Aprilia RSV Mille 1998-2004 Online Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Generation: First Generation (SL1000) Codes Product Code: N/A (Digital Product) 👋 Introduction Market Position Segment: High-performance sportbike Competitive Analysis Key Competitors: Ducati 916/996, Honda CBR900RR, Yamaha YZF-R1, Suzuki GSX-R750/1100, Kawasaki ZX-9R Key Features Engine Layout: V-Twin, offering strong torque and a distinctive power delivery Frame Design: Aluminum twin-spar frame for rigidity and light weight Suspension: High-quality adjustable front forks and rear monoshock, often from Öhlins or Showa Braking Performance: Powerful dual front disc brakes with radial-mount calipers, typically Brembo 📋 Manual Details Coverage Areas Years Covered: 1998, 1999, 2000, 2001, 2002, 2003, 2004 Page Count Estimated Page Count: Approximately 600-800 pages (typical for comprehensive motorcycle service manuals) Manual Type Type: Service Repair Manual / Workshop Manual Language Language: English Format File Format: PDF (compressed with WinRAR) 📖 Manual Coverage Systems Covered Engine: V-Twin engine disassembly, assembly, inspection, tuning, performance diagnostics Fuel Lubrication: Fuel injection system, carburetors (if applicable to specific sub-models), fuel pump, fuel filters, oil pump, lubrication system, oil capacity, oil specifications Cooling System: Radiator, cooling fan, coolant types, coolant capacity, thermostat, water pump, bleed procedures Electrical System: Wiring diagrams, ignition system, starting system, charging system, lighting, battery specifications, ECU troubleshooting, sensor diagnostics Chassis: Frame inspection, front fork (suspension), rear shock absorber, steering system, wheel bearings, swingarm, chain drive system Braking System: Front and rear brake calipers, master cylinders, brake lines, brake fluid specifications, bleeding procedures, rotor and pad inspection Bodywork And Trim: Fairing removal and installation, seat, fuel tank, fenders, decals, fasteners Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, tire pressure checks, spark plug replacement, valve clearance checks Tune Up: Engine tuning, idle speed adjustment, fuel mixture adjustments Troubleshooting: Diagnostic charts, common fault identification, step-by-step problem solving Repair And Rebuild: Detailed instructions for engine rebuilds, transmission repairs, suspension overhauls, electrical component replacement Updates And Modifications: Information on factory updates, recall procedures, and potential modifications Technical Depth Depth: Comprehensive. Covers everything from basic maintenance to full engine and component overhauls, including torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format Compression Format: WinRAR Main Document Format: PDF Print Quality Printability: High quality for printing, suitable for workshop environments. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Compatibility Operating Systems: Win95/98/ME/XP/vista/7/8/Linux/MAC, iOS, Android ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 90-degree V-Twin, four-stroke Displacement: 998cc (for most models) Bore X Stroke: 97 x 67.5 mm (typical) Valve Train: DOHC, 4 valves per cylinder Performance Horsepower: Approx. 125-130 hp at the crank (depending on year and specific tune) Torque: Approx. 70-75 lb-ft at the crank (depending on year and specific tune) Fuel System Fuel Delivery: Fuel Injection (EFI) - various iterations throughout the years, often with dual injectors per cylinder Fuel Type: Unleaded gasoline, minimum 95 RON Lubrication Oil Type: High-quality synthetic motorcycle oil, e.g., 10W-40 or 15W-50 API SG or higher (refer to manual for exact specification) Cooling Cooling Medium: Ethylene glycol based coolant (50% mix with distilled water) 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Hydraulically actuated wet multi-plate clutch Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length: Approx. 2030 mm (80 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1150 mm (45.3 in) Wheelbase: Approx. 1415 mm (55.7 in) Weights Dry Weight: Approx. 190 kg (419 lbs) Wet Weight: Approx. 205 kg (452 lbs) Tires Front Tire: 120/70ZR17 Rear Tire: 190/50ZR17 🛡️ Safety Features Ratings Crash Safety Rating: N/A (Motorcycle - focus is on rider protection via design) Active Features Braking: Powerful Brembo radial-mount front calipers, rear disc brake Suspension: Adjustable front forks and rear shock for optimal handling and stability Passive Features Chassis Integrity: Robust aluminum twin-spar frame designed for high-speed stability Lighting: Dual headlights for improved visibility 💡 Technology Features Infotainment Instrument Cluster: Analog tachometer and speedometer, digital odometer, trip meters, coolant temperature gauge, clock, warning lights Driver Assistance ABS: Not standard on most early models; optional on some later variants or specific markets. Connectivity Diagnostic Ports: On-board diagnostics (OBD) port for electronic troubleshooting (location and protocol may vary by year). 🔧 Maintenance Service Intervals Oil Change: Every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first (refer to manual) Valve Clearance Check: Typically every 10,000-12,000 km (6,000-7,500 miles) Chain Lubrication Adjustment: Regularly, every 500-1000 km (300-600 miles), and check tension before every ride Fluid Specifications Brake Fluid: DOT 4 (refer to manual for specific brand recommendations) Coolant: 50% Ethylene Glycol and Distilled Water mixture Engine Oil Capacity: Approx. 3.5 - 4.0 liters (3.7 - 4.2 US quarts) with filter change (refer to manual) Known Issues Common Problems: Stator failures, regulator/rectifier issues, occasional fuel pump issues, cam chain tensioner wear, valve guide wear (especially on early models), electrical connector corrosion. Preventative Maintenance Tips: Regularly inspect electrical connectors, ensure proper charging system function,...
Information on factory updates, recall procedures, and potential modifications
Technical Depth
Depth:
Comprehensive. Covers everything from basic maintenance to full engine and component overhauls, including torque specifications, clearances, and diagnostic procedures.
📊 Manual Specifications
File Format
Compression Format:
WinRAR
Main Document Format:
PDF
Print Quality
Printability:
High quality for printing, suitable for workshop environments.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Compatibility
Operating Systems:
Win95/98/ME/XP/vista/7/8/Linux/MAC, iOS, Android
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, 90-degree V-Twin, four-stroke
Displacement:
998cc (for most models)
Bore X Stroke:
97 x 67.5 mm (typical)
Valve Train:
DOHC, 4 valves per cylinder
Performance
Horsepower:
Approx. 125-130 hp at the crank (depending on year and specific tune)
Torque:
Approx. 70-75 lb-ft at the crank (depending on year and specific tune)
Fuel System
Fuel Delivery:
Fuel Injection (EFI) - various iterations throughout the years, often with dual injectors per cylinder
Fuel Type:
Unleaded gasoline, minimum 95 RON
Lubrication
Oil Type:
High-quality synthetic motorcycle oil, e.g., 10W-40 or 15W-50 API SG or higher (refer to manual for exact specification)
Cooling
Cooling Medium:
Ethylene glycol based coolant (50% mix with distilled water)
🔧 Transmission
Standard
Type:
6-speed constant mesh
Clutch:
Hydraulically actuated wet multi-plate clutch
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2030 mm (80 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1150 mm (45.3 in)
Wheelbase:
Approx. 1415 mm (55.7 in)
Weights
Dry Weight:
Approx. 190 kg (419 lbs)
Wet Weight:
Approx. 205 kg (452 lbs)
Tires
Front Tire:
120/70ZR17
Rear Tire:
190/50ZR17
🛡️ Safety Features
Ratings
Crash Safety Rating:
N/A (Motorcycle - focus is on rider protection via design)
Active Features
Braking:
Powerful Brembo radial-mount front calipers, rear disc brake
Suspension:
Adjustable front forks and rear shock for optimal handling and stability
Passive Features
Chassis Integrity:
Robust aluminum twin-spar frame designed for high-speed stability
Lighting:
Dual headlights for improved visibility
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, digital odometer, trip meters, coolant temperature gauge, clock, warning lights
Driver Assistance
ABS:
Not standard on most early models; optional on some later variants or specific markets.
Connectivity
Diagnostic Ports:
On-board diagnostics (OBD) port for electronic troubleshooting (location and protocol may vary by year).
🔧 Maintenance
Service Intervals
Oil Change:
Every 4,000-6,000 km (2,500-3,700 miles) or annually, whichever comes first (refer to manual)
Valve Clearance Check:
Typically every 10,000-12,000 km (6,000-7,500 miles)
Chain Lubrication Adjustment:
Regularly, every 500-1000 km (300-600 miles), and check tension before every ride
Fluid Specifications
Brake Fluid:
DOT 4 (refer to manual for specific brand recommendations)
Coolant:
50% Ethylene Glycol and Distilled Water mixture
Engine Oil Capacity:
Approx. 3.5 - 4.0 liters (3.7 - 4.2 US quarts) with filter change (refer to manual)
Regularly inspect electrical connectors, ensure proper charging system function, use high-quality fluids, maintain clean air filters, and address any unusual noises promptly.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Model Evolution
Introduction Year:
1998
Key Changes 1998-2004:
Updates included ECU mapping, fuel injection system refinements, minor chassis tweaks, and styling updates. Some models may have featured upgraded suspension components.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Highly praised by motorcycle journalists for its potent V-Twin engine, strong performance, and handling capabilities upon its release.