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Aprilia SXV RXV 450 550 2006 Motorcycle Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SXV/RXV Model Variants: SXV 450, RXV 450, SXV 550, RXV 550 Year: 2006 Codes Chassis Code General: APRC 👋 Introduction Market Position Segment: High-performance supermoto/motocross hybrid Target Audience: Enthusiasts and off-road riders seeking aggressive styling and potent performance. Competitive Analysis Key Competitors Era: KTM 450/525 EXC, Husqvarna SM/CR models, Yamaha YZ450F/WR450F, Suzuki RM-Z450/RMX450Z, Honda CRF450X. Key Features Engine Configuration: V-twin engine, a distinctive feature in its class. Suspension Type: Premium adjustable suspension (Showa/Marzocchi). Braking System: High-performance Brembo braking components. Design Philosophy: Blend of motocross agility with street-legal supermoto capability. Manual Value Proposition: Provides detailed, technician-level instructions for maintenance and repair, crucial for owners of these specialized machines. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive A-Z for all repairs Model Coverage: All SXV and RXV models (450cc and 550cc) Year Coverage: 2006 onwards Page Count Estimated Page Count: 400+ Manual Type Manual Classification: Service Repair Workshop Manual Intended User: Professional Technicians Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanics: Detailed breakdown of 450cc and 550cc V-twin engines, including cylinder heads, pistons, crankshaft, valve train, lubrication system. Fuel System: Carburetor (Mikuni VM34/26) specifications, adjustment, and overhaul for both displacements. Fuel tank, lines, and filter service. Ignition System: CDI ignition system components, troubleshooting, wiring diagrams, and component testing. Cooling System: Radiator, cooling fan, water pump, thermostat, and coolant specifications and maintenance. Exhaust System: Muffler, header pipes, and catalytic converter (if applicable) service and inspection. Transmission: 6-speed sequential gearbox, clutch operation (hydraulic), internal components, fluid type and capacity, and shift mechanism. Drivetrain: Chain drive maintenance, sprocket inspection, and lubrication recommendations. Suspension Front: Showa upside-down telescopic forks (SXV) and Marzocchi upside-down telescopic forks (RXV). Adjustment, seals, oil change, and internal components. Suspension Rear: Monoshock rear suspension, linkage system, adjustable shock absorber (rebound, compression, preload) service and overhaul. Brakes Front: Dual hydraulic disc brakes with Brembo calipers. Pad replacement, fluid flush, caliper service, and rotor inspection. Brakes Rear: Single hydraulic disc brake with Brembo caliper. Pad replacement, fluid flush, caliper service, and rotor inspection. Electrical System: Complete wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lights, and switches. Bodywork And Frame: Frame inspection, body panel removal/installation, seat, fuel tank, fenders, and fairings. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug checks, coolant level checks. Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly for both 450cc and 550cc variants. Transmission Repair: Gearbox disassembly, inspection of gears, shift forks, and bearings, and reassembly. Suspension Rebuild: Fork seal replacement, fork oil changes, shock absorber damper adjustments, and seal head service. Brake System Service: Bleeding the hydraulic brake system, replacing brake pads and rotors, caliper servicing. Electrical Troubleshooting: Diagnosing electrical faults using wiring diagrams, testing components like ignition coils, starter solenoid, and charging system. Carburetor Tuning: Detailed steps for cleaning, rebuilding, and adjusting Mikuni carburetors for optimal performance. Valve Adjustment: Procedure for checking and adjusting valve clearance (shim type). Wheel Bearing Replacement: Front and rear wheel bearing servicing. Steering Head Bearing Service: Inspection and lubrication of steering head bearings. Technical Depth Diagnostic Information: Comprehensive diagnostic procedures, common fault codes (if applicable for the era), and troubleshooting guides. Torque Specifications: Precise torque values for all critical fasteners (engine, chassis, suspension). Component Tolerances: Specifications for wear limits and clearances for engine and transmission components. Special Tools: Listing and description of any specialized tools required for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (depending on scan quality) Print Quality Image Resolution: Variable, expected to be high for diagrams and low for text scans. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type 450: V-twin, four-stroke, liquid-cooled Engine Type 550: V-twin, four-stroke, liquid-cooled Bore X Stroke 450: 66.0 mm x 64.9 mm (approximate) Bore X Stroke 550: 74.0 mm x 64.9 mm (approximate) Displacement 450: 449 cc Displacement 550: 549 cc Compression Ratio: Approx. 12.0:1 Valvetrain: SOHC, 4 valves per cylinder (desmodromic actuation on some models/years, but typically not these specific SXV/RXV). Performance Horsepower 450 Est: 50-55 HP (estimated at crank) Horsepower 550 Est: 55-60 HP (estimated at crank) Torque 450 Est: 45-50 Nm (estimated at crank) Torque 550 Est: 50-55 Nm (estimated at crank) Fuel System Carburetor Type: Mikuni VM34/26 (dual carburetor setup) Fuel Requirement: Premium Unleaded Gasoline (91-98 RON) Fuel Tank Capacity: Approx. 7.2 Liters (1.9 US Gallons) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, sequential Clutch Type: Wet multi-plate, hydraulic actuation Features Final Drive: Chain drive Gear Ratios: Specific ratios are detailed within the manual. 📐 Dimensions Exterior Wheelbase: Approx. 1450 mm (57.1 inches) Seat Height: Approx. 900 mm (35.4 inches) Weights Dry Weight 450: Approx. 120 kg (265 lbs) Dry Weight 550: Approx. 123 kg...
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Aprilia SXV RXV 450 550 2006 Motorcycle Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV/RXV
Model Variants:
SXV 450, RXV 450, SXV 550, RXV 550
Year:
2006
Codes
Chassis Code General:
APRC
👋 Introduction
Market Position
Segment:
High-performance supermoto/motocross hybrid
Target Audience:
Enthusiasts and off-road riders seeking aggressive styling and potent performance.
Competitive Analysis
Key Competitors Era:
KTM 450/525 EXC, Husqvarna SM/CR models, Yamaha YZ450F/WR450F, Suzuki RM-Z450/RMX450Z, Honda CRF450X.
Key Features
Engine Configuration:
V-twin engine, a distinctive feature in its class.
Suspension Type:
Premium adjustable suspension (Showa/Marzocchi).
Braking System:
High-performance Brembo braking components.
Design Philosophy:
Blend of motocross agility with street-legal supermoto capability.
Manual Value Proposition:
Provides detailed, technician-level instructions for maintenance and repair, crucial for owners of these specialized machines.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive A-Z for all repairs
Model Coverage:
All SXV and RXV models (450cc and 550cc)
Year Coverage:
2006 onwards
Page Count
Estimated Page Count:
400+
Manual Type
Manual Classification:
Service Repair Workshop Manual
Intended User:
Professional Technicians
Language
Language:
English
Format
Digital Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanics:
Detailed breakdown of 450cc and 550cc V-twin engines, including cylinder heads, pistons, crankshaft, valve train, lubrication system.
Fuel System:
Carburetor (Mikuni VM34/26) specifications, adjustment, and overhaul for both displacements. Fuel tank, lines, and filter service.
Ignition System:
CDI ignition system components, troubleshooting, wiring diagrams, and component testing.
Cooling System:
Radiator, cooling fan, water pump, thermostat, and coolant specifications and maintenance.
Exhaust System:
Muffler, header pipes, and catalytic converter (if applicable) service and inspection.
Transmission:
6-speed sequential gearbox, clutch operation (hydraulic), internal components, fluid type and capacity, and shift mechanism.
Drivetrain:
Chain drive maintenance, sprocket inspection, and lubrication recommendations.
Suspension Front:
Showa upside-down telescopic forks (SXV) and Marzocchi upside-down telescopic forks (RXV). Adjustment, seals, oil change, and internal components.
Suspension Rear:
Monoshock rear suspension, linkage system, adjustable shock absorber (rebound, compression, preload) service and overhaul.
Brakes Front:
Dual hydraulic disc brakes with Brembo calipers. Pad replacement, fluid flush, caliper service, and rotor inspection.
Brakes Rear:
Single hydraulic disc brake with Brembo caliper. Pad replacement, fluid flush, caliper service, and rotor inspection.
Electrical System:
Complete wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), starter motor, lights, and switches.
Bodywork And Frame:
Frame inspection, body panel removal/installation, seat, fuel tank, fenders, and fairings.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain adjustment and lubrication, spark plug checks, coolant level checks.
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly for both 450cc and 550cc variants.
Transmission Repair:
Gearbox disassembly, inspection of gears, shift forks, and bearings, and reassembly.
Suspension Rebuild:
Fork seal replacement, fork oil changes, shock absorber damper adjustments, and seal head service.
Brake System Service:
Bleeding the hydraulic brake system, replacing brake pads and rotors, caliper servicing.
Electrical Troubleshooting:
Diagnosing electrical faults using wiring diagrams, testing components like ignition coils, starter solenoid, and charging system.
Carburetor Tuning:
Detailed steps for cleaning, rebuilding, and adjusting Mikuni carburetors for optimal performance.
Valve Adjustment:
Procedure for checking and adjusting valve clearance (shim type).
Wheel Bearing Replacement:
Front and rear wheel bearing servicing.
Steering Head Bearing Service:
Inspection and lubrication of steering head bearings.
Technical Depth
Diagnostic Information:
Comprehensive diagnostic procedures, common fault codes (if applicable for the era), and troubleshooting guides.
Torque Specifications:
Precise torque values for all critical fasteners (engine, chassis, suspension).
Component Tolerances:
Specifications for wear limits and clearances for engine and transmission components.
Special Tools:
Listing and description of any specialized tools required for specific repair procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (depending on scan quality)
Print Quality
Image Resolution:
Variable, expected to be high for diagrams and low for text scans.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type 450:
V-twin, four-stroke, liquid-cooled
Engine Type 550:
V-twin, four-stroke, liquid-cooled
Bore X Stroke 450:
66.0 mm x 64.9 mm (approximate)
Bore X Stroke 550:
74.0 mm x 64.9 mm (approximate)
Displacement 450:
449 cc
Displacement 550:
549 cc
Compression Ratio:
Approx. 12.0:1
Valvetrain:
SOHC, 4 valves per cylinder (desmodromic actuation on some models/years, but typically not these specific SXV/RXV).
Performance
Horsepower 450 Est:
50-55 HP (estimated at crank)
Horsepower 550 Est:
55-60 HP (estimated at crank)
Torque 450 Est:
45-50 Nm (estimated at crank)
Torque 550 Est:
50-55 Nm (estimated at crank)
Fuel System
Carburetor Type:
Mikuni VM34/26 (dual carburetor setup)
Fuel Requirement:
Premium Unleaded Gasoline (91-98 RON)
Fuel Tank Capacity:
Approx. 7.2 Liters (1.9 US Gallons)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, sequential
Clutch Type:
Wet multi-plate, hydraulic actuation
Features
Final Drive:
Chain drive
Gear Ratios:
Specific ratios are detailed within the manual.
📐 Dimensions
Exterior
Wheelbase:
Approx. 1450 mm (57.1 inches)
Seat Height:
Approx. 900 mm (35.4 inches)
Weights
Dry Weight 450:
Approx. 120 kg (265 lbs)
Dry Weight 550:
Approx. 123 kg (271 lbs)
Wet Weight Est:
Approx. 130-135 kg (287-298 lbs) with fluids
🛡️ Safety Features
Ratings
Safety Certification:
Typically built to EC or equivalent standards for road legality in some markets.
Active Features
Braking System Type:
Hydraulic disc brakes front and rear.
Passive Features
Lighting:
Headlight, tail light, brake light, turn signals (road-legal variants).
💡 Technology Features
Infotainment
Display Type:
Analog/Digital instrument cluster with basic readouts (speedometer, tachometer, odometer, trip meter, warning lights).
Driver Assistance
ABS:
Not typically equipped on 2006 SXV/RXV models.
Connectivity
Bluetooth Or Usb:
Not applicable for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (refer to manual for precise details based on usage).
Air Filter Cleaning:
Every 1,000-2,000 km or as needed, especially in dusty conditions.
Spark Plug Replacement:
Every 6,000-10,000 km (NGK CR9EB or similar, refer to manual for exact spec).
Valve Clearance Check:
Every 12,000-18,000 km (Shim type).
Fluid Specifications
Engine Oil Type:
SAE 10W-50, API SG or higher, JASO MA approved synthetic motorcycle oil.
Engine Oil Capacity:
Approx. 1.8 Liters (with filter change)
Coolant Type:
Ethylene glycol-based, permanent antifreeze (e.g., Motul Motocool Expert).
Brake Fluid Type:
DOT 4 (e.g., Brembo LCF DOT 4).
Clutch Fluid Type:
DOT 4 (same as brake fluid).
Known Issues
Cam Chain Tensioner:
Potential wear or failure, leading to rattling noises. Manual covers inspection and replacement.
Carburetor Sync And Tuning:
Requires meticulous synchronization and jetting for optimal performance and reliability. Manual provides detailed guidance.
Electrical Connections:
Corrosion or loose connections in wiring harness can cause intermittent issues. Manual includes wiring diagrams for diagnosis.
Suspension Seals:
Fork and shock seals can wear, leading to leaks. Manual details seal replacement procedures.
📚 Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong racing heritage in Grand Prix motorcycle racing and off-road disciplines.
Model Evolution
Sxv Rxv Introduction:
The SXV/RXV line was Aprilia's foray into the supermoto and off-road crossover segment, introducing a unique V-twin engine for this purpose.
Development Focus:
Designed to offer a potent and distinctive alternative to single-cylinder competitors.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Often praised for its aggressive performance and unique V-twin character, but also noted for its maintenance demands and specific tuning requirements.
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