Aprilia SXV RXV 450-550 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: SXV/RXV Model Variant: 450cc / 550cc Codes Engine Codes: V990 (derived, specific SXV/RXV variants) 👋 Introduction Market Position Market Segment: High-performance supermoto and off-road motorcycles. Competitive Analysis Competitors: KTM SX-F/EXC, Husqvarna FE/FC, Yamaha YZ-F, Honda CRF, Suzuki RM-Z. Key Features Vehicle Type: Dual-purpose, high-performance off-road/supermoto. Unique Selling Points: V-twin engine configuration in an off-road chassis, class-leading torque and power, aggressive styling. Manual Value Value Proposition: Essential for maintaining the performance and longevity of these specialized Aprilia models, empowering owners and mechanics with factory-level repair knowledge. Manual Users Target Audience: Aprilia SXV and RXV owners, motorcycle mechanics, performance tuning shops. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive factory service and repair procedures for all SXV and RXV models equipped with 450cc and 550cc engines. Page Count Page Count Estimated: Likely 500+ pages (typical for a comprehensive factory service manual). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (implied by product description and common industry practice for this type of manual). Format Format: Digital Download (PDF format typically). 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul procedures, cylinder head assembly, piston and connecting rod installation, crankshaft and bearing service, valve timing, lubrication system. Fuel System: Fuel injection system diagnosis and repair, throttle body service, fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines. Ignition System: Ignition coil testing and replacement, spark plug specifications, ECU diagnosis related to ignition. Cooling System: Radiator service, water pump replacement, thermostat operation, coolant specifications and bleeding procedures. Exhaust System: Exhaust pipe and muffler service, oxygen sensor replacement. Transmission Drivetrain: Clutch assembly inspection and replacement, gearbox disassembly and reassembly, gear oil specifications and change intervals, chain and sprockets maintenance. Electrical System: Wiring diagrams, battery maintenance and testing, starter motor service, alternator/charging system diagnosis, lighting system troubleshooting, fuse and relay identification. Chassis Suspension: Front fork service (disassembly, oil change, seal replacement), rear shock absorber service, swingarm and linkage maintenance, wheel bearing replacement. Brakes: Brake caliper service, master cylinder overhaul, brake line replacement, brake pad and rotor specifications, brake fluid type and bleeding procedures. Bodywork Frame: Fairing removal and installation, seat removal, fuel tank removal and installation, frame inspection. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, brake fluid flushes, coolant checks. Diagnostic Troubleshooting: Step-by-step diagnostic flowcharts for common issues, fault code interpretation (if applicable), component testing procedures. Major Repairs: Engine rebuilds, transmission overhauls, suspension fork rebuilds, brake system overhauls, electrical component replacement. Component Replacement: Detailed instructions for replacing wear items and major components across all systems. Technical Depth Depth Level: Full factory diagnostic and repair capabilities, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format), typically optimized for digital viewing and printing. Print Quality Print Quality: High resolution for clear diagrams, text, and images. Searchable text for easy navigation. Binding Type Binding Type: N/A (Digital product, not physically bound). Paper Type Paper Type: N/A (Digital product, not printed on physical paper). ⚙️ Engine Specifications Primary Engine Engine Type: 4-stroke, V-twin (90-degree) Displacement 450: 449 cc Displacement 550: 549 cc Bore X Stroke 450: Approx. 78 mm x 47.4 mm (check specific variant) Bore X Stroke 550: Approx. 80 mm x 54.3 mm (check specific variant) Valvetrain: DOHC, 4 valves per cylinder Performance Horsepower 450 Est: Approx. 60-70 HP (at crankshaft, depending on tune and year) Horsepower 550 Est: Approx. 70-80 HP (at crankshaft, depending on tune and year) Torque 450 Est: Approx. 45-50 Nm (at crankshaft, depending on tune and year) Torque 550 Est: Approx. 55-60 Nm (at crankshaft, depending on tune and year) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Magneti Marelli systems Fuel Type: Unleaded gasoline, minimum 95 RON Engine Components Cooling System: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed manual Features Clutch Type: Wet multi-plate clutch Final Drive: Chain drive Fluid Specifications Gear Oil Type: SAE 10W-40 or 15W-50 motorcycle gear oil (check manual for exact specification and API rating). 📐 Dimensions Exterior Frame Type: Aluminum alloy perimeter frame Weights Dry Weight Est: Approx. 120-130 kg (depending on model and year). Fuel Tank Capacity: Approx. 7-8 liters (check specific model). 🛡️ Safety Features Ratings Safety Certification: Not typically subject to automotive safety ratings (e.g., NHTSA, Euro NCAP) as it is a motorcycle. Active Features Braking System: Hydraulic disc brakes front and rear (often Brembo calipers), braided stainless steel lines. Passive Features Lighting: Headlight, taillight, brake lights, turn signals (depending on street-legal variants). 💡 Technology Features Infotainment Dashboard Display: Digital or analog tachometer, speedometer, odometer, trip meter, and basic indicator lights. Advanced electronic aids are typically absent. Driver Assistance Traction Control: Not standard on most SXV/RXV models. Advanced models or aftermarket kits might exist. Connectivity Connectivity Features: None (standard features). 🔧...
V-twin engine configuration in an off-road chassis, class-leading torque and power, aggressive styling.
Manual Value
Value Proposition:
Essential for maintaining the performance and longevity of these specialized Aprilia models, empowering owners and mechanics with factory-level repair knowledge.
Manual Users
Target Audience:
Aprilia SXV and RXV owners, motorcycle mechanics, performance tuning shops.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive factory service and repair procedures for all SXV and RXV models equipped with 450cc and 550cc engines.
Page Count
Page Count Estimated:
Likely 500+ pages (typical for a comprehensive factory service manual).
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English (implied by product description and common industry practice for this type of manual).
Format
Format:
Digital Download (PDF format typically).
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul procedures, cylinder head assembly, piston and connecting rod installation, crankshaft and bearing service, valve timing, lubrication system.
Fuel System:
Fuel injection system diagnosis and repair, throttle body service, fuel pump, injectors, fuel pressure regulator, fuel tank, fuel lines.
Ignition System:
Ignition coil testing and replacement, spark plug specifications, ECU diagnosis related to ignition.
Cooling System:
Radiator service, water pump replacement, thermostat operation, coolant specifications and bleeding procedures.
Exhaust System:
Exhaust pipe and muffler service, oxygen sensor replacement.
Transmission Drivetrain:
Clutch assembly inspection and replacement, gearbox disassembly and reassembly, gear oil specifications and change intervals, chain and sprockets maintenance.
Electrical System:
Wiring diagrams, battery maintenance and testing, starter motor service, alternator/charging system diagnosis, lighting system troubleshooting, fuse and relay identification.
Chassis Suspension:
Front fork service (disassembly, oil change, seal replacement), rear shock absorber service, swingarm and linkage maintenance, wheel bearing replacement.
Brakes:
Brake caliper service, master cylinder overhaul, brake line replacement, brake pad and rotor specifications, brake fluid type and bleeding procedures.
Bodywork Frame:
Fairing removal and installation, seat removal, fuel tank removal and installation, frame inspection.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, brake fluid flushes, coolant checks.
Diagnostic Troubleshooting:
Step-by-step diagnostic flowcharts for common issues, fault code interpretation (if applicable), component testing procedures.
Detailed instructions for replacing wear items and major components across all systems.
Technical Depth
Depth Level:
Full factory diagnostic and repair capabilities, suitable for professional mechanics and experienced DIY enthusiasts.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format), typically optimized for digital viewing and printing.
Print Quality
Print Quality:
High resolution for clear diagrams, text, and images. Searchable text for easy navigation.
Binding Type
Binding Type:
N/A (Digital product, not physically bound).
Paper Type
Paper Type:
N/A (Digital product, not printed on physical paper).
⚙️ Engine Specifications
Primary Engine
Engine Type:
4-stroke, V-twin (90-degree)
Displacement 450:
449 cc
Displacement 550:
549 cc
Bore X Stroke 450:
Approx. 78 mm x 47.4 mm (check specific variant)
Bore X Stroke 550:
Approx. 80 mm x 54.3 mm (check specific variant)
Valvetrain:
DOHC, 4 valves per cylinder
Performance
Horsepower 450 Est:
Approx. 60-70 HP (at crankshaft, depending on tune and year)
Horsepower 550 Est:
Approx. 70-80 HP (at crankshaft, depending on tune and year)
Torque 450 Est:
Approx. 45-50 Nm (at crankshaft, depending on tune and year)
Torque 550 Est:
Approx. 55-60 Nm (at crankshaft, depending on tune and year)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically Magneti Marelli systems
Fuel Type:
Unleaded gasoline, minimum 95 RON
Engine Components
Cooling System:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
Chain drive
Fluid Specifications
Gear Oil Type:
SAE 10W-40 or 15W-50 motorcycle gear oil (check manual for exact specification and API rating).
📐 Dimensions
Exterior
Frame Type:
Aluminum alloy perimeter frame
Weights
Dry Weight Est:
Approx. 120-130 kg (depending on model and year).
Fuel Tank Capacity:
Approx. 7-8 liters (check specific model).
🛡️ Safety Features
Ratings
Safety Certification:
Not typically subject to automotive safety ratings (e.g., NHTSA, Euro NCAP) as it is a motorcycle.
Active Features
Braking System:
Hydraulic disc brakes front and rear (often Brembo calipers), braided stainless steel lines.
Passive Features
Lighting:
Headlight, taillight, brake lights, turn signals (depending on street-legal variants).
💡 Technology Features
Infotainment
Dashboard Display:
Digital or analog tachometer, speedometer, odometer, trip meter, and basic indicator lights. Advanced electronic aids are typically absent.
Driver Assistance
Traction Control:
Not standard on most SXV/RXV models. Advanced models or aftermarket kits might exist.
Connectivity
Connectivity Features:
None (standard features).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 - 5,000 km or annually (check manual for precise interval and conditions).
Spark Plug Replacement:
Interval varies, often around 8,000 - 12,000 km (check manual for specific plug type and gap).
Valve Clearance Check:
Critical maintenance, typically every 5,000 - 10,000 km. Requires detailed inspection and adjustment.
Fluid Specifications
Engine Oil Capacity:
Approx. 1.5 - 1.8 liters (check specific model and oil filter type).
Coolant Type:
Ethylene glycol based coolant, pre-diluted 50/50 with distilled water (typically green or pink).
Brake Fluid Type:
DOT 4 high-temperature brake fluid.
Known Issues
Engine Reliability:
Some models experienced issues with stator failures, fuel pump reliability, and valve train wear if maintenance was neglected. The V-twin configuration requires diligent attention to cooling and oil levels.
Electrical Gremlins:
As with many high-performance European motorcycles of the era, electrical connections and grounds can be a source of intermittent problems if not maintained.
Common Tasks
Chain Maintenance:
Frequent cleaning, lubrication, and tension adjustment are vital for drivetrain longevity.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer, renowned for its racing heritage in MotoGP and other motorcycle disciplines.
Model Evolution
Launch Period:
The SXV/RXV platform was introduced in the early to mid-2000s, evolving through various iterations.
Production
Production Status:
Production of the SXV/RXV line has ceased in recent years, making service manuals crucial for ongoing ownership.
🏆 Awards & Recognition
Recognitions
Performance Accolades:
While specific awards might be scarce, the SXV/RXV series was lauded for its unique V-twin engine in the supermoto class and its aggressive, track-ready performance.
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