Aprilia RSV4 Factory 2009 Service Manual

SERVICE STATION MANUAL

894159

RSV4 Factory

SERVICE STATION

MANUAL

RSV4 Factory

THE VALUE OF SERVICE

Due to the continuous technical updates and specific mechanic training programs for aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its regular maintenance and using only Original aprilia Spare Parts are essential!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly from the map on our Official Website:

www.aprilia.com

Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were developed and tested together with the actual vehicle itself. All aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability.

The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.

Not all versions/models shown in this publication are available in all Countries. The availability of individual versions/models should be confirmed with the official aprilia sales network.

© Copyright 2009 aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. aprilia - After-sales service.

Aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL

RSV4 Factory

-This manual provides the main information to carry out regular maintenance operations on your vehicle.

-This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures are not described in detail, be extremely cautious so as not to damage components or injure individuals. In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle.

NOTE Provides key information to make the procedure easier to understand and carry out.

CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.

WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.

Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.

Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.

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

INDEX OF TOPICS

CHARACTERISTICS	CHAR
SPECIAL TOOLS	S-TOOLS
MAINTENANCE	MAIN
TROUBLESHOOTING	TROUBL
ELECTRICAL SYSTEM	ELE SYS
ENGINE FROM VEHICLE	ENG VE
ENGINE	ENG
POWER SUPPLY	P SUPP
SUSPENSIONS	SUSP
CHASSIS	CHAS
BRAKING SYSTEM	BRAK SYS
COOLING SYSTEM	COOL SYS
BODYWORK	BODYW
PRE-DELIVERY	PRE DE

INDEX OF TOPICS

CHARACTERISTICS

CHAR

RSV4 Factory	Characteristics

Rules

Safety rules

Carbon monoxide

If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.

CAUTION

EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.

Fuel

CAUTION

THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION.

DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN

Hot components

The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off. When handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down.

Coolant

The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it burns, ethylene glycol produces an invisible flame which however can cause burns.

CAUTION

TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT.

CHAR - 7

Characteristics	RSV4 Factory

KEEP OUT OF THE REACH OF CHILDREN

DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.

THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.

WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.

HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER.

DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN

THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.

KEEP OUT OF REACH OF CHILDREN Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC ACID, MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT OF CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.

KEEP OUT OF THE REACH OF CHILDREN

BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED.

Maintenance rules

GENERAL PRECAUTIONS AND INFORMATION

CHAR - 8

RSV4 Factory	Characteristics

When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully.

BEFORE DISASSEMBLING COMPONENTS

∙Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

∙Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench.

∙Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols.

∙Each component needs to be clearly marked to enable identification during reassembly.

∙Clean and wash the dismantled components carefully using a low-flammability detergent.

∙Keep mated parts together since they have "adjusted" to each other due to normal wear.

∙Some components must be used together or replaced altogether.

∙Keep away from heat sources.

REASSEMBLING COMPONENTS

CAUTION

BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED.

∙Only use ORIGINAL Aprilia SPARE PARTS.

∙Comply with lubricant and consumables use guidelines.

∙Lubricate parts (whenever possible) before reassembling them.

∙When tightening nuts and screws, start either from the components with the largest diameter or from the innermost components, proceeding diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.

∙Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new parts if the thread is damaged.

∙When assembling the bearings, make sure to lubricate them well.

∙Check that each component is assembled correctly.

∙After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic.

∙Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand or batch number facing outward (visible side).

ELECTRIC CONNECTORS

Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness:

Press the relative safety clips, if applicable.

CHAR - 9

Characteristics	RSV4 Factory

∙Grip the two connectors and disconnect them by pulling them in opposite directions.

∙If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air.

∙Ensure that the cables are correctly fastened to the internal connector terminals.

∙Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you

will hear them "click" into place).

CAUTION

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

NOTE

THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM THE RIGHT WAY ROUND.

TIGHTENING TORQUES

CAUTION

REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.

Running-in

Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the runin. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the engine components to cool.

CAUTION

THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUN-IN PERIOD.

Follow the guidelines detailed below:

∙Do not twist the throttle grip abruptly and completely when the engine is working at a low revs, either during or after run-in.

∙During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged braking. That is to permit the adequate adjustment of the pad friction material to the brake discs.

∙It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi).

AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-

CHAR - 10

RSV4 Factory	Characteristics

TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.

Vehicle identification

SERIAL NUMBER LOCATION

These numbers are necessary for vehicle registration.

NOTE

ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PARTICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.

This number consists of numbers and letters, as in the example shown below.

ZD4RK0000YSXXXXXX

KEY:

ZD4: WMI (World manufacturer identifier) code; RK: model;

000: version variation;

0: free digit

Y year of manufacture

S: production plant (S= Scorzè); XXXXXX: serial number (6 digits);

CHASSIS NUMBER

The chassis number is stamped on the right hand side of the headstock.

ENGINE NUMBER

The engine number is printed on the base of the engine crankcase, left hand side.

Engine No. ....................

Dimensions and mass

	DIMENSIONS
Specification	Desc./Quantity
Max. length	2040 mm (80.31 in)
Max width (at handlebar)	735 mm (28.94 in)
Max. height (to windshield)	1120 mm (44.09 in)
Saddle height	847 mm (33.35 in)
Wheelbase	1420 mm (55.90 in)
Minimum ground clearance	130 mm (5.12 in)

CHAR - 11

Characteristics	RSV4 Factory

	Specification	Desc./Quantity
	Kerb weight	189 kg (417 lb)
	Kerb weight	200 kg (441 lb)
	Full loaded weight (rider only)	275 kg (441 lb)
Engine
	ENGINE
	Specification	Desc./Quantity
	Model	V4
	Type	65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double
		overhead camshafts.
	Engine capacity	999 cm³ (60.96 cu.in)
	Bore / stroke	78 mm / 52.26 mm (3.07 in / 2.06 in)
	Compression ratio	13 : 1
	Idle speed	1400 ± 100 rpm
	Max engine speed	14000 ± 100 rpm
	Clutch	Multiplate wet clutch with mechanical control lever on left hand
		side of the handlebar Anti-juddering and slipper clutch systems
	Ignition	electronic
	TIMING SYSTEM	Morse chain on intake camshaft, cam to cam gear, bucket tap-
		pets and valve clearance adjustment with calibrated pads
	Acceptable values with control clearance between cam and	intake: 0.10 - 0.15 mm (0.0039 - 0.0059 in) exhaust: 0.20 - 0.25
	valve	mm (0.0079 - 0.0098 in)
	Lubrication system	Wet sump with oil radiator
	Oil pump	Dual trochoidal pump (lubrication + cooling)
	Oil filter	With external cartridge filter
	Cooling	Fluid
	Cooling system	3-way thermostatic valve, cooling radiator with electric fan and
		expansion tank
	Coolant pump	Centrifugal bearingless aspirating pump with integrated ce-
		ramic gasket
	Air filter	Cotton
	Alternatively:
	Air filter	Paper
Transmission
	GEAR RATIOS
	Specification	Desc./Quantity
	Primary drive ratio	44 / 73 (with gears)
	1st gear ratio	15 / 39 (secondary)
	2nd gear ratio	16 / 33 (secondary)
	3rd gear ratio	20 / 34 (secondary)
	4th gear ratio	22 / 32 (secondary)
	5th gear ratio	26 / 34 (secondary)
	6th gear ratio	27 / 33 (secondary)
	Final drive gear ratio	16 / 40
	Alternatively:
	Final drive ratio (to couple with the 110 link chain)	16 / 42
Capacities
	CAPACITY
	Specification	Desc./Quantity
	Fuel capacity (reserve included)	17 l (3.74 UK gal)
	Fuel tank reserve	3.6 l (0.79 UK gal)
	Engine oil	oil and filter change 4 l (0.88 UK gal)
	Coolant	2.4 l (0.53 UK gal)

CHAR - 12

RSV4 Factory	Characteristics

	Specification	Desc./Quantity
	Seats	1 + 1
		Two seat configuration: if vehicle is fitted with footrests and
		saddle for passenger
	Maximum weight capacity	201 kg (443 lb)
Drive chain
		DRIVE CHAIN
	Specification	Desc./Quantity
	Type	525
		With sealed master link
	Model	Regina 108 links
	Alternatively:
	Model (to couple with 42 teeth sprocket)	Regina 110 links
Electrical system
	ELECTRICAL SYSTEM
	Specification	Desc./Quantity
	Spark plugs	NGK-R CR9EB
		NGK-R CR10E (for competition use)
	Electrode gap	0.7 - 0.8 mm (0.027 - 0.031 in)
	Battery	YUASA YTZ10S, 12 V 8.6 Ah
		alternatively YUASA YT12A-BS, 12 V 9.5 Ah
	Coils	Stick coil
	Recharging system	Flywheel with rare earth magnets
	Generator	450 W
	Main fuses	30 A
	Auxiliary fuses	5A - 7.5A - 15A
		BULBS
	Specification	Desc./Quantity
	Low-/ high-beam light	12V - 55W H11
	Front daylight running light	12V - 5W
	Turn indicators	12V - 10W (White light)
	License plate light	12V - 5W
		WARNING LIGHTS
	Specification	Desc./Quantity
	High-beam light	LED
	Right turn indicator	LED
	Left turn indicator	LED
	General warning	LED
	Gear in neutral	LED
	Side stand down	LED
	Fuel reserve	LED
	ABS	NOT ENABLED
Frame and suspensions
		CHASSIS
	Specification	Desc./Quantity
	Type	Adjustable aluminium, dual beam chassis with pressed and
		cast sheet elements.
	Steering rake angle	26.5° (measurements with reference to bare chassis)
	Trail	107 mm (4.21 in)
		(with adjustable inserts, headstock as a standard feature)

CHAR - 13

Characteristics	RSV4 Factory

	SUSPENSION
Specification	Desc./Quantity
Front fork	Ohlins upside down units with adjustable hydraulic damping
	and 43 mm (1.69 in) diam. stanchions with Tin surface coating)
Front wheel travel	120 mm (4.72 in)
Rear shock absorber	Lateral mounted hydraulic shock absorber with progressive
	APS system. OHLINS shock absorbers with adjustable piggy-
	back preload, centre to centre distance and hydraulic brake in
	compression and rebound damping
Rear wheel travel	130 mm (5.12 in)
	SIZES A AND B
Specification	Desc./Quantity
Size "A"	639.5 mm (25.18 in) (measurements refer to the bare chassis)
Size "B"	329.5 mm (12.97 in) (measurements refer to the bare chassis)

Brakes

		BRAKES
	Specification	Desc./Quantity
	Front	With dual floating disc 320 mm diam. (12.59 inches), monobloc
		calipers with radial fixing and four pistons 34 mm diam. (1.34
		inches) and 4 pads - radial pump and brake pipe in metal braid.
	Rear	disc type -220 mm diam. (8.66 inches), 2-piston calipers - 32
		mm diam. (1.25 inches) - pump with built-in tank and metal
		braid pipe.
Wheels and tyres
		WHEEL RIMS
	Specification	Desc./Quantity
	Front wheel rim	3.50 x 17" Forged
	Rear wheel rim	6.00 x 17" Forged
		TYRES
	Specification	Desc./Quantity
	Tyre model	Pirelli DIABLO Super Corsa SP
		Metzeler RACETEC K3
		Michelin Power One
		Dunlop SPORTMAX GP Racer (Mixture "M" Front)
		Dunlop SPORTMAX GP Racer (Mixture "E" Rear)
	Front tyre	120/70 ZR17 (58W)
	Inflation pressure	1 passenger: 2.3 bar (230 kPa) (33.36 PSI)
		2 passengers: 2.5 bar (250 kPa) (36.26 PSI)

CHAR - 14

RSV4 Factory	Characteristics

Specification	Desc./Quantity
Rear tyre	190/55 ZR17 (75W)
	190/50 ZR17 (73W)
Inflation pressure	1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
	2 passengers: 2.8 bar (280 kPa) (40.61 PSI)

Supply

	FUEL SYSTEM
Specification	Desc./Quantity
Fuel	Premium unleaded petrol, minimum octane rating of 95
	(NORM) and 85 (NOMM)
	FUEL SYSTEM
Specification	Desc./Quantity
Throttle body diameter	48 mm (1.89 in)
Type	Electronic injection with 2 injectors per cylinder, 4 throttle bod-
	ies motorised (Ride by wire). Intake cones at variable height. 2
	dynamic air intakes. Selectable multimap.

Tightening Torques

Chassis

Front side

CHAR - 15

Characteristics	RSV4 Factory

			OIL RADIATOR
	pos.	Description	Type	Quantity	Torque	Notes
	1	Screws fastening oil radiator to	M6	1	7 Nm (5.16 lbf ft)	-
		mounting bracket

			FRONT FORK
	pos.	Description	Type	Quantity	Torque	Notes
	1	Fastener screws for calliper mount-	M6	2 + 2	12 Nm (8.85 lbf ft)	-
		ing bracket (Öhlins)

CHAR - 16

RSV4 Factory	Characteristics

			STEERING
	pos.	Description	Type	Quantity	Torque	Notes
	1	Screws fastening upper yoke to stan-	M8	2	25 Nm (18.44 lbf ft)	-
		chions
	2	Screws fastening lower yoke to stan-	M8	4	25 Nm (18.44 lbf ft)	-
		chions
	3	Headstock lock ring	M35x1	1	60 Nm (44.25 lbf ft)	-
	4	Headstock counter-lock ring	M35x1	1	Manual +35° or -10°	Bend the tabs into
						the notches in the
						lock ring
	5	Upper yoke fixing cap	-	1	100 Nm (73.76 lbf ft)	-
	6	Screw fastening shock absorber to	M6	1	10 Nm (7.37 lbf ft)	-
		frame
	7	Screw fastening shock absorber to	M6	1	10 Nm (7.37 lbf ft)	-
		lower yoke

CHAR - 17

Characteristics	RSV4 Factory

		FRONT WHEEL
pos.	Description	Type	Quantity	Torque	Notes
1	Front wheel spindle nut	M25x1.5	1	80 Nm (59 lbf ft)	-
2	Front brake disc fixing screws	M8	6 + 6	30 Nm (22.13 lbf ft)	Loct. 243

		FRONT BRAKE CALLIPER
pos.	Description	Type	Quantity	Torque	Notes
1	Front brake calliper fixing screws	M10x1.25	2 + 2	50 Nm (36.88 lbf ft)	-

CHAR - 18

RSV4 Factory	Characteristics

			FRONT BRAKE PUMP
	pos.	Description	Type	Quantity		Torque	Notes
	1	Screw fastening front brake fluid res-	M6	1	7 Nm (5.16 lbf ft)		-
		ervoir to bracket
	2	Screw fastening brake fluid reservoir	M6	1	7 Nm (5.16 lbf ft)		-
		mounting bracket to handlebar
	3	Screw fastening brake pipe grommet	M5	1	8	Nm (5.9 lbf ft)	-
		to the lower yoke
	4	Front brake pump U bolt clamp	M6	2	10	Nm (7.37 lbf ft)	-
	5	Front brake lever pin fixing screw	M6	1	10	Nm (7.37 lbf ft)	-

CHAR - 19

Characteristics	RSV4 Factory

		HANDLEBAR AND CONTROLS
	pos.	Description	Type	Quantity			Torque	Notes
	1	Screw fastening the semi-handlebar	M8	1 + 1		25	Nm (18.44 lbf ft)	-
		collar to the fork sleeves
	2	Semi-handlebar safety screw	M6	1+1		10 Nm (7.37 lbf ft)		-
	3	Anti-vibration counterweight fastener	M18x1.5	1+1		20	Nm (14.75 lbf ft)	-
	4	Right light switch	M4	2		1.5 Nm (1.11 lbf ft)		-
	5	Left light switch	M5	2		1.5 Nm (1.11 lbf ft)		-
	6	Throttle control fixing screws	M5	2		2	Nm (1.47 lbf ft)	-

CHAR - 20

RSV4 Factory	Characteristics

		HEADLAMP
pos.	Description	Type	Quantity	Torque	Notes
1	Screw fastening headlamp to front	SWP 4.9	4	2 Nm (1.47 lbf ft)	-
	fairing
2	Headlamp fixing screw	M5	2 + 1	2 Nm (1.47 lbf ft)	-

			INSTRUMENT PANEL
	pos.	Description	Type	Quantity	Torque	Notes
	1	Screws fastening the rubber rings to	SWP 4.9	3	3 Nm (2.21 lbf ft)	-
		the instrument panel
	2	Instrument panel mounting shell fix-	SWP 4.9	5	2 Nm (1.47 lbf ft)	-
		ing screws
	3	Screws fastening instrument panel	M6	4	8 Nm (5.9 lbf ft)	-
		mounting to chassis

CHAR - 21

Characteristics	RSV4 Factory

		WINDSHIELD
pos.	Description	Type	Quantity	Torque	Notes
1	Windshield fixing screws	M4	4	0.5 Nm (0.37 lbf ft)	-
2	Rear-view mirror fixing nuts	M6	2 + 2	10 Nm (7.37 lbf ft)	-
3	- Screws fastening the side fairings	M5	4	1 Nm (0.74 lbf ft)	-
	to front fairing

CHAR - 22

RSV4 Factory	Characteristics

			FRONT MUDGUARD
	pos.	Description	Type	Quantity	Torque	Notes
	1	Front mudguard fixing screws	M5	4	3 Nm (2.21 lbf ft)	-
	2	Lug fixing screws	M5	2	4 Nm (2.95 lbf ft)	-

			CLUTCH LEVER
	pos.	Description	Type	Quantity	Torque	Notes
	1	Clutch lever collar fixing screws	M6	1	10 Nm (7.37 lbf ft)	-

CHAR - 23

Characteristics	RSV4 Factory

			COOLING
	pos.	Description	Type		Quantity	Torque	Notes
	1	Screws fastening water radiator	M6		2	10 Nm (7.37 lbf ft)	-
		mounting bracket to chassis
	2	Screws fastening water radiator to	M6		2	7 Nm (5.16 lbf ft)	-
		mounting bracket
	3	Screw fastening pipe grommet for	M5		1	6 Nm (4.42 lbf ft)	-
		By-pass water hose
	4	Screws fastening electric fan to wa-	M4		6	2 Nm (1.47 lbf ft)	-
		ter radiator

CHAR - 24

RSV4 Factory	Characteristics

Central part

			SIDE STAND
	pos.	Description	Type	Quantity		Torque	Notes
	1	Screws fastening the stand to the	M10	2	45	Nm (33.19 lbf ft)	Loct. 243
		chassis
	2	Linear switch retainer	M5	2	4	Nm (2.95 lbf ft)	-
	-	Rear stand bushing fastening screws	M6	2	7	Nm (5.16 lbf ft)	-

CHAR - 25

Characteristics	RSV4 Factory

			SADDLE
	pos.	Description	Type		Quantity	Torque	Notes
	1	Rider saddle fixing screw	M5		2	6 Nm (4.42 lbf ft)	-

			FUEL TANK
	pos.	Description	Type	Quantity	Torque	Notes
	1	Special screw fastening rider saddle	M6	1	4 Nm (2.95 lbf ft)	-
		to the tank
	2	Screws fixing the filler to the tank	M5	4	4 Nm (2.95 lbf ft)	-
	3	Screws fixing the fuel pump flange to	M5	8	3 Nm (2.21 lbf ft)	-
		the tank
	4	Front screws fastening the tank to	M6	1	8 Nm (5.9 lbf ft)	-
		the chassis
	5	Rear screws fastening the tank to the	M6	2	7 Nm (5.16 lbf ft)	-
		rear chassis
	6	Screws fastening plastic fuel pipe	M5	1	2.5 Nm (1.84 lbf ft)	-
		mounting
	7	Left fairing mounting bracket fixing	M5	1	3 Nm (2.21 lbf ft)	-
		screws
	8	Screws fastening structural tank	M6	4	3 Nm (2.21 lbf ft)	-
		mounting to tank
	-	Central screw fastening the cover to	M4	1	0.5 Nm (0.37 lbf ft)	-
		the tank
	-	Fuel tank breather pipe unions	M7	2	3 Nm (2.21 lbf ft)	-

CHAR - 26

RSV4 Factory	Characteristics

			FOOTPEGS
	pos.	Description	Type	Quantity	Torques	Notes
	1	Screws fastening rider footpegs to	M8	2 + 2	25 Nm (18.44 lbf ft)	-
		chassis
	2	Screws fastening passenger foot-	M8	2 + 2	18 Nm (13.28 lbf ft)	For countries in
		pegs to chassis				which passenger
						footpegs are man-
						datory or for two
						seat configuration
	3	Rider heelrest fixing screws	M6	2 + 2	8 Nm (5.9 lbf ft)	-
	4	Passenger heelrest fixing screws	M6	2 + 2	8 Nm (5.9 lbf ft)	-
	-	Anti-slip pin	M6	1	8 Nm (5.9 lbf ft)	-

CHAR - 27

Characteristics	RSV4 Factory

			FRONT CHASSIS
	pos.	Description	Type	Quantity		Torque	Notes
	1	Headstock locator dowel	M8x1	2	10 Nm (7.37 lbf ft)		-
	2	Threaded intake duct fastener pins	M6	2 + 2	4	Nm (2.95 lbf ft)	Loct. 243
	3	Intake duct fixing nuts	M6	2 + 2		Manual	-
	4	Front mounts	M10	2 + 2	50	Nm (36.88 lbf ft)	-
	5	Lower rear mount	M10	1	50	Nm (36.88 lbf ft)	-
	6	Lower rear right hand adjuster screw	M18x1.5	1	12 Nm (8.85 lbf ft)		-
		bushing
	7	Upper rear right hand adjuster screw	M18x1.5	1	12 Nm (8.85 lbf ft)		-
		bushing
	8	Upper rear right hand mount	M10	1	50	Nm (36.88 lbf ft)	-
	9	Right fairing spacer	M6	1	10 Nm (7.37 lbf ft)		Loct. 243
	10	Upper rear left hand engine mount	M8	3	25	Nm (18.44 lbf ft)	-
		fastener screws
	11	Upper rear mount	M10	1	50	Nm (36.88 lbf ft)	-
	-	Screw fastening the ground cable to	M6	1	6	Nm (4.42 lbf ft)	-
		the left side chassis

CHAR - 28

RSV4 Factory	Characteristics

			REAR CHASSIS
	pos.	Description	Type	Quantity	Torque	Notes
	1	Saddle mounting fixing screws	M10	4	50 Nm (36.88 lbf ft)	-
	2	Screws fastening oil radiator mount-	M6	2	8 Nm (5.9 lbf ft)	-
		ing bracket to engine
	3	Passenger saddle and saddle cover	M6	2	8 Nm (5.9 lbf ft)	-
		catch plate fixing screws

CHAR - 29

Characteristics	RSV4 Factory

LOCKS

	pos.	Description	Type	Quantity	Torque	Notes
	1	Nut fastening saddle lock to tail fair-	M22x1.5	1	5 Nm (3.69 lbf ft)	-
		ing
	2	Lock lever self-tapping screw	M4	1	2 Nm (1.47 lbf ft)	-

			FRONT ELECTRICAL SYSTEM
	pos.	Description		Type	Quantity		Torque	Notes
	1	Fall sensor mounting fixing screw		M6	1	8 Nm (5.9 lbf ft)		-
	2	Horn fixing screw		M8	1	15	Nm (11.06 lbf ft)	-
	3	Screw fastening the voltage regula-		M6	2	6	Nm (4.42 lbf ft)	-
		tor to the inner fairing
	4	Shear head screw (to the left of the		M8	1		Manual	Tighten until the
		ignition lock)						head shears off
	5	Right hand ignition lock screw		M8	1	20	Nm (14.75 lbf ft)	-

CHAR - 30