Aprilia RSV 1000 R, RSV 1000 R FACTORY Workshop Manual

1137 3

00/2003-10

www.serviceaprilia.com

RSV 1000 R - RSV 1000 R FACTORY

workshopmanual

USA

8140742

RSV 1000 R - RSV 1000 R FACTORY

INTRODUCTION

INTRODUCTION 0

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INTRODUCTION

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RSV 1000 R - RSV 1000 R FACTOR

SUMMARY

0.1. INTRODUCTION ............................................................................................................................................. 3

0.1.1. INTRODUCTION.................................................................................................................................... 3

0.1.2. REFERENCE MANUALS....................................................................................................................... 4

0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS..................................................................................... 5

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RSV 1000 R - RSV 1000 R FACTORY

INTRODUCTION

0.1. INTRODUCTION

0.1.1. INTRODUCTION

- This manual provides the information required for normal servicing.

- This publication is intended for use by Aprilia dealerships and their qualified mechanics; many concepts have been

omitted inasmuch as their inclusion would be superfluous for such an audience. Since complete mechanical expla­nations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well
as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazard­ous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to prevent
damage and injury. To ensure maximum customer satisfaction with the vehicle, Aprilia S.p.A. continuously im­proves its products and their documentation. The main technical modifications and changes in repair procedures
are communicated to all Aprilia dealerships and agencies worldwide. Such modifications will be supplied in subse­quent editions of the manual. In case of doubt regarding specific repairs or checks, contact the Aprilia SERVICE
DEPARTMENT; we will be pleased to provide all necessary information and assistance as well as keeping you up­dated on changes and modifications to the vehicle.

Aprilia S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may alter
the essential features of a product as specified in the relevant manual.
All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted,
are reserved in all countries.
The mention of third parties’ products is only made for information purposes, and constitutes no engagement.
Aprilia S.p.A. is not liable in any way for the performance or use of their products.

First edition: October 2003

Designed and printed by:

DECA srl

via Risorgimento, 23/1 - 48022 Lugo (RA) - Italy
Tel. +39 - 0545 35235
Fax +39 - 0545 32844
E-mail: [e-mail]

www.decaweb.it

On behalf of:

Aprilia S.p.A.

Via G. Galilei, 1 – 30033 Noale (VE) – Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 29 190

www.aprilia.com
www.serviceaprilia.com

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RSV 1000 R - RSV 1000 R FACTOR

0.1.2. REFERENCE MANUALS

PARTS CATALOGUES

Aprilia part# (description)
3974

SPECIAL TOOLS CATALOGUES

Aprilia part# (description)
001A00

OWNER’S MANUALS

Aprilia part# (description)
8104334

8104691
8104692
8104693
8104704
8104694
8104695

CYCLE PARTS TECHNICAL MANUAL

Aprilia part# (description)
8140737

8140738
8140739
8140740
8140741
8140742

ENGINE TECHNICAL MANUAL

Aprilia part# (description)
8140743

8140744
8140745
8140746
8140747
8140748

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RSV 1000 R - RSV 1000 R FACTORY

0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS

# = number
< = less than
> = greater than

≤ = less than or equal to
≥ = more than or equal to

~ = approximately

∞ = infinity

°C = degrees Celsius (centigrade)
°F = degrees Fahrenheit

± = plus or minus

AC = alternating current
A = Ampere
Ah =Ampere per hour
API = American Petroleum Institute
HV = high voltage
AV/DC = Anti-Vibration Double Countershaft
bar = pressure measurement (1 bar =100 kPa)
DC. = Direct Current
cc = cubic centimeters
CO = carbon monoxide
CPU = Central Processing Unit
DIN = German industrial standards (Deutsche Industrie Norm)
DOHC = Double Overhead Camshaft
ECU = Electronic Control Unit
rpm = revolutions per minute
HC = unburnt hydrocarbons
ISC = Idle Speed Control
ISO = International Standardization Organization
Kg = kilograms
Kgm = kilogram meter (1 kgm =10 Nm)
km = kilometers
kph = kilometers per hour

Ω = kilo Ohm

k
kPa = kiloPascal (1 kPa =0.01 bar)
KS = clutch side (from the German "Kupplungseite")
kW = kiloWatt

l = liters

LAP = racetrack lap
LED = Light Emitting Diode
LEFT
SIDE = left side
m/s = meters per second
max = maximum
mbar = millibar (1 mbar =0.1 kPa)
mi = miles
MIN = minimum
MPH = miles per hour
MS = flywheel side (from the German "Magnetoseite")

M

Ω = megaOhm

N.A. = Not Available
N.O.M.M. = Motor Octane Number
N.O.R.M. = Research Octane Number
Nm = Newton meter (1 Nm =0.1 kgm)

Ω = ohm

PICK-UP = pick-up
BDC = Bottom Dead Center
TDC = Top Dead Center
PPC = Pneumatic Power Clutch

INTRODUCTION

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INTRODUCTION

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RIGHT
SIDE = right side
SAE = Society of Automotive Engineers
TEST = diagnostic check
T.B.E.I. = crown-head Allen screw
T.C.E.I. = cheese-head Allen screw
T.E. = hexagonal head
TP = flat head screw
TSI = Twin Spark Ignition
UPSIDE­DOWN = inverted fork
V = Volt
W = Watt
Ø = Diameter

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

GENERAL INFORMATION 1

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GENERAL INFORMATION

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RSV 1000 R - RSV 1000 R FACTOR

SUMMARY

1.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3

1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3

1.1.2. SAFETY WARNINGS............................................................................................................................. 4

1.2. GENERAL RULES........................................................................................................................................... 5

1.2.1. BASIC SAFETY RULES......................................................................................................................... 5

1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8

1.3.1. WARNINGS ........................................................................................................................................... 8

1.4. RUNNING-IN ................................................................................................................................................. 12

1.4.1. RUNNING-IN RECOMMENDATIONS.................................................................................................. 12

1.5. VEHICLE IDENTIFICATION.......................................................................................................................... 13

1.5.1. POSITION OF THE SERIAL NUMBERS ............................................................................................. 13

1.6. POSITION OF THE WARNING ADHESIVE LABELS.................................................................................... 15

1.6.1. POSITION OF THE WARNING ADHESIVE LABELS .......................................................................... 15

1.6.2. CALIFORNIA EVAPORATIVE EMISSION SYSTEM .......................................................................... 25

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

1.1. STRUCTURE OF THE MANUAL

1.1.1. CONVENTIONS USED IN THE MANUAL

• This manual is divided in sections and subsections, each covering a set of the most significant components. Refer
to the index of sections when consulting this manual.

• Unless otherwise expressly specified, assemblies are reassembled by reversing the dismantling procedure.

• The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.

• Motorcycle’s operation and basic maintenance are covered in the «OWNER'S MANUAL».

In this manual any variants are identified with these symbols:

optional
catalytic version

- all versions

MP national certification

SF European certification (EURO 1 limits)

VERSION:

Italy
United

Kingdom
Austria
Portugal
Finland

Belgium
Germany
France

Spain

Greece
Holland

Switzerland
Denmark
Japan

Singapore
Slovenia
Israel

South
Korea

Malaysia
Chile

Croatia
Australia
United

States of
America

Brazil
South Africa
New

Zealand
Canada

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GENERAL INFORMATION

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1.1.2. SAFETY WARNINGS

The following precautionary warnings are used throughout this manual in order to convey the following messages:

Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a
personal injury hazard. Non-compliance with the indications given in the messages preceded by this
symbol may result in very serious risks for your and other people's safety and for the vehicle!

WARNING
Indicates a potential hazard which may result in serious injury or even death.

CAUTION
Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.

IMPORTANT: The word "IMPORTANT" in this manual precedes important information or instructions.

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

1.2. GENERAL RULES

1.2.1. BASIC SAFETY RULES

CARBON MONOXIDE

Should it be necessary to perform some operations with the vehicle running, make sure to work outdoors or in a well­aerated room.
Avoid starting the engine in closed or badly ventilated rooms.
In case you are working indoors, use an exhaust gases’ scavenging system.

DANGER
Exhaust gases contain carbon monoxide, which is extremely toxic if inhaled and may cause loss of
consciousness or even lead to death by asphyxia.

FUEL

DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular conditions.
Refueling and engine service should take place in a well-ventilated area with the engine turned off. Do
not smoke when refueling or in the proximity of sources of fuel vapors, avoid flames, sparks and any
element that could ignite fuel or provoke explosions.

DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.

KEEP IT AWAY FROM CHILDREN.

HIGH-TEMPERATURE COMPONENTS

The engine and the exhaust system parts become hot and continue to be hot even for some time after the engine has
been stopped.
Before handling these parts, wear insulating gloves or wait for the engine and the exhaust system to cool completely
down.

USED GEARBOX AND FORK OILS

DANGER
In case any maintenance operation should be required, it is advisable to use latex gloves.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Put it in a sealed container and take it to the filling station where you usually buy it or to an oil salvage
center.
In case any maintenance operation should be required, it is advisable to use latex gloves.

DO NOT DISPOSE OF OIL IN THE ENVIRONMENT

KEEP IT AWAY FROM CHILDREN.

BRAKE FLUID

WARNING
When using the brake fluid, take care not to spill it on the plastic, rubber or painted parts, since it can
damage them.
When carrying out the maintenance operations on the braking system, use a clean cloth to cover these
parts.
Always wear safety goggles when working on the braking system.
The brake fluid is highly irritant. Avoid contact with your eyes.
If the brake fluid gets in contact with the skin or the eyes, carefully wash the parts of your body that get
in contact with the fluid and consult a doctor.

KEEP IT AWAY FROM CHILDREN.

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GENERAL INFORMATION

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COOLANT

The coolant is composed of ethylene glycol that, under certain conditions, can become inflammable and send forth
invisible flames causing severe burns.

RSV 1000 R - RSV 1000 R FACTOR

DANGER
Be careful not to spill the coolant on the red-hot parts of the engine and the exhaust system: it may catch
fire and send forth invisible flames.
In case any maintenance operation should be required, it is advisable to use latex gloves.
Even if toxic, coolant has a sweet flavor. Never leave it inside open containers or within the reach of
animals to prevent the risk of drinking.

KEEP IT AWAY FROM CHILDREN.

Do not remove the radiator plug when the engine is hot. The coolant is under pressure and could cause
severe burns.

HYDROGEN GAS AND BATTERY ELECTROLYTE

DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact.
Always wear tight gloves and protective clothes when handling this fluid.
If the electrolyte gets in contact with the skin, carefully wash the parts of your body that get in contact
with the fluid with abundant fresh water.
Always use a protection for your eyes since even a very small amount of the battery fluid can cause
blindness. In the event of contact with your eyes, carefully wash them with water for fifteen minutes and
then consult immediately an eye specialist.
Should you accidentally drink some fluid, drink abundant water or milk, then drink milk of magnesia or
vegetable oil and consult a doctor immediately. The battery releases explosive gases. Keep flames,
sparks, cigarettes and any other heat source away from it. Make sure the room is well aerated when
servicing or recharging the battery.

KEEP IT AWAY FROM CHILDREN.

The battery fluid is corrosive.
Do not pour it on the plastic parts.
Make sure that the electrolyte acid is suitable for the type of battery used.

GENERAL PRECAUTIONS AND INFORMATION

Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.

DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or inspecting
the motorcycle: stop the engine and remove the key from the ignition switch; allow for the engine and
exhaust system to cool down; where possible, lift the motorcycle using adequate equipment placed on
firm and level ground. Be careful of any parts of the engine or exhaust system which may still be hot to
the touch to avoid scalds or burns.
Never put any mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components is edible. Some components are harmful to the human body
or toxic.
Unless expressly specified otherwise, motorcycle assemblies are refitted or re-assembled by reversing
the removal or dismantling procedure. Where a procedure is cross-referred to relevant sections in the
manual, proceed sensibly to prevent shifting any parts unless strictly necessary. Never attempt to polish
matte-finished surfaces with lapping compounds.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean any rubber or plastic parts or the seat with alcohol, gasoline or solvents. Clean with water
and neutral detergent.
Always disconnect the battery negative (–) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.

BEFORE DISASSEMBLING ANY COMPONENTS

• Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any compo­nents.

• Use the model-specific special tools where specified.

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

DISASSEMBLING THE COMPONENTS

- Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable wrench.

- Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection
using a distinctive symbol or convention.

- Mark each part clearly to avoid confusion when refitting.

- Thoroughly clean and wash any components that you removed using a detergent with low flash point.

- Mated parts should always be refitted together. These parts will have seated themselves against one another in ser­vice as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.

- Certain components are matched-pair parts and should always be replaced as a set.

- Keep the motorcycle and its components well away from heat sources.

REASSEMBLING THE COMPONENTS

DANGER
Never reuse a circlip or snap ring. These parts must always be replaced once they have been shifted.
When fitting a new circlip or snap ring, take care to move the open ends apart just enough to allow fitting
in the shaft.
Make a rule to check that a newly –fitted circlip or snap ring has located fully into its groove.
Never clean a bearing with compressed air.

NOTE All bearings must rotate freely with no hardness or noise. Replace any bearings that do not meet these
requirements.

- Use ORIGINAL Aprilia SPARE PARTS only.

- Use the specified lubricants and consumables.

- Where possible, lubricate a part before assembly.

- When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten e­venly in subsequent steps until achieving the specified torque.

- Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which have
a damaged thread.

- Lubricate the bearings abundantly before assembly.

- Make a rule to check that all components you have fitted are correctly in place.

- After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then drive the
motorcycle in a private estate area or in a safe area away from traffic.

- Clean all joint surfaces, oil seal edges and gaskets before assembly. Apply a light coat of lithium grease along the
edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outwards (in view).

ELECTRICAL CONNECTORS

To disconnect the electrical connector, follow the procedures below. Failure to comply with these procedures may lead to
irreparable damages to the connector and the wiring as well. If present, press the special safety hooks.

WARNING
Do not pull cables to disconnect the two connectors.

• Grasp the two connectors and disconnect them by pulling them in the two opposite directions.

• In case of dirt, rust, moisture, and so on, thoroughly clean the inside of the connectors with compressed air.

• Make sure that the cables are correctly fitted inside the connectors’ terminals.

NOTE The two connectors have just one correct positioning. Make sure to position them in the right direction.

Then fit the two connectors. Make sure they are correctly coupled (a click will be heard).

TIGHTENING TORQUE SETTINGS

DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Make sure that these values are
always within the specified limits.
Check fastening parts tightening torque settings at regular intervals. Upon reassembly, always use a
torque wrench.
Failure to comply with these recommendations could lead to the loosening and detachment of one of
these parts with a consequent locking of the wheel or other serious troubles affecting the vehicle
handling, and thus the risk of falls and serious injuries or death.

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RSV 1000 R - RSV 1000 R FACTOR

1.3. DANGEROUS ELEMENTS

1.3.1. WARNINGS

FUEL

DANGER
The fuel used to operate engines is highly flammable and becomes explosive under particular conditions.
Refueling and engine service should take place in a well-ventilated area with the engine turned off. Do
not smoke when refueling or when near fuel vapors’ sources. Avoid contact with bare flames, sources of
sparks or any other source which may ignite the fuel or lead to explosion.
Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In the
event of accidental fuel spillage, make sure the affected area is fully dry before starting the engine. Fuel
expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refueling.
Avoid contact with skin. Do not inhale vapors. Do not swallow fuel. Do not use a hose to transfer fuel be­tween different containers.
DO NOT RELEASE FUEL INTO THE ENVIRONMENT.
KEEP IT AWAY FROM CHILDREN.

Use only premium grade unleaded gas, min. O.N. 95 (N.O.R.M.) and 85 (N.O.M.M.).

LUBRICANTS

DANGER
A good lubrication ensures the vehicle’s safety.
Failure to keep the lubricants at the recommended level or the use of a non-suitable new and clean type
of lubricant can lead to the engine’s or gearbox’s seizure, thus leading to serious accidents, personal in­jury or even death.
Gear oil may cause serious damage to the skin if handled daily and for long periods.
Wash your hands carefully after use.
Do not dispose of oil into the environment.
Take it to the filling station where you usually buy it or to an oil salvage center.

WARNING
When filling the vehicle with this oil, take care not to spill it out since it could damage the vehicle paint­work.
In case of contact with oil, the tires’ surface will become very slippery, thus becoming a serious danger
for your safety.
In case of leaks, do not use the vehicle. Check and trace the cause of leaks and proceed to repair.

ENGINE OIL

DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage.
Wash your hands thoroughly after handling engine oil.
Do not release it into the environment.
Dispose of engine oil through the nearest waste oil reclamation firm or through the supplier.
Wear latex gloves during servicing.

FRONT FORK FLUID

DANGER
Front suspension response can be modified to a certain extent by changing the damping settings and/or
selecting a particular grade of oil. Standard oil grade is SAE 20 W. Different oil grades can be selected to
obtain a particular suspension response. (Choose SAE 5W for a softer suspension, 20W for a stiffer sus­pension).
The two grades can also be mixed in varying solutions to obtain the desired response.

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

BRAKE FLUID

NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by an independent hydraulic
circuit. The information provided below applies to both braking systems.

DANGER
Do not use the vehicle in case brakes are worn out or do not work properly! The brakes are the parts that
most ensure your safety and for this reason they must always be in perfectly working order. Failure to
comply with these recommendations will probably lead to a crash or an accident, with a consequent risk
of personal injury or death.
A wet surface reduces the brakes’ efficiency.

DANGER
In case of wet ground, double the braking distance since both brakes and tires drives on the road surface
are extremely reduced by the water present on the road’s surface.
Any water on brakes, after washing the vehicle or driving on a wet road surface, crossing puddles or
ditches can wet brakes so as to greatly reduce their efficiency.
Failure to comply with these recommendations may lead to serious accidents, with a consequent risk of
severe personal injuries or death.
Brakes are critical safety components. Do not ride the vehicle in case brakes are not working at their
best.
Check for the brakes’ proper working order before every trip.
Brake fluid is an irritant. Avoid contact with eyes or skin.
In the event of accidental contact, wash the affected body parts thoroughly. In the event of accidental
contact with eyes, contact an eye specialist or seek medical advice.
DO NOT RELEASE BRAKE FLUID INTO THE ENVIRONMENT. KEEP IT AWAY FROM CHILDREN.
When handling brake fluid, take care not to spill it onto plastic or paint-finished parts or they will damage.

DANGER
Do not use any brake fluids other than the specified type. Never mix different types of fluids to top up
level, as this will damage the braking system.
Do not use brake fluid from containers that have been kept open or in storage for long periods.
Any sudden changes in play or hardness in the brake levers are warning signs of problems with the hy­draulic circuits.
Ensure that the brake discs and brake linings have not become contaminated with oil or grease. This is
particularly important after servicing or inspections.
Make sure the brake lines are not twisted or worn.
Prevent accidental entry of water or dust into the circuit.
Wear latex gloves when servicing the hydraulic circuit.

DISC BRAKES

DANGER
The brakes are the parts that most ensure your safety and for this reason they must always be in per­fectly working condition; check them before every trip.
A dirty disc soils the pads.
Dirty pads must be replaced, while dirty discs must be cleaned with a high-quality degreaser.
Perform the maintenance operations with half the indicated frequency if the vehicle is used in rainy or
dusty areas, on uneven surfaces or on racetracks.
When the disc pads wear out, the level of the fluid decreases to automatically compensate for their wear.
The front brake fluid reservoir is located on the right handlebar, near the front brake lever.
The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the braking system is leaking fluid.

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GENERAL INFORMATION

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COOLANT

DANGER
Coolant is toxic when ingested; it is an irritant, contact with eyes or skin may cause irritation.
In the event of contact with eyes, rinse repeatedly with abundant water and seek medical advice. In the
event of ingestion, induce vomiting, rinse mouth and throat with abundant water and seek medical advice
immediately.
DO NOT RELEASE INTO THE ENVIRONMENT.
KEEP IT AWAY FROM CHILDREN.

DANGER
Take care not to spill coolant onto hot engine parts. It may ignite and produce invisible flames. Wear la­tex gloves when servicing.
Do not ride when coolant is below the minimum level.

Coolant mixture is a 50% solution of water and anti-freeze. This is the ideal solution for most operating temperatures and
provides good corrosion protection.
This solution is also suited for the warm season, as it is less prone to evaporative loss and will reduce the need for top­ups.
In addition, less water evaporation means fewer minerals salts depositing in the radiator, which helps preserve the cool­ing system’s efficiency.
When temperature drops below zero degrees centigrade, check the cooling system frequently and add more anti-freeze
(up to 60% maximum) to the solution.
Use distilled water in the coolant mixture. Tap water will damage the engine.
Refer to the chart given below and add water with the quantity of anti-freeze to obtain a solution with the desired freezing
point:

Freezing point F°(C°) Coolant % of volume

-4° (-20°) 35

-22° (-30°) 45

-40° (-40°) 55

NOTE Coolants have different specifications. The protection degree is written on the label.

WARNING
Use nitrate-free coolant only, with a protection until at least -31°F (-35°C).

DRIVE CHAIN

Check the drive chain operation, slack and lubrication at regular intervals.
The vehicle is equipped with an endless chain with a joint link.

WARNING
If too slack, the chain can come off the front or rear sprockets thus leading to serious accidents and
damage to the vehicle, with consequent serious personal injury or death.
Do not use the vehicle if the chain tension has not been correctly adjusted.
To check the chain, take it with your hand where it turns on the rear sprocket and pull it as to separate it
from the crown itself.
If you can move the chain apart of the front sprocket for more than 0.125 in (3 mm), change chain, crown
and pinion.

RSV 1000 R - RSV 1000 R FACTOR

DANGER
If not properly maintained, the chain can undergo early wear out and lead to the damage of both crown
and pinion.
Perform chain maintenance operations more frequently if the vehicle is used on rainy or dusty areas.

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RSV 1000 R - RSV 1000 R FACTORY

TIRES

WARNING
If tires are excessively inflated, the vehicle will be hard and uneasy to ride, thus making you feel not at
your ease.
In addition the roadworthiness, mainly on wet surfaces and during cornering, will be impaired.
Flat tires (insufficient pressure) can slip on the rim and make you lose control of the vehicle.
In this case too, both vehicle roadworthiness, handling and brake efficiency will be impaired.
Tires changing, repair, maintenance and balancing must be carried out by specialized technicians using
suitable equipment.
When new, tires can have a thin slippery protective coating. Drive carefully for the first kilometers (miles).
Never use rubber treating substances on tires.
In particular, avoid contact with fluid fuels, leading to a rapid wear.
In case of contact with oil or fuel, do not clean but change tires.

DANGER
Some of the factory-assembled tires of this vehicle are provided with wear indicators.
There are several kinds of wear indicators.
For more information on how to check the wear, contact your Dealer.
Visually check if the tires are worn and in this case have them changed.
If a tire deflates while driving, stop immediately.
Avoid hard brakings or moves and do not close throttles too abruptly.
Slowly close throttle grip, move to the edge of the road and use the engine brake to slow down until com­ing to a halt.
Failure to comply with these recommendations can lead to serious accidents and consequent personal
injuries or death.
Do not install tires with air tube on rims for tubeless tires and vice versa.

GENERAL INFORMATION

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GENERAL INFORMATION

RSV 1000 R - RSV 1000 R FACTORY

1.4. RUNNING-IN

1.4.1. RUNNING-IN RECOMMENDATIONS

Running-in the engine is essential to ensure its duration and correct functioning.
If possible, drive on hilly roads and/or roads with many bends, so that the engine, the suspensions and the brakes un­dergo a more effective running-in.
During the running-in, change speed.
In this way the components are first "loaded" and then "relieved" and the engine’s parts can thus cool down.
Even if it is important to stress the engine components during running-in, take care not to over do it.

WARNING
You can expect the best performance levels from the vehicle only after the first 932 mi (1500 km) of run­ning-in.

Keep to the following indications:

• Do not open the throttle completely if the speed is low, both during and after the running-in.

• During the first 62 mi (100 km) pull the brakes with caution, avoiding sharp and prolonged braking. This ensures a

correct bedding-in of the pads on the brake disc.

• During the first 621 mi (1000 km) never exceed 6000 rpm (see table).

WARNING
After the first 621 mi (1000 km), Dealers carry out the checks indicated in the column "After running­in", see (REGULAR SERVICE INTERVALS CHART), in order to avoid hurting yourself or other people
and/or damaging the vehicle.

• Between the first 621 mi (1000 km) and 932 mi (1500 km) drive more briskly, change speed and use the maximum
acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 7500 rpm
(see table).

• After the first 932 mi (1500 km) you can expect better performance from the engine, however, without exceeding
the maximum allowed [11000 rpm].

Engine maximum rpm recommended
Mileage mi (Km) rpm
0÷621 (1000 ) 6000
621÷932 (1000÷1500 ) 7500
Over 932 (1500) 11000

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RSV 1000 R - RSV 1000 R FACTORY

1.5. VEHICLE IDENTIFICATION

1.5.1. POSITION OF THE SERIAL NUMBERS

These numbers are necessary for the vehicle’s registration.

IMPORTANT Do not alter the identification numbers if you
do not want to incur severe penal and administrative sanc­tions; in particular, altering the frame number voids the war­ranty.

FRAME NUMBER

The frame number (1) is stamped on the right hand side of
the headstock.

ENGINE NUMBER

The engine number (2) is stamped on the rear part of the
engine, near the pinion.

INFORMATION CONTAINED IN THE VEHICLE IDENTIFI­CATION NUMBER

Description of the vehicle identification number (V.I.N.),
stamped on the steering head of the frame (1) and on the
identification plate (3)

GENERAL INFORMATION

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GENERAL INFORMATION

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RSV 1000 R - RSV 1000 R FACTOR

DIGIT MEANING

1. Manufacturer’s identification alphanumeric code.

2. Vehicle type.

3. Model.

4. Country for which the vehicle is intended.

5. #= Check digit number.

6. Model year.

7. Assembling factory designation

(N = NOALE-VE- ,
S = SCORZÉ -VE- ,
0 = NOT SPECIFIED).

8. Sequential serial number.

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

1.6. POSITION OF THE WARNING ADHESIVE
LABELS

1.6.1. POSITION OF THE WARNING ADHESIVE LA-

BELS

1

2

1 - 15

GENERAL INFORMATION

Y

3

RSV 1000 R - RSV 1000 R FACTOR

4

5

6

1 - 16

RSV 1000 R - RSV 1000 R FACTORY

7

GENERAL INFORMATION

8

9

10

1 - 17

GENERAL INFORMATION

Y

11

RSV 1000 R - RSV 1000 R FACTOR

12

13

14

1 - 18

RSV 1000 R - RSV 1000 R FACTORY

14a

GENERAL INFORMATION

15 Muffler stamping

1 - 19

GENERAL INFORMATION

Y

1

RSV 1000 R - RSV 1000 R FACTOR

2

3

4

1 - 20

RSV 1000 R - RSV 1000 R FACTORY

5

GENERAL INFORMATION

6

7

8

1 - 21

GENERAL INFORMATION

Y

9

RSV 1000 R - RSV 1000 R FACTOR

10

11

12

1 - 22

RSV 1000 R - RSV 1000 R FACTORY

13

GENERAL INFORMATION

14

15

15a

1 - 23

GENERAL INFORMATION

Y

16 Muffler stamping

RSV 1000 R - RSV 1000 R FACTOR

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RSV 1000 R - RSV 1000 R FACTORY

GENERAL INFORMATION

1.6.2. CALIFORNIA EVAPORATIVE EMISSION

SYSTEM

FOR STATE OF CALIFORNIA ONLY.

1. The system consists of:

2. Fuel tank

3. Fuel tank breather line

4. Breather line (to 2 way ventilation valve)

5. 2 way ventilation valve

6. Breather line (to carbon canister)

7. Carbon canister

8. Drain line (to norrow passage)

9. Restrictor Ø 0.06 in (Ø 1.5 mm)

10. Drain line (to tee)

11. Tee

12. Drain line (to manifold vacum port)

13. Manifold vacum port (right front part of throttle body)

14. Warm air inlet (from armosphere to canister)

1 - 25

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

GENERAL TECHNICAL INFORMATION 2

2-1

GENERAL TECHNICAL INFORMATION

Y

RSV 1000 R - RSV 1000 R FACTOR

SUMMARY

2.1. GENERAL TECHNICAL INFORMATION ........................................................................................................ 3

2.1.1. TECHNICAL DATA ................................................................................................................................ 3

2.1.2. PERIODIC MAINTENANCE CHART...................................................................................................... 7

2.1.3. TABLE OF LUBRICANTS ...................................................................................................................... 9

2.1.4. TIGHTENING TORQUES .................................................................................................................... 10

2.1.5. SPECIAL TOOLS................................................................................................................................. 14

2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS..................................................................................... 21

2.1.7. ARRANGEMENT OF THE INSTRUMENTS/CONTROLS.................................................................... 25

2.1.8. DASHBOARD OPERATION ................................................................................................................ 26

2.1.9. SYSTEMS DIAGRAM .......................................................................................................................... 34

2 - 2

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

2.1. GENERAL TECHNICAL INFORMATION

2.1.1. TECHNICAL DATA

DIMENSIONS

Max. length 79.724 in (2025 mm)
Max. length 28.740 in (730 mm)
Max. height (incl. windshield) 44.685 in (1135 mm)
Rider’s seat height 32.283 in (820 mm)
Wheelbase 55.512 in (1410 mm)
Minimum ground clearance 5.118 in (130 mm)
Weight in running order

ENGINE

Model V990 NG
Type 4-stroke V 60* twin-cylinder, with 4 valves per cylinder, DOHC.
No. of cylinders 2
Total displacement 60.902 in3 (998 cm3)
Bore/stroke 3.819 in/2.657 in (97 mm/67,5 mm)
Compression ratio 11,8 ± 0,4: 1
Starting Electric starter
Engine idling speed 1280 ± 100 rpm
Clutch Multiplate wet clutch, hydraulically operated, control on left side of han-

Lubricating system Dry sump with separate oil tank and oil cooler
Air cleaner Dry filter cartridge
Cooling system Liquid coolant

GEARBOX

Type Mechanical, 6 gears with foot control on engine’s left side

CAPACITIES

Fuel (including reserve) 4.755 gal (18 l)
Fuel reserve 1.189 ± 0.264 gal (4,5 ± 1 l)
Engine oil Oil change 225.788 in3 (3700 cm3) - oil and oil filter change 237.993 in3

Front fork oil RSV R
Front fork “R FACTORY” RFACT (RSV R
OPT) oil
Coolant 0.581 gal (2,2 l) (50% water + 50% anti-freeze with ethylene glycol)
Seat
Max. load

TRANSMISSION RATIOS

Ratio Primary Secondary Final drive Total ratio
1st 31/60 = 1: 1,935 15/34 = 1: 2,267 16/40 = 1: 2,500 1:10,968
2nd 19/31 = 1: 1,632 1:7,895
3rd 20/26 = 1: 1,300 1:6,290
4th 22/24 = 1: 1,091 1:5,279
5th 25/24 = 1: 0,960 1:4,645
6th 26/23 = 1: 0,885 1:4,280

DRIVE CHAIN

Type Endless (with no master link) with O-ring links
Endless 525

FUEL SYSTEM

Type Electronic injection (Multipoint)
Choke Ø 2.244 in (Ø 57 mm)

FUEL

Fuel Premium-grade unleaded gas, minimum octane rating 95 (ROM) and 85

RSV R 473.993 lb (215 kg) –RFACT 460.766 lb (209 kg)

dlebar and PPC device

(3900 cm

31.732 ± 0.152 in

30.512 ± 0.152 in

3

)

3

(520 ± 2,5 cm3) (each leg)

3

(500 ± 2,5 cm3) (each leg)

2 (RFACT USA version: single-seater only)
RSV R 396.832 lb (180 kg) (rider + passenger + luggage) – RFACT
USA 231.485 lb (105 kg)

(MON).

2 - 3

GENERAL TECHNICAL INFORMATION

Y

FRAME

Type Two-beam frame with light alloy cast elements and extruded elements
Steering head angle 25°
Trail 3.937 in (100 mm) (with 120/70 front tire)

SUSPENSION

Front Adjustable hydraulic upside-down fork, Ø 1.693 in (Ø 43 mm)
Travel
Rear Light-alloy swinging arm with differentiated profiles on both sides and adjustable air/oil-

Wheel travel 5.31 in (135 mm)

BRAKES

Front Twin floating disk - Ø 12.598 in (Ø 320 mm), four-piston calipers - Ø 1.338 in (Ø 34 mm)
Rear Disk brake - Ø 8.661 in (Ø 220 mm), twin-piston caliper - Ø 1.260 in (Ø 32 mm)

WHEEL RIMS

Type Light alloy, spindle can be removed
Front 3,50 x 17"
Rear 6,00 x 17"

RSV R 4.999 in (127 mm) – RFACT (RSV R OPT) 4.724 in (120 mm)

sprung mono-shock absorber

RSV 1000 R - RSV 1000 R FACTOR

2 - 4

RSV 1000 R - RSV 1000 R FACTORY



GENERAL TECHNICAL INFORMATION

TIRES

Wheel Make Model Type Size

** Front PIRELLI DIABLO CORSA 120/70–

** Rear PIRELLI DIABLO CORSA 190/50–

* Front PIRELLI DRAGON

SUPER-

CORSA

* Rear PIRELLI DRAGON

SUPER-

CORSA

** Front METZELER SPORT-

TEC

Rear METZELER SPORT-

TEC

** Rear METZELER SPORT-

TEC

Front METZELER RENNSPO

RT

Rear METZELER RENNSPO

RT

** Front MICHELIN PILOT

SPORT

** Rear MICHELIN PILOT

SPORT

Front MICHELIN PILOT

SPORT

CUP

Front MICHELIN PILOT

SPORT

CUP

Front MICHELIN PILOT

RACE

Rear MICHELIN PILOT

RACE

** Front DUNLOP SPORT-

MAX

** Rear DUNLOP SPORT-

MAX

Front DUNLOP SPORT-

MAX

Rear DUNLOP SPORT-

MAX

* = standard RFACT **= standard RSV R # = Standard use

ZR 17"

ZR 17"

– 120/70–

ZR 17"

– 180/55–

ZR 17"

M1 120/70–

ZR 17"

M1 180/55–

ZR 17"

M1 190/50–

ZR 17"

– 120/70–

ZR 17"

– 180/55–

ZR 17"

E 120/70–

ZR 17"

E 190/50–

ZR 17"

- 120/70–
ZR 17"

- 180/55–
ZR 17"

H 2 120/70–

ZR 17"

H 2 180/55–

ZR 17"

D 208 120/70–

ZR 17"

D 208 190/50–

ZR 17"

D 208

RR

D 208

RR

120/55–

ZR 17"

180/55–

ZR 17"

TL

TL

Recom­mended

Alternative

# $ RSV R + R

FACT

# $ RSV R + R

FACT

# $ RSV R + R

FACT

# $ RSV R + R

FACT

# $ RSV R + R

FACT

# $ RSV R + R

FACT

# $ RSV R + R

FACT

- $ RSV R + R
FACT

- $ RSV R + R
FACT

Pressure kPa (bar)

# $

Rider

Rider and

passenger

Rider

230 (2,3) 250 (2,5) 210

(2,1)

250 (2,5) 280 (2,8) 200

(2,0)

230 (2,3) 250 (2,5) 210

(2,1)

250 (2,5) 280 (2,8) 200

(2,0)

230 (2,3) 250 (2,5) 210

(2,1)

250 (2,5) 280 (2,8) 200

(2,0)

250 (2,5) 280 (2,8) 200

(2,0)

- - 210
(2,1)

- - 200
(2,0)

# - RSV R 230 (2,3) 250 (2,5) -

# - RSV R 250 (2,5) 280 (2,8) -

– $ RFACT – – 210

(2,1)

– $ RFACT – – 190

(1,9)

– $ RFACT – – 210

(2,1)

– $ RFACT – – 190

(1,9)

# - RSV R+

230 (2,3) 250 (2,5) -

RFACT

# – RSV R+

250 (2,5) 280 (2,8) –

RFACT

- $ RFACT - - 210
(2,1)

- $ RFACT - - 190
(1,9)

$= Racing use

2 - 5

GENERAL TECHNICAL INFORMATION

Y

SPARK PLUGS

Standard NGK R DCPR9E
Electrode gap 0.024– 0.028 in (0,6 – 0,7 mm)
Resistance

ELECTRIC SYSTEM

Battery 12 V – 10 Ah
Main fuses 30 A
Auxiliary fuses 5 A, 15 A, 20 A
Generator (permanent-wound type) 12 V – 500 W

BULBS

Low beam (halogen) 12 V – 55 W H7U x 2
High beam (halogen) 12 V – 55 W H7U x 2
Front parking light 12 V – 5 W
Direction indicators 12 V – 10 W
Number plate light 12 V – 5 W
Stop/rear parking lights LED
Rev counter light LED
Left multifunction display LED

WARNING LIGHTS

Neutral LED
Direction indicators LED
Fuel reserve LED
High beam LED
Stand down LED
General warning LED
Red line LED
Immobilizer LED

5 kΩ

RSV 1000 R - RSV 1000 R FACTOR

2 - 6

RSV 1000 R - RSV 1000 R FACTORY

r

)

2.1.2. PERIODIC MAINTENANCE CHART

OPERATIONS TO BE CARRIED OUT BY THE Aprilia Official Dealer (CAN BE CARRIED OUT BY THE USER AS
WELL).

Key
1 = check and clean, adjust, lubricate or replace, if necessary;
2 = clean;
3 = replace
4 = adjust.

(*) = Check every two weeks or at the specified intervals.

NOTE Halve the maintenance intervals if the vehicle is used in rainy or dusty conditions, on rough roads or for racing.

Post running-in

Component

Spark plug 3 1 3
Air cleaner 3 1 3
Engine oil filter 3 3 3
Engine oil filter (on oil tank) 2 2 2
Light operation/beam setting 1
Light system 1 1
Safety switches 1 1
Clutch fluid 1 1 1
Brake fluid 1 1 1
Coolant 1 1 1
Engine oil 3 3 3
Tires 1 1
Tire pressure (*) 4 4

Error warning light (on
dashboard)
Drive chain slack and

ication

lub

Brake pad wear 1

[625 mi (1000

Km)]

Every 3125 mi (5000

Km) (only for inten-

sive racing use)

each start-up: 1

every 625 mi (1000 Km): 1

every 625 mi (1000

Km

: 1

Every 6250 mi

(10000 Km) or 12

months

before each ride and every 1250 mi

(2000 Km): 1

Every 12500 mi

(20000 Km) or 24

months

GENERAL TECHNICAL INFORMATION

2 - 7

GENERAL TECHNICAL INFORMATION

Y

OPERATIONS TO BE CARRIED OUT BY THE Aprilia Official Dealer.

Key

1 = check and clean, adjust, lubricate or replace, if necessary;
2 = clean;
3 = replace
4 = adjust.

(*) = only for versions with magnesium wheels: check that rim paint is in good conditions.

NOTE Halve the maintenance intervals if the vehicle is used in rainy or dusty conditions, on rough roads or for racing.

Component

Rear shock absorber 1 1
Gearbox every 625 mi (1000

Bowden cables and con­trols
Rear suspension linkage
bearings
Steering bearings and
steering play
Wheel bearings 1 1
Brake discs 1 1 1
Vehicle operation 1 1 1
Valve clearance 4 4
Braking systems 1 1 1
Cooling system 1 1
Clutch fluid every 12 months: 3 every 24 months: 3
Brake fluid every 12 months: 3 every 24 months: 3
Coolant every 24 months: 3
Fork oil (RSV R)

Fork oil (RFACT)
Fork oil seals (RSV R)

Fork oil seals (RFACT)
Brake pads if worn: 3
Wheels/Tires (*) 1 1 1
Nut, bolt, screw tightening 1 1 1
Cylinder synchronization 1 1
Suspension and trim 1 1 1
Final drive (chain, rear
and front sprocket)
Fuel pipes 1 every 4 years: 3
Clutch wear 1
Pistons 1

Post running-in

[625 mi (1000 Km)]

1 1 1

1

1 1 1

After the first 6250 mi (10000 Km) and every

3 3
After the first 18650 mi (30000 Km) and

1 1

1 1

Every 3125 mi (5000

Km) (only for inten-

sive racing use)

Km): 1

RSV 1000 R - RSV 1000 R FACTOR

Every 6250 mi

(10000 Km) or 12

months

12500 mi (20000 Km): afterwards: 3

every 12500 mi (20000 Km):afterwards: 3

Every 12500 mi

(20000 Km) or 24

months

2 - 8

RSV 1000 R - RSV 1000 R FACTORY

2.1.3. TABLE OF LUBRICANTS

LUBRICANT PRODUCT

RECOMMENDED: EXTRA RAID 4, SAE 15W - 50 or TEC 4T,

Engine oil

SAE 15W - 50.
As an alternative to recommended oils, top brand oils meeting or exceeding
CCMC G-4, A.P.I. S.G. specifications can be used.

GENERAL TECHNICAL INFORMATION

RSV R fork oil

RFACT (RSV R OPT) Fork oil type “R

FACTORY”

Bearings and other lubrication points

Battery lead protection

Chains

Brake fluid

RECOMMENDED:
FORK 5W or

When you wish to obtain an intermediate response between those offered
by

F.A. 5W and F.A. 20W oils or FORK 5W and

FORK 20W oils, you may mix the different products as follows:
SAE 10W =

of volume.

SAE 15W =

of volume.

ÖHLINS 5W

RECOMMENDED:

GREASE 30.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30°C - +140°C, with dropping
point 150°C - 230°C, high corrosion protection, good resistance to water
and oxidation.

Use neutral grease or Vaseline.

Spray grease RECOMMENDED:
LUBE.

RECOMMENDED: The system is filled with
braking system is also compatible with DOT 5); BRAKE 5.1 DOT 4

(the braking system is also compatible with DOT 5).

NOTE Use new brake fluid only. Do not mix different brands or types of oil
without having checked bases compatibility.

F.A. 5W, F.A. 20W; as an alternative,

FORK 20W.

F.A. 5W 67% of volume + F.A. 20W 33% of volume, or

FORK 5W 67% of volume + FORK 20W 33%

F.A. 5W 33% of volume + F.A. 20W 67% of volume, or

FORK 5W 33% of volume + FORK 20W 67%

BIMOL GREASE 481 - AUTOGREASE MP or

CHAIN SPRAY or CHAIN

Autofluid FR. DOT 4 (the

Clutch fluid

Engine coolant

F.F., DOT 5 (Compatibile DOT 4) ; BRAKE 5.1 DOT 5 (the

braking system is also compatible with DOT 4).

NOTE Use new clutch fluid only

RECOMMENDED:

NOTE Use only nitrite-free anti-freeze and corrosion inhibitors with a
freezing point of -35°C as a minimum.

ECOBLU -40 °C - COOL.

2 - 9

GENERAL TECHNICAL INFORMATION

Y

2.1.4. TIGHTENING TORQUES

DESCRIPTION

ENGINE

Engine mounting to frame

Front fitting 2+2 M10 36,878 ­Left side upper and lower rear fitting 2 M10 36,878 ­Adjuster bushing right side upper and lower rear fitting 2 M20x1,5 8,851 ­Locknut right side upper and lower rear fitting 2 M20x1,5 36,878 ­Screw right side upper and lower rear fitting 2 M10 36,878 -

Components mounted to engine

Engine oil intake flange 2 M6 7,376 ­Engine oil outlet flange 2 M6 7,376 ­Rear brake lever support 1 M6 7,376 ­Rear brake lever support 1 M8 18,439 ­Rear brake pump support 2 M8 18,439 ­Pinion 1 M10 36,878 Loctite 243
Clutch control cylinder 3 M6 7,376 ­Pinion cover 3 M6 7,376 ­Fuel delivery hose to throttle body 1 M12x1,5 16,226 ­72/78 Kw reduction bushing 1 M5 2,213±10% Loctite 243

SWINGING ARM

RSV 1000 R - RSV 1000 R FACTOR

QUANTITY

SCREW / NUT

TORQUE (ftlb)

NOTES

Swinging arm spindle nut 1 M30x1,5 44,254 ­Swinging arm spindle adjuster bushing 1 M30x1,5 8,851 ­Swinging arm spindle nut 1 M20x1,5 66,38 ­Caliper support pin 1 M12 36,878 Loctite 243
Chain tensioner screw and nut 1+1 M8 man. ­Rear brake hose bracket 3 M5 2,95 ­Chain guard cover 2 M5 2,95 ­Chain shoe 2 M5 2,213 ­Chain guide plate 1 M5 2,213 ­Rear stand bushing 2 M6 7,376 ­Chain guide plate (nut) 1 M6 7,376 -

SIDE STAND

Stand plate to frame 1 M10 29,502 ­Side stand pin 1 M10x1,25 7,376 ­Switch screw 1 M6 7,376 Loctite 243
Locknut 1 M10x1,25 22,127 -

2 - 10

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

FRONT SUSPENSION

Front fork

Fork leg on top yoke 1+1 M8 18,439 ­Fork leg on bottom yoke 2+2 M8 18,439 -

Head stock nut (tighten first, then slacken) 1 M35x1 29,502

tighten first
and then
slacken

Head stock nut (tighten down 2nd time) 1 M35x1 14,751

Head stock locknut 1 M35x1

Top yoke cap 1 M29x1 73,756 ­SHOWA fork hub clamps 2+2 M8 18,226 ­OHLINS fork hub clamps 2+2 M6 8,851 -

Steering damper

Steering damper collar to frame 1 M6 7,376 Loctite 243
Steering damper rod on bottom yoke 1 M6 7,376 -

REAR SUSPENSION

Shock absorber

Shock absorber to frame 1 M10 36,878 -

Linkages

Single conrod to frame 1 M10 36,878 ­Single / double conrod 1 M10 36,878 ­Double conrod swinging arm 1 M10 36,878 ­Double conrod / shock absorber 1 M10 36,878 -

ELECTRICAL SYSTEM

man. + 90
grade

tighten 2nd
time

-

Battery cover bracket 2 M5 1,475 ­Horn mount / bracket 1 M8 18,439 ­Odometer sensor on rear brake caliper support 1 M6 8,851 ­Rear direction indicators 2 M4 0,738 ­Front direction indicators / rear view mirrors 2+2 M6 3,688 ­Voltage regulator 2 M6 3,688 ­Coil to bracket support 1 M6 7,376 ­Tail light to rear fairing end 4 M5 0,738 ­Head lamp to front fairing 6 SWP5x14 1,475 ­Relay box to seat subframe 2 M6 2,213 ­Relay cable to starter motor 1 M6 3,688 ­Relay cable 2 M6 1,475 -

FRONT WHEEL

Wheel axle nut 1 M25x1,5 59,005 -

REAR WHEEL

Sprocket / Sprocket carrier 5 M10 36,878 ­Wheel axle nut 1 M25x1,5 88,507 -

2 - 11

GENERAL TECHNICAL INFORMATION

Y

COOLING SYSTEM

Fan support 2+2 M6 4,425 ­Expansion reservoir to frame 2 M6 3,688 ­Expansion reservoir cap 1 M28x3 man. ­Hose clips (8104097) - - 2,213 -

BRAKE SYSTEM

Front brakes

Right and left brake calipers 2+2 M10x1,25 36,878 ­Brake fluid reservoir to bracket 1 M6 5,163 ­Brake fluid reservoir to bracket support 1 M5 7,376 ­Brake disc 1 M8 22,127 ­Front brake three-way fitting bracket 6+6 M5 2,213 Loctite 243

Rear brakes

Brake caliper 2 M8 18,439 ­Brake lever pin 1 M8 11,036 Loctite 243
Brake fluid reservoir 1 M5 0,738 ­Brake shaft locknut 1 M6 man. ­Brake disc 5 M8 22,127 Loctite 243
Front brake hose three-way bracket 1 M5 2,213 -

EXHAUST SYSTEM

RSV 1000 R - RSV 1000 R FACTOR

Front exhaust hose to engine 4 M6 8,851 -

Rear exhaust hose to engine (upper screws) 2 M6 -

Rear exhaust hose to engine (lower screws) 2 M6 8,851 ­Lambda sensor 1 M18x1,5 28,027 -

FUEL TANK

Fuel pump flange

Fuel return fitting 1 M6 4,425 Loctite 243
Pump support to flange 3 M5 1,475 ­Electrical terminals on flange 2 M5 3,688 ­Fuel return cap 1 M6 7,376 Loctite 243
Fuel delivery hose on flange 1 M12x1,5 18,226 ­Fuel level sensor on pump support 2 SWP2,9x12 0,738 ­Fuel pump cabling on flange 2 M6 7,376 -

Fuel tank

Filler cap to tank 4 M5 3,688 ­Fuel pump flange to tank 8 M5 4,425 -

Fasten by
hand

2 - 12

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

ENGINE OIL RESERVOIR

Oil reservoir ( nuts ) 3 M6 7,376 ­Oil filter shank 1 M20x1,5 22,127 ­Oil drain cap 1 M8 11,063 ­Oil level bracket 2 M10x1 14,751 -

FRAME / FAIRING PANELS

Front fairing to air scoop 1 M6 2,213 ­Windshield to front fairing 8 M4 0,738 ­Fairings to rider's footrest and spacer 2+2 M6 1,475 ­Side fairing panels internal fitting w/ air dam 4 M5 2,213 ­Air dam to cooler's support(s) 2 M5 2,213 ­Front fairing panel to bottom yoke 3 M6 5,163 ­License plate holder to lower seat subframe cover 4 M6 2,213 ­Lower panel to seat subframe 3 M6 3,688 ­Front lower seat subframe panel to frame 2 M5 1,475 ­Side body panels to tank 1+1 M5 3,688 ­Side body panels to seat subframe 2+2 M5 2,213 ­Rear mudguard 4 M5 2,213 ­Front mudguard 4 M5 1,475 ­Rectangular reflector to license plate holder 2 M4 0,738 ­Stand bushing - lower panel to seat subframe 2 M6 8,851 ­Left/right side fairing 4 M5 2,213 ­Rear fairing - passenger's belt to seat subframe 2 M6 8,851 -

HANDLEBAR / CONTROLS

Vibration damping weights 2 M6 7,376 ­Vibration damping weights terminals 2 M18x1 25,815 ­Handlebars to fork legs 2 M8 36,878 ­Handlebar safety screws 2 M6 7,376 ­Left dimmer switch 1 M5x1 0,738 ­Right dimmer switch 1 M4 0,738 ­Front brake pump 2 M6 5,9 ­Clutch pump 2 M6 5,9 ­Clutch reservoir on support 1 M5 2,213 ­Rear fairing lock 2 M6 7,376 ­Seat subframe 4 M10 36,878 -

AIRBOX

Airbox cover 7 SWP5x20 1,475 ­Airbox to throttle body 6 M6 5,163 ­Intake funnels 4 SWP3,9 0,738 ­MAP sensor support 1 SWP5x20 1,475 ­Filter surround 2 SWP5x20 1,475 ­Air scoop to frame 4 M6 7,376 ­Rear view mirrors to air scoop 3+3 M5 3,688 -

2 - 13

GENERAL TECHNICAL INFORMATION

2.1.5. SPECIAL TOOLS

In order to perform assembly, reassembly and settings correctly, special tools suitable for the task must be used.
Using special tools prevents the potential risk of damage as a result of inappropriate tools and/or improvised
methods.
Below is a list of the special tools designed especially for this specific vehicle.
If necessary, request the multi-purpose special tools.

CAUTION
Before using the special tools, consult any documents attached.

SUPPORT STANDS

RSV 1000 R - RSV 1000 R FACTORY

Pos. Aprilia part# (tool description and function)

A

1
2
3

xxxxxxx N.A. = available only with the Aprilia kit part# 8140176 (complete support stand kit)

8140176 (complete support stand kit)
8146486 (front support stand)
xxxxxxx N.A. [center stand]
8705021 (rear support stand)

2 - 14

RSV 1000 R - RSV 1000 R FACTORY

FRAME TOOLS

GENERAL TECHNICAL INFORMATION

Pos. Aprilia part# (tool description and function)

A

1

2
3

FORK TOOLS

8140203 (complete tool kit for frame included)
8140189 [oil seal fitting tool - Ø 43 hole. Kit accessory Aprilia part# 8140151 (complete tool kit for fork

included)]
8140190 (steering tightening tool)
8140191 (rear fork pin and engine support tightening tool)

Pos. Aprilia part# (tool description and function)

A

1

2

3
4
5
6

8140151 (complete tool kit for fork included)
8140145 (Ø 41 mm sealing ring fitting tool)

8140146 [weight to be applied to the tool: Aprilia part# 8140145 (Ø 1.61 in sealing ring fitting tool)]

and Aprilia part# 8140189 [oil seal fitting tool - Ø 1.69 in hole. Kit accessory Aprilia part# 8140151
(complete tool kit for fork included)]

8140147 (spacer holding tool)
8140148 (spacer/pumping element separating plate)
8140149 (protection element for disassembly operations)
8140150 (drilled rod for pumping element bleeding)

2 - 15

GENERAL TECHNICAL INFORMATION

ENGINE TOOLS

RSV 1000 R - RSV 1000 R FACTORY

2 - 16

RSV 1000 R - RSV 1000 R FACTORY

Pos. Aprilia part# (tool description and function)

A
1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34

8140175 (complete tool kit for engine included)
0277680 (gearshift secondary shaft oil seal assembly pad)
0277660 (upper countershaft oil seal assembly pad)
0277670 (coolant pump shaft housing oil seal assembly pad)
0877257 (assembly pad for water pump shaft seat sliding ring)
0277510 (valve guide disassembly pad)
0277210 (valve guide assembly)
0277695 (valve guide oil seal assembly pad)
8140155 (gearshift shaft oil seal - clutch shaft oil seal assembly pad)
0277725 (driving shaft bush inserter pad)
0277720 (driving shaft sleeve puller pad)
0277537 (lower countershaft bush inserter pad)
0277727 (driving shaft - clutch cover bush inserter pad)
0277729 (insertion pad for lower balance shaft clutch cover bushes)
8140177 (plug socket spanner)
0277252 (flywheel magneto cover removal tool)
0277730 (flywheel removal hexagonal bolt)
0240880 (threaded bolt to lock the drive shaft at the TDC)
0277308 (gearshift secondary shaft guide bush)
8140178 (pin installation and removal pad)
8140181 (fuel-oil pressure gauge-compression)
8140182 (rotor bolt bush)
0277881 (clutch blocking tool)
8140156 + 8140157 + 0276377 (clutch cover sleeve puller)
0276479 (valve spring compression tool)
8140179 (valves disassembly and reassembly bow)
8157143 (adhesive for tool holder panel RSV mille)
8140183 (engine lifting eye hook)
8140184 (primary transmission nut disassembly bush)
8140185 (clutch disc extraction hook lever)
8140188 (engine support)
8140186 (piston ring compression tool)
8140197 (perforated bolt for fuel pressure test fuel)
8140205 (camshaft template)
8140426 (panel hooks)

GENERAL TECHNICAL INFORMATION

2 - 17

GENERAL TECHNICAL INFORMATION

MISCELLANEOUS TOOLS

RSV 1000 R - RSV 1000 R FACTORY

2 - 18

RSV 1000 R - RSV 1000 R FACTORY

Pos. Aprilia part# (tool description and function)

1
1
2
3
4
5
6
7
8

9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

8140196 [Plurigas (Italian)]
8140578 [Plurigas (English)]
8140192 (chain installation kit)
8140180 (bearing extractors)
8140202 (exhaust gas analysis probes)
8140267 (intake flange for vacuometer)
8140256 (vacuometer)
8140424 (OHLINS fork wrench)
8140199 (tool panel)
8140426 (panel hooks)
8140432 (pushing extractor)
8140187 (engine support stand)
8124838 (battery charger M.F.)
0897651 [LOCTITE® 243 blue (3.94 in³)]
0899788 [LOCTITE® 648 green (0.176 oz)]
0899784 (LOCTITE® 574 orange)
0297434 (LOCTITE® 767 Anti-Seize 15378)
0297433 [MOLYKOTE® G-N (1.76 oz)]
0897330 (multi-purpose grease bp lz)
0297386 [SILASTIC 732 RTV (3.53 oz)]
8116067 (LOCTITE® 8150)
8202222 (panel adhesive sheet)
8140074 (lower countershaft bush inserter pad)
8140204 (rear stand supports)
0277295 (hose clamp installation pliers)

GENERAL TECHNICAL INFORMATION

2 - 19

GENERAL TECHNICAL INFORMATION

TOOLS USED FOR OTHER Aprilia

RSV 1000 R - RSV 1000 R FACTORY

Pos. Aprilia part# (tool description and function)

0877650 (handle for pads)

1

0277265 (extractor for balance shaft, gearbox input and output shaft)

2

8116050 (engine oil)

–
–

8116053 (grease BIMOL GREASE 481 - AUTOGREASE MP or GREASE 30)
8116038 (grease LUBERING ST)

–

xxxxxxx N.A. (AP-LUBE temporary lubricant)

–

xxxxxxx N.A. (grease DID CHAIN LUBE)

–

8116031 (Fluid “Biosolvent” frame detergent)

–

8116945 (“ACRILICON 28” cyanoacrylic glue)

–

xxxxxxx N.A. (MOTUL MOTOWASH degreaser)

–

8116043 (ANTI-SEIZE MOTAGEPASTE AS 1800 antiscuff paste)

–

xxxxxxx N.A. (alcohol)

–

0898011 (fluorescent green LOCTITE® 275)

–

xxxxxxx N.A. (LOCTITE® 572)

–

xxxxxxx N.A. = not available

2 - 20

RSV 1000 R - RSV 1000 R FACTORY

2.1.6. ARRANGEMENT OF THE MAIN ELEMENTS

GENERAL TECHNICAL INFORMATION

KEY RSV R

1. Left side fairing

2. Adjustable steering damper RSV R OPT

3. Headlight left lamp

4. Front fairing

5. Left rear-view mirror

6. Clutch fluid’s reservoir

7. Engine’s oil filter

8. Left side panel

9. Rider’s seat

10. Battery

11. Main fuse carrier (30 A)

12. Passenger seat’s lock glove/tool kit compartment

13. Passenger left footrest (snaps closed/open)

14. Drive chain

15. Rear swinging arm

16. Rider’s left footrest

17. Side stand

18. Gear shift lever

19. Engine’s oil tank

20. Engine’s oil level

21. Engine oil tank’s cap

2 - 21

GENERAL TECHNICAL INFORMATION

RSV 1000 R - RSV 1000 R FACTORY

KEY RSV R

1. Rear shock absorber

2. Passenger right footrest (snaps closed/open)

3. Tail light

4. Glove/tool kit compartment

5. Passenger seat (glove/tool kit’s compartment cover)

6. Passenger’s grab strap

7. Engine’s Control Unit

8. Right side panel

9. Fuel tank

10. Coolant expansion tank’s cap

11. Fuel tank’s filler cap

12. Air cleaner

13. Right rear-view mirror

14. Front brake fluid’s reservoir

15. Secondary fuse carrier (15 A)

16. Horn

17. Right side fairing

18. Expansion tank

19. Rear brake fluid’s reservoir

20. Rear brake master’s cylinder

21. Rear brake’s lever

22. Rider’s right footrest

2 - 22

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

PRINCIPALI

KEY RFACT

1. Left side fairing

2. Adjustable steering damper

3. Headlight left lamp

4. Front fairing

5. Left rear-view mirror

6. Clutch fluid’s reservoir

7. Engine’s oil filter

8. Left side panel

9. Rider’s seat

10. Battery

11. Main fuse carrier (30A)

12. Passenger seat-Glove/tool kit’s compartment lock

13. Passenger’s left footrest

14. Drive chain

15. Rear swinging arm

16. Rider’s left footrest

17. Side stand

18. Gear shift lever

19. Engine’s oil tank

20. Engine’s oil level

21. Engine oil tank’s cap

2 - 23

GENERAL TECHNICAL INFORMATION

RSV 1000 R - RSV 1000 R FACTORY

KEY RFACT

1. Rear shock absorber

2. Passenger’s right footrest (snaps closed/open)

3. Tail light

4. Glove/tool kit’s compartment

5. Passenger seat (Glove/tool kit’s compartment cover)

6. Passenger’s grab strap

7. Engine’s Control Unit

8. Right side panel

9. Fuel tank

10. Coolant expansion tank’s cap

11. Fuel tank filler’s cap

12. Air cleaner

13. Right rear-view mirror

14. Front brake fluid’s reservoir

15. Secondary fuse carrier (15A)

16. Horn

17. Right side fairing

18. Coolant expansion tank

19. Rear brake fluid’s reservoir

20. Rear brake’s master cylinder

21. Rear brake’s lever

22. Rider’s right footrest

2 - 24

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

2.1.7. ARRANGEMENT OF THE INSTRU­MENTS/CONTROLS

Key:

1. Clutch lever

2. Ignition/steering lock switch (

3. Instruments and indicators

4. Front brake lever

5. Throttle twistgrip

6. High beam flasher ( )/LAP button (multifunction)

7. Light dimmer switch (

8. Direction indicator switch (

9. Horn button (

10. Starter button (

11. Engine kill switch (

Key:

1. Rev counter

2. Red line light

3. Green direction indicator light (

4. Blue high beam light (

5. Amber "stand down" light (

6. Amber low fuel light ( )

7. Red immobilizer light (

is fitted)

8. Green neutral light (

9. Multifunction digital display (coolant temperature - clock

- battery voltage - lap timer - engine oil pressure
diagnostics (

10. Red general warning light (

11. Multifunction computer programming buttons

(+, Trip V, -)

)

)

N

)

)

- - )

- )
)

)

)

)

)

) (where immobilizer system

)

2 - 25

GENERAL TECHNICAL INFORMATION

Y

2.1.8. DASHBOARD OPERATION

When the ignition key is turned to “ ”, the following will light
up on the dashboard for 3 seconds:

- all segments of the multifunction display

- all indicator leds

- display backlighting
The revolution counter pointer (1) will move to the maximum
rpm set by the user.
After 3 seconds the red line led (2) will turn off and the revo­lution counter pointer (1) will return to its initial position.
After the initial self-test, all instruments will indicate their real­time current values.

RSV 1000 R - RSV 1000 R FACTOR

WARNING

If “

ERR” flashes on the dashboard instead of the

water temperature reading and if the stand and
red line leds turn on, then there is a communi­cations problem on the can line between the
dashboard and the ECU.
After the first 1000 Km, the SERVICE icon will
be displayed on the multifunction display. It will
be displayed for a second time after 10,000 Km,
and every 10,000 Km thereafter.
To reset the SERVICE message, hold down the

When the ignition key is turned to “ ” the standard display
settings are:

- current speed

- clock

- coolant temperature

- odometer

+ and – keys for at least 15 seconds at key-ON.

METRIC SYSTEM DISPLAY (Km-mi, kph-MPH, °C-°F)

• To switch between Km/mi, kph/mph, hold down the
TRIP/V and – keys for at least 15 seconds.

• To switch between °C and °F hold down the TRIP/V
and + keys for at least 15 seconds.

2 - 26

RSV 1000 R - RSV 1000 R FACTORY

CURRENT/MAX/AVERAGE SPEED AND BATTERY
VOLTAGE DISPLAY

IMPORTANT The average/max speed and battery voltage
are only displayed with the vehicle stationary. Only the cur­rent speed is displayed when the vehicle is being driven.

When the ignition key is turned to “
displayed. To display the max speed (V max), average
speed (AVS) and battery voltage, press the + key.
To reset the max speed (V max) and average speed (AVS),
press the – key for at least 3 seconds while the values are
being displayed.

IMPORTANT The max and average speed readings refer to
the period since they were last reset.

The battery voltage reading (V) is not modifiable and gives
information on the operating condition of the battery.
The recharger circuit is operating correctly if the battery volt­age reads 13 to 15 V with the headlamp set to low beam and
the engine running at 4000 rpm.

” the current speed is

GENERAL TECHNICAL INFORMATION

Instruments lighting adjustment: the dashboard backlighting
can be adjusted to three levels (30%, 70%, 100%); this is
done by pressing the – key during the first 5 seconds after
the ignition key has been turned to “

”.

TOTAL AND PARTIAL (TRIP 1 / 2) ODOMETER DIS­PLAYS

When the ignition key is turned to “

” the odometer is dis­played. To display the partial odometer readings (TRIP 1 / 2),
press the TRIP/V key.

2 - 27

GENERAL TECHNICAL INFORMATION

Y

To reset partial odometer 1 (TRIP 1), display the reading and
hold down the TRIP/V key for at least 3 seconds.

RSV 1000 R - RSV 1000 R FACTOR

To reset partial odometer 2 (TRIP 2) display the reading and
hold down the TRIP/V key for at least 3 seconds.

IMPORTANT The partial odometer readings refer to the pe­riod since they were last reset.

• The partial odometer readings (TRIP 1 / 2) are reset
when the battery is disconnected from the vehicle.

DISPLAY : COOLANT TEMPERATURE

- The coolant temperature display reads “---” when the

sensor reads a temperature below 34°C (93°F).

- The current temperature reading is displayed without

flashing when the sensor reads a temperature between
35°C (95°F) and 114°C (237°F);

- The display flashes when the reading is between 115° C

(239° F) and 135°C (275°F). The warning led also lights
up to indicate that the temperature is in the danger zone.

- The display will flash 135°C (275°F) if the temperature

exceeds this value (with warning led on).

WARNING
If the coolant temperature sensor is discon­nected or damaged, the dashboard error led
turns on (
read.

Thermometer range : 35-135°C (95-275 °F).

) and the coolant temperature is not

2 - 28

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

SETTING THE DIGITAL CLOCK

The digital clock is at the top of the display.
The clock displays only when the ignition key is turned to
“

”.

IMPORTANT The clock can be set only with the vehicle sta­tionary and the ignition key turned to “

”.

HOURS SETTING

• Hold down the + and – keys for at least 3 seconds so
that the hour digits start to flash.

• Use the + and – keys to set the hour.

• If one of the keys is held down, the setting will run

through the hours one a second.

• Hold down the TRIP/V key for at least 3 seconds to
confirm the new setting. The clock will automatically
move to the minutes setting mode.

MINUTES SETTING

• Press the + or – key to increase/decrease the minute
setting. If one of the keys is held down, the setting runs
through the minutes one a second.

• Hold down the TRIP/V key for at least 3 seconds, at
which point the minute digits will stop flashing to indi­cate that the new setting is confirmed.

• The clock setting is lost when the battery is discon­nected from the vehicle.

CHRONOMETER

The chronometer measures the lap time when driving on
track and stores the data for later reference.
When the chronometer is enabled, the clock function is ex­cluded.
To activate the chronometer :

• Hold down the LAP button and press TRIP/V for more
than 3 seconds. The clock display will be replaced by
“01 LAP 00’00”00 ”.

To de-activate the chronometer :

• Hold down the LAP button and press TRIP/V for more
than 3 seconds. The clock display will return.

2 - 29

GENERAL TECHNICAL INFORMATION

Y

To start the chronometer :

• press and immediately release the LAP button. The
first time the button is pressed, the stop clock starts.
Pressing LAP again within the first 10 seconds will re­set the chronometer. Pressing the LAP button again
starts a new lap; the previous lap time and number are
displayed for 10 seconds at the top left of the display.
At the end of the 10 seconds, the chronometer will dis­play the second lap time and number.

IMPORTANT Up to 40 laps can be stored; pressing the LAP
button after this does not start a new lap and the display will
automatically show the 40 stored lap times. To reset the
chronometer function the 40 stored laps must be reset.

• To reset a stored time, enable the chronometer.
With the LAP button held down, press the – key for at
least 3 seconds.

• The display will read “Ø1 LAP ØØ’ ØØ” ØØ ” to indi­cate that all 40 stored laps have been set to zero.

• Stored lap times are zeroed when the battery is dis­connected from the vehicle.

To display the stored lap times :

• Enable the chronometer function and hold down
TRIP/V for more than 3 seconds. To scroll through the
laps, press the +/- keys (forwards/back respectively).

• To return to the chronometer function, press TRIP/V
again for more than 3 seconds.

DIAGNOSTICS

Whenever the ignition key is turned to “
for 3 seconds.

WARNING
If “EFI” displays together with the warning led
(

) while the engine is running normally, the
ECU has detected a fault.
In most cases the engine will continue to oper­ate although with reduced performance.

”, “EFI” is displayed

RSV 1000 R - RSV 1000 R FACTOR

ENGINE OIL PRESSURE

Whenever the ignition key is turned to “ ”, the engine oil
pressure led turns on for 3 seconds.

WARNING
If the engine oil pressure icon stays on together
with the warning led (
turns on while the engine is running normally,
the engine oil pressure is insufficient.
In this case, stop the engine immediately.

), after starting, or if it

2 - 30

RSV 1000 R - RSV 1000 R FACTORY

RED LINE ADJUSTMENT (ONLY WITH ENGINE OFF)

When the engine rpm exceeds the red line setting, the red
line indicator (2) on the dashboard flashes.

IMPORTANT The red line setting can only be adjusted with
the engine off and the odometer displayed (adjustment range
2000 to 12000 rpm).

The default value is 6000 rpm.
To display the red line setting, hold down TRIP/V for at least
3 seconds. The revolution counter pointer (1) will move to the
set red line value.

GENERAL TECHNICAL INFORMATION

To adjust :

• Turn the ignition key to “ ”.

• Wait for the self-check to complete.

• Press TRIP/V for more than 3 seconds: the revolution

counter pointer (1) will move to the set red line value.

• The red line setting can be adjusted during the 3 sec­onds that the revolution counter pointer (1) is indicating
the set value.

• Adjust the red line setting with the + key: pressing it
briefly will increase the setting by 100 rpm; holding it
down will increase it by 1000 rpm.

• If the pointer reaches the full-scale value (12000 rpm) it
is automatically reset to zero.

• 3 seconds after the last adjustment (+ key) the new red
line setting is stored and confirmed by the red line indi­cator (2) turning on for 3 seconds. The pointer (1) re­turns to zero.

• If the engine is started during the adjustment proce­dure, the previous setting is maintained. The setting is
lost if the battery is disconnected during the adjustment
procedure, and the previous setting is maintained.

DASHBOARD ECU DIAGNOSTICS CODE DISPLAY

Display type :
water temperature digits together with EFI icon and warning
led (

). When a diagnostics code is displayed, the water
temperature’s symbol (thermometer), units’ indication (°C/°F)
and display segments disappear.
Operating modes :
In normal conditions, the “EFI” icon and warning led (

) are
off. If one or more Fault Codes are sent to the dashboard by
the ECU, the dashboard will not display them; it will only turn
on the warning led (

) and “EFI” icon instead.

2 - 31

GENERAL TECHNICAL INFORMATION

Y

To display the diagnostics codes in question, enable diag­nostics mode by pressing the LAP button at key-ON for at
least 15 seconds. To exit the diagnostics code display and
return to the normal display mode, run a key-OFF/ON cycle.
When the faults are eliminated and hence the Fault Code is
no longer being sent to the dashboard by the ECU, the
dashboard will continue to display them until a key-OFF/ON
cycle is run.
If the dashboard is sent a code other than those given in the
following diagnostics code table, it will display PXX where
the XX is the last two digits of the code in question. If the
CAN line does not respond or is disconnected in diagnostics
mode, ERR will flash in place of the code digits.

RSV 1000 R - RSV 1000 R FACTOR

DIAGNOSTICS CODE TABLE

Error Type Error type Aprilia Code

NO error - ­Cam Sensor No signal 11

Crank Sensor

MAP Sensor

TPS

Engine temperature

Air temperature

Barometric pressure

Ignition #1 Ignition signal 1 not present 33
Ignition #2 Ignition signal 2 not present 35
Tip Over Switch Sensor fault / disconnected 41

Injector #1

Injector #2

Stepper motor

Fuel Pump

Lambda

Oil pressure Sensor fault 47

Engine fan relay

Tank purge valve Valve short circuit / open / short circuit with battery +V 49

Starter

Battery voltage

No signal
Faulty signal
Sensor fault
Signal < V
Signal > V
Sensor voltage < V
Sensor voltage > V
Sensor fault
Sensor not adapted
Sensor fault
Sensor voltage < V
Sensor voltage > V
Sensor fault
Sensor voltage < V
Sensor voltage > V
Sensor voltage < V
Sensor voltage > V

Injector 1 short circuit / open
Injector 1 short circuit with battery +V
Injector 2 short circuit / open
Injector 2 short circuit with battery +V
Output fault
Output fault
Pump short circuit / open
Pump in short circuit with battery +V
Sensor voltage </> V or faulty sensor
Sensor short circuit / open / short circuit with battery +V
Sensor not adapted

Fan relay short circuit / open / short circuit with battery
+V

Starter short circuit / open
Starter short circuit with battery +V
Battery voltage < V
Battery voltage < V

12

13

15

21

22

23

42

43

44

45

46

48

50

51

2 - 32

RSV 1000 R - RSV 1000 R FACTORY

SERVICE INTERVALS

Display type : SERVICE icon
Operating modes : the SERVICE icon displays

- after the first 1000 Km (620 mi) ± 5%;

- next after a total 10000 Km (6213 mi), i.e. 9000 Km
(5592 mi) after the first time,

- every 10000 Km (6213 mi) ± 5% thereafter, hence
at 20000 Km (12427 mi); 30000 Km (18641 mi),
etc…

To reset the « SERVICE » function, hold down the + and –
keys together for at least 15 seconds at key-ON.

GENERAL TECHNICAL INFORMATION

2 - 33

GENERAL TECHNICAL INFORMATION

Y

RSV 1000 R - RSV 1000 R FACTOR

2.1.9. SYSTEMS DIAGRAM

BRAKES

2 - 34

RSV 1000 R - RSV 1000 R FACTORY

GENERAL TECHNICAL INFORMATION

GAS RECOVERY FROM CRANKCASE

2 - 35

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

FUEL SYSTEM 3

3-1

FUEL SYSTEM

Y

RSV 1000 R - RSV 1000 R FACTOR

SUMMARY

3.1. FUEL SYSTEM................................................................................................................................................ 3

3.1.1. DIAGRAM .............................................................................................................................................. 3

3.1.2. INJECTION SYSTEM DIAGRAM........................................................................................................... 4

3.1.3. CYLINDER TIMING AND CO LEVEL ADJUSTMENT............................................................................ 6

3.1.4. AXONE................................................................................................................................................... 7

3.1.5. AIRBOX................................................................................................................................................ 11

3.2. FUEL PUMP .................................................................................................................................................. 12

3.2.1. REMOVING THE FUEL PUMP ASSEMBLY ........................................................................................ 12

3.2.2. REMOVING THE FUEL LEVEL SENSOR ........................................................................................... 13

3.2.3. REMOVING THE DELIVERY FILTER.................................................................................................. 14

3.2.4. REMOVING THE FUEL SUPPLY PUMP ............................................................................................. 15

3.3. THROTTLE BODY......................................................................................................................................... 17

3.3.1. REMOVING THE THROTTLE BODY................................................................................................... 17

3.3.2. DISASSEMBLING THE THROTTLE BODY......................................................................................... 20

3.3.3. INSPECTING THE THROTTLE BODY ................................................................................................ 23

3.3.4. REFITTING THE THROTTLE BODY ................................................................................................... 24

3.3.5. REPLACING THE THROTTLE VALVE CONTROL LEVER ................................................................. 26

3.3.6. CHECKING THROTTLE VALVE CONTROL SHAFT END PLAY ........................................................ 27

3 - 2

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

3.1. FUEL SYSTEM

3.1.1. DIAGRAM

Key

1) Fuel tank

2) Filler cap

3) Fuel supply pump unit

4) Fuel vapor breather pipe (for the vapors produced by excessive pressure inside the tank)

5) Fuel “overflow” drainage pipe

6) Fuel level sensor

7) Fuel delivery filter

8) Fuel supply pump

9) Fuel delivery pipe

10) Fuel return pipe

3 - 3

FUEL SYSTEM

Y

RSV 1000 R - RSV 1000 R FACTOR

3.1.2. INJECTION SYSTEM DIAGRAM

3 - 4

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

Legend :

1. ECU location

2. Ignition switch

3. Battery

4. Engine shaft position sensor

5. Camshaft position sensor

6. Engine temperature sensor

7. Air temperature sensor

8. Throttle position sensor

9. Intake pressure sensor

10. Safety system: Side stand, idle sensor

11. Test switch

12. Fall sensor

13. Atmospheric pressure sensor

14. Oil pressure sensor

15. Fan

16. Automatic air

17. Intake flap

18. Lambda sensor

19. Diagnostics connector

20. Starter relay

21. Fuel pump

22. Injector 1

23. Injector 2

24. Coil

3 - 5

FUEL SYSTEM

Y

3.1.3. CYLINDER TIMING AND CO LEVEL ADJUST­MENT

• With the vehicle switched off, connect the Axone 2000

to the diagnostics’ connector and the vehicle’s battery.

• Switch on the instrument.

RSV 1000 R - RSV 1000 R FACTOR

• Connect the exhaust gas analyzer’s lines to their fit-

tings.

• Start with both throttle body bypass screws fully closed.

• Open a single screw to balance the exhaust gas CO

level, as read off the analyzer’s display.

• Read the front and rear cylinder pressure values off the

Axone, and check that they are as follows :

front cylinder pressure = rear cylinder pressure –
(30 ± 10) mbar

IMPORTANT Incorrect pressure value’s readings indicate a
possible malfunction.

3 - 6

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

3.1.4. AXONE

ICON DISPLAY

ISO

ENGINE PARAMETER READING

DEVICE STATUS (generally on/off)

DEVICE ACTIVATION

ERRORS DISPLAY

ADJUSTABLE PARAMETERS

UNITS

DISPLAY DESCRIPTION

ISO

ENGINE
PARAMETER
READING

Aprilia hardware
Aprilia software
Revision number
Engine
Manufactured
Mapping
Date programmed
Last author

Water temperature °C Fans are activated at 101°C

Air temperature °C
Engine speed rpm
Target minimum engine
speed
Engine load -
Intake pressure hPa Value read by sensor connected to the

Effective
throttle
aperture
Spark advance °
Throttle 0-78° ° Reads the throttle aperture in degrees
Throttle offset approx.

Idling control stepper motor - Steps of idling control motor
Battery voltage V
Vehicle speed kph
Cylinder pressure
(front)
Cylinder pressure
(rear)
Lambda correction - Approx. 1 with lambda sensor active

VALUES

(APPROXIMATE)

rpm ECU target engine speed for current

2,7-80 ° Parameter which accounts for the throt-

0,60- 0,63

hPa Intake duct pressure

hPa Intake duct pressure

OF

MEASURE-

MENT

Indicates the ECU mapping code
Most recent mapping date
ID of PC/Axone which loaded the most
recent mapping

operating conditions

two intake ducts

tle aperture and stepper motor position

V Reference after reset (ECU stored

value)

NOTES

3 - 7

FUEL SYSTEM

Y

RSV 1000 R - RSV 1000 R FACTOR

DEVICE
STATUS

Lambda sensor mV Value ranges from 300 to 3000 mV
Type 1 carburetor adjust­ment
Type 2 carburetor adjust­ment
Idling carburetor adjustment

Injection time ms
Atmospheric pressure hPa Sensor located under seat
Spark advance °

Fall sensor normal/

ECU valid/invalid combination The ECU supplies the valid combina-

Oil pressure low/

Idling condition

Full load on/off Engine condition under full load (engine

Engine kill button

Ignition request on/off Thus can be seen with the gear en-

Purge valve on/off
Lambda sensor active on/off Lambda sensor operational
Cut off on/off Activates at certain engine speed /

Throttle self-teaching com­pleted

Engine heating phase

Power latch
completed

Reduced operation

Gear in neutral yes/no
Switch on/off Parameter not assigned
Side stand up/down
Clutch engaged yes/no
Initialization error no / engine speed >0 / vehicle

Purge valve status lambda on / threshold not reached

- Tells the ECU how much air is required
in the type 1 engine load condition

- Tells the ECU how much air is required
in the type 2 engine load condition

- Tells the ECU how much air is required
in the idling engine load condition

tip over

tion signal to the dashboard when it is
installed on a compatible vehicle

normal
on/off Engine condition at idling (see also with

engine off)

must be on)

on/off Engine kill button status

gaged by pressing the starter button: in
this condition the ECU reads the igni­tion permissive (Axone reads ON) but
does not start the engine. For instance,
if the right dimmer switch circuit is inter­rupted, although the ignition button is
pressed, the condition of this parameter
does not change (it stays OFF)

throttle position etc. combinations

on/off If throttle position self-teaching does

not end successfully, the parameter =
OFF

on/off

on/off When power to the ECU is switched off,

a series of parameters is stored during
the power latch

on/off In case of serious engine malfunction, it

will be run at only less than a set en­gine speed

List of the potential reasons why the

speed >0 / stepper error / throttle
out of range / battery voltage / wa­ter temperature / idling control mo­tor off

/ Cut off active / rpm threshold /
speed / Injector defect / HW cut off
/ not active

throttle self-teaching or initialization
failed

Purge valve related reasons why the
lambda sensor does not activate; only
for CALIFORNIA version, check opera­tion

3 - 8

Lambda sensor initialization / wait after start / sen- Lambda sensor status

RSV 1000 R - RSV 1000 R FACTORY

q

DEVICE AC­TIVATION

ADJUSTABLE
PARAME­TERS

Long term adjustment de­activation

Engine variant 1/2 1 if standard mapping is enabled, 2 if

Injectors per cylinder 1cil Not modifiable: 1cil must display
Cylinder head sensor no Not modifiable: no must display
Boost adjustment no Not modifiable: no must display
Lambda sensor yes Modifiable only with password – nor-

Water injection no Not modifiable: no must display
Minimum motor present yes Modifiable only with password – nor-

Purge valve yes/no Modifiable only with password: must be

Electronic reverse no
Electric starting

ECU
initialized

Errors reset

Fuel pump
Intake distribution
Lambda sensor heating
Fan
Purge valve Activation only for USA version
Front injector
Rear injector
Front coil
Rear coil

Initialization To reset adaptive parameters when

Throttle position self­teaching
CO adjustment 1 Modifiable only with password in case

CO adjustment 2 Modifiable only with password in case

Engine variant Set to 1 for standard mapping, 2 for

Lambda sensor Modifiable only with password: for de-

Idling control motor present Modifiable only with password: for de-

Purge valve Modifiable only with password: must be

ECU initialized Activation re

FUEL SYSTEM

sor status recognition / wait after
recognition / de-activated due to
driving / de-activated due to fault /
wait after interruption / lambda
sensor active / saturated
no / max tries / water temperature
over threshold / low battery voltage
/ TWLAD2 running / rpm or load
over threshold / TWLAD running /
long term adjustment completed /
short term carburetor adjustment
not active

yes Not modifiable: yes must display

yes Indicates that the « ECU initialized »

ECU throttle sensor and stepper motor

Reasons for de-activation of long term
adaptivity

racing mapping is enabled

mally yes, i.e. lambda sensor present

mally yes, i.e. minimum motor present

yes only for USA version

parameter has been enabled. If the
ECU is replaced, this parameter must
be enabled

changing the ECU / throttle body / in­jectors (may stay at around 5000 rpm
for the first few seconds after ignition).
The engine ignition number counter
(frozen error parameters) is reset

position self-teaching

the CO level cannot be balanced using
the throttle bypass screws

the CO level cannot be balanced using
the throttle bypass screws

racing mapping

activating the lambda sensor inde­pendently of the mapping type

activating the idling control motor

yes only for USA version

uired for new ECU instal-

3 - 9

FUEL SYSTEM

Y

FROZEN PA­RAMETERS

Engine load % Contrary to the engine parameters dis-

Water temperature °C
Air temperature °C
Battery voltage V
Intake pressure approx. 60 kPa Parameter of little significance, highly

Vehicle speed kph
Engine speed rpm
Throttle position %
Cylinder 1 dwell point °
Engine in VL mode no
Cut off active
Status Not recognized by dashboard Parameter without significance
Frequency 1-2 - Number of times error detected by ECU

Time since ignition 1-0 min Time since ignition for last detection of

Driving cycles 7-8 - Number of times the engine had been

Operating time 72-72 min Total minutes of engine’s operation at

The following options are available from the adjustable pa­rameters display :

• throttle position sensor alignment,

• ECU initialization, including throttle alignment, mini-

mum stepper motor reset and lambda sensor adaptive
parameters reset.

• ECU initialization, required when a new ECU is in­stalled

Throttle position alignment must be done whenever the throt­tle body / ECU is replaced.

• Select function: « Throttle position self-teaching ».

• Make sure the throttle is fully closed

• Press ENTER “

• Turn the key to OFF and wait for at least 30 seconds.

ECU initialization must be performed whenever important
engine components (valves, cylinder, camshaft), the exhaust
system, ECU, fuel system or lambda sensor are replaced.
The three self-adaptive correction factors for lambda sensor
control of injection timing are electronically reset.

• Select the function « initialization »

• Make sure the throttle is fully closed

• Press ENTER “

• Turn the key to OFF and wait for at least 30 seconds.

Initialization enables activation of a new ECU

• Select function: « ECU initialized ».

• Follow the instructions to enable the new ECU

• Turn the key to OFF and wait for at least 30 seconds.

“.

“.

RSV 1000 R - RSV 1000 R FACTOR

lation (activates a set of parameters)

play, here expressed as %

dependent on conditions

(including ECU checks at power up, for
certain error types)

error in question

switched on at the time of detection of
the error in question. The counter re­sets when the Initialization parameter is
enabled

the last time the error in question was
detected. The counter does not reset
when the Initialization parameter is en­abled

3 - 10

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

3.1.5. AIRBOX

Key:

1. Throttle body

2. Front air intake

3. Check valve

4. Membrane

5. Solenoid valve

6. Vacuum chamber

7. Atmospheric pressure

Air intake is controlled by a flap in the duct leading from the windshield to the airbox.
This flap reduces engine noise at low engine speeds.
The flap assembly is composed of: hatch / tie-rod / membrane / solenoid valve
The flap is normally closed and opens in the following circumstances:

minimum 6500 rpm
minimum 30 % throttle opening

The vacuum chamber acts to prevent pressure pulses.
If the check valve is to be replaced, take care to fit it in the correct position: the white part must be facing the vacuum
chamber.

3 - 11

FUEL SYSTEM

Y

3.2. FUEL PUMP

3.2.1. REMOVING THE FUEL PUMP ASSEMBLY

• Completely remove the fuel tank.

IMPORTANT Position the tank on a clean surface with the
pump unit uppermost.

• Loosen and remove the eight screws (1).

IMPORTANT To refit, fasten all screws (1) by hand in their
holes and tighten in a cross pattern.

RSV 1000 R - RSV 1000 R FACTOR

WARNING
When removing the pump assembly make sure
not to damage the fuel hoses and level sensor.

• Remove the entire fuel pump assembly.

3 - 12

RSV 1000 R - RSV 1000 R FACTORY

3.2.2. REMOVING THE FUEL LEVEL SENSOR

• Remove the entire fuel system.

• Disconnect the connector.

FUEL SYSTEM

• Release and remove the 2 screws.

• Remove the fuel level sensor.

3 - 13

FUEL SYSTEM

Y

3.2.3. REMOVING THE DELIVERY FILTER

• Remove the whole fuel supply pump unit.

NOTE: Have the appropriate special tool OPT at hand:

- Aprilia part# 0277295 (hose clamp installation pliers).

CAUTION
Upon installation, replace the hose clamp that
has been removed with a new one having the
same dimensions.
Do not attempt to reinstall the removed hose
clamp, since it is unusable.
Do not replace the removed hose clamp with a
screw clamp or with other types of clamp.

RSV 1000 R - RSV 1000 R FACTOR

• Release the hose clamp (1).

• Slip the pipe off the filter.

• Release the hose clamp (2).

• Slip the filter off the pipe.

CAUTION
Do not use filters that have already been used.

• Replace the filter with a new one of the same type.

3 - 14

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

3.2.4. REMOVING THE FUEL SUPPLY PUMP

• Remove the whole fuel supply pump unit.

NOTE Have the appropriate special tool OPT at hand:

- Aprilia part# 0277295 (hose clamp installation pliers).

CAUTION
Upon installation, replace the hose clamp that
has been removed with a new one having the
same dimensions.
Do not attempt to reinstall the removed hose
clamp, since it is unusable.
Do not replace the removed hose clamp with a
screw clamp or with other types of clamp.

• Release the hose clamp (1).

• Pull the fuel pipe off the pump.

• Disconnect the electric connector.

• Disconnect the electric connector.

3 - 15

FUEL SYSTEM

Y

• Loosen and remove the 3 screws.

RSV 1000 R - RSV 1000 R FACTOR

• Bend the fuel filter over sideways and keep it held
down.

If the filtering mesh shows traces of sediments, clean it
using a compressed air jet pointing it so that the impuri­ties do not get inside.

3 - 16

RSV 1000 R - RSV 1000 R FACTORY

3.3. THROTTLE BODY

3.3.1. REMOVING THE THROTTLE BODY

WARNING
The throttle setting screws (1) are painted over
and cannot be adjusted.
Only if the entire cable fitting (2) is to be re­placed, the setting screws can be adjusted.
The two M4x12 (3) screws securing the throttle
valve potentiometer are painted over and can
only be extracted if the sensor itself is being
removed.

FUEL SYSTEM

• Partially remove the fuel tank.

• Remove the airbox.

• Detach the electrical connectors.

•

- right injector;

- left injector;

- throttle valve potentiometer.

3 - 17

FUEL SYSTEM

Y

IMPORTANT Make sure to use the special OPT tool:

- Aprilia part# 0277295 (snap clip pliers).

• Undo the snap clip (4).

• Undo the snap clip (5).

• Extract the hoses from the throttle body.

RSV 1000 R - RSV 1000 R FACTOR

• Undo the two throttle control cables.

WARNING
During rebody, make sure the two throttle con­trol cable adjusters are correctly mounted to
their fittings and check/adjust their play.

• Extract the airbox flap hose from the throttle body.

3 - 18

RSV 1000 R - RSV 1000 R FACTORY

• Undo the two clips

FUEL SYSTEM

WARNING
When removing the throttle body proceed with
care as it is still connected to the fuel tank via
the fuel hose.

• Grip the throttle body firmly and move it up and away
from the intake flanges with small rocking movements.

• Place the entire throttle body and fuel tank, which are
connected to each other, on a clean surface.

When reassembling :

- the fuel delivery hose must not be twisted or squeezed

by other components; if it is damaged or degraded in
any way, it must be replaced;

- the fuel delivery hose must be positioned in such a way

as to reach the right hand side of the throttle body from
below, passing between the two intake flanges;

- the throttle body must be perfectly seated on the intake

flanges;

- the clips must be fully tightened down.

3 - 19

FUEL SYSTEM

Y

3.3.2. DISASSEMBLING THE THROTTLE BODY

• Unscrew and remove the M8x1 nut (1) and remove the
spring washer.

RSV 1000 R - RSV 1000 R FACTOR

• Turn the throttle valve control lever (2) slightly, un­screw and remove three T.E. M5x12 screws (3).

• Slip the whole support bracket (4) securing the throttle
cables, with the two bushes (5) and the torsion spring
(6), off the throttle body.

• Loosen and remove the two M6x16 screws (7) and re­move the fuel pressure regulator (8) complete with O­ring.

• Loosen and remove the three M6x25 screws (9) and
remove the left injector support (10) - together with the
relevant gasket (11), injector (12) and sealing ring (13)

- from the throttle body.

3 - 20

RSV 1000 R - RSV 1000 R FACTORY

FUEL SYSTEM

• Loosen and remove the two M6x25 screws (14) and
the right injector support (15), together with the rele­vant gasket (16), injector (17) and sealing ring (18).

NOTE The injector’s sealing ring (18) may be kept inserted
in the slot on the throttle body.

3 - 21

FUEL SYSTEM

Y

• Unscrew and remove the M8x1 nut (19) and remove
the spring washer (20), the pulley (21), the two bushes
(22) and torsion spring (23).

RSV 1000 R - RSV 1000 R FACTOR

• Slide the fulcrum pin (24), together with the lock
washer (25), out of the hole on the throttle cable sup­port bracket and remove the two shaft sealing rings
(26) with the torsion spring (27) and cold-start lever
(28).

3 - 22

RSV 1000 R - RSV 1000 R FACTORY

3.3.3. INSPECTING THE THROTTLE BODY

TESTING THE INJECTOR

NOTE The injectors can be controlled electrically.

• Check the following components:

- wiring and connections;

- injector or injection’s signal of the engine control unit.

FUEL SYSTEM

THROTTLE BODY

• Clean all the openings and pipes of the throttle body
(1) using compressed air.

• Check the pipes of the intake pressure sensor (2),
watching out for any clogging.

• Check the throttle valves unit and the cable fastening
mechanism (3), watching out for any signs of mechani­cal damage.

NOTE In the event the synchronization screws (4) or O-rings
(5) are replaced, synchronize the cylinders.

• Loosen the two cylinder synchronization screws (4)
only in case of air escapes.

• When replacing the tie rod of the ball joint (6), disen­gage the tie rod from the throttle valve control lever (7)
and throttle cable pulley (8).

• Once a new ball joint tie rod (6) has been fitted, make
sure it moves freely.

3 - 23

FUEL SYSTEM

Y

3.3.4. REFITTING THE THROTTLE BODY

CAUTION
After disassembling the throttle body, replace
all the gaskets, O-rings, torsion springs,
bushes and seals. These components are sup­plied with the repair kit.

• Fit the new O-rings (1) and seals (2) on both injectors.

• Insert the injector (3) in the left injector support (4) and

in the right injector support (5).

• Fit the left injector support gasket (6), right injector
support gasket (7) and the two seals (8) on the throttle
body.

• Install the complete left injector support (4) and right in­jector support (5) in the throttle body, fastening them
with the new M6x25 (9) (10) screws respectively.

• If the synchronizing screws (11) and respective O-rings
(12) have been replaced, tighten the screws (11) until
they touch the stop and then unscrew them a single
turn.

RSV 1000 R - RSV 1000 R FACTOR

Presetting of synchronizing screws (11): 1 turn.

CAUTION
The precise adjustment of the screws (11) must
be performed using a vacuum gauge.

• Fasten the fuel pressure regulator (13) using the two
M6x16 screws (14).

NOTE Smear a film of grease over the surfaces of the ful­crum pin (18).

• Insert the cold-start lever (15), torsion spring (16) and
shaft-sealing ring (17) on the fulcrum pin (18).

• Insert the complete fulcrum pin (18) in the throttle ca­ble support bracket.

NOTE Make sure the torsion spring is hooked to the cold­start lever (15) and the cable support bracket.

• Spray chain grease on the spring (16).

• Insert the shaft-sealing ring (17) on the fulcrum pin

(18).

• Fit the two bushes (19) and torsion spring (20).

• Fit the pulley (21) on the throttle cable support bracket.

3 - 24

RSV 1000 R - RSV 1000 R FACTORY

CAUTION
Make sure that the ends of the torsion spring
(20) are hooked onto the throttle cable support
bracket and pulley (21).

NOTE Spray a temporary lubricant on the spring (20), see

1.9.2 (USE OF CONSUMABLES).

• Fit the spring washer (22).

NOTE Apply LOCTITE

®

243 on the thread of the nut (23).

FUEL SYSTEM

• Screw the M8x1 nut (23) and tighten it.

®

NOTE Apply LOCTITE

243 on the thread of the screws

(25).

• Fasten the anchoring bracket of the accelerator cables
(24) with the three hex-head screws M5x12 (25).

• Fit the throttle valve control lever (26).

3 - 25

FUEL SYSTEM

Y

3.3.5. REPLACING THE THROTTLE VALVE CON­TROL LEVER

DISASSEMBLY

• Partially remove the fuel tank.

• Remove the air filter casing.

• Unscrew and remove the M8x1 nut (1) and remove the

spring washer.

• Slide out the control lever (2) and retrieve the two

bushes (3) and the torsion spring (4).

• Remove the control lever (2) from the tie rod of the ball

joint (5).

RSV 1000 R - RSV 1000 R FACTOR

ASSEMBLY

• Fit the two bushes (3) and torsion spring (4) on the

throttle body.

• Fit the throttle valve control lever (2) on the throttle

valve spindle.

NOTE Spray a temporary lubricant on the spring (4).

CAUTION
Make sure the ends of the torsion spring (4) are
hooked on the throttle body and throttle valve
control lever (2).

• Fit the spring washer.

NOTE Apply LOCTITE

®

243 on the thread of the nut (1).

• Screw the M8x1 nut (1) and tighten it.

NOTE Once assembly is complete, make sure the levers
rotate freely.

The throttle valve control lever (2) must be returned to its
original position by the torsion spring.
Check for end play on the throttle valve control shaft and ad­just as necessary.

3 - 26

RSV 1000 R - RSV 1000 R FACTORY

3.3.6. CHECKING THROTTLE VALVE CONTROL
SHAFT END PLAY

• Partially remove the fuel tank.

• Remove the air filter casing.

NOTE Have an appropriate thickness gauge (1) with a

0.00197 in (0.05 mm) scale at hand.

With throttle valves closed:

• Use the thickness gauge (1) to measure the minimum

play between the lever (2) and the contact surface (3)
on the throttle body in a number of points.

End play: min. 0.00394 in (0.1 mm).

FUEL SYSTEM

CAUTION
If the minimum value measured is lower than

0.00394 in (0.1 mm), the throttle body must be
replaced.

With throttle valves open:

• Repeat the above procedure.

End play: min. 0.0059 in (0.15 mm).

CAUTION
If the minimum value measured is lower than

0.0059 in (0.15 mm), the throttle body must be
replaced.

3 - 27

RSV 1000 R - RSV 1000 R FACTORY

ENGINE

ENGINE 4

4 - 1

ENGINE

Y

RSV 1000 R - RSV 1000 R FACTOR

SUMMARY

4.1. ENGINE........................................................................................................................................................... 3

4.1.1. REMOVING THE ENGINE..................................................................................................................... 3

4.1.2. REINSTALLING THE ENGINE ............................................................................................................ 26

4.1.3. TIGHTENING TORQUES .................................................................................................................... 51

4 - 2

RSV 1000 R - RSV 1000 R FACTORY

4.1. ENGINE

4.1.1. REMOVING THE ENGINE

• Remove the airbox cover.

ENGINE

• Loosen the screw securing the airbox to the frame.

• Remove the six screws securing the throttle body to

the airbox

4 - 3

ENGINE

Y

RSV 1000 R - RSV 1000 R FACTOR

• Detach the by pass lines to the throttle body and the
stepper motor connector

• Remove the oil vapor recovery line

• Detach the manifold pressure sensor connection and

the lines coming from the throttle body

4 - 4

RSV 1000 R - RSV 1000 R FACTORY

ENGINE

• Remove the airbox

• Disconnect the cabling from the ignition coil

4 - 5

ENGINE

Y

• Disengage the throttle cables

RSV 1000 R - RSV 1000 R FACTOR

• Detach the throttle potentiometer connector

• Remove the vacuum lines from the throttle body

4 - 6