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Aprilia rxv/sxv 450-550 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RXV / SXV Model Variants: 450, 550 Vehicle Type: Dual-Sport / Supermoto Motorcycle Codes Engine Code Family: V990 Series (derived) 👋 Introduction Market Position Niche: High-performance off-road and street-legal supermoto motorcycles Target Audience: Enthusiasts seeking detailed technical information for maintenance and performance tuning Competitive Analysis Competition: KTM EXC/SXC, Husqvarna SM/TE series Key Features Manual Value Proposition: Provides factory-level diagnostic and repair procedures, crucial for complex V-twin engines and high-performance chassis components Vehicle Focus: Emphasis on the unique V-twin engine architecture and advanced suspension systems characteristic of Aprilia's performance off-road line. 📋 Manual Details Coverage Areas Primary Markets: Global (primarily Europe, North America) Vehicle Generations Covered: All production years for RXV450, RXV550, SXV450, SXV550 Page Count Estimated Page Count: 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF likely, based on description) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and overhaul Engine Management: Fuel injection system, ignition system, sensor diagnostics, ECU functions Transmission: Clutch operation, gearbox disassembly and assembly, shift mechanism Fuel System: Fuel pump, injectors, pressure regulator, tank, lines Cooling System: Radiator, water pump, thermostat, coolant flow, fan operation Exhaust System: Muffler, catalytic converter (if applicable), pipework Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, sensors, ECU Chassis Frame: Frame inspection, maintenance, and component replacement Suspension: Front forks (upside-down, adjustable), rear shock absorber, linkage systems, adjustment procedures Brakes: Front and rear brake systems, calipers, master cylinders, lines, bleeding procedures, pad replacement Wheels Tires: Wheel bearing replacement, tire fitting and removal, balancing Bodywork Trim: Fairings, seat, plastics, fuel tank removal and installation Controls: Handlebar, levers, footpegs, cable adjustments Procedures Included Routine Maintenance: Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement Troubleshooting: Diagnostic procedures for common faults, error codes interpretation Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair Component Removal Installation: Step-by-step guides for all major components Torque Specifications: Detailed torque values for all fasteners Technical Depth Depth: Comprehensive - suitable for professional mechanics and advanced DIY enthusiasts Diagnostic Capability: Advanced diagnostics, including electrical system tracing and fuel injection system troubleshooting 📊 Manual Specifications File Format Digital Format: PDF Searchability: Likely searchable text within PDF Print Quality Illustrations: Diagrams, schematics, and photographic illustrations Resolution: High resolution for clarity of diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, Liquid-cooled, V-twin (90-degree) Displacement 450: 449.5 cc Displacement 550: 549.4 cc Bore Stroke 450: 66.0 x 64.4 mm Bore Stroke 550: 75.0 x 64.4 mm Compression Ratio: Approximately 12.5:1 (varies slightly by model year/tune) Valve Train: DOHC, 4 valves per cylinder Lubrication: Wet sump (likely integrated oil tank with dry sump characteristics) Performance Horsepower 450: ~60 hp @ 8500 rpm (estimated) Horsepower 550: ~65-70 hp @ 8000 rpm (estimated) Torque 450: ~40 lb-ft @ 7000 rpm (estimated) Torque 550: ~45-50 lb-ft @ 6500 rpm (estimated) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Throttle Body: Dual throttle bodies (likely 46mm or similar) Fuel Requirement: Unleaded gasoline, minimum 91 octane (RON+MON)/2 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Hydraulic multi-plate wet clutch Optional Gear Ratios: Specific ratios available in manual; often close-ratio for performance Features Gearbox Design: Cassette-type gearbox for easier removal and maintenance 📐 Dimensions Exterior Frame Type: Perimeter frame, aluminum alloy Wheelbase: Approx. 1480-1510 mm (varies by model/settings) Rake Trail: Specific values in manual, optimized for stability and turn-in Weights Dry Weight 450: Approx. 115-120 kg (varies by model) Dry Weight 550: Approx. 118-123 kg (varies by model) Fuel Tank Capacity: Approx. 7.2 liters 🛡️ Safety Features Ratings Safety Certifications: Road-legal certification (e.g., DOT, ECE) for SXV models, off-road specific for RXV Active Features Braking System: High-performance hydraulic disc brakes, often Brembo calipers Tire Grip: Dependant on rider skill and tire choice (dual-sport or supermoto specific) Passive Features Frame Integrity: Robust aluminum perimeter frame designed for rigidity and impact resistance Lighting: Full road-legal lighting system (headlight, taillight, turn signals) on SXV, often simplified on RXV 💡 Technology Features Infotainment Infotainment System: Not applicable (performance motorcycle focus) Driver Assistance Rider Aids: Limited; focus on mechanical and electronic engine management (e.g., EFI mapping). No ABS or traction control typically. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual; typically every 2,000-3,000 km or annually Valve Check Interval: Refer to manual; critical for V-twins, likely around 5,000-7,000 km Spark Plug Replacement: Refer to manual; typically 6,000-10,000 km Fluid Specifications Engine Oil Type: Synthetic motorcycle engine oil, SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (refer to manual for exact spec) Coolant Type: Ethylene glycol based coolant, 50/50 mix with distilled water Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (if hydraulic) Fork Oil Type: Refer to manual; specific...
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Aprilia rxv/sxv 450-550 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RXV / SXV
Model Variants:
450, 550
Vehicle Type:
Dual-Sport / Supermoto Motorcycle
Codes
Engine Code Family:
V990 Series (derived)
👋 Introduction
Market Position
Niche:
High-performance off-road and street-legal supermoto motorcycles
Target Audience:
Enthusiasts seeking detailed technical information for maintenance and performance tuning
Competitive Analysis
Competition:
KTM EXC/SXC, Husqvarna SM/TE series
Key Features
Manual Value Proposition:
Provides factory-level diagnostic and repair procedures, crucial for complex V-twin engines and high-performance chassis components
Vehicle Focus:
Emphasis on the unique V-twin engine architecture and advanced suspension systems characteristic of Aprilia's performance off-road line.
📋 Manual Details
Coverage Areas
Primary Markets:
Global (primarily Europe, North America)
Vehicle Generations Covered:
All production years for RXV450, RXV550, SXV450, SXV550
Page Count
Estimated Page Count:
500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF likely, based on description)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine disassembly, assembly, inspection, and overhaul
Engine Management:
Fuel injection system, ignition system, sensor diagnostics, ECU functions
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism
Fuel System:
Fuel pump, injectors, pressure regulator, tank, lines
Cooling System:
Radiator, water pump, thermostat, coolant flow, fan operation
Exhaust System:
Muffler, catalytic converter (if applicable), pipework
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, sensors, ECU
Chassis Frame:
Frame inspection, maintenance, and component replacement
Suspension:
Front forks (upside-down, adjustable), rear shock absorber, linkage systems, adjustment procedures
Brakes:
Front and rear brake systems, calipers, master cylinders, lines, bleeding procedures, pad replacement
Wheels Tires:
Wheel bearing replacement, tire fitting and removal, balancing
Bodywork Trim:
Fairings, seat, plastics, fuel tank removal and installation
Controls:
Handlebar, levers, footpegs, cable adjustments
Procedures Included
Routine Maintenance:
Oil changes, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement
Troubleshooting:
Diagnostic procedures for common faults, error codes interpretation
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, electrical system diagnosis and repair
Component Removal Installation:
Step-by-step guides for all major components
Torque Specifications:
Detailed torque values for all fasteners
Technical Depth
Depth:
Comprehensive - suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Capability:
Advanced diagnostics, including electrical system tracing and fuel injection system troubleshooting
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Likely searchable text within PDF
Print Quality
Illustrations:
Diagrams, schematics, and photographic illustrations
Resolution:
High resolution for clarity of diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, Liquid-cooled, V-twin (90-degree)
Displacement 450:
449.5 cc
Displacement 550:
549.4 cc
Bore Stroke 450:
66.0 x 64.4 mm
Bore Stroke 550:
75.0 x 64.4 mm
Compression Ratio:
Approximately 12.5:1 (varies slightly by model year/tune)
Valve Train:
DOHC, 4 valves per cylinder
Lubrication:
Wet sump (likely integrated oil tank with dry sump characteristics)
Performance
Horsepower 450:
~60 hp @ 8500 rpm (estimated)
Horsepower 550:
~65-70 hp @ 8000 rpm (estimated)
Torque 450:
~40 lb-ft @ 7000 rpm (estimated)
Torque 550:
~45-50 lb-ft @ 6500 rpm (estimated)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body:
Dual throttle bodies (likely 46mm or similar)
Fuel Requirement:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch:
Hydraulic multi-plate wet clutch
Optional
Gear Ratios:
Specific ratios available in manual; often close-ratio for performance
Features
Gearbox Design:
Cassette-type gearbox for easier removal and maintenance
📐 Dimensions
Exterior
Frame Type:
Perimeter frame, aluminum alloy
Wheelbase:
Approx. 1480-1510 mm (varies by model/settings)
Rake Trail:
Specific values in manual, optimized for stability and turn-in
Weights
Dry Weight 450:
Approx. 115-120 kg (varies by model)
Dry Weight 550:
Approx. 118-123 kg (varies by model)
Fuel Tank Capacity:
Approx. 7.2 liters
🛡️ Safety Features
Ratings
Safety Certifications:
Road-legal certification (e.g., DOT, ECE) for SXV models, off-road specific for RXV
Active Features
Braking System:
High-performance hydraulic disc brakes, often Brembo calipers
Tire Grip:
Dependant on rider skill and tire choice (dual-sport or supermoto specific)
Passive Features
Frame Integrity:
Robust aluminum perimeter frame designed for rigidity and impact resistance
Lighting:
Full road-legal lighting system (headlight, taillight, turn signals) on SXV, often simplified on RXV
💡 Technology Features
Infotainment
Infotainment System:
Not applicable (performance motorcycle focus)
Driver Assistance
Rider Aids:
Limited; focus on mechanical and electronic engine management (e.g., EFI mapping). No ABS or traction control typically.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically every 2,000-3,000 km or annually
Valve Check Interval:
Refer to manual; critical for V-twins, likely around 5,000-7,000 km
Spark Plug Replacement:
Refer to manual; typically 6,000-10,000 km
Fluid Specifications
Engine Oil Type:
Synthetic motorcycle engine oil, SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (refer to manual for exact spec)
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic)
Fork Oil Type:
Refer to manual; specific viscosity and quantity for adjustable forks
Known Issues
Common Wear Items:
Cam chain tensioners, fuel pump, starter motor, electrical connectors, valve guide seals (all covered in manual for diagnosis/repair)
Performance Tuning Considerations:
ECU remapping, exhaust upgrades, camshaft changes; manual provides baseline for modifications
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia is renowned for its performance-oriented motorcycles, particularly in racing and off-road disciplines.
Model Evolution
Development Basis:
These models evolved from Aprilia's extensive experience in off-road racing, particularly Enduro and Supermoto.
Engine Heritage:
The V-twin engine architecture is derived from Aprilia's larger V990 V-twin found in their sportbikes, adapted for off-road use.
Production
Production Period:
Mid-2000s onwards (specific model years covered by manual)
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Industry Perception:
Highly regarded for performance and handling in their respective categories (motocross, supermoto, dual-sport)
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