SXV RXV Chassis

SERVICE STATION MANUAL
854156
SXV RXV 450-550
SERVICE
STATION
MANUAL
SXV RXV 450-550
THE VALUE OF SERVICE
Thanks to continuous technical updates and specific training programs on aprilia products, only apriIia
OfficiaI Network mechanics know this vehicle fully and have the special tools necessary to carry out
maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before
riding, its regular maintenance and the use of OriginaI apriIia Spare Parts only are essential factors!
For information about the nearest OfficiaI DeaIer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.apriIia.com
Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design
stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability
and duration.
The descriptions and illustrations given in this publication are not binding; While the basic
characteristics as described and illustrated in this manual remain unchanged, aprilia 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.
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versions should be confirmed with the official aprilia sales network.
Copyright 2007- aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. aprilia - After sales service.
aprilia trademark is property of Piaggio & C. S.p.A.
SERVICE STATION
MANUAL
SXV RXV 450-550
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.
PersonaI safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the
vehicle to prevent damaging the environment.
VehicIe 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
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
INDEX OF TOPICS
CHARACTERISTICS CHAR
RuIes
Safety ruIes
Carbon monoxide
f you need to keep the engine running in order to carry out any procedure, please ensure that you do
so in an open or very well ventilated area. Never let the engine run in an enclosed area. f you do
work in an enclosed area, make sure to use a smoke-extraction system.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN
CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH.
FueI
CAUTION
FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE RECOMMEN-
DED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED
AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR
FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER
SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components get very hot and remain in this condition for a cer-
tain time interval after the engine has been switched off. Before handling these components, make
sure that you are wearing insulating gloves or wait until the engine and the exhaust system have
cooled down.
CooIant
The coolant contains ethylene glycol which, under certain conditions, can become flammable.
When it burns, ethylene glycol produces invisible flames which however can cause burns.
CAUTION
Characteristics SXV RXV 450-550
CHAR - 2
MAKE SURE NOT TO POUR THE COOLANT ON HOT ENGINE OR EXHAUST SYSTEM COM-
PONENTS; IT MAY CATCH FIRE PRODUCING INVISIBLE FLAMES. WHEN CARRYING OUT
MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN IF IT IS
TOXIC, THE COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO
ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO
ANIMALS AS THEY MAY DRINK IT.
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
UNDER PRESSURE AND MAY CAUSE BURNS.
Used engine oiI and transmission oiI
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE
OR TRANSMISSION OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR
PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS THOR-
OUGHLY AFTER HANDLING IT. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE
NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. IT IS ADVISABLE TO WEAR
LATEX GLOVES WHEN SERVICING THE VEHICLE.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
Brake and cIutch fIuid
THE BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SUR-
FACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT
THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES
WHEN SERVICING THE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARM-
FUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE
THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
SXV RXV 450-550 Characteristics
CHAR - 3
Battery eIectroIyte 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 BAT-
TERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IF THE
FLUID GETS INTO CONTACT WITH THE SKIN, RINSE WELL WITH ABUNDANT FRESH WA-
TER. IT IS EXTREMELY IMPORTANT TO PROTECT THE EYES BECAUSE EVEN A SMALL
QUANTITY OF BATTERY ACID CAN CAUSE BLINDNESS. IF THE FLUID GETS INTO CONTACT
WITH THE EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT
AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK
LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGET-
ABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOS-
IVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT
SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE
BATTERY.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON
PLASTIC COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH
THE BATTERY TO BE ACTIVATED.
Maintenance ruIes
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported be-
low carefully.
BEFORE REMOVING COMPONENTS
Before dismantling components, remove dirt, mud, dust and foreign bodies from the
vehicle. Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
Do not loosen and/or tighten screws and nuts using pliers or other tools than the espe-
cially designed wrench.
Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with distinctive symbols.
CHAR - 4
Each component needs to be clearly marked in order to be identified during reassembly.
Clean and wash the dismantled components carefully using a low-flammability detergent.
Keep coupled parts together since they have "adjusted" to each other due to normal wear
and tear.
Some components must be used together or replaced altogether.
Keep away from heat sources.
REASSEMBLY OF COMPONENTS
CAUTION
THE BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT BINDING AND/OR NOISE,
OTHERWISE THEY NEED REPLACING.
Only use ORGNAL APRLA SPARE PARTS.
Comply with lubricant and consumables usage guidelines.
Lubricate parts (whenever possible) before reassembling them.
When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings(OR), split pins
and screws with new ones if their tread 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 procedure, carry out pre-ride checks and test the
vehicle on private grounds or in an area with low traffic density.
Clean all junction planes, oil guard rims and washers before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassembly the oil guard and the
bearings with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damages to both the connector and the cable harness:
Press the relevant safety hooks, if any.
Grip the two connectors and disconnect them by pulling them in opposite directions.
f there are signs of dirt, rust, humidity, etc., clean the connector internal parts carefully
using a pressurised air jet.
Make sure that the cables are correctly linked to the connector internal terminal ends.
Then insert the two connectors making sure that they couple correctly (if the relevant
CHAR - 5
hooks are provided, you will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT
WAY ROUND.
TIGHTENING TORQUE
CAUTION
DO NOT FORGET THAT TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL PINS AND ANY OTHER SUSPENSION COMPONENTS PLAY A
KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO
COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO
GET LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COM-
PROMISE VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS IN-
JURY OR DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradi-
ents are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during
the run-in. n this way, you allow for the work of components to be "loaded" and then "unloaded", thus
cooling the engine parts. Even if it is important to "stretch" engine components during run-in, make
sure not to strain them.
FoIIow the guideIines detaiIed beIow:
Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
for the first 3 operating hours, do not exceed 50% of the throttle grip travel and never go
over 8000 rpm,
for the next 12 hours, do not exceed 75% of the throttle grip travel.
NOTE
EVEN AFTER THE RUNNING-IN PERIOD, AVOID RUNNING THE ENGINE AT TOP SPEED,
WHEN THE LIMITER CUTS IN:
CHAR - 6
SXV 450 12000 rpm
SXV 550 11500 rpm
RXV 450 11500 rpm
RXV 550 11000 rpm
CAUTION
THE SPEED LIMITER (NOT THE CONTROL UNIT LIMITER) WARNING LIGHT HAS BEEN FACT-
ORY SET AT 8000 rpm
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Maximum length - SXV (450/550) 2165 mm (85.23 in)
Maximum length - RXV (450/550) 2240 mm (88.19 in)
Maximum width - SXV (450/550) 815 mm (32.08 in)
Maximum width - RXV (450/550) 2240 mm (88.19 in)
Maximum height (to windshield) - SXV (450/550) 1170 mm (46.06 in)
Maximum height (to windshield) - RXV (450/550) 1250 mm (49.21 in)
Saddle height - SXV (450/550) 880 mm (34.64 in)
Saddle height - RXV (450/550) 950 mm (37.40 in)
Wheelbase - SXV (450/550) 1470 mm (57.87 in)
Wheelbase - RXV (450/550) 1485 mm (58.46 in)
Minimum ground clearance - SXV (450/550) 270 mm (10.63 in)
Minimum ground clearance - RXV (450/550) 320 mm (12.60 in)
Kerb weight - SXV (450/550) 125 kg (275.58 lb)
Kerb weight - RXV (450/550) 123 kg (271.12 lb)
Engine
ENGINE
Model: SXV (450) 45SX
Model: RXV (450) 45RX
Model: SXV (550) 55SX
Model: RXV (550) 55RX
Type: SXV/RXV (450/550) V-twin, 4-stroke, 4 valves, single overhead cam-
shaft
CHAR - 7
Number of cylinders for SXV/RXV (450/550) 2
Total engine capacity - SXV/RXV (450) 449 cm (27.40 cu.in)
Total engine capacity - SXV/RXV (550) 553 cm (33.75 cu.in)
Bore/stroke - SXV/RXV (450) 76 mm x 49.5 mm (2.99 in x 1.95 in)
Bore/stroke - SXV/RXV (550) 80 mm x 55.0 mm (3.15 in x 2.16 in)
Compression ratio - SXV/RXV (450) (13:1) +/- 0.5
Compression ratio - SXV/RXV (550) (12.5:1) +/- 0.5
dle speed - SXV/RXV (450) (1800 - 2000) +/- 100 rpm
Piston pin hole inside diameter 16.02 - 17.02 mm (0.6307 - 0.6701 in)
Piston outside diameter 75.94 - 79.94 mm (2.9897 - 3.1472 in)
Cylinder liners inside diameter 76.02 - 80.02 mm (2.9929 - 3.1504 in)
Camshaft eccentricity - maximum limit 0.05 mm (0.0020 in)
Valve timing - SXV (450/550) ntake opening: 18 before TDC
ntake closing: 48 after BDC
Outlet opening: 49 before BDC
Outlet closing: 15 after TDC
Valve timing - RXV (450/550) ntake opening: 18 before TDC
ntake closing: 48 after BDC
Outlet opening: 49 before BDC
Outlet closing: 15 after TDC
Valve stem diameter - minimum limit 4.96 mm (0.1952 in)
Bowl diameter - maximum limit: 25.96 mm (1.022 in)
Bowl seating diameter on head - maximum limit: 26.04 mm (1.025 in)
ntake valve seat support width - maximum limit 1.3 mm (0.0512 in)
Outlet valve seat support width - maximum limit 1.5 mm (0.059 in)
ntake valve thickness, sealing side - minimum
limit
2.2 mm (0.0866 in)
Outlet valve thickness, sealing side - minimum
limit
2.5 mm (0.098 in)
ntake valve clearance - SXV/RXV (450/550) 0.07 - 0.12 mm (0.0027 - 0.0047 in)
Outlet valve clearance - SXV/RXV (450/550) 0.17 - 0.22 mm (0.0067 - 0.0087 in)
gnition - SXV/RXV (450/550) Electrical digital
Starting - SXV/RXV (450/550) electric
gnition advance - SXV/RXV (450/550) Variable, controlled by CD
Air filter - SXV/RXV (450/550) with dry cartridge filter
Clutch type - SXV/RXV (450/550) Multiple-disk, oil-bathed clutch with control on the
left side of the handlebar
CHAR - 8
Driving discs 1 - clutch - SXV/RXV (450/550) number of discs: 2; thickness: 1.5 mm (0.059 in)
Driving discs 2 - clutch - SXV/RXV (450/550) number of discs: 5; thickness: 2.0 mm thick
(0.079 in)
Clutch discs - SXV/RXV (450/550) number of discs: 8; thickness: 2.75 mm (0.108 in)
Full disc pack thickness- minimum limit 34 mm (1.34 in)
Clutch disc distortion - maximum limit 0.2 mm (0.0079 in)
Clutch springs - SXV/RXV (450) Number of springs: 6
Unloaded spring length: 46 mm (1.81 in)
Clutch springs - SXV/RXV (550) Number of springs: 6
Unloaded spring length: 46 mm (1.81 in)
Clutch spring length - minimum limit 45.1 mm (1.77 in)
Transmission - SXV/RXV (450/550) Mechanical, 5 speeds with foot lever on the left
hand side of the engine
Lubrication - SXV/RXV (450/550) Separate twin-sump lubrication system with ex-
ternal reservoir:
- gearbox lubrication by splashing specific oil
- engine forced lubrication system with scavenge
oil pump and external reservoir
Oil filter - SXV/RXV (450/550) Paper
Cooling - SXV/RXV (450/550) Fluid
Water pump - SXV/RXV (450/550) Single centrifugal intake pump
Reduction ratio: 44/22
Top ring end clearance 0.45 mm (0.0177 in)
Transmission
TRANSMISSION
Main transmission - SXV/RXV (450/550) 22/56 = 1 : 2.545
Secondary transmission - SXV (450/550) First gear: 12/30 = 1:2.307
Second gear: 15/27 = 1:1.800
Third gear: 16/23 = 1:1.437
Fourth gear: 20/23 = 1:1.150
Fifth gear: 21/21 = 1:1.000
Secondary transmission - RXV (450/550) First gear: 12/31 = 1:1.583
Second gear: 13/25 = 1:1.923
Third gear: 15/23 = 1:1.533
Fourth gear: 19/24 = 1:1.263
Fifth gear: 21/22 = 1:1.047
Final ratio - SXV (450) 15/48: 1:3.067
CHAR - 9
Final ratio - SXV (550) 15/48: 1:2.875
Final ratio - RXV (450/550) 15/48: 1:3.200
Total ratio - SXV (450) First gear: 1:18.013
Second gear: 1:14.050
Third gear: 1:11.221
Fourth gear: 1:8.897
Fifth gear: 1:7.806
Fifth gear: 1:7.318
Total ratio - RXV (450/550) First gear: 1:21.042
Third gear: 1 :12.489
Fifth gear: 1:8.533
Capacities
CAPACITY
Fuel (reserve included) - SXV/RXV (450/550) 7.5 l (1.650 UKgal; 1.981 USgal)
Fuel reserve - SXV/RXV (450/550) 2.2 l (0.484 UKgal; 0.581 USgal)
Coolant - SXV/RXV (450/550) 1.1 l (0.242 UKgal; 0.290 l (50% water + 50%
ethylene glycol antifreeze fluid)
Engine oil - SXV/RXV (450/550) 1.3 l (0.286 UKgal; 0.343 USgal)
After service: 1400 cm (0.308 UKgal; 0.370 US-
gal)
Periodic oil change: 1300 cm (0.286 UKgal;
0.343 USgal)
Fork oil - SXV (450/550) 125 mm (4.92 in) of clearance (for each stem,
measured without spring and under compression)
Fork oil - RXV (450/550) 100 mm (3.94 in) of clearance (for each stem,
measured without spring and under compression)
Seats 1
Drive chain
TRANSMISSION
Main transmission - SXV/RXV (450/550) 22/56 = 1 : 2.545
CHAR - 10
Secondary transmission - SXV (450/550) First gear: 12/30 = 1:2.307
Second gear: 15/27 = 1:1.800
Third gear: 16/23 = 1:1.437
Fourth gear: 20/23 = 1:1.150
Fifth gear: 21/21 = 1:1.000
Secondary transmission - RXV (450/550) First gear: 12/31 = 1:1.583
Second gear: 13/25 = 1:1.923
Third gear: 15/23 = 1:1.533
Fourth gear: 19/24 = 1:1.263
Fifth gear: 21/22 = 1:1.047
Final ratio - SXV (450) 15/48: 1:3.067
Final ratio - SXV (550) 15/48: 1:2.875
Final ratio - RXV (450/550) 15/48: 1:3.200
Fifth gear: 1:7.806
Fifth gear: 1:7.318
Total ratio - RXV (450/550) First gear: 1:21.042
Third gear: 1 :12.489
Fifth gear: 1:8.533
EIectricaI system
ELECTRICAL SYSTEM
1 (Permanent-magnet) generator - SXV/RXV
(450/550)
12V - 350 W
2 Battery 12V - 6 Ah
3 Secondary fuses 5A; 15A; 20A
4 Starter motor - SXV/RXV (450/550) 12V - 350 W
5 Standard spark plug - SXV/RXV (450/550) NGK CR8EB
6 Spark plug electrode gap - SXV/RXV
(450/550)
0.7 - 0.8 mm (0.028 - 0.031 in)
7 Resistance - SXV/RXV (450/550) 5 kOhm
CHAR - 11
8 High-beam light 12V - 60W
9 Low-beam light 12V - 55W
10 Front tail light 12V - 3 W
11 Rear tail light /stop light LED
12 License plate light 12V - 5W
13 Turn indicator lights with micro bulbs (not replaceable)
14 nstrument panel lighting LED
15 Overrevving warning light LED
16 Turn indicator warning light LED
17 High-beam warning light LED
18 Low fuel warning light LED
19 Engine control system warning light LED
20 Engine oil pressure warning light LED
21 Gear in neutral warning light LED
Frame and suspensions
CHASSIS AND SUSPENSIONS
Chassis - SXV/RXV (450/550) Tubular steel perimeter frame and aluminium ver-
tical members
Front suspension - SXV (450/550) Hydraulic action telescopic fork; 48 mm (1.89
in) stems
Front suspension - RXV (450/550) Hydraulic action telescopic fork; 45 mm (1.77
in) stems
Front suspension travel - SXV (450/550) 275 mm (10.83 in)
Front suspension travel - RXV (450/550) 298.5 mm (11.75 in)
Rear suspension - SXV/RXV (450/550) oscillating fork and adjustable hydraulic single
shock absorber
Wheel travel - SXV (450/550) 252 mm (9.92 in) (usable)
Wheel travel - RXV (450/550) 300 mm (11.81 in) (usable)
Brakes
BRAKES
BRAKES
CHAR - 12
Front disc -SXV (450/550) 320 mm (12.60 in) disc with hydraulic transmis-
sion
Front disc - RXV(450/550) 270 mm (10.63 in) disc with hydraulic transmis-
sion
Rear disc - SXV/RXV (450/550) 240 mm (9.45 in) disc with hydraulic transmis-
sion
WheeIs and tyres
WHEELS AND TYRES
Wheel rims - SXV/RXV (450/550) with spokes
Front rim - SXV (450/550) 3.50 x 17''
Front rim - RXV(450/550) 1.60 x 21''
Rear rim -SXV (450/550) 5.50 x 17''
Rear rim - RXV (450/550) 2.15 x 18''
Front tyre - SXV (450/550) 120/70 ZR17 (58W)
Front tyre - RXV(450/550) 90/90 21 54R
Front tyre inflation pressure - SXV (450/550) 180 kPa (1.8 bar) (26.11 PS)
Front tyre inflation pressure - RXV(450/550) 100 kPa (1.0 bar) (14.50 PS)
Rear tyre - SXV (450/550) 180/55 ZR17 (73W)
Rear tyre - RXV (450/550) 140/80 18 70R
Rear tyre inflation pressure - SXV (450/550) 200 kPa (2.0 bar) (29.00 PS)
Rear tyre inflation pressure - RXV (450/550) 110 kPa (1.1 bar) (15.95 PS)
SuppIy
FUEL SUPPLY
Type: SXV/RXV (450/550) V-twin, 4-stroke, 4 valves, single overhead cam-
shaft
Diffuser - SXV/RXV (550) 40 mm (1.57 in)
Diffuser - SXV/RXV (450) 38 mm (1.49 in)
Fuel supply - SXV/RXV (450/550) Electronic injection
Tightening Torques
HANDLEBAR AND CONTROLS LOCKING TORQUES
CHAR - 13
Name Torque in Nm
Clutch control-handlebar fixing screw - M6 10 Nm (7.37 lbf ft)
Throttle grip fixing screw - M6 4 Nm (2.95 lbf ft)
gnition lock fixing screw - M8 24 Nm (17.70 lbf ft)
FOOTRESTS LOCKING TORQUES
Name Torque in Nm
Footrest support bracket fixing screw - M12 55 Nm (40.56 lbf ft) - Loctite 243
Footrest support bracket fixing screw - M8 25 Nm (18.44 lbf ft) - Loctite 243
BODYWORK LOCKING TORQUES
Name Torque in Nm
Rod - mudguard front fixing screw - M6 12 Nm (8.85 lbf ft)
Rod - mudguard rear fixing screw - M6 12 Nm (8.85 lbf ft)
Mudguard - steering base fixing screw - M6 12 Nm (8.85 lbf ft)
Air deflector fixing screws - M6 12 Nm (8.85 lbf ft)
Fairings fixing screws - M6 12 Nm (8.85 lbf ft)
Front tail - frame fixing screw - M6 12 Nm (8.85 lbf ft)
Tail - mudguard - frame central fixing nut - M6 12 Nm (8.85 lbf ft)
Tail - frame rear fixing nut - M6 12 Nm (8.85 lbf ft)
Tail - mudguard fixing screw - M6 12 Nm (8.85 lbf ft)
Upper screw fixing undertail to license plate hold-
er - M5
7 Nm (5.16 lbf ft)
Lower screw fixing undertail to license plate hold-
er - M5
7 Nm (5.16 lbf ft)
Screw fixing undertail - mudguard - remote con-
trol extension - M6
12 Nm (8.85 lbf ft)
Shock absorber protection fixing screw - M5 6 Nm (4.42 lbf ft)
Windshield - instrument panel support fixing
screw - M5
6 Nm (4.42 lbf ft)
nstrument panel support fixing screw - M5 6 Nm (4.42 lbf ft)
Undertail lower fixing screw - M6 12 Nm (8.85 lbf ft)
LIGHTS AND INSTRUMENT PANEL TIGHTENING TORQUES
Name Torque in Nm
Front headlight fixing screw - M6 6 Nm (4.42 lbf ft)
Turn indicators fixing nut - M8 6 Nm (4.42 lbf ft)
Digital instrument panel fixing nut - M5 6 Nm (4.42 lbf ft)
Rear light fixing screw - 3.9 2 Nm (1.47 lbf ft)
CHAR - 14
TANKS/RESERVOIRS TIGHTENING TORQUES
Name Torque in Nm
Plate - fuel tank fixing screw - M6 12 Nm (8.85 lbf ft)
Fuel tank - chassis fixing screw - M6 12 Nm (8.85 lbf ft)
Pump body - fuel tank fixing screw - M6 10 Nm (7.37 lbf ft)
Oil reservoir fixing nut - M6 5 Nm (3.69 lbf ft)
CHASSIS TIGHTENING TORQUES
Name Torque in Nm
Frame fixing screw - M10 49 Nm (36.14 lbf ft)
Upper chain roller fixing screw - M8 22 Nm (16.23 lbf ft)
Lower slider rear fixing screw - M5 4.4 Nm (3.24 lbf ft)
Lower slider front fixing screw - M5 4.4 Nm (3.24 lbf ft)
STAND TIGHTENING TORQUES
Name Torque in Nm
Stand locking plate fixing screw - M8 22 Nm (16.23 lbf ft) - Loctite 243
Side stand fixing nut - M10 34 Nm (25.08 lbf ft) - Loctite 243
EXHAUST LOCKING TORQUES
Name Torque in Nm
Muffler - frame fixing screw - M8 22 Nm (16.23 lbf ft)
Exhaust pipes fixing nut - M6 12 Nm (8.85 lbf ft)
Pipes - head fixing screw - M6 12 Nm (8.85 lbf ft)
Brake - handlebar fixing screw - M6 10 Nm (7.37 lbf ft)
COOLING SYSTEM LOCKING TORQUES
Name Torque in Nm
Radiators upper fixing screw - M6 5 Nm (3.69 lbf ft)
Radiators lower fixing screw - M6 12 Nm (8.85 lbf ft)
FRONT BRAKE LOCKING TORQUES
Name Torque in Nm
SXV 450/550 - Front brake calliper fixing screw -
M10
50 Nm (36.88 lbf ft)
RXV 450/550 - Front brake calliper fixing screw -
M8
25 Nm (18.44 lbf ft)
REAR BRAKE LOCKING TORQUES
Name Torque in Nm
Rear brake pump fixing screw - M6 10 Nm (7.37 lbf ft)
CHAR - 15
Name Torque in Nm
Brake pedal fixing screw - M8 25 Nm (18.44 lbf ft) - Loctite 243
FRONT WHEEL LOCKING TORQUES
Name Torque in Nm
Wheel pin cover - M22 60 Nm (44.25 lbf ft)
REAR WHEEL LOCKING TORQUES
Name Torque in Nm
Wheel pin nut - M25 127 Nm (93.67 lbf ft)
FRONT SUSPENSION LOCKING TORQUES
Name Torque in Nm
Steering head fixing screw - M8 24 Nm (17.70 lbf ft)
Steering base fixing screw - M8 22 Nm (16.23 lbf ft)
SXV 450/550 - Fork feet fixing screw - M8 22 Nm (16.23 lbf ft)
RXV 450/550 - Fork feet fixing screw - M6 10 Nm (7.37 lbf ft)
Upper clamp - handlebar fixing screw - M8 24 Nm (17.70 lbf ft)
Steering pin nut - M26 108 Nm (79.66 lbf ft)
Steering pin ring nut - M30 7 Nm (5.16 lbf ft)
Lower clamp - handlebar fixing nut - M10 32 Nm (23.60 lbf ft)
Stem protection fixing screw - M6 12 Nm (8.85 lbf ft)
REAR SUSPENSION LOCKING TORQUES
Name Torque in Nm
Chassis - rod fixing nut - M12 80 Nm (59.00 lbf ft)
Rod - rocking lever fixing nut - M12 80 Nm (59.00 lbf ft)
Rocking lever - fork fixing nut - M12 80 Nm (59.00 lbf ft)
Shock absorber fixing nut - M10 52 Nm (38.35 lbf ft)
FORK LOCKING TORQUES
Name Torque in Nm
Chain guide fixing nut - M6 12 Nm (8.85 lbf ft)
Fork pin fixing nut - M14 100 Nm (73.76 lbf ft)
Chain tightener set screw - M8 26 Nm (19.18 lbf ft)
Chain slider and pipe guides - rear brake fixing
screw - 4.8
4.4 Nm (3.24 lbf ft)
Rear chain guard fixing screw - 4.8 4.4 Nm (3.24 lbf ft)
Chain guide fixing screw - M6 12 Nm (8.85 lbf ft)
CHAR - 16
ENGINE LOCKING TORQUES
Name Torque in Nm
Engine - chassis fixing nut M10 54 Nm (39.82 lbf ft)
Screw fixing control unit to plate - M4 3.24 lbf ft (4.4 Nm) - Loctite 243
Screw fixing regulator and control unit to chassis -
M6
12 Nm (8.85 lbf ft)
Coil fixing screw - M6 12 Nm (8.85 lbf ft)
Pinion cover - chain guide plate fixing screw - M6 12 Nm (8.85 lbf ft)
Engine oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft)
Gearbox oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft)
Oil filter cover - M56x1.5 25 Nm (18.44 lbf ft)
Piston fitting hole cover - M30x2 30 Nm (22.13 lbf ft)
Spark plug - M10x1.25 12 Nm (8.85 lbf ft)
Gearbox oil check screw - M6x1 9.8 Nm (7.23 lbf ft)
Water pump rotor - M7x1 12 Nm (8.85 lbf ft)
Head cover screw - M6x1 9.8 Nm (7.23 lbf ft)
Water pump cover screw - M6x1 9.8 Nm (7.23 lbf ft)
Clutch cover screw - M6x1 8.0 Nm (5.90 lbf ft)
Right crankcase cover screw - M6x1 9.8 Nm (7.23 lbf ft)
Crankcase clamping screw - M6x1 12 Nm (8.85 lbf ft)
Crankcase clamping screw - M7x1 15 Nm (11.06 lbf ft)
gnition cover screw - M6x1 9.8 Nm (7.23 lbf ft)
Pick-up fixing screw - M5x0.8 8 Nm (5.90 lbf ft) - Loctite 270
Stator fitting screw - M5x0.8 8 Nm (5.90 lbf ft) - Loctite 270
Chain tightener slider screw - M6x1 9.8 Nm (7.23 lbf ft) - Loctite 270
Timing chain tightener fitting screw - M6x1 10 Nm (7.37 lbf ft)
Cable guide ring fixing screw - M6x1 10 Nm (7.37 lbf ft)
Oil pipe plate screw - M6x1 9.8 Nm (7.23 lbf ft) - Loctite 270
Blow-by breather joint - M12x1 18 Nm (13.28 lbf ft) - Use compound
Flywheel nut - M14x1 108 Nm (79.66 lbf ft)
Starter screw - M6x1 9.8 Nm (7.23 lbf ft)
Chain guide plate screw - M6x1 12 Nm (8.85 lbf ft)
Secondary shaft bearing fixing screw - M6x1 10 Nm (7.37 lbf ft) - Loctite 270
Main shaft bearing fixing screw - M6x1 10 Nm (7.37 lbf ft) - Loctite 270
Screw fixing the gear selector drum bearing -
M5x0.8
8 Nm (5.90 lbf ft) - Loctite 270
CHAR - 17
Name Torque in Nm
Gear indicator screw - M5x0.8 6 Nm (4.43 lbf ft) - Loctite 270
Gear pedal fixing screw - M6x1 12 Nm (8.85 lbf ft)
Head fitting screw (pre-torque) - M10x1.25 30 Nm (22.13 lbf ft) - Oil screws and washers
Head fitting screw - M10x1.25 50 Nm (36.88 lbf ft)
Head fitting screw - M6x1 12 Nm (8.85 lbf ft)
Timing system gear fixing nut - M12x1 50 Nm (36.88 lbf ft)
Timing compartment closing cover screw -
M5x0.8
6 Nm (4.42 lbf ft) - Loctite 243
Main transmission pinion nut - M18x1.25 160 Nm (118.00 lbf ft)
Selector locking plate screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 270
Oil collecting plate screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 270
Selector shaft lock screw - M10x1.25 25 Nm (18.44 lbf ft) - Loctite 270
Gear locking pawl rotation screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 243
Selector pin - M18x1.25 22 Nm (16.23 lbf ft)
Clutch hub fixing nut - M18x1.25 75 Nm (55.32 lbf ft)
Clutch spring screw - M6x1 12 Nm (8.85 lbf ft)
Pressure relief valve - M14x.5 20 Nm (14.75 lbf ft)
Pressure pump fitting screw - M6x1 9.8 Nm (7.23 lbf ft)
Scavenge pump fitting screw - M6x1 9.8 Nm (7.23 lbf ft)
Head lubrication nozzle - M7x1 2.5 Nm (1.84 lbf ft)
Valve lifter lock screw - M5x0.8 9 Nm (6.64 lbf ft) - Loctite 270
Water joint plate screw - M6x1 9.8 Nm (7.23 lbf ft)
Crankshaft locking screw - M8x1.25 22 Nm (16.23 lbf ft) - Loctite 270
Freewheel outside ring screws - M6x1 13 Nm (9.58 lbf ft) - Loctite 270
Throttle body fixing screw - M6x1 13 Nm (9.58 lbf ft) - Loctite 243
Camshaft gear fixing screw - M16x1 35 Nm (25.82 lbf ft)
Connecting rod cap screw - M8x1 15+(48-50) Nm (11.06+(48-50) lbf ft)
Oil pressure sensor M10x1 15 Nm (11.06 lbf ft)
Water temperature sensor 18 Nm (13.27 lbf ft)
ELECTRICAL COMPONENTS TIGHTENING TORQUES
Name Torque in Nm
Remote control - fuse box fixing screw - M5 7 Nm (5.16 lbf ft) - Loctite 243
Chassis - ground lead fixing screw - M6 12 Nm (8.85 lbf ft)
Remote control cables fixing screw - M6 12 Nm (8.85 lbf ft)
CHAR - 18
Name Torque in Nm
Horn fixing screw - M8 22 Nm (16.23 lbf ft)
OverhauI data
AssembIy cIearances
Crankcase - crankshaft - connecting rod
To choose the appropriate spare parts for the coupling bushings, check the type of original compon-
ents and the correct bushing on the table.
The type of component is engraved with laser pen
on the components themselves.
NOTE
THE CRANKCASE TYPE IS ENGRAVED ON
BOTH CRANKCASE HALVES.
COUPLING TYPES - SHAFT - CONNECTING ROD
Shaft - Connecting rod: A - A - BLUE types Shaft- A 34.984 mm - 34.991 mm (1.37732 in -
1.37759 in)
Connecting rod - A 38.000 mm - 38.012 mm
(1.49606 in - 1.49653 in)
Colour: BLUE
Shaft - Connecting rod: A - B - YELLOW types Shaft- A 34.984 mm - 34.991 mm (1.37732 in -
1.37791 in)
Connecting rod - B 38.013 mm - 38.025 mm
(1.49657 in - 1.49704 in)
Colour: YELLOW
Shaft - Connecting rod: B - A - GREEN types Shaft- B 34.992 mm - 35.000 mm (1.37763 in -
1.37795 in)
Connecting rod - A 38.000 mm - 38.012 mm
(1.49606 in - 1.50078 in)
Colour: GREEN
Shaft - Connecting rod: B - B - BLUE types Shaft- B 34.992 mm - 35.000 mm (1.37763 in -
1.37795 in)
Connecting rod - B 38.013 mm - 38.025 mm
(1.49657 in - 1.49704 in)
Colour: BLUE
CHAR - 19
COUPLING TYPES - SHAFT - MAIN BEARING
Shaft - Main bearing: A - A - BLUE types Shaft- A 34.984 mm - 34.991 mm (1.37732 in -
1.37759 in)
Main bearing - A 41.000 mm - 41.007 mm
(1.61417 in - 1.61444 in)
Colour: BLUE
Shaft - Main bearing: A - B - YELLOW types Shaft- A 34.984 mm - 34.991 mm (1.37732 in -
1.37759 in)
Main bearing - B 41.008 mm - 41.016 mm
(1.61448 in - 1.61480 in)
Colour: YELLOW
Shaft - Main bearing: B - A - GREEN types Shaft- B 37.992 mm - 38.000 mm (1.49574 in -
1.49606 in)
Main bearing - A 41.000 mm - 41.007 mm
(1.61417 in - 1.61444 in)
Colour: GREEN
Shaft - Main bearing: B - B - BLUE types Shaft- B 37.992 mm - 38.000 mm (1.49574 in -
1.49606 in)
Main bearing - B 41.008 mm - 41.016 mm
(1.61448 in - 1.61480 in)
Colour: BLUE
CHAR - 20
Recommended products chart
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGP RACNG 4T, SAE 10W -
60
Engine oil As an alternative, use top-
branded oils that meet or ex-
ceed the requirements of CCMC
G-4 AP SG SAE 10W - 60 spe-
cifications
AGP GEAR SYNTH SAE
75W-90
Engine oil As an alternative for recommen-
ded oils, top-branded oils that
meet or exceed the require-
ments of CCMC G-4, AP spe-
cifications can be used.
AGP ANTFREEZE PLUS Engine coolant -
AGP BRAKE FLUD DOT 4 Brake fluid FMVSS DOT4+
AGP MP GREASE Bearings and other lubrication
points
As an alternative to the recom-
mended product, use top-
branded grease for roller bear-
ings, useful temperature range: -
30C - +140C (-22F - +284F),
drop point: 150C - +230C
(302F - 446F), high anticorros-
ive protection, good water and
rust resistance.
AGP FORK 7,5W and AGP
FORK 10W
Fork oil SXV 450/550 - AGP FORK
7,5W
RXV 450/550 - AGP FORK
10W
CHAR - 21
CHAR - 22
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS
SPECIAL TOOLS
Stores code Description
853713 Pin ring tool - 450
853714 Pin ring tool - 550
853715 Water pump oil seal guide
853716 Water pump oil seal punch
8140179 Valve spring compressor
8140187 Engine support stand
Special tools SXV RXV 450-550
S-TOOLS - 2
8140188 Engine support
8140838 Flywheel rotor locking
8127819 Walbro Cable for Axone
9100838 Tool for pump pressure plate
9100839 Flywheel extractor
9100840 Punch for crankshaft bushings
SXV RXV 450-550 Special tools
S-TOOLS - 3
9100843 Crankshaft pinion locking tool
9100844 Crankshaft locking tool (timing
pin)
9100884 Crankshaft bushing extractor
9100885 Main shaft/ right side - second-
ary shaft/left side
9100886 Secondary shaft/right side -
Main shaft/left side
9100887 Punch for right crankcase
desmo
S-TOOLS - 4
9100888 Oil pump oil seal punch
9100889 Timing gear crankshaft punch
9100892 Left crankcase desmodromic +
wheel hub
9100893 Left timing gear punch
9100894 Secondary shaft oil seal punch
S-TOOLS - 5
9100895 Water pump oil seal punch
9100896 Clutch bell locking tool
9100897 Cylinder liner extractor
9100898 Fork cages punch
9100900 Punch for fork linkage cages
9100903 Marzocchi fork oil seal; 45 mm
(1.77 in)
S-TOOLS - 6
9100904 Sachs fork oil seal; 48 mm
(1.89 in)
9100938 Pump rotor wrench
9100943 Piston pin extractor
9100942 Crankcase halves support
S-TOOLS - 7
S-TOOLS - 8
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance chart
Periodic maintenance chart for vehicles in the original version (throttled) for road operation,
CAUTION
THE MAINTENANCE OPERATIONS LISTED MUST BE CARRIED OUT BY A DEALER OR AU-
THORISED APRILIA WORKSHOP, OTHERWISE THE WARRANTY WILL BE VOIDED.
NOTE
CARRY OUT THE MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE
VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICA-
TIONS.
END OF RUN-IN PERIOD 500 KM (311 MILES)
Action
Throttle body assembly bolt torque - Check
Throttle bodies - Synchronisation
Air filter and filter case - Check and cleaning
Fuel lines - Check condition and position
dle speed adjustment - Check
Transmission oil - change
Clutch control - Check and adjustment
Coolant level in radiator and expansion tank - Check
Engine oil and engine oil filter - Change
Oil lines - Check condition and position
Throttle cables - Adjustment
Cold start key - Adjustment
Brake fluid level - Check
Brake lines - Check condition and for leaks
Brake circuit screws tightening - Check
Light operation/direction
Electrical system operation - Check
Tyre condition and pressure - Check
Wheel bearing clearance - Check
Wheel spokes and rim coaxiality - Check tension
Tightening of wheel pin nuts and screws - Check
Maintenance SXV RXV 450-550
MAN - 2
Action
Engine mounting bolt torque - Check
Tightening of chassis screws and nuts - Check
Fork - Check for sealing and operation
Tightening of fork plates and feet screws - Check
Shock absorber pins tightening - Check
Shock absorber - Check for sealing and operation
Steering bearings - Check and adjust
Headstock dust guards - Cleaning
Drive chain - Tension
Chain links (RXV), sealed links (SXV), chain sprocket and chain guide - Check for wear
Chain - lubricate
EVERY 3000 KM (1864 MILES)
Action
Clutch springs - check length
Clutch discs - Check for wear
System sealing - Check
Brake discs thickness - Check
Brake pad thickness - Check
Electrical contacts and switches - Treatment with contact activator spray
SXV RXV 450-550 Maintenance
MAN - 3
Action
Battery connections - Greasing
Drainage - check for leaks and alignment
Wheel bearings - check
Fork dust guards - Cleaning
Fork legs - Bleed
Steering bearing clearance - Check
Steering bearings - Lubricate
Clutch lever pin - Lubricate
Throttle cables - Lubricate
Rider footrest bolts - Lubricate
Chain - lubricate
Rear suspension linkage system - Lubricate
Side stand bolt - Lubricate
Front wheel bolt and bearings - Lubricate
Rear fork bolt - Lubricate
Rear wheel bolt and bearings - Lubricate
Action
Paper air filter - Replacement
MAN - 4
Action
Spark plugs - change
Action
Complete transmission - Check for wear
Pressure relief and non-return valve spring - Check
Cylinder liners - Check for wear
Connecting rods and main bushings - Check for wear
Start-up gears - Check for wear
Oil pump gears - Check
Head lubrication nozzles - Cleaning
Pistons and piston rings - Replacement
Piston pin - Check
Cam rockers - radial check
Valve lifter - Check
Camshaft wear - Check
Camshaft bearings - Check
Valve seat sealing - Check
Valves - Check for wear
Valve clearance - Check and adjustment
Valve guides - check for wear
Spring washers, caps, bowls - Check for wear
Chain tightener toothing - Check for wear
Valve springs - check length
Timing chain - Stretching measurement
Drive chain sliders - Check for wear
Fuel pump - Check
Fork - Comprehensive maintenance
Fork oil - Replacement
Shock absorber - Comprehensive maintenance
Crankshaft and connecting rod bearing clearance - Check
Chain guide slider - Check for wear
Chain guide - Check for wear
Chain tightener roller - Check for wear
Chain tightener slider - Check for wear
MAN - 5
EVERY YEAR
Action
Brake fluid - Change
Periodic maintenance chart for vehicles in free version for hobby sports applications.
AFTER THE RUN-IN PERIOD AND EVERY 3 HOURS OF OPERATION
Action
MAN - 6
Action
Chain - lubricate
EVERY 15 HOURS OF OPERATION
Action
MAN - 7
Action
Fork legs - Bleed
Chain - lubricate
Action
Action
MAN - 8
Action
Piston pin - Check
Fuel pump - Check
EVERY YEAR
Action
Periodic maintenance chart for vehicles in free version for competitive sports applications.
END OF RUN-IN PERIOD AND EVERY 3 HOURS OF OPERATION
Action
MAN - 9
Action
Chain - lubricate
Action
MAN - 10
Action
Fork legs - Bleed
MAN - 11
Action
Chain - lubricate
Action
Action
Piston pin - Check
MAN - 12
Action
Fuel pump - Check
EVERY YEAR
Action
CAUTION
IF THE VEHICLE IS USED FOR COMPETITIONS, CARRY OUT THE 15-HOUR SERVICE AFTER
EVERY RACE.
NOTE
- MAINTENANCE OPERATIONS BY THE SPECIALISED APRILIA WORKSHOP DO NOT RE-
PLACE DAILY CHECKING BY THE RIDER!
- IF DISTORTIONS, DAMAGES OR WEAR EXCEEDING THE TOLERATED VALUES ARE
FOUND, REPLACE THE INVOLVED COMPONENTS
- BEFORE CARRYING OUT ANY OPERATION, CLEAN YOUR VEHICLE CAREFULLY
- RIDING ON SANDY OR DUSTY ROADS OR UNDER EXTREME SITUATIONS MAY WEAR
DOWN SOME COMPONENTS EVEN BEFORE THE SCHEDULED CHECK.
- ONLY FOR THE RXV MODEL: IF THE VEHICLE IS USED MAINLY FOR MOTOCROSS RACING,
MAN - 13
CARRY OUT ALL THE MAINTENANCE SERVICES INDICATED IN THE 45-HOUR COLUMN
EVERY 30 HOURS OF USE.
Spark pIug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING.
n order to gain access to the spark plugs:
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS,
LEAVE THE ENGINE AND MUFFLER TO COOL OFF TO AMBIENT TEMPERATURE.
Place the vehicle on the stand.
NOTE
THE VEHICLE HAS A SPARK PLUG (2) FOR EACH CYLINDER. THE FOLLOWING STEPS RE-
LATE TO JUST ONE SPARK PLUG BUT APPLY TO BOTH.
Remove the tube (1) of the spark plug
(2).
Clean off any trace of dirt from the
spark plug (2) base.
nsert the spanner supplied in the tool
kit into the hexagonal head of the
spark plug (2).
Unscrew the spark plug (2) and re-
move it from its seat, making sure no
dust or dirt gets into the cylinder.
Checking and cleaning:
CAUTION
MAN - 14
THE ELECTRODES OF THE SPARK PLUGS
INSTALLED ON THIS VEHICLE ARE PLATIN-
UM ELECTRODES. DO NOT USE METAL
BRUSHES AND/OR ABRASIVE PRODUCTS TO
CLEAN THE SPARK PLUGS. USE ONLY A
COMPRESSED AIR JET.
KEY:
central electrode (3);
insulator (4);
side electrode (5).
Check that the electrodes and the in-
sulator of the spark plug (2) do not
show signs of carbon deposits and
corrosion. f necessary, clean them
using a compressed air jet.
Replace the spark (2) if its insulator is cracked,
the electrodes show signs of corrosion or excess-
ive deposits, or the top of the central electrode
gets rounded (6).
CAUTION
WHEN REPLACING THE SPARK PLUG (2),
CHECK THE PITCH AND LENGTH OF THE
THREAD. IF THE THREADED PART IS TOO
SHORT, CARBON DEPOSITS WILL BUILD UP
ON THE THREAD'S SEAT AND MAY THUS
CAUSE DAMAGE TO THE ENGINE WHEN THE
CORRECT THREADED PART IS INSTALLED.
USE RECOMMENDED SPARK PLUGS ONLY.
USING A SPARK PLUG OTHER THAN SPE-
CIFIED MIGHT COMPROMISE ENGINE PER-
FORMANCE AND LIFE. CHECK THE GAP
BETWEEN THE ELECTRODES WITH A FEEL-
MAN - 15
ER GAUGE TO AVOID DAMAGING THE PLAT-
INUM COATING.
Checking the gap between the electrodes with a feeler gauge.
CAUTION
DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP.
The gap between the electrodes should be
between 0.7 0.8 mm (0.027 0.031 in). Other-
wise, replace the spark plug (2).
Make sure the washer is in good con-
ditions.
nstallation:
Once the washer is fitted, screw the
spark plug (2) manually to avoid dam-
aging the thread.
Tighten using the spanner supplied in
the tool kit. Make each spark plug (2)
complete 1/2 of a turn to compress the
washer.
CAUTION
IT IS ESSENTIAL TO TIGHTEN THE SPARK
PLUG (2) PROPERLY. A LOOSE SPARK PLUG
MAY CAUSE ENGINE OVERHEATING AND
RESULT IN SEVERE DAMAGE.
Locking torques (N*m)
Spark pIug - M10x1.25 12 Nm (8.85 Ibf ft)
Position the spark plug tube (1) correctly so that it does not get detached due to engine vi-
brations.
NOTE
REPEAT THE DESCRIBED OPERATIONS FOR THE SPARK PLUG (2) OF THE OTHER CYLIN-
MAN - 16
DER.
Engine oiI
CAUTION
ENGINE OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR LONG PERI-
ODS. IT IS ADVISABLE TO WASH YOUR HANDS CAREFULLY AFTER HANDLING IT.
CAUTION
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
DISPOSE OF ENGINE OIL STORED IN A SEALED CONTAINER AND TAKE IT TO YOUR SUP-
PLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM.
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
CAUTION
IF THE ENGINE OIL PRESSURE WARNING LIGHT COMES ON DURING NORMAL ENGINE OP-
ERATION, IT MEANS THAT THE ENGINE OIL PRESSURE IN THE CIRCUIT IS TOO LOW.
IN THIS CASE, CHECK THE ENGINE OIL LEVEL AND IF IT IS NOT CORRECT, SHUT OFF THE
ENGINE IMMEDIATELY AND CONTACT AN OfficiaI apriIia deaIer. HANDLE CAREFULLY.
DO NOT SPILL OIL!
AVOID SPILLING OIL OVER COMPONENTS, THE AREA YOUR ARE WORKING IN AND ITS
SURROUNDS. REMOVE ANY TRACE OF OIL CAREFULLY.
IN THE EVENT OF LEAKS OR MALFUNCTIONING, CONTACT AN OfficiaI apriIia deaIer.
NOTE
VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS.
Check
To check:
CAUTION
THIS TYPE OF VEHICLE HAS SEPARATE LUBRICATION CIRCUITS FOR ENGINE AND TRANS-
MISSION/CLUTCH. OIL LEVEL CHECK AND REPLACEMENT MUST BE CARRIED OUT FOR
MAN - 17
BOTH CIRCUITS.
CAUTION
THE ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL. IF ENGINE OIL LEVEL IS
CHECKED WHEN THE ENGINE IS COLD, THE OIL MAY GO TEMPORARILY BELOW THE MIN-
IMUM LEVEL. THIS IS NOT A PROBLEM AS LONG AS THE ENGINE OIL PRESSURE WARNING
LIGHT DOES NOT COME ON.
NOTE
IN ORDER TO WARM-UP THE ENGINE AND BRING THE OIL TO THE RIGHT TEMPERATURE,
RIDE THE VEHICLE FOR A SHORT PERIOD OF TIME (10 - 15 MIN), KEEP THE ENGINE RUN-
NING AT IDLE FOR AT LEAST 30 SECONDS AFTER YOU HAVE COME TO A HALT, THEN CUT
OFF THE ENGINE.
Keep the vehicle upright with the two
wheels on the ground.
Check oil level through the appropriate
transparent pipe (1).
MAX = maximum level
MIN = minimum level
The oil level is correct when it is close
to the MAX level reference mark.
Top up as required:
CAUTION
IF YOU RIDE YOUR VEHICLE IN A SPORTY FASHION WITH OIL LEVEL TOO HIGH, SOME OIL
MAY SPLATTER AND GET INTO THE FILTER CASE THROUGH THE ENGINE VENT.
CAUTION
DO NOT GO BEYOND THE MAX AND BELOW THE MIN LEVEL MARKS TO AVOID SEVERE EN-
GINE DAMAGE.
Unscrew and remove the filler plug
(2).
NOTE
DO NOT ADD ADDITIVES OR OTHER SUB-
STANCES TO THE OIL.
MAN - 18
WHEN USING A FUNNEL OR ANY OTHER
ELEMENT, MAKE SURE IT IS PERFECTLY
CLEAN.
Top-up the oil in the reservoir until you reach the correct level.
RepIacement
Park the vehicle on firm and level
ground.
Rest the vehicle on its stand.
CAUTION
WAIT SOME MINUTES UNTIL THE ENGINE
AND THE EXHAUST SYSTEM ARE COLD.
Stop the engine and let it cool off so
that the oil in the crankcase flows
down and cools as well.
Unscrew and take out the plug.
Place a container to collect the oil un-
derneath the engine oil drainage plug
on the flywheel side.
Unscrew and remove the oil drainage
plug and drain off all the engine oil.
CAUTION
USED OIL CONTAINS SUBSTANCES HARM-
FUL TO THE ENVIRONMENT. DISPOSE OF
USED OIL ACCORDING TO THE REGULA-
TIONS IN FORCE.
MAN - 19
Unscrew the engine oil filter cover.
Remove the engine oil filter cover and
the gasket, collecting the O-ring.
Remove the engine oil filter.
Place a container underneath the en-
gine oil drainage plug of the recovery
reservoir.
Unscrew and remove the oil drainage
plug from the reservoir and drain all
the engine oil.
Fit a new engine oil filter.
Screw the engine oil filter cover.
Screw and tighten the oil drainage
plug.
Pour approx. 1250 cm (76.3 cu.in) of
engine oil through the filler opening.
Screw and tighten the plug.
Start the engine and let it run for sev-
eral minutes.
Stop the engine and let it cool down.
Check the engine oil level.
Gearbox OiI
Inspection
CAUTION
GEAR OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.
Stop the engine.
Wait some minutes for the oil to flow
from the transmission to the clutch.
MAN - 20
Remove the rear brake lever by undo-
ing the screw (1); collect the washer.
Unscrew and remove the cap/dipstick (2).
The oil level is correct when it is close to the cap/dipstick (2) opening.
f necessary:
Remove the filler cap (3).
Top-up with oil up to the cap/dipstick
(2) opening.
CAUTION
STANCES TO THE FLUID.
CLEAN.
Wait some minutes to allow the oil to flow from the clutch to the transmission. Then check
the oil level again.
RepIacement
Lower the oil pan guard.
Place a container with suitable capa-
city under the drainage plug (3).
Unscrew and remove the drainage
MAN - 21
plug (3).
Unscrew and remove the filler plug
(2).
Drain the oil into the container; allow
several minutes for oil to drain out
completely.
Check and if necessary, replace the
drainage plug (3) sealing washers.
Screw and tighten the drainage plug
(3).
Remove the rear brake lever by undo-
ing the screw (1); collect the washer.
Unscrew and remove the cap/dipstick.
Pour new oil up to the cap/dipstick
opening.
Wait several minutes to allow the oil to
flow from the clutch to the transmis-
sion.
Then check the oil level again.
Tighten the filler cap (2).
CAUTION
OIL FLOWING FROM THE CLUTCH TO THE
TRANSMISSION AND FROM THE TRANSMIS-
SION TO THE CLUTCH CAN BE PARTICU-
LARLY SLOW WHEN THE OIL OR ENGINE
TEMPERATURE IS LOW.
CAUTION
CLEAN.
MAN - 22
Refit the rear brake lever, remember to insert the washer between the lever and the
crankcase, by tightening the screw (1).
Air fiIter
Remove the saddle.
Lift the tank.
Release the air filter cover by gripping
and lifting the handles from both sides.
Slide out the air filter case cover from
behind together with the filter.
NOTE
UPON REFITTING THE AIR FILTER, ENSURE
THAT ITS CASE IS PERFECTLY CLEAN. RE-
MOVE ANY TRACE OF DIRT THAT MAY HAVE
ENTERED DURING REMOVAL. UPON REFIT-
TING, MAKE SURE THAT THE AIR INTAKES
ARE CORRECTLY FITTED.
CAUTION
MAKE SURE THAT THE RESERVOIR RETAIN-
ING EDGE NEVER COMES INTO CONTACT
WITH THE BATTERY POSITIVE LEAD.
CAUTION
IN THE EVENT OF A FALL, CLEAN THE AIR
FILTER AND ITS HOUSING CAREFULLY, RE-
MOVING ANY TRACES OF OIL WHICH MAY
HAVE ENTERED FROM THE OIL RESERVOIR
THROUGH THE OIL VAPOUR BREATHER
PIPES.
CAUTION
MAN - 23
REMOVE THE AIR FILTER COVER ONLY
WHEN THE VEHICLE IS PERFECTLY CLEAN
SO AS TO PREVENT ANY TRACE OF DIRT
FROM GETTING INTO THE HOUSING.
CooIing system
LeveI check
Check and top-up
CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE
COOLANT LEVEL.
Shut off the engine and wait until it
cools off.
Park the vehicle on firm and level
ground.
Turn the radiator cap (1) anticlockwise
just one click.
Wait a few seconds so that possible
pressure in the circuit may be purged.
Turn the radiator cap (1) anticlockwise
again and remove it.
Make sure the fluid covers the radiator
plates completely.
Also check the level in the expansion
tank (under the engine sump cover)
through the appropriate sight glass.
The level should be between the MN
and MAX reference marks.
CAUTION
MAN - 24
CLEAN.
CAUTION
COOLANT IS TOXIC IF INGESTED; CONTACT
WITH EYES OR SKIN MAY CAUSE IRRITA-
TION. DO NOT INTRODUCE YOUR FINGERS
OR ANY OTHER OBJECT TO CHECK IF
THERE IS COOLANT OR NOT.
Top-up
Check the coolant level.
f required, top-up with coolant until
the radiator plates are covered. Do not
exceed this level, otherwise the
coolant will spill during engine opera-
tion. When using a funnel or any other
element, make sure it is perfectly
clean.
Refit the radiator cap (1).
CAUTION
IN THE EVENT OF EXCESSIVE COOLANT
CONSUMPTION, CHECK COOLING SYSTEM
FOR LEAKS.
HAVE ANY MALFUNCTIONS REPAIRED BY
AN apriIia OfficiaI DeaIer.
Braking system
MAN - 25
CAUTION
THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OF THEM OPER-
ATED BY AN INDEPENDENT HYDRAULIC CIRCUIT.
NOTE
THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT IS VALID FOR
BOTH.
CAUTION
UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER
ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. CONTACT AN OfficiaI apriIia deaIer IN
CASE OF DOUBTS ON THE CORRECT BRAKING CIRCUIT OPERATION AND WHEN UNABLE
TO CARRY OUT ROUTINE CHECKS. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND
THE FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY
AFTER MAINTENANCE OPERATIONS OR CHECKS. CHECK THAT BRAKE PIPES ARE NOT
TWISTED OR WORN. PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERT-
ENTLY GETS INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVI-
CING THE HYDRAULIC CIRCUIT. BRAKE FLUID MAY CAUSE IRRITATION IF IN CONTACT
WITH SKIN OR EYES. RINSE CAREFULLY ALL BODY PARTS THAT HAVE COME INTO CON-
TACT WITH THE FLUID. SHOULD THE FLUID COME INTO CONTACT WITH YOUR EYES, SEEK
MEDICAL ADVICE OR CONTACT AN EYE SPECIALIST. DO NOT DISPOSE OF THE FLUID INTO
THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN WHEN USING BRAKE FLUID,
PAY ATTENTION NOT TO SPILL IT ONTO PLASTIC OR PAINTED COMPONENTS AS IT WILL
IRREPARABLY DAMAGE THEM.
LeveI check
FRONT BRAKE
Place the vehicle upright and keep the
handlebar right.
Make sure the fluid level in the reser-
voir (1) is above the 'MN' level refer-
ence mark.
MIN = minimum level
MAX = maximum level
MAN - 26
f the fluid does not reach the "MIN" level reference mark:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN.
Check brake pads and discs for wear.
f the pads and/or the disc do not need replacing, top-up the fluid.
REAR BRAKE
Place the vehicle upright
Make sure the fluid level in the reser-
voir (2) is above the "MN" level refer-
ence mark.
f the fluid does not reach at least the "MIN" reference mark:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN.
Check brake pads and discs for wear.
f the pads and/or the disc do not need replacing, top-up the fluid.
Top-up
FRONT BRAKING CIRCUIT TOPPING-UP - SXV
NOTE
RISK OF BRAKE FLUID SPILLS. DO NOT
PULL THE FRONT BRAKE LEVER WHEN THE
SCREWS (1) ARE LOOSE OR, MAINLY, WHEN
MAN - 27
THE BRAKE FLUID RESERVOIR CAP (2) HAS
BEEN REMOVED.
Undo the screws (1) of the brake fluid reservoir using a short Phillips screwdriver.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOP-
IC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID
RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PRO-
CEDURE.
Lift and remove the cover (2) together with the screws (1) and the gasket (3).
CAUTION
TO AVOID SPILLING BRAKE FLUID DURING TOP-UP, DO NOT SHAKE THE VEHICLE. DO NOT
ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY
OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Top-up the reservoir with the brake fluid until the level is over the "MN" level reference
mark.
CAUTION
TOP-UP TO MAX LEVEL MARK ONLY WHEN THE BRAKE PADS ARE NEW. IT IS ADVISABLE
NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE
YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS.
CHECK BRAKING EFFICIENCY.
IN CASE OF EXCESSIVE BRAKE LEVER TRAVEL OR POOR PERFORMANCE OF THE BRAK-
ING CIRCUIT, TAKE YOUR VEHICLE TO AN OfficiaI apriIia deaIer, AS IT MAY BE NECESSARY
TO PURGE AIR IN THE CIRCUIT.
FRONT BRAKING CIRCUIT TOPPING-UP -
MAN - 28
RXV
NOTE
RISK OF BRAKE FLUID SPILLS. DO NOT
PULL THE FRONT BRAKE LEVER WHEN THE
SCREWS (4) ARE LOOSE OR, MAINLY, WHEN
THE BRAKE FLUID RESERVOIR CAP (5) HAS
BEEN REMOVED.
Undo the screws (4) of the brake fluid reservoir using a short Phillips screwdriver.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOP-
IC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID
RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PRO-
CEDURE.
CAUTION
mark.
CAUTION
REAR BRAKING CIRCUIT TOPPING-UP - SXV - RXV
MAN - 29
NOTE
RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE
SCREWS (7) ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR CAP (8) HAS
BEEN REMOVED.
Undo the two screws (7) of the brake
fluid reservoir using a short Phillips
screwdriver.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE
BRAKE FLUID. BRAKE FLUID IS HYGRO-
SCOPIC AND ABSORBS MOISTURE WHEN IN
CONTACT WITH AIR. LEAVE THE BRAKE
FLUID RESERVOIR OPEN ONLY FOR THE
TIME NEEDED TO COMPLETE THE TOPPING
UP PROCEDURE.
CAUTION
mark.
CAUTION
MAN - 30
HeadIight adjustment
NOTE
IN COMPLIANCE WITH LOCAL LEGAL REQUIREMENTS, SPECIFIC PROCEDURES MUST BE
FOLLOWED WHEN CHECKING LIGHT BEAM ADJUSTMENT.
For a quick check of the correct adjustment of the
front light beam:
Place the vehicle 10 m (32.81 ft) away
from a vertical wall and make sure the
ground is level.
Turn on the low-beam light, sit on the
vehicle and check that the light beam
projected to the wall is a little below
the headlight horizontal straight line
(about 9/10 of the total height).
To adjust the light beam:
Use a screwdriver to operate the spe-
cific screw
- TGHTEN the screw (clockwise) to raise the light
beams.
- UNDO the screw (anticlockwise) to lower the
light beams.
After adjusting:
NOTE
CHECK THAT THE LIGHT BEAM VERTICAL
DIRECTION IS CORRECT.
MAN - 31
MAN - 32
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS
EIectricaI system instaIIation
GeneraI wiring diagram
Key:
1. Multiple connectors
Electrical system SXV RXV 450-550
ELE SYS - 2
2. Diagnosis connector
3. Speed sensor
4. nstrument panel
5. Turn indicators
6. Left light switch
7. Horn
8. Key switch
9. Light relay
10.Right light switch
11.Rear stop switch
12.Front stop switch
13.Rear left turn indicator
14.Rear light
15.License plate light
16.Rear right turn indicator
17.Capacitor (buffer)
18.Fan
19.Secondary fuses
20.Fuel level sensor
21.Fuel pump
22.Safety diode
23.Main fuse
24.Start-up relay
25.Starter motor
26.Battery
27.ECR relay
28.Voltage regulator
29.Generator
30.Oil pressure sensor
31.Water temperature sensor
32.Gear sensor
33.Coil 2 (rear cil.) (fitted on the left)
34.Spark plug 2
35.Coil 1 (front cil.) (fitted on the right)
36.Spark plug 1
SXV RXV 450-550 Electrical system
ELE SYS - 3
37.Fall sensor
38.ntake air temperature sensor
39.Throttle sensor (TPS)
40.njector 2 (rear cil.)
41.njector 1 (front cil.)
42.Pick-up
43.Pick-up wire shielding
44.ECU
45.Front right turn indicator
46.Tail light bulb
47.Front headlamp
48.Twin-filament (high-/low-beam) bulb
49.Front left turn indicator
50.Resistance
CabIe coIours - key:
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi violet
Checks and inspections
Dashboard
Activate the set-up when the monitoring icons get
activated because the setting level has been ex-
ceeded (displayed on the LCD).
ELE SYS - 4
Once in the set-up, select the icon to be reset dis-
playing it on the LCD.
Once the corresponding icon is displayed, press
and hold SCROLL until the dashes - - - - are dis-
played. When the key is released, the word NO is
displayed.
The word YES is displayed when SCROLL is
briefly pressed.
Press and hold SCROLL until WS is displayed at
the bottom right angle; when the key is released,
the icon is displayed and the previously pro-
grammed values flash.
f confirmed, wait until it is displayed.
The counter is automatically reset and, con-
sequently, the icon is deactivated.
The service icon WRENCH is displayed when
SCROLL is briefly pressed.
Once the corresponding icon is displayed, press
and hold SCROLL until the dashes - - - - are dis-
played. When the key is released, the Wrench
NO icon is displayed.
The wrench YES icon is displayed when SCROLL
is briefly pressed.
ELE SYS - 5
Press and hold SCROLL until WS is displayed in the bottom right angle; when the key is released,
the icon and the preselected unit of measurement are displayed.
Press SCROLL briefly to select either CLK or km / h as unit of measurement.
Fuses
CAUTION
NEVER ATTEMPT TO REPAIR FAULTY FUSES. NEVER USE A FUSE OF A RATING OTHER
THAN SPECIFIED. THIS COULD DAMAGE THE ELECTRICAL SYSTEM OR CAUSE A SHORT
CIRCUIT, WITH THE RISK OF FIRE.
CAUTION
IF A FUSE BLOWS OUT FREQUENTLY, THAT MAY BE DUE TO A SHORT CIRCUIT OR OVER-
LOAD. IN THIS EVENT, TAKE YOUR VEHICLE TO AN APRILIA OFFICIAL DEALER.
Checking the fuses is necessary whenever an
electrical component fails to operate or is mal-
functioning or when the engine does not start.
Check the auxiliary fuses first and then the main
30A fuse.
To check:
Set the ignition switch to (OFF) to
avoid an accidental short circuit.
Remove the right side fairing by undo-
ing the two screws (1) and slide if off
from its seat.
ELE SYS - 6
Lift the cover (2) of the auxiliary fuse
box.
Take out one fuse at a time and check
whether the filament (3) is broken.
Before replacing the fuse, find and
solve, if possible, the reason that
caused the problem.
f the fuse is damaged, replace it with
one of the same amperage.
NOTE
IF A SPARE FUSE IS USED, SUPPLY ANOTH-
ER OF THE SAME TYPE IN THE CORRES-
PONDING FITTING.
Remove the left side cover, following the same procedure as for the right side cover.
Follow the same steps described above for the auxiliary fuses also for the main fuses.
AUXILIARY FUSES DISTRIBUTION
15A fuse
4 - Control unit relay pickup.
5 - Tail lights, arrows, horn, instrument panel,
stop light
7.5A fuse
6 - Front headlights
7- Control unit relay power
8 - njector coils
9 - Electric fan
5A fuse
ELE SYS - 7
10 - Fuel pump
NOTE
THERE ARE THREE SPARE FUSES (11).
MAIN FUSES - DISTRIBUTION
30A fuse
Battery recharge (there is just one fuse, the
second one is spare).
ControI unit
CONTROL UNIT REMOVAL
Remove the saddle.
Remove the fuel tank.
Disconnect the two connectors.
Unscrew and remove the two screws
fixing the voltage regulator.
Remove the voltage regulator.
ELE SYS - 8
Remove the control unit.
ELE SYS - 9
ELE SYS - 10
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE
VehicIe preparation
Remove the side fairings.
Remove the cooling system.
Remove the engine oil reservoir.
Remove the drive chain.
Remove the exhaust manifolds.
Removing the engine from the vehicIe
Prepare the vehicle as described.
Remove the oil sump guard and the
expansion tank.
Unscrew and remove the threaded pin
(1).
Release the spring (2).
Remove the rear brake pedal (3).
Release the air filter cover by gripping
and lifting the handles from both sides.
Slide out the air filter case cover from
behind together with the filter.
NOTE
Engine from vehicle SXV RXV 450-550
ENG VE - 2
TING, MAKE SURE THAT THE AIR INTAKES
ARE CORRECTLY FITTED.
CAUTION
MAKE SURE THAT THE RESERVOIR RETAIN-
ING EDGE NEVER COMES INTO CONTACT
WITH THE BATTERY POSITIVE LEAD.
Release the two throttle grip cables.
Disconnect the clutch cable.
Disconnect the different electrical con-
nectors.
SXV RXV 450-550 Engine from vehicle
ENG VE - 3
Move the protection along the starter
motor power supply cable.
Undo and remove the fixing screw.
Remove the starter motor power sup-
ply cable.
Unscrew and remove the lower rear
pin fixing nut.
Recover the washer.
CAUTION
THE NUMBER OF WASHERS MAY VARY
ENG VE - 4
FROM ONE SIDE TO THE OTHER OR FROM
ONE VEHICLE TO ANOTHER: CHECK NUM-
BER AND POSITION UPON REMOVAL.
Slide off the lower rear pin.
Undo and remove the front pin fixing
screw.
Slide off the front pin.
Collect the washer.
Lower the engine.
After removing the engine, operate on the engine block and place it on the corresponding
engine support plate.
ENG VE - 5
Specific tooIing
InstaIIing the engine to the vehicIe
Place the engine block.
Place the washer.
Place the front pin.
Tighten the front pin fixing screw.
Place the washer.
CAUTION
RESTORE THE ORIGINAL NUMBER OF
WASHERS AND OBSERVE THEIR ORIGINAL
POSITIONS.
ENG VE - 6
Tighten the lower rear pin fixing nut.
Position the ground lead and tighten
the fixing screw.
Position the starter motor power sup-
ply cable.
Tighten the fixing screw.
Place the protection.
Connect the different electrical con-
nectors.
ENG VE - 7
Fit the drive chain.
Place the clutch cable.
Place the two throttle grip cables.
ENG VE - 8
Place the filter case cover.
CAUTION
TING, MAKE SURE THE AIR INTAKES ARE
CORRECTLY FITTED.
CAUTION
IN THE EVENT OF A FALL, CLEAN THE AIR
FILTER AND ITS CASE CAREFULLY, REMOV-
ING ANY TRACES OF OIL THAT MAY HAVE
ENTERED FROM THE OIL RESERVOIR
THROUGH THE OIL VAPOUR BREATHER
PIPE.
Place the rear brake pedal (3).
Place the spring (2).
Tighten the rear brake pedal fixing
screw (1).
Fit the engine oil reservoir.
Fit the cooling system.
Fit the fairings.
ENG VE - 9
Fit the exhaust manifolds.
Fit the oil sump guard and the expansion tank.
Fit the reservoir.
ENG VE - 10
INDEX OF TOPICS
ENGINE ENG
FITTING ENGINE ONTO PLATE
Fit the engine support plate on the
aprilia engine stand.
Specific tooIing
Fit the engine onto the plate using the
holes of the engine support bolts.
Secure the engine with the appropri-
ate locking nuts.
Pay attention when fixing the eccentric
locking the crankcase halves on the
clutch side. This will be useful to sep-
arate the two crankcase halves.
Gearbox
Diagram
Engine SXV RXV 450-550
ENG - 2
Key:
1. Shaft selector+ratchet gear
2. Selector lock
3. Spring
4. Seeger ring
5. TE flanged screw
SXV RXV 450-550 Engine
ENG - 3
6. Complete index lever
7. Washer
8. Spring
9. Oil seal
10.Complete desmodromic
11.Roller
12.Gear selector drum
13.M8x1.25 threaded pin
14.Selector locking plate
15.M6x12 TE flanged screw
16.Sprocket wheel pawl
17.Pin for spring
18.Spring
19.Selector sprocket wheel
20.Bushing
21.Spring
22.Pin for spring
23.Fork shaft
24.4th - 5th fork
25.1st - 3rd fork (same as for 2nd fork)
26.Fork shaft
27.Gear in neutral warning light switch
29.O-ring
30.Ball bearing
31.Ball bearing
33.Main shaft (SXV Z=13) (RXV Z=12)
34.Bushing
35.5th gear on main shaft Z=21
36.Flat washer
37.Seeger ring for 25 mm (0.98 in) shaft
38.3rd gear on main shaft (SXV Z=16) (RXV Z=15)
39.Special washer
40.4th gear on main shaft (SXV Z=20) (RXV Z=19)
ENG - 4
41.2nd gear on main shaft (SXV Z=15) (RXV Z=13)
42.Washer
43.Ball bearing
44.Ball bearing
45.Secondary shaft
46.Bushing
47.2nd gear on secondary shaft (SXV Z=27) (RXV Z=25)
48.Flat washer
50.4th gear on secondary shaft (SXV Z=23) (RXV Z=24)
51.Special washer
52.3rd gear on secondary shaft Z=23
53.5th gear on secondary shaft (SXV Z=21) (RXV Z=22)
54.Washer
55.Ball bearing cage
56.1st gear on secondary shaft (SXV Z=30) (RXV Z=31)
57.Washer
58.Ball bearing
59.O-ring
60.Ball bearing
61.Oil seal
62.Spacer (SXV 25x32x22) (RXV 25x32x14)
63.Pinion (SXV Z=15) (RXV Z=16)
65.2nd fork (same as for 1st - 3rd fork)
Gearbox shafts
DisassembIing the gearbox
Remove the crankcase on the fly-
wheel side to get access to the gear.
ENG - 5
Remove the forks shafts.
Release the desmodromic drum from
the forks, rotating it outwards.
Remove the gear control desmodrom-
ic drum.
Slide off the forks of the 4th and 5th
gears.
Slide off the fork of the 1st and 3rd
gears and the fork of the 2nd gear.
Take out the main and the secondary
shafts at the same time.
ENG - 6
Removing the primary shaft
Slide off the shim washer (1) from the
generator side.
Slide off the gear of the 2nd gear (2).
Slide off the bushing (3).
Slide off the gear of the 4th gear (4).
Slide off the special washer (5).
Remove the Seeger ring (6).
Slide off the gear of the 3rd gear (7).
Slide off the flat washer (9).
To refit, carry out the removal operations but in
reverse order.
Removing the secondary shaft
Slide off the shim washer (1) from the
clutch side.
Slide off the gear of the 1st gear (2) to-
gether with the ball bearing cage.
ENG - 7
Slide off the gear of the 3rd gear (7).
Slide off the gear of the 2nd gear (14).
Checking the desmodromic drum
Check the desmodromic drum for damage, scratches and wear and replace the assembly if required.
Checking the forks
NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL GEAR FORKS.
Check the gear fork cam bushing (1) and the gear
fork tooth (2) for damage, distortion and wear.
Replace the gear fork if necessary.
Check the gear fork movement on the shaft; re-
place the gear forks if it is not smooth.
AssembIing the gearbox
ENG - 8
Draw together the gear main and sec-
ondary shafts and fit them into the
crankcase on the clutch side.
NOTE
SECURE THE SHIM WASHER TO THE SEC-
ONDARY SHAFT WITH GREASE.
NOTE
MAKE SURE THE SLIDING BUSHING IS PRESENT ON EVERY GEAR CONTROL FORK.
Grease the bushings.
Fit the fork of the 1st and 3rd gears
and the fork of the 2nd gear.
Fit the fork of the 4th and 5th gears.
Fit the gear control desmodromic
drum.
ENG - 9
Fit the fork shafts.
Refit the crankcase on the flywheel
side.
Gear seIector
Removing the gear seIector
Remove the clutch.
Remove the flange from the right
crankcase half.
Working on the clutch side, slide off
the selector control shaft.
Undo and remove the two screws fix-
ing the selector sprocket wheel.
Remove the selector sprocket wheel
together with the plate.
ENG - 10
Undo and remove the gear selector
drum fixing screws.
Lower the gear locking pawl lever and
slide off the lower part of the gear se-
lector drum.
Remove the gear locking pawl and
collect the washer and the spring.
Checking the gear seIector
Check the stop lever for damage and wear and make sure the ball rotates freely.
ENG - 11
f necessary, replace the parts.
Check the gear selector spring for damage and wear.
f necessary, replace the part.
Check the selector shaft and its teeth for damage and wear.
Check the lever spring for damage and wear.
Check the clearance of the washer and the riveted pin that passes through the plate. f it
is excessive, replace the pawl.
ReassembIing the gear seIector
To refit, lubricate and carry out the removal operations but in reverse order.
Starter motor
Removing the starter motor
Unscrew and remove the two starter
motor fixing screws.
Remove the starter motor.
Generator side
Removing the fIywheeI cover
Undo and remove the eleven fixing
screws.
Mark the screws with different lengths.
Remove the flywheel side cover to-
gether with the generator and collect
ENG - 12
the gasket and the two centring dow-
els.
Magneto fIywheeI removaI
Remove the flywheel cover
Remove the two gears that connect
the starter motor to the flywheel.
Lock the flywheel rotor using the spe-
cific tool
Unscrew and remove the nut fixing the
flywheel and collect the washer.
Specific tooIing
8140838 FIywheeI rotor Iocking
ENG - 13
Remove the flywheel using the specific flywheel extractor.
Specific tooIing
9100839 FIywheeI extractor
CIutch side
DisassembIing the cIutch
Remove the clutch cover.
Undo and remove the six screws with
a quarter of a turn at a time, operating
in stages and diagonally, and collect
the washers and the clutch springs.
Remove the pressure plate.
Remove the control rod together with
the thrust bearing, the shim washer
ENG - 14
and the clutch cap.
Remove the discs.
After straightening the tabs of the lock-
ing washers, unscrew and remove the
clutch hub nut with the clutch locking
tool and collect the locking washer.
Specific tooIing
9100896 CIutch beII Iocking tooI
ENG - 15
Remove the clutch hub.
Collect the shim washer.
Collect the clutch bell.
ENG - 16
Collect the spacer and the needle
bearings.
Checking the cIutch pIates
Lay the friction discs and steel discs
on a level surface and check them for
cracks and potential distortions.
NOTE
THE STEEL DISCS MUST SHOW NO SCORES
OR TEMPERING COLOUR. CHECK CLUTCH
DISCS FOR WEAR BY MEASURING THE EN-
TIRE CLUTCH DISC UNIT.
DO NOT MEASURE THE STEEL DISC UNIT
AND THE FRICTION DISC UNIT INDIVIDUALLY
SINCE DOING SO IS IRRELEVANT FOR WEAR
CHECKING.
Characteristic
FuII disc pack thickness- minimum Iimit
34 mm (1.34 in)
CIutch disc distortion - maximum Iimit
ENG - 17
0.2 mm (0.0079 in)
Checking the cIutch housing
Check the clutch bell for damage and wear that may result in clutch irregular operation. f necessary,
replace the bell.
Check the riveted joint between the clutch bell and the main transmission crown for correct sealing
and evenness.
Check the main driven gear for damage and wear
and, if necessary, replace the main transmission
driving gear and the clutch bell all together.
Make sure there is not excessive noise during op-
eration; if necessary, replace the main transmis-
sion driving gear and the clutch bell all together.
Checking the pusher pIate
Check the pressure plate and the bearing for
damage and wear. f necessary, replace the
parts.
Checking the cIutch hub
Check the clutch hub for damage and wear that
may result in clutch irregular operation. f neces-
sary, replace the hub.
ENG - 18
Checking the springs
NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS.
Check the springs for damage and, if
necessary, replace the them all to-
gether.
Measure the clutch spring length when
unloaded; if necessary, replace the
springs all together.
Characteristic
CIutch spring Iength - minimum Iimit
45.1 mm (1.77 in)
AssembIing the cIutch
Fit the needle bearing and the spacer.
Fit the clutch bell.
ENG - 19
Fit the shim washer.
Place the clutch hub.
Place the washer/s with the tab/s.
CAUTION
RESTORE THE ORIGINAL NUMBER OF
WASHERS AND OBSERVE THEIR ORIGINAL
POSITIONS.
Place the clutch hub nut.
ENG - 20
Using the clutch locking tool, tighten
the clutch hub nut to the prescribed
tightening torque.
Fold the locking washer.
Specific tooIing
9100896 CIutch beII Iocking tooI
Use gearbox oil to lubricate the driving
discs and the driven discs.
Place the first friction disc, then the
first 1.5 mm (0.059 in) steel disc. After
that, place a friction disc with the refer-
ence tabs in the same slot as for the
first disc and then place a 2 mm
(0.079 in) steel disc until the penultim-
ate disc that will be the remaining 1.5
mm (0.059 in) metal disc. Lastly, place
the friction disc with the reference tab
one slot away with respect to the pre-
vious discs.
Place the control rod together with the
thrust bearing and the shim washer.
ENG - 21
Place the pressure plate.
Fit the clutch springs.
Fit the screw washers.
Tighten the six screws operating in
stages and diagonally.
InstaIIing the cIutch cover
Place the clutch cover.
ENG - 22
Tighten the five screws fixing the
clutch cover, operating diagonally.
Check the gearbox oil level.
Head and timing
Removing the cyIinder head
NOTE
BEFORE REMOVING THE HEAD CHECK THAT THE CYLINDER PISTON ON WHICH YOU ARE
WORKING IS AT THE TDC IN COMBUSTION PHASE.
Unscrew and remove the four head
cover fixing screws and collect the
sealing O-rings.
Remove the head cover together with
the gasket.
Unscrew and remove the fixing screw
of the chain tensioner thrust spring.
Slide off the chain tensioner (1) intern-
al guide.
Lock the camshaft with the 6 mm
ENG - 23
(0.24 in) pin used for timing.
Unscrew and remove the fixing nut of
the camshaft (2) control toothed
wheel.
NOTE
THE CAMSHAFT FIXING SCREW OF THE
FRONT CYLINDER WORKS ANTICLOCKWISE;
THE FIXING SCREW OF THE REAR CYLIN-
DER, CLOCKWISE.
Remove the camshaft (3) gear and re-
move the timing chain (4) properly.
Unscrew and remove the head fixing
screw on the timing system side.
NOTE
REMOVE THIS SCREW BEFORE REMOVING
THE FOUR MAIN SCREWS.
Unscrew and remove the four head
fixing screws using a roundhead uni-
versal socket wrench if required.
Remove the head and collect the head
gasket and the centring cylinders.
CyIinder head
Removing the decompression system
Remove the rocking levers.
Unscrew and remove the fixing screw
ENG - 24
of the decompressor control lock.
Remove the decompression system
together with the control spring.
Removing the overhead camshaft
Remove the decompression system.
Working on the timing system side, re-
move the camshaft bearing fixing See-
ger ring.
Remove the camshaft together with
the ball bearing on the timing system
side.
ENG - 25
Removing the rocker arms
Remove the cylinder head
Remove the Seeger ring of the dis-
charge valve rocking lever pin.
Remove the discharge valve rocking
lever pin from its position.
Remove the rear rocking lever.
Removing the vaIves
NOTE
THE FOLLOWING PROCEDURE REFERS TO ONE CYLINDER BUT IS VALID FOR BOTH.
Remove the control rocking lever of the exhaust valves and remove the camshaft.
NOTE
BEFORE REMOVING THE CYLINDER HEAD COMPONENTS (VALVES, VALVE SPRINGS, CAPS
AND BOWLS), MAKE SURE THAT THE VALVES ARE PROPERLY CLOSED AND SEALED.
CAUTION
ENG - 26
WHILE REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PIECE VERY CARE-
FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
Remove both pads (1) on both ex-
haust valves.
Remove both bowls (2) and both pads
under them on the intake valves.
Use the valve springs compressor and
the valve springs compressor adaptor
to remove the valve cotters.
Specific tooIing
9100838 TooI for pump pressure pIate
8140179 VaIve spring compressor
Remove the spring of valve (6) and
the corresponding upper cap (5).
Remove the valve.
Remove the stem oil guard of valve
(3) and the lower cap (4).
Checking the overhead camshaft
CAMSHAFT TOOTHED WHEEL CHECK
Check that the camshaft gear works properly: if it is damaged or does not move smoothly,
replace the timing chain and the camshaft gear.
CAMSHAFT LOBES
Check that they do not show blue colouring, cracks or scratches; otherwise, replace the
camshaft, gear and chain.
ENG - 27
Fasten the camshaft in horizontal pos-
ition, as shown in the figure, and make
it spin to check the eccentricity with a
dial gauge; if necessary, replace the
component.
Characteristic
Camshaft eccentricity - maximum Iimit
0.05 mm (0.0020 in)
Checking the rocker arms
ROCKING LEVERS AND ROCKING LEVER SHAFTS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ROCKING LEVERS AND ROCKING LEVER
SHAFTS.
Use an internal micrometer to meas-
ure the rocking lever inside diameter
and replace the lever if necessary.
Characteristic
Rocking Iever inside diameter - maximum Iim-
it:
12.04 mm (0.4740 in)
Check that the outside diameter of the
rocking lever shaft does not show blue
colouring, cracks or scratches; other-
wise, replace the component.
Use a micrometer to measure the
rocking lever shaft outside diameter
and replace the component if neces-
sary.
Characteristic
Rocking Iever shaft outside diameter: maxim-
um Iimit
ENG - 28
11.96 mm (0.4708 in)
Calculate the rocking lever - rocking lever shaft clearance.
NOTE
CALCULATE THE CLEARANCE SUBTRACTING THE OUTSIDE DIAMETER OF THE ROCKING
LEVER SHAFT FROM THE INSIDE DIAMETER OF THE ROCKING LEVER
Replace the component if the calculated clearance value exceeds the limit value indicated
in the table.
Characteristic
Rocking Iever - rocking Iever shaft cIearance: maximum Iimit
0.08 mm (0.0031 in)
BOWLS CHECK
Characteristic
BowI diameter - maximum Iimit:
25.96 mm (1.022 in)
BowI seating diameter on head - maximum Iimit:
26.04 mm (1.025 in)
VaIve check
VALVES AND VALVE GUIDES CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE GUIDES.
Use a micrometer to measure the
valve stem (C) diameter.
Use an internal micrometer to meas-
ure the valve guide (D) inside diamet-
ENG - 29
er.
Characteristic
VaIve stem diameter - minimum Iimit
4.96 mm (0.1952 in)
Check the clearance (G) between stem and valve guide as follows:
G = D - C
Characteristic
Stem - vaIve guide cIearance - maximum Iimit
0.08 mm (0.0031 in)
f the clearance is not within the spe-
cified values, replace the valve guide.
Proceed to check the valves and valve
guides by removing the carbon depos-
its from the valve face and seat.
Check that the valve face does not
show cracks and signs of wear; other-
wise, replace the valve.
Check that the end of the valve stem
is not distorted (mushroom-shaped)
and that its diameter does not exceed
the stem body diameter; otherwise, re-
place the valve.
Check that the value (E) of the valve
support plane of the valve rims is with-
in the specified values; replace the
valve if necessary.
Characteristic
Intake vaIve thickness, seaIing side - minim-
um Iimit
2.2 mm (0.0866 in)
ENG - 30
OutIet vaIve thickness, seaIing side - minim-
um Iimit
2.5 mm (0.098 in)
Check that the valve stem eccentricity
is within the specified values; replace
the valve if necessary.
Fasten the valve in horizontal position,
as shown in the figure, and turn it to
check the eccentricity with a dial
gauge; if necessary, replace the com-
ponent.
NOTE
IF THE VALVE IS REMOVED OR REPLACED,
ALWAYS REPLACE THE VALVE STEM OIL
GUARD AS WELL.
Characteristic
Stem maximum eccentricity
0.01 mm (0.00039 in)
VALVE SEATS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE SEATS.
Remove the carbon deposits from the
valve face and seat.
Check that the valve seat does not
show cracks or signs of wear; other-
wise, grind the seats.
Following the indications below, check
that the valve seat is within the spe-
cified values; grind the seats if neces-
sary.
Characteristic
Intake vaIve seat support width - maximum
Iimit
ENG - 31
1.3 mm (0.0512 in)
OutIet vaIve seat support width - maximum
Iimit
1.5 mm (0.059 in)
VALVE SPRINGS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE SEATS.
Use a gauge to measure the unloaded
valve spring length. f the length
measured is not within the specified
values, replace the valve spring.
Characteristic
UnIoaded vaIve spring Iength:
inlet: 37.8 mm (1.488 in)
outlet: 35.7 mm (1.406 in)
On a contrasting surface, use a
square to measure the valve spring
angle (H). f the length measured is
not within the specified values, replace
the valve spring.
Characteristic
Spring angIe maximum Iimit
2.5
Checking the cyIinder head
Check that cylinder head is not damaged or scratched; replace it if necessary.
Check that there are no mineral deposits or rust in the cylinder head water cooled jacket;
remove them if necessary.
Use a checking ruler and a thickness gauge positioned crosswise to the ruler to measure
the cylinder head distortion.
Characteristic
ENG - 32
Maximum cyIinder head distortion
Maximum limit 0.05 mm (0.002 in)
HEAD COVERS CHECK
Check that the covers are not dam-
aged or worn; replace the defective
parts if necessary.
InstaIIing the vaIves
VALVES AND VALVE SPRINGS FITTING - WARNING
CAUTION
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND THEIR COMPONENTS.
Lubricate the valve stem and the valve
stems oil guard with recommended oil.
Fit the valve, the lower cap (4) and the
valve stem oil guard (3).
Fit the spring of valve (6) and the cor-
responding upper cap (5).
NOTE
FIT THE VALVE SPRING WITH THE LARGEST
PITCH FACING UPWARDS. FIT THE SPRING
WITH THE COLOURED END (RED FOR OUT-
LET, WHITE FOR INLET) FACING DOWN-
WARDS.
Fit the valve spring retaining element.
Compress the valve spring with the
spring compressor and use the valve
spring compressor adapter to fit the
valve cotters.
To fix the valve cotters on the valve
ENG - 33
stem, slightly hit the valve head with a
soft-head mallet.
HITTING THE VALVE HEAD EXCESSIVELY
MAY DAMAGE THE VALVE.
Specific tooIing
9100838 TooI for pump pressure pIate
8140179 VaIve spring compressor
Place both bowls (2) and both pads
under them on both intake valves.
Place both pads (1) on both discharge
valves.
InstaIIing the rocker arms
Position the discharge rocking lever.
Fit the discharge rocking lever shaft.
NOTE
MAKE SURE THAT THE ROCKING LEVER
SHAFT IS FULLY INSERTED IN THE CYLIN-
DER HEAD.
ENG - 34
Position the Seeger ring of the dis-
charge rocking lever pin.
InstaIIing the overhead camshaft
NOTE
LUBRICATE THE BEARING WITH ENGINE OIL BEFORE FITTING.
Fit the bearing on the camshaft.
Lubricate the camshaft, the decom-
pression system control spring and the
decompression system.
Position the decompression system
together with the control spring.
Tighten the fixing screw of the decom-
pression control.
NOTE
LUBRICATE SHAFTS AND ROCKING LEVERS
BEFORE FITTING THEM.
ENG - 35
Fit the camshaft.
NOTE
INSERT THE CAMSHAFT CAREFULLY PAY-
ING ATTENTION TO THE DECOMPRESSION
CONTROL.
Working from the timing system side,
position the camshaft bearing fixing
Seeger ring.
Timing
Checking the chain tensioner
Check that there are no blistering or
damages; replace the component if
necessary.
Check that the one-way cam works
properly: if it does not move smoothly,
replace the timing chain tensioner
housing.
Checking the chain
Check the timing chain for damage or stiffness
while moving.
f necessary, replace the timing chain together
with the camshaft gears.
Check the timing chain guide sliders for damage.
ENG - 36
f necessary, replace the parts.
InstaIIing the chain
Fit the timing gear of the rear cylinder.
Fit the timing chain of the rear cylin-
der.
Position the timing compartment clos-
ing flange.
Tighten the three fixing screws of the
timing compartment closing flange.
Remove the main shaft pinion nut us-
ing the specific special tool.
Position the timing control wheel,
matching the reference with the one
on the main shaft pinion.
Position the locking washer (1).
Screw the fixing nut (2) of the timing
control wheel.
Bend the washer tab (1).
ENG - 37
Specific tooIing
9100843 Crankshaft pinion Iocking tooI
Cam timing
Timing
Make sure that the timing chain is
properly taut.
Remove the timing hole screw from its
seat.
Place the crankshaft lock (timing pin)
in its position.
Specific tooIing
9100844 Crankshaft Iocking tooI (timing pin)
Working on the main transmission nut,
make the crankshaft turn until the front
cylinder reaches the TDC.
nsert the pin in the crankshaft lock
(timing pin) in order to block crank-
shaft rotation.
NOTE
THE SPECIAL TOOL IS ONLY USEFUL TO
IDENTIFY THE CRANKSHAFT CORRECT POS-
ITION.
DO NOT USE IT FOR TIGHTENING OPERA-
TIONS.
Make the timing shaft turn so that the
timing shaft hole matches the head
holes.
Position the pin so as to lock the front
ENG - 38
cylinder timing cam.
NOTE
CHECK THAT THE CAMSHAFT IS FREE, NOT
RESTING ON THE BOWLS.
Tighten the fixing nut of the front cylin-
der timing shaft gear.
Release the front camshaft and the
crankshaft from the locking pins.
Working on the main shaft nut, make
the crankshaft turn clockwise by 283
in order to bring the rear cylinder pis-
ton to the TDC and repeat the same
procedure followed for the front cylin-
der.
CyIinder-piston assembIy
Removing the cyIinder
t is necessary to remove the head be-
fore removing the cylinder
Unscrew and remove the inspection
screw (2); collect the O-ring gasket
(mind the coolant spills).
Use the special tool to remove the
liner (1) and collect the O-ring gasket.
ENG - 39
CAUTION
BEFORE TAKING OUT THE PIN LOCKING
RING, COVER THE CRANKCASE OPENING
WITH A CLEAN CLOTH SO THAT THE RING
DOES NOT FALL INTO THE CRANKCASE.
Specific tooIing
9100897 CyIinder Iiner extractor
Take out the pin locking ring.
DisassembIing the piston
Use a piston pin extractor to remove
the pin.
Remove the piston.
Remove the piston ring (1) and the oil
scraper ring (2).
Specific tooIing
9100943 Piston pin extractor
Characteristic
ENG - 40
CyIinder Iiners inside diameter
76.02 - 80.02 mm (2.9929 - 3.1504 in)
Piston outside diameter
75.94 - 79.94 mm (2.9897 - 3.1472 in)
Piston pin hoIe inside diameter
16.02 - 17.02 mm (0.6307 - 0.6701 in)
Top ring end cIearance
0.45 mm (0.0177 in)
Checking the piston
Fitting the piston
NOTE
WHEN FITTING THE PISTON RINGS, MAKE
SURE THAT THEY ARE REFITTED WITH THE
REFERENCE FACING UPWARDS.
Fit the piston ring (1) with its opening
facing the outlet and the oil scraper
ring (2) with its opening facing the in-
let.
CAUTION
MAKE SURE THAT THE PUNCHING ON THE
PISTON FACES THE CYLINDER OUTLET
SIDE. LUBRICATE THE PIN WITH ENGINE OIL
BEFORE INSERTING IT.
Place the piston in the cylinder liner
(3).
Place the cylinder liner (3) in the
crankcase.
ENG - 41
Fit the pin.
Position the pin locking ring.
Close the cap (4).
InstaIIing the cyIinder head
Fit the centring cylinders.
Fit a new cylinder-head gasket.
Position the cylinder head.
nsert the four cylinder head bolts to-
gether with the washers.
NOTE
LUBRICATE THE HEAD BOLT THREADS AND
THE SEAL SURFACES WITH ENGINE OIL.
Screw the four cylinder head bolts
working in crossed sequence and us-
ing a roundhead universal socket
wrench if required.
NOTE
SCREW THE CYLINDER HEAD BOLTS PAY-
ING ATTENTION TO THE TIGHTENING SE-
QUENCE AND THE CORRECT TORQUE, IN
TWO STAGES.
Place the timing system gear (3) to-
gether with the timing chain (4) on the
camshaft (2).
Screw but do not tighten the screw fix-
ing the timing system gear (3) on the
ENG - 42
camshaft (2).
Position the chain tensioner slider (1).
CAUTION
THE CAMSHAFT SCREW OF THE FRONT
CYLINDER WORKS ANTICLOCKWISE.
Fit the timing chain tensioner, follow
the instructions below:
1- Release the chain tensioner one-
way cam and push its rod completely
into the chain tensioner housing.
2- Fit the tensioner in the proper seat
on the timing system side of the cylin-
der head by tightening both screws to
the pre-set torque.
3- Fit the spring and the threaded cap
of the timing chain tensioner by tight-
ening the cap to the pre-set torque.
Proceed to time camshaft.
Position the valve cover together with
the gasket.
Tighten the four fixing screws together
with new sealing O-rings.
Crankcase - crankshaft
SpIitting the crankcase haIves
Remove the right crankcase half cov-
ENG - 43
er.
Unscrew and remove the main trans-
mission wheel fixing nut.
Remove the main shaft pinion nut us-
ing the special tool.
NOTE
NUT WITH LEFT THREAD.
Remove the shim washer.
NOTE
SHIM WASHERS ARE GALVANISED ANTI-
VIBRATION PARTS THAT MUST BE FITTED
FACING TOWARDS THE PINION.
Slide off the pinion.
Remove the ball bearing cage.
Undo and remove the screw fixing the
plate that fixes the external oil pipes.
ENG - 44
Remove the two external oil pipes.
Undo and remove the screws fixing
the two plates that fix the internal oil
pipes.
Slide off the oil delivery and reverse
pipe.
Before removing the components,
place a container of adequate capacity
ENG - 45
under the engine.
Prepare the engine by carrying out the
following operations.
Remove the starter motor.
Remove the magneto flywheel.
Remove the clutch.
Remove the gear selector.
Remove the head.
Remove the timing chain.
Remove the cotter.
Remove the timing system gear shaft
together with the timing system
toothed wheel of the front cylinder
from generator side.
Undo and remove the fifteen screws
fixing the crankcase, fourteen on the
left side and one on the right side.
NOTE
THE SEVEN FIXING SCREWS ON THE LEFT
SIDE ARE M7 AND THE OTHER SEVEN ARE
M6.
Remove the gearbox oil cap screw.
Lift both cylinder liners 2 / 3 cm (0.79 /
1.18 in).
Separate the crankcase with the aid of
the rubber mallet.
ENG - 46
Remove the crankcase on the gener-
ator side.
CAUTION
BEFORE CARRYING OUT ANY REMOVAL/FIT-
TING OPERATION ON THE CRANKCASE,
WARM IT UP WITH A HEAT GUN TO AVOID
DAMAGING ITS HOUSING.
CAUTION
BEFORE CARRYING OUT THE OPERATIONS
DESCRIBED BELOW, LOCK THE CRANK-
CASE HALVES ON THE CORRESPONDING
SUPPORT PLATE.
REMOVING THE GEAR MAIN SHAFT BEAR-
ING
Remove the bearing locking screw
and the corresponding plate.
Warm up the crankcase halves.
Remove the bearing with an extractor
from the inside.
DESMODROMIC BEARING REMOVAL
from the inside.
ENG - 47
REMOVING THE GEAR SECONDARY SHAFT
BEARING
Remove the Seeger ring.
Remove the oil seal operating on the
crankcase external side.
Warm up the crankcase halves and
take out the bearing with an extractor
from the inside.
GEAR BEARINGS REMOVAL
Remove the three locking screws.
ENG - 48
After warming up the crankcase
halves, remove the bearings with an
extractor from the inside.
TIMING SYSTEM SHAFT BEARING REMOVAL
from the inside.
Removing the main bearings
FLYWHEEL SIDE CRANKCASE HALVES
ENG - 49
CAUTION
BEFORE CARRYING OUT ANY REMOVAL/FITTING OPERATION ON THE CRANKCASE, WARM
IT UP WITH A HEAT GUN TO AVOID DAMAGING ITS HOUSING.
CAUTION
BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, LOCK THE CRANKCASE
HALVES ON THE CORRESPONDING SUPPORT PLATE.
To remove the crankshaft support
bushings use the tool and a rubber
mallet.
Specific tooIing
9100884 Crankshaft bushing extractor
Inspecting the crankcase haIves
Using a non-aggressive solvent thoroughly clean both sections of the engine crankcase, the ball
bearings and all the bearing seats. Clean the seal surfaces and check that they are not damaged.
NOTE
PLACE BOTH CRANKCASE HALVES ON THE PROPER SUPPORT PLATE TO AVOID DAM-
AGING THEM.
Specific tooIing
9100942 Crankcase haIves support
Check that both crankcase halves are not cracked or damaged.
Check that all threads are in proper conditions.
Check that all oil seals remaining in their position are not worn or damaged.
Check all ball bearings for clearance, smoothness and potential distortions.
CAUTION
LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING.
f the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it
means that the bearing is faulty and must be replaced.
Warm up the crankcase properly before fitting each bearing.
ENG - 50
BEARING REFITTING - TIMING SHAFT
Working on the flywheel side and on
the clutch side, refit the bearings using
the specific punches.
Specific tooIing
9100893 Left timing gear punch
Refit the lock screw and the corres-
ponding plate.
GEAR BEARING REFITTING
Refit the bearings using the specific
punches.
Specific tooIing
9100886 Secondary shaft/right side - Main
shaft/Ieft side
Refit the lock screws.
ENG - 51
GEAR SECONDARY SHAFT BEARING REFIT-
TING
Refit the bearing using the specific
punch.
CAUTION
CHECK THAT THE PLATE ADJUSTABLE SUP-
PORT IS FIRMLY STOPPED AND WARM UP
THE BEARING COUPLING AREAS PROP-
ERLY.
Specific tooIing
9100885 Main shaft/ right side - secondary
shaft/Ieft side
Refit the lock ring, the plate and the
relative screw.
Fit a new oil seal using the specific
punch at controlled driving.
ENG - 52
Specific tooIing
9100894 Secondary shaft oiI seaI punch
BEARING REFITTING - DESMODROMIC DRUM
SUPPORT
punch.
Specific tooIing
9100892 Left crankcase desmodromic + wheeI
hub
GEAR PRIMARY SHAFT BEARING REFITTING
punch.
Refit the lock screw with the corres-
ponding plate.
Specific tooIing
9100886 Secondary shaft/right side - Main
shaft/Ieft side
ENG - 53
InstaIIing the main bearings
CAUTION
CAUTION
For refitting, use the specific calibra-
tion punch to match the unions of both
half - bushings with the notch on the
punch.
When refitting match the punch notch with the
grooves for the bushing lubrication oil.
Fit the half - bushings in their seats
with a rubber mallet until they stop, us-
ing the specific special tool.
CAUTION
CHECK THAT THE PLATE ADJUSTABLE SUP-
PORT IS FIRMLY STOPPED AND WARM UP
THE BEARING COUPLING AREAS PROP-
ERLY.
Specific tooIing
9100840 Punch for crankshaft bushings
ENG - 54
Refitting the crankcase haIves
CAUTION
CAUTION
Specific tooIing
CAUTION
BEFORE REFITTING, REPLACE AND LUBRIC-
ATE THE OIL SEALS AND LUBRICATE THE
BALL BEARINGS.
Fit the oil seals and the bearings on
the crankcase halves.
Fit the entire crankshaft on the right
crankcase half.
Place the gear main and secondary
shafts together with the desmodromic
drum and the linkages.
Place the cylinders liners as externally
as possible.
Place the cylinder liners with the refer-
ence mark near the crankcase halves
coupling edge.
Spread the red paste all along the
crankcase perimeter.
Join the crankcase halves.
ENG - 55
Tighten the fifteen screws fixing the
crankcase, fourteen on the left side
and one on the right side.
NOTE
THE SEVEN FIXING SCREWS ON THE LEFT
SIDE ARE M7 AND THE OTHER SEVEN ARE
M6.
Fit the timing system gear shaft on the
generator side.
nsert the cotter.
Fit the timing chain.
CAUTION
BEFORE REFITTING, REPLACE AND LUBRICATE THE OIL SEALS AND LUBRICATE THE
BALL BEARINGS.
ENG - 56
Place the oil reverse and delivery
pipe.
NOTE
DO NOT FORCE THE OIL PIPES INTO THEIR
FITTINGS.
NOTE
MAKE SURE THE O-RINGS ARE IN GOOD
CONDITIONS; OIL THE RINGS.
Place the locking plate of the two oil
pipes and tighten the fixing screws.
Fit the shim washer paying attention to
the fitting direction.
Make sure the O-ring on the toothed
wheel shaft is in good conditions; if
necessary, replace the O-ring with a
new one.
Place the fixing plate and tighten the
plate fixing screw.
Grease the conical surface of the
ENG - 57
crankshaft.
Place the ball bearing cage and the
cotter.
Lubrication
ConceptuaI diagrams
Key:
1. Oil reservoir unit
2. Oil drainage plug
3. 12x18x1.5 washer
4. M20x1.5 oil filler cap
5. O-ring 3075
6. M6x70 TE flanged screw
7. M6x95 TE flanged screw
ENG - 58
8. M6x1 low self-locking nut
9. L=215 Blow-by pipe
10.16.5x6.6 clic clamp
11.15.5x6.6 clic clamp
12.9x14 breather oil pipe
13.Cock clamp
14.Rubber ring
15.Reservoir bushing
16.Oil level pipe
17.Click clamp
18.From the engine
19.To the filter housing
20.n
21.Out
OiI pump
ENG - 59
Removing
EXTERNAL PUMP REMOVAL
Before removing the components,
place a container of adequate capacity
ENG - 60
underneath the engine.
Remove the clutch
Remove the right crankcase half cover
Remove the Seeger ring fixing the oil
pump transmission gear and collect
the shim washer.
Remove the oil pump transmission
gear paying attention to the internal
sliding rollers.
Remove the oil pump gear fixing See-
ger ring.
Remove the oil pump gear and collect the shim washer.
Remove the transmission roller of the
oil pump gear.
Remove the shim washer (1).
ENG - 61
Unscrew and remove the four fixing
screws (2).
Remove the complete oil pump.
Collect the internal transmission roller of the oil pump.
INTERNAL PUMP REMOVAL
NOTE
TO DISASSEMBLE THE INTERNAL SECTION OF THE OIL PUMP IT IS NECESSARY TO DISAS-
SEMBLE THE CRANKCASE AND REMOVE THE EXTERNAL PUMP.
Undo and remove the three fixing
screws.
Remove the cover and the strum box.
ENG - 62
Remove the pump rotor and slide off
the stator.
Collect the transmission roller.
InstaIIing
INTERNAL PUMP FITTING
Position the transmission roller.
Fit the pump rotor and the stator.
Position the strum box and the cover.
Tighten the three fixing screws.
EXTERNAL PUMP FITTING
ENG - 63
Refit the internal pump.
Position the oil pump internal trans-
mission roller.
NOTE
THE INTERNAL AND EXTERNAL PUMP RO-
TORS FEATURE A VERY LONG ROLLER; THE
GEAR FEATURES A SHORT ONE.
Position the oil pump together with the
O-ring gasket.
Tighten the four fixing screws (2) and
position the shim washer (1).
Position the oil pump gear transmis-
sion roller.
Place the shim washer before posi-
tioning the oil pump gear.
ENG - 64
Position a new oil pump gear fixing
Seeger ring.
Position the toothed oil pump control
wheel paying attention to the internal
sliding rollers.
Place the shim washer before posi-
tioning a new oil pump control gear fix-
ing Seeger ring.
Close the crankcase.
Fit the clutch.
ENG - 65
ENG - 66
INDEX OF TOPICS
POWER SUPPLY P SUPP
Circuit diagram
Key:
1. Fuel tank
2. Fuel tank cap
3. Gasket for cover
4. 5x9 pipe
5. Fuel pump unit
6. Fuel filter
7. Sealant
8. Thermistor
Diagram
Power supply SXV RXV 450-550
P SUPP - 2
Key:
1. gnition keys
2. Fuel pump
3. gnition switch
4. nstrument panel
5. ntake air temperature sensor
SXV RXV 450-550 Power supply
P SUPP - 3
6. Throttle position sensor
7. njector
8. ntake air pressure sensor
9. Cooling fans
10.Engine temperature sensor
11.Speed sensor (front wheel)
12.Crankshaft position sensor
13.Gear position switch
CyIinders synchronisation
Remove the saddle by releasing the
corresponding hook.
Lift the tank and fix it with the specific
cable.
Remove the filter housing cover operating on both plastic hooks and remove the filter.
CAUTION
WHEN REMOVING THE DIFFERENT COMPONENTS BE CAREFUL NOT TO DROP THE
SCREWS OR LET DIRT GET IN; BOTH THROTTLE BODIES ARE NOT PROTECTED ONCE THE
FILTERING ELEMENT IS REMOVED.
Unscrew and remove the five fixing
screws on the upper part of the filter
housing.
Remove the upper part of the filter
casing.
P SUPP - 4
Working from the right side, release
the clamps holding the oil breather
pipe.
Slide off the oil breather pipe.
Slide off the atmospheric pressure in-
take pipe.
Working from the left side, release the
rear cylinder spark plug wire.
Release the seal clamp of the by pass
pipe of the rear cylinder throttle body.
Slide off the by pass pipe of the rear
cylinder throttle body.
Get a second by pass pipe and con-
nect it to previously released union.
P SUPP - 5
CAUTION
THE SECOND BY PASS PIPE SHOULD BE OF
THE SAME DIAMETER AND LENGTH AS THE
ONE STILL CONNECTED TO THE FRONT CYL-
INDER THROTTLE BODY.
Connect a differential vacuometer to both by pass pipes.
Slightly lower the tank being careful not to press the vacuometer pipes.
Start the vehicle and check that the
vacuum in both cylinders is the same.
Otherwise, loosen the adjustment
screw and adjust the position of the
slot in order to get a similar vacuum.
Once balance has been obtained,
tighten the adjustment screw.
CAUTION
AFTER SYNCHRONISING THE CYLINDERS IT
IS ABSOLUTELY NECESSARY TO CARRY
P SUPP - 6
OUT THE THROTTLE SELF-LEARNING MINIM-
UM POSITION USING AXONE.
Using axone for injection system
Injection
Iso screen page
ISO
This display shows general data regarding the
control unit, for example software type, mapping,
control unit programming date
ISO DISPLAY
Firmware version C1APR_09 - ECU firmware version
Chassis number ZD4VS - Vehicle frame
Engine number Engine number
Programming date 11/24/2005 - Date the ECU has been initialized in
production
Mapping 14001 - Mapping code present in ECU
Engine parameter reading screen page
ENGINE PARAMETER READING
This display shows the parameters measured by
the several sensors (engine revs, engine temper-
ature, ...) or values set by the control unit
(injection time, ignition advance, ...)
ENGINE PARAMETER READING DISPLAY
P SUPP - 7
Engine rpm rpm
Atmospheric pressure 1010 mbar
Front cylinder injection time ms
Rear cylinder injection time ms
Front cylinder ignition advance
Rear cylinder ignition advance
Throttle 4.6% - At idle, value should be 5% +/- 1%
Air temperature C
Engine temperature C
Battery voltage V
Gear engaged The engaged gears are displayed (neutral = 0)
(not specified = 10)
Vehicle speed 2 - km/h - Vehicle speed (caution: this parameter
is not working at the moment)
Operation time 12.25 - hhmm - Engine operation time (at rpm
higher than zero) in hours and minutes
Throttle self-learning, min. position 30 - Reference value with throttle fully home at
0. This value is stored by means of the "Throttle
self-learning, min. position" procedure in the ad-
justable parameters screen page
Throttle self-learning, max. position 210 - Reference value with throttle fully open.
This value is stored by means of the "Throttle
self-learning, max. position" procedure in the ad-
justable parameters screen page
CO adjustment at idle 1.00 - CO rate adjustment trimmer value: if equal
to 1.00, it has not been changed yet. To change
it, go to Adjustable parameters screen page
Wheel diameter cm
Wheel signals
njection time correction '1,00 - njection time adjustment value outside idle
range: if equal to 1.00, it has not been changed
yet
Device status screen page
DEVICE STATUS
This display show the status (ON/OFF only) of the
vehicle devices or the operation condition of
some vehicle systems (for example, lambda
P SUPP - 8
probe functioning)
DEVICES STATUS SCREEN PAGE
Fall sensor Normal / Tip over / Disconnect - ndicates bank
angle sensor state
Devices activation screen page
DEVICES ACTIVATION
This displays is used to delete errors in the con-
trol unit memory and activate some systems con-
trolled by the control unit
DEVICES ACTIVATION SCREEN PAGE
Error clearing Press "enter" to transfer errors from the memory
(MEM) to the historical record (STO). The next
time Axone is connected to the ECU, the errors in
the historical record (STO) will no longer be dis-
played
Errors dispIay screen page
ERRORS DISPLAY
This displays shows potential errors detected in
the vehicle (ATT) or stored in the control unit
(MEM) and it is possible to check error deletion
(STO)
P SUPP - 9
ERRORS DISPLAY SCREEN PAGE
Engine temperature sensor Error detected on indicated sensor/actuator cir-
cuit. Displayed error state is always MEM: look at
the EF light on the instrument panel to under-
stand if error is live (light on) or memorised (light
off).
Engine temperature sensor Error detected on indicated sensor/actuator cir-
off).
Barometric pressure sensor Error detected on indicated sensor/actuator cir-
off).
Throttle position sensor Error detected on indicated sensor/actuator cir-
off).
Throttle position sensor Error detected on indicated sensor/actuator cir-
off).
Main relay control Error detected on indicated sensor/actuator cir-
off).
Main relay control Error detected on indicated sensor/actuator cir-
P SUPP - 10
off).
Light relay activation Error detected on indicated sensor/actuator cir-
off).
Front injector Error detected on indicated sensor/actuator cir-
off).
Rear injector Error detected on indicated sensor/actuator cir-
off).
Front coil Error detected on indicated sensor/actuator cir-
off).
Rear coil Error detected on indicated sensor/actuator cir-
off).
AdjustabIe parameters screen page
ADJUSTABLE PARAMETERS
This display is used to adjust some control unit
parameters
ADJUSTABLE PARAMETERS SCREEN PAGE
Throttle self-learning, min. position Allows storage of reference value for throttle fully
home at 0: before performing the operation,
loosen the idle screw until Axone reading for
P SUPP - 11
"Throttle position is 0"'
Throttle self-learning, max. position Allows storage of reference value for throttle fully
open by completely turning the throttle twistgrip
open
CO adjustment at idle 1,00 - Allows modification of injection times within
idle range to change the CO rate
Wheel diameter cm
Wheel signals
njection time correction 1.00 - Allows modification of injection times at any
rpm (maximum adjustment is +/- 5% with respect
to injection times set inside mapping)
P SUPP - 12
INDEX OF TOPICS
SUSPENSIONS SUSP
Front
Front fork
CAUTION
TO HAVE THE FRONT FORK OIL CHANGED CONTACT AN OfficiaI apriIia DeaIer WHO WILL
PROVIDE PRECISE AND PROMPT SERVICE.
Replace the fork oil more frequently if the vehicle
is used on dusty or wet roads and when riding off-
road.
Carry out the following checks:
Operating the front brake lever, press
the handlebar repeatedly to send the
fork to the fully down.
The stroke should be soft and there
should be no oil marks on the stems.
Check the tightening of all the ele-
ments and the correct operation of the
front and rear suspension joints.
CAUTION
IN CASE OF FAILURE OR WHEN THE INTER-
VENTION OF SPECIALISED PERSONNEL IS
REQUIRED, TAKE YOUR VEHICLE TO AN OF-
FICIAL apriIia deaIer.
Diagram
Suspensions SXV RXV 450-550
SUSP - 2
Diagram key - SXV - RXV:
1. Left fork unit (SXV)
2. Right fork unit (SXV)
3. Left wheel holder stem (SXV)
4. Right wheel holder stem (SXV)
5. Complete sleeve (SXV)
SXV RXV 450-550 Suspensions
SUSP - 3
6. Ring for spring (SXV)
7. Spring kit (SXV)
8. Complete pumping element (SXV)
9. Complete valve (SXV)
10.Complete cap (SXV)
11.TE flanged screw (SXV)
12.Dust guard + oil guard kit (SXV)
13.Gasket kit; 48 mm (1.89 in) (SXV)
14.Bushing kit (SXV)
15.Adjustment kit; 0.1 mm (0.0039 in) shim (SXV)
19.Left fork unit (RXV)
20.Right fork unit (RXV)
21.Left wheel holder stem (RXV)
22.Right wheel holder stem (RXV)
23.Upper bushing (RXV)
24.Sealing ring (RXV)
25.Cap (RXV)
26.Snap ring (RXV)
27.Dust scraper (RXV)
28.Complete sleeve (RXV)
29.Lockscrew + O-ring (RXV)
30.Ring for spring (RXV)
31.Spring kit (RXV)
32.Complete pumping element (RXV)
33.Flanged screw (RXV)
34.Liner lower bushing (RXV)
35.Complete valve (RXV)
36.Complete cap (RXV)
Adjustment
CAUTION
TO AVOID DAMAGING THE PARTS, DO NOT
SUSP - 4
STRAIN THE ROTATION OF SET SCREWS
(1-2) BEYOND THE END OF THE STROKE IN
BOTH SENSES SET BOTH STEMS WITH THE
SAME HYDRAULIC DAMPING SETTING: RID-
ING THE VEHICLE WITH A DIFFERENT AD-
JUSTMENT FOR THE TWO STEMS REDUCES
ITS STABILITY. IF YOU INCREASE SPRING
PRELOAD, YOU ALSO NEED TO INCREASE
REBOUND DAMPING, IN ORDER TO AVOID
SUDDEN JERKS WHILE RIDING.
Rear shock absorber standard setting is adjusted to suit most low speed riding conditions, whether
the vehicle is partially or fully loaded.
However, this setting can be modified for specific needs according to vehicle use.
CAUTION
TO COUNT THE NUMBER OF CLICKS AND/OR TURNS FOR SET SCREWS (1 -2) ALWAYS
START FROM THE MOST RIGID SETTING (FULLY CLOCKWISE SCREW SETTING).
SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT
ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF
THE RELEVANT AUTHORITIES.
USING SPORT SETTINGS AND RIDING VEHICLES SO SET ON ROADS AND MOTORWAYS IS
STRICTLY FORBIDDEN.
FRONT SUSPENSION STANDARD ADJUSTMENT- SXV:
Hydraulic rebound damping adjustment, screw (1)
(SXV)
Open (anticlockwise) 10 clicks from fully closed
(clockwise)
Hydraulic compression damping adjustment,
screw (2) (SXV)
(clockwise) (H)
Stems (A) protrusion from top plate (excluding
cover) Take your vehicle only to an official aprilia
To the rim
SUSP - 5
Dealer for this type of adjustment (SXV)
FRONT SUSPENSION STANDARD ADJUSTMENT - RXV
Hydraulic rebound damping adjustment, screw (1)
(RXV)
(clockwise)
Hydraulic compression damping adjustment,
screw (2) (RXV)
(clockwise) (H)
Stems (A) protrusion from top plate (excluding
cover) Take your vehicle only to an official aprilia
Dealer for this type of adjustment. (RXV)
1 notch
Removing the fork Iegs
STEM REMOVAL (SXV)
Unscrew and remove both mudguard
front fixing screws.
Unscrew and remove the four
mudguard fixing screws.
Remove the front mudguard.
Place the OPTONAL front stand in
the hole of the fork lower plate
Unscrew and remove both calliper fix-
ing screws.
Slide off the calliper.
SUSP - 6
Working from the left side, unscrew
and remove the front wheel bolt fixing
nut.
Working on both sides, loosen the
screws on the wheel bolt clamps.
Working on the right side, slide off the
wheel bolt.
Remove the wheel.
SUSP - 7
Collect the bushing.
CAUTION
THE FOLLOWING THREE OPERATIONS ARE
ONLY VALID FOR REMOVING THE LEFT
STEM.
Release the stem of the cable holding clamps.
Unscrew and remove both speed
sensor fixing screws.
Remove the speed sensor.
Unscrew and remove the three stem
protection fixing screws.
Remove the stem protection.
Support the fork stem and loosen the
SUSP - 8
screws on the upper and then the
lower plate.
Remove the fork stem.
STEM REMOVAL (RXV)
Unscrew and remove both mudguard
front fixing screws.
Unscrew and remove the four
mudguard fixing screws.
Remove the front mudguard.
SUSP - 9
Place the OPTONAL front stand in
the hole of the fork lower plate.
Unscrew and remove both calliper fix-
ing screws.
Slide off the calliper.
CAUTION
THE SPEED SENSOR CABLE RUNS OUTSIDE
THE CALLIPER AND IS FITTED WITH PRO-
TECTION.
Working from the left side, unscrew
and remove the front wheel bolt fixing
nut.
Working on both sides, loosen the screws on the wheel bolt clamps.
Working on the right side, slide off the
wheel bolt.
SUSP - 10
Remove the wheel.
Collect the bushing.
CAUTION
THE FOLLOWING THREE OPERATIONS ARE
ONLY VALID FOR REMOVING THE LEFT
STEM.
Release the stem of the cable holding clamps.
Unscrew and remove both speed
sensor fixing screws.
Remove the speed sensor.
Unscrew and remove the three stem
SUSP - 11
protection fixing screws.
Remove the stem protection.
Support the fork stem and loosen the
screws on the upper and then the
lower plate.
Remove the fork stem.
Draining oiI
FORK OIL DRAINAGE (SXV)
NOTE
SUSP - 12
THE OPERATIONS DESCRIBED BELOW ARE VALID FOR BOTH STEMS.
CAUTION
DURING OIL DRAINAGE AND REFILLING OPERATIONS, THE STEM AND ITS INNER PARTS
SHOULD BE LOCKED IN A VICE; BE VERY CAREFUL NOT TO DAMAGE THEM BY EXERTING
AN EXCESSIVE FORCE; ALWAYS USE ALUMINIUM JAW CAPS.
To drain out the oil follow these operations:
Remove the fork stem
Place the sleeve (3) in a vice fitted
with protection shoes. Use an Allen
key to unscrew the upper closing cap
(1).
CAUTION
BE CAREFUL NOT TO DAMAGE THE O-RING
(2) WHEN REMOVING IT.
Push the stem inside the sleeve.
CAUTION
THE SLEEVE - STEM UNIT CONTAINS OIL; DO
NOT TURN IT OVER OR TILT IT TOO MUCH
UPON REMOVAL.
Holding the cover (1), unscrew the
lock nut indicated by the arrow using
the specific Allen key.
Remove the cover (1) together with
the plastic bushing (4) and the alu-
minium shim washer.
Remove the spring (5). Completely
drain inside the sleeve the oil settled
on the turns of the spring so as not to
SUSP - 13
be forced to top-up or change the oil.
Empty the oil into the container as
shown in the figure.
CAUTION
FOR EASY DRAINAGE OF THE OIL INSIDE
THE PUMPING MEMBER ROD, PRESS THE
STEM IN THE WHEEL HOLDER SLEEVE TO
PUMP OIL OUT.
FORK OIL DRAINAGE (RXV)
To drain out the oil follow these steps:
Remove the fork stem
Place the sleeve (8) in a vice fitted
with protection shoes. Use an Allen
key to unscrew the upper closing cap
(6).
CAUTION
BE CAREFUL NOT TO DAMAGE THE O-RING
(7) WHEN REMOVING IT.
Push the stem (8) inside the sleeve.
CAUTION
THE SLEEVE - STEM UNIT CONTAINS OIL; DO NOT TURN IT OVER OR TILT IT TOO MUCH
UPON REMOVAL.
Holding the cover (6), unscrew the
lock nut indicated by the arrow using
SUSP - 14
the specific Allen key.
Remove the cap.
Remove the plastic bushing (9).
Remove the spring (5). Completely
drain inside the sleeve the oil settled
on the turns of the spring so as not to
be forced to top-up or change the oil.
Empty the oil into the container as
shown in the figure.
CAUTION
FOR EASY DRAINAGE OF THE OIL INSIDE
THE PUMPING MEMBER ROD, PRESS THE
STEM IN THE WHEEL HOLDER SLEEVE TO
PUMP OIL OUT.
Slide off the preloading pipe.
SUSP - 15
DisassembIing the fork
Drain all the oil from the stem.
Take out the pumping element rod.
Lock the sleeve in a vice in horizontal
position.
CAUTION
PLACE A CONTAINER TO COLLECT THE OIL
UNDER THE STOP PLUG.
Unscrew and remove the stop plug us-
ing a pneumatic gun.
CAUTION
BE CAREFUL NOT TO DAMAGE THE O-RINGS
WHEN REMOVING THEM.
Slide off the pumping member unit.
SUSP - 16
Slide off the dust scraper (1) from the
sleeve using a screwdriver as a lever.
CAUTION
BE CAREFUL NOT TO DAMAGE THE SLEEVE
RIM AND THE DUST SCRAPER (1).
Slide off the snap ring (2) from inside
the sleeve using a thin screwdriver.
BE CAREFUL NOT TO DAMAGE THE SLEEVE
RIM.
Firmly slide off the sleeve from the
stem.
SUSP - 17
On the fork stem there are:
- bushing (3)
- guide ring (4)
- shim washer (5)
- oil seal (6)
- snap ring (2)
- dust scraper (1)
The bushing (3) and the guide ring (4)
are removed with a small screwdriver
and can therefore be removed from
the stem:
the shim washer (5),
SUSP - 18
the oil seal (6),
the snap ring (2) and the dust scraper (1).
ReassembIing the fork
CAUTION
BEFORE PERFORMING THE FOLLOWING OPERATIONS GET THE PROPER OPTIONAL SPE-
SUSP - 19
CIAL TOOL (A) AND SPREAD A THIN LAYER OF FORK OIL OVER GASKETS AND BUSHINGS
BEFORE REFITTING THEM.
Specific tooIing
9100904 Sachs fork oiI seaI; 48 mm (1.89 in)
9100903 Marzocchi fork oiI seaI; 45 mm (1.77 in)
Fit the components on the stem in the following order:
- dust scraper (1);
- snap ring (2);
- oil seal (6);
- shim washer (5);
- guide ring (4);
- bushing (3);
CAUTION
TO FIT THE OIL SEAL, TAPE THE BUSHING (3) HOUSING SLOT SO THAT THE OIL SEAL LIP
IS NOT DAMAGED.
Place shoes made of soft material
(aluminium) before positioning the
stem in a vice.
Place the bushing (3) in its seat on the
stem.
nsert the sleeve on the stem.
Push the guide ring (4) and the shim
washer (5) on the sleeve until they
stop.
Use the proper inserting tool (A) to
push the oil seal (6) in the sleeve until
it stops.
Fit the snap ring (2).
SUSP - 20
Fit the dust scraper (1).
nsert the complete pumping member
in the stem until it stops.
nsert and tighten the stop plug.
SUSP - 21
Fit the pumping element rod.
Fill with oil.
FiIIing oiI
FORK OIL FILLING (SXV)
Pour fork oil inside the sleeve (1) up to
the right detectable level by inserting a
graded rod in the sleeve (1).
CAUTION
THE SLEEVE (1) MUST BE PERFECTLY IN-
SERTED IN THE STEM FOR A CORRECT OIL
LEVEL READING. THE OIL LEVEL MUST BE
THE SAME IN BOTH STEMS.
Characteristic
OiI IeveI - SXV
125 + / - 2 mm (4.92 + /- 0.079 in) from the stem
rim
nsert the spring (3) in the sleeve (1).
SUSP - 22
Place the aluminium shim washer and
the plastic bushing (2) on the spring
(3).
Check that the O-ring (5) is fitted on
the top cap (4).
Holding the lock nut, screw the top
cap (4) on the pumping element rod
manually.
Screw and tighten the cap (4) on the sleeve (1).
FORK OIL FILLING (RXV)
nsert the preloading pipe in the
sleeve (7).
Pour fork oil inside the sleeve (7) up to
the right detectable level by inserting a
graded rod in the sleeve (7).
CAUTION
THE SLEEVE (7) MUST BE PERFECTLY IN-
SERTED IN THE STEM FOR A CORRECT OIL
SUSP - 23
LEVEL READING. THE OIL LEVEL MUST BE
THE SAME IN BOTH STEMS.
Characteristic
Fork oiI IeveI - RXV
100 + / - 2 mm (3.94 + /- 0.079 in) from the stem
rim
nsert the spring (9) together with the
plastic bushing (8) in the sleeve (7).
Check that the O-ring (6) is fitted on
the top cap (10).
Holding the lock nut, screw the top
cap (10) on the pumping element rod
manually.
Screw and tighten the cap (10) on the
sleeve (7).
SUSP - 24
InstaIIing the fork Iegs
STEM FITTING (SXV)
Fit the fork stem in its seat.
Support the fork stem and tighten the
two screws on the upper and lower
plate.
Fit the stem protection, position and
SUSP - 25
tighten the three fixing screws.
Position the speed sensor and screw
the two fixing screws.
Place the bushing.
Position the wheel.
Working on the right side, insert the
wheel bolt.
SUSP - 26
Working on the left side, partially
screw the front wheel bolt fixing nut.
CAUTION
TIGHTEN THE TWO SCREWS ON THE RIGHT
SIDE FORK CLAMP TO AVOID WHEEL BOLT
ROTATION.
Working on the left side, screw the
front wheel bolt fixing nut.
Tighten both screws on the wheel bolt
left fork clamp.
Place the calliper in its position.
Tighten the two calliper fixing screws.
Remove the OPTONAL front stand,
resting the vehicle on the side stand.
Fasten the sensor cable with a clamp.
Position the mudguard and screw the
four fixing screws.
SUSP - 27
Screw the two mudguard front fixing
screws.
STEM FITTING (RXV)
Fit the fork stem in its seat.
Support the fork stem and tighten the
two screws on the upper and lower
plate.
SUSP - 28
Fit the stem protection, position and
tighten the three fixing screws.
Position the speed sensor and screw
the two fixing screws.
Place the bushing.
Position the wheel.
SUSP - 29
Working on the right side, insert the
wheel bolt.
Working on the left side, partially
screw the front wheel bolt fixing nut.
CAUTION
TIGHTEN THE TWO SCREWS ON THE RIGHT
SIDE FORK CLAMP TO AVOID WHEEL BOLT
ROTATION.
Working on the left side, screw the
front wheel bolt fixing nut.
Tighten both screws on the wheel bolt
left fork clamp.
Place the calliper in its position.
Tighten the two calliper fixing screws.
Remove the OPTONAL front stand, resting the vehicle on the side stand.
SUSP - 30
Fasten the sensor cable with a clamp.
Position the mudguard and screw the
four fixing screws.
Screw the two mudguard front fixing
screws.
Rear
Removing the rear wheeI
Rest the vehicle on the specific OP-
TONAL stands.
Unscrew and remove the nut and col-
lect the washer.
SUSP - 31
Working in both sides, loosen the set
screw.
Slide off the chain.
Use a rubber hammer to slide off the
wheel bolt from the vehicle left side;
collect the centring shim washers and
slide off the wheel backwards.
Slide off the bushing.
SUSP - 32
InstaIIing the rear wheeI
Place the bushing.
Position the rear wheel.
Position the chain.
Working on both sides, insert the centring shim washers.
Working from the left side, insert the wheel bolt.
Working on the right side, position the washer and screw but do not tighten the wheel bolt
fixing nut.
Adjust the chain tension operating the set screws.
Tighten the wheel bolt fixing nut.
Shock absorbers
The rear suspension consists of a spring-shock absorber unit linked to the frame via silent-block and
to the rear fork via a linkage system.
To adjust the setting, the shock absorber has one set screw to adjust rebound damping, one set
screw to adjust compression damping, a ring nut for spring preloading adjustment and a locking ring
nut.
Adjusting
Rear shock absorber standard setting is adjusted
to suit most low speed riding conditions, whether
the vehicle is partially or fully loaded.
However, this setting can be modified for specific
SUSP - 33
needs according to vehicle use.
CAUTION
TO COUNT THE CORRECT NUMBER OF
CLICKS AND/OR TURNS FOR SET SCREWS (1
-2) ALWAYS START FROM THE MOST RIGID
SETTING (FULLY CLOCKWISE SCREW SET-
TING).
TO AVOID DAMAGING THE PARTS, DO NOT
STRAIN THE ROTATION OF SET SCREWS
(1-2) BEYOND THE END OF THE STROKE IN
BOTH SENSES..
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT
HALF THE INTERVALS SHOWN IF THE
VEHICLE IS USED IN WET OR DUSTY AREAS,
OFF ROAD OR FOR SPORTING APPLICA-
TIONS.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE
VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICA-
TIONS.
Using the specific spanner, slightly
loosen the locking ring nut (4).
Operate on the adjusting ring nut (3)
to adjust the spring preloading (B).
When the optimal adjustment level
has been obtained, screw the locking
nut ring (4) completely.
Turn the screw (1) to adjust the shock
absorber hydraulic rebound damping.
Turn the screw (2) to adjust the shock
absorber hydraulic compression
SUSP - 34
damping.
CAUTION
SET SPRING PRELOAD AND REBOUND
DAMPING BASED ON THE VEHICLE USE
CONDITIONS. IF YOU INCREASE THE SPRING
PRELOAD, YOU ALSO NEED TO INCREASE
REBOUND DAMPING, IN ORDER TO AVOID
SUDDEN JERKS WHEN RIDING. IF NECES-
SARY, TAKE YOUR VEHICLE TO AN apriIia
OfficiaI DeaIer. TRY RIDING THE VEHICLE ON
THE STREET UNTIL THE OPTIMUM ADJUST-
MENT IS OBTAINED.
TO AVOID COMPROMISING SHOCK AB-
SORBER OPERATION, DO NOT LOOSEN
SCREW (5) AND DO NOT TAMPER WITH THE
SEAL UNDERNEATH, AS NITROGEN MAY
COME OUT RESULTING IN RISK OF ACCI-
DENTS.
STANDARD ADJUSTMENT OF SXV REAR SUSPENSION
Shock absorber distance (A) (SXV) 457 + / - 1.5 mm (18 + / - 0.06 in)
Length of (preloaded) (B) spring (SXV) 245 mm (9.6 in)
Rebound damping adjustment, screw (1) (SXV) 13 clicks
Rebound compression adjustment, screw (2)
(SXV)
16 clicks
By-pass adjustment knob (6) (SXV) Completely open (-)
STANDARD ADJUSTMENT OF RXV REAR SUSPENSION
Shock absorber distance (A) (RXV) 473 + / - 1.5 mm (18.6 + / - 0.06 in)
Length of (preloaded) (B) spring (RXV) 247 mm (9.7 in)
Rebound damping adjustment, screw (1) (RXV) 23 clicks
Rebound compression adjustment, screw (2) Completely open
SUSP - 35
(RXV)
By-pass adjustment knob (6) (RXV) Completely open (-)
SUSP - 36
INDEX OF TOPICS
CHASSIS CHAS
Swinging arm
Removing
Unscrew and remove the nut of the
pin fixing fork / linkage system and
collect the washer.
Slide off the pin fixing fork / linkage
system.
Unscrew and remove the fixing nuts of
the upper protection cover and collect
the spacer.
Remove the upper protection cover.
Chassis SXV RXV 450-550
CHAS - 2
Move the chain together with the chain
guide sideways.
Unscrew and remove the three chain
guide fixing screws and collect both
nuts.
Unscrew and remove the fork pin fix-
ing nut.
(1).
Remove the fork pin.
SXV RXV 450-550 Chassis
CHAS - 3
Drive chain
SXV models feature an endless chain whereas RXV models feature a chain with master link.
CAUTION
INCORRECTLY EFFECTED MAINTENANCE MAY CAUSE EARLY WEAR OF THE CHAIN AND
OR DAMAGE THE PINION AND/OR THE CROWN. CARRY OUT MAINTENANCE OPERATIONS
MORE FREQUENTLY IF YOU RIDE THE VEHICLE IN EXTREME CONDITIONS OR ON DUSTY
AND OR MUDDY ROADS.
AN EXCESSIVELY SLACKEN CHAIN MAY CAUSE NOISE OR CHAIN KNOCKING, RESULTING
IN CHAIN PAD AND GUIDE PLATE WEAR. CHECK CHAIN BACKLASH ON A REGULAR BASIS
AND ADJUST IT AS NECESSARY. TO HAVE THE CHAIN REPLACED, TAKE YOUR VEHICLE
TO AN OfficiaI apriIia deaIer, WHICH WILL PROVIDE ACCURATE AND PROMPT SERVICE. IN-
CORRECTLY EFFECTED MAINTENANCE MAY CAUSE EARLY WEAR OF THE CHAIN AND/OR
DAMAGE THE PINION AND/OR THE CROWN. CARRY OUT MAINTENANCE OPERATIONS
MORE FREQUENTLY IF YOU RIDE THE VEHICLE IN EXTREME CONDITIONS OR ON DUSTY
AND/OR MUDDY ROADS.
To check slack:
Stop the engine.
Place the vehicle on the stand.
Engage neutral gear.
Check that vertical oscillation at a
middle point between pinion and
CHAS - 4
crown on the lower part of the chain is
about 20 25 mm (0.79 0.98 in).
Move the vehicle forward so as to
check vertical oscillation in other posi-
tions too. The slack should remain
constant during all wheel rotation
phases.
f the slack is uniform, but higher or lower than 20
25 mm (0.79 0.98 in), adjust it as required.
CAUTION
IF THERE IS MORE CLEARANCE AT SOME
POSITIONS, THIS MEANS THAT SOME CHAIN
LINKS ARE FLATTENED OR JAMMED. IN THIS
EVENT, CONSULT AN OfficiaI apriIia DeaIer.
TO AVOID THE RISK OF SEIZURE, LUBRIC-
ATE THE CHAIN ON A REGULAR BASIS.
Also check the following parts and make sure that the chain, pinion and crown do not have:
Damaged rollers.
Loosened pins.
Dry, rusty, flattened or jammed chain links.
Excessive wear.
Missing sealing rings.
Excessively worn or damaged pinion or crown teeth.
CAUTION
IF THE CHAIN ROLLERS ARE DAMAGED, THE PINS ARE LOOSENED AND/OR THE O-RINGS
ARE MISSING OR DAMAGED, THE WHOLE CHAIN APPARATUS (PINION, CROWN AND
CHAIN) SHOULD BE REPLACED.
Check the chain guide slider (1) and
the chain tightener slider (2) for wear
Finally, check the fork protection pad
for wear.
CAUTION
LUBRICATE THE CHAIN ON A REGULAR
CHAS - 5
BASIS, PARTICULARLY IF YOU FIND DRY OR
RUSTY PARTS. FLATTENED OR JAMMED
CHAIN LINKS SHOULD BE LUBRICATED AND
GOOD OPERATING CONDITIONS RESTORED.
IF YOU ARE UNABLE TO REPAIR THEM, CON-
TACT AN OfficiaI apriIia DeaIer, WHO WILL
REPLACE THEM.
Lubricate the chain whenever necessary. Lubricate the chain with chain spray grease. Do not wash
the chain with water jets, steam jets, high-pressure water jets and highly flammable solvents.
ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION.
Removing
Unscrew and remove the two pinion
protection fixing screws and remove
the protection collecting the two
screws and the spacers (one in RXV
models, two in SXV models).
Remove the ground lead.
Remove the rear wheel.
(1).
Remove the fork pin.
CHAS - 6
Remove the pinion locking Seeger
ring.
Detach the pinion from the chain.
Slide off the pinion.
InstaIIing
Position the pinion and the chain.
Position the chain locking Seeger ring.
Position the fork pin.
CHAS - 7
Tighten the fork pin fixing nut.
Mount the rear wheel.
Position the ground lead.
Position the pinion protection together
with the spacers (one in RXV models,
two in SXV models) and tighten the
two fixing screws.
Adjusting
f chain tension needs adjusting after the check:
Rest the vehicle on its stand.
Loosen the nut (1) completely.
Loosen both lock nuts (5).
Actuate on the set screws (4) and ad-
just the chain backlash checking that
the references (2 - 3) match on both
sides of the vehicle.
Tighten both lock nuts (5).
Tighten the nut (1).
Check chain clearance.
NOTE
WHEEL CENTRING IS CARRIED OUT USING
THE IDENTIFIABLE FIXED REFERENCES (2-3)
INSIDE THE TENSIONER PAD MOUNTS ON
CHAS - 8
THE FORK ARMS, IN FRONT OF THE WHEEL
BOLT.
Locking torques (N*m)
Tightening torque for wheeI nut (1): 127 Nm
(12.7 kgm)
Exhaust
Removing the taiI pipe
Unscrew and remove the two screws
together with the washers and collect
the nuts.
Make sure the T-shaped bushings re-
main in their seats.
Working on both sides, remove the fix-
ing spring.
Working on both sides, undo and re-
move the two screws and collect the
washers.
Slide off the exhaust end.
CHAS - 9
Removing the exhaust manifoId
Remove the exhaust end.
ing the exhaust manifold of the front
cylinder.
Remove the exhaust manifold of the
front cylinder and collect the metal
clamp.
ing the exhaust manifold of the rear
cylinder.
Remove the exhaust manifold of the
CHAS - 10
rear cylinder.
Engine oiI tank
Removing
Remove the saddle.
Lift the tank.
Remove the cooling system radiators.
Place a container of suitable capacity
underneath the oil reservoir cap.
Unscrew and remove the oil emptying
cap.
Remove the upper clamp.
Slide off the blow-by pipe.
Release the seal clamp.
CHAS - 11
Slide off the pipe.
Release both seal clamps.
Slide off both pipes.
Working on the right side, unscrew
and remove the two screws.
Working from the left side, collect both
nuts.
Remove the oil filler plug.
CHAS - 12
Slide off the oil reservoir from the bot-
tom.
InstaIIing
Position the engine oil reservoir.
Working on the right side, insert both
fixing pins.
Working from the left side, tighten both
nuts.
CHAS - 13
Position the connection pipes and re-
lease the seal clamps.
Position the pipe.
Fix the seal clamp.
Position the blow-by pipe.
Fix the seal clamp.
Screw the oil emptying nut.
CHAS - 14
Fill up the engine oil reservoir through
the top cap.
CHAS - 15
CHAS - 16
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS
Disc brake
CAUTION
BRAKES ARE THE MOST IMPORTANT COMPONENTS TO ENSURE SAFETY AND THERE-
FORE THEY HAVE TO BE ALWAYS IN PERFECT CONDITIONS; CHECK THE BRAKES BE-
FORE EACH RIDE. A DIRTY DISC SOILS THE PADS, LEADING TO LOSS OF BRAKING. DIRTY
PADS MUST BE REPLACED, WHEREAS A DIRTY BRAKE DISC MAY BE CLEANED WITH A
HIGH-QUALITY DEGREASING PRODUCT. HAVE THE BRAKE FLUID CHANGED AT AN APRIL-
IA OFFICIAL DEALER ONCE A YEAR. USE THE BRAKE FLUID SPECIFIED IN THE LUBRICANT
CHART.
NOTE
THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OPERATED BY
AN INDEPENDENT HYDRAULIC CIRCUIT.
The front braking system is single disc (left side).
The rear braking system is single disc (right side).
NOTE
THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT IS VALID FOR
BOTH.
Brake fluid decreases gradually in the reservoirs (1-2) as the brake pads wear down, to compensate
for the wear automatically.
The front brake fluid reservoir (1) is placed near the front brake lever connection.
The rear brake fluid reservoir (2) is integrated in the brake pump fastened to the frame, on the right
side, near the fork.
NOTE
VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTS APPLICATIONS.
NOTE
CHECK THE BRAKE FLUID LEVEL IN THE RESERVOIRS (1 - 2) AND CHECK BRAKE PADS
FOR WEAR BEFORE SETTING OFF.
NOTE
THE FOLLOWING INFORMATION REFERS TO
ONE BRAKING CIRCUIT BUT APPLIES TO
BOTH.
Braking system SXV RXV 450-550
BRAK SYS - 2
NOTE
CARRY OUT THE MAINTENANCE OPERA-
TIONS AT HALF THE INTERVALS SHOWN IF
THE VEHICLE IS USED IN WET OR DUSTY
AREAS, OFF ROAD OR FOR SPORTS APPLIC-
ATIONS.
Disc brake pad wear depend on the use, the riding style and the roads.
CAUTION
WEAR IS GREATER WHEN RIDING ON DIRTY AND WET ROADS OR OFFERED.
CAUTION
CHECK BRAKE PADS FOR WEAR MAINLY BEFORE EACH RIDE.
NOTE
THIS VEHICLE IS FITTED WITH FRONT AND REAR DISC BRAKES WITH INDEPENDENT HY-
DRAULIC CIRCUITS. THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT
BUT IT APPLIES TO BOTH.
SXV RXV 450-550 Braking system
BRAK SYS - 3
CAUTION
UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER
ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. CONTACT AN OfficiaI apriIia deaIer IN
CASE OF DOUBTS ON THE CORRECT BRAKING CIRCUIT OPERATION AND WHEN UNABLE
TO CARRY OUT ROUTINE CHECKS. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND
THE FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY
AFTER MAINTENANCE OPERATIONS OR CHECKS. CHECK THAT BRAKE PIPES ARE NOT
TWISTED OR WORN. PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERT-
ENTLY GETS INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVI-
CING THE HYDRAULIC CIRCUIT. BRAKE FLUID MAY CAUSE IRRITATION IF IN CONTACT
WITH SKIN OR EYES. RINSE CAREFULLY ALL BODY PARTS THAT HAVE COME INTO CON-
TACT WITH THE FLUID. SHOULD THE FLUID COME INTO CONTACT WITH YOUR EYES, SEEK
MEDICAL ADVICE OR CONTACT AN EYE SPECIALIST. DO NOT DISPOSE OF THE FLUID INTO
THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN WHEN USING BRAKE FLUID,
PAY ATTENTION NOT TO SPILL IT ONTO PLASTIC OR PAINTED COMPONENTS AS IT WILL
IRREPARABLY DAMAGE THEM.
Front brake pads
SXV
Check the front brake caIIiper pads:
NOTE
THE FRONT CALLIPER IS FITTED WITH FOUR BREAK PADS.
Visually inspect the area between the
brake callipers and pads as follows:
- from the back top side;
RXV
Check the front brake caIIiper pads:
NOTE
BRAK SYS - 4
THE FRONT CALLIPER IS FITTED WITH TWO BREAK PADS.
Visually inspect the area between the
brake callipers and pads as follows:
- from the front top side.
Rear brake pads
SXV
Checking the rear brake caIIiper pads:
NOTE
THE REAR CALLIPER IS FITTED WITH TWO BREAK PADS.
Visually inspect the area between the brake callipers and pads as follows:
- from the back top side;
RXV
Checking the rear brake caIIiper pads:
NOTE
THE REAR BRAKE CALLIPER IS THE SAME AS THE ONE IN THE SXV VERSION, SO FOLLOW
THE STEPS INDICATED IN THE SXV PARAGRAPH.
NOTE
EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET IN-
TO CONTACT WITH THE DISC, WHICH RESULTS IN METALLIC NOISE AND SPARKS IN THE
CALLIPER; THEREFORE, BRAKING EFFICIENCY AND DISC SAFETY AND INTEGRITY ARE AT
RISK.
When the lining material of even just one of the
brake pads is worn down to nearly 1.5 mm (0.06
in) (or even if one of the wear indicators is no
longer visible), replace both brake pads.
BRAK SYS - 5
BIeeding the braking system
Front
f there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from
the brake pump and minimising calliper efficiency during braking.
The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY,
AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR
USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HY-
DRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE
FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE
RESERVOIR.
Remove the rubber protection cover
from the bleed valve.
nsert the transparent plastic pipe in
the front brake calliper bleed valve
and slide the other end of this pipe in
a container to collect the fluid.
Quickly press and release the front
brake lever several times and then
keep it fully pressed.
Loosen the bleed valve 1/4 of a turn
so that the brake fluid flows into the
BRAK SYS - 6
container. This will release tension on
the brake lever and will make it go to
the end of stroke.
Close the bleed valve before the lever
reaches its end of stroke.
Repeat the operation until the fluid
draining into the container is air-
bubble free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM,
FILL THE RESERVOIR WITH THE NECES-
SARY QUANTITY OF BRAKE FLUID CHECK
THAT, DURING THE OPERATION, THERE IS
ALWAYS BRAKE FLUID IN THE RESERVOIR.
Screw the bleed valve and remove the pipe.
Top-up the reservoir until the right brake fluid level is obtained.
Refit the rubber protection cover.
Rear
f there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from
the brake pump and minimising calliper efficiency during braking.
The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY,
AFTER REFITTING BRAKES AND RESTORING THE BREAKING SYSTEM TO THE REGULAR
USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HY-
DRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE
FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE
RESERVOIR.
Remove the rubber protection cover
from the bleed valve.
BRAK SYS - 7
nsert the transparent plastic pipe in
the front brake calliper bleed valve
and slide the other end of this pipe in
a container to collect the fluid.
Quickly press and release the front
brake lever several times and then
keep it fully pressed.
Loosen the bleed valve 1/4 of a turn
so that the brake fluid flows into the
container. This will release tension on
the brake lever and will make it go to
the end of stroke.
Close the bleed valve before the lever
reaches its end of stroke.
Repeat the operation until the fluid
draining into the container is air-
bubble free.
NOTE
WHILE PURGING THE HYDRAULIC SYSTEM,
FILL THE RESERVOIR WITH THE NECES-
SARY QUANTITY OF BRAKE FLUID CHECK
THAT, DURING THE OPERATION, THERE IS
ALWAYS BRAKE FLUID IN THE RESERVOIR.
Screw the bleed valve and remove the pipe.
Top-up the reservoir until the right brake fluid level is obtained.
Refit the rubber protection cover.
BRAK SYS - 8
INDEX OF TOPICS
COOLING SYSTEM COOL SYS
Circuit diagram
Key:
1. Left radiator
2. Right radiator
3. Expansion tank
4. Fan unit
5. Fan support
6. D10 pipe - d5.5
7. Left radiator / right radiator upper connection pipe
8. Left radiator / right radiator lower connection pipe
9. Radiator / water pump connection pipe
10.Radiator / rear head connection pipe
11.Radiator / front head connection pipe
12.Expansion tank gasket
13.Expansion tank cap
14.Radiator cap
Water pump - overhauI
CAUTION
Cooling system SXV RXV 450-550
COOL SYS - 2
IT IS NOT NECESSARY TO REMOVE THE COOLANT PUMP UNLESS THE COOLANT LEVEL IS
EXTREMELY LOW OR WHEN THE COOLANT DOES NOT HAVE ENGINE OIL.
NOTE
PLACE A CLOTH UNDER THE PUMP BEFORE REMOVING ITS COMPONENTS.
Unscrew and remove the four pump
cover fixing screws.
Remove the water pump cover and
collect the seal gasket.
Remove the pump rotor using the spe-
cial spanner.
Specific tooIing
9100938 Pump rotor wrench
Remove the shim washer.
Collect the two centring cylinders.
SXV RXV 450-550 Cooling system
COOL SYS - 3
Remove the water pump cover
spacer.
NOTE
WHEN REFITTING, FOLLOW THE STEPS DE-
SCRIBED BEFORE BUT IN REVERSE ORDER;
USE ONLY CIRCULAR GASKETS AND NEW
CLAMPS.
Removing the radiator
Working on both sides, unscrew and
remove the three side fairing fixing
screws.
Place a container of suitable capacity
underneath the sleeve.
Release the clamp.
COOL SYS - 4
Slide off the coupling.
Empty the liquid into the container.
Open the radiator cap to facilitate
drainage.
Working on both sides, release the
clamps.
Remove the right and left delivery
pipes.
Working on the left side, release the
clamp and disconnect the pipe.
Working on the right side slide off the
coupling.
COOL SYS - 5
Remove the radiator breather pipe.
Working on the right side, undo the
lower screw; collect the nut and the
washer from the left side.
Slide off the radiators downwards.
CAUTION
THE RADIATORS ARE INTERCONNECTED
COOL SYS - 6
THROUGH THE LOWER PIPE.
COOL SYS - 7
COOL SYS - 8
INDEX OF TOPICS
BODYWORK BODYW
Seat
Turn the fastening clip.
Remove the saddle.
Side body paneIs
REMOVAL
Working on both sides, unscrew and
remove the three side fairing fixing
screws.
To refit the fairings, follow the steps described be-
fore but in reverse order.
FueI tank
Remove the saddle.
Working from one side, undo and re-
move the two screws and collect the
washer.
Bodywork SXV RXV 450-550
BODYW - 2
Remove the lower side fairing.
CAUTION
THE RESERVOIR CAN BE REMOVED
WITHOUT THE NEED TO TAKE OUT THE
LOWER SIDE FAIRING BY CUTTING THE
FAIRING ALONG THE MARKS (A).
Undo and remove the screw fixing the
reservoir and collect the centring
bushing.
Remove the fuel tank breather pipe.
Lift the tank.
Keep the fuel tank lifted with the re-
taining edge.
CAUTION
MAKE SURE THAT THE TANK RETAINING
EDGE NEVER COMES INTO CONTACT WITH
THE BATTERY POSITIVE LEAD.
Release the quick coupler.
Disconnect the connector.
SXV RXV 450-550 Bodywork
BODYW - 3
Remove the split pin from the side of
the vehicle that still has the fairing.
Remove the pin fixing the reservoir
from the side without the lower side
fairing.
Battery
Bodywork SXV RXV 450-550
BODYW - 4
Remove the saddle.
Unscrew and remove the negative
lead fixing screw and collect the wash-
er.
Unscrew and remove the negative
lead fixing screw and collect the wash-
er.
Remove the battery.
SXV RXV 450-550 Bodywork
BODYW - 5

SXV RXV Chassis

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