APRILIA 854239 Service Station Manual Download Page 139

Page: 139 / 216

16.04 mm (0.631 in)

Refitting the crankcase halves

CAUTION

BEFORE REFITTING, REPLACE AND LUBRICATE 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 shim washer on the right

crankcase half in the hole of the trans-

mission secondary crankcase.

•

Fit the transmission main and secon-

dary shafts in the right crankcase half,

together with the desmodromic drum

and the levers.

•

Place the cylinders liners as externally

as possible.

•

Place the cylinder liners with the refer-

ence mark near the crankcase halves

coupling edge.

•

Apply Three Bond sealant (code

855252) all along the crankcase pe-

rimeter.

•

Place the shim washer on the trans-

mission main shaft.

MXV 450

Engine

ENG - 139

Summary of Contents for 854239

Page 1: ...SERVICE STATION MANUAL 854239 MXV 450 ...

Page 2: ...ed 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 pub...

Page 3: ... changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult aprilia CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and te...

Page 4: ......

Page 5: ...R 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 PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust system have cooled down Coolant The coolant ...

Page 8: ...MELY DANGEROUS TO THE EYES IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES RINSE THEM IMMEDIATELY WITH PLENTY OF COLD CLEAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Maintenance rules GENERAL PRECAUTIONS AND INFORMATION When repairing dismantling and reassembling the vehicle follow the recommendations given below carefully BEFORE DISASSEMBLING COMPONENTS Before dismantling c...

Page 9: ... hicle on private grounds Clean all coupling surfaces oil guard rims and gaskets before refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble bearings with the brand or lot number facing outward visible side ELECTRICAL CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both ...

Page 10: ... is used During this time avoid setting off at too high a speed or sudden accelerations These procedures have to be carried out each time pistons are replaced piston rings are replaced cylinder liners are replaced crankshaft main bearings and connecting rod bushings are replaced NOTE EVEN AFTER THE RUNNING IN PERIOD AVOID RUNNING THE ENGINE AT TOP SPEED WHEN THE LIMITER CUTS IN MXV 450 12500 rpm D...

Page 11: ...y including reserve 7 4 l 1 63 UKgal Engine oil capacity replacing oil filter 1200 cm 73 23 cu in Gearbox oil 650 cm 39 66 cu in Coolant capacity 1 2 l 0 26 Ukgal 50 water 50 antifreeze solution with ethylene glycol Seats 1 Electrical system ELECTRICAL COMPONENTS Specification Desc Quantity 1 Ignition Electronic digital batteryless 2 Standard spark plug NGK CR8EKB 3 Spark plug electrode gap 0 7 0 ...

Page 12: ...15 x 19 Tyres type Dunlop Front tyre 80 100 21 51M Front tyre pressure 1 0 bar 100 kPa 14 5 PSI Rear tyre 110 90 19 62M Rear tyre pressure 1 0 bar 100 kPa 14 5 PSI Supply FUEL SYSTEM Specification Desc Quantity Diffuser Ø 38 mm 1 49 in Fuel system premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Fuel system Integrated ignition injection management Tightening Torques HANDLEBAR AND ...

Page 13: ...Nm 4 42 lbf ft Number plate retainer screw M5 6 Nm 4 42 lbf ft TANKS AND RESERVOIRS Name Torque in Nm Fuel tank chassis fixing screw M6 12 Nm 8 85 lbf ft Fuel pump fixing ring nut 20 Nm 14 75 lbf ft Screw fixing saddle guide bushing M5 5 Nm 3 69 lbf ft Loctite 243 Screw fixing tank buffers M5 5 Nm 3 69 lbf ft Loctite 243 OUTLET Name Torque in Nm Screw fixing silencer to frame M6 12 Nm 8 85 lbf ft ...

Page 14: ...fixing nut M12 80 Nm 59 00 lbf ft Rod rocker fixing nut M12 80 Nm 59 00 lbf ft Rocker swingarm fixing nut M12 80 Nm 59 00 lbf ft Nut fixing rear shock absorber M10 50 Nm 36 88 lbf ft SWINGARM Name Torque in Nm Chain guide fixing nut M6 12 Nm 8 85 lbf ft Swingarm pin fixing nut M14 100 Nm 73 76 lbf ft Chain tightener set screw M8 25 Nm 18 44 lbf ft Screw fixing chain slider and rear brake pipe guid...

Page 15: ...0 Nm 22 13 lbf ft Oil screws and washers Head fixing screw M10x1 25 55 Nm 40 56 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 Plate screw for sprocket M6x1 9 8 Nm 7 23 lbf ft Loctite 270...

Page 16: ...m 1 37732 in 1 37759 in Connecting rod A ø 38 000 mm 38 012 mm 1 49606 in 1 49653 in Colour BLUE Shaft Connecting rod A B YELLOW types Shaft A ø 34 984 mm 34 991 mm 1 37732 in 1 37791 in Connecting rod B ø 38 013 mm 38 025 mm 1 49657 in 1 49704 in Colour YELLOW Shaft Connecting rod B A GREEN types Shaft B ø 34 992 mm 35 000 mm 1 37763 in 1 37795 in Connecting rod A ø 38 000 mm 38 012 mm 1 49606 in...

Page 17: ... that meet or exceed the required specifications may be used SAE J1703 NHTSA 116 DOT 4 ISO 4925 Synthetic fluid AGIP MP GREASE Grease for bearings joints couplings and leverages As an alternative to the recommended product use top brand grease for roller bearings with an operating temperature range of 30 C 140 C 22 F 284 F a drop point of 150 C 230 C 302 F 446 F high corrosion protection qualities...

Page 18: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 19: ...iption 853715 Water pump oil seal guide 853716 Water pump oil seal punch AP8140179 Valve spring compressor AP8140187 Engine support stand 8140188 Engine support AP9100838 Tool for valve pressure plate MXV 450 Special tools S TOOLS 19 ...

Page 20: ...on locking tool 9100844 Crankshaft locking tool timing pin 9100885 Main shaft right side secondary shaft left side 9100886 Secondary shaft right side Main shaft left side 9100887 Punch for right crankcase desmo 9100888 Oil pump oil seal punch Special tools MXV 450 S TOOLS 20 ...

Page 21: ...nch 9100890 Timing gear crankshaft punch 9100892 Left crankcase desmodromic wheel hub 9100893 Left timing gear punch 9100894 Secondary shaft oil seal punch 9100895 Water pump oil seal punch 9100896 Clutch housing locking tool MXV 450 Special tools S TOOLS 21 ...

Page 22: ...r 9100898 Swingarm cages punch 9100900 Punch for swingarm linkage cages AP8140758 tool to fit oil seals and dust gaiter for ø 50 mm 1 97 in stems 9100938 Pump rotor wrench 9100943 Piston pin extractor 9100841 Engine support Special tools MXV 450 S TOOLS 22 ...

Page 23: ...Stores code Description 9100942 Crankcase halves support 020376Y Adapter handle 020483Y 30 mm guide 020684Y Ø 58 60 mm 2 28 2 36 in guide MXV 450 Special tools S TOOLS 23 ...

Page 24: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 25: ...5 L Connecting rod bushings I Spark plugs I R Cylinder liners I Filter box check bleed pipe I Drive chain remark 1 I L Camshaft drive chain and shoes I Clutch control I Electrical contacts and switches I Camshaft bearings I Rear wheel bearings R Steering head bearings I Primary side crankshaft bearing ball bearing I Nuts bolts and fasteners I Chain tensioner teeth I Clutch plates wear I Air filter...

Page 26: ... head bearings I Primary side crankshaft bearing ball bearing I Nuts bolts and fasteners I Chain tensioner teeth I Clutch plates wear I Air filter remark 1 C Engine oil filter remarks 2 3 R Throttle grip operation I Swingarm L Oil jets C Valve clearance remark 4 I Oil pumps gears and rotors I Gearbox gears and selector I Starter gears and components I Brake fluid remark 2 I Radiator coolant remark...

Page 27: ...RE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE Remove the tube 1 of the spark plug 2 Clean off any trace of dirt from the spark plug 2 base Insert 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 in...

Page 28: ...EAT AND MAY THUS CAUSE DAMAGE TO THE ENGINE WHEN THE CORRECT THREA DED PART IS INSTALLED USE RECOMMENDED SPARK PLUGS ONLY USING A SPARK PLUG OTHER THAN SPECIFIED MIGHT COMPROMISE ENGINE PERFORM ANCE AND LIFE CHECK THE GAP BETWEEN THE ELEC TRODES WITH A FEELER GAUGE TO AVOID DAMAGING THE PLATINUM COATING Check the gap between the electrodes with a feeler gauge CAUTION DO NOT ATTEMPT TO READJUST THE...

Page 29: ...E CARRIED OUT FOR BOTH CIRCUITS CAUTION ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM A COUPLE OF MINUTES AFTER THE ENGINE HAS BEEN SHUT OFF IF ENGINE OIL LEVEL IS CHECKED WHEN THE ENGINE IS COLD OIL MAY DROP TEMPORARILY BELOW THE MINIMUM LEVEL THIS SHOULD NOT BE CONSIDERED A PROBLEM NOTE IN ORDER TO WARM UP THE ENGINE AND BRING THE OIL TO THE RIGHT TEMPERATURE RIDE THE VEHICLE FOR A SH...

Page 30: ...IS PERFECTLY CLEAN NOTE USE OIL RECOMMENDED IN THE PRODUCTS TABLE Replacement Keep the vehicle upright with the two wheels on the ground Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well Undo the screws and lower the oil sump guard Unscrew and take out the oil filler plug 1 Place a container to collect the oil un derneath the engine oil drainage plug...

Page 31: ...e engine oil filter cover 2 with O rings Add engine oil through the fill opening 1 Screw and tighten the oil filling drain age plugs Start the engine and let it run for sev eral minutes Stop the engine Unscrew and take out the oil filler plug 1 Check engine oil level and top up if re quired Refit the oil sump guard BY PASS VALVE CLEANING Drain off the engine oil completely Working on the right sid...

Page 32: ... pressure regulating valve cap 2 Add engine oil through the fill opening 1 Screw and tighten the oil filling drain age plugs Start the engine and let it run for sev eral minutes Stop the engine Unscrew and take out the oil filler plug 1 Check engine oil level and top up if re quired Refit the oil sump guard Gearbox Oil Inspection CAUTION GEAR OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM Maint...

Page 33: ...ler cap 3 Top up with oil up to the cap dipstick 2 opening CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Wait some minutes to allow the oil to flow from the clutch to the transmission Then check the oil level again Replacement Lower the oil pan guard Place on the left side of the vehicle a container of adequat...

Page 34: ...rear brake lever by tightening the screw 1 Refit the oil sump guard CAUTION OIL FLOWING FROM THE CLUTCH TO THE TRANSMIS SION AND FROM THE TRANSMISSION TO THE CLUTCH CAN BE PARTICULARLY SLOW WHEN THE OIL OR EN GINE TEMPERATURE IS LOW NOTE USE OIL RECOMMENDED IN THE PRODUCTS TABLE Characteristic Gearbox oil 650 cm 39 66 cu in Air filter Undo and remove the two screws 1 Remove the filter casing cover...

Page 35: ...es replacement Loosen tension of the throttle grip ca bles of the throttle body Remove the rubber protection Undo and remove the two screws Disconnect the throttle grip cables from the throttle grip Cooling system Level check Check and top up CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP THE COOLANT LEVEL MXV 450 Maintenance MAIN 35 ...

Page 36: ...ero degrees centigrade check the cooling system fre quently and add more antifreeze solution if needed up to 60 max Use distilled water in the coolant mixture to avoid damaging the engine Top up CAUTION WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING UP THE COOLANT LEVEL If topping up is necessary after the check do as follows Remove the radiator cap 1 Loosen the bleed valve 2 located ...

Page 37: ...AULIC CIRCUIT CONTACT AN Official aprilia dealer 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 I...

Page 38: ... reference mark Check brake pads and discs for wear If the pads and or the disc do not need replacing top up the fluid CAUTION FLUID LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN Top up CAUTION RISK OF BRAKE FLUID SPILLING DO NOT PULL THE BRAKE LEVER WHEN THE SCREWS ARE LOOSE OR MAINLY WHEN THE BRAKE FLUID RESERVOIR COVER HAS BEEN REMOVED PLACE A CLOTH UNDER THE BRAKE FLUID RESERVOIR TO PROTEC...

Page 39: ...hillips screwdriver CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESER VOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE Lift and remove the cover 4 together with the screws 3 and the gasket CAUTION TO AVOID SPILLING BRAKE FLUID DURING TOP UP DO NOT SHAKE THE VEHICLE DO N...

Page 40: ...erating as follows With a commercially available Ø 3mm pin and a rubber mallet perforate the rivets Using a drill with a Ø 5mm point perfo rate the rivets completely If necessary use a commercially avail able Ø 5mm pin and a rubber mallet to remove any remaining shank of the riv ets making sure that both half shell holes are free CAUTION MAKE SURE THAT NO RIVET SHANKS ARE LEFT INSIDE THE HALF SHEL...

Page 41: ... the acoustic insulation mate rial of the upper half shell Remove the acoustic insulation mate rial of the lower half shell Make sure that there are no residues of any kind inside the half shells for example rivet residues silicone acoustic insulation material etc MXV 450 Maintenance MAIN 41 ...

Page 42: ...shells Couple both half shells being careful not to pinch the acoustic insulation ma terial Fit in all rivets to get the correct posi tion using TT Inox rivets Ø 4 8x12 9 rivet again both half shells clockwise Clean excess silicone after closing Replacing exhaust ends acoustic insulation material CAUTION BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW WEAR A PAIR OF SAFETY GLOVES Maintenance MX...

Page 43: ...ly and the si lencer body operating as follows With a commercially available Ø 3mm pin and a mallet take out the pin of the rivets Using a drill with a Ø 5mm point perfo rate the rivets completely If necessary use a commercially avail able Ø 5mm pin and a rubber mallet to remove any remaining shank of the riv ets making sure that both holes the exhaust end hole and the silencer body one are free C...

Page 44: ...al wool once it is fully adhered glue the edges together Refit the exhaust end body until the front bottom holes are aligned with the body itself CAUTION THE ACOUSTIC INSULATION MATERIAL MUST BE COR RECTLY POSITIONED BE CAREFUL THAT IT IS NOT FOL DED AT THE SAME POINT OR PINCHED BETWEEN THE FRONT BASE AND THE SILENCER BODY Using TT Inox rivets Ø 4 8x12 9 rivet again clockwise having previously fit...

Page 45: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 46: ...Components arrangement Key 1 Fuel supply unit 2 Right injector 3 Fuses Electrical system MXV 450 ELE SYS 46 ...

Page 47: ...ical components like Injection Ignition ECU Stick type coils Condenser Air temperature sensor Voltage regulator external Electrical wiring For this reason while fitting be careful with the possible interferences between the cable harness and the moving parts such as throttle control cable and throttle body levers Throttle control cables are prefitted on the throttle body Once the throttle body has...

Page 48: ...ipe laying the cable harness towards the rear throttle body so as to avoid excessive vertical extension that hinders placing the cover 2 On the rear throttle body along with the right coil supply cable Clamp 3 locks the connecting cable to the left in jector Electrical system MXV 450 ELE SYS 48 ...

Page 49: ...ble harness must also be secured ex ternally by locking it to the filter housing with clamp 7 on the left side The connectors of both current generator and rev olution timing sensor are protected by a rubber cover 8 and inserted under the filter housing be tween the front and rear heads MXV 450 Electrical system ELE SYS 49 ...

Page 50: ...the front exhaust manifold be especially careful when laying the clutch control cable the transmission bleed pipe 9 and cable 10 connecting the right coil and the front cylinder spark plug Electrical system MXV 450 ELE SYS 50 ...

Page 51: ...General wiring diagram Key 1 Multiple connectors 2 Diagnosis connector 3 Capacitor buffer 4 Fuse MXV 450 Electrical system ELE SYS 51 ...

Page 52: ...mperature sensor 14 Throttle sensor TPS 15 Injector 2 rear cil 16 Injector 1 front cil 17 Pick up 18 Pick up wire shielding 19 ECU 20 Engine stop 21 Map switch 22 Stepper 23 Pinion speed sensor optional 24 Capacitor filter Cable colour Ar Orange Az Sky blue B Blue Bi White G Yellow Gr Grey M Brown N Black R Red V Green Vi Purple Ro Pink Checks and inspections Electrical system MXV 450 ELE SYS 52 ...

Page 53: ...ottle It is commanded by the electronic control unit that manages idle speed and engine warming phase in this phases the control unit actuates the slider to reach the optimal engine speed The Stepper motor set to zero coincides with the slider mechanical stop on the plastic body 3 This zero position is automatically identified by the con trol unit during the first engine operating phases closing r...

Page 54: ...eps This position is kept for the next start up During this phase before the engine stops a raise in idle speed is noticeable At every intentional vehicle stop e g shutoff while riding when it is not possible to correctly position the Stepper slider caused by control unit supply interruption the following strategy takes place for the next start up With the first pedal kick the control unit employs...

Page 55: ...B of the Stepper motor connector if NOT OK restore if OK check that there is no short circuit to ground or to positive of one of the 4 cables of the idle motor white black white brown white green white blue If NOT OK restore if OK replace the WALBRO control unit Fuses CAUTION NEVER ATTEMPT TO REPAIR FAULTY FUSES NEVER USE A FUSE OF A RATING OTHER THAN SPECIFIED THIS COULD DAMAGE THE ELECTRICAL SYS...

Page 56: ...harges there is only one fuse the second is a spare one Control unit ECU New bi mapping type control unit with 48 pins specific for MXV and RXV MY2009 For throttle minimum and maximum remapping and self learning see details in the AXONE chap ter See also Adjustable parameters screen page Remove the fuel tank Remove the filter casing cover Disconnect the connector of the control unit Remove the con...

Page 57: ...upply voltage 5V approx green cable on sensor side ground connection REMARK blue green cable on sensor side shielding CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT CIRCUITED OR NO ERROR IS DIS PLAYED CHECK THE REVOLUTION SENSOR CONNECTOR AND THE WALBRO CONTROL UNIT CONNECTOR IF NOT OK RESTORE IF OK CHECK THAT THE SENSOR ELECTRICAL SPECIFICATION IS THE CORRECT ONE IF IT IS NOT REPLACE THE...

Page 58: ...hrottle closed approx 1 3 kOhm throttle open approx 4 3 kOhm at 20 C 68 F PIN 1 3 approx 4 3 kOhm at 20 C 68 F Pin out PIN 1 ground connection PIN 2 potentiometer signal from 0 8 V with closed throttle to 4 V with throttle open PIN 3 supply voltage 5V AXONE PARAMETERS Potentiometer on throttle 0 8 at minimum 4 full load V Correct throttle position 0 minimum 95 full load AXONE ELECTRICAL ERRORS thr...

Page 59: ... the cable harness if there is continuity check continuity of the sensor between PIN 1 and PIN 2 if there is no continuity replace the potentiometer if there is continuity check the resistance If resistance is over 4 3 kOhm it will indicate that the orange cable is shorted to positive and the cable harness should be restored adjustable parameters Throttle position self learning it allows the contr...

Page 60: ...ror cause If shorted to negative voltage equal to zero has been detected at PIN D4 of the control unit connector Troubleshooting If shorted to negative check sensor correct resistance if resistance 0 replace the sensor if resistance is correct it means that the brown cable has ground connection restore the cable harness engine temperature sensor 119 open circuit shorted to positive Error cause If ...

Page 61: ...4 of the control unit and PIN 1 of the sensor brown cable cable harness side should be restored If the intake air temperature sensor error is displayed at the same time this means that the blue green cable common for both sensors is shorted to positive Air temperature sensor Remove the air filter casing cover Undo and remove the screw Disconnect the air temperature sensor connector Remove the sens...

Page 62: ...cause If the circuit is open shorted to positive excessive voltage has been detected at PIN B2 of the control unit connector Troubleshooting If the circuit is open shorted to positive check the sensor connector and the Walbro control unit connector If they are not OK restore the cable harness if OK check the continuity of the sensor if it is not OK replace the sensor if it is OK check the continui...

Page 63: ...it is OK check the sensor connector and the Walbro control unit connector Injector Function To supply the correct amount of petrol at the right timing Operation operating principle Injector coil is excited for the petrol passage to open Level in wiring diagram Coils and injectors Location on the intake manifold connector on injector Electrical characteristics 12 Ohm 5 at 20 C 68 F Pin out PIN 1 Su...

Page 64: ...ble harness if OK replace the control unit Rear cylinder injector 1202 malfunction Error cause malfunction Troubleshooting Check injector resistance if NOT OK replace the injector if OK check connectors injector side control unit side and voltage regulator battery side if NOT OK restore the connectors if OK check that there is continuity of the ground cable between control unit connector and injec...

Page 65: ... the pump to keep a pressure of about 3 5 bar 350 kPa 50 76 PSI TECHNICAL SPECIFICATIONS Fuel pump resistance 1 5 Ω approx pins 1 and 2 Diagram key 1 Pressure regulator 2 Fine filter 3 Pump 4 Pre filter Coil Remove the fuel tank Remove the filter casing cover Disconnect the coil connector MXV 450 Electrical system ELE SYS 65 ...

Page 66: ...e filter cas ing right side Rear cylinder coil inside the filter cas ing left side Connector on the coils Electrical specifications Primary winding resistance 1 4 Ohm 15 at 20 5 C 68 41 F and Secondary winding resistance 3 kOhm 15 at 20 5 C 68 41 F and output Tube resistance 5 kOhm 10 NOTE Pay particular attention to check there are no loose contacts on the main fastom cir cuit Pin out orange red ...

Page 67: ...heck that there is continuity of the supply ca ble between voltage regulator battery connector and coil connector If OK check ground insulation of the positive cable or ground insulation with battery connected but engine off or that the negative cable is shorted to positive If NOT OK restore cable harness if OK replace the control unit Rear coil 1352 malfunction Error cause malfunction Troubleshoo...

Page 68: ...he control unit if the rider wishes to stop the engine Operation operating principle if the engine is to be turned off the switch must be closed that is the Walbro control unit must feel the ground connection at PIN F2 Level in wiring diagram engine stop Position on vehicle close to the left hand grip connector if available behind the front number holder table Electrical characteristics STOP posit...

Page 69: ... har ness or control unit connector if it does replace Walbro control unit The engine does not turn off with the switch set to STOP disconnect the connector and with the switch set to STOP check if there is continuity be tween the black white and black cables sensor side If there is no continuity replace the switch If there is it means that with engine started battery con nected the white cable ca...

Page 70: ... G2 H2 Ground connection J2 K2 L2 M2 A3 Front injector control output B3 C3 Throttle position sensor input D3 E3 Speed signal input F3 G3 H3 Ground connection J3 K3 L3 Ground connection M3 Injection ground connection A4 Rear injector control output B4 Revolution sensor input C4 Revolution sensor input D4 Engine temperature sensor input E4 F4 RX signal output G4 TX signal output Electrical system M...

Page 71: ...o ground for reprogramming J4 Control unit power supply ground connection K4 Control unit power supply ground connection L4 Rear coil control output M4 Front coil control output MXV 450 Electrical system ELE SYS 71 ...

Page 72: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 73: ...emove the chain Remove the exhaust system Remove the saddle Remove the fuel tank Remove the air filter Drain off the cooling system Disconnect the throttle grip cables from the throttle control Slacken the clutch cable on the han dlebar Disconnect the clutch cable from the engine block MXV 450 Engine from vehicle ENG VE 73 ...

Page 74: ...r Move the regulator connected to the cable harness at the back of the filter housing Remove the rear brake lever by undo ing the screw 1 Release the cable harness from the clamps on the chassis Working from both sides release the clamp between the aluminium tube and the rubber hose in the radiator Engine from vehicle MXV 450 ENG VE 74 ...

Page 75: ...and to keep them in their correct position Working from both sides release the inlet duct Working from the left side unscrew and remove the swingarm pin nut Partially slide off the swingarm pin and insert a plug with a diameter suitable to fit the hole on the left side Do not remove the swingarm pin completely Undo and remove the engine lower fix ing screw MXV 450 Engine from vehicle ENG VE 75 ...

Page 76: ...ngine block and place it on the corresponding engine support plate Specific tooling 9100841 Engine support Installing the engine to the vehicle Place the engine block Move the engine with small alternating movements until it is perfectly aligned with the fixing holes Fit the swingarm pin Insert the upper screw fit the washers and tighten the nut Engine from vehicle MXV 450 ENG VE 76 ...

Page 77: ...side fit the en gine lower pin Screw the nut Position the oil sump guard Fit the two bushings Insert the screw Tighten the nut from the opposite side Tighten the nut from the opposite side MXV 450 Engine from vehicle ENG VE 77 ...

Page 78: ...um tubes Place the radiators Working from both sides insert the rubber hose in the radiator into the alu minium tube in the crankcase Fasten hoses and tubes with a clamp Working from both sides tighten the radiator screw Place the two throttle grip cables Engine from vehicle MXV 450 ENG VE 78 ...

Page 79: ... cable Position the voltage regulator again and fasten it by tightening both screws Connect the front cable harness Fasten the electrical cable harness on the chassis with the clamps Fill the cooling system and adjust clearance chain clutch cable and throttle grip cables MXV 450 Engine from vehicle ENG VE 79 ...

Page 80: ...INDEX OF TOPICS ENGINE ENG ...

Page 81: ...ine support Fit the engine onto the plate using the holes of the engine support bolts Secure the engine with the appropriate 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 MXV 450 Engine ENG 81 ...

Page 82: ...Shaft selector ratchet gear 2 Selector lock 3 Spring 4 Seeger ring 5 TE flanged screw 6 Complete index lever 7 Washer 8 Spring 9 Oil seal 10 Complete desmodromic 11 Roller 12 Gear selector drum Engine MXV 450 ENG 82 ...

Page 83: ...shing 30 Ball bearing 31 Flat washer 32 Seeger ring for D25 shaft 33 4th Gear on main shaft 34 Ball bearing 35 3rd Gear on main shaft 36 2nd Gear on main shaft 37 Washer 38 Ball bearing cage 39 Secondary shaft 40 Bushing 41 2nd Gear on transmission shaft 42 Flat washer 43 Seeger ring for D25 shaft 44 3rd Gear on transmission shaft 45 Seeger ring for D25 shaft 46 4th Gear on transmission shaft 47 P...

Page 84: ... Spacer Gearbox shafts Disassembling the gearbox Remove the crankcase on the flywheel side to get access to the gear Remove the forks shafts Release the desmodromic drum from the forks rotating it outwards Remove the gear control desmodromic drum Engine MXV 450 ENG 84 ...

Page 85: ...ide Slide off the bushing 3 Slide off the gear of the 2nd gear 2 Remove the Seeger ring 6 Slide off the special washer 5 Slide off the gear of the 3rd gear 4 Remove the Seeger ring 8 Slide off the flat washer 9 Slide off the gear of the 4th gear 7 Slide off the bushing 10 To refit carry out the removal operations but in re verse order MXV 450 Engine ENG 85 ...

Page 86: ... gear of the 3rd gear 8 Remove the Seeger ring 9 Slide off the flat washer 10 Slide off the gear of the 2nd gear 11 Slide off the bushing 12 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...

Page 87: ...holes to enhance lubrication of gears III and IV Check that they are not clogged 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 SECONDARY SHAFT WITH GREASE NOTE MAKE SURE THE SLIDING BUSHING IS PRESENT ON EV ERY GEAR CONTROL FORK Grease the bushings MXV 450 Engine ENG 87 ...

Page 88: ... Introduce the forks in their respective seats Fit the gear control desmodromic drum Fit the fork shafts Refit the crankcase on the flywheel side Gear selector Engine MXV 450 ENG 88 ...

Page 89: ...remove the selector control shaft Undo and remove the two screws fixing the selector sprocket wheel Remove the selector sprocket wheel together with the plate 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 MXV 450 Engine ENG 89 ...

Page 90: ...lector spring for damage and wear If necessary replace the part Check the selector shaft and its teeth for damage and wear If necessary replace the part Check the lever spring for damage and wear If necessary replace the part Check the clearance of the washer and the riveted pin that passes through the plate If it is excessive replace the pawl Reassembling the gear selector To refit lubricate and ...

Page 91: ...stator and collect the gasket and the two centring dowels Magneto flywheel removal Remove the flywheel side crankcase half and the clutch side crankcase half Lock primary gear rotation using the specific tool Lock primary gear rotation using the specific tool Unscrew and remove the nut fixing the flywheel and collect the washer Specific tooling 020685Y Crankshaft pinion locking tool MXV 450 Engine...

Page 92: ...wels sup plied in the specific holes and fit the ring there is only one possible posi tion Fit the six fixing screws supplied and tighten them to the prescribed torque Locking torques N m Freewheel outside ring screws M6x1 13 Nm 9 58 lbf ft Loctite 270 Refit the flywheel and tighten the fixing nut to the prescribed torque Refit the ignition cover and tighten the fixing screws to the prescribed tor...

Page 93: ...oil seal is in good condition When replacing the oil seal bare in mind the cor rect fitting direction The flat section should face the fitting punch while the lip should face the fly wheel cover Clutch side Removing the clutch cover Undo and remove the screw Slide off the kick start pedal MXV 450 Engine ENG 93 ...

Page 94: ...t screw 3 Remove the clutch side crankcase and collect the engine oil filter the gasket and the two dowel pins Disassembling the clutch Remove the clutch cover Unscrew and remove the six screws by loosening them 1 4 of a turn at a time operate in stages and diagonally and retrieve the washers and the clutch springs Engine MXV 450 ENG 94 ...

Page 95: ... Remove the thrust plate Remove the control rod together with the thrust bearing the shim washer and the clutch cap Remove the discs MXV 450 Engine ENG 95 ...

Page 96: ...e tabs of the lock ing washers unscrew and remove the clutch hub nut with the clutch locking tool and collect the locking washer Specific tooling 9100896 Clutch housing locking tool Remove the clutch hub Engine MXV 450 ENG 96 ...

Page 97: ...and potential distortions NOTE THE STEEL DISCS MUST SHOW NO SCORES OR TEM PERING COLOUR CHECK CLUTCH DISCS FOR WEAR BY MEASURING THE ENTIRE CLUTCH DISC UNIT DO NOT MEASURE THE STEEL DISC UNIT AND THE FRIC TION DISC UNIT INDIVIDUALLY SINCE DOING SO IS IR RELEVANT FOR WEAR CHECKING Characteristic Full disc pack thickness minimum limit 34 mm 1 34 in Clutch plate distortion maximum limit MXV 450 Engin...

Page 98: ...place the bell Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness Check the primary driven gear for damage and wear and if necessary replace the primary driven gear and the clutch bell all together Make sure there is not excessive noise during op eration if necessary replace the primary drive gear and the clutch bell all together Chec...

Page 99: ...E FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS Check the springs for damage and if necessary replace the them all togeth er Measure the clutch spring length when unloaded if necessary replace the springs all together Characteristic Clutch spring length minimum limit 45 1 mm 1 77 in Assembling the clutch Fit the needle bearing and the spacer MXV 450 Engine ENG 99 ...

Page 100: ... Fit the clutch bell causing it to engage with the engine pinion the kick start pedal gear and the lubrication gear Fit the shim washer Position the clutch hub Engine MXV 450 ENG 100 ...

Page 101: ...ng locking tool 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 reference tabs in the same slot as for the first disc and then place a 2 mm 0 079 in steel disc until the penultimate disc that will be the remaining 1 5 mm 0 059 in metal disc Lastly place the friction...

Page 102: ...ing the clutch cover In case of replacement fit the bearing flush with the machined surface and fit the bushing with the two oil seals water and oil of the water pump using the specific punches The drainage hole is turned either 7 5 or 7 5 with respect to an imaginary line drawn between the bushing centre and the centre of the lower hole used for fixing the water pump cover See figure Engine MXV 4...

Page 103: ...ove the two screws 1 and the two head cover stud bolts 2 and collect the sealing O rings Remove the head cover together with the gasket Removing the cylinder head NOTE BEFORE REMOVING THE HEAD CHECK THAT THE CYLINDER PISTON ON WHICH YOU ARE WORKING IS AT THE TDC IN COMBUSTION PHASE MXV 450 Engine ENG 103 ...

Page 104: ...E REAR CYLINDER CLOCKWISE NOTE REMOVE THIS SCREW BEFORE REMOVING THE FOUR MAIN SCREWS Undo and remove the four head fixing screws using a roundhead universal socket wrench if required Remove the head and collect the head gasket and the centring bushings Cylinder head Removing the decompression system Remove the rockers Lock the camshaft with the 6 mm 0 24 in pin used for timing Undo and remove the...

Page 105: ...e fixing screw of the chain tensioner thrust spring Slide off the chain tensioner 1 internal guide Lock the camshaft with the 6 mm 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 CYLINDER CLOCKWISE Remove the camshaft 3 gear and re move the tim...

Page 106: ...r ring Remove the camshaft together with the ball bearing on the timing system side See also Removing the decompression system Removing the rocker arms Remove the cylinder head Remove the Seeger ring of the exhaust valves rocker pin Remove the exhaust valve rocker pin from its position Engine MXV 450 ENG 106 ...

Page 107: ...S ARE PROPERLY CLOSED AND SEALED CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove both pads 1 on both exhaust valves Remove both bucket tappets 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 S...

Page 108: ...es 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 Fasten the camshaft in horizontal po sition as shown in the figure and make it spin to check the eccentricity with a dial gauge if necessary replace the part Characteristic Camshaft eccentricity maximum limit...

Page 109: ...imit 11 96 mm 0 4708 in Calculate the rocker rocker shaft clearance NOTE CALCULATE THE CLEARANCE SUBTRACTING THE OUTSIDE DIAMETER OF THE ROCKER SHAFT FROM THE INSIDE DIAMETER OF THE ROCKER Replace the component if the calculated clearance value exceeds the limit value indicated in the table Characteristic Rocker rocker shaft clearance maximum limit 0 08 mm 0 0031 in BUCKET TAPPETS CHECK Characteri...

Page 110: ...If the clearance is not within the speci fied 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 ...

Page 111: ...asten 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 part NOTE IF THE VALVE IS REMOVED OR REPLACED ALWAYS RE PLACE THE VALVE STEM OIL SEAL AS WELL Characteristic Stem maximum eccentricity 0 01 mm 0 00039 in Cotter pins and plates deformation check Check distance between valve stem and cap The distance should ...

Page 112: ... it 1 3 mm 0 0512 in Exhaust valve seat support width maximum limit 1 5 mm 0 059 in Inspecting the springs and half cones Use a gauge to measure the unloaded valve spring length If the length meas ured is not within the specified values replace the valve spring Characteristic Unloaded valve spring length intake 37 8 mm 1 488 in exhaust 35 7 mm 1 406 in On a contrasting surface use a square to meas...

Page 113: ...2 in HEAD COVERS CHECK Check that the covers are not dam aged or worn replace the defective parts if necessary Installing the valves 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 seal with recommended oil Fit the valve the lower cap 4 and the valve stem oil guard 3 Fit the spring ...

Page 114: ...e stem slightly hit the valve head with a soft head mallet HITTING THE VALVE HEAD EXCESSIVELY MAY DAMAGE THE VALVE Specific tooling AP9100838 Tool for valve pressure plate AP8140179 Valve spring compressor Place both bucket tappets 2 and both pads under them on both intake valves Place both pads 1 on both exhaust valves Installing the rocker arms Position the exhaust rocker Engine MXV 450 ENG 114 ...

Page 115: ...G 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 to gether with the control spring Lock the camshaft with the 6 mm 0 24 in pin used for timing Tighten the fixing screw of the decom pression control NOTE LUBRICATE SHAFTS AND ROCKERS BEFORE FITTING THEM MXV 4...

Page 116: ...o sition the camshaft bearing fixing Seeger ring Adjusting valve clearance To adjust valve clearance insert the correct cali brated pad on the valve stem Characteristic Values correct with control clearance between rocker and valve intake 0 08 0 13 mm 0 0031 0 0051 in exhaust 0 18 0 23 mm 0 0071 0 0091 in Timing Engine MXV 450 ENG 116 ...

Page 117: ...hain slider Slide off the chain Remove the gear and collect the cotter See also Removing the cylinder head Removing the flywheel cover REAR Remove the rear cylinder head Remove the clutchside crankcase Lock the primary gear using the spe cific tool Unscrew and remove the timing sys tem gear nut Remove the timing system gear MXV 450 Engine ENG 117 ...

Page 118: ...ng careful not to damage the O ring See also Removing the cylinder head Removing the clutch cover Slide off the chain from the gear Remove the gear and collect the cotter Working from the opposite side re move the timing system shaft Engine MXV 450 ENG 118 ...

Page 119: ...gears Check the timing chain guide sliders for damage If necessary replace the parts Checking the camshaft The camshafts are different one from the other in the rear cylinder the cams are aligned and in the front cylinder the outlet cam is opposed The camshafts gears and the timing system gears are specific for this vehicle they have both 21 teeth and currently they do not have any identification ...

Page 120: ...AIN WITH THE COLOURED SIDE FACING OUT WARD Fit the movable chain guide slider Tighten the slider screw REAR Fit the timing system shaft CAUTION FIT THE TIMING SYSTEM SHAFT WITH BOTH MILLED SIDES FACING DOWNWARDS Place the cotter Fit the gear Fit the chain CAUTION FIT THE CHAIN WITH THE COLOURED SIDE FACING OUT WARD Engine MXV 450 ENG 120 ...

Page 121: ... control wheel Bend the washer tab 1 Cam timing Timing BIG BANG TIMING IF THE ENGINE IS TO BE TIMED WITH THE Big Bang METHOD IT IS COMPULSORY TO CHECK WITH AXONE IF THE CONTROL UNIT IS MAPPED WITH THE SAME METHOD SO AS TO AVOID ANY MALFUNCTION Preassemble chains chain guide slid ers and chain tensioner and release the free camshaft gears fitted on not keyed taper seats Remove the timing hole screw...

Page 122: ...UCKET TAPPETS Tighten the fixing screw of the rear cyl inder timing shaft gear Release the rear camshaft and the crankshaft from the locking pins Operating on the primary gear nut turn the crankshaft by 77 clockwise so as to bring the front cylinder piston to the TDC in combustion phase Insert the pin in the crankshaft lock timing pin in order to block crankshaft rotation NOTE THE SPECIAL TOOL IS ...

Page 123: ...ears fitted on not keyed taper seats Remove the timing hole screw from its seat Place the crankshaft lock timing pin in its position Specific tooling 9100844 Crankshaft locking tool timing pin Working on the main transmission nut make the crankshaft turn until the front cylinder reaches the TDC in combus tion phase Insert the pin in the crankshaft lock timing pin in order to block crankshaft rotat...

Page 124: ...k crankshaft rotation NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSI TION DO NOT USE IT FOR TIGHTENING OPERATIONS Make the timing shaft turn so that the timing shaft hole matches the head holes Position the pin so as to lock the rear cylinder timing cam Tighten the fixing screw of the rear cyl inder timing shaft gear NOTE CHECK THAT THE CAMSHAFT IS FREE NOT RESTING ...

Page 125: ...O THAT THE RING DOES NOT FALL INTO THE CRANKCASE Specific tooling 9100897 Cylinder liner extractor Take out the pin locking ring See also Removing the cylinder head Disassembling 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 tooling 9100943 Piston pin extractor Checking the cylinder If cylinder liners are repl...

Page 126: ...Top ring end clearance 0 45 mm 0 0177 in Fitting the piston NOTE WHEN FITTING THE PISTON RINGS MAKE SURE THAT THEY ARE REFITTED WITH THE REFERENCE FACING UP WARDS Fit the piston ring 1 with its opening facing the exhaust and the oil scraper ring 2 with its opening facing the in take CAUTION MAKE SURE THAT THE PUNCHING ON THE PISTON FACES THE CYLINDER EXHAUST SIDE LUBRICATE THE PIN WITH ENGINE OIL ...

Page 127: ...E 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 PAYING ATTEN TION TO THE TIGHTENING SEQUENCE AND THE COR RECT TORQUE IN TWO STAGES Place the timing system gear 3 to gether with the timing chain 4 on the camshaft 2 Screw...

Page 128: ... 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 two screws 1 and the two fixing stud bolts 2 together with the O rings or new gaskets See also Timing Installing the head cover In case of replacing the blow by pipe of the head cover restore the inclination angle Use Lo...

Page 129: ...e both heads Remove the timing system shaft Unscrew and remove the main trans mission gear fixing nut Remove the main transmission gear NOTE NUT WITH LEFT THREAD See also Disassembling the clutch Magneto flywheel removal Removing the cylinder head Chain removal Remove the clutch shaft MXV 450 Engine ENG 129 ...

Page 130: ...n See also Removing the gear selector Remove the oil seal from the crank shaft Align the cotter with the hole and re move the shim washer Turn the engine support and place it horizontally with respect to the ground Undo and remove the two nuts Engine MXV 450 ENG 130 ...

Page 131: ... Undo and remove the eight M6 screws Undo and remove the two long screws Undo and remove the seven M7 screws Working from the clutch side undo and remove the screw MXV 450 Engine ENG 131 ...

Page 132: ...OVAL FITTING OPER ATION 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 COR RESPONDING SUPPORT PLATE REMOVING THE GEAR MAIN SHAFT BEARING Remove the bearing grub screw and the corresponding plate Warm up the crankcase halves Remove the bearing with an extractor from the inside Engi...

Page 133: ...OVING THE GEAR SECONDARY SHAFT BEARING Remove the two bearing grub screws plus their plates Remove the oil seal working 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 MXV 450 Engine ENG 133 ...

Page 134: ...FT BEARING REMOVAL Remove the bearing grub screw and the corresponding plate Warm up the crankcase halves Remove the bearing with an extractor from the inside Removing the crankshaft Remove the crankcase on the flywheel side Take out the crankshaft See also Splitting the crankcase halves Engine MXV 450 ENG 134 ...

Page 135: ...58 60 mm 2 28 2 36 in guide Inspecting the crankcase halves Using a non aggressive solvent thoroughly clean both sections of the engine crankcase the ball bear ings 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 DAMAGING THEM Specific tooling 9100942 Crankcase halves support Check that both...

Page 136: ...refit the bearings using the specific punches Specific tooling 9100893 Left timing gear punch 9100889 Timing gear crankshaft punch Refit the grub screw and the corre sponding plate GEAR BEARING REFITTING Refit the bearings using the specific punches Specific tooling 9100886 Secondary shaft right side Main shaft left side Engine MXV 450 ENG 136 ...

Page 137: ...TABLE SUPPORT IS FIRMLY STOPPED AND WARM UP THE BEARING COU PLING AREAS PROPERLY Specific tooling 9100885 Main shaft right side secondary shaft left side Position the plates and tighten the screws Fit a new oil seal using the specific punch at controlled driving Specific tooling 9100894 Secondary shaft oil seal punch MXV 450 Engine ENG 137 ...

Page 138: ...kcase desmodromic wheel hub GEAR PRIMARY SHAFT BEARING REFITTING Refit the bearing using the specific punch Refit the grub screw with the corre sponding plate Specific tooling 9100886 Secondary shaft right side Main shaft left side Checking the connecting rod Characteristic Rod small end inside diameter maximum allowed Engine MXV 450 ENG 138 ...

Page 139: ...ht crankcase half in the hole of the trans mission secondary crankcase Fit the transmission main and secon dary shafts in the right crankcase half together with the desmodromic drum and the levers Place the cylinders liners as externally as possible Place the cylinder liners with the refer ence mark near the crankcase halves coupling edge Apply Three Bond sealant code 855252 all along the crankcas...

Page 140: ... Join the crankcase halves Screw without tightening the M7 screw on the clutch side Screw without tightening the seven M7 screws Screw without tightening the eight short M6 screws Engine MXV 450 ENG 140 ...

Page 141: ...ightening the two long screws Tighten the seventeen screws operat ing diagonally and in stages Screw the gearbox oil cap Place the cotter and the shim washer on the crankshaft Fit a new oil seal MXV 450 Engine ENG 141 ...

Page 142: ...primary gear Screw the nut Time THE GEAR HAS THE SAME SHAPE AS THAT FOR THE STREET MODEL BUT IT IS NOT INTERCHANGEABLE IN ORDER TO IDENTIFY THE GEAR THAT BELONGS TO THIS VEHICLE CHECK THAT THERE IS THE CORRE SPONDING CUT ALONG THE TOOTH WHEEL CAUTION THE THREAD IS ANTICLOCKWISE Lubrication Engine MXV 450 ENG 142 ...

Page 143: ...Conceptual diagrams Key 1 Clutch side 2 Flywheel side 3 Calibrated nozzle 4 Cartridge filter MXV 450 Engine ENG 143 ...

Page 144: ...ket 15 To the pressure pump 16 From the oil scavenge pump An aluminium plate with two metal core gaskets separates the oil in the reservoir from the crankcase oil An ascent space found inside the cover allows the scavenged oil to flow into the reservoir along a communication channel Oil pump Key 1 Oil pump shaft 2 Pin 3 Inner and outer rotors 4 Oil pump body 5 TE flanged screw Engine MXV 450 ENG 1...

Page 145: ...gear Z 19 20 Thrust washer 21 Seeger ring 22 Oil seal Removing EXTERNAL PUMP REMOVAL Before removing the components place a container of suitable capacity 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...

Page 146: ...Seeg er 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 Undo and remove the four fixing screws 2 Remove the complete oil pump Engine MXV 450 ENG 146 ...

Page 147: ... 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 Remove the pump rotor and slide off the stator Collect the transmission roller Remove the oil pump shaft See also Disassembling the clutch Splitting the crankcase halves MXV 450 Engine ENG 147 ...

Page 148: ...e strum box and the cover Tighten the three fixing screws EXTERNAL PUMP FITTING Refit the internal pump Position the oil pump internal transmis sion roller NOTE THE INTERNAL AND EXTERNAL PUMP ROTORS FEA TURE A VERY LONG ROLLER THE GEAR FEATURES A SHORT ONE Position the oil pump together with the O ring gasket Engine MXV 450 ENG 148 ...

Page 149: ...ing screws 2 and position the shim washer 1 Position the oil pump gear transmis sion roller Place the shim washer before position ing the oil pump gear Position a new oil pump gear fixing Seeger ring MXV 450 Engine ENG 149 ...

Page 150: ...ng Close the crankcase Fit the clutch THE COUPLE OF GEARS HAS THE SAME SHAPE AS THAT FOR THE STREET MODEL BUT IT IS NOT INTERCHANGE ABLE IN ORDER TO IDENTIFY THE CORRECT COUPLE OF GEARS THAT BELONG TO THIS VEHICLE CHECK THAT THERE IS THE CORRESPONDING CUT ALONG THE TOOTH WHEEL Kickstart Start up pedal removal Remove the clutch Loosen the spring grub screw Engine MXV 450 ENG 150 ...

Page 151: ...de of the gear slide off the spring 1 and the start up sprocket 2 Carry out the checks described on all the components mentioned and also on the shaft 3 Start up pedal overhaul Check gear for cracks and wear and replace it if necessary Check gears movement and if it is not regular re place the faulty part Check the spring and replace it if it is deformed by over stretching MXV 450 Engine ENG 151 ...

Page 152: ... Seeger ring 8 Working from the left side of the gear fit the start up sprocket 2 and the spring 1 Align the gear reference with that of the grooved shaft Introduce the spring into the grooved shaft hole Introduce the locking bushing Fit the kick start pedal system on the engine Lock the spring with the screw Engine MXV 450 ENG 152 ...

Page 153: ...MXV 450 Engine ENG 153 ...

Page 154: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 155: ...ubber ring 5 T shaped bushing 6 Screw 7 Gasket 8 Complete fuel pump unit 9 Pipe 10 Tank breather valve 11 Fuel pump fixing ring nut 12 Rubber washer 13 Plain iron washer 14 TE flanged screw 15 TE flanged screw 16 Bushing MXV 450 Power supply P SUPP 155 ...

Page 156: ... tank Unscrew the ring nut Take out the fuel pump Injection Removing the throttle body Remove the air filter casing cover Disconnect the throttle grip cables from the throttle grip Loosen both clamps on the inlet mani folds Power supply MXV 450 P SUPP 156 ...

Page 157: ...replacement Disconnect the throttle valve position sensor connector Release the cable harness from the clamp Disconnect the front cylinder injector connector CAUTION UPON REMOVING THE CONNECTOR MARK IT IN ORDER NOT TO INVERT WHEN REFITTING Lift the throttle body and disconnect the connector of the Stepper motor Disconnect the throttle grip cables from the throttle body MXV 450 Power supply P SUPP ...

Page 158: ...ed by using the hole 2 and reprogramming the control unit with a spe cific mapping The only possible adjustment is checking imbal ance level The rear throttle valve begins opening once the front throttle has completed 10 of the angular stroke TPS value If this is not so the value must be brought to the 10 by operating on the screw 3 Removing the Stepper motor from the throttle body Undo and remove...

Page 159: ...cs Cylinders synchronisation Cylinders cannot be synchronised Ecu mapping The mapping type of the control unit of this vehicle can be selected at any time via the key on the handlebar You can choose between two different output curves one more aggressive and one more pro gressive one Using axone for injection system This control unit requires using the Walbro cable for Axone Navigator It consists ...

Page 160: ...In order to diagnose injection use cable 1 together with joint 2 3 Axone Navigator 4 Motorcycle For reprogramming use only cable 1 Power supply MXV 450 P SUPP 160 ...

Page 161: ...use does not feature an RS 232 serial port connection is possible by purchasing the specific adaptor 10 Cable 11 Multiple connector 12 Battery Use cable 10 to start the engine under critical conditions or to self diagnosis the injection ECU via AXONE with the vehicle off Replace the key The diode protects the control unit if cable 10 is wrongly connected to the battery terminals 12 in verted poles...

Page 162: ...etc ENGINE PARAMETER READING SCREEN PAGE Specification Desc Quantity 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 The value at idle must be 0 If the circuit is interrupted or short circuited with voltage over 5 V it takes the fixed value of 127 regardless the po...

Page 163: ...Adjustable parameters screen page advance correction 5 0 5 0 To change it go to the Adjustable Parameters screen page Stepper motor 100 Device status screen page DEVICE STATUS This screen page shows the status usually ON OFF of the vehicle devices or the operation con dition of some vehicle systems for example lamb da probe functioning status DEVICES STATUS SCREEN PAGE Specification Desc Quantity ...

Page 164: ...the control unit The error status is always displayed as MEM stored In order to identify whether an error is current or stored it is ad visable to write down the error on paper so as not to forget it carry out the Error clearing operation and restart the vehicle if the error occurs again this means it is current Otherwise it is a stored error carry out the specific checks anyway Engine temperature...

Page 165: ...as MEM stored In order to identify whether an error is current or stored it is ad visable to write down the error on paper so as not to forget it carry out the Error clearing operation and restart the vehicle if the error occurs again this means it is current Otherwise it is a stored error carry out the specific checks anyway Front coil Irregular voltage has been detected at PIN M4 of the control ...

Page 166: ...esponding to 5 Wheel diameter Wheel signals To obtain a correct indication of the vehicle speed the listed parameters can be set REMARK In case the ECU has been taken from the spare parts warehouse the following opera tions checks will be necessary Throttle self learning operation min max position Entering the vehicle mapping includ ing correct wheel diameter setting and qty of screws per diameter...

Page 167: ...Injection time correction Allows modification of injection times at any rpm maximum adjustment 5 1 99 0 00 with respect to the mapping in jection times Advance correction Allows to correct advance between 5 and 5 MXV 450 Power supply P SUPP 167 ...

Page 168: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 169: ...ht fork unit 3 Left wheel holder stem 4 Right wheel holder stem 5 Upper bushing 6 Cap 7 Sealing ring 8 Snap ring 9 Dust scraper 10 Complete sleeve 11 Screw O ring 12 Ring for spring 13 Spring Kit 14 Complete pumping element MXV 450 Suspensions SUSP 169 ...

Page 170: ...ont fork is adjusted so as to satisfy all main high and low speed riding conditions both with reduced and full vehicle load It is at any rate possible to insert personal settings depending on vehicle usage Front suspension standard adjustment Rebound damping adjustment screw 1 open 18 clicks from fully closed Compression damping adjustment screw 2 open 18 clicks from fully closed Stems protrusion ...

Page 171: ...ONAL front stand in the hole of the fork lower plate Undo and remove both calliper fixing screws Slide off the calliper CAUTION THE SPEED SENSOR CABLE RUNS OUTSIDE THE CAL LIPER AND IS FITTED WITH PROTECTION Working on the left side unscrew and remove the front wheel axle fixing nut Working on both sides loosen the screws on the wheel axle clamps MXV 450 Suspensions SUSP 171 ...

Page 172: ... side slide off the wheel axle 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 Suspensions MXV 450 SUSP 172 ...

Page 173: ...emove the two screws fas tening the front brake pipe to the stem protection Undo and remove the three stem pro tection fixing screws Remove the stem protection Support the stanchion and loosen the screws on the upper and then the lower plate MXV 450 Suspensions SUSP 173 ...

Page 174: ...n 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 the specific Allen key Remove the cap Suspensions MXV 450 SUSP 174 ...

Page 175: ...urns 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 HOLD ER SLEEVE TO PUMP OIL OUT Slide off the preloading pipe MXV 450 Suspensions SUSP 175 ...

Page 176: ... 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 RE MOVING THEM Slide off the pumping member unit Suspensions MXV 450 SUSP 176 ...

Page 177: ... RIM AND THE DUST SCRAPER 1 Slide off the retainer 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 On the fork stem there are bushing 3 guide ring 4 shim washer 5 oil seal 6 retainer ring 2 dust scraper 1 MXV 450 Suspensions SUSP 177 ...

Page 178: ... 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 the oil seal 6 Suspensions MXV 450 SUSP 178 ...

Page 179: ...n the screw repeat the operation for both stems Reassembling the fork CAUTION BEFORE PERFORMING THE FOLLOWING OPERATIONS GET THE PROPER OPTIONAL SPE CIAL TOOL A AND SPREAD A THIN LAYER OF FORK OIL OVER GASKETS AND BUSHINGS BEFORE REFITTING THEM Specific tooling AP8140758 tool to fit oil seals and dust gaiter for ø 50 mm 1 97 in stems Fit the components on the stem in the following order dust scrap...

Page 180: ...Place shoes made of soft material alu minium before positioning the stem in a vice Place the bushing 3 in its seat on the stem Insert 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 retainer ring 2 Suspensions MXV 450 SUSP 180 ...

Page 181: ... Fit the dust scraper 1 Insert the complete pumping member in the stem until it stops Insert and tighten the stop plug Fit the pumping member rod Fill with oil MXV 450 Suspensions SUSP 181 ...

Page 182: ... all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil level and the rim CAUTION THE SLEEVE 7 MUST BE PERFECTLY INSERTED IN THE STEM FOR A CORRECT OIL LEVEL READING THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Characteristic Fork oil level 100 2 mm 3 94 0 079 in from the stem rim Insert the spring 9 together with the plastic bushing 8 in the sleeve 7 Sus...

Page 183: ...k nut screw the top stem 10 on the pumping member rod manually Screw and tighten the cap 10 on the sleeve 7 Installing the fork legs Fit the fork stem in its seat Support the fork stem and tighten the two screws on the upper and lower plate MXV 450 Suspensions SUSP 183 ...

Page 184: ... Fit the stem protection position and tighten the three fixing screws Tighten the two screws fastening the front brake pipe to the left stem protec tion Place the bushing Suspensions MXV 450 SUSP 184 ...

Page 185: ... side partially screw the front wheel axle fixing nut CAUTION TIGHTEN THE TWO SCREWS ON THE RIGHT SIDE FORK CLAMP TO AVOID WHEEL AXLE ROTATION Working on the left side screw the front wheel axle fixing nut Tighten both screws on the wheel axle left fork clamp MXV 450 Suspensions SUSP 185 ...

Page 186: ...on the side stand Fasten the sensor cable with a clamp Position the mudguard and tighten the four fixing screws Tighten the two screws fixing the front mudguard tie rod Rear Removing the rear wheel Rest the vehicle on the specific OP TIONAL stands Unscrew and remove the nut and re trieve the washer Suspensions MXV 450 SUSP 186 ...

Page 187: ...ubber hammer to slide off the wheel axle from the vehicle left side collect the centring shim washers and slide off the wheel backwards Slide off the bushing Installing the rear wheel Place the bushing MXV 450 Suspensions SUSP 187 ...

Page 188: ...t M25 120 Nm 88 51 lbf ft See also Adjusting Shock absorbers Adjusting The rear suspension consists of a spring shock absorber unit linked to the frame via uniball joints and to the rear swingarm via a linkage system To adjust the setting the shock absorber is fitted with a set screw that adjusts hydraulic rebound damping 1 with a set screw 2 that adjusts hydraulic compres sion damping low speed w...

Page 189: ...ut 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 Operate on screw 2 to adjust hydraul ic compression damping at low speeds see chart Operate on knob 6 to adjust hydraulic compression damping at high speeds see chart CAUTION SET SPRING PRELOAD AND REBOUND DAMPING BASED ON THE VEHICL...

Page 190: ...ebound adjustment screw 1 16 clicks from fully closed Compression damping adjustment low speeds screw 2 12 clicks from fully closed Compression damping adjustment high speeds knob 6 10 clicks from fully closed Removing Remove the fuel tank Undo and remove the suspension re tainer upper screw Undo and remove the suspension re tainer lower screw Suspensions MXV 450 SUSP 190 ...

Page 191: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 192: ...art to the workbench Remove the rear wheel Unscrew and remove the nut of the pin fixing the swingarm linkage system and collect the washer Slide off the pin fixing the swingarm linkage system Slide the brake pipe off the two hose guides Remove the rear brake calliper from the swingarm Chassis MXV 450 CHAS 192 ...

Page 193: ...hain without O rings and with master link EXCESSIVE CHAIN SLACKENING MAY CAUSE IT TO COME OFF THE PINION OR THE CROWN WHICH IN TURN COULD CAUSE AN ACCIDENT OR SERIOUSLY DAMAGE THE VEHICLE CHECK THE CHAIN SLACK ON A REGULAR BASIS AND ADJUST IT AS NECESSARY TO CHANGE THE CHAIN TAKE YOUR VEHICLE TO AN Official aprilia Dealer WHO WILL PROVIDE ACCURATE PROMPT SERVICE CAUTION MXV 450 Chassis CHAS 193 ...

Page 194: ...er link can be identified Slide off the clip Remove the plate underneath Remove the master link from the op posite side Remove the chain CAUTION REPLACE THE ENTIRE UNIT IF THE CHAIN IS PARTICU LARLY WORN inspection To check backslash Stop the engine Place the vehicle upright on a specific stand Engage neutral gear Check that vertical oscillation at the middle point between pinion and crown on the ...

Page 195: ... ARE FLATTENED OR JAMMED TO AVOID RISK OF SEIZURE LUBRICATE THE CHAIN ON A REGULAR BASIS Check the chain protection slider for wear 1 Check the swingarm 2 protection slid er for wear as well as the lower slider 3 and the chain roller 4 CAUTION LUBRICATE THE CHAIN ON A REGULAR BASIS PARTIC ULARLY IF YOU FIND DRY OR RUSTY PARTS FLAT TENED OR JAMMED CHAIN LINKS SHOULD BE LUBRI CATED AND GOOD OPERATIN...

Page 196: ...pinion and the sprocket on the lower branch of the chain Join the two ends of the chain and fit the master link pins from the inside to the outside Fit the plate in the master link pins CAUTION THE PLATE MUST BE FITTED WITH THE OPEN PART FAC ING THE SENSE OPPOSITE THE ADVANCE DIRECTION Fit the clip in the master link pins Chassis MXV 450 CHAS 196 ...

Page 197: ...ust the chain backlash checking that the references 2 3 match on both sides of the vehicle Tighten both lock nuts 4 Tighten the nut 1 Check chain clearance NOTE WHEEL CENTRING IS CARRIED OUT USING THE IDENTI FIABLE FIXED REFERENCES 2 3 INSIDE THE CHAIN TENSIONER PAD MOUNTS ON THE SWINGARM ARMS IN FRONT OF THE WHEEL AXLE Locking torques N m Wheel nut 1 120 Nm 88 5 lbf ft MXV 450 Chassis CHAS 197 ...

Page 198: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 199: ...LID FOR BOTH Brake fluid decreases gradually in the reservoirs 1 2 as brake pads wear down to compensate for the wear automatically The front brake fluid reservoir 1 is placed near the front brake lever con nection The rear brake fluid reservoir 2 is in tegrated in the brake pump fastened to the frame on the right side near the swingarm NOTE CHECK THE BRAKE FLUID LEVEL IN THE RESERVOIRS 1 2 AND CH...

Page 200: ...ing power of the calliper 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 BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE H...

Page 201: ...STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC 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 c...

Page 202: ...M FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit the rubber protection cover Braking system MXV 450 BRAK SYS 202 ...

Page 203: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 204: ...tor cap 2 Air bleed 3 Holes for chassis retainer 4 Right radiator 5 Left radiator 6 Delivery pipe to the pump 7 Breather pipe 8 Return pipe from the front head 9 Return pipe from the rear head Cooling system MXV 450 COOL SYS 204 ...

Page 205: ...and fasten it with a new clamp Top up with coolant See also Top up Water pump CAUTION 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 Undo and remove the four pump cover fixing screws Remove the water pump cover and col lect the seal gasket MXV 450 ...

Page 206: ... the two centring bushings Remove the water pump cover spacer Check that the two O rings present on the bushing are not damaged NOTE WHEN REFITTING FOLLOW THE STEPS DESCRIBED BE FORE BUT IN REVERSE ORDER USE ONLY CIRCULAR GASKETS AND NEW CLAMPS Removing the radiator Drain off the coolant Cooling system MXV 450 COOL SYS 206 ...

Page 207: ...emove the right and left delivery pipes Slide off the radiator breather pipe Working from both sides undo and re move the two screws Remove the radiators by sliding them off from the clamps on the head cover CAUTION THE RADIATORS ARE INTERCONNECTED THROUGH THE LOWER PIPE MXV 450 Cooling system COOL SYS 207 ...

Page 208: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 209: ...ong Sharpen only the teeth ends If the grooves are exceedingly filed the footrests are weakened Make sure that the footrests can rotate freely and that the pins stop split pins are in good conditions Air box Remove the fuel tank Remove the voltage regulator Remove the fuse box Undo and remove the six screws Remove the air filter casing cover MXV 450 Bodywork BODYW 209 ...

Page 210: ... the fuel pipe Disconnect the fuel pump connector Undo and remove the front fixing screw and collect the washer Undo and remove the screw fixing the reservoir and collect the centring bush ing Remove the fuel tank Bodywork MXV 450 BODYW 210 ...

Page 211: ...filter cover 2 by undoing the two fixing screws 1 Working on both sides undo and re move the three side air deflector fixing screws Remove the side air deflectors To refit the air deflectors follow the steps described before but in reverse order MXV 450 Bodywork BODYW 211 ...

Page 212: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 213: ...front and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Levels check Hydraulic braking system fluid level Clutch system fluid level if present Gearbox oil level if present Transmission oil level if present Engine coolant level if present Engine oil level Mixer oil level if present Road test Test ride Cold start Response to throttle control Stability when ac...

Page 214: ...resent Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check Tyre pressure check NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJUST ...

Page 215: ...90 128 129 134 135 139 147 Crankshaft 16 128 134 Cylinder 103 104 113 117 118 125 127 129 D Desmodromic drum 86 Display 164 Drive chain 193 E ECU 69 159 Electrical system 11 46 47 Engine oil 29 Engine temperature sensor 59 Exhaust 40 F Fork 169 171 176 179 183 Forks 86 Front wheel Fuel 65 156 210 Fuel pump 65 156 Fuses 55 G Gearbox oil 32 H Handlebar Head cover 103 128 M Magneto flywheel 91 129 ...

Page 216: ...85 R Radiator 206 Rear wheel 186 187 Recommended products 17 Run Stop switch 68 S Secondary shaft 86 Shock absorbers 188 Spark plug 27 Start up 150 152 Stepper motor 158 T Tank 210 Throttle body 156 158 Tyres 12 V Voltage regulator 53 W Water pump 205 Wiring diagram 51 ...

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