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Aprilia SXV RXV 450 2006-2013 Factory Service Manual Repair

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🏷️ Basic Information Identification Make: Aprilia Model: SXV 450 / RXV 450 Production Years Covered: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013 Product Type: Factory Service Manual / Repair Manual Codes Chassis Code S: SXV450 / RXV450 👋 Introduction Market Position Segment: High-performance V-twin supermoto/motard and dual-sport motorcycles. Target Audience: Enthusiasts seeking to maintain, repair, and optimize their Aprilia SXV/RXV 450 motorcycles. Competitive Analysis Competitors During Era: KTM EXC series, Husqvarna SM/TE series, Beta RR series, Yamaha WR series, Honda CRF series. Key Features Unique Selling Proposition Of Vehicle: Powerful V-twin engine in a lightweight chassis, renowned for its aggressive styling and track-focused performance, transitioning from off-road (RXV) to supermoto (SXV) configurations. Value Of Manual: Essential for owners of these specialized motorcycles due to their complex engineering and performance-oriented nature. Provides critical information for proper maintenance and longevity. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for Aprilia SXV 450 and RXV 450 models. Page Count Estimated Page Count: Approximately 500+ pages (typical for comprehensive factory service manuals). Manual Type Manual Classification: Factory Service Manual (FSM) Language Language: English (assumed primary language for factory manuals unless otherwise specified) Format Digital Format: PDF (Portable Document Format) 📖 Manual Coverage Systems Covered Engine System: Complete overhaul procedures, internal component diagnostics and repair, valve adjustments, ignition system, fuel injection system, cooling system. Transmission Drivetrain System: Clutch operation and adjustment, gearbox disassembly and reassembly, chain and sprocket maintenance, lubrication specifications. Chassis Suspension Steering: Front fork disassembly, tuning, and seal replacement; rear shock absorber removal and service; swingarm and linkage maintenance; steering head bearing inspection and replacement; wheel bearing service. Braking System: Brake fluid replacement and bleeding procedures, caliper overhaul, master cylinder service, pad and rotor inspection and replacement. Electrical System: Wiring diagrams, starter motor and charging system (stator, regulator/rectifier), battery maintenance, lighting system diagnostics, ignition coil and spark plug testing, sensor diagnostics (TPS, MAP, etc.). Fuel System: Fuel pump operation and testing, fuel filter replacement, injector cleaning and testing, fuel tank maintenance. Bodywork And Trim: Fairing removal and installation, seat maintenance, handlebar adjustments, footpeg installation, plastic component repair and replacement. Procedures Included Scheduled Maintenance: Detailed service intervals for oil changes, filter replacements, chain lubrication, valve clearance checks, brake fluid flushes, and general inspection points. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting charts. Engine Rebuilding: Complete step-by-step instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications for critical fasteners. Suspension Tuning And Adjustment: Guidance on adjusting suspension settings for different riding conditions, including compression and rebound damping adjustments. Electrical Diagnostics: Flowcharts and tests for diagnosing electrical faults, including testing sensors, actuators, and wiring harnesses. Technical Depth Depth Of Coverage: Factory-level technical depth, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic checks to complete engine and chassis overhauls. 📊 Manual Specifications File Format PDF Quality: High-resolution scans with clear text and diagrams, optimized for digital viewing and printing. Searchable text functionality is highly probable. Print Quality Printable Pages: Designed to be printable, allowing users to create physical copies of specific sections or the entire manual. Binding Type Digital Binding Equivalent: N/A (Digital Format) Paper Type Digital Paper Equivalent: N/A (Digital Format - rendered on screen) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke, liquid-cooled Bore X Stroke: Approx. 84 mm x 77 mm (exact specifications may vary slightly by year) Displacement: 449 cc (approximate) Compression Ratio: Typically around 12.5:1 to 13.0:1 (requires manual verification) Valve Train: SOHC (Single Overhead Camshaft) per cylinder, 4 valves per cylinder Performance Horsepower Output: Estimated 50-60+ HP (requires manual verification for specific year/tune) Torque Output: Estimated 45-50+ Nm (requires manual verification for specific year/tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) - typically Weber Marelli or Keihin ECU Fuel Type: Unleaded Gasoline, Minimum 91 Octane (RON+MON)/2) Ignition System: Digital CDI with dual spark plugs per cylinder. 🔧 Transmission Standard Transmission Type: 6-speed sequential manual transmission Features Clutch Type: Hydraulically operated wet multi-plate clutch Final Drive: Chain drive 📐 Dimensions Exterior Length Overall: Variable depending on configuration (RXV generally longer/taller than SXV) Width Overall: Variable Height Overall: Variable Weights Dry Weight: Approx. 120-130 kg (requires manual verification) Wet Weight: Approx. 135-145 kg (with fluids, requires manual verification) Fuel Tank Capacity: Approx. 7-9 Liters (requires manual verification) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle segment not typically subjected to automotive crash testing protocols) Active Features Braking System Type: Hydraulic disc brakes, front and rear. Brembo calipers are common. Anti Lock Braking System: Optional on some later models, not standard across all years/variants. Passive Features Lighting System: Halogen headlight, LED taillight (on some models), turn signals. Instrumentation: Digital LCD display with tachometer, speedometer, odometer, trip meters, and diagnostic indicators. 💡 Technology Features Infotainment Infotainment System: N/A (Motorcycle, basic digital dashboard provided) Driver Assistance...
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Aprilia SXV RXV 450 2006-2013 Factory Service Manual Repair
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
SXV 450 / RXV 450
Production Years Covered:
2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013
Product Type:
Factory Service Manual / Repair Manual
Codes
Chassis Code S:
SXV450 / RXV450
👋 Introduction
Market Position
Segment:
High-performance V-twin supermoto/motard and dual-sport motorcycles.
Target Audience:
Enthusiasts seeking to maintain, repair, and optimize their Aprilia SXV/RXV 450 motorcycles.
Competitive Analysis
Competitors During Era:
KTM EXC series, Husqvarna SM/TE series, Beta RR series, Yamaha WR series, Honda CRF series.
Key Features
Unique Selling Proposition Of Vehicle:
Powerful V-twin engine in a lightweight chassis, renowned for its aggressive styling and track-focused performance, transitioning from off-road (RXV) to supermoto (SXV) configurations.
Value Of Manual:
Essential for owners of these specialized motorcycles due to their complex engineering and performance-oriented nature. Provides critical information for proper maintenance and longevity.
📋 Manual Details
Coverage Areas
Manual Coverage Scope:
Comprehensive service and repair for Aprilia SXV 450 and RXV 450 models.
Page Count
Estimated Page Count:
Approximately 500+ pages (typical for comprehensive factory service manuals).
Manual Type
Manual Classification:
Factory Service Manual (FSM)
Language
Language:
English (assumed primary language for factory manuals unless otherwise specified)
Format
Digital Format:
PDF (Portable Document Format)
📖 Manual Coverage
Systems Covered
Engine System:
Complete overhaul procedures, internal component diagnostics and repair, valve adjustments, ignition system, fuel injection system, cooling system.
Transmission Drivetrain System:
Clutch operation and adjustment, gearbox disassembly and reassembly, chain and sprocket maintenance, lubrication specifications.
Chassis Suspension Steering:
Front fork disassembly, tuning, and seal replacement; rear shock absorber removal and service; swingarm and linkage maintenance; steering head bearing inspection and replacement; wheel bearing service.
Braking System:
Brake fluid replacement and bleeding procedures, caliper overhaul, master cylinder service, pad and rotor inspection and replacement.
Electrical System:
Wiring diagrams, starter motor and charging system (stator, regulator/rectifier), battery maintenance, lighting system diagnostics, ignition coil and spark plug testing, sensor diagnostics (TPS, MAP, etc.).
Fuel System:
Fuel pump operation and testing, fuel filter replacement, injector cleaning and testing, fuel tank maintenance.
Bodywork And Trim:
Fairing removal and installation, seat maintenance, handlebar adjustments, footpeg installation, plastic component repair and replacement.
Procedures Included
Scheduled Maintenance:
Detailed service intervals for oil changes, filter replacements, chain lubrication, valve clearance checks, brake fluid flushes, and general inspection points.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon issues, including symptom-based troubleshooting charts.
Engine Rebuilding:
Complete step-by-step instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications for critical fasteners.
Suspension Tuning And Adjustment:
Guidance on adjusting suspension settings for different riding conditions, including compression and rebound damping adjustments.
Electrical Diagnostics:
Flowcharts and tests for diagnosing electrical faults, including testing sensors, actuators, and wiring harnesses.
Technical Depth
Depth Of Coverage:
Factory-level technical depth, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic checks to complete engine and chassis overhauls.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution scans with clear text and diagrams, optimized for digital viewing and printing. Searchable text functionality is highly probable.
Print Quality
Printable Pages:
Designed to be printable, allowing users to create physical copies of specific sections or the entire manual.
Binding Type
Digital Binding Equivalent:
N/A (Digital Format)
Paper Type
Digital Paper Equivalent:
N/A (Digital Format - rendered on screen)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke, liquid-cooled
Bore X Stroke:
Approx. 84 mm x 77 mm (exact specifications may vary slightly by year)
Displacement:
449 cc (approximate)
Compression Ratio:
Typically around 12.5:1 to 13.0:1 (requires manual verification)
Valve Train:
SOHC (Single Overhead Camshaft) per cylinder, 4 valves per cylinder
Performance
Horsepower Output:
Estimated 50-60+ HP (requires manual verification for specific year/tune)
Torque Output:
Estimated 45-50+ Nm (requires manual verification for specific year/tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) - typically Weber Marelli or Keihin ECU
Fuel Type:
Unleaded Gasoline, Minimum 91 Octane (RON+MON)/2)
Ignition System:
Digital CDI with dual spark plugs per cylinder.
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual transmission
Features
Clutch Type:
Hydraulically operated wet multi-plate clutch
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length Overall:
Variable depending on configuration (RXV generally longer/taller than SXV)
Width Overall:
Variable
Height Overall:
Variable
Weights
Dry Weight:
Approx. 120-130 kg (requires manual verification)
Wet Weight:
Approx. 135-145 kg (with fluids, requires manual verification)
Fuel Tank Capacity:
Approx. 7-9 Liters (requires manual verification)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle segment not typically subjected to automotive crash testing protocols)
Active Features
Braking System Type:
Hydraulic disc brakes, front and rear. Brembo calipers are common.
Anti Lock Braking System:
Optional on some later models, not standard across all years/variants.
Passive Features
Lighting System:
Halogen headlight, LED taillight (on some models), turn signals.
Instrumentation:
Digital LCD display with tachometer, speedometer, odometer, trip meters, and diagnostic indicators.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle, basic digital dashboard provided)
Driver Assistance
Driver Assistance Features:
Limited to standard motorcycle safety features like effective brakes and lighting. Advanced electronic rider aids like traction control or advanced ABS were not widespread on this model during its initial production.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 3,000-5,000 km or annually (refer to manual for exact recommendation based on usage).
Oil Filter Replacement Interval:
At every engine oil change.
Air Filter Cleaning Interval:
Every 1,500-3,000 km, or more frequently in dusty conditions.
Valve Clearance Check Interval:
Typically around 6,000-10,000 km (critical check for V-twin performance).
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA/MA2 compliant - consult manual for precise grade).
Engine Oil Capacity:
Approx. 1.7-2.0 Liters (dry fill) / 1.5-1.7 Liters (oil change with filter - requires manual verification).
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Specific Aprilia coolant may be recommended.
Brake Fluid Type:
DOT 4 (or DOT 5.1 if specified) hydraulic brake fluid.
Clutch Fluid Type:
DOT 4 hydraulic fluid (shared with brakes on many models).
Known Issues
Common Wear Items:
Clutch plates, wheel bearings, steering head bearings, fork seals, chain and sprockets, spark plugs, exhaust gaskets.
Potential Electrical Gremlins:
Wiring harness chafing, stator failure, regulator/rectifier issues can occur if not properly maintained or if aftermarket parts are poorly implemented.
Engine Specific Considerations:
Proper oil level and quality are crucial for the V-twin engine. Valve clearance maintenance is paramount for optimal performance and longevity.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, particularly in the 125cc and 250cc Grand Prix classes.
Model Evolution
Development Philosophy:
The SXV/RXV line represented Aprilia's push into the high-performance V-twin supermoto and dual-sport market, leveraging their engine expertise from road racing.
Key Developments During Production:
Improvements in fuel injection systems, engine management, chassis refinements, and suspension components throughout the 2006-2013 period.
Production
Manufacturing Location:
Italy
Production Timeline Overview:
The SXV/RXV 450 was a significant model for Aprilia, competing in a niche but popular segment, and continued production for several years with iterative updates.
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Praised for its aggressive styling, powerful V-twin engine, and nimble handling, often winning comparisons against contemporary competitors in the supermoto and dual-sport categories.
Ratings
Performance Ratings:
Highly rated for on-road performance (SXV) and off-road capability (RXV), though sometimes criticized for the high maintenance demands associated with its performance focus.
Certifications
Emissions Compliance:
Meets relevant emissions standards for its production years (e.g., Euro 3 in Europe), as detailed in the manual.
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