RXV Rights & Wrongs

[RXV_Poor]

Things I forgot Part II:

If you want some pic’s of things I’ll post. Just ask for what you want.

Some Things I Did/Do:

Rights:
Oil Change:
• Keep a small supply of oil filters, crush washers, oil cap o-rings, and polished flow control valves.
• I also suggest going to a thrift store and buying a small plastic container with separators in it to store all of your oil change stuff. It makes things a lot easier.
• Proper measuring cup/ratio right. Put the right amount of oil in and ignore the useless oil sight tube.

Rear Brake Lever: I used a Pro Moto Billet brake saver on my rear brake.
• I removed the brake lever and ground off the rivet that holds the pedal head/pad on.
• Next drill and tap the hole to thread/bolt size that suits you. I used a low height flat head bolt that was long enough to put a lock nut on the inside.
• Measure the length of the brake saver (With the pedal down.) and run the cable to the inside of the skid plate (I have the Alu Mecca.).
• I drilled and tapped a hole in the skid plate at my mark. I used an Allen cap/machine bolt with a nut with the threads facing the motor. I placed the other end of the cable on the bolt then used a second nut and lock washer to secure it in place.
Mecca Radiator Guards: The install is a pain in the @$$. ¼ drive sockets with wobblies help a bunch.
• Leave everything loose.
• The top inside bolts (Next to the oil tank.) flip around so the head faces the oil tank. I used a thin flat head bolt here. It makes it harder for the bolt to puncture the oil tank (Remember you will be hauling @$$.)
• Then snug everything from the inside out.
• Tighten the 10mm head bolt that is on outside plates (It attaches to the frame.) and tighten from the outside in.
• Loosen the bolts that you need to put the radiator shrouds on and go ride.

Wrongs:
Oil Change:
• Over tightening the oil filter cover will cause it to leak. Use a torque wrench and safety wire.
• Not polishing/replacing a scarred flow control valve can lead to improper oiling in the motor.
• Don’t over use the crush gaskets. Come On Man and I’ve done this and it was stupid.
• Not checking the o-ring on the oil filter cover. You have to lube it so you might as well inspect it.
• Not measuring your oil and putting the wrong oil in the wrong hole. Many have done this so don’t feel bad if you do. Drain it and refill, it’s cheaper that way.

[RXV_Poor]

I copied this oil change procedure to a word doc and saved it.

Proper Oil Change Procedure
Gearbox Oil
1. Measure out 525cc of fresh gear oil.
2. Ensure bike is upright on a level surface.
3. Drain the gearbox and tighten drain plug when done.
4. Refill (oil should be just visible through peep hole).
Engine Oil
1. Measure out 1250cc of fresh engine oil.
2. Ensure bike is upright on a level surface.
3. Drain both the oil reservoir and engine sump and tighten drain plugs when done.
4. There is a small amount of oil above the Flow Control Valve (FCV) that you may want to drain as well, but it's less important than the other two drain locations. The FCV screw is 19mm, located on the bottom of the engine in front of the brake pedal. You'll see allen two set screws above it (don't touch those; they're an artifact of the engine manufacturing process). Above the 19mm screw, there is a spring and above that finally the FCV piston. The piston is threaded on the bottom, so if it doesn't come out by itself, you can stick the spring up there (or an allen key or something) and pull it down. After the oil has finished draining, replace the assembly (the spring fits inside the piston and the screw) and tighten.
5. Lay bike on its side, oil filter cavity up.
6. Remove oil filter cover, filter and spring.
7. Pour 50-100cc oil into the oil filter cavity.
8. Insert oil filter, including the spring, and replace cover.
9. Set bike upright.
10. Refill with the remainder of the 1250cc of oil.
11. Start bike and allow it to completely warm.
12. With the bike still running, ensure oil level in the sight tube is just above the min mark (5mm); add or drain oil from reservoir as necessary.
Note: When you have the oil filter out, you may find it convenient to bend the end of the oil filter spring so it sticks inside the filter without falling out.
Note #2: If you removed the FCV piston, while it's out you may want to check it for scoring, an indicator that it may be sticking. People have had success buffing it to round the edges a bit.

[RXV_Poor]

I copied these common torque specs to a word doc and saved it.

MAINTENANCE
3 - 28
SXV / RXV 450 - 550
3.1.12. TIGHTENING TORQUE SETTINGS
TIGHTENING
TORQUE
DESCRIPTION SCREW / SETTINGS
NUT
Nm
NOTES
HANDLEBAR AND CONTROLS
Screw securing clutch control to handlebar M6 10
Throttle control screw M6 4
Ignition switch screw M8 24
FOOTRESTS
Footrest support bracket screw M12 55 loctite 243
Footrest support bracket screw M8 25 loctite 243
CHASSIS
Screw securing linkage to mudguard at front end M6 12
Screw securing linkage to mudguard at rear end M6 12
Screw securing mudguard to bottom yoke M6 12
Conveyors screw M6 12
Side body panels screw M6 12
Front screw securing tail end to subframe M6 12
Central nut securing tail end – mudguard – subframe M6 12
Rear screw securing tail end to subframe M6 12
Screw securing tail end to mudguard M6 12
Top screw securing under-tail end to number plate
holder M5 7
Bottom screw securing under-tail end to number plate
holder M5 7
Screw securing under-tail end – mudguard – starter
contactor ext. M6 12
Shock absorber guard screw M5 6
Screw securing headlight fairing to instrument support M5 6
Instrument support screw M5 6
Under-tail end lower screw M6 12
LIGHTS AND INSTRUMENT PANEL
Tail light screw 3.9 2
Turn indicators nut M8 6
Digital instrument nut M5 6
Headlight screw M6 6
TANKS
Screw securing plate to fuel tank M6 12
Screw securing fuel tank to frame M6 12
Screw securing pump body to fuel tank M6 10
Oil tank nut M6 5
FRAME
Subframe screw M10 49
Upper chain roller screw M8 22
Lower slider rear screw M5 4.4
Lower slider front screw M5 4.4
STAND
Stand plate screw M8 22 loctite 243
Side stand nut M10 34 loctite 243
MAINTENANCE
3 - 29
SXV / RXV 450 - 550
TIGHTENING
TORQUE
DESCRIPTION SCREW SETTINGS
/ NUT
Nm
NOTES
EXHAUST SYSTEM
Screw securing silencer to subframe M8 22
Exhaust pipes nut M6 12
Screw securing tubes to head M6 12
Screw securing brake to handlebar M6 10
COOLING SYSTEM
Radiators upper screw M6 5
Radiators lower screw M6 12
FRONT BRAKE
Front brake calliper screw - RXV 450/550 M8 25
Front brake calliper screw - SXV 450/550 M10 50
REAR BRAKE
Rear brake master cylinder screw M6 10
Brake pedal screw M8 25 loctite 243
FRONT WHEEL
Wheel shaft cap M22 60
REAR WHEEL
Wheel shaft nut M25 127
FRONT SUSPENSION
Steering head screw M8 24
Bottom yoke screw M8 22
Wheel shaft pinch bolt - RXV 450/550 M6 10
Wheel shaft pinch bolt - SXV 450/550 M8 22
Handlebar upper clamps screw M8 24
Steering shaft nut M26 108
Steering shaft ring nut M30 7
Handlebar lower clamp nut M10 32
Leg guard screw M6 12
REAR SUSPENSION
Nut securing frame to linkage M12 80
Nut securing linkage to rocker M12 80
Nut securing rocker to swinging arm M12 80
Shock absorber nut M10 52
SWINGING ARM
Chain guide nut M6 12
Nut securing swinging arm shaft M14 100
Chain stretcher adjuster nut M8 26
Screw securing chain slider and tube guides to rear brake 4.8 4.4
Rear chain guard screw 4.8 4.4
Chain guide screw M6 12
MAINTENANCE
3 - 30
SXV / RXV 450 - 550
TIGHTENING
TORQUE
DESCRIPTION SCREW / SETTINGS
NUT
Nm
NOTES
ENGINE
Nut securing engine to frame M10 54
Screw securing throttle body to head M6 12 loctite 243
Screw securing control unit to plate M4 4.4 loctite 243
Screw securing voltage regulator and control unit to
frame M6 12
Coil screw M6 12
Screw securing sprocket cover and chain guide plate M6 12
Engine oil drain cap M12x1.5 18
Gearbox fluid drain cap M10X1.5 18
Oil filter cover M56x1.5 25
Piston mounting hole plug M30x2 30
Spark plug M10X1.25 12
Gearbox fluid check screw M6x1 9.8
Water pump impeller M7x1 12
Head cover screw M6x1 9.8
Water pump cover screw M6x1 9.8
Clutch cover screw M6x1 9.8
Right casing cover screw M6x1 9.8
Casing jointing bolt M6x1 13
Ignition cover screw M6x1 9.8
Pick-up screw M5x0.8 8 loctite 270
Stator fixing screw M5x0.8 8 loctite 270
Chain stretcher sliding shoe screw M6x1 9.8 loctite 270
Timing chain stretcher screw M6x1 10
Cable guide ring screw M6x1 10
Oil lines mounting plate screw M6x1 9.8 loctite 270
Blow-by breather union M12x1 18 Use sealant
Flywheel nut M14x1 98
Starter motor screw M6x1 9.8
Chain guide plate screw M6x1 12
Screw securing primary shaft bearing M6x1 12 loctite 270
Screw securing lay shaft bearing M6x1 12 loctite 270
Desmo bearing screw M5x0.8 8 loctite 270
Gear indicator screw M5x0.8 6 loctite 270
Gear change pedal screw M6x1 12
Head bolt (pre-torque) M10X1.25 30 Smear screws and
washers with oil
Head bolt M10X1.25 50
Head bolt M6x1 12
Timing gear nut M12x1 50
Timing compartment cover screw M5x0.8 6 loctite 243
Primary sprocket nut M18x1.25 160
Gear selector stop plate screw M6x1 12 loctite 270
Oil collector plate screw M6x1 12 loctite 270
Gear selector shaft stop screw M10X1.25 25 loctite 270
Gear ratchet rotation screw M6x1 12 loctite 243
Selector shaft M8x1.25 22 loctite 270
Clutch hub nut M18x1.25 75
Clutch spring screw M6x1 12
Pressure reducing valve M14x1.5 20
Feed pump retaining screw M6x1 9.8
Scavenge pump retaining screw M6x1 9.8
Head lubricating nozzle M7x1 2.5
Valve lift block screw M5x0.8 9 loctite 270
Water union plate screw M5x0.8 9
MAINTENANCE
3 - 31
SXV / RXV 450 - 550
TIGHTENING
TORQUE
DESCRIPTION SCREW / SETTINGS
NUT
Nm
NOTES
Crankshaft stop screw M8x1.25 22 loctite 270
Freewheel outer ring screws M6x1 13 loctite 270
Throttle body screws M6x1 13
Camshaft gear retaining screw M16x1 35
ELECTRICAL COMPONENTS
Screw securing solenoid starter and fuse holder M5 7 loctite 243
Frame ground retaining screw M6 12
Solenoid starter cables screw M6 12
Horn screw M8 22

[RXV_Poor]

Originally Posted by G.T

HI RXV poor

Great information, it is about time we had an RXV thread.

Attached is a pic of the RXV 450 I have been working on, intended for Rallye use.

Cheers

I've been following your build. I think it's a great idea and I really want to see it succeed. If I can help let me know even if it's a what not to do type of thing. No sense in both of us waisting time and $.

Are you going to try to address the oil volume issue? If so how?

[LJRockstar]

Learn to fill it up with gas immediately after the low fuel light comes on. Failure means you're going to be walking.

X2!!!!!!!!!!!!!!!!!

a side note related to this.... The old 2 stroke gas that you buddy's Uncle Bob had in his shed will kill your plugs faster than a rag sucked into your intake.

Who makes that tank? Or at least, where can I find some more information about it?

[G.T]

G'day LJ

Here is the link to the Aprilia build you should find answers to your questions there.


http://www.advrider.com/forums/showthread.php?t=419251

RXVpoor

Thanks for the offer to help, I have been reading the info you have been posting with great interest.

I have increased the oil capacity (marginally)with the use of an external oil cooler.

I have also been chatting with FORZA about do and don'ts.

The first really test (race) for the bike is over the Easter weekend April 7,8,9, . looking forward to it.

My brother should be posting a few more photo's with the new exhaust this week.

Cheers

[kimzx1000r]

Yeah RXV has become part of the forum. Thanks Poor! On the same page with almost all items!

[mtothef]

damn, poor, this weather making you as stir crazy as it is me?

kinda trippy how we were running about the same time on similar bikes, learning exactly the same things about them, on equidistant sides of highway 80, huh?

to reinforce everything rxv_poor has said so far, i've had a close to bone stock 07 550 bought new in november 06 (has it really been that long? damn...) that is only used on dirt, and can only echo much of what he says:

meca radiator guards and skid plates
14t countershaft sprocket
renthal bars
acerbis guards
dunlop 739 desert AT rear rubber
G2 throttle cam
5.6 rear spring, .50 fronts

ride, ride, ride.

make sure the ignition stator bolts are tight when new
keep the battery charged
keep some spare plugs (they don't have to be iridium)
learn the oil change drill and do it often
keep an eye on throttle cable freeplay and idle speed
keep an eye on the header bolts (and yes, the flanges are made of butter)
check wiring routing - some people report problems around the head tube, on my bike it was the fuel wiring under the tank that was rubbed through

ride some more!

[RXV_Poor]

Originally Posted by mtothef

damn, poor, this weather making you as stir crazy as it is me?

kinda trippy how we were running about the same time on similar bikes, learning exactly the same things about them, on equidistant sides of highway 80, huh?

to reinforce everything rxv_poor has said so far, i've had a close to bone stock 07 550 bought new in november 06 (has it really been that long? damn...) that is only used on dirt, and can only echo much of what he says:

meca radiator guards and skid plates
14t countershaft sprocket
renthal bars
acerbis guards
dunlop 739 desert AT rear rubber
G2 throttle cam
5.6 rear spring, .50 fronts

ride, ride, ride.

make sure the ignition stator bolts are tight when new
keep the battery charged
keep some spare plugs (they don't have to be iridium)
learn the oil change drill and do it often
keep an eye on throttle cable freeplay and idle speed
keep an eye on the header bolts (and yes, the flanges are made of butter)
check wiring routing - some people report problems around the head tube, on my bike it was the fuel wiring under the tank that was rubbed through

ride some more!

Nice to see you still lurk around.

Yeah it's been that long. At the end of summer either I'm gonna have to go your way or you're gonna have to come mine. I'm riding to AK this summer and I'm healing up so I'm off the bike for a while.

I'm getting a group together to do the Trans America Trail in 2011 from Colorado to Oregon. If you or anyone else is up for it you're more than welcome. 1 catch though, there is a 200 mile stretch with no gas. So I'll either doing a rally kit on my RXV 550 or a rally kit on my KTM 525XC (If I can get them plated out of state.). We are thinking 2 weeks for the trip. It should be a blast.

[mtothef]

heal fast, my man... sounds like you've got some good saddle time planned ahead.

not sure how to handle gas on the TAT segment. can i bring my 8 gallon non-aprilia wart of doom along? it'll make the gas requirement, if the damn thing ever gets finished and/or stays in one piece:

http://advrider.com/forums/showthread.php?t=405327

that also explains where much of my time (and money) has been going lately. thank god the aprilia has been way more troublefree than everyone initially thought it would.

otherwise, i's gonna require coming up to your neck of the woods. i moved back down to santa cruz, so riding is limited to shitholes like hollister. i get hall passes to roost the high country around downieville or the pine nuts once the snow has melted off, but otherwise the bike is gathering dust down here in the off-season. living up there, i kinda forgot how easy we had it.

so, is the rekluse really all that? on one hand, i've got the local ktm mechanic telling me that he notices bikes overheat easier and foul their oil sooner than without. on the other hand, everyone i know who rides them raves about how they work...

Originally Posted by RXV_Poor

Nice to see you still lurk around.

Yeah it's been that long. At the end of summer either I'm gonna have to go your way or you're gonna have to come mine. I'm riding to AK this summer and I'm healing up so I'm off the bike for a while.

I'm getting a group together to do the Trans America Trail in 2011 from Colorado to Oregon. If you or anyone else is up for it you're more than welcome. 1 catch though, there is a 200 mile stretch with no gas. So I'll either doing a rally kit on my RXV 550 or a rally kit on my KTM 525XC (If I can get them plated out of state.). We are thinking 2 weeks for the trip. It should be a blast.

[RXV_Poor]

Great write up. I was thinking about something like that to a XR650L next year.

Please feel free to bring the beast if you want to go. There will be at least 1 DR650 with a Exxon Valdez size tank on it.

The Rekluse is cheating and will turn you into a hero. I have 1 in my RXV, 525XC & 950 ADV S. I change my oil often and if you are on the street and put the bike in neutral, pay attention and don't rely on it to do everything for you, you shouldn't have any issues at all, I haven't.

Conga lining in late Sept at Pipi. Crashing is at my house open to whomever wants to attend.

Originally Posted by mtothef

heal fast, my man... sounds like you've got some good saddle time planned ahead.

not sure how to handle gas on the TAT segment. can i bring my 8 gallon non-aprilia wart of doom along? it'll make the gas requirement, if the damn thing ever gets finished and/or stays in one piece:

http://advrider.com/forums/showthread.php?t=405327

that also explains where much of my time (and money) has been going lately. thank god the aprilia has been way more troublefree than everyone initially thought it would.

otherwise, i's gonna require coming up to your neck of the woods. i moved back down to santa cruz, so riding is limited to shitholes like hollister. i get hall passes to roost the high country around downieville or the pine nuts once the snow has melted off, but otherwise the bike is gathering dust down here in the off-season. living up there, i kinda forgot how easy we had it.

so, is the rekluse really all that? on one hand, i've got the local ktm mechanic telling me that he notices bikes overheat easier and foul their oil sooner than without. on the other hand, everyone i know who rides them raves about how they work...

[mantan]

Originally Posted by RXV_Poor

Motor:

I’ve heard that the SXV 5th gear fits. When I have to split the cases I’ll find out.

Thanks RXV_Poor. What is the benefit of SXV's 5th gear in the RXV? Is it lower or higher than the RXV's 5th?

[BC61]

sxv is a 1:1 final ratio
rxv is a 1:1.04 under driven ratio

[RXV_Poor]

After looking at this again is this thread worth being a sticky?

I think it would be a decent start for RXV owners.

[Pilota]

It was a great start for this new RXV owner.

Thanks again for sharing all the info.