Aprilia SXV RXV 450 550 2009 Service Repair Workshop Manual

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Type: Motorcycle

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Sku: 82338

Tags: 2009 Aprilia Misc Motorcycle Motorcycles RXV 450 RXV 550 SXV 450 SXV 550

Product variants

Description

The Aprilia SXV 450, SXV 550, RXV 450, and RXV 550 models, produced in 2009, represent a significant offering in the high-performance dual-sport and supermoto segments. These Italian-manufactured motorcycles are renowned for their potent V-twin engines, available in 450cc and 550cc displacements, delivering impressive horsepower and torque figures for their class. Featuring race-derived chassis, advanced suspension components, and powerful braking systems, these machines are engineered for exhilarating performance on both the street and track. Their aggressive styling and lightweight construction further enhance their appeal to enthusiasts seeking a track-inspired riding experience. This comprehensive service repair workshop manual provides in-depth guidance for the maintenance and repair of the 2009 Aprilia SXV and RXV models. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, cooling, exhaust, transmission, drivetrain, front and rear suspension, brakes, wheels, tires, and the electrical system. The manual also includes troubleshooting guides, routine maintenance schedules, and specific instructions for component overhauls and diagnostics. This resource is designed to assist owners, mechanics, and technicians in ensuring the optimal performance, reliability, and longevity of their Aprilia motorcycles.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

SXV 450, SXV 550, RXV 450, RXV 550

Year:

Codes

Chassis Codes:

RK, RN (SXV 450/550), RG, RL (RXV 450/550)

Engine Codes:

V994 L (450cc), V992 L (550cc) - V-twin configurations

👋 Introduction

Market Position

Positioning:

High-performance dual-sport/supermoto motorcycles known for their potent V-twin engines and capable chassis, catering to a niche market of enthusiasts seeking track-inspired street performance.

Competitive Analysis

Competitors:

KTM 690 SMC/Enduro, Husqvarna SM/TE series, Ducati Hypermotard (older generations).

Key Features

Features:

Powerful V-twin engines, race-derived chassis, high-quality suspension components (often from WP, Marzocchi, or Paioli), potent braking systems, lightweight construction, and aggressive styling.

📋 Manual Details

Coverage Areas

Primary Coverage:

Aprilia SXV 450, RXV 450, SXV 550, RXV 550

Secondary Coverage:

Related components and variations within the 2009 model year

Page Count

Estimated Pages:

300-400 pages (typical for comprehensive service manuals)

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of V-twin engines (450cc & 550cc), including cylinders, pistons, crankshaft, camshafts, valves, timing systems.

Fuel System:

Carburetor systems (Mikuni VM series or similar), fuel pump, fuel lines, fuel tank, and associated components.

Ignition System:

CDI ignition, spark plugs, ignition coils, stator, and wiring diagrams.

Cooling System:

Radiator, coolant hoses, thermostat, water pump, and fan operation.

Exhaust System:

Exhaust headers, mufflers, and associated mounting hardware.

Transmission:

Clutch system (wet multi-plate), gearbox disassembly, inspection, and reassembly, including gear sets, shift drum, and shift forks.

Drivetrain:

Chain drive system, sprockets, and swingarm maintenance.

Suspension Front:

Upside-down telescopic forks (e.g., Marzocchi or Paioli), including disassembly, seal replacement, oil changes, and adjustment procedures.

Suspension Rear:

Monoshock rear suspension, including linkage maintenance, shock absorber inspection and service, and spring pre-load adjustments.

Brakes Front:

Dual hydraulic disc brakes, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures.

Brakes Rear:

Single hydraulic disc brake, including caliper service, master cylinder overhaul, brake pad replacement, fluid flush, and bleeding procedures.

Wheels Tires:

Wheel bearing service, tire removal and installation, and rim maintenance.

Electrical System:

Battery maintenance, starter motor, lighting system (headlight, taillight, turn signals), horn, and wiring diagrams for all circuits.

Frame Bodywork:

Frame inspection and repair, body panel removal and installation, seat, fuel tank, and fairing components.

Troubleshooting:

Diagnostic procedures for common issues, symptom-based troubleshooting guides, and fault finding.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, chain adjustment, spark plug inspection, and general lubrication.

Engine Rebuild:

Complete engine teardown, component measurement, wear assessment, and reassembly with torque specifications.

Suspension Service:

Fork seal replacement, fork oil changes, shock absorber fluid replacement, and linkage bearing service.

Brake System Overhaul:

Complete brake caliper rebuilding, master cylinder servicing, and brake line replacement.

Electrical Diagnostics:

Wiring harness tracing, component testing (e.g., ignition coil resistance, stator output), and troubleshooting electrical faults.

Carburetor Tuning:

Adjustment of idle speed, mixture screws, and jetting recommendations for different conditions.

Technical Depth

Depth:

Comprehensive, from basic maintenance to complete engine and component overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Format Details:

Searchable PDF for easy navigation and printing of specific sections. High-resolution diagrams and clear text.

Print Quality

Print Quality:

Printable pages with clear schematics and legible text for workshop use.

Binding Type

Binding:

N/A (Digital PDF download)

Paper Type

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Configuration:

V-twin, 4-stroke, liquid-cooled

Displacement 450:

449.8 cc

Bore Stroke 450:

74 mm x 52.3 mm (approximate)

Displacement 550:

549.5 cc

Bore Stroke 550:

84 mm x 50 mm (approximate)

Performance

Horsepower 450:

Approx. 50-55 HP (may vary by tuning)

Horsepower 550:

Approx. 60-65 HP (may vary by tuning)

Torque 450:

Approx. 32-35 lb-ft

Torque 550:

Approx. 38-40 lb-ft

Fuel System

Induction Type:

Carbureted (typically dual Mikuni VM36 or similar)

Fuel Type:

Unleaded gasoline (91+ octane recommended)

Valvetrain

Actuation:

DOHC, 4 valves per cylinder

🔧 Transmission

Standard

Type:

6-speed manual transmission

Clutch:

Wet multi-plate clutch, hydraulically actuated

Features

Gear Ratios:

Specific ratios detailed in the manual, designed for aggressive acceleration and high-end performance.

Final Drive:

Chain drive

📐 Dimensions

Exterior

Wheelbase:

Approx. 1475 mm (58.1 in) (varies slightly between models)

Seat Height:

Approx. 900-920 mm (35.4-36.2 in) (subject to suspension setting)

Weights

Dry Weight:

Approx. 130-135 kg (287-298 lbs) (varies by model and specific configuration)

Fuel Tank Capacity:

Approx. 7.2 Liters (1.9 US Gallons)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable to motorcycles in the same way as automobiles. Focus is on rider control and active safety features.

Active Features

Braking System:

High-performance hydraulic disc brakes front and rear for effective stopping power.

Suspension Performance:

Adjustable suspension components contribute to rider control and stability in various riding conditions.

Passive Features

Frame Construction:

Sturdy frame design (often a steel trellis) for chassis rigidity and rider confidence.

💡 Technology Features

Infotainment

Features:

Basic instrumentation cluster (speedometer, tachometer, odometer, trip meter, warning lights). No advanced infotainment systems.

Driver Assistance

Features:

No electronic rider aids like ABS or traction control on standard models of this era.

Connectivity

Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 km (1,800-3,000 miles) or annually, whichever comes first. More frequent changes recommended for hard riding.

Air Filter Service:

Every 1,000-2,000 km (600-1,200 miles), or more often in dusty conditions.

Spark Plug Replacement:

Every 6,000-10,000 km (3,700-6,000 miles), check condition at oil changes.

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles) or as specified by the manual.

Fork Oil Change:

Every 1-2 years or 10,000-20,000 km (6,000-12,000 miles), or if performance degrades.

Fluid Specifications

Engine Oil:

API SG/SH/SJ, JASO MA, SAE 10W-40 or 15W-50 (refer to manual for specific viscosity based on climate).

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors, mixed 50/50 with distilled water.

Brake Fluid:

DOT 4 synthetic brake fluid.

Clutch Fluid:

DOT 4 or DOT 5.1 synthetic brake fluid (check manual for exact specification).

Fork Oil:

Specific viscosity oil (e.g., Showa SS-08, Motul Fork Oil Expert 7.5W) as per manual; quantity specified per fork leg.

Known Issues

Common Complaints:

Potential for electrical gremlins, clutch slave cylinder leaks, starter motor issues, and occasional carburetor tuning sensitivities. Cam chain tensioner wear on high-mileage examples. Valve seat wear on earlier models.

Common Issues

Maintenance Recommendations:

Strict adherence to maintenance schedule, regular cleaning of air filter, and keeping electrical connections clean and protected are crucial for longevity.

📚 Vehicle History

Brand Heritage

Heritage:

Aprilia has a rich history in motorcycle racing, particularly in off-road and sportbike categories, known for innovative engineering and performance-oriented machines.

Model Evolution

Evolution:

The SXV/RXV line represented Aprilia's foray into the supermoto and dual-sport segments, leveraging their V-twin engine technology from other racing platforms.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards are not widely documented, the SXV/RXV line was highly regarded by enthusiasts and the motorcycling press for its aggressive performance and handling characteristics, often winning comparison tests in its segment.