2006–2013 Aprilia SXV / RXV 450 Service Manual (P/N 9100650)

This official 148-page Aprilia PDF publication (P/N 9100650, first edition June 2006) serves as the primary technical reference for 2006–2013 SXV 450, RXV 450, SXV 550, and RXV 550 twin-cylinder motorcycles. Designed specifically for professional technicians and experienced mechanics, it details the core mechanical parameters for engine repair, lubrication, and transmission servicing throughout the production life of the 45SX, 45RX, 55SX, and 55RX engine builds.

• Contains 47 high-detail engine component breakdown photos
• Provides 15 complete torque-setting specification tables
• Includes 26 specialized factory tool identification listings
• Covers step-by-step instructions for splitting the engine crankcases, cam timing adjustments, complete gearbox rebuilds, primary transmission gear removal, and cylinder synchronization
• Explains the servicing of internal oil pumps, gear shift selectors, generator side assemblies, desmodromic drums, and valve springs

Engine Service and Component Walkthrough

This documentation breaks down the exact specifications needed to maintain and assemble the 450 and 550 series engines. It highlights essential mechanical overviews, offering complete outlines for engine removal, water pump servicing, and cylinder head teardowns. Inside, you will find authoritative reference material covering camshaft and rocker arm assembly, piston maintenance, and clutch pack replacement. The manual delivers clear procedures for advanced tasks that normally require an expensive dealership visit, such as separating the crankcase halves, rebuilding the secondary shafts, and precisely synchronizing the cylinders using a differential vacuum meter. The layout is structured logically. Mechanics can quickly locate critical reference data for timing chain tensioner inspections or lubrication system diagnostics. Specific visual aids, including limit values charts, the complete lubrication system diagram, gear ratio charts, Axone screen views, and valve spring uncompressed length drawings, heavily support the workflow.

Technical Specifications and Calibration Data

Engine performance data is heavily documented for all model variants. This includes compression ratios, valve timing angles, and gear ratios. The publication features extensive torque settings for critical engine components like the primary shaft, head bolts, and crankshaft bearings. A specialized section details the use of the Axone tool. This allows technicians to read engine parameters, manage ECU mapping, and troubleshoot error codes. Intake valve clearances for the 450 and 550 series are specified at 0.07–0.12 mm. Additionally, engine oil capacity for periodic changes is documented at 1300 cc. Crankcase class markings for bearing selection are explicitly detailed for precise component matching. Cross-referencing these laser-printed A/B tolerance classes ensures correct clearances and directly reduces the time spent at the workbench during a complete bottom-end rebuild.

When tackling major overhauls on these V-twins, technicians must navigate highly specific mechanical traps. The front cylinder camshaft retaining screw utilizes a left-hand thread, whereas the rear features a standard right-hand thread; applying force in the wrong direction will instantly shear the camshaft. Additionally, properly sealing the crankcase halves is absolutely critical, as these specific powerplants are prone to internal coolant and engine oil cross-contamination if the mating surfaces are not meticulously prepped. Operating on high-performance motorcycles carries inherent physical risks. Mechanics must strictly follow standard shop safety protocols, ensure adequate workspace ventilation against exhaust gases, and verify all specifications prior to starting heavy engine teardowns.