2006 Aprilia SXV 450, SXV 550, RXV 450, and RXV 550 Workshop Manual

• Official 177-page Aprilia factory workshop PDF, first edition January 2006, for the SXV/RXV 450-550 platform.
• Covers SXV 450 (45SX), SXV 550 (55SX), RXV 450 (45RX), and RXV 550 (55RX), with separate motard/enduro specifications and model-specific chassis data.
• Separates scheduled service requirements for original/derated road machines and open-version sport machines used for hobby or competitive riding.
• Documents engine-oil and gearbox-fluid service, cooling-system service, drive-chain inspection and adjustment, brake-fluid checks and front/rear brake bleeding, throttle-cable adjustment, and suspension setup.
• Provides model-specific SXV and RXV front-fork removal, fluid change, disassembly, seal and bushing replacement, reassembly, and installation procedures.
• Includes fuel-feed, injection, cooling, external oil-tank, and fork-assembly diagrams plus a full electrical-system schematic, component torque tables, capacity data, adjustment specifications, and Aprilia special-tool numbers.

SXV/RXV Coverage and Build Differences

This January 2006 factory 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. It combines operating and identification information with maintenance and repair procedures, making it useful both for confirming the exact machine and for carrying out the service work actually covered.

The manual does not treat the SXV motard and RXV enduro as interchangeable. Its technical tables distinguish engine model codes, transmission and final-drive ratios, chain construction, fork assemblies, brakes, wheel and tire packages, suspension travel, and chassis dimensions. The 450 and 550 versions are also separated by displacement-specific engine data and throttle-body sizing. Both use electronic fuel injection, liquid cooling, and separate engine and gearbox lubrication, with an external engine-oil reservoir.

Three service schedules address the original derated road configuration, the open sport version for hobby use, and the open sport version for competition. The schedules cover routine fluids and filters as well as higher-stress checks involving valve clearance, pistons and rings, camshafts, valve gear, connecting-rod bearings, clutch components, gearbox wear, cylinder balancing, throttle units, suspension, brakes, wheel bearings, and drive components.

Service and Repair Depth

Procedural coverage is strongest in routine maintenance, chassis removal work, and front suspension repair. The manual details spark-plug and fuse service, switch checks, headlight aiming, brake-pad and chain inspection, engine-oil and filter changes, gearbox-fluid service, coolant checks, throttle-cable adjustment, suspension adjustment, and hydraulic brake bleeding.

The chassis section covers removal of the battery, ECU, rear wheel, swingarm, exhaust system, fuel tank, air filter, radiators, and external oil tank, with rear-wheel installation also documented. Separate SXV and RXV fork chapters take the technician through fork-leg removal and installation, oil replacement, damper-rod removal, seal and bushing service, and complete fork reassembly. These are real factory repair procedures rather than a parts-list overview.

Diagrams, Specifications, and Special Tools

The system illustrations include the fuel-tank/pump/filter layout, injection sensor and actuator diagram, dual-radiator cooling circuit, external oil-tank plumbing, exploded SXV/RXV fork assemblies, and the full SXV-RXV wiring diagram. The electrical schematic identifies the diagnosis connector, ECU, twin injectors and coils, throttle-position and temperature sensors, crankshaft pickup, bank-angle sensor, 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 the 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.

The fork instructions flag two easy ways to damage parts: clamping the stanchion without protected jaws can mark or crush it, and sliding an oil seal over an uncovered bushing groove can cut the seal lip. They also show the left-leg speed-sensor lead routed outside the brake caliper with its protector so the cable is not pinched or misplaced during reassembly.

Scope Limits and Workshop Safety

This is not a complete internal-engine repair manual. It supplies engine specifications, torque tables, and scheduled inspection requirements, but it does not provide detailed procedures for engine removal, cylinder-head teardown, valve-clearance adjustment, cam-timing setup, piston or connecting-rod replacement, clutch or gearbox overhaul, or ECU fault isolation and programming. The electrical section is a wiring schematic, not a set of diagnostic flowcharts.

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. Those limits and precautions matter when deciding whether this PDF covers the planned repair or whether additional engine documentation is needed.