APRILIA SXV / RXV 450 550 Use And Maintenance Book
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APRILIA SXV / RXV 450 550 Use And Maintenance Book

Sxv / rxv 450 550
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Summary of Contents for APRILIA SXV / RXV 450 550

  • Page 2: Introduction

    INTRODUCTION SXV / RXV 450 – 550 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION SXV / RXV 450 – 550 TABLE OF CONTENTS 0.1. INTRODUCTION ..........................3 0.1.1. FOREWORD ........................... 3 0.1.2. ABBREVIATIONS/SYMBOLS/CONVENTIONS..............4 0 - 2...

  • Page 4: Foreword

    INTRODUCTION 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.

  • Page 5: Abbreviations/Symbols/Conventions

    INTRODUCTION SXV / RXV 450 – 550 0.1.2. ABBREVIATIONS/SYMBOLS/CONVENTIONS = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F = degrees Fahrenheit ±...
  • Page 6 INTRODUCTION SXV / RXV 450 – 550 RIGHT SIDE = right side = 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 = Twin Spark Ignition UPSIDE- DOWN = inverted fork...
  • Page 7 GENERAL INFORMATION SXV / RXV 450 – 550 GENERAL INFORMATION 1 - 1...

  • Page 8: Table Of Contents

    GENERAL INFORMATION SXV / RXV 450 – 550 TABLE OF CONTENTS 1.1. STRUCTURE OF THE MANUAL........................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.

  • Page 9: Structure Of The Manual

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. •...

  • Page 10: Dangerous Elements

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.2. DANGEROUS ELEMENTS FUEL DANGER The fuel used to operate engines is highly flammable and becomes explosive under particular conditions. Refueling and engine service should take place in a well-ventilated area with the engine stopped. Do not smoke when refueling or in the proximity of sources of fuel vapors, avoid flames, sparks and any element that could ignite fuel or provoke explosions.
  • Page 11 GENERAL INFORMATION SXV / RXV 450 – 550 BRAKE FLUID NOTE This vehicle is fitted with front and rear disk brakes. Each braking system is operated by an independent hydraulic circuit. The information provided below applies to both braking systems. DANGER Do not use the vehicle in case brakes are worn out or do not work properly.
  • Page 12 GENERAL INFORMATION SXV / RXV 450 – 550 COOLANT DANGER Coolant is toxic when ingested, contact with eyes or skin may cause irritation. In the event of contact with skin or eyes, rinse repeatedly with abundant water and seek medical advice.
  • Page 13 GENERAL INFORMATION SXV / RXV 450 – 550 TIRES WARNING If tires are over-inflated, the vehicle will feel stiff and be difficult and uncomfortable to ride. In addition, its roadworthiness will be impaired, especially on wet surfaces and during cornering. Flat tires (insufficient pressure) can slip on the rim and make you lose the control of the vehicle.

  • Page 14: Safety Warnings

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.3. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety Warning: When you see this symbol on the vehicle or in the manual, pay particular attention to the potential risk of personal injury or death.

  • Page 15: Basic Safety Rules

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.4. BASIC SAFETY RULES CARBON MONOXIDE If it is necessary to run the engine in order to carry out maintenance operation, make sure that the area in which you are operating is properly ventilated. Never run the engine in enclosed spaces. If it is necessary to work indoors, use an exhaust evacuation system.
  • Page 16 GENERAL INFORMATION SXV / RXV 450 – 550 WARNING Avoid spilling the engine coolant on the exhaust system or on the engine components. They may be hot enough to cause the coolant to ignite and burn without a visible flame. The coolant (ethylene glycol) can cause skin irritation and is poisonous if swallowed.
  • Page 17 GENERAL INFORMATION SXV / RXV 450 – 550 DISASSEMBLING THE COMPONENTS Never use pliers or similar tools to slacken and/or tighten nuts and bolts. Always use the suitable wrench. Mark all connections (hoses, wiring, etc.) with their positions before disconnecting them. Identify each connection using a distinctive symbol or convention.

  • Page 18: Warnings - Precautions - General Recommendations

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.5. WARNINGS – PRECAUTIONS – GENERAL RECOMMENDATIONS Your safety and that of those around you depends not only on your skill as a rider, but also your knowledge about your vehicle and about riding safely. Therefore it is essential that you do not operate your vehicle on public streets or highways until you have received instructions from a qualified safety organization such as the Motorcycle Safety Foundation, and are properly trained and licensed.
  • Page 19 GENERAL INFORMATION SXV / RXV 450 – 550 • Removal or puncturing of the muffler, baffles, header pipes or any other component wich conducts exhaust gases. • Removal or puncturing of any part of the intake system. • Lack of proper maintenance. •...

  • Page 20: Position Of The Adhesive Warning Labels

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.6. POSITION OF THE ADHESIVE WARNING LABELS 1) V.I.N 2) Polluting 450 3) Polluting 550 1 - 14...
  • Page 21 GENERAL INFORMATION SXV / RXV 450 – 550 4) Noise SXV450 5) Noise SXV550 6) Gomme RXV 7) Gomme SXV 1 - 15...
  • Page 22 GENERAL INFORMATION SXV / RXV 450 – 550 8) Sonore RXV450 9) Sonore RXV550 10) Hang tag 450 11) Hang tag 550 1 - 16...
  • Page 23 GENERAL INFORMATION SXV / RXV 450 – 550 12) Polluting 450 Off road 13) Polluting 550 Off road 1 - 17...

  • Page 24: Emission & Noise Control System Warranty Statement

    GENERAL INFORMATION SXV / RXV 450 – 550 1.1.7. EMISSION & NOISE CONTROL SYSTEM WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The United States Environmental Protection Agency, the California Air Resources Board and Aprilia Division of Piaggio & C. S.p.A. (hereinafter Aprilia) are pleased to explain the emission control system warranty on your 2007 and later off-road motorcycle.
  • Page 25 GENERAL INFORMATION SXV / RXV 450 – 550 LIMITED WARRANTY ON EMISSION CONTROL SYSTEM Aprilia warrants that each new 2007 and after Aprilia off-road motorcycle: is designed, built and equipped to comply at the time of initial retail purchase with all applicable regulations of the United States Environmental Protection Agency, and the California Air Resources Board;...
  • Page 26 GENERAL INFORMATION SXV / RXV 450 – 550 Inspections, replacement of parts and other services and adjustments required for required maintenance. Any off-road motorcycle on which the odometer mileage has been changed so that actual mileage cannot be readily determined. III.
  • Page 27 GENERAL INFORMATION SXV / RXV 450 – 550 1 - 21...
  • Page 28 SXV / RXV 450 - 550 2 - 1...
  • Page 29 SXV / RXV 450 - 550 TABLE OF CONTENTS 2.1. IDENTIFICATION DATA ..........................3 2.1.1. VEHICLE IDENTIFICATION NUMBER (ENGINE NUMBER) (FRAME NUMBER) (V.I.N) ..... 3 2.2. RIDING IN SAFETY ............................5 2.2.1. BASIC SAFETY RULES ......................... 5 2.2.2. CLOTHING ............................10 2.2.3.

  • Page 30: Identification Data

    SXV / RXV 450 - 550 2.1. IDENTIFICATION DATA 2.1.1. VEHICLE IDENTIFICATION NUMBER (ENGINE NUMBER) (FRAME NUMBER) (V.I.N) It is a good rule to write down the frame and engine numbers in the space provided in this manual. The frame number can be used for the purchase of spare parts.
  • Page 31 SXV / RXV 450 - 550 V.I.N Every vehicle produced by aprilia receives a vehicle identification number (V.I.N). DIGIT MEANING Check digit Year Assembling factory designation (N = NOALE VE, S = SCORZE VE) 2 - 4...

  • Page 32: Riding In Safety

    SXV / RXV 450 - 550 2.2. RIDING IN SAFETY 2.2.1. BASIC SAFETY RULES The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you.
  • Page 33 SXV / RXV 450 - 550 Make sure you are in good physical condition and not ill before riding your vehicle. Do not ride your vehicle when you are particularly tired or fatigued. Alcohol, drugs and fatigue are leading causes of vehicle accidents. Many accidents are caused by the rider s inexperience and lack of training.
  • Page 34 SXV / RXV 450 - 550 It is very important to your safety that you give full attention to the act of riding. Watch what you are doing, do not allow yourself to be distracted by other cars, people or things on the roadside, etc.
  • Page 35 SXV / RXV 450 - 550 Do not attempt to modify the position, angle or color of your license plate. Do not even protect it with a clear plastic covering. Do not modify any of the safety equipment of your vehicle, especially such safety related items as directional indicators, rearview mirrors, lights or horns.
  • Page 36 SXV / RXV 450 - 550 Always ride at the appropriate speed and avoid unnecessary hard acceleration. This not only is safer, but also reduces fuel consumption and increases the life of the vehicle. If you must ride your vehicle in rainy weather, or on loose surfaces, remember that traction is greatly reduced.

  • Page 37: Clothing

    SXV / RXV 450 - 550 2.2.2. CLOTHING Before riding your vehicle, ensure that your riding gear is in good condition. To be effective, your helmet must fit properly, and the visor or other eye protection must be clean. Both research and experience have shown that drivers of other vehicles often do not see vehicles or riders.

  • Page 38: Accessories

    SXV / RXV 450 - 550 2.2.3. ACCESSORIES The owner of the vehicle is responsible for the choice, installation and use of any accessory. The installation of inappropriate accessories or the overloading of the vehicle may result in the instability of the vehicle itself and cause accidents with consequent risk of serious injuries or even death.

  • Page 39: Load

    SXV / RXV 450 - 550 2.2.4. LOAD Do not overload your vehicle. Attach luggage or packages as close as possible to the center of your vehicle and distribute the load from side to side as evenly as possible, to keep imbalance to a minimum.

  • Page 40: Controls

    SXV / RXV 450 - 550 2.3. CONTROLS 2.3.1. LOCATION OF KEY COMPONENTS Key: Left coolant radiator Left rearview mirror Fuel tank filler cap Fuel tank Battery Seat Tail light swing arm Drive chain 10. Rear left side body panel 11.
  • Page 41 SXV / RXV 450 - 550 Key: Front right side body panel Right coolant radiator Coolant expansion tank cap Right rearview mirror Air box Auxiliary fuse box Rear right side body panel Master cylinder w/ rear brake fluid tank Rider right footrest 10.
  • Page 42 SXV / RXV 450 - 550 Key: Left coolant radiator Left rearview mirror Fuel tank filler cap Fuel tank Battery Seat Tail light swing arm Drive chain 10. Rear left side body panel 11. Side stand 12. Rider left footrest 13.
  • Page 43 SXV / RXV 450 - 550 Key: Front right side body panel Right coolant radiator Coolant expansion tank cap Right rearview mirror Air box Auxiliary fuse box Rear right side body panel Master cylinder w/ rear brake fluid tank Rider right footrest 10.

  • Page 44: Controls Layout

    SXV / RXV 450 - 550 2.3.2. CONTROLS LAYOUT CONTROLS Key: Left rearview mirror Clutch lever Instruments and indicators Ignition switch/steering lock ( Front brake lever Right rearview mirror Throttle grip 2 - 17...

  • Page 45: Instruments And Indicators

    SXV / RXV 450 - 550 2.4. INSTRUMENTS AND INDICATORS 2.4.1. INSTRUMENTS AND INDICATORS Key: MODE button Green neutral light ( Red engine oil pressure warning light ( Engine control system warning light ( Multifunction digital display. Orange low fuel warning light ( ) Blue high beam warning light ( Green turn indicator warning light ( Red line light...

  • Page 46: Instruments And Indicators Table

    SXV / RXV 450 - 550 2.4.2. INSTRUMENTS AND INDICATORS TABLE Description Function Turn indicator repeater ( Blinks when the direction indicators are on. Engine control system warning light Comes on when the ignition switch is set to ( ) with the engine stopped as a lamp test.

  • Page 47: Multifunction Digital Display

    SXV / RXV 450 - 550 2.4.3. MULTIFUNCTION DIGITAL DISPLAY CONTROLS 1 MODE pushbutton; to display and make adjustments (works only when vehicle is stopped). 2 SCROLL pushbutton; to display and set all functions except the time. When you turn the ignition key to " ", the following instrument panel lights will turn on for 3 seconds: all warning lights;...
  • Page 48 SXV / RXV 450 - 550 Press again MODE, if vehicle is stopped, or SCROLL, if vehicle is running, and TRIP indication will switch to AVERAGE SPEED (AVS) indication, as calculated within the trip. To reset TRIP and corresponding AVERAGE SPEED (AVS) counter press MODE or SCROLL for more than five seconds, with vehicle stopped, and value displayed in area B of the display will change into four dashes.
  • Page 49 SXV / RXV 450 - 550 Proceed in the same way to set minutes and seconds, data will be stored after two seconds of inactivity (as previously explained). If unit of measurement is miles, when time is set, AM and PM blink alternately, press MODE to set correct indication;...
  • Page 50 SXV / RXV 450 - 550 BATTERY ICON 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: Main Independent Controls

    SXV / RXV 450 - 550 2.5. MAIN INDEPENDENT CONTROLS 2.5.1. CONTROLS ON THE RIGHT PART OF THE HANDLEBAR NOTE The electrical parts work only when the ignition switch is in position 1 ENGINE STOP SWITCH ( WARNING Do not operate the engine stop switch while riding.

  • Page 52: Controls On The Left Part Of The Handlebar

    SXV / RXV 450 - 550 2.5.2. CONTROLS ON THE LEFT PART OF THE HANDLEBAR NOTE The electrical parts work only when the ignition switch is in position 1 HIGH BEAM SIGNALING PUSHBUTTON ( It makes it possible to use the high beam for signalling to forthcoming vehicles in case of danger and/or emergency.

  • Page 53: Ignition Switch

    SXV / RXV 450 - 550 2.5.3. IGNITION SWITCH The ignition switch (1) is positioned on the upper plate of the steering column. NOTE The key operates the ignition switch/steering lock. Two keys are supplied together with the vehicle (one spare key).

  • Page 54: Steering Lock

    SXV / RXV 450 - 550 2.5.4. STEERING LOCK DANGER Never turn 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 "...

  • Page 55: Instructions For Use

    SXV / RXV 450 - 550 2.6. INSTRUCTIONS FOR USE 2.6.1. GENERAL WARNINGS FUEL DANGER The fuel used to operate engines is highly flammable becomes explosive under certain conditions. Refueling engine service should take place in a well-ventilated area with the engine stopped. Do not smoke while refueling or near fuel vapors.
  • Page 56 SXV / RXV 450 - 550 DANGER Take care not to spill fuel out of the filler, or it may ignite when in contact with hot engine parts. In case fuel has accidentally spilled, make sure that the area has completely dried, and before starting the vehicle check that there is no fuel inside the fuel filler neck.
  • Page 57 SXV / RXV 450 - 550 By contrast, if inflation pressure is too low, the tire walls are placed under greater stress, and the tire may slip on the rim or become loose, with consequent loss of control of the vehicle. In case of sudden braking, the tires could even come off the rims.

  • Page 58: Pre-Ride Checks Chart

    SXV / RXV 450 - 550 2.6.2. PRE-RIDE CHECKS CHART DANGER Before departure, always carry out a preliminary check of the vehicle to ensure that it functions correctly and safely. See the PRE-RIDE CHECKS CHART. Failure to comply with these checking procedures can cause severe personal injuries or damage to the vehicle.

  • Page 59: Starting

    SXV / RXV 450 - 550 2.6.3. STARTING DANGER Do not position any object inside the front fairing (between handlebar instrument panel), in order not to hinder the rotation of the handlebar and visibility toward the instrument panel. NOTE Before starting the engine, carefully read chapter safe drive , see (SAFE DRIVE).
  • Page 60 SXV / RXV 450 - 550 The following occurs: Starting page is shown for three seconds on display. All the lights on instrument panel turn on for three seconds. WARNING If the low fuel warning light " on the instrument panel comes on, provide for topping up as soon as possible, see (FUEL).
  • Page 61 SXV / RXV 450 - 550 exaggerate starting attempts or the starter motor could damage. It is recommended to keep the vehicle indoors, especially in winter. Contact an Aprilia Authorized dealer who will make any possible arrangement to solve the problem: e.g.

  • Page 62: Moving Off And Riding

    SXV / RXV 450 - 550 2.6.4. MOVING OFF AND RIDING DANGER Do not position any object inside the front fairing (between handlebar instrument panel), in order not to hinder the rotation of the handlebar and visibility toward the instrument panel. NOTE Before moving off, carefully read the riding in safety chapter, see page (RIDING IN SAFETY).
  • Page 63 SXV / RXV 450 - 550 To engage the second gear: WARNING Proceed quickly. Never ride the vehicle at too low of an rpm. Release throttle grip (2) (Pos.A), pull the clutch lever (3) and pull up the gear change lever (4). Release the clutch lever (3) and accelerate.
  • Page 64 SXV / RXV 450 - 550 Using one brake only reduces braking force significantly and may lock a wheel resulting in loss of grip. If you stop uphill, decelerate completely and use the brakes only to keep the vehicle steady. The use of the engine to keep the vehicle steady may cause the overheating of the clutch.

  • Page 65: Running-In

    SXV / RXV 450 - 550 2.6.5. RUNNING-IN The running-in of the engine is essential to ensure its life and correct operation. If possible, drive on hilly roads and/or roads with many bends, so that the engine, suspensions and brakes undergo a more effective running-in.

  • Page 66: Stopping

    SXV / RXV 450 - 550 2.6.6. STOPPING DANGER If possible, avoid stopping abruptly, slowing down suddenly and limit braking. Release the throttle grip, gradually put on the brakes and at the same time shift down in order to decrease the speed, see (MOVING OFF AND RIDING).

  • Page 67: Parking

    SXV / RXV 450 - 550 2.6.7. PARKING It is very important to choose a suitable parking area. Take care to obey traffic signs and the adhere to recommedations below. DANGER Park the vehicle on firm and flat ground, to prevent it from falling down.

  • Page 68: Positioning The Vehicle On The Stand

    SXV / RXV 450 - 550 2.6.8. POSITIONING THE VEHICLE ON THE STAND DANGER Make sure that the parking surface is free of obstacles, firm and flat. Carefully read the previous paragraph (PARKING). Grasp the left grip (1) and place your right hand on the rear upper part of the vehicle (2).

  • Page 69: Suggestions To Prevent Theft

    SXV / RXV 450 - 550 2.6.9. SUGGESTIONS TO PREVENT THEFT WARNING Do not use any brake lock devices. Failure to heed this warning can seriously damage the 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.

  • Page 70: Transport

    SXV / RXV 450 - 550 2.6.10. TRANSPORT 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: Cleaning

    SXV / RXV 450 - 550 2.6.11. CLEANING Clean the vehicle frequently if it is used in particular areas or conditions, such as: Polluted areas (cities and industrial areas). Areas characterized by a high percentage of salinity and humidity (coastlines, hot and humid climates). Special conditions (use of salt and deicing chemical products on the roads during the winter).
  • Page 72 SXV / RXV 450 - 550 Do not use water (or fluids) at a temperature exceeding 40°C (104°F) to clean the plastic components of the vehicle. Do not aim high-pressure water or air jets or steam jets onto the following components: wheel hubs, controls on the right and left side of the handlebar, bearings, brake master cylinders, instruments and indicators, exhaust...

  • Page 73: Long Periods Of Inactivity

    SXV / RXV 450 - 550 2.6.12. LONG PERIODS OF INACTIVITY WARNING In case the vehicle is left unridden for more than twenty days, disconnect the 30 A fuse to avoid early wear of the battery. After a long period of inactivity some precautions are necessary to avoid problems.

  • Page 74: After A Period Of Inactivity

    SXV / RXV 450 - 550 2.6.13. AFTER A PERIOD OF INACTIVITY Uncover and clean the vehicle, see (CLEANING). NOTE Withdraw the plastic 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).

  • Page 75: Rxv Accessories

    SXV / RXV 450 - 550 2.6.14. RXV ACCESSORIES RXV models are delivered together with a set of accessories not installed: Cooling fan Safety rubber band 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...
  • Page 76 SXV / RXV 450 - 550 2 - 49...
  • Page 77 MAINTENANCE SXV / RXV 450 - 550 MAINTENANCE 3 - 1...
  • Page 78 MAINTENANCE SXV / RXV 450 - 550 TABLE OF CONTENTS 3.1. GENERAL TECHNICAL INFORMATION ......................3 3.1.1. TECHNICAL DATA ..........................3 3.1.2. LUBRICANT TABLE..........................7 3.1.3. REGULAR SERVICE INTERVALS CHART ................... 8 3.1.4. CHECKING THE SWITCHES ......................14 3.1.5. BULBS ..............................15 3.1.6.

  • Page 79: General Technical Information

    MAINTENANCE SXV / RXV 450 - 550 3.1. GENERAL TECHNICAL INFORMATION 3.1.1. TECHNICAL DATA Aprilia RXV 450 – 550 DIMENSIONS Max. length 2240 mm (88.19 in.) Max. width 830 mm (32.68 in.) Max. height (front fairing included) 1250 mm (49.21 in.) Seat height 950 mm (37.40 in) Wheelbase...
  • Page 80 MAINTENANCE SXV / RXV 450 - 550 FUEL SYSTEM Type electronic injection Throttle (RXV 450) ø 1.49 in. (38 mm) Throttle (RXV 550) ø 1.57 in. (40 mm) FUEL SYSTEM Fuel premium grade unleaded gas, min. O.N. 95 (RON) and 85 (MON). FRAME Type Aluminum stanchion and steel tubes trellis...
  • Page 81 MAINTENANCE SXV / RXV 450 - 550 Aprilia SXV 450 – 550 DIMENSIONS Max. length 85.23 in (2165 mm) Max. width 32.08 in (815 mm) Max. height (front fairing included) 46.06 in. (1170 mm) Seat height 880 mm (34.64 in.) Wheelbase 57.87 in.
  • Page 82 MAINTENANCE SXV / RXV 450 - 550 FUEL SYSTEM Type electronic injection Throttle (SXV 450) ø 1.49 in (38 mm) Throttle (SXV 550) ø 1.57 in (40 mm) FUEL SYSTEM Fuel premium grade unleaded gas, min. O.N. 95 (RON) and 85 (MON). FRAME Type Aluminum stanchion and steel tubes trellis...

  • Page 83: Lubricant Table

    MAINTENANCE SXV / RXV 450 - 550 3.1.2. LUBRICANT TABLE SXV 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 10W or mix of oils in such percentage so...

  • Page 84: Regular Service Intervals Chart

    MAINTENANCE SXV / RXV 450 - 550 3.1.3. REGULAR SERVICE INTERVALS CHART REGULAR SERVICE INTERVALS CHART - For vehicles in homologated version (OFF HIGHWAY) WARNING Have the indicated operations performed by an Aprilia Dealer or Authorized Service Center or the warranty will become null and void.
  • Page 85 MAINTENANCE SXV / RXV 450 - 550 After running- Every Every Every Parts in 311 mi 1864 mi (3000 3728 mi (6000 9000 mi (5592 (500 km) Check brake system screws tightening ■ ■ Check Spark arrestor ■ ■ Check thickness of brake disks ■...
  • Page 86 MAINTENANCE SXV / RXV 450 - 550 REGULAR SERVICE INTERVALS CHART - For vehicles in open version for sport use (hobby purposes) WARNING Have the indicated operations performed by an Aprilia Dealer or Authorized Service Center or the warranty will become null and void. WARNING Halve maintenance intervals if you are riding in rainy or dusty conditions, on rough road surfaces or when the vehicle is used in competitions.
  • Page 87 MAINTENANCE SXV / RXV 450 - 550 After running- Every 15h of Every 60h of Every 90h of Parts in 3h of use Check brake system screws tightening ■ ■ Check Spark arrestor ■ ■ Check thickness of brake disks ■...
  • Page 88 MAINTENANCE SXV / RXV 450 - 550 REGULAR SERVICE INTERVALS CHART - For vehicles in open version for sport use (competitive purposes) WARNING Have the indicated operations performed by an aprilia Dealer or authorized service center or the warranty will become null and void. WARNING Halve maintenance intervals if you are riding in rainy or dusty conditions, on rough road surfaces or when the vehicle is used in competitions.
  • Page 89 MAINTENANCE SXV / RXV 450 - 550 After running- Every 15h of Every 30h of Every 45h of Parts in 3h of use Check pad thickness ■ Treat electric contacts and switches with suitable ■ spray Grease battery connections ■ Light operation/direction ■...

  • Page 90: Checking The Switches

    MAINTENANCE SXV / RXV 450 - 550 3.1.4. CHECKING THE SWITCHES Carefully read (MAINTENANCE). The vehicle is provided with two switches: Stop light switch (1) on rear brake lever. Stop light switch (2) on front brake lever. For the check, proceed as follows: •...

  • Page 91: Bulbs

    MAINTENANCE SXV / RXV 450 - 550 3.1.5. BULBS Carefully read (MAINTENANCE). DANGER Risk of fire. Keep fuel and other flammable substances away from the electrical components. WARNING Before proceeding to change a bulb, set the ignition switch to “ ”...
  • Page 92 MAINTENANCE SXV / RXV 450 - 550 LOW BEAM/HIGH BEAM BULB (2) DANGER To extract the bulb electric connector, do not pull its electric wires. • Grasp the bulb electric connector (3), pull it and disconnect it from the bulb holder. •...

  • Page 93: Spark Plug

    MAINTENANCE SXV / RXV 450 - 550 3.1.6. SPARK PLUG Carefully read (MAINTENANCE). NOTE Halve indicated maintenance intervals if the vehicle is used in rainy or dusty areas, on uneven surfaces, or in competitions. WARNING Check, clean or replace both spark plugs, one by one.
  • Page 94 MAINTENANCE SXV / RXV 450 - 550 WARNING When changing the spark plug (2), check the thread pitch and length. If the threaded part is too short, the carbon deposits will accumulate on the thread seat, and therefore the engine may be damaged during the installation of the right spark plug.

  • Page 95: Fuses

    MAINTENANCE SXV / RXV 450 - 550 3.1.7. FUSES CHANGING THE FUSES Carefully read (MAINTENANCE). WARNING Do not repair faulty fuses. Never fuses different from recommended ones. The use of unsuitable fuses may cause damages to the electric system or, in case of short circuit, even a fire.
  • Page 96 MAINTENANCE SXV / RXV 450 - 550 LAYOUT OF AUXILIARY FUSES 15A Fuse: 1 - Control unit relay energizing 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:...

  • Page 97: Headlight Beam Vertical Adjustment

    MAINTENANCE SXV / RXV 450 - 550 3.1.8. HEADLIGHT BEAM VERTICAL ADJUSTMENT NOTE To check the direction of the headlight beam, specific procedures must be adopted, in accordance with the regulations in force in the country where the vehicle is used. To make a quick check that the beam points in the correct direction, •...

  • Page 98: Disk Brakes

    MAINTENANCE SXV / RXV 450 - 550 3.1.9. DISK BRAKES DANGER The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working; check them before every trip. A dirty disk will soil the pads, leading to loss of braking efficiency.
  • Page 99 MAINTENANCE SXV / RXV 450 - 550 CAUTION After servicing the brakes, always check that they are working properly. If the stroke of the lever is excessive, or if you detect that the effectiveness of the brakes is reduced in any way, have your vehicle serviced by your Local aprilia Dealer.
  • Page 100 MAINTENANCE SXV / RXV 450 - 550 Checking the rear brake caliper pads: NOTE The rear brake caliper has two brake pads. • Carry out a visual check between the brake caliper and the pads, proceeding: from above, on the rear end; Checking the front brake caliper pads: NOTE The front brake caliper has two brake pads.

  • Page 101: Drive Chain

    MAINTENANCE SXV / RXV 450 - 550 3.1.10. DRIVE CHAIN Carefully read (MAINTENANCE). SXV fits an endless chain, while RXV fits a chain with master link. DANGER An excessive slackening of the chain may make the chain detach from the sprocket, resulting in an accident or vehicle serious damage.
  • Page 102 MAINTENANCE SXV / RXV 450 - 550 • Tighten the nut (1). Wheel nut (1) tightening torque: 127 Nm (12.7 kgm) • Check chain slack, see (CHECKING THE SLACK). CHECKING CHAIN AND SPROCKETS FOR WEAR Also check the chain and sprockets and make sure that they do not present: damaged rollers;...

  • Page 103: Special Tools

    MAINTENANCE SXV / RXV 450 - 550 3.1.11. SPECIAL TOOLS Pos. Description Part number Tool for fitting fork oil seal Ø 1.77 in. (45 mm) RXV 9100903 Tool for fitting fork oil seal Ø 1.89 in.(48 mm) SXV 9100904 swing arm cages punch 9100898 Punch for left casing desmo + wheel hub 9100892...

  • Page 104: Tightening Torque Settings

    MAINTENANCE SXV / RXV 450 - 550 3.1.12. TIGHTENING TORQUE SETTINGS TIGHTENING SCREW / TORQUE DESCRIPTION NOTES SETTINGS Nm (LbFt)) HANDLEBAR AND CONTROLS Screw securing clutch control to handlebar 10 (7.4) Throttle control screw 4 (3.0) Ignition switch screw 24 (17.7) FOOTRESTS Footrest support bracket screw 55 (40.6)
  • Page 105 MAINTENANCE SXV / RXV 450 - 550 TIGHTENIN SCREW G TORQUE DESCRIPTION NOTES / NUT SETTINGS EXHAUST SYSTEM Screw securing silencer to subframe 22 (16.2) Exhaust pipes nut 12 (8.9) Screw securing tubes to head 12 (8.9) Screw securing brake to handlebar 10 (7.4) COOLING SYSTEM Radiators upper screw...
  • Page 106 MAINTENANCE SXV / RXV 450 - 550 TIGHTENING SCREW / TORQUE DESCRIPTION NOTES SETTINGS ENGINE Oil filter cover M56x1.5 25 (18.4) Piston mounting hole plug M30x2 30 (22.1) Spark plug M10X1.25 12 (8.9) Gearbox fluid check screw M6x1 9.8 (7.23) Water pump impeller M7x1 12 (8.9)

  • Page 107: Scheduled Maintenance

    MAINTENANCE SXV / RXV 450 - 550 3.2. SCHEDULED MAINTENANCE 3.2.1. CHECKING BRAKE FLUID LEVEL AND TOPPING UP NOTE This vehicle is fitted with front and rear disk brakes. Each braking system is operated by an independent hydraulic circuit. The following information refers to a single braking system, but is valid for both.
  • Page 108 MAINTENANCE SXV / RXV 450 - 550 DISK BRAKES DANGER The brakes are the parts that most ensure your safety and for this reason they must always be perfectly working; check them before every trip. The brake fluid must be changed every year by an aprilia Authorized Dealer.
  • Page 109 MAINTENANCE SXV / RXV 450 - 550 WARNING Avoid any prolonged exposure of the brake fluid to the air. The brake fluid is hygroscopic and when in contact with the air it absorbs its humidity. Leave the brake fluid tank (1) open ONLY for the time necessary for topping up.
  • Page 110 MAINTENANCE SXV / RXV 450 - 550 WARNING Top up to "MAX" 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 the braking efficiency.
  • Page 111 MAINTENANCE SXV / RXV 450 - 550 • Top up the reservoir (2) by adding brake fluid, see (LUBRICANT TABLE), until exceeding “MIN” level mark. WARNING Top up to "MAX" 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.

  • Page 112: Checking The Engine Oil Level And Topping Up

    MAINTENANCE SXV / RXV 450 - 550 3.2.2. CHECKING THE ENGINE OIL LEVEL AND TOPPING UP DANGER Engine oil may cause serious damage to the skin if handled daily and for long periods. Wash your hands carefully after use. KEEP AWAY FROM CHILDREN. RELEASE INTO ENVIRONMENT.
  • Page 113 MAINTENANCE SXV / RXV 450 - 550 NOTE To warm the engine and have the engine oil reach the operating temperature ride the vehicle for a while (10 - 15 min), then let the engine idle with the vehicle at rest for at least 30 seconds, and stop the engine.

  • Page 114: Changing Engine Oil And Oil Filter

    MAINTENANCE SXV / RXV 450 - 550 3.2.3. CHANGING ENGINE OIL AND OIL FILTER • Move the sump guard down. • Position the vehicle on firm and flat ground. • Position the vehicle on the stand. WARNING Allow several minutes for the engine and exhaust system to cool down.

  • Page 115: Gearbox Fluid

    MAINTENANCE SXV / RXV 450 - 550 3.2.4. GEARBOX FLUID CHECKING AND TOPPING UP WARNING gearbox oil level must be checked when the engine is warm. • Stop the engine. • Wait a few minutes to allow oil to get from the gearbox to the clutch.
  • Page 116 MAINTENANCE SXV / RXV 450 - 550 • Unscrew and remove the inspection plug (2). • Fill with new oil, see (LUBRICANT TABLE), until oil reaches inspection plug hole (2). • Wait a few minutes to allow oil to get from the clutch to the gearbox, then check level again.

  • Page 117: Coolant

    MAINTENANCE SXV / RXV 450 - 550 3.2.5. COOLANT Do not ride when coolant is below the minimum level. NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions, on rough road surfaces or when the vehicle used competitions.
  • Page 118 MAINTENANCE SXV / RXV 450 - 550 CHECKING AND TOPPING UP DANGER Check the coolant level and top up the expansion tank with cold engine. • Stop the engine and wait until it has cooled down. • Position the vehicle on firm and flat ground. •...

  • Page 119: Adjustments

    MAINTENANCE SXV / RXV 450 - 550 3.3. ADJUSTMENTS 3.3.1. TENSIONING THE THROTTLE CABLES Carefully read (MAINTENANCE). NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions, on rough road surfaces or when the vehicle is used in competitions. The idle stroke of the throttle grip must be 0.079 ±...

  • Page 120: Suspensions

    MAINTENANCE SXV / RXV 450 - 550 3.3.2. SUSPENSIONS CHECKING THE FRONT SUSPENSION DANGER To change the fork fluid, contact an aprilia Authorized Dealer, who will ensure you prompt and accurate servicing. Carefully read (MAINTENANCE). Change fork fluid more frequently if the vehicle is used in rainy or dusty areas and in off-road conditions.
  • Page 121 MAINTENANCE SXV / RXV 450 - 550 However, suspension setting may be modified to suit specific needs in accordance with vehicle use. 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).
  • Page 122 MAINTENANCE SXV / RXV 450 - 550 REAR SUSPENSION The rear suspension consists of a spring-shock absorber unit, fixed to the frame by means of a rubber cush drive and to the swing arm by means of lever systems. The rear shock absorber is fitted with suitable adjusters to modify suspension set-up.
  • Page 123 MAINTENANCE SXV / RXV 450 - 550 WARNING Do not loosen screw (5) or disturb the membrane underneath or the resulting nitrogen loss will impair shock absorber operation making the motorcycle unsafe to ride. DANGER Racing settings may only be used during official competitions sports...

  • Page 124: Bleeding

    MAINTENANCE SXV / RXV 450 - 550 3.4. BLEEDING 3.4.1. BLEEDING THE FRONT BRAKE SYSTEM The air, if any, present inside the hydraulic circuit will serve as "pad" by absorbing most of the pressure coming from the brake master cylinder and thus reducing the caliper efficiency during braking.
  • Page 125 MAINTENANCE SXV / RXV 450 - 550 • Loosen the bleed valve by 1/4 of a turn so as the brake fluid flows in the container, this will remove any tension from the lever and help it travel fully home. •...

  • Page 126: Bleeding The Rear Brake System

    MAINTENANCE SXV / RXV 450 - 550 3.4.2. BLEEDING THE REAR BRAKE SYSTEM The air, if any, present inside the hydraulic circuit will serve as "pad" by absorbing most of the pressure coming from the brake master cylinder and thus reducing the caliper efficiency during braking.

  • Page 127: Spark Arrestor

    MAINTENANCE 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. 3 - 51...
  • Page 128 CHASSIS SXV / RXV 450 - 550 CHASSIS 4 - 1...
  • Page 129 CHASSIS SXV / RXV 450 - 550 TABLE OF CONTENTS 4.1. CHASSIS ................................. 3 4.1.1. REMOVING THE SEAT ......................... 3 4.1.2. REMOVING THE BATTERY ........................4 4.1.3. REMOVING THE CONTROL UNIT......................5 4.1.4. REMOVING THE REAR WHEEL ......................6 4.1.5. REMOVING THE SWING ARM ......................

  • Page 130: Chassis

    CHASSIS SXV / RXV 450 - 550 4.1. CHASSIS 4.1.1. REMOVING THE SEAT • Turn the lip. • Remove the seat. 4 - 3...

  • Page 131: Removing The Battery

    CHASSIS SXV / 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.

  • Page 132: Removing The Control Unit

    CHASSIS SXV / RXV 450 - 550 4.1.3. REMOVING 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.

  • Page 133: Removing The Rear Wheel

    CHASSIS SXV / RXV 450 - 550 4.1.4. REMOVING THE REAR WHEEL • Place the vehicle on the suitable supports (OPT). • Unscrew and remove the nut and collect the washer. • Working on either side, loosen adjuster. • Remove the chain. •...
  • Page 134 CHASSIS SXV / RXV 450 - 550 • Remove the bush. 4 - 7...

  • Page 135: Removing The Swing Arm

    CHASSIS SXV / RXV 450 - 550 4.1.5. REMOVING 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.
  • Page 136 CHASSIS SXV / RXV 450 - 550 • Loosen and remove 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. •...
  • Page 137 CHASSIS SXV / RXV 450 - 550 • Remove swing arm shaft. 4 - 10...

  • Page 138: Installing The Rear Wheel

    CHASSIS SXV / RXV 450 - 550 4.1.6. INSTALLING THE REAR WHEEL • Refit the bush. • Fit the rear wheel. • Refit the chain. • Working on either side, fit the shims. • Working on the left side, fit the wheel shaft. •...

  • Page 139: Removing The Exhaust System

    CHASSIS SXV / RXV 450 - 550 4.1.7. REMOVING THE EXHAUST SYSTEM • Unscrew 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. •...
  • Page 140 CHASSIS SXV / RXV 450 - 550 • Loosen 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.

  • Page 141: Fuel Feeding System

    CHASSIS SXV / RXV 450 - 550 4.2. FUEL FEEDING SYSTEM 4.2.1. DIAGRAM Key: Fuel tank Fuel tank filler cap Plug gasket 5x9 Tube Fuel pump assy Fuel filter Gasket Thermistor 4 - 14...

  • Page 142: Removing The Fuel Tank

    CHASSIS SXV / RXV 450 - 550 4.2.2. REMOVING THE FUEL TANK • Remove the seat, see (REMOVING THE SEAT). • Working on one side, loosen and remove the two screws, collect the washer. • Remove the lower side body panel. NOTE Cutting the side body panel along marks (A) allows you to remove the tank without removing the lower side panel first.
  • Page 143 CHASSIS 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. •...

  • Page 144: Removing The Air Filter

    CHASSIS SXV / RXV 450 - 550 4.2.3. REMOVING THE AIR FILTER • Remove the seat, see (REMOVING THE SEAT). • Raise the fuel tank, see (REMOVING THE FUEL TANK). • Grasp and release the handles on either sides to release the air box cover.

  • Page 145: Injection

    CHASSIS SXV / RXV 450 - 550 4.3. INJECTION 4.3.1. DIAGRAM 4 - 18...
  • Page 146 CHASSIS SXV / RXV 450 - 550 Key: Ignition keys Fuel pump Ignition switch Instrument panel Intake air temperature sensor Throttle position sensor Injector Intake air pressure sensor Cooling fans 10. Engine temperature sensor 11. Speed sensor (front wheel) 12. Crankshaft position sensor 13.

  • Page 147: Cooling System

    CHASSIS SXV / RXV 450 - 550 4.4. COOLING SYSTEM 4.4.1. DIAGRAM Key: Left radiator Right radiator Expansion tank Complete fan Fan support Tube D10 – d5.5 Tube connecting left to right radiator - upper Tube connecting left to right radiator - lower Tube connecting radiator to water pump 10.

  • Page 148: Removing The Radiator

    CHASSIS SXV / RXV 450 - 550 4.4.2. REMOVING THE RADIATOR • Working on either side, loosen and remove the three side body panel screws. • Remove the side body panels. • Prepare a container of suitable capacity under the hose.
  • Page 149 CHASSIS 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. 4 - 22...
  • Page 150 CHASSIS SXV / RXV 450 - 550 • Working on the right side, loosen the lower screw and collect the nut and washer on 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.

  • Page 151: Lubrication System

    CHASSIS SXV / RXV 450 - 550 4.5. LUBRICATION SYSTEM 4.5.1. DIAGRAM Key: Oil tank assembly Oil drain plug Washer 12x18x1.5 Oil filler plug M20x1.5 O-ring 3075 Flanged hex.head screw M6x70 Flanged hex.head screw M6x95 Narrow self-locking nut M6x1 Blow-by hose L=215 10.

  • Page 152: Removing The Oil Tank

    CHASSIS SXV / RXV 450 - 550 4.5.2. REMOVING THE OIL TANK • Remove the seat, see (REMOVING THE SEAT). • Raise the fuel tank, see (REMOVING THE FUEL TANK). • Remove the radiators from the cooling system, see (REMOVING THE RADIATORS). •...
  • Page 153 CHASSIS SXV / 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.
  • Page 154 CHASSIS SXV / RXV 450 - 550 4 - 27...
  • Page 155 CYCLE PARTS SXV / RXV 450 – 550 CYCLE PARTS 5 - 1...
  • Page 156 CYCLE PARTS SXV / RXV 450 – 550 TABLE OF CONTENTS 5.1. FRONT FORK (SXV) ........................3 5.1.1. DIAGRAM (SXV) ........................3 5.1.2. REMOVING THE FORK LEGS (SXV)..................4 5.1.3. CHANGING THE FORK FLUID (SXV) ..................8 5.1.4. DISASSEMBLING THE FRONT FORK (SXV) ..............11 5.1.5.

  • Page 157: Front Fork (Sxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.1. FRONT FORK (SXV) 5.1.1. DIAGRAM (SXV) Key: Left fork assembly Right fork assembly Left stanchion Right stanchion Complete sleeve Ring for spring Spring Kit Complete damper rod Complete valve Complete plug Flanged TE screw Dust seal + oil seal kit Seal Kit Ø...

  • Page 158: Removing The Fork Legs (Sxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.1.2. REMOVING THE FORK LEGS (SXV) • Loosen and remove the two front screws securing the mudguard. • Loosen and remove the four screws securing the mudguard. • Remove the front mudguard •...
  • Page 159 CYCLE PARTS SXV / RXV 450 – 550 • Working 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.
  • Page 160 CYCLE PARTS SXV / 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 SXV / RXV 450 – 550 • Remove the fork leg. 5 - 7...

  • Page 162: Changing The Fork Fluid (Sxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.1.3. CHANGING THE FORK FLUID (SXV) NOTE The following procedure applies to both fork legs. Periodically change the fork fluid, see (REGULAR SERVICE INTERVALS CHART). NOTE While draining and filling fork fluid, the stanchion and its parts should be clamped in a vice;...
  • Page 163 CYCLE PARTS SXV / RXV 450 – 550 • Drain all oil inside the container as shown. NOTE Pump the leg inside the sleeve to help oil drain out completely from the damper rod. FILLING UP: • Pour fork fluid inside the sleeve (3) up to the correct level that can be measured by inserting a graduated rod inside sleeve (3).
  • Page 164 CYCLE PARTS 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). 5 - 10...

  • Page 165: Disassembling The Front Fork (Sxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.1.4. DISASSEMBLING THE FRONT FORK (SXV) • Drain all fluid from inside the 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.
  • Page 166 CYCLE PARTS SXV / RXV 450 – 550 • Slide out the dust seal (1) from the sleeve prising it out with a screwdriver. 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.
  • Page 167 CYCLE PARTS 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), 5 - 13...
  • Page 168 CYCLE PARTS SXV / RXV 450 – 550 snap ring (2) and dust scraper seal (1). 5 - 14...

  • Page 169: Reassembling The Front Fork (Sxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.1.5. REASSEMBLING THE FRONT FORK (SXV) NOTE Take the suitable special tool OPT (A) (part no. 9100904) before proceeding and smear the gaskets and bushings with fork fluid before refitting them. • Fit the components onto the fork leg in the following order: dust scraper seal (1).
  • Page 170 CYCLE PARTS 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: Installing The Fork Legs (Sxv)

    CYCLE PARTS 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 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. 5 - 18...
  • Page 173 CYCLE PARTS SXV / RXV 450 – 550 • Working on the left side, partially tighten the front wheel shaft nut. NOTE To lock wheel shaft rotation tighten the two screws on fork clamp, right side. • Working on the left side, tighten the front wheel shaft nut.
  • Page 174 CYCLE PARTS SXV / RXV 450 – 550 • Tighten the two mudguard front screws. 5 - 20...

  • Page 175: Front Fork (Rxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.2. FRONT FORK (RXV) 5.2.1. DIAGRAM (RXV) Key: Left fork assembly Right fork assembly Left stanchion Right stanchion Upper bushing Seal Retainer Snap ring Dust scraper ring Complete sleeve Dowel + O-ring Ring for spring Spring Kit Complete damper rod...

  • Page 176: Removing The Fork Legs (Rxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.2.2. REMOVING THE FORK LEGS (RXV) • Loosen and remove the two front screws securing the mudguard. • Loosen and remove the four screws securing the mudguard. • Remove the front mudguard. •...
  • Page 177 CYCLE PARTS SXV / RXV 450 – 550 • Working 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.
  • Page 178 CYCLE PARTS SXV / 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 SXV / RXV 450 – 550 • Remove the fork leg. 5 - 25...

  • Page 180: Changing The Fork Fluid (Rxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.2.3. CHANGING THE FORK FLUID (RXV) NOTE The following procedure applies to both fork legs. Periodically change the fork fluid, see (REGULAR SERVICE INTERVALS CHART). NOTE While draining and filling fork fluid, the stanchion and its parts should be clamped in a vice;...
  • Page 181 CYCLE PARTS SXV / RXV 450 – 550 • Remove the spring (5). Let oil drip from the 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.
  • Page 182 CYCLE PARTS SXV / RXV 450 – 550 • Pour fork fluid inside the sleeve (3) up to the correct level that can be measured by inserting a graduated rod inside sleeve (3). level: 3.94 ± 0.079 (100 ± 2 mm) (from leg edge) NOTE To correctly measure the fluid level, ensure that fork leg (3) is perfectly vertical and fully home in the sleeve.

  • Page 183: Disassembling The Front Fork (Rxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.2.4. DISASSEMBLING THE FRONT FORK (RXV) • Drain all fluid from inside the 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.
  • Page 184 CYCLE PARTS SXV / RXV 450 – 550 • Slide out the dust seal (1) from the sleeve prising it out with a screwdriver. 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.
  • Page 185 CYCLE PARTS 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), 5 - 31...
  • Page 186 CYCLE PARTS SXV / RXV 450 – 550 snap ring (2); dust scraper seal (1). 5 - 32...

  • Page 187: Reassembling The Front Fork (Rxv)

    CYCLE PARTS SXV / RXV 450 – 550 5.2.5. REASSEMBLING THE FRONT FORK (RXV) NOTE Take the suitable special tool OPT (A) (part no. 9100903) before proceeding and smear the gaskets and bushings with fork fluid before refitting them. • Fit the components onto the fork leg in the following order: dust scraper seal (1).
  • Page 188 CYCLE PARTS 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: Installing The Fork Legs (Rxv)

    CYCLE PARTS 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 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. 5 - 36...
  • Page 191 CYCLE PARTS SXV / RXV 450 – 550 • Working on the left side, partially tighten the front wheel shaft nut. NOTE To lock wheel shaft rotation tighten the two screws on fork clamp, right side. • Working on the left side, tighten the front wheel shaft nut.
  • Page 192 CYCLE PARTS SXV / RXV 450 – 550 • Tighten the two mudguard front screws. 5 - 38...
  • Page 193 CYCLE PARTS SXV / RXV 450 – 550 5 - 39...
  • Page 194 ELECTRICAL SYSTEM Engine 450 - 550 ELECTRICAL SYSTEM 6 - 1...
  • Page 195 ELECTRICAL SYSTEM Engine 450 - 550 TABLE OF CONTENTS 6.1. ELECTRICAL SYSTEM........................... 3 6.1.1. SXV - RXV DIAGRAM..........................3 6 - 2...
  • Page 196 ELECTRICAL SYSTEM Engine 450 - 550 6.1. ELECTRICAL SYSTEM 6.1.1. SXV - RXV DIAGRAM 6 - 3...
  • Page 197 ELECTRICAL SYSTEM Engine 450 - 550 Key: Multiple connectors Diagnosis connector Speed sensor Instrument panel Repeater LH dimmer switch Horn Ignition switch Light relay RH dimmer switch Rear stop switch Front stop switch Rear LH turn indicator Tail light Number plate light Rear RH turn indicator (Buffer) capacitor Auxiliary fuses...
  • Page 198 ELECTRICAL SYSTEM Engine 450 - 550 6 - 5...

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