APRILIA RSV 1000 R Factory Manuale del Proprietario

www.serviceaprilia.comworkshopmanualRSV 1000 R - RSV 1000 R FACTORY 1137 300/2003-108140742USA

GENERAL INFORMATION1 - 3RSV 1000 R - RSV 1000 R FACTORY 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divi

ENGINE 4 - 6 RSV 1000 R - RSV 1000 R FACTORY• Disengage the throttle cables • Detach the throttle potentiometer connector • Remove the vacuum

ENGINE4 - 7RSV 1000 R - RSV 1000 R FACTORY • Disconnect the injector connectors • Loosen the clamps on the intake manifolds

ENGINE 4 - 8 RSV 1000 R - RSV 1000 R FACTORY• Remove the throttle body • Close the lines so that impurities are unable to enter the cylinders

ENGINE4 - 9RSV 1000 R - RSV 1000 R FACTORY • Detach the engine casing oil lines • Loosen the three screws securing the oil tank

ENGINE 4 - 10 RSV 1000 R - RSV 1000 R FACTORY• Remove the oil tank and extract the line coming from the cooler. • Remove the fairing air dam by

ENGINE4 - 11RSV 1000 R - RSV 1000 R FACTORY • Extract the bleed lines from their seat • Remove the oil line on the engine casing. • Undo the

ENGINE 4 - 12 RSV 1000 R - RSV 1000 R FACTORY• Release and remove the four screws securing the oil cooler’s subframe. IMPORTANT To remove the le

ENGINE4 - 13RSV 1000 R - RSV 1000 R FACTORY • Loosen the screws securing the rear brake pump • Undo the clip securing the pump to the brake leve

ENGINE 4 - 14 RSV 1000 R - RSV 1000 R FACTORY• Detach the engine oil pressure sensor connector • Detach the lambda sensor, stop light switch, sp

ENGINE4 - 15RSV 1000 R - RSV 1000 R FACTORY • Remove the lower cooler mounts and move it away while holding it in a vertical position. • Unscre

GENERAL INFORMATION 1 - 4 RSV 1000 R - RSV 1000 R FACTORY1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual

ENGINE 4 - 16 RSV 1000 R - RSV 1000 R FACTORY• Remove the silencers • Release the clip securing the front cylinder manifold to the exhaust •

ENGINE4 - 17RSV 1000 R - RSV 1000 R FACTORY • Keep the gasket • Undo the clip securing the rear manifold to the exhaust • Extract the lambda

ENGINE 4 - 18 RSV 1000 R - RSV 1000 R FACTORY• Undo the four nuts fixing the manifold to the rear cylin-der • Remove the exhaust manifold and k

ENGINE4 - 19RSV 1000 R - RSV 1000 R FACTORY • Detach the spark plug cap

ENGINE 4 - 20 RSV 1000 R - RSV 1000 R FACTORY • Remove the gearshift lever • Remove the clutch lever and flange

ENGINE4 - 21RSV 1000 R - RSV 1000 R FACTORY • Remove the pinion casing and guide plate on the en-gine casing • Undo the bolt securing the pin

ENGINE 4 - 22 RSV 1000 R - RSV 1000 R FACTORY• Open the clamps and remove the coolant lines on the radiator • Undo the engine casing ground

ENGINE4 - 23RSV 1000 R - RSV 1000 R FACTORY • Remove the rear brake lever • Remove the lever mount and rear brake pump • Remove the brake pump

ENGINE 4 - 24 RSV 1000 R - RSV 1000 R FACTORY• Loosen the screws mounting the engine to the frame at the rear • Loosen the four screws on the

ENGINE4 - 25RSV 1000 R - RSV 1000 R FACTORY • Slacken the adjuster bushings between the engine and the frame • Fully lower the engine

GENERAL INFORMATION1 - 5RSV 1000 R - RSV 1000 R FACTORY 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to per

ENGINE 4 - 26 RSV 1000 R - RSV 1000 R FACTORY4.1.2. REINSTALLING THE ENGINE • Place the engine on a suitable support • Partly raise the engine.

ENGINE4 - 27RSV 1000 R - RSV 1000 R FACTORY • Fit the two screws to the front left mount. • Locate the rear left spacer and tighten the screw to

ENGINE 4 - 28 RSV 1000 R - RSV 1000 R FACTORY• Fit the two screws to the front right mount. • Tighten down the four left side screws. • Tighten

ENGINE4 - 29RSV 1000 R - RSV 1000 R FACTORY • Tighten the lower right nut to the prescribed torque. • Fit the upper right screw. • Fit the lo

ENGINE 4 - 30 RSV 1000 R - RSV 1000 R FACTORY• Refit the pneumatic clutch actuator vacuum line and secure it with a clamp • Fit the rear brake l

ENGINE4 - 31RSV 1000 R - RSV 1000 R FACTORY • Fit the rear brake pump and connect it to the brake lever • Screw in the neutral sensor connector

ENGINE 4 - 32 RSV 1000 R - RSV 1000 R FACTORY• Fit the coolant lines to the radiator and secure them with clamps • Fit the pinion in the r

ENGINE4 - 33RSV 1000 R - RSV 1000 R FACTORY • Mount the pinion, tightening it to the specified torque • Fit the pinion casing and guide plate an

ENGINE 4 - 34 RSV 1000 R - RSV 1000 R FACTORY• Mount the gear shift lever • Fit the spark plug caps • Hook up the temperature sensor, timing

ENGINE4 - 35RSV 1000 R - RSV 1000 R FACTORY • Mount the rear cylinder exhaust manifold with its gas-ket

GENERAL INFORMATION 1 - 6 RSV 1000 R - RSV 1000 R FACTORYCOOLANT The coolant is composed of ethylene glycol that, under certain conditions, can beco

ENGINE 4 - 36 RSV 1000 R - RSV 1000 R FACTORY• Tighten the studbolt nuts to their specified torque • Fit the entire exhaust assembly complete wi

ENGINE4 - 37RSV 1000 R - RSV 1000 R FACTORY • Fit the manifold to the cylinder studbolts and exhaust • Tighten the four nuts securing the ma

ENGINE 4 - 38 RSV 1000 R - RSV 1000 R FACTORY• Refit the silencers • Screw on the silencer clamp screws • Clip on the silencer clips • Sc

ENGINE4 - 39RSV 1000 R - RSV 1000 R FACTORY • Move the cooler towards the engine and refit the lower mounts • Hook up the lambda sensor, stop li

ENGINE 4 - 40 RSV 1000 R - RSV 1000 R FACTORY • Connect up the engine oil pressure sensor connector • Fit the expansion tank and screw in the

ENGINE4 - 41RSV 1000 R - RSV 1000 R FACTORY • Engage the brake lever pump clip • Tighten the screws securing the rear brake pump • Fit the re

ENGINE 4 - 42 RSV 1000 R - RSV 1000 R FACTORY • Connect the oil hose from the right side. • Screw in the stud mounting the oil line clamp to t

ENGINE4 - 43RSV 1000 R - RSV 1000 R FACTORY • Insert the bleed lines in their seats. • Screw in the two screws securing the conveyor to the cool

ENGINE 4 - 44 RSV 1000 R - RSV 1000 R FACTORY • Fit the oil tank and the oil cooler line • Tighten down the three screws securing the oil tank

ENGINE4 - 45RSV 1000 R - RSV 1000 R FACTORY • Tighten the clamps on the lubrication circuit lines lead-ing to the oil tank • Remove the protect

GENERAL INFORMATION1 - 7RSV 1000 R - RSV 1000 R FACTORY DISASSEMBLING THE COMPONENTS - Never use pliers or similar tools to loosen and/or tighten n

ENGINE 4 - 46 RSV 1000 R - RSV 1000 R FACTORY• Hook the connectors to the injectors • Fit the vacuum lines to the throttle body

ENGINE4 - 47RSV 1000 R - RSV 1000 R FACTORY • Refit the throttle potentiometer connector • Fit the throttle control cables and adjust their p

ENGINE 4 - 48 RSV 1000 R - RSV 1000 R FACTORY• Fit the airbox • Tighten the six screws securing the airbox to the throt-tle body to the specifi

ENGINE4 - 49RSV 1000 R - RSV 1000 R FACTORY • Tighten the screw mounting the airbox to the frame at the front to the specified torque • Hook up

ENGINE 4 - 50 RSV 1000 R - RSV 1000 R FACTORY• Connect the stepper motor and bypass lines leading to the throttle body • Fit the airbox cover

ENGINE4 - 51RSV 1000 R - RSV 1000 R FACTORY 4.1.3. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESFront fitting 2+2 M10 36,87

CYCLE PARTS5 - 1RSV 1000 R - RSV 1000 R FACTORY CYCLE PARTS 5

CYCLE PARTS 5 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 5.1. BODY PANELS ...

CYCLE PARTS5 - 3RSV 1000 R - RSV 1000 R FACTORY 5.10. CLUTCH...

CYCLE PARTS 5 - 4 RSV 1000 R - RSV 1000 R FACTORY5.1. BODY PANELS 5.1.1. REMOVING THE BODY PANELS • Remove the screws securing the fairing to the

GENERAL INFORMATION 1 - 8 RSV 1000 R - RSV 1000 R FACTORY1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is

CYCLE PARTS5 - 5RSV 1000 R - RSV 1000 R FACTORY • Remove the upper front fairing panels by loosening the front fairing’s retaining screws • Det

CYCLE PARTS 5 - 6 RSV 1000 R - RSV 1000 R FACTORY• Remove the clips using a pair of pliers. • Partially extract the front fairing. • Detach t

CYCLE PARTS5 - 7RSV 1000 R - RSV 1000 R FACTORY • Undo the two screws securing the rider’s seat and lift it off • Unlock the passenger’s seat

CYCLE PARTS 5 - 8 RSV 1000 R - RSV 1000 R FACTORY• Extract the passenger’s seat from the belt and remove it • Undo the screw securing the belt a

CYCLE PARTS5 - 9RSV 1000 R - RSV 1000 R FACTORY • Undo the screws securing the side panels • Extract the side panels • Undo the screws secu

CYCLE PARTS 5 - 10 RSV 1000 R - RSV 1000 R FACTORY• Separate the tail from the tail light • Detach the direction indicator connectors • Remo

CYCLE PARTS5 - 11RSV 1000 R - RSV 1000 R FACTORY • Remove the screws and turn the tank over • Detach the bleed tubes • Detach the fuel delive

CYCLE PARTS 5 - 12 RSV 1000 R - RSV 1000 R FACTORY• Disconnect the fuel pump connector • Remove the rear tank retaining screw • Remove the

CYCLE PARTS5 - 13RSV 1000 R - RSV 1000 R FACTORY 5.1.2. BODY PANEL REASSEMBLY • Place the tank and its cabling on the frame. • Fit the rear ta

CYCLE PARTS 5 - 14 RSV 1000 R - RSV 1000 R FACTORY• Fit the fuel delivery and return lines • Connect the bleed lines and secure them with their

GENERAL INFORMATION1 - 9RSV 1000 R - RSV 1000 R FACTORY BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking syste

CYCLE PARTS5 - 15RSV 1000 R - RSV 1000 R FACTORY • Fit the tail • Connect the direction indicator connectors • Tighten the six screws securi

CYCLE PARTS 5 - 16 RSV 1000 R - RSV 1000 R FACTORY• Fit the side panels • Secure the side panels to the tank and the seat sub-frame • Conn

CYCLE PARTS5 - 17RSV 1000 R - RSV 1000 R FACTORY • Fit the spacers between the tail and the seat’s sub-frame • Fit the passenger’s belt and tigh

CYCLE PARTS 5 - 18 RSV 1000 R - RSV 1000 R FACTORY • Hook up the six lamp connectors • Fit the front fairing • Secure the clips

CYCLE PARTS5 - 19RSV 1000 R - RSV 1000 R FACTORY • Fit the rear view mirrors • Hook up the direction indicator connectors • Mount the front f

CYCLE PARTS 5 - 20 RSV 1000 R - RSV 1000 R FACTORY• With the aid of a screwdriver, secure the clips securing the fairing to the front fairing •

CYCLE PARTS5 - 21RSV 1000 R - RSV 1000 R FACTORY 5.1.3. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESFront fairing to air sc

CYCLE PARTS 5 - 22 RSV 1000 R - RSV 1000 R FACTORY5.2. FRONT FORK 5.2.1. DIAGRAM (RSV R)

CYCLE PARTS5 - 23RSV 1000 R - RSV 1000 R FACTORY Key: 1. Retainer ring 2. Spring preload adjuster 3. Spring preload pusher 4. Slider upper plug

CYCLE PARTS 5 - 24 RSV1000 R - RSV 1000 R FACTORY5.2.2. REMOVING THE FORK LEGS • Support the front part of the motorcycle. • Undo the screws s

GENERAL INFORMATION 1 - 10 RSV 1000 R - RSV 1000 R FACTORYCOOLANT DANGER Coolant is toxic when ingested; it is an irritant, contact with eyes or s

CYCLE PARTS5 - 25RSV 1000 R - RSV 1000 R FACTORY • Keep the seal washer • Slacken the screws on the wheel axle clamps • Lightly knock the whe

CYCLE PARTS 5 - 26 RSV1000 R - RSV 1000 R FACTORY• While removing the axle, support the wheel and then remove it • Slacken the screws securing t

CYCLE PARTS5 - 27RSV 1000 R - RSV 1000 R FACTORY • Extract the fork leg.

CYCLE PARTS 5 - 28 RSV 1000 R - RSV 1000 R FACTORY5.2.3. FITTING THE FORK LEGS • Insert the fork leg. • Adjust the slider resistance and tight

CYCLE PARTS5 - 29RSV 1000 R - RSV 1000 R FACTORY • Fit the wheel axle • Tighten down the clamp screws (nut side) to secure the wheel axle • F

CYCLE PARTS 5 - 30 RSV 1000 R - RSV 1000 R FACTORY• Tighten the screws securing the wheel axle clamps to the specified torque • Tighten the scre

CYCLE PARTS5 - 31RSV 1000 R - RSV 1000 R FACTORY 5.2.4. CHANGING THE FORK FLUID (RSV R) • Clamp the slider with the specified tool. • Set the

CYCLE PARTS 5 - 32 RSV 1000 R - RSV 1000 R FACTORY• Fit the special tool to the spring coupling • Push the tool downwards to compress the sprin

CYCLE PARTS5 - 33RSV 1000 R - RSV 1000 R FACTORY • Remove the spacer and the washer • Press downwards to compress the spring and extract the space

CYCLE PARTS 5 - 34 RSV 1000 R - RSV 1000 R FACTORY5.2.5. TOPPING UP THE FORK FLUID (RSV R) • Fill the fork so that any air inside it is vented •

GENERAL INFORMATION1 - 11RSV 1000 R - RSV 1000 R FACTORY TIRES WARNING If tires are excessively inflated, the vehicle will be hard and uneasy to r

CYCLE PARTS5 - 35RSV 1000 R - RSV 1000 R FACTORY • Screw the top cap on the cartridge leg • Clamp the slider in a vice using the special t

CYCLE PARTS 5 - 36 RSV 1000 R - RSV 1000 R FACTORY• Tighten the top cap to the specified torque

CYCLE PARTS5 - 37RSV 1000 R - RSV 1000 R FACTORY 5.2.6. REPLACING THE OIL/DUST SEAL (RSV R) • Clamp the slider with the specified tool. • Set

CYCLE PARTS 5 - 38 RSV 1000 R - RSV 1000 R FACTORY• Fit the special tool to the spring coupling • Push the tool downwards to compress the sprin

CYCLE PARTS5 - 39RSV 1000 R - RSV 1000 R FACTORY • Remove the spacer and the washer • Press downwards to compress the spring and extract the space

CYCLE PARTS 5 - 40 RSV 1000 R - RSV 1000 R FACTORY• Extract the washer and lower spacer • Undo the cartridge retainer screw on the fork end

CYCLE PARTS5 - 41RSV 1000 R - RSV 1000 R FACTORY • With a screwdriver, extract the wiper seal from the slider • Take care not to damage the rim o

CYCLE PARTS 5 - 42 RSV 1000 R - RSV 1000 R FACTORY • Remove the ring and wiper seal

CYCLE PARTS5 - 43RSV 1000 R - RSV 1000 R FACTORY

CYCLE PARTS 5 - 44 RSV 1000 R - RSV 1000 R FACTORY5.2.7. REFITTING THE OIL/DUST SEAL (RSV R) • Clamp the fork leg in such as way as not to damage

GENERAL INFORMATION 1 - 12 RSV 1000 R - RSV 1000 R FACTORY1.4. RUNNING-IN 1.4.1. RUNNING-IN RECOMMENDATIONS Running-in the engine is essential to en

CYCLE PARTS5 - 45RSV 1000 R - RSV 1000 R FACTORY • The seal ring must be installed with the stamped side facing the wiper seal • Now fit the rin

CYCLE PARTS 5 - 46 RSV 1000 R - RSV 1000 R FACTORY• Fit the slider to the stem and install the oil seal in its correct position with the special to

CYCLE PARTS5 - 47RSV 1000 R - RSV 1000 R FACTORY • Tighten the cartridge retainer screw on the fork end to the specified torque • Fit the lower

CYCLE PARTS 5 - 48 RSV 1000 R - RSV 1000 R FACTORY• Fill the fork so that any air inside it is vented • Fit the spring coupling • Fit the s

CYCLE PARTS5 - 49RSV 1000 R - RSV 1000 R FACTORY • Screw the top cap on the cartridge leg • Clamp the slider in a vice using the special t

CYCLE PARTS 5 - 50 RSV 1000 R - RSV 1000 R FACTORY• Tighten the top cap to the specified torque

CYCLE PARTS5 - 51RSV 1000 R - RSV 1000 R FACTORY 5.2.8. CHECKING THE COMPONENTS WHEEL-HOLDER TUBE Check the sliding surface, which must be neither

CYCLE PARTS 5 - 52 RSV 1000 R - RSV 1000 R FACTORY- pumping element. If excessive wear or any damage is noticed, change the component in question.

CYCLE PARTS5 - 53RSV 1000 R - RSV 1000 R FACTORY FORK RSV R Factory setting is designed for any riding condition, low or high speed, with reduced o

CYCLE PARTS 5 - 54 RSV 1000 R - RSV 1000 R FACTORY“R FACTORY” FORK (RSV R OPT) Factory setting is designed for racing. However, front suspension set

INTRODUCTION0 - 1RSV 1000 R - RSV 1000 R FACTORY INTRODUCTION 0

GENERAL INFORMATION1 - 13RSV 1000 R - RSV 1000 R FACTORY 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necess

CYCLE PARTS5 - 55RSV 1000 R - RSV 1000 R FACTORY 5.2.9. FRONT FORK DIAGRAM (RSV FACT) Key: 1. Complete RH fork leg 2. Complete LH fork leg 3. Top

CYCLE PARTS 5 - 56 RSV 1000 R - RSV 1000 R FACTORY5.2.10. CHANGING THE FORK FLUID (RSV FACT) NOTE The same internal components are used in both fo

CYCLE PARTS5 - 57RSV 1000 R - RSV 1000 R FACTORY • Remove the stanchion and slider assembly (5) from the vice. • Turn stanchion and slider over (5

CYCLE PARTS 5 - 58 RSV 1000 R - RSV 1000 R FACTORY5.2.11. TOPPING UP THE FORK FLUID (RSV FACT) NOTE Make sure to have the special tools A (no.8140

CYCLE PARTS5 - 59RSV 1000 R - RSV 1000 R FACTORY • Grasp the damping cylinder assembly (1) and pump it up and down a dozen of times to expel any ai

CYCLE PARTS 5 - 60 RSV 1000 R - RSV 1000 R FACTORY5.2.12. REPLACING THE OIL/DUST SEAL (RSV FACT) REMOVAL NOTE Make sure to have the special tools B

CYCLE PARTS5 - 61RSV 1000 R - RSV 1000 R FACTORY NOTE Protect the slider edge with a rubber strip to avoid denting during the oil seal’s removal (5)

CYCLE PARTS 5 - 62 RSV 1000 R - RSV 1000 R FACTORY• Insert the retaining ring (4) into its groove in the slider (2). • Push the dust seal (3) in

CYCLE PARTS5 - 63RSV 1000 R - RSV 1000 R FACTORY 5.2.13. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESFork leg on top yoke

CYCLE PARTS 5 - 64 RSV 1000 R - RSV 1000 R FACTORY5.3. STEERING BEARING 5.3.1. DIAGRAM

GENERAL INFORMATION 1 - 14 RSV 1000 R - RSV 1000 R FACTORYDIGIT MEANING 1. Manufacturer’s identification alphanumeric code. 2. Vehicle type. 3. Mode

CYCLE PARTS5 - 65RSV 1000 R - RSV 1000 R FACTORY Key: 1. Upper bush 2. Washer 3. Upper plate 4. Lock ring 5. Lock washer 6. Adjuster ring 7. Anti

CYCLE PARTS 5 - 66 RSV 1000 R - RSV 1000 R FACTORY5.3.2. CHECKING THE BEARING SLACK STEERING Steering bearings and steering clearance: • Position

CYCLE PARTS5 - 67RSV 1000 R - RSV 1000 R FACTORY 5.3.3. STEERING BEARING ADJUSTMENT • Undo the upper steering column bolt. • Slacken the screws

CYCLE PARTS 5 - 68 RSV 1000 R - RSV 1000 R FACTORY• Settle the safety washer on the steering column • Unscrew the upper ring nut and remove the

CYCLE PARTS5 - 69RSV 1000 R - RSV 1000 R FACTORY • Position the safety washer • Install the upper ring nut and tighten it so that the grooves fi

CYCLE PARTS 5 - 70 RSV 1000 R - RSV 1000 R FACTORY• Fit and tighten the upper steering column bolt to the specified torque • Tighten the screws

CYCLE PARTS5 - 71RSV 1000 R - RSV 1000 R FACTORY 5.3.4. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESFork leg on top yoke

CYCLE PARTS 5 - 72 RSV 1000 R - RSV 1000 R FACTORY5.4. REAR SUSPENSION 5.4.1. DIAGRAM Key: 1. Shock absorber 2. Double conrod 3. Needle bearing

CYCLE PARTS5 - 73RSV 1000 R - RSV 1000 R FACTORY 5.4.2. REMOVING THE REAR SUSPENSION • Support the rear end of the motorcycle • Undo the clips

CYCLE PARTS 5 - 74 RSV 1000 R - RSV 1000 R FACTORY• Remove the panel and extract the cable bundles • Undo the nuts on the double connecting rods

GENERAL INFORMATION1 - 15RSV 1000 R - RSV 1000 R FACTORY 1.6. POSITION OF THE WARNING ADHESIVE LABELS 1.6.1. POSITION OF THE WARNING ADHESIVE LA-B

CYCLE PARTS5 - 75RSV 1000 R - RSV 1000 R FACTORY • Undo the screws and remove the double connecting rods • Undo the screw on the rear suspens

CYCLE PARTS 5 - 76 RSV 1000 R - RSV 1000 R FACTORY

CYCLE PARTS5 - 77RSV 1000 R - RSV 1000 R FACTORY 5.4.3. CHECKING THE COMPONENTS CAUTION Make sure that none of the components ap-pear to be visib

CYCLE PARTS 5 - 78 RSV 1000 R - RSV 1000 R FACTORY CAUTION Racing settings may only be used during of-ficial competitions or sports events author-i

CYCLE PARTS5 - 79RSV 1000 R - RSV 1000 R FACTORY 5.4.4. REFITTING THE REAR SUSPENSION • Fit the rear suspension into its seat • Fit the upper s

CYCLE PARTS 5 - 80 RSV 1000 R - RSV 1000 R FACTORY• Install the remaining screws to the double connecting rod • Fit the left hand double connect

CYCLE PARTS5 - 81RSV 1000 R - RSV 1000 R FACTORY • Tighten the two screws securing the panel to the frame to the specified torque • Fit the clips

CYCLE PARTS 5 - 82 RSV 1000 R - RSV 1000 R FACTORY5.4.5. DISASSEMBLING THE REAR SUSPENSION LINKAGE • Working from the right-hand side of the vehic

CYCLE PARTS5 - 83RSV 1000 R - RSV 1000 R FACTORY 5.4.6. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESShock absorber to frame

CYCLE PARTS 5 - 84 RSV 1000 R - RSV 1000 R FACTORY5.5. SWINGING ARM 5.5.1. REMOVING THE SWINGING ARM • Position the vehicle on its center stand (O

GENERAL INFORMATION 1 - 16 RSV 1000 R - RSV 1000 R FACTORY3 4 5 6

CYCLE PARTS5 - 85RSV 1000 R - RSV 1000 R FACTORY • From the left side, release and remove the lower shock absorber nut. • Extract the screw from t

CYCLE PARTS 5 - 86 RSV 1000 R - RSV 1000 R FACTORY • Place a support beneath the front of the swinging arm. • Support the front of the swinging a

CYCLE PARTS5 - 87RSV 1000 R - RSV 1000 R FACTORY 5.5.2. CHECKING THE COMPONENTS CAUTION Make sure that all the components are intact, particularly

CYCLE PARTS 5 - 88 RSV 1000 R - RSV 1000 R FACTORY5.5.3. DISASSEMBLING THE REAR FORK GASKETS • Remove the fork. • Use a cloth to clean both sides

CYCLE PARTS5 - 89RSV 1000 R - RSV 1000 R FACTORY 5.5.4. REFITTING THE SWINGING ARM • Grease the entire length of the swinging arm spindle. • Fit

CYCLE PARTS 5 - 90 RSV 1000 R - RSV 1000 R FACTORYIMPORTANT Make sure to use the special tool (OPT): - Aprilia part# 8140191 (swinging arm spindle

CYCLE PARTS5 - 91RSV 1000 R - RSV 1000 R FACTORY • Working from the right side, fit the lower shock ab-sorber screw. • Tighten down the nut from t

CYCLE PARTS 5 - 92 RSV 1000 R - RSV 1000 R FACTORY5.5.5. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESShock absorber to f

CYCLE PARTS5 - 93RSV 1000 R - RSV 1000 R FACTORY 5.6. FRONT WHEEL 5.6.1. DIAGRAM Key: 1. Wheel pin 2. Nut 3. Seal 4. Bearing 5. Inner spacer 6.

CYCLE PARTS 5 - 94 RSV 1000 R - RSV 1000 R FACTORY5.6.2. REMOVING THE WHEEL • Support the front part of the motorcycle. • Undo the screws secu

GENERAL INFORMATION1 - 17RSV 1000 R - RSV 1000 R FACTORY 7 8 9 10

CYCLE PARTS5 - 95RSV 1000 R - RSV 1000 R FACTORY • Keep the seal washer • Slacken the screws on the wheel axle clamps • Lightly knock the whe

CYCLE PARTS 5 - 96 RSV 1000 R - RSV 1000 R FACTORY• While removing the axle, support the wheel and then remove it

CYCLE PARTS5 - 97RSV 1000 R - RSV 1000 R FACTORY 5.6.3. CHECKING THE FRONT WHEEL COMPONENTS CAUTION Make sure that all the components are intact

CYCLE PARTS 5 - 98 RSV 1000 R - RSV 1000 R FACTORYFRONT WHEEL RIM • Using a comparator, make sure that the radial (A) and axial (B) eccentricity of

CYCLE PARTS5 - 99RSV 1000 R - RSV 1000 R FACTORY 5.6.4. DISASSEMBLING THE FRONT WHEEL BEAR-INGS • Remove the front wheel. • Use a cloth to clean

CYCLE PARTS 5 - 100 RSV 1000 R - RSV 1000 R FACTORY5.6.5. ASSEMBLING THE FRONT WHEEL BEARINGS If provided: • remove the front wheel bearings. Wor

CYCLE PARTS5 - 101RSV 1000 R - RSV 1000 R FACTORY

CYCLE PARTS 5 - 102 RSV 1000 R - RSV 1000 R FACTORY5.6.6. REFITTING THE FRONT WHEEL • Fit the front wheel • Fit the wheel axle • Tighten dow

CYCLE PARTS5 - 103RSV 1000 R - RSV 1000 R FACTORY • Tighten the screws securing the wheel axle clamps to the specified torque • Tighten the s

CYCLE PARTS 5 - 104 RSV 1000 R - RSV 1000 R FACTORY5.7. REAR WHEEL 5.7.1. DIAGRAM Key: 1. Nut 2. Washer 3. Side spacers 4. Left chain tightener

GENERAL INFORMATION 1 - 18 RSV 1000 R - RSV 1000 R FACTORY11 12 13 14

CYCLE PARTS5 - 105RSV 1000 R - RSV 1000 R FACTORY 5.7.2. REMOVING THE REAR WHEEL • Support the motorcycle on the rear stand • Slacken and remov

CYCLE PARTS 5 - 106 RSV 1000 R - RSV 1000 R FACTORY• Lightly knock on the wheel axle so that its head thrusts forth from its seat • Move the whe

CYCLE PARTS5 - 107RSV 1000 R - RSV 1000 R FACTORY 5.7.3. REMOVING THE FINAL DRIVE UNIT • Remove the rear wheel. CAUTION Proceed with care. If th

CYCLE PARTS 5 - 108 RSV 1000 R - RSV 1000 R FACTORY

CYCLE PARTS5 - 109RSV 1000 R - RSV 1000 R FACTORY 5.7.4. CHECKING THE REAR WHEEL COMPONENTS CAUTION Make sure that all the components are intact,

CYCLE PARTS 5 - 110 RSV 1000 R - RSV 1000 R FACTORYREAR WHEEL PIN • Using a comparator, check the eccentricity of the pin wheel (1). If the eccent

CYCLE PARTS5 - 111RSV 1000 R - RSV 1000 R FACTORY FINAL DRIVE UNIT BEARINGS • Carry out the check with the bearings mounted on the final drive unit

CYCLE PARTS 5 - 112 RSV 1000 R - RSV 1000 R FACTORYFLEXIBLE COUPLINGS • Make sure the rubber elements (5) of the flexible cou-plings are not damage

CYCLE PARTS5 - 113RSV 1000 R - RSV 1000 R FACTORY 5.7.5. DISASSEMBLING THE REAR WHEEL BEAR-INGS • Remove the rear wheel. • Use a cloth to clean b

CYCLE PARTS 5 - 114 RSV 1000 R - RSV 1000 R FACTORY5.7.6. ASSEMBLING THE REAR WHEEL BEARINGS If provided: • Remove the rear wheel bearings. Work

GENERAL INFORMATION1 - 19RSV 1000 R - RSV 1000 R FACTORY 14a 15 Muffler stamping

CYCLE PARTS5 - 115RSV 1000 R - RSV 1000 R FACTORY

CYCLE PARTS 5 - 116 RSV 1000 R - RSV 1000 R FACTORY5.7.7. DISASSEMBLING THE FINAL DRIVE UNIT BEARINGS • Remove the final drive unit. • Use a cloth

CYCLE PARTS5 - 117RSV 1000 R - RSV 1000 R FACTORY 5.7.8. ASSEMBLING THE FINAL DRIVE UNIT BEAR-INGS If provided: • Remove the final drive unit bear

CYCLE PARTS 5 - 118 RSV 1000 R - RSV 1000 R FACTORY5.7.9. REMOVING THE FLEXIBLE COUPLINGS • Remove the final drive unit. NOTE The flexible coupling

CYCLE PARTS5 - 119RSV 1000 R - RSV 1000 R FACTORY 5.7.10. REMOVING THE CROWN GEAR • Working on the appropriate seat (1) with an hexagon wrench, lo

CYCLE PARTS 5 - 120 RSV 1000 R - RSV 1000 R FACTORY5.7.11. REFITTING THE REAR WHEEL • Fit the wheel axle together with right hand chain guide sho

CYCLE PARTS5 - 121RSV 1000 R - RSV 1000 R FACTORY • Tighten the nut hand tight • Check the chain tension • Tighten the nut to the specified

CYCLE PARTS 5 - 122 RSV 1000 R - RSV 1000 R FACTORY5.7.12. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESSprocket / Sprocket

CYCLE PARTS5 - 123RSV 1000 R - RSV 1000 R FACTORY 5.8. FRONT BRAKE 5.8.1. CHANGING THE FRONT BRAKE PADS (RSV R) WARNING This vehicle is equippe

CYCLE PARTS 5 - 124 RSV 1000 R - RSV 1000 R FACTORY5.8.2. CHANGING THE FRONT BRAKE PADS (RSV FACT) TORQUE WRENCH SETTINGS Brake caliper bolts (1)

GENERAL INFORMATION 1 - 20 RSV 1000 R - RSV 1000 R FACTORY1 2 3 4

CYCLE PARTS5 - 125RSV 1000 R - RSV 1000 R FACTORY WARNING The four brake pads must always be replaced to-gether. Ensure they become properly seated

CYCLE PARTS 5 - 126 RSV 1000 R - RSV 1000 R FACTORY5.8.3. CHECKING THE FRONT BRAKE DISCS Brake discs: NOTE These operations must be performed with

CYCLE PARTS5 - 127RSV 1000 R - RSV 1000 R FACTORY 5.8.4. REMOVING THE FRONT BRAKE DISCS • Remove the front wheel. NOTE The following procedure ref

CYCLE PARTS 5 - 128 RSV 1000 R - RSV 1000 R FACTORY5.8.5. BLEEDING THE BRAKE CIRCUIT • Connect the hose to the brake pump bleed nipple. • Opera

CYCLE PARTS5 - 129RSV 1000 R - RSV 1000 R FACTORY 5.9. REAR BRAKE 5.9.1. CHANGING THE REAR BRAKE PADS • Position the vehicle on the stand.· • Rem

CYCLE PARTS 5 - 130 RSV 1000 R - RSV 1000 R FACTORY5.9.2. CHECKING THE REAR BRAKE DISC NOTE These operations must be performed with the brake disc

CYCLE PARTS5 - 131RSV 1000 R - RSV 1000 R FACTORY 5.9.3. REMOVING THE REAR BRAKE DISC • Remove the rear wheel. NOTE To unscrew the screws (1), it

CYCLE PARTS 5 - 132 RSV 1000 R - RSV 1000 R FACTORY5.10. CLUTCH 5.10.1. BLEEDING THE CLUTCH CIRCUIT • Connect the hose to the clutch pump bleed ni

CYCLE PARTS5 - 133RSV 1000 R - RSV 1000 R FACTORY 5.11. DRIVE CHAIN 5.11.1. DRIVE CHAIN The vehicle is fitted with an endless chain that has no mast

CYCLE PARTS 5 - 134 RSV 1000 R - RSV 1000 R FACTORYCHECKING CHAIN AND SPROCKETS FOR WEAR Check the following parts every 10000 Km (6250 mi). Visuall

GENERAL INFORMATION1 - 21RSV 1000 R - RSV 1000 R FACTORY 5 6 7 8

CYCLE PARTS5 - 135RSV 1000 R - RSV 1000 R FACTORY 5.11.2. INSPECTING THE DRIVING CHAIN SHOE • Position the vehicle on the stand. • Make sure the s

CYCLE PARTS 5 - 136 RSV 1000 R - RSV 1000 R FACTORY5.11.3. REMOVING THE CHAIN SHOE • Position the vehicle on its rear stand (OPT). • Release and

CYCLE PARTS5 - 137RSV 1000 R - RSV 1000 R FACTORY • Loosen and remove the lower chain shoe screw and collect its washer. • Pull the lower part o

CYCLE PARTS 5 - 138 RSV 1000 R - RSV 1000 R FACTORY5.11.4. LOWER CHAIN SHOE IMPORTANT The shoe must be disassembled to check its wear. • Release a

COOLING SYSTEM6-1RSV 1000 R - RSV 1000 R FACTORY COOLING SYSTEM 6

COOLING SYSTEM 6 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 6.1. COOLING SYSTEM ...

COOLING SYSTEM6 - 3RSV 1000 R - RSV 1000 R FACTORY 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: 1. Radiator 2. Fans 3. Expansion reservoir 4. Filler

COOLING SYSTEM 6 - 4 RSV 1000 R - RSV 1000 R FACTORY6.1.2. FILLING THE COOLING SYSTEM • Filling the cooling system requires around 0.58 gal (2.2 l

COOLING SYSTEM6 - 5RSV 1000 R - RSV 1000 R FACTORY • Tighten down the filler cap and the expansion reservoir cap. • If fluid does not issue from t

ELECTRICAL SYSTEM7-1RSV 1000 R - RSV 1000 R FACTORY ELECTRICAL SYSTEM 7

GENERAL INFORMATION 1 - 22 RSV 1000 R - RSV 1000 R FACTORY9 10 11 12

ELECTRICAL SYSTEM 7 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 7.1. ELECTRICAL SYSTEM...

ELECTRICAL SYSTEM7 - 3RSV 1000 R - RSV 1000 R FACTORY 7.1. ELECTRICAL SYSTEM 7.1.1. COMPONENT LOCATION

ELECTRICAL SYSTEM 7 - 4 RSV 1000 R - RSV 1000 R FACTORYKey: 1. Engine speed sensor 2. Sensor 3. Camshaft sensor 4. Coolant temperature sensor 5

ELECTRICAL SYSTEM7 - 5RSV 1000 R - RSV 1000 R FACTORY 7.1.2. ELECTRICAL EQUIPMENT CHECK TABLE

ELECTRICAL SYSTEM 7 - 6 RSV 1000 R - RSV 1000 R FACTORY1 ENGINE SPEED SENSOR inductive sensor winding resistance 1 KΩ (across pins 1 and 2) output

ELECTRICAL SYSTEM7 - 7RSV 1000 R - RSV 1000 R FACTORY 5 INTAKE AIR TEMPERATURE SENSOR NTC sensor resistance 1.9 KΩ (at 68°F) 6 FALL SENSOR resist

ELECTRICAL SYSTEM 7 - 8 RSV 1000 R - RSV 1000 R FACTORY9 IGNITION COIL primary resistance 0.4-0.5 Ω 10 THROTTLE POTENTIOMETER (TPS) resistance 4.

ELECTRICAL SYSTEM7 - 9RSV 1000 R - RSV 1000 R FACTORY 13 INTAKE FLAP winding resistance 30 Ω 14 STEPPER phase resistance 50 Ω 15 GENERATOR thre

ELECTRICAL SYSTEM 7 - 10 RSV 1000 R - RSV 1000 R FACTORY17 FUEL PUMP absorption 3.9 A 18 FUEL RESERVE SENSOR The vehicle does not have a fuel ga

ELECTRICAL SYSTEM7 - 11RSV 1000 R - RSV 1000 R FACTORY 19 ECU ECU pinout Connector A Pin Description Signal type 1 Rear cylinder coil control P

INTRODUCTION 0 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 0.1. INTRODUCTION ...

GENERAL INFORMATION1 - 23RSV 1000 R - RSV 1000 R FACTORY 13 14 15 15a

ELECTRICAL SYSTEM 7 - 12 RSV 1000 R - RSV 1000 R FACTORYConnector B Pin Description Signal type 1 ECU power (ground) Power 2 ECU power (ground)

ELECTRICAL SYSTEM7 - 13RSV 1000 R - RSV 1000 R FACTORY 21 TAIL LIGHT Number plate light 12 V – 5W 22 SECONDARY FUSES A – From key to: lights re

ELECTRICAL SYSTEM 7 - 14 RSV 1000 R - RSV 1000 R FACTORY7.1.3. CAN LINE A CAN (Controller Area Network) line is a connection be-tween the vehicle’s

ELECTRICAL SYSTEM7 - 15RSV 1000 R - RSV 1000 R FACTORY STARTING Before it starts the engine, the ECU waits for permission from the dashboard over t

ELECTRICAL SYSTEM 7 - 16 RSV 1000 R - RSV 1000 R FACTORY7.1.4. IMMOBILIZER IMMOBILIZER The vehicle is equipped with an immobilizer that stops the en

ELECTRICAL SYSTEM7 - 17RSV 1000 R - RSV 1000 R FACTORY ADDITIONAL KEY STORE PROCEDURE The immobilizer system can recognize up to 4 keys. The storag

ELECTRICAL SYSTEM 7 - 18 RSV 1000 R - RSV 1000 R FACTORY7.1.5. WIRING DIAGRAM

ELECTRICAL SYSTEM7 - 19RSV 1000 R - RSV 1000 R FACTORY 1. Multiple connectors 2. Fall sensor 3. High beam relay 4. Low beam relay 5. Horn 6. Clutch

aprilia s.p.a.via G.Galilei, 130033 Noale (VE) Italytel. +39 041.5829111fax +39 041.5829190www.serviceaprilia.comwww.aprilia.com

GENERAL INFORMATION 1 - 24 RSV 1000 R - RSV 1000 R FACTORY16 Muffler stamping

GENERAL INFORMATION1 - 25RSV 1000 R - RSV 1000 R FACTORY 1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM FOR STATE OF CALIFORNIA ONLY. 1. The sys

GENERAL TECHNICAL INFORMATION2-1RSV 1000 R - RSV 1000 R FACTORY GENERAL TECHNICAL INFORMATION 2

GENERAL TECHNICAL INFORMATION 2 - 2 RSV 1000 R - RSV 1000 R FACTORYSUMMARY 2.1. GENERAL TECHNICAL INFORMATION ...

GENERAL TECHNICAL INFORMATION2 - 3RSV 1000 R - RSV 1000 R FACTORY 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max. length

GENERAL TECHNICAL INFORMATION 2 - 4 RSV 1000 R - RSV 1000 R FACTORY FRAME Type Two-beam frame with light alloy cast elements and extruded elements

GENERAL TECHNICAL INFORMATION2 - 5RSV 1000 R - RSV 1000 R FACTORY TIRES Pressure kPa (bar) # $ Wheel Make Model Type Size Recom-mended Altern

GENERAL TECHNICAL INFORMATION 2 - 6 RSV 1000 R - RSV 1000 R FACTORY SPARK PLUGS Standard NGK R DCPR9E Electrode gap 0.024– 0.028 in (0,6 – 0,7 mm

GENERAL TECHNICAL INFORMATION2 - 7RSV 1000 R - RSV 1000 R FACTORY 2.1.2. PERIODIC MAINTENANCE CHART OPERATIONS TO BE CARRIED OUT BY THE Aprilia Offi

INTRODUCTION0 - 3RSV 1000 R - RSV 1000 R FACTORY 0.1. INTRODUCTION 0.1.1. INTRODUCTION - This manual provides the information required for normal s

GENERAL TECHNICAL INFORMATION 2 - 8 RSV 1000 R - RSV 1000 R FACTORYOPERATIONS TO BE CARRIED OUT BY THE Aprilia Official Dealer. Key 1 = check an

GENERAL TECHNICAL INFORMATION2 - 9RSV 1000 R - RSV 1000 R FACTORY 2.1.3. TABLE OF LUBRICANTS LUBRICANT PRODUCT Engine oil RECOMMENDED: EXTRA RAI

GENERAL TECHNICAL INFORMATION 2 - 10 RSV 1000 R - RSV 1000 R FACTORY2.1.4. TIGHTENING TORQUES DESCRIPTIONQUANTITYSCREW / NUTTORQUE (ftlb)NOTESFron

GENERAL TECHNICAL INFORMATION2 - 11RSV 1000 R - RSV 1000 R FACTORY Fork leg on top yoke 1+1 M8 18,439 -Fork leg on bottom yoke 2+2 M8 18,439 -He

GENERAL TECHNICAL INFORMATION 2 - 12 RSV 1000 R - RSV 1000 R FACTORY Fan support 2+2 M6 4,425 -Expansion reservoir to frame 2 M6 3,688 -Expansion r

GENERAL TECHNICAL INFORMATION2 - 13RSV 1000 R - RSV 1000 R FACTORY Oil reservoir ( nuts ) 3 M6 7,376 -Oil filter shank 1 M20x1,5 22,127 -Oil drain

GENERAL TECHNICAL INFORMATION 2 - 14 RSV 1000 R - RSV 1000 R FACTORY2.1.5. SPECIAL TOOLS In order to perform assembly, reassembly and settings corre

GENERAL TECHNICAL INFORMATION2 - 15RSV 1000 R - RSV 1000 R FACTORY FRAME TOOLS Pos. Aprilia part# (tool description and function) A 8140203 (

GENERAL TECHNICAL INFORMATION 2 - 16 RSV 1000 R - RSV 1000 R FACTORYENGINE TOOLS

GENERAL TECHNICAL INFORMATION2 - 17RSV 1000 R - RSV 1000 R FACTORY Pos. Aprilia part# (tool description and function) A 8140175 (complete tool kit

INTRODUCTION 0 - 4 RSV 1000 R - RSV 1000 R FACTORY0.1.2. REFERENCE MANUALS PARTS CATALOGUES Aprilia part# (description) 3974 SPECIAL TOOL

GENERAL TECHNICAL INFORMATION 2 - 18 RSV 1000 R - RSV 1000 R FACTORY MISCELLANEOUS TOOLS

GENERAL TECHNICAL INFORMATION2 - 19RSV 1000 R - RSV 1000 R FACTORY Pos. Aprilia part# (tool description and function) 1 8140196 [Plurigas (Italian)

GENERAL TECHNICAL INFORMATION 2 - 20 RSV 1000 R - RSV 1000 R FACTORY TOOLS USED FOR OTHER Aprilia Pos. Aprilia part# (tool description and funct

GENERAL TECHNICAL INFORMATION2 - 21RSV 1000 R - RSV 1000 R FACTORY 2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS KEY RSV R 1. Left side fairing 2. Ad

GENERAL TECHNICAL INFORMATION 2 - 22 RSV 1000 R - RSV 1000 R FACTORY KEY RSV R 1. Rear shock absorber 2. Passenger right footrest (snaps closed/o

GENERAL TECHNICAL INFORMATION2 - 23RSV 1000 R - RSV 1000 R FACTORY PRINCIPALI KEY RFACT 1. Left side fairing 2. Adjustable steering damper 3. He

GENERAL TECHNICAL INFORMATION 2 - 24 RSV 1000 R - RSV 1000 R FACTORY KEY RFACT 1. Rear shock absorber 2. Passenger’s right footrest (snaps closed

GENERAL TECHNICAL INFORMATION2 - 25RSV 1000 R - RSV 1000 R FACTORY 2.1.7. ARRANGEMENT OF THE INSTRU-MENTS/CONTROLS Key: 1. Clutch lever 2. Igni

GENERAL TECHNICAL INFORMATION 2 - 26 RSV 1000 R - RSV 1000 R FACTORY2.1.8. DASHBOARD OPERATION When the ignition key is turned to “ ”, the following

GENERAL TECHNICAL INFORMATION2 - 27RSV 1000 R - RSV 1000 R FACTORY CURRENT/MAX/AVERAGE SPEED AND BATTERY VOLTAGE DISPLAY IMPORTANT The average/max

INTRODUCTION0 - 5RSV 1000 R - RSV 1000 R FACTORY 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = less than > = greater than ≤ = les

GENERAL TECHNICAL INFORMATION 2 - 28 RSV 1000 R - RSV 1000 R FACTORYTo reset partial odometer 1 (TRIP 1), display the reading and hold down the TRIP

GENERAL TECHNICAL INFORMATION2 - 29RSV 1000 R - RSV 1000 R FACTORY SETTING THE DIGITAL CLOCK The digital clock is at the top of the display. The clo

GENERAL TECHNICAL INFORMATION 2 - 30 RSV 1000 R - RSV 1000 R FACTORYTo start the chronometer : • press and immediately release the LAP button. The

GENERAL TECHNICAL INFORMATION2 - 31RSV 1000 R - RSV 1000 R FACTORY RED LINE ADJUSTMENT (ONLY WITH ENGINE OFF) When the engine rpm exceeds the red li

GENERAL TECHNICAL INFORMATION 2 - 32 RSV 1000 R - RSV 1000 R FACTORYTo display the diagnostics codes in question, enable diag-nostics mode by pressi

GENERAL TECHNICAL INFORMATION2 - 33RSV 1000 R - RSV 1000 R FACTORY SERVICE INTERVALS Display type : SERVICE icon Operating modes : the SERVICE icon

GENERAL TECHNICAL INFORMATION 2 - 34 RSV 1000 R - RSV 1000 R FACTORY2.1.9. SYSTEMS DIAGRAM BRAKES

GENERAL TECHNICAL INFORMATION2 - 35RSV 1000 R - RSV 1000 R FACTORY GAS RECOVERY FROM CRANKCASE

FUEL SYSTEM3-1RSV 1000 R - RSV 1000 R FACTORY FUEL SYSTEM 3

FUEL SYSTEM 3 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 3.1. FUEL SYSTEM...

INTRODUCTION 0 - 6 RSV 1000 R - RSV 1000 R FACTORYRIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic check T.B.E.

FUEL SYSTEM3 - 3RSV 1000 R - RSV 1000 R FACTORY 3.1. FUEL SYSTEM 3.1.1. DIAGRAM Key 1) Fuel tank 2) Filler cap 3) Fuel supply pump unit 4) Fuel

FUEL SYSTEM 3 - 4 RSV 1000 R - RSV 1000 R FACTORY3.1.2. INJECTION SYSTEM DIAGRAM

FUEL SYSTEM3 - 5RSV 1000 R - RSV 1000 R FACTORY Legend : 1. ECU location 2. Ignition switch 3. Battery 4. Engine shaft position sensor 5. Camshaft

FUEL SYSTEM 3 - 6 RSV 1000 R - RSV 1000 R FACTORY3.1.3. CYLINDER TIMING AND CO LEVEL ADJUST-MENT • With the vehicle switched off, connect the Axone

FUEL SYSTEM3 - 7RSV 1000 R - RSV 1000 R FACTORY 3.1.4. AXONE ICON DISPLAY ISO ENGINE PARAMETER READING DEVICE STATUS (generally on/off) DEVICE

FUEL SYSTEM 3 - 8 RSV 1000 R - RSV 1000 R FACTORY Lambda sensor mV Value ranges from 300 to 3000 mV Type 1 carburetor adjust-ment - Tells th

FUEL SYSTEM3 - 9RSV 1000 R - RSV 1000 R FACTORY sor status recognition / wait after recognition / de-activated due to driving / de-activated due to

FUEL SYSTEM 3 - 10 RSV 1000 R - RSV 1000 R FACTORYlation (activates a set of parameters) FROZEN PA-RAMETERS Engine load % Contrary to the engine

FUEL SYSTEM3 - 11RSV 1000 R - RSV 1000 R FACTORY 3.1.5. AIRBOX Key: 1. Throttle body 2. Front air intake 3. Check valve 4. Membrane 5. Solenoid

FUEL SYSTEM 3 - 12 RSV 1000 R - RSV 1000 R FACTORY3.2. FUEL PUMP 3.2.1. REMOVING THE FUEL PUMP ASSEMBLY • Completely remove the fuel tank. IMPORTA

GENERAL INFORMATION1 - 1RSV 1000 R - RSV 1000 R FACTORY GENERAL INFORMATION 1

FUEL SYSTEM3 - 13RSV 1000 R - RSV 1000 R FACTORY 3.2.2. REMOVING THE FUEL LEVEL SENSOR • Remove the entire fuel system. • Disconnect the connecto

FUEL SYSTEM 3 - 14 RSV 1000 R - RSV 1000 R FACTORY3.2.3. REMOVING THE DELIVERY FILTER • Remove the whole fuel supply pump unit. NOTE: Have the appr

FUEL SYSTEM3 - 15RSV 1000 R - RSV 1000 R FACTORY 3.2.4. REMOVING THE FUEL SUPPLY PUMP • Remove the whole fuel supply pump unit. NOTE Have the appr

FUEL SYSTEM 3 - 16 RSV 1000 R - RSV 1000 R FACTORY• Loosen and remove the 3 screws. • Bend the fuel filter over sideways and keep it held do

FUEL SYSTEM3 - 17RSV 1000 R - RSV 1000 R FACTORY 3.3. THROTTLE BODY 3.3.1. REMOVING THE THROTTLE BODY WARNING The throttle setting screws (1) are

FUEL SYSTEM 3 - 18 RSV 1000 R - RSV 1000 R FACTORYIMPORTANT Make sure to use the special OPT tool: - Aprilia part# 0277295 (snap clip pliers). • U

FUEL SYSTEM3 - 19RSV 1000 R - RSV 1000 R FACTORY • Undo the two clips WARNING When removing the throttle body proceed with care as it is still c

FUEL SYSTEM 3 - 20 RSV 1000 R - RSV 1000 R FACTORY3.3.2. DISASSEMBLING THE THROTTLE BODY • Unscrew and remove the M8x1 nut (1) and remove the spri

FUEL SYSTEM3 - 21RSV 1000 R - RSV 1000 R FACTORY • Loosen and remove the two M6x25 screws (14) and the right injector support (15), together

FUEL SYSTEM 3 - 22 RSV 1000 R - RSV 1000 R FACTORY• Unscrew and remove the M8x1 nut (19) and remove the spring washer (20), the pulley (21), the tw

GENERAL INFORMATION 1 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 1.1. STRUCTURE OF THE MANUAL...

FUEL SYSTEM3 - 23RSV 1000 R - RSV 1000 R FACTORY 3.3.3. INSPECTING THE THROTTLE BODY TESTING THE INJECTOR NOTE The injectors can be controlled elec

FUEL SYSTEM 3 - 24 RSV 1000 R - RSV 1000 R FACTORY3.3.4. REFITTING THE THROTTLE BODY CAUTION After disassembling the throttle body, replace all th

FUEL SYSTEM3 - 25RSV 1000 R - RSV 1000 R FACTORY CAUTION Make sure that the ends of the torsion spring (20) are hooked onto the throttle cable sup

FUEL SYSTEM 3 - 26 RSV 1000 R - RSV 1000 R FACTORY3.3.5. REPLACING THE THROTTLE VALVE CON-TROL LEVER DISASSEMBLY • Partially remove the fuel tank.

FUEL SYSTEM3 - 27RSV 1000 R - RSV 1000 R FACTORY 3.3.6. CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY • Partially remove the fuel tank. • Remove

ENGINE4 - 1RSV 1000 R - RSV 1000 R FACTORY ENGINE 4

ENGINE 4 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 4.1. ENGINE...

ENGINE4 - 3RSV 1000 R - RSV 1000 R FACTORY 4.1. ENGINE 4.1.1. REMOVING THE ENGINE • Remove the airbox cover. • Loosen the screw securing the a

ENGINE 4 - 4 RSV 1000 R - RSV 1000 R FACTORY • Detach the by pass lines to the throttle body and the stepper motor connector • Remove the oil

ENGINE4 - 5RSV 1000 R - RSV 1000 R FACTORY • Remove the airbox • Disconnect the cabling from the ignition coil