APRILIA RXV 450 UPGRADE BOOK User manual

APRILIA RXV 450
Replica MERRIMAN
MY 08
E
NG
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V
ER
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I
ON
UPGRADE BOOK

2
CONTENTS
SPECIFICATION OVERVIEW TABLE 3
VEHICLE START-UP 4
CHANGING ECU MAPPING 5
HEADLIGHT 5
FOOTPEG GUARDS 6
ENGINE GUARD 6
REAR MONO SHOCK ABSORBER 7
SLIPPER CLUTCH 9

3
SPECIFICATION OVERVIEW TABLE
FRONT FORK
Type Marzocchi Shiver 50
Travel 300 mm
Standard setting of compression damping 15 clicks out from fully in
Standard setting of rebound damping 15 clicks out from fully in
Steering angle 27°
Fork offset 20 mm
REAR SHOCK ABSORBER
Type Sachs racing mono-shock
Travel 139 mm
Spring rate (K) of standard spring 5.2 kgf/mm
Standard setting of high-speed compression damping 9 clicks out from fully in
Standard setting of low-speed compression damping 14 clicks out from fully in
Standard setting of rebound damping 15 clicks out from fully in
APTC CLUTCH
Assembled w/spring preload adjusting washers as standard /
3 spring preload washers supplied as standard thickness 1 mm
3 spring preload washers supplied as standard thickness 1,5 mm
3 washers to reduce spring preload supplied as standard thickness 1 mm
Clutch plate pack wear limit 34.20 mm
FRONT / REAR CHAIN SPROCKETS
Standard front chain sprocket RXV Merriman 450 z=14
Standard rear chain sprocket RXV Merriman 450 z=50

4
VEHICLE START-UP
Switch on the electric system using the ON/OFF
button on the left side of the vehicle, before the
radiator.
Start the engine using the starter button on the
right side of the handlebar.
To stop the engine, press the stop button on the
left side of the handlebar.

5
CHANGING ECU MAPPING
When you replace the standard exhaust with
the supplied exhaust and update ECU mappings,
you may choose between two different ECU
mappings.
Mappings may be changed while running.
Operate the button on the left side of the
handlebar to choose between the HARD and SOFT
mode.
HEADLIGHT
SWITCHING ON THE HEADLIGHT
Only the low beam is available.
Operate the switch on the right side of the trim
frame.
BEAM SETTING
Turn the adjusting screw under the headlight.

6
FOOTPEG GUARDS
This vehicle is equipped with metal guards under
the rider footpegs.
Their purpose is to keep out any debris which may
prevent the footpegs from folding out in the event
of accidental closing.
To install/remove the guards, bend their ends.
ENGINE GUARD
ENGINE GUARD REMOVAL
Loosen and remove the two screws.
Unscrew the screw 1.
To remove the bracket, unscrew nut 2 from both
sides.
1
2

7
REAR MONO SHOCK ABSORBER
DAMPING ADJUSTMENT
To set compression damping, turn the golden
screw inside the light blue knob.
To set the kick-in threshold for the bypass valve
(high-speed compression damping), turn the light
blue knob.
To set rebound damping, turn the indicated
screw.
WARNING
Do not force the screws beyond their
end stops. Overtightening may
damage the hydraulic sys-tem
(NEGATIVE) SPRING PRELOAD ADJUSTMENT
Loosen the set screw of the spring preload
adjusting ring nut.
Use the supplied adjusting pin to turn the ring nut
until achieving the desired spring preload.
When finished, tighten the set screw.

8
RIDE HEIGHT ADJUSTMENT
There are three ride height settings available.
Ride height is adjusted by changing or rotating
the bush shown in the picture into the desired
position.
There are two bushes available:
A ÆMean height bush
B ÆEccentric bush for maximum or minimum
height (de-pending on mounting position)
A
B

9
SLIPPER CLUTCH
WARNINGA
SPECIAL TOOL IS REQUIRED TO REFIT THE CLUTCH. TO BUILD YOUR OWN
TOOL, SEE TECHNICAL DRAWINGS AT WWW.SERVICEAPRILIA.COM (OFF-ROAD
SECTION).
REMOVING THE CLUTCH FROM THE ENGINE
Remove the engine guard.
Remove the rear brake lever.
Remove the clutch casing.
Install the three service sleeves.
Remove the three screws complete with springs.
WARNING
On refitting, tighten the screws to 8
Nm.

10
Remove the pressure plate.
Make sure to collect the washer located on the
inside of the pressure plate.
Remove the stud (1).
Bend the tab of the safety washer.
Unscrew and remove the nut (2).
Withdraw the clutch plate pack.
WARNING
Use the appropriate special tool for
removal and reassembly procedures.
WARNING
Tighten the nut to 85 Nm.
CLUTCH INSTALLATION
One of the clutch plates has a smaller friction
surface than the other plates.
This plate must be mated to shim and Belleville
washer, and goes in first when installing the
plates on the mobile hub.
1
2

11
Fit shim and Belleville washer with the concave
side facing up to the mobile hub.
Place the mobile hub into the clutch housing.
This will facilitate plate installation and
positioning.
Insert the clutch plates; install the plate with the
smaller friction surface first.
Position the three springs into their seats in the
fixed hub.

12
Remove the mobile hub complete with plates
from the housing.
Ensure the plates do not rotate relative to one
another.
Turn over the mobile hub complete with plates so
as to bring mark 1 in view.
Insert the mobile hub complete with plates into
the fixed hub so as to line up mark 1 with mark 2.
Ensure that the springs are in the correct position
between the two hubs.
The springs have their seats.
Position and tighten the service studs making sure
the plain plates do not slip off the mobile hub.
Do not tighten yet so you will be able to easily
turn the plates and facilitate correct positioning
into the housing.
Insert the hubs complete with plates into the
housing, rotating the last plate by one position.
This will reduce clutch noise.
2
1

13
AVAILABLE ADJUSTMENTS
Clutch stiffness can be adjusted by modifying
spring preload. Spring preload may be changed by
adding one washer for each spring. The kit
supplied with the vehicle includes three types of
washers:
A – n.3 1.5-mm washers to add preload
B – n.3 1-mm washers to add preload
C – n.3 washers to decrease preload
WARNING
Install only one washer for each
spring.
WASHER INSTALLATION TO INCREASE PRELOAD
(fit between Belleville washer and spring)
WASHER INSTALLATION TO DECREASE PRELOAD
A
B
C