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Aprilia RSV Mille 2004 Factory Service Repair Manual

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Basic Information Identification Make: Aprilia Model: RSV Mille Factory Year: 2004 Codes Engine Code Designation: Rotax 990 V-Twin (specific factory designation likely internal to Aprilia, not commonly listed as a separate code for user reference) Introduction Market Position Positioning: High-performance sportbike, a premium offering in its class during its production era. Competitive Analysis Competitors 2004: Ducati 996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR954RR, Kawasaki ZX-10R. Key Features Sportbike Attributes: Powerful V-twin engine, advanced chassis geometry, premium suspension components (often Ohlins on Factory models), race-derived aerodynamics. Manual Value Proposition Dealer Equivalence: Provides the same information as the official dealer workshop manual. Ease Of Use: Designed to be simple to use with clear instructions and diagrams. Manual Details Coverage Areas General Information: Yes Periodic Maintenance: Yes Tune Up Procedures: Yes Engine: Yes Fuel And Lubrication System: Yes Cooling System: Yes Electrical System: Yes Chassis: Yes Servicing Information: Yes Updates: Yes Page Count Estimated Pages: Comprehensive (exact number not provided, but implied to be extensive covering all aspects) Manual Type Type: Factory Service Repair Manual Language Language: English (implied by product description and target market) Format Format: PDF Manual Coverage Systems Covered Engine: Full engine disassembly, assembly, component inspection, timing, valve clearance adjustment, etc. Fuel System: Fuel injection system (throttle body, injectors, sensors), fuel pump, fuel filter, fuel tank service. Lubrication System: Oil pump, oil filter, oil cooler, oil change procedures, oil capacity specifications. Cooling System: Radiator, cooling fan, water pump, thermostat, coolant capacity, bleeding procedures. Electrical System: Wiring diagrams, ignition system, lighting, starting system, charging system, ECU diagnostics, sensor testing. Chassis: Front suspension (forks, steering head bearings), rear suspension (shock absorber, swingarm, linkage), wheel bearings, brake system (discs, calipers, master cylinders, lines), clutch system. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake fluid checks, coolant checks, tire pressure checks, spark plug replacement. Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems. Repair: Step-by-step instructions for component replacement and repair. Adjustment: Carburetor (if applicable, though likely EFI), throttle cables, clutch cables, suspension settings. Torque Settings: Precise torque specifications for all critical fasteners. Fluid Capacities: Engine oil, coolant, brake fluid, clutch fluid capacities. Technical Depth Depth Level: Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts. Diagnostic Capabilities: Includes electrical system diagnostics, sensor testing, and fault code interpretation (if applicable). Diagrams: Step-by-step diagrams for all procedures and detailed electrical schematics. Manual Specifications File Format Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader & WinZip Interactivity: Zoom In/Out functionality Print Quality Printability: Printable pages (implied by PDF format, though specific print optimization is not stated) Binding Type Binding: N/A (Digital PDF Format) Paper Type Paper: N/A (Digital PDF Format) Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90-degree V-twin Displacement: 998 cc (cc) Bore X Stroke: 97 mm x 67.5 mm (typical for this engine family) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower Crank: Approx. 130-135 HP (at crank, depending on specific tuning and region) Torque Crank: Approx. 105 Nm (at crank, depending on specific tuning and region) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder (likely). Ignition System: Electronic ignition Fuel Type: Unleaded gasoline, minimum 95 RON Transmission Standard Transmission Type: 6-speed sequential manual gearbox Optional Optional Transmission: N/A (No automatic or other transmission options typically offered for this model) Features Clutch Type: Hydraulically operated wet multi-plate clutch Final Drive: O-ring sealed chain drive Dimensions Exterior Length: Approx. 2030 mm (specific for 2004 Factory) Width: Approx. 720 mm (at handlebars) Height: Approx. 1130 mm (at seat) Wheelbase: Approx. 1410 mm Weights Dry Weight: Approx. 185 kg (for RSV Mille Factory, may vary slightly based on specific year/options) Wet Weight: Approx. 205 kg (with all fluids) Fuel Tank Capacity: Approx. 21 Liters Safety Features Ratings Safety Ratings: N/A (Motorcycle safety ratings are not standardized in the same way as cars; focus is on rider safety features and handling characteristics). Active Features Braking System Front: Dual 320 mm discs, radial-mount Brembo calipers Braking System Rear: Single 220 mm disc, Brembo caliper Suspension Front: Adjustable upside-down telescopic forks (likely Öhlins on Factory models) Suspension Rear: Adjustable monoshock with linkage (likely Öhlins on Factory models) Passive Features Frame Type: Aluminum alloy twin-spar frame Tire Size Front: 120/70 ZR17 Tire Size Rear: 190/50 ZR17 Technology Features Infotainment Infotainment System: N/A (Focus is on performance, not infotainment. Basic dashboard instrumentation: speedometer, tachometer, coolant temperature, clock). Driver Assistance Rider Aids: N/A (No electronic rider aids like traction control or ABS were standard on this model). Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Every 5,000 km or 12 months (typical, refer to manual for exact) Air Filter Check: Every 5,000 km Spark Plug Replacement: Every 10,000 km (typical for iridium plugs) Valve Clearance Check: Every 10,000 km (critical for V-twins) Fluid Specifications...
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Aprilia RSV Mille 2004 Factory Service Repair Manual
Basic Information
Identification
Make: Aprilia
Model: RSV Mille Factory
Year: 2004
Codes
Engine Code Designation: Rotax 990 V-Twin (specific factory designation likely internal to Aprilia, not commonly listed as a separate code for user reference)
Introduction
Market Position
Positioning: High-performance sportbike, a premium offering in its class during its production era.
Competitive Analysis
Competitors 2004: Ducati 996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR954RR, Kawasaki ZX-10R.
Key Features
Sportbike Attributes: Powerful V-twin engine, advanced chassis geometry, premium suspension components (often Ohlins on Factory models), race-derived aerodynamics.
Manual Value Proposition
Dealer Equivalence: Provides the same information as the official dealer workshop manual.
Ease Of Use: Designed to be simple to use with clear instructions and diagrams.
Manual Details
Coverage Areas
General Information: Yes
Periodic Maintenance: Yes
Tune Up Procedures: Yes
Engine: Yes
Fuel And Lubrication System: Yes
Cooling System: Yes
Electrical System: Yes
Chassis: Yes
Servicing Information: Yes
Updates: Yes
Page Count
Estimated Pages: Comprehensive (exact number not provided, but implied to be extensive covering all aspects)
Manual Type
Type: Factory Service Repair Manual
Language
Language: English (implied by product description and target market)
Format
Format: PDF
Manual Coverage
Systems Covered
Engine: Full engine disassembly, assembly, component inspection, timing, valve clearance adjustment, etc.
Fuel System: Fuel injection system (throttle body, injectors, sensors), fuel pump, fuel filter, fuel tank service.
Lubrication System: Oil pump, oil filter, oil cooler, oil change procedures, oil capacity specifications.
Cooling System: Radiator, cooling fan, water pump, thermostat, coolant capacity, bleeding procedures.
Electrical System: Wiring diagrams, ignition system, lighting, starting system, charging system, ECU diagnostics, sensor testing.
Chassis: Front suspension (forks, steering head bearings), rear suspension (shock absorber, swingarm, linkage), wheel bearings, brake system (discs, calipers, master cylinders, lines), clutch system.
Procedures Included
Routine Maintenance: Oil changes, filter replacements, chain adjustment, brake fluid checks, coolant checks, tire pressure checks, spark plug replacement.
Troubleshooting: Diagnostic procedures for common and uncommon issues across all systems.
Repair: Step-by-step instructions for component replacement and repair.
Adjustment: Carburetor (if applicable, though likely EFI), throttle cables, clutch cables, suspension settings.
Torque Settings: Precise torque specifications for all critical fasteners.
Fluid Capacities: Engine oil, coolant, brake fluid, clutch fluid capacities.
Technical Depth
Depth Level: Comprehensive factory-level detail, suitable for professional mechanics and advanced DIY enthusiasts.
Diagnostic Capabilities: Includes electrical system diagnostics, sensor testing, and fault code interpretation (if applicable).
Diagrams: Step-by-step diagrams for all procedures and detailed electrical schematics.
Manual Specifications
File Format
Compatibility: All Versions of Windows & Mac
Requirements: Adobe PDF Reader & WinZip
Interactivity: Zoom In/Out functionality
Print Quality
Printability: Printable pages (implied by PDF format, though specific print optimization is not stated)
Binding Type
Binding: N/A (Digital PDF Format)
Paper Type
Paper: N/A (Digital PDF Format)
Engine Specifications
Primary Engine
Engine Type: Four-stroke, liquid-cooled, 90-degree V-twin
Displacement: 998 cc (cc)
Bore X Stroke: 97 mm x 67.5 mm (typical for this engine family)
Valve Train: DOHC, 4 valves per cylinder
Performance
Horsepower Crank: Approx. 130-135 HP (at crank, depending on specific tuning and region)
Torque Crank: Approx. 105 Nm (at crank, depending on specific tuning and region)
Fuel System
Fuel Delivery: Electronic Fuel Injection (EFI) with dual injectors per cylinder (likely).
Ignition System: Electronic ignition
Fuel Type: Unleaded gasoline, minimum 95 RON
Transmission
Standard
Transmission Type: 6-speed sequential manual gearbox
Optional
Optional Transmission: N/A (No automatic or other transmission options typically offered for this model)
Features
Clutch Type: Hydraulically operated wet multi-plate clutch
Final Drive: O-ring sealed chain drive
Dimensions
Exterior
Length: Approx. 2030 mm (specific for 2004 Factory)
Width: Approx. 720 mm (at handlebars)
Height: Approx. 1130 mm (at seat)
Wheelbase: Approx. 1410 mm
Weights
Dry Weight: Approx. 185 kg (for RSV Mille Factory, may vary slightly based on specific year/options)
Wet Weight: Approx. 205 kg (with all fluids)
Fuel Tank Capacity: Approx. 21 Liters
Safety Features
Ratings
Safety Ratings: N/A (Motorcycle safety ratings are not standardized in the same way as cars; focus is on rider safety features and handling characteristics).
Active Features
Braking System Front: Dual 320 mm discs, radial-mount Brembo calipers
Braking System Rear: Single 220 mm disc, Brembo caliper
Suspension Front: Adjustable upside-down telescopic forks (likely Öhlins on Factory models)
Suspension Rear: Adjustable monoshock with linkage (likely Öhlins on Factory models)
Passive Features
Frame Type: Aluminum alloy twin-spar frame
Tire Size Front: 120/70 ZR17
Tire Size Rear: 190/50 ZR17
Technology Features
Infotainment
Infotainment System: N/A (Focus is on performance, not infotainment. Basic dashboard instrumentation: speedometer, tachometer, coolant temperature, clock).
Driver Assistance
Rider Aids: N/A (No electronic rider aids like traction control or ABS were standard on this model).
Connectivity
Connectivity Features: N/A
Maintenance
Service Intervals
Oil Change Interval: Every 5,000 km or 12 months (typical, refer to manual for exact)
Air Filter Check: Every 5,000 km
Spark Plug Replacement: Every 10,000 km (typical for iridium plugs)
Valve Clearance Check: Every 10,000 km (critical for V-twins)
Fluid Specifications
Engine Oil Type: SAE 10W-40, API SG or higher, JASO MA (refer to manual for exact Aprilia specification)
Coolant Type: Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motul Motocool Expert, Castrol Radicool)
Brake Fluid Type: DOT 4
Clutch Fluid Type: DOT 4 (hydraulic clutch)
Known Issues
Common Problems: Regulator/rectifier failure (common on many Aprilias of this era), cam chain tensioner issues, fuel pressure regulator leaks, clutch slave cylinder leaks. Precise diagnosis and solutions are detailed in the manual.
Vehicle History
Brand Heritage
Brand Origin: Aprilia is an Italian manufacturer with a strong racing heritage, particularly in motorcycle racing.
Model Evolution
Rsv Mille Lineage: The RSV Mille was Aprilia's flagship superbike, introduced in 1998, competing with established Japanese and Italian rivals. The 'Factory' model typically represented the highest specification, often featuring upgraded components like Öhlins suspension and carbon fiber parts.
Production
Production Period: The RSV Mille series was produced from 1998 to 2003, with the RSV1000R and RSV1000R Factory (which this manual likely covers for 2004, as the original Mille line evolved) continuing the lineage.
Awards & Recognition
Recognitions
Motorcycle Reviews: The RSV Mille series was consistently praised for its engine character, handling, and braking performance, often receiving high marks in contemporary motorcycle publications.
Ratings
Performance Ratings: Class-leading torque and exhilarating V-twin power delivery.
Certifications
Manual Certification: Factory authorized
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