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.