APRILIA RSV 1000 R FACTORY 2003 Instruction manual

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

INTRODUCTION
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RSV 1000 R - RSV 1000 R FACTORY
INTRODUCTION 0

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

INTRODUCTION
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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: [e-mail]
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

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RSV 1000 R - RSV 1000 R FACTOR
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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

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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

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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
Ø = Diameter

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

GENERAL INFORMATION
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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
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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:
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Belgium Singapore Brazil
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