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Aprilia RSV Mille-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Year: 2002 Codes Engine Code: Rotax 998 👋 Introduction Market Position Market Position: The 2002 Aprilia RSV Mille positioned itself as a high-performance Italian sportbike, directly competing with established Japanese superbikes and other European exotic motorcycles. It was lauded for its potent V-twin engine and sophisticated chassis dynamics. Competitive Analysis Competitive Analysis: Competed against models such as the Ducati 996/998 series, Yamaha YZF-R1, Honda CBR929RR/CBR954RR, and Suzuki GSX-R1000. The RSV Mille offered a distinct V-twin character and often a more exotic feel. Key Features Key Features: Powerful Rotax V-twin engine, lightweight aluminum frame, advanced suspension components (Öhlins optional on some variants), aerodynamic fairing, high-performance braking system, sophisticated electronics for its era. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive service and repair for the 2002 Aprilia RSV Mille Page Count Page Count: Hundreds of pages Manual Type Manual Type: Service and Repair Manual Language Language: English (assumed, typical for service manuals of this nature) Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Chassis, Suspension (Front and Rear), Brakes (Front and Rear), Wheels and Tires, Electrical System, Lighting, Instruments, Bodywork, Fairings, Maintenance Procedures, Troubleshooting Procedures Included Procedures Included: Routine maintenance, scheduled servicing, detailed disassembly and reassembly of all major components, diagnostic procedures, troubleshooting guides, repair instructions, specifications for adjustments and tolerances, electrical circuit diagrams, torque specifications, special tool requirements Technical Depth Technical Depth: Expert-level detail suitable for professional technicians and experienced DIY mechanics, covering everything from basic fluid changes to complete engine rebuilds and electrical system diagnostics. 📊 Manual Specifications File Format File Format: Portable Document Format (PDF) Print Quality Print Quality: High-resolution scans of original factory manual, optimized for clear viewing and printing. Includes legible diagrams and schematics. Binding Type Binding Type: Digital (PDF). For print versions, binding would typically be comb or spiral for lay-flat usability. Paper Type Paper Type: N/A (Digital Format). If printed, would be high-quality paper to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 60-degree V-twin Displacement: 997.6 cc Bore X Stroke: 97 mm x 67.5 mm Compression Ratio: 11.3:1 Performance Horsepower: Approx. 128 hp @ 9,700 rpm Torque: Approx. 72 lb-ft @ 7,000 rpm Fuel System Fuel System: Electronic Fuel Injection (EFI) with dual throttle bodies, 54mm diameter Fuel Type: Unleaded Premium Gasoline (95 RON / 91 AKI) Ignition System Ignition System: Electronic ignition with independent spark advance for each cylinder Cooling System Cooling System: Liquid-cooled, with thermostatically controlled fan Lubrication System Lubrication System: Wet sump, forced lubrication with oil cooler 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Hydraulically operated, multi-plate wet clutch Final Drive: Chain driven Fluid Specifications Transmission Fluid Type: SAE 75W/90 API GL-4 or GL-5 (refer to manual for specific viscosity recommendation) Fluid Capacities Transmission Oil Capacity: Approx. 0.75 Liters 📐 Dimensions Exterior Length: Approx. 2,050 mm Width: Approx. 720 mm (at handlebars) Height: Approx. 1,150 mm (at windshield) Wheelbase: Approx. 1,410 mm Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 215 kg (fully fueled) Fuel Tank Capacity: 21 Liters (including 3-liter reserve) Suspension Front Suspension Type: 43mm upside-down telescopic fork (e.g., Showa or Öhlins) Front Suspension Travel: Approx. 120 mm Rear Suspension Type: Monoshock with progressive linkage (e.g., Öhlins) Rear Suspension Travel: Approx. 130 mm Wheels Tires Front Wheel Size: 3.50 x 17 Rear Wheel Size: 5.50 x 17 Front Tire Size: 120/70ZR17 Rear Tire Size: 180/55ZR17 Wheel Bolt Pattern: N/A (typical for cast aluminum wheels) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily based on rider skill and component performance. No formal crash test ratings as with automobiles. Active Features Active Features: Powerful dual front disc brakes with radial-mount calipers, single rear disc brake, advanced chassis geometry for stability, well-tuned suspension. Passive Features Passive Features: Robust frame construction, integrated fairings for rider protection, standard rider controls. Braking System Front Brake Type: Dual 320 mm discs, radial-mount Brembo calipers (4-piston) Rear Brake Type: Single 220 mm disc, Brembo caliper (2-piston) 💡 Technology Features Infotainment Infotainment System: N/A (No infotainment system on this model) Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like traction control or ABS on the standard 2002 model) Performance Electronics Performance Electronics: Engine control unit (ECU) managing fuel injection and ignition timing. Digital dashboard with basic readouts. 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual (typically every 5,000 - 7,500 km or annually, whichever comes first) Valve Clearance Check Interval: Refer to manual (typically every 10,000 - 15,000 km) Spark Plug Replacement Interval: Refer to manual (typically every 15,000 - 20,000 km) Fluid Specifications Engine Oil Type: Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG/SH/SJ or higher, JASO MA certified (refer to manual for exact specification) Coolant...
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Aprilia RSV Mille-2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
2002
Codes
Engine Code:
Rotax 998
👋 Introduction
Market Position
Market Position:
The 2002 Aprilia RSV Mille positioned itself as a high-performance Italian sportbike, directly competing with established Japanese superbikes and other European exotic motorcycles. It was lauded for its potent V-twin engine and sophisticated chassis dynamics.
Competitive Analysis
Competitive Analysis:
Competed against models such as the Ducati 996/998 series, Yamaha YZF-R1, Honda CBR929RR/CBR954RR, and Suzuki GSX-R1000. The RSV Mille offered a distinct V-twin character and often a more exotic feel.
Key Features
Key Features:
Powerful Rotax V-twin engine, lightweight aluminum frame, advanced suspension components (Öhlins optional on some variants), aerodynamic fairing, high-performance braking system, sophisticated electronics for its era.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive service and repair for the 2002 Aprilia RSV Mille
Page Count
Page Count:
Hundreds of pages
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English (assumed, typical for service manuals of this nature)
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Chassis, Suspension (Front and Rear), Brakes (Front and Rear), Wheels and Tires, Electrical System, Lighting, Instruments, Bodywork, Fairings, Maintenance Procedures, Troubleshooting
Procedures Included
Procedures Included:
Routine maintenance, scheduled servicing, detailed disassembly and reassembly of all major components, diagnostic procedures, troubleshooting guides, repair instructions, specifications for adjustments and tolerances, electrical circuit diagrams, torque specifications, special tool requirements
Technical Depth
Technical Depth:
Expert-level detail suitable for professional technicians and experienced DIY mechanics, covering everything from basic fluid changes to complete engine rebuilds and electrical system diagnostics.
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution scans of original factory manual, optimized for clear viewing and printing. Includes legible diagrams and schematics.
Binding Type
Binding Type:
Digital (PDF). For print versions, binding would typically be comb or spiral for lay-flat usability.
Paper Type
Paper Type:
N/A (Digital Format). If printed, would be high-quality paper to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 60-degree V-twin
Displacement:
997.6 cc
Bore X Stroke:
97 mm x 67.5 mm
Compression Ratio:
11.3:1
Performance
Horsepower:
Approx. 128 hp @ 9,700 rpm
Torque:
Approx. 72 lb-ft @ 7,000 rpm
Fuel System
Fuel System:
Electronic Fuel Injection (EFI) with dual throttle bodies, 54mm diameter
Fuel Type:
Unleaded Premium Gasoline (95 RON / 91 AKI)
Ignition System
Ignition System:
Electronic ignition with independent spark advance for each cylinder
Cooling System
Cooling System:
Liquid-cooled, with thermostatically controlled fan
Lubrication System
Lubrication System:
Wet sump, forced lubrication with oil cooler
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Final Drive:
Chain driven
Fluid Specifications
Transmission Fluid Type:
SAE 75W/90 API GL-4 or GL-5 (refer to manual for specific viscosity recommendation)
Fluid Capacities
Transmission Oil Capacity:
Approx. 0.75 Liters
📐 Dimensions
Exterior
Length:
Approx. 2,050 mm
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1,150 mm (at windshield)
Wheelbase:
Approx. 1,410 mm
Weights
Dry Weight:
Approx. 195 kg
Wet Weight:
Approx. 215 kg (fully fueled)
Fuel Tank Capacity:
21 Liters (including 3-liter reserve)
Suspension
Front Suspension Type:
43mm upside-down telescopic fork (e.g., Showa or Öhlins)
Front Suspension Travel:
Approx. 120 mm
Rear Suspension Type:
Monoshock with progressive linkage (e.g., Öhlins)
Rear Suspension Travel:
Approx. 130 mm
Wheels Tires
Front Wheel Size:
3.50 x 17
Rear Wheel Size:
5.50 x 17
Front Tire Size:
120/70ZR17
Rear Tire Size:
180/55ZR17
Wheel Bolt Pattern:
N/A (typical for cast aluminum wheels)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily based on rider skill and component performance. No formal crash test ratings as with automobiles.
Active Features
Active Features:
Powerful dual front disc brakes with radial-mount calipers, single rear disc brake, advanced chassis geometry for stability, well-tuned suspension.
Passive Features
Passive Features:
Robust frame construction, integrated fairings for rider protection, standard rider controls.
Braking System
Front Brake Type:
Dual 320 mm discs, radial-mount Brembo calipers (4-piston)
Rear Brake Type:
Single 220 mm disc, Brembo caliper (2-piston)
💡 Technology Features
Infotainment
Infotainment System:
N/A (No infotainment system on this model)
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids like traction control or ABS on the standard 2002 model)
Performance Electronics
Performance Electronics:
Engine control unit (ECU) managing fuel injection and ignition timing. Digital dashboard with basic readouts.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual (typically every 5,000 - 7,500 km or annually, whichever comes first)
Valve Clearance Check Interval:
Refer to manual (typically every 10,000 - 15,000 km)
Spark Plug Replacement Interval:
Refer to manual (typically every 15,000 - 20,000 km)
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG/SH/SJ or higher, JASO MA certified (refer to manual for exact specification)
Coolant Type:
Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio)
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for exact specification)
Fluid Capacities
Engine Oil Capacity:
Approx. 3.5 Liters (with filter change)
Cooling System Capacity:
Approx. 2.3 Liters
Known Issues
Known Issues:
Potential issues include stator failure, voltage regulator issues, occasional fuel pump problems, and some electrical connector degradation over time. Early models had camshaft recall. Proper maintenance is key to longevity.
Filter Part Numbers
Oil Filter Part Number:
Commonly compatible with HiFloFiltro HF153, K&N KN-153 (verify with manual or cross-reference)
Air Filter Part Number:
Commonly compatible with K&N RU-2810 (verify with manual or cross-reference)
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia, an Italian manufacturer, has a rich history in motorcycle racing, particularly in Grand Prix championships. This racing pedigree heavily influenced the design and performance of their road-going sportbikes.
Model Evolution
Model Evolution:
The RSV Mille was introduced in 1997 as Aprilia's flagship superbike. The 2002 model represents a significant iteration, often featuring styling updates and mechanical refinements over earlier versions. It paved the way for later models like the RSV1000R and the groundbreaking RSV4.
Production
Production Period:
1997 - 2003 (for the original RSV Mille design, with the 2002 model being a key year in its development)
Production Location
Production Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 2002 model are difficult to pinpoint without access to contemporary reviews, the RSV Mille series was consistently praised by motorcycle journalists for its potent V-twin engine, handling, and distinctive Italian character.
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