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Aprilia SXV RXV 450 550 2006-2013 Service Repair Manual

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๐Ÿท๏ธ Basic Information Identification Make: Aprilia Model: SXV RXV 450/550 Generation Generation: First Generation Codes Model Codes: SXV450, SXV550, RXV450, RXV550 ๐Ÿ‘‹ Introduction Market Position Category: Performance Supermoto/V-Twin Off-Road Target Audience: Enthusiast owners, independent repair shops, competition mechanics. Competitive Analysis Competitors: KTM 450/560 SMR, Husqvarna SM450R/SM530RR, Ducati Hypermotard (in spirit of performance). Key Features Unique Selling Points: High-performance V-twin engine in a lightweight chassis, dual-purpose capability (motocross track to street legal supermoto), exclusive Italian engineering. Manual Advantage: Provides the critical factory data needed to properly maintain and repair these specialized machines, which often lack widespread support compared to mainstream brands. ๐Ÿ“‹ Manual Details Coverage Areas Vehicle Years: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Engine Variants Covered: 450cc, 550cc Page Count Page Count Estimated: 500+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) ๐Ÿ“– Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, valve timing, piston/ring replacement, cylinder head service, crankshaft and connecting rod inspection/replacement, oil pump operation and repair. Fuel System: Fuel injection system diagnosis and repair, injector testing and replacement, fuel pump operation, throttle body service, fuel filter replacement. Ignition System: Spark plug diagnosis and replacement, ignition coil testing, ECU (Engine Control Unit) signals and troubleshooting. Cooling System: Radiator inspection and repair, coolant flow diagnosis, water pump service, thermostat operation and replacement, fan operation. Transmission Drivetrain: Clutch inspection and replacement, gearbox disassembly and reassembly, gear selection mechanism, primary drive, chain and sprocket maintenance. Electrical System: Wiring diagrams for all circuits, battery testing and maintenance, starter motor operation, lighting system troubleshooting, fuse and relay identification and testing, sensor diagnostics. Braking System: Brake pad replacement, caliper service, brake fluid bleeding and replacement, master cylinder inspection, brake hose inspection and replacement. Suspension Steering: Front fork (USD) service and adjustment, rear shock absorber inspection and adjustment, linkage bearings, steering head bearing service, wheel bearing replacement. Chassis Frame: Frame inspection for damage, subframe mounting, swingarm service, footpeg and control lever adjustments. Bodywork Fairings: Fairing removal and installation, seat service, tank mounting, fender replacement. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, coolant level checks, brake checks. Troubleshooting: Detailed diagnostic flowcharts for common running issues, electrical faults, starting problems, and performance complaints. Component Overhaul: Complete procedures for engine rebuilds, transmission overhauls, suspension fork and shock absorber servicing, and brake caliper rebuilding. Electrical Diagnostics: Wiring diagram interpretation, multimeter usage for testing circuits, sensor signal tracing, ECU diagnostic codes (if applicable). Torque Specifications: Precise torque values for all critical fasteners, including engine, chassis, and suspension components. Technical Depth Depth Level: Comprehensive Factory Level Diagnostic Capability: Advanced troubleshooting and fault diagnosis for all major systems. Rebuild Procedures: Detailed, step-by-step instructions for complete engine and component rebuilds. ๐Ÿ“Š Manual Specifications File Format File Type: PDF Searchability: Fully searchable text Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: N/A (Digital) Paper Type Paper Type: N/A (Digital) โš™๏ธ Engine Specifications Primary Engine Engine Type: V-twin, Four-stroke Cylinder Angle: 75 degrees Bore X Stroke 450: 90 mm x 57.4 mm (450cc) Bore X Stroke 550: 95 mm x 76.4 mm (549cc) Compression Ratio Approx: 12.0:1 - 12.5:1 (varies by model/year) Valvetrain: SOHC, 4 valves per cylinder Performance Horsepower 450 Approx: 50-55 HP Horsepower 550 Approx: 60-65 HP Torque Approx: 45-55 Nm (varies by model) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - Keihin or Mikuni variants Fuel Type: Unleaded gasoline, minimum 95 RON Throttle Body Size Approx: 42-45mm ๐Ÿ”ง Transmission Standard Transmission Type: 6-speed manual Clutch Type: Wet, multi-plate Features Gear Ratios: Specific ratios detailed in manual Final Drive: Chain drive ๐Ÿ“ Dimensions Exterior Wheelbase Approx: 1470 mm - 1500 mm Seat Height Approx: 910 mm - 930 mm Weights Dry Weight Approx: 120 kg - 130 kg Fuel Tank Capacity: 7.0 Liters (approx) ๐Ÿ›ก๏ธ Safety Features Ratings Safety Certification: Generally street-legal configurations require compliance with local regulations, but no formal NCAP/IIHS ratings apply to this type of motorcycle. Active Features Braking System Type: Hydraulic disc brakes (front and rear) Suspension Type: Upside-down (USD) telescopic front forks, Monoshock rear suspension Passive Features Frame Construction: Chrome-molybdenum steel trellis frame ๐Ÿ’ก Technology Features Infotainment Dashboard: Analog tachometer and digital multi-function display (speed, odometer, trip meters, clock). Driver Assistance Traction Control: Not typically equipped on these models. ABS: Not typically equipped on these models. Connectivity Diagnostics Port: Diagnostic connector for ECU access, requiring specialized tools or adapters for full diagnostic capability (covered by manual). ๐Ÿ”ง Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually, whichever comes first (refer to manual for precise intervals). Spark Plug Inspection: Every 6,000-8,000 km Valve Clearance Check: Every 10,000-15,000 km (critical for performance) Fluid Specifications Engine Oil Type: SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (e.g., Motul 7100 10W40) Engine Oil Capacity:...
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Aprilia SXV RXV 450 550 2006-2013 Service Repair ManualAprilia SXV RXV 450 550 2006-2013 Service Repair ManualAprilia SXV RXV 450 550 2006-2013 Service Repair ManualAprilia SXV RXV 450 550 2006-2013 Service Repair Manual
๐Ÿท๏ธ Basic Information
Identification
Make:
Aprilia
Model:
SXV RXV 450/550
Generation
Generation:
First Generation
Codes
Model Codes:
SXV450, SXV550, RXV450, RXV550
๐Ÿ‘‹ Introduction
Market Position
Category:
Performance Supermoto/V-Twin Off-Road
Target Audience:
Enthusiast owners, independent repair shops, competition mechanics.
Competitive Analysis
Competitors:
KTM 450/560 SMR, Husqvarna SM450R/SM530RR, Ducati Hypermotard (in spirit of performance).
Key Features
Unique Selling Points:
High-performance V-twin engine in a lightweight chassis, dual-purpose capability (motocross track to street legal supermoto), exclusive Italian engineering.
Manual Advantage:
Provides the critical factory data needed to properly maintain and repair these specialized machines, which often lack widespread support compared to mainstream brands.
๐Ÿ“‹ Manual Details
Coverage Areas
Vehicle Years:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Engine Variants Covered:
450cc, 550cc
Page Count
Page Count Estimated:
500+
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
๐Ÿ“– Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, valve timing, piston/ring replacement, cylinder head service, crankshaft and connecting rod inspection/replacement, oil pump operation and repair.
Fuel System:
Fuel injection system diagnosis and repair, injector testing and replacement, fuel pump operation, throttle body service, fuel filter replacement.
Ignition System:
Spark plug diagnosis and replacement, ignition coil testing, ECU (Engine Control Unit) signals and troubleshooting.
Cooling System:
Radiator inspection and repair, coolant flow diagnosis, water pump service, thermostat operation and replacement, fan operation.
Transmission Drivetrain:
Clutch inspection and replacement, gearbox disassembly and reassembly, gear selection mechanism, primary drive, chain and sprocket maintenance.
Electrical System:
Wiring diagrams for all circuits, battery testing and maintenance, starter motor operation, lighting system troubleshooting, fuse and relay identification and testing, sensor diagnostics.
Braking System:
Brake pad replacement, caliper service, brake fluid bleeding and replacement, master cylinder inspection, brake hose inspection and replacement.
Suspension Steering:
Front fork (USD) service and adjustment, rear shock absorber inspection and adjustment, linkage bearings, steering head bearing service, wheel bearing replacement.
Chassis Frame:
Frame inspection for damage, subframe mounting, swingarm service, footpeg and control lever adjustments.
Bodywork Fairings:
Fairing removal and installation, seat service, tank mounting, fender replacement.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, coolant level checks, brake checks.
Troubleshooting:
Detailed diagnostic flowcharts for common running issues, electrical faults, starting problems, and performance complaints.
Component Overhaul:
Complete procedures for engine rebuilds, transmission overhauls, suspension fork and shock absorber servicing, and brake caliper rebuilding.
Electrical Diagnostics:
Wiring diagram interpretation, multimeter usage for testing circuits, sensor signal tracing, ECU diagnostic codes (if applicable).
Torque Specifications:
Precise torque values for all critical fasteners, including engine, chassis, and suspension components.
Technical Depth
Depth Level:
Comprehensive Factory Level
Diagnostic Capability:
Advanced troubleshooting and fault diagnosis for all major systems.
Rebuild Procedures:
Detailed, step-by-step instructions for complete engine and component rebuilds.
๐Ÿ“Š Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper Type:
N/A (Digital)
โš™๏ธ Engine Specifications
Primary Engine
Engine Type:
V-twin, Four-stroke
Cylinder Angle:
75 degrees
Bore X Stroke 450:
90 mm x 57.4 mm (450cc)
Bore X Stroke 550:
95 mm x 76.4 mm (549cc)
Compression Ratio Approx:
12.0:1 - 12.5:1 (varies by model/year)
Valvetrain:
SOHC, 4 valves per cylinder
Performance
Horsepower 450 Approx:
50-55 HP
Horsepower 550 Approx:
60-65 HP
Torque Approx:
45-55 Nm (varies by model)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - Keihin or Mikuni variants
Fuel Type:
Unleaded gasoline, minimum 95 RON
Throttle Body Size Approx:
42-45mm
๐Ÿ”ง Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Wet, multi-plate
Features
Gear Ratios:
Specific ratios detailed in manual
Final Drive:
Chain drive
๐Ÿ“ Dimensions
Exterior
Wheelbase Approx:
1470 mm - 1500 mm
Seat Height Approx:
910 mm - 930 mm
Weights
Dry Weight Approx:
120 kg - 130 kg
Fuel Tank Capacity:
7.0 Liters (approx)
๐Ÿ›ก๏ธ Safety Features
Ratings
Safety Certification:
Generally street-legal configurations require compliance with local regulations, but no formal NCAP/IIHS ratings apply to this type of motorcycle.
Active Features
Braking System Type:
Hydraulic disc brakes (front and rear)
Suspension Type:
Upside-down (USD) telescopic front forks, Monoshock rear suspension
Passive Features
Frame Construction:
Chrome-molybdenum steel trellis frame
๐Ÿ’ก Technology Features
Infotainment
Dashboard:
Analog tachometer and digital multi-function display (speed, odometer, trip meters, clock).
Driver Assistance
Traction Control:
Not typically equipped on these models.
ABS:
Not typically equipped on these models.
Connectivity
Diagnostics Port:
Diagnostic connector for ECU access, requiring specialized tools or adapters for full diagnostic capability (covered by manual).
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually, whichever comes first (refer to manual for precise intervals).
Spark Plug Inspection:
Every 6,000-8,000 km
Valve Clearance Check:
Every 10,000-15,000 km (critical for performance)
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (e.g., Motul 7100 10W40)
Engine Oil Capacity:
Approximately 1.5 - 1.8 Liters (with filter change)
Coolant Type:
Ethylene glycol-based antifreeze, silicate-free, with corrosion inhibitors (e.g., Aprilia-recommended or Motul Motocool Expert)
Brake Fluid Type:
DOT 4 (or DOT 5.1 as per manual recommendations for higher performance)
Clutch Fluid Type:
DOT 4 (if hydraulic clutch)
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, exhaust valve mechanism (carbon buildup), fuel pump reliability, starter solenoid.
Typical Performance Quirks:
Sensitivity to fuel quality, occasional ECU sensor issues, vibration at certain RPMs due to V-twin configuration.
Specialized Maintenance Points:
Regular cleaning and lubrication of the exhaust control valve mechanism is crucial for smooth engine operation. Proper bleeding of the clutch hydraulic system is vital.
๐Ÿ“š Vehicle History
Brand Heritage
Manufacturer:
Aprilia S.p.A. (Italy)
Specialty:
Renowned for racing pedigree, particularly in Grand Prix motorcycle racing and off-road disciplines. Known for innovative V-twin engines.
Model Evolution
Development Focus:
Designed to bridge the gap between off-road capability and supermoto performance, featuring a potent V-twin engine in a lightweight, agile chassis.
Sxv Rxv Distinction:
SXV is typically the Supermoto version (street-oriented tires, suspension setup), RXV is the dual-sport/off-road version (knobby tires, softer suspension, sometimes different gearing).
Production
Production Period:
2006 - 2013
Manufacturing Location:
Italy
๐Ÿ† Awards & Recognition
Recognitions
Industry Perception:
Highly regarded for their unique V-twin performance and exceptional handling in the supermoto and performance off-road categories. Often praised for their raw character and thrilling ride.
Motorcycle Press:
Frequently lauded in reviews for their powerful engines and agile chassis, making them a favorite among experienced riders seeking excitement.
Ratings
Performance Benchmark:
Set a high benchmark for V-twin powered supermotos of their era.
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