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Aprilia SXV RXV 450 550 2008 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SXV 450/550 RXV 450/550 Year: 2008 Codes Chassis Code Sxv 450: Factory designation may vary, consult specific model VIN Chassis Code Sxv 550: Factory designation may vary, consult specific model VIN Chassis Code Rxv 450: Factory designation may vary, consult specific model VIN Chassis Code Rxv 550: Factory designation may vary, consult specific model VIN 👋 Introduction Market Position Vehicle Segment: High-performance dual-sport / supermoto motorcycle Target Audience: Enthusiasts and experienced riders seeking off-road capability and street performance. Competitive Analysis Key Competitors 2008: KTM 450/560 SMR, Husqvarna SM450R/SM530R, Yamaha WR450F, Honda CRF450X Key Features Engine Architecture: V-twin engine (unique for this class in 2008), high-revving and potent. Suspension Components: Premium Öhlins front forks and adjustable rear shock absorber. Braking System: High-performance Brembo braking components. Frame Design: Chromoly steel trellis frame for rigidity and light weight. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, Maintenance, and Rebuilding Procedures Diagnostic Coverage: Troubleshooting and Fault Diagnosis for all Systems Electrical Coverage: Wiring Diagrams, Electrical Component Location, Troubleshooting Engine Coverage: Top-end and Bottom-end Rebuilds, Carburetion, Ignition Drivetrain Coverage: Clutch, Transmission, Final Drive (Chain and Sprocket) Suspension Coverage: Front Forks (Öhlins), Rear Shock Absorber, Linkages Braking System Coverage: Front and Rear Brake Systems, Master Cylinders, Calipers, Lines Fuel System Coverage: Fuel Tank, Fuel Pump, Fuel Lines, Carburetor Tuning (Keihin FCR41) Page Count Estimated Pages: Likely 300-500+ pages (typical for a full service manual) Manual Type Type: Full Service and Repair Manual Language Language: English (assumed based on product description) Format Format: Digital (PDF) or Printed Copy (product dependent) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Clutch, Lubrication System Chassis: Frame, Swingarm, Suspension (Front & Rear), Steering Braking: Hydraulic Front and Rear Brake Assemblies, Parking Brake Fuel System: Fuel Delivery, Carburetion, Fuel Tank and Lines Electrical System: Ignition System, Lighting, Instrumentation, Battery, Wiring Diagrams Bodywork: Fairings, Seat, Handlebars, Controls Cooling System: Radiator, Coolant Hoses, Water Pump Procedures Included Routine Maintenance: Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service Engine Rebuild: Top-end Overhaul (Piston, Rings, Valves), Bottom-end Reassembly (Crankshaft, Bearings) Transmission Repair: Gearbox Disassembly, Reassembly, Component Inspection Suspension Service: Fork Seal Replacement, Fork Oil Change, Shock Absorber Service Carburetor Rebuild: Disassembly, Cleaning, Reassembly, Jetting Adjustments Electrical Troubleshooting: Wiring Diagram Interpretation, Fault Finding for Ignition, Lighting, and Accessories Brake System Maintenance: Brake Fluid Flush, Pad Replacement, Caliper Servicing Technical Depth Depth Level: Comprehensive: From basic maintenance to full engine and transmission rebuilds, including diagnostics. Diagnostic Capabilities: Detailed troubleshooting flowcharts and symptom-based diagnostic guidance. Torque Specifications: Extensive list of torque values for all critical fasteners. Clearances And Tolerances: Precise measurements for engine components, bearing clearances, etc. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) - High resolution, searchable text (likely) Print Quality Print Quality: High-resolution images, diagrams, and text suitable for printing. Binding Type Binding: N/A (for digital); If printed, likely saddle-stitched or comb-bound. Paper Type Paper Type: N/A (for digital); If printed, typically on durable, coated paper for workshop use. ⚙️ Engine Specifications Primary Engine Engine Type Sxv 450: 4-stroke, V-twin, liquid-cooled, DOHC, 8 valves Engine Type Sxv 550: 4-stroke, V-twin, liquid-cooled, DOHC, 8 valves Engine Type Rxv 450: 4-stroke, V-twin, liquid-cooled, DOHC, 8 valves Engine Type Rxv 550: 4-stroke, V-twin, liquid-cooled, DOHC, 8 valves Bore X Stroke 450: 60 mm x 64 mm (approximate, consult manual for exact) Bore X Stroke 550: 74 mm x 64 mm (approximate, consult manual for exact) Displacement 450: 449cc Displacement 550: 549cc Performance Horsepower 450: Approx. 58-60 HP (at crankshaft, varies with tuning) Horsepower 550: Approx. 65-70 HP (at crankshaft, varies with tuning) Torque 450: Approx. 48-50 Nm (at crankshaft, varies with tuning) Torque 550: Approx. 58-62 Nm (at crankshaft, varies with tuning) Fuel System Carburetor Type: Dual Keihin FCR 41mm flatslide carburetors Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating) Fuel Capacity: Approx. 7.2 Liters (1.9 US Gallons) Ignition System: Electronic ignition (CDI) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Gear Ratios: Not applicable, standard ratios provided in manual. Features Clutch Type: Wet multi-plate clutch, hydraulically operated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2170 mm (85.4 in) Width: Approx. 800 mm (31.5 in) Height: Approx. 1200 mm (47.2 in) (to top of handlebars) Wheelbase: Approx. 1450 mm (57.1 in) Weights Dry Weight 450: Approx. 135 kg (297 lbs) Dry Weight 550: Approx. 139 kg (306 lbs) Wet Weight Estimate: Approx. 150-155 kg (330-342 lbs) (with all fluids) Seat Height: Approx. 915 mm (36.0 in) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles generally do not receive standardized crash test ratings like cars. Focus is on rider safety through design and equipment. Active Features Braking System: Dual front discs with radial-mount Brembo calipers, single rear disc with Brembo caliper. Suspension Performance: Öhlins suspension provides excellent control and feedback. Tire Choice: Tire...
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Aprilia SXV RXV 450 550 2008 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV 450/550 RXV 450/550
Year:
2008
Codes
Chassis Code Sxv 450:
Factory designation may vary, consult specific model VIN
Chassis Code Sxv 550:
Factory designation may vary, consult specific model VIN
Chassis Code Rxv 450:
Factory designation may vary, consult specific model VIN
Chassis Code Rxv 550:
Factory designation may vary, consult specific model VIN
👋 Introduction
Market Position
Vehicle Segment:
High-performance dual-sport / supermoto motorcycle
Target Audience:
Enthusiasts and experienced riders seeking off-road capability and street performance.
Competitive Analysis
Key Competitors 2008:
KTM 450/560 SMR, Husqvarna SM450R/SM530R, Yamaha WR450F, Honda CRF450X
Key Features
Engine Architecture:
V-twin engine (unique for this class in 2008), high-revving and potent.
Suspension Components:
Premium Öhlins front forks and adjustable rear shock absorber.
Braking System:
High-performance Brembo braking components.
Frame Design:
Chromoly steel trellis frame for rigidity and light weight.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service, Repair, Maintenance, and Rebuilding Procedures
Diagnostic Coverage:
Troubleshooting and Fault Diagnosis for all Systems
Electrical Coverage:
Wiring Diagrams, Electrical Component Location, Troubleshooting
Engine Coverage:
Top-end and Bottom-end Rebuilds, Carburetion, Ignition
Drivetrain Coverage:
Clutch, Transmission, Final Drive (Chain and Sprocket)
Suspension Coverage:
Front Forks (Öhlins), Rear Shock Absorber, Linkages
Braking System Coverage:
Front and Rear Brake Systems, Master Cylinders, Calipers, Lines
Fuel System Coverage:
Fuel Tank, Fuel Pump, Fuel Lines, Carburetor Tuning (Keihin FCR41)
Page Count
Estimated Pages:
Likely 300-500+ pages (typical for a full service manual)
Manual Type
Type:
Full Service and Repair Manual
Language
Language:
English (assumed based on product description)
Format
Format:
Digital (PDF) or Printed Copy (product dependent)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Clutch, Lubrication System
Chassis:
Frame, Swingarm, Suspension (Front & Rear), Steering
Braking:
Hydraulic Front and Rear Brake Assemblies, Parking Brake
Fuel System:
Fuel Delivery, Carburetion, Fuel Tank and Lines
Electrical System:
Ignition System, Lighting, Instrumentation, Battery, Wiring Diagrams
Bodywork:
Fairings, Seat, Handlebars, Controls
Cooling System:
Radiator, Coolant Hoses, Water Pump
Procedures Included
Routine Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service
Engine Rebuild:
Top-end Overhaul (Piston, Rings, Valves), Bottom-end Reassembly (Crankshaft, Bearings)
Transmission Repair:
Gearbox Disassembly, Reassembly, Component Inspection
Suspension Service:
Fork Seal Replacement, Fork Oil Change, Shock Absorber Service
Carburetor Rebuild:
Disassembly, Cleaning, Reassembly, Jetting Adjustments
Electrical Troubleshooting:
Wiring Diagram Interpretation, Fault Finding for Ignition, Lighting, and Accessories
Brake System Maintenance:
Brake Fluid Flush, Pad Replacement, Caliper Servicing
Technical Depth
Depth Level:
Comprehensive: From basic maintenance to full engine and transmission rebuilds, including diagnostics.
Diagnostic Capabilities:
Detailed troubleshooting flowcharts and symptom-based diagnostic guidance.
Torque Specifications:
Extensive list of torque values for all critical fasteners.
Clearances And Tolerances:
Precise measurements for engine components, bearing clearances, etc.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format) - High resolution, searchable text (likely)
Print Quality
Print Quality:
High-resolution images, diagrams, and text suitable for printing.
Binding Type
Binding:
N/A (for digital); If printed, likely saddle-stitched or comb-bound.
Paper Type
Paper Type:
N/A (for digital); If printed, typically on durable, coated paper for workshop use.
⚙️ Engine Specifications
Primary Engine
Engine Type Sxv 450:
4-stroke, V-twin, liquid-cooled, DOHC, 8 valves
Engine Type Sxv 550:
4-stroke, V-twin, liquid-cooled, DOHC, 8 valves
Engine Type Rxv 450:
4-stroke, V-twin, liquid-cooled, DOHC, 8 valves
Engine Type Rxv 550:
4-stroke, V-twin, liquid-cooled, DOHC, 8 valves
Bore X Stroke 450:
60 mm x 64 mm (approximate, consult manual for exact)
Bore X Stroke 550:
74 mm x 64 mm (approximate, consult manual for exact)
Displacement 450:
449cc
Displacement 550:
549cc
Performance
Horsepower 450:
Approx. 58-60 HP (at crankshaft, varies with tuning)
Horsepower 550:
Approx. 65-70 HP (at crankshaft, varies with tuning)
Torque 450:
Approx. 48-50 Nm (at crankshaft, varies with tuning)
Torque 550:
Approx. 58-62 Nm (at crankshaft, varies with tuning)
Fuel System
Carburetor Type:
Dual Keihin FCR 41mm flatslide carburetors
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating)
Fuel Capacity:
Approx. 7.2 Liters (1.9 US Gallons)
Ignition System:
Electronic ignition (CDI)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Optional Gear Ratios:
Not applicable, standard ratios provided in manual.
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2170 mm (85.4 in)
Width:
Approx. 800 mm (31.5 in)
Height:
Approx. 1200 mm (47.2 in) (to top of handlebars)
Wheelbase:
Approx. 1450 mm (57.1 in)
Weights
Dry Weight 450:
Approx. 135 kg (297 lbs)
Dry Weight 550:
Approx. 139 kg (306 lbs)
Wet Weight Estimate:
Approx. 150-155 kg (330-342 lbs) (with all fluids)
Seat Height:
Approx. 915 mm (36.0 in)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles generally do not receive standardized crash test ratings like cars. Focus is on rider safety through design and equipment.
Active Features
Braking System:
Dual front discs with radial-mount Brembo calipers, single rear disc with Brembo caliper.
Suspension Performance:
Öhlins suspension provides excellent control and feedback.
Tire Choice:
Tire selection critical for intended use (street or off-road).
Passive Features
Frame Integrity:
Robust chromoly steel trellis frame.
Ergonomics:
Rider-focused ergonomics for control.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable to this performance-oriented motorcycle.
Driver Assistance
Traction Control:
Not equipped with electronic rider aids like traction control or ABS.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first (consult manual).
Valve Clearance Check:
Typically every 6,000-10,000 km (3,700-6,200 miles), very crucial for V-twins.
Spark Plug Replacement:
Every 6,000-8,000 km (3,700-5,000 miles).
Chain And Sprocket Inspection:
Regular inspection and lubrication every 500-1,000 km (300-600 miles).
Air Filter Cleaning:
Frequent cleaning recommended, especially for off-road use (every 1,000-2,000 km).
Fluid Specifications
Engine Oil Type:
SAE 10W-50, API SG or higher, JASO MA certified (e.g., Motul 7100 10W50).
Engine Oil Capacity:
Approx. 1.6 - 1.8 Liters (1.7 - 1.9 US Quarts) (Dry fill, consult manual).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives, 50% mix with distilled water.
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid.
Clutch Fluid Type:
DOT 4 Hydraulic Brake Fluid (shared with brakes).
Known Issues
Vibration Management:
V-twin engines can be prone to vibration; proper mounting and balance are key. Manual will detail engine mount checks.
Carburetor Tuning Sensitivity:
Keihin FCR carbs can be sensitive to altitude and temperature; jetting adjustments may be required. Manual covers this.
Cooling System Efficiency:
High-performance V-twins can run hot; ensuring cooling system is clean and fan operates is vital. Manual details checks.
Electrical Reliability:
While generally good, early models might have specific wiring harness or stator issues. Manual provides diagnostic procedures.
📚 Vehicle History
Brand Heritage
Aprilia Heritage:
Aprilia has a strong racing heritage, particularly in off-road and smaller displacement classes, known for innovative engineering.
Model Evolution
Sxv Rxv Introduction:
Introduced in the mid-2000s, the SXV/RXV range represented Aprilia's aggressive push into the high-performance dual-sport and supermoto market.
Sxv Rxv 2008 Updates:
The 2008 models typically featured refinements to the V-twin engine, chassis, and suspension based on earlier feedback and racing experience.
Production
Production Location:
Italy
Production Years:
Approx. 2006-2010 for the V-twin generation.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The SXV/RXV series was generally lauded for its performance, handling, and unique V-twin engine, though sometimes criticized for service complexity and cost.
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