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Aprilia SXV RXV 450 550 2006-2013 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SXV RXV Model Variants: SXV 450, RXV 450, SXV 550, RXV 550 Codes Chassis Codes: RK, RL (SXV), RM, RN (RXV) - Specific prefixes vary based on year and sub-model 👋 Introduction Market Position Market Segment: High-performance off-road motorcycles (motocross/supermoto). Competitive Analysis Competitors: KTM EXC/SX, Husqvarna WR/TC, Beta RR, Yamaha YZ, Honda CRF, Suzuki RM-Z, Kawasaki KX. Key Features Vehicle Focus: Agile handling, potent V-twin engines, capable off-road performance. Manual Value Proposition: Essential resource for owners and technicians seeking to maintain, diagnose, and repair these specialized motorcycles. 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF (Digital Download) Page Count: Estimated 500-800+ pages (typical for comprehensive factory service manuals) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair for both 450cc and 550cc V-twin engines. Fuel System: Fuel injection system diagnosis and repair, fuel pump, injectors, throttle body, ECU mapping, fuel tank, fuel lines. Ignition System: Spark plugs, coils, ECU control, wiring diagrams related to ignition. Cooling System: Radiator, hoses, water pump, thermostat, coolant flow, fan operation. Exhaust System: Exhaust manifold, catalytic converter (if applicable), mufflers, lambda sensors. Transmission Drivetrain: Clutch operation, gear selection, internal transmission components, final drive, chain maintenance. Electrical System: Battery, charging system, starter motor, lighting, instrumentation, fuses, relays, wiring diagrams. Chassis Frame: Frame inspection, welding points, steering head bearings. Suspension Front: Fork disassembly, assembly, oil changes, seal replacement, damping adjustments, spring rates. Suspension Rear: Shock absorber service, linkage inspection, bearing maintenance, spring adjustments. Braking System: Front and rear brake calipers, master cylinders, brake lines, fluid flush and bleed procedures, rotor inspection. Wheels Tires: Wheel bearing inspection, tire mounting and balancing, spoke tension (if applicable). Steering System: Handlebar components, steering stem bearings, linkage. Bodywork Fairings: Fairing removal and installation, seat, tank, fenders. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustments, brake inspections, tire pressure checks, lubrication points. Troubleshooting Diagnostics: Common starting issues, engine performance problems, electrical faults, diagnostic codes (if applicable). Engine Rebuild: Detailed steps for engine disassembly, component inspection, piston, ring, cylinder, valve, crankshaft, and camshaft service. Suspension Service: Fork seal replacement, oil viscosity and level, shock absorber service, linkage rebuild. Brake System Overhaul: Caliper rebuild, master cylinder service, bleeding procedures, pad and rotor replacement. Electrical Diagnostics: Use of multimeters, continuity testing, troubleshooting wiring harnesses, component testing. Clutch Replacement: Clutch plate and spring replacement procedures. Valve Adjustment: Clearance checking and adjustment for valve tappets. Timing Chain Replacement: Procedures for timing chain and tensioner replacement. Technical Depth Depth Level: Comprehensive, covering basic maintenance to complete engine and chassis overhauls. Includes detailed specifications and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Typically yes for factory PDFs, allowing easy navigation. Printable: Yes, pages can be printed as needed. Digital Rights: Instant download for immediate access. Print Quality Quality Assessment: High resolution, suitable for clear viewing of diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin (90-degree) Displacement 450: 449.8 cc Displacement 550: 549.0 cc Bore X Stroke 450: 72 mm x 54.2 mm (approximate, refer to manual for exact figures) Bore X Stroke 550: 84 mm x 50 mm (approximate, refer to manual for exact figures) Valve Train: SOHC, 4 valves per cylinder Compression Ratio: Varies by model year and specific engine tune, typically around 12.5:1 to 13.0:1 Performance Horsepower 450: Approx. 60-65 HP (crank) Horsepower 550: Approx. 70-75 HP (crank) Torque 450: Approx. 45-50 Nm Torque 550: Approx. 55-60 Nm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Keihin or Mikuni throttle bodies common. Fuel Type: Unleaded gasoline, minimum 95 RON (equivalent to 91+ AKI). Fuel Tank Capacity: Approximately 7.2 - 8.5 liters (depending on model variant and year). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate, hydraulic actuation Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Varies by model, typically around 1470-1500 mm (57.9-59.1 inches). Weights Dry Weight: Approx. 115-125 kg (253-275 lbs) without fluids. Wet Weight: Approx. 130-140 kg (286-308 lbs) with all fluids. 🛡️ Safety Features Ratings Safety Ratings: Not applicable for off-road competition motorcycles in typical road safety rating systems. Active Features Braking System Type: Hydraulic disc brakes, front and rear. Often radial-mount calipers. Passive Features Frame Design: Chromoly steel or aluminum perimeter/trellis frame for rigidity and impact absorption. 💡 Technology Features Infotainment Infotainment System: N/A (basic digital display for speed, RPM, trip meter). 🔧 Maintenance Service Intervals Engine Oil Change: Every 10-15 operating hours or annually. Refer to manual for specific riding conditions. Air Filter Cleaning: Every 5-10 operating hours or as needed based on riding environment. Spark Plug Replacement: Every 20-30 operating hours or as per manual recommendations. Valve Clearance Check: Every 20-40 operating hours. Chain Lubrication...
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Sku: 475802
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Aprilia SXV RXV 450 550 2006-2013 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV RXV
Model Variants:
SXV 450, RXV 450, SXV 550, RXV 550
Codes
Chassis Codes:
RK, RL (SXV), RM, RN (RXV) - Specific prefixes vary based on year and sub-model
👋 Introduction
Market Position
Market Segment:
High-performance off-road motorcycles (motocross/supermoto).
Competitive Analysis
Competitors:
KTM EXC/SX, Husqvarna WR/TC, Beta RR, Yamaha YZ, Honda CRF, Suzuki RM-Z, Kawasaki KX.
Key Features
Vehicle Focus:
Agile handling, potent V-twin engines, capable off-road performance.
Manual Value Proposition:
Essential resource for owners and technicians seeking to maintain, diagnose, and repair these specialized motorcycles.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Manual
Language:
English
Format:
PDF (Digital Download)
Page Count:
Estimated 500-800+ pages (typical for comprehensive factory service manuals)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and repair for both 450cc and 550cc V-twin engines.
Fuel System:
Fuel injection system diagnosis and repair, fuel pump, injectors, throttle body, ECU mapping, fuel tank, fuel lines.
Ignition System:
Spark plugs, coils, ECU control, wiring diagrams related to ignition.
Cooling System:
Radiator, hoses, water pump, thermostat, coolant flow, fan operation.
Exhaust System:
Exhaust manifold, catalytic converter (if applicable), mufflers, lambda sensors.
Transmission Drivetrain:
Clutch operation, gear selection, internal transmission components, final drive, chain maintenance.
Electrical System:
Battery, charging system, starter motor, lighting, instrumentation, fuses, relays, wiring diagrams.
Chassis Frame:
Frame inspection, welding points, steering head bearings.
Suspension Front:
Fork disassembly, assembly, oil changes, seal replacement, damping adjustments, spring rates.
Suspension Rear:
Shock absorber service, linkage inspection, bearing maintenance, spring adjustments.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, fluid flush and bleed procedures, rotor inspection.
Wheels Tires:
Wheel bearing inspection, tire mounting and balancing, spoke tension (if applicable).
Steering System:
Handlebar components, steering stem bearings, linkage.
Bodywork Fairings:
Fairing removal and installation, seat, tank, fenders.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustments, brake inspections, tire pressure checks, lubrication points.
Troubleshooting Diagnostics:
Common starting issues, engine performance problems, electrical faults, diagnostic codes (if applicable).
Engine Rebuild:
Detailed steps for engine disassembly, component inspection, piston, ring, cylinder, valve, crankshaft, and camshaft service.
Suspension Service:
Fork seal replacement, oil viscosity and level, shock absorber service, linkage rebuild.
Brake System Overhaul:
Caliper rebuild, master cylinder service, bleeding procedures, pad and rotor replacement.
Electrical Diagnostics:
Use of multimeters, continuity testing, troubleshooting wiring harnesses, component testing.
Clutch Replacement:
Clutch plate and spring replacement procedures.
Valve Adjustment:
Clearance checking and adjustment for valve tappets.
Timing Chain Replacement:
Procedures for timing chain and tensioner replacement.
Technical Depth
Depth Level:
Comprehensive, covering basic maintenance to complete engine and chassis overhauls. Includes detailed specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Typically yes for factory PDFs, allowing easy navigation.
Printable:
Yes, pages can be printed as needed.
Digital Rights:
Instant download for immediate access.
Print Quality
Quality Assessment:
High resolution, suitable for clear viewing of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V-twin (90-degree)
Displacement 450:
449.8 cc
Displacement 550:
549.0 cc
Bore X Stroke 450:
72 mm x 54.2 mm (approximate, refer to manual for exact figures)
Bore X Stroke 550:
84 mm x 50 mm (approximate, refer to manual for exact figures)
Valve Train:
SOHC, 4 valves per cylinder
Compression Ratio:
Varies by model year and specific engine tune, typically around 12.5:1 to 13.0:1
Performance
Horsepower 450:
Approx. 60-65 HP (crank)
Horsepower 550:
Approx. 70-75 HP (crank)
Torque 450:
Approx. 45-50 Nm
Torque 550:
Approx. 55-60 Nm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Keihin or Mikuni throttle bodies common.
Fuel Type:
Unleaded gasoline, minimum 95 RON (equivalent to 91+ AKI).
Fuel Tank Capacity:
Approximately 7.2 - 8.5 liters (depending on model variant and year).
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate, hydraulic actuation
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase:
Varies by model, typically around 1470-1500 mm (57.9-59.1 inches).
Weights
Dry Weight:
Approx. 115-125 kg (253-275 lbs) without fluids.
Wet Weight:
Approx. 130-140 kg (286-308 lbs) with all fluids.
🛡️ Safety Features
Ratings
Safety Ratings:
Not applicable for off-road competition motorcycles in typical road safety rating systems.
Active Features
Braking System Type:
Hydraulic disc brakes, front and rear. Often radial-mount calipers.
Passive Features
Frame Design:
Chromoly steel or aluminum perimeter/trellis frame for rigidity and impact absorption.
💡 Technology Features
Infotainment
Infotainment System:
N/A (basic digital display for speed, RPM, trip meter).
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 10-15 operating hours or annually. Refer to manual for specific riding conditions.
Air Filter Cleaning:
Every 5-10 operating hours or as needed based on riding environment.
Spark Plug Replacement:
Every 20-30 operating hours or as per manual recommendations.
Valve Clearance Check:
Every 20-40 operating hours.
Chain Lubrication Adjustment:
Every 5-10 operating hours, or after washing/wet riding.
Fluid Specifications
Engine Oil Type:
High-quality synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA approved). Refer to manual for precise specification.
Engine Oil Capacity:
Approximately 1.5 - 1.9 liters (depending on year and whether filter is changed).
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (check manual for specific compatibility).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.
Fork Oil Viscosity:
Typically SAE 5W or 10W (refer to manual for precise specification and level).
Known Issues
Common Wear Items:
Clutch plates, valve stem seals, wheel bearings, steering head bearings, fork seals, piston rings due to high-performance nature.
Engine Potential Concerns:
Valve train wear, potential oil consumption if not maintained rigorously, occasional fuel injection glitches.
Electrical Potential Concerns:
Wiring harness integrity, connector corrosion, especially in off-road conditions.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, known for performance and innovation in various racing disciplines.
Model Evolution
Development Focus:
The SXV/RXV line represented Aprilia's foray into high-performance V-twin off-road bikes, blending motocross and supermoto capabilities.
Production
Production Period:
2006-2013
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Awards:
While specific awards for these models might not be widely publicized, Aprilia's V-twin off-road platform was recognized for its unique approach and performance in niche markets.
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