Aprilia SXV550 Winter Project

[spaceboy]

After searching for an SXV since August, I finally found one that was reasonably priced.
I picked up this 08 from Quebec a week ago. It's a non-runner and the tranny wont go into gear. Let the fun begin!

The goal for this project is to build a very clean and reliable SXV that I will ride on the street, annoy sportbikes at the track, and compete in the provincial supermoto series at Shannonville.
The engine will be sent to Noland Trans-World Cycle in Maryland. Allen is one of the top 'XV engine specialists in the world. The entire process will be photo-documented and shared here.

To-Do List
Basic Mods/Work:

• Rebuild motor/transmission
• Clean frame/bodywork/misc. parts
• Replace some bodywork
• Silmoto exhaust (http://youtu.be/ISdUcJHXza4)
• Fender eliminator
• Water temp gauge
• 17T (+1) front sprocket
• Handguards
• Powerdercoat wheels

Engine Work:

• Tranny rebuild
• Motor refresh, various reliability upgrades
• Valve adjustment
• MXV rear valve cover
• TPS adjustment
• ECU remap
• Sync throttle bodies

Race Mods:

• Front number plate
• Safety wire
• Crash protection
• Suspension refresh and respring
• Adjustable triple clamps

 

[spaceboy]

Engine is out and the bike is mostly stripped.

First bike I've owned with a dry-sump oil system.

The heart of the beast. In need of a good cleaning.

 

[reciprocity]

Add a Suter slipper clutch to your Race mods,, you'll thank me for it.

A 14 and 15t front sprocket would be a good idea if you plan to do any racing here, even with the 16t the gearbox is long and the bike just feels lazy, makes it very little fun, put some gear to them and you'll enjoy it much more.

Not sure what kind of MX background you have but I HATE going across neutral in the dirt so I always gear to use 2nd and up in the dirt sections at any particular track.

the OEM shifter and brake pedal are also TERRRRRRRIIIIBLLLE!!!!, no feel at all with either, not sure if hammerhead designs makes replacements for this bike but they are worth their weight in gold if you can get them.

 

[Shaman]

So glad you bought that bike. I thought I was going to end up owning it. lol

 

[georgy]

Love these bikes. Good luck with the project and I hope you join us next year.

 

[spaceboy]

Add a Suter slipper clutch to your Race mods,, you'll thank me for it.

A 14 and 15t front sprocket would be a good idea if you plan to do any racing here, even with the 16t the gearbox is long and the bike just feels lazy, makes it very little fun, put some gear to them and you'll enjoy it much more.

Not sure what kind of MX background you have but I HATE going across neutral in the dirt so I always gear to use 2nd and up in the dirt sections at any particular track.

the OEM shifter and brake pedal are also TERRRRRRRIIIIBLLLE!!!!, no feel at all with either, not sure if hammerhead designs makes replacements for this bike but they are worth their weight in gold if you can get them.

Good call, the suter comes well recommended. Most CRF450 slippers also fit the ape so it shouldn't be too hard to find a used one.
I think I have a 15T lying around. The 17T was more to quiet it down on short highway blasts. Some MX experience so I know what you mean.
I will definitely look into replacement pedals, I was planning on having a spare set anyways.

So glad you bought that bike. I thought I was going to end up owning it. lol

Lol, you're welcome. I jumped on it right away, didn't want to risk not finding one over the winter.

Love these bikes. Good luck with the project and I hope you join us next year.

Thanks, I can't wait.

 

[reciprocity]

careful buying used slipper clutches,, they make a mess when they go wrong.

If you're buying used, get a billet clutch hub as well.

 

[spaceboy]

Update! The engine shop is closed Dec 11th to Jan 8th, so I've put everything on hold until then. Hopefully nothing too bad is lurking between these cases.
I did order a complete Ti exhaust by Arrow that's very similar to the silmoto I mentioned above. Also ordered some smaller items: sliders, hand guards, fender eliminator, black front fender and side plastics.

I made a crate for the engine yesterday. The parts are waiting for me in Buffalo and it's quite a bit cheaper to ship the engine from there so I'm planning a trip for the 11th.

 

[spaceboy]

Shipped the motor today and picked up some parts. It will arrive by Wednesday and I should have an estimate for the rebuild by the end of the week.
The arrow titanium exhaust is incredibly light and the build quality is excellent. They are about ~$1500 new, so I'm glad I was able to find a used one in great shape. Supposed to sound even better than it looks, so I'm looking forward to that.

Next step is to clean up all the parts for reassembly. I may also have my wheels powder-coated white, but undecided at the moment.

 

[spaceboy]

Update on the engine. It arrived at Allen's on Wednesday and he opened it up today.

The transmission was run without oil and "got hotter than I've ever seen." The entire assembly will need to be replaced. The gears actually melted and welded to the shift fork. I can't help but laugh. Previous owner was a complete moron.
Apparently this was a blessing, a few more kms and it would have taken the crank with it. They are stupid expensive and constantly back-ordered.

He found some latte in the crankcase (oil+water). Very common with these motors, unfortunately. Doesn't take long for parts to get damaged. The bottom end bearings are down to the copper, but the crank and rods are not damaged (phew).

Engine was also run very hot at some point. Exhaust valves and seats are cooked.

These motors originally came with chrome plated buckets, which eventually flake. When they flake, they take the cams with them. Aprilia replaced them with DLC pieces in 2011. Mine are flaked and the cams are toast. About $500 for new cams and buckets.

Otherwise, just some small things that need to be replaced from neglect/ignorance.


None of this comes as a huge surprise. Most owners don't know how to care for these bikes and most shops don't know how to work on them. Case and point, the previous owner had a piston/liner replaced due to a cracked ring. The shop did not bother inspect the head before reinstalling it. Nor did they lap it or apply any sealant to the gasket. The cylinder base was also sealed with yamabond (wtf?), which found its way in to the oil pickup.

Photos of the carnage to follow.

 

[spaceboy]

Milky oil sitting in the head

Flattened front cam, rear is not much better

Transmission shavings

Not what you want sitting in your oil pickup

I don't know how the crank survived this

Transmission, melted gears

Flaked buckets

Pitted Valves

 

[spaceboy]

Out with the old, in with the new

The rebuild is going to cost a fair bit more than I expected, so I'll be extending my timeline. Cosmetic and suspension upgrades are going to be done later in the season.

 

[N3WMAN]

That engine could have been worse, but not by much.

Keep the melted tranny as a souvenir.

 

[Brian P]

Melted top gear ... nice. I wonder how long that engine ran without oil.

Condition like that gets pretty close to "radiator cap overhaul": Remove radiator cap, chuck away everything underneath and connected to, reinstall everything new, replace radiator cap, because that's pretty much the only thing you can re-use.

 

[mxs]

Wouldn't it be less expensive to just buy a rebuilt engine from a reliable source?

 

[spaceboy]

That engine could have been worse, but not by much.

Keep the melted tranny as a souvenir.

I plan to. Definitely lucked out with the crank.

Melted top gear ... nice. I wonder how long that engine ran without oil.

Condition like that gets pretty close to "radiator cap overhaul": Remove radiator cap, chuck away everything underneath and connected to, reinstall everything new, replace radiator cap, because that's pretty much the only thing you can re-use.

I'm guessing quite a while. Luckily the trans and crankcase are separate, like some Honda MX bikes.
Besides the engine it really doesn't need much. The previous owner didn't have it long enough to screw up anything else.

Wouldn't it be less expensive to just buy a rebuilt engine from a reliable source?

You would think so but a rebuilt 550 motor goes for about $3100 and they are in very short supply. Allen actually has a waiting list. Going this route I'll have a motor that is almost new internally for a bit less.

I'm still okay with the total cost. All-in I'm a bit less than the price that used '08s are going for. I'd rather have a motor that I know the history of than one that is supposedly well maintained and surprises me.

 

[spaceboy]

Also, the rebuild will give me a good foundation for this:

And maybe a bit of that:

 

[rye]

Out with the old, in with the new

The rebuild is going to cost a fair bit more than I expected, so I'll be extending my timeline. Cosmetic and suspension upgrades are going to be done later in the season.

Damn that's jacked up!!

 

[spaceboy]

Another quick update. I was waiting on some back-ordered engine parts that finally arrived last week. Unfortunately the "complete" piston kit is missing two rings, so the wait continues.
In the meantime I got the bike mostly disassembled for cleaning. Now to remove years of caked on gunk.

Engine partially assembled, awaiting piston rings.

 

[spaceboy]

Rings arrived this afternoon and Allen got it mostly buttoned up. Just waiting on a few small items.