APRILIA RXV 450 UPGRADE BOOK Use And Maintenance Book Download Page 4 | Manualshive

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INTRODUCTION

0 - 3

SXV / RXV 450 – 550

0.1. INTRODUCTION

0.1.1. FOREWORD

NOTE

This manual must be considered as an integral part of the vehicle and must always accompany it, even in case

of resale.

aprilia has drafted this manual with the maximum attention in order to provide the user with user with correct and
updated information.
However, since

aprilia

constantly improves the design of its products, there may be slight discrepancies between the

characteristics of your vehicle and those described in this manual. Such modifications will be entered in subsequent
editions of the manual. Should you need assistance or clarification regarding inspection and repair procedures, please
contact the aprilia SERVICE DEPT. They will be pleased to give you all pertinent information or supply you with
details on updates and technical changes applied to the vehicle.
For inspections and repair operations not expressly described in this publication, for the purchase of aprilia genuine
spare parts, accessories and other products, as well as for specific advice, contact exclusively aprilia Authorized
Dealers and Service Centers, which guarantee prompt and accurate assistance.
Thank you for choosing aprilia. Have a great ride!
All rights regarding electronic storage, reproduction and total or partial adaptation by any means are reserved for all
countries.

NOTE

In some countries the antipollution and noise regulations in force require periodical inspections.

The products of third parties are mentioned only for informational purposes and constitute no obligation.
aprilia s.p.a. is not liable whatsoever for the performance or use of these products.

First edition: May 2006

Produced and printed by:

VALLEY FORGE DECA

Ravenna, Modena, Torino

DECA s.r.l.

Registered Main Office
Via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy -
Tel. 0545-216611
Fax 0545-216610

www.vftis.com

[email protected]

for:

aprilia

via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 – (0)41 58 29 111
Fax +39 – (0)41 58 01 674

www.aprilia.com

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Summary of Contents for RXV 450 UPGRADE BOOK

Page 1: ......

Page 2: ...INTRODUCTION 0 1 SXV RXV 450 550 INTRODUCTION 0 ...

Page 3: ...INTRODUCTION 0 2 SXV RXV 450 550 TABLE OF CONTENTS 0 1 INTRODUCTION 3 0 1 1 FOREWORD 3 0 1 2 ABBREVIATIONS SYMBOLS CONVENTIONS 4 ...

Page 4: ...ons not expressly described in this publication for the purchase of aprilia genuine spare parts accessories and other products as well as for specific advice contact exclusively aprilia Authorized Dealers and Service Centers which guarantee prompt and accurate assistance Thank you for choosing aprilia Have a great ride All rights regarding electronic storage reproduction and total or partial adapt...

Page 5: ...ad Camshaft ECU Electronic Control Unit rpm revolutions per minute HC unburned hydrocarbons ISC Idle Speed Control ISO International Standardization Organisation kg kilograms kgm kilograms per meter 1 kgm 10 Nm km kilometers km h kilometers per hour kΩ kilo Ohm kPa kiloPascal 1 kPa 0 01 bar KS clutch side from the German Kupplungsseite kW kilowatt ℓ liters LAP racetrack lap LED Light Emitting Diod...

Page 6: ...E right side SAE Society of Automotive Engineers TEST diagnostic check T B E I crownhead Allen screw T C E I cheesehead Allen screw T E hexagonal head T P flathead screw TSI Twin Spark Ignition UPSIDE DOWN inverted fork V volt W watt Ø diameter ...

Page 7: ...GENERAL INFORMATION 1 1 SXV RXV 450 550 GENERAL INFORMATION 1 ...

Page 8: ...UAL 3 1 1 1 CONVENTIONS USED IN THE MANUAL 3 1 1 2 DANGEROUS ELEMENTS 4 1 1 3 SAFETY WARNINGS 8 1 1 4 BASIC SAFETY RULES 9 1 1 5 WARNINGS PRECAUTIONS GENERAL RECOMMENDATIONS 12 1 1 6 POSITION OF THE ADHESIVE WARNING LABELS 14 1 1 7 EMISSION NOISE CONTROL SYSTEM WARRANTY STATEMENT 18 ...

Page 9: ...as prepared this manual to supply you the user with correct and current information However since aprilia constantly improves the design of its vehicles there may be slight discrepancies between your vehicle and the material given in this manual If you have any questions about your vehicle contact your Local aprilia Dealer as he will have the very latest technical information available from the fa...

Page 10: ...of lubricant may lead to engine or gearbox seizure causing serious accidents personal injury or even death Gear fluid may cause serious damage to the skin if handled daily and for long periods Wash your hands carefully after use Do not release oil into the environment Take it to the filling station where you usually buy it or to an oil salvage center WARNING When filling the vehicle with this oil ...

Page 11: ...E BRAKE FLUID INTO THE ENVIRONMENT KEEP AWAY FROM CHILDREN When handling brake fluid take care not to spill it onto plastic or paint finished parts or they will become damaged DANGER Do not use any brake fluids other than the specified type Never mix different types of fluids to top up level as this will damage the braking system Do not use brake fluid from containers which have been kept open or ...

Page 12: ...n if needed Use distilled water in the coolant mixture Tap water will damage the engine Refer to the chart given below and add water with the quantity of antifreeze to obtain a solution with the desired freezing point Freezing point F C Coolant of volume 4 F 20 C 35 22 F 30 C 45 40 F 40 C 55 NOTE Coolants have different specifications The protection degree is written on the label WARNING Use only ...

Page 13: ... rubber treating substances on tires In particular avoid contact with fluid fuels which can lead to rapid wear In case of contact with oil or fuel do not clean Change the tires instead DANGER Some of the original equipment tires of this vehicle are provided with wear indicators There are several kinds of wear indicators For more information on how to check the wear contact your Dealer Visually che...

Page 14: ...k of personal injury or death Failure to comply with the instructions given in the warning messages preceded by this symbol may result in grave risk for your and other people s safety and for the vehicle DANGER Indicates a potential hazard which may result in serious injury or even death WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle or othe...

Page 15: ...rtain conditions KEEP GASOLINE AWAY FROM CHILDREN HOT COMPONENTS WARNING The engine and all parts of the exhaust system as well as the braking system become very hot and remain hot for some time after the vehicle and the engine are stopped Before handling any component of your vehicle after riding make sure that it has cooled sufficiently to be safe to handle USED ENGINE OIL WARNING Use latex glov...

Page 16: ... swallowed drink large quantities of water or milk and then milk of magnesia or vegetable oil Immediately consult a health professional KEEP BATTERIES AND ELECTROLYTE AWAY FROM CHILDREN KEEP BATTERIES AND ELECTROLYTE AWAY FROM CHILDREN GENERAL PRECAUTIONS AND INFORMATION Follow these instructions closely when repairing disassembling or reassembling the motorcycle or its components DANGER Using nak...

Page 17: ...d Lubricate the bearings abundantly before assembly Make it a rule to check that all components you have fitted are correctly in place After repairing the motorcycle and after each service inspection perform the preliminary checks and then operate the motorcycle in a private estate area or in a safe area away from traffic Clean all mating surfaces oil seal edges and gaskets before assembly Apply a...

Page 18: ...roads or trails It is not designed for off road competition or for cross country riding Do not use this vehicle on rough or unimproved surfaces or in other off road areas Failure to heed this warning could lead to an upset with subsequent injury and even death NOISE EMISSION WARRANTY Aprilia Division of Piaggio C S p A warrants that this exhaust system at the time of sale meets all applicable U S ...

Page 19: ...mericas Inc 140 East 45th Street 17th Floor New York NY 10017 U S A CAUTION This product should be checked for repair or replacement if the vehicle noise has increased significantly through use Otherwise the owner may become subject to penalties under state and local ordinances PROBLEMS THAT MAY AFFECT THE VEHICLE EMISSIONS If any of the following symptoms are observed immediately have your vehicl...

Page 20: ...GENERAL INFORMATION 1 14 SXV RXV 450 550 1 1 6 POSITION OF THE ADHESIVE WARNING LABELS 1 V I N 2 Polluting 450 3 Polluting 550 ...

Page 21: ...GENERAL INFORMATION 1 15 SXV RXV 450 550 4 Noise SXV450 5 Noise SXV550 6 Gomme RXV 7 Gomme SXV ...

Page 22: ...GENERAL INFORMATION 1 16 SXV RXV 450 550 8 Sonore RXV450 9 Sonore RXV550 10 Hang tag 450 11 Hang tag 550 ...

Page 23: ...GENERAL INFORMATION 1 17 SXV RXV 450 550 12 Polluting 450 Off road 13 Polluting 550 Off road ...

Page 24: ... Off Road Motorcycles 70 cc for a period of use of 30 months 2 5 years or 3 100 mi 5 000 km whichever comes first If an emission related part on your off road motorcycle is defective the part will be repaired or replaced by Aprilia This is your emission control system DEFECTS WARRANTY OWNER S WARRANTY RESPONSIBILITIES As the motorcycle owner you are responsible for the performance of the required ...

Page 25: ...rburetor and internal parts intake manifold fuel injection system spark advance mechanism crankcase breather air cutoff valves ignition coils ignition wires ignition points condensers and spark plugs if failure occurs prior to the first scheduled replacement and hoses clamps fittings and tubing used directly in these parts Since emission related parts may vary from model to model certain models ma...

Page 26: ...EMISSION CONTROL SYSTEM WARRANTY IS GIVEN BY APRILIA EXCEPT AS SPECIFICALLY SET FORTH HEREIN ANY EMISSION CONTROL SYSTEM WARRANTY IMPLIED BY LAW INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE IS LIMITED TO THE EXPRESS EMISSION CONTROL SYSTEM WARRANTY TERMS STATED IN THIS WARRANTY THE FOREGOING STATEMENTS OF WARRANTY ARE EXCLUSIVE AND IN LIEU OF ALL OTHER REMEDIES SOM...

Page 27: ...GENERAL INFORMATION 1 21 SXV RXV 450 550 ...

Page 28: ...USE 2 1 SXV RXV 450 550 USE 2 ...

Page 29: ...CTION DIGITAL DISPLAY 20 2 5 MAIN INDEPENDENT CONTROLS 24 2 5 1 CONTROLS ON THE RIGHT PART OF THE HANDLEBAR 24 2 5 2 CONTROLS ON THE LEFT PART OF THE HANDLEBAR 25 2 5 3 IGNITION SWITCH 26 2 5 4 STEERING LOCK 27 2 6 INSTRUCTIONS FOR USE 28 2 6 1 GENERAL WARNINGS 28 2 6 2 PRE RIDE CHECKS CHART 31 2 6 3 STARTING 32 2 6 4 MOVING OFF AND RIDING 35 2 6 5 RUNNING IN 38 2 6 6 STOPPING 39 2 6 7 PARKING 40 ...

Page 30: ...be used for the purchase of spare parts WARNING Do not alter the identification numbers if you do not want to incur in severe penal and administrative sanctions In particular the alteration of the frame number results in the immediate invalidity of the warranty ENGINE NUMBER The engine number is stamped on the left side of engine block Engine no FRAME NUMBER The frame number is stamped on the righ...

Page 31: ...USE 2 4 SXV RXV 450 550 V I N Every vehicle produced by aprilia receives a vehicle identification number V I N DIGIT MEANING 1 Check digit 2 Year 3 Assembling factory designation N NOALE VE S SCORZE VE ...

Page 32: ...rescribed by local law including driver s license minimum age training insurance taxes vehicle registration license plate etc When you first receive your vehicle practice by riding in areas where there is little traffic Do not attempt to ride in heavy traffic until you are thoroughly experienced and riding your vehicle has become second nature to you Although this vehicle is legal for operation on...

Page 33: ...yours Before changing lanes look over your shoulder to make sure that the way is clear Do not rely exclusively on the rearview mirror you may miscalculate the distance and speed of a vehicle or you may even not see it at all Avoid obstacles that could damage the vehicle or make you lose control Do not tailgate do not attempt to increase your gas mileage by following in the slip stream of cars or t...

Page 34: ...t automatically return to the idle position This double cable arrangement enhances safety by providing for positive closing of the throttle WARNING In the event of a throttle sticking emergency always kill the engine using the engine stop switch located near the throttle grip on the right handlebar Never use your vehicle if the throttle does not automatically fully return to the idle position when...

Page 35: ...ich affects performance or safety voids your warranty completely Tampering with the emissions or noise control systems on your vehicle is against the law and can be punished by large fines In some jurisdictions it can even lead to the confiscation of your vehicle This vehicle was not designed to be equipped with a sidecar or be used to tow trailers or other vehicles aprilia does not manufacture si...

Page 36: ...n rough road surfaces slow down and ride with particular care Try to avoid wide open throttle accelerations unless they are necessary for such things as passing Don t allow your engine to lug that is run at too low an rpm Shift down to a lower gear Also don t over rev the engine Observe the red line on the tachometer Remember that excessively aggressive cornering can cause your vehicle s tires to ...

Page 37: ...ront of the vehicle Inevitably the driver will look right at you and yet swear that they did not see you before they turned directly into your path Ride alert Wear protective clothing preferably in light and or reflecting colours In this way you will make yourself more visible to the other drivers thus notably reducing the risk of being knocked down and you will be more protected in case of fall A...

Page 38: ...ctions limit the suspension stroke and the steering angle hamper the operation of the controls and reduce the distance from the ground and the angle of inclination in turns Avoid using accessories that hamper access to the controls since this can prolong reaction times during an emergency Fairings and windshields installed on the vehicle may produce aerodynamic forces that will affect the stabilit...

Page 39: ...re less efficient and the center of gravity is higher and further to the rear This makes it more likely that the front wheel will come up off the ground especially on acceleration Therefore you should avoid hard acceleration and hard braking Many accidents are caused by inexperienced riders carrying passengers Remember that allowance must be made for the extra weight of the passenger for all drivi...

Page 40: ... Left coolant radiator 2 Left rearview mirror 3 Fuel tank filler cap 4 Fuel tank 5 Battery 6 Seat 7 Tail light 8 swing arm 9 Drive chain 10 Rear left side body panel 11 Side stand 12 Rider left footrest 13 Gearbox control lever 14 Main fuse carrier 30A 15 Front left side body panel ...

Page 41: ...ide body panel 2 Right coolant radiator 3 Coolant expansion tank cap 4 Right rearview mirror 5 Air box 6 Auxiliary fuse box 7 Rear right side body panel 8 Master cylinder w rear brake fluid tank 9 Rider right footrest 10 Rear brake control lever ...

Page 42: ...2 Left rearview mirror 3 Fuel tank filler cap 4 Fuel tank 5 Battery 6 Seat 7 Tail light 8 swing arm 9 Drive chain 10 Rear left side body panel 11 Side stand 12 Rider left footrest 13 Gearbox control lever 14 Main fuse carrier 30A 15 Front left side body panel ...

Page 43: ...ide body panel 2 Right coolant radiator 3 Coolant expansion tank cap 4 Right rearview mirror 5 Air box 6 Auxiliary fuse box 7 Rear right side body panel 8 Master cylinder w rear brake fluid tank 9 Rider right footrest 10 Rear brake control lever ...

Page 44: ... SXV RXV 450 550 2 3 2 CONTROLS LAYOUT CONTROLS Key 1 Left rearview mirror 2 Clutch lever 3 Instruments and indicators 4 Ignition switch steering lock 5 Front brake lever 6 Right rearview mirror 7 Throttle grip ...

Page 45: ...ND INDICATORS Key 1 MODE button 2 Green neutral light 3 Red engine oil pressure warning light 4 Engine control system warning light 5 Multifunction digital display 6 Orange low fuel warning light 7 Blue high beam warning light 8 Green turn indicator warning light 9 Red line light ...

Page 46: ...is in neutral Engine oil pressure warning light Comes on when the ignition switch is set to with the engine stopped as a lamp test If the light does not come on in this phase contact an aprilia Authorized Dealer WARNING If the engine oil pressure warning light remains on after engine starting or comes on during the normal operation of the engine this means that the engine oil pressure in the circu...

Page 47: ...ights Backlighting All segments on the multifunction digital display After the first check routine the multifunction display will immediately indicate current battery charge and then display the measured values in the page that was active before switch off ODO CURRENT SPEED zone A ODOMETER zone B GRAPHICAL REV COUNTER with engine running zone C TRIP TRIP configuration shows trip partial data To se...

Page 48: ...dashes Dashes will turn into four zeroes when button is released 000 0 TIME With AVERAGE SPEED AVS page displayed press MODE if vehicle is stopped or SCROLL if vehicle is running to enter the TIME function If speed current unit of measurement is km h time is displayed in 24 hour format while if speed unit is mph time format is 12 hour with AM PM indication ADJUSTMENT Press MODE until hour figures ...

Page 49: ...want to advance this warning indication stop the vehicle and the engine and proceed as follows Press MODE and SCROLL pushbuttons at the same time for more than 5 seconds Area B will show five zeroes 00000 the first will be flashing Every time MODE is pressed the flashing value will increase by one unit Leave it untouched for two seconds to store the value and go on with minutes setting Proceed in ...

Page 50: ...The battery icon comes on when battery charge is low if this condition occurs while vehicle is running check battery charge and the recharging system This icon normally comes on before and after starting it goes off when engine has started ...

Page 51: ...e can be stopped by pressing the switch to position WARNING With the engine stopped and the ignition switch in position the battery may run down WARNING When the vehicle has come to a standstill and you have stopped the engine set the ignition switch to position 2 STARTER BUTTON When the starter button is pressed the starter motor will crank the engine For the starting procedure see STARTING 3 COL...

Page 52: ...or emergency NOTE Release the button to turn off the high beam flasher 2 Dimmer switch When the light dimmer switch is in position the high beam comes on while in position the low beam comes on 3 SCROLL PUSHBUTTON 4 DIRECTION INDICATOR SWITCH To indicate the turn to the left move the switch to the left to indicate the turn to the right move the switch to the right Press the switch to turn off the ...

Page 53: ... key NOTE Set the ignition switch to to automatically turn on the lights The lights will turn off when the ignition switch is set to Position Function Key removal The steering is locked It is not possible to start the engine or switch on the lights It is possible to remove the key Neither the engine nor the lights will operate It is possible to remove the key The engine and the lights can be opera...

Page 54: ... the key to position when riding or you will lose control of the vehicle OPERATION To lock the steering Turn the handlebar fully to the left Turn the key to Press and turn the key left anticlockwise slowly turn the handlebar until key can be set to Remove the key ...

Page 55: ... clothes immediately wash it off with soap and water and change clothes Should gasoline accidentally come in contact with your eyes flush with a large quantity of water and immediately contact a health professional Should you accidentally get gasoline into your mouth do not induce vomiting Drink a large quantity of milk or clear water and immediately contact a health professional WARNING Never try...

Page 56: ...ters 13 6 pt TANK RESERVE 2 2 liters 4 pt mechanical reserve To refuel proceed as follows Unscrew and remove the fuel tank cap 1 Refuel TIRES This vehicle is provided with tires with tube DANGER Periodically check tire inflation pressure at ambient temperature see TECHNICAL DATA If tires are hot the measurement will not be correct Perform the measurement especially before and after long rides If t...

Page 57: ...the size indicated see TECHNICAL DATA Make sure that the inflation valves always have their sealing caps on to prevent the tires from suddenly going flat Tire replacement and repair as well as wheel servicing and balancing are delicate operations that should be carried out using adequate tools and are best left to experienced mechanics For this reason it is advisable to have the above operations c...

Page 58: ...essure wear and tear and any damage Remove any foreign matter that may be stuck in the tread grooves Brake levers Make sure that they work smoothly Lubricate the articulations and adjust the stroke if necessary Clutch Check for proper operation check clutch lever free play clutch fluid level and check for leaks If necessary top up the fluid the clutch must work without snatching and or slipping St...

Page 59: ...experienced trained motorcycle rider WARNING Be careful not to make the vehicle fall when you first sit on it WARNING Ensure that the side stand is correctly stowed DANGER Exhaust emissions contain carbon oxide a poisonous gas and extremely harmful if inhaled Avoid starting the engine in closed or poorly ventilated areas WARNING Failure to heed this warning may cause loss of consciousness or even ...

Page 60: ...s the starter button 3 do not open the throttle yet and release the button as soon as the engine starts STARTING THE COLD ENGINE Turn the throttle twistgrip Press the cold start button 4 Release the throttle control The throttle control will stay slightly accelerated to keep the engine running while warming up Take the throttle control to rest position to disable the system WARNING Avoid pressing ...

Page 61: ...will make any possible arrangement to solve the problem e g replacing the spark plug replacing the battery with one featuring a higher starting current using an engine oil with reduced viscosity grade etc WARNING Never move off abruptly with the engine cold To reduce the emission of polluting substances and the consumption of fuel warm the engine up by proceeding at low speed for the first miles ...

Page 62: ...NG With the vehicle at rest try to get acquainted with the use of the rearview mirrors Start the engine see STARTING With released throttle grip 2 Pos A and engine idling pull the clutch lever 3 completely Engage the first gear by pushing the gear lever 4 downwards Release the brake lever pulled on the starting WARNING On departure the abrupt release of the clutch lever may cause the engine to sta...

Page 63: ...aximum rpm red line Before and during downshifting release the throttle grip and decelerate in order to avoid the red line To shift down proceed as follows Release the throttle grip 2 Pos A If necessary pull the brake levers moderately and decrease the speed of the vehicle Pull the clutch lever 3 and lower the gear shift lever 4 to shift down If the brake levers are pulled release them Release the...

Page 64: ... make your vehicle more visible In case of wet surfaces or poor grip snow ice mud etc ride slowly and avoid sudden braking or maneuvers that could make you lose grip and fall DANGER Pay the utmost attention to any obstacle or unevenness in the surface Uneven road surfaces rails inspection covers painted signals construction site metal covers become slippery in rainy weather and must be negotiated ...

Page 65: ...ine components during running in take care not to exceed Follow these recommendations Do not open the throttle completely if the speed is low both during and after running in for the first 3 hours of operation never open throttles more than half their way and never go beyond 8000 rpm for the following 12 hours never open throttles more than 75 of their travel NOTE Even after running in avoid ridin...

Page 66: ... brakes and at the same time shift down in order to decrease the speed see MOVING OFF AND RIDING Once the speed has decreased before stopping the vehicle Pull the clutch lever in order to prevent the engine from stalling When the vehicle has come to rest Select neutral green warning light on Release of the clutch lever In case of a brief stop keep at least one brake on ...

Page 67: ...ion switch DANGER The fall or excessive inclination of the vehicle may cause the fuel to flow out of the tank The fuel used for internal combustion engines is extremely inflammable and in particular conditions it can become explosive To park the vehicle Choose a suitable parking area Stop the vehicle see STOPPING Set the engine stop switch 1 to position Turn the key and set the ignition switch 2 t...

Page 68: ... read the previous paragraph PARKING Grasp the left grip 1 and place your right hand on the rear upper part of the vehicle 2 Press the side stand with your right foot and extend it completely 3 Keep it extended and incline the vehicle until the stand rests on the ground Steer the handlebar completely leftwards DANGER Make sure that the vehicle is stable ...

Page 69: ...e braking system and lead to an accident possibly causing serious injuries or death NEVER leave the key in the ignition switch and always use the steering lock Park the vehicle in a safe place possibly in a garage or a protected place When possible use an additional antitheft device Make sure that all documents are in order and the road tax has been paid ...

Page 70: ...RANSPORT During transport the vehicle must be kept in vertical position and firmly anchored with the first gear engaged in order to avoid any leak of fuel oil coolant WARNING In case of failure do not tow the vehicle ask for assistance ...

Page 71: ...e ride checks see PRE RIDE CHECKS CHART To remove dirt and mud from the painted surfaces use a low pressure water jet carefully wet the dirty parts remove mud and filth with a soft car sponge impregnated with a lot of water and shampoo 2 4 parts of shampoo in water Then rinse with plenty of water and dry with chamois leather To clean the outer parts of the engine use a degreaser brushes and wipers...

Page 72: ...onto the following components wheel hubs controls on the right and left side of the handlebar bearings brake master cylinders instruments and indicators exhaust pipes ignition switch steering lock Do not clean any rubber or plastic parts or the seat with alcohol or solvents Clean with water and mild detergent DANGER Do not apply protection waxes onto the seat to avoid it from becoming slippery ...

Page 73: ...nce you could forget to carry them out later Proceed as follows Remove the battery see REMOVING THE BATTERY and LONG INACTIVITY OF THE BATTERY Wash and dry the vehicle see CLEANING Polish the painted surfaces with wax Inflate the tires see TIRES Place the vehicle in an unheated not humid room away from sunlight with minimum temperature variations Wrap and tie a plastic bag around the exhaust pipe ...

Page 74: ...stic bags from the exhaust tailpipes Uncover and clean the vehicle see CLEANING Check the charge of the battery see CHARGING THE BATTERY and install it see INSTALLING THE BATTERY Refill the fuel tank see FUEL Perform the pre ride checks see PRE RIDE CHECKS CHART DANGER Have a test ride at moderate speed in a low traffic area ...

Page 75: ...and for side stand For the RXV models a series of optional accessories is also available Racing headlight fairing to eliminate the instrument panel Connector for racing headlight Retainer for front brake line Racing tail light number plate holder WARNING Do not use the vehicle off road when the homologated number plate holder tail light is installed ...

Page 76: ...USE 2 49 SXV RXV 450 550 ...

Page 77: ...MAINTENANCE 3 1 SXV RXV 450 550 MAINTENANCE 3 ...

Page 78: ...BRAKES 22 3 1 10 DRIVE CHAIN 25 3 1 11 SPECIAL TOOLS 27 3 1 12 TIGHTENING TORQUE SETTINGS 28 3 2 SCHEDULED MAINTENANCE 31 3 2 1 CHECKING BRAKE FLUID LEVEL AND TOPPING UP 31 3 2 2 CHECKING THE ENGINE OIL LEVEL AND TOPPING UP 36 3 2 3 CHANGING ENGINE OIL AND OIL FILTER 38 3 2 4 GEARBOX FLUID 39 3 2 5 COOLANT 41 3 3 ADJUSTMENTS 43 3 3 1 TENSIONING THE THROTTLE CABLES 43 3 3 2 SUSPENSIONS 44 3 4 BLEED...

Page 79: ...n x 2 16 in Compression ratio RXV 450 13 0 5 Compression ratio RXV 550 12 5 0 5 Starting electric Engine idling rpm 1800 2000 rpm Clutch Multiplate in oil bath Lubricating system Double separate lubrication with external reservoir Air filter with dry filter cartridge Cooling system liquid cooled gearbox Type mechanical 5 gears with foot control on the left side of the engine CAPACITIES Fuel includ...

Page 80: ...EL RIMS Type spoke type Front 1 60 x 21 Rear 2 15 x 18 FRONT TIRE Type 90 90 21 54R Inflating pressure 100 kPa 1 0 bar REAR TIRE Type 140 80 18 70R Inflation pressure 110 kPa 1 1 bar IGNITION Type Digital electronic SPARK PLUGS Standard NGK CR8EB Spark plug electrode gap 0 028 0 031 in 0 7 0 8 mm Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V 6 Ah Auxiliary fuses 5 A 15 A 20 A Generator with permane...

Page 81: ...bricating system Double separate lubrication with external reservoir Air filter with dry filter cartridge Cooling system liquid cooled gearbox Type mechanical 5 gears with foot control on the left side of the engine CAPACITIES Fuel including reserve 1 98 gal 7 5 l Fuel reserve 0 58 gal 2 2 l Engine oil 0 34 gal 1 3 l Fork oil 4 92 in 125 mm of air per leg measured without spring and compressed rod...

Page 82: ...MS Type spoke type Front 3 50 x 17 Rear 5 50 x 17 FRONT TIRE Type 120 70 ZR17 58W Inflation pressure 180 kPa 1 8 bar REAR TIRE Type 180 55 ZR17 73W Inflation pressure 200 kPa 2 0 bar IGNITION Type Digital electronic SPARK PLUGS Standard NGK CR8EB Spark plug electrode gap 0 028 0 031 in 0 7 0 8 mm Resistance 5 kΩ ELECTRICAL SYSTEM Battery 12 V 6 Ah Auxiliary fuses 5 A 15 A 20 A Generator with perma...

Page 83: ...luid only Do not mix different makes or types of oil without having checked bases compatibility Engine coolant ANTIFREEZE PLUS RXV 450 550 LUBRICANT PRODUCT Engine oil RACING 4T 10W 60 Use top brand oils meeting or exceeding CCMC G 4 A P I SG SAE 10W 60 specifications gearbox fluid RECOMMENDED GEAR SINTH 75W 90 Front fork fluid RECOMMENDED FORK 7 5W or mix of oils in such percentage so as to obtai...

Page 84: ...check valve Check cylinder barrel for wear Check con rod and main bearings for wear Check starting gears for wear Check clutch spring length Check clutch plates for wear Check and adjust clutch cable Check coolant level in radiator and expansion tank Check system for sealing Check oil pump gears Change engine oil and engine oil filter Clean head lubrication jets Check oil lines condition and posit...

Page 85: ...k shock absorber for sealing and operation Check con rod bearings play Check steering bearings play Clean headstock dust seal C Check chain guide slider for wear Check chain guide for wear Check chain tensioner roller for wear Check chain tensioner slider for wear Tension drive chain Check chain joint RXV sealed link SXV front and rear sprocket and chain guide for wear Lubricate steering bearings ...

Page 86: ...r barrel for wear Check con rod and main bearings for wear Check starting gears for wear Check clutch spring length Check clutch plates for wear Check and adjust clutch cable Check coolant level in radiator and expansion tank Check system for sealing Check oil pump gears Change engine oil and engine oil filter Clean head lubrication jets Check oil lines condition and position Replace pistons and p...

Page 87: ...ck absorber for sealing and operation Check con rod bearings play Check steering bearings play Clean headstock dust seal Check chain guide slider for wear Check chain guide for wear Check chain tensioner roller for wear Check chain tensioner slider for wear Tension drive chain Check chain joint RXV sealed link SXV front and rear sprocket and chain guide for wear Lubricate steering bearings Lubrica...

Page 88: ...bearings for wear Check starting gears for wear Check clutch spring length Check clutch plates for wear Check and adjust clutch cable Check coolant level in radiator and expansion tank Check system for sealing Check oil pump gears Change engine oil and engine oil filter Clean head lubrication jets Check oil lines condition and position Replace pistons and piston rings Check piston gudgeon pin Chan...

Page 89: ... wear Check chain tensioner roller for wear Check chain tensioner slider for wear Tension drive chain Check chain joint RXV sealed link SXV front and rear sprocket and chain guide for wear Lubricate steering bearings Lubricate clutch lever pin Lubricate throttle cables Lubricate rider footrest pins Lubricate drive chain Lubricate rear suspension lever systems Lubricate side stand pin Lubricate fro...

Page 90: ...ar brake lever Stop light switch 2 on front brake lever For the check proceed as follows Make sure that there are no dirt or mud deposits on the switch the pin must be able to move without interference returning automatically to its initial position Make sure that the cables are connected correctly Check the spring it must not be damaged worn or weakened ...

Page 91: ...bulb with bare hands remove any fingerprint with alcohol in order to avoid any damage DO NOT FORCE THE ELECTRIC CABLES NOTE Before changing a bulb check the fuses see CHANGING THE FUSES CHANGING THE HEADLIGHT BULB The headlight contains One parking light bulb 1 One low beam bulb high beam 2 To change the bulbs Place the vehicle on the stand see POSITIONING THE VEHICLE ON THE STAND DANGER Handle th...

Page 92: ... DANGER To extract the bulb electric connector do not pull its electric wires Release the two ends of the clip 5 from the bulb holder Extract the bulb from its seat When reassembling NOTE Insert the bulb in the bulb holder making the relevant positioning seats coincide Correctly install a new bulb of the same type Correctly refit the protection element 4 into lamp terminals and reflector seat Conn...

Page 93: ...ation provided below applies to both spark plugs Remove the cap 1 of the spark plug 2 Remove any trace of dirt from the spark plug base 2 Fit the wrench supplied with the tool kit into spark plug 2 hexagonal flat Unscrew the spark plug 2 and extract it from its seat taking care to prevent dust or other substances from getting inside the cylinder For the check and cleaning WARNING This vehicle is f...

Page 94: ...ire gauge WARNING Never attempt to adjust electrode gap Electrode gap should be 0 7 0 8 mm 0 027 0 031 in change spark plug 2 if reference value is not respected Make sure that the washer is in good condition For the installation Position the washer and screw in the spark plug 2 by hand in order not to damage the thread Tighten the spark plug 2 with the wrench included in the tool kit making half ...

Page 95: ...irregularly or if the vehicle fails to start Check the auxiliary fuses first and then the 30A main fuse Check as follows Turn the ignition switch to position to avoid any accidental short circuit Remove the right side panel loosen the two screws 1 and slide it off its seat Lift the cover 2 of the auxiliary fuse box Extract the fuses one by one and check if the filament 3 is broken Before replacing...

Page 96: ...rgizing 2 Parking lights turn indicators horn instrument panel stop light 7 5A Fuse 3 Headlights 4 Control unit relay power 5 Injector coils 6 Electric fan 5A Fuse 7 Fuel pump NOTE There are three spare fuses 8 LAYOUT OF MAIN FUSES 30A Fuse Battery charge one fuse only the second one is spare ...

Page 97: ...e correct direction place the vehicle on flat ground 10 m away from a wall Turn on the low beam sit on the vehicle and make sure that the beam projected on the wall is slightly under the horizontal line of the headlight about 9 10th of the total height To adjust the headlight beam Turn screw 1 using a screwdriver TIGHTEN clockwise to raise the beam SLACKEN counter clockwise to lower the beam After...

Page 98: ...he rear brake uses a single disk right side The following information refers to a single braking system but is valid for both When the disk pads wear out the level of the fluid inside tank 1 2 decreases to automatically compensate for their wear The front brake fluid reservoir 1 is mounted near the front brake lever mount The rear brake fluid reservoir 2 is built in the master cylinder fixed to th...

Page 99: ...E If the reservoir is dirty wipe it with a clean cloth so that you can see the MIN and MAX marks Carefully read paragraphs BRAKE diskS CHECKING BRAKE FLUID LEVEL and MAINTENANCE NOTE The following information refer to a single braking system but are valid for both Halve maintenance intervals if you are riding in rainy or dusty conditions on rough road surfaces or when the vehicle is used in compet...

Page 100: ... caliper pads NOTE The rear brake caliper is the same as the one fitted to the SXV version proceed as described in the paragraph about SXV version DANGER Excessive wear of the friction material causes the contact of the pad metal support with the disk resulting in metallic noise and production of sparks from the caliper this negatively affects braking efficiency safety and integrity of the disk If...

Page 101: ...ower section midway between the sprockets Movement should be approximately 0 79 0 98 in 20 25 mm Move the motorcycle forward in such a way as to check the vertical oscillation of the chain even in other positions the slack must be constant in all the wheel rotation phases DANGER If in some positions the slack is higher than in others this means that there are crushed or seized links in this case c...

Page 102: ...maged or missing it is necessary to change the whole chain unit both sprockets and chain Finally check the wear of the swing arm protection shoe CLEANING AND LUBRICATION DANGER Lubricate the chain frequently especially if there are dry or rusty parts The crushed or seized links must be lubricated and made work again If this is not possible contact an aprilia Authorized Dealer who will provide for ...

Page 103: ...ption Part number 1 Tool for fitting fork oil seal Ø 1 77 in 45 mm RXV 9100903 2 Tool for fitting fork oil seal Ø 1 89 in 48 mm SXV 9100904 3 swing arm cages punch 9100898 4 Punch for left casing desmo wheel hub 9100892 5 Punch for swing arm levers at cases 9100900 ...

Page 104: ...ame M6 12 8 9 Screw securing tail end to mudguard M6 12 8 9 Top screw securing under tail end to number plate holder M5 7 5 2 Bottom screw securing under tail end to number plate holder M5 7 5 2 Screw securing under tail end mudguard starter contactor ext M6 12 8 9 Shock absorber guard screw M5 6 4 4 Screw securing headlight fairing to instrument support M5 6 4 4 Instrument support screw M5 6 4 4 ...

Page 105: ... Handlebar upper clamps screw M8 24 17 7 Steering shaft nut M26 108 79 7 Steering shaft ring nut M30 7 5 2 Handlebar lower clamp nut M10 32 23 6 Leg guard screw M6 12 8 9 REAR SUSPENSION Nut securing frame to linkage M12 80 59 0 Nut securing linkage to rocker M12 80 59 0 Nut securing rocker to swing arm M12 80 59 0 Shock absorber nut M10 52 38 3 swing arm Chain guide nut M6 12 8 9 Nut securing swi...

Page 106: ...ar indicator screw M5x0 8 6 4 4 loctite 270 Gear change pedal screw M6x1 12 8 9 Head bolt pre torque M10X1 25 30 22 1 Smear screws and washers with oil Head bolt M10X1 25 50 36 9 Head bolt M6x1 12 8 9 Timing gear nut M12x1 50 36 9 Timing compartment cover screw M5x0 8 6 4 4 loctite 243 Primary sprocket nut M18x1 25 160 118 1 Gear selector stop plate screw M6x1 12 8 9 loctite 270 Oil collector plat...

Page 107: ...act your aprilia Authorized Dealer Make sure that the brake disks are neither oily nor greasy especially after maintenance or checking operations Make sure the brake lines are not twisted or worn Prevent water or dust from accidentally getting into the circuit Wear latex gloves when servicing the hydraulic circuit Brake fluid is an irritant Avoid contact with eyes or skin DANGER In the event of ac...

Page 108: ...hicle is used in competitions Before leaving check brake fluid level in the reservoirs Have the brake fluid changed every two years by an aprilia Authorized Dealer DANGER Do not use the vehicle if the braking system leaks fluid FRONT BRAKE Check Place the vehicle in vertical position and keep handlebar in the direction of travel Make sure that the fluid level in tank 1 exceeds the MIN mark MIN min...

Page 109: ...ssive stroke of the brake lever or reduced efficiency of the braking system contact an aprilia Authorized dealer since it may be necessary to bleed the system TOPPING UP RXV WARNING The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 6 are loose or most important if the brake fluid tank cover 7 has been removed Unscrew the screws 6 of the brake fluid reservo...

Page 110: ...pad wear and the disk wear If the pads and or the disk do not need replacing provide for topping up TOPPING UP WARNING The brake fluid may flow out of the tank Do not operate the front brake lever if the screws 9 are loose or most important if the brake fluid tank cover 10 has been removed Using a wrench loosen the two screws 9 from the brake fluid reservoir 2 WARNING Avoid any prolonged exposure ...

Page 111: ...X level only after changing the brake pads Do not reach the MAX level with worn out pads since this will cause a fluid outflow when the pads are changed Check braking efficiency In case of excessive stroke of the brake lever or reduced efficiency of the braking system contact an aprilia Authorized Dealer since it may be necessary to bleed the system ...

Page 112: ...top the engine immediately and contact an aprilia Authorized Dealer Proceed with care Do not spill the oil Take care not to smear any component the area in which you are working and the surrounding area Remove any trace In case of leakage or malfunctions contact an aprilia Authorized Dealer NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions on rough road surfaces or wh...

Page 113: ...st reaches the MAX mark If necessary top up the engine oil by proceeding as follows WARNING If the vehicle is used for sport with the oil level too high it is possible that some oil splashes reach the air box through engine breather hose WARNING Never exceed the MAX mark nor let the oil get below the MIN mark in order to avoid serious damage to the engine Unscrew and remove the filler plug 2 WARNI...

Page 114: ...ide Loosen and remove the oil drain plug 2 and let oil drain off completely WARNING Used oil contains substances that are very dangerous for the environment Dispose of used oil in accordance with regulations Take off the engine oil filter cover 3 Remove it with its gasket keep the O ring Remove the oil filter Install a new oil filter Refit the engine oil filter cover 3 Screw and tighten the oil dr...

Page 115: ...ee LUBRICANT TABLE until oil reaches inspection plug hole 2 WARNING Do not put additives or other substances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean Wait a few minutes to allow oil to get from the clutch to the gearbox then check level again REPLACEMENT NOTE Warm oil is more fluid and will drain out more easily Move the sump guard down Plac...

Page 116: ... check level again Tighten the filler plug 3 WARNING Oil flow from clutch to gearbox and vice versa can be particularly slow if the ambient temperature oil or engine temperature is low WARNING Do not put additives or other substances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean Refit the rear brake lever ensure you fit the washer in between leve...

Page 117: ...of the engine it may catch fire and send out invisible flames If maintenance operation are required it is advisable to use latex gloves WARNING Have it changed by an aprilia Authorized Dealer Coolant mixture is a 50 solution of water and antifreeze This is the ideal solution for most operating temperatures and provides good corrosion protection This solution is also suited to warm weather as it is...

Page 118: ...d between MIN and MAX references DANGER Coolant is toxic when ingested Contact with eyes or skin may cause irritation Do not use your fingers or any other object to check if there is enough coolant Do not put additives or other substances into the fluid WARNING Do not put additives or other substances into the fluid If you use a funnel or other similar items make sure that they are perfectly clean...

Page 119: ...proceed as follows Place the vehicle on the stand see POSITIONING THE VEHICLE ON THE STAND Withdraw the protection element 1 Loosen by screwing the lock nut 2 Rotate the adjuster 3 in such a way as to restore the prescribed value After the adjustment tighten the lock nut 2 loosening it and check the idle stroke again Put back the protection element 1 WARNING After the adjustment make sure that the...

Page 120: ...ualified servicing is necessary contact your aprilia Authorized Dealer FRONT SUSPENSION The front suspension is managed by a hydraulic fork which is held to the steering tube by two yokes Each fork leg is fitted with suitable adjusters to modify suspension response An upper adjuster screw 1 controls rebound damping whereas a lower adjuster screw 2 controls compression damping SETTING THE FRONT FOR...

Page 121: ...t adjustments for the use of the vehicle on racetracks and then ride it on roads or motorways SXV Front suspension Standard setting Hydraulic rebound adjustment screw 1 tighten fully and then slacken by 10 clicks Hydraulic compression damping screw 2 tighten fully H and then slacken by 10 clicks Fork height A over top yoke not including top cap Flush with plug RXV Front suspension Standard setting...

Page 122: ...odified to suit specific needs in accordance with vehicle usage WARNING For a correct setting of adjusters 1 2 first set the damper to the stiffest position adjuster fully clockwise then set desired position clicks and or turns Do not force the adjusters 1 2 beyond their limit stops in either direction or the threads may strip Slightly unscrew the locking ring nut 4 by means of the appropriate wre...

Page 123: ...ly prohibited to carry out adjustments for the use of the vehicle on racetracks and then ride it on roads or highways SXV Rear suspension Standard setting Shock absorber center distance A 457 1 5 mm 18 0 06 in Spring length preloaded B 245 mm 9 6 in Rebound adjustment screw 1 13 clicks Compression adjustment screw 2 16 clicks Bypass adjuster knob 6 Fully open RXV Rear suspension Standard setting S...

Page 124: ...circuit after the brakes have been refitted and the braking system has been restored to its standard operating conditions since it would be very dangerous for the vehicle and the rider not to do so NOTE Bleed air with vehicle on flat ground While bleeding the hydraulic circuit top up reservoir with brake fluid as required Make sure there is always some fluid in the reservoir throughout the process...

Page 125: ... the bleed valve before the lever is fully squeezed in Repeat process until the fluid draining into the container is totally clear of air bubbles NOTE While bleeding the hydraulic circuit top up reservoir with brake fluid as required Make sure there is always some fluid in the reservoir throughout the process Tighten the bleed valve and remove the tubing Top up fluid inside tank Refit the rubber c...

Page 126: ...oir with brake fluid as required Make sure there is always some fluid in the reservoir throughout the process Remove the bleed valve rubber cap Insert one end of a transparent plastic tubing inside the rear brake caliper bleed valve and the other end in a container for collection Pull and quickly release the rear brake lever a few times then keep it pulled Loosen the bleed valve by 1 4 of a turn s...

Page 127: ...MAINTENANCE 3 51 SXV RXV 450 550 3 4 3 SPARK ARRESTOR Loosen and remove the two screws 1 on final closure 2 Remove final closure 2 Slide off screen 3 Clean or replace screen 3 if damaged ...

Page 128: ...CHASSIS 4 1 SXV RXV 450 550 CHASSIS 4 ...

Page 129: ... 5 REMOVING THE SWING ARM 8 4 1 6 INSTALLING THE REAR WHEEL 11 4 1 7 REMOVING THE EXHAUST SYSTEM 12 4 2 FUEL FEEDING SYSTEM 14 4 2 1 DIAGRAM 14 4 2 2 REMOVING THE FUEL TANK 15 4 2 3 REMOVING THE AIR FILTER 17 4 3 INJECTION 18 4 3 1 DIAGRAM 18 4 4 COOLING SYSTEM 20 4 4 1 DIAGRAM 20 4 4 2 REMOVING THE RADIATOR 21 4 5 LUBRICATION SYSTEM 24 4 5 1 DIAGRAM 24 4 5 2 REMOVING THE OIL TANK 25 ...

Page 130: ...CHASSIS 4 3 SXV RXV 450 550 4 1 CHASSIS 4 1 1 REMOVING THE SEAT Turn the lip Remove the seat ...

Page 131: ...RXV 450 550 4 1 2 REMOVING THE BATTERY Remove the seat see REMOVING THE SEAT Loosen and remove the negative cable screw keep the fastener Loosen and remove the positive cable screw keep the fastener Remove the battery ...

Page 132: ...G THE CONTROL UNIT Remove the seat see REMOVING THE SEAT Remove the fuel tank see REMOVING THE FUEL TANK Detach the connectors Loosen and remove the two screws securing the voltage regulator Remove the voltage regulator Remove the control unit ...

Page 133: ...le on the suitable supports OPT Unscrew and remove the nut and collect the washer Working on either side loosen adjuster Remove the chain Using a rubber mallet slide out the wheel shaft on the left side of the vehicle collect the shims and remove the wheel from the rear end ...

Page 134: ...CHASSIS 4 7 SXV RXV 450 550 Remove the bush ...

Page 135: ...THE SWING ARM Loosen and remove the nut securing the swing arm levers shaft and collect the washer Slide out the swing arm levers shaft Loosen and remove the screws from top protection cover and collect the spacer Remove the top protection cover ...

Page 136: ...e the three screws from chain guide and collect the two nuts Move the chain to the side completed with chain guide Unscrew and remove the swing arm shaft nut Unscrew and remove the threaded pin 1 Release the spring 2 Remove the rear brake pedal 3 ...

Page 137: ...CHASSIS 4 10 SXV RXV 450 550 Remove swing arm shaft ...

Page 138: ...he rear wheel Refit the chain Working on either side fit the shims Working on the left side fit the wheel shaft Working on the right side fit the washer and start the wheel shaft nut do not tighten it yet Adjust chain tension using the suitable adjusters Tighten the wheel shaft nut ...

Page 139: ... and remove the two retaining screws with washers and collect the nuts Ensure that the T shaped bushings stay in place Working on either side remove the mounting spring Working on either side loosen and remove the two screws collect the washers Remove the exhaust silencer ...

Page 140: ...and remove the two screws from front cylinder exhaust manifold Remove the front cylinder exhaust manifold and collect the clamp Loosen and remove the two screws from rear cylinder exhaust manifold Remove the rear cylinder exhaust manifold ...

Page 141: ...CHASSIS 4 14 SXV RXV 450 550 4 2 FUEL FEEDING SYSTEM 4 2 1 DIAGRAM Key 1 Fuel tank 2 Fuel tank filler cap 3 Plug gasket 4 5x9 Tube 5 Fuel pump assy 6 Fuel filter 7 Gasket 8 Thermistor ...

Page 142: ...Cutting the side body panel along marks A allows you to remove the tank without removing the lower side panel first Unscrew and remove the tank retaining screw and collect the pilot bush Remove the fuel tank plug breather hose Raise the fuel tank Hold the fuel tank up using a retaining cord WARNING Make sure the tank retaining cord never touches the battery positive pole Release the quick release ...

Page 143: ...16 SXV RXV 450 550 Disconnect the connector Remove the split pin from the side still fitted with the side body panel Remove the tank retaining pin from the side without lower side body panel Remove the fuel tank ...

Page 144: ...air box is clean before refitting Remove any dirt that might have entered during the removal procedure When refitting pay attention to correctly refit the air scoops WARNING Ensure the tank retaining cord never touches the battery positive pole WARNING If it falls to the ground carefully clean the air filter and the air box from oil possibly coming from the oil tank via the oil breather hose WARNI...

Page 145: ...CHASSIS 4 18 SXV RXV 450 550 4 3 INJECTION 4 3 1 DIAGRAM ...

Page 146: ... Ignition switch 4 Instrument panel 5 Intake air temperature sensor 6 Throttle position sensor 7 Injector 8 Intake air pressure sensor 9 Cooling fans 10 Engine temperature sensor 11 Speed sensor front wheel 12 Crankshaft position sensor 13 Gearbox position switch ...

Page 147: ... 5 Fan support 6 Tube D10 d5 5 7 Tube connecting left to right radiator upper 8 Tube connecting left to right radiator lower 9 Tube connecting radiator to water pump 10 Tube connecting radiator to rear cylinder head 11 Tube connecting radiator to front cylinder head 12 Expansion tank gasket 13 Expansion tank plug 14 Radiator plug ...

Page 148: ...loosen and remove the three side body panel screws Remove the side body panels Prepare a container of suitable capacity under the hose Release the clamp Remove the hose Drain the fluid in the container Open radiator plug to drain all fluid Working on either side release the clamps ...

Page 149: ... 4 22 SXV RXV 450 550 Remove the right and left delivery hoses Working on the left side release the clamp and disconnect the hose Working on the right side slide out the hose Remove the radiator breather hose ...

Page 150: ...the left side Working on the right side loosen the upper screw and collect the nut and washer on the left side WARNING Before removing the screw support the cooling fan or it will fall down Slide out the radiators in a downward motion WARNING The radiators are connected one to the other by means of the lower hose ...

Page 151: ...lug M20x1 5 5 O ring 3075 6 Flanged hex head screw M6x70 7 Flanged hex head screw M6x95 8 Narrow self locking nut M6x1 9 Blow by hose L 215 10 Click clamp 16 5x6 6 11 Click clamp 15 5x6 6 12 Oil breather hose 9x14 13 Cock clamp 14 Rubber block 15 Tank bushing 16 Oil sight glass 17 Click clamp 18 From engine 19 To air box 20 Inlet 21 Outlet ...

Page 152: ...Raise the fuel tank see REMOVING THE FUEL TANK Remove the radiators from the cooling system see REMOVING THE RADIATORS Prepare a container of suitable capacity under the oil tank plug Loosen and remove oil drain cap Remove the top clamp Slide out the blow by hose Release the clamp Remove the hose ...

Page 153: ...XV RXV 450 550 Release the two clips Remove the two hoses Working on the right side loosen and remove the two screws Working on the left side remove the two nuts Remove oil filler plug Remove the oil tank from below ...

Page 154: ...CHASSIS 4 27 SXV RXV 450 550 ...

Page 155: ...CYCLE PARTS 5 1 SXV RXV 450 550 CYCLE PARTS 5 ...

Page 156: ... 8 5 1 4 DISASSEMBLING THE FRONT FORK SXV 11 5 1 5 REASSEMBLING THE FRONT FORK SXV 15 5 1 6 INSTALLING THE FORK LEGS SXV 17 5 2 FRONT FORK RXV 21 5 2 1 DIAGRAM RXV 21 5 2 2 REMOVING THE FORK LEGS RXV 22 5 2 3 CHANGING THE FORK FLUID RXV 26 5 2 4 DISASSEMBLING THE FRONT FORK RXV 29 5 2 5 REASSEMBLING THE FRONT FORK RXV 33 5 2 6 INSTALLING THE FORK LEGS RXV 35 ...

Page 157: ...5 Complete sleeve 6 Ring for spring 7 Spring Kit 8 Complete damper rod 9 Complete valve 10 Complete plug 11 Flanged TE screw 12 Dust seal oil seal kit 13 Seal Kit Ø 1 89 in 48 mm 14 Bushing Kit 15 Adjust kit thickness 0 0039 in 0 1 mm 16 Adjust kit thickness 0 0059 in 0 15 mm 17 Adjus kit thickness 0 0079 in 0 2 mm 18 Adjust Kit thck 0 0118 in 0 3 mm ...

Page 158: ...ecuring the mudguard Loosen and remove the four screws securing the mudguard Remove the front mudguard Place the front stand OPT in the fork bottom plate Loosen and remove the two screws securing the brake caliper Remove the brake caliper Working on the left side loosen and remove the front wheel shaft nut ...

Page 159: ...ing on either side loosen the wheel shaft pinch bolts Working on the right side slide out the wheel shaft Remove the wheel Collect the bush NOTE The next three operations only apply to the left fork leg Remove cable ties from the fork leg ...

Page 160: ...RXV 450 550 Loosen and remove the two speed sensor screws Remove the speed sensor Loosen and remove the three leg guard screws Remove the fork leg guard Support the fork leg and loosen the screws from top and bottom plate ...

Page 161: ...CYCLE PARTS 5 7 SXV RXV 450 550 Remove the fork leg ...

Page 162: ...ows Remove the fork leg see REMOVING THE FORK LEGS SXV Set sleeve 3 in a vice with safety jaws Use a hexagonal wrench to loosen the top cap 1 NOTE Make sure the O ring 2 is not damaged during removal Push the fork leg into the sleeve WARNING The fork leg sleeve unit is filled with oil do not tilt it too much or turn it upside down during removal Loosen the lock nut indicated by the arrow holding t...

Page 163: ...nside the sleeve 3 up to the correct level that can be measured by inserting a graduated rod inside sleeve 3 Oil level 4 92 0 079 in 125 2 mm from leg edge NOTE To correctly measure the fluid level ensure that sleeve 3 is perfectly vertical and fully home in the leg Fluid level shall be the same in both fork legs Fit spring 5 in the sleeve Fit aluminum shim and plastic bushing 4 onto spring 5 ...

Page 164: ...CYCLE PARTS 5 10 SXV RXV 450 550 Ensure that O ring 2 is fitted to top cap 1 Hold the lock nut and tighten the top cap 1 finger tight onto damper rod Tighten the cap 1 onto sleeve 3 ...

Page 165: ...fork leg see CHANGING THE FORK FLUID SXV Slide out the damper rod Clamp the sleeve in a vice in horizontal position WARNING Place a container under the bottom plug Loosen and remove the bottom plug using an air gun NOTE Make sure the O rings are not damaged during removal Slide out the complete damper rod ...

Page 166: ...er WARNING Be careful not to damage the tube edge and the dust seal 1 Remove the snap ring 2 from inside the sleeve using a screwdriver WARNING Be careful not to damage the sleeve edge Firmly remove the sleeve The fork leg still holds bushing 3 guide ring 4 shim 5 oil seal 6 stop ring 2 dust scraper seal 1 ...

Page 167: ...CYCLE PARTS 5 13 SXV RXV 450 550 Bushing 3 and guide ring 4 can be removed using a small screwdriver then the following parts can also be removed shim 5 oil seal 6 ...

Page 168: ...CYCLE PARTS 5 14 SXV RXV 450 550 snap ring 2 and dust scraper seal 1 ...

Page 169: ...dust scraper seal 1 stop ring 2 oil seal 6 shim 5 guide ring 4 bushing 3 WARNING Tape the bushing 3 groove before fitting the oil seal so to avoid damaging the seal lip Vice the fork leg using pads in soft material to avoid damages such as aluminum Fit bushing 3 in its seat on the fork leg Fit the sleeve to the fork leg Take the guide ring 4 and shim 5 fully home against the sleeve Using the suita...

Page 170: ... 16 SXV RXV 450 550 Fit the dust scraper ring 1 Fit the complete damper rod fully home in the fork leg Fit and tighten the bottom plug Fit the damper rod Proceed by filling with fluid see CHANGING THE FORK FLUID SXV ...

Page 171: ...ARTS 5 17 SXV RXV 450 550 5 1 6 INSTALLING THE FORK LEGS SXV Fit the fork leg Support the fork leg and tighten the two screws on top and bottom plate Install the leg guard position and tighten the three screws ...

Page 172: ...CYCLE PARTS 5 18 SXV RXV 450 550 Fit the speed sensor and tighten the two screws Refit the bush Refit the wheel Working on the right side fit the wheel shaft ...

Page 173: ...de Working on the left side tighten the front wheel shaft nut Tighten the two screws on wheel shaft left fork clamp Position the brake caliper in its seat Tighten the two brake caliper screws Remove the front support OPT and place the vehicle on the side stand see POSITIONING THE VEHICLE ON THE STAND Secure the sensor cable using a tie Fit the mudguard and tighten the four screws ...

Page 174: ...CYCLE PARTS 5 20 SXV RXV 450 550 Tighten the two mudguard front screws ...

Page 175: ...ly 2 Right fork assembly 3 Left stanchion 4 Right stanchion 5 Upper bushing 6 Seal 7 Retainer 8 Snap ring 9 Dust scraper ring 10 Complete sleeve 11 Dowel O ring 12 Ring for spring 13 Spring Kit 14 Complete damper rod 15 Flanged TE screw 16 Tube lower bushing 17 Complete valve 18 Complete plug ...

Page 176: ...screws securing the mudguard Remove the front mudguard Place the front stand OPT in the fork bottom plate Loosen and remove the two screws securing the brake caliper Remove the brake caliper NOTE The speed sensor cable is routed outside the brake caliper and is fitted with a protection Working on the left side loosen and remove the front wheel shaft nut ...

Page 177: ...ing on either side loosen the wheel shaft pinch bolts Working on the right side slide out the wheel shaft Remove the wheel Collect the bush NOTE The next three operations only apply to the left fork leg Remove cable ties from the fork leg ...

Page 178: ... RXV 450 550 Loosen and remove the two speed sensor screws Remove the speed sensor Loosen and remove the three leg guard screws Remove the fork leg guard Support the fork leg and loosen the screws from top and bottom plate ...

Page 179: ...CYCLE PARTS 5 25 SXV RXV 450 550 Remove the fork leg ...

Page 180: ... always use aluminum protections DRAINING Drain oil as follows Remove the fork leg see REMOVING THE FORK LEGS RXV Set fork leg 3 in a vice with safety jaws Use a hexagonal wrench to loosen the top cap 1 NOTE Make sure the O ring 2 is not damaged during removal Push the fork leg into the sleeve WARNING The fork leg sleeve unit is filled with oil do not tilt it too much or turn it upside down during...

Page 181: ...he spring into the sleeve to avoid topping up or fluid change Drain all oil inside the container as shown NOTE Pump the tube inside the stanchion to help oil drain out completely from the damper rod Remove the preload tube FILLING UP Install the preload tube in the sleeve 3 ...

Page 182: ... from leg edge NOTE To correctly measure the fluid level ensure that fork leg 3 is perfectly vertical and fully home in the sleeve Fluid level shall be the same in both fork legs Install in sleeve 3 the spring 5 completed with plastic bushing 4 Ensure that O ring 2 is fitted to top cap 1 Hold the lock nut and tighten the top cap 1 finger tight onto damper rod Tighten the cap 1 onto sleeve 3 ...

Page 183: ...fork leg see CHANGING THE FORK FLUID RXV Slide out the damper rod Clamp the sleeve in a vice in horizontal position WARNING Place a container under the bottom plug Loosen and remove the bottom plug using an air gun NOTE Make sure the O rings are not damaged during removal Slide out the complete damper rod ...

Page 184: ...er WARNING Be careful not to damage the tube edge and the dust seal 1 Remove the snap ring 2 from inside the sleeve using a screwdriver WARNING Be careful not to damage the sleeve edge Firmly remove the sleeve The fork leg still holds bushing 3 guide ring 4 shim 5 oil seal 6 snap ring 2 dust scraper seal 1 ...

Page 185: ...CYCLE PARTS 5 31 SXV RXV 450 550 Bushing 3 and guide ring 4 can be removed using a small screwdriver then the following parts can also be removed shim 5 oil seal 6 ...

Page 186: ...CYCLE PARTS 5 32 SXV RXV 450 550 snap ring 2 dust scraper seal 1 ...

Page 187: ... snap ring 2 oil seal 6 shim 5 guide ring 4 bushing 3 WARNING Tape the bushing 3 groove before fitting the oil seal in order to avoid damaging the seal lip Vice the fork leg using pads in soft material to avoid damages such as aluminum Fit bushing 3 in its seat on the fork leg Fit the sleeve to the fork leg Take the guide ring 4 and shim 5 fully home against the sleeve Using the suitable insertion...

Page 188: ...CYCLE PARTS 5 34 SXV RXV 450 550 Fit the complete damper rod fully home in the fork leg Fit and tighten the bottom plug Fit the damper rod Proceed by filling with fluid see CHANGING THE FORK FLUID RXV ...

Page 189: ...ARTS 5 35 SXV RXV 450 550 5 2 6 INSTALLING THE FORK LEGS RXV Fit the fork leg Support the fork leg and tighten the two screws on top and bottom plate Install the leg guard position and tighten the three screws ...

Page 190: ...CYCLE PARTS 5 36 SXV RXV 450 550 Fit the speed sensor and tighten the two screws Refit the bush Refit the wheel Working on the right side fit the wheel shaft ...

Page 191: ...eel shaft nut Tighten the two screws on wheel shaft left fork clamp Position the brake caliper in its seat Tighten the two brake caliper screws Remove the front support OPT and place the vehicle on the side stand see POSITIONING THE VEHICLE ON THE STAND NOTE The speed sensor cable is routed outside the brake caliper and is fitted with a protection Secure the sensor cable using a tie Fit the mudgua...

Page 192: ...CYCLE PARTS 5 38 SXV RXV 450 550 Tighten the two mudguard front screws ...

Page 193: ...CYCLE PARTS 5 39 SXV RXV 450 550 ...

Page 194: ...ELECTRICAL SYSTEM 6 1 Engine 450 550 ELECTRICAL SYSTEM 6 ...

Page 195: ...ELECTRICAL SYSTEM 6 2 Engine 450 550 TABLE OF CONTENTS 6 1 ELECTRICAL SYSTEM 3 6 1 1 SXV RXV DIAGRAM 3 ...

Page 196: ...ELECTRICAL SYSTEM 6 3 Engine 450 550 6 1 ELECTRICAL SYSTEM 6 1 1 SXV RXV DIAGRAM ...

Page 197: ...r 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 cyl mounted to the left 34 Spark plug 2 35 Coil 1 front cyl mounted to the right 36 Spark plug 1 37 Bank angle sensor 38 Intake air temperature sensor 39 Throttle position sensor TPS 40 Injector 2 rear cylinder 41 Injector 1 front cylinder 42 Pick up 43...

Page 198: ...ELECTRICAL SYSTEM 6 5 Engine 450 550 ...

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