APRILIA RSV4 RR Leitfaden

SERVICE STATION MANUAL

2Q000152

RSV4 RR/RF

SERVICE STATION

MANUAL

RSV4 RR/RF

THE VALUE OF SERVICE

As a result of continuous updates and specific technical training programmes for Aprilia products, only

Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry

out maintenance and repair operations correctly.

Thereliabilityofthevehiclealsodependsonitsmechanicalconditions.Checkingthevehiclebeforeriding

it, its regular maintenance and the use of original Aprilia spare parts only are essential factors!

For information on the nearest Official Dealer and/or Service Centre consult our website:

www.aprilia.com

Only by requesting aprilia original spare parts can you be sure of purchasing products that were

developed and tested during the actual vehicle design stage. All aprilia original spare parts undergo

quality control procedures to guarantee reliability and durability.

Thedescriptionsandimagesinthispublicationaregivenforillustrativepurposesonlyandarenotbinding.

Piaggio & C. While the basic characteristics as described and illustrated in this booklet remain

unchanged, Piaggio & C. S.p.A. 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.

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

in part is prohibited.

Piaggio & C. S.p.A. Viale Rinaldo Piaggio, 25 - 56025 PONTEDERA (PI), Italy

www.piaggio.com

SERVICE STATION MANUAL

RSV4 RR/RF

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 changeswill beintroduced inthe subsequenteditions ofthe manual.In caseof 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 Sectionsmarked with thissymbol indicatethe correctuse of thevehicle

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 POISONOUSGASWHICHCANCAUSE

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

THEENGINE SWITCHED OFF. DO NOTSMOKEDURINGREFUELLINGORNEAR FUEL VAPOUR.

AVOIDANY CONTACT WITH NAKEDFLAME, SPARKSOR OTHERHEAT SOURCESWHICH 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 PARTICULAR CARE NOT TO SPILL COOLANT ONTO HOT PARTS OR THE ENGINE AND

EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN WITH INVISIBLE FLAMES. WHEN

CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES.

WHILE POISONOUS, COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY AP-

PEALING TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY BE

REACHED AND DRUNK BY AN ANIMAL.

RSV4 RR/RF Characteristics

CHAR - 7

KEEP OUT OF THE REACH OF CHILDREN.

NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER

PRESSURE AND MAY CAUSE BURNS.

Used engine oil and transmission oil

CAUTION

IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-

HICLE.

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 THE REACH OF CHILDREN.

Battery electrolyte and hydrogen gas

CAUTION

THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,

IT CAN CAUSE BURNS WHEN IN 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

AMOUNTSOF BATTERY ACIDMAYCAUSEBLINDNESS.IF THE FLUID GETSINCONTACTWITH

YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE

SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY

FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-

QUATE 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

When repairs, disassembly and reassembly of the vehicle is carried out, follow the following recom-

mendations strictly.

BEFORE DISASSEMBLING COMPONENTS

Characteristics RSV4 RR/RF

CHAR - 8

•Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com-

ponents. Wherever required, use the special tools designed for this vehicle.

DISASSEMBLING COMPONENTS

•Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use

the specific wrench.

•Mark the positions on all the connection joints (hoses, cables, etc.) before separating them

and identify them with different distinctive marks.

•Each piece should be clearly marked in order to be identified during the installation phase.

•Carefully clean and wash the disassembled components with detergents with a low flam-

mability grade.

•Keep the coupled parts together because they have "adapted" to one another following

normal wear.

•Some components must be used together or replaced entirely.

•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.

•Whentighteningnuts andscrews,start eitherfrom thecomponentswith thelargestdiameter

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).

ELECTRICAL 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 RR/RF 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 TORQUE

CAUTION

REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELEMENTS LOCATED ON

WHEELS, BRAKES, WHEEL AXLES AND OTHER SUSPENSION COMPONENTS PLAY A FUN-

DAMENTAL ROLE IN GUARANTEEING THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT

THE PRESCRIBED VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING

ELEMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE WARNINGS

ARE NOT OBSERVED, ONE OF THESE COMPONENTS COULD LOOSEN AND COME OFF,

BLOCKING A WHEEL OR CAUSING OTHER PROBLEMS THAT WOULD COMPROMISE MA-

NOEUVRABILITY, LEADING TO A CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN

DEATH.

Running-in

Runningthe engine in correctly isessential forensuring enginelongevity andfunctionality. Twistyroads

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 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 RR/RF

CHAR - 10

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