MSS RXV 450 550 MY09 English 45325 75 - 100810153921

SERVICE STATION MANUAL
854297
RXV 450-550
RXV 450-550
THE VALUE OF SERVICE Due to the continuous technical updates and specific mechanic training programs for aprilia products, only aprilia Official Network mechanics know this vehicle fully and have the special tools necessary to carry out maintenance and repair operations correctly. The reliability of the vehicle also depends on its mechanical state. Checking the vehicle before riding, its regular maintenance and using only Original aprilia Spare Parts are essential! For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or search directly from the map on our Official Website: www.aprilia.com Only by requesting aprilia Original Spare Parts can you be sure of purchasing products that were developed and tested together with the actual vehicle itself. All aprilia Original Spare Parts undergo quality control procedures to guarantee reliability and durability. The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons. Not all versions/models shown in this publication are available in all Countries. The availability of individual versions/models should be confirmed with the official aprilia sales network. Copyright 2009 aprilia. All rights reserved. Reproduction of this publication in whole or in part is prohibited. aprilia - After-sales service. Aprilia trademark is property of Piaggio & C. S.p.A.

RXV 450-550
- 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 scooters. Without this knowledge, repairing or checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures are not described in detail, be extremely cautious so as not to damage components or injure individuals. In order to optimise customer satisfaction when using our vehicles, aprilia s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all aprilia Sales Outlets and its International Subsidiaries. These changes will be introduced in the subsequent editions of the manual. In case of need or further queries on repair and check procedures, consult aprilia CUSTOMER DEPARTMENT, which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle.
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS SPECIAL TOOLS MAINTENANCE ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENGINE POWER SUPPLY SUSPENSIONS CHASSIS BRAKING SYSTEM COOLING SYSTEM BODYWORK
CHAR S-TOOLS MAIN ELE SYS ENG VE ENG P SUPP SUSP CHAS BRAK SYS COOL SYS BODYW
INDEX OF TOPICS
CHARACTERISTICS
CHAR
RXV 450-550
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.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH. Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION. DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off. When handling these components, wear insulating gloves or wait until the engine and the exhaust system have cooled down. Coolant The coolant contains ethylene glycol which, under certain conditions, can become flammable. When it burns, ethylene glycol produces an invisible flame which however can cause burns.
CAUTION
TAKE CARE NOT TO SPILL COOLANT ONTO HOT ENGINE OR EXHAUST SYSTEM COMPONENTS; THE FLUID MAY IGNITE AND BURN WITH AN INVISIBLE FLAME. WHEN CARRYING OUT MAINTENANCE, IT IS ADVISABLE TO WEAR LATEX GLOVES. EVEN THOUGH IT IS TOXIC, COOLANT HAS A SWEET FLAVOUR WHICH MAKES IT VERY ATTRACTIVE TO ANIMALS. NEVER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS THEY MAY DRINK IT. CHAR - 7
Characteristics
RXV 450-550
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 transmission oil
CAUTION
IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS. WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL. HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER. DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES, RINSE THEM IMMEDIATELY WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE. KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND, AS IT CONTAINS SULPHURIC ACID, MAY CAUSE BURNING IF IT COMES INTO CONTACT WITH THE SKIN. WHEN HANDLING BATTERY ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IN THE EVENT OF CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED, DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY. KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION CHAR - 8
RXV 450-550
Characteristics
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below carefully. BEFORE DISASSEMBLING COMPONENTS Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle. Use the special tools designed for this bike, as required. COMPONENTS REMOVAL Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific wrench. Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and identify them with different distinctive symbols. Each component needs to be clearly marked to enable identification during reassembly. Clean and wash the dismantled components carefully using a low-flammability detergent. Keep mated parts together since they have "adjusted" to each other due to normal wear. Some components must be used together or replaced altogether. Keep away from heat sources.
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. When tightening nuts and screws, start either from the components with the largest diameter or from the innermost components, proceeding diagonally. Tighten nuts and screws in successive steps before applying the tightening torque. Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins and screws with new parts if the thread is damaged. When assembling the bearings, make sure to lubricate them well. Check that each component is assembled correctly. After a repair or routine maintenance, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic. Clean all mating surfaces, oil seal rims and gaskets before refitting. Smear a thin layer of lithium-based grease on the oil seal rims. Reassemble oil seals and bearings with the brand or batch number facing outward (visible side). ELECTRIC CONNECTORS Electric connectors must be disconnected as described below; failure to comply with this procedure causes irreparable damage to both the connector and the wiring harness: Press the relative safety clips, if applicable. CHAR - 9
Characteristics
RXV 450-550
Grip the two connectors and disconnect them by pulling them in opposite directions. If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. Ensure that the cables are correctly fastened to the internal connector terminals. Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you will hear them "click" into place).
CAUTION
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM THE RIGHT WAY ROUND. TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS, BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS MAY LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients are ideal to run in engine, brakes and suspensions effectively. Vary your driving speed during the runin. In this way, you allow for the work of components to be "loaded" and then "unloaded", thus cooling the engine parts. Even if it is important to "stretch" engine components during run-in, make sure not to strain them. Follow the guidelines detailed below:
NOTE
Do not fully open the throttle grip abruptly at low engine speeds, either during or after the running in period. for the first 3 operating hours, do not exceed 50% of the throttle grip travel and never go over 8000 rpm, for the next 12 hours, do not exceed 75% of the throttle grip travel.
EVEN AFTER THE RUNNING-IN PERIOD, AVOID RUNNING THE ENGINE AT TOP SPEED, WHEN THE LIMITER CUTS IN: RXV 450 11500 rpm RXV 550 11000 rpm
CAUTION
THE SPEED LIMITER (NOT THE CONTROL UNIT LIMITER) WARNING LIGHT HAS BEEN FACTORY SET AT 8000 rpm
CHAR - 10
RXV 450-550
Characteristics
Dimensions and mass

TECHNICAL DATA RXV 450 - RXV 550 (VEHICLE)
Specification Max. length Max. width Max. height (to windshield) Saddle height Wheelbase Minimum ground clearance Dry weight (of each liquid) Fuel tank capacity (including reserve) Fuel reserve Engine oil capacity Oil capacity for each fork Coolant capacity Seats Frame Front suspension Front suspension travel Rear suspension Rear wheel travel Front brake Rear brake Wheel rims Front wheel rim Rear wheel rim Front tyre Front tyre inflation pressure Rear tyre Rear tyre inflation pressure Desc./Quantity 2240 mm (88.19 in) 830 mm (32.68 in) 1250 mm (49.21 in) 940 mm (37.01 in) 1485 mm (58.46 in) 320 mm (12.60 in) 116.5 kg (256.84 lb) 7.5 l (1.65 UK gal) 2.2 l (0.48 UK gal) 1.3 l (0.28 UK gal) 90 mm (3.54 in) of clearance (for each stem, measured without spring and under compression) 1.1 l (0.24 Ukgal) (50% water + 50% antifreeze solution with ethylene glycol) 1 Tubular steel perimeter frame and aluminium vertical members hydraulic telescopic fork, 45 mm (1.77 in) stems 298.5 mm (11.75 in) oscillating swingarm and adjustable hydraulic single shock absorber 300 mm (11.81 in) (usable) 270 mm ( 10.63 in) disc brake with hydraulic transmission 240 mm ( 9.45 in) disc brake with hydraulic transmission with spokes 1.60 x 21 2.15 x 18" 90/90 21 54M 100 kPa (1.0 bar) 140/80 18 70M 110 kPa (1.1 bar)
Engine
TECHNICAL DATA RXV 450 (ENGINE)
Specification Model ENGINE Number of cylinders Overall engine capacity Bore/stroke Compression ratio Ignition Idle speed Clutch Lubrication system Air filter Cooling Gearbox Gear ratio 1st 2nd 3rd 4th Desc./Quantity 45RX twin cylinder, 4-stroke with 4 valves per cylinder, single overhead camshaft 2 449 cm (27.40 cu.in) 76 mm / 49.5 mm (2.99 in / 1.95 in) 13 0.5 Electronic 1800 2000 rpm multiplate wet clutch Separate twin-sump lubrication with external reservoir Sponge Coolant mechanical, 5 speeds with foot lever on the left hand side of the engine Primary: 22/56 = 1 : 2.545 Final: 15/50 = 1 : 3.200 12/31 = 1 : 2.583 (secondary) 1: 21.042 (total) 13/25 = 1 : 1.923 (secondary) 1: 15.664 (total) 15/23 = 1 : 1.533 (secondary) 1: 12.489 (total) 19/24 = 1 : 1.263 (secondary)
CHAR - 11
Characteristics
RXV 450-550
Specification 5 Drive chain Fuel system Diffuser Fuel system
Desc./Quantity 1: 10.288 (total) 21/22 = 1 : 1.047 (secondary) 1: 8.533 (total) with master link electronic injection 38 mm (1.49 in) premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM)
TECHNICAL DATA RXV 550 (ENGINE)

Specification Model ENGINE Number of cylinders Overall engine capacity Bore/stroke Compression ratio Ignition Idle speed Clutch Lubrication system Air filter Cooling Gearbox Gear ratio 1st 2nd 3rd 4th 5 Drive chain Fuel system Diffuser Fuel system Desc./Quantity 55RX twin cylinder, 4-stroke with 4 valves per cylinder, single overhead camshaft 2 553 cm (33.75 cu.in) 80 mm / 55.0 mm (3.15 in / 2.16 in) 12.5 0.5 Electronic 1800 2000 rpm multiplate wet clutch Separate twin-sump lubrication with external reservoir Sponge Coolant mechanical, 5 speeds with foot lever on the left hand side of the engine Primary: 22/56 = 1 : 2.545 Final: 15/50 = 1 : 3.200 12/31 = 1 : 2.583 (secondary) 1: 21.042 (total) 13/25 = 1 : 1.923 (secondary) 1: 15.664 (total) 15/23 = 1 : 1.533 (secondary) 1: 12.489 (total) 19/24 = 1 : 1.263 (secondary) 1: 10.288 (total) 21/22 = 1 : 1.047 (secondary) 1: 8.533 (total) with master link electronic injection 40 mm (1.57 in) premium unleaded petrol, minimum octane rating of 95 (NORM) and 85 (NOMM)
Electrical system
ELECTRICAL COMPONENTS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Specification Ignition Standard spark plug Spark plug electrode gap Resistance Battery Main fuse Secondary fuses (Permanent-magnet) Alternator Low-beam bulb High-beam bulb Front daylight running light bulb Turn indicators bulb License plate light bulb Rear daylight running light /stop light bulb Neutral gear warning light Low fuel warning light Desc./Quantity Electronic NGK CR8EKB 0.7 0.8 mm (0.028 in 0.031 in) 5 k 12V - 6 Ah 30 A 5 A, 7.5 A, 15 A 12 V - 350 W 12 V - 55 W 12 V - 60 W 12V - 3W With micro-bulbs 12V - 5W LED LED LED
CHAR - 12
RXV 450-550
Characteristics
17 18
Specification High-beam warning light Turn indicator warning light
Desc./Quantity LED LED
Tightening Torques
HANDLEBAR AND CONTROLS
Name Clutch control-handlebar fixing screw - M6 Throttle grip fixing screw - M6 Torque in Nm 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft)
FOOTRESTS LOCKING TORQUES

Name Footrest support bracket fixing screw - M12 Footrest support bracket fixing screw - M8 Torque in Nm 55 Nm (40.56 lbf ft) - Loctite 243 25 Nm (18.44 lbf ft) - Loctite 243
BODYWORK
Name Rod - mudguard front fixing screw - M6 Rod - mudguard rear fixing screw - M6 Mudguard - steering base fixing screw - M6 Air duct fixing screws - M6 Fairings fixing screws - M6 Front tail - frame fixing screw - M6 Tail - mudguard - frame central fixing nut - M6 Rear tail - frame fixing screw - M6 Tail - mudguard fixing screw - M6 Upper screw fixing undertail to license plate holder - M5 Lower screw fixing undertail to license plate holder - M5 Screw fixing undertail - mudguard - frame extension - M6 Shock absorber protection fixing screw - M5 Windshield - instrument panel support fixing screw - M5 Instrument panel support fixing screw - M5 Undertail lower fixing screw - M6 Torque in Nm 8 Nm (5.9 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 7 Nm (5.16 lbf ft) 7 Nm (5.16 lbf ft) 12 Nm (8.85 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 12 Nm (8.85 lbf ft)
LIGHTS AND INSTRUMENT PANEL

Name Front headlamp fixing screw - M6 Turn indicators fixing nut - M8 Taillight fixing screw - 3.9 License plate light fixing screw Torque in Nm 6 Nm (4.42 lbf ft) 6 Nm (4.42 lbf ft) 2 Nm (1.47 lbf ft) 2 Nm (1.47 lbf ft)
TANKS AND RESERVOIRS

Name Plate - fuel tank fixing screw - M6 Fuel tank - chassis fixing screw - M6 Pump body - fuel tank fixing screw - M6 Saddle quick release plate fixing screw - M4 Oil reservoir fixing nut - M6 Torque in Nm 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 10 Nm (7.37 lbf ft) 2 Nm (1.47 lbf ft) 5 Nm (3.69 lbf ft)
CHASSIS TIGHTENING TORQUES

Name Frame fixing screw - M10 Upper chain roller fixing screw - M8 Lower slider rear fixing screw - M5 Lower slider front fixing screw - M5 Torque in Nm 49 Nm (36.14 lbf ft) 22 Nm (16.23 lbf ft) 4.4 Nm (3.24 lbf ft) 4.4 Nm (3.24 lbf ft)
STAND
Name Stand locking plate fixing screw - M8 Torque in Nm 22 Nm (16.23 lbf ft) - Loctite 243
CHAR - 13
Characteristics
RXV 450-550
Name Side stand fixing nut - M10
Torque in Nm 50 Nm (36.88 lbf ft) - Loctite 243
EXHAUST
Name Pipes - head fixing screw - M6 Muffler - frame fixing screw - M8 Torque in Nm 12 Nm (8.85 lbf ft) 30 Nm (22.13 lbf ft)
COOLING SYSTEM LOCKING TORQUES

Name Radiators upper fixing screw - M6 Radiators lower fixing screw - M6 Torque in Nm 5 Nm (3.69 lbf ft) 12 Nm (8.85 lbf ft)
FRONT BRAKE
Name Brake - handlebar fixing screw - M6 Screw fixing front brake calliper - M8 Torque in Nm 10 Nm (7.37 lbf ft) 25 Nm (18.44 lbf ft)
REAR BRAKE LOCKING TORQUES

Name Rear brake pump fixing screw - M6 Brake pedal fixing screw - M8 Torque in Nm 10 Nm (7.37 lbf ft) 25 Nm (18.44 lbf ft) - Loctite 243
FRONT WHEEL LOCKING TORQUES

Name Wheel axle cover - M22 Torque in Nm 60 Nm (44.25 lbf ft)
REAR WHEEL
Name Wheel axle nut - M25 Torque in Nm 120 Nm (88.51 lbf ft)
FRONT SUSPENSION
Name Steering head fixing screw - M8 Steering base fixing screw - M8 Calliper mounting bracket fixing screw - M6 Upper clamp - handlebar fixing screw - M8 Steering pin nut - M26 Steering pin ring nut - M30 Lower clamp - handlebar fixing nut - M10 Stem protection fixing screw - M6 Torque in Nm 24 Nm (17.70 lbf ft) 22 Nm (16.23 lbf ft) 10 Nm (7.37 lbf ft) 24 Nm (17.70 lbf ft) 108 Nm (79.66 lbf ft) 7 Nm (5.16 lbf ft) 32 Nm (23.60 lbf ft) 12 Nm (8.85 lbf ft)
REAR SUSPENSION LOCKING TORQUES

Name Chassis - rod fixing nut - M12 Rod - rocker fixing nut - M12 Rocker - swingarm fixing nut - M12 Shock absorber fixing nut - M10 Torque in Nm 80 Nm (59.00 lbf ft) 80 Nm (59.00 lbf ft) 80 Nm (59.00 lbf ft) 52 Nm (38.35 lbf ft)
SWINGARM LOCKING TORQUES

Name Chain guide fixing nut - M6 Swingarm pin fixing nut - M14 Chain tensioner set screw - M8 Chain slider and pipe grommet - rear brake fixing screw - 4.8 Rear chain guard fixing screw - 4.8 Chain guide fixing screw - M6 Torque in Nm 12 Nm (8.85 lbf ft) 100 Nm (73.76 lbf ft) 26 Nm (19.18 lbf ft) 4.4 Nm (3.24 lbf ft) 4.4 Nm (3.24 lbf ft) 12 Nm (8.85 lbf ft)
CHAR - 14
RXV 450-550
Characteristics
ENGINE
Name Engine - chassis fixing nut M10 Screw fixing control unit to plate - M4 Screw fixing regulator and control unit to chassis - M6 Coil fixing screw - M6 Pinion cover - chain guide plate fixing screw - M6 Engine oil drainage plug - M12x1.5 Gearbox oil drainage plug - M12x1.5 Oil filter cover - M56x1.5 Piston fitting hole cover - M30x2 Spark plug - M10x1.25 Gearbox oil check screw - M6x1 Water pump rotor - M7x1 Head cover screw - M6x1 Water pump cover screw - M6x1 Clutch cover screw - M6x1 Clutch cover screw (torque first removal) - M6x1 Right crankcase cover screw (torque first removal) - M6x1 Right crankcase cover screw - M6x1 Crankcase clamping screw - M6x1 Crankcase clamping screw - M7x1 Ignition cover screw - M6x1 Ignition cover screw (torque first removal) - M6x1 Pick-up fixing screw - M5x0.8 Stator fitting screw - M5x0.8 Chain tensioner slider screw - M6x1 Timing chain tensioner fitting screw - M6x1 Cable guide ring fixing screw - M6x1 Oil pipe plate screw - M6x1 Blow-by breather joint - M12x1 Flywheel nut - M14x1 Starter screw - M6x1 Chain guide plate screw - M6x1 Secondary shaft bearing fixing screw - M6x1 Main shaft bearing fixing screw - M6x1 Screw fixing the gear selector drum bearing - M5x0.8 Gear indicator screw - M5x0.8 Gear pedal fixing screw - M6x1 Head fitting screw (pre-torque) - M10x1.25 Head fitting screw - M10x1.25 Head fitting screw - M6x1 Water joint plate screw - M6x1 Water Temperature Sensor Timing system gear fixing nut - M12x1 Timing compartment closing cover screw - M5x0.8 Main transmission pinion nut - M18x1.25 Selector locking plate screw - M6x1 Oil collecting plate screw - M6x1 Selector shaft grub screw - M10x1.25 Gear locking pawl rotation screw - M6x1 Selector pin - M18x1.25 Clutch hub fixing nut - M18x1.25 Clutch spring screw - M6x1 Pressure relief valve - M14x.5 Pressure pump fitting screw - M6x1 Scavenge pump fitting screw - M6x1 Head lubrication nozzle - M7x1 Valve lifter lock screw - M5x0.8 Crankshaft grub screw - M8x1.25 Freewheel outside ring screws - M6x1 Throttle body fixing screw - M6x1 Camshaft gear fixing screw - M16x1 Connecting rod cap screw - M8x1 Oil pressure sensor M10x1 APTC Clutch hub fixing nut - M18x1.25 Torque in Nm 54 Nm (39.82 lbf ft) 3 Nm (2.21 lbf ft) - Loctite 243 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 18 Nm (13.28 lbf ft) 18 Nm (13.28 lbf ft) 25 Nm (18.44 lbf ft) 30 Nm (22.13 lbf ft) 12 Nm (8.85 lbf ft) 9.8 Nm (7.23 lbf ft) 12 Nm (8.85 lbf ft) 9.8 Nm (7.23 lbf ft) 8.0 Nm (5.90 lbf ft) 8.0 Nm (5.90 lbf ft) 5.5 Nm (4.06 lbf ft) 9.8 Nm (7.23 lbf ft) 9.8 Nm (7.23 lbf ft) 12 Nm (8.85 lbf ft) 15 Nm (11.06 lbf ft) 9.8 Nm (7.23 lbf ft) 9.8 Nm (7.23 lbf ft) 8 Nm (5.90 lbf ft) - Loctite 270 8 Nm (5.90 lbf ft) - Loctite 270 9.8 Nm (7.23 lbf ft) - Loctite 270 10 Nm (7.37 lbf ft) 10 Nm (7.37 lbf ft) 9.8 Nm (7.23 lbf ft) - Loctite 270 18 Nm (13.28 lbf ft) - Use compound 108 Nm (79.66 lbf ft) 9.8 Nm (7.23 lbf ft) 12 Nm (8.85 lbf ft) 10 Nm (7.37 lbf ft) - Loctite 270 10 Nm (7.37 lbf ft) - Loctite 270 8 Nm (5.90 lbf ft) - Loctite 270 6 Nm (4.43 lbf ft) - Loctite 270 12 Nm (8.85 lbf ft) 30 Nm (22.13 lbf ft) - Oil screws and washers 50 Nm (36.88 lbf ft) 12 Nm (8.85 lbf ft) 9.8 Nm (7.23 lbf ft) 18 Nm (13.27 lbf ft) 50 Nm (36.88 lbf ft) 6 Nm (4.42 lbf ft) - Loctite 243 160 Nm (118.00 lbf ft) 12 Nm (8.85 lbf ft) - Loctite 270 12 Nm (8.85 lbf ft) - Loctite 270 25 Nm (18.44 lbf ft) - Loctite 270 12 Nm (8.85 lbf ft) - Loctite 243 22 Nm (16.23 lbf ft) 75 Nm (55.32 lbf ft) 12 Nm (8.85 lbf ft) 20 Nm (14.75 lbf ft) 9.8 Nm (7.23 lbf ft) 9.8 Nm (7.23 lbf ft) 2.5 Nm (1.84 lbf ft) 9 Nm (6.64 lbf ft) - Loctite 270 22 Nm (16.23 lbf ft) - Loctite 270 13 Nm (9.58 lbf ft) - Loctite 270 13 Nm (9.58 lbf ft) - Loctite 242 35 Nm (25.82 lbf ft) 15+(48-50) Nm (11.06+(48-50) lbf ft) 15 Nm (11.06 lbf ft) 80 Nm (59.0 lbf ft)
CHAR - 15
Characteristics
RXV 450-550
Name APTC thrust plate fixing screw - M5x0.8
Torque in Nm 8 Nm (5.9 lbf ft)
ELECTRICAL COMPONENTS
Name Solenoid - fuse box fixing screw - M5 Chassis - ground lead fixing screw - M6 Solenoid cables fixing screw - M6 Speed sensor fixing screw M4 Horn fixing screw - M8 Left light switch fixing screw - M4 Right light switch fixing screw - M4 Torque in Nm 7 Nm (5.16 lbf ft) - Loctite 243 12 Nm (8.85 lbf ft) 12 Nm (8.85 lbf ft) 2 Nm (1.47 lbf ft) - Loctite 243 22 Nm (16.23 lbf ft) 2 Nm (1.47 lbf ft) 2 Nm (1.47 lbf ft)
AIR FILTER BOX

Name Base union screw - filter housing intermediate part - M4 Torque in Nm 1.5 Nm (1.11 lbf ft)
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.
NOTE THE CRANKCASE TYPE IS ENGRAVED ON BOTH CRANKCASE HALVES.
COUPLING TYPES - SHAFT - CONNECTING ROD

Specification Shaft - Connecting rod: A - A - BLUE types Desc./Quantity Shaft- A 34.984 mm - 34.991 mm (1.37732 in - 1.37759 in) Connecting rod - A 38.000 mm - 38.012 mm (1.49606 in 1.49653 in) Colour: BLUE Shaft- A 34.984 mm - 34.991 mm (1.37732 in - 1.37791 in) Connecting rod - B 38.013 mm - 38.025 mm (1.49657 in 1.49704 in) Colour: YELLOW Shaft- B 34.992 mm - 35.000 mm (1.37763 in - 1.37795 in) Connecting rod - A 38.000 mm - 38.012 mm (1.49606 in 1.50078 in) Colour: GREEN Shaft- B 34.992 mm - 35.000 mm (1.37763 in - 1.37795 in) Connecting rod - B 38.013 mm - 38.025 mm (1.49657 in 1.49704 in) Colour: BLUE
Shaft - Connecting rod: A - B - YELLOW types
Shaft - Connecting rod: B - A - GREEN types
Shaft - Connecting rod: B - B - BLUE types
CHAR - 16
RXV 450-550
Characteristics
COUPLING TYPES - SHAFT - MAIN BEARING

Specification Shaft - Main bearing: A - A - BLUE types Desc./Quantity Shaft- A 34.984 mm - 34.991 mm (1.37732 in - 1.37759 in) Main bearing - A 41.000 mm - 41.007 mm (1.61417 in 1.61444 in) Colour: BLUE Shaft- A 34.984 mm - 34.991 mm (1.37732 in - 1.37759 in) Main bearing - B 41.008 mm - 41.016 mm (1.61448 in 1.61480 in) Colour: YELLOW Shaft- B 37.992 mm - 38.000 mm (1.49574 in - 1.49606 in) Main bearing - A 41.000 mm - 41.007 mm (1.61417 in 1.61444 in) Colour: GREEN Shaft- B 37.992 mm - 38.000 mm (1.49574 in - 1.49606 in) Main bearing - B 41.008 mm - 41.016 mm (1.61448 in 1.61480 in) Colour: BLUE
Shaft - Main bearing: A - B - YELLOW types
Shaft - Main bearing: B - A - GREEN types
Shaft - Main bearing: B - B - BLUE types
CHAR - 17
Characteristics
RXV 450-550
Recommended products chart

RECOMMENDED PRODUCTS TABLE
Product AGIP RACING 4T 10W-60 Description Engine oil Specifications Use top-branded oils that meet or exceed the CCMC G-4 API SG. SAE 10W-60 specifications requirements Ready for use mixed biodegradable coolant with "long life" technology and characteristics (red). Freezing protection up to -40C. Compliant with CUNA 956-16 standard. As an alternative to the recommended fluid, other fluids that meet or exceed the required specifications may be used. SAE J1703, NHTSA 116 DOT 4, ISO 4925 Synthetic fluid As an alternative to the recommended product, use top branded grease for roller bearings with an operating temperature range of -30C to +140C (-22F to +284 F), a drop point between 150C and 230 C (302F and 446F), high corrosion protection qualities and good water and rust resistance. SAE 7.5W
AGIP RACING 4T 10W-60 AGIP PERMANENT SPEZIAL
Gearbox oil Coolant
AGIP BRAKE 4
Brake fluid
AGIP MP GREASE
Grease for bearings, joints, couplings and linkages
AGIP FORK 7.5W
Fork oil
CHAR - 18
INDEX OF TOPICS
SPECIAL TOOLS
S-TOOLS
Special tools
RXV 450-550
SPECIAL TOOLS
Stores code 853713 Description Pin ring tool - 450
853714
Pin ring tool - 550
853715
Water pump oil seal guide
853716
Water pump oil seal punch
AP8140179
Valve spring compressor
AP8140187
Engine support stand
S-TOOLS - 20
RXV 450-550
Special tools
Stores code 8140188
Description Engine support
AP8140838
Flywheel rotor locking
8127819
Walbro Cable for Axone
AP9100838
Tool for valve pressure plate
9100839
Flywheel extractor
9100840
Punch for crankshaft bushings
9100843
Crankshaft pinion locking tool
S-TOOLS - 21
Special tools
RXV 450-550
Stores code 9100844
Description Crankshaft locking tool (timing pin)
9100884
Crankshaft bushing extractor
9100885
Main shaft/ right side - secondary shaft/ left side
9100886
Secondary shaft/right side - Main shaft/ left side
9100887
Punch for right crankcase desmo
9100888
Oil pump oil seal punch
9100889
Timing gear crankshaft punch
S-TOOLS - 22
RXV 450-550
Special tools
Stores code 9100890
Description Timing gear crankshaft punch
9100892
Left crankcase desmodromic + wheel hub
9100893
Left timing gear punch
9100894
Secondary shaft oil seal punch
9100895
Water pump oil seal punch
9100896
Clutch bell locking tool
9100897
Cylinder liner extractor
S-TOOLS - 23
Special tools
RXV 450-550
Stores code 9100898
Description Swingarm cages punch
9100900
Punch for swingarm linkage cages
9100903
Marzocchi fork oil seal; 45 mm (1.77 in)
9100904
Sachs fork oil seal; 48 mm (1.89 in)
9100938
Pump rotor wrench
9100943
Piston pin extractor
9100841
Engine support
S-TOOLS - 24
RXV 450-550
Special tools
Stores code 9100942
Description Crankcase halves support
S-TOOLS - 25
INDEX OF TOPICS
MAINTENANCE
MAIN
RXV 450-550
Maintenance
Maintenance chart
PERIODIC MAINTENANCE CHART FOR VEHICLES IN THE ORIGINAL VERSION (POWER-RESTRICTED) FOR ROAD USE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * After run-in ** Carry out bleeding *** Replace every year km x 1,000 Throttle unit screws tightening Throttle body Air filter and filter box Fuel piping idle speed adjustment Gearbox oil Clutch springs Clutch discs Clutch control Radiator and expansion tank coolant level System sealing Engine oil and engine oil filter Oil pipes Gas cables Brake fluid level Brake pipes Brake circuit screws tightening Brake disc thickness Brake pad thickness Electrical contacts and switches Battery connections Light operation/direction Electrical system operation Exhaust Tyre pressure and conditions Wheel bearings Wheel spokes and wheel rim coaxiality Tightening of wheel axle nuts and screws Screws fixing engine tightening Tightening of chassis screws and nuts Fork dust gaiters Fork struts ** Fork Tightening of fork plates and calliper mounting bracket screws Shock absorber pins tightening Shock absorber Steering bearings clearance Headstock dust gaiters Drive chain Chain link, chain sprocket and chain guide Steering bearing Clutch lever pin Gas cables Rider footrest pins Rear suspension levers Side stand bolt Front wheel bolt and bearings Rear swingarm pin Rear wheel bolt and bearings Sponge air filter Spark plugs Complete transmission Pressure relief and check valve spring 0.5 I A I I A R I I R I A I I I A I I I I I I I I I I I I C I I L 3 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L 6 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R 9 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L I I 12 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R 15 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L 18 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R I I 21 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L 24 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R 27 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L I I 30 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R -
MAIN - 27
Maintenance
RXV 450-550
km x 1,000 Cylinder liners Connecting rod and main bushings Ignition gears Oil pump gears Head lubrication jets Pistons and piston rings Piston pin Rocker rollers Valve lifter Camshaft wear Camshaft bearings Valve seats sealing Valve Valve clearance Valve guides Spring washers, caps, bucket tappets Chain tensioner toothing Valve springs Timing chain Drive chain sliders Fuel pump Fork (full maintenance) Fork oil Shock absorber (full maintenance) Crankshaft assembly bearing clearance Chain guide slider Chain guide Chain tensioner roller Chain tensioner pad Brake fluid ***
0.5 -
3 -
6 -
9 I I I I C R I I I I I I I A I I I I I I I I R I I I I I I -
12 -
15 -
21 -
24 -
30 -
PERIODIC MAINTENANCE CHART FOR VEHICLES IN FREE VERSION FOR HOBBY SPORTS APPLICATIONS
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * After run-in ** Carry out bleeding *** Replace every year Hours of operation Throttle unit screws tightening Throttle body Air filter and filter box Fuel piping idle speed adjustment Gearbox oil Clutch springs Clutch discs Clutch control Radiator and expansion tank coolant level System sealing Engine oil and engine oil filter Oil pipes Gas cables Brake fluid level Brake pipes Brake circuit screws tightening Brake disc thickness Brake pad thickness Electrical contacts and switches Battery connections Light operation/direction Electrical system operation Exhaust Tyre pressure and conditions Wheel bearings Wheel spokes and wheel rim coaxiality 3 I A I I A R I I R I A I I I A I I I I 15 I A I I A R I I I I I R I A I I I I I I I A I I I I I 30 I A I I A R I I I I I R I A I I I I I I I A I I I I I 45 I A I I A R I I I I I R I A I I I I I I I A I I I I I 60 I A I I A R I I I I I R I A I I I I I I I A I I I I I 75 I A I I A R I I I I I R I A I I I I I I I A I I I I I 90 I A I I A R I I I I I R I A I I I I I I I A I I I I I 105 I A I I A R I I I I I R I A I I I I I I I A I I I I I 120 I A I I A R I I I I I R I A I I I I I I I A I I I I I 135 I A I I A R I I I I I R I A I I I I I I I A I I I I I 150 I A I I A R I I I I I R I A I I I I I I I A I I I I I
MAIN - 28
RXV 450-550
Maintenance
Hours of operation Tightening of wheel axle nuts and screws Screws fixing engine tightening Tightening of chassis screws and nuts Fork dust gaiters Fork struts ** Fork Tightening of fork plates and calliper mounting bracket screws Shock absorber pins tightening Shock absorber Steering bearings clearance Headstock dust gaiters Drive chain Chain link, chain sprocket and chain guide Steering bearing Clutch lever pin Gas cables Rider footrest pins Rear suspension levers Side stand bolt Front wheel bolt and bearings Rear swingarm pin Rear wheel bolt and bearings Sponge air filter Spark plugs Complete transmission Pressure relief and check valve spring Cylinder liners Connecting rod and main bushings Ignition gears Oil pump gears Head lubrication jets Pistons and piston rings Piston pin Rocker rollers Valve lifter Camshaft wear Camshaft bearings Valve seats sealing Valve Valve clearance Valve guides Spring retainer washers, caps, bucket tappets Chain tensioner toothing Valve springs Timing chain Drive chain sliders Fuel pump Fork (full maintenance) Fork oil Shock absorber (full maintenance) Crankshaft assembly bearing clearance Chain guide slider Chain guide Chain tensioner roller Chain tensioner pad Brake fluid ***
3 I I I I I I I I C I I L -
15 I I I C I I I I I I C I I L L L L L L L L L -
60 I I I C I I I I I I C I I L L L L L L L L L R R -
90 I I I C I I I I I I C I I L L L L L L L L L I I I I I I C R I I I I I I I A I I I I I I I I R I I I I I I -
120 I I I C I I I I I I C I I L L L L L L L L L R R -
PERIODIC MAINTENANCE CHART FOR VEHICLES IN FREE VERSION FOR COMPETITIVE SPORTS APPLICATIONS
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * After run-in ** Carry out bleeding *** Replace every year
MAIN - 29
Maintenance
RXV 450-550
Hours of operation Throttle unit screws tightening Throttle body Air filter and filter box Fuel piping idle speed adjustment Gearbox oil Clutch springs Clutch discs Clutch control Radiator and expansion tank coolant level System sealing Engine oil and engine oil filter Oil pipes Gas cables Brake fluid level Brake pipes Brake circuit screws tightening Brake disc thickness Brake pad thickness Electrical contacts and switches Battery connections Light operation/direction Electrical system operation Exhaust Tyre pressure and conditions Wheel bearings Wheel spokes and wheel rim coaxiality Tightening of wheel axle nuts and screws Screws fixing engine tightening Tightening of chassis screws and nuts Fork dust gaiters Fork struts ** Fork Tightening of fork plates and calliper mounting bracket screws Shock absorber pins tightening Shock absorber Steering bearings clearance Headstock dust gaiters Drive chain Chain link, chain sprocket and chain guide Steering bearing Clutch lever pin Gas cables Rider footrest pins Rear suspension levers Side stand bolt Front wheel bolt and bearings Rear swingarm pin Rear wheel bolt and bearings Sponge air filter Spark plugs Complete transmission Pressure relief and check valve spring Cylinder liners Connecting rod and main bushings Ignition gears Oil pump gears Head lubrication jets Pistons and piston rings Piston pin Rocker rollers Valve lifter Camshaft wear Camshaft bearings Valve seats sealing
3 I A I I A R I I R I A I I I A I I I I I I I I I I I I C I I L -
15 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L -
45 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R -
75 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L I I I I I I C R I I I I I I
105 I A I I A R I I I I I R I A I I I I I I I A I I I I I I I I C I I I I I I C I I L L L L L L L L L R R -
MAIN - 30
RXV 450-550
Maintenance
Hours of operation Valve Valve clearance Valve guides Spring retainer washers, caps, bucket tappets Chain tensioner toothing Valve springs Timing chain Drive chain sliders Fuel pump Fork (full maintenance) Fork oil Shock absorber (full maintenance) Crankshaft assembly bearing clearance Chain guide slider Chain guide Chain tensioner roller Chain tensioner pad Brake fluid ***
3 -
15 -
30 -
45 -
60 -
75 I A I I I I I I I I R I I I I I I -
90 -
105 -
120 -
135 -
150 -
Spark plug
At regular intervals, remove the spark plug and clean off any carbon deposits or replace as required.
CAUTION
ALWAYS REPLACE BOTH SPARK PLUGS, EVEN IF ONLY ONE NEEDS REPLACING. In order to reach the spark plugs:
CAUTION
BEFORE CARRYING OUT THE FOLLOWING OPERATIONS AND IN ORDER TO AVOID BURNS, LEAVE ENGINE AND SILENCER TO COOL OFF TO AMBIENT TEMPERATURE.
NOTE
Rest the vehicle on its stand.
THE VEHICLE HAS A SPARK PLUG (2) FOR EACH CYLINDER. THE FOLLOWING STEPS RELATE TO JUST ONE SPARK PLUG BUT APPLY TO BOTH. Remove the tube (1) of the spark plug (2). Clean off any trace of dirt from the spark plug (2) base. Insert the spanner supplied in the tool kit into the hexagonal head of the spark plug (2). Unscrew the spark plug (2) and remove it from its seat, making sure no dust or dirt gets into the cylinder.
MAIN - 31
Maintenance
RXV 450-550
Checking and cleaning:

CAUTION
DO NOT USE METAL BRUSHES AND/OR ABRASIVE PRODUCTS TO CLEAN THE SPARK PLUGS. USE ONLY A COMPRESSED AIR JET.
KEY: - central electrode (3); - insulator (4); - side electrode (5). Check that the electrodes and the insulator of the spark plug (2) do not show signs of carbon deposits and corrosion. If necessary, clean them using a compressed air jet. Replace the spark plug (2) if its insulator is cracked, the electrodes show signs of corrosion or excessive deposits, or the top of the central electrode gets rounded (6).
CAUTION USE ONLY THE RECOMMENDED TYPE OF SPARK PLUG, OTHERWISE, THE ENGINE DURATION AND PERFORMANCE COULD BE COMPROMISED. CHECK THE GAP BETWEEN THE ELECTRODES WITH A THICKNESS FEELER GAUGE TO AVOID DAMAGING THE PLATINUM COATING.
CAUTION
Check the gap between the electrodes with a feeler gauge.
DO NOT ATTEMPT TO READJUST THE ELECTRODE GAP. The gap between the electrodes should be between 0.7 - 0.8 mm (0.027 - 0.031 in). Otherwise, replace the spark plug (2). Make sure the washer is in good conditions. Installation: Once the washer is fitted, screw the spark plug (2) manually to avoid damaging the thread. Tighten using the spanner supplied in the tool kit. Make each spark plug (2) MAIN - 32
RXV 450-550
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) Position the spark plug tube (1) correctly so that it does not get detached due to engine vibrations.
NOTE
REPEAT THE DESCRIBED OPERATIONS FOR THE SPARK PLUG (2) OF THE OTHER CYLINDER.
Engine oil
CAUTION
ENGINE OIL MAY CAUSE SKIN DAMAGE IF HANDLED FREQUENTLY AND FOR LONG PERIODS. IT IS ADVISABLE TO WASH YOUR HANDS CAREFULLY AFTER HANDLING IT.
CAUTION
KEEP OUT OF THE REACH OF CHILDREN
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE.
CAUTION
DO NOT SPILL OIL! AVOID SPILLING OIL OVER COMPONENTS, THE AREA YOUR ARE WORKING IN AND ITS SURROUNDS. REMOVE ANY TRACE OF OIL CAREFULLY.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Check
To check:
CAUTION
THIS TYPE OF VEHICLE HAS SEPARATE LUBRICATION CIRCUITS FOR ENGINE AND TRANSMISSION/CLUTCH. OIL LEVEL CHECK AND REPLACEMENT MUST BE CARRIED OUT FOR BOTH CIRCUITS. MAIN - 33
Maintenance
RXV 450-550
CAUTION
ENGINE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM, A COUPLE OF MINUTES AFTER THE ENGINE HAS BEEN SHUT OFF. IF ENGINE OIL LEVEL IS CHECKED WHEN THE ENGINE IS COLD, OIL MAY DROP TEMPORARILY BELOW THE MINIMUM LEVEL. THIS SHOULD NOT BE CONSIDERED A PROBLEM.
NOTE
IN ORDER TO WARM-UP THE ENGINE AND BRING THE OIL TO THE RIGHT TEMPERATURE, RIDE THE VEHICLE FOR A SHORT PERIOD OF TIME (10 - 15 MIN), KEEP THE ENGINE RUNNING AT IDLE FOR AT LEAST 30 SECONDS AFTER YOU HAVE COME TO A HALT, THEN CUT OFF THE ENGINE. Keep the vehicle upright with the two wheels on the ground. Check oil level through the appropriate transparent pipe (1). MAX = maximum level MIN = minimum level The oil level is correct when it is close to the MAX level reference mark. Top up as required:
CAUTION
IF YOU RIDE YOUR VEHICLE IN A SPORTY FASHION WITH OIL LEVEL TOO HIGH, SOME OIL MAY SPLATTER AND GET INTO THE FILTER BOX THROUGH THE ENGINE BREATHER.
CAUTION
DO NOT GO BEYOND THE MAX OR BELOW THE MIN LEVEL MARKS TO AVOID SEVERE ENGINE DAMAGE.
NOTE DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE OIL. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. NOTE USE OIL RECOMMENDED IN THE PRODUCTS TABLE.
Unscrew and remove the filler plug (2).
Top-up the oil in the reservoir until you reach the correct level.
See also
Recommended products chart
MAIN - 34
RXV 450-550
Maintenance
Replacement
Park the vehicle on firm and level ground. Rest the vehicle on its stand.
Stop the engine and let it cool off so that the oil in the crankcase flows down and cools as well.
Remove the oil sump guard. Unscrew and take out the oil filler plug (1). Place a container to collect the oil underneath the engine oil drainage plug on the flywheel side.
Unscrew and remove the oil drainage plug (2) and then drain all the engine oil.
Unscrew the engine oil filter cover (4). Remove the engine oil filter cover (4) and collect the O-ring. Remove the engine oil filter. Place a container underneath the engine oil drainage plug (3) of the recovery reservoir.
Unscrew and remove the engine oil drainage plug (3) of the recovery reservoir and then drain all engine oil. Fit a new engine oil filter.
MAIN - 35
Maintenance
RXV 450-550
Screw the engine oil filter cover (4). Screw and tighten the oil filling/drainage plugs (2)(3). Pour approx. 1000 cm (61.02 cu.in) of engine oil through the filler hole. Screw and tighten the oil drainage plug (1). Start the engine and let it run for several minutes. Stop the engine. Unscrew and take out the oil filler plug (1). Top up with other 250 cc (15.25 cu in) of oil. Screw and tighten the cap (1). Start the engine and let it run for several minutes. Stop the engine and let it cool down. Check the engine oil level.
Characteristic
Engine oil capacity 1.3 l (0.28 UK gal)
Gearbox Oil Inspection

CAUTION
GEAR OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. 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 undoing the screw (1); collect the washer.
MAIN - 36
RXV 450-550
Maintenance
Unscrew and remove the cap/dipstick (2). The oil level is correct when it is close to the cap/dipstick (2) opening.
If necessary: Remove the filler cap (3). Top-up with oil up to the cap/dipstick (2) opening.
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Wait some minutes to allow the oil to flow from the clutch to the transmission. Then check the oil level again.
Refit the rear brake lever, remember to insert the washer between the lever and the crankcase, by tightening the screw (1).
NOTE
HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
Replacement
Lower the oil sump guard. Place a container with suitable capacity under the drainage plug (3). Unscrew and remove the drainage plug (3). Unscrew and remove the filler cap (2). Drain the oil into the container; allow several minutes for oil to drain out completely. Check and if necessary, replace the drainage plug (3) sealing washers.
MAIN - 37
Maintenance
RXV 450-550
Screw and tighten the drainage plug (3). Remove the rear brake lever by undoing the screw (1); collect the washer. Unscrew and remove the cap/dipstick. Pour new oil up to the cap/dipstick opening. Wait some minutes to allow the oil to flow from the clutch to the transmission.

CAUTION
Then check the oil level again. Tighten the filler cap (2).
OIL FLOWING FROM THE CLUTCH TO THE TRANSMISSION AND FROM THE TRANSMISSION TO THE CLUTCH CAN BE PARTICULARLY SLOW WHEN THE OIL OR ENGINE TEMPERATURE IS LOW. CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Refit the rear brake lever, remember to insert the washer between the lever and the crankcase, by tightening the screw (1).
NOTE
USE OIL RECOMMENDED IN THE PRODUCTS TABLE.
Air filter
Remove the saddle. Remove the side fairings. Lift the tank being careful with the fuel pipe. Release the air filter box cover by gripping and lifting the handles from both sides. Slide out the air filter box cover, together with the air filter from the back, being careful not to damage the control unit connector (if necessary, remove it).
NOTE
MAIN - 38
RXV 450-550
Maintenance
DURING FUEL TANK LIFTING AND REPOSITIONING, PLACE MANUALLY THE FUEL TANK AND CHECK IT IS CORRECTLY POSITIONED IN ITS SEAT. CAUTION OIL THE SPONGE FILTER AS INSTRUCTED IN THE SCHEDULED MAINTENANCE CHART. NOTE UPON REFITTING THE AIR FILTER, ENSURE THAT ITS BOX IS PERFECTLY CLEAN. REMOVE ANY TRACE OF DIRT THAT MAY HAVE ENTERED DURING REMOVAL. UPON REFITTING, MAKE SURE THAT THE AIR INTAKES ARE CORRECTLY FITTED. CAUTION
MAKE SURE THAT THE RESERVOIR RETAINING EDGE NEVER COMES INTO CONTACT WITH THE BATTERY POSITIVE LEAD. CAUTION
IN THE EVENT OF A FALL, CLEAN THE AIR FILTER AND ITS BOX CAREFULLY, REMOVING ANY TRACES OF OIL WHICH MAY HAVE ENTERED FROM THE OIL RESERVOIR THROUGH THE OIL VAPOUR BREATHER PIPES. CAUTION
REMOVE THE AIR FILTER COVER ONLY WHEN THE VEHICLE IS PERFECTLY CLEAN SO AS TO PREVENT ANY TRACE OF DIRT FROM GETTING INTO THE BOX.
Cooling system Level check

Check and top-up
CAUTION
WAIT FOR THE ENGINE TO COOL DOWN BEFORE CHECKING OR TOPPING-UP THE COOLANT LEVEL. 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.
MAIN - 39
Maintenance
RXV 450-550
Wait a few seconds so that possible pressure in the circuit may be purged. Turn the radiator cap (1) anticlockwise again and remove it. Make sure the fluid covers the radiator plates completely. Also check the level in the expansion tank (under the engine sump cover) through the appropriate sight glass.
The level should be between the MIN and MAX reference marks.
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. CAUTION
COOLANT IS TOXIC IF INGESTED; CONTACT WITH EYES OR SKIN MAY CAUSE IRRITATION. DO NOT INTRODUCE YOUR FINGERS OR ANY OTHER OBJECT TO CHECK IF THERE IS COOLANT OR NOT.
Top-up
Check the coolant level. If required, top-up with coolant until the radiator plates are covered. Do not exceed this level, otherwise the coolant will spill during engine operation. When using a funnel or any other element, make sure it is perfectly clean.
CAUTION IN CASE OF EXCESSIVE COOLANT CONSUMPTION OR WHEN THE EXPANSION TANK IS EMPTY, CHECK THAT THERE ARE NO LEAKS IN THE CIRCUIT.
Refit the radiator cap (1).
Braking system
CAUTION
THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OF THEM OPERATED BY AN INDEPENDENT HYDRAULIC CIRCUIT.
NOTE
MAIN - 40
RXV 450-550
Maintenance
THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT APPLIES TO BOTH.
CAUTION
UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND THE FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY AFTER MAINTENANCE OPERATIONS OR CHECKS. CHECK THAT BRAKE PIPES ARE NOT TWISTED OR WORN. PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT. BRAKE FLUID MAY CAUSE IRRITATION IF IN CONTACT WITH SKIN OR EYES. RINSE CAREFULLY ALL BODY PARTS THAT HAVE COME INTO CONTACT WITH THE FLUID. SHOULD THE FLUID COME INTO CONTACT WITH YOUR EYES, SEEK MEDICAL ADVICE OR CONTACT AN EYE SPECIALIST. DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN WHEN USING BRAKE FLUID, PAY ATTENTION NOT TO SPILL IT ONTO PLASTIC OR PAINTED COMPONENTS AS IT WILL IRREPARABLY DAMAGE THEM.
Level check
FRONT BRAKE 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:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. Check brake pads and discs for wear.
If the pads and/or the disc do not need replacing, top-up the fluid. REAR BRAKE Place the vehicle upright Make sure the fluid level in the reservoir (2) is above the "MIN" level reference mark.
If the fluid does not reach at least the "MIN" reference mark:
CAUTION
BRAKE LEVEL DECREASES GRADUALLY AS BRAKE PADS WEAR DOWN. MAIN - 41
Maintenance
RXV 450-550
Check brake pads and discs for wear.
If the pads and/or the disc do not need replacing, top-up the fluid.
Top-up
Front braking system top-up
NOTE RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE SCREWS (4) ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR CAP (5) HAS BEEN REMOVED.
CAUTION
Undo the screws (4) of the brake fluid reservoir using a short Phillips screwdriver.
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.
CAUTION
Lift and remove the cover (5) together with the screws (4) and the gasket (6).
TO AVOID SPILLING BRAKE FLUID DURING TOP-UP, DO NOT SHAKE THE VEHICLE. DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
CAUTION
Top-up the reservoir with the brake fluid until the level is over the "MIN" level reference mark.
TOP-UP TO MAX LEVEL MARK ONLY WHEN THE BRAKE PADS ARE NEW. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS. CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORMANCE OF THE BRAKING SYSTEM, IT MAY BE NECESSARY TO PURGE THE AIR IN THE SYSTEM. Rear brake system top-up
NOTE
RISK OF BRAKE FLUID SPILLS. DO NOT PULL THE FRONT BRAKE LEVER WHEN THE SCREWS (7) ARE LOOSE OR, MAINLY, WHEN THE BRAKE FLUID RESERVOIR CAP (8) HAS BEEN REMOVED.
MAIN - 42
RXV 450-550
Maintenance
Undo the two screws (7) of the brake fluid reservoir using a short Phillips screwdriver.
CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE.
CAUTION
Lift and remove the cover (8) together with the screws (7) and the gasket (9).
TO AVOID SPILLING BRAKE FLUID DURING TOP-UP, DO NOT SHAKE THE VEHICLE. DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
CAUTION
Top-up the reservoir with the brake fluid until the level is over the "MIN" level reference mark.
TOP-UP TO MAX LEVEL MARK ONLY WHEN THE BRAKE PADS ARE NEW. IT IS ADVISABLE NOT TO TOP-UP TO THE MAX LEVEL MARK WHEN THE BRAKE PADS ARE WORN BECAUSE YOUR RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS. CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORMANCE OF THE BRAKING SYSTEM, IT MAY BE NECESSARY TO PURGE THE AIR IN THE SYSTEM.
Headlight adjustment
NOTE
IN COMPLIANCE WITH LOCAL REGULATIONS IN FORCE, SPECIFIC PROCEDURES MUST BE FOLLOWED WHEN CHECKING LIGHT BEAM ADJUSTMENT. For a quick check of the correct adjustment of the front light beam: Place the vehicle 10 m (32.81 ft) away from a vertical wall and make sure the ground is level. Turn on the low-beam light, sit on the vehicle and check that the light beam projected to the wall is a little below the headlight horizontal straight line (about 9/10 of the total height). To adjust the light beam:
MAIN - 43
Maintenance
RXV 450-550
Operating on both sides, undo the screw. Adjust the headlamp until the desired position is obtained. Working from both sides, tighten the screw. After adjusting:
NOTE CHECK THAT THE LIGHT BEAM VERTICAL DIRECTION IS CORRECT.
MAIN - 44
INDEX OF TOPICS
ELECTRICAL SYSTEM
ELE SYS
Electrical system
RXV 450-550
Electrical system installation General wiring diagram
Key 1. MULTIPLE CONNECTORS
ELE SYS - 46
RXV 450-550
Electrical system
2. DIAGNOSIS CONNECTOR 3. SPEED SENSOR 4. INSTRUMENT PANEL 5. TURN INDICATORS 6. LEFT LIGHT SWITCH 7. HORN 8. IGNITION KEY 9. LIGHT RELAY 10.RIGHT LIGHT SWITCH 11.REAR STOP SWITCH 12.FRONT STOP SWITCH 13.REAR LEFT TURN INDICATOR 14.TAILLIGHT 15.LICENSE PLATE LIGHT 16.REAR RIGHT TURN INDICATOR 17.CAPACITOR (BUFFER) 18.FAN 19.SECONDARY FUSES 20.FUEL LEVEL SENSOR 21.FUEL PUMP 22.SAFETY DIODE 23.MAIN FUSE 24.START-UP RELAY 25.STARTER MOTOR 26.BATTERY 27."ECR" RELAY 28.Voltage regulator 29.ALTERNATOR 30.SWITCH FOR MAPPING CHANGE 31.Water Temperature Sensor 32.GEAR SENSOR 33.COIL 2 (REAR CYLINDER) - FITTED ON THE LEFT 34.SPARK PLUG 2 35.COIL 1 (FRONT CYLINDER) - FITTED ON THE RIGHT 36.SPARK PLUG 1 37.IDLE MOTOR 38.INTAKE AIR TEMPERATURE SENSOR 39.THROTTLE SENSOR (TPS) ELE SYS - 47
Electrical system
RXV 450-550
40.INJECTOR 2 (REAR CYLINDER) 41.INJECTOR 1 (FRONT CYLINDER) 42.PICK-UP 43.PICK-UP WIRE SHIELDING 44.ECU 45.FRONT RIGHT TURN INDICATOR 46.TAIL LIGHT BULB 47.FRONT HEADLAMP 48.HIGH-BEAM/LOW-BEAM TWIN-FILAMENT BULB 49.FRONT LEFT TURN INDICATOR 50.RESISTANCE 51.NEUTRAL WARNING LIGHT 52."KEY TO ON" WARNING LIGHT LED Cable colours - key: Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple
Checks and inspections
ELE SYS - 48
RXV 450-550
Electrical system
Dashboard
Activate the set-up when the monitoring icons get activated because the setting level has been exceeded (displayed on the LCD). Once in the set-up, select the icon to be reset displaying it on the LCD. Once the corresponding icon is displayed, press and hold SCROLL until the dashes - - - - are displayed. When the key is released, the word NO is displayed. The word YES is displayed when SCROLL is briefly pressed.
Press and hold SCROLL until WS is displayed at the bottom right angle; when the key is released, the icon is displayed and the previously programmed values flash. If confirmed, wait until it is displayed. The counter is automatically reset and, consequently, the icon is deactivated. The service icon WRENCH is displayed when SCROLL is briefly pressed. Once the corresponding icon is displayed, press and hold SCROLL until the dashes - - - - are displayed. When the key is released, the Wrench NO icon is displayed.
ELE SYS - 49
Electrical system
RXV 450-550
The wrench YES icon is displayed when SCROLL is briefly pressed.
Press and hold SCROLL until WS is displayed in the bottom right angle; when the key is released, the icon and the preselected unit of measurement are displayed. Press SCROLL briefly to select either CLK or km / h as unit of measurement.
Fuses
CAUTION
NEVER ATTEMPT TO REPAIR FAULTY FUSES. NEVER USE A FUSE OF A RATING OTHER THAN SPECIFIED. THIS COULD DAMAGE THE ELECTRICAL SYSTEM OR CAUSE A SHORT CIRCUIT, WITH THE RISK OF FIRE.
CAUTION
IF A FUSE BLOWS OUT FREQUENTLY, THAT MAY BE DUE TO A SHORT CIRCUIT OR OVERLOAD. IF THIS OCCURS, CONTACT AN Official Aprilia Dealer. Checking the fuses is necessary whenever an electrical component fails to operate or is malfunctioning or when the engine does not start. Check the secondary fuses first and then the main 30A fuse. To check: Set the ignition switch to (OFF) to avoid an accidental short circuit. Remove the right side fairing by undoing the two screws (1) and slide if off from its seat.
ELE SYS - 50
RXV 450-550
Electrical system
Lift the cover (2) of the secondary fuse box.
Take out one fuse at a time and check whether the filament (3) is broken. Before replacing the fuse, find and solve, if possible, the reason that caused the problem.
If the fuse is damaged, replace it with one of the same amperage.
NOTE IF A SPARE FUSE IS USED, SUPPLY ANOTHER OF THE SAME TYPE IN THE CORRESPONDING FITTING.
Remove the left side fairing by following the same procedure for the right side fairing. To check the main fuses, carry out the same operations described above for secondary fuses.
SECONDARY FUSES DISTRIBUTION

1 2 3 4 5 6 7 Specification (1) Fuse (2) 15A fuse (3) 15A fuse (4) 15A fuse (5) 7.5A fuse (6) 7.5A fuse (7) 7.5A fuse Desc./Quantity NOT USED Control unit relay power Tail lights, turn indicators, horn, instrument panel, stop light ECU relay energising Injectors coils Electric fan Fuel pump
NOTE THERE ARE THREE SPARE FUSES 8.
ELE SYS - 51
Electrical system
RXV 450-550
MAIN FUSES - DISTRIBUTION

1 Specification 30A fuse Desc./Quantity Battery recharge (there is just one fuse, the second one is spare).
Control unit
Remove the saddle. Remove the fuel tank. Disconnect the connectors.
Undo and remove the two screws by holding the control unit from below. Remove the control unit.
ELE SYS - 52
RXV 450-550
Electrical system
Remove the voltage regulator.
See also
Seat Fuel tank Remove the voltage regulator.
See also
Seat Fuel tank
Speed sensor
Function To indicate the vehicle speed by reading the front wheel turning speed. Operation / Operating principle HALL effect sensor: a square-wave pulse is generated with voltage between 12 V and 0.3-0.4V approx. Location: sensor: left side, next to the front brake calliper connector: under front headlamp cowl
Electrical characteristics: Pin-out: Voltage PIN "+" and PIN "-": approx. 12 V Voltage PIN "S" and PIN "-": variable 0.4V-4,8V (by turning the front wheel)
ELE SYS - 53
Electrical system
RXV 450-550
"+": Power supply voltage (Green) "S": Output signal (Grey/White) "-": Ground (Blue/Orange)
AXONE: PARAMETERS - Speed (km/h) - vehicle speed. AXONE: LOGIC ERRORS Speed sensor - invalid signal Error cause Error signal if a speed below the default value set by the manufacturer for the running vehicle is detected. Possibly shorted to ground, to battery or speed sensor circuit open: lack of supply from the control unit also possible. Troubleshooting CARRY OUT THE CASCADE OPERATIONS UNTIL THE FAILURE IS FOUND Check correct position of the sensor in its fitting. Check voltage between PINS "+" and "-" of the sensor. If no voltage is detected, check cable continuity between PIN "+" of the sensor and PIN F1 of Green/Orange connector of the control unit. Check the Green/Orange connector of PIN F1. Check cable continuity between PIN "-" of sensor and PIN H2 of Blue/Green connector of the control unit (ground). Check the Blue/Green connector of PIN H2. Check cable continuity between PIN "S" of sensor and PIN E3 of the Brown/Yellow connector of the control unit. Check the Brown/Yellow connector of PIN E3. If there is no failure after all these checks, replace the sensor.
Speed sensor - Above max threshold Error cause Error signal if a speed above the default value set by the manufacturer for the running vehicle is detected. Troubleshooting Replace the speed sensor
Engine rpm sensor

Function It indicates the crankshaft position and speed to the Walbro control unit. Operation / Operating principle inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the reference position. ELE SYS - 54
RXV 450-550
Electrical system
Location: sensor: inside the flywheel cover connector: under the left-side tank next to the filter box
Electrical characteristics: Resistance at ambient temperature: 112 +/- 10 % Ohm Pin-out: "+" (blue cable on sensor side): Supply "-" (green cable on sensor side): Ground connection
NB: blue/green cable on sensor side, shielding. CAUTION: IF THE ELECTRIC CIRCUIT IS SHUTDOWN OR SHORT-CIRCUITED OR NO ERROR IS DISPLAYED, CHECK THE ENGINE SPEED SENSOR CONNECTOR AND THE WALBRO CONTROL UNIT CONNECTOR: IF NOT OK, RESTORE; IF OK, CHECK THAT THE SENSOR ELECTRICAL SPECIFICATION IS THE CORRECT ONE: IF NOT OK, REPLACE THE SENSOR; IF OK, PERFORM THE TEST FROM PIN B4 AND C4 OF WALBRO CONTROL UNIT CONNECTOR TO SENSOR CONNECTOR.
Throttle position sensor

Function It sends 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. Location: sensor: on the front cylinder throttle body connector: on the potentiometer
Electrical characteristics: Pin-out: ELE SYS - 55 PIN 1-2: closed throttle approx. 1.3 kOhm; open throttle approx. 4.3 kOhm. PIN 1-3: approximately 4.3 kOhm (at 20 C)
Electrical system
RXV 450-550
PIN 1: ground (Blue/Green) PIN 2: potentiometer signal (Grey) (from 0.8 V with closed throttle to 4 V with throttle open) PIN 3: power supply voltage (Orange) + 5 V
AXONE: PARAMETERS Potentiometer on throttle - 0.8 (minimum) / 4 V (full load) Correct throttle position - 0 % (minimum) / 95 % (full load)
AXONE: FUEL INJECTION SYSTEM ELECTRICAL ERRORS throttle sensor 122 - shorted to negative Error cause If shorted to negative: voltage equal to zero has been detected at PIN C3 of the control unit connector. Troubleshooting shorted to negative: disconnect the sensor connector and check ground insulation of the orange cable (from throttle sensor connector to multiple connector and from multiple connector to 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; therefore, replace the throttle body. throttle sensor 123 -open circuit, shorted to positive Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN C3 of the control unit connector. Troubleshooting Circuit is open, shorted to positive: check the injection ECU connector, the multiple connector and the sensor connector: if NOT OK, restore it; if OK, check continuity between PIN C3 of control unit connector and the PIN related to multiple connector and between the multiple connector PIN and the sensor PIN 2 (Grey cable): if there is no continuity, restore the cable harness; if there is continuity, check continuity of the sensor between PIN 1 and PIN 2: if there is no continuity, replace the potentiometer; if there is continuity, check the ELE SYS - 56
RXV 450-550
Electrical system
resistance. If resistance is over 4.3 kOhm, it indicates that the orange cable is shorted to positive and the cable harness should be restored. ADJUSTABLE PARAMETERS Throttle position self-acquisition - Allows the control unit to detect the closed throttle position: just press the enter button. This must be done in case the potentiometer throttle body, the throttle body or the injection control unit have to be replaced. NOTE - Mechanical and electrical refit and zero reset procedure. Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis instrument selecting FUEL INJECTION and carry out the operation: Throttle self-acquisition, min. position / Throttle self-acquisition, max. position
Engine temperature sensor

Function It indicates the engine temperature to the control unit so as to optimise carburetion and idle control. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Location: sensor: left side over pinion connector: on the sensor
Electrical characteristics: Pin-out: PIN 1 (brown cable on cable harness side): 0-5 V signal PIN 2 (blue/green cable on cable harness side): Ground connection Resistance at -20 C (-4 F): 15 k 5% Resistance at 0 C (32 F): 5.8 k 5% Resistance at 40 C (104 F): 1.1 k 5% Resistance at 60 C (140 F): 0.6 k 5% Resistance at 80 C (176 F): 0.3 k 5% Resistance at 100 C (212 F): 0.19 k 5%
ELE SYS - 57
Electrical system
RXV 450-550
AXONE: PARAMETERS - Air temperature AXONE: ELECTRICAL ERRORS engine temperature sensor 118 - shorted to negative Error cause If shorted to negative: voltage equal to zero has been detected at PIN D4 of the control unit connector. Troubleshooting If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor; if resistance is 0, it means that the brown cable has ground connection: restore the cable harness. engine temperature sensor 119 - open circuit, shorted to positive Error cause If the circuit is open, shorted to positive: excessive voltage has been detected at PIN D4 of the control unit connector. Troubleshooting If the circuit is open, shorted to positive: check the sensor connector and the Walbro control unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of the sensor; if it is not OK, replace the sensor; if it is OK, check the continuity between PIN D4 of the control unit connector and PIN 1 of the sensor brown cable: restore cable harness if there is not continuity; if OK, connect the control unit connector again and check if there is continuity between the 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 there is continuity, it means that the cause for the error is that the cable is shorted to positive and now the cable harness between PIN D4 of the control unit and PIN 1 of the sensor brown cable (cable harness side) should be restored. If the intake air temperature sensor error is displayed at the same time, this means that the blue/green cable common for both sensors is shorted to positive. FITTING 1. Mechanical/electrical refit. 2. Zero reset procedure (if present).
Air temperature sensor

Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to optimise the petrol quantity necessary for correct combustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Location: ELE SYS - 58
RXV 450-550
Electrical system
Pin-out:
sensor: front part inside filter box connector: on the sensor
Electrical characteristics: Resistance at 0 C (32 F): 6 +/- 0.6 kOhm 5% Resistance at 80 C (176 F): 0.290 - 0.390 kOhm
"+" (pink cable): Supply voltage 5V approx. "-" (blue/green cable): Ground connection
AXONE: PARAMETERS - Air temperature
AXONE: ELECTRICAL ERRORS Air temperature sensor 1501 - shorted to negative If shorted to negative: voltage equal to zero has been detected at PIN B2 of the control unit connector. If shorted to negative, check sensor resistance: if resistance = 0, replace the sensor; if resistance is 0, it means that the pink cable has ground connection: restore the cable harness. air temperature sensor 1502 - open circuit, shorted to positive If the circuit is open, shorted to positive: excessive voltage has been detected at PIN B2 of the control unit connector. If the circuit is open, shorted to positive: check the sensor connector and the Walbro control unit connector and multiple connector. If they are not OK, restore the cable harness; if OK, check the continuity of the sensor; if it is not OK, replace the sensor; if it is OK, check the continuity between PIN B2 of the control unit connector and the multiple connector and the PIN related to the pink cable of the sensor: restore cable harness if there is not continuity; if OK, connect the control unit connector again and check if there is continuity between the PIN of the blue/green cable of the sensor and the vehicle ground connection: if there is no continuity, restore the cable harness; if there is continuity, it means that the cause for the error is that the cable is shorted to positive. Then, the cable harness between PIN B2 of the control unit and multiple connector and between multiple connector and the PIN of the sensor pink cable (cable harness side) should be restored. If the engine temperature sensor error 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 ELE SYS - 59
Electrical system
RXV 450-550
in relation to the ambient temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector, the multiple connector and the Walbro control unit connector
Injector
FRONT CYLINDER INJECTOR - Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in electrical circuit diagram:Coils and injectors Location: on vehicle: intake manifold connector: on injector
Electrical characteristics:12 Ohm +/- 5% (at 20 C) (68 F) Pin-out: +: red/yellow power cable -: black/orange ground cable
AXONE: PARAMETERS Rear cylinder injection time AXONE: ELECTRICAL ERRORS Front cylinder injector 1201 - Malfunction Check injector resistance; if NOT OK, replace the injector; if OK, check connectors in the injector side, control unit side, secondary fuses side and multiple connector side; if NOT OK restore connectors; if OK, check ground lead (black/orange) continuity between control unit connector and multiple connector and between multiple connector and injector connector; if NOT OK restore cable harness; if OK, check power cable (red/yellow) continuity between secondary fuses connector and multiple connector and between multiple connector and injector connector; if OK, check positive lead ground insulation or positive wires of the negative lead. If NOT OK, restore cable harness; if OK, replace the control unit. FITTING 1. Mechanical/electrical refit. 2. Zero reset procedure (if present). REAR CYLINDER INJECTOR Function ELE SYS - 60
RXV 450-550
Electrical system
To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in electrical circuit diagram:Coils and injectors Location: on vehicle: intake manifold connector: on injector
Electrical characteristics:12 Ohm +/- 5% (at 20 C) (68 F) Pin-out: +: red/yellow power cable -: black/pink ground cable
AXONE: PARAMETERS Rear cylinder injection time AXONE: ELECTRICAL ERRORS Rear cylinder injector 1202 - Malfunction Check injector resistance; if NOT OK, replace the injector; if OK, check connectors in the injector side, control unit side, secondary fuses side and multiple connector side; if NOT OK, restore connectors; if OK, check ground lead (black/pink) continuity between control unit connector and multiple connector and between multiple connector and injector connector; if NOT OK restore cable harness; if OK, check power cable (red/yellow) continuity between secondary fuses connector and multiple connector and between multiple connector and injector connector; if OK, check positive lead ground insulation or positive wires of the negative lead. If NOT OK, restore cable harness; if OK, replace the control unit. FITTING 1. Mechanical/electrical refit. 2. Zero reset procedure (if present).
Coil
FRONT CYLINDER COIL - Function Spark generation. Operation / Operating principle Inductive discharge system. Level in electrical circuit diagram:Coils and injectors Location: on vehicle: under the tank, next to the right-side radiator connector: on the coils
Electrical characteristics: ELE SYS - 61
Electrical system
RXV 450-550
Pin-out:
Primary winding resistance: 3.5 Ohm +/- 15% (at 20C +/- 5 C) (68F +/- 41F); Tube resistance: 25 kOhm +/- 10%
+: orange/red cable, power supply, approximately 12V -: black/white cable, ground/coil control
AXONE: PARAMETERS Front coil ignition advance AXONE: ELECTRICAL ERRORS Front coil 1351 - Malfunction Check coil primary resistance; if NOT OK, replace the coil; if OK, check connectors in the injector side, control unit side and secondary fuses side; if NOT OK, restore the connectors; if OK, check that there is continuity of the ground cable between control unit connector and coil connector; if NOT OK, restore cable harness; if OK, check power cable continuity between secondary fuses connector and coil connector; if OK, check positive lead ground insulation or positive insulation of negative lead. If NOT OK, restore cable harness; if OK, replace the control unit. FITTING 1. Mechanical/electrical refit. 2. Zero reset procedure (if present). REAR CYLINDER COIL - Function Spark generation. Operation / Operating principle Inductive discharge system. Level in electrical circuit diagram:Coils and injectors Location: on vehicle: under the tank, next to the left-side radiator connector: on the coils
Electrical characteristics: Pin-out: +: orange/red cable, power supply, approximately 12V -: yellow/black cable, ground/coil control Primary winding resistance: 3.5 Ohm +/- 15% (at 20C +/- 5 C) (68F +/- 41F); Tube resistance: 25 kOhm +/- 10%
AXONE: PARAMETERS Rear coil ignition advance AXONE: ELECTRICAL ERRORS Front coil 1351 - Malfunction ELE SYS - 62
RXV 450-550
Electrical system
Check coil primary resistance; if NOT OK, replace the coil; if OK, check connectors in the injector side, control unit side and secondary fuses side; if NOT OK, restore the connectors; if OK, check that there is continuity of the ground cable between control unit connector and coil connector; if NOT OK, restore cable harness; if OK, check power cable continuity between secondary fuses connector and coil connector; if OK, check positive lead ground insulation or positive insulation of negative lead. If NOT OK, restore cable harness; if OK, replace the control unit. FITTING 1. Mechanical/electrical refit. 2. Zero reset procedure (if present).
Neutral sensor
Function Indicates the gear position to the control unit: if it is in neutral or in gear. Operation / Operating principle For neutral gear, the circuit is closed to ground connection: then the control unit sends the signal to the instrument panel which turns on the neutral speed warning light. Location: sensor: on the gearbox upper part connector: on the sensor
Electrical characteristics: Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity). Gearshift engaged: open circuit (5 V on wire from control unit to sensor) / open switch, infinite resistance. Pin-out: PIN 1: Voltage 5V
AXONE: PARAMETERS Gear in neutral - yes/no AXONE: ELECTRICAL ERRORS Indication on the instrument panel always gear engaged: check the control unit connector and the sensor connector: if it is no OK, restore cable harness; if it is OK, disconnect the connector and check, with gear in neutral, the continuity between the ground connection and the terminal on the sensor side: if there is not continuity, replace the sensor (after checking cable harness continuity on the sensor side and the correct mechanical position); if there is, check cable continuity between the sensor connector and PIN B3 of the purple connector: if there is no continuity, restore the cable harness. If there is, replace the instrument panel if the vehicle performance is correct (the engine starts with gear in neutral but the neutral warning light is off) or replace the control unit if the vehicle performance is not correct (the engine does not start with gear in neutral). Indication on the instrument panel always gear in neutral: disconnect the terminals from the sensor and check if there is continuity between the ground connection and the PIN towards the sensor, with ELE SYS - 63
Electrical system
RXV 450-550
gear engaged: if there is continuity, replace the sensor. If it is insulated from the ground connection, it means that the purple cable from sensor PIN 1 to purple connector PIN B3 is shorted to ground: restore the cable harness. FITTING Removal: Undo the sensor and remove it Mechanical/electrical refit: tighten the sensor in its seat, connect the cable.
RUN/STOP switch
Function It indicates to the control unit if the rider wishes to stop the engine. Operation / Operating principle If the engine is to be turned off, the switch must be closed; that is, the Walbro control unit must detect the ground connection at PIN F2. Location: sensor: close to the right hand grip connector: behind the front headlamp
Electrical characteristics: Pin-out: grey/black cable (cable harness side): Voltage 5V blue cable (on cable harness side): ground connection blue/black cable (cable harness side): Voltage 12V STOP position: closed circuit (continuity between both grey/sky blue and red/green cables) RUN position: open circuit (between both grey/sky blue and red/green cables)
AXONE: LOGIC ERRORS The engine does not start:disconnect the connector and, with switch set to RUN, check that there is no continuity between the two yellow/sky blue and yellow/red cables (sensor side): if there is, replace the switch; if there is not, check switch connector. If NOT OK, restore cable harness; if OK, check if there is continuity in the grey/black cable on the cable harness side. If NOT OK, restore cable harness; if OK, with key to ON, check if there is voltage (5 V) in grey/black cable (cable harness side); if there is not, restore cable harness or control unit connector. The engine does not turn off with the switch set to "STOP":disconnect the connector and, with the switch set to STOP, check if there is continuity between both yellow/sky blue and red/green cables (sensor side), if there is not, replace the switch; if there is, check the blue cable (cable harness side), if the cable is NOT OK, restore cable harness; if cable harness is OK, check if there is voltage (5V) in the grey/black cable (cable harness side); if there is no voltage, check cable continuity and check control unit connector; if it is NOT OK, restore; if OK, replace control unit.
ELE SYS - 64
RXV 450-550
Electrical system
ELE SYS - 65
INDEX OF TOPICS
ENGINE FROM VEHICLE
ENG VE
RXV 450-550
Engine from vehicle
Vehicle preparation
For vehicle preparation, remove the following components: fairings; exhaust system; radiator; oil reservoir; chain; fuel tank.
Removing the engine from the vehicle

Remove the oil sump guard and the expansion tank. Unscrew and remove the threaded pin (1). Release the spring (2). Remove the rear brake pedal (3).
Release the air filter box cover by gripping and lifting the handles from both sides.
Slide out the air filter box cover from behind together with the filter.
CAUTION WHEN REMOVING THE DIFFERENT COMPONENTS, BE CAREFUL NOT TO DROP THE SCREWS OR LET DIRT GET IN; PROTECT BOTH THROTTLE BODIES WHICH ARE NOT PROTECTED ONCE THE FILTERING ELEMENT IS REMOVED. NOTE UPON REFITTING THE AIR FILTER, ENSURE THAT ITS BOX IS PERFECTLY CLEAN. REMOVE ANY TRACE OF DIRT THAT MAY HAVE ENTERED DURING REMOVAL. UPON REFITTING, MAKE SURE THAT THE AIR INTAKES ARE CORRECTLY FITTED.
ENG VE - 67
Engine from vehicle
RXV 450-550
CAUTION
MAKE SURE THAT THE RESERVOIR RETAINING EDGE NEVER COMES INTO CONTACT WITH THE BATTERY POSITIVE LEAD.
Release the two throttle cables from the control.
Remove the pinion protection. Disconnect the clutch cable.
Disconnect the different electrical connectors.
ENG VE - 68
RXV 450-550
Engine from vehicle
Move the protection along the starter motor power supply cable. Undo and remove the fixing screw. Remove the starter motor power supply cable.
Unscrew and remove the nut by working on the right side of the vehicle.
CAUTION
Collect the washer.
THE NUMBER OF WASHERS MAY VARY FROM ONE SIDE TO THE OTHER OR FROM ONE VEHICLE TO ANOTHER: CHECK NUMBER AND POSITION UPON REMOVAL.
Slide off the lower rear pin.
ENG VE - 69
Engine from vehicle
RXV 450-550
Unscrew and remove the swingarm pin fixing nut.
Remove the swingarm pin.
Undo and remove the front pin fixing screw. Slide the front pin from the right side and collect the nut from the left side.
Remove the swingarm. Collect the spacers. Lower the engine.
After removing the engine, operate on the engine block and place it on the corresponding engine support plate.
Specific tooling
9100841 Engine support ENG VE - 70
RXV 450-550
Engine from vehicle
See also
Vehicle preparation Removing
Installing the engine to the vehicle

Place the engine block. Place the washer.
Insert the front pin from the right side and tighten it to the prescribed torque on the nut inserted on the left side of the vehicle.
Tighten the front pin fixing screw.
CAUTION
Place the washer.
RESTORE THE ORIGINAL NUMBER OF WASHERS AND OBSERVE THEIR ORIGINAL POSITIONS.
ENG VE - 71
Engine from vehicle
RXV 450-550
Tighten the lower rear pin fixing nut.
Position the ground lead and tighten the fixing screw.
Position the starter motor power supply cable. Tighten the fixing screw. Place the protection.
Connect the different electrical connectors. Fit the drive chain. Place the clutch cable.
ENG VE - 72
RXV 450-550
Engine from vehicle
Place the two throttle grip cables.
CAUTION
Place the filter box cover.
UPON REFITTING THE AIR FILTER, ENSURE THAT ITS BOX IS PERFECTLY CLEAN. REMOVE ANY TRACE OF DIRT THAT MAY HAVE ENTERED DURING REMOVAL. UPON REFITTING, MAKE SURE THE AIR INTAKES ARE CORRECTLY FITTED. CAUTION IN THE EVENT OF A FALL, CLEAN THE AIR FILTER AND ITS BOX CAREFULLY, REMOVING ANY TRACES OF OIL THAT MAY HAVE ENTERED FROM THE OIL RESERVOIR THROUGH THE OIL VAPOUR BREATHER PIPE.
Place the rear brake pedal (3). Place the spring (2). Tighten the rear brake pedal fixing screw (1).
Fit the swingarm. Fit the engine oil reservoir. Fit the cooling system. Fit the fairings. Fit the exhaust manifolds.
ENG VE - 73
Engine from vehicle
RXV 450-550
Fit the expansion tank and the oil sump guard. Fit the tank and the saddle.
ENG VE - 74
INDEX OF TOPICS
ENGINE
ENG
Engine
RXV 450-550
FITTING ENGINE ONTO PLATE Fit the engine support plate on the Aprilia engine stand.
Specific tooling
9100841 Engine support
Fit the engine onto the plate using the holes of the engine support bolts.
Secure the engine with the appropriate locking nuts. Pay attention when fixing the eccentric locking the crankcase halves on the clutch side. This will be useful to separate the two crankcase halves.
Gearbox
ENG - 76
RXV 450-550
Engine
Diagram
Key: 1. Shaft selector+ratchet gear 2. Selector lock 3. Spring 4. Seeger ring
ENG - 77
Engine
RXV 450-550
5. TE flanged screw 6. Complete index lever 7. Washer 8. Spring 9. Oil seal 10.Complete desmodromic 11.Roller 12.Gear selector drum 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.Spring 22.Pin for spring 23.Fork shaft 24.4th - 5th fork 25.1st - 3rd fork (same as for 2nd fork) 26.Fork shaft 27.Gear in neutral warning light switch 28.M5x12 TE flanged screw 29.O-ring 30.Ball bearing 31.Ball bearing 32.M5x12 TE flanged screw 33.Main shaft (SXV Z=13) (RXV Z=12) 34.Bushing 35.5th gear on main shaft Z=21 36.Flat washer 37.Seeger ring for 25 mm (0.98 in) shaft 38.3rd gear on main shaft (SXV Z=16) (RXV Z=15) 39.Special washer 40.4th gear on main shaft (SXV Z=20) (RXV Z=19) 41.2nd gear on main shaft (SXV Z=15) (RXV Z=13) 42.Washer ENG - 78
RXV 450-550
Engine
43.Ball bearing 44.Ball bearing 45.Secondary shaft 46.Bushing 47.2nd gear on secondary shaft (SXV Z=27) (RXV Z=25) 48.Flat washer 49.Seeger ring for 25 mm (0.98 in) shaft 50.4th gear on secondary shaft (SXV Z=23) (RXV Z=24) 51.Special washer 52.3rd gear on secondary shaft Z=23 53.5th gear on secondary shaft (SXV Z=21) (RXV Z=22) 54.Washer 55.Roller cage 56.1st gear on secondary shaft (SXV Z=30) (RXV Z=31) 57.Washer 58.Ball bearing 59.O-ring 60.Ball bearing 61.Oil seal 62.Spacer (SXV 25x32x22) (RXV 25x32x14) 63.Pinion (SXV Z=15) (RXV Z=16) 64.Seeger ring for 25 mm (0.98 in) shaft 65.2nd fork (same as for 1st - 3rd fork)
Gearbox shafts Disassembling the gearbox

Remove the crankcase on the flywheel side to get access to the gear.
ENG - 79
Engine
RXV 450-550
Remove the forks shafts. Release the desmodromic drum from the forks, rotating it outwards.
Remove the gear control desmodromic drum.
Slide off the forks of the 4th and 5th gears. Slide off the fork of the 1st and 3rd gears and the fork of the 2nd gear.
Take out the main and the secondary shafts at the same time.
See also
Splitting the crankcase halves
ENG - 80
RXV 450-550
Engine
Removing the primary shaft

Slide off the shim washer (1) from the generator side. Slide off the gear of the 2nd gear (2). Slide off the bushing (3). Slide off the gear of the 4th gear (4). Slide off the special washer (5). Remove the Seeger ring (6). Slide off the gear of the 3rd gear (7). Remove the Seeger ring (8). Slide off the flat washer (9). Slide off the gear of the 5th gear (10). Slide off the bushing (11).
To refit, carry out the removal operations but in reverse order.
Removing the secondary shaft

Slide off the shim washer (1) from the clutch side. Slide off the gear of the 1st gear (2) together with the ball roller cage. Slide off the flat washer (3). Slide off the gear of the 5th gear (4). Remove the Seeger ring (5). Slide off the special washer (6). Slide off the gear of the 3rd gear (7). Slide off the bushing (8). Slide off the special washer (9). Remove the Seeger ring (10). Slide off the gear of the 4th gear (11). Remove the Seeger ring (12). Slide off the flat washer (13). Slide off the gear of the 2nd gear (14). Slide off the bushing (15).
ENG - 81
Engine
RXV 450-550
Checking the desmodromic drum

Check the desmodromic drum for damage, scratches and wear and replace the assembly if required.
Checking the forks

NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL GEAR FORKS. Check the gear fork cam bushing (1) and the gear fork tooth (2) for damage, distortion and wear. Replace the gear fork if necessary.
Check the gear fork movement on the shaft; replace the gear forks if it is not smooth.
Assembling the gearbox

Draw together the gear main and secondary shafts and fit them into the crankcase on the clutch side.
NOTE SECURE THE SHIM WASHER TO THE SECONDARY SHAFT WITH GREASE.
NOTE
MAKE SURE THE SLIDING BUSHING IS PRESENT ON EVERY GEAR CONTROL FORK.
ENG - 82
RXV 450-550
Engine
Grease the bushings.
Fit the fork of the 1st and 3rd gears and the fork of the 2nd gear. Fit the fork of the 4th and 5th gears.
Fit the gear control desmodromic drum.
Fit the fork shafts.
ENG - 83
Engine
RXV 450-550
Refit the crankcase on the flywheel side.
See also
Refitting the crankcase halves
Gear selector 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.
Remove the selector sprocket wheel together with the plate.
ENG - 84
RXV 450-550
Engine
Undo and remove the gear selector drum fixing screws.
Lower the gear locking pawl lever and slide off the lower part of the gear selector drum.
Remove the gear locking pawl and retrieve 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. If necessary, replace the parts. Check the gear selector spring for damage and wear. If necessary, replace the part. Check the selector shaft and its teeth for damage and wear. If necessary, replace the part. Check the lever spring for damage and wear. If necessary, replace the part. ENG - 85
Engine
RXV 450-550
Check the clearance of the washer and the riveted pin that passes through the plate. If it is excessive, replace the pawl.
Reassembling the gear selector

To refit, lubricate and carry out the removal operations but in reverse order.
Starter motor Removing the starter motor

Unscrew and remove the two starter motor fixing screws. Remove the starter motor.
Generator side Removing the flywheel cover

Undo and remove the eleven fixing screws. Mark the screws with different lengths. Remove the flywheel side cover together with the generator and collect the gasket and the two alignment dowels.
ENG - 86
RXV 450-550
Engine
Magneto flywheel removal

Remove the flywheel cover Remove the two gears that connect the starter motor to the flywheel.
Lock the flywheel rotor using the specific tool Unscrew and remove the nut fixing the flywheel and collect the washer.
Specific tooling
AP8140838 Flywheel rotor locking
Remove the flywheel using the specific flywheel extractor.
Specific tooling
9100839 Flywheel extractor
See also
ENG - 87
Engine
RXV 450-550
Removing the flywheel cover
Clutch side Disassembling the clutch

Remove the clutch side crankcase cover. Unscrew and remove the six screws by loosening them 1/4 of a turn at a time; operate in stages and diagonally, and retrieve the washers and the clutch springs.
Remove the thrust plate.
Remove the control rod together with the thrust bearing, the shim washer and the clutch cap.
ENG - 88
RXV 450-550
Engine
Remove the discs.
After straightening the tabs of the locking washers, unscrew and remove the clutch hub nut with the clutch locking tool and collect the locking washer.
Specific tooling
9100896 Clutch bell locking tool
ENG - 89
Engine
RXV 450-550
Remove the clutch hub.
Collect the shim washer.
Collect the clutch bell.
Collect the spacer and the needle bearings.
ENG - 90
RXV 450-550
Engine
Checking the clutch plates

Lay the friction discs and steel discs on a level surface and check them for cracks and potential distortions.
NOTE THE STEEL DISCS MUST SHOW NO SCORES OR TEMPERING COLOUR. CHECK CLUTCH DISCS FOR WEAR BY MEASURING THE ENTIRE CLUTCH DISC UNIT. DO NOT MEASURE THE STEEL DISC UNIT AND THE FRICTION DISC UNIT INDIVIDUALLY SINCE DOING SO IS IRRELEVANT FOR WEAR CHECKING.
Characteristic
Full disc pack thickness- minimum limit 34 mm (1.34 in) Clutch disc distortion - maximum limit 0.2 mm (0.0079 in)
Checking the clutch housing

Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch bell and the primary drive sprocket for correct sealing and evenness. Check the primary drive gear for damage and wear and, if necessary, replace the primary drive gear and the clutch bell all together. Make sure there is not excessive noise during operation; if necessary, replace the primary drive gear and the clutch bell all together.
ENG - 91
Engine
RXV 450-550
Checking the pusher plate

Check the thrust plate and the bearing for damage and wear. If necessary, replace the parts.
Checking the clutch hub

Check the clutch hub for damage and wear that may result in clutch irregular operation. If necessary, replace the hub.
Checking the springs

NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. Check the springs for damage and, if necessary, replace the them all together. Measure the clutch spring length when unloaded; if necessary, replace the springs all together.
Characteristic
Clutch spring length - minimum limit 45.1 mm (1.77 in)
ENG - 92
RXV 450-550
Engine
Assembling the clutch

Fit the needle bearing and the spacer.
Fit the clutch bell.
Fit the shim washer.
Position the clutch hub.
ENG - 93
Engine
RXV 450-550
CAUTION
Place the washer/s with the tab/s.
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.
Fold the locking washer.
Specific tooling
9100896 Clutch bell locking tool
Use gearbox oil to lubricate the driving discs and the driven discs. Place the first friction disc, then the first 1.5 mm (0.059 in) steel disc. After that, place a friction disc with the reference tabs in the same slot as for the first disc and then place a 2 mm (0.079 in) steel disc until the penultimate disc that will be the remaining 1.5 mm (0.059 in) metal disc. Lastly, place the friction disc with the reference tab one slot away with respect to the previous discs.
ENG - 94
RXV 450-550
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.
ENG - 95
Engine
RXV 450-550
Installing the clutch cover

Place the clutch cover. Tighten the five screws fixing the clutch cover, operating diagonally. Check the gearbox oil level.
Head and timing Removing the cylinder head

NOTE
BEFORE REMOVING THE HEAD CHECK THAT THE CYLINDER PISTON ON WHICH YOU ARE WORKING IS AT THE TDC IN COMBUSTION PHASE. Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. Remove the head cover together with the gasket.
Undo and remove the fixing screw of the chain tensioner thrust spring.
ENG - 96
RXV 450-550
Engine
Slide off the chain tensioner (1) internal guide. Lock the camshaft with the 6 mm (0.24 in) pin used for timing. Unscrew and remove the fixing nut of the camshaft (2) control toothed wheel.
NOTE THE CAMSHAFT FIXING SCREW OF THE FRONT CYLINDER WORKS ANTICLOCKWISE; THE FIXING SCREW OF THE REAR CYLINDER, CLOCKWISE.
Remove the camshaft (3) gear and remove the timing chain (4) properly. Undo and remove the head fixing screw on the timing system side.
NOTE REMOVE THIS SCREW BEFORE REMOVING THE FOUR MAIN SCREWS.
Undo and remove the four head fixing screws using a roundhead universal socket wrench if required.
Remove the head and collect the head gasket and the centring cylinders.
Cylinder head Removing the decompression system

Remove the rockers. Lock the camshaft with the 6 mm (0.24 in) pin used for timing. Undo and remove the fixing screw of the decompressor control lock.
ENG - 97
Engine
RXV 450-550
Remove the decompression system together with the control spring.
See also
Removing the rocker arms
Removing the overhead camshaft

Remove the decompression system. Working on the timing system side, remove 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
ENG - 98
RXV 450-550
Engine
Removing the rocker arms

Remove the cylinder head Remove the Seeger ring of the exhaust valves rocker pin.
Remove the exhaust valve rocker pin from its position.
Remove the rear rocker.
Removing the valves

NOTE
THE FOLLOWING PROCEDURE REFERS TO ONE CYLINDER BUT IS VALID FOR BOTH.
NOTE
Remove the control rocker of the exhaust valves and remove the camshaft.
BEFORE REMOVING THE CYLINDER HEAD COMPONENTS (VALVES, VALVE SPRINGS, CAPS AND BUCKET TAPPETS), MAKE SURE THAT THE VALVES ARE PROPERLY CLOSED AND SEALED.
CAUTION
WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
ENG - 99
Engine
RXV 450-550
Remove both pads (1) on both exhaust valves. Remove both bucket tappets (2) and both pads under them on the intake valves.
Use the valve springs compressor and the valve springs compressor adaptor to remove the valve cotters.
Specific tooling
AP9100838 Tool for valve pressure plate AP8140179 Valve spring compressor
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 Removing the overhead camshaft Removing the rocker arms
Checking the overhead camshaft

CAMSHAFT TOOTHED WHEEL CHECK Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
ENG - 100
RXV 450-550
Engine
Fasten the camshaft in horizontal position, as shown in the figure, and make it spin to check the eccentricity with a dial gauge; if necessary, replace the part.
Characteristic
Camshaft eccentricity - maximum limit 0.05 mm (0.0020 in)
Checking the rocker arms

ROCKERS AND ROCKER SHAFTS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ROCKERS AND ROCKER SHAFTS. 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 colouring, cracks or scratches; otherwise, replace the component.
Use a micrometer to measure the rocker shaft outside diameter and replace the component if necessary.
Characteristic
Rocker shaft outside diameter: maximum limit 11.96 mm (0.4708 in)
NOTE
Calculate the rocker - rocker shaft clearance.
CALCULATE THE CLEARANCE SUBTRACTING THE OUTSIDE DIAMETER OF THE ROCKER SHAFT FROM THE INSIDE DIAMETER OF THE ROCKER Replace the component if the calculated clearance value exceeds the limit value indicated in the table.
Characteristic
ENG - 101
Engine
RXV 450-550
Rocker - rocker shaft clearance: maximum limit 0.08 mm (0.0031 in) BUCKET TAPPETS CHECK
Characteristic
Bucket tappets diameter - maximum limit: 25.96 mm (1.022 in) Bucket tappet seating diameter on head - maximum limit: 26.04 mm (1.025 in)
Valve check
VALVES AND VALVE GUIDES CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE GUIDES. 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: G=D-C
Characteristic
Stem - valve guide clearance - maximum limit 0.08 mm (0.0031 in)
ENG - 102
RXV 450-550
Engine
If the clearance is not within the specified values, replace the valve guide. Proceed to check the valves and valve guides by removing the carbon deposits from the valve face and seat.
Check that the valve face does not show cracks and signs of wear; otherwise, replace the valve.
Check that the end of the valve stem is not distorted (mushroom-shaped) and that its diameter does not exceed the stem body diameter; otherwise, replace the valve.
Check that the value (E) of the valve support plane of the valve rims is within 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 - minimum limit 2.5 mm (0.098 in) Check that the valve stem eccentricity is within the specified values; replace the valve if necessary. Fasten the valve in horizontal position, as shown in the figure, and turn it to check the eccentricity with a dial gauge; if necessary, replace the part.
NOTE IF THE VALVE IS REMOVED OR REPLACED, ALWAYS REPLACE THE VALVE STEM OIL SEAL AS WELL.
Characteristic
Stem maximum eccentricity 0.01 mm (0.00039 in) VALVE SEATS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE SEATS. ENG - 103
Engine
RXV 450-550
Remove the carbon deposits from the valve face and seat. Check that the valve seat does not show cracks or signs of wear; otherwise, grind the seats.
Following the indications below, check that the valve seat is within the specified values; grind the seats if necessary.
Characteristic
Intake valve seat support width - maximum limit 1.3 mm (0.0512 in) Exhaust valve seat support width - maximum limit 1.5 mm (0.059 in) VALVE SPRINGS CHECK
NOTE
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND VALVE SEATS. Use a gauge to measure the unloaded valve spring length. If the length measured is not within the specified values, replace the valve spring.
Characteristic
Unloaded valve spring length: intake: 37.8 mm (1.488 in)
exhaust: 35.7 mm (1.406 in)
On a contrasting surface, use a square to measure the valve spring angle (H). If the length measured is not within the specified values, replace the valve spring.
Characteristic
Spring angle maximum limit 2.5
Checking the cylinder head

ENG - 104 Check that cylinder head is not damaged or scratched; replace it if necessary.
RXV 450-550
Engine
Check that there are no mineral deposits or rust in the cylinder head water cooled jacket; remove them if necessary. Use a checking ruler and a feeler gauge positioned crosswise to the ruler to measure the cylinder head distortion.
Characteristic
Maximum cylinder head distortion Maximum limit 0.05 mm (0.002 in) HEAD COVERS CHECK Check that the covers are not damaged or worn; replace the defective parts if necessary.
Installing the valves

VALVES AND VALVE SPRINGS FITTING - WARNING
CAUTION
THE FOLLOWING PROCEDURE APPLIES TO ALL VALVES AND THEIR COMPONENTS. Lubricate the valve stem and the valve stems oil seal with recommended oil. Fit the valve, the lower cap (4) and the valve stem oil guard (3). Fit the spring of valve (6) and the corresponding upper cap (5).
NOTE FIT THE VALVE SPRING WITH THE LARGEST PITCH FACING UPWARDS. FIT THE SPRING WITH THE COLOURED END (RED FOR EXHAUST, WHITE FOR INTAKE) FACING DOWNWARDS.
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.
ENG - 105
Engine
RXV 450-550
HITTING THE VALVE HEAD EXCESSIVELY MAY DAMAGE THE VALVE.
Specific tooling
AP9100838 Tool for valve pressure plate AP8140179 Valve spring compressor Make sure the maximum distance between valve stem and plate is Dmax=1.90 mm (0.748 in).
Place both bucket tappets (2) and both pads under them on both intake valves. Place both pads (1) on both exhaust valves.
Installing the rocker arms

Position the exhaust rocker.
ENG - 106
RXV 450-550
Engine
NOTE
Fit the exhaust rocker shaft.
MAKE SURE THAT THE ROCKER SHAFT IS FULLY INSERTED 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. Fit the bearing on the camshaft. Lubricate the camshaft, the decompression system control spring and the decompression system. Position the decompression system together with the control spring. Lock the camshaft with the 6 mm (0.24 in) pin used for timing. Tighten the fixing screw of the decompression control.
NOTE LUBRICATE SHAFTS AND ROCKERS BEFORE FITTING THEM.
ENG - 107
Engine
RXV 450-550
NOTE
Fit the camshaft.
INSERT THE CAMSHAFT CAREFULLY PAYING ATTENTION TO THE DECOMPRESSION CONTROL.
Working on the timing system side, position the camshaft bearing fixing Seeger ring.
Timing 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.
ENG - 108
RXV 450-550
Engine
Checking the chain

Check the timing chain for damage or stiffness while moving. If necessary, replace the timing chain together with the camshaft gears. Check the timing chain guide sliders for damage. If necessary, replace the parts.
Installing the chain

Fit the timing gear of the rear cylinder. Fit the timing chain of the rear cylinder.
Position the timing compartment closing flange. Tighten the three fixing screws of the timing compartment closing flange.
Remove the main shaft pinion nut using the specific special tool. Position the timing control wheel, matching the reference with the one on the main shaft pinion.
Position the locking washer (1). Screw the fixing nut (2) of the timing control wheel. Bend the washer tab (1).
ENG - 109
Engine
RXV 450-550
Specific tooling
9100843 Crankshaft pinion locking tool
Cam timing Timing

Make sure that the timing chain is properly taut. Remove the timing hole screw from its seat. Place the crankshaft lock (timing pin) in its position.
Specific tooling
9100844 Crankshaft locking tool (timing pin) Working on the primary drive nut, make the crankshaft turn until the front cylinder reaches the TDC. Insert the pin in the crankshaft lock (timing pin) in order to block crankshaft rotation.
NOTE THE SPECIAL TOOL IS ONLY USED FOR IDENTIFYING THE CORRECT CRANKSHAFT POSITION. DO NOT USE IT FOR TIGHTENING OPERATIONS.
Make the timing shaft turn so that the timing shaft hole matches the head holes.
Position the pin so as to lock the front cylinder timing cam.
NOTE CHECK THAT THE CAMSHAFT IS FREE, NOT RESTING ON THE BUCKET TAPPETS.
ENG - 110
RXV 450-550
Engine
Tighten the fixing nut of the front cylinder timing shaft gear. Release the front camshaft and the crankshaft from the locking pins.
Working on the primary gear nut, make the crankshaft turn clockwise by 283 in order to bring the rear cylinder piston to the TDC and repeat the same procedure followed for the front cylinder.
Cylinder-piston assembly Removing the cylinder

It is necessary to remove the head before 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.
CAUTION BEFORE TAKING OUT THE PIN LOCKING RING, COVER THE CRANKCASE OPENING WITH A CLEAN CLOTH SO THAT THE RING DOES NOT FALL INTO THE CRANKCASE.
Specific tooling
9100897 Cylinder liner extractor
ENG - 111
Engine
RXV 450-550
Take out the pin locking ring.
See also
Removing the cylinder head
Disassembling the piston

Use a piston pin extractor to remove the pin. Remove the piston. Remove the piston ring (1) and the oil scraper ring (2).
Specific tooling
9100943 Piston pin extractor
Characteristic
Cylinder liners inside diameter 76.02 - 80.02 mm (2.9929 - 3.1504 in) Piston outside diameter 75.94 - 79.94 mm (2.9897 - 3.1472 in) Piston pin hole inside diameter 16.02 - 17.02 mm (0.6307 - 0.6701 in) Top ring end clearance 0.45 mm (0.0177 in)
Checking the piston
ENG - 112
RXV 450-550
Engine
Fitting the piston

NOTE WHEN FITTING THE PISTON RINGS, MAKE SURE THAT THEY ARE REFITTED WITH THE REFERENCE FACING UPWARDS.
Fit the piston ring (1) with its opening facing the exhaust and the oil scraper ring (2) with its opening facing the intake.
CAUTION MAKE SURE THAT THE PUNCHING ON THE PISTON FACES THE CYLINDER EXHAUST SIDE. LUBRICATE THE PIN WITH ENGINE OIL BEFORE INSERTING IT.
Place the piston in the cylinder liner (3). Place the cylinder liner (3) in the crankcase. Fit the pin. Position the pin locking ring. Close the cap (4).
Installing the cylinder head

Fit the centring cylinders. Fit a new cylinder-head gasket. Position the cylinder head. Insert the four cylinder head bolts together with the washers.
NOTE LUBRICATE THE HEAD BOLT THREADS AND THE SEAL SURFACES WITH ENGINE OIL.
ENG - 113
Engine
RXV 450-550
Screw the four cylinder head bolts working in crossed sequence and using a roundhead universal socket wrench if required.
NOTE SCREW THE CYLINDER HEAD BOLTS PAYING ATTENTION TO THE TIGHTENING SEQUENCE AND THE CORRECT TORQUE, IN TWO STAGES.
Place the timing system gear (3) together with the timing chain (4) on the camshaft (2).
Screw but do not tighten the screw fixing the timing system gear (3) on the camshaft (2).
CAUTION
Position the chain tensioner slider (1).
THE CAMSHAFT SCREW OF THE FRONT CYLINDER WORKS ANTICLOCKWISE.
Fit the timing chain tensioner, follow the instructions below: 1- Release the chain tensioner oneway cam and push its rod completely into the chain tensioner housing.
2- Fit the tensioner in the proper seat on the timing system side of the cylinder head by tightening both screws to the pre-set torque.
3- Fit the spring and the threaded cap of the timing chain tensioner by tightening the cap to the pre-set torque.
Proceed to time camshaft. Position the valve cover together with the gasket. Tighten the four fixing screws together with new sealing O-rings.
See also
ENG - 114
RXV 450-550
Engine
Timing
Crankcase - crankshaft Splitting the crankcase halves

Remove the right crankcase half cover. Unscrew and remove the primary drive wheel fixing nut.
Remove the main shaft pinion nut using the special tool.
NOTE NUT WITH LEFT THREAD.
NOTE
Remove the shim washer.
SHIM WASHERS ARE GALVANISED ANTI-VIBRATION PARTS THAT MUST BE FITTED FACING TOWARDS THE PINION.
Slide off the pinion. Remove the ball bearing cage.
ENG - 115
Engine
RXV 450-550
Undo and remove the screw fixing the plate that fixes the external oil pipes.
Remove the two external oil pipes.
Undo and remove the screws fixing the two plates that fix the internal oil pipes.
Slide off the oil delivery and reverse pipe.
ENG - 116
RXV 450-550
Engine
Before removing the components, place a container of adequate capacity under the engine.
Prepare the engine by carrying out the following operations. Remove the starter motor. Remove the magneto flywheel. Remove the clutch. Remove the gearbox selector. Remove the head. Remove the timing chain. Remove the cotter. Remove the timing system gear shaft together with the timing system toothed wheel of the front cylinder from generator side.
Undo and remove the fifteen screws fixing the crankcase, fourteen on the left side and one on the right side.
NOTE THE SEVEN FIXING SCREWS ON THE LEFT SIDE ARE M7 AND THE OTHER SEVEN ARE M6.
Remove the gearbox oil cap screw.
ENG - 117
Engine
RXV 450-550
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 generator side.
CAUTION BEFORE CARRYING OUT ANY REMOVAL/FITTING OPERATION ON THE CRANKCASE, WARM IT UP WITH A HEAT GUN TO AVOID DAMAGING ITS HOUSING. CAUTION BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, LOCK THE CRANKCASE HALVES ON THE CORRESPONDING SUPPORT PLATE.
REMOVING THE GEAR MAIN SHAFT BEARING Remove the bearing grub screw and the corresponding plate.
Warm up the crankcase halves. Remove the bearing with an extractor from the inside.
DESMODROMIC BEARING REMOVAL Warm up the crankcase halves. Remove the bearing with an extractor from the inside.
ENG - 118
RXV 450-550
Engine
REMOVING THE GEAR SECONDARY SHAFT BEARING Remove the bearing grub screw and the corresponding plate.
Remove the retainer ring.
Remove the oil seal working on the crankcase external side. Warm up the crankcase halves and take out the bearing with an extractor from the inside.
GEAR BEARINGS REMOVAL Remove the three locking screws.
ENG - 119
Engine
RXV 450-550
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. Remove the bearing with an extractor from the inside.
See also
Removing the flywheel cover
Removing the main bearings

FLYWHEEL SIDE CRANKCASE HALVES
CAUTION
BEFORE CARRYING OUT ANY REMOVAL/FITTING OPERATION ON THE CRANKCASE, WARM IT UP WITH A HEAT GUN TO AVOID DAMAGING ITS HOUSING.
CAUTION
BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, LOCK THE CRANKCASE HALVES ON THE CORRESPONDING SUPPORT PLATE.
ENG - 120
RXV 450-550
Engine
To remove the crankshaft support bushings use the tool and a rubber mallet.
Specific tooling
9100884 Crankshaft bushing extractor
Inspecting the crankcase halves

Using a non-aggressive solvent thoroughly clean both sections of the engine crankcase, the ball bearings and all the bearing seats. Clean the seal surfaces and check that they are not damaged.
NOTE
PLACE BOTH CRANKCASE HALVES ON THE PROPER SUPPORT PLATE TO AVOID DAMAGING THEM.
Specific tooling
9100942 Crankcase halves support Check that both crankcase halves are not cracked or damaged. Check that all threads are in proper conditions. Check that all oil seals remaining in their position are not worn or damaged. Check all ball bearings for clearance, smoothness and potential distortions.
CAUTION
LUBRICATE BALL BEARINGS WITH ENGINE OIL BEFORE FURTHER CHECKING. If the internal ring does not rotate smoothly and silently or if there is some noise while it turns, it means that the bearing is faulty and must be replaced. 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
ENG - 121
Engine
RXV 450-550
Refit the grub screw and the corresponding plate.
GEAR BEARING REFITTING Refit the bearings using the specific punches.
Specific tooling
9100886 Secondary shaft/right side - Main shaft/left side
Refit the lock screws.
ENG - 122
RXV 450-550
Engine
GEAR SECONDARY SHAFT BEARING REFITTING Refit the bearing using the specific punch.
CAUTION CHECK THAT THE PLATE ADJUSTABLE SUPPORT IS FIRMLY STOPPED AND WARM UP THE BEARING COUPLING AREAS PROPERLY.
Specific tooling
9100885 Main shaft/ right side - secondary shaft/left side
Refit the retainer ring, the plate and the relative screw. Fit a new oil seal using the specific punch at controlled driving.
Specific tooling
9100894 Secondary shaft oil seal punch
ENG - 123
Engine
RXV 450-550
BEARING REFITTING - DESMODROMIC DRUM SUPPORT Refit the bearing using the specific punch.
Specific tooling
9100892 Left crankcase desmodromic + wheel hub
GEAR PRIMARY SHAFT BEARING REFITTING Refit the bearing using the specific punch. Refit the grub screw with the corresponding plate.
Specific tooling
9100886 Secondary shaft/right side - Main shaft/left side
Installing the main bearings

CAUTION
CAUTION
ENG - 124
RXV 450-550
Engine
BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, LOCK THE CRANKCASE HALVES ON THE CORRESPONDING SUPPORT PLATE. For refitting, use the specific calibration punch to match the unions of both half - bushings with the notch on the punch. When refitting match the punch notch with the grooves for the bushing lubrication oil. Fit the half - bushings in their seats with a rubber mallet until they stop, using the specific special tool.
CAUTION CHECK THAT THE PLATE ADJUSTABLE SUPPORT IS FIRMLY STOPPED AND WARM UP THE BUSHINGS COUPLING AREAS PROPERLY.
Specific tooling
9100840 Punch for crankshaft bushings
See also
Crankcase - crankshaft - connecting rod
Refitting the crankcase halves

CAUTION
CAUTION
BEFORE CARRYING OUT THE OPERATIONS DESCRIBED BELOW, LOCK THE CRANKCASE HALVES ON THE CORRESPONDING SUPPORT PLATE.
Specific tooling
9100841 Engine support
CAUTION BEFORE REFITTING, REPLACE AND LUBRICATE THE OIL SEALS AND LUBRICATE THE BALL BEARINGS.
ENG - 125
Engine
RXV 450-550
Fit the oil seals and the bearings on the crankcase halves. Fit the entire crankshaft on the right crankcase half. Place the gear main and secondary shafts together with the desmodromic drum and the linkages.
Place the cylinders liners as externally as possible. Place the cylinder liners with the reference mark near the crankcase halves coupling edge.
Spread the red paste all along the crankcase perimeter.
Join the crankcase halves.
Tighten the fifteen screws fixing the crankcase, fourteen on the left side and one on the right side.
NOTE THE SEVEN FIXING SCREWS ON THE LEFT SIDE ARE M7 AND THE OTHER SEVEN ARE M6.
ENG - 126
RXV 450-550
Engine
Fit the timing system gear shaft on the generator side. Insert the cotter. Fit the timing chain.
CAUTION
BEFORE REFITTING, REPLACE AND LUBRICATE THE OIL SEALS AND LUBRICATE THE BALL BEARINGS.
NOTE DO NOT FORCE THE OIL PIPES INTO THEIR FITTINGS. NOTE MAKE SURE THE O-RINGS ARE IN GOOD CONDITIONS; OIL THE RINGS.
Place the oil reverse and delivery pipe.
Place the locking plate of the two oil pipes and tighten the fixing screws.
ENG - 127
Engine
RXV 450-550
Fit the shim washer paying attention to the fitting direction. Make sure the O-ring on the toothed wheel shaft is in good conditions; if necessary, replace the O-ring with a new one.
Place the fixing plate and tighten the plate fixing screw.
Grease the conical surface of the crankshaft. Place the ball bearing cage and the cotter.
See also
Assembling the gearbox
Lubrication
ENG - 128
RXV 450-550
Engine
Conceptual diagrams
key: 1. Oil reservoir 2. Oil drainage plug 3. Sealing washer 4. M20x1.5 oil cap 5. Sealing ring 6. TE flanged screw M6x25 7. TE flanged screw M6x35 8. Blow-by pipe 9. Clamp clic D16.5x6.6 10.Clamp clic d. 15.5x6.6 11.Oil breather pipe 12.Rubber ring 13.Bushing 14.Oil level pipe 15.Clic clamp 16.Rubber pipe 12.8x8.8 17.Hood 18.M6x1 TE flanged screw 19.M6x1 Flanged self-locking nut
ENG - 129
Engine
RXV 450-550
20.From the engine 21.Out 22.In 23.To the filter housing
Oil pump
ENG - 130
RXV 450-550
Engine
Removing
EXTERNAL PUMP REMOVAL Before removing the components, place a container of suitable capacity underneath the engine. Remove the clutch Remove the right crankcase half cover Remove the Seeger ring fixing the oil pump transmission gear and collect the shim washer. Remove the oil pump transmission gear paying attention to the internal sliding rollers.
Remove the oil pump gear fixing Seeger ring.
Remove the oil pump gear and collect the shim washer. Remove the transmission roller of the oil pump gear.
ENG - 131
Engine
RXV 450-550
Remove the shim washer (1). Undo and remove the four fixing screws (2).
Remove the complete oil pump.
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 DISASSEMBLE THE CRANKCASE AND REMOVE THE EXTERNAL PUMP. Undo and remove the three fixing screws. Remove the cover and the strum box.
ENG - 132
RXV 450-550
Engine
Remove the pump rotor and slide off the stator. Collect the transmission roller.
See also
Disassembling the clutch Splitting the crankcase halves
Installing
INTERNAL PUMP FITTING Position the transmission roller. Fit the pump rotor and the stator.
Position the strum box and the cover. Tighten the three fixing screws.
ENG - 133
Engine
RXV 450-550
EXTERNAL PUMP FITTING Refit the internal pump. Position the oil pump internal transmission roller.
NOTE THE INTERNAL AND EXTERNAL PUMP ROTORS FEATURE A VERY LONG ROLLER; THE GEAR FEATURES A SHORT ONE.
Position the oil pump together with the O-ring gasket.
Tighten the four fixing screws (2) and position the shim washer (1).
Position the oil pump gear transmission roller.
ENG - 134
RXV 450-550
Engine
Place the shim washer before positioning the oil pump gear.
Position a new oil pump gear fixing Seeger ring.
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.
ENG - 135
INDEX OF TOPICS
POWER SUPPLY
P SUPP
RXV 450-550
Power supply
Circuit diagram
key: 1. Fuel tank 2. Fuel tank cap 3. Gasket for cover 4. 5x9 pipe 5. Fuel pump unit 6. Fuel filter 7. Gasket 8. Thermistor
Injection
P SUPP - 137
Power supply
RXV 450-550
Diagram
key: 1. Ignition key 2. Fuel pump 3. Ignition switch 4. Instrument panel
P SUPP - 138
RXV 450-550
Power supply
5. Intake air temperature sensor 6. Throttle position sensor 7. Injector 8. Intake air pressure sensor 9. Cooling fans 10.Engine temperature sensor 11.Speed sensor (front wheel) 12.Crankshaft position sensor 13.Gear position switch
Stepper motor
Function it keeps the idle speed set by the control unit and makes the engine more dynamic (if the throttle is closed or immediately opened) Operation / Operating principle The control unit activates a current circulation (pulses) in both stepper windings. Thus, the shaft rotates in an always equal pre-set angle (step). Depending on how power is supplied in both circuits, rotation is in one direction or in the opposite. Location: Pin out:
CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Stepper motor: in the filter housing, connected under the throttle body Connector: on stepper motor
PIN A: Idle motor output - (Sky Blue/ Purple) PIN B: Idle motor output - (Orange/ White) PIN C: Idle motor output - (Pink/Green) Pin D: Idle motor output - (Pink/Yellow)
DIAGNOSIS INSTRUMENT CHECK: ELECTRICAL ERRORS P SUPP - 139
Power supply
RXV 450-550
generic error: Idle motor 505 Error cause open circuit, shorted to positive, shorted to negative.
Troubleshooting Disconnect the connector from the Stepper motor and check the electrical specifications: if NOT OK, replace the Stepper motor; if OK, check the Stepper motor connectors, the multiple connector and the Walbro control unit connector. If they are not OK, restore the connectors; if OK, check if there is continuity between PIN B1 of the control unit connector and the multiple connector, and between the multiple connector and PIN A of the Stepper motor connector. If NOT OK, restore; if OK, check if there is continuity between PIN D1 of the control unit connector and the multiple connector, and between multiple connector and PIN C of the Stepper motor connector, if NOT OK, restore; if OK, check if there is continuity between PIN A1 of the control unit connector and multiple connector and between multiple connector and PIN D of the Stepper motor connector. If NOT OK, restore; if OK, check if there is continuity between PIN C1 of the control unit connector and the multiple connector, and between multiple connector and PIN B of the Stepper motor connector; if OK, check that one of the 4 idle motor cables (Light Blue/Purple, Orange/White, Pink/Green, Pink/ Yellow) is not in short circuit or shorted to positive. If NOT OK, restore, if OK, replace WALBRO control unit. Figure key: stepper motor (1) cursor (2) plastic body (3)
Air flow in the body of the stepper: To rear cylinder (4) Filter housing intake (5) To front cylinder (6)
P SUPP - 140
RXV 450-550
Power supply
Cylinders synchronisation
Remove the saddle. Lift the tank and fix it with the specific cable.
Remove the filter housing cover and the filter.
CAUTION WHEN REMOVING THE DIFFERENT COMPONENTS, BE CAREFUL NOT TO DROP THE SCREWS OR LET DIRT GET IN; PROTECT BOTH THROTTLE BODIES WHICH ARE NOT PROTECTED ONCE THE FILTERING ELEMENT IS REMOVED.
Remove the upper part of the filter box.
Working from the right side, release the clamps holding the oil breather pipe.
P SUPP - 141
Power supply
RXV 450-550
Get a second by-pass pipe and connect it to previously released union.
CAUTION THE SECOND BY PASS PIPE SHOULD BE OF THE SAME DIAMETER AND LENGTH AS THE ONE STILL CONNECTED TO THE FRONT CYLINDER THROTTLE BODY.
Start the vehicle and check that the vacuum in both cylinders is the same.
P SUPP - 142
RXV 450-550
Power supply
Otherwise, loosen the adjustment screw and adjust the position of the slot in order to get a similar vacuum.
Once balance has been obtained, tighten the adjustment screw.
CAUTION AFTER SYNCHRONISING THE CYLINDERS IT IS ABSOLUTELY NECESSARY TO CARRY OUT THE THROTTLE SELF-LEARNING MINIMUM POSITION USING AXONE.
Using axone for injection system Injection Iso screen page

ISO This screen page shows general data regarding the control unit, for example software type, mapping, control unit programming date
ISO SCREEN PAGE

Specification Firmware version Chassis number Engine number Programming date Mapping Desc./Quantity C1APR_09 - ECU firmware version ZD4VS - Vehicle frame Engine number 11/24/2005 - Date the ECU has been initialised in production 14001 - Mapping code present in ECU
P SUPP - 143
Power supply
RXV 450-550
Engine parameter reading screen page

ENGINE PARAMETER READING This screen page shows the parameters measured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.)
ENGINE PARAMETER READING SCREEN PAGE

Specification Engine rpm Atmospheric pressure Front cylinder injection time Rear cylinder injection time Front cylinder ignition advance Rear cylinder ignition advance Throttle Air temperature Engine temperature Battery voltage Gear engaged Vehicle speed Operation time Throttle self-acquisition, min. position Desc./Quantity rpm 1010 mbar ms ms 4.6% - At idle, value should be 5% +/- 1% C C V The engaged gears are displayed (neutral = 0) (not specified = 10) 2 - km/h - Vehicle speed (caution: this parameter is not working at the moment) 12.25 - hhmm - Engine operation time (at rpm higher than zero) in hours and minutes 30 - Reference value with throttle fully home at 0. This value is stored by means of the "Throttle self-acquisition, min. position" procedure in the adjustable parameters screen page 210 - Reference value with throttle fully open. This value is stored by means of the "Throttle self-acquisition, max. position" procedure in the adjustable parameters screen page 1.00 - CO rate adjustment trimmer value: if equal to 1.00, it has not been changed yet. To change it, go to Adjustable parameters screen page cm '1,00 - Injection time adjustment value outside idle range: if equal to 1.00, it has not been changed yet
Throttle self-acquisition, max. position
CO adjustment at idle
Wheel diameter Wheel signals Injection time correction
P SUPP - 144
RXV 450-550
Power supply
Device status screen page

DEVICE STATUS This screen page shows the status (usually ON/ OFF) of the vehicle devices or the operation condition of some vehicle systems (for example, lambda probe functioning status).
DEVICES STATUS SCREEN PAGE

Specification fall sensor Desc./Quantity Normal / Tip over / Disconnect - Indicates bank angle sensor state
Devices activation screen page

DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit.
DEVICES ACTIVATION SCREEN PAGE

Specification Error clearing Desc./Quantity Press "enter" to transfer errors from the memory (MEM) to the historical record (STO). The next time Axone is connected to the ECU, the errors in the historical record (STO) will no longer be displayed
P SUPP - 145
Power supply
RXV 450-550
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).
ERRORS DISPLAY SCREEN PAGE

Specification Engine temperature sensor Desc./Quantity Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off). Error detected on indicated sensor/actuator circuit. Displayed error state is always MEM: look at the EFI light on the instrument panel to understand if error is live (light on) or memorised (light off).
Engine temperature sensor
Barometric pressure sensor
Main relay control
Main relay control 12V
Light relay activation
Front injector
Rear injector
Front coil
Rear coil
P SUPP - 146
RXV 450-550
Power supply
Adjustable parameters screen page

ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters.
ADJUSTABLE PARAMETERS SCREEN PAGE

Specification Throttle self-acquisition, min. position Desc./Quantity Allows storage of reference value for throttle fully home at 0: before performing the operation, loosen the idle screw until Axone reading for "Throttle position is 0"' Allows storage of reference value for throttle fully open by completely turning the throttle twistgrip open 1,00 - Allows modification of injection times within idle range to change the CO rate cm 1.00 - Allows modification of injection times at any rpm (maximum adjustment is +/- 5% with respect to injection times set inside mapping)
Throttle self-acquisition, max. position CO adjustment at idle Wheel diameter Wheel signals Injection time correction
P SUPP - 147
INDEX OF TOPICS
SUSPENSIONS
SUSP
RXV 450-550
Suspensions
Front Front fork

Replace the fork oil more frequently if the vehicle is used on dusty or wet roads and when riding offroad. Carry out the following checks: Operating the front brake lever, press the handlebar repeatedly to send the fork to the fully down. The stroke should be soft and there should be no oil marks on the stems. Check the tightening of all the elements and the correct operation of the front and rear suspension joints.
Diagram
key: 1. Left fork unit 2. Right fork unit SUSP - 149
Suspensions
RXV 450-550
3. Left wheel holder stem 4. Right wheel holder stem 5. Upper bushing 6. Sealing ring 7. Cap 8. Retainer ring 9. Dust scraper 10.Complete sleeve 11.Dowel + O-ring 12.Ring for spring 13.Spring Kit 14.Complete pumping member pin 15.Flanged screw 16.Lower bushing 17.Complete valve 18.Complete cap
Adjustment
CAUTION TO AVOID DAMAGING THE PARTS, DO NOT STRAIN THE ROTATION OF SET SCREWS (1-2) BEYOND THE END OF THE STROKE IN BOTH SENSES SET BOTH STEMS WITH THE SAME HYDRAULIC DAMPING SETTING: RIDING THE VEHICLE WITH A DIFFERENT ADJUSTMENT FOR THE TWO STEMS REDUCES ITS STABILITY. IF YOU INCREASE SPRING PRELOAD, YOU ALSO NEED TO INCREASE REBOUND DAMPING, IN ORDER TO AVOID SUDDEN JERKS WHILE RIDING.
Front shock absorber standard setting is adjusted to suit most of low speed riding conditions, whether the vehicle is partially or fully loaded. However, this setting can be modified for specific needs according to vehicle use.
CAUTION
SUSP - 150
RXV 450-550
Suspensions
TO COUNT THE NUMBER OF CLICKS AND/OR TURNS FOR SET SCREWS (1 -2) ALWAYS START FROM THE MOST RIGID SETTING (FULLY CLOCKWISE SCREW SETTING).
SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES.
FRONT SUSPENSION STANDARD ADJUSTMENT

Specification Rebound damping adjustment, screw (1) Compression damping adjustment, screw (2) Stems (A) protrusion from top plate (excluding cover): Desc./Quantity Open (anticlockwise) 12 clicks from fully closed (clockwise) Open (anticlockwise) 12 clicks from fully closed (clockwise) (H) 1 notch
Removing the fork legs

STEM REMOVAL Unscrew and remove both mudguard front fixing screws.
Undo and remove the four mudguard fixing screws. Remove the front mudguard.

CAUTION
Place the OPTIONAL front stand in the hole of the fork lower plate. Undo and remove both calliper fixing screws. Slide off the calliper.
THE SPEED SENSOR CABLE RUNS OUTSIDE THE CALLIPER AND IS FITTED WITH PROTECTION.
SUSP - 151
Suspensions
RXV 450-550
Working on the left side, unscrew and remove the front wheel axle fixing nut.
Working on both sides, loosen the screws on the wheel axle clamps. Working on the right side, slide off the wheel axle.
Remove the wheel.
SUSP - 152
RXV 450-550
Suspensions
CAUTION
Collect the bushing.
THE FOLLOWING THREE OPERATIONS ARE ONLY VALID FOR REMOVING THE LEFT STEM.
Release the stem of the cable holding clamps. Unscrew and remove both speed sensor fixing screws. Remove the speed sensor.
Only for the left stem: before removing the stem protection, undo and remove the two screws fastening the front brake pipe to the stem protection.
Undo and remove the three stem protection fixing screws. Remove the stem protection.
SUSP - 153
Suspensions
RXV 450-550
Support the fork stem and loosen the screws on the upper and then the lower plate.
Remove the fork stem.
Draining oil
FORK OIL DRAINAGE To drain out the oil follow these steps: Remove the fork stem Place the sleeve (8) in a vice fitted with protection shoes. Use an Allen key to unscrew the upper closing cap (6).
CAUTION BE CAREFUL NOT TO DAMAGE THE O-RING (7) WHEN REMOVING IT.
CAUTION
Push the stem (8) inside the sleeve.
THE SLEEVE - STEM UNIT CONTAINS OIL; DO NOT TURN IT OVER OR TILT IT TOO MUCH UPON REMOVAL. SUSP - 154
RXV 450-550
Suspensions
Holding the cover (6), unscrew the lock nut indicated by the arrow using the specific Allen key.
Remove the cap.
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.
Empty the oil into the container as shown in the figure.
CAUTION FOR EASY DRAINAGE OF THE OIL INSIDE THE PUMPING MEMBER ROD, PRESS THE STEM IN THE WHEEL HOLDER SLEEVE TO PUMP OIL OUT.
SUSP - 155
Suspensions
RXV 450-550
Slide off the preloading pipe.
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.
Unscrew and remove the stop plug using a pneumatic gun.
CAUTION BE CAREFUL NOT TO DAMAGE THE O-RINGS WHEN REMOVING THEM.
SUSP - 156
RXV 450-550
Suspensions
Slide off the pumping member unit.
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.
BE CAREFUL NOT TO DAMAGE THE SLEEVE RIM.
Firmly slide off the sleeve from the stem.
SUSP - 157
Suspensions
RXV 450-550
On the fork stem there are:
- bushing (3) - guide ring (4) - shim washer (5) - oil seal (6) - retainer ring (2) - dust scraper (1)
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),
SUSP - 158
RXV 450-550
Suspensions
the oil seal (6),
the retainer ring (2) and the dust scraper (1).
See also
Draining oil
Reassembling the fork

CAUTION
BEFORE PERFORMING THE FOLLOWING OPERATIONS GET THE PROPER OPTIONAL SPECIAL TOOL (A) AND SPREAD A THIN LAYER OF FORK OIL OVER GASKETS AND BUSHINGS BEFORE REFITTING THEM.
Specific tooling
9100903 Marzocchi fork oil seal; 1.77 in (45 mm) Fit the components on the stem in the following order:
- dust scraper (1); - retainer ring (2); - oil seal (6); - shim washer (5); SUSP - 159
Suspensions
RXV 450-550
- 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. Place shoes made of soft material (aluminium) before positioning the stem in a vice. Place the bushing (3) in its seat on the stem. Insert the sleeve on the stem. Push the guide ring (4) and the shim washer (5) on the sleeve until they stop. Use the proper inserting tool (A) to push the oil seal (6) in the sleeve until it stops.
Fit the retainer ring (2).
Fit the dust scraper (1).
SUSP - 160
RXV 450-550
Suspensions
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.
Filling oil
FORK OIL FILLING Insert the preloading pipe in the sleeve (7). Pour fork oil inside the sleeve (7) up to the right detectable level by inserting a graded rod in the sleeve (7).
CAUTION THE SLEEVE (7) MUST BE PERFECTLY INSERTED IN THE STEM FOR A CORRECT OIL LEVEL READING. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Characteristic
Fork oil level SUSP - 161
Suspensions
RXV 450-550
90 + / - 2 mm (3.54 + /- 0.079 in) (from the stem rim) Insert the spring (9) together with the plastic bushing (8) in the sleeve (7).
Check that the O-ring (6) is fitted on the top cap (10). Holding the lock nut, screw the top cap (10) on the pumping member rod manually.
Screw and tighten the cap (10) on the sleeve (7).
SUSP - 162
RXV 450-550
Suspensions
Installing the fork legs

STEM FITTING Fit the fork stem in its seat.
Support the fork stem and tighten the two screws on the upper and lower plate.
Fit the stem protection, position and tighten the three fixing screws.
SUSP - 163
Suspensions
RXV 450-550
Tighten the two screws fastening the front brake pipe to the left stem protection.
Position the speed sensor and screw the two fixing screws.
Place the bushing.
Position the wheel.
SUSP - 164
RXV 450-550
Suspensions
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.
Working on the left side, screw the front wheel axle fixing nut. Tighten both screws on the wheel axle left fork clamp.
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.
SUSP - 165
Suspensions
RXV 450-550
Position the mudguard and tighten the four fixing screws.
Screw the two mudguard front fixing screws.
Rear Removing the rear wheel

Rest the vehicle on the specific OPTIONAL stands. Unscrew and remove the nut and retrieve the washer.
SUSP - 166
RXV 450-550
Suspensions
Working in both sides, loosen the set screw. 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.
SUSP - 167
Suspensions
RXV 450-550
Installing the rear wheel

Place the bushing.
Position the rear wheel. Position the chain. Working on both sides, insert the centring 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.
Adjust the chain tension operating the set screws.
Tighten the wheel axle fixing nut.
See also
Adjusting
Shock absorbers
The rear suspension consists of a spring-shock absorber unit linked to the frame via silent-block and to the rear swingarm via a linkage system. To adjust the setting, the shock absorber has one set screw to adjust rebound damping, one set screw to adjust compression damping, a ring nut for spring preloading adjustment and a locking ring nut.
SUSP - 168
RXV 450-550
Suspensions
Adjusting
Standard rear shock absorber setting is adjusted to suit most of high and low speed riding conditions, both with reduced and full vehicle load. However, this setting can be modified for specific needs according to vehicle use.
CAUTION
TO COUNT THE CORRECT NUMBER OF CLICKS AND/OR TURNS FOR SET SCREWS (1 - 2) ALWAYS START FROM THE MOST RIGID SETTING (FULLY CLOCKWISE SCREW SETTING). TO AVOID DAMAGING THE PARTS, DO NOT STRAIN THE ROTATION OF SET SCREWS (1-2) BEYOND THE END OF THE STROKE IN BOTH SENSES.. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
Using the specific spanner, slightly loosen the locking ring nut (4). Operate on the adjusting ring nut (3) to adjust the spring preloading (B). When the optimal adjustment level has been obtained, screw the locking ring nut (4) completely.
Operate on knob (6) to adjust hydraulic compression damping at high speeds (see chart).
Operate on screw (2) to adjust hydraulic compression damping at low speeds (see chart).
CAUTION SET SPRING PRELOAD AND REBOUND DAMPING BASED ON THE VEHICLE USE CONDITIONS. IF YOU INCREASE THE SPRING PRELOAD, YOU ALSO NEED TO INCREASE REBOUND DAMPING, IN ORDER TO AVOID SUDDEN JERKS WHEN RIDING. IF NECESSARY, TAKE YOUR VEHICLE TO AN Aprilia Official Dealer. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
SUSP - 169
Suspensions
RXV 450-550
TO AVOID COMPROMISING SHOCK ABSORBER OPERATION, DO NOT LOOSEN SCREW (5) AND DO NOT TAMPER WITH THE SEAL UNDERNEATH, AS NITROGEN MAY COME OUT RESULTING IN RISK OF ACCIDENTS.
REAR SUSPENSION STANDARD ADJUSTMENT

Specification Shock absorber wheelbase (A) (preloaded) Spring (B) length Rebound adjustment, screw (1) Compression damping adjustment, (low speeds), screw (2) Compression damping adjustment, (high speeds), knob (6) Desc./Quantity 473 +/- 1.5 mm (18.6 +/- 0.06 in) 241 1 mm (9.48 in) 16 clicks from fully closed 13 clicks from fully closed 14 clicks from fully closed
SUSP - 170
INDEX OF TOPICS
CHASSIS
CHAS
Chassis
RXV 450-550
Swinging arm Removing

Remove the rear wheel. Unscrew and remove the nut of the pin fixing the swingarm / linkage system and collect the washer.
Slide off the pin fixing the swingarm / linkage system.
Unscrew and remove the fixing nuts of the upper protection cover and collect the spacer. Remove the upper protection cover.
Unscrew and remove the three chain guide fixing screws and collect both nuts.
Move the chain together with the chain guide sideways.
CHAS - 172
RXV 450-550
Chassis
Unscrew and remove the swingarm pin fixing nut.
Unscrew and remove the threaded pin (1). Release the spring (2). Remove the rear brake pedal (3).
Remove the swingarm pin.
Drive chain
This vehicle is equipped with a chain with master link.
CAUTION
INCORRECT MAINTENANCE MAY CAUSE EARLY WEAR OF THE DRIVE CHAIN AND/OR DAMAGE THE FRONT PINION AND/OR THE REAR SPROCKET. PERFORM DRIVE CHAIN MAINTENANCE OPERATIONS MORE FREQUENTLY IF YOU RIDE THE VEHICLE IN EXTREME CONDITIONS OR ON DUSTY AND/OR MUDDY ROADS.
AN EXCESSIVELY SLACKEN CHAIN MAY CAUSE NOISE OR CHAIN KNOCKING, RESULTING IN CHAIN PAD AND GUIDE PLATE WEAR. CHECK CHAIN CLEARANCE ON A REGULAR BASIS AND ADJUST IT AS NECESSARY. INCORRECTLY EFFECTED MAINTENANCE MAY CAUSE CHAS - 173
Chassis
RXV 450-550
EARLY WEAR OF THE CHAIN AND/OR DAMAGE THE PINION AND/OR THE SPROCKET. CARRY OUT MAINTENANCE OPERATIONS MORE FREQUENTLY IF YOU RIDE THE VEHICLE IN EXTREME CONDITIONS OR ON DUSTY AND/OR MUDDY ROADS. To check clearance: Stop the engine. Rest the vehicle on its stand. Engage neutral gear. Check that vertical oscillation at the middle point between pinion and sprocket on the lower part of the chain is of about 20 25 mm (0.79 0.98 in). Move the vehicle forward so as to check vertical oscillation in other positions too. clearance should remain constant at all wheel rotation phases. If the clearance is uniform, but higher or lower than 20 25 mm (0.79 0.98 in), adjust it as required.
CAUTION IF CLEARANCE IS GREATER AT SOME POSITIONS, THIS MEANS THAT SOME CHAIN LINKS ARE FLATTENED OR JAMMED. TO AVOID THE RISK OF SEIZURE, LUBRICATE THE CHAIN ON A REGULAR BASIS.
Also check the following parts and make sure that the chain, pinion and sprocket do not have:
CAUTION
Damaged rollers. Loosened pins. Dry, rusty, flattened or jammed chain links. Excessive wear. Missing sealing rings. Excessively worn or damaged pinion or sprocket teeth.
IF THE CHAIN ROLLERS ARE DAMAGED, PINS ARE LOOSENED AND/OR SEAL RINGS MISSING OR DAMAGED, THE WHOLE CHAIN ASSEMBLY (PINION, SPROCKET AND CHAIN) SHOULD BE REPLACED.
CHAS - 174
RXV 450-550
Chassis
Check the chain guide slider (1) and the chain tensioner slider (2) for wear Finally, check the swingarm protection pad for wear.
CAUTION LUBRICATE THE CHAIN ON A REGULAR BASIS, PARTICULARLY IF YOU FIND DRY OR RUSTY PARTS. FLATTENED OR JAMMED CHAIN LINKS MUST LUBRICATED AND REPAIRED. IF IT IS NOT POSSIBLE, REPLACE IT.
Lubricate the chain whenever necessary. Lubricate the chain with chain spray grease. Do not wash the chain with water jets, steam jets, high-pressure water jets and highly flammable solvents.
ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION.
Removing
Loosen the chain tension. Rotate the rear wheel until the master link can be identified. Slide off the clip. Remove the plate underneath.
CHAS - 175
Chassis
RXV 450-550

CAUTION
Remove the master link from the opposite side. Remove the chain.
REPLACE THE ENTIRE UNIT IF THE CHAIN IS PARTICULARLY WORN.
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. Join the two ends of the chain and fit the master link pins from the inside to the outside.
CAUTION THE PLATE MUST BE FITTED WITH THE OPEN PART FACING THE SENSE OPPOSITE THE ADVANCE DIRECTION.
Fit the plate in the master link pins.
Fit the clip in the master link pins.
CHAS - 176
RXV 450-550
Chassis
Adjusting
If you need to adjust chain tension after the check: Rest the vehicle on its stand. Loosen the nut (1) completely. Loosen both lock nuts (4). Actuate on the set screws (5) and adjust the chain clearance checking that the references (2 - 3) match on both sides of the vehicle.
NOTE WHEEL CENTRING IS CARRIED OUT USING THE IDENTIFIABLE FIXED REFERENCES (2-3) INSIDE THE CHAIN TENSIONER PAD MOUNTS ON THE SWINGARM ARMS, IN FRONT OF THE WHEEL AXLE.
Tighten both lock nuts (4). Tighten the nut (1). Check chain clearance.
Locking torques (N*m)

Tightening torque for wheel nut (1): 127 Nm (12.7
kgm)
Exhaust Removing the tail pipe

Remove the spring.
CHAS - 177
Chassis
RXV 450-550
Working from the right side, undo and remove the screw and collect the nut and the washer.
Undo and remove the upper screw and collect the nut and the washer.
Slide off the exhaust end.
Removing the exhaust manifold

FRONT CYLINDER Remove the exhaust end. Release the two springs from the cylinder. Undo and remove the two screws fixing the exhaust manifold of the front cylinder.
CHAS - 178
RXV 450-550
Chassis
See also
Removing the tail pipe REAR CYLINDER Remove the exhaust end. Release the two springs from the rear cylinder. Undo and remove the two screws fixing the exhaust manifold of the rear cylinder.
See also
Removing the tail pipe
Engine oil tank Removing

Remove the saddle. Lift the tank. Remove the cooling system radiators. Place a container of suitable capacity underneath the oil reservoir cap. Unscrew and remove the oil emptying cap.
CHAS - 179
Chassis
RXV 450-550
Remove the upper clamp. Slide off the blow-by pipe.
Release the sealing clamp Slide off the pipe
Release both sealing clamps Slide off both pipes By working on the right side, unscrew and remove the screws. By working from the left side, collect the nuts.
CHAS - 180
RXV 450-550
Chassis
Remove the oil filler plug.
Slide off the oil reservoir from the bottom.
See also
Seat Fuel tank Removing the radiator
Installing
Position the engine oil reservoir. Working on the right side, insert the fixing pins. Working on the left side, tighten the nuts.
CHAS - 181
Chassis
RXV 450-550
Position the connection pipes and release the seal clamps.
Position the pipe.
Fix the seal clamp.
Position the blow-by pipe. Fix the seal clamp.
CHAS - 182
RXV 450-550
Chassis
Screw the oil emptying nut.
Fill up the engine oil reservoir through the top cap.
CHAS - 183
INDEX OF TOPICS
BRAKING SYSTEM
BRAK SYS
RXV 450-550
Braking system
NOTE
THIS VEHICLE IS EQUIPPED WITH FRONT AND REAR DISC BRAKES, EACH OPERATED BY AN INDEPENDENT HYDRAULIC CIRCUIT.
CAUTION
BRAKES ARE THE MOST IMPORTANT COMPONENTS TO ENSURE SAFETY AND THEREFORE THEY HAVE TO BE ALWAYS IN PERFECT CONDITIONS; CHECK THE BRAKES BEFORE EACH RIDE. A DIRTY DISC SOILS THE PADS, LEADING TO LOSS OF BRAKING. DIRTY PADS MUST BE REPLACED, WHEREAS A DIRTY BRAKE DISC MAY BE CLEANED WITH A HIGH-QUALITY DEGREASING PRODUCT. HAVE THE BRAKE FLUID CHANGED ONCE A YEAR. USE THE BRAKE FLUID SPECIFIED IN THE RECOMMENDED PRODUCT TABLE. The front braking system is single disc (left side). The rear braking system is single disc (right side).
NOTE
THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT APPLIES TO BOTH. Brake fluid decreases gradually in the reservoirs (1-2) as brake pads wear down, to compensate for the wear automatically. The front brake fluid reservoir (1) is placed near the front brake lever connection. The rear brake fluid reservoir (2) is integrated in the brake pump fastened to the frame, on the right side, near the swingarm.
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
NOTE
CHECK THE BRAKE FLUID LEVEL IN THE RESERVOIRS (1 - 2) AND CHECK BRAKE PADS FOR WEAR BEFORE SETTING OFF.
NOTE THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT APPLIES TO BOTH. NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE.
BRAK SYS - 185
Braking system
RXV 450-550
Disc brake pad wear depend on the use, the riding style and the roads.
CAUTION
WEAR IS GREATER WHEN RIDING ON DIRTY AND WET ROADS OR OFFERED.

CAUTION
CHECK BRAKE PADS FOR WEAR MAINLY BEFORE EACH RIDE.

NOTE
THIS VEHICLE IS FITTED WITH FRONT AND REAR DISC BRAKES WITH INDEPENDENT HYDRAULIC CIRCUITS. THE FOLLOWING INFORMATION REFERS TO ONE BRAKING CIRCUIT BUT IT APPLIES TO BOTH.
CAUTION
UNEXPECTED CLEARANCE VARIATIONS OR ELASTIC RESISTANCE IN THE BRAKE LEVER ARE DUE TO FAILURE IN THE HYDRAULIC CIRCUIT. PAY SPECIAL ATTENTION TO THE BRAKE DISC AND THE FRICTION GASKETS AND CHECK THAT THEY ARE NOT OILY OR GREASY, SPECIALLY AFTER MAINTENANCE OPERATIONS OR CHECKS. CHECK THAT BRAKE PIPES ARE NOT TWISTED OR WORN. PAY UTMOST ATTENTION THAT NO WATER OR DUST INADVERTENTLY GETS INTO THE CIRCUIT. IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE HYDRAULIC CIRCUIT. BRAKE FLUID MAY CAUSE IRRITATION IF IN CONTACT WITH SKIN OR EYES. RINSE CAREFULLY ALL BODY PARTS THAT HAVE COME INTO CONTACT WITH THE FLUID. SHOULD THE FLUID COME INTO CONTACT WITH YOUR EYES, SEEK MEDICAL ADVICE OR CONTACT AN EYE SPECIALIST. DO NOT DISPOSE OF THE FLUID INTO THE ENVIRONMENT. KEEP OUT OF THE REACH OF CHILDREN WHEN USING BRAKE FLUID, PAY ATTENTION NOT TO SPILL IT ONTO PLASTIC OR PAINTED COMPONENTS AS IT WILL IRREPARABLY DAMAGE THEM.
Front brake pads

Check the front brake calliper pads:
NOTE
THE FRONT CALLIPER IS FITTED WITH TWO BREAK PADS.
BRAK SYS - 186
RXV 450-550
Braking system
Visually inspect the area between the brake callipers and pads as follows:
- from the front top side.
Rear brake pads

Checking the rear brake calliper pads:
NOTE
EXCESSIVE WEAR OF THE FRICTION MATERIAL MAKES THE PAD METAL SUPPORT GET INTO CONTACT WITH THE DISC, WHICH RESULTS IN A METALLIC NOISE AND SPARKS IN THE CALLIPER; THEREFORE, BRAKING EFFICIENCY AND DISC SAFETY AND INTEGRITY ARE AT RISK. When the lining material of even just one of the brake pads is worn down to nearly 1.5 mm (0.06 in) (or even if one of the wear indicators is no longer visible), replace both brake pads.
Bleeding the braking system Front

Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
BRAK SYS - 187
Braking system
RXV 450-550
Remove the rubber protection cover from the bleed valve. Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid.
Quickly press and release the front brake lever several times and then keep it fully pressed.
Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container. This will release tension on the brake lever and will make it go to the end of stroke.
Close the bleed valve before the lever reaches its end of stroke. 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.
Screw the bleeding valve and remove the pipe. Top-up the reservoir until the correct brake fluid level is obtained. Refit the rubber protection cover.
Rear
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess" of the brake control and poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
BRAK SYS - 188
RXV 450-550
Braking system
Remove the rubber protection cover from the bleed valve. Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a container to collect the fluid.
Quickly press and release the front brake lever several times and then keep it fully pressed.
Loosen the bleed valve 1/4 of a turn so that the brake fluid flows into the container. This will release tension on the brake lever and will make it go to the end of stroke.
Close the bleed valve before the lever reaches its end of stroke. 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.
Screw the bleeding valve and remove the pipe. Top-up the reservoir until the correct brake fluid level is obtained. Refit the rubber protection cover.
BRAK SYS - 189
INDEX OF TOPICS
COOLING SYSTEM
COOL SYS
RXV 450-550
Cooling system
Circuit diagram
key: 1. Left radiator 2. Right radiator 3. Expansion tank 4. Fan unit 5. Fan support 6. Closing cap 7. Special TBEI screw 8. Washer 9. Low self-locking nut 10.Bushing 11.Silent-block 12.Washer 13.Fuel pipe 14.Breather pipe 15.Pipe 16.Radiator-pump pipe 17.Pipe 18.Pipe
COOL SYS - 191
Cooling system
RXV 450-550
19.Pipe clamp 20.Clic clamp 21.Clic clamp 22.Clic clamp 23.Clic clamp 24.Green clic clamp 25.Adhesive backed foam 26.Gasket 27.Expansion tank cap 28.Rubber ring 29.Radiator cap 30.TBEI screw 31.Plain iron washer 32.Radiator left guard 33.Radiator right guard 34.Plain iron washer 35.Clip 36.From front head 37.From rear head
Water pump - overhaul

CAUTION
IT IS NOT NECESSARY TO REMOVE THE COOLANT PUMP UNLESS THE COOLANT LEVEL IS EXTREMELY LOW OR WHEN THE COOLANT DOES NOT HAVE ENGINE OIL.
NOTE
PLACE A CLOTH UNDER THE PUMP BEFORE REMOVING ITS COMPONENTS. Undo and remove the four pump cover fixing screws. Remove the water pump cover and collect the seal gasket.
COOL SYS - 192
RXV 450-550
Cooling system
Remove the pump rotor using the special spanner.
Specific tooling
9100938 Pump rotor wrench
Remove the shim washer.
Collect the two centring cylinders.
NOTE
Remove the water pump cover spacer.
WHEN REFITTING, FOLLOW THE STEPS DESCRIBED BEFORE BUT IN REVERSE ORDER; USE ONLY CIRCULAR GASKETS AND NEW CLAMPS.
COOL SYS - 193
Cooling system
RXV 450-550
Removing the radiator

Working on both sides, unscrew and remove the three side fairing fixing screws. Remove the side fairings.
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.
Working on both sides, release the clamps between the aluminium tube and the rubber hose in the radiator.
COOL SYS - 194
RXV 450-550
Cooling system
Remove the right and left delivery pipes.
Working on the left side, release the clamp and disconnect the pipe.
Working on the right side slide off the sleeve.
Remove the radiator breather pipe.
COOL SYS - 195
Cooling system
RXV 450-550
Working from both sides, undo and remove the two screws and collect the collar.
Working on the right side, undo the lower screw; collect the nut and the washer from the left side.
CAUTION
Slide off the radiators downwards.
THE RADIATORS ARE INTERCONNECTED THROUGH THE LOWER PIPE.
COOL SYS - 196
INDEX OF TOPICS
BODYWORK
BODYW
Bodywork
RXV 450-550
Seat
Turn the fastening clip. Push the saddle forwards.
Remove the saddle by moving it forwards.
CAUTION WHEN REFITTING, CHECK LOWER HOOKS.
Side body panels

Removal Working on both sides, unscrew and remove the three side fairing fixing screws. Remove the side fairings.
To refit the fairings, follow the steps described before but in reverse order.
BODYW - 198
RXV 450-550
Bodywork
Lower cowl
By working from the right side, unscrew and remove the nut and collect the collar.
By working from the left side, move the breather pipe and remove the screw; collect the collar.
Undo and remove the two screws and collect the collar.
Slide the pipe off the two hooks. Remove the underpan jack, paying attention to rest the expansion tank.
BODYW - 199
Bodywork
RXV 450-550
Fuel tank
Remove the saddle. Remove the side fairing. Remove the lower left-side fairing by pulling it downwards.
Undo and remove the screw fixing the reservoir and collect the centring bushing.
Remove the fuel tank breather pipe. Lift the tank. Keep the fuel tank lifted with the retaining edge.
CAUTION MAKE SURE THAT THE TANK RETAINING EDGE NEVER COMES INTO CONTACT WITH THE BATTERY POSITIVE LEAD.
CAUTION PAY ATTENTION TO THE FUEL PIPE.
BODYW - 200
RXV 450-550
Bodywork
Release the quick coupler.
Disconnect the connector.
Remove the cotter pin from one side.
Remove the tank fixing pin, from the opposite side.
Remove the fuel tank.
BODYW - 201
Bodywork
RXV 450-550
CAUTION DURING FUEL TANK LIFTING AND REPOSITIONING, BE CAREFUL SO AS NOT TO CRUSH/BEND OR SLIDE OFF TANK BREATHERS FROM THE CORRESPONDING TUBEGUIDES
See also
Seat
Battery
Remove the saddle. Unscrew and remove the negative lead fixing screw and collect the washer.
Unscrew and remove the positive lead fixing screw and collect the washer.
Remove the battery.
See also
BODYW - 202
RXV 450-550
Bodywork
Seat
Tail guard
Remove the tail fairing. Undo and remove the central screw.
Remove the clamp and disconnect the rear turn indicator connectors and the rear taillight.
Remove the license plate holder.
See also
Tail guard Remove the side fairings. Undo and remove the two screws; collect the collars.
BODYW - 203
Bodywork
RXV 450-550
Undo and remove the two rear screws; collect the collars. Remove the tail fairing.
See also
Side body panels
BODYW - 204
A
Air filter: 38
B
Battery: 202 Brake: 186, 187
C
Chain: 108, 109, 173 Clutch: 85, 88, 9193, 96, 133
D
Display: 146
E
Engine oil: 33, 179
F
Fork: 149, 151, 156, 159, 163 Forks: 82 Fuel: 53, 181, 200 Fuses: 50
G
Gearbox oil: 36
H
Headlight: 43
I
Instrument panel:
M
Maintenance: 8, 27
R
Recommended products: 18, 34
S
Shock absorbers: 168 Spark plug: 31 Stand:
T
Tank: 53, 179, 181, 200 Technical data:

MSS RXV 450 550 MY09 English 45325 75 - 100810153921

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MSS RXV 450 550 MY09 English 45325 75 - 100810153921

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SERVICE STATION MANUAL

SERVICE STATION MANUAL

SERVICE STATION MANUAL

Rules Safety rules

DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.

Dimensions and mass

Specification 5 Drive chain Fuel system Diffuser Fuel system

TECHNICAL DATA RXV 550 (ENGINE)

Specification High-beam warning light Turn indicator warning light

Desc./Quantity LED LED

FOOTRESTS LOCKING TORQUES

LIGHTS AND INSTRUMENT PANEL

TANKS AND RESERVOIRS

CHASSIS TIGHTENING TORQUES

Name Side stand fixing nut - M10

Torque in Nm 50 Nm (36.88 lbf ft) - Loctite 243

COOLING SYSTEM LOCKING TORQUES

REAR BRAKE LOCKING TORQUES

FRONT WHEEL LOCKING TORQUES

REAR SUSPENSION LOCKING TORQUES

SWINGARM LOCKING TORQUES

Name APTC thrust plate fixing screw - M5x0.8

Torque in Nm 8 Nm (5.9 lbf ft)

AIR FILTER BOX

Overhaul data Assembly clearances Crankcase - crankshaft - connecting rod

COUPLING TYPES - SHAFT - CONNECTING ROD

Shaft - Connecting rod: A - B - YELLOW types

Shaft - Connecting rod: B - A - GREEN types

Shaft - Connecting rod: B - B - BLUE types

COUPLING TYPES - SHAFT - MAIN BEARING

Shaft - Main bearing: A - B - YELLOW types

Shaft - Main bearing: B - A - GREEN types

Shaft - Main bearing: B - B - BLUE types

Recommended products chart

AGIP RACING 4T 10W-60 AGIP PERMANENT SPEZIAL

Gearbox oil Coolant

Grease for bearings, joints, couplings and linkages

AGIP FORK 7.5W

Pin ring tool - 550

Water pump oil seal guide

Water pump oil seal punch

Valve spring compressor

Engine support stand

Stores code 8140188

Description Engine support

Flywheel rotor locking

Walbro Cable for Axone

Tool for valve pressure plate

Punch for crankshaft bushings

Crankshaft pinion locking tool

Stores code 9100844

Description Crankshaft locking tool (timing pin)

Crankshaft bushing extractor

Main shaft/ right side - secondary shaft/ left side

Secondary shaft/right side - Main shaft/ left side

Punch for right crankcase desmo

Oil pump oil seal punch

Timing gear crankshaft punch

Stores code 9100890

Description Timing gear crankshaft punch

Left crankcase desmodromic + wheel hub

Left timing gear punch