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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...
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Aprilia SXV RXV 450 550 2006-2013 WSM Service Manual Repair
🏷️ 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
ABS Availability:
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.
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