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Aprilia RSV Mille 956X 1999 2000 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Variant: RSV Mille 956X Year: 1999-2000 Codes Chassis Code Prefix: ZDNA 👋 Introduction Market Position Segment: High-performance sportbike Competitive Analysis Key Competitors Era: Ducati 916/996, Honda VTR1000F Firestorm, Suzuki TL1000R/S, Yamaha YZF1000R Thunderace. Key Features Engine Layout: V-Twin, 90-degree cylinder angle Frame Design: Aluminum twin-spar frame Suspension Frontend: Fully adjustable upside-down forks Braking System: High-performance radial-mount calipers 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Page Count: Hundreds Manual Type Type: Factory Service Manual Manual Purpose: Service and Repair Language Language: English Format Format: Downloadable (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, overhaul, and reassembly of engine components. Fuel System: Fuel injection system, fuel pump, injectors, regulators, and tank maintenance. Ignition System: ECU, ignition coils, spark plugs, wiring diagrams, and timing. Cooling System: Radiator, cooling fan, water pump, thermostat, and coolant circuit maintenance. Exhaust System: Catalytic converter, mufflers, and exhaust pipe inspection and replacement. Transmission Manual: Gearbox disassembly, repair, clutch service, and final drive maintenance. Brakes: Front and rear brake systems, including calipers, master cylinders, lines, fluid replacement, and bleeding procedures. Suspension: Front forks (including internals, seals, and oil), rear shock absorber, linkages, and swingarm. Steering: Handlebars, triple clamps, steering head bearings, and adjustments. Electrical System: Full wiring diagrams, battery, charging system, starter motor, lighting, instrumentation, and sensors. Bodywork And Fairings: Fairing removal and installation, panel repair, and component fitment. Wheels And Tires: Wheel bearing maintenance, tire mounting and balancing, and wheel specifications. Procedures Included Preventative Maintenance: Scheduled maintenance checks, lubrication points, and fluid changes. Troubleshooting: Diagnostic flowcharts, fault finding for various systems, and common problem solutions. Repair Procedures: Step-by-step instructions for component repair, replacement, and adjustment. Engine Rebuild: Detailed instructions for complete engine teardown and rebuild. Suspension Setup: Fork oil level and viscosity recommendations, rear shock adjustments. Electrical Diagnostics: Fault finding based on symptoms and electrical schematics. Clutch Replacement: Step-by-step guide for clutch pack replacement and adjustment. Brake Bleeding: Correct procedures for bleeding the hydraulic brake system. Torque Specifications: All critical fastener torque values for engine, chassis, and suspension components. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and chassis rebuilds. Diagnostic Capability: Advanced diagnostic procedures, including troubleshooting for electronic control units (ECU). 📊 Manual Specifications File Format File Type: PDF (assumed for download) Print Quality Printability: Designed for full printing of hundreds of pages. Binding Type Binding Type: N/A (Downloadable format) Paper Type Paper Type: N/A (Downloadable format) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90° V-Twin Displacement: 955 cc (58.3 cu in) Bore X Stroke: 97 mm x 63.8 mm (3.82 in x 2.51 in) Valvetrain: DOHC, 4 valves per cylinder Compression Ratio: 10.8:1 Performance Horsepower Claimed: Approx. 130 HP (97 kW) @ 9,200 rpm Torque Claimed: Approx. 94 Nm (69 lb-ft) @ 7,000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with twin injectors per cylinder Fuel Type: Unleaded gasoline, premium octane recommended (95-98 RON) Lubrication System Oil Type: API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 or 15W-50 recommended. Oil Capacity: Approx. 3.5 Liters (3.7 US qt) with filter change. 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Optional Optional Transmissions: N/A Features Clutch Type: Hydraulic, wet multi-plate Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2040 mm (80.3 in) Width: Approx. 720 mm (28.3 in) at handlebars Height: Approx. 1100 mm (43.3 in) at handlebars Weights Dry Weight Claimed: Approx. 195 kg (430 lbs) Wet Weight Claimed: Approx. 215 kg (474 lbs) Wheels And Tires Front Tire Size: 120/70ZR17 Rear Tire Size: 190/50ZR17 Wheel Bolt Pattern: N/A (spoked or cast wheels typically use hub mounting) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycles are not subject to traditional crash test ratings like cars.) Active Features Front Brakes: Dual 320mm discs, radial-mount 4-piston calipers (Brembo) Rear Brakes: Single 220mm disc, 2-piston caliper (Brembo) ABS: Not typically equipped on this model year, check specific market configurations. Passive Features Frame Construction: High-strength aluminum alloy twin-spar frame for rigidity and impact protection. Lighting: Dual Halogen headlights, LED taillight (on some variations). 💡 Technology Features Infotainment Infotainment System: N/A (Focus on performance, not infotainment features) Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like traction control or advanced ABS typically found on this generation.) Connectivity Connectivity Options: N/A Instrumentation Dashboard: Analog tachometer and speedometer, digital display for odometer, trip meter, fuel gauge, and warning lights. Engine Management ECU: Engine Control Unit (ECU) managing fuel injection and ignition timing. 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or annually. Filter Change Interval: With every oil change. Valve Clearance Check: Every 12,000 km (7,500 miles). Chain Cleaning Lubrication: Every 1,000 km (600 miles) or after riding in wet conditions. Fluid Specifications Coolant Type: Ethylene...
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Aprilia RSV Mille 956X 1999 2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Model Variant:
RSV Mille 956X
Year:
1999-2000
Codes
Chassis Code Prefix:
ZDNA
👋 Introduction
Market Position
Segment:
High-performance sportbike
Competitive Analysis
Key Competitors Era:
Ducati 916/996, Honda VTR1000F Firestorm, Suzuki TL1000R/S, Yamaha YZF1000R Thunderace.
Key Features
Engine Layout:
V-Twin, 90-degree cylinder angle
Frame Design:
Aluminum twin-spar frame
Suspension Frontend:
Fully adjustable upside-down forks
Braking System:
High-performance radial-mount calipers
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Page Count
Estimated Page Count:
Hundreds
Manual Type
Type:
Factory Service Manual
Manual Purpose:
Service and Repair
Language
Language:
English
Format
Format:
Downloadable (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, overhaul, and reassembly of engine components.
Fuel System:
Fuel injection system, fuel pump, injectors, regulators, and tank maintenance.
Ignition System:
ECU, ignition coils, spark plugs, wiring diagrams, and timing.
Cooling System:
Radiator, cooling fan, water pump, thermostat, and coolant circuit maintenance.
Exhaust System:
Catalytic converter, mufflers, and exhaust pipe inspection and replacement.
Transmission Manual:
Gearbox disassembly, repair, clutch service, and final drive maintenance.
Brakes:
Front and rear brake systems, including calipers, master cylinders, lines, fluid replacement, and bleeding procedures.
Suspension:
Front forks (including internals, seals, and oil), rear shock absorber, linkages, and swingarm.
Steering:
Handlebars, triple clamps, steering head bearings, and adjustments.
Electrical System:
Full wiring diagrams, battery, charging system, starter motor, lighting, instrumentation, and sensors.
Bodywork And Fairings:
Fairing removal and installation, panel repair, and component fitment.
Wheels And Tires:
Wheel bearing maintenance, tire mounting and balancing, and wheel specifications.
Procedures Included
Preventative Maintenance:
Scheduled maintenance checks, lubrication points, and fluid changes.
Troubleshooting:
Diagnostic flowcharts, fault finding for various systems, and common problem solutions.
Repair Procedures:
Step-by-step instructions for component repair, replacement, and adjustment.
Engine Rebuild:
Detailed instructions for complete engine teardown and rebuild.
Suspension Setup:
Fork oil level and viscosity recommendations, rear shock adjustments.
Electrical Diagnostics:
Fault finding based on symptoms and electrical schematics.
Clutch Replacement:
Step-by-step guide for clutch pack replacement and adjustment.
Brake Bleeding:
Correct procedures for bleeding the hydraulic brake system.
Torque Specifications:
All critical fastener torque values for engine, chassis, and suspension components.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and chassis rebuilds.
Diagnostic Capability:
Advanced diagnostic procedures, including troubleshooting for electronic control units (ECU).
📊 Manual Specifications
File Format
File Type:
PDF (assumed for download)
Print Quality
Printability:
Designed for full printing of hundreds of pages.
Binding Type
Binding Type:
N/A (Downloadable format)
Paper Type
Paper Type:
N/A (Downloadable format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90° V-Twin
Displacement:
955 cc (58.3 cu in)
Bore X Stroke:
97 mm x 63.8 mm (3.82 in x 2.51 in)
Valvetrain:
DOHC, 4 valves per cylinder
Compression Ratio:
10.8:1
Performance
Horsepower Claimed:
Approx. 130 HP (97 kW) @ 9,200 rpm
Torque Claimed:
Approx. 94 Nm (69 lb-ft) @ 7,000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Fuel Type:
Unleaded gasoline, premium octane recommended (95-98 RON)
Lubrication System
Oil Type:
API SG or higher, JASO MA certified motorcycle oil, SAE 10W-40 or 15W-50 recommended.
Oil Capacity:
Approx. 3.5 Liters (3.7 US qt) with filter change.
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh
Optional
Optional Transmissions:
N/A
Features
Clutch Type:
Hydraulic, wet multi-plate
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2040 mm (80.3 in)
Width:
Approx. 720 mm (28.3 in) at handlebars
Height:
Approx. 1100 mm (43.3 in) at handlebars
Weights
Dry Weight Claimed:
Approx. 195 kg (430 lbs)
Wet Weight Claimed:
Approx. 215 kg (474 lbs)
Wheels And Tires
Front Tire Size:
120/70ZR17
Rear Tire Size:
190/50ZR17
Wheel Bolt Pattern:
N/A (spoked or cast wheels typically use hub mounting)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycles are not subject to traditional crash test ratings like cars.)
Active Features
Front Brakes:
Dual 320mm discs, radial-mount 4-piston calipers (Brembo)
Rear Brakes:
Single 220mm disc, 2-piston caliper (Brembo)
ABS:
Not typically equipped on this model year, check specific market configurations.
Passive Features
Frame Construction:
High-strength aluminum alloy twin-spar frame for rigidity and impact protection.
Lighting:
Dual Halogen headlights, LED taillight (on some variations).
💡 Technology Features
Infotainment
Infotainment System:
N/A (Focus on performance, not infotainment features)
Driver Assistance
Driver Assistance Features:
N/A (No electronic rider aids like traction control or advanced ABS typically found on this generation.)
Connectivity
Connectivity Options:
N/A
Instrumentation
Dashboard:
Analog tachometer and speedometer, digital display for odometer, trip meter, fuel gauge, and warning lights.
Engine Management
ECU:
Engine Control Unit (ECU) managing fuel injection and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or annually.
Filter Change Interval:
With every oil change.
Valve Clearance Check:
Every 12,000 km (7,500 miles).
Chain Cleaning Lubrication:
Every 1,000 km (600 miles) or after riding in wet conditions.
Fluid Specifications
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Clutch Fluid Type:
DOT 4 hydraulic clutch fluid (if separate reservoir).
Fork Oil Type:
Specific viscosity as per manual, typically SAE 5W or 10W.
Known Issues
Common Concerns:
Stator failure, regulator/rectifier issues, cam chain tensioner wear, occasional fuel injector clogging, potential for electrical gremlins due to complex wiring.
Maintenance Priority:
Regular electrical system checks, proper cooling system maintenance, and attention to chain adjustment/lubrication are crucial.
📚 Vehicle History
Brand Heritage
Brand History:
Aprilia is an Italian manufacturer with a rich history in racing, particularly in Grand Prix and Superbike championships, known for innovative engineering and performance-oriented motorcycles.
Model Evolution
Mille Introduction:
The RSV Mille was introduced in 1997 as Aprilia's flagship V-twin sportbike, designed to compete directly with established Italian and Japanese rivals.
1999 2000 Updates:
The 1999-2000 models represent the initial production run of the RSV Mille, featuring the iconic 956cc Rotax-derived engine and an aluminum twin-spar frame, setting the stage for later performance enhancements and variations.
Production
Manufacturing Location:
Noale, Italy
🏆 Awards & Recognition
Recognitions
Motorsport Success:
The RSV Mille platform has a strong racing pedigree, contributing to Aprilia's reputation for performance. While the specific 99-00 model might not have direct racing awards, its lineage is built on racing success.
Ratings
Magazine Reviews Era:
Highly praised by contemporary motorcycle publications for its powerful V-twin engine, sharp handling, and exotic Italian styling.
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