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Aprilia RST Mille 2000 Workshop Repair Service Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Year: 2000 Vehicle Type: Sport-Touring Motorcycle Codes Engine Code: Rotax 990 V60 Magnesium 👋 Introduction Market Position Positioning: The Aprilia RST Mille 2000 was positioned as a high-performance Italian sport-touring motorcycle, blending potent engine performance with comfortable ergonomics for long-distance riding. It targeted experienced riders seeking a blend of speed, handling, and touring capability. Competitive Analysis Competitors: Competed against sport-touring machines from Japanese manufacturers like Yamaha (YZF1000R Thunderace), Kawasaki (ZZ-R1100/1200), and Suzuki (GSX1300R Hayabusa), as well as European offerings like Ducati's ST series. Key Features Distinguishing Features: Powerful V-twin engine, advanced chassis design, aggressive styling, sophisticated suspension, and an emphasis on Italian engineering and performance. 📋 Manual Details Coverage Areas Engine: Complete overhaul, tuning, diagnostics, fuel system, lubrication, cooling system, ignition system, exhaust system. Transmission: Gearbox inspection, maintenance, repair, clutch operation, final drive. Chassis: Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings. Brakes: Brake system maintenance, hydraulic components, caliper servicing, disc inspection, bleeding procedures. Electrical: Wiring diagrams, battery, charging system, starter motor, lighting, instrumentation, fault finding. Bodywork: Fairing removal and installation, seat, fuel tank, body panel maintenance. Troubleshooting: Common problems, diagnostic flowcharts, error code interpretation. Page Count Estimated Pages: ~500-700 Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered All Systems: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission, Drive Train, Chassis, Suspension, Steering, Brakes, Wheels, Tires, Electrical System, Instrumentation, Lighting, Bodywork, Maintenance Procedures, Troubleshooting. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain lubrication, brake pad replacement, coolant flush. Repair: Engine rebuild, gearbox overhaul, suspension component replacement, electrical component repair, brake caliper servicing. Troubleshooting: Diagnostic steps for starting issues, running problems, electrical faults, braking performance. Diagnostics: Systematic fault finding, use of diagnostic tools (if applicable), interpretation of symptoms. Technical Depth Depth: Comprehensive, covering basic servicing to full mechanical and electrical overhauls. Includes detailed specifications and procedures. 📊 Manual Specifications File Format Format: Digital PDF Searchability: Text-searchable for efficient information retrieval. Print Quality Quality: High-resolution scans, clear diagrams and text suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 60-degree V-twin Displacement: 998 cc (996 cm³) Bore X Stroke: 97 mm x 68 mm Performance Horsepower Peak: Approx. 130-135 hp (96-100 kW) at 9,000 rpm Torque Peak: Approx. 100-105 Nm (74-77 lb-ft) at 7,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder Fuel Type: Unleaded Gasoline (95-98 RON recommended) Ignition System Type: Digital electronic ignition with dual spark plugs per cylinder Lubrication System Type: Wet sump with oil cooler Cooling System Type: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate, hydraulically operated Features Final Drive: O-ring sealed chain drive 📐 Dimensions Exterior Length: Approx. 2,100 mm (82.7 in) Width: Approx. 760 mm (30 in) Height: Approx. 1,220 mm (48 in) Wheelbase: Approx. 1,450 mm (57.1 in) Weights Dry Weight: Approx. 205 kg (452 lbs) Wet Weight: Approx. 230 kg (507 lbs) (with fluids) 🛡️ Safety Features Ratings Safety Features General: High-performance braking system, advanced chassis stability, good rider visibility. Active Features Braking System: Dual 320mm discs with 4-piston radial calipers (front), Single 240mm disc with 2-piston caliper (rear). Brembo components. Suspension Features: Fully adjustable front forks (e.g., Showa or Paioli) and adjustable rear monoshock (e.g., Ohlins or Sachs) for optimized handling and stability. Passive Features Lighting: Halogen headlight, LED taillight, turn signals for visibility. 💡 Technology Features Infotainment Instrumentation: Digital dashboard with analog tachometer, LCD display for speed, odometer, trip meters, fuel level, coolant temperature, clock, and indicator lights. Driver Assistance Rider Aids: While primarily a mechanical machine, its advanced chassis and suspension contribute to rider stability and control. Connectivity Connectivity Features: N/A (Pre-smartphone era, no integrated digital connectivity). 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or annually (whichever comes first) Air Filter Replacement: Every 12,000 km Spark Plug Replacement: Every 12,000 km Coolant Flush: Every 2 years Brake Fluid Change: Every 2 years Fluid Specifications Engine Oil Type: API SG/SH/SJ or JASO MA certified, SAE 10W-40 or 10W-50 motorcycle specific oil. Engine Oil Capacity: Approx. 3.2 liters (3.4 US qt) with filter change Coolant Type: Ethylene glycol-based antifreeze with corrosion inhibitors (50% mix with distilled water recommended) Brake Fluid Type: DOT 4 hydraulic brake fluid Fork Oil Type: SAE 5W or 7.5W (check specific model variant for exact viscosity) Known Issues Common Wear Items: Clutch wear, regulator/rectifier failures, occasional electrical gremlins, fuel pump issues. Maintenance Tips: Regular cleaning of fuel injectors, proper chain tension adjustment, and proactive inspection of electrical connections are recommended for longevity. 📚 Vehicle History Brand Heritage Heritage: Aprilia, an Italian manufacturer with a strong racing pedigree, is known for...
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Aprilia RST Mille 2000 Workshop Repair Service Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RST Mille
Year:
2000
Vehicle Type:
Sport-Touring Motorcycle
Codes
Engine Code:
Rotax 990 V60 Magnesium
👋 Introduction
Market Position
Positioning:
The Aprilia RST Mille 2000 was positioned as a high-performance Italian sport-touring motorcycle, blending potent engine performance with comfortable ergonomics for long-distance riding. It targeted experienced riders seeking a blend of speed, handling, and touring capability.
Competitive Analysis
Competitors:
Competed against sport-touring machines from Japanese manufacturers like Yamaha (YZF1000R Thunderace), Kawasaki (ZZ-R1100/1200), and Suzuki (GSX1300R Hayabusa), as well as European offerings like Ducati's ST series.
Key Features
Distinguishing Features:
Powerful V-twin engine, advanced chassis design, aggressive styling, sophisticated suspension, and an emphasis on Italian engineering and performance.
📋 Manual Details
Coverage Areas
Engine:
Complete overhaul, tuning, diagnostics, fuel system, lubrication, cooling system, ignition system, exhaust system.
Transmission:
Gearbox inspection, maintenance, repair, clutch operation, final drive.
Chassis:
Frame inspection, suspension (front forks, rear shock absorber), steering system, wheel bearings.
Brakes:
Brake system maintenance, hydraulic components, caliper servicing, disc inspection, bleeding procedures.
Electrical:
Wiring diagrams, battery, charging system, starter motor, lighting, instrumentation, fault finding.
Bodywork:
Fairing removal and installation, seat, fuel tank, body panel maintenance.
Troubleshooting:
Common problems, diagnostic flowcharts, error code interpretation.
Page Count
Estimated Pages:
~500-700
Manual Type
Type:
Workshop Repair Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
All Systems:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Clutch, Transmission, Drive Train, Chassis, Suspension, Steering, Brakes, Wheels, Tires, Electrical System, Instrumentation, Lighting, Bodywork, Maintenance Procedures, Troubleshooting.
Procedures Included
Maintenance:
Routine checks, oil changes, filter replacements, chain lubrication, brake pad replacement, coolant flush.
Repair:
Engine rebuild, gearbox overhaul, suspension component replacement, electrical component repair, brake caliper servicing.
Troubleshooting:
Diagnostic steps for starting issues, running problems, electrical faults, braking performance.
Diagnostics:
Systematic fault finding, use of diagnostic tools (if applicable), interpretation of symptoms.
Technical Depth
Depth:
Comprehensive, covering basic servicing to full mechanical and electrical overhauls. Includes detailed specifications and procedures.
📊 Manual Specifications
File Format
Format:
Digital PDF
Searchability:
Text-searchable for efficient information retrieval.
Print Quality
Quality:
High-resolution scans, clear diagrams and text suitable for printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 60-degree V-twin
Displacement:
998 cc (996 cm³)
Bore X Stroke:
97 mm x 68 mm
Performance
Horsepower Peak:
Approx. 130-135 hp (96-100 kW) at 9,000 rpm
Torque Peak:
Approx. 100-105 Nm (74-77 lb-ft) at 7,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual injectors per cylinder
Fuel Type:
Unleaded Gasoline (95-98 RON recommended)
Ignition System
Type:
Digital electronic ignition with dual spark plugs per cylinder
Lubrication System
Type:
Wet sump with oil cooler
Cooling System
Type:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate, hydraulically operated
Features
Final Drive:
O-ring sealed chain drive
📐 Dimensions
Exterior
Length:
Approx. 2,100 mm (82.7 in)
Width:
Approx. 760 mm (30 in)
Height:
Approx. 1,220 mm (48 in)
Wheelbase:
Approx. 1,450 mm (57.1 in)
Weights
Dry Weight:
Approx. 205 kg (452 lbs)
Wet Weight:
Approx. 230 kg (507 lbs) (with fluids)
🛡️ Safety Features
Ratings
Safety Features General:
High-performance braking system, advanced chassis stability, good rider visibility.
Active Features
Braking System:
Dual 320mm discs with 4-piston radial calipers (front), Single 240mm disc with 2-piston caliper (rear). Brembo components.
Suspension Features:
Fully adjustable front forks (e.g., Showa or Paioli) and adjustable rear monoshock (e.g., Ohlins or Sachs) for optimized handling and stability.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals for visibility.
💡 Technology Features
Infotainment
Instrumentation:
Digital dashboard with analog tachometer, LCD display for speed, odometer, trip meters, fuel level, coolant temperature, clock, and indicator lights.
Driver Assistance
Rider Aids:
While primarily a mechanical machine, its advanced chassis and suspension contribute to rider stability and control.
Connectivity
Connectivity Features:
N/A (Pre-smartphone era, no integrated digital connectivity).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or annually (whichever comes first)
Air Filter Replacement:
Every 12,000 km
Spark Plug Replacement:
Every 12,000 km
Coolant Flush:
Every 2 years
Brake Fluid Change:
Every 2 years
Fluid Specifications
Engine Oil Type:
API SG/SH/SJ or JASO MA certified, SAE 10W-40 or 10W-50 motorcycle specific oil.
Engine Oil Capacity:
Approx. 3.2 liters (3.4 US qt) with filter change
Coolant Type:
Ethylene glycol-based antifreeze with corrosion inhibitors (50% mix with distilled water recommended)
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Fork Oil Type:
SAE 5W or 7.5W (check specific model variant for exact viscosity)
Known Issues
Common Wear Items:
Clutch wear, regulator/rectifier failures, occasional electrical gremlins, fuel pump issues.
Maintenance Tips:
Regular cleaning of fuel injectors, proper chain tension adjustment, and proactive inspection of electrical connections are recommended for longevity.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia, an Italian manufacturer with a strong racing pedigree, is known for its innovative engineering and high-performance motorcycles, particularly in the sportbike and racing categories.
Model Evolution
Evolution:
The RST Mille 2000 is part of Aprilia's V-twin sportbike lineage, evolving from earlier models and laying the groundwork for subsequent generations of RSV Mille and Tuono models. It aimed to offer a more comfortable yet still potent package for touring.
Production
Production Period:
The original RSV Mille and its variants, including the sport-touring RST Mille, were produced from 1997 through the early 2000s.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
Received praise in contemporary reviews for its strong V-twin engine, capable chassis, and attractive Italian styling, though often noted for its slightly firm ride and potentially demanding maintenance compared to Japanese rivals.
Ratings
Performance Ratings:
Considered a top-tier sport-touring machine for its era, offering competitive performance against established benchmarks.
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