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WARNING!
Read all instructions first before beginning installation.
Clean tank interior thoroughly before installation. Install
this fuel tank ONLY in a well ventilated area, as gasoline fumes are
EXTREMELY dangerous. DO NOT START OR OPERATE THE
6240 Box Springs Blvd., Unit E VEHICLE IF THERE ARE ANY FUEL LEAKS! IMS recommends that a
Riverside, CA 92507 licensed mechanic do installation.
Web: http://www.imsproducts.com
Orders: (800) 237-9906
Information: (951) 653-7720
FAX: (951) 653-1060 NOTES
Aprilia RXV/SXV In order to make a 5.2-gallon tank for this bike and have the best
4.5/5.5 2006-10 ergonomics possible for the rider we chose to incorporate the two
FUEL TANK: radiator shrouds into the main body of the fuel tank. The trade off with
5.2 GALLONS this is that you lose the ability to raise the tank on the rear hinge mounts
IMS Tank ID: AP-1 to access your air filter. Also with the tank and both shrouds now one
IMS Part #: piece it can be hard to line up the tank and the side mounting points.
119680 The IMS tank was designed around the 12-liter OEM Aprilia
fuel tank and matching seat # 851328. The 8-liter seat can be used with
IMS PARTS LIST our tank, but it is not the best fit.
(1)Gas Cap & Seal TANK REMOVAL
(2) 6x35 mm Flange Head Bolts Drain all fuel from OEM fuel tank into a government approved fuel
(2) 6x40 mm Flange Head Bolts container with a greater capacity than fuel tank on vehicle.
(4) 6x18 mm Flat Washers Remove the seat, unbolt tank. Disconnect fuel line & electrical cable
from fuel pump, pull the hinge pin and remove tank. Remove the seat latch,
(6) 5x16 mm Flange Head Bolts
rear tank brackets, rubber spacers, pump, mounting grommet and sleeve from
(2) 6x12mm Button Head Bolts OEM tank. Remove the shrouds & the two clip-on nuts from the brackets
(6) 6-inch ty raps where the tops of the shrouds mount to the frame, these are not used with the
(2) #6-32 x 3/8” Pan Head IMS tank.
Screws TANK INSTALLATION
(1) Reserve Pump Wiring Transfer EFI pump to IMS tank taking care not to pinch the fuel filter
Harness bag between tank and pump base. The tank will leak if filter bag is not
(1) Female T-Tap completely inside of the tank. Bolt the pump down using the six 5mm x
16mm flange head bolts supplied. Mount the rear tank brackets. Bolt the
OEM ITEMS TO USE rubber spacers on using the 6x12mm button heads instead of OEM wood
• Fuel Pump screws. To mount seat latch you must swap out OEM wood screws for the
• Rear Tank Mounting Brackets two #6-32 machine screws provided. Install OEM front mounting grommet
and sleeve into loop on the IMS tank. Do not install the fuel tank at this time.
& Bolts
Remove the air box top cover to clear the way to mount Reserve
• Seat latch Pump switch and wiring harness. Remove 6mm nut holding top bolt of oil
• Front Mounting Grommet, tank just above filler cap. This will be the mounting point for pump switch.
Sleeve & Bolt Feed wiring through frame between steering head and oil tank and mount the
• Vent Hose switch. Route the single wire with fuse holder towards the headlight. Run the
two-wire section down and along side the oil tank, over to the left side
10% OFF ignition coil with the gray two wire connector coming out right above the air
box.
YOUR NEXT PURCHASE
Date___________________________
Address________________________
______________________________ “FOR COMPETITION USE ONLY”
______________________________ “Legal in California ONLY for racing vehicles
Phone_________________________
6240 Box Springs Blvd., Unit E, which may never be used upon a highway.”
Riverside, CA 92507
Phone (951) 653-7720
FAX (951) 653-1060 Due to uncontrolled variables in the manufacturing process of
DISCLAIMER: rotationally molded fuel tanks, the fuel tank may vary in size and shape
by up to 7% of the manufacturer’s original listed capacity
Find the rear-mounting bolt for the coil, remove it and attach the ring terminal to ground the harness,
replace the air box cover. Remove headlight shell and locate the six wire electrical connector for the ignition
switch. You want to tap a power source that is activated only when the ignition is in the “on” position to prevent
the Reserve pump from draining the battery if the reserve switch is left on without the engine running. On the
2007 RXV used for this project the yellow wire with a pink stripe on the main wiring loom side of the
connector was used. This wire is red on the switch side of the connector. We don’t know if Aprilia is consistent
with this color code on other year models, so it is best to use a voltage tester to find the correct wire to tap. Use
a pair of pliers to crimp the t-tap onto the wire and plug in the connector on the end of the fuse holder. This
would be a good time to check the reserve switch. With the rear part of the rocker switch pushed in, this is the
“on” position, turn the ignition switch on & off to see if the lighted rocker switch is lit only when the ignition is
on. Secure the new wiring with the ty-raps and replace the headlight shell.
Sit the tank on the bike and reconnect the fuel line and electrical connectors for both pumps. Install the
hinge pin & clips.
Note; after the tank is removed from the mold there are many factors that can distort the shape before
you receive it. Even the air temperature at the time of installation can affect the shape. Because the tank &
shrouds are no longer three separate pieces lining up the mounting bolts might be a challenge.
Using the stock hardware start the mounting bolt at the front of the tank first, do not tighten any of the
mounting bolts until all five have been started. We suggest that you install the bolts (6x35mm flange head bolts
& flat washers) into the frame first and then the radiator (6x40 mm flange head bolts and flat washers), again
leaving everything loose. It maybe necessary to push or pull the wings of the tank to get the holes lined up.
Once the tank is mounted and warmed up it will conform to your bike. Now tighten the bolts and add fuel.
Check carefully for possible gas leaks before doing anything else.
Install your seat. Turn the ignition key to the on position, then check the lift pump by setting the reserve
switch to on. The pump may take several seconds to prime; it is self-priming and will be quite loud until then.
We suggest that you switch on the Reserve pump only after the low fuel light comes on and off again
after refueling. Use it like the traditional on-off-reserve petcock. If you run the lift pump 100% of the time the
shroud sections of the tank will run dry way before the main body of the tank taking away the advantage of
keeping your reserve fuel at the lowest point of the bike until needed.
Switch in Off position
Reserve Switch
Reserve Pump
Connector
Ring Terminal
Ground
T-Tap
