2006-2013 Aprilia SXV/RXV 450/550 Engine Service Manual

This Aprilia engine workshop manual covers the SXV 450, RXV 450, SXV 550, and RXV 550. First published in June 2006, it documents engine and gearbox repair, component inspection, and the associated factory adjustment data.

• Engine repair: Engine removal and refitting, cylinder-head and piston work, crankcase separation, bearing replacement, and cam-timing procedures.

• Clutch and gearbox: Clutch disassembly, wear checks, and reassembly, plus primary and secondary shaft service, selector-fork inspection, and selector-drum checks.

• Lubrication and cooling: Internal and external oil-pump removal and installation, a lubrication-system diagram, and water-pump impeller and seal service.

• Injection and diagnostics: Cylinder synchronization and Axone reference tables for engine parameters, fault displays, throttle self-learning, and injection adjustments.

• Factory specifications: Component-specific torque tables, bearing-selection charts, wear limits, lubricant requirements, and special-tool identification.

• Instrument panel: Measurement-unit selection, oil-change monitoring, service-reminder settings, and maintenance-warning resets.

Aprilia wrote this manual for its dealers and qualified mechanics, assuming familiarity with basic mechanics and established repair procedures.

Engine Disassembly, Inspection, and Timing

Cylinder-head work extends to camshaft and exhaust-rocker removal, valve and spring disassembly, valve-guide measurements, seat inspection, and timing-chain-tensioner checks. The cylinder and piston sections cover removal, dimensional wear checks, and installation.

Measurement drawings illustrate camshaft runout, rocker-arm inspection, valve and guide dimensions, and valve-spring checks. These accompany the component-specific inspection text and limit-value tables.

Cam-timing instructions distinguish front- and rear-cylinder positioning and the different thread directions of their camshaft fasteners. The crankshaft locating pin is identified as a positioning tool, with an explicit warning against using it to hold tightening loads.

Clutch, Gearbox Shafts, and Shift Selection

Clutch inspection addresses complete plate-pack wear, plate deformation, spring condition, and wear in the hub and housing. The manual also covers the pusher plate, thrust bearing, and primary-drive components.

Gearbox procedures extend to stripping the primary and secondary shafts, checking selector forks and the desmodromic selector drum, and rebuilding the shaft assemblies. The exploded gearbox-shaft drawing and its numbered key distinguish SXV and RXV gears and spacers.

Oil Pumps, Water Pump, and Crankcase Bearings

The lubrication-system diagram shows the relationship between the external oil tank and engine. Separate procedures cover the internal and external oil pumps; access to the internal pump requires crankcase separation.

Water-pump coverage includes impeller removal, cover and spacer handling, and reassembly with replacement sealing components. Engine removal and cooling-system work involve the fuel-vapor and hot-coolant hazards described in the safety section.

Bearing-selection charts cross-reference crankshaft, connecting-rod, and crankcase classes with bearing-shell colors. This helps match replacement shells to the marked components before reassembly.

The bearing-replacement sections warn that working on an inadequately warmed crankcase can damage its bearing housings.

Axone References and Workshop Equipment

Axone tables distinguish engine-parameter reading, device status, error displays, and adjustable parameters. They address front and rear injector and ignition-coil faults, throttle-position learning, idle CO adjustment, and injection-time correction.

The fault-display notes explain the relationship between the MEM indication and the EFI warning light when distinguishing current from stored faults. Mapping information is presented as an identification readout.

A 26-item special-tool list identifies equipment such as valve spring compressor 9100838, flywheel puller 9100839, and clutch housing locking tool 9100896.

The final Electrical System chapter is limited to instrument-panel setup and maintenance reminders. Vehicle wiring diagrams are outside this publication’s scope.

A Preview of Valve Clearances and Head Inspection Limits

The following figures are a small sample of the engine adjustment and inspection data in this manual.

For both 450 and 550 engines, the technical-data tables specify intake valve clearance of 0.07–0.12 mm and exhaust valve clearance of 0.17–0.22 mm.

For cylinder-head inspection, the limit-values chart specifies maximum head deformation of 0.05 mm. The corresponding inspection section describes checking the head against this limit.

Searchable Text, Bookmarks, and Illustration Detail

Text search and drawing detail: The manual’s body text is searchable, and 87 embedded PDF bookmarks provide access to chapters and individual procedures. Labels within the lubrication and gearbox drawings are graphical and are not included in text searches. The lubrication diagram has pale lettering that is easier to read when enlarged.

Supplied as one printable, English-language 148-page PDF. The total includes the chapter-opening and contents pages.