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Aprilia SXV RXV 450 550 Engine Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012

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🏷️ Basic Information Identification Make: Aprilia Model: SXV/RXV 450/550 Model Variant: SXV 450, RXV 450, SXV 550, RXV 550 Codes Engine Code 450: V990 Twin (modified 450cc variant) Engine Code 550: V990 Twin (modified 550cc variant) 👋 Introduction Market Position Segment: High-performance Supermoto/Motard and Dual-Sport motorcycles Competitive Analysis Competitors: KTM EXC, Husqvarna SM/TE, Husaberg FE/FS, Yamaha WR, Honda CRF X Key Features Engine Configuration: High-performance V-twin engines, uncommon in this displacement class for dual-sport Chassis Design: Race-bred chassis, often featuring premium suspension components Intended Use: Aggressive riding, track days (SXV), off-road performance (RXV), adaptable for street legality 📋 Manual Details Coverage Areas Covered Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012 Page Count Estimated Page Count: Extensive (Specific count not provided, but described as 'Complete') Manual Type Type: Workshop Service Repair Manual Language Language: English (assumed based on typical market) Format Format: Downloadable (Digital format, likely PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnosis, maintenance, specifications, assembly, disassembly Transmission: Gearbox service, clutch operation, maintenance, repair Fuel System: Carburetor/EFI systems (depending on specific model variant), fuel pump, filters, fuel tank service Ignition System: Ignition coils, CDI unit, spark plugs, timing adjustments Cooling System: Radiator, coolant, water pump, fan operation, thermostat Exhaust System: Muffler, headers, catalytic converter (if applicable), gasket replacement Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays Chassis: Frame, suspension (forks, shock absorber), steering, bearings Brakes: Hydraulic system, calipers, master cylinders, brake pads, discs, fluid replacement Wheels And Tires: Wheel bearings, tire pressure, rim specifications Bodywork And Fairings: Panel removal, installation, care Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain lubrication, general inspection points Troubleshooting: Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting Repair: Step-by-step repair instructions for all major components and systems Rebuilds: Complete engine and gearbox rebuild procedures Specifications: Torque values, clearances, fluid capacities, electrical specifications Component Testing: Methods for testing electrical components, sensors, and mechanical parts Technical Depth Depth: Comprehensive (covers from basic maintenance to complete engine rebuilds and diagnostics) 📊 Manual Specifications File Format Digital Format: PDF (likely, given 'downloadable') Print Quality Print Recommendation: High-quality printing recommended for clarity of diagrams and schematics Binding Type Binding For Printed: Comb or spiral binding recommended for lay-flat use in a workshop environment Paper Type Paper Recommendation: Durable, high-weight paper recommended if printing for workshop use ⚙️ Engine Specifications Primary Engine Engine Type 450: 4-stroke, V-twin, liquid-cooled, DOHC Engine Type 550: 4-stroke, V-twin, liquid-cooled, DOHC Performance Bore X Stroke 450: Approx. 70 mm x 55.8 mm (Estimated, specific factory spec needed) Bore X Stroke 550: Approx. 74 mm x 64.7 mm (Estimated, specific factory spec needed) Horsepower 450: Approx. 50-55 HP (Estimated, varies by year/tune) Horsepower 550: Approx. 60-65 HP (Estimated, varies by year/tune) Torque 450: Approx. 30-33 lb-ft (Estimated) Torque 550: Approx. 35-38 lb-ft (Estimated) Fuel System Carburetion: Dell'Orto 38mm (common, but may vary) Fuel Injection: Later models or specific variants may feature EFI Lubrication Oil Type Recommendation: API SG or higher, SAE 10W-40 or 15W-50 (Specific viscosity depends on ambient temperature, consult manual) Oil Capacity With Filter: Approx. 1.7 - 1.9 Liters (Specific value to be confirmed in manual) 🔧 Transmission Standard Type: 6-speed constant mesh Optional Clutch Type: Wet multi-plate, hydraulic actuation Features Final Drive: Chain drive Transmission Oil Type: API GL-4 or GL-5, SAE 75W-90 or 80W-90 (Consult manual for precise specification) 📐 Dimensions Exterior Frame Type: Chrome-moly steel trellis frame Weights Dry Weight Approx 450: Approx. 240-250 lbs (110-115 kg) Dry Weight Approx 550: Approx. 245-255 lbs (112-115 kg) Fuel Capacity: Approx. 7.2 Liters (1.9 US gallons) 🛡️ Safety Features Ratings Crash Test Results: Not applicable for this type of motorcycle Active Features Brakes Front: Dual 320mm discs, radial-mount calipers (e.g., Brembo) Brakes Rear: 240mm disc, caliper Passive Features Lighting: Headlight, taillight, brake light, turn signals (for street-legal variants) 💡 Technology Features Infotainment Dashboard Display: Digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and basic warning lights. Driver Assistance ABS: Not typically standard on these models, though some later or specialized versions might have offered it. Manual will detail its presence or absence. Connectivity Smartphone Integration: Not applicable for this era of performance motorcycle. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually (Consult manual for exact interval and conditions) Spark Plug Replacement: As per manual, typically every 6,000-10,000 km Valve Clearance Check: First check around 1,000 km, then every 5,000-10,000 km (Crucial for these engines) Chain And Sprockets Inspection: Regularly, adjust tension and lubricate every 500-1000 km Fluid Specifications Coolant Type: Ethylene glycol based coolant with corrosion inhibitors (e.g., Motorex M3.0 or equivalent, refer to manual) Brake Fluid Type: DOT 4 or DOT 5.1 (Consult manual for specific requirement) Known Issues Engine Temperature Management: Can run hot, especially in stop-and-go traffic or aggressive off-road use. Proper cooling system maintenance...
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Aprilia SXV RXV 450 550 Engine Complete Workshop Service Repair Manual 2006 2007 2008 2009 2010 2011 2012
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV/RXV 450/550
Model Variant:
SXV 450, RXV 450, SXV 550, RXV 550
Codes
Engine Code 450:
V990 Twin (modified 450cc variant)
Engine Code 550:
V990 Twin (modified 550cc variant)
👋 Introduction
Market Position
Segment:
High-performance Supermoto/Motard and Dual-Sport motorcycles
Competitive Analysis
Competitors:
KTM EXC, Husqvarna SM/TE, Husaberg FE/FS, Yamaha WR, Honda CRF X
Key Features
Engine Configuration:
High-performance V-twin engines, uncommon in this displacement class for dual-sport
Chassis Design:
Race-bred chassis, often featuring premium suspension components
Intended Use:
Aggressive riding, track days (SXV), off-road performance (RXV), adaptable for street legality
📋 Manual Details
Coverage Areas
Covered Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012
Page Count
Estimated Page Count:
Extensive (Specific count not provided, but described as 'Complete')
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English (assumed based on typical market)
Format
Format:
Downloadable (Digital format, likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnosis, maintenance, specifications, assembly, disassembly
Transmission:
Gearbox service, clutch operation, maintenance, repair
Fuel System:
Carburetor/EFI systems (depending on specific model variant), fuel pump, filters, fuel tank service
Ignition System:
Ignition coils, CDI unit, spark plugs, timing adjustments
Cooling System:
Radiator, coolant, water pump, fan operation, thermostat
Exhaust System:
Muffler, headers, catalytic converter (if applicable), gasket replacement
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays
Chassis:
Frame, suspension (forks, shock absorber), steering, bearings
Brakes:
Hydraulic system, calipers, master cylinders, brake pads, discs, fluid replacement
Wheels And Tires:
Wheel bearings, tire pressure, rim specifications
Bodywork And Fairings:
Panel removal, installation, care
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, chain lubrication, general inspection points
Troubleshooting:
Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting
Repair:
Step-by-step repair instructions for all major components and systems
Rebuilds:
Complete engine and gearbox rebuild procedures
Specifications:
Torque values, clearances, fluid capacities, electrical specifications
Component Testing:
Methods for testing electrical components, sensors, and mechanical parts
Technical Depth
Depth:
Comprehensive (covers from basic maintenance to complete engine rebuilds and diagnostics)
📊 Manual Specifications
File Format
Digital Format:
PDF (likely, given 'downloadable')
Print Quality
Print Recommendation:
High-quality printing recommended for clarity of diagrams and schematics
Binding Type
Binding For Printed:
Comb or spiral binding recommended for lay-flat use in a workshop environment
Paper Type
Paper Recommendation:
Durable, high-weight paper recommended if printing for workshop use
⚙️ Engine Specifications
Primary Engine
Engine Type 450:
4-stroke, V-twin, liquid-cooled, DOHC
Engine Type 550:
4-stroke, V-twin, liquid-cooled, DOHC
Performance
Bore X Stroke 450:
Approx. 70 mm x 55.8 mm (Estimated, specific factory spec needed)
Bore X Stroke 550:
Approx. 74 mm x 64.7 mm (Estimated, specific factory spec needed)
Horsepower 450:
Approx. 50-55 HP (Estimated, varies by year/tune)
Horsepower 550:
Approx. 60-65 HP (Estimated, varies by year/tune)
Torque 450:
Approx. 30-33 lb-ft (Estimated)
Torque 550:
Approx. 35-38 lb-ft (Estimated)
Fuel System
Carburetion:
Dell'Orto 38mm (common, but may vary)
Fuel Injection:
Later models or specific variants may feature EFI
Lubrication
Oil Type Recommendation:
API SG or higher, SAE 10W-40 or 15W-50 (Specific viscosity depends on ambient temperature, consult manual)
Oil Capacity With Filter:
Approx. 1.7 - 1.9 Liters (Specific value to be confirmed in manual)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Optional
Clutch Type:
Wet multi-plate, hydraulic actuation
Features
Final Drive:
Chain drive
Transmission Oil Type:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (Consult manual for precise specification)
📐 Dimensions
Exterior
Frame Type:
Chrome-moly steel trellis frame
Weights
Dry Weight Approx 450:
Approx. 240-250 lbs (110-115 kg)
Dry Weight Approx 550:
Approx. 245-255 lbs (112-115 kg)
Fuel Capacity:
Approx. 7.2 Liters (1.9 US gallons)
🛡️ Safety Features
Ratings
Crash Test Results:
Not applicable for this type of motorcycle
Active Features
Brakes Front:
Dual 320mm discs, radial-mount calipers (e.g., Brembo)
Brakes Rear:
240mm disc, caliper
Passive Features
Lighting:
Headlight, taillight, brake light, turn signals (for street-legal variants)
💡 Technology Features
Infotainment
Dashboard Display:
Digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and basic warning lights.
Driver Assistance
ABS:
Not typically standard on these models, though some later or specialized versions might have offered it. Manual will detail its presence or absence.
Connectivity
Smartphone Integration:
Not applicable for this era of performance motorcycle.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually (Consult manual for exact interval and conditions)
Spark Plug Replacement:
As per manual, typically every 6,000-10,000 km
Valve Clearance Check:
First check around 1,000 km, then every 5,000-10,000 km (Crucial for these engines)
Chain And Sprockets Inspection:
Regularly, adjust tension and lubricate every 500-1000 km
Fluid Specifications
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (e.g., Motorex M3.0 or equivalent, refer to manual)
Brake Fluid Type:
DOT 4 or DOT 5.1 (Consult manual for specific requirement)
Known Issues
Engine Temperature Management:
Can run hot, especially in stop-and-go traffic or aggressive off-road use. Proper cooling system maintenance is vital.
Valve Train Wear:
Due to high-revving nature and performance tuning, valve train components (e.g., valve seats, shims) can require attention. Strict adherence to valve clearance checks is paramount.
Electrical Gremlins:
Older models can sometimes suffer from wiring harness issues or connector problems. Thorough inspection and dielectric grease application are recommended.
Clutch Wear:
Aggressive use can lead to premature clutch wear. Proper engagement and avoidance of prolonged slipping are key.
📚 Vehicle History
Brand Heritage
Marque Origin:
Italian manufacturer with a strong racing pedigree, particularly in off-road and Grand Prix racing.
Model Evolution
Development Goal:
Designed to bridge the gap between dedicated off-road bikes and street-legal supermotos, offering high performance and unique V-twin character.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motocross Supermoto Recognition:
Often praised by riders and media for their potent engines and agile handling in their respective classes.
Ratings
Performance Reviews:
Consistently rated highly for raw performance and track capability.
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