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1999 Aprilia RSV Mille Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Year: 1999 Product Type: Factory Service Repair Manual Codes Chassis Code: RP 👋 Introduction Market Position Positioning: High-performance sportbike, targeted at enthusiasts seeking track-day capability and exhilarating road performance. Competitive Analysis Competitors: Competed against other 900cc-1000cc sportbikes of the era, such as the Ducati 916, Yamaha YZF-R1, and Suzuki GSX-R1000. Key Features Engine Layout: V-twin engine, known for its torque and character. Chassis Design: Sturdy aluminum twin-spar frame providing excellent rigidity and handling characteristics. Suspension Components: High-quality, adjustable suspension components, typically from reputable manufacturers. Braking System: Powerful Brembo braking system, offering strong stopping power and feel. 📋 Manual Details Coverage Areas General Coverage: Comprehensive repair and service procedures for the 1999 Aprilia RSV Mille. Specific Areas: Engine, fuel supply, cooling, electrical systems, chassis, repair information, updates, and analytical index. Page Count Estimated Pages: Detailed page count not specified, but implied to be extensive covering all repair procedures. Manual Type Type: Factory Service Repair Manual Language Language: English Format Digital Format: PDF/ZIP Compatibility Operating Systems: WIN/MAC/LINUX 📖 Manual Coverage Systems Covered Engine: Detailed procedures for engine disassembly, assembly, tuning, and component diagnostics. Fuel Supply System: Fuel injection system operation, troubleshooting, component testing, and adjustments. Cooling System: Radiator, fan, coolant flow, thermostat operation, and leak detection procedures. Electrical System: Wiring diagrams, starter, ignition system, lighting, battery maintenance, and electronic component testing. Chassis Parts: Front and rear suspension, steering system, braking system (including hydraulic components), wheels, and tires. Bodywork Fairings: Procedures for removing and installing body panels, fairings, and trim components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, lubrication points, and fluid checks. Troubleshooting: Diagnostic flowcharts and symptom-based problem resolution for various systems. Repair Overhaul: Detailed step-by-step instructions for component disassembly, repair, and reassembly. Technical Specifications: Torque values, clearances, fluid capacities, and performance parameters. Assembly Disassembly: Complete step-by-step guides for taking apart and putting back together all major motorcycle components. Torque Specifications: Detailed torque values for all fasteners critical for safety and proper function. Diagrams Illustrations: Likely includes exploded views and clear diagrams to illustrate complex procedures. Technical Depth Depth Of Coverage: Comprehensive, suitable for both DIY enthusiasts and professional technicians, covering detailed repairs and diagnostics. Diagnostic Capabilities: Advanced diagnostic procedures for engine and electrical systems, enabling identification of faults beyond simple visual checks. 📊 Manual Specifications File Format Primary Format: PDF Compression: ZIP Print Quality Digital Quality: High-resolution digital content, optimized for on-screen viewing and printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke Displacement: 998 cc (60.9 cu in) Bore X Stroke: 97.0 mm x 67.5 mm (3.82 x 2.66 in) Compression Ratio: 10.8:1 (typical) Performance Horsepower: Approximately 124 hp (92.5 kW) @ 9,500 rpm (factory figures may vary slightly by market/tuning) Torque: Approximately 71 lb-ft (96 Nm) @ 7,500 rpm (factory figures may vary slightly by market/tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with two injectors per cylinder Fuel Type: Unleaded gasoline, minimum 95 RON Cooling System Cooling Method: Liquid-cooled 🔧 Transmission Standard Transmission Type: 6-speed sequential manual Clutch Type: Wet, multi-plate, hydraulic actuation Features Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2,050 mm (80.7 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1,130 mm (44.5 in) Weights Dry Weight: Approx. 190 kg (419 lbs) Wet Weight: Approx. 203 kg (448 lbs) 🛡️ Safety Features Ratings Safety Standards: Motorcycle safety standards applicable at the time of manufacture (no formal crash ratings like cars). Active Features Braking System: Dual front disc brakes with four-piston calipers, single rear disc brake with two-piston caliper. Typically Brembo components. Suspension Adjustability: Fully adjustable front forks and rear shock absorber for customizable handling and stability. Passive Features Frame Construction: Rigid aluminum twin-spar frame for rider control and stability. 💡 Technology Features Infotainment Infotainment System: Basic dashboard instrumentation focused on performance and essential information (tachometer, speedometer, fuel gauge, warning lights). No advanced infotainment. Driver Assistance Driver Assistance Features: None (No ABS, traction control, or electronic rider aids standard on the 1999 model). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first. Refer to manual for exact spec. Valve Clearance Check: Every 10,000-12,000 km (6,000-7,500 miles). Requires engine disassembly. Chain Maintenance: Regular cleaning, lubrication, and tension adjustment (check tension every 1,000 km or after spirited riding). Fluid Specifications Engine Oil: API SG or higher, SAE 10W-40 or 10W-50 synthetic motorcycle oil (confirm with manual). Coolant: Ethylene glycol-based coolant with a 50% mixture of distilled water. Check manual for specific type. Brake Fluid: DOT 4 or DOT 5.1 hydraulic brake fluid (ensure compatibility with seals). Clutch Fluid: DOT 4 hydraulic fluid, same as brake fluid. Known Issues Stator Failure: Early models can be prone to...
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1999 Aprilia RSV Mille Factory Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
1999
Product Type:
Factory Service Repair Manual
Codes
Chassis Code:
RP
👋 Introduction
Market Position
Positioning:
High-performance sportbike, targeted at enthusiasts seeking track-day capability and exhilarating road performance.
Competitive Analysis
Competitors:
Competed against other 900cc-1000cc sportbikes of the era, such as the Ducati 916, Yamaha YZF-R1, and Suzuki GSX-R1000.
Key Features
Engine Layout:
V-twin engine, known for its torque and character.
Chassis Design:
Sturdy aluminum twin-spar frame providing excellent rigidity and handling characteristics.
Suspension Components:
High-quality, adjustable suspension components, typically from reputable manufacturers.
Braking System:
Powerful Brembo braking system, offering strong stopping power and feel.
📋 Manual Details
Coverage Areas
General Coverage:
Comprehensive repair and service procedures for the 1999 Aprilia RSV Mille.
Specific Areas:
Engine, fuel supply, cooling, electrical systems, chassis, repair information, updates, and analytical index.
Page Count
Estimated Pages:
Detailed page count not specified, but implied to be extensive covering all repair procedures.
Manual Type
Type:
Factory Service Repair Manual
Language
Language:
English
Format
Digital Format:
PDF/ZIP
Compatibility
Operating Systems:
WIN/MAC/LINUX
📖 Manual Coverage
Systems Covered
Engine:
Detailed procedures for engine disassembly, assembly, tuning, and component diagnostics.
Fuel Supply System:
Fuel injection system operation, troubleshooting, component testing, and adjustments.
Cooling System:
Radiator, fan, coolant flow, thermostat operation, and leak detection procedures.
Electrical System:
Wiring diagrams, starter, ignition system, lighting, battery maintenance, and electronic component testing.
Chassis Parts:
Front and rear suspension, steering system, braking system (including hydraulic components), wheels, and tires.
Bodywork Fairings:
Procedures for removing and installing body panels, fairings, and trim components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, lubrication points, and fluid checks.
Troubleshooting:
Diagnostic flowcharts and symptom-based problem resolution for various systems.
Repair Overhaul:
Detailed step-by-step instructions for component disassembly, repair, and reassembly.
Technical Specifications:
Torque values, clearances, fluid capacities, and performance parameters.
Assembly Disassembly:
Complete step-by-step guides for taking apart and putting back together all major motorcycle components.
Torque Specifications:
Detailed torque values for all fasteners critical for safety and proper function.
Diagrams Illustrations:
Likely includes exploded views and clear diagrams to illustrate complex procedures.
Technical Depth
Depth Of Coverage:
Comprehensive, suitable for both DIY enthusiasts and professional technicians, covering detailed repairs and diagnostics.
Diagnostic Capabilities:
Advanced diagnostic procedures for engine and electrical systems, enabling identification of faults beyond simple visual checks.
📊 Manual Specifications
File Format
Primary Format:
PDF
Compression:
ZIP
Print Quality
Digital Quality:
High-resolution digital content, optimized for on-screen viewing and printing.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke
Displacement:
998 cc (60.9 cu in)
Bore X Stroke:
97.0 mm x 67.5 mm (3.82 x 2.66 in)
Compression Ratio:
10.8:1 (typical)
Performance
Horsepower:
Approximately 124 hp (92.5 kW) @ 9,500 rpm (factory figures may vary slightly by market/tuning)
Torque:
Approximately 71 lb-ft (96 Nm) @ 7,500 rpm (factory figures may vary slightly by market/tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with two injectors per cylinder
Fuel Type:
Unleaded gasoline, minimum 95 RON
Cooling System
Cooling Method:
Liquid-cooled
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Clutch Type:
Wet, multi-plate, hydraulic actuation
Features
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2,050 mm (80.7 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1,130 mm (44.5 in)
Weights
Dry Weight:
Approx. 190 kg (419 lbs)
Wet Weight:
Approx. 203 kg (448 lbs)
🛡️ Safety Features
Ratings
Safety Standards:
Motorcycle safety standards applicable at the time of manufacture (no formal crash ratings like cars).
Active Features
Braking System:
Dual front disc brakes with four-piston calipers, single rear disc brake with two-piston caliper. Typically Brembo components.
Suspension Adjustability:
Fully adjustable front forks and rear shock absorber for customizable handling and stability.
Passive Features
Frame Construction:
Rigid aluminum twin-spar frame for rider control and stability.
💡 Technology Features
Infotainment
Infotainment System:
Basic dashboard instrumentation focused on performance and essential information (tachometer, speedometer, fuel gauge, warning lights). No advanced infotainment.
Driver Assistance
Driver Assistance Features:
None (No ABS, traction control, or electronic rider aids standard on the 1999 model).
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first. Refer to manual for exact spec.
Valve Clearance Check:
Every 10,000-12,000 km (6,000-7,500 miles). Requires engine disassembly.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment (check tension every 1,000 km or after spirited riding).
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-40 or 10W-50 synthetic motorcycle oil (confirm with manual).
Coolant:
Ethylene glycol-based coolant with a 50% mixture of distilled water. Check manual for specific type.
Brake Fluid:
DOT 4 or DOT 5.1 hydraulic brake fluid (ensure compatibility with seals).
Clutch Fluid:
DOT 4 hydraulic fluid, same as brake fluid.
Known Issues
Stator Failure:
Early models can be prone to stator failure, leading to charging system issues. Manual will detail testing procedures.
Regulator Rectifier:
The regulator/rectifier can also be a point of failure, often related to heat and charging system load.
Cam Chain Tensioner:
Some owners report the automatic cam chain tensioner becoming noisy or failing; manual will cover inspection.
Electrical Connectors:
Corrosion or poor connections in the electrical system can cause intermittent faults; manual details connector locations and cleaning.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer, renowned for its racing heritage and high-performance motorcycles.
Model Evolution
First Generation:
The RSV Mille was Aprilia's first large-displacement sportbike, introduced in 1998 as a competitor in the litre-bike segment.
Production
Production Period:
The first generation RSV Mille (RP chassis) was produced from 1998 to 2003, with the 1999 model being a key early iteration.
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The RSV Mille was generally well-received by motorcycle journalists for its performance, handling, and distinctive V-twin character, often praised for its track capability.
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