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2002 Aprilia RST Mille Motorcycle Service Repair Manual

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🏷️ Basic Information Identification Make: Aprilia Model: RST Mille Year: 2002 Generation Model Generation: First Generation (RSV Mille derived) Codes Chassis Code: RP (refer to specific VIN) 👋 Introduction Market Position Segment: Sport Touring / GT (Grand Tourer) Target Audience: Riders seeking a comfortable yet powerful motorcycle for long-distance touring and sporty riding Competitive Analysis Key Competitors Era: Honda VFR800, Yamaha FZ1, Suzuki Bandit 1200/1250, Kawasaki ZZR1200, Ducati ST series Key Features Engine Layout: V-Twin (providing strong torque and character) Chassis Design: Aluminum twin-spar frame for rigidity and light weight Suspension Quality: Often equipped with high-quality, adjustable suspension components Braking System: Powerful dual front disc brakes with radial-mount calipers 📋 Manual Details Coverage Areas Systems Covered Overview: Engine, Fuel System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Maintenance, Troubleshooting Page Count Estimated Page Count: 300+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Aprilia Rotax 60-degree V-Twin, 998cc (detailed internal components, cooling system, lubrication) Fuel System: Fuel injection system (EFI), throttle bodies, injectors, fuel pump, fuel pressure regulator Ignition System: ECU controlled ignition, spark plugs, ignition coils Electrical System: Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instrumentation Exhaust System: Catalytic converter (if applicable), mufflers, exhaust pipe routing and mounting Transmission: 6-speed sequential gearbox, clutch operation, lubrication Suspension Front: Upside-down telescopic forks (e.g., Öhlins or Showa depending on sub-model), adjustment procedures, seal replacement Suspension Rear: Monoshock rear suspension, linkage system, adjustment procedures, shock absorber rebuild Brakes Front: Dual disc brakes, Brembo calipers (likely radial mount), master cylinders, brake lines, pad replacement, bleeding procedures Brakes Rear: Single disc brake, caliper, master cylinder, brake lines, pad replacement, bleeding procedures Wheels Tires: Wheel bearing inspection and replacement, tire fitting and balancing Frame Chassis: Aluminum twin-spar frame, subframe, steering head bearings Bodywork: Fairings, fuel tank, seat, tail section, mounting hardware, disassembly and reassembly Procedures Included Engine Rebuild: Complete engine tear-down, component inspection, reassembly, piston, cylinder, valve service Routine Maintenance: Oil and filter changes, air filter service, chain lubrication and adjustment, spark plug replacement, coolant flush Troubleshooting: Diagnostic procedures for common electrical, fuel, and mechanical issues Suspension Adjustment: Sag adjustment, damping and preload settings Brake System Service: Bleeding, pad and rotor replacement, caliper overhaul Electrical Diagnostics: Fault finding using wiring diagrams, testing components Fuel Injection Tuning: Basic troubleshooting and adjustment of EFI system Technical Depth Depth Of Coverage: Comprehensive (covers everything from routine maintenance to complete engine and chassis rebuilds) Diagnostic Focus: Detailed troubleshooting flowcharts and symptom-based diagnostics Repair Information: Step-by-step repair procedures with accompanying diagrams Component Diagrams: Exploded views and part identification for all major assemblies 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text (if scanned correctly) Print Quality Image Resolution: High-resolution scans suitable for printing Binding Type Binding Type Digital: N/A (Digital) Paper Type Paper Type Digital: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, four-stroke, 60-degree V-Twin Displacement: 998 cc (998 cubic centimeters) Bore X Stroke: 97 mm x 68 mm (approximate, verify with manual) Valve Train: DOHC (Double Overhead Camshafts), 4 valves per cylinder Compression Ratio: 10.5:1 (approximate, verify with manual) Performance Horsepower: ~130 HP (approximate, verify with manual for specific tuning) Torque: ~100 Nm (approximate, verify with manual for specific tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Weber Marelli or similar Fuel Type: Unleaded gasoline, minimum 95 RON Cooling System Cooling Method: Liquid-cooled Coolant Type: Ethylene glycol based coolant (specific Aprilia or equivalent) Lubrication System Oil Capacity: ~3.8 Liters (check manual for exact specification and filter change) Oil Specification: Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (verify manual recommendation) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh, sequential gearbox Optional Optional Transmission: N/A (standard for this model) Features Clutch Type: Hydraulically operated, wet multi-plate clutch Final Drive: Chain drive Gear Ratios: Specific gear ratios will be detailed in the manual 📐 Dimensions Exterior Length: Approx. 2100 mm (verify with manual) Width: Approx. 800 mm (verify with manual) Height: Approx. 1200 mm (verify with manual) Weights Dry Weight: Approx. 205 kg (verify with manual) Wet Weight: Approx. 225 kg (with fluids, verify with manual) Fuel Tank Capacity: Approx. 21 Liters (verify with manual) 🛡️ Safety Features Ratings Safety Ratings: Motorcycles are not subject to standard automotive crash test ratings. Safety depends on rider skill and adherence to maintenance. Active Features Braking System Type: High-performance hydraulic disc brakes (front and rear) Optional ABS: ABS was typically an optional feature on some 2002 models, confirm with VIN. Passive Features Lighting: Full lighting system (headlight, taillight, turn signals, brake lights) Chassis Integrity: Rigid aluminum frame designed for stability 💡 Technology Features Infotainment Infotainment System: N/A (Motorcycle of this era typically did not feature complex infotainment systems) Driver Assistance ABS Availability: Optional ABS (Anti-lock Braking System) may be present...
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2002 Aprilia RST Mille Motorcycle Service Repair Manual
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RST Mille
Year:
2002
Generation
Model Generation:
First Generation (RSV Mille derived)
Codes
Chassis Code:
RP (refer to specific VIN)
👋 Introduction
Market Position
Segment:
Sport Touring / GT (Grand Tourer)
Target Audience:
Riders seeking a comfortable yet powerful motorcycle for long-distance touring and sporty riding
Competitive Analysis
Key Competitors Era:
Honda VFR800, Yamaha FZ1, Suzuki Bandit 1200/1250, Kawasaki ZZR1200, Ducati ST series
Key Features
Engine Layout:
V-Twin (providing strong torque and character)
Chassis Design:
Aluminum twin-spar frame for rigidity and light weight
Suspension Quality:
Often equipped with high-quality, adjustable suspension components
Braking System:
Powerful dual front disc brakes with radial-mount calipers
📋 Manual Details
Coverage Areas
Systems Covered Overview:
Engine, Fuel System, Electrical System, Chassis, Suspension, Brakes, Bodywork, Maintenance, Troubleshooting
Page Count
Estimated Page Count:
300+
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Aprilia Rotax 60-degree V-Twin, 998cc (detailed internal components, cooling system, lubrication)
Fuel System:
Fuel injection system (EFI), throttle bodies, injectors, fuel pump, fuel pressure regulator
Ignition System:
ECU controlled ignition, spark plugs, ignition coils
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), starter motor, lighting, instrumentation
Exhaust System:
Catalytic converter (if applicable), mufflers, exhaust pipe routing and mounting
Transmission:
6-speed sequential gearbox, clutch operation, lubrication
Suspension Front:
Upside-down telescopic forks (e.g., Öhlins or Showa depending on sub-model), adjustment procedures, seal replacement
Suspension Rear:
Monoshock rear suspension, linkage system, adjustment procedures, shock absorber rebuild
Brakes Front:
Dual disc brakes, Brembo calipers (likely radial mount), master cylinders, brake lines, pad replacement, bleeding procedures
Brakes Rear:
Single disc brake, caliper, master cylinder, brake lines, pad replacement, bleeding procedures
Wheels Tires:
Wheel bearing inspection and replacement, tire fitting and balancing
Frame Chassis:
Aluminum twin-spar frame, subframe, steering head bearings
Bodywork:
Fairings, fuel tank, seat, tail section, mounting hardware, disassembly and reassembly
Procedures Included
Engine Rebuild:
Complete engine tear-down, component inspection, reassembly, piston, cylinder, valve service
Routine Maintenance:
Oil and filter changes, air filter service, chain lubrication and adjustment, spark plug replacement, coolant flush
Troubleshooting:
Diagnostic procedures for common electrical, fuel, and mechanical issues
Suspension Adjustment:
Sag adjustment, damping and preload settings
Brake System Service:
Bleeding, pad and rotor replacement, caliper overhaul
Electrical Diagnostics:
Fault finding using wiring diagrams, testing components
Fuel Injection Tuning:
Basic troubleshooting and adjustment of EFI system
Technical Depth
Depth Of Coverage:
Comprehensive (covers everything from routine maintenance to complete engine and chassis rebuilds)
Diagnostic Focus:
Detailed troubleshooting flowcharts and symptom-based diagnostics
Repair Information:
Step-by-step repair procedures with accompanying diagrams
Component Diagrams:
Exploded views and part identification for all major assemblies
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Searchable text (if scanned correctly)
Print Quality
Image Resolution:
High-resolution scans suitable for printing
Binding Type
Binding Type Digital:
N/A (Digital)
Paper Type
Paper Type Digital:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, 60-degree V-Twin
Displacement:
998 cc (998 cubic centimeters)
Bore X Stroke:
97 mm x 68 mm (approximate, verify with manual)
Valve Train:
DOHC (Double Overhead Camshafts), 4 valves per cylinder
Compression Ratio:
10.5:1 (approximate, verify with manual)
Performance
Horsepower:
~130 HP (approximate, verify with manual for specific tuning)
Torque:
~100 Nm (approximate, verify with manual for specific tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Weber Marelli or similar
Fuel Type:
Unleaded gasoline, minimum 95 RON
Cooling System
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol based coolant (specific Aprilia or equivalent)
Lubrication System
Oil Capacity:
~3.8 Liters (check manual for exact specification and filter change)
Oil Specification:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50 (verify manual recommendation)
🔧 Transmission
Standard
Transmission Type:
6-speed, constant mesh, sequential gearbox
Optional
Optional Transmission:
N/A (standard for this model)
Features
Clutch Type:
Hydraulically operated, wet multi-plate clutch
Final Drive:
Chain drive
Gear Ratios:
Specific gear ratios will be detailed in the manual
📐 Dimensions
Exterior
Length:
Approx. 2100 mm (verify with manual)
Width:
Approx. 800 mm (verify with manual)
Height:
Approx. 1200 mm (verify with manual)
Weights
Dry Weight:
Approx. 205 kg (verify with manual)
Wet Weight:
Approx. 225 kg (with fluids, verify with manual)
Fuel Tank Capacity:
Approx. 21 Liters (verify with manual)
🛡️ Safety Features
Ratings
Safety Ratings:
Motorcycles are not subject to standard automotive crash test ratings. Safety depends on rider skill and adherence to maintenance.
Active Features
Braking System Type:
High-performance hydraulic disc brakes (front and rear)
Optional ABS:
ABS was typically an optional feature on some 2002 models, confirm with VIN.
Passive Features
Lighting:
Full lighting system (headlight, taillight, turn signals, brake lights)
Chassis Integrity:
Rigid aluminum frame designed for stability
💡 Technology Features
Infotainment
Infotainment System:
N/A (Motorcycle of this era typically did not feature complex infotainment systems)
Driver Assistance
ABS Availability:
Optional ABS (Anti-lock Braking System) may be present on some models.
Instrumentation
Instrument Cluster:
Analog tachometer, digital speedometer, odometer, trip meters, fuel gauge, coolant temperature, warning lights.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually (verify with manual)
Valve Check Interval:
Typically every 10,000 - 15,000 km (critical for V-Twins)
Chain Maintenance:
Lubricate and adjust chain every 500-1000 km or after riding in wet conditions.
Fluid Specifications
Engine Oil Viscosity:
SAE 10W-40 or 15W-50 (fully synthetic)
Coolant Type:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic clutch)
Known Issues
Common Issue 1:
Stator or regulator/rectifier failure (common on many Aprilias of this era)
Common Issue 2:
Fueling issues related to aging fuel pump or clogged injectors
Common Issue 3:
Cam chain tensioner wear (especially on earlier Rotax V990 engines)
Common Issue 4:
Vibration at certain RPMs, though generally manageable for a V-Twin
📚 Vehicle History
Brand Heritage
Manufacturer:
Aprilia is an Italian manufacturer known for its performance-oriented motorcycles, particularly in racing.
Model Evolution
Lineage:
The RST Mille (often referred to as the 'Falco' or 'SL1000 Falco' for this specific touring variant) is derived from the sport-focused RSV Mille platform. It adapts the engine and chassis for improved comfort and touring capability.
Positioning In Lineup:
The RST Mille offered a sport-touring alternative to Aprilia's more aggressive RSV Mille and Tuono models.
Production
Production Years:
The SL1000 Falco (RST Mille equivalent) was produced from 2000 to 2005.
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Manufacturer Awards:
Aprilia has a strong racing heritage and numerous championship wins, reflecting their engineering prowess.
Ratings
Review Ratings:
Contemporary reviews often praised the RST Mille's performance, handling, and V-twin character, though some noted Aprilia's less established dealer network and potential for minor electrical gremlins compared to Japanese rivals.
Certifications
Emissions Certification:
Euro 2 compliant (for European markets)
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