Aprilia RSV Mille 956X 1999-2000 All Service Repair Manual
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Basic Information Identification Make: Aprilia Model: RSV Mille Engine Variant: 956X Model Years Covered: 1999, 2000 Codes Chassis Codes: RP, RP00 Introduction Market Position Segment: High-performance sportbike, premium European motorcycle segment. Target Audience: Enthusiast riders, DIY mechanics, and professional workshops seeking in-depth repair and maintenance information. Competitive Analysis Competitors Era: Ducati 916/996, Honda RC45, Yamaha YZF-R1, Suzuki GSX-R750/1100, Kawasaki ZX-9R. Key Features Vehicle Design Philosophy: Italian design, V-twin engine character, track-focused performance with road usability. Key Features Manual Value Proposition: Empowers owners and technicians with the knowledge to maintain and repair the RSV Mille accurately, ensuring optimal performance and longevity. Manual Details Coverage Areas Primary Coverage: Service and Repair Page Count Estimated Pages: Approximately 300-500 pages (typical for this era's comprehensive manuals) Manual Type Type: Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) Manual Coverage Systems Covered Engine Mechanical: Engine teardown and reassembly, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod service, timing chain and sprockets, oil pump and cooling system. Fuel System: Fuel injection system (EFI), throttle bodies, fuel pump, injectors, fuel pressure regulator, fuel filter replacement. Ignition System: Ignition coils, spark plugs, ECU (Engine Control Unit) parameters, diagnostic trouble codes (DTCs). Exhaust System: Catalytic converter, mufflers, exhaust manifold inspection and replacement. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, gear selection mechanism, final drive (chain and sprockets maintenance and replacement). Brakes: Brake system bleeding, pad and disc replacement, caliper service, master cylinder overhaul, brake line inspection. Suspension: Front fork service (oil change, seal replacement, spring adjustment), rear shock absorber inspection and replacement, linkage systems. Steering: Steering head bearing adjustment and replacement, handlebar and grip service. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting circuits, starter motor, instrument cluster. Chassis Frame: Frame inspection, fairing removal and installation, seat, fuel tank, and body panel service. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, chain lubrication and adjustment, spark plug inspection/replacement, brake fluid flush. Troubleshooting: Diagnostic procedures for common performance issues, electrical faults, and starting problems. Major Repairs: Engine rebuilding, transmission overhauls, suspension component replacement, electrical system diagnosis and repair. Special Tools: Identification and usage of specialized tools required for specific procedures. Torque Specifications: Detailed torque values for all critical fasteners and components. Wiring Diagrams: Comprehensive electrical schematics for easy diagnosis and repair. Technical Depth Depth: Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Manual Specifications File Format File Type: PDF Searchable: Likely searchable text within the PDF for quick information retrieval. Resolution: High-resolution scans for clear readability of text and diagrams. Print Quality Quality: Designed for clear viewing on screen and printable for workshop use. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Engine Specifications Primary Engine Type: V-Twin, Four-Stroke Displacement: 956 cc (956X designation refers to a specific engine variant, likely related to bore/stroke or internal components, a common practice for performance models) Bore X Stroke: 97 mm x 63.4 mm (typical for this engine family) Compression Ratio: 10.4:1 Valve Train: DOHC, 4 valves per cylinder, chain-driven Performance Horsepower: Approximately 128-130 hp @ 9,200 rpm (at crankshaft) Torque: Approximately 96-98 Nm @ 7,000 rpm (at crankshaft) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with multi-point injection Fuel Type: Unleaded gasoline, minimum 95 RON (91 AKI) Cooling System Type: Liquid-cooled Lubrication System Type: Wet sump Engine Management ECU: Magneti Marelli ECU, programmable parameters for ignition and fueling. Transmission Standard Type: 6-speed constant mesh Clutch: Hydraulically operated, multi-plate wet clutch Features Final Drive: O-ring sealed chain drive Fluid Specifications Transmission Oil: API GL-4 or GL-5, SAE 75W-90 synthetic gear oil. Consult manual for specific Aprilia recommendations. Dimensions Exterior Length: Approximately 2,040 mm (80.3 in) Width: Approximately 720 mm (28.3 in) (excluding mirrors) Height: Approximately 1,130 mm (44.5 in) (seat height) Weights Dry Weight: Approximately 194 kg (428 lbs) Wet Weight: Approximately 210 kg (463 lbs) (fully fueled) Wheelbase Wheelbase: Approximately 1,420 mm (55.9 in) Fuel Capacity Fuel Tank Capacity: 18 Liters (4.75 US gal) Safety Features Ratings Safety Standards: Compliant with European motorcycle safety standards of the era. Active Features Braking System: Dual 320 mm front discs with 4-piston radial calipers (Brembo), single 220 mm rear disc with 2-piston caliper. Suspension Adjustability: Fully adjustable front forks (preload, compression, rebound), adjustable rear shock absorber (preload, rebound). Passive Features Lighting: Halogen headlights, LED taillight. Frame Design: Aluminum twin-spar frame for torsional rigidity and light weight. Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, clock, and indicator lights. Driver Assistance ABS: Optional ABS was available on some models, though not standard on all 1999-2000 models. The manual would detail ABS system specifics if equipped. Connectivity ECU Diagnostics: Access to engine control unit data via diagnostic port for...
Italian design, V-twin engine character, track-focused performance with road usability.
Key Features Manual
Value Proposition:
Empowers owners and technicians with the knowledge to maintain and repair the RSV Mille accurately, ensuring optimal performance and longevity.
Manual Details
Coverage Areas
Primary Coverage:
Service and Repair
Page Count
Estimated Pages:
Approximately 300-500 pages (typical for this era's comprehensive manuals)
Manual Type
Type:
Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
Manual Coverage
Systems Covered
Engine Mechanical:
Engine teardown and reassembly, valve clearance adjustment, piston and cylinder inspection, crankshaft and connecting rod service, timing chain and sprockets, oil pump and cooling system.
Catalytic converter, mufflers, exhaust manifold inspection and replacement.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear selection mechanism, final drive (chain and sprockets maintenance and replacement).
Brakes:
Brake system bleeding, pad and disc replacement, caliper service, master cylinder overhaul, brake line inspection.
Suspension:
Front fork service (oil change, seal replacement, spring adjustment), rear shock absorber inspection and replacement, linkage systems.
Steering:
Steering head bearing adjustment and replacement, handlebar and grip service.
Frame inspection, fairing removal and installation, seat, fuel tank, and body panel service.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter replacement, chain lubrication and adjustment, spark plug inspection/replacement, brake fluid flush.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, and starting problems.
Major Repairs:
Engine rebuilding, transmission overhauls, suspension component replacement, electrical system diagnosis and repair.
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Torque Specifications:
Detailed torque values for all critical fasteners and components.
Wiring Diagrams:
Comprehensive electrical schematics for easy diagnosis and repair.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds.
Manual Specifications
File Format
File Type:
PDF
Searchable:
Likely searchable text within the PDF for quick information retrieval.
Resolution:
High-resolution scans for clear readability of text and diagrams.
Print Quality
Quality:
Designed for clear viewing on screen and printable for workshop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Engine Specifications
Primary Engine
Type:
V-Twin, Four-Stroke
Displacement:
956 cc (956X designation refers to a specific engine variant, likely related to bore/stroke or internal components, a common practice for performance models)
Bore X Stroke:
97 mm x 63.4 mm (typical for this engine family)
Compression Ratio:
10.4:1
Valve Train:
DOHC, 4 valves per cylinder, chain-driven
Performance
Horsepower:
Approximately 128-130 hp @ 9,200 rpm (at crankshaft)
Torque:
Approximately 96-98 Nm @ 7,000 rpm (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with multi-point injection
Fuel Type:
Unleaded gasoline, minimum 95 RON (91 AKI)
Cooling System
Type:
Liquid-cooled
Lubrication System
Type:
Wet sump
Engine Management
ECU:
Magneti Marelli ECU, programmable parameters for ignition and fueling.
Transmission
Standard
Type:
6-speed constant mesh
Clutch:
Hydraulically operated, multi-plate wet clutch
Features
Final Drive:
O-ring sealed chain drive
Fluid Specifications
Transmission Oil:
API GL-4 or GL-5, SAE 75W-90 synthetic gear oil. Consult manual for specific Aprilia recommendations.
Dimensions
Exterior
Length:
Approximately 2,040 mm (80.3 in)
Width:
Approximately 720 mm (28.3 in) (excluding mirrors)
Height:
Approximately 1,130 mm (44.5 in) (seat height)
Weights
Dry Weight:
Approximately 194 kg (428 lbs)
Wet Weight:
Approximately 210 kg (463 lbs) (fully fueled)
Wheelbase
Wheelbase:
Approximately 1,420 mm (55.9 in)
Fuel Capacity
Fuel Tank Capacity:
18 Liters (4.75 US gal)
Safety Features
Ratings
Safety Standards:
Compliant with European motorcycle safety standards of the era.
Active Features
Braking System:
Dual 320 mm front discs with 4-piston radial calipers (Brembo), single 220 mm rear disc with 2-piston caliper.
Aluminum twin-spar frame for torsional rigidity and light weight.
Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, clock, and indicator lights.
Driver Assistance
ABS:
Optional ABS was available on some models, though not standard on all 1999-2000 models. The manual would detail ABS system specifics if equipped.
Connectivity
ECU Diagnostics:
Access to engine control unit data via diagnostic port for fault code retrieval and live data monitoring, typically requiring a dealer-specific tool or compatible aftermarket scanner.
Maintenance
Service Intervals
Oil Filter Change:
Every 5,000-7,500 km (3,000-4,500 miles) or annually.
Engine Oil Change:
Every 5,000-7,500 km (3,000-4,500 miles) or annually, whichever comes first. Use high-quality synthetic motorcycle oil.
Valve Clearance Check:
Every 10,000-15,000 km (6,000-9,000 miles).
Chain Lubrication:
Every 500-800 km (300-500 miles) and after riding in wet conditions.
Brake Fluid Flush:
Every 2 years, regardless of mileage.
Fluid Specifications
Engine Oil:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (check manual for specific viscosity based on ambient temperature). API SG or higher.
Coolant:
Ethylene glycol-based coolant, 50/50 mix with distilled water. Typically red or pink colored coolant for this era.
Fork Oil:
SAE 10W fork oil. Capacity: 480 cc per fork leg (check manual for exact quantity and level).
Known Issues
Electrical Gremlins:
Early models sometimes suffered from wiring harness issues or regulator/rectifier failures. Proper diagnostic procedures in the manual are crucial.
Clutch Slave Cylinder:
Can be prone to leaks, requiring seal replacement. The manual will detail the procedure.
Fuel Pump Reliability:
While generally robust, a weak fuel pump can cause performance issues. Checking fuel pressure is a key manual procedure.
Charging System Performance:
Regularly check stator output and regulator/rectifier function, especially if experiencing battery issues.
Parts Numbers
Oil Filter Example:
Hiflofiltro HF153 or OEM equivalent.
Air Filter Example:
K&N or OEM equivalent (specific part number would be in the manual).
Spark Plug Example:
NGK CR9EKB or equivalent.
Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its racing pedigree and high-performance motorcycles, particularly in smaller displacement categories before venturing into larger sportbikes.
Model Evolution
Origins:
The RSV Mille was Aprilia's first foray into the open-class sportbike segment, aimed at challenging established Japanese and Italian rivals. It shared a strong V-twin engine platform with Rotax, a renowned engine manufacturer.
Predecessors:
While not direct predecessors in the open-class, Aprilia had success with models like the RS250 and MX series, building a reputation for sporty handling and V-twin expertise.
Production
Manufacturing Location:
Noale, Italy.
Production Years Range:
1998-2003 (First Generation Mille).
Awards & Recognition
Recognitions
Motorcycle Press:
The RSV Mille generally received positive reviews for its powerful V-twin, excellent chassis, and sharp handling, often praised for its blend of track capability and road comfort compared to some more extreme rivals of the era.
European Bike Of The Year:
While not a specific winner of major awards in its debut years, it was considered a strong contender in the liter-class sportbike segment and a significant achievement for Aprilia.