APRILIA RSV4 FACTORY Leitfaden

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.

prohibited. aprilia - After-sales service.

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

SERVICE STATION MANUAL

RSV4 Factory

-Thismanualprovidesthemaininformationtocarryoutregularmaintenanceoperationsonyourvehicle.

- 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.Thesechangeswillbeintroducedinthesubsequenteditions of the manual. In case ofneed

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 Sectionsmarked 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

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

EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,A POISONOUSGASWHICHCAN 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

THEENGINESWITCHEDOFF.DONOTSMOKEDURINGREFUELLINGORNEARFUELVAPOUR.

AVOIDANY CONTACT WITH NAKED FLAME, SPARKS OR OTHERHEAT 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 COMPO-

NENTS; 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. NEV-

ER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS

THEY MAY DRINK IT.

RSV4 Factory Characteristics

CHAR - 7

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 CON-

TACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON-

SULT 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 EX-

PLOSIVE 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

Characteristics RSV4 Factory

CHAR - 8

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

carefully.

BEFORE DISASSEMBLING COMPONENTS

•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.

Use the special tools designed for this bike, as required.

COMPONENTS REMOVAL

•Donot 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.

•Whentightening nutsand screws,start eitherfrom thecomponents withthelargest diameter

or from the innermost components, proceeding diagonally. Tighten nuts and screws in suc-

cessive steps before applying the tightening torque.

•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter 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.

RSV4 Factory Characteristics

CHAR - 9

•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

REMEMBERTHATTHETIGHTENING 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 run-

in. 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-

Characteristics RSV4 Factory

CHAR - 10

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