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APRILIA RSV4 1100 Factory User Manual

APRILIA RSV4 1100 Factory
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SERVICE STATION MANUAL
2Q000401
RSV4 1100 Factory

Table of Contents

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APRILIA RSV4 1100 Factory Specifications

General IconGeneral
Front Tire120/70 ZR 17
Rear Tire200/55 ZR 17
Engine TypeV4, 4-stroke
Displacement1078 cc
Max Power217 hp (159.5 kW) @ 13, 000 rpm
Max Torque122 Nm @ 11, 000 rpm
Transmission6-speed
Fuel SystemElectronic fuel injection
Front SuspensionÖhlins NIX 43 mm fork, fully adjustable
Rear SuspensionÖhlins TTX, fully adjustable monoshock
Front BrakeDual 330 mm discs, Brembo Stylema calipers
Rear Brake220 mm disc, Brembo caliper
Dry Weight199 kg
Fuel Tank Capacity18.5 liters
FrameAluminum dual beam chassis
Seat Height851 mm
ElectronicsAPRC (Aprilia Performance Ride Control) including traction control, wheelie control, launch control, quick shift

Summary

CHARACTERISTICS

Rules

Safety rules for handling fuel, coolant, and oils, plus general maintenance precautions.

Vehicle Identification

Details serial number, chassis, and engine number locations and formats.

Dimensions and Mass

Provides technical specifications for vehicle dimensions, weight, engine, and transmission.

Capacities

Lists fuel tank, engine oil, and coolant capacities.

Electrical System

Details spark plugs, battery, coils, fuses, bulbs, and indicator lamps.

Frame and Suspensions

Covers chassis type, steering rake, front fork, rear shock absorber, and steering damper.

Brakes

Details specifications for front and rear brake systems, including discs and calipers.

Wheels and Tyres

Specifies wheel rims, tyre sizes, and inflation pressures.

Supply

Details fuel specifications and the fuel supply system.

SPECIAL TOOLS

Engine support

Tool for supporting the engine during maintenance operations.

Flywheel extractor

Tool used to remove the flywheel.

Camshaft timing pin

Tool used for aligning camshaft timing.

Valve spring compressor

Tool used to compress valve springs for removal/installation.

Bearing extractor

Tool for extracting bearings.

Diagnostic tool

Tool used for vehicle diagnostics and error reporting.

MAINTENANCE

Scheduled maintenance table

Table outlining maintenance intervals and operations for various vehicle components.

Engine oil

Procedures for checking and replacing engine oil.

Engine oil filter

Instructions for replacing the engine oil filter.

Air filter

Procedure for removing and checking the air filter.

Checking the valve clearance

Steps for checking valve clearance on front and rear cylinder heads.

ELECTRICAL SYSTEM

Components arrangement

Diagram showing the location of electrical components on the motorcycle.

Electrical system installation

Defines cable harness routing and lists necessary materials and parts.

Special Checks for Cable Connection and Routing

Highlights critical connector checks for proper engine and vehicle operation.

Troubleshooting

General guidance for troubleshooting electrical faults, including connector, continuity, and ground checks.

Immobiliser

Details immobiliser system components, function, electrical specifications, and error codes.

ENGINE

Gearbox

Lists gearbox components, quantities, and torque specifications for assembly.

Removing camshafts

Procedure for removing camshafts, including crankshaft rotation and timing pin usage.

Crankshaft fitting

Instructions for installing the primary drive gear and crankshaft, including timing pin usage.

Connecting rods - pistons

Details piston ring fitting and connecting rod coupling according to balancing class.

Crankcase closing

Steps for assembling the crankcase, including inserting dowels, oil seals, and pre-tightening nuts.

SUSPENSIONS

Handlebar

Details handlebar and controls, including screws, switches, and throttle controls.

Front fork

Details front fork specifications and adjustment procedures for preload and damping.

Steering damper

Adjusting the steering damper for rigidity or softness.

Steering bearing

Details steering bearing components, torque specifications, and adjustment procedures.

Shock absorbers

Details rear shock absorber components and torque specifications for mounting.

Adjusting play

Procedures for adjusting rear shock absorber rebound, compression, and spring pre-load.

CHASSIS

CHASSIS

Lists chassis components, types, quantities, and torque specifications for screws and nuts.

Front wheel

Details front wheel components, removal, and bearing checks, including eccentricity.

Rear wheel

Specifies rear wheel components, removal, and sprocket support procedures.

Swinging arm

Details rear swingarm components, specifications, and installation procedures.

Drive chain

Instructions for checking chain wear, cleaning, lubrication, and slider replacement.

Adjusting

Procedure for adjusting chain tension and checking wear of chain, pinion, and sprocket.

BRAKING SYSTEM

ABS

Details ABS control unit, operating diagram, general specifications, and stages in ABS cycle.

Guide to diagnosis

Provides a step-by-step guide for ABS fault diagnosis using a diagnostic tool.

Component maintenance

Procedures for checking and replacing tone wheels and sensors.

Rear brake calliper

Details rear brake calliper components, torque specifications, and removal/installation.

Front brake pads

Steps for removing and installing front brake pads, including piston separation.

Bleeding the braking system

Procedures for bleeding front and rear brake hydraulic circuits.

COOLING SYSTEM

Circuit diagram

Diagram of the self-bleeding cooling circuit with key components identified.

WATER PUMP

Details specifications and removal/installation of the water pump.

Electric fan

Instructions for removing the front underfairings and disconnecting the cooling fan connector.

Coolant replacement

Procedure for draining, refilling, and checking coolant levels.

BODYWORK

HEADLAMP

Details headlamp components, screws, and torque specifications.

INSTRUMENT PANEL

Details instrument panel components, screws, and torque specifications.

FRONT MUDGUARD

Lists front mudguard components, types, quantities, and torque specifications for screws.

FUEL TANK

Details fuel tank components, screws, and torque specifications.

FAIRINGS

Details various fairing mounting screws, clips, and brackets with torque specifications.

Instrument cluster support

Steps for removing and fitting the instrument panel and its support.

Headlight assy.

Steps to remove headlights, fairings, and associated screws.

PRE-DELIVERY

Aesthetic inspection

Checks related to paintwork, plastic parts fitting, scratches, and dirt.

Tightening torques inspection

Inspection of safety fasteners, suspension units, brake calipers, and engine mounts.

Electrical system

Checks for main switch, headlamps, rear brake light, turn indicators, and instrument panel.

RECHARGE

Procedures for recharging the battery, including normal and quick charge modes.

Levels check

Checks for hydraulic braking system fluid, clutch system fluid, engine coolant, and engine oil levels.

Road test

Procedures for conducting a road test, checking controls, and braking performance.

Specific operations for the vehicle

Operations like removing screws, plastic covers, and fitting rear pedal.

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