2002 Aprilia RSV Mille Workshop Service Repair Manual Downlod
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🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
2002
Codes
Model Code:
RP
Generation
Generation Name:
First Generation
Generation Years:
1999-2003
👋 Introduction
Market Position
Market Segment:
High-performance sport motorcycle, competing in the superbike category.
Competitive Analysis
Key Competitors:
Ducati 916/996/998, Honda CBR900RR Fireblade, Yamaha YZF-R1, Suzuki GSX-R1000, Kawasaki ZX-9R.
Key Features
Vehicle Highlights:
Italian design, powerful V-twin engine, advanced chassis, sport-focused ergonomics.
📋 Manual Details
Coverage Areas
Coverage Summary:
Comprehensive service and repair information for the 2002 Aprilia RSV Mille.
Page Count
Estimated Page Count:
Not specified, but described as 'comprehensive'.
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Covered Systems:
Engine, Fuel Supply System, Cooling System, Electrical System, Chassis Parts.
Procedures Included
Included Procedures:
General Information, Service and Setting Up, Engine Overhaul, Fuel System Repair, Cooling System Maintenance, Electrical System Diagnostics, Chassis Component Repair, General Repair Information, Troubleshooting.
Technical Depth
Technical Depth Level:
In-depth technical data, diagrams, parts lists, and step-by-step instructions for immediate repairs and routine maintenance. Suitable for 'Do-It-Yourself' enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Print Quality
Printability:
All pages are printable.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Digital Requirements:
Adobe PDF Reader required.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke, Liquid-cooled
Displacement:
998 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
11.4:1
Performance
Horsepower:
Approx. 130 hp @ 9,500 rpm (claimed)
Torque:
Approx. 101 Nm (74.5 lb-ft) @ 7,500 rpm (claimed)
Fuel System
Fuel Delivery:
Fuel Injection (Weber Marelli, twin injectors per cylinder)
Fuel Type:
Unleaded Premium Gasoline
Lubrication
Oil System:
Wet sump
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Hydraulically operated wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 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)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 210 kg (463 lbs) (with all fluids)
🛡️ Safety Features
Active Features
Braking System Front:
Dual 320 mm discs, radial-mount 4-piston calipers (Brembo)
Braking System Rear:
Single 220 mm disc, 2-piston caliper (Brembo)
Passive Features
Frame Type:
Aluminum twin-spar perimeter frame
Suspension Front:
43mm upside-down telescopic fork (Öhlins optional, Showa standard), adjustable preload, compression, and rebound damping
Suspension Rear:
Monoshock with progressive linkage, adjustable preload, compression, and rebound damping
Wheels:
3-spoke cast aluminum alloy
Tire Size Front:
120/70 ZR17
Tire Size Rear:
190/50 ZR17
💡 Technology Features
Infotainment
Dashboard Features:
Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, clock, and warning lights.
Driver Assistance
Electronics Suite:
Basic electronic fuel injection, ignition system. No advanced rider aids like traction control or ABS were standard on this model.
Connectivity
Diagnostic Ports:
Diagnostic connector for ECU access (refer to manual for location and use).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically every 3,000-6,000 miles or annually).
Major Service Interval:
Refer to manual for valve clearance checks and other major service items (typically 7,500-15,000 miles).
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, API SG/SH/SJ or higher, JASO MA, SAE 10W-40 or 15W-50 (refer to manual for exact recommendation).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (typically 50/50 mix with distilled water).
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (shared with brake system)
Known Issues
Common Complaints:
Potential for stator failure, voltage regulator issues, occasional fuel injection mapping quirks, and clutch slave cylinder leaks. Regular maintenance is key.
Maintenance Focus:
Importance of timely oil changes, chain maintenance, and checking coolant levels. Valve clearance checks are critical for engine longevity.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia is an Italian manufacturer known for its racing heritage and high-performance motorcycles, particularly in the sportbike and off-road segments.
Model Evolution
Development Goal:
The RSV Mille was developed as Aprilia's flagship sportbike to compete directly with established Japanese and European superbike manufacturers.
Production
Manufacturing Origin:
Italy
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Often praised for its distinctive V-twin character, strong performance, and sharp handling, though sometimes critiqued for weight and ergonomics compared to some rivals.
General Information, Service and Setting Up, Engine Overhaul, Fuel System Repair, Cooling System Maintenance, Electrical System Diagnostics, Chassis Component Repair, General Repair Information, Troubleshooting.
Technical Depth
Technical Depth Level:
In-depth technical data, diagrams, parts lists, and step-by-step instructions for immediate repairs and routine maintenance. Suitable for 'Do-It-Yourself' enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Print Quality
Printability:
All pages are printable.
Binding Type
Binding Type:
Digital Download (PDF)
Paper Type
Digital Requirements:
Adobe PDF Reader required.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-stroke, Liquid-cooled
Displacement:
998 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
11.4:1
Performance
Horsepower:
Approx. 130 hp @ 9,500 rpm (claimed)
Torque:
Approx. 101 Nm (74.5 lb-ft) @ 7,500 rpm (claimed)
Fuel System
Fuel Delivery:
Fuel Injection (Weber Marelli, twin injectors per cylinder)
Fuel Type:
Unleaded Premium Gasoline
Lubrication
Oil System:
Wet sump
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Features
Clutch Type:
Hydraulically operated wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 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)
Wheelbase:
Approx. 1,410 mm (55.5 in)
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 210 kg (463 lbs) (with all fluids)
🛡️ Safety Features
Active Features
Braking System Front:
Dual 320 mm discs, radial-mount 4-piston calipers (Brembo)
Monoshock with progressive linkage, adjustable preload, compression, and rebound damping
Wheels:
3-spoke cast aluminum alloy
Tire Size Front:
120/70 ZR17
Tire Size Rear:
190/50 ZR17
💡 Technology Features
Infotainment
Dashboard Features:
Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, clock, and warning lights.
Driver Assistance
Electronics Suite:
Basic electronic fuel injection, ignition system. No advanced rider aids like traction control or ABS were standard on this model.
Connectivity
Diagnostic Ports:
Diagnostic connector for ECU access (refer to manual for location and use).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual for specific mileage/time intervals (typically every 3,000-6,000 miles or annually).
Major Service Interval:
Refer to manual for valve clearance checks and other major service items (typically 7,500-15,000 miles).
Fluid Specifications
Engine Oil Type:
Fully synthetic motorcycle oil, API SG/SH/SJ or higher, JASO MA, SAE 10W-40 or 15W-50 (refer to manual for exact recommendation).
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives (typically 50/50 mix with distilled water).
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (shared with brake system)
Known Issues
Common Complaints:
Potential for stator failure, voltage regulator issues, occasional fuel injection mapping quirks, and clutch slave cylinder leaks. Regular maintenance is key.
Maintenance Focus:
Importance of timely oil changes, chain maintenance, and checking coolant levels. Valve clearance checks are critical for engine longevity.
📚 Vehicle History
Brand Heritage
Brand Focus:
Aprilia is an Italian manufacturer known for its racing heritage and high-performance motorcycles, particularly in the sportbike and off-road segments.
Model Evolution
Development Goal:
The RSV Mille was developed as Aprilia's flagship sportbike to compete directly with established Japanese and European superbike manufacturers.
Production
Manufacturing Origin:
Italy
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Often praised for its distinctive V-twin character, strong performance, and sharp handling, though sometimes critiqued for weight and ergonomics compared to some rivals.
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