APRILIA SXV 450 UPGRADE BOOK 2008 User manual

APRILIA SXV 450-550
Replica VAN DEN BOSCH
MY 08
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UPGRADE BOOK

2
CONTENTS
SUMMARY TABLE OF TECHNICAL DATA 3
VEHICLE START-UP 4
REMOTE ADJUSTMENT OF THE POSITION OF THE FRONT BRAKE LEVER 5
CHANGING ECU MAPPING 5
ACTIVATION/DEACTIVATION OF THE ELECTRONIC TRASMISSION 6
STARTING DEVICE 6
ASYMMETRIC CHAIN TENSIONER PADS 7
FRONT FORK 8
REAR MONO SHOCK ABSORBER 13
SADDLE SUPPORT CHASSIS 14
STM SLIPPERING CLUTCH 15

3
SUMMARY TABLE OF TECHNICAL DATA
FRONT FORK
Type Marzocchi Shiver 50
Travel 267 mm
Std. adjustment hydraulic brake under compression 20 clicks from all closed
Std. adjustment hydraulic brake under extension 20 clicks from all closed
Steering angle with centred bushings 25°
Steering angle with eccentric bushings 24° - 26°
Fork offset with centred bushings 14 mm
Fork offset with eccentric bushings 11 mm – 17 mm
REAR SHOCK ABSORBER
Type Mono Sachs racing
Travel 120 mm
Std. spring elasticity (K) 6 kgf/mm
Std. adjustment hydraulic brake under compression at high speed 7 clicks from all closed
Std. adjustment of the hydraulic brake under compression at low speed 12 clicks from all closed
Std. adjustment hydraulic brake under extension 15 clicks from all closed
STM CLUTCH
Calibration of primary standard spring SXV VDB 450 (wet race) 120 kg
Calibration of primary supplied spring SXV VDB 450 130 kg
Calibration of secondary standard spring SXV VDB 450 (wet race) 30 kg
Calibration of secondary supplied spring SXV VDB 450 40 kg
Calibration of primary standard spring SXV VDB 550 (wet race) 130 kg
Calibration of primary supplied spring SXV VDB 550 140 kg
Calibration of secondary standard spring SXV VDB 550 (wet race) 30 kg
Calibration of secondary supplied spring SXV VDB 550 40 kg
Wear limit clutch pack 35 mm
FRONT / REAR CHAIN SPROCKETS
Standard pinion SXV VDB 450 z=14
Supplied pinion SXV VDB 450 z=15
Standard sprocket SXV VDB 450 z=45
Supplied sprocket SXV VDB 450 z=44, z=46
Standard pinion SXV VDB 550 z=16
Supplied pinion SXV VDB 550 z=15
Standard sprocket SXV VDB 550 z=46
Supplied sprocket SXV VDB 550 z=45, z=47

4
VEHICLE START-UP
This vehicle, having been designed for exclusive
use in competitions, is equipped with a small and
lightweight battery, sufficient for amperages
needed during warm start-up and for the normal
operation of the engine.
For cold start it is necessary to use the external
battery that comes with as an accessory to the
vehicle.
Remove the saddle.
Disconnect the jack from the regular battery and
connect it to the external battery.
Feed the injection circuit of the vehicle by
connecting the key jack on the handlebar.
Start the engine using the ignition button on the
right side of the handlebar.
With the engine running, disconnect the external
battery and reconnect the installed battery.
To turn off the vehicle just press the off button
on the left side of the handlebar.
WARNING
After use the key jack has to be
disconnected.

5
REMOTE ADJUSTMENT OF THE POSITION OF THE FRONT BRAKE LEVER
The vehicle is prearranged for a remote
adjustment of the distance of the front brake
lever from the handlebar.
Use the adjustment knob on the left handlebar
until the desired distance is obtained.
CHANGING ECU MAPPING
The vehicle offers the possibility of choosing
between two different mappings of the control
unit.
The mapping change can be accomplished while
the vehicle is in motion.
Push the button on the left side of the handlebar
to chose between HARD and SOFT modes.

6
ACTIVATION/DEACTIVATION OF THE ELECTRONIC TRASMISSION
The vehicle is supplied with an electronic
control mechanism for the gear ratio.With the
electronic control mechanism activated, it is
possible to change the ratio upward without the
aid of friction and while keeping the throttle
control open.
Push the button on the right side of the handlebar
to activate or deactivate the electronic control
mechanism:
1 - Device OFF
2 - Device ON
STARTING DEVICE
FITTING
The distance between two components should be:
D = 11 mm
DMAX = 13 mm
USE
The vehicle is set up for locking the fork under
compression as a launch control.
Press the fork all the way.
Press on the locking pin.
Release the fork so that the pin engages on the
slot of the ring mounted on the fork.
Release the pin.
1
2
D

7
ASYMMETRIC CHAIN TENSIONER PADS
The vehicle is provided with two different chain
sprockets.
It is possible to replace the chain sprocket and to
rotate the chain tensioner pads without having to
adjust the slack of the chain again.
Mount the chain tensioner pads in the direction
indicated when installing the sprocket with more
teeth.
Mount the chain tensioner pads in the direction
indicated when installing the sprocket with less
teeth.
WARNING
Changing the direction of the chain
tensioner pads corresponds to 1 tooth
of the sprocket.
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FRONT FORK
ADJUSTMENT OF THE HYDRAULIC BRAKE
In order to adjust the hydraulic brake under
compression operate on the screw shown to the
side.
In order to adjust the hydraulic brake in extension
operate on the screw shown to the side.
DE-AERATION OF THE FRONT FORK
To extract the air from the clutch stem, remove
the dust cap on each one of the fork legs.
With the help of a screwdriver open the bleed
valve until the air inside is completely expelled.

9
ADJUSTMENT OF THE STEERING ANGLE
WARNING
To adjust the steering angle the
eccentric bushings must be first
assembled.
Loosen the headstock nut.
Loosen the screw that closes the upper plate.
By operating on both fork legs, loosen the
tightening screws on the upper plate.
Slightly lift the upper plate, by pulling it out by a
few millimetres from the fork legs.

10
Using a hook spanner, loosen the bearings preload
ring nut.
The ring nut to work on is the upper one,
immediately below the steering plate.
WARNING
At this stage do not work on the ring
nut for adjusting the steering angle,
located immediately under the
bearings preload ring gear.
Loosen the screw that locks the lower eccentric
ring nut.
Loosen the screw that locks the upper eccentric
ring nut.

11
Using a hook spanner, turn the upper eccentric
ring nut by 180°.
WARNING
Accurately line up the notch on the
ring nut with the point where the
tubes of the frame meet (vehicle
axis).
Restore the vehicle following, in reverse, the
procedure just described.
FORK OFFSET ADJUSTMENT
Loosen the headstock nut.
Loosen the screw that closes the upper plate.
Loosen the screw that closes the lower plate.

12
Operating on the square drive nut, turn the
headstock strut by 180°.
Minimum offset reference.
WARNING
Precisely line up the notch on the
eccentric bushing with the reference
on the steering plate.
Maximum offset reference.
WARNING
Precisely line up the notch on the
eccentric bushing with the reference
on the steering plate.

13
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.

14
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)
SADDLE SUPPORT CHASSIS
ADJUSTMENT OF THE SADDLE SUPPORT CHASSIS
HEIGHT
To adjust the saddle support chassis, turn the set
screws on both sides of the vehicle at the same
time.
¼ turn ≈2.5 mm of movement of the rear-most
point of the rear end
The maximum movement is imposed by the limits of
the coupling between the discharge fitting and the
muffler. Do not continue tightening the set screws
when the resistance becomes excessive.
A
B

15
STM SLIPPERING CLUTCH
DISASSEMBLY OF THE CLUTCH FROM THE ENGINE
Remove the six screws that secure the ergal flange.
Remove the ergal flange.
Lock the clutch with the lock wrench (provided)
and remove the nut.
Pull out the clutch unit from the main shaft of the
gear box and continue the disassembly on the
bench.
Remove the central cup.

16
Remove the thrust ring.
Remove the outside spring.
Remove the clutch pressure plate and the complete
pack of disks.
Remove the inside spring.

17
Remove the ring.
Remove the disc drum.
Remove the six steel balls.
WARNING
The steel balls have to be greased
before reassembly.
The two springs can be replaced with springs with a
different elastic constant K to adapt the response
of the clutch to its requirements.