Aprilia RSV Mille 2002 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Year: 2002 Model Variant: Factory Codes Chassis Code: RP (RSV Mille) 👋 Introduction Market Position Positioning: The Aprilia RSV Mille (RP) was a high-performance Italian sportbike, a direct competitor to contemporary superbikes from Japan and Europe, known for its sophisticated chassis and potent V-twin engine. Competitive Analysis Competitors 2002: Ducati 996, Yamaha YZF-R1, Honda CBR954RR, Suzuki GSX-R1000, Kawasaki ZX-9R. Key Features Vehicle Features: V-twin engine, advanced chassis geometry, high-quality suspension components (often Öhlins on Factory models), powerful braking system, aerodynamic fairings. Manual Value Proposition Value: Provides the definitive guide for owners and technicians to maintain, diagnose, and repair the 2002 Aprilia RSV Mille Factory, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Systems Covered: Engine, Fuel System, Ignition System, Cooling System, Lubrication System, Clutch, Transmission, Chassis, Suspension, Brakes, Electrical System, Bodywork, Troubleshooting, Special Tools, Maintenance Schedules, Wiring Diagrams, Specifications. Page Count Page Count: Hundreds of pages (Exact count not specified, but implied to be comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (Assumed based on typical availability for this model and market) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair procedures for the Aprilia Rotax V-Twin engine. Fuel System: Carburetor (Mikuni BSR40) tuning, cleaning, overhaul, fuel pump, fuel lines, and tank maintenance. Ignition System: ECU, ignition coils, spark plugs, wiring, and troubleshooting for ignition performance. Cooling System: Radiator, fan, hoses, thermostat, coolant specifications, and flushing procedures. Lubrication System: Oil pump, oil filter, oil cooler, oil specifications, and oil change procedures. Transmission: Clutch operation, gearbox disassembly, assembly, inspection, gear selection, and lubrication. Chassis Suspension: Front fork (Öhlins or Showa depending on exact variant) adjustment, service, rear shock absorber service, swingarm, linkage, and bearing maintenance. Brakes: Brake caliper overhaul, master cylinder service, brake fluid specifications, bleeding procedures, rotor inspection, and pad replacement. Electrical System: Wiring diagrams, lighting, starting system, charging system, battery maintenance, fuses, relays, and instrument panel functionality. Bodywork: Fairing removal and installation, seat, fuel tank, and accessory mounting. Procedures Included Maintenance: Routine maintenance checks, lubrication points, filter replacements, fluid changes, and battery care. Troubleshooting: Diagnostic guides for common issues, symptom-based problem solving, and fault finding procedures. Repair: Comprehensive step-by-step repair instructions for all major mechanical and electrical components. Disassembly Assembly: Detailed instructions for taking apart and reassembling engine, transmission, suspension, and electrical components. Specifications Torque: Critical torque specifications for engine fasteners, chassis bolts, and suspension components. Technical Depth Depth: Factory-level diagnostic and repair procedures, suitable for professional mechanics and experienced DIY enthusiasts. Scope: Covers everything from basic fluid checks to complete engine rebuilds and electrical system diagnostics. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution, allowing for clear printing of diagrams and text. Binding Type Binding Type: Not Applicable (Digital Download PDF) Paper Type Paper Type: Not Applicable (Digital Download PDF) Searchability Searchability: Searchable text within the PDF for quick information retrieval. Editability Editability: Not editable (Standard PDF) Accessibility Accessibility: Downloadable for offline access on multiple devices. ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, Four-stroke Engine Displacement: 998 cc (998cc) Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Compression Ratio: 10.8:1 Performance Horsepower: ~128 hp (95.5 kW) @ 9,500 rpm (Approximate, can vary slightly by market and specific tune) Torque: ~101 Nm (74.5 lb-ft) @ 7,500 rpm (Approximate) Fuel System Fuel Delivery: Twin Carburettors: Mikuni BSR40 CV Fuel Type: Unleaded gasoline, minimum 95 RON (Octane Rating) Lubrication System Oil Type: SAE 10W-40 or 15W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA) Oil Capacity: Approx. 3.0 liters (3.2 US qt) with filter change 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Features Clutch Type: Hydraulically operated, wet multi-plate Final Drive: O-ring sealed chain Gear Ratios Gear Ratios: Manual (Specific ratios typically detailed in the manual, e.g., 1st: 2.46, 2nd: 1.73, 3rd: 1.36, 4th: 1.16, 5th: 1.04, 6th: 0.92 - these are representative and should be confirmed from the manual) Transmission Fluid Transmission Oil: Dedicated transmission oil (e.g., SAE 75W-90 GL-4, or as specified by Aprilia - manual essential for exact spec) 📐 Dimensions Exterior Length: Approx. 2020 mm (79.5 in) Width: Approx. 720 mm (28.3 in) at handlebars Height: Approx. 1150 mm (45.3 in) at windshield Wheelbase: Approx. 1405 mm (55.3 in) Ground Clearance: Approx. 130 mm (5.1 in) Weights Dry Weight: Approx. 190 kg (419 lbs) Wet Weight: Approx. 210 kg (463 lbs) (with fluids) Fuel Capacity: 21 liters (5.5 US gal) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not typically assigned crash test ratings like cars; safety is judged by design, braking, handling, and rider assistance systems. Active Features Braking System: Dual 320 mm front discs with 4-piston radial calipers (Brembo), Single 220 mm...
The Aprilia RSV Mille (RP) was a high-performance Italian sportbike, a direct competitor to contemporary superbikes from Japan and Europe, known for its sophisticated chassis and potent V-twin engine.
Provides the definitive guide for owners and technicians to maintain, diagnose, and repair the 2002 Aprilia RSV Mille Factory, ensuring optimal performance and longevity.
Diagnostic guides for common issues, symptom-based problem solving, and fault finding procedures.
Repair:
Comprehensive step-by-step repair instructions for all major mechanical and electrical components.
Disassembly Assembly:
Detailed instructions for taking apart and reassembling engine, transmission, suspension, and electrical components.
Specifications Torque:
Critical torque specifications for engine fasteners, chassis bolts, and suspension components.
Technical Depth
Depth:
Factory-level diagnostic and repair procedures, suitable for professional mechanics and experienced DIY enthusiasts.
Scope:
Covers everything from basic fluid checks to complete engine rebuilds and electrical system diagnostics.
📊 Manual Specifications
File Format
File Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution, allowing for clear printing of diagrams and text.
Binding Type
Binding Type:
Not Applicable (Digital Download PDF)
Paper Type
Paper Type:
Not Applicable (Digital Download PDF)
Searchability
Searchability:
Searchable text within the PDF for quick information retrieval.
Editability
Editability:
Not editable (Standard PDF)
Accessibility
Accessibility:
Downloadable for offline access on multiple devices.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke
Engine Displacement:
998 cc (998cc)
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Compression Ratio:
10.8:1
Performance
Horsepower:
~128 hp (95.5 kW) @ 9,500 rpm (Approximate, can vary slightly by market and specific tune)
Torque:
~101 Nm (74.5 lb-ft) @ 7,500 rpm (Approximate)
Fuel System
Fuel Delivery:
Twin Carburettors: Mikuni BSR40 CV
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane Rating)
Lubrication System
Oil Type:
SAE 10W-40 or 15W-50 Synthetic Motorcycle Oil (API SG or higher, JASO MA)
Oil Capacity:
Approx. 3.0 liters (3.2 US qt) with filter change
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Features
Clutch Type:
Hydraulically operated, wet multi-plate
Final Drive:
O-ring sealed chain
Gear Ratios
Gear Ratios:
Manual (Specific ratios typically detailed in the manual, e.g., 1st: 2.46, 2nd: 1.73, 3rd: 1.36, 4th: 1.16, 5th: 1.04, 6th: 0.92 - these are representative and should be confirmed from the manual)
Transmission Fluid
Transmission Oil:
Dedicated transmission oil (e.g., SAE 75W-90 GL-4, or as specified by Aprilia - manual essential for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 2020 mm (79.5 in)
Width:
Approx. 720 mm (28.3 in) at handlebars
Height:
Approx. 1150 mm (45.3 in) at windshield
Wheelbase:
Approx. 1405 mm (55.3 in)
Ground Clearance:
Approx. 130 mm (5.1 in)
Weights
Dry Weight:
Approx. 190 kg (419 lbs)
Wet Weight:
Approx. 210 kg (463 lbs) (with fluids)
Fuel Capacity:
21 liters (5.5 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not typically assigned crash test ratings like cars; safety is judged by design, braking, handling, and rider assistance systems.
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 Damping:
Fully adjustable front forks and rear shock absorber (Öhlins or Showa depending on variant) allow for precise tuning of ride characteristics.
Passive Features
Frame:
Aluminum alloy twin-spar frame for rigidity and low weight.
Lighting:
Dual Halogen Headlights for superior night visibility.
💡 Technology Features
Infotainment
Infotainment System:
Basic analog instrument cluster with digital odometer and trip meters. No advanced infotainment features.
Driver Assistance
Rider Aids:
No electronic rider aids (e.g., ABS, traction control) were standard on the 2002 model. Focus is on mechanical grip and rider skill.
Connectivity
Connectivity:
N/A
Engine Management
ECU:
Factory ECU controlling fuel injection (if applicable, but this model uses carburetors) and ignition timing.
🔧 Maintenance
Service Intervals
Oil Filter Change:
Every 6,000 km (3,700 miles) or annually, whichever comes first.
Air Filter Cleaning:
Every 6,000 km (3,700 miles) or annually.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or as per manual recommendation.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or as specified in the manual.
Chain Lubrication:
Every 500 km (300 miles) and after washing or riding in rain.
Brake Fluid Change:
Every 2 years, regardless of mileage.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant (50% mixture with distilled water), e.g., Aprilia-recommended coolant or equivalent.
Brake Fluid Type:
DOT 4
Known Issues
Common Issues:
Regulator/rectifier failure, electrical connector corrosion, clutch slave cylinder leaks, stator winding issues, fairing vibration, occasional gearbox notching. The manual will detail diagnostics for these.
Tools
Special Tools:
Manual specifies necessary special tools for specific procedures, e.g., fork seal drivers, clutch holding tools, engine timing tools.
📚 Vehicle History
Brand Heritage
Heritage:
Aprilia is an Italian manufacturer with a rich history in motorcycle racing, known for producing innovative and high-performance sportbikes.
Model Evolution
Evolution Rsv Mille:
The RSV Mille was introduced in 1998, evolving through various updates. The 2002 model year represents a refinement of the original design, with the 'Factory' designation typically indicating a higher specification, often including premium suspension components.
Production
Production Period:
The RSV Mille platform was produced from 1998 to 2003, before being replaced by the RSV1000R and RSV1000R Factory models.
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Performance Awards:
The RSV Mille range consistently received praise from motorcycle publications for its performance, handling, and sophisticated V-twin character, often placing highly in comparison tests against major competitors.
Ratings
Magazine Reviews:
Motorcycle magazines of the era frequently awarded high marks for track performance and road holding.
Certifications
Emissions Compliance:
Compliant with prevailing emissions standards for the year of manufacture (e.g., Euro 2 or equivalent).
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