Aprilia RSV Mille 956X 1999-2000 Workshop Service Repair Manual
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๐ท๏ธ Basic Information Identification Make: Aprilia Model: RSV Mille Model Variant: RSV Mille 956X Model Years: 1999, 2000 Codes Internal Project Code: RP56 (for Mille) ๐ Introduction Market Position Segment: High-performance sportbike, superbike class. Target Audience: Enthusiasts, performance riders, track day participants, and owners seeking in-depth maintenance capabilities. Competitive Analysis Key Competitors: Ducati 916/996, Honda CBR900RR FireBlade, Yamaha YZF-R1, Suzuki GSX-R750/1000, Kawasaki ZX-9R. Key Features Vehicle Philosophy: Italian performance engineering, focused on raw power, sharp handling, and distinctive styling. Manual Value Proposition: Empowers owners with the knowledge to maintain, diagnose, and repair their RSV Mille, saving on dealership service costs and ensuring optimal performance. ๐ Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Page Count Estimated Page Count: 300-400 (typical for comprehensive workshop manuals of this era) Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English (common for international models and service literature) Format Format: PDF Download ๐ Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, component inspection, lubrication, cooling system, fuel system (carburetor specifics for early models if applicable, or early EFI), exhaust system. Transmission And Drivetrain: Gearbox operation, clutch service, chain drive maintenance, torque specifications. Chassis And Suspension: Front fork service (including damping adjustments and seal replacement), rear shock absorber, swingarm inspection, wheel bearing maintenance, steering head bearing service. Braking System: Brake caliper service, master cylinder overhaul, brake pad replacement, bleeding procedures, hydraulic line inspection, disc inspection. Electrical System: Wiring diagrams, ignition system troubleshooting, lighting circuits, battery service, charging system (stator, regulator/rectifier), starter motor, component testing. Fuel System: Fuel tank removal/installation, fuel pump operation (if applicable), fuel lines, carburetor synchronization and adjustment (likely Dell'Orto for this model). Bodywork And Fairings: Fairing removal and installation, seat service, fuel tank access, mounting hardware. Procedures Included Maintenance Procedures: Routine servicing, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid replacement. Repair Procedures: Engine rebuild (top and bottom end), transmission overhaul, suspension component replacement, electrical component repair, bodywork repair. Troubleshooting Guidelines: Diagnostic charts, common problems and solutions, fault finding for engine performance, electrical issues, and chassis components. Technical Depth Depth Of Information: Comprehensive workshop level, covering disassembly, inspection, repair, and reassembly of all major vehicle systems. Diagnostic Capabilities: Detailed procedures for diagnosis of mechanical and electrical faults, including expected readings and tolerances. Special Tool Requirements: Identification and usage of specific Aprilia or general motorcycle tools required for various procedures. ๐ Manual Specifications File Format Digital Format: PDF Print Quality Readability: High resolution, clear text and diagrams for easy reading and printing. Binding Type Digital Format Binding: N/A (Digital Download) Paper Type Digital Format Paper: N/A (Digital Download) โ๏ธ Engine Specifications Primary Engine Engine Type: V-Twin, Four-Stroke Displacement: 996 cc (often referred to as 956X in product titles, likely referencing an internal code or specific variant) Bore X Stroke: 97.0 mm x 65.0 mm (typical for 996cc Aprilia V-twin) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Peak: Approx. 130-135 hp @ 9,200 rpm (variant dependent) Torque Peak: Approx. 95-100 Nm @ 7,000 rpm (variant dependent) Fuel System Fuel Delivery: Carbureted (likely Dell'Orto PHM40 or similar for early models) or early Fuel Injection depending on specific sub-model and market. The '956X' designation might hint at a specific carb setup. Ignition System: Electronic, CDI Cooling System Cooling Method: Liquid-cooled ๐ง Transmission Standard Transmission Type: 6-speed manual sequential gearbox Features Clutch Type: Wet, multi-plate, hydraulic actuation Final Drive: Chain drive ๐ Dimensions Exterior Length: Approx. 2030 mm Width: Approx. 720 mm (at handlebars) Height: Approx. 1140 mm (at seat) Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 215 kg (fully fueled, fluids) ๐ก๏ธ Safety Features Ratings Motorcycle Safety Features: Performance-oriented braking system, advanced chassis geometry for stability. Active Features Braking System Front: Dual 320 mm discs, 4-piston radial calipers (e.g., Brembo) Braking System Rear: Single 220 mm disc, 2-piston caliper (e.g., Brembo) Passive Features Frame Type: Aluminum twin-spar frame ๐ก Technology Features Infotainment Instrument Panel: Analog tachometer, digital speedometer, coolant temperature gauge, clock, odometer, trip meters, warning lights. Driver Assistance Electronics Features: Basic electronic ignition, no rider aids like ABS or traction control on these early models. ๐ง Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 12 months (typical for the era) Valve Clearance Check: Every 12,000 - 24,000 km (critical for V-twin engines) Fluid Specifications Engine Oil Type: Fully synthetic 10W-40 motorcycle oil (e.g., API SG/SH/SJ, JASO MA) Coolant Type: Ethylene glycol-based coolant with anti-corrosion additives (50/50 mix with distilled water) Brake Fluid Type: DOT 4 or DOT 5.1 (check manual for specific recommendation) Clutch Fluid Type: DOT 4 (often shared with brake fluid) Known Issues Common Wear Items: Cam chain tensioners, voltage regulator, clutch slave cylinder, fuel pump (early EFI models), front fork seals. Performance Tuning Considerations: Carburetor synchronization, jetting adjustments for aftermarket exhausts or air...
Italian performance engineering, focused on raw power, sharp handling, and distinctive styling.
Manual Value Proposition:
Empowers owners with the knowledge to maintain, diagnose, and repair their RSV Mille, saving on dealership service costs and ensuring optimal performance.
๐ Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Page Count
Estimated Page Count:
300-400 (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English (common for international models and service literature)
Format
Format:
PDF Download
๐ Manual Coverage
Systems Covered
Engine Systems:
Engine disassembly, assembly, component inspection, lubrication, cooling system, fuel system (carburetor specifics for early models if applicable, or early EFI), exhaust system.
Front fork service (including damping adjustments and seal replacement), rear shock absorber, swingarm inspection, wheel bearing maintenance, steering head bearing service.
Braking System:
Brake caliper service, master cylinder overhaul, brake pad replacement, bleeding procedures, hydraulic line inspection, disc inspection.
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting circuits, battery service, charging system (stator, regulator/rectifier), starter motor, component testing.
Fuel System:
Fuel tank removal/installation, fuel pump operation (if applicable), fuel lines, carburetor synchronization and adjustment (likely Dell'Orto for this model).
Bodywork And Fairings:
Fairing removal and installation, seat service, fuel tank access, mounting hardware.
Procedures Included
Maintenance Procedures:
Routine servicing, oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment and lubrication, brake fluid replacement.
Diagnostic charts, common problems and solutions, fault finding for engine performance, electrical issues, and chassis components.
Technical Depth
Depth Of Information:
Comprehensive workshop level, covering disassembly, inspection, repair, and reassembly of all major vehicle systems.
Diagnostic Capabilities:
Detailed procedures for diagnosis of mechanical and electrical faults, including expected readings and tolerances.
Special Tool Requirements:
Identification and usage of specific Aprilia or general motorcycle tools required for various procedures.
๐ Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Readability:
High resolution, clear text and diagrams for easy reading and printing.
Binding Type
Digital Format Binding:
N/A (Digital Download)
Paper Type
Digital Format Paper:
N/A (Digital Download)
โ๏ธ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-Stroke
Displacement:
996 cc (often referred to as 956X in product titles, likely referencing an internal code or specific variant)
Bore X Stroke:
97.0 mm x 65.0 mm (typical for 996cc Aprilia V-twin)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower Peak:
Approx. 130-135 hp @ 9,200 rpm (variant dependent)
Torque Peak:
Approx. 95-100 Nm @ 7,000 rpm (variant dependent)
Fuel System
Fuel Delivery:
Carbureted (likely Dell'Orto PHM40 or similar for early models) or early Fuel Injection depending on specific sub-model and market. The '956X' designation might hint at a specific carb setup.
Ignition System:
Electronic, CDI
Cooling System
Cooling Method:
Liquid-cooled
๐ง Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox
Features
Clutch Type:
Wet, multi-plate, hydraulic actuation
Final Drive:
Chain drive
๐ Dimensions
Exterior
Length:
Approx. 2030 mm
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1140 mm (at seat)
Weights
Dry Weight:
Approx. 195 kg
Wet Weight:
Approx. 215 kg (fully fueled, fluids)
๐ก๏ธ Safety Features
Ratings
Motorcycle Safety Features:
Performance-oriented braking system, advanced chassis geometry for stability.
Active Features
Braking System Front:
Dual 320 mm discs, 4-piston radial calipers (e.g., Brembo)
Braking System Rear:
Single 220 mm disc, 2-piston caliper (e.g., Brembo)
Passive Features
Frame Type:
Aluminum twin-spar frame
๐ก Technology Features
Infotainment
Instrument Panel:
Analog tachometer, digital speedometer, coolant temperature gauge, clock, odometer, trip meters, warning lights.
Driver Assistance
Electronics Features:
Basic electronic ignition, no rider aids like ABS or traction control on these early models.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or 12 months (typical for the era)
Valve Clearance Check:
Every 12,000 - 24,000 km (critical for V-twin engines)
Fluid Specifications
Engine Oil Type:
Fully synthetic 10W-40 motorcycle oil (e.g., API SG/SH/SJ, JASO MA)
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (50/50 mix with distilled water)
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for specific recommendation)
Clutch Fluid Type:
DOT 4 (often shared with brake fluid)
Known Issues
Common Wear Items:
Cam chain tensioners, voltage regulator, clutch slave cylinder, fuel pump (early EFI models), front fork seals.
Performance Tuning Considerations:
Carburetor synchronization, jetting adjustments for aftermarket exhausts or air filters.
๐ Vehicle History
Brand Heritage
Aprilia Legacy:
Aprilia has a strong racing heritage, particularly in smaller displacement categories, before venturing into larger sportbikes.
Model Evolution
Rsv Mille Introduction:
The RSV Mille was Aprilia's flagship sportbike, designed to compete with established European and Japanese superbikes, marking a significant step for the company.
Production
Manufacturing Location:
Noale, Italy
๐ Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Praised for its powerful V-twin engine, sophisticated chassis, and distinctive Italian character, though sometimes criticized for minor electrical gremlins or ergonomics.