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APRILIA RSV1000R RSV 1000R Factory Digital Workshop Repair Manual 2004 Onward

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🏷️ Basic Information Identification Make: Aprilia Model: RSV1000R Factory Model Variant: Factory Year Coverage: 2004 onwards Codes Chassis Code: RP (often indicated by VIN) 👋 Introduction Market Position Category: High-Performance Sportbike Target Audience: Enthusiast owners, independent workshops, performance tuners Competitive Analysis Rivals: Ducati 999, Yamaha R1, Suzuki GSX-R1000, Honda CBR1000RR Key Features Unique Selling Points: V-twin engine character, premium components (Ohlins, Brembo on Factory), Italian design and performance pedigree Manual Value Proposition: Empowers owners with the knowledge to maintain and repair a sophisticated Italian motorcycle, saving on dealer costs and ensuring optimal performance. 📋 Manual Details Coverage Areas Primary Coverage: Full Workshop Repair and Maintenance Diagnostic Coverage: Comprehensive Diagnostic Procedures Rebuild Coverage: Engine, Transmission, Chassis Rebuild Procedures Restoration Coverage: Detailed Restoration Guidance Page Count Estimated Pages: Extensive (Digital format, typically hundreds of pages equivalent) Manual Type Type: Digital Workshop Repair Manual Language Language: English (assumed, standard for international manuals) Format Format: Digital (PDF or similar, searchable and printable) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, tuning, diagnostics, component identification, torque specs, clearances Fuel System: Fuel injection system, injectors, fuel pump, pressure regulator, throttle body, TPS Ignition System: ECU, coils, spark plugs, timing, diagnostic codes Cooling System: Radiator, coolant, thermostat, water pump, fan operation Transmission Clutch: Clutch assembly, hydraulic system, gearbox internal inspection and repair Electrical System: Wiring diagrams, component testing, starter, alternator, battery, lighting, charging system Braking System: Brake calipers, discs, master cylinders, ABS (if equipped), fluid replacement, bleeding procedures Suspension Steering: Front forks (Telescopic, Cartridge type), rear shock absorber, linkage, steering head bearings, wheel bearings Wheels Tires: Wheel specifications, tire pressures, balancing, mounting Frame Chassis: Frame integrity inspection, subframe, bodywork removal and installation Bodywork Fairings: Fairing removal, installation, repair, plastic welding, graphics Instrumentation Controls: Dashboard, switches, levers, cables Exhaust System: Exhaust manifold, muffler, lambda sensors Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, chain adjustment), pre-ride inspections Troubleshooting: Diagnostic flowcharts for common and uncommon issues, error code interpretation Repair: Step-by-step repair instructions for all major and minor components Rebuild: Detailed procedures for engine and gearbox rebuilds Calibration Adjustment: Throttle position sensor (TPS) calibration, idle speed adjustment, chain slack adjustment Wiring Diagrams: Full vehicle wiring schematics Torque Specifications: All critical fasteners with precise torque values Technical Depth Depth: Comprehensive from basic service to full engine rebuilds and advanced diagnostics Diagnostic Level: Includes ECU error code interpretation and troubleshooting trees Rebuild Level: Component-level rebuilds for engine, gearbox, and suspension 📊 Manual Specifications File Format Format: PDF (Portable Document Format) - allowing for searchability, zooming, and printing Searchability: Text-based PDF for efficient keyword searching Printability: Printable pages for on-the-bench use Print Quality Image Resolution: High-resolution images, diagrams, and schematics Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin (90-degree) Engine Code: Aprilia V60 Magnesium Displacement: 997.6 cc Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower: Approx. 139 hp @ 9,500 rpm (may vary slightly by region/tune) Torque: Approx. 101 Nm (74.5 lb-ft) @ 7,500 rpm (may vary slightly by region/tune) Fuel System Fuel Delivery: Electronic Fuel Injection (Weber Marelli ECU, dual injectors per cylinder) Fuel Type: Unleaded Petrol (min. 95 RON recommended) Throttle Body: Dual throttle bodies with electronic throttle control (ETC) on some later models 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch Type: Hydraulically operated, wet multi-plate clutch Features Gear Ratios: Specific ratios detailed in manual, crucial for performance tuning Final Drive: O-ring sealed chain Fluid Specifications Gearbox Oil Type: API GL-4 or GL-5, SAE 75W/90 Synthetic Gear Oil (refer to manual for exact Aprilia specification) 📐 Dimensions Exterior Length: Approx. 2,030 mm (varies slightly) Width: Approx. 720 mm (at handlebars) Height: Approx. 1,100 mm (at seat) Wheelbase: Approx. 1,415 mm Weights Dry Weight: Approx. 185 kg Wet Weight: Approx. 205 kg (with fluids) Fuel Tank Capacity: 18 Liters (including 3.5L reserve) 🛡️ Safety Features Ratings Safety Certification: CE Certified (European Conformity), relevant for road legality. Active Features Braking System: High-performance Brembo radial-mount calipers (front), Brembo caliper (rear), braided steel brake lines ABS: Optional ABS system available on some models Passive Features Frame Construction: Lightweight aluminum alloy twin-spar frame for rigidity and handling Lighting: Dual Halogen headlights, LED taillight 💡 Technology Features Infotainment Dashboard Display: Digital LCD instrument cluster with analog tachometer, displaying speed, RPM, odometer, trip meters, clock, engine temp, fuel level, diagnostic codes. Driver Assistance Ride Modes: No specific rider-selectable modes like modern bikes; performance is inherent to the machine. Connectivity Diagnostic Port: On-board diagnostic (OBD) port for ECU communication and error code retrieval. Other Tech ECU: Weber Marelli (specific model dependent, important for tuning and diagnostics) Throttle Control: Cable operated throttle, with potential for electronic throttle control (ETC) on later 2004+ models. 🔧 Maintenance Service Intervals Oil Change...
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APRILIA RSV1000R RSV 1000R Factory Digital Workshop Repair Manual 2004 Onward
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV1000R Factory
Model Variant:
Factory
Year Coverage:
2004 onwards
Codes
Chassis Code:
RP (often indicated by VIN)
👋 Introduction
Market Position
Category:
High-Performance Sportbike
Target Audience:
Enthusiast owners, independent workshops, performance tuners
Competitive Analysis
Rivals:
Ducati 999, Yamaha R1, Suzuki GSX-R1000, Honda CBR1000RR
Key Features
Unique Selling Points:
V-twin engine character, premium components (Ohlins, Brembo on Factory), Italian design and performance pedigree
Manual Value Proposition:
Empowers owners with the knowledge to maintain and repair a sophisticated Italian motorcycle, saving on dealer costs and ensuring optimal performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Workshop Repair and Maintenance
Diagnostic Coverage:
Comprehensive Diagnostic Procedures
Rebuild Coverage:
Engine, Transmission, Chassis Rebuild Procedures
Restoration Coverage:
Detailed Restoration Guidance
Page Count
Estimated Pages:
Extensive (Digital format, typically hundreds of pages equivalent)
Manual Type
Type:
Digital Workshop Repair Manual
Language
Language:
English (assumed, standard for international manuals)
Format
Format:
Digital (PDF or similar, searchable and printable)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, tuning, diagnostics, component identification, torque specs, clearances
Fuel System:
Fuel injection system, injectors, fuel pump, pressure regulator, throttle body, TPS
Ignition System:
ECU, coils, spark plugs, timing, diagnostic codes
Cooling System:
Radiator, coolant, thermostat, water pump, fan operation
Transmission Clutch:
Clutch assembly, hydraulic system, gearbox internal inspection and repair
Electrical System:
Wiring diagrams, component testing, starter, alternator, battery, lighting, charging system
Braking System:
Brake calipers, discs, master cylinders, ABS (if equipped), fluid replacement, bleeding procedures
Suspension Steering:
Front forks (Telescopic, Cartridge type), rear shock absorber, linkage, steering head bearings, wheel bearings
Wheels Tires:
Wheel specifications, tire pressures, balancing, mounting
Frame Chassis:
Frame integrity inspection, subframe, bodywork removal and installation
Bodywork Fairings:
Fairing removal, installation, repair, plastic welding, graphics
Instrumentation Controls:
Dashboard, switches, levers, cables
Exhaust System:
Exhaust manifold, muffler, lambda sensors
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, chain adjustment), pre-ride inspections
Troubleshooting:
Diagnostic flowcharts for common and uncommon issues, error code interpretation
Repair:
Step-by-step repair instructions for all major and minor components
Rebuild:
Detailed procedures for engine and gearbox rebuilds
Calibration Adjustment:
Throttle position sensor (TPS) calibration, idle speed adjustment, chain slack adjustment
Wiring Diagrams:
Full vehicle wiring schematics
Torque Specifications:
All critical fasteners with precise torque values
Technical Depth
Depth:
Comprehensive from basic service to full engine rebuilds and advanced diagnostics
Diagnostic Level:
Includes ECU error code interpretation and troubleshooting trees
Rebuild Level:
Component-level rebuilds for engine, gearbox, and suspension
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format) - allowing for searchability, zooming, and printing
Searchability:
Text-based PDF for efficient keyword searching
Printability:
Printable pages for on-the-bench use
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin (90-degree)
Engine Code:
Aprilia V60 Magnesium
Displacement:
997.6 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower:
Approx. 139 hp @ 9,500 rpm (may vary slightly by region/tune)
Torque:
Approx. 101 Nm (74.5 lb-ft) @ 7,500 rpm (may vary slightly by region/tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Weber Marelli ECU, dual injectors per cylinder)
Fuel Type:
Unleaded Petrol (min. 95 RON recommended)
Throttle Body:
Dual throttle bodies with electronic throttle control (ETC) on some later models
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Features
Gear Ratios:
Specific ratios detailed in manual, crucial for performance tuning
Final Drive:
O-ring sealed chain
Fluid Specifications
Gearbox Oil Type:
API GL-4 or GL-5, SAE 75W/90 Synthetic Gear Oil (refer to manual for exact Aprilia specification)
📐 Dimensions
Exterior
Length:
Approx. 2,030 mm (varies slightly)
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1,100 mm (at seat)
Wheelbase:
Approx. 1,415 mm
Weights
Dry Weight:
Approx. 185 kg
Wet Weight:
Approx. 205 kg (with fluids)
Fuel Tank Capacity:
18 Liters (including 3.5L reserve)
🛡️ Safety Features
Ratings
Safety Certification:
CE Certified (European Conformity), relevant for road legality.
Active Features
Braking System:
High-performance Brembo radial-mount calipers (front), Brembo caliper (rear), braided steel brake lines
ABS:
Optional ABS system available on some models
Passive Features
Frame Construction:
Lightweight aluminum alloy twin-spar frame for rigidity and handling
Lighting:
Dual Halogen headlights, LED taillight
💡 Technology Features
Infotainment
Dashboard Display:
Digital LCD instrument cluster with analog tachometer, displaying speed, RPM, odometer, trip meters, clock, engine temp, fuel level, diagnostic codes.
Driver Assistance
Ride Modes:
No specific rider-selectable modes like modern bikes; performance is inherent to the machine.
Connectivity
Diagnostic Port:
On-board diagnostic (OBD) port for ECU communication and error code retrieval.
Other Tech
ECU:
Weber Marelli (specific model dependent, important for tuning and diagnostics)
Throttle Control:
Cable operated throttle, with potential for electronic throttle control (ETC) on later 2004+ models.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000 km or annually, whichever comes first (refer to manual for precise interval)
Valve Clearance Check:
Every 12,000 km or 24,000 km, depending on specific service schedule (crucial for V-twins)
Chain Maintenance:
Lubrication and adjustment every 1,000 km or as needed
Fluid Specifications
Engine Oil Type:
Fully Synthetic SAE 10W-50 (API SG/SH/SJ or higher, JASO MA/MA2 certified) - consult manual for specific Aprilia approval
Engine Oil Capacity:
Approx. 3.4 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 Synthetic Brake Fluid
Fork Oil Type:
SAE 5W or 10W Fork Oil (specific viscosity crucial, refer to manual for Ohlins specs)
Known Issues
Common Wear Items:
Clutch wear, steering head bearings, wheel bearings, regulator/rectifier failures (on some models)
Electrical Gremlins:
Potential for intermittent electrical issues, often related to wiring loom integrity or grounding points.
Fuel Pump Reliability:
Early models might have had fuel pump issues, addressed in later revisions.
Voltage Regulator:
Known for overheating and failure, leading to charging system problems. Upgraded units are available.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its racing pedigree and high-performance motorcycles.
Model Evolution
Predecessor:
RSV Mille series
Development Focus:
The RSV1000R represented an evolution of the RSV Mille, aiming for improved performance, handling, and aesthetics, with the Factory model being the top-tier specification.
Production
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Motorsport Heritage:
Aprilia's extensive experience in World Superbike (WSBK) and MotoGP directly influences the RSV1000R's design and performance capabilities.
Ratings
Editorial Reviews:
Consistently praised for its V-twin character, handling prowess, and premium componentry (especially the Factory model with Ohlins suspension).
Certifications
Emission Standards:
Euro 2 or Euro 3 compliant, depending on specific year and market regulations. Manual will detail relevant standards.
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