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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...
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Aprilia RSV Mille 956X 1999-2000 All Service Repair Manual
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 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.
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