Aprilia RSV Mille 956X 1999 2000 Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Designation: RSV Mille 956X Production Years: 1999, 2000 Codes Engine Code Suffix: 956X (indicating displacement variant) 👋 Introduction Market Position Motorcycle Segment: Sportbike / Superbike Brand Heritage: Aprilia is renowned for its racing pedigree and high-performance motorcycles. Competitive Analysis Key Rivals: Honda RC51, Ducati 996, Yamaha YZF-R1, Suzuki GSX-R1000, Kawasaki ZX-9R Key Features Performance Focus: The RSV Mille was Aprilia's flagship sportbike, designed for track performance and aggressive road riding. Engineering Philosophy: Italian engineering, exotic design, and potent V-twin performance. 📋 Manual Details Coverage Areas Primary Coverage: Service, Maintenance, Troubleshooting, Repair Specific Systems: Engine, Fuel System, Ignition System, Clutch, Transmission, Drivetrain, Frame, Suspension, Brakes, Electrical System, Cooling System, Exhaust System, Bodywork, Wheels, Tires Page Count Estimated Page Count: 400+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine disassembly, assembly, inspection, and overhaul procedures including valve adjustment, piston ring replacement, crankshaft and connecting rod inspection, cylinder head service. Fuel And Ignition: Carburetor (or fuel injection for later models, though this manual specifies older carb setup) tuning and overhaul, fuel pump testing, ignition timing, spark plug specifications, coil testing. Clutch And Transmission: Clutch operation, adjustment, inspection, and replacement; gearbox disassembly, inspection, assembly, and troubleshooting; gear ratio details. Frame And Suspension: Frame inspection, front fork (telescopic) service, rear shock absorber service and adjustment, swingarm maintenance, steering head bearing service. Brakes: Hydraulic brake system servicing, caliper disassembly and rebuild, master cylinder service, brake fluid specifications, bleeding procedures, pad replacement, rotor inspection. Electrical: Wiring diagrams, battery maintenance, charging system (alternator/stator and regulator/rectifier) testing, starter motor troubleshooting, lighting system service, fuse identification and replacement, instrument cluster diagnostics. Cooling System: Radiator service, coolant specifications and capacity, fan operation, thermostat replacement, water pump inspection and maintenance. Exhaust System: Exhaust component inspection, gasket replacement, common leaks. Bodywork And Trim: Fairing removal and installation, seat removal, minor panel repair guidance. Procedures Included Routine Maintenance: Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, tire pressure checks. Troubleshooting Diagnostics: Step-by-step diagnostic charts for common performance issues, electrical faults, and starting problems. Component Overhaul: Detailed instructions for the complete disassembly, inspection, cleaning, repair, and reassembly of major components. Calibration And Adjustment: Carburetor synchronization, idle speed adjustment, clutch lever free play, brake lever free play. Wiring Diagrams: Comprehensive electrical schematics for all model years covered, aiding in diagnosis and repair of electrical faults. Technical Depth Depth: Comprehensive - covers everything from basic scheduled maintenance to full engine rebuilds and advanced electrical diagnostics. Diagnostic Capabilities: Detailed diagnostic trees and fault code interpretation (if applicable to the era's systems). Rebuild Procedures: Detailed torque specifications, clearances, and assembly sequences for all major internal engine and transmission components. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Searchability: Likely text-searchable if professionally digitized, allowing quick access to specific information. Print Quality Print Readability: High (assuming a well-scanned original document), ensuring clarity of diagrams and text. Binding Type Original Binding: Likely a professionally bound softcover or hardcover manual. Digital Access: Instant download, accessible on computers, tablets, and smartphones. Paper Type Original Paper Type: Durable, coated paper to withstand workshop use and oil/grease. ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, Four-Stroke Displacement: 956 cc Bore X Stroke: 97 mm x 64.8 mm Valvetrain: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower Approx: 120-130 hp (at crankshaft, depending on dyno and specific tuning) Torque Approx: 70-75 lb-ft (at crankshaft) Fuel System Fuel Delivery: Carburetor (likely 46mm Keihin or Mikuni on early models), potentially Weber or Dell'Orto Fuel Type: Unleaded gasoline, minimum 95 RON 🔧 Transmission Standard Transmission Type: 6-speed manual Clutch Type: Hydraulically operated wet multi-plate clutch Features Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning. Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approximately 1400-1420 mm (55.1-55.9 inches) Seat Height: Approximately 810-830 mm (31.9-32.7 inches) Weights Dry Weight: Approximately 195-200 kg (430-441 lbs) Wet Weight: Approximately 210-215 kg (463-474 lbs) 🛡️ Safety Features Ratings Safety Certification: Typically meets European ECE standards for road legality. Active Features Braking System: High-performance dual front disc brakes with multi-piston calipers, single rear disc brake. Suspension Type: Adjustable front telescopic forks and adjustable rear monoshock absorber. Passive Features Lighting: Halogen headlamp, LED taillight. 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer and speedometer, digital odometer, trip meter, clock, coolant temperature gauge, warning lights. Driver Assistance ABS: Not typically equipped on standard 1999-2000 models; ABS was an optional or later feature. Connectivity Connectivity Features: N/A (no modern connectivity features expected on this era of motorcycle) 🔧 Maintenance Service Intervals Oil Filter Change: Every 4,000-6,000 km or annually Engine Oil Change: Every 4,000-6,000 km or annually Valve Clearance Check: Every 12,000-16,000 km Spark Plug Replacement:...
Full engine disassembly, assembly, inspection, and overhaul procedures including valve adjustment, piston ring replacement, crankshaft and connecting rod inspection, cylinder head service.
Fuel And Ignition:
Carburetor (or fuel injection for later models, though this manual specifies older carb setup) tuning and overhaul, fuel pump testing, ignition timing, spark plug specifications, coil testing.
Clutch And Transmission:
Clutch operation, adjustment, inspection, and replacement; gearbox disassembly, inspection, assembly, and troubleshooting; gear ratio details.
Frame And Suspension:
Frame inspection, front fork (telescopic) service, rear shock absorber service and adjustment, swingarm maintenance, steering head bearing service.
Brakes:
Hydraulic brake system servicing, caliper disassembly and rebuild, master cylinder service, brake fluid specifications, bleeding procedures, pad replacement, rotor inspection.
Electrical:
Wiring diagrams, battery maintenance, charging system (alternator/stator and regulator/rectifier) testing, starter motor troubleshooting, lighting system service, fuse identification and replacement, instrument cluster diagnostics.
Cooling System:
Radiator service, coolant specifications and capacity, fan operation, thermostat replacement, water pump inspection and maintenance.
Exhaust System:
Exhaust component inspection, gasket replacement, common leaks.
Bodywork And Trim:
Fairing removal and installation, seat removal, minor panel repair guidance.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, tire pressure checks.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts for common performance issues, electrical faults, and starting problems.
Component Overhaul:
Detailed instructions for the complete disassembly, inspection, cleaning, repair, and reassembly of major components.
Calibration And Adjustment:
Carburetor synchronization, idle speed adjustment, clutch lever free play, brake lever free play.
Wiring Diagrams:
Comprehensive electrical schematics for all model years covered, aiding in diagnosis and repair of electrical faults.
Technical Depth
Depth:
Comprehensive - covers everything from basic scheduled maintenance to full engine rebuilds and advanced electrical diagnostics.
Diagnostic Capabilities:
Detailed diagnostic trees and fault code interpretation (if applicable to the era's systems).
Rebuild Procedures:
Detailed torque specifications, clearances, and assembly sequences for all major internal engine and transmission components.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if professionally digitized, allowing quick access to specific information.
Print Quality
Print Readability:
High (assuming a well-scanned original document), ensuring clarity of diagrams and text.
Binding Type
Original Binding:
Likely a professionally bound softcover or hardcover manual.
Digital Access:
Instant download, accessible on computers, tablets, and smartphones.
Paper Type
Original Paper Type:
Durable, coated paper to withstand workshop use and oil/grease.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-Stroke
Displacement:
956 cc
Bore X Stroke:
97 mm x 64.8 mm
Valvetrain:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
120-130 hp (at crankshaft, depending on dyno and specific tuning)
Torque Approx:
70-75 lb-ft (at crankshaft)
Fuel System
Fuel Delivery:
Carburetor (likely 46mm Keihin or Mikuni on early models), potentially Weber or Dell'Orto
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Hydraulically operated wet multi-plate clutch
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase:
Approximately 1400-1420 mm (55.1-55.9 inches)
Seat Height:
Approximately 810-830 mm (31.9-32.7 inches)
Weights
Dry Weight:
Approximately 195-200 kg (430-441 lbs)
Wet Weight:
Approximately 210-215 kg (463-474 lbs)
🛡️ Safety Features
Ratings
Safety Certification:
Typically meets European ECE standards for road legality.
Active Features
Braking System:
High-performance dual front disc brakes with multi-piston calipers, single rear disc brake.
Suspension Type:
Adjustable front telescopic forks and adjustable rear monoshock absorber.
Passive Features
Lighting:
Halogen headlamp, LED taillight.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, digital odometer, trip meter, clock, coolant temperature gauge, warning lights.
Driver Assistance
ABS:
Not typically equipped on standard 1999-2000 models; ABS was an optional or later feature.
Connectivity
Connectivity Features:
N/A (no modern connectivity features expected on this era of motorcycle)
🔧 Maintenance
Service Intervals
Oil Filter Change:
Every 4,000-6,000 km or annually
Engine Oil Change:
Every 4,000-6,000 km or annually
Valve Clearance Check:
Every 12,000-16,000 km
Spark Plug Replacement:
Every 8,000-12,000 km
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (refer to manual for exact spec)
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Clutch Fluid Type:
DOT 4 hydraulic clutch fluid (if hydraulic)
Known Issues
Common Wear Items:
Clutch wear, cam chain tensioner issues (early models), voltage regulator/rectifier failures, minor electrical gremlins.
Performance Tuning:
Carburetor tuning can be sensitive; proper synchronization is critical for smooth running.
📚 Vehicle History
Brand Heritage
Founding Era:
Aprilia was founded in 1945 in Italy.
Model Evolution
First Generation:
The RSV Mille was launched in 1997 and represented Aprilia's serious entry into the superbike market, powered by a Rotax-derived V-twin engine.
Updates:
The 1999-2000 models represent early iterations of the RSV Mille, with subsequent models receiving updates to suspension, engine management, and styling.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Contemporary Reviews:
Highly praised by motorcycle publications for its V-twin character, chassis dynamics, and braking performance, often noted for its exotic appeal.
Performance Benchmarks:
Competed strongly in its class for track day performance and outright speed.
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