2006-2013 Aprilia SXV/RXV 450/550 OEM Service & Repair Manual

INTRODUCTION 0-1 Engine 450 - 550 INTRODUCTION 0

INTRODUCTION 0 - 2 Engine 450 - 550 SUMMARY 0.1. INTRODUCTION ............................................................................................................................................. 3 0.1.1. FOREWORD .......................................................................................................................................... 3 0.1.2. REFERENCE MANUALS ....................................................................................................................... 4 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS ..................................................................................... 5

INTRODUCTION 0-3 Engine 450 - 550 0.1. INTRODUCTION 0.1.1. FOREWORD This manual provides the information required for normal servicing. This publication is intended for use by aprilia Dealers and their qualified mechanics; many concepts have been omitted on purpose as their inclusion would be superfluous. Since complete mechanical explanations have not been included in this manual, the reader must be familiar with basic notions of mechanics, as well as with basic repair procedures. Without such familiarity, repairs and checks could be ineffective and even hazardous. Since the repair and vehicle check instructions are not exhaustive, special care must be taken to avoid damage and injury. aprilia Piaggio & C. S.p.A. undertakes to constantly improve the design of its products and the relevant literature to ensure maximum customer satisfaction. The main technical modifications and changes in repair procedures are communicated to all aprilia dealers and agencies worldwide. Such modifications will be entered in subsequent editions of the manual. Should you need assistance or clarifications about the inspection and repair procedures, please contact the aprilia SERVICE DEPT., they will be glad to give you any information on the matter, or supply you with any detail on updates and technical changes applied to the vehicle. Piaggio & C. S.p.A. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. Third parties’ products are only mentioned for information purposes, and constitute no engagement. Piaggio & C. S.p.A. is not liable in any way for the performance or use of these products. First edition: June 2006 Produced and printed by: VALLEY FORGE DECA Ravenna , Modena, Torino DECA s.r.l. Registered Main Office Via Vincenzo Giardini, 11 48022 Lugo (RA) - Italy - Tel. 0545-216611 Fax 0545-216610 www.vftis.com deca@vftis.spx.com on behalf of: Piaggio & C. S.p.A. via G. Galilei, 1 - 30033 Noale (VE) - Italy Tel. +39  (0)41 58 29 111 Fax +39  (0)41 58 29 190 www.aprilia.com www.serviceaprilia.com

INTRODUCTION 0 - 4 Engine 450 - 550 0.1.2. REFERENCE MANUALS OWNER’S MANUALS aprilia part# (description) 9100650 9100651 9100652

INTRODUCTION 0-5 Engine 450 - 550 0.1.3. ABBREVIATIONS/SYMBOLS/CONVENTIONS # = number < = less than > = greater than ≤ = less than or equal to ≥ = more than or equal to ~ = approximately ∞ = infinity C = degrees Celsius (centigrade) F = degrees Fahrenheit – = plus or minus a.c = alternating current A = Ampere Ah = Ampere per hour API = American Petroleum Institute AT = high voltage AV/DC = Anti-Vibration Double Countershaft bar = pressure measurement unit (1 bar = 100 kPa) d.c. = direct current cc = cubic centimetres CO = carbon monoxide CPU = Central Processing Unit DIN = German industrial standards (Deutsche Industrie Norm) DOHC = Double Overhead Camshaft ECU = Electronic Control Unit rpm = revolutions per minute HC = unburnt hydrocarbons ISC = Idle Speed Control ISO = International Standardisation Organisation kg = kilograms kgm = kilograms per metre (1 kgm = 10 Nm) km = kilometres km/h = kilometres per hour kΩ = kilo Ohm kPa = kiloPascal (1 kPa = 0.01 bar) KS = clutch side (from the German "Kupplungsseite") kW = kilowatt ℓ = litres LAP = racetrack lap LED = Light Emitting Diode LEFT SIDE = left side m/s = metres per second max = maximum mbar = millibar (1 mbar = 0.1 kPa) mi = miles MIN = minimum MPH = miles per hour MS = flywheel side (from the German "Magnetoseite") MΩ = MegaOhm N.A. = Not Available N.O.M.M. = Motor Octane Number N.O.R.M. = Research Octane Number Nm = Newton metre (1 Nm = 0.1 kgm) Ω = ohm PICK-UP = pick-up BDC = Bottom Dead Centre TDC = Top Dead Centre PPC = Pneumatic Power Clutch

INTRODUCTION 0 - 6 Engine 450 - 550 RIGHT SIDE = right side SAE = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw TSI = Twin Spark Ignition UPSIDE- DOWN = inverted fork V = volt W = watt  = diameter

GENERAL INFORMATION 1-1 Engine 450 - 550 GENERAL INFORMATION 1

GENERAL INFORMATION 1 - 2 Engine 450  550 SUMMARY 1.1. STRUCTURE OF THE MANUAL..................................................................................................................... 3 1.1.1. CONVENTIONS USED IN THE MANUAL ............................................................................................. 3 1.1.2. SAFETY WARNINGS............................................................................................................................. 4 1.2. GENERAL RULES........................................................................................................................................... 5 1.2.1. BASIC SAFETY RULES......................................................................................................................... 5 1.3. DANGEROUS ELEMENTS ............................................................................................................................. 8 1.3.1. WARNINGS ........................................................................................................................................... 8 1.4. RUNNING-IN ................................................................................................................................................. 12 1.4.1. RUNNING-IN........................................................................................................................................ 12

GENERAL INFORMATION 1-3 Engine 450 - 550 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. Refer to the index of sections when consulting the manual. • Unless expressly specified otherwise, assemblies are reassembled by reversing the dismantling procedure. • The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position. • Motorcycle operation and basic maintenance are covered in the "OWNER’S MANUAL". In this manual any variants are identified with these symbols: optional catalytic version - all versions MP national certification SF European certification (EURO 2 limits) VERSION: Italy Greece Malaysia United Kingdom Holland Chile Austria Switzerland Croatia Portugal Denmark Australia Finland Japan United States of America Belgium Singapore Brazil Germany Slovenia South Africa France Israel New Zealand Spain South Korea Canada

GENERAL INFORMATION 1 - 4 Engine 450  550 1.1.2. SAFETY WARNINGS The following precautionary warnings are used throughout this manual in order to convey the following messages: Safety warning. This symbol appears, whether in the manual or on the vehicle itself, to indicate a personal injury hazard. Non-compliance with the indications given in the messages preceded by this symbol may result in grave risks for your and other peoples safety and for the vehicle! DANGER Indicates a potential hazard which may result in serious injury or even death. WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle. NOTE The word "NOTE" in this manual precedes important information or instructions.

2006-2013 Aprilia SXV/RXV 450/550 OEM Service & Repair Manual

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