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Aprilia RSV Mille 956X 1999 2000 Service Repair Manual

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The RSV Mille, specifically the RSV Mille 956X model produced in 1999 and 2000, represents a pinnacle of Italian sportbike engineering. Renowned for its powerful V-twin engine and sophisticated chassis,...
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Aprilia RSV Mille 956X 1999 2000 Service Repair Manual
The RSV Mille, specifically the RSV Mille 956X model produced in 1999 and 2000, represents a pinnacle of Italian sportbike engineering. Renowned for its powerful V-twin engine and sophisticated chassis, this motorcycle was designed for enthusiasts seeking exhilarating performance on both the road and the track. The heritage in racing is evident in the RSV Mille's dynamic handling, potent braking capabilities, and aggressive styling, making it a compelling choice in the superbike segment of its era. Its potent 956 cc liquid-cooled V-Twin engine delivers robust power and torque, complemented by a precise 6-speed transmission and a responsive suspension system. This comprehensive workshop service repair manual provides essential information for the maintenance, troubleshooting, and repair of your RSV Mille 956X. It covers a wide array of systems, including the engine, fuel, ignition, clutch, transmission, brakes, electrical systems, and bodywork. With detailed procedures for routine maintenance, component overhauls, and diagnostic troubleshooting, this manual is an indispensable resource for owners, technicians, and mechanics. It ensures that your RSV Mille remains in optimal condition, offering detailed technical specifications, torque values, and electrical diagrams to facilitate accurate and efficient servicing.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Model Designation:
RSV Mille 956X
Production Years:
1999, 2000
Codes
Engine Code Suffix:
956X (indicating displacement variant)
👋 Introduction
Market Position
Motorcycle Segment:
Sportbike / Superbike
Brand Heritage:
Aprilia is renowned for its racing pedigree and high-performance motorcycles.
Competitive Analysis
Key Rivals:
Honda RC51, Ducati 996, Yamaha YZF-R1, Suzuki GSX-R1000, Kawasaki ZX-9R
Key Features
Performance Focus:
The RSV Mille was Aprilia's flagship sportbike, designed for track performance and aggressive road riding.
Engineering Philosophy:
Italian engineering, exotic design, and potent V-twin performance.
📋 Manual Details
Coverage Areas
Primary Coverage:
Service, Maintenance, Troubleshooting, Repair
Specific Systems:
Engine, Fuel System, Ignition System, Clutch, Transmission, Drivetrain, Frame, Suspension, Brakes, Electrical System, Cooling System, Exhaust System, Bodywork, Wheels, Tires
Page Count
Estimated Page Count:
400+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full engine disassembly, assembly, inspection, and overhaul procedures including valve adjustment, piston ring replacement, crankshaft and connecting rod inspection, cylinder head service.
Fuel And Ignition:
Carburetor (or fuel injection for later models, though this manual specifies older carb setup) tuning and overhaul, fuel pump testing, ignition timing, spark plug specifications, coil testing.
Clutch And Transmission:
Clutch operation, adjustment, inspection, and replacement; gearbox disassembly, inspection, assembly, and troubleshooting; gear ratio details.
Frame And Suspension:
Frame inspection, front fork (telescopic) service, rear shock absorber service and adjustment, swingarm maintenance, steering head bearing service.
Brakes:
Hydraulic brake system servicing, caliper disassembly and rebuild, master cylinder service, brake fluid specifications, bleeding procedures, pad replacement, rotor inspection.
Electrical:
Wiring diagrams, battery maintenance, charging system (alternator/stator and regulator/rectifier) testing, starter motor troubleshooting, lighting system service, fuse identification and replacement, instrument cluster diagnostics.
Cooling System:
Radiator service, coolant specifications and capacity, fan operation, thermostat replacement, water pump inspection and maintenance.
Exhaust System:
Exhaust component inspection, gasket replacement, common leaks.
Bodywork And Trim:
Fairing removal and installation, seat removal, minor panel repair guidance.
Procedures Included
Routine Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug checks, chain adjustment and lubrication, tire pressure checks.
Troubleshooting Diagnostics:
Step-by-step diagnostic charts for common performance issues, electrical faults, and starting problems.
Component Overhaul:
Detailed instructions for the complete disassembly, inspection, cleaning, repair, and reassembly of major components.
Calibration And Adjustment:
Carburetor synchronization, idle speed adjustment, clutch lever free play, brake lever free play.
Wiring Diagrams:
Comprehensive electrical schematics for all model years covered, aiding in diagnosis and repair of electrical faults.
Technical Depth
Depth:
Comprehensive - covers everything from basic scheduled maintenance to full engine rebuilds and advanced electrical diagnostics.
Diagnostic Capabilities:
Detailed diagnostic trees and fault code interpretation (if applicable to the era's systems).
Rebuild Procedures:
Detailed torque specifications, clearances, and assembly sequences for all major internal engine and transmission components.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if professionally digitized, allowing quick access to specific information.
Print Quality
Print Readability:
High (assuming a well-scanned original document), ensuring clarity of diagrams and text.
Binding Type
Original Binding:
Likely a professionally bound softcover or hardcover manual.
Digital Access:
Instant download, accessible on computers, tablets, and smartphones.
Paper Type
Original Paper Type:
Durable, coated paper to withstand workshop use and oil/grease.
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin, Four-Stroke
Displacement:
956 cc
Bore X Stroke:
97 mm x 64.8 mm
Valvetrain:
DOHC, 4 valves per cylinder
Cooling System:
Liquid-cooled
Performance
Horsepower Approx:
120-130 hp (at crankshaft, depending on dyno and specific tuning)
Torque Approx:
70-75 lb-ft (at crankshaft)
Fuel System
Fuel Delivery:
Carburetor (likely 46mm Keihin or Mikuni on early models), potentially Weber or Dell'Orto
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed manual
Clutch Type:
Hydraulically operated wet multi-plate clutch
Features
Gear Ratios:
Specific gear ratios are detailed within the manual, crucial for performance tuning.
Final Drive:
Chain drive
📐 Dimensions
Exterior
Wheelbase:
Approximately 1400-1420 mm (55.1-55.9 inches)
Seat Height:
Approximately 810-830 mm (31.9-32.7 inches)
Weights
Dry Weight:
Approximately 195-200 kg (430-441 lbs)
Wet Weight:
Approximately 210-215 kg (463-474 lbs)
🛡️ Safety Features
Ratings
Safety Certification:
Typically meets European ECE standards for road legality.
Active Features
Braking System:
High-performance dual front disc brakes with multi-piston calipers, single rear disc brake.
Suspension Type:
Adjustable front telescopic forks and adjustable rear monoshock absorber.
Passive Features
Lighting:
Halogen headlamp, LED taillight.
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and speedometer, digital odometer, trip meter, clock, coolant temperature gauge, warning lights.
Driver Assistance
ABS:
Not typically equipped on standard 1999-2000 models; ABS was an optional or later feature.
Connectivity
Connectivity Features:
N/A (no modern connectivity features expected on this era of motorcycle)
🔧 Maintenance
Service Intervals
Oil Filter Change:
Every 4,000-6,000 km or annually
Engine Oil Change:
Every 4,000-6,000 km or annually
Valve Clearance Check:
Every 12,000-16,000 km
Spark Plug Replacement:
Every 8,000-12,000 km
Fluid Specifications
Engine Oil Type:
SAE 10W-40 or 15W-50, API SG or higher, JASO MA certified (refer to manual for exact spec)
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4 hydraulic brake fluid
Clutch Fluid Type:
DOT 4 hydraulic clutch fluid (if hydraulic)
Known Issues
Common Wear Items:
Clutch wear, cam chain tensioner issues (early models), voltage regulator/rectifier failures, minor electrical gremlins.
Performance Tuning:
Carburetor tuning can be sensitive; proper synchronization is critical for smooth running.
📚 Vehicle History
Brand Heritage
Founding Era:
Aprilia was founded in 1945 in Italy.
Model Evolution
First Generation:
The RSV Mille was launched in 1997 and represented Aprilia's serious entry into the superbike market, powered by a Rotax-derived V-twin engine.
Updates:
The 1999-2000 models represent early iterations of the RSV Mille, with subsequent models receiving updates to suspension, engine management, and styling.
Production
Manufacturing Location:
Italy
🏆 Awards & Recognition
Recognitions
Contemporary Reviews:
Highly praised by motorcycle publications for its V-twin character, chassis dynamics, and braking performance, often noted for its exotic appeal.
Performance Benchmarks:
Competed strongly in its class for track day performance and outright speed.
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