Aprilia RSV Mille 2000-2003 Factory Service Manual Repair
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Code: RP Year: 2000-2003 Codes Chassis Vin Prefix: ZDA... 👋 Introduction Market Position Segment: High-performance sportbike Reputation: Known for its potent V-twin engine, advanced chassis, and track-bred performance. Competitive Analysis Key Competitors: Ducati 916/996, Honda VTR1000F Firestorm, Suzuki TL1000R/S, Yamaha YZF-R1 (early models) Key Features Engine Design: Powerful Rotax-designed V-twin engine, delivering strong mid-range torque and top-end horsepower. Suspension Quality: Often equipped with premium Öhlins suspension components, offering superior adjustability and ride quality. Braking Performance: High-spec Brembo brakes providing exceptional stopping power and feel. Chassis Rigidity: Stiff and communicative aluminum twin-spar frame contributing to precise handling. 📋 Manual Details Coverage Areas Model Years Covered: 2000, 2001, 2002, 2003 Geographic Coverage: Global (specifications applicable to primary markets) Page Count Estimated Page Count: Approximately 500+ Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: V-Twin, 60-degree, 998cc liquid-cooled, DOHC, 4 valves per cylinder Fuel System: Mikuni BSR32 CV carburetors (early models), Aprilia/Dell'Orto Electronic Fuel Injection (later models/updates) Ignition System: Electronic Ignition System (CDI) Transmission: 6-speed sequential gearbox Clutch: Hydraulically actuated wet multi-plate clutch Cooling System: Liquid cooling with electric fan Exhaust System: Dual under-seat mufflers (stock) Frame: Aluminum twin-spar frame Suspension Front: Öhlins or Marzocchi USD forks, fully adjustable Suspension Rear: Öhlins or Sachs Monoshock, fully adjustable with progressive linkage Brakes Front: Dual 320mm discs, Brembo 4-piston radial calipers Brakes Rear: Single 220mm disc, Brembo 2-piston caliper Wheels: 3.50 x 17" front, 6.00 x 17" rear, Cast Aluminum Tires Front: 120/70 ZR17 Tires Rear: 190/50 ZR17 Electrical System: 12V system, charging system, lighting, starter Bodywork: Full fairing, tail section, seat, fuel tank Procedures Included Routine Maintenance: Oil change, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement Engine Overhaul: Top-end rebuild (cylinder head, valves), bottom-end rebuild (crankshaft, con-rods, pistons) Transmission Repair: Gearbox disassembly, inspection, and reassembly Fuel System Diagnosis And Repair: Carburetor tuning and overhaul, fuel injection system troubleshooting and component replacement Suspension Service: Fork seal replacement, shock absorber service, linkage maintenance Brake System Maintenance And Repair: Brake fluid flush, caliper rebuild, disc replacement, hose replacement Electrical Troubleshooting: Wiring diagrams, circuit testing, component diagnosis (stator, regulator/rectifier, ECU) Chassis And Bodywork Repair: Fairing repair, frame inspection, seat mounting, fuel tank removal/installation Torque Specifications: Detailed torque values for all critical fasteners Troubleshooting Guides: Problem-solving charts for common issues Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to full engine and transmission rebuilds. Suitable for professional technicians and experienced home mechanics. Diagnostic Information: Includes diagnostic procedures for fuel injection systems, ignition timing, and sensor testing. Special Tools: Lists and descriptions of specialized tools required for specific procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable for quick information retrieval Printability: Printable pages for physical reference Print Quality Image Resolution: High resolution for clear diagrams and illustrations Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: V-Twin, 60-degree Displacement: 998 cc (cc) Bore X Stroke: 97 x 67.5 mm (mm) Valve Train: DOHC, 4 valves per cylinder Cooling System: Liquid-cooled Performance Horsepower Peak: Approx. 128-130 hp (95-97 kW) @ 9,000 rpm Torque Peak: Approx. 98-100 Nm (72-74 lb-ft) @ 7,000 rpm Fuel System Fuel Delivery: Mikuni BSR32 CV carburetors or Electronic Fuel Injection (EFI) Fuel Type: Unleaded gasoline (95 RON recommended) Fuel Tank Capacity: 18 Liters (approx.) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch Type: Wet, multi-plate, hydraulic actuation Features Gear Ratios: Specific ratios detailed within the manual Final Drive: O-ring sealed chain Transmission Fluid: API SG or higher, SAE 10W-40 or 20W-50 (refer to manual for exact specification) 📐 Dimensions Exterior Length: Approx. 2060 mm (mm) Width: Approx. 740 mm (mm) Height: Approx. 1150 mm (mm) Wheelbase: Approx. 1415 mm (mm) Weights Dry Weight: Approx. 195 kg (kg) Wet Weight: Approx. 215 kg (kg) (fully fueled) 🛡️ Safety Features Ratings Safety Ratings: N/A (Motorcycle safety is assessed through design and component quality, not standardized crash tests like cars). Active Features Braking System: High-performance Brembo brakes with large discs offer superior stopping power and modulation. Suspension Design: Advanced, fully adjustable suspension contributes to stable handling and rider control. Passive Features Chassis Structure: Rigid aluminum frame designed for stability and predictable handling. Ergonomics: Sport-oriented riding position designed for control and rider input. 💡 Technology Features Infotainment Infotainment System: N/A (Basic analog instrumentation with LCD display for odometer, trip meters, and basic warning lights). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control were standard on these early models). Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 6,000 km or 12 months (whichever comes first), or more frequently under hard use (refer to manual). Oil Filter...
Some models may experience premature stator failure. Testing and replacement procedures are covered.
Fuel Pump Issues:
EFI models can sometimes suffer from fuel pump degradation or clogging, especially with lower quality fuel.
Electrical Connector Corrosion:
Corrosion in electrical connectors, particularly in humid environments, can lead to intermittent electrical faults.
Cam Chain Tensioner:
Potential for wear or failure of the automatic cam chain tensioner requiring inspection and possible replacement.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Aprilia is an Italian manufacturer renowned for its racing pedigree and high-performance motorcycles.
Model Evolution
Introduction Year:
The RSV Mille was first introduced in 1998, with significant updates and refinements occurring for the 2000 model year and continuing through 2003.
Engine Development:
Utilized a Rotax-designed V-twin engine, which was a significant departure from Aprilia's earlier 2-stroke offerings, marking their entry into the liter-class sportbike market.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Magazine Reviews:
Consistently received high praise from motorcycle publications for its performance, handling, and sophisticated engineering during its production run.
Ratings
Performance Ratings:
Regarded as one of the benchmark liter-class sportbikes of its era.