Page 1 SERVICE STATION MANUAL 854239 MXV 450...
Page 2: The Value Of Service
Not all versions shown in this publication are available in all countries. The availability of individual versions should be confirmed with the official Aprilia sales network. © Copyright 2008 - Aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Aprilia - After sales service.
Page 3 - This manual provides the main information to carry out regular maintenance operations on your vehicle. - This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing vehicles.
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7: Safety Rules
MXV 450 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 MXV 450 Characteristics KEEP OUT OF THE REACH OF CHILDREN. DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING. Used engine oil and gearbox oil CAUTION IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE- HICLE.
Page 9: Electrical Connectors
REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10: Dimensions And Mass
NOTE EVEN AFTER THE RUNNING-IN PERIOD, AVOID RUNNING THE ENGINE AT TOP SPEED, WHEN THE LIMITER CUTS IN: • MXV 450 12500 rpm Dimensions and mass EIGHT AND DIMENSIONS Specification Desc./Quantity Max.
Page 11 MXV 450 Characteristics Specification Desc./Quantity Squish 1 mm (0.039 in) Electric Kick-start Engine speed at idle Mapped in relation to coolant temperature Clutch 8 disc wet clutch Lubrication system Pressure-fed circuit, dry sump system with internal reservoir Air filter Sponge...
Page 12: Wheels And Tyres
MXV 450 Characteristics SIZES A Specification Desc./Quantity Size "A" 581.3 mm (22.89 in) Size "B" 422.5 mm (16.6 in) Brakes RAKES Specification Desc./Quantity Front disc Ø 270 mm (Ø 10.63 in) hydraulic disc brake Rear drum Ø 240 mm (Ø 9.45 in) hydraulic disc brake...
Page 13 MXV 450 Characteristics Name Torque in Nm Upper clamp - handlebar fixing screw - M8 24 Nm (17.70 lbf ft) FOOTRESTS Name Torque in Nm Footrest support bracket fixing screw - M12 50 Nm (36.88 lbf ft) - Loctite 243 Footrest support bracket fixing screw - M8 25 Nm (18.44 lbf ft) - Loctite 243...
Page 14: Front Wheel
MXV 450 Characteristics FRONT WHEEL Name Torque in Nm Wheel axle cover - M22 60 Nm (44.25 lbf ft) Screw fixing front disc - M6 12 Nm (8.85 lbf ft) Nut fixing cover clamps - M8 10 Nm (7.37 lbf ft) Spoke nipples - M4 38 Nm (28.03 lbf ft)
Page 15 MXV 450 Characteristics NGINE Name Torque in Nm Engine oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft) Engine oil drainage plug on ignition cover - M12x1.5 18 Nm (13.28 lbf ft) Gearbox oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft) Oil filter cover - M56x1.5...
Page 16: Overhaul Data
MXV 450 Characteristics Overhaul data Assembly clearances Crankcase - crankshaft - connecting rod To choose the appropriate spare parts for the coupling bushings, check the type of original components and the correct bushing on the table. The type of component is engraved with laser pen on the components themselves.
Page 17 MXV 450 Characteristics Recommended products chart RECOMMENDED PRODUCTS TABLE Product Description Specifications AGIP RACING 4T 10W-60 engine oil Use top-branded oils that meet or exceed the CCMC G-4 API SG. SAE 10W-60 specifications requirements AGIP GEAR SYNTH SAE 75W-90 Synthetic lubricant for gearboxes and API GL4 - API GL5 transmissions.
Page 18 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 19: Special Tools
MXV 450 Special tools SPECIAL TOOLS Stores code Description 853715 Water pump oil seal guide 853716 Water pump oil seal punch AP8140179 Valve spring compressor AP8140187 Engine support stand 8140188 Engine support AP9100838 Tool for valve pressure plate S-TOOLS - 19...
Page 20 MXV 450 Special tools Stores code Description 9100839 Flywheel extractor 020685Y Crankshaft pinion locking tool 9100844 Crankshaft locking tool (timing pin) 9100885 Main shaft/ right side - secondary shaft/ left side 9100886 Secondary shaft/right side - Main shaft/ left side...
Page 21 MXV 450 Special tools Stores code Description 9100889 Timing gear crankshaft punch 9100890 Timing gear crankshaft punch 9100892 Left crankcase desmodromic + wheel 9100893 Left timing gear punch 9100894 Secondary shaft oil seal punch 9100895 Water pump oil seal punch...
Page 22 MXV 450 Special tools Stores code Description 9100897 Cylinder liner extractor 9100898 Swingarm cages punch 9100900 Punch for swingarm linkage cages AP8140758 tool to fit oil seals and dust gaiter for ø 50 mm (1.97 in) stems 9100938 Pump rotor wrench...
Page 23 MXV 450 Special tools Stores code Description 9100942 Crankcase halves support 020376Y Adapter handle 020483Y 30-mm guide 020684Y Ø 58 - 60 mm (2.28 - 2.36 in) guide S-TOOLS - 23...
Page 24: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 25: Maintenance Chart
MXV 450 Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS RECOMMENDED IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS. EGULAR MAINTENANCE TABLE ACCORDING TO OPERATING HOURS I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY...
Page 26 MXV 450 Maintenance Operating hours Every 2.5 Every 7.5 Every 15 Every 22.5 Every 45 Brake pad thickness (remark 1) Fork bleeding Valve and valve guide seal tightness Blow-by pipe Throttle grip cable linkage Fuel pipes Exhaust pipe / silencer (remark 6)
Page 27: Spark Plug
MXV 450 Maintenance Number of races Every Every 3 Every 6 Every 9 Every 18 race races races races races Fuel pipes Exhaust pipe / silencer (remark 6) Camshaft wear Break pad wear Cotter, valve and bucket tappet wear Oil pressure regulator valve Spark plug At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
Page 28 MXV 450 Maintenance KEY: central electrode (3); insulator (4); side electrode (5). • Check that the electrodes and the in- sulator of the spark plug (2) do not show signs of carbon deposits and cor- rosion. If necessary, clean them using a compressed air jet.
Page 29: Engine Oil
MXV 450 Maintenance complete 1/2 of a turn to compress the washer. CAUTION IT IS ESSENTIAL TO TIGHTEN THE SPARK PLUG (2) PROPERLY. A LOOSE SPARK PLUG MAY CAUSE ENGINE OVERHEATING AND RESULT IN SEVERE DAMAGE. Locking torques (N*m) Spark plug - M10x1.25 12 Nm (8.85 lbf ft)
Page 30 MXV 450 Maintenance IF YOU RIDE THE VEHICLE IN A SPORTY FASHION, SOME OIL SPLATTER MAY GET TO THE AIR FILTER HOUSING THROUGH THE ENGINE VENT. IN THIS CASE EXCESS OIL GETS DE- POSITED INSIDE THE TRANSPARENT PIPE (2). CAUTION DO NOT GO BEYOND THE MAX AND BELOW THE MIN LEVEL MARKS TO AVOID SEVERE EN- GINE DAMAGE.
Page 31: Engine Oil Filter
MXV 450 Maintenance Characteristic Engine oil capacity, replacing oil filter 1200 cm³ (73.23 cu.in) Engine oil filter • Drain off the engine oil completely. • Unscrew the engine oil filter cover (2). • Remove the engine oil filter cover (2) and collect the O-ring.
Page 32: Gearbox Oil
MXV 450 Maintenance • Remove spring (3). • Remove valve (4) from its seat using a M10x1.25 screw, if required. • Clean valve (4) with a jet of com- pressed air. • Let oil flow out of the seat, refit valve (4) and check smoothness.
Page 33 MXV 450 Maintenance • Stop the engine. • Wait some minutes for the oil to flow from the transmission to the clutch. • Keep the vehicle upright with the two wheels on the ground. • Remove the rear brake lever by undo- ing the screw (1).
Page 34: Air Filter
MXV 450 Maintenance • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and if necessary, replace the drainage plug (3) sealing washers. • Screw and tighten the drainage plug (3).
Page 35: Cooling System
MXV 450 Maintenance CAUTION REMOVE THE AIR FILTER COVER ONLY WHEN THE VE- HICLE IS PERFECTLY CLEAN SO AS TO PREVENT ANY TRACE OF DIRT FROM GETTING INTO THE BOX. Throttle grip cables replacement • Loosen tension of the throttle grip ca- bles of the throttle body.
Page 36 MXV 450 Maintenance • Shut off the engine and wait until it cools off. • Park the vehicle on firm and level ground. • Keep the vehicle upright with the two wheels on the ground. • Turn the radiator cap (1) anticlockwise just one click.
Page 37: Braking System
CAUTION UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. CONTACT AN Official aprilia dealer IN CASE OF DOUBTS ON THE CORRECT BRAKING CIRCUIT OPERATION AND WHEN UNABLE TO CARRY OUT ROUTINE CHECKS. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND THE FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY AFTER MAINTENANCE OPERATIONS OR CHECKS.
Page 38: Rear Brake
MXV 450 Maintenance • Place the vehicle upright and keep the handlebar right. • Make sure the fluid level in the reservoir (1) is above the 'MIN' level reference mark. MIN = minimum level MAX = maximum level If the fluid does not reach at least the "MIN" level reference mark: •...
Page 39 RISK SPILLING THE FLUID WHEN CHANGING THE BRAKE PADS. CHECK BRAKING EFFICIENCY. WHEN THE BRAKE LEVER HAS EXCEEDING TRAVEL OR IF YOU NOTICE A LOSS OF BREAK- ING, CONTACT AN APRILIA OFFICIAL DEALER. THE BRAKING SYSTEM MAY NEED BLEEDING. REAR BRAKE •...
Page 40: Exhaust System
MXV 450 Maintenance Exhaust system Replace silencer acoustic insulation material CAUTION BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, WEAR A PAIR OF SAFETY GLOVES • Remove the connection rivets between the silencer upper and lower half-shells operating as follows: With a commercially available Ø 3mm pin and a rubber mallet "perforate"...
Page 41 MXV 450 Maintenance • With the aid of a cutter detach both half-shells and clean them with black silicone. • Remove the acoustic insulation mate- rial of the upper half-shell. • Remove the acoustic insulation mate- rial of the lower half-shell.
Page 42 MXV 450 Maintenance • Place the new acoustic insulation ma- terial (prepacked packets and materi- al) in the upper and lower half-shells. • Apply liquid gasket for high tempera- tures (at least 250°C) on the faying surfaces between both half-shells.
Page 43 MXV 450 Maintenance CAUTION THIS PROCEDURE IS VALID FOR BOTH EXHAUST ENDS • With an indelible pen mark the phase between the front bottom (that welded to the joint) and the muffler body as visual reference to check the correct orientation during refitting phase.
Page 44 MXV 450 Maintenance • Slide off the exhaust end cover, being careful that the acoustic insulation ma- terial remains attached to the exhaust end. • Detach the acoustic insulation material which covers the metal wool. CAUTION IT IS ADVISABLE TO LEAVE THE METAL WOOL PLACED AROUND THE SILENCER MESH, IF NECESSARY (WHEN THERE ARE "HOLES"...
Page 45: Index Of Topics
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 46 MXV 450 Electrical system Components arrangement 1. Fuel supply unit 2. Right injector 3. Fuses ELE SYS - 46...
Page 47: Electrical System Installation
MXV 450 Electrical system 4. Right coil 5. Right spark plug 6. Engine temperature sensor 7. Throttle position sensor (TPS) 8. Crankshaft revolution/timing sensor 9. Intake air temperature sensor 10.ECU 11.Left injector 12.Left coil 13.Left spark plug 14.Stepper motor 15.Voltage regulator 16.Condenser...
Page 48 MXV 450 Electrical system The main cable harness is locked with clamps at two points: 1) On the injector connecting fuel pipe, laying the cable harness towards the rear throttle body so as to avoid excessive vertical extension that hinders placing the cover.
Page 49 MXV 450 Electrical system Coils (4) and (5) are so placed that the connector is suitably positioned. Clamp (6) locks the left coil supply cable. The main cable harness must also be secured ex- ternally by locking it to the filter housing with clamp (7) on the left side.
Page 50 MXV 450 Electrical system Due to the closeness of the front exhaust manifold, be especially careful when laying the clutch control cable, the transmission bleed pipe (9) and cable (10) connecting the right coil and the front cylinder spark plug.
Page 51: General Wiring Diagram
MXV 450 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Diagnosis connector 3. Capacitor (buffer) 4. Fuse ELE SYS - 51...
Page 52: Checks And Inspections
MXV 450 Electrical system 5. Fuel pump 6. Voltage regulator 7. Generator 8. Water Temperature Sensor 9. Coil 2 (rear cil.) (fitted on the left) 10.Spark plug 2 11.Coil 1 (front cil.) (fitted on the right) 12.Spark plug 1 13.Intake air temperature sensor 14.Throttle sensor (TPS)
Page 53: Stepper Motor
MXV 450 Electrical system Voltage regulator check • Remove the fuel tank. • Disconnect the voltage regulator con- nector. • Undo and remove the two fixing screws and remove the voltage regulator. Checking the idle speed adj.system STEPPER MOTOR The Stepper motor (1) is a step-by-step electric motor used to control a slider (2) that adjusts the air flow under the throttle.
Page 54 MXV 450 Electrical system • connector: on Stepper Electrical characteristics: Electrical resistance: 50+/-5% Ω, measured be- tween: • Pin A and Pin D (1st stator start-up) • Pin B and Pin C (2nd stator start-up) NOTE the screw that fixes the Stepper motor...
Page 55 IF A FUSE BLOWS OUT FREQUENTLY, THAT MAY BE DUE TO A SHORT CIRCUIT OR OVER- LOAD. IF THIS OCCURS, CONTACT AN Official Aprilia Dealer. Checking the fuse is necessary whenever an electrical component fails to operate or is malfunctioning or when the engine does not start.
Page 56: Control Unit
MXV 450 Electrical system IF THE SPARE FUSE IS USED, REPLACE IT WITH ANOTH- ER OF THE SAME TYPE IN THE CORRESPONDING FIT- TING. USE DISTRIBUTION Specification Desc./Quantity 30A fuse Recharges the battery, if connected, and protects elec- trical system against potential overcharges (there is only one fuse;...
Page 57: Engine Rpm Sensor
MXV 450 Electrical system Engine rpm sensor Engine revolution sensor - Pick up Function It informs crankshaft position and speed to the Walbro control unit. Operation and operating principle Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the ref-...
Page 58: Throttle Position Sensor
MXV 450 Electrical system Throttle position sensor Function To tell the position of the throttle to the throttle control unit. Operation / operating principle The throttle valve position sensor works as a variable resistance according to the throttle rotation. Level in wiring diagram:throttle position sensor (TPS).
Page 59: Engine Temperature Sensor
MXV 450 Electrical system • shorted to negative: disconnect the sensor connector and check ground insulation of the orange cable (from throttle sensor connector or control unit connector): if there is continuity with the ground connection, restore the cable harness; if insulated from ground connection, the resistance between PIN 1 and PIN 2 is below 1.3 kOhm;...
Page 60 MXV 450 Electrical system Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature) Level in wiring diagram:water temperature sensor Location: • Sensor: on the left cylinder, externally • Connector: on the sensor Electrical characteristics: Resistance at -20 °C (-4 °F): 15 kΩ ± 5% Resistance at 0 °C (32 °F): 5.8 kΩ...
Page 61: Air Temperature Sensor
MXV 450 Electrical system if there is not continuity; if OK, connect the control unit connector again, and with battery connected, check if there is continuity between PIN 2 of the blue/green cable of the sensor and the vehicle ground connection: if there is no continuity, restore the cable harness; if...
Page 62 MXV 450 Electrical system Operation / operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in wiring diagram:intake air temperature sensors. Location: • sensor: filter casing front part, on control unit left side. • connector: on the sensor.
Page 63 MXV 450 Electrical system is displayed at the same time, this means that the blue/green cable common for both sensors is shorted to positive. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Axone if the temperature indicated is plausible in relation to the ambient temperature.
Page 64 MXV 450 Electrical system • Check injector resistance; if NOT OK, replace the injector; if OK, check connectors, injector side, control unit side and voltage regulator/battery side; if NOT OK, restore the connectors; if OK, check that there is continuity of the ground cable between control unit connector and injector connector;...
Page 65: Fuel Pump
MXV 450 Electrical system Fuel pump FUEL SUPPLY UNIT Fitted on the tank upper part, returnless type. The fuel circuit pressure regulator is placed inside the pump to keep a pressure of about 3.5 bar (350 kPa; 50.76 PSI). TECHNICAL SPECIFICATIONS Fuel pump resistance: 1.5 Ω...
Page 66 MXV 450 Electrical system • Lift the coil by sliding off the spark plug tube wiring. NOTE UPON REFITTING, LOCK THE SPARK PLUG TUBE WITH A PAIR OF PLIERS AND INSERT THE COIL. COILS Function: spark generation Operation / Operating principle: Inductive dis-...
Page 67 MXV 450 Electrical system • Rear coil - (yellow/black cable): ground / coil control Parameters: coil ignition advance AXONE: ELECTRICAL ERRORS Front coil 1351- malfunction Error cause: • malfunction Troubleshooting: • Check coil primary resistance; if NOT OK, replace the coil; if OK, check con- nectors, injector side, control unit side and voltage regulator /battery side;...
Page 68: Run/Stop Switch
MXV 450 Electrical system nector and coil connector; if NOT OK, restore cable harness; if OK, check that there is continuity of the supply ca- ble between voltage regulator/battery connector and coil connector. If OK, check ground insulation of the positive...
Page 69 MXV 450 Electrical system • The engine does not start: disconnect the connector and, with the switch in RUN mode, check that there is no con- tinuity between black/white and black cables (sensor side): if there is, replace the switch; if there is not, check switch connector.
Page 70 MXV 450 Electrical system F1 Supply input G1 Supply input H1 Reference voltage +5V output J1 - K1 - L1 Fuel pump control output M1 - A2 Injection ground connection B2 Air temperature sensor input C2 - D2 - E2 Mapping selection input F2 "Engine stop"...
Page 71 MXV 450 Electrical system H4 Connect to ground for reprogramming J4 Control unit power supply ground connection K4 Control unit power supply ground connection L4 Rear coil control output M4 Front coil control output ELE SYS - 71...
Page 72: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 73: Vehicle Preparation
MXV 450 Engine from vehicle Vehicle preparation • Undo and remove the screw that fixes the sump guard. • Remove the two bushings. • Remove the oil sump guard. • Remove the chain. • Remove the exhaust system. • Remove the saddle.
Page 74: Removing The Engine From The Vehicle
MXV 450 Engine from vehicle Removing the engine from the vehicle • Disconnect the front electrical cable harness connector. • Remove the two screws fixing the reg- ulator. • Move the regulator, connected to the cable harness, at the back of the filter housing.
Page 75 MXV 450 Engine from vehicle • Working from both sides, undo and re- move the radiator upper screw. • Lift both radiators by sliding them off the aluminium tubes on the crankcase. • Plug and tie the aluminium tubes using an elastic band to keep them in their correct position.
Page 76 MXV 450 Engine from vehicle • Working from the right side, unscrew and remove the upper nut. • From the opposite side, slide off the screw. • Collect the spacers. • Lower the engine. • After removing the engine, operate on the engine block and place it on the corresponding engine support plate.
Page 77 MXV 450 Engine from vehicle • Working from the right side, fit the en- gine lower pin. • Screw the nut. • Position the oil sump guard. • Fit the two bushings. • Insert the screw. • Tighten the nut from the opposite side.
Page 78 MXV 450 Engine from vehicle • Working from both sides, attach the in- let duct. • Take off the elastic band from the alu- minium tubes. • Place the radiators. • Working from both sides, insert the rubber hose in the radiator into the alu- minium tube in the crankcase.
Page 79 MXV 450 Engine from vehicle • Place the rear brake pedal. • Tighten the rear brake pedal fixing screw (1). • Fit the drive chain. • Place the clutch cable. • Position the voltage regulator again and fasten it by tightening both screws.
Page 80 INDEX OF TOPICS NGINE...
Page 81 MXV 450 Engine FITTING ENGINE ONTO PLATE • Fit the engine support plate on the Apri- lia engine stand. Specific tooling 9100841 Engine support • Fit the engine onto the plate using the holes of the engine support bolts. •...
Page 82 MXV 450 Engine Diagram Key: 1. Shaft selector+ratchet gear 2. Selector lock 3. Spring 4. Seeger ring 5. TE flanged screw 6. Complete index lever 7. Washer 8. Spring 9. Oil seal 10.Complete desmodromic 11.Roller 12.Gear selector drum ENG - 82...
Page 83 MXV 450 Engine 13.M8x1.25 threaded pin 14.Selector locking plate 15.M6x12 TE flanged screw 16.Sprocket wheel pawl 17.Pin for spring 18.Spring 19.Selector sprocket wheel 20.Bushing 21.Fork shaft 22.4th - 5th Fork 23.1st - 3rd Fork 24.Fork shaft 25.Ball bearing 26.Ball bearing 27.TE flanged screw...
Page 84: Gearbox Shafts
MXV 450 Engine 51.Washer 52.Ball bearing 53.O-ring 54.Ball bearing 55.Oil seal 56.Spacer Gearbox shafts Disassembling the gearbox • Remove the crankcase on the flywheel side to get access to the gear. • Remove the forks shafts. • Release the desmodromic drum from the forks, rotating it outwards.
Page 85 MXV 450 Engine • Slide off the forks. • Take out the main and the secondary shafts at the same time. Removing the primary shaft • Slide off the shim washer (1) from the generator side. • Slide off the bushing (3).
Page 86 MXV 450 Engine Removing the secondary shaft • Slide off the gear of the 1st gear (1) to- gether with the ball bearing cage. • Remove the Seeger ring (2). • Slide off the shim washer (3). • Slide off the gear of the 4th gear (4).
Page 87: Assembling The Gearbox
MXV 450 Engine Check the gear fork movement on the shaft; re- place the gear forks if it is not smooth. Assembling the gearbox On the engine crankcase there are two 3mm (0.12 in) holes to enhance lubrication of gears III and IV.
Page 88 MXV 450 Engine • Introduce the forks in their respective seats. • Fit the gear control desmodromic drum. • Fit the fork shafts. • Refit the crankcase on the flywheel side. Gear selector ENG - 88...
Page 89 MXV 450 Engine Removing the gear selector • Remove the clutch. • Remove the flange from the right crankcase half. • Working from the clutch side, remove the selector control shaft. • Undo and remove the two screws fixing the selector sprocket wheel.
Page 90: Generator Side
MXV 450 Engine • Remove the gear locking pawl and re- trieve the washer and the spring. See also Disassembling the clutch Splitting the crankcase halves Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely.
Page 91: Magneto Flywheel Removal
MXV 450 Engine Removing the flywheel cover • Undo and remove the ten short screws (1). • Undo and remove the two longer screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths. • Remove the flywheel-side cover to- gether with the stator and collect the gasket and the two centring dowels.
Page 92: Specific Tooling
MXV 450 Engine • Remove the flywheel using the specific flywheel extractor. Specific tooling 9100839 Flywheel extractor Installing the flywheel INERTIAL RING FITTING PROCEDURE CAUTION FIT THE INERTIAL RING IF YOU WISH TO OBTAIN A SOFT- ER ENGINE OUTPUT WHEN ACCELERATING AND IM- PROVED VEHICLE SMOOTHNESS WHEN RELEASING THE THROTTLE GRIP.
Page 93: Flywheel Cover Installation
MXV 450 Engine Flywheel cover installation Every time the flywheel cover is removed, check that the flywheel cover - crankshaft oil seal is in good condition. When replacing the oil seal, bare in mind the cor- rect fitting direction. The flat section should face the fitting punch while the lip should face the fly- wheel cover.
Page 94: Disassembling The Clutch
MXV 450 Engine • Remove the water pump rotor. • Undo and remove the twelve short screws (1). • Undo and remove the two middle screws (2). • Undo and remove the longest screw (3). • Remove the clutch-side crankcase and collect the engine oil filter, the gasket and the two dowel pins.
Page 95 MXV 450 Engine • Remove the thrust plate. • Remove the control rod together with the thrust bearing, the shim washer and the clutch cap. • Remove the discs. ENG - 95...
Page 96 MXV 450 Engine • After straightening the tabs of the lock- ing washers, unscrew and remove the clutch hub nut with the clutch locking tool and collect the locking washer. Specific tooling 9100896 Clutch housing locking tool • Remove the clutch hub.
Page 97: Checking The Clutch Plates
MXV 450 Engine • Collect the shim washer. • Collect the clutch housing. • Collect the spacer and the needle bearings. Checking the clutch plates • Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions.
Page 98: Checking The Clutch Housing
MXV 450 Engine 0.2 mm (0.0079 in) Checking the clutch housing The clutch bell for this vehicle can be identified by a line on the toothing outside diameter and it engages with the engine pinion, the kick-start pedal gear and the lubrication gear.
Page 99: Assembling The Clutch
MXV 450 Engine Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation. If neces- sary, replace the hub. Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS.
Page 100 MXV 450 Engine • Fit the clutch bell causing it to engage with the engine pinion, the kick-start pedal gear and the lubrication gear • Fit the shim washer. • Position the clutch hub. ENG - 100...
Page 101 MXV 450 Engine • Place the washer/s with the tab/s. CAUTION RESTORE THE ORIGINAL NUMBER OF WASHERS AND OBSERVE THEIR ORIGINAL POSITIONS. • Place the clutch hub nut. • Using the clutch locking tool, tighten the clutch hub nut to the prescribed tightening torque.
Page 102: Installing The Clutch Cover
MXV 450 Engine • Place the control rod together with the thrust bearing and the shim washer. • Place the thrust plate. • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally.
Page 103: Removing The Head Cover
MXV 450 Engine Specific tooling 9100895 Water pump oil seal punch Head and timing Removing the head cover • Undo and remove the two screws (1) and the two head cover stud bolts (2) and collect the sealing O-rings. •...
Page 104: Cylinder Head
MXV 450 Engine • Remove the head cover. • Remove the camshaft gear and re- move the timing chain properly. • Remove the fix slider. • Undo and remove the head fixing screw on the timing system side. NOTE THE CAMSHAFT FIXING SCREW OF THE FRONT CYLIN- DER WORKS ANTICLOCKWISE;...
Page 105 MXV 450 Engine • Remove the decompression system together with the control spring. See also Removing the rocker arms Removing the overhead camshaft NOTE TAKE THE PISTON OF THE CYLINDER YOU ARE WORKING ON TO THE TDC IN THE COMBUS- TION PHASE.
Page 106 MXV 450 Engine • Remove the decompression system. • Working on the timing system side, re- move the camshaft bearing fixing Seeger ring. • Remove the camshaft together with the ball bearing on the timing system side. See also Removing the decompression system Removing the rocker arms •...
Page 107: Removing The Valves
MXV 450 Engine • Remove the rocking lever. Removing the valves NOTE THE FOLLOWING PROCEDURE REFERS TO ONE CYLINDER BUT IS VALID FOR BOTH. • Remove the control rocker of the exhaust valves and remove the camshaft. NOTE BEFORE REMOVING THE CYLINDER HEAD COMPONENTS (VALVES, VALVE SPRINGS, CAPS AND BUCKET TAPPETS), MAKE SURE THAT THE VALVES ARE PROPERLY CLOSED AND SEALED.
Page 108 MXV 450 Engine • Remove the spring of valve (6) and the corresponding upper cap (5). • Remove the valve. • Remove the stem oil seal of valve (3) and the lower cap (4). See also Removing the decompression system...
Page 109: Valves And Valve Guides Check
MXV 450 Engine • Use an internal micrometer to measure the rocker inside diameter and replace the lever if necessary. Characteristic Rocker inside diameter - maximum limit: 12.04 mm (0.4740 in) • Check that the outside diameter of the rocker shaft does not show blue col- ouring, cracks or scratches;...
Page 110 MXV 450 Engine • Use a micrometer to measure the valve stem (C) diameter. • Use an internal micrometer to measure the valve guide (D) inside diameter. Characteristic Valve stem diameter - minimum limit 4.96 mm (0.1952 in) Check the clearance (G) between stem and valve guide as follows:...
Page 111 MXV 450 Engine the specified values; replace the valve if necessary. Characteristic Intake valve thickness, sealing side - minimum limit 2.2 mm (0.0866 in) Exhaust valve thickness, sealing side - mini- mum limit 2.5 mm (0.098 in) • Check that the valve stem eccentricity is within the specified values;...
Page 112 MXV 450 Engine Inspecting the valve housings • Remove the carbon deposits from the valve face and seat. • Check that the valve seat does not show cracks or signs of wear; other- wise, replace the component. • Check that the valve seat is within the indicated values;...
Page 113: Checking The Cylinder Head
MXV 450 Engine Checking the cylinder head • Check that cylinder head surface is not damaged or scratched; replace it if necessary. • Check that there are no mineral deposits or rust in the cylinder head water cooled jacket; remove them if necessary.
Page 114 MXV 450 Engine • Fit the valve spring retaining element. • Compress the valve spring with the spring compressor and use the valve spring compressor adapter to fit the valve cotters. • To fix the valve cotters on the valve stem, slightly hit the valve head with a soft-head mallet.
Page 115 MXV 450 Engine • Fit the exhaust rocker shaft. NOTE MAKE SURE THAT THE ROCKER SHAFT IS FULLY INSER- TED IN THE CYLINDER HEAD. • Position the Seeger ring of the exhaust rocker pin. Installing the overhead camshaft NOTE LUBRICATE THE BEARING WITH ENGINE OIL BEFORE FITTING.
Page 116: Adjusting Valve Clearance
MXV 450 Engine • Fit the camshaft. NOTE INSERT THE CAMSHAFT CAREFULLY PAYING ATTEN- TION TO THE DECOMPRESSION CONTROL. • Working on the timing system side, po- sition the camshaft bearing fixing Seeger ring. Adjusting valve clearance To adjust valve clearance insert the correct cali- brated pad on the valve stem.
Page 117: Chain Removal
MXV 450 Engine Chain removal FRONT • Remove the front cylinder head. • Remove the generator crankcase. • Undo and remove the movable chain guide slider screw. • Remove the chain slider. • Slide off the chain. • Remove the gear and collect the cotter.
Page 118 MXV 450 Engine • Undo and remove the three screws. • Remove the cover being careful not to damage the O-ring. See also Removing the cylinder head Removing the clutch cover • Slide off the chain from the gear. •...
Page 119: Checking The Chain
MXV 450 Engine Checking the chain tensioner • Check that there are no blistering or damages; replace the component if necessary. • Check that the one-way cam works properly: if it does not move smoothly, replace the timing chain tensioner housing.
Page 120: Installing The Chain
MXV 450 Engine • Inlet 34.83 mm (1.37 in) • Outlet 24.815 mm (0.97 in) Installing the chain FRONT • Place the cotter. • Fit the gear. • Fit the chain. CAUTION FIT THE CHAIN WITH THE COLOURED SIDE FACING OUT- WARD.
Page 121: Cam Timing
MXV 450 Engine • Position the timing compartment clos- ing flange. • Tighten the three fixing screws of the timing compartment closing flange. • Lock the primary drive pinion using the specific special tool. • Position the timing gear control gear, matching the reference with the one on the main drive pinion.
Page 122 MXV 450 Engine • Working on the main transmission nut, make the crankshaft turn until the rear cylinder reaches the TDC in combus- tion phase. • Insert the pin in the crankshaft lock (timing pin) in order to block crankshaft rotation.
Page 123: Specific Tooling
MXV 450 Engine CHECK THAT THE CAMSHAFT IS FREE, NOT RESTING ON THE BUCKET TAPPETS. • Release the front camshaft and the crankshaft from the locking pins. • Undo and remove the timing slot screw. • Tighten the screw in the timing hole.
Page 124 MXV 450 Engine NOTE CHECK THAT THE CAMSHAFT IS FREE, NOT RESTING ON THE BUCKET TAPPETS. • Tighten the fixing screw of the front cyl- inder timing shaft gear. • Release the front camshaft and the crankshaft from the locking pins.
Page 125: Removing The Cylinder
MXV 450 Engine Removing the cylinder • It is necessary to remove the head be- fore removing the cylinder • Undo and remove the inspection screw (2); collect the O-ring gasket (mind the coolant spills). • Use the special tool to remove the liner (1) and collect the O-ring gasket.
Page 126: Checking The Piston
MXV 450 Engine 76.02 mm (2.9929 in) Checking the piston These pistons feature oversized crowns and can be recognised by the three holes on the skirt Characteristic Piston pin hole inside diameter 16.02 mm (0.6307 in) Piston outside diameter 75.94 mm (2.9897 in) Top ring end clearance 0.45 mm (0.0177 in)
Page 127: Installing The Cylinder Head
MXV 450 Engine • Place the piston in the cylinder liner (3). • Place the cylinder liner (3) in the crank- case. • Fit the pin. • Position the pin locking ring. • Close the cap (4). Installing the cylinder head •...
Page 128: Crankcase - Crankshaft
MXV 450 Engine • Fit the timing chain tensioner, follow the instructions below: • 1- Release the chain tensioner one- way cam and push its rod completely into the chain tensioner housing. • 2- Fit the tensioner in the proper seat...
Page 129 MXV 450 Engine Splitting the crankcase halves • Remove the clutch. • Remove the kick-start pedal gear. • Remove the flywheel. • Remove both heads. • Remove the timing system shaft. • Unscrew and remove the main trans- mission gear fixing nut.
Page 130 MXV 450 Engine • Remove the gear selector. • Remove the Seeger ring. • Remove the pinion. See also Removing the gear selector • Remove the oil seal from the crank- shaft. • Align the cotter with the hole and re- move the shim washer.
Page 131 MXV 450 Engine • Undo and remove the eight M6 screws. • Undo and remove the two long screws. • Undo and remove the seven M7 screws. • Working from the clutch side, undo and remove the screw. ENG - 131...
Page 132 MXV 450 Engine • Remove the gearbox oil cap screw. • Lift both cylinder liners 2 / 3 cm (0.79 / 1.18 in). • Separate the crankcase with the aid of the rubber mallet. • Remove the crankcase on the genera- tor side.
Page 133 MXV 450 Engine DESMODROMIC BEARING REMOVAL • Warm up the crankcase halves. • Remove the bearing with an extractor from the inside. REMOVING THE GEAR SECONDARY SHAFT BEARING • Remove the two bearing grub screws plus their plates. • Remove the oil seal working on the crankcase external side.
Page 134: Removing The Crankshaft
MXV 450 Engine • After warming up the crankcase halves, remove the bearings with an extractor from the inside. TIMING SYSTEM SHAFT BEARING REMOVAL • Remove the bearing grub screw and the corresponding plate. • Warm up the crankcase halves.
Page 135 MXV 450 Engine Removing the main bearings The crankshaft turns on a roller bearing on the fly- wheel-side crankcase half, whereas there is a ball bearing on the clutch-side crankcase half. CAUTION BEFORE CARRYING OUT ANY REMOVAL/FITTING OPER- ATION ON THE CRANKCASE, WARM IT UP WITH A HEAT GUN TO AVOID DAMAGING ITS HOUSING.
Page 136 MXV 450 Engine • Warm up the crankcase properly before fitting each bearing. BEARING REFITTING - TIMING SHAFT • Working on the flywheel side and on the clutch side, refit the bearings using the specific punches. Specific tooling 9100893 Left timing gear punch 9100889 Timing gear crankshaft punch •...
Page 137 MXV 450 Engine • Refit the lock screws. GEAR SECONDARY SHAFT BEARING REFIT- TING • Refit the bearing using the specific punch. CAUTION CHECK THAT THE PLATE ADJUSTABLE SUPPORT IS FIRMLY STOPPED AND WARM UP THE BEARING COU- PLING AREAS PROPERLY.
Page 138: Checking The Connecting Rod
MXV 450 Engine MAIN BEARINGS FITTING BEARING REFITTING - DESMODROMIC DRUM SUPPORT • Refit the bearing using the specific punch. Specific tooling 9100892 Left crankcase desmodromic + wheel GEAR PRIMARY SHAFT BEARING REFITTING • Refit the bearing using the specific punch.
Page 139 MXV 450 Engine 16.04 mm (0.631 in) Refitting the crankcase halves CAUTION BEFORE REFITTING, REPLACE AND LUBRICATE THE OIL SEALS AND LUBRICATE THE BALL BEARINGS. • Fit the oil seals and the bearings on the crankcase halves. • Fit the entire crankshaft on the right crankcase half.
Page 140 MXV 450 Engine • Join the crankcase halves. • Screw without tightening the M7 screw on the clutch side. • Screw without tightening the seven M7 screws. • Screw without tightening the eight short M6 screws. ENG - 140...
Page 141 MXV 450 Engine • Screw without tightening the two long screws. • Tighten the seventeen screws operat- ing diagonally and in stages. • Screw the gearbox oil cap. • Place the cotter and the shim washer on the crankshaft. •...
Page 142 MXV 450 Engine • Fit the chain pinion. • Fit the gear selection system. • Fit the clutch shaft. • Fit the start-up transmission gear. • Fit primary gear. • Screw the nut. • Time. THE GEAR HAS THE SAME SHAPE AS THAT FOR THE STREET MODEL BUT IT IS NOT INTERCHANGEABLE.
Page 143 MXV 450 Engine Conceptual diagrams Key: 1. Clutch-side 2. Flywheel-side 3. Calibrated nozzle 4. Cartridge filter ENG - 143...
Page 144: Oil Pump
MXV 450 Engine 5. Pressure-relief valve 6. Pressure pump 7. Air filter casing 8. Oil reservoir 9. Wire mesh filter 10.Scavenge oil pump 11.Piston cooling jet 12.Cover-side gasket 13.Separation plate 14.Crankcase-side gasket 15.To the pressure pump 16.From the oil scavenge pump An aluminium plate with two metal-core gaskets separates the oil in the reservoir from the crankcase oil.
Page 145 MXV 450 Engine 6. Mesh filter for intake 7. TE flanged screw 8. Pin 9. Inner and outer rotors 10.O-ring 11.Oil pump body 12.Oil seal 13.Thrust washer 14.Oil pump gear Z=12 15.Thrust washer 16.Seeger ring 17.Pin 18.Ball bearing cage 19.Transmission gear Z=19 20.Thrust washer...
Page 146 MXV 450 Engine • Remove the oil pump gear fixing Seeg- er ring. • Remove the oil pump gear and collect the shim washer. • Remove the transmission roller of the oil pump gear. • Remove the shim washer (1).
Page 147 MXV 450 Engine • Collect the internal transmission roller of the oil pump. INTERNAL PUMP REMOVAL NOTE TO DISASSEMBLE THE INTERNAL SECTION OF THE OIL PUMP IT IS NECESSARY TO DISAS- SEMBLE THE CRANKCASE AND REMOVE THE EXTERNAL PUMP. •...
Page 148 MXV 450 Engine Installing INTERNAL PUMP FITTING • Place the oil pump shaft and the trans- mission roller. • Fit the pump rotor and the stator. • Position the strum box and the cover. • Tighten the three fixing screws.
Page 149 MXV 450 Engine • Tighten the four fixing screws (2) and position the shim washer (1). • Position the oil pump gear transmis- sion roller. • Place the shim washer before position- ing the oil pump gear. • Position a new oil pump gear fixing Seeger ring.
Page 150 MXV 450 Engine • Position the toothed oil pump control wheel paying attention to the internal sliding rollers. • Place the shim washer before positioning a new oil pump control gear fixing Seeger ring. • Close the crankcase. • Fit the clutch.
Page 151 MXV 450 Engine • Turn and remove the start-up system. • Disassemble the gear by removing the Seeger ring (8), the shim washer (7), the toothed wheel (6), the ball bearing cage (5), and the shim washer (4). • Working from the left side of the gear, slide off the spring (1) and the start-up sprocket (2).
Page 152 MXV 450 Engine Start-up pedal fitting • On the shaft (3), place the shim washer (4), the ball bearing cage (5), the tooth- ed wheel (6), the shim washer (7) and the Seeger ring (8). • Working from the left side of the gear, fit the start-up sprocket (2) and the spring (1).
Page 153 MXV 450 Engine ENG - 153...
Page 154: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 155: Circuit Diagram
MXV 450 Power supply Circuit diagram Key: 1. Fuel tank 2. Cap 3. Gasket 4. Rubber ring 5. T-shaped bushing 6. Screw 7. Gasket 8. Complete fuel pump unit 9. Pipe 10.Tank breather valve 11.Fuel pump fixing ring nut 12.Rubber washer 13.Plain iron washer...
Page 156 MXV 450 Power supply Fuel pump Removing • Remove the fuel tank. • Empty the fuel tank. • Unscrew the ring nut. • Take out the fuel pump. Injection Removing the throttle body • Remove the air filter casing cover.
Page 157 MXV 450 Power supply • Disconnect the rear cylinder injector connector. • Release the cable harness from the clamp. CAUTION UPON REMOVING THE CONNECTOR MARK IT IN ORDER NOT TO INVERT WHEN REFITTING. See also Throttle grip cables replacement •...
Page 158: Checking The Throttle Body
MXV 450 Power supply • Remove the throttle body. Checking the throttle body The imbalance advances the front throttle opening with respect to the rear throttle in the throttle con- trol first degrees. This allows to improve motorcy- cle output and handling.
Page 159: Ecu Mapping
MXV 450 Power supply Stepper motor removal • Undo and remove the two screws. • Open the Stepper motor, being careful with the O-ring. Refitting the Stepper motor • Carry out the removal steps but in reverse order, remember to replace the O-ring with a new one with the same characteristics.
Page 160 MXV 450 Power supply In order to diagnose injection, use cable (1) together with joint (2). 3 - Axone / Navigator 4 - Motorcycle For reprogramming, use only cable (1) P SUPP - 160...
Page 161 MXV 450 Power supply 6 - Ground connection 7 - Motorcycle (reprogramming) 8 - Motorcycle (data / diagnosis reading) 9 - PC RS-232 The motorcycle is supplied with a CD-Rom that contains control unit interface self-installing software plus connection cable (5).
Page 162 MXV 450 Power supply Iso screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO SCREEN PAGE Specification Desc./Quantity Chassis number ZD4VP.. - Vehicle chassis Engine number...
Page 163: Device Status
MXV 450 Power supply Specification Desc./Quantity Throttle self-learning, min. position 45 - Reference value with throttle completely homed at 0°. This value is stored by means of the "Throttle self-learning, min. po- sition" procedure in the adjustable parameters screen page Throttle self-learning, max.
Page 164: Errors Display
MXV 450 Power supply DEVICES ACTIVATION SCREEN PAGE Specification Desc./Quantity Throttle self-learning, min. position Used to store in the memory the reference value for throttle fully homed at 0°: Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO).
Page 165 MXV 450 Power supply Specification Desc./Quantity occurs again, this means it is current. Otherwise, it is a stored error (carry out the specific checks anyway) Throttle position sensor An interruption on the cable harness from PIN C3 of the ECU to the sensor has been detected, or voltage equal to 5 V or higher has been detected.
Page 166: Adjustable Parameters
MXV 450 Power supply Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters. Throttle self-learning, min. position / Throttle self-learning, max. position The throttle position self-learning must be carried out either with the throttle grip fully untwisted (idle) or with the throttle grip fully twisted (fully open).
Page 167 MXV 450 Power supply Specification Desc./Quantity Wheel signals Injection time correction Allows modification of injection times at any rpm; maximum adjustment +/- 5% (1.99/0.00) with respect to the mapping in- jection times) Advance correction Allows to correct advance between -5° and + 5°...
Page 168: Index Of Topics
INDEX OF TOPICS SUSP USPENSIONS...
Page 169: Front Fork
MXV 450 Suspensions Front Front fork Diagram Key: 1. Left fork unit 2. Right fork unit 3. Left wheel holder stem 4. Right wheel holder stem 5. Upper bushing 6. Cap 7. Sealing ring 8. Snap ring 9. Dust scraper 10.Complete sleeve...
Page 170 • Stems (***) protrusion from top plate (excluding cover): 1 notch. (*)= Clockwise (**)= Anticlockwise (***)= Only use an Official aprilia Dealer for this type of adjustment CAUTION TO COUNT THE NUMBER OF CLICKS AND/OR TURNS FOR ADJUSTER SCREWS (1 -2) ALWAYS START FROM THE STIFFEST SETTING (ADJUSTER SCREW TURNED FULLY CLOCKWISE).
Page 171: Removing The Fork Legs
MXV 450 Suspensions Removing the fork legs • Undo and remove the two screws fixing the front mudguard tie rod. • Undo and remove the four mudguard fixing screws. • Remove the front mudguard. • Place the OPTIONAL front stand in the hole of the fork lower plate.
Page 172 MXV 450 Suspensions • Working on the right side, slide off the wheel axle. • Remove the wheel. • Collect the bushing. CAUTION THE FOLLOWING THREE OPERATIONS ARE ONLY VALID FOR REMOVING THE LEFT STEM. • Release the stem of the cable holding clamps.
Page 173 MXV 450 Suspensions Only for the left stem: • before removing the stem protection, undo and remove the two screws fas- tening the front brake pipe to the stem protection. • Undo and remove the three stem pro- tection fixing screws.
Page 174: Draining Oil
MXV 450 Suspensions • Remove the fork stem. Draining oil To drain out the oil follow these steps: • Remove the stanchion • Place the stanchion (8) in a vice fitted with protection shoes. Use an Allen key to unscrew the upper closing cap (6).
Page 175 MXV 450 Suspensions • Remove the plastic bushing (9). • Remove the spring (5). Completely drain inside the sleeve the oil settled on the turns of the spring so as not to be forced to top-up or change the oil.
Page 176: Disassembling The Fork
MXV 450 Suspensions Disassembling the fork • Drain all the oil from the stem. • Take out the pumping member rod. • Lock the sleeve in a vice in horizontal position. CAUTION PLACE A CONTAINER TO COLLECT THE OIL UNDER THE STOP PLUG.
Page 177 MXV 450 Suspensions • Slide off the dust scraper (1) from the sleeve using a screwdriver as a lever. CAUTION BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM AND THE DUST SCRAPER (1). • Slide off the retainer ring (2) from inside the sleeve using a thin screwdriver.
Page 178 MXV 450 Suspensions • The bushing (3) and the guide ring (4) are removed with a small screwdriver and can therefore be removed from the stem: the shim washer (5), the oil seal (6), SUSP - 178...
Page 179: Checking The Components
MXV 450 Suspensions the retainer ring (2) and the dust scraper (1). See also Draining oil Checking the components FORK BLEEDING The front fork must be fully extended to bleed air: • loosen the screw located on the stem cover;...
Page 180 MXV 450 Suspensions - retainer ring (2); - oil seal (6); - shim washer (5); - guide ring (4); - bushing (3); CAUTION TO FIT THE OIL SEAL, TAPE THE BUSHING (3) HOUSING SLOT SO THAT THE OIL SEAL LIP IS NOT DAMAGED.
Page 181 MXV 450 Suspensions • Fit the dust scraper (1). • Insert the complete pumping member in the stem until it stops. • Insert and tighten the stop plug. • Fit the pumping member rod. • Fill with oil. SUSP - 181...
Page 182: Filling Oil
MXV 450 Suspensions Filling oil • Place sleeve (7) upright in a vice fitted with protection jaws. • Compress sleeve (7) in the stem. • Insert the preloading pipe in the sleeve (7). • Pour part of the fork oil into sleeve (7).
Page 183: Installing The Fork Legs
MXV 450 Suspensions • Check that the O-ring (6) is fitted on the top cap (10). • Holding the lock nut, screw the top stem (10) on the pumping member rod manually. • Screw and tighten the cap (10) on the sleeve (7).
Page 184 MXV 450 Suspensions • Fit the stem protection, position and tighten the three fixing screws. • Tighten the two screws fastening the front brake pipe to the left stem protec- tion. • Place the bushing. SUSP - 184...
Page 185 MXV 450 Suspensions • Position the wheel. • Working on the right side, insert the wheel axle. • Working on the left side, partially screw the front wheel axle fixing nut. CAUTION TIGHTEN THE TWO SCREWS ON THE RIGHT SIDE FORK CLAMP TO AVOID WHEEL AXLE ROTATION.
Page 186: Removing The Rear Wheel
MXV 450 Suspensions • Place the calliper in its position. • Tighten the two calliper fixing screws. • Remove the OPTIONAL front stand, resting the vehicle on the side stand. • Fasten the sensor cable with a clamp. • Position the mudguard and tighten the four fixing screws.
Page 187: Installing The Rear Wheel
MXV 450 Suspensions • Slide off the chain. • Use a rubber hammer to slide off the wheel axle from the vehicle left side; collect the centring shim washers and slide off the wheel backwards. • Slide off the bushing.
Page 188: Shock Absorbers
MXV 450 Suspensions • Position the rear wheel. • Position the chain. • Working on both sides, insert the cen- tring shim washers. • Working from the left side, insert the wheel axle. • Working on the right side, position the washer and screw but do not tighten the wheel axle fixing nut.
Page 189: Rear Shock Absorber Adjustment
CREASE THE SPRING PRELOAD, YOU ALSO NEED TO INCREASE REBOUND DAMPING, IN ORDER TO AVOID SUDDEN JERKS WHEN RIDING. SHOULD YOU NEED ANY ASSISTANCE, CONTACT AN Official aprilia Dealer. TO AVOID COMPROMISING THE SHOCK ABSORBER'S OPERATION, DO NOT LOOSEN SCREW «5» AND DO NOT...
Page 190 MXV 450 Suspensions REAR SUSPENSION STANDARD ADJUSTMENT Specification Desc./Quantity Shock absorber axial distance (A) 474 ± 1.5 mm (18.7 ± 0.06 in) Length of (pre-loaded) spring (B) 249 ± 1 mm (9.8 ± 0.04 in) Rebound adjustment, screw (1) 16 clicks from fully closed...
Page 191: Index Of Topics
INDEX OF TOPICS CHAS HASSIS...
Page 192: Swinging Arm
MXV 450 Chassis Swinging arm Removing • Place the service stand under the engine block. • Using a belt secure the vehicle front part to the workbench. • Remove the rear wheel. • Unscrew and remove the nut of the pin fixing the swingarm / linkage system and collect the washer.
Page 193: Drive Chain
WHICH IN TURN COULD CAUSE AN ACCIDENT OR SERIOUSLY DAMAGE THE VEHICLE. CHECK THE CHAIN SLACK ON A REGULAR BASIS AND ADJUST IT AS NECESSARY. TO CHANGE THE CHAIN TAKE YOUR VEHICLE TO AN Official aprilia Dealer, WHO WILL PROVIDE ACCURATE, PROMPT SERVICE.
Page 194 MXV 450 Chassis INCORRECTLY EFFECTED MAINTENANCE MAY CAUSE EARLY WEAR OF THE CHAIN AND OR DAMAGE THE PINION AND/OR THE CROWN. PERFORM MAINTENANCE OPERATIONS MORE FREQUENTLY IF YOU RIDE THE VEHICLE IN EXTREME AMBIENT CONDITIONS. Removing • Loosen the chain tension.
Page 195 ULARLY IF YOU FIND DRY OR RUSTY PARTS. FLAT- TENED OR JAMMED CHAIN LINKS SHOULD BE LUBRI- CATED AND GOOD OPERATING CONDITIONS RE- STORED. IF REPAIR IS NOT POSSIBLE, CONTACT AN Official Aprilia Dealer TO HAVE IT REPLACED. CHAS - 195...
Page 196 MXV 450 Chassis Installing • Check the correct positioning of the chain on the pinion and the sprocket. • Fit the chain with the two ends joined at a point between the pinion and the sprocket on the lower branch of the chain.
Page 197 MXV 450 Chassis Adjusting If you need to adjust chain tension after the check: • Place the vehicle upright on a specific stand. • Loosen the nut (1) completely. • Loosen both lock nuts (4). • Actuate on the set screws (5) and ad-...
Page 198 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 199 CAUTION UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. CONTACT AN Official aprilia dealer IN CASE OF DOUBTS ON THE CORRECT BRAKING CIRCUIT OPERATION AND WHEN UNABLE TO CARRY OUT ROUTINE CHECKS. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND THE...
Page 200 MXV 450 Braking system FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY AFTER MAINTENANCE OPERATIONS OR CHECKS. CHECK THAT BRAKE PIPES ARE NOT TWISTED OR WORN. PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIRCUIT.
Page 201 MXV 450 Braking system • Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
Page 202 MXV 450 Braking system • Repeat the operation until the fluid draining into the container is air-bubble free. NOTE WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
Page 203 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 204 MXV 450 Cooling system Circuit diagram Key: 1. Radiator cap 2. Air bleed 3. Holes for chassis retainer 4. Right radiator 5. Left radiator 6. Delivery pipe to the pump 7. Breather pipe 8. Return pipe from the front head 9.
Page 205 MXV 450 Cooling system Coolant replacement • Place a container of suitable capacity underneath the sleeve. • Release the clamp. • Slide off the sleeve. • Empty the liquid into the container. • Open the radiator cap to facilitate drainage.
Page 206: Removing The Radiator
MXV 450 Cooling system • Remove the pump rotor using the spe- cial spanner. Specific tooling 9100938 Pump rotor wrench • Remove the shim washer. • Collect the two centring bushings. • Remove the water pump cover spacer. • Check that the two O-rings present on the bushing are not damaged.
Page 207 MXV 450 Cooling system • Working on both sides, release the clamps between the aluminium tube and the rubber hose in the radiator. • Remove the right and left delivery pipes. • Slide off the radiator breather pipe. • Working from both sides, undo and re- move the two screws.
Page 208 INDEX OF TOPICS BODYW ODYWORK...
Page 209 MXV 450 Bodywork Footrest • The footrest worn teeth can be re- stored by filing the grooves between them with a triangular file. • Note that if the teeth are too sharp, boot soles do not last long. • Sharpen only the teeth ends.
Page 210 MXV 450 Bodywork Fuel tank • Remove the saddle. • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Undo and remove the front fixing screw and collect the washer. • Undo and remove the screw fixing the reservoir and collect the centring bush- ing.
Page 211 MXV 450 Bodywork Side air deflectors • In order to remove the air deflectors, first remove filter cover (2) by undoing the two fixing screws (1). • Working on both sides, undo and re- move the three side air deflector fixing screws.
Page 212 INDEX OF TOPICS PRE DE DELIVERY...
Page 213 MXV 450 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 214: Static Test
MXV 450 Pre-delivery - Front and rear suspension efficiency - Abnormal noise level Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 215 Air filter: 34 Air temperature sensor: 61 Brake: Chain: 117, 119, 120, 129, 193 Chain tensioner: 119 Clutch: 90, 93, 94, 97–99, 102, 118, 129, 147 Coil: 65 Connectors: 69 coolant: 205 Coolant: 205 Crankcase: 16, 90, 128, 129, 134, 135, 139, 147 Crankshaft: 16, 128, 134 Cylinder: 103, 104, 113, 117, 118, 125, 127, 129 Desmodromic drum: 86...
Page 216 Maintenance: 8, 25 Maintenance Table: Oil filter: 31 Primary shaft: 85 Radiator: 206 Rear wheel: 186, 187 Recommended products: 17 Run/Stop switch: 68 Secondary shaft: 86 Shock absorbers: 188 Spark plug: 27 Start-up: 150–152 Stepper motor: 158 Tank: 210 Throttle body: 156, 158 Tyres: 12 Voltage regulator: 53 Water pump: 205...

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