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1999 Aprilia RSV Mille Workshop Repair Manual

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Basic Information Identification Make: Aprilia Model: RSV Mille Year: 1999 Codes Chassis Code: RP Introduction Market Position Market Segment: High-performance sportbike segment, directly competing with established European and Japanese manufacturers....
Type: Motorcycles
Vendor:
Sku: 131910
1999 Aprilia RSV Mille Workshop Repair Manual
Basic Information
Identification
Make: Aprilia
Model: RSV Mille
Year: 1999
Codes
Chassis Code: RP
Introduction
Market Position
Market Segment: High-performance sportbike segment, directly competing with established European and Japanese manufacturers.
Competitive Analysis
Competitors: Ducati 916, Yamaha YZF-R1, Honda CBR900RR Fireblade, Suzuki GSX-R750, Kawasaki ZX-9R Ninja.
Key Features
Key Selling Points Of Vehicle: Powerful V-twin engine, agile handling, premium components, Italian styling.
Manual Value Proposition
Value For Owner: Enables owners to perform complex maintenance and repairs, understand vehicle systems, save on labor costs, and maintain optimal performance.
Manual Details
Coverage Areas
Coverage: Comprehensive workshop and service procedures for the 1999 Aprilia RSV Mille.
Page Count
Page Count: Not specified, but implied to be extensive for a workshop manual.
Manual Type
Manual Type: Workshop Repair Manual / Service Manual
Content Type: Authoritative guide for technicians and knowledgeable enthusiasts.
Language
Language: English
Format
Format: PDF
Manual Coverage
Systems Covered
Systems: Engine, Fuel System, Cooling System, Electrical System, Chassis, Troubleshooting.
Electrical System Details: Ignition system, starting system, charging system, lighting, instruments, ECU, sensors, and fault codes.
Chassis Details: Frame, suspension (front and rear), steering, wheels, tires, brakes, and bodywork.
Procedures Included
Procedures: Service, Setting Up, Repair, Diagnostics, Troubleshooting, Routine Maintenance.
Engine Procedures: Engine removal/installation, cylinder head service, piston and connecting rod assembly, crankshaft service, gearbox inspection and repair, clutch overhaul.
Fuel System Procedures: Fuel injection system diagnostics, injector cleaning/replacement, fuel pump testing, throttle body inspection.
Technical Depth
Depth: In-depth, professional level covering detailed disassembly, assembly, repair, and diagnostic procedures.
Torque Specifications: Provides precise torque values for all fasteners, critical for engine and chassis integrity.
Diagnostic Charts: Includes troubleshooting flowcharts and symptom-based diagnostic procedures.
Special Tools: Lists any specialized tools required for specific tasks, allowing for proper preparation.
Manual Specifications
File Format
File Format: PDF
Compatibility
Compatibility: All Versions of Windows & Mac
Requirements
Software Requirements: Adobe PDF Reader
Print Quality
Print Quality: Assumed high quality suitable for professional use, given the product description.
Binding Type
Binding Type: N/A (Digital PDF)
Paper Type
Paper Type: N/A (Digital PDF)
Engine Specifications
Primary Engine
Engine Type: V-twin, four-stroke
Engine Displacement: 998 cc (998 cubic centimeters)
Bore X Stroke: 97.0 mm x 67.5 mm
Valve Train: DOHC, 4 valves per cylinder
Performance
Horsepower Peak: Approximately 128 hp (95.5 kW) @ 10,500 rpm (claimed)
Torque Peak: Approximately 10.3 kgf·m (101 Nm; 74.5 lb-ft) @ 7,500 rpm (claimed)
Fuel System
Fuel Delivery: Fuel Injection (Weber Marelli electronic fuel injection)
Fuel Type: Unleaded gasoline (95-98 RON recommended)
Cooling System
Cooling Method: Liquid-cooled
Coolant Type: Ethylene glycol-based coolant (50% mix with distilled water recommended)
Transmission
Standard
Transmission Type: 6-speed manual
Features
Clutch Type: Wet, multi-plate, hydraulic actuation
Final Drive: Chain drive
Dimensions
Exterior
Length: Approx. 2,030 mm (79.9 in)
Width: Approx. 720 mm (28.3 in) at handlebars
Height: Approx. 1,160 mm (45.7 in) at handlebars
Weights
Dry Weight: Approx. 195 kg (430 lbs)
Wet Weight: Approx. 217 kg (478 lbs) (with fluids, est.)
Fuel Tank Capacity: 21 liters (5.5 US gal)
Wheels Tires
Front Tire Size: 120/70 ZR17 M/C (58W)
Rear Tire Size: 190/50 ZR17 M/C (73W)
Wheelbase: Approx. 1,410 mm (55.5 in)
Safety Features
Active Features
Braking System Front: Dual 320 mm discs with 4-piston radial calipers (Brembo)
Braking System Rear: Single 240 mm disc with 2-piston caliper (Brembo)
Suspension Front: 43 mm Marzocchi upside-down telescopic fork, adjustable preload, compression, and rebound damping.
Suspension Rear: Monoshock, adjustable preload, compression, and rebound damping, Öhlins or similar premium unit likely.
Passive Features
Frame Type: Aluminum alloy twin-spar frame
Technology Features
Infotainment
Instrumentation: Analog tachometer and speedometer, digital odometer, trip meters, clock, and warning lights.
Driver Assistance
ABS: Not standard on the 1999 model. ABS was introduced later on some variants.
Connectivity
Wiring Diagrams: The manual includes detailed wiring diagrams crucial for diagnosing electrical faults.
Maintenance
Service Intervals
Oil Change Interval: Typically every 3,000-5,000 km (1,800-3,000 miles) or annually. Manual will provide precise interval.
Spark Plug Replacement: Refer to manual; typically around 10,000-15,000 km (6,000-9,000 miles).
Valve Clearance Check: Crucial for V-twins, refer to manual for interval (e.g., 10,000-20,000 km).
Fluid Specifications
Engine Oil Type: High-quality synthetic motorcycle oil, API SG/SH or higher, JASO MA certified. Viscosity typically 10W-40 or 15W-50 depending on climate. Specific Aprilia recommendation is critical.
Engine Oil Capacity: Approx. 3.5 - 4.0 liters with filter change. Exact capacity in manual.
Brake Fluid Type: DOT 4 or DOT 5.1 (check manual for specific recommendation). Always use fresh fluid.
Coolant Type: Ethylene glycol-based antifreeze/coolant, 50% mixture with distilled water. Avoid tap water.
Chain Lube: Specific motorcycle chain lubricant (e.g., W. D. 40 Chain Lube, Motul C2 Chain Lube).
Known Issues
Potential Wear Items: Cam chain tensioners (early models), clutch slave cylinder leaks, regulator/rectifier failures, and fuel pump issues can be common on older Italian bikes. Manual provides diagnostic steps.
Electrical Gremlins: While Italian bikes improved significantly, older models can still exhibit minor electrical faults. Proper diagnosis is key, covered in the manual.
Vehicle History
Brand Heritage
Brand Focus: Aprilia is an Italian manufacturer known for its racing heritage, particularly in smaller displacement categories, and its entry into the litre-class sportbike market with the RSV Mille was a significant expansion.
Model Evolution
Genesis: Developed as Aprilia's flagship sportbike to compete with established European and Japanese models. The V-twin engine architecture was chosen to provide a distinctive character and torque delivery.
First Generation: The 1999 model is the inaugural year of the RSV Mille, marking its debut in the superbike segment.
Production
Manufacturing Location: Italy
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