2004-2010 Aprilia RSV 1000 R Service & Repair Manual

www.serviceaprilia.com workshopmanual RSV 1000 R - RSV 1000 R FACTORY 1137 3 00/2003-10 8140742 USA

INTRODUCTION 0 - 1 RSV 1000 R - RSV 1000 R FACTORY INTRODUCTION 0

INTRODUCTION 0 - 2 RSV 1000 R - RSV 1000 R FACTORY SUMMARY 0.1. INTRODUCTION ............................................................................................................................................. 3 0.1.1. INTRODUCTION.................................................................................................................................... 3 0.1.2. REFERENCE MANUALS ....................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................................................................................... 5

INTRODUCTION 0 - 3 RSV 1000 R - RSV 1000 R FACTORY 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 expla- nations 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 hazard- ous. 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 im- proves 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 subse- quent 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 up- dated 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: deca@decaweb.it 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

INTRODUCTION 0 - 4 RSV 1000 R - RSV 1000 R FACTORY 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

INTRODUCTION 0 - 5 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 kΩ = kilo Ohm 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") MΩ = 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 0 - 6 RSV 1000 R - RSV 1000 R FACTORY 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 UPSIDE- DOWN = inverted fork V = Volt W = Watt  = Diameter

GENERAL INFORMATION 1 - 1 RSV 1000 R - RSV 1000 R FACTORY GENERAL INFORMATION 1

GENERAL INFORMATION 1 - 2 RSV 1000 R - RSV 1000 R FACTORY 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

GENERAL INFORMATION 1 - 3 RSV 1000 R - RSV 1000 R FACTORY 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 Greece Malaysia United Kingdom Holland Chile Austria Switzerland Croatia Portugal Denmark Australia Finland Japan United States of America Belgium Singapore Brazil Germany Slovenia South Africa France Israel New Zealand Spain South Korea Canada

2004-2010 Aprilia RSV 1000 R Service & Repair Manual

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