEAR RE TAINER SCREWS ON THE INTAKE CAMSHAFT RSV4 RR R...

Page 350: ... U bolts with the nine O rings and locator pins Install the oil pipe Fit the new washers under the screws 2 near the spark plug holes only Tighten the ten screws 1 2 working in stages and diagonally Cut the clamp that binds the chain to the gear Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot Insert the specific timing pin Spe...

Page 351: ... head with rubber Load the chain tensioner with special tool Specific tooling 020981Y Lever for disarming the hydraulic tensioner of the timing chain Block crankshaft rotation using one of the specific tools Tighten the gear fixing screw on the camshaft to exactly the torque speci fied Remove the crankshaft locking tool Specific tooling 020850Y Primary gear lock 020914Y Flywheel retainer RSV4 RR R...

Page 352: ...pecific tooling 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020914Y Flywheel retainer 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 ...

Page 353: ... specific wrench and with the spring compressing tool Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal Remove the cotters using a magnet RSV4 RR RF Engine ENG 353 ...

Page 354: ...UTION 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 Characteristic Valve stem distortion Engine RSV4 RR RF ENG 354 ...

Page 355: ...5 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 angle to the valve head face and measure the eccentricity If the eccentricity exceeds the specified limit re place the valve Characteristic Valve...

Page 356: ...are marked blue and the old exhaust springs are marked green 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 Engine RSV4 RR RF ENG 356 ...

Page 357: ...the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs Release the wrench checking that the cotters are positioned correctly in the valve grooves Position the adjusting shims Position the bucket tappets RSV4 RR RF Engine ENG 357 ...

Page 358: ...44 lb ft Lubricate the thread and under the head 6 SHC screw 2 10 Nm 7 38 lb ft Lubricate the thread and under the head 7 TE Flanged screw 2 10 Nm 7 38 lb ft Lubricate the thread and under the head 8 TB TORX screw 4 3 5 Nm 2 58 lb ft Loctite 2045 9 Screw 2 6 Nm 4 43 lb ft 10 Stud bolt 1 Move to 33mm from table 11 SHC screw 1 10 Nm 7 38 lb ft Lubricate the thread and under the head 12 Special nut 1...

Page 359: ...otes 1 Hex headed nut cl 10 type 2 iso 8674 M10x1 1 50 Nm 36 88 lb ft Loct 243 CRANKSHAFT pos Description Type Quantity Torque Notes 1 Connecting rod screws 8 15 20 Nm 11 06 14 75 lb ft 130 Lubricate the head and under head with RSV4 RR RF Engine ENG 359 ...

Page 360: ...50 Nm 36 88 lb ft Loct 3M or 270 Balancing countershaft removal To extract the balancing countershaft first remove the clutch cover and the alternator cover Turn the crankshaft so as to position the thicker side of countershaft gear on the side opposite to crankcase bulk head Block crankshaft rotation using the specific tool Specific tooling 020850Y Primary gear lock See also Removing the clutch c...

Page 361: ... Remove the countershaft from the al ternator side Remove the countershaft gear Remove the key on countershaft RSV4 RR RF Engine ENG 361 ...

Page 362: ...THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR Engine RSV4 RR RF ENG 362 ...

Page 363: ...untershaft Block crankshaft rotation using the specific tool Tighten the nut on the countershaft Specific tooling 020849Y Clutch 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 crankshaft rotation using the specific tool Specific tooling 020850Y Primary gear lock RSV4 RR RF Engine ENG 363 ...

Page 364: ...screw Remove the tone wheel See also Disassembling the clutch Unscrew and remove the primary shaft fixing nut Remove the crankshaft blocking tool Specific tooling 020850Y Primary gear lock Remove the primary shaft gear Engine RSV4 RR RF ENG 364 ...

Page 365: ...NTIFIED 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 Prepa...

Page 366: ...and intermediate gear countershaft See also Magneto flywheel removal Water pump Disassembling the gearbox Main transmission gear removal Front head removal Rear head removal Removing the oil sump Balancing countershaft removal Crankcase opening Position the engine with the heads fac ing upward unscrew and remove the screw 24 Engine RSV4 RR RF ENG 366 ...

Page 367: ...s 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 RR RF Engine ENG 367 ...

Page 368: ...ng 020857Y Crankshaft support U bolt See also Front head removal Rear head removal Unscrew and remove the two connect ing rod screws Remove the connecting rod cap NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING Remove the piston connected to the connecting rod from the cylinder side Take out the Seeger ring Engine RSV4 RR RF ENG 368 ...

Page 369: ...s removing the lower part If the heads were removed position the specific special tool to keep the pis tons from coming out Specific tooling 020858Y Maintenance of the pistons in the cyl inders Unscrew and remove the eight con necting rod screws Remove the four connecting rod caps NOTE MARK THE COMPONENTS TO PREVENT INCORRECT RE FITTING RSV4 RR RF Engine ENG 369 ...

Page 370: ...Remove the lower crankcase Remove the countershaft FLYWHEEL SIDE Unscrew and remove the bearing re tainer screw Remove the lock Heat up the crankcase to 150 C 302 F Position the general tool to pull out bearings Remove the bearing See also Crankcase opening Engine RSV4 RR RF ENG 370 ...

Page 371: ...s Remove the bearing Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0 5 mm 0 0197 in Maximum radial play between main bushings and crankpins 0 07 mm 0 00275 in Balancing countershaft check Characteristic Maximum countershaft axial clearance after closing the crankcase 0 1 mm 0 0039 in RSV4 RR RF Engine ENG 371 ...

Page 372: ...um piston diameter 77 934 mm 3 0683 in Maximum clearance between the cylinder and piston 0 08 mm 0 0031 in Maximum wear limit of the clearance between pin and pin hole on the piston 0 040 mm 0 0016 in Maximum allowed clearance between the first piston ring and respective slot on the piston 0 1 mm 0 0039 in Maximum allowed clearance between the second piston ring and respective slot on the piston 0...

Page 373: ...he first piston ring and respective slot on the piston 0 1 mm 0 0039 in Maximum allowed clearance between the sec ond piston ring and respective slot on the pis ton 0 1 mm 0 0039 in Maximum opening of the piston ring fit on the pin First piston ring 0 5 mm 0 0197 in Second piston ring 0 7 mm 0 0275 in Selecting connecting rods SELECTING CRANKSHAFTS AND CONNECTING RODS ACCORDING TO BALANCING CLASS ...

Page 374: ...ss combinations for primary drive side connecting rod pair HH AA AA AA AA LL BB BB AA CC BB BB AA CC MM CC CC BB DD CC CC BB DD NN DD DD CC EE DD DD CC EE OO EE EE EE EE CRANKSHAFT CONNECTING ASSISTANCE ROD BALANCING CLASSES Crankshaft balancing classes Balancing class combinations for alternator side connecting rod pair Balancing class combinations for primary drive side connecting rod pair HH BB...

Page 375: ... classes are available A B C which differentiate in the diameter of the hole in the bearings The category is marked on the crankcase on the right side in the area below the gearbox Different classes of bearings can be used e g A B C or B B C or A B A A number that indicates the position of the main journal is stamped on the crankcase 1 flywheel side 2 central 3 clutch side RSV4 RR RF Engine ENG 37...

Page 376: ...ou pling e g A B A or B B A etc o e g C D E or D C C etc CRANKSHAFT CATEGORIES Specification Desc Quantity Class C Main journals diameter 46 028 46 023 mm 1 8121 1 8119 in Class D Main journals diameter 46 023 46 018 mm 1 8119 1 8117 in Class E Main journals diameter 46 018 46 013 mm 1 8117 1 8115 in Once the categories below are checked 1 crankcase 2 flywheel side main journal 3 centre main journ...

Page 377: ...arings are different from the central ones and therefore so are the respective replacement part numbers CRANKSHAFT BUSHINGS CONNECTING RODS Three types of semi bushing are available for the connecting rods Blue Yellow RSV4 RR RF Engine ENG 377 ...

Page 378: ...olours Provided clearance X 35 885 35 880 mm Blue Yellow 1 0 055 0 026 Y 35 880 35 874 mm Yellow Yellow 0 056 0 026 Z 35 874 35 869 mm Yellow Green 1 0 056 0 027 Key 1 If using bushing of different thickness install the thickest on the side of the connecting rod shank BIG END BUSHING REPLACEMENT PROCEDURE When replacing the big end bushings make sure that the tang of the semi bushing is correctly ...

Page 379: ...ward with respect to the crankcase In this way it will be possible to install the bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw CLUTCH SIDE Heat up the crankcase to 150 C 302 F Prepare the following tools Specific tooling 020363Y 20 mm diam punch for crankshaft oil ...

Page 380: ...e bearing retainer in the groove Using the suitable tools fit the bearing in the crankcase until tool stops Fit the retainer in the bearing groove Tighten the bearing retainer screw Install the balancing countershaft Crankshaft fitting When refitting the primary gear remember to first place the lining as shown in the figure The greater diameter side is facing outwards the engine Engine RSV4 RR RF ...

Page 381: ... the pistons in the cyl inders Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side Make the references on the gears of the primary shaft and the countershaft coincide NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR Install the crankshaft blocking tool Tighten the primary shaft ...

Page 382: ...be fitted with the markings N or KDN5 for the upper one and RN for the lower one 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 The fitted pistons have two selections A and B Therefore they are coupled with the cylinder ac cord...

Page 383: ...tor fit the connecting rod shank with the bevelling 2 on the hole of the rod head on the right side Position the special tool on the crank case Partially insert the connecting rod shank piston assembly in the 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 pi...

Page 384: ...od screws lubri cating the thread and under the head Proceed with tightening according to the procedure described in the tighten ing torque table using the torque wrench and angular tightening with a goniometer 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...

Page 385: ...ayer of sealing paste along the external edge of the crankcase Join the two crankcases Recommended products Three bond Sealing paste Pretighten the six nuts on the stud bolts proceeding in the following order 1 2 3 4 5 6 Then tighten them fully following the same order RSV4 RR RF Engine ENG 385 ...

Page 386: ...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 Turn the engine with the heads facing upward Tighten the screw 24 Engine RSV4 RR RF ENG 386 ...

Page 387: ...Thermal group CYLINDERS PISTON pos Description Type Quantity Torque Notes 1 Screws fastening water union onto crankcase M6x40 2 10 Nm 7 38 lb ft Lubrication RSV4 RR RF Engine ENG 387 ...

Page 388: ...der the table 5 Oil pressure sensor 1 15 Nm 11 06 lb ft 6 TE Flanged screw 1 10 Nm 7 38 lb ft Loct 243 7 SHC screw 5 10 Nm 7 38 lb ft 8 SHC screw 1 10 Nm 7 38 lb ft 9 TE Flanged screw 1 6 Nm 4 43 lb 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 w...

Page 389: ...rews 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 RR RF Engine ENG 389 ...

Page 390: ...rication 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 RR RF ENG 390 ...

Page 391: ...ion 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 RR RF Engine ENG 391 ...

Page 392: ...Position the oil cooling pump s internal rotor Position the dowel pins and the exter nal rotor on the cooling oil pump cover Fit the pump cover on the internal rotor Tighten the four cooling oil pump cover screws Fit a new gasket Engine RSV4 RR RF ENG 392 ...

Page 393: ...r gasket Remove the rose pipe together with the gasket CAUTION THE ROSE PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL DURING REFITTING REPLACE THE GASKET WITH A NEW ONE OF THE SAME TYPE RSV4 RR RF Engine ENG 393 ...

Page 394: ... Remove the metal gasket Remove the lower gasket Remove the overpressure valve together with gasket Blow by The Blow by system uses the rotation of the countershaft 1 to separate the engine oil into oil vapour and liquid Engine RSV4 RR RF ENG 394 ...

Page 395: ...s 1 Secondary air solenoid screws 2 10 Nm 7 38 lb 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 conditions e g at idle or low engine speeds RSV4 RR RF Engi...

Page 396: ...Inspecting the one way valve Unscrew and remove the three screws Remove the cover together with the two secondary air system valves Engine RSV4 RR RF ENG 396 ...

Page 397: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 398: ...ing Remove and empty the fuel tank Remove the pipe grommet Disconnect the fuel pipe from the fuel pump Unscrew and remove the six fixing screws of the fuel pump Remove the fuel pump Power supply RSV4 RR RF P SUPP 398 ...

Page 399: ...Injection Diagram key 1 Control unit position 2 Throttle grip position sensor RSV4 RR RF Power supply P SUPP 399 ...

Page 400: ...ening from their engines but actually a specific torque The Ride by Wire system has been so designed that the throttles of the throttle bodies are mechanically isolated from the throttle control their actuation depends exclusively on 2 electrical motors controlled by the control unit The control unit refers to specific handle maps to determine by how much and how quickly the throttle valves are op...

Page 401: ...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 To remove the complete injectors unit disconnect and remove the engine control unit complete with support Undo the four screws fixing the injec tors unit to the fil...

Page 402: ...e 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 Disconnect the lower injector connec tors See also Air box Disconnect the connector Remove the complete throttle body Power supply RSV4 RR RF P SUPP 402 ...

Page 403: ...on possible before replacing the com ponent is checking the connectors and cable har nesses Installing the throttle body When installing the throttle body refer to the electrical system section for the correct cable routing Ensure that the injector connectors are correctly fastened Connect the control unit connector en suring that the security lock is in the locked position Stepper motor The contr...

Page 404: ...AR CARE DURING REASSEMBLY THE POSITIVE SIDE 1 OF THE CONNECTOR MUST MATCH WITH THE SIDE WHERE A NOTCH 2 IS INDICATED a variable geometry control unit for managing the system interfaced with the engine injection control unit Operation At key ON the variable geometry control unit lowers the ducts if still in the raised position Subsequently depending on the control voltage on PIN 2 from the injectio...

Page 405: ...ime 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 message is sent immediately to the engine injection ECU The variable geometry control unit does store errors RSV4 RR RF Power supply P SUPP 405 ...

Page 406: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 407: ...59 00 lb ft 2 Front brake disk fastening screws M8 6 6 30 Nm 22 13 lb ft Loct 243 Removing the front wheel Support the front part of the motorcycle Remove the front mudguard Unscrew the screws fixing the front pli ers and slide them off the disc See also Front mudguard RSV4 RR RF Suspensions SUSP 407 ...

Page 408: ...he holes on the pin Support the wheel while extracting the pin and then remove it Checking the front wheel FRONT WHEEL BEARINGS Check the bearings installed on the wheel CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR CHECKING ROTATION Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or bot...

Page 409: ...LWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE WHEEL AXLE Use a dial gauge to check the wheel axle eccentricity Replace the wheel axle if the eccentricity exceeds the limit value Characteristic Maximum eccentricity 0 25 mm 0 0098 in Using a dial gauge check that the ra dial A and the axial B eccentricities of the rim do not exceed the limit value An excessive eccentricity is usually caus...

Page 410: ...lb ft 2 Handlebar safety screw M6 1 1 10 Nm 7 38 lb ft 3 Anti vibration counterweight fastener M18x1 5 1 1 20 Nm 14 75 lb ft 4 Right hand light switch M4 2 1 5 Nm 1 11 lb ft 5 Left light switch M5 2 1 5 Nm 1 11 lb ft 6 Throttle control fixing screws M5 2 2 Nm 1 48 lb ft 7 Traction control unit fixing screw M4 1 2 5 Nm 1 84 lb ft Suspensions RSV4 RR RF SUSP 410 ...

Page 411: ...CLUTCH LEVER Pos Description Type Quantity Torque Notes 1 Clutch lever collar fastening screws M6 1 10 Nm 7 38 lb ft Front fork OHLINS FORKS RSV4 RR RF Suspensions SUSP 411 ...

Page 412: ...6 4 12 Nm 8 85 lb ft 2 Speed sensor fastening screw M5 1 6 Nm 4 43 lb ft 3 Upper cap 2 20 Nm 14 75 lb ft 4 Upper cap locking nut 2 20 Nm 14 75 lb ft Adjustment Standard front fork setting is adjusted to suit most high and low speed riding conditions whether the vehicle is partially or fully loaded However the setting can be modified for specific needs according to vehicle use RACING TRACK SETTINGS...

Page 413: ...on from top plate excluding cover 3 notches 12 mm 3 notches 0 47 in FRONT FORK RSV4 1000 RF RACING ADJUSTMENT RANGE OHLINS TRACK USE ONLY Specification Desc Quantity Rebound damping adjustment screw 1 Unscrew 6 clicks from fully closed Compression damping adjustment screw 2 Unscrew 4 clicks from fully closed Spring preloading nut 3 screw 10 turns from fully open Stems A protrusion from top plate e...

Page 414: ...RT FROM THE STIFFEST SETTING ADJUSTER SCREW TURNED FULLY CLOCKWISE Removing the fork legs Remove the front wheel Support the fork shaft and loosen the screws on the upper plate Loosen the screws on the semi han dlebars Loosen the screws on the lower plate Slide out the fork stanchion See also Removing the front wheel Draining oil PROCEDURE FOR OHLINS FORKS Suspensions RSV4 RR RF SUSP 414 ...

Page 415: ...imum spring preloading Unscrew the upper cap from the sleeve using a specific Öhlins tool Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring Unscrew the upper adjustment cap Remove the complete cap RSV4 RR RF Suspensions SUSP 415 ...

Page 416: ...ain ing ring Remove the pre loading spring Drain the fork oil into a specific con tainer taking care not to allow the pre load pipe and the hydraulic rebound damping brake adjustment pipe to es cape PROCEDURE FOR SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Suspensions RSV4 RR RF SUSP 416 ...

Page 417: ...mbly opera tions Operating on the upper screw unload the spring Loosen the cover without unscrewing it completely Place the fork vertically locking it in a vice by the specific tool Completely unscrew the plug Specific tooling AP8140149 Protection for assembly opera tions RSV4 RR RF Suspensions SUSP 417 ...

Page 418: ...g pipe compress the spring Insert a spanner in the lock nut of the cover Specific tooling 020888Y Clamp for pre load pipe Unscrew the cap and remove it Remove the spring preload pipe Remove the lock nut and the washer Suspensions RSV4 RR RF SUSP 418 ...

Page 419: ...INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE Disassembling the fork PROCEDURE FOR OHLINS FORKS Fix the fork again in a vice taking care not to damage the fork Remove the preload pipe Remove the wheel holder shaft 1 and the sleeve 2 RSV4 RR RF Suspensions SUSP 419 ...

Page 420: ...e oil seal 5 CAUTION PLACE A STRIP OF RUBBER ON THE EDGE OF THE SLEEVE TO PROTECT IT FROM DAMAGE WHEN REMOV ING THE OIL SEAL 5 Replace the following components with new ones shaft seal 5 anti dust seal 3 CAUTION PROCEED WITH EXTREME CAUTION IN ORDER TO PREVENT FOREIGN BODIES FROM EN TERING THE SLEEVE OR THE WHEEL HOLDER SHAFT DO NOT REUSE THE OIL THAT WAS DRAINED EARLIER Suspensions RSV4 RR RF SUS...

Page 421: ... Remove the spring guide support ring 2 Remove the spring guide 3 noting its direction of installation to ensure cor rect reassembly Remove the other spring guide snap ring 4 Remove the ring 5 and extract the rubber buffer 6 Remove the ring nut on which the threaded pipe is attached from the pumping member pin RSV4 RR RF Suspensions SUSP 421 ...

Page 422: ...e internal dipstick of the pumping member pin 1 and the washer 2 Operate repeatedly on the pumping member pin 3 so as to drain com pletely the oil from inside Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Suspensions RSV4 RR RF SUSP 422 ...

Page 423: ...g 1 the movable bushing 2 the ring 3 and the oil seal 4 from the stem Remove the lock seeger ring of the spring guide Remove the spring guide Using a hook spanner lock the pump ing member pin Remove the stem bottom screw Specific tooling 020889Y Wrench for locking pumping unit ring nut RSV4 RR RF Suspensions SUSP 423 ...

Page 424: ...AUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED SINCE ITS STRUCTURE WOULD BE WEAK ENED MAKING THE VEHICLE DANGEROUS TO USE Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Springs Check that the springs are in good condition Check that the length of the springs is within the specified tolerance range Replace the springs if the...

Page 425: ...ACES Replace the following components with new ones seal dust gaiter the two OR on the regulator PROCEDURE FOR SACHS FORKS Stem Check that the sliding surface is not scratched or scored Any scoring can be removed by sanding with damp sandpaper grain 1 If the scratches are deep replace the stem Using a dial gauge check than any bending of the stem is below the limit value If it is over the limit re...

Page 426: ...itions Check that the spring length is within the limit value Replace the spring if its length does not fall within the limit values SPRING MINIMUM LENGTH WHEN UNLOADED 265 mm 10 4 in Check that the following components are in good conditions upper bushing lower bushing plunger If there is evidence of excessive wear or damage replace the component concerned CAUTION REMOVE ANY IMPURITIES FROM THE B...

Page 427: ... the following components with new ones seal ring dust gaiter O Ring on the cap Reassembling the fork PROCEDURE FOR OHLINS FORKS Insert the guide bushing and the coun terspring RSV4 RR RF Suspensions SUSP 427 ...

Page 428: ...he internal milling allowing the spring guide retainer ring to be instal led against the support ring Insert the spring guide retainer ring 4 Insert the spring guide 3 Insert the spring guide retainer ring 1 Insert the spring guide support ring 2 noting the internal milling allowing the spring guide retainer ring to be instal led against the support ring Suspensions RSV4 RR RF SUSP 428 ...

Page 429: ... 1 in the order given dust gaiter 3 retainer ring 4 and oil seal 5 Fix the sleeve in a vice taking care not to damage the sleeve Insert the stanchion 1 into the sleeve 2 Fit the two half shells of the special tool on the wheel holder stanchion 1 be hind the oil seal 5 Grip the special tool and push the oil seal 5 into its seat on the sleeve 2 Remove the tool RSV4 RR RF Suspensions SUSP 429 ...

Page 430: ...E WITHOUT OBSTRUCTIONS Insert the pumping member pin unit CAUTION THE SHAFT MUST SLIDE FREELY WITHIN THE SLEEVE WITHOUT OBSTRUCTIONS PROCEDURE FOR SACHS FORKS NOTE THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit the dust gait...

Page 431: ...bushing Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling AP8140189 Tool for fitting oil seal for 43 mm 1 69 in diameter hole AP8140146 Weight Insert the retainer ring in its position RSV4 RR RF Suspensions SUSP 431 ...

Page 432: ... AP8140146 Weight Insert the pumping member pin in the stem Fill the forks with oil according to the indicated quantities Insert the spring CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRING AND ENSURE THAT THE PART WHERE THE SPI RAL IS MORE COMPRESSED IS FACING DOWNWARDS See also Filling oil Suspensions RSV4 RR RF SUSP 432 ...

Page 433: ...g Position the forks vertically Insert the base washer Insert the washer that will be supported on the spring Insert and hand tighten the nut on the pumping member pin Place the preload pipe Tighten the appropriate tool on the pumping member pin rod and keep it raised to allow inserting a wrench in the nut by compressing the spring Specific tooling 020890Y Support rod of pumping unit stan chion AP...

Page 434: ...leeve to the prescribed torque Filling oil PROCEDURE FOR OHLINS FORKS Place the sleeve in a vertical position Insert the pumping member pin unit and tighten to the specified torque with the Öhlins tool Insert the preload pipe Fill the forks with oil until the air bubbles trapped inside are forced out Suspensions RSV4 RR RF SUSP 434 ...

Page 435: ...SAME IN BOTH STANCHIONS Characteristic Fork oil 530 cc 0 12 Uk gal for each stanchion Insert the pre loading spring while maintaining the pin in the raised posi tion Insert the pre loading spring retaining ring 1 Insert the nut 2 While maintaining the spring com pressed tighten the nut as far as it will go Screw the complete cap into place on the plunger pin RSV4 RR RF Suspensions SUSP 435 ...

Page 436: ...some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS Specific tooling AP8140149 Protection for assembly operations Oil level 110 2 mm 4 33 0 08 in from edge of sleeve without ...

Page 437: ...S FREE IN BOTH DIREC TIONS 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...

Page 438: ... 76 lb ft 6 Screw fastening shock absorber to frame M6 1 10 Nm 7 38 lb ft Loctite 243 7 Screw fastening shock absorber to lower yoke M6 1 10 Nm 7 38 lb ft Loctite 243 8 Lower cover fixing screws M6 2 8 Nm 5 90 lb ft Adjusting play Place the vehicle so that the front wheel is off the ground Carry out a handlebar rotation test using a dynamometer at the hand grip external end The handlebar resistanc...

Page 439: ...olt on the headstock and retrieve the washer Loosen the screws fixing the fork stan chions to the upper yoke Working from both sides unscrew and remove the semi handlebar screws Remove the upper yoke RSV4 RR RF Suspensions SUSP 439 ...

Page 440: ... correctly Tighten the lower lock ring to a torque of 70 Nm 51 63 lb ft Steer repeatedly completely left and completely right to allow the bearings to settle Loosen the ring nut Retighten the lock ring to the prescri bed torque of 60 Nm 9 Nm 44 25 lb ft 6 64 lb ft Steer completely left and completely right and check that the steering ro Suspensions RSV4 RR RF SUSP 440 ...

Page 441: ...he lock ring Fit the counter lock ring hand tighten ing only To allow the tabs to be bent into the notches of the counter lock ring in 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 retaine...

Page 442: ... collar Unscrew and remove the upper dowel fastening the collar Remove the upper collar CAUTION ALWAYS CHANGE BOTH COLLARS UPPER AND LOW ER Upper and lower collars are not interchangeable To identify them check the number printed on them lower collar 0 49 mm 3 mm 0 30 in 1 86 in upper collar 0 49 mm 1 5 mm 0 30 in 0 93 in Suspensions RSV4 RR RF SUSP 442 ...

Page 443: ...it the bushing in its seat ensuring that the seal in the groove in the bushing remains in place Press the bushing into place with a rub ber mallet Tighten the dowel to the specified tor que Repeat the procedure for the lower bushing Fit the steering assembly and restore the correct steering bearing free play See also Adjusting play RSV4 RR RF Suspensions SUSP 443 ...

Page 444: ... sprocket on sprocket mount M10 5 55 Nm 40 57 lb ft 2 C Nuts fastening sprocket on sprocket mount M10 5 50 Nm 36 88 lb ft 3 Rear brake disc fastening screws M8 5 30 Nm 22 13 lb ft Loct 243 Removing the rear wheel Place the vehicle on its rear service stand Loosen and remove the nut on the wheel axle Retrieve the thrust washer and the left hand chain tensioner slider Suspensions RSV4 RR RF SUSP 444...

Page 445: ... wheel by freeing the disc from the brake calliper Parastrappi REMOVAL Remove the final transmission unit NOTE THE FLEXIBLE COUPLINGS REMAIN FITTED ON THEIR WHEEL REMOVAL Place the final transmission unit on a vice TO PROTECT THE CROWN GEAR INSTALL WOODEN OR ALUMINIUM PROTECTIONS ON THE VICE JAWS LOCK THE CROWN GEAR ONLY IN A VICE DO NOT LOCK ANY OTHER COMPONENT OF THE FINAL TRANSMISSION UNIT RSV4...

Page 446: ...pins Remove the sprocket 3 and the flange 4 FITTING Fit the sprocket 3 and the flange 4 on the crown gear Place the pins 1 with the corresponding DAX nuts 2 paying attention so the pins are directed towards the inside the machining on the flange CAUTION WITH EVERY REMOVAL REPLACE THE PINS AND NUTS WITH THE NEW COMPONENTS Suspensions RSV4 RR RF SUSP 446 ...

Page 447: ...Manually rotate the inner race of each bearing The race must turn smoothly without im pediment or noise If one or both bearings do not fall within the control parameters Replace both wheel bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE Check the radial and axial play Axial play minimal axial play is permitted Radial none If one or both bearings d...

Page 448: ...gs Replace the rim 2 if after replacing the bearings the value is not within the specified limit Characteristic Maximum radial and axial eccentricity 0 8 mm 0 031 in FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit ROTATION CHECK Remove the left spacer 3 Remove the right spacer 4 Manually rotate the inside ring of each bearing Rotation must be constant...

Page 449: ...er 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 NEW COMPONENTS FROM WEARING PREMATURELY THE REAR SPROCKET FRONT SPROCKET AND DRIVE CHAIN MUST ALWAYS BE REPLACED TOGETHER AS A SET REAR...

Page 450: ...aring 13 Specific tooling AP8140180 Bearing extractor Retrieve the inner spacer 12 On the left hand side of the wheel Use the extractor tool to remove the left hand bearing 16 Specific tooling AP8140180 Bearing extractor Clean the interior of the hub thoroughly CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION Suspensions RSV4 RR RF SUSP 450 ...

Page 451: ...P 17 IS FITTED ONLY ON THE FINAL DRIVE UNIT LEFT SIDE Remove the left bearing 18 with the specific extractor Collect the inside spacer 19 Remove the right bearing 20 with the specific extractor Retrieve the right hand spacer 21 Clean the inside of the hub thoroughly CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION Specific tooling AP8140180 Bearing extractor RSV4 RR RF Suspensions SUSP 45...

Page 452: ...ion damping by adjusting the thumbscrew with the knob 2 Spring preload by adjusting the ring nut 3 blocked in its seat by the lock ring nut 4 NOTE THE VEHICLE HAS A HEIGHT ADJUSTABLE SUSPENSION FOR USE ON THE TRACK PLEASE OBSERVE THE VALUES RECOMMENDED FOR USE ON THE ROAD TO CHANGE THE HEIGHT YOU MUST CONTACT AN Official Aprilia Dealer TO COUNT THE NUMBER OF RELEASES AND OR REVOLUTIONS OF ADJUSTME...

Page 453: ...RATION DO NOT LOOSEN THE SCREW 7 AND DO NOT TAMPER WITH THE SEAL UNDERNEATH AS NITROGEN MAY COME OUT RESULTING IN RISK OF ACCIDENTS SET SPRING PRE LOADING AND SHOCK ABSORBER REBOUND DAMPING ACCORDING TO THE VEHICLE USE CONDITIONS IF THE SPRING PRE LOADING IS INCREASED IT IS NECESSARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING CAUTION ALWAYS OBSERVE THE RECOMMENDE...

Page 454: ...d Compression adjustment knob 2 open 10 clicks from fully closed My2016 REAR SHOCK ABSORBER RSV4 1000 RF STANDARD ADJUSTMENT OHLINS FOR ROAD USE ONLY Specification Desc Quantity Shock absorber centre to centre distance A 312 mm 12 28 in preloaded Spring B length 149 mm 5 87 in Rebound adjustment ring nut 1 open 20 clicks from fully closed Compression adjustment knob 2 open 20 clicks from fully clo...

Page 455: ...m fully closed Compression adjustment knob 2 open 2 click from fully closed REAR SHOCK ABSORBER RSV4 1000 RR RACING ADJUSTMENT RANGE TRACK USE ONLY Specification Desc Quantity Shock absorber centre to centre distance A 314 mm 12 36 in preloaded Spring B length 144 mm 5 67 in Rebound adjustment ring nut 1 open 8 clicks from fully closed Compression adjustment knob 2 from completely closed open 1 2 ...

Page 456: ... 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 Linkages Suspensions RSV4 RR RF SUSP 456 ...

Page 457: ...om the opposite side Loosen and remove the nut 5 Slide off the screw 6 from the opposite side Remove the complete suspension connecting rod assembly unit CAUTION UPON REFITTING GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV ERAL TIMES THAT JOINTS MOVE SMOOTHLY RSV4 RR RF Suspensions SUSP 457 ...

Page 458: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 459: ...lb ft 8 RH upper rear coupling M10 1 50 Nm 36 88 lb ft 9 Right fairing spacer M6 1 10 Nm 7 37 lb ft Loct 243 10 Upper rear left hand engine mount fastener screws M8 3 25 Nm 18 44 lb ft 11 Upper rear mount M10 1 50 Nm 36 88 lb ft 12 Saddle mounting fixing screws M10 4 50 Nm 36 88 lb ft 13 Passenger saddle and saddle cover catch plate fixing screws M6 2 8 Nm 5 9 lb ft 14 Taillight mounting bracket f...

Page 460: ...rear fastening nut M6 1 7 Nm 5 16 lb ft 7 Chain feeder shoe fastening screws M5 2 2 Nm 1 48 lb ft 8 Chain tensioner fastener screw M8 2 Manual 9 Rear stand bushing fastening screws M6 2 7 Nm 5 16 lb ft Lower chain shoe fastening screws M6 2 10 Nm 7 38 lb ft Removing Remove the exhaust system Remove the rear mudguard Remove the rear shock absorber Remove the rear wheel Secure the rear part of the v...

Page 461: ...ion cover Unscrew and remove the screw and retrieve the washer Slide off the pinion from the chain and remove Unscrew and remove the nut and re trieve the washer Working from the right side loosen and remove the locking ring nut RSV4 RR RF Chassis CHAS 461 ...

Page 462: ...OM 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 completely from the ve hicle from the rear Remove the adjustment bushing from the swingarm pin 2 UPON REM...

Page 463: ... THE BEARINGS AFTER EVERY BEARING REMOVAL Specific tooling AP8140180 Bearing extractor Remove the inner spacer 7 and collect the two OR seals 8 Carefully clean inside the bearing seat CAUTION WASH ALL COMPONENTS WITH CLEAN DETERGENT SOLUTION UPON REFITTING USE A BUFFER WITH A DIAMETER EQUAL TO THE EXTERNAL RING OF THE BEARINGS TO INSERT THE BEARINGS DO NOT HIT THE BALLS AND OR THE INTERNAL RING CH...

Page 464: ...th swingarm bearings ALWAYS REPLACE BOTH BEARINGS ALWAYS REPLACE THE BEARINGS WITH COMPONENTS OF THE SAME TYPE SWINGARM SEALS Check that the gaskets are in good conditions replace them if they show signs of damage or excessive wear ALWAYS REPLACE BOTH SEALS TOGETHER ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE SWINGARM PIN Use a dial gauge to check the swing arm pin eccentricity If th...

Page 465: ...earing in mind that the arrow must face downward WARNING PAY PARTICULAR ATTENTION TO THE DIRECTION OF THE INSERTS WHEN REFITTING IN CORRECT ASSEMBLY MAY CAUSE SEVERE DAMAGE TO THE VEHICLE THE ARROW MUST FACE DOWNWARD Spread a thin layer of lubricating grease all along the swingarm pin Fit the adjustment bushing 3 to its seat and tighten it manually CAUTION THE ADJUSTMENT BUSHING 3 MUST NOT PROTRUD...

Page 466: ...y a few turns 1 Put some grease on the swingarm pin nut as indicated Fit and the washer and the swingarm pin fixing nut on the pin and hand tighten the nut Working from the right hand side of the vehicle turn the swingarm pin 2 clockwise This turns the adjustment bushing 3 driving the swingarm in until fully seated Tighten the locking ring nut 1 Chassis RSV4 RR RF CHAS 466 ...

Page 467: ... THE TRANSMISSION PINION Fit the pinion and the chain on the shaft CAUTION APPLY LOCTITE 243 ON THE SCREW THREAD Fit the washer on the screw Tighten the screw Install the rear shock absorber and the linkages Fit the rear brake calliper plate Fasten the two pipe grommets on the swingarm RSV4 RR RF Chassis CHAS 467 ...

Page 468: ...r nominal value 2 Chain with chain stretch of 1 5 3 Chain with chain stretch of 3 which must therefore be replaced in accordance with ap plicable legislation Perform the procedure described as follows to check chain wear Tauten the chain Place the jaws of the tool on the rollers at the opposite ends of a STRAIGHT length of chain consisting of 8 chain links Check that the notch on the sliding jaw m...

Page 469: ...st chain tension after the check Place the vehicle on its rear service stand OPT Loosen the nut 1 completely Loosen both lock nuts 4 Actuate on the adjuster screws 5 and adjust the chain clearance checking that the references 2 3 match on both sides of the vehicle Tighten both lock nuts 4 Tighten the nut 1 Check chain clearance CAUTION WHEEL CENTRING IS CARRIED OUT USING THE IDENTI FIABLE FIXED RE...

Page 470: ...SIDE BE EXTREMELY CAREFUL WHEN ADJUSTING LUBRICATING WASHING AND REPLACING THE CHAIN CLEANING AND LUBRICATION Do not wash the chain with water jets vapour jets high pressure water jets and highly flammable sol vents Wash the chain with naphtha or kerosene If it tends to rust quickly carry out the mainte nance operations more frequently Lubricate the chain at the intervals shown in the routine main...

Page 471: ...on Remove the rear wheel Unscrew and remove the upper screw fixing the chain slider and retrieve the washer See also Removing the rear wheel Unscrew and remove the lower screw fixing the chain pad and retrieve the washers Remove the chain skid 1 RSV4 RR RF Chassis CHAS 471 ...

Page 472: ... Screws for fastening the stand to the frame M10 2 45 Nm 33 19 lb ft Loct 243 2 Linear switch retainer M5 2 4 Nm 2 95 lb ft Rear stand bushing retaining screw M6 2 7 Nm 5 16 lb ft Side stand Remove the fuel tank Remove the pinion cover Chassis RSV4 RR RF CHAS 472 ...

Page 473: ... Remove the clamps Disconnect the stand connector Unscrew and remove the two screws Remove the side stand RSV4 RR RF Chassis CHAS 473 ...

Page 474: ...he silencer to the RH footrest support M8 1 25 Nm 18 44 lb ft 4 Cosmetic silencer shield fixing screw M5 3 5 Nm 3 69 lb ft 5 Lambda probe fastener M18x1 5 2 38 Nm 28 03 lb ft 6 Exhaust valve actuator fixing screws M6 2 10 Nm 7 38 lb ft Exhaust valve opening closure fixing nuts M6 2 5 Nm 3 69 lb ft Removing the tail pipe Loosen the sealing clamp between the exhaust and the central manifold Chassis ...

Page 475: ...he collar the washer and the nut DURING THIS OPERATION SUPPORT THE EXHAUST PIPE SO THAT IT DOES NOT FALL Remove the exhaust end Removing the catalytic converter Remove the exhaust end Remove the front exhaust manifold Remove the pinion crankcase Disconnect the lambda sensor con nector Release the oxygen sensor cable har ness from the clamps RSV4 RR RF Chassis CHAS 475 ...

Page 476: ... CAUTION ON REASSEMBLY POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET Release the springs between the rear exhaust manifolds and the catalytic converter Remove the catalytic converter Removing the exhaust manifold 2 IN 1 FRONT EXHAUST MANIFOLD Remove the front underfairings Remove the hand grip position sensor control unit Chassis RSV4 RR RF CHAS 476 ...

Page 477: ...istgrip 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 Remove the front exhaust manifold RSV4 RR RF Chassis CHAS 477 ...

Page 478: ...ifolds 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 Lower cowl Chassis RSV4 RR RF CHAS 478 ...

Page 479: ...e the two valve ac tuator motor screws Remove the valve actuator motor to gether with the heat shield Engine oil cooler RADIATORE OLIO Pos Descrizione Tipo Quantità Coppia Note 1 Screws fastening oil radiator to mounting bracket M6 1 7 Nm 5 16 lb ft RSV4 RR RF Chassis CHAS 479 ...

Page 480: ...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 RR RF CHAS 480 ...

Page 481: ... Unscrew and remove the lower radia tor retainer Remove the radiator draining com pletely of oil RSV4 RR RF Chassis CHAS 481 ...

Page 482: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 483: ...e ABS control unit pinout PIN 1 Blue Valve ground and ECU PIN 2 Orange CAN H line high speed PIN 3 White Front speed sensor input PIN 4 Red Brown Control unit positive live PIN 5 White Blue K serial line for Diagnosis PIN 9 Orange Red Battery for valve positive PIN 10 Blue Pump engine ground PIN 11 White Black CAN L line low speed RSV4 RR RF Braking system BRAK SYS 483 ...

Page 484: ...positive PIN 13 Yellow Brown Rear speed sensor positive PIN 14 Yellow Rear speed sensor input PIN 17 Blue Red ABS warning light PIN 18 Orange Green Battery for ABS pump engine positive Operating diagram Braking system RSV4 RR RF BRAK SYS 484 ...

Page 485: ...lliper 2 callipers 10 Front brake circuit intake solenoid valve normally open 11 Rear brake circuit intake solenoid valve normally open 12 Rear brake exhaust circuit solenoid valve normally closed 13 Rear front brake circuit low pressure accumulator 14 Front brake exhaust circuit solenoid valve normally closed 15 DC electric motor 16 Double circuit hydraulic pump ABS RSV4 RR RF Braking system BRAK...

Page 486: ...the rider starts braking as he would usually do B Pressure reduction coincides with the recognition of the dangerous situation wheel slippage exceeds the threshold the system closes the inlet valve 10 11 and opens the outlet valve 12 13 temporarily At this stage the rider cannot increase the pressure on the callipers 8 9 and the system reduces the pressure on the callipers partially Excess fluid t...

Page 487: ...icle A position sensor 3 on the tone wheel 2 forming an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly CAUTION WHEN THE ABS STARTS WORKING A PULSING IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN...

Page 488: ... THIS SYSTEM ABS enable disable Only at a motorcycle standstill with a long press of the mode button it is possible to access the menu a PRC Settings When ABS is selected shown in negative in ad dition to varying its level by short pressing it can be deactivated To do this position it to level one and press with a long pressure the button To reactivate it press with a short pressure the button CAU...

Page 489: ...f replacement or refitting of the front brake lines take care that the steel ends are correctly lodged in the respective seats on the radiator sup port Use clamps to secure any axial move ments of the hoses Reposition the front brake steel pipes in the conduit secure the pipes using clamps and observing the tolerances indicated in the figure Characteristic Pipe axial clearance 0 0 10 mm 0 0 39 in ...

Page 490: ...ith the diagnostics instrument on the ABS control unit and on the 7SM one Before returning the vehicle carry out a functional road test REPLACING ACTIVATING NEW ABS CONTROL UNIT In case of replacement of the ABS control unit ensure that the new one has caps on all four hydraulic connections and then proceed as follows Before disconnecting the electrical connections switch the key OFF After hydraul...

Page 491: ...le guide 3 Cable grommet 4 Cable grommet TABLE C ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure TABLE D ABS PIPES ROUTING 1 Delivery rear calliper 2 Input from the rear pump 3 Delivery front calliper 4 Input from the front pump 5 Medium clamp RSV4 RR RF Braking system BRAK SYS 491 ...

Page 492: ... other braking system without ABS The detection of malfunctions may require more or less time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist within a given time If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able to diagnose the ...

Page 493: ...reen pages ECU INFO screen page This screen shows general data regarding the con trol unit for example software type mapping con trol unit programming date PARAMETERS screen page This screen shows the parameters measured by the several sensors engine revs engine temper ature etc or values set by the control unit injec tion time ignition advance etc PARAMETERS P A D S characteristic Value example U...

Page 494: ...zes and saves the parameter and states values ERRORS screen page This display shows potential errors detected in the vehicle ATT or stored in the control unit MEM and it allows to check error clearing STO ERRORS P A D S characteristic Value example Units of measure ment Notes Comparison of front and rear wheel C1024 Excessive difference Rear wheel speed sensor electrical diagnosis C1031 Short circ...

Page 495: ...r supply voltage C1059 Configuration error C1089 CAN error U2921 Controller error CAN error U2922 Line failure busoff CAN error U2924 Failed reception from instrument panel CAN error U2925 Failed reception from injection ECU button U2926 Connect to the injection control unit diagnostics button U2927 Connect to the injection control unit diagnostics Inside error C1331 Pressure sensor failure Inside...

Page 496: ...ow the Ambient parameter error where provided Repeat the operation by selecting each error and showing the corresponding Ambient parameter error where provi ded Go to the page Report and then on Print and select the virtual PDF printer Braking system RSV4 RR RF BRAK SYS 496 ...

Page 497: ...ETTINGS screen page This screen is used to adjust some control unit pa rameters ADJUSTMENTS P A D S Navigator characteristic Value example Unit of measure ment Notes Coding Reset the vehicle code and it performs the self learning from CAN line to the key ON Diagnosis SPEED SENSOR ERRORS C1024 Comparison of front and rear wheel Excessive difference Error cause Wrong wheel or tone wheel sizes Troubl...

Page 498: ... the cable harness otherwise replace the sensor Shorted to positive Disconnect the sensor connector Check the battery supply insulation of the two PIN If there is no insulation restore the cable harness otherwise replace the sensor C1032 Rear wheel speed sensor functional diagnosis signal not valid Error cause Possible tone wheel fault due to deformations or dirt Troubleshooting Check the tone whe...

Page 499: ...due to deformations or dirt Troubleshooting Check the tone wheel is in good condition and that it is clean Check that the number of teeth on the tone wheel is correct Check the correct positioning of the tone wheel and the sensor Check the correct size of the tyre If all the above tested have a positive result replace the sensor VOLTAGE ERRORS C1058 Low power supply voltage C1059 High power supply...

Page 500: ...el probable CAN line contact Troubleshooting Check wiring continuity between ABS control unit PIN 2 and instrument panel PIN 26 Orange cable between ABS control unit PIN 11 and instrument panel PIN 27 White Black cable U2925 Failed reception from injection ECU Error cause Communication problem with the injection ECU probable CAN line contact Troubleshooting Check wiring continuity between ABS cont...

Page 501: ... with button closed the button must be opened Modulator Disconnect the ABS connector Disconnect and remove the brake pipes inserts from the ABS control unit Undo the fixing screw of the ABS con trol unit Disconnect the ABS control unit from its rear inserts Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever that couples the connect...

Page 502: ...e driving lever is not that shown in fig 1 the connector will not be prop erly coupled and the distance meas ured will be greater 12 mm approx 0 47 in In this case repeat the oper ation as described in the two previous points IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN SERTION Fit the protection casing Braking system RSV4 RR RF BRAK SYS 502 ...

Page 503: ... 1 AND OR THE TONE WHEEL 2 AND REPEAT THE CHECKS MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIM ITS TONE WHEELS 2 CLEANING It is important to check that all the tone wheels 2 are always clean Otherwise gently remove any possible dirt deposits with a cloth or metal brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 TONE WHEEL SENSOR REPLACEMENT Disconnec...

Page 504: ...r support plate re taining pin M12 1 50 Nm 36 88 lb ft Loct 243 3 Rear brake calliper fastening screw M5 2 25 Nm 18 44 lb ft 4 Brake pipe bracket fastening screw M5 1 4 Nm 2 95 lb ft Screw fastening brake pipe clamp M5 2 4 Nm 2 95 lb ft Screw fastening odometer sensor onto brake calliper mounting M6 1 12 Nm 8 85 lb ft Braking system RSV4 RR RF BRAK SYS 504 ...

Page 505: ...r FRONT BRAKE CALLIPER Pos Description Type Quantity Torque Notes 1 Front brake calliper fastening screws M10x1 25 2 2 50 Nm 36 88 lb ft Rear brake disc Removal Remove the rear wheel RSV4 RR RF Braking system BRAK SYS 505 ...

Page 506: ...rations must be carried out with the brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the minimum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Using a dial gauge check that the max imum oscillation of the disc does not exceed...

Page 507: ...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 less than the minimum value replace th...

Page 508: ...UTION THE FOLLOWING OPERATIONS REFER TO A SINGLE CALLIPER BUT APPLY TO BOTH Unscrew and remove the two screws 1 Slide off the disc from the front brake calliper Separate the brake calliper pistons Remove the pads from the brake cal liper Retrieve the clip AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEA...

Page 509: ... 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 POSITION...

Page 510: ...new pads and the vibration damping plates placing them so that the holes are aligned with the calliper holes UPON REFITTING MAKE SURE THE ARROWS ON THE VI BRATION DAMPING PLATES FACE THE DIRECTION OF ROTATION OF THE WHEEL CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Place the safety spring 3 Hold the centre of the safety spring 3 depressed and in...

Page 511: ...BRAKE FLUID IN THE RESERVOIR La procedura di spurgo può essere eseguita in modo tradizionale o con l uso di attrezzi specifici quali pompe a vuoto o simili E importante però procedere spurgando l impianto nell ordine che segue Pompa freno Pinza destra Pinza sinistra Pompa freno rifinitura Sotto è riportata la procedura di spurgo tradizionale CAUTION IN CASO DI SOSTITUZIONE DEL LIQUIDO FRENI PROCED...

Page 512: ... The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAUL IC SYSTEM ...

Page 513: ...ock the rear brake oil reservoir cap Refit the rubber protection cover Front brake pump FRONT BRAKE PUMP pos Description Type Quantity Torque Notes 1 Screw fastening front brake fluid res ervoir to bracket M6 1 7 Nm 5 16 lb ft 2 Screw fastening brake fluid reservoir mounting bracket to handlebar M6 1 7 Nm 5 16 lb ft 3 Front brake pump U bolt clamp M6 2 10 Nm 7 38 lb ft 4 Front brake lever pin fixi...

Page 514: ... 1 Rear brake rod lock nut M6 1 12 Nm 8 85 lb ft 2 Rear brake pump retaining screws M6 2 8 Nm 5 90 lb ft Loctite 243 3 Rear brake lever fixing pin M8 1 25 Nm 18 44 lb ft Loctite 243 Brake lever push rod fixing screw M6 1 8 Nm 5 90 lb ft Braking system RSV4 RR RF BRAK SYS 514 ...

Page 515: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 516: ...ram 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 Cooling system RSV4 RR RF COOL SYS 516 ...

Page 517: ...hex head screws for fasten ing the water radiator support brack et to the frame M6x20 2 10 Nm 7 38 lb ft 2 Flanged hex head screws for fasten ing the water radiator to the support bracket M6x20 2 7 Nm 5 16 lb ft 3 Screws for fastening the water by pass pipe tube gland M5 1 6 Nm 4 43 lb ft 4 Screws fastening electric fan to wa ter radiator M4 6 2 Nm 1 48 lb ft 5 Expansion tank support fixing screw ...

Page 518: ...m 7 38 lb ft Electric fan Remove the front underfairings and the hand grip position sensor Disconnect the cooling fan connector to be replaced Internally blocking the nuts unscrew the fixing screw from the internal part Make sure that the nuts and washers are retrieved See also Cooling system RSV4 RR RF COOL SYS 518 ...

Page 519: ...both fairings Place a container with a suitable ca pacity under the coolant pump Remove the radiator cap valve to help the fluid drain out Unscrew and remove the system drain screw and retrieve the sealing washer Wait for the entire circuit to drain en gine pipes radiator Refit the system drain screw complete with a new washer FILLING Via the filler orifice on the radiator fill with the quantity o...

Page 520: ...urn 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 replacemen...

Page 521: ...the coolant pump Unscrew and remove the two external pump cover fixing screws Unscrew and remove the inner screw Remove the pump cover TO PREVENT IRREPARABLE DAMAGE TO THE PUMP UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER RSV4 RR RF Cooling system COOL SYS 521 ...

Page 522: ...GE ORIFICES ARE NOT OBSTRUCTED Removing the radiator RADIATOR BRACKET REMOVAL Operating from the right side of the mo torcycle move the main cable harness and remove the screw fixing the radia tor to the retainer bracket Remove the two chassis bracket fixing screws Then remove the radiator retainer bracket Cooling system RSV4 RR RF COOL SYS 522 ...

Page 523: ...NT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF RADIATOR REMOVAL Drain off the cooling system Remove the front underfairings and the hand grip position sensor Disconnect both cooling fan connec tors Disconnect the expansion tank breath er pipe from the pipe grommet See also Coolant replacement Fairing mounting panels Twistgrip position sensor...

Page 524: ...ON CLAMP REMOVED PREVI OUSLY AS IT IS NO LONGER USABLE DO NOT REPLACE THE CLIP ON CLAMP REMOVED PRE VIOUSLY WITH A SCREW CLAMP OR ANY OTHER TYPE OF CLAMP Release the clamp fastening the deliv ery pipe to the radiator pipe UPON REFITTING REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE DO NOT REFIT THE CLIP ON CLAMP REMOVED PREVI OUSLY AS IT IS NO LONGER USABLE DO NOT REPLACE THE CLIP ON CLA...

Page 525: ... Remove the split pin From the opposite site remove the coolant radiator oil radiator connector pin Remove the radiator RSV4 RR RF Cooling system COOL SYS 525 ...

Page 526: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 527: ...s Description Type Quantity Torque Notes 1 Screw for fastening the front head light to the front mudguard SWP 4 9 4 2 Nm 1 48 lb ft 2 Headlamp fastener screw M5 x 12 1 2 Nm 1 48 lb ft RSV4 RR RF Bodywork BODYW 527 ...

Page 528: ... Instrument panel support shell fas tening screws SWP 4 9 5 2 Nm 1 48 lb ft 3 Screws used to fasten the instrument panel support to the chassis M6 4 8 Nm 5 90 lb ft TOP FAIRING pos Description Type Quantity Torque Notes 1 Windshield fixing screws M4 4 0 5 Nm 0 37 lb ft 2 Rear view mirror fixing nuts M6 2 2 10 Nm 7 38 lb ft Bodywork RSV4 RR RF BODYW 528 ...

Page 529: ...screws M5 2 4 Nm 2 95 lb ft 3 Screws fixing the side fairings to the side spacers M5 2 1 5 Nm 1 11 lb ft 4 Screws fastening the lower fairing to the lug M5 2 2 Nm 1 48 lb ft 5 Lower fairing lower fastening screws M5 2 2 Nm 1 48 lb ft 6 Centre screws fastening lower fairing M6 2 10 Nm 7 38 lb ft RSV4 RR RF Bodywork BODYW 529 ...

Page 530: ...bracket retaining screws M5 1 3 Nm 2 21 lb ft 7 Fastening screws tilting sensor M6x16 stainless steel 2 6 Nm 4 43 lb ft Central fuel tank cover retaining screw M4 1 0 5 Nm 0 37 lb ft Fuel tank breather couplings M7 2 3 Nm 2 21 lb ft Fuel return coupling M6 1 6 Nm 4 43 lb ft Loctite 243 Pump support to flange fastening M5 3 4 Nm 2 95 lb ft Lug to flange fastening M5 2 5 Nm 3 69 lb ft Petrol return ...

Page 531: ...COVER Pos Description Type Quantity Torque Notes 1 Screws fastening front tank to frame M6 1 8 Nm 5 90 lb ft 2 Screws fastening tank structural sup port to tank M6 4 3 Nm 2 21 lb ft RSV4 RR RF Bodywork BODYW 531 ...

Page 532: ... screws M5 2 3 Nm 2 21 lb ft 4 Taillight cover self tapping fixing screw SWP 3 9 1 0 5 Nm 0 37 lb ft Screws fastening license plate mounting to saddle mounting casting M6 3 4 Nm 2 95 lb ft CENTRAL BODYWORK Pos Description Type Quantity Torque Notes 1 Screws fastening fairing to tail fairing M5 2 1 Nm 0 74 lb ft 2 Screws fastening fairing to tank M5 2 2 2 Nm 1 48 lb ft Bodywork RSV4 RR RF BODYW 532...

Page 533: ...ng closure to the intake duct self tapping 2 1 Nm 0 74 lb ft Screws for securing the upper fairing closure to the front headlight self tapping 2 1 Nm 0 74 lb ft Screws for fastening the lower fairing to the bracket M5 2 2 1 Nm 0 74 lb ft Screws for fastening the lower fairing to the stanchion M5 2 2 Nm 1 47 lb ft Lower fairing fastening screws M5 2 2 Nm 1 47 lb ft Lower forks closure fastening scr...

Page 534: ...M5 4 2 Nm 1 48 lb ft 7 Lower saddle mounting fastener fix ing screws M5 5 3 Nm 2 21 lb ft 8 Screws for fastening license plate holder to saddle mounting plate M6 3 4 Nm 2 95 lb ft 9 Screws for fastening the rear number plate holder to the front number plate holder SWP 3 9 4 1 Nm 0 74 lb ft 10 Self tapping screws for fastening the rear number plate holder to the front number plate holder SWP 4 9 2 ...

Page 535: ...5 Nm 3 69 lb ft 2 Lock lever self tapping screw M4 1 2 Nm 1 48 lb ft 3 Shear head screw to the left of the ignition lock M8 1 Manual Tighten until the head shears off 4 Right hand ignition lock screw M8 1 20 Nm 14 75 lb ft 5 Passenger saddle fixing screws M6 2 8 Nm 5 90 lb ft RSV4 RR RF Bodywork BODYW 535 ...

Page 536: ... is mandatory to fit the passenger s footrests or for the two seater configu ration 3 Rider s heel guard retaining screws M6 2 2 8 Nm 5 90 lb ft 4 Passenger s heel guard retaining screws M6 2 2 8 Nm 5 90 lb ft 5 Anti creep pin M6 1 8 Nm 5 90 lb ft REAR MUDGUARD pos Description Type Quantity Torque Notes 1 Rear mudguard fixing screws M6 2 5 Nm 3 69 lb ft For plastic mud guard 1 Rear mudguard fixing...

Page 537: ...f the pin on the tank Driving mirrors The following procedure is for a single rear view mirror but is applicable to both mirrors Disconnect the turn indicator connector from the relative fixed connector on the instrument panel Unscrew and remove the two nuts supporting the rear view mirror RSV4 RR RF Bodywork BODYW 537 ...

Page 538: ...nel Remove the windshield Unscrew and remove the two screws Remove the instrument panel mount ing cover Move the instrument panel removing the rubber rings from the seats on the support Rotate the instrument panel connector retainer lever Remove the connector Remove the instrument panel NOTE Bodywork RSV4 RR RF BODYW 538 ...

Page 539: ...E THE LIMIT STOP IS REACHED Headlight assy Remove the top fairing complete Remove the side air deflectors from the top fairing Remove the four fixing screws 1 Remove the lower fixing screw 2 pay ing attention to collect the bush 3 Remove the headlight assembly com plete 4 Slide off the support 5 of the headlight from the top fairing RSV4 RR RF Bodywork BODYW 539 ...

Page 540: ...air deflector Remove the upper screw 2 fixing the top fairing to the air deflector Remove the central screw 3 fixing the top fairing to the support frame Remove the previously described screws also for the right side of the motorcycle Remove the three clips 4 under the top fairing which are fixing it to the central underfairing Bodywork RSV4 RR RF BODYW 540 ...

Page 541: ...t bulb connectors Disconnect the front headlamp con nectors 5 Remove the top fairing complete SIDE AIR DEFLECTOR COVERS To disassemble the side air deflector covers connected to the top fairing the lower screw 1 must be removed Remove the inner screw 2 RSV4 RR RF Bodywork BODYW 541 ...

Page 542: ...side of the top fairing to remove the side air deflector covers PLEXIGLAS Remove the four fixing screws paying attention to collect the Teflon washers Slide the plexiglas from the lower pins and remove it Taillight assy Carry out the tail fairing removal pro cedure Unscrew and remove the two screws 1 Bodywork RSV4 RR RF BODYW 542 ...

Page 543: ...connect the connector 4 Remove the taillight 5 Rider footrest plate LEFT RIDER FOOTREST REMOVAL GEAR BOX LEVER Remove the fuel tank Loosen the screw 1 and ease off the gear lever Remove the three fixing screws 2 of the pinion cover 3 RSV4 RR RF Bodywork BODYW 543 ...

Page 544: ... 6 that connect the wiring of the quick shift to the wiring of the side stand and of the lambda probe Disconnect the connector 7 of the quick shift and release the wiring Remove the two fixing screws 8 of the footrest complete with leverage Bodywork RSV4 RR RF BODYW 544 ...

Page 545: ... DOES NOT NEED TO BE DISCONNECTED FOR THIS OPERATION Side body panels Remove the rider saddle Working from the left side of the mo torcycle remove the three fixing screws of the side fairing Remove the side fairing To remove the right side fairing perform the previously described operations RSV4 RR RF Bodywork BODYW 545 ...

Page 546: ...he mo torcycle detaching the three clips 1 placed on the inner fairing Remove the four screws 2 Detach the inner fixing clip 3 with the air deflector Slide the side fairing paying attention to the fittings with the lug Bodywork RSV4 RR RF BODYW 546 ...

Page 547: ...ing mounting panels Previously remove the side fairings LATERAL UNDERFAIRINGS Working from the left side of the mo torcycle remove the clamp 1 locking the wiring of the connectors 2 of the alternator to the radiator Disconnect the connectors 2 of the alternator to the radiator Remove the lower fixing screw 3 of the left inner fairing RSV4 RR RF Bodywork BODYW 547 ...

Page 548: ...RFAIRING Remove the three clips 1 and the two screws 2 fixing the central underfair ing to the top fairing In case the side underfairing are not removed remove the internal screws 3 from both sides Ease off the central underfairing taking care not to damage the fittings with the lateral un derfairings and the top fairing Bodywork RSV4 RR RF BODYW 548 ...

Page 549: ...rry out the licence plate support re moval procedure Remove the tank Remove the battery Working from both sides of the motor cycle undo and remove the two screws 2 Working from both sides of the motor cycle undo and remove the two screws 3 Remove the two auxiliary fuse boxes 4 from the corresponding supports in dicated in the figure RSV4 RR RF Bodywork BODYW 549 ...

Page 550: ... Unscrew and remove the screw 5 Unhook the underfairing 6 from the point indicated in the figure Remove the underfairing 6 License plate holder Remove the plastic cover 1 Bodywork RSV4 RR RF BODYW 550 ...

Page 551: ...ews 2 together with the nuts 3 Disconnect the connector 4 Remove the support 5 Air box FILTER BOX COVER REMOVAL Remove the control unit complete with support Undo the four screws fixing the injec tors unit to the filter box Remove the injectors from the filter box RSV4 RR RF Bodywork BODYW 551 ...

Page 552: ...nnect the air temperature sensor connector Remove the screw fixing the wiring harness to the filter box and move it away Unscrew and remove the eight air filter box cover screws Bodywork RSV4 RR RF BODYW 552 ...

Page 553: ...emove the two clamps blocking the wiring harness to the filter box cover Remove the four screws fixing the var iable geometry intake system and re move it Remove the fixing screws of the intake duct supports RSV4 RR RF Bodywork BODYW 553 ...

Page 554: ...w and remove the air pressure sensors fixing screws Operating from both sides unscrew and remove the air pressure sensors fixing screws Operating from the left side of the mo torcycle remove the clamp blocking the main wiring harness to the filter box Bodywork RSV4 RR RF BODYW 554 ...

Page 555: ...nec tor previously placed on the filter box Release the cable harness from the cable grommet on the filter box Remove the filter box Rear mudguard Unscrew and remove the two screws Remove the rear mudguard RSV4 RR RF Bodywork BODYW 555 ...

Page 556: ...g from both sides remove the front fixing screws 1 Remove the lower fixing screw 2 holding the lug Remove the clip 3 and the two screws 4 to divide the lug Fuel tank Unscrew and remove the front screw fixing the tank Bodywork RSV4 RR RF BODYW 556 ...

Page 557: ... 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 RSV4 RR RF Bodywork BODYW 557 ...

Page 558: ...the clamp Remove the front mudguard Instrument 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 Bodywork RSV4 RR RF BODYW 558 ...

Page 559: ...the two semi 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 RSV4 RR RF Bodywork BODYW 559 ...

Page 560: ... 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 ...

Page 561: ...TO PLACE ONCE THE LIMIT STOP IS REACHED Radiator cover Remove the side fairings Remove the fairing lug Operating from both sides unscrew and remove the fixing screws Remove the radiator cover Tail guard Carry out the saddle removal proce dure Carry out the side fairing removal pro cedure Undo and remove the six fixing screws 1 RSV4 RR RF Bodywork BODYW 561 ...

Page 562: ...he two plastic inserts 2 from both sides of the motorcycle Unscrew and remove the screw 3 Unhook the saddle opening cable 4 from its seat Remove the left 5 and right 6 tail fairing Bodywork RSV4 RR RF BODYW 562 ...

Page 563: ...to both Remove the windshield Unscrew and remove the two fixing nuts Remove the duct from its seat on the frame CAUTION DURING REASSEMBLY THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS See also Headlight fairing RSV4 RR RF Bodywork BODYW 563 ...

Page 564: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 565: ... 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 light...

Page 566: ...Y COMES INTO CONTACT WITH YOUR EYES OR SKIN WASH WITH ABUN DANT WATER FOR APPROX 15 MIN AND SEEK IMMEDIATE MEDICAL ATTENTION IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHE...

Page 567: ...present Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NE...

Page 568: ...OPERATIONS REQUIRED TO RENDER VEHICLE COMPLIANT WITH TWO SEATER TYPE AP PROVAL Remove the screw 2 Remove the plastic cover 1 Fit the rear pedal in its seat Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm 13 27 lbf ft NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE Saddle replacement Pre delivery RSV4 RR RF PRE DE 568 ...

Page 569: ... the mirror check that the nut is closed properly as indicated by the arrow you should be able to see about 0 5 mm 1 mm 0 02 in 0 04 in of the threaded pin projecting from the nut and the Loctite 270 If the nut is not closed correctly proceed as fol lows Close the mirror base turned 90 in re lation to the mirror Remove the glass from the indicator light RSV4 RR RF Pre delivery PRE DE 569 ...

Page 570: ...en the nut so its upper surface is about 0 5 mm 0 02 in above the end of the threaded pin Put some Loctite 270 inside the nut Screw the nut back down until its upper surface is about 0 5 mm 1 mm 0 02 in 0 04 in away from the end of the pin Wait 24 hours for the Loctite to dry well before moving the mirror Pre delivery RSV4 RR RF PRE DE 570 ...

Page 571: ...ear view mirror Pass the wiring harness through the specific hole and place the rear view mirror in its seat Tighten the two fixing nuts of the rear view mirror Connect the connector RSV4 RR RF Pre delivery PRE DE 571 ...

Page 572: ... 468 470 Clutch 84 215 284 302 303 306 308 313 337 344 360 364 Coil 197 Connecting rods 368 373 382 Connectors 234 coolant 519 520 523 Coolant 519 520 523 Countershaft 360 362 366 371 Crankcase 358 366 370 384 Crankshaft 369 371 380 Cylinder 78 84 D Desmodromic drum 289 Diagnostics 493 Drive chain 13 468 E ECU 234 493 Electric fan 218 518 Electrical system 13 104 107 565 Engine oil 70 479 Engine t...

Page 573: ... Magneto flywheel 299 366 Maintenance 8 64 67 503 Maintenance Table 67 Mirrors 537 Mudguard 407 555 558 O Oil filter 74 Oil pressure sensor 212 Oil sump 366 393 One way valve 396 P Pistons 368 372 382 Primary shaft 289 R Radiator 522 561 Rear cylinder head valves 84 Rear head 336 343 346 347 353 366 368 Rear wheel 444 447 471 506 Recommended products 68 Ride by wire 400 Run Stop switch 221 S Saddl...

Page 574: ... 216 472 Start up 147 296 Starter motor 296 Steering damper 436 Stepper motor 403 T Tank 556 Throttle body 76 77 200 402 403 Top fairing Track 67 Transmission 12 363 366 Tyres 14 U Use 67 493 V Variable geometry intake 161 404 W Warning lights Water pump 366 388 520 Wiring diagram 135 ...

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Summary of Contents for RSV4 RF

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APRILIA RSV4 RF, Service Station Manual, Page: 381 / 574

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Summary of Contents for RSV4 RF

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