APRILIA RSV4 RR Guide

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.
© Copyright 2015 - Piaggio & C. S.p.A. All rights reserved. Reproduction of this publication in whole or
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

TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE
VEHICLE.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
This number consists of numbers and letters, as in
the example shown below.
ZD4RKL000YSXXXXXX
KEY:
ZD4: WMI (World manufacturer identifier) code;
RK: model;
L00: Race Pack/RF or RR
0: free digit
Yyear of manufacture
S: production plant (S= Scorzè);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right side
of the headstock.
ENGINE NUMBER
The engine number is printed on the base of the
engine crankcase, left hand side.
Engine No. ....................
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Max. length 2,055 mm (80.90 in)
Max. width (at handlebar) 735 mm (28.94 in)
Max. height (to windshield) 1,150 mm (45.27 in)
Saddle height 847 mm (33.35 in)
Wheelbase 1,435 mm (56.50 in)
Minimum ground clearance 130 mm (5.12 in)
RSV4 RR/RF Characteristics
CHAR - 11

Specification Desc./Quantity
Kerb weight 190 kg (419 lb)
Kerb weight 201 kg (443 lb)
Full loaded weight (rider only) 276 kg (608 lb)
Engine
ENGINE
Specification Desc./Quantity
Model V4
Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double
overhead camshafts.
Engine capacity 999 cc (60.96 cu in)
Bore / stroke 78 mm / 52.26 mm (3.07 in / 2.06 in)
Compression ratio 13.5 +/- 0.5: 1
Engine idle speed 1500 +/- 100 rpm
Engine revs at maximum speed 13900 +/- 100 rpm
Clutch Multi plate wet clutch with mechanical control lever on left side
of the handlebar. Anti-juddering and slipper clutch systems
Start-up Electric
Timing system Morse chain on intake camshaft, cam to cam gear, bucket tap-
pets and valve clearance adjustments with calibrated pads
Lubrication Wet sump with oil radiator
Oil pump Dual trochoidal pump (lubrication + cooling)
Oil filter With external cartridge filter
Liquid Liquid
Cooling system 3-way thermostatic valve, cooling radiator with electric fan and
expansion tank
Coolant pump Centrifugal bearingless aspirating pump with integrated ce-
ramic gasket
Air filter In cotton
Transmission
GEAR RATIOS
Specification Desc./Quantity
Primary drive ratio 44 / 73 (with gears)
Drive ratio, 1st gear 15 / 39 (secondary)
Drive ratio, 2nd gear 16 / 33 (secondary)
Drive ratio, 3rd gear 20 / 34 (secondary)
Drive ratio, 4th gear 21 / 31 (secondary)
Drive ratio, 5th gear 23 / 31 (secondary)
Drive ratio, 6th gear 27 / 34 (secondary)
Final drive ratio 16 / 41
TRACTION CONTROL
Specification Desc./Quantity
a-PRC system (Aprilia Performance Ride Control), which includes traction
control,wheeliecontrol,launchcontrolandclutchlessgearshift
functions both going up and down the gears.
Capacities
CAPACITY
Specification Desc./Quantity
Fuel tank (reserve included) 18.5 l (4.07 UKgal; 4.88 US gal)
Fuel tank reserve 4 l (0.88 UK gal; 1.06 US gal)
Engine oil oil and filter change 4.1 l (0.90 UK gal)
Characteristics RSV4 RR/RF
CHAR - 12

Specification Desc./Quantity
Coolant 2.7 l (0.59 UK gal)
Seats 2
Maximum weight capacity 201 kg (443 lb)
Drive chain
DRIVE CHAIN
Specification Desc./Quantity
Type 525
With sealed master link
Model Regina 110 links
Electrical system
ELECTRICAL SYSTEM
Specification Desc./Quantity
Spark plugs NGK-R CR9EKB
Alternatively:
NGK-R CR9EB
NGK-R CR10E (for competition use)
Electrode gap 0.7 - 0.8 mm (0.027 - 0.031 in)
Battery YUASA YT12A-BS, 12 V 9.5 Ah or YUASA YTZ10S, 12 V 8.6
Ah
Coils Stick coil
Recharging system Flywheel with rare earth magnets
Alternator 450 W
Main fuses 30 A
Secondary fuses 5A - 7.5A - 15A
ABS fuses 15 A - 30 A
BULBS
Specification Desc./Quantity
High beam/low beam light 12 V - 55 W H7
Front daylight running lights LED
Turn indicator light LED
Rear daylight running light /stop light LED
Licence plate light 12 V - 5 W
WARNING LIGHTS
Specification Desc./Quantity
High beam light LED
Turn indicators LED
General warning LED
Gear in neutral LED
a-PRC LED
Fuel reserve LED
MI LED
ABS LED
Overrevving LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type Adjustable aluminium, dual beam chassis with pressed and
cast sheet elements.
Steering rake 26.5° (measurements with reference to bare chassis)
RSV4 RR/RF Characteristics
CHAR - 13

SUSPENSION
Specification Desc./Quantity
Front fork - RSV4 1000 RR Race Pack/RF Öhlins upside down units with adjustable hydraulic damping
and 43 mm (1.69 in) diam. stanchions with Tin surface coating)
Front fork - RSV4 1000 RR Sachs upside-down stanchions with adjustable hydraulic
damping and 43mm (1.69 in) diameter stanchions.
Front wheel stroke - RSV4 1000 RR Race Pack/RF 120 mm (4.72 in)
Front wheel stroke - RSV4 1000 RR 121 mm (4.76 in)
Rear shock absorber - RSV4 1000 RR Race Pack/RF With progressive linkage with APS system. Öhlins shock ab-
sorber with adjustable spring preload piggy-back, wheel-
base,compression damping and rebound damping.
Rear shock absorber - RSV4 1000 RR With progressive linkage with APS system. Sachs shock ab-
sorber with adjustable spring preload piggy-back, wheel-
base,compression damping and rebound damping.
Rear wheel stroke - RSV4 1000 RR Race Pack/RF 137 mm (5.39 in)
Rear wheel stroke - RSV4 1000 RR 138.5 mm (5.45 in)
SIZES A AND B
Specification Desc./Quantity
Size "A" 639.5 mm (25.18 in) (measurements refer to the bare chassis)
Size "B" 329.5 mm (12.97 in) (measurements refer to the bare chassis)
Brakes
BRAKES
Specification Desc./Quantity
Front Dual 320 mm (12.59 inches) diam. floating disc, forged radial-
mounted single block calipers and four pistons 30 mm diam.
(1.18 inches) and 2 pads - radial pump and brake pipe in metal
braid.
Rear disc brake -220 mm diam. (8.66 inches), 2-piston callipers - 32
mm diam. (1.25 inches) - pump with built-in tank and metal
braid pipe.
Wheels and tyres
WHEEL RIMS
Specification Desc./Quantity
Front wheel rim 3.50 x 17" RSV4 1000 RR - forging for the version RSV4 1000
RR Race Pack/RF
Rear wheel rim 6.00 x 17" RSV4 1000 RR - forging for the version RSV4 1000
RR Race Pack/RF
Characteristics RSV4 RR/RF
CHAR - 14

TYRES
Specification Desc./Quantity
Tyre model Pirelli DIABLO Supercorsa SP V2
Pirelli DIABLO Supercorsa SP
Front tyre 120/70 ZR17 (58W)
Inflation pressure 1 passenger: 2.3 bar (230 KPa) (33.36 PSI)
2 passengers: 2.5 bar (250 KPa) (36.26 PSI)
Rear tyre 200/55 ZR17 (78W) (*)
190/55 ZR17 (75W)
(*) With these dimensions use only Pirelli Diablo Super-
corsa SP and Diablo Supercorsa SP V2 tyres.
Inflation pressure 1 passenger: 2.5 bar (250 KPa) (36.26 PSI)
2 passengers: 2.8 bar (280 KPa) (40.61 PSI)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Fuel Unleaded petrol max E10 (95 RON)
FUEL SYSTEM
Specification Desc./Quantity
Throttle body diameter 48 mm (1.89 in)
Type Electronic injection with 2 injectors per cylinder, 4 throttle bod-
ies motorised (Ride by wire). Intake ducts at variable height. 2
dynamic air intakes. Selectable multimap.
Tightening Torques
Chassis
RSV4 RR/RF Characteristics
CHAR - 15

Front side
COOLING
pos. Description Type Quantity Torque Notes
1Flangedhex.head screws for fasten-
ing the water radiator support brack-
et to the frame
M6x20 2 10 Nm (7.38 lb ft) -
2Flangedhex.head screws for fasten-
ing the water radiator to the support
bracket
M6x20 2 7 Nm (5.16 lb ft) -
3 Screws for fastening the water by-
pass pipe tube gland M5 1 6 Nm (4.43 lb ft) -
4 Screws fastening electric fan to wa-
ter radiator M4 6 2 Nm (1.48 lb ft) -
5 Expansion tank support fixing screw M6 1 5 Nm (3.69 lb ft) -
Characteristics RSV4 RR/RF
CHAR - 16

OIL RADIATOR
pos. Description Type Quantity Torque Notes
1 Screws fastening oil radiator to
mounting bracket M6 1 7 Nm (5.16 lb ft) -
(OHLINS FORKS)
RSV4 RR/RF Characteristics
CHAR - 17

FRONT FORK - OHLINS
pos. Description Type Quantity Torque Notes
1 Fork feet hub fastening screws (Oh-
lins) M6 2 + 2 12 Nm (8.85 lb ft) -
2 Speed sensor fastening screw M5 1 6 Nm (4.43 lb ft) -
3 Speed sensor bracket screws M5 2 8 Nm (5.90 lb ft) -
(SACHS FORKS)
FRONT FORKS - SACHS
Pos. Description Type Quantity Torque Notes
1 Calliper bracket fixing screws
(Sachs) M6 4 12 Nm (8.85 lb ft) -
2 Speed sensor fastening screw M5 1 6 Nm (4.43 lb ft) -
3 Upper cap - 2 20 Nm (14.75 lb ft) -
4 Upper cap locking nut - 2 20 Nm (14.75 lb ft) -
Characteristics RSV4 RR/RF
CHAR - 18

STEERING
pos. Description Type Quantity Torque Notes
1Screwsfasteningupper yoke to stan-
chions M8 2 25 Nm (18.44 lb ft) -
2Screws fastening lower yoke to stan-
chions M8 4 25 Nm (18.44 lb ft) -
3 Headstock ring nut - pre-tightening M35x1 1 70 Nm (51.63 lb ft) Unscrew after pre-
tightening
3 Headstock ring nut - tightening M35x1 1 60 +/- 9 Nm (44.25 +/-
6.64 lb ft) -
4 Headstock counter-lock ring M35x1 1 Manual +35° or -10° Bend the tabs into
the notches in the
lock ring
5 Upper yoke fixing cap M29x1 1 100 Nm (73.76 lb ft) -
6 Screw fastening shock absorber to
frame M6 1 10 Nm (7.38 lb ft) Loctite 243
7 Screw fastening shock absorber to
lower yoke M6 1 10 Nm (7.38 lb ft) Loctite 243
8 Lower cover fixing screws M6 2 8 Nm (5.90 lb ft) -
RSV4 RR/RF Characteristics
CHAR - 19

FRONT WHEEL
Pos. Description Type Quantity Torque Notes
1 Front wheel pin nut M25x1.5 1 80 Nm (59.00 lb ft) -
2 Front brake disk fastening screws M8 6 + 6 30 Nm (22.13 lb ft) Loct. 243
FRONT BRAKE CALLIPER
Pos. Description Type Quantity Torque Notes
1Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) -
Characteristics RSV4 RR/RF
CHAR - 20