Aprilia RSV Mille 1998-2003 Service & Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Code: SL1000 Model Generation: First Generation (SL1000) Applicable Years: 1998, 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Category: Superbike, Sport Touring Target Audience: Owners, mechanics, and enthusiasts seeking in-depth knowledge for maintenance and repair. Competitive Analysis Competitors: Honda VTR1000F, Suzuki TL1000R/S, Yamaha YZF-R1, Ducati 916 Unique Selling Points: Powerful V-Twin engine, distinctive Italian styling, excellent chassis dynamics. Key Features Engine Type: Rotax-designed 998cc V-Twin Chassis Design: Lightweight aluminum twin-spar frame for rigidity and handling. Braking System: High-performance Brembo radial-mount brakes. Suspension Setup: Fully adjustable front and rear suspension for customizable ride and handling. 📋 Manual Details Coverage Areas Manual Type: Service and Repair Manual Language: English Format: PDF Delivery Method: Email delivery with download link 📖 Manual Coverage Systems Covered Engine: V-Twin, 60-degree, Liquid-Cooled, 4-Stroke Fuel System: Electronic Fuel Injection (EFI) Ignition System: Electronic Ignition, Dual Spark Plugs per Cylinder Transmission: 6-Speed Constant Mesh Clutch: Hydraulic Actuated Wet Multi-Plate Clutch Cooling System: Liquid Cooling with Fan Exhaust System: Stainless Steel Headers and Muffler Frame: Aluminum Twin-Spar Frame Suspension Front: Adjustable Upside-Down Telescopic Forks (Öhlins optional on some models) Suspension Rear: Adjustable Monoshock with Progressive Linkage Brakes Front: Dual 320mm Discs, Radial Mount Calipers (Brembo) Brakes Rear: Single 220mm Disc, 2-Piston Caliper (Brembo) Wheels: 3-Spoke Aluminum Alloy Tires Front: 120/70ZR17 Tires Rear: 190/50ZR17 Electrical System: 12V System, Battery, Alternator, Starter Motor, Lighting, Instruments Bodywork: Full Fairing, Fuel Tank, Seat, Tail Section Procedures Included Scheduled Maintenance: Oil changes, filter replacements, chain adjustments, coolant flushes, brake fluid changes, spark plug replacement, valve clearance checks Engine Disassembly Reassembly: Complete engine teardown, inspection, and rebuild procedures Fuel System Diagnosis Repair: EFI system troubleshooting, injector cleaning/replacement, fuel pump testing, throttle body synchronization Transmission Service: Gearbox inspection, clutch plate replacement, shift drum and fork adjustments Suspension Overhaul: Fork seal replacement, damper rod service, shock absorber rebuild Brake System Maintenance: Brake pad replacement, caliper service, bleeding procedures, master cylinder overhaul Electrical Troubleshooting: Wiring diagrams, fault finding for lighting, ignition, instrumentation, sensors Chassis Adjustment: Steering head bearing adjustment, swingarm bearing service Torque Specifications: Detailed torque values for all critical fasteners Diagnostic Troubleshooting: Systematic approaches to identifying and resolving common issues Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and chassis rebuilds. Diagnostic Capabilities: Advanced diagnostics for electrical and fuel injection systems. Rebuild Procedures: Detailed, step-by-step instructions for engine, gearbox, and suspension component rebuilds. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF for efficient information retrieval. Printability: Printable pages for workshop use. Print Quality Quality: High-resolution scans or digital creation ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Type: Four-stroke, 60° V-twin, liquid-cooled, DOHC, 8 valves Displacement: 998 cc (60.9 cu in) Bore X Stroke: 97.0 mm x 67.5 mm Compression Ratio: 10.8:1 Performance Horsepower: Approx. 130-135 hp (96-100 kW) @ 9,500 rpm (varies by model year/market) Torque: Approx. 105 Nm (77 lb-ft) @ 7,500 rpm (varies by model year/market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with 54mm throttle bodies (later models may have different sizing) Fuel Type: Unleaded gasoline, minimum 95 RON (Octane rating) Oil Specifications Engine Oil Type: API SG, JASO MA Certified Synthetic Motorcycle Oil Engine Oil Viscosity: 10W-40 or 15W-50 (depending on ambient temperature) Oil Capacity: Approx. 3.8 - 4.0 Liters (4.0 - 4.2 US qt) with filter change Cooling System Coolant Type: Permanent Antifreeze/Coolant mixture (ethylene glycol based), typically 50/50 with distilled water Coolant Capacity: Approx. 2.0 Liters (2.1 US qt) 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Final Drive: O-ring sealed chain Features Clutch Type: Hydraulic actuated, wet multi-plate Fluid Specifications Transmission Oil Type: API GL-4 or GL-5 Gear Oil, SAE 75W/90 or 80W/90 Fluid Capacities Transmission Oil Capacity: Approx. 1.5 Liters (1.6 US qt) 📐 Dimensions Exterior Length: Approx. 2,060 mm (81.1 in) Width: Approx. 720 mm (28.3 in) (at handlebars) Height: Approx. 1,160 mm (45.7 in) (at windscreen) Wheelbase: Approx. 1,415 mm (55.7 in) Ground Clearance: Approx. 130 mm (5.1 in) Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 215 kg (474 lbs) (fully fueled) Fuel Tank Capacity: 21 Liters (5.5 US gal) Dimensions Seat Height: Approx. 810 mm (31.9 in) 🛡️ Safety Features Ratings Crash Test Ratings: Motorcycle safety is not rated by governmental bodies like automotive crash tests; emphasis is on design and component quality. Active Features Braking System: Powerful dual front and single rear disc brakes with high-performance calipers offer excellent stopping power. Suspension Adjustability: Allows riders to tune suspension for optimal stability and control in various conditions. Passive Features Chassis Design: Stiff aluminum frame contributes to predictable handling and stability. Lighting: Halogen headlamp and LED taillight for enhanced visibility. 💡 Technology Features Infotainment Instrumentation:...
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