Aprilia RSV Mille 2000-2003 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Generation Generation Name: First Generation (RP) Codes Chassis Code Series: RP 👋 Introduction Market Position Segment: Sportbike / Superbike Performance Class: High-performance, track-capable motorcycle. Competitive Analysis Key Competitors: Ducati 916/996, Yamaha YZF-R1, Honda CBR900RR Fireblade, Suzuki GSX-R1000, Kawasaki ZX-9R Key Features Design Philosophy: Italian design and engineering with a focus on V-twin performance and handling. Engine Configuration: 996cc V-twin engine known for its torque and character. Handling Characteristics: Renowned for its exceptional chassis and suspension tuning, providing precise feedback and agility. 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002, 2003 Page Count Estimated Page Count: Refer to product listing for exact count, typically 500+ pages for full service manuals. Manual Type Type: Full Service Repair Manual Language Language: English Format Format: Digital (likely PDF), potentially printable 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition System, Exhaust System, Cooling System, Lubrication System Chassis: Frame, Suspension (Front and Rear), Steering System, Wheels, Tires Brakes: Front and Rear Brake Systems (Hydraulic Components, Calipers, Rotors, Pads) Electrical: Wiring Diagrams, Lighting System, Battery, Charging System, Ignition System, Starter System, Instruments and Controls Bodywork And Maintenance: Body panels, Fairings, Seat, Fuel Tank, Maintenance Procedures, Troubleshooting Procedures Included Routine Maintenance: Oil changes, Filter replacements, Chain adjustment, Spark plug service, Brake fluid flush, Coolant flush Engine Overhaul: Disassembly, Inspection, Reassembly, Valve adjustment, Piston and cylinder servicing, Crankshaft and connecting rod service Transmission Service: Clutch adjustment and replacement, Gearbox disassembly and reassembly, Gear inspection Suspension And Steering: Fork seal replacement, Shock absorber servicing, Steering head bearing adjustment/replacement Electrical Troubleshooting: Diagnostic procedures, Fault finding for common electrical issues, Component testing Technical Depth Depth: Comprehensive. Covers everything from basic adjustments to complete engine and transmission rebuilds. Diagnostic Capabilities: Detailed diagnostic charts, troubleshooting guides, and step-by-step problem-solving procedures. Rebuild Procedures: Includes specifications for tolerances, torque values, and detailed instructions for rebuilding major components. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format), optimized for clarity and searchability. Print Quality Print Readability: High-resolution scans ensuring clear text and legible diagrams for printing. Binding Type Digital Binding Analogue: Navigable via digital bookmarks and hyperlinking, mimicking a well-organized physical manual. Paper Type Digital Paper Analogue: Designed for clarity on screen and when printed, ensuring diagrams and schematics are easily understood. ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90-degree V-twin Displacement: 996 cc (60.8 cu in) Bore X Stroke: 98 mm x 66 mm Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 124 hp (92.5 kW) @ 9,000 rpm (depending on specific market tuning) Torque: Approx. 71 lb-ft (96 Nm) @ 7,000 rpm (depending on specific market tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with twin injectors per cylinder Ignition System: Digital electronic ignition Cooling System Cooling Type: Liquid-cooled Lubrication System Oil Type: Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 10W-50 recommended. Refer to manual for specific API/JASO rating. Oil Capacity: Approx. 3.7 liters (3.9 US qt) with filter change. Refer to manual for exact capacity. 🔧 Transmission Standard Type: 6-speed sequential manual Optional None: N/A Features Clutch Type: Wet multi-plate clutch Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2,020 mm (79.5 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1,130 mm (44.5 in) Wheelbase: Approx. 1,410 mm (55.5 in) Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 215 kg (474 lbs) (fully fueled) Fuel Capacity Fuel Tank Capacity: 22 liters (5.8 US gallons) 🛡️ Safety Features Ratings NHTSA Rating: N/A (Motorcycle safety is typically not rated by governmental bodies like NHTSA in the same way as cars). Active Features Braking System: Dual front disc brakes with radial-mount calipers, single rear disc brake. Suspension Performance: Adjustable front forks and rear shock absorber contribute to stable handling and braking. Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and impact absorption. 💡 Technology Features Infotainment System Type: Basic analog instrumentation with digital odometer and clock. No advanced infotainment features. Driver Assistance ABS: Not standard on all models/markets. Some later versions or optional packages may have featured ABS. Connectivity Smartphone Integration: None 🔧 Maintenance Service Intervals Oil Change Interval: Every 4,000-6,000 km (2,500-3,700 miles) or annually. Refer to manual for exact mileage and time. Valve Check Interval: Every 10,000-12,000 km (6,200-7,500 miles). Crucial for V-twin performance. Chain Maintenance: Lubricate and adjust chain every 1,000 km (600 miles) or as needed. Check for wear and replace if necessary. Fluid Specifications Coolant: Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Refer to manual for specific Aprilia coolant or compatible OEM specification. Brake Fluid: DOT 4 or DOT 5.1 brake fluid. Replace every 2 years. Always use fresh fluid. Clutch Fluid: DOT 4 or DOT 5.1 brake fluid (same as brakes). Check and top off as...
Disassembly, Inspection, Reassembly, Valve adjustment, Piston and cylinder servicing, Crankshaft and connecting rod service
Transmission Service:
Clutch adjustment and replacement, Gearbox disassembly and reassembly, Gear inspection
Suspension And Steering:
Fork seal replacement, Shock absorber servicing, Steering head bearing adjustment/replacement
Electrical Troubleshooting:
Diagnostic procedures, Fault finding for common electrical issues, Component testing
Technical Depth
Depth:
Comprehensive. Covers everything from basic adjustments to complete engine and transmission rebuilds.
Diagnostic Capabilities:
Detailed diagnostic charts, troubleshooting guides, and step-by-step problem-solving procedures.
Rebuild Procedures:
Includes specifications for tolerances, torque values, and detailed instructions for rebuilding major components.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format), optimized for clarity and searchability.
Print Quality
Print Readability:
High-resolution scans ensuring clear text and legible diagrams for printing.
Binding Type
Digital Binding Analogue:
Navigable via digital bookmarks and hyperlinking, mimicking a well-organized physical manual.
Paper Type
Digital Paper Analogue:
Designed for clarity on screen and when printed, ensuring diagrams and schematics are easily understood.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90-degree V-twin
Displacement:
996 cc (60.8 cu in)
Bore X Stroke:
98 mm x 66 mm
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 124 hp (92.5 kW) @ 9,000 rpm (depending on specific market tuning)
Torque:
Approx. 71 lb-ft (96 Nm) @ 7,000 rpm (depending on specific market tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Ignition System:
Digital electronic ignition
Cooling System
Cooling Type:
Liquid-cooled
Lubrication System
Oil Type:
Semi-synthetic or fully synthetic motorcycle oil, SAE 10W-40 or 10W-50 recommended. Refer to manual for specific API/JASO rating.
Oil Capacity:
Approx. 3.7 liters (3.9 US qt) with filter change. Refer to manual for exact capacity.
🔧 Transmission
Standard
Type:
6-speed sequential manual
Optional
None:
N/A
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2,020 mm (79.5 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1,130 mm (44.5 in)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 215 kg (474 lbs) (fully fueled)
Fuel Capacity
Fuel Tank Capacity:
22 liters (5.8 US gallons)
🛡️ Safety Features
Ratings
NHTSA Rating:
N/A (Motorcycle safety is typically not rated by governmental bodies like NHTSA in the same way as cars).
Active Features
Braking System:
Dual front disc brakes with radial-mount calipers, single rear disc brake.
Suspension Performance:
Adjustable front forks and rear shock absorber contribute to stable handling and braking.
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and impact absorption.
💡 Technology Features
Infotainment
System Type:
Basic analog instrumentation with digital odometer and clock. No advanced infotainment features.
Driver Assistance
ABS:
Not standard on all models/markets. Some later versions or optional packages may have featured ABS.
Connectivity
Smartphone Integration:
None
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,700 miles) or annually. Refer to manual for exact mileage and time.
Valve Check Interval:
Every 10,000-12,000 km (6,200-7,500 miles). Crucial for V-twin performance.
Chain Maintenance:
Lubricate and adjust chain every 1,000 km (600 miles) or as needed. Check for wear and replace if necessary.
Fluid Specifications
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water. Refer to manual for specific Aprilia coolant or compatible OEM specification.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid. Replace every 2 years. Always use fresh fluid.
Clutch Fluid:
DOT 4 or DOT 5.1 brake fluid (same as brakes). Check and top off as needed.
Known Issues
Stator Reliability:
Early models sometimes experienced stator failures. Regular voltage output checks are recommended.
Fuel Pump Issues:
Occasional fuel pump failures or performance degradation.
Regulator Rectifier:
Similar to many bikes of this era, the regulator/rectifier can be a failure point. Upgraded units are available.
Cam Chain Tensioner:
The automatic cam chain tensioner can sometimes develop issues or leak oil. Inspection and potential manual tensioner conversion are common for enthusiasts.
Recommended Parts
Air Filter Part Number:
Refer to manual or reputable aftermarket supplier (e.g., K&N, BMC) for specific part numbers for your year.
Oil Filter Part Number:
Refer to manual or reputable aftermarket supplier (e.g., HiFloFiltro HF152, K&N KN-152).
Spark Plug Type:
NGK CR9EKB or equivalent. Check manual for exact specification and gap.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Specialization:
Known for sportbikes, scooters, and racing heritage.
Model Evolution
Introduction Year:
1998
Updates In Coverage:
The 2000-2003 models represent the initial generation (RP) and saw minor updates and refinements over this period, including potential ECU mapping changes and component revisions.
Production
Manufacturing Location:
Noale, Italy
Rsv Mille Legacy:
The RSV Mille was Aprilia's flagship sportbike and a significant step into the liter-bike category, laying the groundwork for future models like the RSV1000R and RSV4.
🏆 Awards & Recognition
Recognitions
Editorial Reviews:
Consistently praised by motorcycle journalists for its V-twin engine character, handling, and braking performance.
Ratings
Performance Reviews:
Considered a benchmark sportbike of its era, often winning comparison tests against Japanese rivals for its unique Italian flavour and dynamic capabilities.
Certifications
Emission Standards:
Compliant with relevant emissions standards for its production years in various markets. Specific details would be in the manual or vehicle documentation.
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