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Aprilia RSV Mille 956X 1999-2000 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Designation: RSV Mille R / RSV Mille SP Engine Code: 956X (Rotax V990 V-twin) Generation Generation Identifier: First Generation (SL1000) Codes Chassis Codes: RP / RPV 👋 Introduction Market Position Motorcycle Segment: Superbike / Sportbike Target Audience: Performance motorcycle enthusiasts, track day riders, and professional motorcycle mechanics. Competitive Analysis Key Competitors Era: Ducati 916/996, Honda RC51, Yamaha R1, Suzuki GSX-R750/1000, Kawasaki ZX-9R. Key Features Performance Focus: Renowned for its potent V-twin engine and track-bred chassis, offering a raw and engaging riding experience. Premium Components: Often featured high-spec components like Öhlins suspension and Brembo brakes as standard or optional. Manual Value Proposition: Essential resource for maintaining the performance and longevity of this iconic Italian superbike. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service and repair for Aprilia RSV Mille 956X models. Specific Models Covered: Aprilia RSV Mille 956X, RSV Mille R, RSV Mille SP Model Years Covered: 1999, 2000 Page Count Estimated Page Count: 500-700 pages (typical for this era's factory service manuals) Manual Type Manual Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, torque specifications, valve clearances, piston/cylinder details, crankshaft, connecting rods. Engine Fuel System: Carburetor overhaul (Keihin CVK), fuel pump, fuel lines, fuel tank maintenance. Engine Ignition System: ECU mapping, spark plug specifications, ignition timing, stator/rotor inspection. Cooling System: Radiator, fan, thermostat, coolant types and capacities, bleeding procedures. Exhaust System: Exhaust manifold, mufflers, emissions components (where applicable). Transmission Drivetrain: Clutch operation, gear shifting mechanisms, chain/sprocket inspection and maintenance. Suspension Front: Öhlins or Showa fork service, damping adjustments, spring rates, fork seal replacement, steering head bearing service. Suspension Rear: Monoshock absorber service (Öhlins), linkage lubrication and inspection, swingarm bearings. Brakes Front: Brembo caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, fluid type and bleeding. Brakes Rear: Brembo caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, fluid type and bleeding. Wheels Tires: Wheel bearing maintenance, tire pressure recommendations, wheel alignment checks. Electrical System: Wiring diagrams, battery maintenance, charging system (alternator/regulator), starter motor, lighting, fuses, relays. Instrumentation Controls: Dashboard component troubleshooting, switchgear operation, throttle/clutch cable adjustments. Bodywork Frame: Fairing removal and installation, frame inspection, seat and tank mounting. Procedures Included Routine Maintenance: Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid flush. Troubleshooting Diagnostics: Systematic diagnosis of common faults, fault code interpretation (if applicable to era), electrical system troubleshooting charts. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls. Component Overhaul: Detailed steps for rebuilding carburetors, calipers, master cylinders, and suspension units. Electrical Diagnostics: Wiring diagram interpretation, continuity testing, voltage drop testing. Technical Depth Depth Level: In-depth, professional-grade diagnostic and repair information suitable for experienced technicians. Diagnostic Tools: Information on required special tools, torque wrenches, multimeters, and diagnostic aids. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (OCR processed for efficient information retrieval) Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, V-twin (90-degree) Displacement: 998 cc (996 cc for some variants) Bore X Stroke: 97 mm x 68 mm Valvetrain: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Compression Ratio: 10.8:1 (typical) Performance Horsepower: Approx. 130-135 hp @ 9,500 rpm Torque: Approx. 97-100 Nm @ 7,500 rpm Fuel System Fuel Delivery: Dual Keihin CVK 40 carburetors Fuel Type: Unleaded gasoline, 95-98 RON Fuel Tank Capacity: Approx. 21 liters 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch: Wet multi-plate, hydraulic actuation Final Drive: Chain drive Features Gear Ratios: Specific ratios detailed in manual. Transmission Fluid Type: Motorcycle-specific gear oil (e.g., SAE 80W-90 GL-5) 📐 Dimensions Exterior Length: Approx. 2040 mm Width: Approx. 720 mm (at handlebars) Height: Approx. 1140 mm (at seat) Wheelbase: Approx. 1410 mm Weights Dry Weight: Approx. 185 kg Wet Weight: Approx. 205 kg (fully fueled) Payload Capacity: N/A (Sportbike design) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle safety ratings not standardized in the same way as cars) Active Features Braking System: Dual 320mm discs with 4-piston Brembo calipers (front), 220mm disc with 2-piston Brembo caliper (rear). Suspension Handling: High-quality, adjustable suspension (Öhlins/Showa) contributes to stability and control. Passive Features Frame Design: Aluminum twin-spar frame for rigidity and rider feedback. Lighting: Dual halogen headlights, LED tail light. 💡 Technology Features Infotainment Infotainment System: N/A (Designed for pure performance, not infotainment). Driver Assistance Traction Control: No factory-fitted traction control system on these early models. ABS: No factory-fitted ABS on these early models. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for specific recommendations). Valve Clearance...
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Aprilia RSV Mille 956X 1999-2000 Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Model Designation:
RSV Mille R / RSV Mille SP
Engine Code:
956X (Rotax V990 V-twin)
Generation
Generation Identifier:
First Generation (SL1000)
Codes
Chassis Codes:
RP / RPV
👋 Introduction
Market Position
Motorcycle Segment:
Superbike / Sportbike
Target Audience:
Performance motorcycle enthusiasts, track day riders, and professional motorcycle mechanics.
Competitive Analysis
Key Competitors Era:
Ducati 916/996, Honda RC51, Yamaha R1, Suzuki GSX-R750/1000, Kawasaki ZX-9R.
Key Features
Performance Focus:
Renowned for its potent V-twin engine and track-bred chassis, offering a raw and engaging riding experience.
Premium Components:
Often featured high-spec components like Öhlins suspension and Brembo brakes as standard or optional.
Manual Value Proposition:
Essential resource for maintaining the performance and longevity of this iconic Italian superbike.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair for Aprilia RSV Mille 956X models.
Specific Models Covered:
Aprilia RSV Mille 956X, RSV Mille R, RSV Mille SP
Model Years Covered:
1999, 2000
Page Count
Estimated Page Count:
500-700 pages (typical for this era's factory service manuals)
Manual Type
Manual Type:
Factory Service Repair Manual (FSM)
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine disassembly, assembly, inspection, torque specifications, valve clearances, piston/cylinder details, crankshaft, connecting rods.
Engine Fuel System:
Carburetor overhaul (Keihin CVK), fuel pump, fuel lines, fuel tank maintenance.
Engine Ignition System:
ECU mapping, spark plug specifications, ignition timing, stator/rotor inspection.
Cooling System:
Radiator, fan, thermostat, coolant types and capacities, bleeding procedures.
Exhaust System:
Exhaust manifold, mufflers, emissions components (where applicable).
Transmission Drivetrain:
Clutch operation, gear shifting mechanisms, chain/sprocket inspection and maintenance.
Suspension Front:
Öhlins or Showa fork service, damping adjustments, spring rates, fork seal replacement, steering head bearing service.
Suspension Rear:
Monoshock absorber service (Öhlins), linkage lubrication and inspection, swingarm bearings.
Brakes Front:
Brembo caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, fluid type and bleeding.
Brakes Rear:
Brembo caliper service, brake pad replacement, rotor inspection, master cylinder overhaul, fluid type and bleeding.
Wheels Tires:
Wheel bearing maintenance, tire pressure recommendations, wheel alignment checks.
Electrical System:
Wiring diagrams, battery maintenance, charging system (alternator/regulator), starter motor, lighting, fuses, relays.
Instrumentation Controls:
Dashboard component troubleshooting, switchgear operation, throttle/clutch cable adjustments.
Bodywork Frame:
Fairing removal and installation, frame inspection, seat and tank mounting.
Procedures Included
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid flush.
Troubleshooting Diagnostics:
Systematic diagnosis of common faults, fault code interpretation (if applicable to era), electrical system troubleshooting charts.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacement, brake system overhauls.
Component Overhaul:
Detailed steps for rebuilding carburetors, calipers, master cylinders, and suspension units.
Electrical Diagnostics:
Wiring diagram interpretation, continuity testing, voltage drop testing.
Technical Depth
Depth Level:
In-depth, professional-grade diagnostic and repair information suitable for experienced technicians.
Diagnostic Tools:
Information on required special tools, torque wrenches, multimeters, and diagnostic aids.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (OCR processed for efficient information retrieval)
Print Quality
Image Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, V-twin (90-degree)
Displacement:
998 cc (996 cc for some variants)
Bore X Stroke:
97 mm x 68 mm
Valvetrain:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Compression Ratio:
10.8:1 (typical)
Performance
Horsepower:
Approx. 130-135 hp @ 9,500 rpm
Torque:
Approx. 97-100 Nm @ 7,500 rpm
Fuel System
Fuel Delivery:
Dual Keihin CVK 40 carburetors
Fuel Type:
Unleaded gasoline, 95-98 RON
Fuel Tank Capacity:
Approx. 21 liters
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Clutch:
Wet multi-plate, hydraulic actuation
Final Drive:
Chain drive
Features
Gear Ratios:
Specific ratios detailed in manual.
Transmission Fluid Type:
Motorcycle-specific gear oil (e.g., SAE 80W-90 GL-5)
📐 Dimensions
Exterior
Length:
Approx. 2040 mm
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1140 mm (at seat)
Wheelbase:
Approx. 1410 mm
Weights
Dry Weight:
Approx. 185 kg
Wet Weight:
Approx. 205 kg (fully fueled)
Payload Capacity:
N/A (Sportbike design)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety ratings not standardized in the same way as cars)
Active Features
Braking System:
Dual 320mm discs with 4-piston Brembo calipers (front), 220mm disc with 2-piston Brembo caliper (rear).
Suspension Handling:
High-quality, adjustable suspension (Öhlins/Showa) contributes to stability and control.
Passive Features
Frame Design:
Aluminum twin-spar frame for rigidity and rider feedback.
Lighting:
Dual halogen headlights, LED tail light.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Designed for pure performance, not infotainment).
Driver Assistance
Traction Control:
No factory-fitted traction control system on these early models.
ABS:
No factory-fitted ABS on these early models.
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for specific recommendations).
Valve Clearance Check:
Every 10,000 - 12,000 km.
Chain Lubrication Adjustment:
Every 500-1,000 km, and after washing or riding in rain.
Fluid Specifications
Engine Oil Type:
API SG/SH or JASO MA compliant, viscosity 10W-40 or 10W-50 synthetic motorcycle oil.
Engine Oil Capacity:
Approx. 3.5 liters (with filter change).
Coolant Type:
Ethylene glycol-based coolant (e.g., Motul Motocool Expert or equivalent), mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 4 brake fluid.
Fork Oil Type:
Specific viscosity and type (e.g., SAE 5W or 7.5W) depending on Öhlins/Showa configuration, detailed in manual.
Known Issues
Starter Solenoid Reliability:
Some models may experience issues with the starter solenoid or wiring harness leading to starting problems.
Carburetor Sync And Cleaning:
Regular carburetor synchronization and cleaning are crucial for optimal performance due to the carburetor fuel system.
Cam Chain Tensioner:
The automatic cam chain tensioner can sometimes wear out, leading to rattling noises.
Regulator Rectifier Heat:
Early models might have had issues with heat management of the regulator/rectifier, potentially leading to failure.
📚 Vehicle History
Brand Heritage
Aprilia Motorsport Legacy:
Aprilia has a rich history in Grand Prix motorcycle racing, known for innovative engineering and performance.
Model Evolution
Rsv Mille Introduction:
The RSV Mille was Aprilia's first attempt at a large-displacement sportbike, aiming to compete with established Japanese and Italian rivals.
Engine Development Rotax:
Utilized the powerful Rotax V990 engine, a collaborative effort that provided a strong foundation for the Mille.
Variant Development:
The 'R' and 'SP' variants offered higher-spec components like fully adjustable Öhlins suspension and lighter wheels for enhanced performance.
Production
Production Period Early:
1997-2003 (First Generation SL1000)
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Industry Reviews:
Consistently praised for its V-twin character, handling, and Italian flair by motorcycle publications of its era.
Performance Accolades:
Considered a formidable competitor in the superbike class during its production run.
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