APRILIA MXV 450 - Guide

SERVICE STATION MANUAL
854239
MXV 450

SERVICE STATION
MANUAL
MXV 450
THE VALUE OF SERVICE
Thanks to continuous technical updates and specific training programs on 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 conditions. Checking the vehicle before
riding, its regular maintenance and the use of Original Aprilia Spare Parts only are essential factors!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.aprilia.com
Only aprilia Original Spare Parts ensure products already studied and tested during the vehicle design
stage. All aprilia Original Spare Parts undergo quality control procedures to guarantee full reliability and
duration.
The descriptions and illustrations given in this publication are not binding; While the basic characteristics
as described and illustrated in this manual 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 shown in this publication are available in all countries. The availability of individual
versions should be confirmed with the official Aprilia sales network.
© Copyright 2008 - Aprilia. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Aprilia - After sales service.
aprilia trademark is property of Piaggio & C. S.p.A.

SERVICE STATION MANUAL
MXV 450
-Thismanualprovidesthemaininformationtocarryoutregularmaintenanceoperationsonyourvehicle.
- This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been
deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing vehicles. 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 Sectionsmarkedwiththissymbolindicatethecorrectuseofthevehicle
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 CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE

INDEX OF TOPICS
CHARACTERISTICS CHAR

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
EXHAUSTEMISSIONSCONTAINCARBONMONOXIDE,APOISONOUSGASWHICHCANCAUSE
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
THEENGINESWITCHED OFF. DONOTSMOKEDURING REFUELLINGORNEARFUEL VAPOUR.
AVOIDANY CONTACTWITH NAKEDFLAME, 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 COMPO-
NENTS; 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. NEV-
ER LEAVE THE COOLANT IN OPEN CONTAINERS IN AREAS ACCESSIBLE TO ANIMALS AS
THEY MAY DRINK IT.
MXV 450 Characteristics
CHAR - 7

KEEP OUT OF THE REACH OF CHILDREN.
DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS
PRESSURISED AND MAY CAUSE SCALDING.
Used engine oil and gearbox oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VE-
HICLE.
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 fluid
THE BRAKE FLUID MAY DAMAGE PAINTED, PVC OR RUBBER SURFACES. WHEN SERVICING
THE BRAKING SYSTEM, PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS
WEAR PROTECTIVE GOGGLES WHEN SERVICING THE BRAKING SYSTEM. THE BRAKE FLUID
IS EXTREMELY DANGEROUS TO THE EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH
THE EYES, RINSE THEM IMMEDIATELY WITH PLENTY OF COLD, CLEAN WATER AND SEEK
MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING COMPONENTS
•Beforedismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•Donotloosenand/ortightenscrewsandnutsusingpliersoranyothertoolsthanthespecific
wrench.
•Mark positions on all connection joints (pipes, cables etc.) before separating them, and
identify them with 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.
Characteristics MXV 450
CHAR - 8

•Some components must be used together or replaced completely.
•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 from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before ap-
plying the tightening torque.
•Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), split pins
and screws with new ones if their tread 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 procedure, carry out pre-ride checks and test the ve-
hicle on private grounds.
•Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble bearings with the brand or
lot number facing outward (visible side).
ELECTRICAL 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.
•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 TORQUE
CAUTION
MXV 450 Characteristics
CHAR - 9

DO NOT FORGET THAT TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL PINS AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY
ROLE IN ENSURING THE VEHICLE'S SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO OB-
SERVE THESE INSTRUCTIONS MAY CAUSE ONE OF THESE COMPONENTS TO BECOME
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISING
YOUR PROPERLY HANDLING THE VEHICLE. THIS CAN LEAD TO FALLS, WITH THE RISK OF
SERIOUS PERSONAL INJURIES OR EVEN DEATH.
Running-in
In order to ensure enhanced reliability and performance along time, special attention should be given
to the first riding day or during the first 2 hours the vehicle is used.
During this time, avoid setting off at too high a speed or sudden accelerations.
These procedures have to be carried out each time:
•pistons are replaced
•piston rings are replaced
•cylinder liners are replaced
•crankshaft, main bearings and connecting rod bushings are replaced.
NOTE
EVEN AFTER THE RUNNING-IN PERIOD, AVOID RUNNING THE ENGINE AT TOP SPEED, WHEN
THE LIMITER CUTS IN:
•MXV 450 12500 rpm
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification Desc./Quantity
Max. length 2190 mm (86.22 in)
Max. width (at brake levers) 815 mm (32.09 in)
Max. height 1285 mm (50.59 in)
Saddle height 960 mm (37.79 in)
Wheelbase 1499 mm (59.01 in)
Minimum ground clearance 340 mm (13.38 in)
Kerb weight (full tank) 112.7 kg (248.5 lb)
Engine
ENGINE
Specification Desc./Quantity
Model MXV 450
ENGINE 77° V-twin, 4-stroke, 4 valves per cylinder, single overhead
camshaft.
Number of cylinders 2
Total engine capacity 449 cm³ (27.40 cu.in)
Bore/stroke 76 mm / 49.5 mm (2.99 in / 1.95 in)
Compression ratio 13/1
Characteristics MXV 450
CHAR - 10

Specification Desc./Quantity
Squish 1 mm (0.039 in)
Electric Kick-start
Engine speed at idle Mapped in relation to coolant temperature
Clutch 8 disc wet clutch
Lubrication system Pressure-fed circuit, dry sump system with internal reservoir
Air filter Sponge
Cooling Coolant
Valuescorrectwithcontrolclearancebetweenrockerandvalve intake: 0.08 - 0.13 mm (0.0031 - 0.0051 in)
exhaust: 0.18 - 0.23 mm (0.0071 - 0.0091 in)
Gearbox mechanical, 4 speeds with foot lever on the left hand side of
the engine
Gearbox lubrication Oil splash lubrication
Gear ratio Primary: 23/65 = 1 : 2.83
Final: 14/49 = 1 : 3.50
1st 14/29 = 1 : 2.07
2nd 15/26 = 1 : 1.73
3rd 17/25 = 1 : 1.47
4th 19/24 = 1 : 1.26
Drive chain Regina chain without O-rings 5/8" x 1/4" 114 links
Capacities
CAPACITY
Specification Desc./Quantity
Fuel tank capacity (including reserve) 7.4 l (1.63 UKgal)
Engine oil capacity, replacing oil filter 1200 cm³ (73.23 cu.in)
Gearbox oil 650 cm³ (39.66 cu.in)
Coolant capacity 1.2 l (0.26 Ukgal) (50% water + 50% antifreeze solution with
ethylene glycol)
Seats 1
Electrical system
ELECTRICAL COMPONENTS
Specification Desc./Quantity
1 Ignition Electronic, digital (batteryless)
2 Standard spark plug NGK CR8EKB
3 Spark plug electrode gap 0.7 ± 0.8 mm (0.028 in ± 0.031 in)
4 Main fuse 30 A
5 (Permanent-magnet) Alternator Kokusan 220 W
Frame and suspensions
CHASSIS AND SUSPENSIONS
Specification Desc./Quantity
Frame - type Steel and aluminium perimetric frame
Steering rake 26.2°
Trail 111 mm (4.37 in)
Front suspension Marzocchiupside-down fork,Ø 50 mm (1.97 in)with adjustable
compression damping and return.
Front suspension travel 302 mm (11.89 in)
Rear suspension Pro-Link with Sachs monoshock, with adjustable compression
damping (fast and slow) and rebound damping.
Rear suspension travel 310 mm (12.20 in)
MXV 450 Characteristics
CHAR - 11

SIZES A AND B
Specification Desc./Quantity
Size "A" 581.3 mm (22.89 in)
Size "B" 422.5 mm (16.6 in)
Brakes
BRAKES
Specification Desc./Quantity
Front disc Ø 270 mm (Ø 10.63 in) hydraulic disc brake
Rear drum Ø 240 mm (Ø 9.45 in) hydraulic disc brake
Wheels and tyres
WHEELS AND TYRES
Specification Desc./Quantity
Wheel rims with spokes
Front wheel rim 1.60 x 21
Rear wheel rim 2.15 x 19"
Tyres - type Dunlop
Front tyre 80/100-21 51M
Front tyre pressure 1.0 bar (100 kPa) (14.5 PSI)
Rear tyre 110/90-19 62M
Rear tyre pressure 1.0 bar (100 kPa) (14.5 PSI)
Supply
FUEL SYSTEM
Specification Desc./Quantity
Diffuser Ø 38 mm (1.49 in)
Fuel system premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Fuel system Integrated ignition-injection management .
Tightening Torques
HANDLEBAR AND CONTROLS
Name Torque in Nm
Clutch control-handlebar fixing screw - M6 10 Nm (7.37 lbf ft)
Throttle grip fixing screw - M6 10 Nm (7.37 lbf ft)
Characteristics MXV 450
CHAR - 12

Name Torque in Nm
Upper clamp - handlebar fixing screw - M8 24 Nm (17.70 lbf ft)
FOOTRESTS
Name Torque in Nm
Footrest support bracket fixing screw - M12 50 Nm (36.88 lbf ft) - Loctite 243
Footrest support bracket fixing screw - M8 25 Nm (18.44 lbf ft) - Loctite 243
BODYWORK
Name Torque in Nm
Rod - mudguard front fixing screw - M6 12 Nm (8.85 lbf ft)
Rod - mudguard rear fixing screw - M6 12 Nm (8.85 lbf ft)
Mudguard - steering base fixing screw - M6 12 Nm (8.85 lbf ft)
Filter side lock upper fixing screw - M5 5 Nm (3.69 lbf ft)
Filter side lock lower fixing screw - M5 3 Nm (2.21 lbf ft)
Filter upper lock fixing screw - M5 4 Nm (2.95 lbf ft)
Air duct fixing screws - M6 12 Nm (8.85 lbf ft)
Fairing fixing screws - M6 12 Nm (8.85 lbf ft)
Front tail - frame fixing screw - M6 12 Nm (8.85 lbf ft)
Tail - mudguard - frame central fixing nut - M6 12 Nm (8.85 lbf ft)
Rear tail - frame fixing screw - M6 12 Nm (8.85 lbf ft)
Screw fixing undertail - mudguard - frame extension - M6 12 Nm (8.85 lbf ft)
Shock absorber protection fixing screw - M5 6 Nm (4.42 lbf ft)
Number plate retainer screw - M5 6 Nm (4.42 lbf ft)
TANKS AND RESERVOIRS
Name Torque in Nm
Fuel tank - chassis fixing screw - M6 12 Nm (8.85 lbf ft)
Fuel pump fixing ring nut 20 Nm (14.75 lbf ft)
Screw fixing saddle guide bushing - M5 5 Nm (3.69 lbf ft) - Loctite 243
Screw fixing tank buffers - M5 5 Nm (3.69 lbf ft) - Loctite 243
OUTLET
Name Torque in Nm
Screw fixing silencer to frame - M6 12 Nm (8.85 lbf ft)
Exhaust ends fixing nut - M6 12 Nm (8.85 lbf ft)
Pipes - head fixing screw - M6 12 Nm (8.85 lbf ft)
COOLING SYSTEM
Name Torque in Nm
Radiators upper fixing screw - M6 12 Nm (8.85 lbf ft)
Lower screw fixing radiators - M5 5 Nm (3.69 lbf ft) - Loctite 243
CHASSIS
Name Torque in Nm
Screw fixing frame - M8 25 Nm (18.44 lbf ft)
Upper chain roller fixing screw - M8 22 Nm (16.23 lbf ft)
Lower slider rear fixing screw - M5 5 Nm (3.69 lbf ft)
Lower slider front fixing screw - M5 5 Nm (3.69 lbf ft)
FRONT BRAKE
Name Torque in Nm
Brake - handlebar fixing screw - M6 10 Nm (7.37 lbf ft)
Screw fixing front brake calliper - M8 25 Nm (18.44 lbf ft)
REAR BRAKE
Name Torque in Nm
Rear brake pump fixing screw - M6 12 Nm (8.85 lbf ft)
Brake pedal fixing screw - M8 25 Nm (18.44 lbf ft) - Loctite 243
MXV 450 Characteristics
CHAR - 13

FRONT WHEEL
Name Torque in Nm
Wheel axle cover - M22 60 Nm (44.25 lbf ft)
Screw fixing front disc - M6 12 Nm (8.85 lbf ft)
Nut fixing cover clamps - M8 10 Nm (7.37 lbf ft)
Spoke nipples - M4 38 Nm (28.03 lbf ft)
REAR WHEEL
Name Torque in Nm
Wheel axle nut - M25 120 Nm (88.51 lbf ft)
Screw fixing rear disc - M6 12 Nm (8.85 lbf ft)
Nut fixing crown - M8 32 Nm (23.60 lbf ft)
Nut fixing cover clamps - M8 10 Nm (7.37 lbf ft)
Spoke nipples - M4 38 Nm (28.03 lbf ft)
FRONT SUSPENSION
Name Torque in Nm
Steering head fixing screw - M8 24 Nm (17.70 lbf ft)
Steering base fixing screw - M8 22 Nm (16.23 lbf ft)
Calliper mounting bracket fixing screw - M6 10 Nm (7.37 lbf ft)
Steering pin nut - M26 110 Nm (81.13 lbf ft)
Steering pin ring nut - M30 7 Nm (5.16 lbf ft)
Lower clamp - handlebar fixing nut - M10 32 Nm (23.60 lbf ft)
Stem protection fixing screw - M6 12 Nm (8.85 lbf ft)
REAR SUSPENSION
Name Torque in Nm
Chassis - rod fixing nut - M12 80 Nm (59.00 lbf ft)
Rod - rocker fixing nut - M12 80 Nm (59.00 lbf ft)
Rocker - swingarm fixing nut - M12 80 Nm (59.00 lbf ft)
Nut fixing rear shock absorber - M10 50 Nm (36.88 lbf ft)
SWINGARM
Name Torque in Nm
Chain guide fixing nut - M6 12 Nm (8.85 lbf ft)
Swingarm pin fixing nut - M14 100 Nm (73.76 lbf ft)
Chain tightener set screw - M8 25 Nm (18.44 lbf ft)
Screw fixing chain slider and rear brake pipe guides - M5 5 Nm (3.69 lbf ft) - Loctite 243
FILTER HOUSING
Name Torque in Nm
Screw fixing filter housing duct coupling - M4 1.3 Nm (0.96 lbf ft)
Screw fixing filter housing cover - M4 1.3 Nm (0.96 lbf ft)
ELECTRICAL SYSTEM
Name Torque in Nm
Screw fixing mapping switch - M4 2 Nm (1.47 lbf ft)
Screw fixing engine - stop - M3 1.5 Nm (1.1 lbf ft)
ENGINE - CHASSIS RETAINERS
Name Torque in Nm
Engine - chassis fixing nut M10 55 Nm (40.56 lbf ft)
Front nut fixing engine guard - M6 12 Nm (8.85 lbf ft)
Lower nut fixing engine - chassis - M10 50 Nm (36.88 lbf ft)
Pinion cover - chain guide plate fixing screw - M6 12 Nm (8.85 lbf ft)
Gear pedal fixing screw - M6x1 12 Nm (8.85 lbf ft)
Characteristics MXV 450
CHAR - 14

ENGINE
Name Torque in Nm
Engine oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft)
Engine oil drainage plug on ignition cover - M12x1.5 18 Nm (13.28 lbf ft)
Gearbox oil drainage plug - M12x1.5 18 Nm (13.28 lbf ft)
Oil filter cover - M56x1.5 35 Nm (25.81 lbf ft) - Oil threading and O-ring
Piston fitting hole cover - M30x2 30 Nm (22.13 lbf ft)
Spark plug - M10x1.25 12 Nm (8.85 lbf ft)
Gearbox oil check screw - M6x1 9.8 Nm (7.23 lbf ft)
Oil pressure inlet conical cap - M10x1 18 Nm (13.28 lbf ft)
Water pump rotor - M7x1 12 Nm (8.85 lbf ft)
Head cover screw - M6x1 9.8 Nm (7.23 lbf ft)
Water pump cover screw - M6x1 8.0 Nm (5.90 lbf ft)
Clutch cover screw - M6x1 8.0 Nm (5.90 lbf ft) - Torque first removal 5.5 Nm (4.06 lbf ft)
Right crankcase cover screw - M6x1 9.8 Nm (7.23 lbf ft) - Torque first removal 5.5 Nm (4.06 lbf ft)
Crankcase clamping screw - M6x1 12 Nm (8.85 lbf ft)
Crankcase clamping screw - M7x1 15 Nm (11.06 lbf ft) - Pretorque 12 Nm (8.85 lbf ft)
Ignition cover screw - M6x1 9.8 Nm (7.23 lbf ft) - Torque first removal 5.5 Nm (4.05 lbf ft)
Pick-up fixing screw - M5x0.8 8 Nm (5.90 lbf ft) - Loctite 243
Stator fitting screw - M5x0.8 8 Nm (5.90 lbf ft) - Loctite 243
Screw fixing ignition cover flange - M5x0.8 8 Nm (5.9 lbf ft) - Loctite 243
Chain tensioner slider screw - M6x1 9.8 Nm (7.23 lbf ft) - Loctite 270
Timing chain tensioner fitting screw - M6x1 10 Nm (7.37 lbf ft)
Cable guide ring fixing screw - M6x1 10 Nm (7.37 lbf ft)
Flywheel nut - M14x1 108 Nm (79.66 lbf ft)
Screw fixing crankshaft bearing - M6x1 12 Nm (8.85 lbf ft) - Loctite 270
Secondary shaft bearing fixing screw - M6x1 10 Nm (7.37 lbf ft) - Loctite 270
Main shaft bearing fixing screw - M6x1 10 Nm (7.37 lbf ft) - Loctite 270
Screw fixing the gear selector drum bearing - M5x0.8 8 Nm (5.90 lbf ft) - Loctite 270
Head fitting screw (pre-torque) - M10x1.25 30 Nm (22.13 lbf ft) - Oil screws and washers
Head fixing screw - M10x1.25 55 Nm (40.56 lbf ft)
Timing system gear fixing nut - M12x1 50 Nm (36.88 lbf ft)
Timing compartment closing cover screw - M5x0.8 6 Nm (4.42 lbf ft) - Loctite 243
Main transmission pinion nut - M18x1.25 160 Nm (118.00 lbf ft)
Selector locking plate screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 270
Plate screw for sprocket - M6x1 9.8 Nm (7.23 lbf ft) - Loctite 270
Spring retention plate screw - M6x1 9.8 Nm (7.23 lbf ft) - Loctite 270
Selector shaft grub screw - M10x1.25 25 Nm (18.44 lbf ft) - Loctite 270
Selector shaft grub screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 270
Gear locking pawl rotation screw - M6x1 12 Nm (8.85 lbf ft) - Loctite 243
Selector pin - M18x1.25 22 Nm (16.23 lbf ft) - Loctite 270
APTC Clutch hub fixing nut - M18x1.25 80 Nm (59 lbf ft)
Clutch spring screw - M6x1 12 Nm (8.85 lbf ft)
Pressure relief valve - M14x.5 20 Nm (14.75 lbf ft)
Pressure pump fitting screw - M6x1 9.8 Nm (7.23 lbf ft)
Scavenge pump fitting screw - M6x1 9.8 Nm (7.23 lbf ft)
Head lubrication nozzle - M6x1 2.5 Nm (1.84 lbf ft)
Valve lifter lock screw - M5x0.8 9 Nm (6.64 lbf ft) - Loctite 270
Water joint plate screw - M6x1 9.8 Nm (7.23 lbf ft)
Crankshaft grub screw - M8x1.25 22 Nm (16.23 lbf ft) - Loctite 270
Inertial ring screws - M6x1 13 Nm (9.58 lbf ft) - Loctite 270
Start-up lever grub screw - M8x1.25 10 Nm (7.37 lbf ft) - Loctite 243
Screw fixing start-up shaft extension - M8x1.25 25 Nm (18.44 lbf ft) - Loctite 243
Screw fixing Stepper to Stepper body- self-threading ø5 mm
(0.20 in) 1.5 Nm (1.1 lbf ft)
Screw fixing Stepper to throttle body - 5x0.8 7 Nm (5.16 lbf ft) - Loctite 270
Clamps fixing throttle body sleeves - 4x0.6 4 Nm (2.95 lbf ft)
Screws fixing throttle body sleeves - M6x1 13 Nm (9.58 lbf ft) - Loctite 242
Camshaft gear fixing screw - M16x1 35 Nm (25.82 lbf ft)
Water Temperature Sensor 18 Nm (13.27 lbf ft)
Blow-by bleed joint - 48x1.5 20 Nm (14.75 lbf ft) - Loctite 243
APTC Screw fixing pressure plate - M5x0.8 8 Nm (5.9 lbf ft)
MXV 450 Characteristics
CHAR - 15

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

Recommended products chart
RECOMMENDED PRODUCTS TABLE
Product Description Specifications
AGIP RACING 4T 10W-60 engine oil Use top-branded oils that meet or exceed
the CCMC G-4 API SG. SAE 10W-60
specifications requirements
AGIP GEAR SYNTH SAE 75W-90 Synthetic lubricant for gearboxes and
transmissions. API GL4 - API GL5
AGIP PERMANENT SPEZIAL Coolant Ready mixed biodegradable coolant with
"long life" technology and characteristics
(red). Freezing protection up to -40°C.
Compliant with CUNA 956-16 standard.
AGIP BRAKE 4 Brake fluid 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
AGIP MP GREASE Grease for bearings, joints, couplings
and leverages As an alternative to the recommended product, use top brand grease for roller
bearings with an operating temperature
range of -30°C...+140°C (-22°F...+284°
F), a drop point of 150°C...230°C (302°
F...446°F), high corrosion protection
qualities and good water and rust resist-
ance.
AGIP FORK 7.5W Fork oil SAE 7.5W
CHAIN GREASE Chain spray grease Adhesive, non-drip lubricating grease
spray for chains. Recommended for all
types of chains, including those with O-
ring gaskets. High adhesive strength. A
thin and resistant layer protects chains
against wear, reduces stretching and
keeps them flexible
MXV 450 Characteristics
CHAR - 17

INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS

SPECIAL TOOLS
Stores code Description
853715 Water pump oil seal guide
853716 Water pump oil seal punch
AP8140179 Valve spring compressor
AP8140187 Engine support stand
8140188 Engine support
AP9100838 Tool for valve pressure plate
MXV 450 Special tools
S-TOOLS - 19

Stores code Description
9100839 Flywheel extractor
020685Y Crankshaft pinion locking tool
9100844 Crankshaft locking tool (timing pin)
9100885 Main shaft/ right side - secondary shaft/
left side
9100886 Secondary shaft/right side - Main shaft/
left side
9100887 Punch for right crankcase desmo
9100888 Oil pump oil seal punch
Special tools MXV 450
S-TOOLS - 20