Aprilia SXV RXV 450 550 2006-2013 WSM Service Manual Repair
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🏷️ Basic Information Identification Make: Aprilia Model: SXV/RXV Model Variants: SXV 450, RXV 450, SXV 550, RXV 550 Generation Covered Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Codes Engine Codes: VDBA1M (450cc), VDBB1M (550cc) - V-twin configurations 👋 Introduction Market Position Vehicle Segment: High-performance Supermoto / Motocross (off-road focused with street legality in some configurations) Competitive Analysis Key Competitors: KTM EXC/SXC, Husqvarna SM/TE, Ducati Hypermotard (less direct), Beta RR Key Features Powertrain Philosophy: Aprilia's potent V-twin engine architecture, known for strong mid-range torque and unique character. Chassis Design: Lightweight, agile chassis geometry optimized for aggressive riding and handling. Purpose Built: Designed for track-day performance and spirited off-road riding, often requiring dedicated maintenance. 📋 Manual Details Coverage Areas Technical Scope: Comprehensive repair, maintenance, and troubleshooting for Aprilia SXV/RXV models Page Count Estimated Pages: Approx. 500-700 pages (typical for WSM of this era and complexity) Manual Type Manual Classification: Workshop Service Manual (WSM) Language Documentation Language: English Format Digital Format: PDF Searchability: Fully searchable PDF allows for quick access to specific topics and procedures. Printability: Designed for easy printing of individual sections or the entire manual for workshop use. 📖 Manual Coverage Systems Covered Powertrain: Engine (all aspects of rebuild, tuning, diagnostics), Fuel System (injection, pumps, lines), Exhaust System, Ignition System, Cooling System, Lubrication System. Chassis And Suspension: Frame, Swingarm, Front Fork (USD, adjustments, internals), Rear Shock Absorber (adjustments, rebuild), Bearings (headstock, swingarm, wheel). Brakes And Wheels: Brake System (hydraulic lines, calipers, master cylinders, bleeding procedures), Wheel Hubs, Spoked Wheels, Tire Mounting and Balancing. Electrical And Electronics: Wiring Diagrams, Battery, Starter Motor, Charging System (Stator, Regulator/Rectifier), Lighting, Instrumentation, ECU and Sensor diagnostics. Bodywork And Controls: Body Panels, Seat, Handlebars, Levers, Footpegs, Cables (throttle, clutch), Airbox. Procedures Included Routine Maintenance: Oil Changes, Filter Replacements (oil, air), Spark Plug Service, Chain Adjustment and Lubrication, Valve Clearance Checks and Adjustments, Coolant Flush and Replacement. Major Repairs: Engine Top-End Rebuild (piston, rings, valves), Engine Bottom-End Rebuild (crankshaft, bearings, seals), Clutch Replacement, Transmission Overhaul, Fork Seal Replacement, Shock Absorber Rebuild, Wheel Bearing Replacement. Troubleshooting: Diagnostic Flowcharts for engine performance issues, electrical faults, starting problems, overheating, etc. Special Tools And Techniques: Identification and use of required specialized tools for engine disassembly, suspension service, and electrical diagnostics. Suspension Tuning: Detailed instructions on adjusting front and rear suspension for various riding conditions and rider weights. Engine Tuning And Mapping: Information on ignition timing, fuel injection mapping basics, and potential modifications (though advanced ECU remapping is usually aftermarket). Technical Depth Diagnostic Capability: Advanced diagnostics including fuel injection system analysis, ignition timing verification, and electrical circuit testing. Rebuild Specification: Detailed torque specifications, clearances, tolerances, and assembly sequences for all major components. Servicing Level: Suitable for both DIY enthusiasts performing advanced maintenance and professional mechanics. Wiring Diagrams Detail: Comprehensive, color-coded wiring diagrams for all electrical systems, including fault-finding guides. 📊 Manual Specifications File Format Digital Quality: High-resolution PDF, text-searchable, with clear diagrams and schematics. Print Quality Layout And Readability: Professionally formatted with clear headings, step-by-step instructions, and embedded images/diagrams. Binding Type Physical Format: N/A (Digital PDF) Paper Type Physical Material: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, Four-stroke, Liquid-cooled Displacement: 449.9 cc (SXV/RXV 450), 549.3 cc (SXV/RXV 550) Bore X Stroke 450: 92 mm x 64.4 mm Bore X Stroke 550: 92 mm x 80.3 mm Compression Ratio 450: Approx. 12.5:1 Compression Ratio 550: Approx. 12.0:1 Performance Horsepower 450 Approx: 60+ hp @ 9,500 RPM Torque 450 Approx: 35+ lb-ft @ 7,500 RPM Horsepower 550 Approx: 70+ hp @ 9,500 RPM Torque 550 Approx: 40+ lb-ft @ 7,500 RPM Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Dell'Orto throttle bodies Fuel Type: Unleaded Premium Gasoline (91 Octane or higher recommended) Engine Internals Valve Train: DOHC, 4 valves per cylinder Lubrication Oil Capacity Approx: 1.5 - 1.8 Liters (check manual for exact dry/wet fill) Cooling Coolant Type: Ethylene Glycol based coolant (50/50 mix with distilled water recommended) 🔧 Transmission Standard Transmission Type: 6-speed Sequential Manual Transmission Features Clutch Type: Hydraulic Actuated Wet Multi-plate Clutch Lubrication Transmission Oil Spec: API SG/SH/SJ/SL Grade SAE 10W-40 or 15W-50 Motorcycle Specific Engine Oil 📐 Dimensions Exterior Wheelbase Approx: 1460 - 1480 mm (varies slightly by model/year) Weights Dry Weight Approx: 115 - 125 kg Wet Weight Approx: 130 - 140 kg (with fluids) 🛡️ Safety Features Ratings Vehicle Type Approval: Primarily off-road/competition use; street legality varies by region and specific model configurations (e.g., SXV vs. RXV). Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) - typically Brembo calipers Tire Specifications Front: 120/70-17 (Supermoto) or 80/100-21 (Motocross) Tire Specifications Rear: 160/60-17 (Supermoto) or 110/100-18 (Motocross) Passive Features Frame Construction: Aluminum perimeter frame, designed for rigidity and light weight. 💡 Technology Features Infotainment Dashboard Instrumentation: Digital/Analog combination cluster displaying speed, RPM, odometer, trip meter, and basic warning lights. Driver Assistance...
Generally not equipped with ABS, prioritizing rider feedback and weight reduction for performance.
Connectivity
Charging Port:
Some models may feature a 12V accessory socket or USB charging port, but this is not standard across all configurations.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 km or annually, whichever comes first. More frequently for hard use.
Air Filter Service:
Check every 1,000 km, clean or replace as needed. Critical for engine longevity.
Valve Clearance Check:
Every 6,000 km or annually.
Spark Plug Replacement:
Every 6,000 km.
Chain Maintenance:
Lubricate and adjust chain every 500 km, or more frequently in adverse conditions.
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ/SL Grade SAE 10W-40 or 15W-50 Motorcycle Specific Engine Oil
Brake Fluid Spec:
DOT 4 Hydraulic Brake Fluid
Coolant Spec:
50/50 mixture of Ethylene Glycol antifreeze and distilled water.
Known Issues
Engine Reliability:
Early models could experience issues with stator failure, voltage regulator instability, and occasional vibration-related component wear. Regular maintenance is paramount. Valve seat wear can occur with aggressive use.
Electrical System:
Stator and regulator/rectifier can be prone to overheating and failure if not adequately cooled or maintained. Wiring harness integrity is important.
Suspension Maintenance:
Requires regular servicing of forks and rear shock, especially if used off-road or aggressively on track. Seal leaks are common if not maintained.
Cooling System:
Fan operation is critical; ensure it functions correctly to prevent overheating, particularly in traffic or slow off-road sections.
Maintenance Tips
Preventative Care:
Regularly inspect for oil and coolant leaks, check electrical connections, and adhere strictly to the maintenance schedule to ensure longevity and optimal performance.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer with a rich history in motorcycle racing and performance street bikes.
Model Evolution
Development Focus:
The SXV/RXV series represented Aprilia's foray into the high-performance supermoto and dual-sport segments, leveraging their V-twin engine expertise.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Acclaim:
The SXV/RXV series was widely recognized for its potent V-twin engine and aggressive supermoto styling, appealing to a niche market of performance enthusiasts.
Ratings
Magazine Reviews:
Frequently praised in motorcycle publications for its power delivery and handling, though often noted for its demanding maintenance requirements.