Aprilia RST Mille 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Year: 2002 Generation Model Generation: First Generation (RSV Mille basis) Codes Chassis Code Prefix: APRC Engine Code Family: Rotax V990 👋 Introduction Market Position Motorcycle Segment: Sport-touring motorcycle, derived from the RSV Mille superbike platform. Target Audience: Motorcyclists seeking a blend of performance, comfort, and long-distance capability, often with an appreciation for Italian engineering. Competitive Analysis Key Competitors: Honda VFR800, Yamaha YZF1000R Thunderace, Kawasaki Ninja ZX-10R (early models), Ducati ST series. Key Features Unique Selling Points: V-twin engine character, sophisticated chassis design, higher comfort ergonomics compared to the RSV Mille, Italian styling. Factory Documentation Advantage: Provides authentic, manufacturer-approved procedures and specifications, crucial for maintaining optimal performance and resale value. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive Factory Service and Repair Page Count Estimated Page Count: Hundreds of pages (specific number not provided in product info, indicating a complete manual) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (Standard for factory manuals, assumed unless otherwise specified) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine System Coverage: Engine assembly, disassembly, component inspection, timing, valve clearance, lubrication system, cooling system, fuel injection system, ignition system, exhaust system, engine management. Transmission System Coverage: Clutch operation and adjustment, gearbox disassembly and assembly, gear inspection, shift mechanism. Chassis And Frame Coverage: Frame inspection, steering head bearings, swingarm, rear shock absorber, front forks (including internal components and adjustments). Braking System Coverage: Brake fluid replacement, caliper overhaul, master cylinder service, brake line inspection, bleeding procedures, disc and pad inspection. Electrical System Coverage: Wiring diagrams, component testing, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instrumentation, ECU functions. Fuel System Coverage: Fuel pump, fuel filter, fuel lines, fuel tank inspection, throttle body synchronization. Bodywork And Fairings Coverage: Fairing removal and installation, seat removal, other body component service. Procedures Included Maintenance Procedures: Scheduled maintenance, oil and filter changes, chain adjustment and lubrication, brake fluid changes, coolant checks and changes, spark plug replacement, air filter cleaning/replacement, battery maintenance. Diagnostic Procedures: Troubleshooting charts for common symptoms, diagnostic codes (if applicable via OBD-II or proprietary diagnostics), component testing procedures. Repair Procedures: Step-by-step instructions for disassembly, repair, and reassembly of all major and minor components, including engine rebuilds, suspension servicing, and electrical component replacement. Adjustment Procedures: Carburetor (or fuel injection) synchronization, idle speed adjustment, clutch lever play, suspension settings, steering head bearing torque. Technical Depth Diagnostic Capability: Advanced diagnostic procedures for electrical and mechanical systems, fault finding guides. Rebuild Capability: Full engine and transmission rebuild procedures, including torque specifications, clearances, and assembly sequences. Calibration Procedures: Fuel injection system calibration (if applicable), throttle body synchronization procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Readability: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Text Searchability: Typically searchable PDF, allowing for quick keyword lookup of specific topics or parts. ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, V-twin (90-degree) Displacement: 998 cc (998cm³) Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approximately 130-135 HP (at crank) Torque: Approximately 100 Nm (at crank) Fuel System Fuel Delivery: Electronic Fuel Injection (Weber Marelli or similar) Fuel Type: Unleaded gasoline, minimum 95 RON Ignition System Ignition Type: Digital electronic ignition Lubrication System Oil Type: High-performance motorcycle engine oil, e.g., Motul 5100 10W-40 or equivalent (API SG/SH/SJ or higher, JASO MA certified) Cooling System Coolant Type: Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. 🔧 Transmission Standard Transmission Type: Constant mesh, 6-speed sequential gearbox Features Clutch Type: Hydraulically operated, wet multi-plate clutch Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2,060 mm Width: Approx. 780 mm (at handlebars) Height: Approx. 1,220 mm (at windshield) Weights Dry Weight: Approx. 190 kg Wet Weight: Approx. 210 kg (fully fueled and fluids) Fuel Tank Capacity: Approx. 21 liters 🛡️ Safety Features Ratings Safety Certification: CE Certification (European Market Standard) Active Features Braking System: Dual 320 mm discs with 4-piston radial calipers (front), Single 220 mm disc with 2-piston caliper (rear) – Brembo components common. Suspension Frontend: Adjustable 43mm upside-down telescopic fork (e.g., Showa or Marzocchi) Suspension Rear: Adjustable monoshock with progressive linkage Passive Features Lighting System: Halogen headlights, LED taillight (typical for era) Instrumentation: Analog tachometer, digital speedometer, coolant temperature gauge, trip computer, warning lights. 💡 Technology Features Infotainment Infotainment System: Basic instrumentation; no advanced infotainment or connectivity features typical of modern motorcycles. Driver Assistance Rider Aids: No electronic rider aids such as ABS or traction control were standard on the 2002 RST Mille. These would be aftermarket additions or found on later models/variants. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or...
Fuel pump, fuel filter, fuel lines, fuel tank inspection, throttle body synchronization.
Bodywork And Fairings Coverage:
Fairing removal and installation, seat removal, other body component service.
Procedures Included
Maintenance Procedures:
Scheduled maintenance, oil and filter changes, chain adjustment and lubrication, brake fluid changes, coolant checks and changes, spark plug replacement, air filter cleaning/replacement, battery maintenance.
Diagnostic Procedures:
Troubleshooting charts for common symptoms, diagnostic codes (if applicable via OBD-II or proprietary diagnostics), component testing procedures.
Repair Procedures:
Step-by-step instructions for disassembly, repair, and reassembly of all major and minor components, including engine rebuilds, suspension servicing, and electrical component replacement.
Adjustment Procedures:
Carburetor (or fuel injection) synchronization, idle speed adjustment, clutch lever play, suspension settings, steering head bearing torque.
Technical Depth
Diagnostic Capability:
Advanced diagnostic procedures for electrical and mechanical systems, fault finding guides.
Rebuild Capability:
Full engine and transmission rebuild procedures, including torque specifications, clearances, and assembly sequences.
Calibration Procedures:
Fuel injection system calibration (if applicable), throttle body synchronization procedures.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Readability:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Searchability
Text Searchability:
Typically searchable PDF, allowing for quick keyword lookup of specific topics or parts.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, V-twin (90-degree)
Displacement:
998 cc (998cm³)
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approximately 130-135 HP (at crank)
Torque:
Approximately 100 Nm (at crank)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (Weber Marelli or similar)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Ignition System
Ignition Type:
Digital electronic ignition
Lubrication System
Oil Type:
High-performance motorcycle engine oil, e.g., Motul 5100 10W-40 or equivalent (API SG/SH/SJ or higher, JASO MA certified)
Cooling System
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
🔧 Transmission
Standard
Transmission Type:
Constant mesh, 6-speed sequential gearbox
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2,060 mm
Width:
Approx. 780 mm (at handlebars)
Height:
Approx. 1,220 mm (at windshield)
Weights
Dry Weight:
Approx. 190 kg
Wet Weight:
Approx. 210 kg (fully fueled and fluids)
Fuel Tank Capacity:
Approx. 21 liters
🛡️ Safety Features
Ratings
Safety Certification:
CE Certification (European Market Standard)
Active Features
Braking System:
Dual 320 mm discs with 4-piston radial calipers (front), Single 220 mm disc with 2-piston caliper (rear) – Brembo components common.
Suspension Frontend:
Adjustable 43mm upside-down telescopic fork (e.g., Showa or Marzocchi)
Suspension Rear:
Adjustable monoshock with progressive linkage
Passive Features
Lighting System:
Halogen headlights, LED taillight (typical for era)
Instrumentation:
Analog tachometer, digital speedometer, coolant temperature gauge, trip computer, warning lights.
💡 Technology Features
Infotainment
Infotainment System:
Basic instrumentation; no advanced infotainment or connectivity features typical of modern motorcycles.
Driver Assistance
Rider Aids:
No electronic rider aids such as ABS or traction control were standard on the 2002 RST Mille. These would be aftermarket additions or found on later models/variants.
Connectivity
Connectivity Features:
None.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km or annually, whichever comes first (typical for Italian V-twins).
Air Filter Service:
Every 12,000 km or annually.
Spark Plug Replacement:
Every 12,000 km or as per manual specification.
Valve Clearance Check:
Every 24,000 km.
Fluid Specifications
Engine Oil Capacity:
Approx. 3.2 liters (with filter change).
Brake Fluid Spec:
DOT 4 (refer to manual for specific formulation/grade).
Coolant Capacity:
Approx. 2.0 liters.
Known Issues
Common Wear Items:
Cam chain tensioners (potential for wear and noise), fuel pump reliability, regulator/rectifier failure (common on many Italian bikes of this era), clutch slave cylinder leaks.
Electrical Gremlins:
Wiring harness connectors can be susceptible to corrosion; regular inspection and cleaning are advised. ECU issues can arise but are less common than other electrical faults.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian manufacturer with a long history in motorcycle racing and performance street bikes.
Model Evolution
Predecessor Basis:
The RST Mille is based on the chassis and engine architecture of the RSV Mille superbike, adapted for sport-touring comfort.
Key Design Philosophy:
To create a more comfortable and versatile motorcycle for longer distances without compromising the sporty character inherited from the RSV Mille.
Production
Production Period:
The RST Mille was produced roughly from 2001 to 2003 before being succeeded by updated models.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
While specific awards are not universally documented, the RST Mille was generally well-received for its blend of performance, comfort, and Italian flair, often praised for its V-twin character and handling compared to some Japanese rivals in the sport-touring segment.
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