Aprilia RST Mille 2000-2005 Workshop Service Manual Repair
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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Model Designation: RST1000 Futura Covered Years: 2000, 2001, 2002, 2003, 2004, 2005 Codes Vin Code Vehicle Year 1: X Vin Code Vehicle Year 2: Y Vin Code Vehicle Year 3: 1 Vin Code Vehicle Year 4: 2 Vin Code Vehicle Year 5: 3 👋 Introduction Market Position Category: Sport Touring Motorcycle Target Audience: Riders seeking a versatile motorcycle for longer journeys with sporty performance. Competitive Analysis Competitors: Honda VFR800, Yamaha FJR1300, Kawasaki GTR1000, BMW R1100/1150RT. Key Features Design Philosophy: Blend of sporty handling with long-distance comfort and practicality. Distinctive Elements: Sharp styling, powerful V-twin engine, capable chassis. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English Format: PDF Download Page Count Estimated Page Count: High (typically 400-600 pages for this type of manual) 📖 Manual Coverage Systems Covered Engine: Complete disassembly, inspection, assembly, tuning, diagnostics for the V-twin engine. Fuel System: Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator. Ignition System: ECU, ignition coils, spark plugs, wiring diagrams. Cooling System: Radiator, coolant hoses, water pump, thermostat, fan operation. Transmission: Clutch operation, gear shifting mechanisms, gearbox internal components, lubrication. Chassis Frame: Frame construction, mounting points, inspection. Suspension Front: Telescopic forks, damping adjustments, seals, fork oil specifications, steering head bearings. Suspension Rear: Monoshock rear suspension, linkage, swingarm, adjustments, pivot bearings. Brakes Front: Brake calipers (likely Brembo), master cylinder, brake fluid type and bleeding, disc inspection. Brakes Rear: Rear brake caliper, master cylinder, brake fluid, disc inspection. Wheels Tires: Wheel bearings, tire pressure, mounting and balancing. Electrical System: Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, horn, fuses, relays. Instrumentation: Dashboard, gauges, warning lights, speed sensor, tachometer. Bodywork Fairings: Removal and installation of fairings, seat, fuel tank, body panel repairs. Exhaust System: Exhaust manifold, mufflers, catalytic converter (if applicable), gasket replacement. Controls: Throttle cables, clutch cable, brake levers, gear shift linkage. Diagnostics: Troubleshooting guides, fault codes (if applicable), diagnostic procedures. Procedures Included Preventative Maintenance: Scheduled maintenance, fluid changes, filter replacements, chain adjustment. Troubleshooting: Step-by-step guides for diagnosing common and uncommon problems. Engine Repair: Complete engine rebuild procedures, piston, rings, cylinder head service, valve adjustment. Transmission Repair: Clutch replacement, gearbox disassembly and reassembly. Suspension Overhaul: Fork seal replacement, shock absorber service, bearing replacement. Brake System Service: Brake fluid flush, caliper rebuilding, pad replacement. Electrical Diagnostics And Repair: Wiring harness repair, component testing, charging system diagnosis. Bodywork Refinishing: Fairing repair, panel alignment, mounting procedures. Technical Depth Depth: Comprehensive; covers basic maintenance to full engine and chassis rebuilds. Detail Level: Detailed exploded diagrams, torque specifications, service limits. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Likely searchable if professionally scanned, but depends on the source. Print Quality Image Clarity: High resolution diagrams and illustrations expected for a quality service manual. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90-degree V-twin Displacement: 998 cc Bore X Stroke: 97 mm x 68 mm Valvetrain: DOHC, 4 valves per cylinder Compression Ratio: 10.8:1 Performance Horsepower Est: 115-125 hp @ 8500 rpm (approx.) Torque Est: 9.8-10.3 kgm @ 7000 rpm (approx.) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with twin injectors per cylinder Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 21 Liters (approx.) 🔧 Transmission Standard Type: 6-speed sequential Clutch: Wet multi-plate, hydraulic actuation Features Final Drive: O-ring sealed chain 📐 Dimensions Exterior Length Est: 2150 mm (approx.) Width Est: 780 mm (approx.) Height Est: 1280 mm (approx.) Wheelbase Est: 1445 mm (approx.) Weights Dry Weight Est: 210 kg (approx.) Wet Weight Est: 230 kg (approx.) 🛡️ Safety Features Ratings Safety Features: Integral braking system (linked front and rear brakes, though some models might have linked options). Active Features Braking System: Dual 320mm discs with 4-piston calipers (front), Single 270mm disc with 2-piston caliper (rear). Brembo components common. Passive Features Lighting: Halogen headlights, LED taillight. 💡 Technology Features Infotainment Dashboard: Analog tachometer, digital speedometer, odometer, trip meters, clock, fuel gauge, temperature gauge, warning lights. Driver Assistance Braking System Design: Optional integrated braking system (linked front/rear brakes on some configurations). 🔧 Maintenance Service Intervals Oil Change: Every 5,000 - 6,000 km or annually, whichever comes first. Air Filter: Inspect every 6,000 km, replace as needed or every 12,000 km. Spark Plugs: Replace every 12,000 - 18,000 km (depending on plug type). Valve Clearance: Check every 12,000 - 18,000 km. Brake Fluid Flush: Every 2 years or as per manual. Coolant Flush: Every 2-3 years or as per manual. Fluid Specifications Engine Oil: SAE 10W-40 API SG or higher, or JASO MA certified. Engine Oil Capacity: Approx. 3.8 Liters without filter change, 4.0 Liters with filter change. Coolant: 50/50 mixture of ethylene glycol coolant and distilled water. Brake Fluid: DOT 4. Fork...
Comprehensive; covers basic maintenance to full engine and chassis rebuilds.
Detail Level:
Detailed exploded diagrams, torque specifications, service limits.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Likely searchable if professionally scanned, but depends on the source.
Print Quality
Image Clarity:
High resolution diagrams and illustrations expected for a quality service manual.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90-degree V-twin
Displacement:
998 cc
Bore X Stroke:
97 mm x 68 mm
Valvetrain:
DOHC, 4 valves per cylinder
Compression Ratio:
10.8:1
Performance
Horsepower Est:
115-125 hp @ 8500 rpm (approx.)
Torque Est:
9.8-10.3 kgm @ 7000 rpm (approx.)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with twin injectors per cylinder
Fuel Type:
Unleaded gasoline (95 RON recommended)
Fuel Tank Capacity:
21 Liters (approx.)
🔧 Transmission
Standard
Type:
6-speed sequential
Clutch:
Wet multi-plate, hydraulic actuation
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length Est:
2150 mm (approx.)
Width Est:
780 mm (approx.)
Height Est:
1280 mm (approx.)
Wheelbase Est:
1445 mm (approx.)
Weights
Dry Weight Est:
210 kg (approx.)
Wet Weight Est:
230 kg (approx.)
🛡️ Safety Features
Ratings
Safety Features:
Integral braking system (linked front and rear brakes, though some models might have linked options).
Active Features
Braking System:
Dual 320mm discs with 4-piston calipers (front), Single 270mm disc with 2-piston caliper (rear). Brembo components common.
Passive Features
Lighting:
Halogen headlights, LED taillight.
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, odometer, trip meters, clock, fuel gauge, temperature gauge, warning lights.
Driver Assistance
Braking System Design:
Optional integrated braking system (linked front/rear brakes on some configurations).
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 6,000 km or annually, whichever comes first.
Air Filter:
Inspect every 6,000 km, replace as needed or every 12,000 km.
Spark Plugs:
Replace every 12,000 - 18,000 km (depending on plug type).
Valve Clearance:
Check every 12,000 - 18,000 km.
Brake Fluid Flush:
Every 2 years or as per manual.
Coolant Flush:
Every 2-3 years or as per manual.
Fluid Specifications
Engine Oil:
SAE 10W-40 API SG or higher, or JASO MA certified.
Engine Oil Capacity:
Approx. 3.8 Liters without filter change, 4.0 Liters with filter change.
Coolant:
50/50 mixture of ethylene glycol coolant and distilled water.
Brake Fluid:
DOT 4.
Fork Oil:
Typically SAE 7.5W or 10W (refer to specific manual section for exact type and level).
Known Issues
Common Problems:
Regulator/rectifier failure (common on many Aprilias of this era), occasional electrical gremlins, rear shock absorber wear, clutch slave cylinder leaks.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its racing heritage and performance motorcycles.
Model Evolution
Predecessor:
The RST Mille was based on the RSV Mille sportbike platform, adapted for sport-touring.
Successor:
The model was later succeeded by updated Aprilia sport-touring offerings.
Production
Manufacturing Location:
Italy
Production Period:
Launched in 1999/2000, production ran until around 2003/2004 for this specific iteration, with minor updates for the later covered years.
🏆 Awards & Recognition
Recognitions
Industry Reviews:
Generally well-received for its performance and touring capabilities, though Aprilia's reliability was sometimes a point of discussion compared to Japanese rivals.