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1998-2003 Aprilia RST/RSV Mille Motorcycle Workshop Repair & Service Manual (360 Pages Searchable Bookmarked iPad-ready)
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Basic Information Identification Make: Aprilia Model: RST / RSV Mille Product Type: Workshop Repair & Service Manual Applicable Years: 1998, 1999, 2000, 2001, 2002, 2003 Introduction Market Position Segment: High-performance...
Type: Motorcycles
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Sku: 153541
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| Basic Information | |
| Identification | |
| Make: | Aprilia |
| Model: | RST / RSV Mille |
| Product Type: | Workshop Repair & Service Manual |
| Applicable Years: | 1998, 1999, 2000, 2001, 2002, 2003 |
| Introduction | |
| Market Position | |
| Segment: | High-performance sportbike/naked sportbike. |
| Target Audience: | Enthusiast riders and independent repair shops. |
| Competitive Analysis | |
| Competitors: | Ducati 916/996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR900RR. |
| Key Features | |
| Unique Selling Points Vehicle: | V-twin engine, Italian design and craftsmanship, agile handling. |
| Unique Selling Points Manual: | Digital format, extensive coverage, ease of access and searchability. |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Comprehensive repair and service information for Aprilia RST and RSV Mille motorcycles. |
| Page Count | |
| Total Pages: | 360 |
| Manual Type | |
| Type: | Workshop Repair and Service Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | Digital (PDF) |
| Features: | Searchable, Bookmarked, Printable, iPad-ready |
| Manual Coverage | |
| Systems Covered | |
| Engine: | Engine assembly, disassembly, inspection, troubleshooting, and repair. |
| Fuel System: | Fuel injection system (EFI), fuel pump, injectors, sensors, and troubleshooting. |
| Ignition System: | Ignition coils, spark plugs, ECU, and troubleshooting. |
| Cooling System: | Radiator, cooling fan, water pump, thermostat, coolant specifications, and maintenance. |
| Exhaust System: | Exhaust pipes, mufflers, catalytic converter (if applicable), and inspection. |
| Transmission Drivetrain: | Clutch operation, gearbox disassembly, assembly, inspection, and final drive maintenance. |
| Suspension Front: | Front forks (telescopic), seals, oil, springs, adjustments, and rebuild procedures. |
| Suspension Rear: | Rear shock absorber, linkage, swingarm, bearings, and adjustments. |
| Brakes Front: | Brake calipers, master cylinder, brake lines, discs, pads, bleeding procedures, and troubleshooting. |
| Brakes Rear: | Rear brake caliper, master cylinder, brake lines, disc, pads, bleeding procedures, and troubleshooting. |
| Wheels Tires: | Wheel bearings, tire inspection, replacement, and recommended pressures. |
| Electrical System: | Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, wiring diagrams, and component testing. |
| Instrumentation Controls: | Dashboard, gauges, switches, throttle, clutch lever, and brake lever adjustments. |
| Bodywork Frame: | Fairings, seat, fuel tank, frame inspection, and minor bodywork repairs. |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, chain adjustment, spark plug checks, brake fluid checks, coolant checks. |
| Troubleshooting: | Diagnostic procedures for common electrical, engine, and mechanical issues. |
| Engine Rebuild: | Complete engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), and reassembly. |
| Suspension Fork Rebuild: | Detailed steps for disassembling, cleaning, replacing seals and oil, and reassembling front forks. |
| Brake System Service: | Brake pad replacement, caliper servicing, master cylinder replacement, and brake fluid flushing/bleeding. |
| Electrical Diagnostics: | Wiring harness testing, component voltage checks, and fault diagnosis using wiring diagrams. |
| Torque Specifications: | Critical torque values for all major fasteners and components. |
| Technical Depth | |
| Depth: | Comprehensive, covering routine maintenance to major component overhaul and repair. |
| Manual Specifications | |
| File Format | |
| Format: | |
| Searchability: | Yes (text-based PDF) |
| Printability: | Yes |
| Device Compatibility: | iPad-ready |
| Organization: | Bookmarked for easy navigation |
| Engine Specifications | |
| Primary 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 (3.86 x 2.60 in) |
| Valve Train: | DOHC, 4 valves per cylinder |
| Performance | |
| Horsepower Approx: | 123 hp (91.7 kW) @ 9500 rpm |
| Torque Approx: | 70 ft-lb (95 Nm) @ 7500 rpm |
| Fuel System | |
| Fuel Delivery: | Electronic Fuel Injection (EFI) with sequential multi-point injection |
| Fuel Type: | Unleaded gasoline, minimum 95 RON |
| Lubrication | |
| Oil Type: | API SG/SH or JASO MA certified 10W-40 or 15W-50 synthetic motorcycle oil |
| Oil Capacity: | Approximately 3.4 liters (3.6 US qt) with filter change |
| Transmission | |
| Standard | |
| Type: | 6-speed, constant mesh |
| Clutch: | Hydraulically operated, wet multi-plate clutch |
| Features | |
| Gear Ratios: | Specific ratios detailed within the manual for each gear. |
| Final Drive: | O-ring sealed chain |
| Dimensions | |
| Exterior | |
| Length Approx: | 2050 mm (80.7 in) - varies by model variant |
| Width Approx: | 720 mm (28.3 in) - varies by model variant |
| Height Approx: | 1150 mm (45.3 in) - varies by model variant |
| Weights | |
| Dry Weight Approx: | 195 kg (430 lbs) - varies by model variant |
| Fuel Tank Capacity: | 21 liters (5.5 US gal) |
| Safety Features | |
| Active Features | |
| Brakes: | Dual front disc brakes, single rear disc brake. |
| Suspension: | Adjustable front forks and rear shock absorber for improved stability and control. |
| Passive Features | |
| Lighting: | Dual headlights for improved night visibility. |
| Frame: | Aluminum twin-spar frame providing rigidity and stability. |
| Technology Features | |
| Infotainment | |
| Features: | N/A (focus on performance and mechanicals, no digital infotainment system typical of modern bikes). |
| Driver Assistance | |
| Features: | N/A (no electronic rider aids like ABS or traction control common on this era of performance bike). |
| Connectivity | |
| Features: | N/A (no electronic connectivity features). |
| Maintenance | |
| Service Intervals | |
| Oil Change: | Every 6,000 km (3,750 miles) or annually. |
| Air Filter Check: | Every 6,000 km (3,750 miles), replace as needed. |
| Spark Plug Check: | Every 12,000 km (7,500 miles), replace as needed. |
| Coolant Flush: | Every 24,000 km (15,000 miles) or every two years. |
| Brake Fluid Flush: | Every 24,000 km (15,000 miles) or every two years. |
| Fluid Specifications | |
| Coolant: | Ethylene glycol-based antifreeze, 50% mixture with distilled water. |
| Brake Fluid: | DOT 4 hydraulic brake fluid. |
| Fork Oil: | Specific viscosity and quantity detailed in the manual (e.g., Showa SS-02 or equivalent). |
| Known Issues | |
| Electrical Gremlins: | Common issues with wiring harness integrity and stator failures, as detailed in troubleshooting sections. |
| Cam Chain Tensioner: | Potential wear on automatic cam chain tensioners, requiring periodic inspection or replacement with manual units. |
| Regulator Rectifier: | Tendency for early regulator/rectifier units to overheat and fail, impacting charging system. |
| Vehicle History | |
| Brand Heritage | |
| Manufacturer: | Aprilia is an Italian manufacturer known for its performance-oriented motorcycles. |
| Model Evolution | |
| Launch Year: | RSV Mille launched in 1997, RST Futura derived from it in 1999. |
| Key Updates During Period: | Improvements to ECU mapping, suspension components, and minor styling updates across the model years. |
| Production | |
| Manufacturing Location: | Italy |
| Awards & Recognition | |
| Recognitions | |
| General: | The RSV Mille was critically acclaimed for its performance, handling, and V-twin character upon release. |