Aprilia SXV/RXV 450/550 Workshop Manual (2006)

This Aprilia factory workshop manual, first edition January 2006, covers SXV 450 (45SX), SXV 550 (55SX), RXV 450 (45RX), and RXV 550 (55RX). It combines operating and identification information with maintenance and repair procedures, helping identify the machine and carry out the service work covered.

PDF Text Search and Wiring Detail

Search, navigation, and diagram labels: The main text supports PDF search, but labels within the wiring diagram are not searchable. There are no embedded PDF bookmarks. Small wiring labels require zooming, and the schematic lines are light. Some diagram labels are in Italian; the accompanying component and wire-color keys are in English.

The ZIP download contains one printable English PDF with 177 pages, including seven original section-divider pages.

Scheduled Service, Chassis Work, and Fork Repair

The following selected topics outline the main workshop content. Other sections include multifunction-display settings and storage procedures.

• Maintenance schedules and fluids: Separate road, hobby sport, and competition schedules, plus engine-oil/filter changes, gearbox-fluid service, coolant checks, and throttle-cable adjustment.

• Brakes and drive chain: Brake-pad wear checks, front and rear hydraulic brake bleeding, chain inspection, slack adjustment, cleaning, and lubrication.

• Chassis removal: Battery, ECU, rear wheel, swingarm, exhaust system, fuel tank, air filter, radiators, and external oil tank, with rear-wheel installation also documented.

• SXV and RXV forks: Step-by-step removal, fluid replacement, disassembly, seal and bushing service, reassembly, and installation procedures for each version.

• Electrical service: Spark-plug and bulb replacement, fuse and brake-light switch checks, headlight aiming, and the SXV-RXV wiring diagram.

• Technical references: Fuel-feed, injection, cooling, and lubrication diagrams, plus model-specific gearing, suspension settings, torque tables, capacities, and Aprilia special-tool references.

This publication is suited to professional technicians and experienced owners who already have normal motorcycle workshop skills and the equipment needed for brake, chassis, and suspension work.

SXV/RXV Build Differences and Service Planning

The manual does not treat the SXV motard and RXV enduro as interchangeable. Its technical tables distinguish transmission and final-drive ratios, chain construction, fork assemblies, brakes, wheel and tire packages, suspension travel, and chassis dimensions.

The displacement-specific engine data and throttle-body sizing also distinguish the two engine sizes. Separate engine and gearbox lubrication, including the external engine-oil reservoir, is explained in the fluid-service sections and system drawings.

Three service schedules address the original derated road configuration, the open sport version for hobby use, and the open sport version for competition. Beyond routine service, they list checks involving valve clearance, pistons and rings, camshafts, valve gear, connecting-rod bearings, clutch components, gearbox wear, cylinder balance, and throttle-unit fasteners.

Suspension, brake, wheel-bearing, and drive-component checks are included in those schedules. These entries support maintenance planning; they do not establish that the corresponding internal overhaul procedures are included.

Fork Repair and Assembly Details

The separate fork chapters extend to damper-rod removal and the oil seal, dust seal, guide ring, shim, and bushing stack. Exploded SXV/RXV fork diagrams and assembly photographs accompany the procedures.

The fork instructions flag two ways to damage parts: excessive or unprotected vise clamping can mark or crush the stanchion, and an exposed bushing groove can cut the oil-seal lip during assembly. The RXV instructions also identify the protected speed-sensor cable route outside the brake caliper.

System Diagrams and Special Tools

Fuel, cooling, and lubrication: Illustrations show the fuel-tank/pump/filter layout, injection sensors and actuators, dual-radiator cooling circuit, and external oil-tank plumbing. These drawings help identify connections and components before removal work.

Electrical reference: The wiring schematic identifies the diagnosis connector, ECU, twin injectors and coils, throttle-position and temperature sensors, crankshaft pickup, and bank-angle sensor. It also maps the charging system, fan, fuel pump, starter circuit, lighting, and fuses.

Reference tables cover approved lubricants, capacities, gearing, suspension settings, tire and brake data, electrical ratings, inspection criteria, and assembly-specific torque values.

The special-tool list identifies RXV fork-seal driver 9100903, SXV fork-seal driver 9100904, swingarm cage punch 9100898, left-case desmo/wheel-hub punch 9100892, and swingarm-lever punch 9100900.

Internal-Engine and Diagnostic Limits

This is not a complete internal-engine repair manual. It supplies engine specifications, torque tables, and scheduled inspection requirements, but no detailed procedures for engine removal, cylinder-head teardown, valve-clearance adjustment, cam-timing setup, piston or connecting-rod replacement, or clutch and gearbox overhaul.

The electrical section provides a wiring schematic rather than diagnostic flowcharts. ECU fault isolation and programming are outside this publication’s scope.

Fuel-system work is accompanied by ventilation and fire-safety warnings, while brake bleeding and fork service require stable vehicle support and careful handling of brake fluid and fork oil.

Selected Fork-Level and Brake-Wear Specifications

Fork-fluid service specifies an air gap of 125 ± 2 mm for SXV forks and 100 ± 2 mm for RXV forks, measured from the leg edge. The measurement conditions call for the spring removed, the fork compressed, and the assembly held vertically.

The brake-pad inspection section gives approximately 1.5 mm of remaining friction material as a replacement threshold and also addresses wear-indicator visibility.