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2002-2003 Aprilia RST Mille Service Repair Workshop Manual (2002 2003)

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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Model Variant: RST 1000 Futura Model Nickname: Futura Generation Generation Code: RSV Mille based Codes Chassis Codes: APRC00 (pre-facelift), APRC01 (facelift) Engine Codes: Rotax V990 👋 Introduction Market Position Category: Sport Touring Motorcycle Target Audience: Enthusiast riders, DIY mechanics, independent workshops Competitive Analysis Competitors 2002 2003: Honda VFR800 VTEC, Yamaha FZ1, Suzuki GSX1250FA (though later), Kawasaki ZZ-R1100/1200 Key Features Vehicle Sport Touring Blend: Combines sportbike performance with long-distance comfort Engine Configuration: V-Twin architecture for strong torque and character Aerodynamics: Integrated fairings for wind protection and stability Key Features Manual Value Proposition: Empowers owners and technicians with in-depth knowledge for maintenance and repair Diagrams: High-quality, detailed diagrams and illustrations 📋 Manual Details Coverage Areas Years Covered: 2002, 2003 Trim Levels Covered: All Aprilia RST Mille / Futura models Page Count Estimated Pages: Approximately 700+ Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Exhaust System, Ignition System, Cooling System Chassis: Frame, Front Suspension (Forks), Rear Suspension (Shock Absorber), Steering, Wheels, Tires Drivetrain: Clutch, Transmission (Gearbox), Final Drive (Chain) Brakes: Front Brakes (Dual Discs, Calipers), Rear Brakes (Single Disc, Caliper), Brake Lines, Master Cylinders, ABS (if applicable) Electrical: Wiring Diagrams, Lighting System, Battery, Charging System (Alternator, Regulator), Starter Motor, ECU (Engine Control Unit), Sensors, Dashboard Instruments Bodywork: Fairings, Seat, Fuel Tank, Body Panels, Fasteners, Graphics Procedures Included Maintenance: Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Coolant Flush, Brake Fluid Flush Troubleshooting: Diagnostic codes, symptom-based troubleshooting, electrical system diagnosis Repair: Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement Disassembly Assembly: Complete motorcycle disassembly and reassembly procedures Technical Depth Depth: Comprehensive: from routine maintenance to full engine and transmission rebuilds Diagnostics: Detailed diagnostic procedures, including electrical troubleshooting with wiring diagrams Specifications: Torque specifications, clearances, fluid types and capacities, electrical values 📊 Manual Specifications File Format Quality: High-resolution scans, clear text, searchable Searchability: Full text search enabled Print Quality Recommendation: Suitable for home printing of specific sections Binding Type Digital Format: PDF Paper Type Digital Format: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, liquid-cooled, 90-degree V-Twin Displacement: 997.6 cc Bore X Stroke: 97 mm x 67.5 mm Valve Train: DOHC, 4 valves per cylinder Compression Ratio: 10.8:1 Performance Horsepower Claimed: Approx. 130 HP @ 9,200 rpm Torque Claimed: Approx. 98 Nm (72 lb-ft) @ 7,000 rpm Fuel System Fuel Delivery: Fuel Injection (Weber Marelli or Keihin, depending on market/revision) Throttle Body Size: 48 mm Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating) Ignition System Ignition Type: Electronic ignition system with digital ignition control Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol-based antifreeze/coolant (e.g., Motul Motocool Expert, Castrol Radicool-SF) Coolant Capacity: Approx. 2.8 Liters (including expansion tank) 🔧 Transmission Standard Transmission Type: 6-speed manual Clutch Type: Hydraulically operated, wet multi-plate clutch Final Drive: Chain drive Transmission Oil Fluid Type: API GL-4 or GL-5, SAE 80W-90 hypoid gear oil (e.g., Motul Gear 300 75W-90, Castrol EPX 80W-90) Capacity: Approx. 0.8 - 0.9 Liters (check level via sight glass or fill plug) 📐 Dimensions Exterior Length: Approx. 2,140 mm (84.3 in) Width: Approx. 760 mm (30 in) Height: Approx. 1,250 mm (49.2 in) Wheelbase: Approx. 1,445 mm (56.9 in) Weights Dry Weight: Approx. 210 kg (463 lbs) Wet Weight: Approx. 230 kg (507 lbs) (fully fueled) Cargo Luggage Capacity: Integrated pannier mounting points, optional luggage solutions available 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycle safety ratings are not standardized like cars) Active Features Braking System: Powerful twin 320mm front discs with 4-piston radial calipers, 220mm rear disc with 2-piston caliper. Optional ABS (Anti-lock Braking System) may be available on certain models/markets. Lighting: Dual Halogen Headlights, LED Taillight Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and light weight Ergonomics: Adjustable ergonomics for rider comfort on long journeys 💡 Technology Features Infotainment Dashboard: Analog tachometer, digital speedometer, LCD multi-function display showing fuel level, engine temperature, clock, trip meters, and diagnostic warnings. Driver Assistance ABS: Optional ABS system available on certain market variants. Connectivity ECU: Engine Control Unit (ECU) for managing fuel injection, ignition timing, and other engine parameters. Diagnostic port for ECU access. Lighting Headlight Type: Dual Halogen Taillight Type: LED 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 km (4,600 miles) or 12 months, whichever comes first. Oil Filter Replacement: With every oil change. Air Filter Service: Every 7,500 km (4,600 miles). Replacement if damaged or excessively dirty. Spark Plug Replacement: Every 15,000 km (9,300 miles). Coolant Replacement: Every 24 months (2 years). Chain Adjustment Lubrication: Every 1,000 km (600 miles) or more frequently if conditions demand. Fluid Specifications Engine Oil Type: SAE 10W-40 or 15W-50, API SG/SH/SJ, JASO MA/MA2 (e.g., Motul 5100 10W-40, Castrol...
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2002-2003 Aprilia RST Mille Service Repair Workshop Manual (2002 2003)
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RST Mille
Model Variant:
RST 1000 Futura
Model Nickname:
Futura
Generation
Generation Code:
RSV Mille based
Codes
Chassis Codes:
APRC00 (pre-facelift), APRC01 (facelift)
Engine Codes:
Rotax V990
👋 Introduction
Market Position
Category:
Sport Touring Motorcycle
Target Audience:
Enthusiast riders, DIY mechanics, independent workshops
Competitive Analysis
Competitors 2002 2003:
Honda VFR800 VTEC, Yamaha FZ1, Suzuki GSX1250FA (though later), Kawasaki ZZ-R1100/1200
Key Features Vehicle
Sport Touring Blend:
Combines sportbike performance with long-distance comfort
Engine Configuration:
V-Twin architecture for strong torque and character
Aerodynamics:
Integrated fairings for wind protection and stability
Key Features Manual
Value Proposition:
Empowers owners and technicians with in-depth knowledge for maintenance and repair
Diagrams:
High-quality, detailed diagrams and illustrations
📋 Manual Details
Coverage Areas
Years Covered:
2002, 2003
Trim Levels Covered:
All Aprilia RST Mille / Futura models
Page Count
Estimated Pages:
Approximately 700+
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Fuel System, Exhaust System, Ignition System, Cooling System
Chassis:
Frame, Front Suspension (Forks), Rear Suspension (Shock Absorber), Steering, Wheels, Tires
Drivetrain:
Clutch, Transmission (Gearbox), Final Drive (Chain)
Brakes:
Front Brakes (Dual Discs, Calipers), Rear Brakes (Single Disc, Caliper), Brake Lines, Master Cylinders, ABS (if applicable)
Electrical:
Wiring Diagrams, Lighting System, Battery, Charging System (Alternator, Regulator), Starter Motor, ECU (Engine Control Unit), Sensors, Dashboard Instruments
Bodywork:
Fairings, Seat, Fuel Tank, Body Panels, Fasteners, Graphics
Procedures Included
Maintenance:
Oil Changes, Filter Replacements, Chain Adjustment, Spark Plug Service, Air Filter Cleaning/Replacement, Coolant Flush, Brake Fluid Flush
Troubleshooting:
Diagnostic codes, symptom-based troubleshooting, electrical system diagnosis
Repair:
Engine Overhaul, Transmission Rebuild, Suspension Component Replacement, Brake System Repair, Electrical Component Replacement
Disassembly Assembly:
Complete motorcycle disassembly and reassembly procedures
Technical Depth
Depth:
Comprehensive: from routine maintenance to full engine and transmission rebuilds
Diagnostics:
Detailed diagnostic procedures, including electrical troubleshooting with wiring diagrams
Specifications:
Torque specifications, clearances, fluid types and capacities, electrical values
📊 Manual Specifications
File Format
Quality:
High-resolution scans, clear text, searchable
Searchability:
Full text search enabled
Print Quality
Recommendation:
Suitable for home printing of specific sections
Binding Type
Digital Format:
PDF
Paper Type
Digital Format:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90-degree V-Twin
Displacement:
997.6 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
10.8:1
Performance
Horsepower Claimed:
Approx. 130 HP @ 9,200 rpm
Torque Claimed:
Approx. 98 Nm (72 lb-ft) @ 7,000 rpm
Fuel System
Fuel Delivery:
Fuel Injection (Weber Marelli or Keihin, depending on market/revision)
Throttle Body Size:
48 mm
Fuel Type:
Unleaded gasoline, minimum 95 RON (Octane rating)
Ignition System
Ignition Type:
Electronic ignition system with digital ignition control
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based antifreeze/coolant (e.g., Motul Motocool Expert, Castrol Radicool-SF)
Coolant Capacity:
Approx. 2.8 Liters (including expansion tank)
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
Chain drive
Transmission Oil
Fluid Type:
API GL-4 or GL-5, SAE 80W-90 hypoid gear oil (e.g., Motul Gear 300 75W-90, Castrol EPX 80W-90)
Capacity:
Approx. 0.8 - 0.9 Liters (check level via sight glass or fill plug)
📐 Dimensions
Exterior
Length:
Approx. 2,140 mm (84.3 in)
Width:
Approx. 760 mm (30 in)
Height:
Approx. 1,250 mm (49.2 in)
Wheelbase:
Approx. 1,445 mm (56.9 in)
Weights
Dry Weight:
Approx. 210 kg (463 lbs)
Wet Weight:
Approx. 230 kg (507 lbs) (fully fueled)
Cargo
Luggage Capacity:
Integrated pannier mounting points, optional luggage solutions available
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A (Motorcycle safety ratings are not standardized like cars)
Active Features
Braking System:
Powerful twin 320mm front discs with 4-piston radial calipers, 220mm rear disc with 2-piston caliper. Optional ABS (Anti-lock Braking System) may be available on certain models/markets.
Lighting:
Dual Halogen Headlights, LED Taillight
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and light weight
Ergonomics:
Adjustable ergonomics for rider comfort on long journeys
💡 Technology Features
Infotainment
Dashboard:
Analog tachometer, digital speedometer, LCD multi-function display showing fuel level, engine temperature, clock, trip meters, and diagnostic warnings.
Driver Assistance
ABS:
Optional ABS system available on certain market variants.
Connectivity
ECU:
Engine Control Unit (ECU) for managing fuel injection, ignition timing, and other engine parameters. Diagnostic port for ECU access.
Lighting
Headlight Type:
Dual Halogen
Taillight Type:
LED
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 km (4,600 miles) or 12 months, whichever comes first.
Oil Filter Replacement:
With every oil change.
Air Filter Service:
Every 7,500 km (4,600 miles). Replacement if damaged or excessively dirty.
Spark Plug Replacement:
Every 15,000 km (9,300 miles).
Coolant Replacement:
Every 24 months (2 years).
Chain Adjustment Lubrication:
Every 1,000 km (600 miles) or more frequently if conditions demand.
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG/SH/SJ, JASO MA/MA2 (e.g., Motul 5100 10W-40, Castrol Power 1 10W-40)
Engine Oil Capacity:
Approx. 3.2 Liters (with filter change), 2.8 Liters (without filter change)
Brake Fluid Type:
DOT 4 (e.g., Motul DOT 4 Brake Fluid, Castrol React Performance DOT 4)
Known Issues
Common Problems:
Stator failure (rectifier/regulator issues), electrical connector corrosion, occasional cam chain tensioner noise, fuel pump issues, some instances of regulator failure. The manual will detail diagnostic procedures for these.
Maintenance Importance:
Regular maintenance is crucial for the longevity and reliability of the Rotax V-Twin engine and electrical system.
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer renowned for its sporting heritage, particularly in motorcycle racing (MotoGP, WSBK).
Model Evolution
Predecessor:
Derived from the RSV Mille sportbike platform, adapted for touring.
Key Changes 2002 2003:
Early models focused on RSV Mille adaptation; later models (often referred to as '01 or '02 on) received updates including revised fairings for better airflow, improved ECU mapping, and potentially suspension tweaks. The '02-'03 manual covers these refinements.
Production
Production Years:
2000-2004
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Generally praised for its potent engine, comfortable ergonomics for a sport-tourer, and distinctive styling. Competed in the 'all-rounder' sport-touring category.
Ratings
Reliability Reputation:
Reputation for strong performance but requires diligent maintenance, particularly regarding the electrical system.
Certifications
Emissions:
Meets Euro 2 emissions standards for its model years.
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