Aprilia RSV Mille 2002 Workshop Manual

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Art.-Nr: 132447

Stichworte: 2002 Aprilia Motorcycle Motorcycles RSV Mille RSV Models

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Beschreibung

The Aprilia RSV Mille, a high-performance sportbike first introduced in 1998 and refined for the 2002 model year, embodies Italian engineering prowess. Manufactured in Italy, this V-Twin, four-stroke motorcycle boasts a 998 cc engine, liquid-cooled with DOHC and four valves per cylinder, delivering an estimated 125-130 horsepower. Its aluminum twin-spar frame provides rigidity and stability, complemented by powerful braking systems and a 6-speed transmission. Designed for riders seeking an exhilarating experience, the RSV Mille is recognized for its racing pedigree and is a testament to Aprilia's commitment to performance and quality. This comprehensive workshop and service repair manual, presented in English, is an indispensable resource for owners and technicians. It covers all essential aspects of the Aprilia RSV Mille, including detailed procedures for engine assembly and disassembly, fuel system maintenance, cooling system service, electrical system diagnostics, chassis and suspension adjustments, and brake system upkeep. The manual also provides guidance on scheduled maintenance, troubleshooting common issues, and understanding technical specifications, ensuring the vehicle remains in optimal condition.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Year:

Codes

Chassis Code:

👋 Introduction

Market Position

Segment:

High-performance sportbike

Key Features

Appeal:

Targeted at Aprilia owners for DIY maintenance and repairs, essential for parts ordering

Value Proposition

Benefit:

Enables owners to perform comprehensive maintenance and repairs, saving on dealership costs and ensuring proper upkeep

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive workshop and service repair

Page Count

Pages:

Manual Type

Type:

Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine assembly, disassembly, tuning, and diagnostics

Fuel System:

Fuel injection system, fuel pump, injectors, throttle body, and fuel tank maintenance

Cooling System:

Radiator, coolant, water pump, thermostat, and fan system service

Electric System:

Wiring diagrams, ignition system, lighting, charging system, starter, sensors, and ECU diagnostics

Chassis:

Frame, suspension (front and rear), steering, wheels, and bearings

Brakes:

Brake system maintenance, caliper service, master cylinder, hydraulic lines, and bleeding procedures

Exhaust System:

Exhaust manifold, pipes, and muffler service

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, chain adjustment, and general upkeep

Repair:

Complete tear-down and rebuild procedures for all major components

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault code interpretation

Settings And Adjustments:

Valve clearances, idle speed, ignition timing (if applicable), suspension settings

Technical Depth

Depth:

Full technical specifications, including torque values, tolerances, and diagnostic parameters

📊 Manual Specifications

File Format

File Type:

Adobe PDF

Print Quality

Printability:

Fully printable pages

Compatibility

Operating Systems:

Windows and Mac compatible

Features

Visuals:

Includes numerous pictures and diagrams for clarity

Index:

Analytical index for easy navigation

⚙️ Engine Specifications

Primary Engine

Configuration:

V-Twin, four-stroke

Displacement:

998 cc

Bore X Stroke:

97 mm x 67.5 mm

Cooling System:

Liquid-cooled

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower Estimate:

Approx. 125-130 HP (at crank)

Torque Estimate:

Approx. 95-100 Nm (at crank)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline, min. 95 RON

Ignition

System:

Digital electronic ignition with variable ignition timing

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch

Type:

Wet multi-plate clutch

Final Drive

Type:

O-ring sealed chain

📐 Dimensions

Exterior

Length Estimate:

Approx. 2060 mm

Width Estimate:

Approx. 720 mm (handlebar)

Height Estimate:

Approx. 1125 mm

Weights

Dry Weight Estimate:

Approx. 195 kg

Wheels

Front Wheel Size:

3.50 x 17 inches

Rear Wheel Size:

5.50 x 17 inches

Tires

Front Tire Size:

120/70 ZR17

Rear Tire Size:

190/50 ZR17

🛡️ Safety Features

Active Features

Brakes:

Dual 320mm discs with 4-piston calipers (front), Single 220mm disc with 2-piston caliper (rear)

Passive Features

Frame Design:

Aluminum twin-spar frame for rigidity and stability

💡 Technology Features

Infotainment

Features:

Basic instrumentation: speedometer, tachometer, odometer, trip meters, engine temperature, clock. No advanced infotainment systems.

Driver Assistance

Features:

No electronic rider aids such as ABS or traction control as standard on this model year.

Diagnostics

Diagnostic Port:

Diagnostic connector for ECU access (specific type and location detailed in manual)

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km or 12 months (refer to manual for specifics)

Valve Check:

Every 12,000 km (refer to manual for specifics)

Fluid Specifications

Engine Oil:

SAE 10W-40 Synthetic motorcycle oil (API SG/SH/SJ or higher, JASO MA compliant - specific Aprilia recommendations in manual)

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors (50% mixture with distilled water - refer to manual for specific type)

Brake Fluid:

DOT 4 or DOT 5.1 (refer to manual for exact specification)

Clutch Fluid:

DOT 4 (refer to manual for exact specification)

Known Issues

Common Wear Items:

Cam chain tensioner, clutch slave cylinder seals, electrical connectors (corrosion), fuel pump relays

Typical Fixes:

Replacement of cam chain tensioner with updated aftermarket unit, seal replacement, cleaning/sealing electrical connections

📚 Vehicle History

Brand Heritage

Heritage:

Aprilia is an Italian manufacturer known for its racing pedigree and performance motorcycles.

Model Evolution

First Generation:

The RSV Mille was first introduced in 1998, representing Aprilia's entry into the litre-class superbike market. The 2002 model represents a refined version with various updates.

Production

Origin:

Manufactured in Italy