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Aprilia RST Mille 2000-2005 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Model Variant: Foil Fairing Model Years Covered: 2000, 2001, 2002, 2003, 2004, 2005 Codes Vin Code Start: ZDA Vin Code End: ZDA 👋 Introduction Market Position Category: Sport Touring Motorcycle Target Audience: Motorcyclists seeking performance, comfort, and long-distance capability Competitive Analysis Key Competitors: Honda VFR, Yamaha FJR, Suzuki GSX-R S, Kawasaki GTR Key Features Engine Layout: V-Twin, high-performance Suspension Front: Premium adjustable front forks (often Öhlins or Marzocchi) Suspension Rear: Advanced monoshock rear suspension Braking Front: Dual Brembo disc brakes Aerodynamics: Integrated fairing for wind protection 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive workshop service and repair Diagnostic Coverage: Troubleshooting and fault diagnosis Maintenance Coverage: Scheduled maintenance and routine servicing Repair Coverage: Engine, transmission, chassis, electrical, bodywork Special Procedures: Torque specifications, special tool usage, component alignment Page Count Estimated Pages: Approximately 500+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, piston, rings, cylinder head, camshafts, crankshaft, timing system Fuel System: Fuel injection system (EFI), injectors, fuel pump, pressure regulator, throttle body Ignition System: Ignition coils, spark plugs, ECU control Cooling System: Radiator, hoses, water pump, thermostat, fan operation Exhaust System: Exhaust manifold, catalytic converter, muffler, O2 sensors Transmission Clutch: Clutch operation, hydraulic system, gearbox disassembly and assembly, gear selection Chassis Suspension: Front forks (Öhlins/Marzocchi), rear shock absorber (Monoshock), swingarm, linkage, steering head bearings Braking System: Front and rear brake calipers (Brembo), master cylinders, brake lines, fluid bleeding, disc replacement Electrical System: Wiring diagrams, battery, starter motor, alternator, lighting, instrumentation, ECU, sensors Bodywork Fairings: Fairing removal and installation, panel fitting, seat, fuel tank Procedures Included Routine Maintenance: Oil change, filter replacement, chain adjustment, brake pad inspection, tire pressure checks Major Repairs: Engine rebuild, transmission overhaul, suspension fork servicing, brake system overhaul Troubleshooting: Diagnostic charts, symptom-based troubleshooting for electrical and mechanical issues Component Replacement: Step-by-step guides for replacing all major components Torque Specifications: Detailed torque values for all critical fasteners Technical Depth Depth: Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts Diagnostic Tools: Information on using diagnostic equipment and interpreting fault codes Wiring Diagrams: Detailed, color-coded electrical schematics 📊 Manual Specifications File Format Type: PDF (Portable Document Format) Searchability: Text-searchable for quick information retrieval Printable: Printable pages for workshop use Print Quality Image Resolution: High-resolution images and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 90-degree V-Twin, four-stroke Displacement: 998 cc (998cc) Bore X Stroke: 97 x 67.5 mm Valve Train: DOHC, four valves per cylinder Cooling System: Liquid-cooled Performance Horsepower Peak: Approx. 130-135 hp @ 9,500 rpm Torque Peak: Approx. 100 Nm (74 lb-ft) @ 7,500 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline, minimum 95 RON Fuel Tank Capacity: 23 Liters (6.07 US gal) 🔧 Transmission Standard Transmission Type: 6-speed manual Features Clutch Type: Wet multi-plate clutch, hydraulically operated Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2140 mm (84.3 in) Width: Approx. 750 mm (29.5 in) Height: Approx. 1230 mm (48.4 in) Wheelbase: Approx. 1440 mm (56.7 in) Weights Dry Weight: Approx. 207 kg (456 lbs) Wet Weight: Approx. 220 kg (485 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle Specific) Active Features Front Brakes: Dual 320 mm discs with Brembo 4-piston calipers Rear Brakes: Single 220 mm disc with Brembo 2-piston caliper Optional ABS: Available on some later models (check specific bike) Passive Features Lighting: Halogen headlight, LED taillight Instrumentation: Analog tachometer, digital speedometer, multi-function display 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer, digital speedometer, LCD display for trip meter, clock, fuel level, engine temp Driver Assistance ABS Availability: Optional on some models, not standard Connectivity Connectivity Features: None (as per era of design) 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km (3,700 miles) or 12 months Oil Filter Replacement: At every oil change Air Filter Inspection: Every 6,000 km (3,700 miles) Spark Plug Replacement: Every 12,000 km (7,500 miles) Valve Clearance Check: Every 12,000 km (7,500 miles) Fluid Specifications Engine Oil Type: API SG, JASO MA, SAE 10W-40 Synthetic Motorcycle Oil Engine Oil Capacity: 3.5 Liters (3.7 US qt) with filter change Coolant Type: Ethylene glycol-based antifreeze coolant (50% mixture with distilled water) Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 Fork Oil Type: SAE 5W or 7.5W (check specific fork manufacturer/model) Known Issues Common Complaints: Stalling at low RPM, potential stator failure, occasional fuel injection issues, electrical connectors corrosion Maintenance Tips: Regular cleaning of fuel injectors, checking electrical connections, ensuring proper battery maintenance 📚 Vehicle History Brand Heritage Brand Origin: Italy, founded in 1945 Brand Focus: Performance motorcycles, racing heritage Model Evolution Predecessor: Aprilia RSV Mille (1998-2003) Successor: Aprilia RST1000 Futura (2001-2004, sharing...
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Aprilia RST Mille 2000-2005 Workshop Service Repair ManualAprilia RST Mille 2000-2005 Workshop Service Repair ManualAprilia RST Mille 2000-2005 Workshop Service Repair ManualAprilia RST Mille 2000-2005 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RST Mille
Model Variant:
Foil Fairing
Model Years Covered:
2000, 2001, 2002, 2003, 2004, 2005
Codes
Vin Code Start:
ZDA
Vin Code End:
ZDA
👋 Introduction
Market Position
Category:
Sport Touring Motorcycle
Target Audience:
Motorcyclists seeking performance, comfort, and long-distance capability
Competitive Analysis
Key Competitors:
Honda VFR, Yamaha FJR, Suzuki GSX-R S, Kawasaki GTR
Key Features
Engine Layout:
V-Twin, high-performance
Suspension Front:
Premium adjustable front forks (often Öhlins or Marzocchi)
Suspension Rear:
Advanced monoshock rear suspension
Braking Front:
Dual Brembo disc brakes
Aerodynamics:
Integrated fairing for wind protection
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive workshop service and repair
Diagnostic Coverage:
Troubleshooting and fault diagnosis
Maintenance Coverage:
Scheduled maintenance and routine servicing
Repair Coverage:
Engine, transmission, chassis, electrical, bodywork
Special Procedures:
Torque specifications, special tool usage, component alignment
Page Count
Estimated Pages:
Approximately 500+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine overhaul, piston, rings, cylinder head, camshafts, crankshaft, timing system
Fuel System:
Fuel injection system (EFI), injectors, fuel pump, pressure regulator, throttle body
Ignition System:
Ignition coils, spark plugs, ECU control
Cooling System:
Radiator, hoses, water pump, thermostat, fan operation
Exhaust System:
Exhaust manifold, catalytic converter, muffler, O2 sensors
Transmission Clutch:
Clutch operation, hydraulic system, gearbox disassembly and assembly, gear selection
Chassis Suspension:
Front forks (Öhlins/Marzocchi), rear shock absorber (Monoshock), swingarm, linkage, steering head bearings
Braking System:
Front and rear brake calipers (Brembo), master cylinders, brake lines, fluid bleeding, disc replacement
Electrical System:
Wiring diagrams, battery, starter motor, alternator, lighting, instrumentation, ECU, sensors
Bodywork Fairings:
Fairing removal and installation, panel fitting, seat, fuel tank
Procedures Included
Routine Maintenance:
Oil change, filter replacement, chain adjustment, brake pad inspection, tire pressure checks
Major Repairs:
Engine rebuild, transmission overhaul, suspension fork servicing, brake system overhaul
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting for electrical and mechanical issues
Component Replacement:
Step-by-step guides for replacing all major components
Torque Specifications:
Detailed torque values for all critical fasteners
Technical Depth
Depth:
Comprehensive, suitable for professional mechanics and advanced DIY enthusiasts
Diagnostic Tools:
Information on using diagnostic equipment and interpreting fault codes
Wiring Diagrams:
Detailed, color-coded electrical schematics
📊 Manual Specifications
File Format
Type:
PDF (Portable Document Format)
Searchability:
Text-searchable for quick information retrieval
Printable:
Printable pages for workshop use
Print Quality
Image Resolution:
High-resolution images and diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
90-degree V-Twin, four-stroke
Displacement:
998 cc (998cc)
Bore X Stroke:
97 x 67.5 mm
Valve Train:
DOHC, four valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower Peak:
Approx. 130-135 hp @ 9,500 rpm
Torque Peak:
Approx. 100 Nm (74 lb-ft) @ 7,500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded gasoline, minimum 95 RON
Fuel Tank Capacity:
23 Liters (6.07 US gal)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Features
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2140 mm (84.3 in)
Width:
Approx. 750 mm (29.5 in)
Height:
Approx. 1230 mm (48.4 in)
Wheelbase:
Approx. 1440 mm (56.7 in)
Weights
Dry Weight:
Approx. 207 kg (456 lbs)
Wet Weight:
Approx. 220 kg (485 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle Specific)
Active Features
Front Brakes:
Dual 320 mm discs with Brembo 4-piston calipers
Rear Brakes:
Single 220 mm disc with Brembo 2-piston caliper
Optional ABS:
Available on some later models (check specific bike)
Passive Features
Lighting:
Halogen headlight, LED taillight
Instrumentation:
Analog tachometer, digital speedometer, multi-function display
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer, digital speedometer, LCD display for trip meter, clock, fuel level, engine temp
Driver Assistance
ABS Availability:
Optional on some models, not standard
Connectivity
Connectivity Features:
None (as per era of design)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 6,000 km (3,700 miles) or 12 months
Oil Filter Replacement:
At every oil change
Air Filter Inspection:
Every 6,000 km (3,700 miles)
Spark Plug Replacement:
Every 12,000 km (7,500 miles)
Valve Clearance Check:
Every 12,000 km (7,500 miles)
Fluid Specifications
Engine Oil Type:
API SG, JASO MA, SAE 10W-40 Synthetic Motorcycle Oil
Engine Oil Capacity:
3.5 Liters (3.7 US qt) with filter change
Coolant Type:
Ethylene glycol-based antifreeze coolant (50% mixture with distilled water)
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4
Fork Oil Type:
SAE 5W or 7.5W (check specific fork manufacturer/model)
Known Issues
Common Complaints:
Stalling at low RPM, potential stator failure, occasional fuel injection issues, electrical connectors corrosion
Maintenance Tips:
Regular cleaning of fuel injectors, checking electrical connections, ensuring proper battery maintenance
📚 Vehicle History
Brand Heritage
Brand Origin:
Italy, founded in 1945
Brand Focus:
Performance motorcycles, racing heritage
Model Evolution
Predecessor:
Aprilia RSV Mille (1998-2003)
Successor:
Aprilia RST1000 Futura (2001-2004, sharing engine but different chassis/styling), Aprilia Dorsoduro, Aprilia Tuono V4
R S T Lineage:
Developed as a more comfortable, touring-oriented variant of the RSV Mille superbike
Production
Production Period:
2000 - 2005
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Awards Received:
Generally praised for its V-twin engine character and sport-touring capability, often featured in comparative reviews of its class.
Ratings
Owner Satisfaction:
Mixed to positive; high for performance, some concerns regarding reliability compared to Japanese counterparts.
Certifications
Certification Type:
N/A (Motorcycle Specific)
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