1999 Aprilia RSV Mille Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Year: 1999 Product Type: Workshop Service Repair Manual Codes Manual Identifier: Not specified in provided information Chassis Code: RP (for RSV Mille) 👋 Introduction Market Position Motorcycle Segment: High-performance sportbike Target Audience: Enthusiast owners, independent motorcycle repair shops Competitive Analysis Competitors 1999: • Ducati 916 • Honda CBR900RR Fireblade • Suzuki GSX-R750/1100 • Yamaha YZF-R1 Key Features Vehicle Engine Layout: V-twin, longitudinal Design Philosophy: Italian sportbike with focus on power and handling Key Features Manual Usability: Quickly searchable for efficient diagnostics and repairs Support: Email support available for questions 📋 Manual Details Coverage Areas Coverage Focus: Comprehensive service, repair, maintenance, troubleshooting, and setup Included Chapters: • General Information • Service and Setting up • Periodic Maintenance and Adjustment • Engine • Fuel Supply System • Cooling System • Electrical System • Chassis • Repair Information • Troubleshooting • Updates • Index Page Count Estimated Page Count: Typically 500-800 pages for this era and complexity of motorcycle Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Digital Compatibility: Windows / Macintosh (Win/Max) 📖 Manual Coverage Systems Covered Engine: V-twin engine: disassembly, assembly, component testing, specifications Fuel System: Carburetor systems (if applicable), fuel injection (if applicable), fuel pump, fuel filter, fuel tank maintenance Cooling System: Radiator, coolant hoses, water pump, thermostat, fan operation, coolant specifications Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting, starter motor, fuses, relays, electronic control unit (ECU) overview Chassis: Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear calipers, master cylinders, lines, pads, rotors), drivetrain (chain, sprockets) Procedures Included Maintenance: Oil changes, filter replacement, chain adjustment and lubrication, brake fluid changes, coolant flushes, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments Repair: Engine rebuilds, gearbox servicing, suspension overhaul, brake system repairs, electrical component replacement, bodywork repairs Troubleshooting: Diagnostic procedures for common faults, fault codes (if applicable), symptom-based troubleshooting guides Setup And Adjustment: Carburetor synchronization, suspension setup, idle speed adjustment, clutch adjustment Technical Depth Depth: Comprehensive workshop level, suitable for DIY mechanics and professional technicians. Includes detailed diagrams, torque specifications, and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content within the PDF Print Quality Printability: Designed for printing, with clear legible text and diagrams Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90° V-twin Displacement: 998 cc Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Compression Ratio: 10.5:1 Performance Horsepower: Approximately 120-130 hp (depending on market and tuning) Torque: Approximately 98-105 Nm Fuel System Fuel Delivery: Carbureted (Mikuni BSR 40 twin carburetors) or Fuel Injection (depending on market variant; early European models often carbureted, North American often FI) Fuel Type: Unleaded gasoline, minimum 95 RON 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Hydraulically operated, wet multi-plate Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2040 mm Width: Approx. 700 mm Height: Approx. 1135 mm Weights Dry Weight: Approx. 195 kg Wet Weight: Approx. 210 kg (fully fueled) Fuel Tank Capacity: 18 liters 🛡️ Safety Features Ratings Safety Certification: EC type-approval (European markets) Active Features Braking System Front: Dual 320mm discs, 4-piston radial calipers Braking System Rear: Single 220mm disc, 2-piston caliper Suspension Front: Inverted cartridge forks, adjustable preload, compression, and rebound damping Suspension Rear: Monoshock, adjustable preload, compression, and rebound damping Passive Features Frame Type: Aluminum alloy twin-spar frame 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog instrumentation, no infotainment) Driver Assistance Driver Assistance Features: None (No ABS, traction control, or rider aids in the 1999 model) Connectivity Connectivity Features: None Ecu ECU Function: Manages fuel injection (if applicable), ignition timing, and other engine parameters 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 6,000-10,000 km or annually Valve Clearance Interval: Typically every 12,000-20,000 km Chain Adjustment Interval: Check every 1,000 km, adjust as needed Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil Coolant Type: Ethylene glycol-based coolant, 50/50 mix with distilled water Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (if hydraulic) Known Issues Common Problems: • Stator failure (charging system) • Fuel pump issues (on FI models) • Cam chain tensioner noise • Carburetor synchronization drift • Leaking fork seals • Electrical connector corrosion Maintenance Focus: Emphasis on regular maintenance to prevent common wear-related issues 📚 Vehicle History Brand Heritage Manufacturer Origin: Italy Brand Focus: Performance motorcycles, racing heritage Model Evolution Introduction Year: 1998 Generation 1: First generation RSV Mille, significant updates throughout its production run Production Manufacturing Location: Aprilia factory, Noale, Italy 🏆 Awards & Recognition Recognitions Notable Reviews: Critically acclaimed...
Comprehensive workshop level, suitable for DIY mechanics and professional technicians. Includes detailed diagrams, torque specifications, and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content within the PDF
Print Quality
Printability:
Designed for printing, with clear legible text and diagrams
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90° V-twin
Displacement:
998 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
10.5:1
Performance
Horsepower:
Approximately 120-130 hp (depending on market and tuning)
Torque:
Approximately 98-105 Nm
Fuel System
Fuel Delivery:
Carbureted (Mikuni BSR 40 twin carburetors) or Fuel Injection (depending on market variant; early European models often carbureted, North American often FI)
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated, wet multi-plate
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2040 mm
Width:
Approx. 700 mm
Height:
Approx. 1135 mm
Weights
Dry Weight:
Approx. 195 kg
Wet Weight:
Approx. 210 kg (fully fueled)
Fuel Tank Capacity:
18 liters
🛡️ Safety Features
Ratings
Safety Certification:
EC type-approval (European markets)
Active Features
Braking System Front:
Dual 320mm discs, 4-piston radial calipers
Braking System Rear:
Single 220mm disc, 2-piston caliper
Suspension Front:
Inverted cartridge forks, adjustable preload, compression, and rebound damping
Suspension Rear:
Monoshock, adjustable preload, compression, and rebound damping
Passive Features
Frame Type:
Aluminum alloy twin-spar frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation, no infotainment)
Driver Assistance
Driver Assistance Features:
None (No ABS, traction control, or rider aids in the 1999 model)
Connectivity
Connectivity Features:
None
Ecu
ECU Function:
Manages fuel injection (if applicable), ignition timing, and other engine parameters
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-10,000 km or annually
Valve Clearance Interval:
Typically every 12,000-20,000 km
Chain Adjustment Interval:
Check every 1,000 km, adjust as needed
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic)
Known Issues
Common Problems:
• Stator failure (charging system)
• Fuel pump issues (on FI models)
• Cam chain tensioner noise
• Carburetor synchronization drift
• Leaking fork seals
• Electrical connector corrosion
Maintenance Focus:
Emphasis on regular maintenance to prevent common wear-related issues
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Focus:
Performance motorcycles, racing heritage
Model Evolution
Introduction Year:
1998
Generation 1:
First generation RSV Mille, significant updates throughout its production run
Production
Manufacturing Location:
Aprilia factory, Noale, Italy
🏆 Awards & Recognition
Recognitions
Notable Reviews:
Critically acclaimed for its potent V-twin engine and sharp handling upon release, often praised as a viable alternative to Italian rivals.
Ratings
Performance Class:
Superbike / Hyperbike
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