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

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Engine Code: 956X (V6 Rotax) Codes Product Code Derived: APRR-Mille-9900-SRM Generation Production Years Covered: 1999-2000 👋 Introduction Market Position Class: High-performance sportbike, Superbike contender Target Audience: Enthusiast riders, mechanics specializing in Italian motorcycles, owners seeking in-depth maintenance and repair knowledge. Competitive Analysis Competitors 1999-2000: Ducati 916, Yamaha R1 (YZF-R1), Honda Fireblade (CBR900RR), Suzuki GSX-R750/1100, Kawasaki ZX-9R. Key Features Engine Layout: V-Twin Frame Type: Aluminum twin-spar frame Suspension Front: Often equipped with premium suspension components like Öhlins or high-spec Showa forks. Braking System Front: Dual 320mm discs with multi-piston Brembo calipers. Performance Focus: Emphasis on torque delivery and track-capable performance. 📋 Manual Details Coverage Areas Primary Coverage: Full Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Rebuilding Page Count Estimated Page Count: 800+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, tuning, lubrication, cooling, fuel injection (Weber Marelli IAW 15M), ignition, exhaust. Transmission: Clutch operation, gearbox disassembly and reassembly, shift mechanism, final drive. Chassis And Frame: Frame inspection, steering head bearing, swingarm, rear suspension (monoshock), front forks (Öhlins/Showa depending on variant). Brakes: Brake system overhaul, hydraulic lines, master cylinders, calipers (Brembo), ABS (if equipped), bleeding procedures. Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, ECU diagnostics, sensors, relays, fuses. Fuel System: Fuel tank, fuel pump, fuel injectors, pressure regulator, fuel filter replacement. Bodywork And Fairings: Fairing removal and installation, seat, tail section, fuel tank cover, cosmetic repairs. Procedures Included Maintenance: Regular service checks, oil and filter changes, spark plug replacement, chain adjustment, coolant flush, brake pad replacement. Repair: Component-level repair and replacement for all major systems, engine rebuilds, transmission fixes, electrical fault tracing. Troubleshooting: Diagnostic charts for common problems, fault code interpretation, performance issues. Rebuilding: Comprehensive instructions for complete engine and gearbox rebuilds, including torque specifications and clearances. Technical Depth Depth: Expert Level (Full Engine Rebuilds, Advanced Electronics Diagnostics) Detail Level: Includes detailed exploded diagrams, torque values, clearances, wiring schematics, and diagnostic flowcharts. 📊 Manual Specifications File Format Digital Format: PDF Searchability: Fully searchable text for quick information retrieval. Print Quality Image Resolution: High-resolution images and diagrams suitable for printing. Binding Type Digital Binding: N/A (Digital File) Paper Type Digital Paper: N/A (Digital File) ⚙️ Engine Specifications Primary Engine Type: Four-stroke, Liquid-cooled, DOHC, V-Twin (90-degree) Displacement: 996 cc Bore X Stroke: 97 mm x 66 mm Compression Ratio: 11.4:1 Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Peak Hp: Approx. 130-135 HP (at crank) Torque Peak Lb-Ft: Approx. 70-75 lb-ft (at crank) Fuel System Fuel Delivery: Weber Marelli IAW 15M Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication Oil Capacity Filter Change: Approx. 3.7 liters (with filter) Cooling System Coolant Type: Mixture of water and anti-freeze (e.g., 50/50 ethylene glycol based) 🔧 Transmission Standard Type: 6-speed sequential manual Clutch: Wet, multi-plate, hydraulic actuation Final Drive: Chain drive Features Gear Ratios: Specific ratios detailed in manual (e.g., 1st: 2.46, 2nd: 1.88, 3rd: 1.50, 4th: 1.27, 5th: 1.12, 6th: 1.00) Transmission Fluid: Gear oil (e.g., SAE 75W-90 API GL-4 or GL-5, check manual for specific Aprilia recommendation) 📐 Dimensions Exterior Length: Approx. 2030 mm (203 cm) Width: Approx. 700 mm (70 cm) (at handlebars) Height: Approx. 1160 mm (116 cm) (seat height) Wheelbase: Approx. 1410 mm (141 cm) Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 215 kg (474 lbs) (fully fueled, all fluids) Cargo Cargo Capacity: N/A (Sportbike) 🛡️ Safety Features Ratings Crash Test Data: N/A (Motorcycle safety ratings typically differ from cars; manual focuses on mechanical safety and roadworthiness). Active Features Braking: High-performance Brembo brakes, steel-braided lines, adjustable levers. Handling Stability: Sport-tuned suspension, rigid frame, aerodynamic fairings designed for stability at speed. Passive Features Lighting: Dual Halogen headlights, LED taillight. Ergonomics: Sport riding position, though more relaxed than later models, aids rider control. 💡 Technology Features Infotainment System Type: N/A (Basic Instrumentation) Display: Analog tachometer and speedometer, LCD for odometer, trip meters, and basic indicators. Driver Assistance ABS: Optional on some models/markets, not standard for the initial release of the '99-'00 models. Traction Control: N/A Connectivity Bluetooth: N/A Usb: N/A Engine Management ECU: Weber Marelli IAW 15M, providing sophisticated fuel and ignition mapping. 🔧 Maintenance Service Intervals First Service: 1,000 km (600 miles) - Includes oil change, filter check, chain adjustment, general inspection. Subsequent Oil Change: Every 6,000 km (3,750 miles) or 12 months, whichever comes first. Spark Plug Replacement: Recommended at 12,000 km (7,500 miles) or as per manual inspection. Valve Clearance Check: Recommended at 12,000 km (7,500 miles) or 24,000 km (15,000 miles) depending on specific engine requirements (refer to manual). Fluid Specifications Engine Oil Viscosity: Fully synthetic 10W-40 or 10W-50 (API SG or higher, JASO MA/MA2 recommended for wet clutch compatibility). Coolant: 50%...
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Aprilia RSV Mille 956X 1999-2000 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Engine Code:
956X (V6 Rotax)
Codes
Product Code Derived:
APRR-Mille-9900-SRM
Generation
Production Years Covered:
1999-2000
👋 Introduction
Market Position
Class:
High-performance sportbike, Superbike contender
Target Audience:
Enthusiast riders, mechanics specializing in Italian motorcycles, owners seeking in-depth maintenance and repair knowledge.
Competitive Analysis
Competitors 1999-2000:
Ducati 916, Yamaha R1 (YZF-R1), Honda Fireblade (CBR900RR), Suzuki GSX-R750/1100, Kawasaki ZX-9R.
Key Features
Engine Layout:
V-Twin
Frame Type:
Aluminum twin-spar frame
Suspension Front:
Often equipped with premium suspension components like Öhlins or high-spec Showa forks.
Braking System Front:
Dual 320mm discs with multi-piston Brembo calipers.
Performance Focus:
Emphasis on torque delivery and track-capable performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Full Service and Repair
Secondary Coverage:
Maintenance, Troubleshooting, Rebuilding
Page Count
Estimated Page Count:
800+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, overhaul, tuning, lubrication, cooling, fuel injection (Weber Marelli IAW 15M), ignition, exhaust.
Transmission:
Clutch operation, gearbox disassembly and reassembly, shift mechanism, final drive.
Chassis And Frame:
Frame inspection, steering head bearing, swingarm, rear suspension (monoshock), front forks (Öhlins/Showa depending on variant).
Brakes:
Brake system overhaul, hydraulic lines, master cylinders, calipers (Brembo), ABS (if equipped), bleeding procedures.
Electrical System:
Wiring diagrams, battery, alternator, starter motor, lighting, instrumentation, ECU diagnostics, sensors, relays, fuses.
Fuel System:
Fuel tank, fuel pump, fuel injectors, pressure regulator, fuel filter replacement.
Bodywork And Fairings:
Fairing removal and installation, seat, tail section, fuel tank cover, cosmetic repairs.
Procedures Included
Maintenance:
Regular service checks, oil and filter changes, spark plug replacement, chain adjustment, coolant flush, brake pad replacement.
Repair:
Component-level repair and replacement for all major systems, engine rebuilds, transmission fixes, electrical fault tracing.
Troubleshooting:
Diagnostic charts for common problems, fault code interpretation, performance issues.
Rebuilding:
Comprehensive instructions for complete engine and gearbox rebuilds, including torque specifications and clearances.
Technical Depth
Depth:
Expert Level (Full Engine Rebuilds, Advanced Electronics Diagnostics)
Detail Level:
Includes detailed exploded diagrams, torque values, clearances, wiring schematics, and diagnostic flowcharts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Searchability:
Fully searchable text for quick information retrieval.
Print Quality
Image Resolution:
High-resolution images and diagrams suitable for printing.
Binding Type
Digital Binding:
N/A (Digital File)
Paper Type
Digital Paper:
N/A (Digital File)
⚙️ Engine Specifications
Primary Engine
Type:
Four-stroke, Liquid-cooled, DOHC, V-Twin (90-degree)
Displacement:
996 cc
Bore X Stroke:
97 mm x 66 mm
Compression Ratio:
11.4:1
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Peak Hp:
Approx. 130-135 HP (at crank)
Torque Peak Lb-Ft:
Approx. 70-75 lb-ft (at crank)
Fuel System
Fuel Delivery:
Weber Marelli IAW 15M Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Lubrication
Oil Capacity Filter Change:
Approx. 3.7 liters (with filter)
Cooling System
Coolant Type:
Mixture of water and anti-freeze (e.g., 50/50 ethylene glycol based)
🔧 Transmission
Standard
Type:
6-speed sequential manual
Clutch:
Wet, multi-plate, hydraulic actuation
Final Drive:
Chain drive
Features
Gear Ratios:
Specific ratios detailed in manual (e.g., 1st: 2.46, 2nd: 1.88, 3rd: 1.50, 4th: 1.27, 5th: 1.12, 6th: 1.00)
Transmission Fluid:
Gear oil (e.g., SAE 75W-90 API GL-4 or GL-5, check manual for specific Aprilia recommendation)
📐 Dimensions
Exterior
Length:
Approx. 2030 mm (203 cm)
Width:
Approx. 700 mm (70 cm) (at handlebars)
Height:
Approx. 1160 mm (116 cm) (seat height)
Wheelbase:
Approx. 1410 mm (141 cm)
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 215 kg (474 lbs) (fully fueled, all fluids)
Cargo
Cargo Capacity:
N/A (Sportbike)
🛡️ Safety Features
Ratings
Crash Test Data:
N/A (Motorcycle safety ratings typically differ from cars; manual focuses on mechanical safety and roadworthiness).
Active Features
Braking:
High-performance Brembo brakes, steel-braided lines, adjustable levers.
Handling Stability:
Sport-tuned suspension, rigid frame, aerodynamic fairings designed for stability at speed.
Passive Features
Lighting:
Dual Halogen headlights, LED taillight.
Ergonomics:
Sport riding position, though more relaxed than later models, aids rider control.
💡 Technology Features
Infotainment
System Type:
N/A (Basic Instrumentation)
Display:
Analog tachometer and speedometer, LCD for odometer, trip meters, and basic indicators.
Driver Assistance
ABS:
Optional on some models/markets, not standard for the initial release of the '99-'00 models.
Traction Control:
N/A
Connectivity
Bluetooth:
N/A
Usb:
N/A
Engine Management
ECU:
Weber Marelli IAW 15M, providing sophisticated fuel and ignition mapping.
🔧 Maintenance
Service Intervals
First Service:
1,000 km (600 miles) - Includes oil change, filter check, chain adjustment, general inspection.
Subsequent Oil Change:
Every 6,000 km (3,750 miles) or 12 months, whichever comes first.
Spark Plug Replacement:
Recommended at 12,000 km (7,500 miles) or as per manual inspection.
Valve Clearance Check:
Recommended at 12,000 km (7,500 miles) or 24,000 km (15,000 miles) depending on specific engine requirements (refer to manual).
Fluid Specifications
Engine Oil Viscosity:
Fully synthetic 10W-40 or 10W-50 (API SG or higher, JASO MA/MA2 recommended for wet clutch compatibility).
Coolant:
50% Ethylene Glycol based antifreeze and 50% distilled water.
Brake Fluid:
DOT 4 specification, high-temperature brake fluid.
Fork Oil:
ISO VG 10 (or as specified by Öhlins/Showa, manual will confirm specific type and level).
Known Issues
Electrical Gremlins:
Some owners report intermittent issues with wiring harnesses or sensor connections, often resolved with thorough inspection and cleaning.
Regulator Rectifier:
Early models could be prone to regulator/rectifier failure, leading to battery charging issues.
Clutch Slave Cylinder:
Some units may develop leaks or a stiff clutch action from the slave cylinder.
Cam Chain Tensioner:
Potential for wear or failure of automatic cam chain tensioners, often manifesting as a rattling noise.
Fuel Line Connections:
Risk of vacuum leaks or fuel leaks from aging fuel line connections or clamps.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia S.p.A., an Italian manufacturer known for performance motorcycles.
Reputation:
Renowned for racing success and producing technically advanced, distinctive sportbikes.
Model Evolution
Predecessor:
RSV 1000 (early versions, leading to Mille platform)
Successor:
RSV-R, RSV1000R (later generations with revised engines and chassis).
Key Changes 99-00:
Initial launch of the RSV Mille, establishing the V-Twin platform, refined chassis and engine tuning from prototype phases.
Production
Manufacturing Location:
Italy
Production Period:
First generation of the RSV Mille model.
🏆 Awards & Recognition
Recognitions
Motorcycle Press:
Consistently reviewed as a top-tier sportbike of its era, praised for its V-Twin character and chassis dynamics.
Performance Awards:
Received acclaim for its track performance and road-going usability.
Ratings
Rider Satisfaction:
Highly regarded by owners for its raw performance and distinctive Italian character.
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