Aprilia RSV Mille 2000-2003 Factory Service Repair Manual

Normale prijs: $133.00
Aanbiedingsprijs: $133.00
Normale prijs
Eenheidsprijs: per

🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Year Range: 2000-2003 Codes Vin Code Engine: Rotax 60 V2 👋 Introduction Market Position Market Segment: High-performance sportbike, competing in the premium liter-bike category of its era. Target Audience: Enthusiast riders, performance-oriented motorcyclists, and those seeking a track-capable machine. Competitive Analysis Key Competitors Era: Ducati 916/996, Yamaha R1, Honda CBR900RR Fireblade, Suzuki GSX-R1000, Kawasaki ZX-9R. Key Features Engine Architecture: V-twin engine, known for its torque and character. Handling Chassis: Renowned for its sophisticated chassis and excellent handling dynamics, often featuring high-quality suspension components. Braking System: Typically equipped with premium braking components for superior stopping power. 📋 Manual Details Coverage Areas Coverage Years: 2000, 2001, 2002, 2003 Engine Variants Covered: All RSV Mille V2 engine configurations for the specified years. Trim Levels Covered: RSV Mille, RSV Mille R (if applicable to the manual's scope). Page Count Estimated Page Count: Likely 500-800 pages (typical for comprehensive factory service manuals of this era). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (standard for international service manuals unless specified otherwise). Format Format: Digital (PDF) is most common for reproduction, but original might be printed. 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, repair, and reassembly of the V2 engine (cylinder head, pistons, crankshaft, connecting rods, valve train, timing system). Fuel System: Fuel injection system diagnostics, cleaning, component testing (injectors, fuel pump, regulators), throttle body service, fuel tank maintenance. Ignition System: Ignition coil testing, spark plug specifications and replacement, ECU diagnostics related to ignition timing. Cooling System: Radiator, fan, thermostat, water pump, coolant types, bleeding procedures, leak detection. Exhaust System: Exhaust manifold, catalytic converter (if applicable), mufflers, gasket replacement, torque specifications. Transmission Clutch: Clutch operation, slave cylinder service, master cylinder service, clutch disc inspection, gear shifting mechanism. Gearbox Drivetrain: Gearbox disassembly, inspection, reassembly, gearset inspection, bearing replacement, final drive chain and sprocket maintenance. Chassis Frame: Frame inspection, alignment checks, welding integrity, swingarm pivot bearing service. Suspension Front: Front fork disassembly, seal replacement, oil type and level specifications, spring rates, damping adjustments, steering head bearing service. Suspension Rear: Rear shock absorber service, linkage inspection, bearing service, preload and damping adjustments. Brakes Front: Brake caliper service, piston seals, brake pad replacement, rotor inspection, brake line replacement, bleeding procedures, master cylinder service. Brakes Rear: Rear brake caliper service, piston seals, brake pad replacement, rotor inspection, brake line replacement, bleeding procedures, master cylinder service. Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, tire wear indicators, wheel balancing. Electrical System General: Wiring diagrams, fuse box locations and specifications, relay functions, battery maintenance and testing. Lighting System: Headlight, taillight, turn signal bulb replacement and troubleshooting, wiring for lighting. Instrumentation Gauges: Speedometer, tachometer, fuel gauge, warning light diagnostics and repair. ECU Electronics: Engine Control Unit (ECU) overview, sensor diagnostics (TPS, MAP, IAT, Crankshaft Position Sensor), actuator testing. Bodywork Fairings: Fairing removal and installation, bolt specifications, cosmetic repair guidance. Seat Fuel Tank: Seat removal, fuel tank mounting and removal, fuel line connections. Controls Levers: Handlebar controls, clutch lever, brake lever service and replacement. Procedures Included Preventative Maintenance: Regular service checks, lubrication points, fastener torque checks, filter replacement schedules. Troubleshooting: Diagnostic charts, symptom-to-cause analysis for common issues, electrical system fault finding. Engine Overhaul: Step-by-step instructions for engine rebuilds, including component measurements and tolerances. Suspension Tuning: Guidance on adjusting suspension for different riding conditions. Brake System Bleeding: Detailed instructions for bleeding hydraulic brake systems. Electrical Component Replacement: Instructions for replacing starter motor, alternator, ECU, sensors, etc. Drivetrain Adjustment: Chain adjustment, sprocket replacement procedures. Technical Depth Depth Of Information: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and troubleshooting. Diagnostic Capabilities: Advanced diagnostics for electronic systems, including sensor data interpretation and fault code lookup (if applicable to factory diagnostics). Torque Specifications: Extensive list of all critical torque specifications for engine, chassis, suspension, and brake components. Clearances Tolerances: Detailed specifications for component clearances and wear tolerances during engine rebuilding. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Print Quality Print Quality: High-resolution for clear diagrams and text. Binding Type Binding Type: N/A (for digital format); Spiral-bound or perfect-bound (if printed). Paper Type Paper Type: N/A (for digital format); High-quality, durable paper suitable for workshop environments (if printed). ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, 4-stroke Displacement: 998 cc (approximately) Bore X Stroke: 97 mm x 68 mm (typical for this engine) Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Compression Ratio: 10.8:1 (approximate) Performance Horsepower: 130-137 HP (at crank, depending on specific model year and tuning) Torque: 102-105 Nm (at crank, depending on specific model year and tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 95 RON (recommended) Throttle Body Size: 54 mm...

26 people are viewing this right now

Type: Motorcycle

Verkoper:

Sku: 172961

Collecties: ALL

Beschikbaarheid: Op voorraad

Labels: 2000 2001 2002 2003 Aprilia Misc Motorcycle Motorcycles RSV Mille

Productvarianten

Description

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Model Year Range:

2000-2003

Codes

Vin Code Engine:

Rotax 60 V2

👋 Introduction

Market Position

Market Segment:

High-performance sportbike, competing in the premium liter-bike category of its era.

Target Audience:

Enthusiast riders, performance-oriented motorcyclists, and those seeking a track-capable machine.

Competitive Analysis

Key Competitors Era:

Ducati 916/996, Yamaha R1, Honda CBR900RR Fireblade, Suzuki GSX-R1000, Kawasaki ZX-9R.

Key Features

Engine Architecture:

V-twin engine, known for its torque and character.

Handling Chassis:

Renowned for its sophisticated chassis and excellent handling dynamics, often featuring high-quality suspension components.

Braking System:

Typically equipped with premium braking components for superior stopping power.

📋 Manual Details

Coverage Areas

Coverage Years:

2000, 2001, 2002, 2003

Engine Variants Covered:

All RSV Mille V2 engine configurations for the specified years.

Trim Levels Covered:

RSV Mille, RSV Mille R (if applicable to the manual's scope).

Page Count

Estimated Page Count:

Likely 500-800 pages (typical for comprehensive factory service manuals of this era).

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English (standard for international service manuals unless specified otherwise).

Format

Format:

Digital (PDF) is most common for reproduction, but original might be printed.

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the V2 engine (cylinder head, pistons, crankshaft, connecting rods, valve train, timing system).

Fuel System:

Fuel injection system diagnostics, cleaning, component testing (injectors, fuel pump, regulators), throttle body service, fuel tank maintenance.

Ignition System:

Ignition coil testing, spark plug specifications and replacement, ECU diagnostics related to ignition timing.

Cooling System:

Radiator, fan, thermostat, water pump, coolant types, bleeding procedures, leak detection.

Exhaust System:

Exhaust manifold, catalytic converter (if applicable), mufflers, gasket replacement, torque specifications.

Transmission Clutch:

Clutch operation, slave cylinder service, master cylinder service, clutch disc inspection, gear shifting mechanism.

Gearbox Drivetrain:

Gearbox disassembly, inspection, reassembly, gearset inspection, bearing replacement, final drive chain and sprocket maintenance.

Chassis Frame:

Frame inspection, alignment checks, welding integrity, swingarm pivot bearing service.

Suspension Front:

Front fork disassembly, seal replacement, oil type and level specifications, spring rates, damping adjustments, steering head bearing service.

Suspension Rear:

Rear shock absorber service, linkage inspection, bearing service, preload and damping adjustments.

Brakes Front:

Brake caliper service, piston seals, brake pad replacement, rotor inspection, brake line replacement, bleeding procedures, master cylinder service.

Brakes Rear:

Rear brake caliper service, piston seals, brake pad replacement, rotor inspection, brake line replacement, bleeding procedures, master cylinder service.

Wheels Tires:

Wheel bearing inspection and replacement, tire pressure recommendations, tire wear indicators, wheel balancing.

Electrical System General:

Wiring diagrams, fuse box locations and specifications, relay functions, battery maintenance and testing.

Lighting System:

Headlight, taillight, turn signal bulb replacement and troubleshooting, wiring for lighting.

Instrumentation Gauges:

Speedometer, tachometer, fuel gauge, warning light diagnostics and repair.

ECU Electronics:

Engine Control Unit (ECU) overview, sensor diagnostics (TPS, MAP, IAT, Crankshaft Position Sensor), actuator testing.

Bodywork Fairings:

Fairing removal and installation, bolt specifications, cosmetic repair guidance.

Seat Fuel Tank:

Seat removal, fuel tank mounting and removal, fuel line connections.

Controls Levers:

Handlebar controls, clutch lever, brake lever service and replacement.

Procedures Included

Preventative Maintenance:

Regular service checks, lubrication points, fastener torque checks, filter replacement schedules.

Troubleshooting:

Diagnostic charts, symptom-to-cause analysis for common issues, electrical system fault finding.

Engine Overhaul:

Step-by-step instructions for engine rebuilds, including component measurements and tolerances.

Suspension Tuning:

Guidance on adjusting suspension for different riding conditions.

Brake System Bleeding:

Detailed instructions for bleeding hydraulic brake systems.

Electrical Component Replacement:

Instructions for replacing starter motor, alternator, ECU, sensors, etc.

Drivetrain Adjustment:

Chain adjustment, sprocket replacement procedures.

Technical Depth

Depth Of Information:

Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including detailed electrical schematics and troubleshooting.

Diagnostic Capabilities:

Advanced diagnostics for electronic systems, including sensor data interpretation and fault code lookup (if applicable to factory diagnostics).

Torque Specifications:

Extensive list of all critical torque specifications for engine, chassis, suspension, and brake components.

Clearances Tolerances:

Detailed specifications for component clearances and wear tolerances during engine rebuilding.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Print Quality

Print Quality:

High-resolution for clear diagrams and text.

Binding Type

Binding Type:

N/A (for digital format); Spiral-bound or perfect-bound (if printed).

Paper Type

Paper Type:

N/A (for digital format); High-quality, durable paper suitable for workshop environments (if printed).

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, 4-stroke

Displacement:

998 cc (approximately)

Bore X Stroke:

97 mm x 68 mm (typical for this engine)

Valve Train:

DOHC, 4 valves per cylinder

Cooling System:

Liquid-cooled

Compression Ratio:

10.8:1 (approximate)

Performance

Horsepower:

130-137 HP (at crank, depending on specific model year and tuning)

Torque:

102-105 Nm (at crank, depending on specific model year and tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, minimum 95 RON (recommended)

Throttle Body Size:

54 mm (typical)

🔧 Transmission

Standard

Transmission Type:

6-speed manual sequential gearbox

Optional

Optional Transmissions:

N/A (typically single transmission option)

Features

Clutch Type:

Wet multi-plate clutch, hydraulically operated

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length:

Approx. 2030 mm

Width:

Approx. 720 mm (at handlebars)

Height:

Approx. 1150 mm (at screen)

Wheelbase:

Approx. 1415 mm

Ground Clearance:

Approx. 130 mm

Weights

Dry Weight:

Approx. 195 kg

Wet Weight:

Approx. 214 kg (fully fueled)

Fuel Tank Capacity:

21 Liters

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (motorcycle safety is typically assessed through independent tests and rider experience, not standardized ratings like cars).

Active Features

Braking System Type:

Hydraulic disc brakes front and rear, often with radial-mount calipers.

Front Brake Discs:

Dual 320 mm discs

Rear Brake Disc:

Single 220 mm disc

Suspension ABSorption:

Advanced suspension systems designed for stability and control at high speeds.

Passive Features

Frame Construction:

Robust twin-spar aluminum frame providing rigidity and rider feedback.

Ergonomics:

Sport-oriented riding position designed for aerodynamic efficiency and control.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This era of sportbike did not feature integrated infotainment systems in the modern sense).

Driver Assistance

Driver Assistance Features:

N/A (No electronic rider aids like traction control or ABS on base models of this period).

Connectivity

Connectivity Features:

N/A (No Bluetooth, USB ports, or smartphone integration).

Electronics

Engine Management:

Advanced (for its time) ECU-based engine management for fuel and ignition timing.

Instrument Cluster:

Digital/analog combination instrument cluster providing essential riding information.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 4,000-6,000 km or annually, whichever comes first.

Oil Filter Replacement:

At every oil change.

Spark Plug Replacement:

Typically every 12,000-16,000 km, depending on plug type.

Air Filter Cleaning Replacement:

Inspect every 6,000 km, clean or replace as needed.

Chain Maintenance:

Lubricate and check tension every 1,000 km or after riding in wet conditions.

Valve Clearance Check:

Typically every 12,000-24,000 km (refer to manual for precise interval).

Fluid Specifications

Engine Oil Type:

Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (API SG or higher, JASO MA/MA2 compliant).

Engine Oil Capacity:

Approx. 3.5 - 4.0 Liters (with filter change).

Coolant Type:

Ethylene glycol based coolant, 50/50 mix with distilled water.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid.

Clutch Fluid Type:

DOT 4 hydraulic fluid (if hydraulically actuated).

Fork Oil Type:

Suspension fluid, viscosity typically SAE 5W or 10W (refer to manual for exact spec and level).

Known Issues

Fuel Pump Reliability:

Some early models may have experienced fuel pump issues; regular checking and proper fuel can mitigate.

Regulator Rectifier:

As with many motorcycles of this era, the regulator/rectifier unit can be a failure point; ensuring good airflow and battery health is important.

Stator Output:

Stator output can degrade over time, affecting charging system performance.

Cam Chain Tensioner:

Early models might exhibit cam chain rattle; ensuring proper tensioner operation is key.

Electrical Connections:

Corrosion on electrical connectors can lead to intermittent issues; regular inspection and dielectric grease application are recommended.

📚 Vehicle History

Brand Heritage

Brand Origin:

Aprilia is an Italian motorcycle manufacturer with a strong racing heritage, founded in 1945.

Model Evolution

Rsv Mille Introduction:

The RSV Mille was Aprilia's first foray into the superbike market, launched in 1998, and was a significant technological statement for the brand.

Engine Source:

The V-twin engine was sourced from Rotax (then part of Bombardier Recreational Products), a highly regarded engine manufacturer.

Year Updates 00-03:

Minor updates typically occurred annually, focusing on ECU mapping, suspension tuning, and cosmetic changes.

Production

Manufacturing Location:

Noale, Italy

🏆 Awards & Recognition

Recognitions

Editorial Reviews:

The RSV Mille was generally well-received by motorcycle press for its performance, handling, and V-twin character, often praised for its Italian flair and racing pedigree.

Race Success:

The RSV Mille platform formed the basis for Aprilia's successful entries in various racing series, including World Superbike (WSBK), contributing to its reputation.