APRILIA SXV 450 - 2008 User manual

Congratulations on your new SXV.
This innovative motorcycle is designed to provide high performance and great fun under all usage conditions - in other words, with an intent to
revolutionise the concept of supermotard motorcycles. aprilia's first and foremost commitment is to build motorcycles with high technological content,
that are extremely safe to ride and will retain their value over time.
IMPORTANT NOTICE ON VEHICLE USE AND LEGAL WARRANTY
aprilia SXV motorcycles have been conceived and designed for race-track and off-road competitions. As a result, they meet the rules and class
requirements currently adopted by major international motorcycling associations.
Having the motorcycle serviced at the recommended intervals as specified in the maintenance charts provided in this manual is critical to avoiding
premature wear and severe failures. To preserve motorcycle performance and avoid severe damage, have the recommended maintenance procedures
performed by Authorised aprilia Dealers or Service Centres or - at the track - by a qualified mechanic.
The SXV come in a derated version which can be legally used on public roads and is covered by a legal warranty. In order to maintain the warranty,
the recommended maintenance must be performed at the specified intervals by Authorised aprilia Dealers or Service Centres and each service must
be recorded in the warranty booklet.
Please note that these motorcycles are not suitable for road use. Gear ratios, cooling system, suspension set-up, braking system and engine power
delivery are designed and tuned up for racing, and the operating conditions encountered in competitions differ greatly from those experienced when
riding on public roads. Below is a short non-exhaustive list of typical operating conditions that may lead to severe engine damage: long stops at traffic
lights, motorway trips with the engine steadily running at maximum rpm, or drafting vehicles.
Any changes or modifications to the motorcycle, especially performance enhancing modifications, will make the motorcycle illegal to ride on public roads
and void the legal warranty. A modified motorcycle may be used for racing in organised races approved by competent authorities.
For your own safety, use only genuine aprilia parts and accessories. aprilia disclaims all liabilities for the event non-genuine parts are used and for
resulting damage.
APRILIA WOULD LIKE TO THANK YOU
for having chosen one of its products. We have compiled this booklet to provide a comprehensive overview of your vehicle's quality features. Please
read it carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features,
details and devices to assure you that you have made the right choice. We believe that if you follow our suggestions, you will soon find yourself in
harmony with your new vehicle, and ride it fully satisfied for a long time. This booklet forms an integral part of the vehicle; should the vehicle be sold, it
must be transferred to the new owner.
SXV 450-550
Ed. 03 2008

Ed. 03 2008

Theinstructionsgiveninthismanualareintendedtoprovideaclear,simpleguidetousingyourvehicle;italsodescribesroutinemaintenanceprocedures
and regular checks that should be carried out on the vehicle at an Aprilia Dealer or Authorised Workshop. The booklet also contains instructions for
simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical knowledge: for these
operations, please take your vehicle to an Aprilia Dealer or Authorised Workshop.
3

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 dam-
aging 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
The symbols illustrated above are very important. They are used to highlight parts of the
booklet that should be read with particular care. The different symbols are used to make
each topic in the manual simple and quick to locate. Before starting the engine, read this
booklet carefully, particularly the "SAFE RIDING" section. Your safety as well as other's
does not only depend on the quickness of your reflexes and agility, but also on how well
youknow yourvehicle, thestate ofmaintenance ofthe vehicleitself andyour knowledge
of the rules for SAFE RIDING. For your safety, get to know your vehicle well so as to
safely ride and master it given any riding condition. IMPORTANT This booklet is an
integral part of the vehicle, and must be handed over to the new owner in the event of
sale.
4

INDEX
GENERAL RULES....................................................................... 7
Carbon monoxide.................................................................. 8
Fuel....................................................................................... 8
Hot components.................................................................... 9
Coolant.................................................................................. 9
Used engine oil and gearbox oil............................................ 10
Brake and clutch fluid............................................................ 10
Battery hydrogen gas and electrolyte.................................... 11
Reporting of defects that affect safety................................... 11
VEHICLE...................................................................................... 15
Arrangement of the main components...................................... 16
Dashboard................................................................................ 19
Analog instrument panel........................................................... 19
Light unit................................................................................... 20
Digital lcd display...................................................................... 22
Key switch................................................................................. 27
Locking the steering wheel.................................................... 28
Horn button............................................................................... 28
Switch direction indicators........................................................ 29
High/low beam selector............................................................. 29
Start-up button.......................................................................... 30
Engine stop switch.................................................................... 30
Manual starter control............................................................... 31
Opening the saddle............................................................... 31
USE.............................................................................................. 33
Checks...................................................................................... 34
Refuelling.................................................................................. 36
Rear shock absorbers adjustment............................................ 38
Front fork adjustment................................................................ 40
Running in................................................................................. 41
Starting up the engine............................................................... 42
Difficult start up......................................................................... 45
Stopping the engine.................................................................. 46
Stand......................................................................................... 47
Safe driving............................................................................... 48
Load.......................................................................................... 52
MAINTENANCE........................................................................... 53
Engine oil level.......................................................................... 54
Engine oil change.................................................................. 56
Gearbox oil level....................................................................... 57
Tyres......................................................................................... 60
Spark plug dismantlement........................................................ 62
Removing the air filter............................................................... 65
Cooling fluid level...................................................................... 66
Checking the brake oil level...................................................... 69
Battery....................................................................................... 76
Fuses........................................................................................ 77
Lamps....................................................................................... 81
Front light group........................................................................ 81
Headlight adjustment............................................................. 83
Front and rear disc brake.......................................................... 84
Periods of inactivity................................................................... 86
Cleaning the vehicle.................................................................. 88
Transport................................................................................... 91
Chain backlash check........................................................... 91
Chain backlash adjustment................................................... 92
Checking wear of chain, front and rear sprockets................. 92
Chain lubrication and cleaning.............................................. 93
TECHNICAL DATA...................................................................... 95
PROGRAMMED MAINTENANCE............................................... 103
Scheduled maintenance table................................................... 104
SPECIAL FITTINGS..................................................................... 125
5

6

SXV 450-550
Chap. 01
General rules
7

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.
CAUTION
CARBON MONOXIDE IS ODOURLESS AND COLOURLESS, THEREFORE IT
CANNOT BE DETECTED BY SMELL, SIGHT OR OTHER SENSES. DO NOT
BREATHE IN EXHAUST FUMES UNDER ANY CIRCUMSTANCES.
Fuel
CAUTION
FUEL USED TO DRIVE EXPLOSION ENGINES IS HIGHLY INFLAMMABLE AND
CAN BECOME EXPLOSIVE UNDER SPECIFIC CONDITIONS. IT IS THEREFORE
RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCE-
DURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF. DO NOT
SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR. AVOID ANY CON-
8
1 General rules

TACT 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 get very hot and remain in this con-
ditionforacertaintimeinterval after the engine hasbeenswitchedoff.Beforehandling
these components, make sure that you are wearing insulating gloves or wait until the
engine and the exhaust system have cooled down.
Coolant
Coolant contains ethylene glycol, which may be flammable in certain conditions. Eth-
ylene glycol burns with an invisible flame which may still cause burns.
CAUTION
TAKEPARTICULARCARENOTTO SPILLCOOLANTONTO HOTPARTSOR THE
ENGINE AND EXHAUST SYSTEM; THE FLUID MAY CATCH FIRE AND BURN
WITH INVISIBLE FLAMES. WHEN CARRYING OUT MAINTENANCE OPERA-
TIONS, IT IS ADVISABLE TO WEAR LATEX GLOVES. WHILE POISONOUS,
COOLANT HAS A SWEET TASTE WHICH MAKES IT EXTREMELY APPEALING
TO ANIMALS. NEVER LEAVE COOLANT IN OPEN CONTAINERS WHERE IT MAY
BE REACHED AND DRUNK BY AN ANIMAL.
KEEP OUT OF THE REACH OF CHILDREN.
NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT.
COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS.
9
1 General rules

Used engine oil and gearbox oil
CAUTION
WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO
WEAR PROTECTIVE IMPERMEABLE GLOVES.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN
IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BA-
SIS.
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 FLUID CAN DAMAGE PAINT FINISH, PLASTIC AND RUBBER. WHEN
SERVICING THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A
CLEAN CLOTH. ALWAYS WEAR PROTECTIVE EYEWEAR WHEN WORKING ON
THE BRAKE SYSTEM. BRAKE FLUID IS EXTREMELY HARMFUL FOR THE
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE
EYES IMMEDIATELY WITH PLENTY OF COOL, CLEAN WATER AND SEEK IM-
MEDIATE MEDICAL ATTENTION.
KEEP OUT OF THE REACH OF CHILDREN.
10
1 General rules

Battery hydrogen gas and electrolyte
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
GLOVESAND PROTECTIVE APPAREL. IN THEEVENTOFSKIN 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. THE BATTERY
RELEASESEXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIG-
ARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADEQUATE VENTILA-
TION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN.
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COM-
PONENTS IN PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COM-
PATIBLE WITH THE BATTERY BEING ACTIVATED.
Reporting of defects that affect safety
GENERAL PRECAUTIONS AND INFORMATION
When repairs, disassembly and reassembly of the vehicle is carried out, follow the
following recommendations strictly.
BEFORE DISASSEMBLING COMPONENTS
11
1 General rules

•Remove the dirt, mud, dust and foreign objects from the vehicle before dis-
assembling components. Wherever required, use the special tools designed
for this vehicle.
DISASSEMBLING COMPONENTS
•Do not loosen and/or tighten the screws and nuts using pliers or other tools,
but always use the specific wrench.
•Mark the positions on all the connection joints (hoses, cables, etc.) before
separating them and identify them with different distinctive marks.
•Each piece should be clearly marked in order to be identified during the in-
stallation phase.
•Carefullycleanandwashthedisassembledcomponentswithdetergentswith
a low flammability grade.
•Keepthecoupledpartstogetherbecausetheyhave"adapted"tooneanother
following normal wear.
•Some components must be used together or replaced entirely.
•Keep away from heat sources.
REASSEMBLING THE COMPONENTS
CAUTION
THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE,
OTHERWISE THEY MUST BE REPLACED.
•Use only aprilia ORIGINAL SPARE PARTS.
•Always use the recommended lubricants and consumable material.
•Lubricate the parts (when possible) before reassembling them.
•When tightening screws and nuts, begin with the larger diameter or internal
ones, proceeding diagonally. Tighten with subsequent steps before applying
the prescribed torque.
•Always replace the locknuts, gaskets, seal rings, snap rings, O-Rings (OR),
cotter pins and screws if they have damaged thread, with new ones.
•When disassembling the bearings, lubricate them abundantly.
•Ensure that each component has been assembled correctly.
12
1 General rules

•After a repair or periodic maintenance operation, carry out the preliminary
checks and test the vehicle on private property or in an area with light traffic.
•Clean all coupling surfaces, oil seal rims and gaskets before refitting them.
Smear a light layer of lithium-based grease on the oil seal rims. Reassemble
oil seals and bearings with the brand or lot number facing outward (visible
side).
ELECTRICAL CONNECTORS
The electrical connectors should be disconnected as follows. Failure to observe these
procedures will cause irreparable damage to the connector and the wiring:
If present, press on the specific safety catches.
•Grip the two connectors and unplug them, pulling them apart in opposite di-
rections.
•If there is dirt, rust, moisture, etc., carefully clean the inside of the connector
using pressurised air.
•Ensure that the cables make correct contact with the terminals inside the
connectors.
•Then plug in the two connectors, ensuring correct coupling (if the specific
catches are present, you will hear a typical "click").
CAUTION
TO UNPLUG THE TWO CONNECTORS, DO NOT PULL ON THE CABLES.
NOTE
THE TWO CONNECTORS CAN BE PLUGGED IN ONLY IN ONE DIRECTION,
THEREFORE JOIN THEM TOGETHER IN THE RIGHT DIRECTION.
TIGHTENING TORQUE
CAUTION
REMEMBER THAT THE TIGHTENING TORQUE FOR ALL THE FIXING ELE-
MENTS LOCATED ON WHEELS, BRAKES, WHEEL AXLES AND OTHER SUS-
13
1 General rules

PENSION COMPONENTS PLAY A FUNDAMENTAL ROLE IN GUARANTEEING
THE SAFETY OF THE VEHICLE AND MUST BE KEPT AT THE PRESCRIBED
VALUES. REGULARLY CHECK THE TIGHTENING TORQUE OF THE FIXING EL-
EMENTS AND ALWAYS USE A TORQUE WRENCH WHEN REFITTING. IF THESE
WARNINGS ARE NOT OBSERVED, ONE OF THESE COMPONENTS COULD
LOOSEN AND COME OFF, BLOCKING A WHEEL OR CAUSING OTHER PROB-
LEMS THAT WOULD COMPROMISE MANOEUVRABILITY, LEADING TO A
CRASH WITH THE RISK OF SERIOUS INJURY OR EVEN DEATH.
14
1 General rules

SXV 450-550
Chap. 02
Vehicle
15

02_01
Arrangement of the main components (02_01)
LEGEND Ieft side
1. Left coolant radiator
2. Left rear-view mirror
3. Fuel tank cap
4. Fuel tank
5. Battery
6. Saddle
7. Rear light
16
2 Vehicle

8. Rear fork
9. Transmission chain
10. Rear left side
11. Side stand
12. Driver's left footrest
13. Gear control lever
14. Main fuse holder (30A)
15. Left front side
02_02
17
2 Vehicle

Right side KEY
1. Right front side
2. Right coolant radiator
3. Coolant expansion tank cap
4. Right rear-view mirror
5. Air filter housing
6. Secondary fuse holder
7. Right rear side
8. Pump with rear brake fluid reservoir
9. Driver's right footrest
10. Rear brake control lever
02_03
18
2 Vehicle

Dashboard (02_03)
KEY
1. Left rear-view mirror
2. Clutch control lever
3. Instruments and gauges
4. Ignition switch - steering lock (ON - OFF - LOCK)
5. Front brake lever
6. Right rear-view mirror
7. Throttle grip
02_04
Analog instrument panel (02_04)
KEY
1. MODE button
2. Neutral gear warning light (green)
3. Engine oil pressure warning light (red)
4. Engine control system warning light
5. Multifunctional digital display
6. Low fuel warning light, (orange)
7. High-beam warning light, (blue)
19
2 Vehicle

8. Turn indicator warning light (green)
9. Overrevving warning light
Light unit
Turn indicator warning light
Flashes when the turning indication is activated
Engine control system warning light
It comes on when the ignition switch is set to ON and the engine has not been started,
thus performing the warning light activation test. If the warning light does not come on
at this stage, contact an Official aprilia Dealer.
CAUTION
IF THE ENGINE CONTROL LIGHT (4) STAYS ON AFTER START-UP OR COMES
ON DURING REGULAR ENGINE OPERATION, THIS MEANS THAT THERE IS A
FAULTIN THESTART-UP/IGNITION SYSTEM.SHOULDTHIS OCCUR,CONTACT
AN Official aprilia Dealer AS SOON AS POSSIBLE.
High-beam warning light
Comes on when the high beam light is activated or the high beam light is flashed.
Low fuel warning light
Comes on when 2.2 ± 1 l (4 ± 1.8 in) of fuel are left in the fuel tank.
20
2 Vehicle