Aprilia RSV Mille Complete Workshop Service Repair Manual 2001 2002 2003
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Variant: Standard / R (likely) Generation Generation Name: Second Generation (SL1000) Codes Engine Code Series: Rotax V990 👋 Introduction Market Position Category: High-performance sportbike, often considered a premium European alternative to Japanese superbikes of the era. Competitive Analysis Competitors: Honda RC51, Suzuki GSX-R1000, Yamaha YZF-R1, Ducati 996/998, Kawasaki ZX-10R. Key Features Engine Type: V-Twin engine known for its torque and distinctive sound. Chassis Design: Advanced chassis and suspension components, often featuring top-tier brands like Brembo brakes and Öhlins suspension (on 'R' models). Handling: Renowned for sharp handling and stability. 📋 Manual Details Coverage Areas Applicable Years: 2001, 2002, 2003 Page Count Estimated Pages: 500-700 (estimated for a complete workshop manual) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnosis, tuning, lubrication, cooling system, fuel system (including fuel injection), exhaust system, ignition system. Transmission Drivetrain: Clutch operation and adjustment, gearbox inspection and repair, final drive, chain maintenance. Chassis Frame: Frame inspection, steering head bearings, swingarm and linkage service. Suspension: Front fork (Öhlins/Showa variants likely) disassembly, service, and reassembly; rear shock absorber service; suspension geometry adjustment. Brakes: Front and rear brake system inspection, service, bleeding, component replacement (calipers, master cylinders, lines), rotor specifications. Electrical System: Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, ignition system troubleshooting, starter motor, electronic control unit (ECU) diagnostics. Bodywork Fairings: Fairing removal and installation, cosmetic component service, seat removal. Procedures Included Maintenance: Scheduled maintenance, oil and filter changes, spark plug replacement, air filter service, chain adjustment and lubrication, brake fluid flush, coolant flush. Troubleshooting: Diagnostic procedures for common performance issues, electrical faults, starting problems, and engine malfunctions. Repair Rebuild: Detailed step-by-step instructions for engine rebuilds, gearbox overhauls, suspension component replacement, and electrical system repairs. Specifications: Torque specifications for all fasteners, component clearances, fluid capacities, electrical system specifications. Technical Depth Depth: Comprehensive. Covers everything from basic user maintenance to complete engine and gearbox teardowns and reassembly, including detailed diagnostic procedures for the electronic fuel injection (EFI) system. 📊 Manual Specifications File Format Format: PDF Searchable: Typically yes, for PDF documents of this nature. Printable: Yes, the PDF is designed for printing. Print Quality Quality: High-resolution, clear text and diagrams. Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-Twin, four-stroke Displacement: 997.6 cc (998 cc) Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 130-135 HP (at crankshaft, depending on specific model year and tune) Torque: Approx. 100-105 Nm (at crankshaft, depending on specific model year and tune) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder Throttle Body Size: Likely 54mm Fuel Type: Unleaded gasoline, Octane rating 95 RON recommended. Lubrication Oil Type: API SG or higher, JASO MA compliant motorcycle engine oil, SAE 10W-40 or 15W-50 (refer to manual for exact specification). Oil Capacity: Approx. 3.8 - 4.0 Liters (with filter change) Cooling System Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors, 50% concentration with distilled water. Coolant Capacity: Approx. 2.5 Liters 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet, multi-plate, hydraulic actuation Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2030 mm (203 cm) Width: Approx. 720 mm (72 cm) at handlebars Height: Approx. 1160 mm (116 cm) at screen Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 212 kg (467 lbs) (with fluids) Fuel Tank Capacity: 21 Liters (4.6 UK gal; 5.5 US gal) 🛡️ Safety Features Ratings Crash Safety: Motorcycle safety is primarily rider-dependent; no formal crash ratings like cars. Active Features Braking System: Dual 320 mm front discs with 4-piston radial calipers (Brembo), Single 220 mm rear disc with 2-piston caliper (Brembo). Suspension Features: Adjustable front forks (preload, compression, rebound damping), adjustable rear shock (preload, rebound damping). Passive Features Lighting: Dual halogen headlights for optimal visibility. 💡 Technology Features Infotainment System: Basic motorcycle instrumentation: speedometer, tachometer, odometer, trip meters, coolant temperature gauge, basic warning lights. Driver Assistance Features: No electronic rider aids like traction control or ABS were standard on these models (though some later variations or aftermarket options might exist). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 6,000 km (3,700 miles) or annually. Spark Plugs: Every 12,000 km (7,500 miles) (refer to manual for specific plug type and gap). Air Filter: Inspect every 6,000 km (3,700 miles), clean or replace as needed. Chain Maintenance: Clean and lubricate every 1,000 km (600 miles) and after riding in wet conditions. Coolant Flush: Every 24,000 km (15,000 miles) or every 2 years. Brake Fluid Flush: Every 24,000 km (15,000 miles) or every 2 years. Fluid Specifications Engine Oil: SAE 10W-40 or 15W-50, API SG...
Clutch operation and adjustment, gearbox inspection and repair, final drive, chain maintenance.
Chassis Frame:
Frame inspection, steering head bearings, swingarm and linkage service.
Suspension:
Front fork (Öhlins/Showa variants likely) disassembly, service, and reassembly; rear shock absorber service; suspension geometry adjustment.
Brakes:
Front and rear brake system inspection, service, bleeding, component replacement (calipers, master cylinders, lines), rotor specifications.
Electrical System:
Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, ignition system troubleshooting, starter motor, electronic control unit (ECU) diagnostics.
Bodywork Fairings:
Fairing removal and installation, cosmetic component service, seat removal.
Procedures Included
Maintenance:
Scheduled maintenance, oil and filter changes, spark plug replacement, air filter service, chain adjustment and lubrication, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic procedures for common performance issues, electrical faults, starting problems, and engine malfunctions.
Repair Rebuild:
Detailed step-by-step instructions for engine rebuilds, gearbox overhauls, suspension component replacement, and electrical system repairs.
Specifications:
Torque specifications for all fasteners, component clearances, fluid capacities, electrical system specifications.
Technical Depth
Depth:
Comprehensive. Covers everything from basic user maintenance to complete engine and gearbox teardowns and reassembly, including detailed diagnostic procedures for the electronic fuel injection (EFI) system.
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Typically yes, for PDF documents of this nature.
Printable:
Yes, the PDF is designed for printing.
Print Quality
Quality:
High-resolution, clear text and diagrams.
Binding Type
Type:
N/A (Digital Download)
Paper Type
Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 90-degree V-Twin, four-stroke
Displacement:
997.6 cc (998 cc)
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 130-135 HP (at crankshaft, depending on specific model year and tune)
Torque:
Approx. 100-105 Nm (at crankshaft, depending on specific model year and tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual injectors per cylinder
Throttle Body Size:
Likely 54mm
Fuel Type:
Unleaded gasoline, Octane rating 95 RON recommended.
Lubrication
Oil Type:
API SG or higher, JASO MA compliant motorcycle engine oil, SAE 10W-40 or 15W-50 (refer to manual for exact specification).
Oil Capacity:
Approx. 3.8 - 4.0 Liters (with filter change)
Cooling System
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, 50% concentration with distilled water.
Coolant Capacity:
Approx. 2.5 Liters
🔧 Transmission
Standard
Type:
6-speed constant mesh
Features
Clutch Type:
Wet, multi-plate, hydraulic actuation
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2030 mm (203 cm)
Width:
Approx. 720 mm (72 cm) at handlebars
Height:
Approx. 1160 mm (116 cm) at screen
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 212 kg (467 lbs) (with fluids)
Fuel Tank Capacity:
21 Liters (4.6 UK gal; 5.5 US gal)
🛡️ Safety Features
Ratings
Crash Safety:
Motorcycle safety is primarily rider-dependent; no formal crash ratings like cars.
Active Features
Braking System:
Dual 320 mm front discs with 4-piston radial calipers (Brembo), Single 220 mm rear disc with 2-piston caliper (Brembo).
No electronic rider aids like traction control or ABS were standard on these models (though some later variations or aftermarket options might exist).
Connectivity
Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change:
Every 6,000 km (3,700 miles) or annually.
Spark Plugs:
Every 12,000 km (7,500 miles) (refer to manual for specific plug type and gap).
Air Filter:
Inspect every 6,000 km (3,700 miles), clean or replace as needed.
Chain Maintenance:
Clean and lubricate every 1,000 km (600 miles) and after riding in wet conditions.
Coolant Flush:
Every 24,000 km (15,000 miles) or every 2 years.
Brake Fluid Flush:
Every 24,000 km (15,000 miles) or every 2 years.
Fluid Specifications
Engine Oil:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant (Consult manual for definitive recommendation).
Coolant:
50/50 mix of ethylene glycol-based coolant and distilled water.
Brake Fluid:
DOT 4
Clutch Fluid:
DOT 4 (if hydraulic clutch system)
Known Issues
Charging System:
Stator and regulator/rectifier failure can be an issue on some Aprilia models of this era. Regular testing is advised.
Camshaft Wear:
Some early Rotax V990 engines experienced camshaft wear; the manual will detail inspection procedures.
Fuel Pump:
Occasional issues with the fuel pump, especially after long periods of storage. The manual provides diagnostic steps.
Electrical Connectors:
Corrosion or looseness in electrical connectors can lead to various electrical gremlins.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia is an Italian manufacturer with a strong racing pedigree, particularly in smaller displacement classes before venturing into superbikes.
Model Evolution
First Generation:
The first generation RSV Mille (SL1000) was launched in 1997, featuring the Rotax V990 engine.
Updates 2001-2003:
These years saw various refinements, including ECU updates, chassis tweaks, and potentially minor suspension and brake component upgrades. The 'R' model typically offered higher-spec components.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Press Reviews:
The RSV Mille was generally well-received by motorcycle press for its performance, handling, and distinctive character, often praised for challenging the established Japanese superbikes.
Ratings
Track Day Performance:
Consistently rated as a capable track day machine due to its chassis and engine characteristics.