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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 Engine Variants: 450cc, 550cc Codes Model Codes: SXV450, SXV550, RXV450, RXV550 👋 Introduction Market Position Motorcycle Type: High-performance Supermoto / Dual-sport Target Audience: Enthusiasts, mechanics, owners requiring in-depth repair knowledge. Competitive Analysis Competitors: KTM EXC, Husqvarna SM/TE, Beta RR. Key Features Unique Selling Points: Powerful V-twin engines (550cc), sophisticated chassis and suspension, capable off-road and on-road performance. 📋 Manual Details Coverage Areas Model Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Page Count Estimated Page Count: 500+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Disassembly, assembly, inspection, overhaul of engine components (crankshaft, pistons, cylinders, valves, camshafts). Fuel System: Fuel injection system (throttle bodies, injectors, fuel pump, ECU mapping), carburetors (if applicable to specific variants). Ignition System: Ignition coil, spark plugs, ignition control module, timing. Cooling System: Radiator, coolant hoses, water pump, thermostat, coolant specifications. Exhaust System: Muffler, exhaust pipes, catalytic converter (if equipped), emission controls. Transmission Drivetrain: Clutch operation, gearbox disassembly and assembly, gear ratios, chain drive maintenance, sprocket replacement. Suspension: Front fork (Sachs/Marzocchi), rear shock absorber (Ohlins/Sachs), linkage systems, adjustment procedures, service. Brakes: Brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, pad replacement. Wheels Tires: Wheel bearing service, tire pressure recommendations, rim specifications. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor. Frame Chassis: Frame inspection, subframe, steering head bearing service. Bodywork Trim: Fairing removal and installation, seat, fuel tank. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, brake checks. Troubleshooting Diagnostics: Fault finding guides for engine, electrical, and mechanical issues, diagnostic codes. Repair Rebuild: Detailed step-by-step instructions for component disassembly, repair, and reassembly. Technical Specifications Data: Torque values, clearances, tolerances, fluid capacities, electrical specifications. Special Tools Equipment: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic checks to full engine and chassis overhauls. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text for quick information retrieval. Print Quality Image Resolution: High-resolution for clear diagrams and illustrations. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, V-twin Displacement 450: 449.8 cc Displacement 550: 549.3 cc Bore Stroke 450: 60 mm x 63.4 mm Bore Stroke 550: 72 mm x 68 mm Compression Ratio: Approximately 12.5:1 (varies by year/model) Performance Horsepower 450: Approx. 60-65 HP Horsepower 550: Approx. 70-75 HP Torque Peak: Significant torque across the rev range, specific figures vary by engine size. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with Keihin throttle bodies. Fuel Type: Unleaded gasoline (95-98 RON recommended) Fuel Tank Capacity: Approx. 7.4 Liters (1.95 Gallons) 🔧 Transmission Standard Transmission Type: 6-speed sequential gearbox Features Clutch Type: Wet, multi-plate clutch Final Drive: Chain drive (DID or similar quality recommended) 📐 Dimensions Exterior Length: Varies slightly by model year, typical range around 2200 mm Width: Varies slightly by model year, typical range around 800 mm Height: Varies slightly by model year, typical range around 1200 mm Weights Dry Weight: Approx. 130-140 kg (depending on model and year) Wet Weight: Approx. 150-160 kg (with fluids) Wheelbase: Approx. 1475 mm 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle, not subject to automotive crash testing standards). Active Features Braking System: Hydraulic disc brakes front and rear. Brembo calipers are common. Suspension Performance: Adjustable high-performance suspension contributes to stability and control. Passive Features Lighting: Halogen headlight, LED taillight/brake light. 💡 Technology Features Infotainment Display System: Digital LCD dashboard with speed, RPM, odometer, trip meter, fuel level, clock. 🔧 Maintenance Service Intervals Engine Oil Change: Every 3000-5000 km or annually, whichever comes first (refer to manual for exact interval). Air Filter Cleaning: Regular inspection, clean or replace as needed, especially after off-road use. Spark Plug Replacement: Refer to manual, typically around 10,000-15,000 km. Valve Clearance Check: Refer to manual, critical for engine performance and longevity, typically 10,000-15,000 km. Chain Lubrication Adjustment: Check and lubricate every 500 km or after riding in wet conditions; adjust slack as needed. Fluid Specifications Engine Oil Type: Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA/MA2). Engine Oil Capacity: Approx. 1.3-1.5 Liters (check dipstick/level plug). Coolant Type: Ethylene glycol based antifreeze coolant, mixed 50/50 with distilled water. Brake Fluid Type: DOT 4 or DOT 5.1 (refer to manual for specific recommendation). Fork Oil Type Viscosity: Refer to manual; typically specific motorcycle fork oil with viscosity around 5W or 7.5W. Known Issues Common Wear Items: Clutch plates, wheel bearings, stator, regulator/rectifier can be prone to wear with high mileage. Engine Performance Quirks: V-twin engines can be sensitive to fuel quality and tuning; occasional desmodromic valve adjustments...
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Aprilia SXV RXV 450 550 2006-2013 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV / RXV
Engine Variants:
450cc, 550cc
Codes
Model Codes:
SXV450, SXV550, RXV450, RXV550
👋 Introduction
Market Position
Motorcycle Type:
High-performance Supermoto / Dual-sport
Target Audience:
Enthusiasts, mechanics, owners requiring in-depth repair knowledge.
Competitive Analysis
Competitors:
KTM EXC, Husqvarna SM/TE, Beta RR.
Key Features
Unique Selling Points:
Powerful V-twin engines (550cc), sophisticated chassis and suspension, capable off-road and on-road performance.
📋 Manual Details
Coverage Areas
Model Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Page Count
Estimated Page Count:
500+
Manual Type
Manual Type:
Factory Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Disassembly, assembly, inspection, overhaul of engine components (crankshaft, pistons, cylinders, valves, camshafts).
Fuel System:
Fuel injection system (throttle bodies, injectors, fuel pump, ECU mapping), carburetors (if applicable to specific variants).
Ignition System:
Ignition coil, spark plugs, ignition control module, timing.
Cooling System:
Radiator, coolant hoses, water pump, thermostat, coolant specifications.
Exhaust System:
Muffler, exhaust pipes, catalytic converter (if equipped), emission controls.
Transmission Drivetrain:
Clutch operation, gearbox disassembly and assembly, gear ratios, chain drive maintenance, sprocket replacement.
Suspension:
Front fork (Sachs/Marzocchi), rear shock absorber (Ohlins/Sachs), linkage systems, adjustment procedures, service.
Brakes:
Brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, pad replacement.
Wheels Tires:
Wheel bearing service, tire pressure recommendations, rim specifications.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor.
Frame Chassis:
Frame inspection, subframe, steering head bearing service.
Bodywork Trim:
Fairing removal and installation, seat, fuel tank.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, brake checks.
Troubleshooting Diagnostics:
Fault finding guides for engine, electrical, and mechanical issues, diagnostic codes.
Repair Rebuild:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Technical Specifications Data:
Torque values, clearances, tolerances, fluid capacities, electrical specifications.
Special Tools Equipment:
Identification and usage of specialized tools required for specific repair procedures.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from basic checks to full engine and chassis overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Print Quality
Image Resolution:
High-resolution for clear diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, V-twin
Displacement 450:
449.8 cc
Displacement 550:
549.3 cc
Bore Stroke 450:
60 mm x 63.4 mm
Bore Stroke 550:
72 mm x 68 mm
Compression Ratio:
Approximately 12.5:1 (varies by year/model)
Performance
Horsepower 450:
Approx. 60-65 HP
Horsepower 550:
Approx. 70-75 HP
Torque Peak:
Significant torque across the rev range, specific figures vary by engine size.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Keihin throttle bodies.
Fuel Type:
Unleaded gasoline (95-98 RON recommended)
Fuel Tank Capacity:
Approx. 7.4 Liters (1.95 Gallons)
🔧 Transmission
Standard
Transmission Type:
6-speed sequential gearbox
Features
Clutch Type:
Wet, multi-plate clutch
Final Drive:
Chain drive (DID or similar quality recommended)
📐 Dimensions
Exterior
Length:
Varies slightly by model year, typical range around 2200 mm
Width:
Varies slightly by model year, typical range around 800 mm
Height:
Varies slightly by model year, typical range around 1200 mm
Weights
Dry Weight:
Approx. 130-140 kg (depending on model and year)
Wet Weight:
Approx. 150-160 kg (with fluids)
Wheelbase:
Approx. 1475 mm
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle, not subject to automotive crash testing standards).
Active Features
Braking System:
Hydraulic disc brakes front and rear. Brembo calipers are common.
Suspension Performance:
Adjustable high-performance suspension contributes to stability and control.
Passive Features
Lighting:
Halogen headlight, LED taillight/brake light.
💡 Technology Features
Infotainment
Display System:
Digital LCD dashboard with speed, RPM, odometer, trip meter, fuel level, clock.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3000-5000 km or annually, whichever comes first (refer to manual for exact interval).
Air Filter Cleaning:
Regular inspection, clean or replace as needed, especially after off-road use.
Spark Plug Replacement:
Refer to manual, typically around 10,000-15,000 km.
Valve Clearance Check:
Refer to manual, critical for engine performance and longevity, typically 10,000-15,000 km.
Chain Lubrication Adjustment:
Check and lubricate every 500 km or after riding in wet conditions; adjust slack as needed.
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA/MA2).
Engine Oil Capacity:
Approx. 1.3-1.5 Liters (check dipstick/level plug).
Coolant Type:
Ethylene glycol based antifreeze coolant, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for specific recommendation).
Fork Oil Type Viscosity:
Refer to manual; typically specific motorcycle fork oil with viscosity around 5W or 7.5W.
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, stator, regulator/rectifier can be prone to wear with high mileage.
Engine Performance Quirks:
V-twin engines can be sensitive to fuel quality and tuning; occasional desmodromic valve adjustments (if applicable) might be needed.
Electrical Gremlins:
Wiring harness integrity, especially around vibration points, should be checked periodically.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Model Evolution
Development Focus:
Designed for aggressive off-road riding and supermoto competition, with a focus on power and agility.
Key Changes Over Years:
Refinements in fuel injection mapping, suspension components, and minor chassis updates.
Production
Production Period:
2006-2013
🏆 Awards & Recognition
Recognitions
Motorsport Heritage:
The SXV/RXV platform has a strong racing pedigree in Supermoto and Enduro competitions.
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