Aprilia SXV RXV 450 550 2009 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Aprilia Model: SXV 450, SXV 550, RXV 450, RXV 550 Year: 2009 Codes Chassis Codes: RK, RN (SXV 450/550), RG, RL (RXV 450/550) Engine Codes: V994 L (450cc), V992 L (550cc) - V-twin configurations 👋 Introduction Market Position Positioning: High-performance dual-sport/supermoto motorcycles known for their potent V-twin engines and capable chassis, catering to a niche market of enthusiasts seeking track-inspired street performance. Competitive Analysis Competitors: KTM 690 SMC/Enduro, Husqvarna SM/TE series, Ducati Hypermotard (older generations). Key Features Features: Powerful V-twin engines, race-derived chassis, high-quality suspension components (often from WP, Marzocchi, or Paioli), potent braking systems, lightweight construction, and aggressive styling. 📋 Manual Details Coverage Areas Primary Coverage: Aprilia SXV 450, RXV 450, SXV 550, RXV 550 Secondary Coverage: Related components and variations within the 2009 model year Page Count Estimated Pages: 300-400 pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of V-twin engines (450cc & 550cc), including cylinders, pistons, crankshaft, camshafts, valves, timing systems. Fuel System: Carburetor systems (Mikuni VM series or similar), fuel pump, fuel lines, fuel tank, and associated components. Ignition System: CDI ignition, spark plugs, ignition coils, stator, and wiring diagrams. Cooling System: Radiator, coolant hoses, thermostat, water pump, and fan operation. Exhaust System: Exhaust headers, mufflers, and associated mounting hardware. Transmission: Clutch system (wet multi-plate), gearbox disassembly, inspection, and reassembly, including gear sets, shift drum, and shift forks. Drivetrain: Chain drive system, sprockets, and swingarm maintenance. Suspension Front: Upside-down telescopic forks (e.g., Marzocchi or Paioli), including disassembly, seal replacement, oil changes, and adjustment procedures. Suspension Rear: Monoshock rear suspension, including linkage maintenance, shock absorber inspection and service, and spring pre-load adjustments. Brakes Front: Dual hydraulic disc brakes, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures. Brakes Rear: Single hydraulic disc brake, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures. Wheels Tires: Wheel bearing service, tire removal and installation, and rim maintenance. Electrical System: Battery maintenance, starter motor, lighting system (headlight, taillight, turn signals), horn, and wiring diagrams for all circuits. Frame Bodywork: Frame inspection and repair, body panel removal and installation, seat, fuel tank, and fairing components. Troubleshooting: Diagnostic procedures for common issues, symptom-based troubleshooting guides, and fault finding. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug inspection, and general lubrication. Engine Rebuild: Complete engine teardown, component measurement, wear assessment, and reassembly with torque specifications. Suspension Service: Fork seal replacement, fork oil changes, shock absorber fluid replacement, and linkage bearing service. Brake System Overhaul: Complete brake caliper rebuilding, master cylinder servicing, and brake line replacement. Electrical Diagnostics: Wiring harness tracing, component testing (e.g., ignition coil resistance, stator output), and troubleshooting electrical faults. Carburetor Tuning: Adjustment of idle speed, mixture screws, and jetting recommendations for different conditions. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and component overhauls. Suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Format Details: Searchable PDF for easy navigation and printing of specific sections. High-resolution diagrams and clear text. Print Quality Print Quality: Printable pages with clear schematics and legible text for workshop use. Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Type: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Configuration: V-twin, 4-stroke, liquid-cooled Displacement 450: 449.8 cc Bore Stroke 450: 74 mm x 52.3 mm (approximate) Displacement 550: 549.5 cc Bore Stroke 550: 84 mm x 50 mm (approximate) Performance Horsepower 450: Approx. 50-55 HP (may vary by tuning) Horsepower 550: Approx. 60-65 HP (may vary by tuning) Torque 450: Approx. 32-35 lb-ft Torque 550: Approx. 38-40 lb-ft Fuel System Induction Type: Carbureted (typically dual Mikuni VM36 or similar) Fuel Type: Unleaded gasoline (91+ octane recommended) Valvetrain Actuation: DOHC, 4 valves per cylinder 🔧 Transmission Standard Type: 6-speed manual transmission Clutch: Wet multi-plate clutch, hydraulically actuated Features Gear Ratios: Specific ratios detailed in the manual, designed for aggressive acceleration and high-end performance. Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approx. 1475 mm (58.1 in) (varies slightly between models) Seat Height: Approx. 900-920 mm (35.4-36.2 in) (subject to suspension setting) Weights Dry Weight: Approx. 130-135 kg (287-298 lbs) (varies by model and specific configuration) Fuel Tank Capacity: Approx. 7.2 Liters (1.9 US Gallons) 🛡️ Safety Features Ratings Safety Ratings: Not applicable to motorcycles in the same way as automobiles. Focus is on rider control and active safety features. Active Features Braking System: High-performance hydraulic disc brakes front and rear for effective stopping power. Suspension Performance: Adjustable suspension components contribute to rider control and stability in various riding conditions. Passive Features Frame Construction: Sturdy frame design (often a steel trellis) for chassis rigidity...
V994 L (450cc), V992 L (550cc) - V-twin configurations
👋 Introduction
Market Position
Positioning:
High-performance dual-sport/supermoto motorcycles known for their potent V-twin engines and capable chassis, catering to a niche market of enthusiasts seeking track-inspired street performance.
No electronic rider aids like ABS or traction control on standard models of this era.
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. More frequent changes recommended for hard riding.
Air Filter Service:
Every 1,000-2,000 km (600-1,200 miles), or more often in dusty conditions.
Spark Plug Replacement:
Every 6,000-10,000 km (3,700-6,000 miles), check condition at oil changes.
Valve Clearance Check:
Every 10,000-15,000 km (6,000-9,000 miles) or as specified by the manual.
Fork Oil Change:
Every 1-2 years or 10,000-20,000 km (6,000-12,000 miles), or if performance degrades.
Fluid Specifications
Engine Oil:
API SG/SH/SJ, JASO MA, SAE 10W-40 or 15W-50 (refer to manual for specific viscosity based on climate).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Brake Fluid:
DOT 4 synthetic brake fluid.
Clutch Fluid:
DOT 4 or DOT 5.1 synthetic brake fluid (check manual for exact specification).
Fork Oil:
Specific viscosity oil (e.g., Showa SS-08, Motul Fork Oil Expert 7.5W) as per manual; quantity specified per fork leg.
Known Issues
Common Complaints:
Potential for electrical gremlins, clutch slave cylinder leaks, starter motor issues, and occasional carburetor tuning sensitivities. Cam chain tensioner wear on high-mileage examples. Valve seat wear on earlier models.
Common Issues
Maintenance Recommendations:
Strict adherence to maintenance schedule, regular cleaning of air filter, and keeping electrical connections clean and protected are crucial for longevity.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia has a rich history in motorcycle racing, particularly in off-road and sportbike categories, known for innovative engineering and performance-oriented machines.
Model Evolution
Evolution:
The SXV/RXV line represented Aprilia's foray into the supermoto and dual-sport segments, leveraging their V-twin engine technology from other racing platforms.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards:
While specific awards are not widely documented, the SXV/RXV line was highly regarded by enthusiasts and the motorcycling press for its aggressive performance and handling characteristics, often winning comparison tests in its segment.
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