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Aprilia SXV RXV 450 550 2012 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: SXV RXV Year: 2012 Codes Vin Prefix: ZDA 👋 Introduction Market Position Segment: High-performance off-road/supermoto motorcycle Target Audience: Enthusiast owners, independent repair shops, track day riders Competitive Analysis Key Competitors 2012: KTM 690 SMC/Enduro R, Husqvarna SMS4/TE series, Yamaha WR450F/YZ450F Key Features Engine Type: Liquid-cooled, four-stroke, V-twin engine Frame Design: Trellis frame for rigidity and lightness Suspension Brand: Premium components (Sachs/Marzocchi) offering adjustability 📋 Manual Details Coverage Areas Manual Type: Full Service Repair Manual Language: English Format: Digital (Likely PDF) Page Count Page Count Estimate: Extensive (typical for full service manuals, likely 500+ pages) 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the V-twin engine (450cc and 550cc variants) Fuel System: Carburetor tuning and rebuilding (if applicable), fuel injection system diagnostics and repair (if applicable), fuel pump, fuel filter replacement Ignition System: Spark plugs, ignition coils, timing, CDI unit troubleshooting Cooling System: Radiator, hoses, coolant, water pump inspection and replacement Exhaust System: Muffler, headers, catalytic converter (if applicable) inspection and replacement Transmission: Gearbox disassembly, inspection, and repair, clutch operation and adjustment, chain and sprocket maintenance Chassis Frame: Frame inspection, alignment, and repair procedures Suspension: Front fork (Sachs/Marzocchi) disassembly, servicing, seal replacement, and adjustment; rear shock absorber (Sachs) servicing and adjustment Braking System: Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding, master cylinder inspection Wheel Hubs Spokes: Wheel bearing replacement, spoke tensioning, hub maintenance Electrical System: Wiring diagrams, battery maintenance, starter motor, alternator, lighting system troubleshooting Bodywork Fairings: Fairing removal, installation, and repair, seat maintenance Procedures Included Preventative Maintenance: Scheduled maintenance tasks, lubrication points, fluid level checks Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based fault finding Engine Rebuild: Complete engine overhaul, piston replacement, ring installation, valve lapping, gasket replacement Suspension Servicing: Fork oil change, seal replacement, shock absorber service Brake System Overhaul: Caliper rebuilding, master cylinder servicing, line replacement Electrical Diagnostics: Wiring harness checks, component testing, fault code interpretation (if applicable) Technical Depth Depth: Comprehensive, covering everything from basic adjustments to complete engine and chassis rebuilds Diagnostics: Detailed diagnostic flowcharts and troubleshooting guides Torque Specifications: Precise torque values for all critical fasteners Clearances: Engine component clearances (valve lash, piston-to-cylinder wall, etc.) 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchable: Yes (typically, if digitally produced and not scanned OCR) Printable: Yes (standard PDF functionality) Print Quality Print Quality Recommendation: High-resolution for clear diagrams and text Binding Type Binding Type Recommendation: Coil-bound or comb-bound for lay-flat use in workshop environments (for physical prints) Paper Type Paper Type Recommendation: Durable, matte finish paper to reduce glare and handle workshop conditions (for physical prints) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, V-twin Bore X Stroke 450: Approx. 72 mm x 54.2 mm Bore X Stroke 550: Approx. 75 mm x 63.7 mm Displacement 450: 449.5 cc Displacement 550: 549.2 cc Compression Ratio 450: Approx. 12.5:1 Compression Ratio 550: Approx. 12.0:1 Valve Train: SOHC (Single Overhead Camshaft), 4 valves per cylinder Performance Horsepower 450 Estimate: ~50-55 HP Horsepower 550 Estimate: ~60-65 HP Torque 450 Estimate: ~35-40 lb-ft Torque 550 Estimate: ~40-45 lb-ft Fuel System Fuel Delivery: Mikuni VM38 (450) / Keihin FCR41 (550) Carburetors or Electronic Fuel Injection (check specific variant) Fuel Type: Unleaded Premium Gasoline (91+ Octane) Lubrication Oil Capacity W Filter: Approx. 1.5 - 1.7 Liters (check manual for exact spec) Engine Oil Type Recommendation: JASO MA certified, SAE 10W-40 or 10W-50 Synthetic Motorcycle Oil (check manual for precise grade) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Transmission Options: N/A (single configuration) Features Clutch Type: Wet multi-plate Transmission Oil Capacity: Approx. 0.7 Liters (check manual for exact spec) Transmission Oil Type: API SG or higher, SAE 75W-90 Gear Oil (check manual for precise grade) 📐 Dimensions Exterior Length: Approx. 2180 mm (SXV/RXV vary slightly) Width: Approx. 800 mm Height: Approx. 1250 mm Weights Dry Weight 450: Approx. 119 kg (262 lbs) Dry Weight 550: Approx. 125 kg (275 lbs) Wet Weight Estimate: Approx. 135-140 kg (with fluids) Wheelbase Wheelbase: Approx. 1470 mm (1485 mm for RXV) Ground Clearance Ground Clearance: Approx. 290 mm 🛡️ Safety Features Ratings Safety Certification: CE Certified (for European markets, not a US DOT rating) Active Features Braking System: Hydraulic disc brakes front and rear (Brembo calipers typically) Front Brake Disc Size: 320 mm Rear Brake Disc Size: 240 mm Passive Features Lighting: Halogen headlight, LED taillight Frame Strength: High-tensile steel trellis frame designed for off-road abuse 💡 Technology Features Infotainment Infotainment System: N/A (focused on performance, not rider amenities) Driver Assistance ABS: Optional/Market Dependent (rarely fitted to this model) Instrumentation Dashboard Type: Digital LCD display (speedometer, tachometer, odometer, trip meter, clock, warning lights) 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000-5,000 km or annually, whichever comes first (refer to manual) Air Filter...
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Aprilia SXV RXV 450 550 2012 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV RXV
Year:
2012
Codes
Vin Prefix:
ZDA
👋 Introduction
Market Position
Segment:
High-performance off-road/supermoto motorcycle
Target Audience:
Enthusiast owners, independent repair shops, track day riders
Competitive Analysis
Key Competitors 2012:
KTM 690 SMC/Enduro R, Husqvarna SMS4/TE series, Yamaha WR450F/YZ450F
Key Features
Engine Type:
Liquid-cooled, four-stroke, V-twin engine
Frame Design:
Trellis frame for rigidity and lightness
Suspension Brand:
Premium components (Sachs/Marzocchi) offering adjustability
📋 Manual Details
Coverage Areas
Manual Type:
Full Service Repair Manual
Language:
English
Format:
Digital (Likely PDF)
Page Count
Page Count Estimate:
Extensive (typical for full service manuals, likely 500+ pages)
📖 Manual Coverage
Systems Covered
Engine:
Detailed disassembly, assembly, inspection, and repair of the V-twin engine (450cc and 550cc variants)
Fuel System:
Carburetor tuning and rebuilding (if applicable), fuel injection system diagnostics and repair (if applicable), fuel pump, fuel filter replacement
Ignition System:
Spark plugs, ignition coils, timing, CDI unit troubleshooting
Cooling System:
Radiator, hoses, coolant, water pump inspection and replacement
Exhaust System:
Muffler, headers, catalytic converter (if applicable) inspection and replacement
Transmission:
Gearbox disassembly, inspection, and repair, clutch operation and adjustment, chain and sprocket maintenance
Chassis Frame:
Frame inspection, alignment, and repair procedures
Suspension:
Front fork (Sachs/Marzocchi) disassembly, servicing, seal replacement, and adjustment; rear shock absorber (Sachs) servicing and adjustment
Braking System:
Front and rear brake caliper overhaul, brake pad replacement, brake fluid bleeding, master cylinder inspection
Wheel Hubs Spokes:
Wheel bearing replacement, spoke tensioning, hub maintenance
Electrical System:
Wiring diagrams, battery maintenance, starter motor, alternator, lighting system troubleshooting
Bodywork Fairings:
Fairing removal, installation, and repair, seat maintenance
Procedures Included
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, fluid level checks
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based fault finding
Engine Rebuild:
Complete engine overhaul, piston replacement, ring installation, valve lapping, gasket replacement
Suspension Servicing:
Fork oil change, seal replacement, shock absorber service
Brake System Overhaul:
Caliper rebuilding, master cylinder servicing, line replacement
Electrical Diagnostics:
Wiring harness checks, component testing, fault code interpretation (if applicable)
Technical Depth
Depth:
Comprehensive, covering everything from basic adjustments to complete engine and chassis rebuilds
Diagnostics:
Detailed diagnostic flowcharts and troubleshooting guides
Torque Specifications:
Precise torque values for all critical fasteners
Clearances:
Engine component clearances (valve lash, piston-to-cylinder wall, etc.)
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchable:
Yes (typically, if digitally produced and not scanned OCR)
Printable:
Yes (standard PDF functionality)
Print Quality
Print Quality Recommendation:
High-resolution for clear diagrams and text
Binding Type
Binding Type Recommendation:
Coil-bound or comb-bound for lay-flat use in workshop environments (for physical prints)
Paper Type
Paper Type Recommendation:
Durable, matte finish paper to reduce glare and handle workshop conditions (for physical prints)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, V-twin
Bore X Stroke 450:
Approx. 72 mm x 54.2 mm
Bore X Stroke 550:
Approx. 75 mm x 63.7 mm
Displacement 450:
449.5 cc
Displacement 550:
549.2 cc
Compression Ratio 450:
Approx. 12.5:1
Compression Ratio 550:
Approx. 12.0:1
Valve Train:
SOHC (Single Overhead Camshaft), 4 valves per cylinder
Performance
Horsepower 450 Estimate:
~50-55 HP
Horsepower 550 Estimate:
~60-65 HP
Torque 450 Estimate:
~35-40 lb-ft
Torque 550 Estimate:
~40-45 lb-ft
Fuel System
Fuel Delivery:
Mikuni VM38 (450) / Keihin FCR41 (550) Carburetors or Electronic Fuel Injection (check specific variant)
Fuel Type:
Unleaded Premium Gasoline (91+ Octane)
Lubrication
Oil Capacity W Filter:
Approx. 1.5 - 1.7 Liters (check manual for exact spec)
Engine Oil Type Recommendation:
JASO MA certified, SAE 10W-40 or 10W-50 Synthetic Motorcycle Oil (check manual for precise grade)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Transmission Options:
N/A (single configuration)
Features
Clutch Type:
Wet multi-plate
Transmission Oil Capacity:
Approx. 0.7 Liters (check manual for exact spec)
Transmission Oil Type:
API SG or higher, SAE 75W-90 Gear Oil (check manual for precise grade)
📐 Dimensions
Exterior
Length:
Approx. 2180 mm (SXV/RXV vary slightly)
Width:
Approx. 800 mm
Height:
Approx. 1250 mm
Weights
Dry Weight 450:
Approx. 119 kg (262 lbs)
Dry Weight 550:
Approx. 125 kg (275 lbs)
Wet Weight Estimate:
Approx. 135-140 kg (with fluids)
Wheelbase
Wheelbase:
Approx. 1470 mm (1485 mm for RXV)
Ground Clearance
Ground Clearance:
Approx. 290 mm
🛡️ Safety Features
Ratings
Safety Certification:
CE Certified (for European markets, not a US DOT rating)
Active Features
Braking System:
Hydraulic disc brakes front and rear (Brembo calipers typically)
Front Brake Disc Size:
320 mm
Rear Brake Disc Size:
240 mm
Passive Features
Lighting:
Halogen headlight, LED taillight
Frame Strength:
High-tensile steel trellis frame designed for off-road abuse
💡 Technology Features
Infotainment
Infotainment System:
N/A (focused on performance, not rider amenities)
Driver Assistance
ABS:
Optional/Market Dependent (rarely fitted to this model)
Instrumentation
Dashboard Type:
Digital LCD display (speedometer, tachometer, odometer, trip meter, clock, warning lights)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 km or annually, whichever comes first (refer to manual)
Air Filter Cleaning:
Check/clean every 1,000-2,000 km, replace as needed
Spark Plug Replacement:
Every 6,000-10,000 km
Valve Clearance Check:
Every 6,000-10,000 km
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, valve guides/seals, fork seals, wheel bearings, swingarm/steering head bearings
Potential Issues To Monitor:
Fuel pump reliability, starter motor engagement, coolant leaks, electrical connections
Common Fixes
Overheating Prevention:
Ensure cooling system is free of air, clean radiator fins, proper coolant level
Clutch Adjustment Issues:
Proper lever play, clutch slave cylinder seal integrity
📚 Vehicle History
Brand Heritage
Brand Origin:
Italy
Brand Focus:
Performance motorcycles, particularly in racing and off-road segments
Model Evolution
Sxv Rxv Introduction Year:
Early 2000s (V-twin models started around 2004-2006)
Key Innovations:
Introduction of V-twin engines in supermoto/off-road platforms, high-spec suspension components
Production
Manufacturing Location:
Italy
Production Status 2012:
Ongoing (2012 model year)
🏆 Awards & Recognition
Recognitions
Historical Reputation:
Respected for its powerful V-twin engine and potent supermoto/off-road capabilities, though sometimes noted for demanding maintenance
Ratings
Industry Reviews:
Generally praised for performance and handling, but criticized for complexity and maintenance requirements compared to single-cylinder competitors.
Certifications
Emissions Compliance:
Euro 3 (for European models)
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