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OFF ROAD
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CONTENTS
CONTENTS
Maintenance operations
Engine
Vehicle presentation
We will talk
about
and do
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Dashboard
Electrical system and Axone
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Cycle parts
Main characteristics
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Vehicle Presentation
Vehicle Presentation
Gallery
Target
SXV-RXV
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SXV
5
RXV
6
4.5 5.5 2V77
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TARGET
Vehicles designed specifically for track or off-road
competition.
They respect the technical characteristics required by
the category rules of the main Supermotard and Enduro
world championships.
They are sold in 25KW reduced power conformation,
Euro2 type approved for use on roads open to the
public.
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Main characteristics
Main characteristics
Cycle parts
Engine
OFF ROAD
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Cycle parts
Frame with aluminium upright and steel tube lattice.
Sachs 48 mm (SXV) Marzocchi 45 mm (Enduro) front
fork with compression and rebound hydraulic damping
adjustment.
Sachs rear shock with spring preload and high speed
compression, low speed compression and rebound
hydraulic damping.
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Cycle parts
Front brake:
SXV: 320mm disk FTE radial caliper RXV: 270mm disk NISSIN radial caliper
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Engine
Head-cylinder group:
77 V twin
4 titanium valves per
cylinder, single overhead
camshaft with
decompressor.
Head covers, clutch,
flywheel in magnesium.
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Engine
Lubrication:
Dry sump forced lubrication, coaxial
pressure and scavenge pump.
Overpressure valve
(engine emptying)
Non-return valve (requires pump
priming)
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Engine
Lubrication diagram 1
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Engine
Lubrication 2
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Engine
Cooling diagram
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4
5
6
1
7
3
3
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Maintenance operations
Maintenance operations
Run-In
Coupons
Special tools
Main operations
OFF ROAD
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Run-In
From 0 to 3 hours of running: keep the vehicle in reduced
power conformation and do not exceed 8000 rpm
From 2 to 15 hours of running: the vehicle can be used in free
conformation (the warranty expires); do not exceed 75% throttle
turn; avoid reaching engine speeds where the rev-limiter cuts
in:
SXV 450: 12500 rpm SXV 550: 12000 rpm
RXV 450: 11500 rpm RXV 550: 11000 rpm
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Coupons
Depending on type of use:
Competition use: Every 15 hours of running
Sport use: Every 30 hours of running
Road use (motorcycle code): Every 3000 km
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Special Tools
In green, the tools already existing for other Aprilia vehicles
code name notes
1
9100838 Valve spring pusher tool
2
8140179 Valve fitting/removal bow Use bow for rotax V990
3
9100839 Flywheel extractor
4
9100943 Piston pin extractor With fittings for 4.5 and 5.5
5
9100841 Engine mount V990 engine mount adapter plate
6 Clutch housing tool Use tool for Minarelli 660 engine
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8140838 Rotor clamping Use tool for Minarelli 660 engine
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9100844 Crankshaft clamping Pin for clamping crankshaft for timing
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9100942 Right crankcase support
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9100840 Crankshaft bush pusher With notch for coupling directon
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9100884 Crankshaft bush extractor
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9100885 Gearbox main/right- transmission/left Inside right and left half casing (bearings on main shaft right and transmission shaft left)
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9100886 Gearbox transmission/right-main left Inside right and left half casing (bearings on main shaft left and transmission shaft right)
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9100887 Right casing desmodrom pusher On right inside casing
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9100888 Oil pump oil seal pusher Inside right casing
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9100889 Timing transmission crankshaft pusher On outside right casing
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9100890 Crankshaft oil seal pusher On outside right casing
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Special Tools
In green, the tools already existing for other Aprilia vehicles
codice nome note
18 9100938 Left casing support
With support references (3) and (2) and transmission shaft bearing support adjustable in
h=5 mm for motard vers. (+ high for wide wheel) and enduro
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9100892 Desmo. left casing + wheel hub On left inside casing
20
9100893 Left timing transmission pusher On left outside casing
21
9100894 Transmission shaft oil seal pusher On left outside casing, approx. 0.5 with respect to hole area
22 9100895 Coolant pump oil seal pusher
On right clutch casing for flush fitting; there are 2 oil seals (coolant and oil), one on the
pump cover and the other on the clutch casing (press from outside)
23
9100897 Cylinder barrel extractor
24 9100843 Crankshaft pinion clamping
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9100898 Swing-arm cage pusher
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9100900 Swing-arm linkage cage pusher on one side for flush assembly; on the other for centering (where there is single bearing)
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9100903 Marzocchi d.45 fork oil seal
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9100904 Sachs d.48 fork oil seal
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8127819 Walbro cable for Axone
8140595 Axone 230V50Hz battery charger For countries with 220V, 50 Hz power suply
8202311 Axone 110V60Hz battery charger For countries with 110V, 60 Hz power supply
8104520 Axone/PC connection cable
Optional cable for upgrading Axone via PC. The kit for online upgrading is supplied
together with the Axone
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Main operations
Engine oil change
Empty the entire system
(via the overpressure valve)
Fill the tank with 800cc of oil; prime the circuit, filling the
filter; run the engine then top-up to level.
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Main operations
Air filter change
Make sure the tank holding cable does not touch the battery
+ pole.
Ensure the correct position of the cable glands and tightening
of the filter box fins.
Pay attention to the position of the fuel/pump union (it could
break if pressed against the filter box cover).
In case of a fall, oil will enter the airbox (from the engine
breather pipe): replace the filter and clean the airbox.
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Main operations
Minimum adjustment
After bringing the engine to working temperature, the
minimum must be set at 1900 +/- 100 rpm by means of the
knob located on the airbox, corresponding to about 5 +/- 1
throttle opening.
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Cylinder balancing
Disconnect the tube connecting the two intake ducts and
connect a differential pressure gauge (use tubes of equal
section and length).
Main operations
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Main operations
If the vacuums are not balanced, loosen the unmatching
screw on the front cylinder body and adjust the position of the
rear cylinder throttle until obtaining correct balance.
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Main operations
Throttle cable adjustment
Adjust the throttle cables with every coupon service, and
after every maintenance operation (pay attention to the
return).
Test opening and
return with the
handlebar turned all the
way to the right. In case
of doubt, check the
cable paths.
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Engine
Engine
Cylinder
head
Clutch
Oil circuit
Gearbox
Crankcase
OFF ROAD
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Cylinder head
Valve clearance adjustment
To adjust the valve clearances
(0.10 in 0.20 ex) insert the
correct shim on the valve stem.
Titanium valves: not grindable.
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Cylinder head
Remove the chain
tensioners before
removing the camshaft
gears
Refit the chain
tensioners before doing
the timing
Timing system
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Cylinder head
The camshafts are
different: the rear
cylinder has aligned
cams whereas the front
cylinder has the exhaust
cam opposed
The screw of the front
camshaft gear has a left
thread
Cams
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Cylinder head
When refitting, apply
Loctite 510 under the
gasket, at the couplings
of the two casings.
The head has 5
connection screws: the
6mm side screw must
be removed first and
tightened last
Cylinder head
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Cylinder head
To clamp the crankshaft,
remove the screw in the
photo and use the pin
code 9100844.
CAUTION: remember to
tighten the screw before
closing the clutch cover.
Timing
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Cylinder head
Timing
To align the camshafts,
use the special tool
code 0000000
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Clutch
Clutch Plates
The packed plates are
all the same, and all
must be aligned except
the outside plate which
must be misaligned.
There five 2mm and
two 1.5mm steel plates.
The two thinnest plates
go first and last.
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Oil circuit
The oil pump is of the coaxial
two-stage trochoidal type. The
external rotor (pressure) has a
longer shaft coupling pin. The
inside pump (scavenge) has
the shorter pin.
The head oil delivery pipes are
in aluminium, in the section
inside the flywheel cover: they
must not be forced.
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Crankcase opening
CAUTION: the nut of the
primary has a left thread.
There is shim under the
gear of the primary: the
steel part must be towards
the crankcase.
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Crankcase opening
There are 16 screws
joining the two casings:
14 on the flywheel side,
1 on the clutch side and
1 is the gearbox oil plug.
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Gearbox
Pay attention to the sliding
bushings on the fork
control pin (the
desmodromic drum is in
aluminium)
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Cycle
Cycle
parts
parts
Fork
Rear shock
Airbox
Stand
Expansion tank
Engine removal
OFF ROAD
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Fork
1 notch Level with cap
Leg projection
12 clicks 10 clicks
Rebound damping
12 clicks 10 clicks
Compression
damping
SAE 7.5W SAE 10W
Oil type
100 mm of air 125 mm of air
Oil quantity
Marzocchi 45 mm Sachs 48 mm
Type
RXV SXV
Adjustments are always understood as from the "fully closed" position
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Rear shock
In addition to the normal
adjustments, there is a knob
for setting high speed
compression hydraulic
damping (6).
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Rear shock
Fully open Fully open
High speed compression
damping
Fully open 16 clicks
Low speed compression
damping
23 clicks 13 clicks
Rebound damping
473 mm 245mm
Preloaded spring length
RXV SXV
Adjustments are always understood as from the "fully closed" position
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Airbox
Operate with maximum
cleanliness when the airbox
is open.
When refitting, ensure
correct positioning of the air
intakes.
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Stand
The side stand is of the automatic
return type (without safety sensor).
For sports use, fix the safety
elastic behind the left side panel.
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Expansion tank
The tube connecting
the radiators and
expansion tank must be
positioned on the special
seats to avoid
squashing.
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Engine mounts
On the bottom engine
coupling pin there are
several shims that differ
between left and right
and from vehicle to
vehicle. Check the
number and position
during removal.
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Dashboard
Dashboard
Dashboard and scroll button
LCD
Dashboard setting
OFF ROAD
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The dashboard and scroll button
1. SCROLL button
2. Neutral light, green
3. Engine oil pressure warning light,
red
4. Engine management indicator light.
5. Multifunction digital display.
6. Fuel reserve warning light, orange
7. High beam indicator light, blue
8. Turn indicators light, green
9. Overrev warning light
1
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LCD
DASHBOARD FUNCTIONS
1. SPEED
2. ODO
3. TRP
4. AVS
5. LAP (in format hh:mm:ss or
mm:ss:1/10ss)
6. CLK
7. TACHOMETER (graphic or numerical)
8. MAX SPEED
9. Indicates low battery
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Dashboard setting
Overrev setting:
On the TACHOMETER screen, press MODE and SCROLL at the same
until it shows - - - -. Release and then set the required value by
repeatedly pressing the SCROLL button.
Setting Km/h Mph
Keep the SCROLL button pressed, turn the key and wait until the
message WS is displayed, then release the SCROLL button.
Press the SCROLL button using short presses to go to the various
functions; press the SCROLL button using long presses to return to
the modified page.
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Fuel injection
Fuel injection

Electrical system
Electrical system
Sensors - Actuators
Fuel injection
Axone
OFF ROAD
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Sensors and actuators
BASE
Crankshaft position sensor
Throttle position sensor
CORRECTION
Intake air temperature sensor
Coolant temperature sensor
Atmospheric pressure sensor (inside
the control unit)
OTHER SENSORS
Tip over sensor
Speed sensor
Gear sensor
Ignition coils
Fuel injectors
Fuel injection system relay
High beam/low beam relay (activation for
value above 800 rpm)
Cooling fan relay
ECU
BATTERY
SENSORS ACTUATORS
FUEL
INJECTION
IGNITION
MAP alpha/n
RX-TX lines for communication with Axone
Other
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Crankshaft position sensor
Crankshaft position sensor resistance:
500 +/- 20 % at 20C
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Throttle position sensor
Non-slotted sensor: serves learning of
throttle position by means of Axone
(see detail in Axone chapter)
Maximum resistance of throttle position
sensor:
From 4.0 to 6.0 k at 20 C
1 2 3
1 blue
ground
2 Grey
+ 5 V (signal)
3 orange
+ 5V
feed
Values with connector
disconnected
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Intake air temperature sensor
Resistance of intake air temperature sensor,
positioned inside airbox:
6 +/- 0.6 k at 0 C
0.29 - 0.39 k at 80 C
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Coolant temperature sensor
Resistance of coolant temperature
sensor:
2.45 k +/- 0.14 at 20 C
0.32 k at 80 C
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Tip over sensor
It is positioned inside the filter box
The 3 connection cables are ground, control unit 5V feed, signal: normal pos.
0.4 1.4 V, reversed pos. (65 +/- 10 from the vertical) 3.7 4.4 V.
If disconnected, unlike mechanical sensors it does NOT allow starting of the
vehicle.
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Gear sensor
The control unit detects the gear engaged, thanks to the gear sensor
Sensor fed at approx. 4.5 V by the control unit (with connector disconnected)
3.4 2700 +/-27 R5
2.8 1500 +/-15 R4
2.3 1000 +/-10 R3
1.9 680 +/- 6.8 R2
1.0 270 +/-2.7 R1
1.5 470 +/-4.7 Rn
voltage (V) resist (ohm) GEAR
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ECU
A single type of control unit for all
vehicles
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ECU connections
Lights relay on the left of control unit; fuel injection relay on the right
PIN NAME PIN NAME
1 coil 1 ground 18 for remapping control unit
2 fuel injection ground 19 gear sensor
3 lambda probe signal 20 air temperature signal
4 engine kill (ground) 21 ground
5 digital line for Axone 22 tip over sensor signal
6 pick up - 23 speed sensor signal
7 ground 24 -
8 supply voltage 25 output speed signal
9 supply voltage 26 fuel injection relay
10 coil 2 ground 27 -
11 lambda probe feed 28 lights relay
12 throttle signal 29 -
13 engine temperature signal 30 throttle and tip over sensor feed
14 digital line for Axone 31 fuel injector 1 ground
15 pick up + 32 fuel injector 2 ground
16 tachometer signal for dashboard 33 fan ground
17 EFI indicator light 34 fuel pump ground
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Fuel pump
The fuel circuit pressure regulator is positioned inside the
pump, for maintaining a pressure of approx. 3.6 bar.
Fuel pump resistance: approx. 1.5 (red or black cables)
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Fuel injector
Fuel injector resistance
12 a 20 C
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Ignition: coils
1 Primary coil resistance 3.5 +/- 15% at 20 C
2 Secondary coil resistance 20.1 k +/- 15% at 20 C
The spark plug cap has a resistance of approx. 5 k (+/-25%) at 20C
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Ignition: spark plug
MANUFACTURER: NGK
TYPE: CR8EB
CAP RESISTANCE: 5 K
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Starter motor relay
Relay induction coil resistance: 4.4 +/- 10%at 20 C
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Vehicle speed sensor
Hall effect sensor.
The above voltages are read with connector disconnected.
With connector connected the signal decreases by steps to 0.5 V near the screws.
The distance between the sensor and the bolt surface must be: 1.5 +0.7/-0.9 mm
Ground
blue
+12 V
red-brown
Signal +5V
Yellow-
brown
clip
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Axone: version 5.0.5
As of version 5.0.5, software is available for FUEL
INJECTION self-diagnosis (dialogue with control unit).
REPROGRAMMING (mapping upgrading) with
mapping upgrades and specific mapping according to
vehicle use will be available from version 5.0.6 and
subsequent.
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Axone: connection cable
With this control unit, instead of the usual cable
forself-diagnosis, it is necessary to use the
Walbro cable for Axone
code 8127819 (code Texa AP014)
It consists of a cable
and a connection
to the clips
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Axone: connection cable
They must be used as follows:
both (cable + connection) for FUEL INJECTION
only the cable for REPROGRAMMING
Axone
Motor-
cycle
Axone
motorcycle
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Axone: connector position
The connector is positioned on the left side at the
front area of the vehicle.
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Axone: ISO screen
The screen shows:
frame number
engine number
control unit initialization date
Also the code of the mapping in the control unit is
also shown.
When loaded in the control unit, the mappings, as files
and identification, will be with 5 numbers of type:
14001.
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Axone: ISO screen
The first number identifies vehicle type
1. for SXV
2. for RXV
The second number identifies displacement
4. for 450
5. for 550
From the third to fifth numbers
Mapping identification progressive number
Therefore, for example, the mapping 14001 will indicate:
SXV 450 map 001
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Axone: engine parameters screen
In addition to the classic parameters (engine speed, intake air
temperature, fuel injection times) the screen also gives the
settings of parameters modifiable from the adjustable
parameters screen that will be seen later and the parameter
Running time expressed in hhmm (hours and minutes):
this is the engine running time (rpm > 0)
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Axone: device status screen
The screen only shows the status of the tip over
sensor:
if in correct position it indicates Normal
if tipped over it indicates Tip over
if disconnected it indicates ?
In the second and third cases the vehicle cannot be
started
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Adistinction between current and stored errors is not
provided for: Errorsare always indicated by the
message MEM.
To know if an error is present or stored check the
fuel injection system malfunction LED on the
dashboard; if lit, the error is present ; if off, the error is
stored.
Also, some errors (coils, fuel injectors, throttle,) are
read only when the engine is switched on.
Axone: errors screen
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Throttle sensor
Intake air temperature sensor
Coolant temperature sensor
Atmospheric pressure sensor
Main fuel injection relay (feed to fuel pump, injectors,
coils and fans)
Lights relay
Battery voltage
Fuel Injectors
Coils
Axone: errors screen
Self-diagnosis of:
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Axone: errors screen
Errors are not detected by the control unit if the
following circuits and respective devices have
malfunctions:
Vehicle speed (signal from sensor)
Tip over sensor (only the sensor status is shown on
the Device status screen)
Fuel pump (activation by control unit)
Fan (activation by control unit)
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Axone: device activation screen
The screen only shows the cancel errors function
which cancels errors from the control unit memory.
The vehicle's devices cannot be activated.
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Axone: adjustable parameters screen
Minimum throttle position self-learning
Maximum throttle position self-learning
Unlike the usual fuel injection systems, self-learning
must be carried out with the twist-grip released (at
minimum) and with it fully turned (maximum opening)
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Axone: adjustable parameters screen
CO minimum adjustment
Fuel injection time correction
Fuel injection times can be modified in the minimum
range and for any engine speed value
(max. adjustment +/- 5%)
The standard value for both parameters is: 1.00
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Axone: adjustable parameters screen
Wheel circumference
Wheel signals
The above parameters can be set for correct
indication of vehicle speed.
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Axone: adjustable parameters screen
In case of control unit drawn from spare parts warehouse, the
following must be carried out:
Throttle self-learning operation (min + max)
Setting of correct wheel circumference and no. of screws for
circumference
Entering of vehicle mapping
The frame, engine number and activation date can no longer
be entered.