APRILIA MXV 450

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.

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

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