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APRILIA SXV RXV 450 550 Service Repair Manual 2006 ONWARD

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🏷️ Basic Information Identification Make: Aprilia Model: SXV 450/550 Model Variant: RXV 450/550 Applicable Model Years: 2006 onwards Codes Engine Code Sxv450: 450 V-Twin Engine Code Sxv550: 550 V-Twin 👋 Introduction Market Position Vehicle Segment: High-performance supermoto/motard and dual-sport motorcycles, known for their aggressive styling and potent V-twin engines. Competitive Analysis Key Competitors Era: Models from KTM (e.g., SMC, EXC series), Husqvarna (e.g., SM series), and other European manufacturers offering similar off-road derived performance for street use. Key Features Powertrain Emphasis: Highlighting the unique and powerful Aprilia V-twin engine, offering significant torque and a distinctive riding character. Chassis Design: Mentioning the high-quality chassis components, advanced suspension, and powerful braking systems characteristic of Aprilia's performance lineage. Manual Purpose Purpose: To empower owners and technicians to perform all necessary maintenance, diagnostics, and repairs, ensuring optimal performance and longevity of the Aprilia SXV/RXV models. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and maintenance for Aprilia SXV 450/550 and RXV 450/550 models from 2006 onwards. Page Count Estimated Page Count: Highly detailed, exceeding 500 pages (typical for factory service manuals of this complexity). Manual Type Type: Factory-type PDF Service Repair Workshop Manual Language Language: English (presumed for North American/international market sales) Format Format: Digital PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, assembly, and troubleshooting of the V-twin engine (450cc and 550cc variants), including cylinder head, valves, camshafts, crankshaft, pistons, connecting rods, oil pump, and lubrication system. Fuel System: Carburetor (Mikuni VM series typically) or fuel injection system components, fuel pump, fuel filter, fuel lines, and throttle body diagnostics and servicing. Ignition System: Ignition coil, spark plugs, CDI unit, wiring diagrams, timing adjustments, and troubleshooting. Cooling System: Radiator, coolant, hoses, water pump, thermostat, fan operation, and bleeding procedures. Exhaust System: Exhaust headers, mufflers, gaskets, and emission control components (if applicable). Transmission Drivetrain: Clutch assembly (hydraulic or cable), gearbox components, gear selection mechanism, chain drive, sprockets, and lubrication. Suspension Front: Upside-down (USD) fork assembly, damping adjustments, spring preload, seal replacement, oil levels, and fork leg servicing. Suspension Rear: Monoshock absorber, linkage system, adjustment procedures (rebound, compression, preload), and rear shock servicing. Braking System Front: Brake calipers (typically Brembo), master cylinder, brake lines, brake pads, rotors, bleeding procedures, and hydraulic system troubleshooting. Braking System Rear: Rear brake caliper, master cylinder, brake pedal, brake pads, rotor, bleeding procedures, and hydraulic system troubleshooting. Electrical System: Battery, starter motor, alternator, lighting (headlight, taillight, indicators), wiring harness, fuses, relays, and electrical component testing. Chassis Frame: Frame inspection, steering head bearings, swingarm, and general chassis integrity. Bodywork Panels: Fairing removal, installation, and repair; seat, tank, and fender components. Wheels Tires: Wheel bearing inspection and replacement, tire mounting and balancing, and spoke tensioning (if applicable). Procedures Included Preventative Maintenance: Detailed schedules for oil changes, filter replacements, chain adjustment/lubrication, brake fluid flushes, coolant checks, and general inspections. Troubleshooting Diagnostics: Systematic diagnostic procedures for identifying and resolving common and uncommon issues across all vehicle systems. Engine Rebuild: Step-by-step instructions for complete engine disassembly, overhaul, and reassembly, including torque specifications and component tolerances. Suspension Setup: Guidance on adjusting suspension for various riding conditions and rider preferences, including fork and shock service. Brake System Overhaul: Instructions for caliper rebuilding, master cylinder servicing, brake line replacement, and bleeding procedures. Electrical Diagnosis: Detailed wiring diagrams, troubleshooting charts for electrical faults, and guidance on testing components. Technical Depth Depth Level: Comprehensive, covering everything from basic fluid checks and adjustments to full engine and transmission rebuilds, complex electrical diagnostics, and suspension tuning. Target Audience: Professional mechanics, experienced DIY enthusiasts, and motorcycle owners seeking to perform all levels of maintenance and repair. 📊 Manual Specifications File Format Format Details: PDF (Portable Document Format) providing clear, high-resolution images and text. Likely searchable text for ease of navigation. Print Quality Quality Assessment: Professional quality, factory-type documentation, ensuring accuracy and clarity of diagrams and text. Binding Type Binding For Digital: N/A (Digital format) Paper Type Paper For Digital: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin four-stroke Displacement 450: Approximately 449cc Displacement 550: Approximately 549cc Bore Stroke 450 Approx: e.g., 78mm x 58mm (requires manual confirmation for exact figures) Bore Stroke 550 Approx: e.g., 84mm x 50mm (requires manual confirmation for exact figures) Compression Ratio Approx: Typically around 12.0:1 to 13.0:1 (requires manual confirmation) Performance Horsepower 450 Approx: Around 60-65 hp (requires manual confirmation) Horsepower 550 Approx: Around 70-75 hp (requires manual confirmation) Torque 450 Approx: Around 35-40 lb-ft (requires manual confirmation) Torque 550 Approx: Around 45-50 lb-ft (requires manual confirmation) Fuel System Fuel Delivery: Dual carburetors (e.g., Mikuni VM41) or Electronic Fuel Injection (EFI) depending on specific market/year variant. Manual will detail specific system. Fuel Type Recommendation: Unleaded gasoline, octane rating typically 91 or higher (refer to manual for exact specification). 🔧 Transmission Standard Type: 6-speed sequential manual gearbox Features Clutch Type: Hydraulically operated...
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APRILIA SXV RXV 450 550 Service Repair Manual 2006 ONWARD
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV 450/550
Model Variant:
RXV 450/550
Applicable Model Years:
2006 onwards
Codes
Engine Code Sxv450:
450 V-Twin
Engine Code Sxv550:
550 V-Twin
👋 Introduction
Market Position
Vehicle Segment:
High-performance supermoto/motard and dual-sport motorcycles, known for their aggressive styling and potent V-twin engines.
Competitive Analysis
Key Competitors Era:
Models from KTM (e.g., SMC, EXC series), Husqvarna (e.g., SM series), and other European manufacturers offering similar off-road derived performance for street use.
Key Features
Powertrain Emphasis:
Highlighting the unique and powerful Aprilia V-twin engine, offering significant torque and a distinctive riding character.
Chassis Design:
Mentioning the high-quality chassis components, advanced suspension, and powerful braking systems characteristic of Aprilia's performance lineage.
Manual Purpose
Purpose:
To empower owners and technicians to perform all necessary maintenance, diagnostics, and repairs, ensuring optimal performance and longevity of the Aprilia SXV/RXV models.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service, repair, and maintenance for Aprilia SXV 450/550 and RXV 450/550 models from 2006 onwards.
Page Count
Estimated Page Count:
Highly detailed, exceeding 500 pages (typical for factory service manuals of this complexity).
Manual Type
Type:
Factory-type PDF Service Repair Workshop Manual
Language
Language:
English (presumed for North American/international market sales)
Format
Format:
Digital PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, assembly, and troubleshooting of the V-twin engine (450cc and 550cc variants), including cylinder head, valves, camshafts, crankshaft, pistons, connecting rods, oil pump, and lubrication system.
Fuel System:
Carburetor (Mikuni VM series typically) or fuel injection system components, fuel pump, fuel filter, fuel lines, and throttle body diagnostics and servicing.
Ignition System:
Ignition coil, spark plugs, CDI unit, wiring diagrams, timing adjustments, and troubleshooting.
Cooling System:
Radiator, coolant, hoses, water pump, thermostat, fan operation, and bleeding procedures.
Exhaust System:
Exhaust headers, mufflers, gaskets, and emission control components (if applicable).
Transmission Drivetrain:
Clutch assembly (hydraulic or cable), gearbox components, gear selection mechanism, chain drive, sprockets, and lubrication.
Suspension Front:
Upside-down (USD) fork assembly, damping adjustments, spring preload, seal replacement, oil levels, and fork leg servicing.
Suspension Rear:
Monoshock absorber, linkage system, adjustment procedures (rebound, compression, preload), and rear shock servicing.
Braking System Front:
Brake calipers (typically Brembo), master cylinder, brake lines, brake pads, rotors, bleeding procedures, and hydraulic system troubleshooting.
Braking System Rear:
Rear brake caliper, master cylinder, brake pedal, brake pads, rotor, bleeding procedures, and hydraulic system troubleshooting.
Electrical System:
Battery, starter motor, alternator, lighting (headlight, taillight, indicators), wiring harness, fuses, relays, and electrical component testing.
Chassis Frame:
Frame inspection, steering head bearings, swingarm, and general chassis integrity.
Bodywork Panels:
Fairing removal, installation, and repair; seat, tank, and fender components.
Wheels Tires:
Wheel bearing inspection and replacement, tire mounting and balancing, and spoke tensioning (if applicable).
Procedures Included
Preventative Maintenance:
Detailed schedules for oil changes, filter replacements, chain adjustment/lubrication, brake fluid flushes, coolant checks, and general inspections.
Troubleshooting Diagnostics:
Systematic diagnostic procedures for identifying and resolving common and uncommon issues across all vehicle systems.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, overhaul, and reassembly, including torque specifications and component tolerances.
Suspension Setup:
Guidance on adjusting suspension for various riding conditions and rider preferences, including fork and shock service.
Brake System Overhaul:
Instructions for caliper rebuilding, master cylinder servicing, brake line replacement, and bleeding procedures.
Electrical Diagnosis:
Detailed wiring diagrams, troubleshooting charts for electrical faults, and guidance on testing components.
Technical Depth
Depth Level:
Comprehensive, covering everything from basic fluid checks and adjustments to full engine and transmission rebuilds, complex electrical diagnostics, and suspension tuning.
Target Audience:
Professional mechanics, experienced DIY enthusiasts, and motorcycle owners seeking to perform all levels of maintenance and repair.
📊 Manual Specifications
File Format
Format Details:
PDF (Portable Document Format) providing clear, high-resolution images and text. Likely searchable text for ease of navigation.
Print Quality
Quality Assessment:
Professional quality, factory-type documentation, ensuring accuracy and clarity of diagrams and text.
Binding Type
Binding For Digital:
N/A (Digital format)
Paper Type
Paper For Digital:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin four-stroke
Displacement 450:
Approximately 449cc
Displacement 550:
Approximately 549cc
Bore Stroke 450 Approx:
e.g., 78mm x 58mm (requires manual confirmation for exact figures)
Bore Stroke 550 Approx:
e.g., 84mm x 50mm (requires manual confirmation for exact figures)
Compression Ratio Approx:
Typically around 12.0:1 to 13.0:1 (requires manual confirmation)
Performance
Horsepower 450 Approx:
Around 60-65 hp (requires manual confirmation)
Horsepower 550 Approx:
Around 70-75 hp (requires manual confirmation)
Torque 450 Approx:
Around 35-40 lb-ft (requires manual confirmation)
Torque 550 Approx:
Around 45-50 lb-ft (requires manual confirmation)
Fuel System
Fuel Delivery:
Dual carburetors (e.g., Mikuni VM41) or Electronic Fuel Injection (EFI) depending on specific market/year variant. Manual will detail specific system.
Fuel Type Recommendation:
Unleaded gasoline, octane rating typically 91 or higher (refer to manual for exact specification).
🔧 Transmission
Standard
Type:
6-speed sequential manual gearbox
Features
Clutch Type:
Hydraulically operated wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase Approx:
1490 mm (58.7 in) (for SXV/RXV models, requires manual confirmation)
Weights
Dry Weight Approx:
Around 135-140 kg (298-309 lbs) (requires manual confirmation)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles typically do not have standardized crash test ratings like cars; focus is on rider protection through design and equipment).
Active Features
Braking System:
High-performance disc brakes front and rear, often with Brembo components, providing strong stopping power.
Suspension:
Adjustable USD front forks and monoshock rear suspension contribute to stability and rider control.
Passive Features
Frame Integrity:
Robust chassis design for torsional rigidity and handling stability.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on performance and functionality, not typically equipped with infotainment systems.)
Driver Assistance
Driver Assistance Features:
N/A (Motorcycles of this era generally do not feature electronic rider aids like traction control or ABS, unless specified for a particular market variant.)
Instrumentation
Dashboard:
Analog tachometer and digital display for speedometer, odometer, trip meters, and basic indicator lights. Manual covers instrument cluster diagnostics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first (refer to manual for precise interval).
Valve Clearance Check:
Around 6,000-10,000 km (3,700-6,200 miles) (refer to manual for exact interval).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment, recommended every 500-1000 km (300-600 miles).
Fluid Specifications
Engine Oil Type:
High-quality synthetic motorcycle oil, SAE 10W-40 or 15W-50, meeting API SG or higher, JASO MA/MA2 specifications (refer to manual for exact grade and capacity).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Refer to manual for specific Aprilia-approved coolant or equivalent.
Brake Fluid Type:
DOT 4 hydraulic brake fluid (refer to manual for exact specification).
Fork Oil Type Viscosity:
Suspension fluid of specified viscosity (e.g., SAE 5W or 10W) and quantity as per manual.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, fork seals, valve guide wear, and chain/sprockets are common wear items that require periodic inspection and replacement.
Electrical Gremlins:
Some earlier models may have experienced minor electrical connectivity issues, often resolved with thorough inspection and cleaning of grounds and connectors.
Engine Maintenance Criticality:
The high-performance V-twin engine requires meticulous adherence to maintenance schedules, particularly regarding oil changes and valve adjustments, to maintain peak performance and prevent premature wear.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, particularly in off-road and road racing disciplines.
Model Evolution
Lineage:
The SXV and RXV lines represent Aprilia's foray into the high-performance supermoto and dual-sport segments, leveraging their expertise in V-twin engine technology and chassis dynamics.
Production
Production Period:
Introduced around 2006, with continuous updates and variations through the late 2000s and into the 2010s.
🏆 Awards & Recognition
Recognitions
Industry Recognition:
Aprilia's SXV/RXV models have generally been praised by motorcycle journalists and enthusiasts for their potent engines, sharp handling, and aggressive styling, cementing their reputation in the performance motorcycle segment.
Ratings
Performance Ratings:
Consistently rated highly for performance and excitement within their respective categories.
Certifications
Certification Standards:
The manual adheres to factory-level documentation standards, providing accurate and reliable information for repairs.
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