APRILIA RSV MILLE Service Repair Manual 2002 ONWARD

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Art.-Nr: 135974

Stichworte: 2002 Aprilia Misc Motorcycle Motorcycles RSV MILLE

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Beschreibung

The Aprilia RSV Mille, produced from 2002 onwards, is a high-performance sportbike celebrated for its Italian engineering, distinctive styling, and powerful V-twin engine. Designed for spirited road riding and track use, this model competes with other premier sportbikes of its era, offering a capable chassis and a 998cc liquid-cooled V-twin engine that typically produces around 125-130 horsepower. Its robust aluminum twin-spar frame and advanced braking system, featuring dual 320mm front discs, underscore its performance-oriented nature. This comprehensive Service Repair Workshop Manual provides in-depth guidance for the maintenance and repair of all Aprilia RSV Mille models from 2002 onward. It covers essential procedures including scheduled maintenance, engine and transmission overhauls, chassis and suspension servicing, brake system maintenance, and electrical system diagnostics. The manual includes detailed troubleshooting charts, specific repair instructions, and technical specifications, making it an invaluable resource for owners, mechanics, and technicians seeking to maintain the optimal performance and reliability of their RSV Mille.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Year:

2002 onwards

Codes

Vin Decoder Reference:

Refer to manual for specific VIN decoding

👋 Introduction

Market Position

Class:

High-performance sportbike, competitor to Ducati 916/996, Yamaha R1, Suzuki GSX-R1000.

Competitive Analysis

Unique Selling Points:

Italian engineering, powerful V-twin engine, capable chassis, distinctive styling.

Key Features

Engine Configuration:

V-twin, 90-degree angle, four-stroke.

Performance Orientation:

Designed for track use and spirited road riding.

📋 Manual Details

Coverage Areas

Covered Variants:

All RSV Mille models from 2002 onwards, including potential R or Factory variants if applicable to the year range.

Page Count

Estimated Page Count:

Comprehensive coverage suggests 500+ pages, typical for a full workshop manual.

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

Assumed English (standard for professional manuals sold globally).

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, diagnosis, maintenance, fuel system, ignition system, cooling system, lubrication system, internal components.

Transmission:

Gearbox removal and installation, clutch operation and adjustment, internal gearbox components, shift mechanism.

Chassis And Suspension:

Front fork service (oil changes, seals, disassembly), rear shock absorber adjustment and removal, swingarm, steering head bearings, wheel bearings.

Brakes:

Brake system overhaul (calipers, master cylinders, lines), bleeding procedures, pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, lighting system, charging system (alternator, regulator), starter motor, ignition coils, ECU diagnosis (if applicable), sensor testing.

Fuel System:

Fuel injection system (injectors, fuel pump, pressure regulator), throttle body servicing, fuel filter replacement.

Exhaust System:

Exhaust manifold, muffler, catalytic converter (if applicable) inspection and replacement.

Bodywork:

Fairing removal and installation, seat, fuel tank, body panel fasteners.

Procedures Included

Maintenance:

Scheduled maintenance, oil and filter changes, chain adjustment, spark plug replacement, air filter cleaning/replacement, coolant flush.

Troubleshooting:

Diagnostic charts, common fault finding, error code interpretation (if applicable).

Repair:

Step-by-step repair instructions for all major components and systems.

Overhaul:

Detailed procedures for complete engine and transmission rebuilds.

Diagnostics:

Wiring diagrams, component testing procedures, fault code identification.

Technical Depth

Depth:

Factory-level detail, suitable for professional technicians and experienced DIY mechanics.

Specific Procedures:

Valve clearance adjustment, piston ring replacement, crankshaft inspection, fuel injector testing, ignition timing verification.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable for quick information retrieval.

Print Quality

Quality:

High-resolution, suitable for printing individual pages or sections.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-twin, 4-stroke

Displacement:

998cc (approximate, may vary slightly by specific sub-model)

Bore X Stroke:

97mm x 68mm (typical for this engine)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 125-130 hp at rear wheel (varies by year and tuning)

Torque:

Approx. 70-75 lb-ft at rear wheel (varies by year and tuning)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI), typically with dual injectors per cylinder.

Throttle Body Size:

Typically 54mm or similar

Cooling System

Cooling Type:

Liquid-cooled

Lubrication System

Oil Type:

High-performance motorcycle engine oil, e.g., 10W-40 or 15W-50 synthetic.

Oil Capacity:

Approx. 3.5-4.0 liters without filter change, 4.0-4.5 liters with filter change.

🔧 Transmission

Standard

Type:

6-speed sequential manual

Optional

Type:

N/A (Standard 6-speed)

Features

Clutch Type:

Hydraulic wet multi-plate clutch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Wheelbase:

Approx. 1415-1420 mm

Seat Height:

Approx. 810-820 mm

Weights

Dry Weight:

Approx. 195-200 kg

Wet Weight:

Approx. 210-215 kg (fully fueled)

🛡️ Safety Features

Ratings

Sportbike Segment:

N/A (Motorcycle safety is assessed differently than automobiles).

Active Features

Braking System:

Dual 320mm front discs with multi-piston calipers (e.g., Brembo), single 220mm rear disc with caliper.

Passive Features

Frame Construction:

Aluminum twin-spar frame.

💡 Technology Features

Infotainment

Features:

Basic analog instrumentation, tachometer, speedometer, fuel gauge, trip meter.

Driver Assistance

Features:

No electronic rider aids like ABS or traction control standard on most 2002 models; these may have been optional or introduced in later iterations.

Connectivity

Features:

N/A (No connectivity features on this model).

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 6,000-8,000 km or annually.

Valve Clearance Check:

Every 12,000-16,000 km.

Coolant Change:

Every 2 years or 24,000 km.

Spark Plug Replacement:

Every 12,000-16,000 km.

Fluid Specifications

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 or DOT 5.1 (refer to manual for specific recommendation).

Clutch Fluid:

DOT 4 (typically shared with brake system).

Known Issues

Electrical Gremlins:

Some owners report intermittent electrical issues, often related to connectors or the rectifier/regulator.

Fuel Pressure Regulator:

Potential for failure, leading to poor running or starting issues.

Clutch Slave Cylinder:

Can sometimes develop leaks.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian motorcycle manufacturer known for its performance-oriented and racing pedigree.

Model Evolution

Introduction:

The RSV Mille was first introduced in 1998, evolving through various updates and versions. The 2002 model year represents a significant update, particularly with its fuel injection system.

Production

Production Location:

Italy

🏆 Awards & Recognition

Recognitions

Performance Reviews:

Consistently praised for its powerful V-twin engine and capable handling in period reviews by motorcycle publications.