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Aprilia RSV Mille 956X 1999-2000 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Variant: RSV Mille 956X Model Years: 1999, 2000 Codes Internal Project Code: RP56 (for Mille) 👋 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. 📋 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 📖 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. 📊 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) ⚙️ 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 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox Features Clutch Type: Wet, multi-plate, hydraulic actuation Final Drive: Chain drive 📐 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) 🛡️ 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 💡 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. 🔧 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...
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Aprilia RSV Mille 956X 1999-2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Model Variant:
RSV Mille 956X
Model Years:
1999, 2000
Codes
Internal Project Code:
RP56 (for Mille)
👋 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.
📋 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
📖 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.
📊 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)
⚙️ 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
🔧 Transmission
Standard
Transmission Type:
6-speed manual sequential gearbox
Features
Clutch Type:
Wet, multi-plate, hydraulic actuation
Final Drive:
Chain drive
📐 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)
🛡️ 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
💡 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.
🔧 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.
📚 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
🏆 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.
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