Aprilia RSV Mille 956X 1999-2000 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Aprilia Model: RSV Mille Model Variant: RSV Mille 956X Codes Production Code: RP Generation Generation Name: First Generation (SL1000) Generation Years: 1998-2003 👋 Introduction Market Position Segment: Superbike, high-performance motorcycle Target Audience: Enthusiast owners, independent workshops, performance tuners Competitive Analysis Competitors 1999: Ducati 916, Honda CBR900RR Fireblade, Yamaha YZF-R1, Suzuki GSX-R750 Key Features Design Philosophy: Italian performance engineering, focus on V-twin power delivery and chassis dynamics Distinctive Aspects: V-twin engine architecture, advanced suspension components (often Öhlins), distinctive styling 📋 Manual Details Coverage Areas Years Covered: 1999-2000 Page Count Estimated Pages: 400+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, overhaul, diagnostics, tuning Fuel System: Fuel injection, fuel pump, injectors, throttle body, fuel pressure regulator Cooling System: Radiator, water pump, thermostat, coolant types and capacities Ignition System: Ignition coils, spark plugs, ECU control, timing Transmission: Clutch operation, gear shifting mechanism, gearbox internal components, oil specifications Chassis: Frame inspection, alignment, body panels, fairings Suspension: Front forks (Öhlins/Marzocchi), rear shock absorber, linkage system, adjustments, maintenance Brakes: Brembo radial calipers, master cylinders, brake lines, bleeding, pad replacement, rotor specifications Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting, fuses, relays, ECU Wheels And Tires: Wheel bearings, tire pressures, wheel removal/installation, balancing Exhaust System: Exhaust headers, catalytic converter (if applicable), muffler, gasket replacement Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid flush Troubleshooting: Diagnostic flowcharts for common performance issues, electrical faults, starting problems Repair: Step-by-step instructions for component replacement and repair Overhaul: Complete engine and transmission rebuild procedures Technical Specifications: Torque values, clearances, fluid capacities, component tolerances Wiring Diagrams: Detailed electrical schematics Technical Depth Depth: Comprehensive, from basic maintenance to full engine rebuilds and advanced diagnostics 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text Print Quality Resolution: High-resolution, clear images and text Binding Type Binding: N/A (Digital) Paper Type Paper: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine Type: V-twin, four-stroke Engine Code: V60 Magnesium Displacement: 998 cc (996 cc for some early models, 956cc is likely a typo for 996 or 998) Bore X Stroke: 98 mm x 66 mm Valvetrain: DOHC, 4 valves per cylinder Cooling: Liquid-cooled Performance Horsepower Claimed: Approximately 130-135 hp @ 9000 rpm Torque Claimed: Approximately 94-98 Nm @ 7000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with single throttle body per cylinder Fuel Type: Unleaded gasoline, premium octane recommended Ignition: Electronic ignition with ECU control 🔧 Transmission Standard Type: 6-speed manual Features Clutch: Wet multi-plate clutch, hydraulic actuation Final Drive: Chain drive 📐 Dimensions Exterior Length: Approx. 2010 mm (80.7 in) Width: Approx. 720 mm (28.3 in) Height: Approx. 1140 mm (44.9 in) Weights Dry Weight: Approx. 195 kg (430 lbs) Wet Weight: Approx. 217 kg (478 lbs) Fuel Capacity: 21 Liters (5.5 US gal) 🛡️ Safety Features Ratings Safety Features Focus: Primarily focused on rider control and braking performance rather than passive crash structures Active Features Braking System: Dual 320 mm front discs with 4-piston Brembo radial calipers, 220 mm rear disc with 2-piston caliper Suspension Feedback: Adjustable front and rear suspension for optimal handling and stability Passive Features Frame Construction: Aluminum twin-spar frame for rigidity and responsiveness 💡 Technology Features Infotainment Infotainment System: N/A (focus on performance, not infotainment) Driver Assistance Driver Assistance Features: N/A (no electronic rider aids like ABS or traction control on early models) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first. Valve Clearance Check: Typically every 10,000-15,000 km (6,000-9,000 miles) Chain Adjustment: Check and adjust chain slack regularly, typically every 1,000-2,000 km (600-1,200 miles) Fluid Specifications Engine Oil Type: SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant (e.g., Motul 5100 10W-40) Coolant Type: Ethylene glycol-based coolant, mixed with distilled water (50/50 ratio), typically blue or green Brake Fluid Type: DOT 4 Clutch Fluid Type: DOT 4 (shared with brake system) Known Issues Electrical Gremlins: Early models could be prone to voltage regulator issues or intermittent electrical connections. Cam Chain Tensioner: Some users report potential issues with the automatic cam chain tensioner, recommending manual replacement with upgraded units. Stator: Stator failures have been reported, impacting charging system performance. Fuel Pump Reliability: Occasional issues with fuel pump reliability have been noted. Clutch Slave Cylinder: The original clutch slave cylinder can be a point of failure; aftermarket upgrades are available. 📚 Vehicle History Brand Heritage Brand Origin: Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, particularly in smaller displacement categories. Model Evolution Rs V Millle Debut: The RSV Mille (model code SL1000) was Aprilia's first foray into the litre-class superbike market, aiming to compete with established Japanese and European rivals. Early Variants: Initial models featured the...
Comprehensive, from basic maintenance to full engine rebuilds and advanced diagnostics
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text
Print Quality
Resolution:
High-resolution, clear images and text
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-twin, four-stroke
Engine Code:
V60 Magnesium
Displacement:
998 cc (996 cc for some early models, 956cc is likely a typo for 996 or 998)
Bore X Stroke:
98 mm x 66 mm
Valvetrain:
DOHC, 4 valves per cylinder
Cooling:
Liquid-cooled
Performance
Horsepower Claimed:
Approximately 130-135 hp @ 9000 rpm
Torque Claimed:
Approximately 94-98 Nm @ 7000 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with single throttle body per cylinder
Fuel Type:
Unleaded gasoline, premium octane recommended
Ignition:
Electronic ignition with ECU control
🔧 Transmission
Standard
Type:
6-speed manual
Features
Clutch:
Wet multi-plate clutch, hydraulic actuation
Final Drive:
Chain drive
📐 Dimensions
Exterior
Length:
Approx. 2010 mm (80.7 in)
Width:
Approx. 720 mm (28.3 in)
Height:
Approx. 1140 mm (44.9 in)
Weights
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 217 kg (478 lbs)
Fuel Capacity:
21 Liters (5.5 US gal)
🛡️ Safety Features
Ratings
Safety Features Focus:
Primarily focused on rider control and braking performance rather than passive crash structures
Active Features
Braking System:
Dual 320 mm front discs with 4-piston Brembo radial calipers, 220 mm rear disc with 2-piston caliper
Suspension Feedback:
Adjustable front and rear suspension for optimal handling and stability
Passive Features
Frame Construction:
Aluminum twin-spar frame for rigidity and responsiveness
💡 Technology Features
Infotainment
Infotainment System:
N/A (focus on performance, not infotainment)
Driver Assistance
Driver Assistance Features:
N/A (no electronic rider aids like ABS or traction control on early models)
Connectivity
Connectivity Features:
N/A
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-5,000 miles) or annually, whichever comes first.
Valve Clearance Check:
Typically every 10,000-15,000 km (6,000-9,000 miles)
Chain Adjustment:
Check and adjust chain slack regularly, typically every 1,000-2,000 km (600-1,200 miles)
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA compliant (e.g., Motul 5100 10W-40)
Coolant Type:
Ethylene glycol-based coolant, mixed with distilled water (50/50 ratio), typically blue or green
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (shared with brake system)
Known Issues
Electrical Gremlins:
Early models could be prone to voltage regulator issues or intermittent electrical connections.
Cam Chain Tensioner:
Some users report potential issues with the automatic cam chain tensioner, recommending manual replacement with upgraded units.
Stator:
Stator failures have been reported, impacting charging system performance.
Fuel Pump Reliability:
Occasional issues with fuel pump reliability have been noted.
Clutch Slave Cylinder:
The original clutch slave cylinder can be a point of failure; aftermarket upgrades are available.
📚 Vehicle History
Brand Heritage
Brand Origin:
Aprilia is an Italian motorcycle manufacturer with a strong racing pedigree, particularly in smaller displacement categories.
Model Evolution
Rs V Millle Debut:
The RSV Mille (model code SL1000) was Aprilia's first foray into the litre-class superbike market, aiming to compete with established Japanese and European rivals.
Early Variants:
Initial models featured the V60 Magnesium engine, known for its character and torque. Later models saw updates to the engine and chassis.
Production
Manufacturing Location:
Noale, Italy
Production Period Covered:
1999-2000 models represent the early production run of the first-generation RSV Mille.
🏆 Awards & Recognition
Recognitions
Motorcycle Press Reviews:
Generally well-received by motorcycle press for its powerful V-twin engine, sharp handling, and distinctive Italian character, though sometimes criticized for minor electrical quirks or perceived build quality compared to Japanese rivals.
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