APRILIA MXV 450 - Owner's Manual

INTRODUCTION0-1Engine 450 - 550 INTRODUCTION 0

GENERAL INFORMATION 1 - 4 Engine 450 –5501.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to con

LUBRICATION 3 - 62 Engine 450 - 5503.6.2. REMOVING THE EXTERNAL PUMP • Before removing any components, place a container of adequate capacity und

LUBRICATION3-63Engine 450 - 550 • Remove oil pump gear transmission roller. • Remove the shim (2). • Loosen and remove the four screws (3). •

LUBRICATION 3 - 64 Engine 450 - 5503.6.3. REMOVING THE INTERNAL PUMP NOTE To disassemble the oil pump inner part, it is necessary to separate the

LUBRICATION3-65Engine 450 - 550 3.6.4. INSTALLING THE INTERNAL PUMP • Fit transmission roller. • Install pump impellers and slide off stator. •

LUBRICATION 3 - 66 Engine 450 - 5503.6.5. INSTALLING THE EXTERNAL PUMP • Refit the internal pump, see (INSTALLING THE INTERNAL PUMP). • Fit the oi

LUBRICATION3-67Engine 450 - 550 • Fit oil pump gear with the shim. • Fit a new circlip to secure oil pump gear in place. • Install oil pump c

LUBRICATION 3 - 68 Engine 450 - 5503.7. PRIMARY TRANSMISSION GEAR 3.7.1. REMOVING THE PRIMARY GEAR • Before removing any components, place a con

LUBRICATION3-69Engine 450 - 550 3.7.2. INSTALLING THE PRIMARY GEAR WARNING One side of the shim is galvanised (friction proof treatment) and it sh

LUBRICATION 3 - 70 Engine 450 - 5503.8. GEAR SHIFT SELECTOR 3.8.1. REMOVAL, INSPECTION, REFITTING REMOVAL • Remove the clutch, see (REMOVING THE

LUBRICATION3-71Engine 450 - 550 • Move down ratchet lever and slide off selector drum lower part. • Remove ratchet, washer and spring. CHECK

GENERAL INFORMATION1-5Engine 450 - 550 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE Should it be necessary to perform some operatio

LUBRICATION 3 - 72 Engine 450 - 550CHECKING THE RATCHET Check clearance of washer and riveted pin passing through plate. If it is excessive, change

LUBRICATION3-73Engine 450 - 550 3.9. GENERATOR SIDE 3.9.1. REMOVAL • Loosen and remove the eleven screws. • Mark the screws with different length.

LUBRICATION 3 - 74 Engine 450 - 550• Using the suitable tool (no. 8140838), lock the flywheel rotor. • Loosen and remove flywheel nut and remove w

LUBRICATION3-75Engine 450 - 550 • Loosen and remove the screw on external oilways retaining plate. • Remove the two external oilways. • Loose

LUBRICATION 3 - 76 Engine 450 - 5503.9.2. CHANGING BEARINGS AND OIL SEALS WARNING before performing any removing/assembling operation, heat the cr

LUBRICATION3-77Engine 450 - 550 • Heat the crankcase. • Remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using

LUBRICATION 3 - 78 Engine 450 - 550GEARBOX SECONDARY SHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Remove the

LUBRICATION3-79Engine 450 - 550 • Fit a new oil seal by means of the special tool, part no. 9100894 LAYSHAFT BEARING REMOVAL • Warm the crankc

LUBRICATION 3 - 80 Engine 450 - 550 GEARBOX BEARINGS REMOVAL Proceed as described for the flywheel-side crankcase. • Remove the three retainin

LUBRICATION3-81Engine 450 - 550 LAYSHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Heat the crankcase. • Remove

GENERAL INFORMATION 1 - 6 Engine 450 –550 DANGER Take care not to spill coolant onto hot engine parts and exhaust system. It may ignite and produce

LUBRICATION 3 - 82 Engine 450 - 5503.10. ENGINE CRANKCASES 3.10.1. HOW TO TAKE THE ENGINE CRANKCASES APART • Before removing any components, place

LUBRICATION3-83Engine 450 - 550 • Slide out the rear cylinder timing gearwheel. • Remove the timing chain. • Remove the key. • From generato

LUBRICATION 3 - 84 Engine 450 - 550 • Remove the gearbox fluid plug screw. • Raise by 2-3 cm [(0.79-1.18) in] both cylinder barrels. • Separa

LUBRICATION3-85Engine 450 - 550 3.10.2. CHECK CHECKING THE BEARINGS AND OIL SEALS Carefully clean with a mild solvent the two crankcases, the ball

LUBRICATION 3 - 86 Engine 450 - 5503.10.3. CHANGING BEARINGS AND OIL SEALS WARNING before performing any removing/assembling operation, heat the c

LUBRICATION3-87Engine 450 - 550 • Heat the crankcase. • Remove the bearing using an internal puller. REASSEMBLY • Reassemble the bearing using

LUBRICATION 3 - 88 Engine 450 - 550GEARBOX SECONDARY SHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Remove the

LUBRICATION3-89Engine 450 - 550 • Fit a new oil seal by means of the special tool, part no. 9100894 LAYSHAFT BEARING REMOVAL • Warm the crankc

LUBRICATION 3 - 90 Engine 450 - 550 GEARBOX BEARINGS REMOVAL Proceed as described for the flywheel-side crankcase. • Remove the three retainin

LUBRICATION3-91Engine 450 - 550 LAYSHAFT BEARING REMOVAL • Remove bearing retaining screws and relevant plate. • Heat the crankcase. • Remove

GENERAL INFORMATION1-7Engine 450 - 550 DISASSEMBLING THE COMPONENTS - Never use pliers or similar tools to slacken and/or tighten nuts and bolts. A

LUBRICATION 3 - 92 Engine 450 - 5503.10.4. ASSEMBLING THE CRANKCASES NOTE Before reassembling, change and lubricate the oil seals and lubricate the

LUBRICATION3-93Engine 450 - 550 • Fit timing layshaft on generator shaft. • Fit the key. • Fit rear cylinder timing gear. • Fit rear cylind

LUBRICATION 3 - 94 Engine 450 - 550• Fit primary gear, see (REMOVING THE PRIMARY GEAR). • Use the suitable special tool (no. 9100843) to tighten p

LUBRICATION3-95Engine 450 - 550 3.11. TIMING 3.11.1. CAM TIMING • Ensure timing chains are correctly tight. • Remove the blanking screw from timin

LUBRICATION 3 - 96 Engine 450 - 550• Tighten front cylinder camshaft gear retaining nut. • Remove front camshaft and crankshaft locking tools. •

GEARBOX4-1Engine 450 - 550 GEARBOX 4

GEARBOX 4 - 2 Engine 450 - 550SUMMARY 4.1. GEARBOX SHAFTS...

GEARBOX4-3Engine 450 - 550 4.1. GEARBOX SHAFTS 4.1.1. DIAGRAM

GEARBOX 4 - 4 Engine 450 - 550Key: 1. Selector shaft+pawls 2. Selector pin 3. Spring 4. Circlip 5. Flanged hex.head screw 6. Complete index lever

GEARBOX4-5Engine 450 - 550 4.1.2. DISASSEMBLING THE GEARBOX • To gain access to gearbox, it is necessary to remove generator-side casing, see (HOW

GENERAL INFORMATION 1 - 8 Engine 450 –5501.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable

GEARBOX 4 - 6 Engine 450 - 550• Slide off primary and secondary shafts at the same time. DISASSEMBLING THE PRIMARY SHAFT • Remove

GEARBOX4-7Engine 450 - 550 4.1.3. CHECK CHECKING THE GEARBOX FORKS NOTE The following procedure applies to all gearbox forks. Check selector fork ca

GEARBOX 4 - 8 Engine 450 - 5504.1.4. REASSEMBLING THE GEARBOX • Correctly couple gearbox primary and secondary shafts and insert them into clutch-

GEARBOX4-9Engine 450 - 550 • Install the fork shafts. • Refit generator-side crankcase, see (ASSEMBLING THE CRANKCASE).

ELECTRICAL SYSTEM5-1Engine 450 - 550 ELECTRICAL SYSTEM 5

ELECTRICAL SYSTEM 5 - 2 Engine 450 - 550SUMMARY 5.1. ELECTRIC COMPONENTS ...

ELECTRICAL SYSTEM5-3Engine 450 - 550 5.1. ELECTRIC COMPONENTS 5.1.1. INSTRUMENT PANEL INSTRUMENT PANEL SET-UP The set-up function allows you to sele

ELECTRICAL SYSTEM 5 - 4 Engine 450 - 550Resetting the monitoring parameters Activate set-up when monitoring symbols are activated because their set

ELECTRICAL SYSTEM5-5Engine 450 - 550 Select the measure unit and press SCROLL until it goes off. The newly set value will be displayed after releasi

GENERAL INFORMATION1-9Engine 450 - 550 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each braking system is operated by a

GENERAL INFORMATION 1 - 10 Engine 450 –550COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the ev

GENERAL INFORMATION1-11Engine 450 - 550 TYRES WARNING If tyres are excessively inflated, the vehicle will be hard, difficult and uncomfortable to

GENERAL INFORMATION 1 - 12 Engine 450 –5501.4. RUNNING-IN 1.4.1. RUNNING-IN Correct engine running-is essential to ensuring proper performance and d

TECHNICAL INFORMATION2-1Engine 450 - 550 TECHNICAL INFORMATION 2

INTRODUCTION 0 - 2 Engine 450 - 550SUMMARY 0.1. INTRODUCTION ...

TECHNICAL INFORMATION2 - 2 Engine 450 - 550SUMMARY 2.1. TECHNICAL INFORMATION ...

TECHNICAL INFORMATION2-3Engine 450 - 550 2.1. TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA ENGINE 450 ENGINE Model (SXV 450) 45SX Model (RXV 450) 4

TECHNICAL INFORMATION2 - 4 Engine 450 - 550SXV450 TRANSMISSION Gear ratios Ratio Primary Secondary Final ratio Total ratio 1st 22/56 = 1: 2.545

TECHNICAL INFORMATION2-5Engine 450 - 550 Clutch Type Multiplate, wet clutch with control on the left side of the handlebar Driving plates 1 # plat

TECHNICAL INFORMATION2 - 6 Engine 450 - 5502.1.2. LUBRICANT TABLE ENGINE 450 - 550 LUBRICANT PRODUCT Engine oil RECOMMENDED RACING 4T, SAE 10W –

TECHNICAL INFORMATION2-7Engine 450 - 550 2.1.3. TIGHTENING TORQUE SETTINGS TIGHTENING TORQUE SETTINGS DESCRIPTION SCREW / NUT Nm (Lbft) NOTES ENGINE

TECHNICAL INFORMATION2 - 8 Engine 450 - 550TIGHTENING TORQUE SETTINGS DESCRIPTION SCREW / NUT Nm NOTES Crankshaft stop screw M8x1.25 22 (16.23) l

TECHNICAL INFORMATION2-9Engine 450 - 550 2.1.4. SPECIAL TOOLS In order to perform assembly, reassembly and settings correctly, special tools suitabl

TECHNICAL INFORMATION2 - 10 Engine 450 - 550Pos. Description Part number 1 Swinging arm cages drift 9100898 2 Drift for swinging arm levers cag

TECHNICAL INFORMATION2-11Engine 450 - 550 2.1.5. ASSEMBLING ENGINE TO PLATE • Fit the engine support part no. 9100841 on the aprilia engine suppor

INTRODUCTION0-3Engine 450 - 550 0.1. INTRODUCTION 0.1.1. FOREWORD This manual provides the information required for normal servicing. This publicati

TECHNICAL INFORMATION2 - 12 Engine 450 - 5502.1.6. LIMIT VALUES LIMIT VALUES CHART Description Limit value (mm) Max. head deformation 0.05 Maximu

TECHNICAL INFORMATION2-13Engine 450 - 550 2.1.7. COUPLING: MAIN BEARINGS - CONNECTING ROD Before selecting the right spare bearing, please verify t

TECHNICAL INFORMATION2 - 14 Engine 450 - 5502.2. ADJUSTMENTS 2.2.1. CYLINDER SYNCHRONISATION • Release the special hook to remove the seat. • Lift

TECHNICAL INFORMATION2-15Engine 450 - 550 • Working on the right side, release the tie from oil breather hose. • Take the oil breather hose out

TECHNICAL INFORMATION2 - 16 Engine 450 - 550• Connect a differential vacuum meter to both by-pass hoses. • Lower tank gently avoiding to squash va

TECHNICAL INFORMATION2-17Engine 450 - 550 2.2.2. AXONE SYMBOL SCREEN PAGE ISO ENGINE PARAMETER READING DEVICE STATUS (usually “On – Off” values)

TECHNICAL INFORMATION2 - 18 Engine 450 - 550SCREEN PAGE DESCRIPTION APPROXIMATE VALUES MEASURE UNIT NOTES ENGINE PARAMETER READING Engine rpm -

TECHNICAL INFORMATION2-19Engine 450 - 550 SCREEN PAGE Description APPROXIMATE VALUES MEASURE UNIT NOTES ERRORS DISPLAY Engine temperature sensor

TECHNICAL INFORMATION2 - 20 Engine 450 - 550SCREEN PAGE Description APPROXIMATE VALUES MEASURE I UNIT NOTES ERRORS DISPLAY Rear injector Error

LUBRICATION3-1Engine 450 - 550 LUBRICATION 3

INTRODUCTION 0 - 4 Engine 450 - 5500.1.2. REFERENCE MANUALS OWNER'S MANUALS aprilia part# (description) 9100650 9100651 9100652

LUBRICATION 3 - 2 Engine 450 - 550SUMMARY 3.1. REMOVING AND REFITTING THE ENGINE...

LUBRICATION3-3Engine 450 - 550 3.1. REMOVING AND REFITTING THE ENGINE 3.1.1. REMOVING THE ENGINE • Set the engine support stand. • Working on

LUBRICATION 3 - 4 Engine 450 - 550• Remove the hose. • Drain the fluid in the container. • Open radiator plug to drain all fluid. • Working on

LUBRICATION3-5Engine 450 - 550 • Working on the right side, slide out the hose. • Remove the radiator breather hose. • Working on the right s

LUBRICATION 3 - 6 Engine 450 - 550• Slide out the radiators in a downward motion. WARNING The radiators are connected one to the other by means o

LUBRICATION3-7Engine 450 - 550 • Remove the hose. • Release the two clamps. • Remove the two hoses. • Working on the right side, loosen and

LUBRICATION 3 - 8 Engine 450 - 550• Remove the oil tank from below. • Loosen and remove the two screws on sprocket protection and remove protect

LUBRICATION3-9Engine 450 - 550 • Working on either side, loosen adjuster. • Remove the chain. • Unscrew and remove the swinging arm shaft nu

LUBRICATION 3 - 10 Engine 450 - 550• Remove swinging arm shaft. • Grasp and release the handles on either sides to release the air box cover. •

LUBRICATION3-11Engine 450 - 550 • Disconnect the clutch cable. • Remove the sprocket circlip. • Remove the chain from the sprocket. • Remove t

INTRODUCTION0-5Engine 450 - 550 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = less than > = greater than ≤ = less than or equal

LUBRICATION 3 - 12 Engine 450 - 550 • Slide the protection along the starter motor power cable. • Loosen and remove the securing screw. • Remov

LUBRICATION3-13Engine 450 - 550 • Slide off the lower rear pin. • Loosen and remove the securing screw from the front pin. • Remove the front

LUBRICATION 3 - 14 Engine 450 - 5503.1.2. REFITTING THE ENGINE • Position the engine. • Fit the washer. • Fit the front pin. • Tighten the f

LUBRICATION3-15Engine 450 - 550 • Fit the washer. WARNING Refit washers restoring their original number and position. • Tighten the lower rear

LUBRICATION 3 - 16 Engine 450 - 550• Connect all connectors. • Fit sprocket and chain. • Fit the chain circlip.

LUBRICATION3-17Engine 450 - 550 • Fit the clutch cable. • Fit the two throttle cables. • Fit the air box cover. NOTE Please ensure the air b

LUBRICATION 3 - 18 Engine 450 - 550• Fit the swinging arm shaft. • Fit the rear brake pedal (3). • Fit the spring (2). • Tighten the screw (1)

LUBRICATION3-19Engine 450 - 550 • Fit the washer. • Tighten the rear wheel shaft nut. • Fit the sprocket guard together with the two spacers a

LUBRICATION 3 - 20 Engine 450 - 550• Working on the right side, fit the two pins. • Working on the left side, tighten the two nuts. • Fit the c

LUBRICATION3-21Engine 450 - 550 • Fit the blow-by hose. • Fasten tie. • Tighten the oil drain nut. • Fill the tank with engine oil from the top

INTRODUCTION 0 - 6 Engine 450 - 550RIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head

LUBRICATION 3 - 22 Engine 450 - 550• Insert the pin, fit the washer and tighten the nut. • Insert the pin, fit the washer and tighten the nut.

LUBRICATION3-23Engine 450 - 550 • Working on the left side, fit the hose and clamp. • Fit delivery hoses on either side. • Fasten tie on eith

LUBRICATION 3 - 24 Engine 450 - 550• Fasten tie. • Fill the system through the radiator plug. • Fit the side body panels. • Tighten the three s

LUBRICATION3-25Engine 450 - 550 3.1.3. REMOVING ENGINE ACCESSORIES • Position the engine on the engine support plate (part no. 9100841), see (ASSEM

LUBRICATION 3 - 26 Engine 450 - 550 • Working on either piston-cylinder assy, remove the spark plug. • Working on clutch side, loosen and remo

LUBRICATION3-27Engine 450 - 550 3.2. WATER PUMP 3.2.1. REMOVING THE WATER PUMP WARNING Usually, it is not necessary to remove the water pump excep

LUBRICATION 3 - 28 Engine 450 - 550• Remove the two centring pins. • Remove the water pump cover spacer.

LUBRICATION3-29Engine 450 - 550 3.2.2. INSTALLING THE WATER PUMP WARNING When installing, only use new seals and clamps. • Fit the water pump co

LUBRICATION 3 - 30 Engine 450 - 550• Fit the water pump cover and the gasket. • Fit and tighten the five water pump cover screws.

LUBRICATION3-31Engine 450 - 550 3.3. CYLINDER HEAD 3.3.1. REMOVING THE CYLINDER HEAD NOTE The following procedure applies to both cylinders. NOTE E

GENERAL INFORMATION1-1Engine 450 - 550 GENERAL INFORMATION 1

LUBRICATION 3 - 32 Engine 450 - 550• Loosen and remove the head retaining screw on timing side. WARNING Remove this screw before removing the four

LUBRICATION3-33Engine 450 - 550 3.3.2. REMOVING THE ROCKER ARMS AND CAMSHAFT • Remove the head, see (REMOVING THE CYLINDER HEAD). • Remove the ex

LUBRICATION 3 - 34 Engine 450 - 550• Slide off the decompression system together with control spring. • Working on timing side, remove the circl

LUBRICATION3-35Engine 450 - 550 3.3.3. REMOVING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to both cylinders. • Remove the

LUBRICATION 3 - 36 Engine 450 - 5503.3.4. CHECK CHECKING THE HEAD • Check for damages or scratches in the head and change it, if necessary. • Ch

LUBRICATION3-37Engine 450 - 550 CHECKING THE CAMSHAFT GEARWHEEL • Check camshaft gear for proper operation: change timing chain and camshaft gear

LUBRICATION 3 - 38 Engine 450 - 550CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS NOTE The following procedure applies to rocker arms and rocker arm

LUBRICATION3-39Engine 450 - 550 • Using an inner micrometer gauge, measure valve guide inner diameter (D). • Calculate valve stem to valve guide

LUBRICATION 3 - 40 Engine 450 - 550• Check that valve stem out of round falls within indicated values, change the valve if needed. • Secure the va

LUBRICATION3-41Engine 450 - 550 3.3.5. INSTALLING THE VALVES AND VALVE SPRINGS NOTE The following procedure applies to all valves and their compone

GENERAL INFORMATION 1 - 2 Engine 450 –550SUMMARY 1.1. STRUCTURE OF THE MANUAL...

LUBRICATION 3 - 42 Engine 450 - 550• Fit the two buckets (2) and the two shims below onto both intake valves. • Fit the two shims (1) on exhaust v

LUBRICATION3-43Engine 450 - 550 3.3.6. INSTALLING THE CAMSHAFT AND ROCKER ARMS NOTE Before refitting, smear bearing with engine oil; see (LUBRICANT

LUBRICATION 3 - 44 Engine 450 - 550• Install exhaust rocker arm shaft. NOTE Ensure the rocker arm shaft is fully home in the head. • Fit the exh

LUBRICATION3-45Engine 450 - 550 3.3.7. INSTALLING THE HEAD • Install the centring pins. • Install a new head gasket. • Install the head. • Inse

LUBRICATION 3 - 46 Engine 450 - 550• Install the chain tensioner as follows: • 1 – Release the chain tensioner single-direction cam and push its r

LUBRICATION3-47Engine 450 - 550 3.4. CYLINDER AND PISTON 3.4.1. REMOVAL • Before removing the cylinder it is necessary to remove the head, see (RE

LUBRICATION 3 - 48 Engine 450 - 550• Using piston pin puller (no. 9100943), remove gudgeon pin. • Remove the piston. • Remove piston ring (3) and

LUBRICATION3-49Engine 450 - 550 3.4.2. CHECKING THE LIMIT VALUES NOTE During inspection, check the specified parts for wear, referring to the follo

LUBRICATION 3 - 50 Engine 450 - 5503.4.3. INSTALLATION NOTE When assembling the piston rings, ensure their reference faces up. • Install piston rin

LUBRICATION3-51Engine 450 - 550 3.5. CLUTCH 3.5.1. REMOVAL • Working in a cross pattern, loosen the five screws on clutch cover by one fourth of a

GENERAL INFORMATION1-3Engine 450 - 550 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections an

LUBRICATION 3 - 52 Engine 450 - 550• Remove the pushrod together with thrust bearing, shim and bearing support. • Remove the plates. • Str

LUBRICATION3-53Engine 450 - 550 • Remove clutch hub. • Collect the shim.

LUBRICATION 3 - 54 Engine 450 - 550• Remove the clutch housing. • Remove spacer and needle roller bearing.

LUBRICATION3-55Engine 450 - 550 3.5.2. CHECK CLUTCH PLATES • Rest the friction plates and steel plates on a flat surface and check for cracks and

LUBRICATION 3 - 56 Engine 450 - 550CHECKING THE PUSHER PLATE Check the pusher plate and bearing for damages and wear. Change the components, if ne

LUBRICATION3-57Engine 450 - 550 3.5.3. REASSEMBLY • Insert needle roller bearing and spacer. • Install the clutch housing. • Fit shim. • In

LUBRICATION 3 - 58 Engine 450 - 550• Install the wing washer(s). WARNING Refit washers restoring their original number and position. • Install

LUBRICATION3-59Engine 450 - 550 • Fit the pushrod with thrust bearing and shim. • Fit the pusher plate. • Install the clutch springs. • Fi

LUBRICATION 3 - 60 Engine 450 - 550• Install the clutch cover. • Tighten the five clutch cover screws, proceeding in a cross pattern. • Check gea

LUBRICATION3-61Engine 450 - 550 3.6. OIL PUMP 3.6.1. LUBRICATION SYSTEM DIAGRAM