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Aprilia RSV Mille Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003

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$133.00
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$133.00
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Codes Engine Code: Rotax 990 V-Twin 👋 Introduction Market Position Market Position: The Aprilia RSV Mille was positioned as a premium, high-performance Italian sportbike, directly competing with established European and Japanese liter-class superbikes of its era. It was known for its powerful V-twin engine and sophisticated chassis. Competitive Analysis Competitive Analysis: Competed against motorcycles such as the Ducati 916/996 series, Honda CBR900RR Fireblade, Yamaha YZF-R1, and Suzuki GSX-R750/1100. The RSV Mille offered a unique blend of Italian flair, V-twin character, and high-end components. Key Features Key Features: Rotax 60-degree V-twin engine, advanced chassis design, high-quality suspension components (Ohlins optional on some models), potent braking systems, aerodynamic fairings, and a distinctive Italian aesthetic. 📋 Manual Details Coverage Areas Years Covered: 1998, 1999, 2000, 2001, 2002, 2003 Page Count Page Count: Estimated 500+ pages (typical for this level of detail) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Wiring Diagrams, Chassis, Frame, Bodywork, Instrumentation, Wheels, Tires, Troubleshooting, Diagnostics Procedures Included Procedures Included: Routine Maintenance, Scheduled Service, Engine Overhaul, Transmission Repair, Clutch Replacement, Suspension Adjustment & Overhaul, Brake System Service, Electrical Troubleshooting, Wiring Harness Repair, Body Panel Removal & Installation, Fuel System Cleaning & Repair, Ignition System Tuning, Diagnostic Procedures, Special Tool Usage, Torque Specifications, Component Removal & Installation Technical Depth Technical Depth: Comprehensive. Covers from basic oil changes and adjustments to full engine rebuilds, electrical system diagnostics, and frame-level repairs. Includes detailed exploded views, diagrams, and step-by-step instructions. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans of original documentation, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 60-degree V-twin Displacement: 998 cc (990cc) Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Compression Ratio: 10.3:1 (typically) Cooling System: Liquid-cooled with fan assist Performance Horsepower: Approx. 130-136 HP (at crank, depending on year and specific tuning) Torque: Approx. 100-105 Nm (at crank, depending on year) Fuel System Fuel Induction: Electronic Fuel Injection (EFI), dual throttle bodies Fuel Type: Unleaded gasoline, minimum 95 RON Engine Lubrication Oil Type: SAE 10W-40 Synthetic Motorcycle Oil (API SG, JASO MA) Oil Capacity: Approx. 3.7 liters (with filter change) 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch Type: Hydraulically operated, wet multi-plate Features Final Drive: O-ring sealed chain Gear Ratios: Specific ratios will be detailed in the manual, varying slightly by year but generally optimized for performance. Transmission Fluid Transmission Oil Type: Dedicated transmission oil or heavy-duty gear oil (manual specifies exact type and viscosity) 📐 Dimensions Exterior Length: Approx. 2040 mm (varies slightly by year) Width: Approx. 720 mm (at handlebars) Height: Approx. 1130 mm (at seat) Weights Dry Weight: Approx. 195 kg (varies by year and options) Wet Weight: Approx. 217 kg (fully fueled) Wheels And Tires Front Tire Size: 120/70 ZR17 M/C (58W) Rear Tire Size: 190/50 ZR17 M/C (73W) (may vary, e.g., 180/55) Wheel Bolt Pattern: N/A (Spoked or Cast Wheels, specific axle nut sizes detailed in manual) Fuel Capacity Fuel Tank Capacity: Approx. 21 liters 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not typically assigned automotive safety ratings (e.g., NCAP). Safety focus is on rider control and braking performance. Active Features Active Safety Features: Powerful Brembo braking systems, adjustable suspension for optimal handling, responsive throttle control. Passive Features Passive Safety Features: Sturdy aluminum twin-spar frame, aerodynamic fairings designed to deflect wind, rider ergonomics promoting control. Braking System Front Brakes: Dual 320 mm discs with 4-piston radial-mount Brembo calipers Rear Brakes: 220 mm disc with 2-piston caliper Brake Fluid Type: DOT 4 or DOT 5.1 (manual will specify) 💡 Technology Features Infotainment Infotainment System: N/A for this era of sportbike; focus is on performance instrumentation. Driver Assistance Driver Assistance Features: None (ABS was not standard on these early models, though some later variants may have offered it as an option). Instrumentation Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, indicator lights for turn signals, high beam, neutral, oil pressure, and engine warning. Electronics Ignition System: Electronic ignition with dual spark plugs per cylinder for improved combustion. Wiring Wiring Diagrams Included: Yes, the manual includes detailed electrical system diagrams and wiring schematics. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 6 months (whichever comes first), as per manual recommendation. Major Service Interval: Valve clearance check/adjustment every 10,000-12,000 km. Timing chain check at similar intervals. Full details in manual. Fluid Specifications...
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Aprilia RSV Mille Complete Workshop Service Repair Manual 1998 1999 2000 2001 2002 2003
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Codes
Engine Code:
Rotax 990 V-Twin
👋 Introduction
Market Position
Market Position:
The Aprilia RSV Mille was positioned as a premium, high-performance Italian sportbike, directly competing with established European and Japanese liter-class superbikes of its era. It was known for its powerful V-twin engine and sophisticated chassis.
Competitive Analysis
Competitive Analysis:
Competed against motorcycles such as the Ducati 916/996 series, Honda CBR900RR Fireblade, Yamaha YZF-R1, and Suzuki GSX-R750/1100. The RSV Mille offered a unique blend of Italian flair, V-twin character, and high-end components.
Key Features
Key Features:
Rotax 60-degree V-twin engine, advanced chassis design, high-quality suspension components (Ohlins optional on some models), potent braking systems, aerodynamic fairings, and a distinctive Italian aesthetic.
📋 Manual Details
Coverage Areas
Years Covered:
1998, 1999, 2000, 2001, 2002, 2003
Page Count
Page Count:
Estimated 500+ pages (typical for this level of detail)
Manual Type
Manual Type:
Complete Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine Mechanical, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Suspension (Front & Rear), Brakes (Front & Rear), Electrical System, Wiring Diagrams, Chassis, Frame, Bodywork, Instrumentation, Wheels, Tires, Troubleshooting, Diagnostics
Procedures Included
Procedures Included:
Routine Maintenance, Scheduled Service, Engine Overhaul, Transmission Repair, Clutch Replacement, Suspension Adjustment & Overhaul, Brake System Service, Electrical Troubleshooting, Wiring Harness Repair, Body Panel Removal & Installation, Fuel System Cleaning & Repair, Ignition System Tuning, Diagnostic Procedures, Special Tool Usage, Torque Specifications, Component Removal & Installation
Technical Depth
Technical Depth:
Comprehensive. Covers from basic oil changes and adjustments to full engine rebuilds, electrical system diagnostics, and frame-level repairs. Includes detailed exploded views, diagrams, and step-by-step instructions.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans of original documentation, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 60-degree V-twin
Displacement:
998 cc (990cc)
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
10.3:1 (typically)
Cooling System:
Liquid-cooled with fan assist
Performance
Horsepower:
Approx. 130-136 HP (at crank, depending on year and specific tuning)
Torque:
Approx. 100-105 Nm (at crank, depending on year)
Fuel System
Fuel Induction:
Electronic Fuel Injection (EFI), dual throttle bodies
Fuel Type:
Unleaded gasoline, minimum 95 RON
Engine Lubrication
Oil Type:
SAE 10W-40 Synthetic Motorcycle Oil (API SG, JASO MA)
Oil Capacity:
Approx. 3.7 liters (with filter change)
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Clutch Type:
Hydraulically operated, wet multi-plate
Features
Final Drive:
O-ring sealed chain
Gear Ratios:
Specific ratios will be detailed in the manual, varying slightly by year but generally optimized for performance.
Transmission Fluid
Transmission Oil Type:
Dedicated transmission oil or heavy-duty gear oil (manual specifies exact type and viscosity)
📐 Dimensions
Exterior
Length:
Approx. 2040 mm (varies slightly by year)
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1130 mm (at seat)
Weights
Dry Weight:
Approx. 195 kg (varies by year and options)
Wet Weight:
Approx. 217 kg (fully fueled)
Wheels And Tires
Front Tire Size:
120/70 ZR17 M/C (58W)
Rear Tire Size:
190/50 ZR17 M/C (73W) (may vary, e.g., 180/55)
Wheel Bolt Pattern:
N/A (Spoked or Cast Wheels, specific axle nut sizes detailed in manual)
Fuel Capacity
Fuel Tank Capacity:
Approx. 21 liters
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned automotive safety ratings (e.g., NCAP). Safety focus is on rider control and braking performance.
Active Features
Active Safety Features:
Powerful Brembo braking systems, adjustable suspension for optimal handling, responsive throttle control.
Passive Features
Passive Safety Features:
Sturdy aluminum twin-spar frame, aerodynamic fairings designed to deflect wind, rider ergonomics promoting control.
Braking System
Front Brakes:
Dual 320 mm discs with 4-piston radial-mount Brembo calipers
Rear Brakes:
220 mm disc with 2-piston caliper
Brake Fluid Type:
DOT 4 or DOT 5.1 (manual will specify)
💡 Technology Features
Infotainment
Infotainment System:
N/A for this era of sportbike; focus is on performance instrumentation.
Driver Assistance
Driver Assistance Features:
None (ABS was not standard on these early models, though some later variants may have offered it as an option).
Instrumentation
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meter, coolant temperature gauge, indicator lights for turn signals, high beam, neutral, oil pressure, and engine warning.
Electronics
Ignition System:
Electronic ignition with dual spark plugs per cylinder for improved combustion.
Wiring
Wiring Diagrams Included:
Yes, the manual includes detailed electrical system diagrams and wiring schematics.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 km or 6 months (whichever comes first), as per manual recommendation.
Major Service Interval:
Valve clearance check/adjustment every 10,000-12,000 km. Timing chain check at similar intervals. Full details in manual.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (manual specifies exact type and mix ratio).
Brake Fluid Replacement:
Recommended every 2 years or as per manual, using DOT 4 or DOT 5.1.
Fork Oil Type:
Specific viscosity fork oil (e.g., 5W or 10W) as per manual, depending on suspension variant.
Known Issues
Common Issues:
Potential for stator failure, electrical connector corrosion (especially on earlier models), cam chain tensioner issues, and occasional fuel pump irregularities. Manual provides diagnostic and repair steps for these and other potential issues.
Filters
Oil Filter Part Number:
Likely compatible with HiFloFiltro HF153 or similar OEM equivalent (verify in manual).
Air Filter Part Number:
Specific part number will be in the manual, often a high-flow aftermarket option exists.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in Grand Prix motorcycle racing. This experience significantly influenced the development of their road-going sportbikes.
Model Evolution
Model Evolution:
The RSV Mille was Aprilia's flagship sportbike, introduced in 1998. It evolved through various iterations, including the 'R' model with higher-spec components, and later updates to the engine and electronics. This manual covers the early, foundational models.
Production
Production Years:
1998 - 2003 (for models covered by this manual). Production continued with updated models beyond 2003.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Recognitions:
The Aprilia RSV Mille received critical acclaim for its performance, handling, and unique character, often praised by motorcycle journalists as a serious contender in the superbike class.
Ratings
Rider Reviews General Rating:
Highly regarded by enthusiasts for its V-twin character and track-day capability, though sometimes noted for requiring more diligent maintenance than Japanese counterparts.
Certifications
Certifications:
N/A (Manual certification is not applicable in this context).
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