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Aprilia RSV Mille 2002 Service Repair Manual

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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Year: 2002 Codes Chassis Code: RP Engine Code Prefix: Rotax 60° V-twin 👋 Introduction Market Position Market Segment: High-performance sportbike, known for its V-twin engine character and track-day capabilities. Competitive Analysis Competitors: Ducati 996, Honda VTR1000 Firestorm, Suzuki TL1000R/S, Yamaha YZF-R1. Key Features Engine Type: V-twin, renowned for its torque and distinctive sound. Handling: Sportbike chassis and suspension tuned for agile handling and track performance. Design: Aggressive Italian sportbike styling. 📋 Manual Details Coverage Areas Coverage: Complete service and repair for Aprilia RSV Mille 2002 model year. Page Count Page Count: Estimate: 300-500 pages (typical for comprehensive service manuals) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Likely PDF (digital format) for easy search and access 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust. Drivetrain Systems: Clutch, gearbox, final drive (chain). Chassis Systems: Frame, suspension (front forks, rear shock), steering, wheels, brakes (front and rear hydraulic disc). Electrical Systems: Wiring diagrams, battery, charging system, lighting, starter, instrumentation, ECU. Bodywork And Fairings: Disassembly, assembly, and repair of all body panels and fairings. Procedures Included Maintenance Procedures: Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement. Diagnostic Procedures: Troubleshooting guides for common issues, fault code interpretation (if applicable). Repair Procedures: Step-by-step instructions for engine rebuilds, transmission overhauls, suspension servicing, electrical system repairs. Disassembly And Assembly: Detailed procedures for removing and reinstalling major components. Technical Depth Depth Of Information: Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including torque specifications and diagnostic procedures. 📊 Manual Specifications File Format File Format: Digital (PDF) optimized for searching and printing. Print Quality Print Quality: High-resolution, clear diagrams and text suitable for printing. Binding Type Binding Type: N/A (for digital format) Paper Type Paper Type: N/A (for digital format) ⚙️ Engine Specifications Primary Engine Engine Type: 998cc, 4-stroke, liquid-cooled, 60° V-twin, DOHC, 4 valves per cylinder. Bore X Stroke: 97 mm x 67.5 mm Performance Horsepower: Approx. 125-130 hp (at crank) Torque: Approx. 70-75 lb-ft (at crank) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual throttle bodies. Ignition System: Digital CDI with electronic advance. Lubrication Oil Capacity: Approx. 3.5 liters (including filter) Cooling System Coolant Type: Ethylene glycol-based coolant (50/50 mix with distilled water). Engine Management ECU: ECU controlled, likely with diagnostic port. 🔧 Transmission Standard Gearbox Type: 6-speed manual transmission. Clutch Type: Hydraulically operated wet multi-plate clutch. Features Final Drive: Chain drive. Oil Specifications Gearbox Oil Type: Refer to manual for specific API GL-4 or GL-5 rated gear oil. Clutch Fluid Type: DOT 4 brake fluid. 📐 Dimensions Exterior Length: Approx. 2020 mm (80 inches) Width: Approx. 720 mm (28 inches) Height: Approx. 1150 mm (45 inches) Weights Dry Weight: Approx. 192 kg (423 lbs) Wet Weight: Approx. 215 kg (474 lbs) Wheels And Tires Front Tire Size: 120/70 ZR17 Rear Tire Size: 190/50 ZR17 Wheel Bolt Pattern: N/A (Cast alloy wheels with hub mounting) 🛡️ Safety Features Ratings Safety Ratings: Motorcycle safety is primarily determined by rider skill and adherence to road regulations, not formal crash test ratings. Active Features Braking System: Dual 320 mm front discs with 4-piston calipers, single 220 mm rear disc with 2-piston caliper. Suspension Adjustability: Fully adjustable front forks (compression, rebound, preload) and rear shock (preload, rebound, compression). Passive Features Lighting: Dual Halogen headlights, LED tail light. Chassis Design: Aluminum twin-spar frame for rigidity and rider feedback. 💡 Technology Features Infotainment Infotainment System: N/A (Focus on performance, not infotainment features). Driver Assistance ABS: No ABS as standard on the 2002 model. Later models or 'R' variants might have offered it. Connectivity Connectivity: N/A (No modern connectivity features like Bluetooth or smartphone integration). Instrumentation Dashboard: Analog tachometer and speedometer, digital display for odometer, trip meter, clock, and warning lights. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, whichever comes first. Consult manual for exact recommendation. Valve Clearance Check: Every 10,000 - 12,000 km (6,000 - 7,500 miles). Requires engine disassembly. Chain Maintenance: Lubricate and adjust chain every 500-1000 km (300-600 miles) or as needed. Fluid Specifications Engine Oil Grade: Viscosity: 10W-40. API SG or higher, JASO MA certified. Refer to manual for precise specification. Coolant Specifications: 50% Ethylene Glycol and 50% distilled water. Brake Fluid Type: DOT 4. Known Issues Common Wear Items: Clutch plates, cam chain tensioner (potential failure), swingarm bearings, fork seals, regulator/rectifier. Potential Electrical Quirks: Older Italian motorcycles can sometimes exhibit minor electrical gremlins if wiring is damaged or connections are corroded. Manual provides crucial wiring diagrams. Recommended Parts Air Filter Part Number: Refer to manual or reputable aftermarket suppliers (e.g., K&N, BMC) for specific part numbers. Oil Filter Part Number: Refer to manual or...
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Aprilia RSV Mille 2002 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
2002
Codes
Chassis Code:
RP
Engine Code Prefix:
Rotax 60° V-twin
👋 Introduction
Market Position
Market Segment:
High-performance sportbike, known for its V-twin engine character and track-day capabilities.
Competitive Analysis
Competitors:
Ducati 996, Honda VTR1000 Firestorm, Suzuki TL1000R/S, Yamaha YZF-R1.
Key Features
Engine Type:
V-twin, renowned for its torque and distinctive sound.
Handling:
Sportbike chassis and suspension tuned for agile handling and track performance.
Design:
Aggressive Italian sportbike styling.
📋 Manual Details
Coverage Areas
Coverage:
Complete service and repair for Aprilia RSV Mille 2002 model year.
Page Count
Page Count:
Estimate: 300-500 pages (typical for comprehensive service manuals)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Likely PDF (digital format) for easy search and access
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust.
Drivetrain Systems:
Clutch, gearbox, final drive (chain).
Chassis Systems:
Frame, suspension (front forks, rear shock), steering, wheels, brakes (front and rear hydraulic disc).
Electrical Systems:
Wiring diagrams, battery, charging system, lighting, starter, instrumentation, ECU.
Bodywork And Fairings:
Disassembly, assembly, and repair of all body panels and fairings.
Procedures Included
Maintenance Procedures:
Regular scheduled maintenance, oil changes, filter replacements, chain adjustment, brake pad replacement.
Diagnostic Procedures:
Troubleshooting guides for common issues, fault code interpretation (if applicable).
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension servicing, electrical system repairs.
Disassembly And Assembly:
Detailed procedures for removing and reinstalling major components.
Technical Depth
Depth Of Information:
Comprehensive, covering everything from basic maintenance to complete engine and transmission rebuilds, including torque specifications and diagnostic procedures.
📊 Manual Specifications
File Format
File Format:
Digital (PDF) optimized for searching and printing.
Print Quality
Print Quality:
High-resolution, clear diagrams and text suitable for printing.
Binding Type
Binding Type:
N/A (for digital format)
Paper Type
Paper Type:
N/A (for digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
998cc, 4-stroke, liquid-cooled, 60° V-twin, DOHC, 4 valves per cylinder.
Bore X Stroke:
97 mm x 67.5 mm
Performance
Horsepower:
Approx. 125-130 hp (at crank)
Torque:
Approx. 70-75 lb-ft (at crank)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual throttle bodies.
Ignition System:
Digital CDI with electronic advance.
Lubrication
Oil Capacity:
Approx. 3.5 liters (including filter)
Cooling System
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water).
Engine Management
ECU:
ECU controlled, likely with diagnostic port.
🔧 Transmission
Standard
Gearbox Type:
6-speed manual transmission.
Clutch Type:
Hydraulically operated wet multi-plate clutch.
Features
Final Drive:
Chain drive.
Oil Specifications
Gearbox Oil Type:
Refer to manual for specific API GL-4 or GL-5 rated gear oil.
Clutch Fluid Type:
DOT 4 brake fluid.
📐 Dimensions
Exterior
Length:
Approx. 2020 mm (80 inches)
Width:
Approx. 720 mm (28 inches)
Height:
Approx. 1150 mm (45 inches)
Weights
Dry Weight:
Approx. 192 kg (423 lbs)
Wet Weight:
Approx. 215 kg (474 lbs)
Wheels And Tires
Front Tire Size:
120/70 ZR17
Rear Tire Size:
190/50 ZR17
Wheel Bolt Pattern:
N/A (Cast alloy wheels with hub mounting)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycle safety is primarily determined by rider skill and adherence to road regulations, not formal crash test ratings.
Active Features
Braking System:
Dual 320 mm front discs with 4-piston calipers, single 220 mm rear disc with 2-piston caliper.
Suspension Adjustability:
Fully adjustable front forks (compression, rebound, preload) and rear shock (preload, rebound, compression).
Passive Features
Lighting:
Dual Halogen headlights, LED tail light.
Chassis Design:
Aluminum twin-spar frame for rigidity and rider feedback.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on performance, not infotainment features).
Driver Assistance
ABS:
No ABS as standard on the 2002 model. Later models or 'R' variants might have offered it.
Connectivity
Connectivity:
N/A (No modern connectivity features like Bluetooth or smartphone integration).
Instrumentation
Dashboard:
Analog tachometer and speedometer, digital display for odometer, trip meter, clock, and warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, whichever comes first. Consult manual for exact recommendation.
Valve Clearance Check:
Every 10,000 - 12,000 km (6,000 - 7,500 miles). Requires engine disassembly.
Chain Maintenance:
Lubricate and adjust chain every 500-1000 km (300-600 miles) or as needed.
Fluid Specifications
Engine Oil Grade:
Viscosity: 10W-40. API SG or higher, JASO MA certified. Refer to manual for precise specification.
Coolant Specifications:
50% Ethylene Glycol and 50% distilled water.
Brake Fluid Type:
DOT 4.
Known Issues
Common Wear Items:
Clutch plates, cam chain tensioner (potential failure), swingarm bearings, fork seals, regulator/rectifier.
Potential Electrical Quirks:
Older Italian motorcycles can sometimes exhibit minor electrical gremlins if wiring is damaged or connections are corroded. Manual provides crucial wiring diagrams.
Recommended Parts
Air Filter Part Number:
Refer to manual or reputable aftermarket suppliers (e.g., K&N, BMC) for specific part numbers.
Oil Filter Part Number:
Refer to manual or reputable aftermarket suppliers (e.g., HiFlofiltro, K&N) for specific part numbers.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in smaller displacement categories before entering the superbike market.
Model Evolution
Generation:
The RSV Mille was Aprilia's first foray into the litre-class sportbike segment, launched in 1997. The 2002 model represents an evolution with updates to performance and styling.
Production
Manufacturing Location:
Noale, Italy.
Production Years:
1997-2003 (First Generation) before the introduction of the RSV-R and later the RSV1000R.
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
The RSV Mille generally received positive reviews for its V-twin character, handling, and value compared to some European rivals. Often praised for its track prowess.
Ratings
Performance Ratings:
Considered a top-tier sportbike of its era, competing with the best from Japan and Europe.
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