Aprilia RSV4 Factory 2009 2013 Workshop 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 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 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 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 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 REMOVING 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 positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with 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 completely.
•
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), split 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 BOLTS 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
Running the engine in correctly is essential for ensuring engine longevity and functionality. Twisty roads
and gradients are ideal for running in the engine, brakes and suspension effectively. Vary your riding
speed during the running in period. This ensures that components operate in "loaded" conditions and
then "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 RUNNING IN PERIOD.
Follow the guidelines detailed below:
•
Do not fully open the throttle grip abruptly at low engine speeds, either during or after the
running in period.
•
During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. This allows the brake pad friction material to bed in correctly with the brake discs.
•
Preferably do not exceed 7500 rpm during the first 1000 km (621 mi) and 9500 rpm from
1000 to 2000 km (1243 mi).
AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official aprilia Dealer FOR THE
CHECKS INDICATED IN THE "SCHEDULED MAINTENANCE" TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURY TO YOURSELF OR OTHERS AND /OR DAMAGING THE
VEHICLE.
CHAR - 10
RSV4 Factory Characteristics
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
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)
Kerb weight 189 kg (417 lb)
Kerb weight 200 kg (441 lb)
Full loaded weight (rider only) 275 kg (441 lb)
Desc./Quantity
CHAR - 11
Characteristics RSV4 Factory
Engine
ENGINE
Specification Desc./Quantity
Model V4
Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double
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
Engine speed at idle 1400 ± 100 rpm
Engine revs at maximum speed 14000 ± 100 rpm
Clutch Multiplate wet clutch with mechanical control lever on left side
Ignition electronic
TIMING SYSTEM Morse chain on intake camshaft, cam to cam gear, bucket tap-
Acceptable values with control clearance between cam and
valve
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
Coolant pump Centrifugal bearingless aspirating pump with integrated ce-
Air filter In cotton
of the handlebar Anti-juddering and slipper clutch systems
pets and valve clearance adjustments with calibrated pads
intake: 0.10 - 0.15 mm (0.0039 - 0.0059 in) exhaust: 0.20 - 0.25
overhead camshafts.
mm (0.0079 - 0.0098 in)
expansion tank
ramic gasket
Transmission
Capacities
Fuel capacity (reserve included) 17 l (3.74 UK gal)
Maximum weight capacity 201 kg (443 lb)
GEAR RATIOS
Specification
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
Desc./Quantity
CAPACITY
Specification
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)
Seats 1 + 1
Two seat configuration: if vehicle is fitted with footrests and
Desc./Quantity
saddle for passenger
CHAR - 12
RSV4 Factory Characteristics
Drive chain
DRIVE CHAIN
Specification Desc./Quantity
Type 525
Model Regina 108 links
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plugs NGK-R CR9EB
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
Alternator 420 W
Main fuses 30 A
Auxiliary fuses 5A - 7.5A - 15A
With sealed master link
NGK-R CR10E (for competition use)
Specification
Low-/ high-beam light 12V - 55W H11
Front daylight running light 12V - 5W
Turn indicators 12V - 10W (White light)
License plate light 12V - 5W
Specification
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 NON ATTIVA
Frame and suspensions
Specification
Type Adjustable aluminium, dual beam chassis with pressed and
Steering inclination angle 26.5° (measurements with reference to bare chassis)
Trail 107 mm (4.21 in)
BULBS
Desc./Quantity
SPIE
Desc./Quantity
CHASSIS
Desc./Quantity
cast sheet elements.
(with adjustable inserts, headstock as a standard feature)
SUSPENSION
Specification
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-
Desc./Quantity
CHAR - 13
Characteristics RSV4 Factory
Specification Desc./Quantity
back preload, centre to centre distance and hydraulic brake in
Rear wheel travel 130 mm (5.12 in)
compression and rebound damping
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
Specification
Wheels and tyres
Specification
Front wheel rim 3.50 x 17"
Rear wheel rim 6.00 x 17"
Specification
Tyre model Pirelli DIABLO Super Corsa SP
Front tyre 120/70 ZR17 (58W)
Inflation pressure 1 passenger: 2.3 bar (230 kPa) (33.36 PSI)
Rear tyre 190/55 ZR17 (75W)
Inflation pressure 1 passenger: 2.5 bar (250 kPa) (36.26 PSI)
BRAKES
Desc./Quantity
Front With dual floating disc 320 mm diam. (12.59 inches), enbloc
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.
WHEEL RIMS
Desc./Quantity
TYRES
Desc./Quantity
Metzeler RACETEC K3
Michelin Power One
Dunlop SPORTMAX GP Racer (Mixture "M" Front)
Dunlop SPORTMAX GP Racer (Mixture "E" Rear)
2 passengers: 2.5 bar (250 kPa) (36.26 PSI)
190/50 ZR17 (73W)
2 passengers: 2.8 bar (280 kPa) (40.61 PSI)
CHAR - 14
RSV4 Factory Characteristics
Supply
FUEL SYSTEM
Specification Desc./Quantity
Fuel Premium unleaded petrol, minimum octane rating of 95
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
Tightening Torques
Chassis
(NORM) and 85 (NOMM)
dynamic air intakes. Selectable multimap.
Front side
pos.
1 Screws fastening oil radiator to
Description Type Quantity Torque Notes
mounting bracket
OIL RADIATOR
M6 1 7 Nm (5.16 lbf ft) -
CHAR - 15
Characteristics RSV4 Factory
pos.
1 Fastener screws for calliper mount-
Description Type Quantity Torque Notes
ing bracket (Öhlins)
FRONT FORK
M6 2 + 2 12 Nm (8.85 lbf ft) -
CHAR - 16
RSV4 Factory Characteristics
STEERING
pos. Description Type Quantity Torque Notes
1 Screws fastening upper yoke to stan-
chions
2 Screws fastening lower yoke to stan-
chions
3 Headstock ring nut M35x1 1 60 Nm (44.25 lbf ft) 4 Headstock counter ring nut M35x1 1 Manual +35° or -10° 5 Upper yoke fixing cap - 1 100 Nm (73.76 lbf ft) 6 Screw fastening shock absorber to
frame
7 Screw fastening shock absorber to
lower yoke
M8 2 25 Nm (18.44 lbf ft) M8 4 25 Nm (18.44 lbf ft) -
M6 1 10 Nm (7.37 lbf ft) M6 1 10 Nm (7.37 lbf ft) -
FRONT WHEEL
pos.
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
Description Type Quantity Torque Notes
CHAR - 17
Characteristics RSV4 Factory
FRONT BRAKE CALLIPER
pos.
1 Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) -
Description Type Quantity Torque Notes
pos.
1 Screw fastening front brake fluid res-
Description Type Quantity Torque Notes
ervoir to bracket
CHAR - 18
FRONT BRAKE PUMP
M6 1 7 Nm (5.16 lbf ft) -
RSV4 Factory Characteristics
pos. Description Type Quantity Torque Notes
2 Screw fastening brake fluid reservoir
mounting bracket to handlebar
3 Screw fastening brake pipe grommet
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) -
M6 1 7 Nm (5.16 lbf ft) M5 1 8 Nm (5.9 lbf ft) -
HANDLEBAR AND CONTROLS
pos.
1 Screw fastening the semi-handlebar
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) -
Description Type Quantity Torque Notes
M8 1 + 1 25 Nm (18.44 lbf ft) -
collar to the fork sleeves
CHAR - 19
Characteristics RSV4 Factory
HEADLAMP
pos.
1 Screw fastening headlamp to front
2 Headlamp fixing screw M5 2 + 1 2 Nm (1.47 lbf ft) -
Description Type Quantity Torque Notes
SWP 4.9 4 2 Nm (1.47 lbf ft) -
fairing
CHAR - 20
RSV4 Factory Characteristics
INSTRUMENT PANEL
pos. Description Type Quantity Torque Notes
1 Screws fastening the rubber rings to
the instrument panel
2 Instrument panel mounting shell fix-
ing screws
3 Screws fastening instrument panel
mounting to chassis
SWP 4.9 3 3 Nm (2.21 lbf ft) SWP 4.9 5 2 Nm (1.47 lbf ft) -
M6 4 8 Nm (5.9 lbf ft) -
WINDSHIELD
pos.
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
Description Type Quantity Torque Notes
M5 4 1 Nm (0.74 lbf ft) -
to front fairing
CHAR - 21
Characteristics RSV4 Factory
FRONT MUDGUARD
pos.
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) -
Description Type Quantity Torque Notes
CLUTCH LEVER
pos.
1 Clutch lever collar fixing screws M6 1 10 Nm (7.37 lbf ft) -
CHAR - 22
Description Type Quantity Torque Notes
RSV4 Factory Characteristics
pos.
1 Screws fastening water radiator
2 Screws fastening water radiator to
3 Screw fastening pipe grommet for
4 Screws fastening electric fan to wa-
Description Type Quantity Torque Notes
mounting bracket to chassis
mounting bracket
By-pass water hose
ter radiator
COOLING
M6 2 10 Nm (7.37 lbf ft) M6 2 7 Nm (5.16 lbf ft) M5 1 6 Nm (4.42 lbf ft) M4 6 2 Nm (1.47 lbf ft) -
CHAR - 23
Characteristics RSV4 Factory
Central part
SIDE STAND
pos.
1 Screws fastening the stand to the
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) -
Description Type Quantity Torque Notes
M10 2 45 Nm (33.19 lbf ft) Loct. 243
chassis
CHAR - 24
RSV4 Factory Characteristics
SADDLE
pos. Description Type Quantity Torque Notes
1 Rider saddle fixing screw M5 2 6 Nm (4.42 lbf ft) -
FUEL TANK
pos.
1 Special screw fastening rider saddle
2 Screws fixing the filler to the tank M5 4 4 Nm (2.95 lbf ft) -
3 Screws fixing the fuel pump flange to
4 Front screws fastening the tank to
5 Rear screws fastening the tank to the
6 Screws fastening plastic fuel pipe
7 Left fairing mounting bracket fixing
8 Screws fastening structural tank
- Central screw fastening the cover to
- Fuel tank breather pipe unions M7 2 3 Nm (2.21 lbf ft) -
Description Type Quantity Torque Notes
M6 1 4 Nm (2.95 lbf ft) -
to the tank
M5 8 3 Nm (2.21 lbf ft) -
the tank
M6 1 8 Nm (5.9 lbf ft) -
the chassis
M6 2 7 Nm (5.16 lbf ft) -
rear chassis
M5 1 2.5 Nm (1.84 lbf ft) -
mounting
M5 1 3 Nm (2.21 lbf ft) -
screws
M6 4 3 Nm (2.21 lbf ft) -
mounting to tank
M4 1 0.5 Nm (0.37 lbf ft) -
the tank
CHAR - 25
Characteristics RSV4 Factory
FOOTPEGS
pos.
1 Screws fastening rider footpegs to
2 Screws fastening passenger foot-
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) -
Description Type Quantity Torques Notes
chassis
pegs to chassis
M8 2 + 2 25 Nm (18.44 lbf ft) M8 2 + 2 18 Nm (13.28 lbf ft) For countries in
which passenger
footpegs are man-
datory or for two
seat configuration
CHAR - 26
RSV4 Factory Characteristics
FRONT CHASSIS
pos.
1 Headstock locator dowel M8x1 2 10 Nm (7.37 lbf ft) 2 Threaded inlet duct fastener pins M6 2 + 2 4 Nm (2.95 lbf ft) Loct. 243
3 Inlet 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
7 Upper rear right hand adjuster screw
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
11 Upper rear mount M10 1 50 Nm (36.88 lbf ft) -
- Screw fastening the ground cable to
Description Type Quantity Torque Notes
M18x1.5 1 12 Nm (8.85 lbf ft) -
bushing
M18x1.5 1 12 Nm (8.85 lbf ft) -
bushing
M8 3 25 Nm (18.44 lbf ft) -
fastener screws
M6 1 6 Nm (4.42 lbf ft) -
the left side chassis
CHAR - 27
Characteristics RSV4 Factory
REAR CHASSIS
pos.
1 Saddle mounting fixing screws M10 4 50 Nm (36.88 lbf ft) 2 Screws fastening oil radiator mount-
3 Passenger saddle and saddle cover
Description Type Quantity Torque Notes
M6 2 8 Nm (5.9 lbf ft) -
ing bracket to engine
M6 2 8 Nm (5.9 lbf ft) -
catch plate fixing screws
CHAR - 28
RSV4 Factory Characteristics
LOCKS
pos. Description Type Quantity Torque Notes
1 Nut fastening saddle lock to tail fair-
ing
2 Lock lever self-tapping screw M4 1 2 Nm (1.47 lbf ft) -
M22x1.5 1 5 Nm (3.69 lbf ft) -
FRONT ELECTRICAL SYSTEM
pos.
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-
4 Shear head screw (to the left of the
5 Right hand ignition lock screw M8 1 20 Nm (14.75 lbf ft) -
Description Type Quantity Torque Notes
M6 2 6 Nm (4.42 lbf ft) -
tor to the inner fairing
M8 1 Manual Tighten until the
ignition lock)
head shears off
CHAR - 29
Characteristics RSV4 Factory
pos.
1 Upper Silentblock nut, demand sen2 Demand sensor fixing screw to
Description Type Quantity Torque Notes
sor mounting bracket
mounting plate
CENTRAL ELECTRICAL SYSTEM
M6 1 5 Nm (3.69 lbf ft) -
SWP 4.9 4 1.2 Nm (0.88 lbf ft) -
CHAR - 30
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