Segment:
High-performance sportbike segment.
Target Audience:
Enthusiasts and professional mechanics working on Aprilia RSV Mille motorcycles.
Competitors:
Honda CBR1000RR, Yamaha YZF-R1, Suzuki GSX-R1000, Ducati 999/1098.
Distinctive Traits:
Italian engineering, distinctive V-Twin engine character, racing heritage, sophisticated chassis design.
Value:
Provides comprehensive and authoritative repair information, enabling owners and technicians to perform accurate diagnostics and repairs, thus maintaining optimal performance and longevity of the motorcycle.
Applicable Model Years:
2002 Onwards
Model Variants Covered:
All RSV Mille models from 2002 onwards, including potential variations in regional specifications or minor updates.
Estimated Page Count:
Typically 500-800+ pages for a comprehensive service manual of this nature. Exact count not provided, but described as 'Full & Complete'.
Type:
Service Repair Workshop Manual
Language:
English (Assumed based on product description and typical market for this manual)
Powertrain:
Engine (V-Twin), Fuel System (EFI), Ignition System, Exhaust System, Cooling System, Lubrication System.
Chassis And Suspension:
Frame, Front Suspension (Fork), Rear Suspension (Monoshock), Steering System, Wheel Bearings, Swingarm.
Brakes:
Front and Rear Brake Systems (Hydraulic), Master Cylinders, Calipers, Discs, Lines, Fluid Specifications.
Electrical System:
Wiring Diagrams, Battery, Alternator, Starter Motor, Lighting System, Instrumentation, ECU (Engine Control Unit), Sensors, Fuses, Relays.
Body And Fairings:
Fairing Removal and Installation, Seat, Fuel Tank, Body Panels, Graphics.
Maintenance:
Scheduled Maintenance Intervals, Oil and Filter Changes, Air Filter Replacement, Spark Plug Service, Chain Adjustment and Lubrication, Brake Fluid Replacement, Coolant Flush and Refill.
Troubleshooting:
Diagnostic Procedures for Common Issues, Fault Code Interpretation (if applicable), Symptom-Based Troubleshooting Guides.
Repair And Rebuild:
Engine Overhaul (Top End and Bottom End), Transmission Disassembly and Reassembly, Suspension Component Replacement, Brake System Overhaul, Electrical Component Repair.
Technical Specifications:
Torque Specifications for all fasteners, Valve Clearances, Engine Timing, Fluid Capacities, Electrical Resistance Values, Diagnostic Parameters.
Depth:
Comprehensive: Covers everything from basic routine maintenance to complete engine and component rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.
Compatibility:
Compatible with all PDF readers (Adobe Acrobat Reader, Foxit Reader, etc.).
Searchability:
Likely text-searchable within the PDF for efficient information retrieval.
Quality:
High Resolution: Designed for clear viewing on screen and potential printing, ensuring legibility of text and diagrams.
Binding:
Not Applicable (Digital PDF Format)
Paper:
Not Applicable (Digital PDF Format)
Engine Type:
V-Twin, Four-stroke, Liquid-cooled
Displacement:
Typically 998cc to 1078cc depending on specific RSV Mille variant within the 2002 onwards timeframe (e.g., Mille R, Mille SP, RSV1000R).
Bore X Stroke:
Approximately 97 mm x 68 mm (for 998cc variants). Manual will detail exact specifications.
Valve Train:
DOHC, 4 valves per cylinder, Desmodromic valve actuation (or similar high-performance system).
Horsepower:
Typically in the range of 130-145+ HP at the crank, depending on the specific model year and configuration. Manual will provide definitive figures.
Torque:
Typically in the range of 95-105+ Nm at the crank. Manual will provide definitive figures.
Fuel Delivery:
Electronic Fuel Injection (EFI) - Multi-point injection system.
Fuel Type:
Unleaded gasoline, minimum 95 RON (Research Octane Number).
Ignition Type:
Digital CDI (Capacitor Discharge Ignition) with electronic timing control.
Cooling Method:
Liquid-cooled
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives. Manual will specify exact type and mixture ratio (e.g., 50/50).
Oil Type:
High-performance motorcycle-specific 4-stroke engine oil, typically JASO MA certified. Viscosity grade will be specified (e.g., 10W-40 or 15W-50).
Oil Capacity:
Approximately 3.5 - 4.0 liters (including filter change). Manual will state precise capacity.
Engine Family:
Rotax V60 Magnesium / Aprilia V60 Race Engine
Transmission Type:
6-speed constant mesh sequential gearbox.
Clutch Type:
Hydraulically operated, multi-plate wet clutch.
Gear Ratios:
Specific gear ratios for each of the 6 speeds will be detailed in the manual, crucial for performance tuning and diagnostics.
Fluid Type:
Refer to engine oil specifications (shared engine/gearbox oil). Manual will confirm.
Fluid Capacity:
Integrated with engine oil capacity. Manual will specify if a separate gearbox oil fill is present.
Overall Length:
Approx. 2030 mm (may vary slightly by model year). Manual will provide exact dimensions.
Overall Width:
Approx. 720 mm (excluding mirrors, may vary). Manual will provide exact dimensions.
Seat Height:
Approx. 810 mm (may vary by model year and suspension setup). Manual will provide exact dimensions.
Dry Weight:
Approx. 185-195 kg (depending on model variant and materials used, e.g., Magnesium components). Manual will provide exact dry weight.
Wet Weight:
Approximately 205-215 kg (with fluids). Manual will provide exact wet weight.
Wheelbase:
Approx. 1420 mm. Manual will provide exact wheelbase.
Safety Standards:
Manufactured to meet applicable European (CE) and International motorcycle safety standards. Specific crash test ratings are not typically available for motorcycles in the same way as cars.
Braking System:
High-performance dual front disc brakes with radial-mount calipers (e.g., Brembo), single rear disc brake. Anti-lock Braking System (ABS) may be an option on later models or specific variants, which the manual would cover.
Suspension System:
Fully adjustable front and rear suspension (e.g., Öhlins or Marzocchi forks, Sachs or Öhlins rear shock) for optimal handling and stability.
Frame Construction:
Lightweight and rigid twin-spar frame, often using aluminum or alloy, contributing to high-speed stability and predictable handling.
Lighting:
Halogen or HID headlight systems, LED tail lights and indicators on some later models. Wiring diagrams in the manual are critical for maintenance.
Dashboard:
Analog tachometer and digital speedometer, LCD display for trip computer, fuel level, clock, engine temperature. Manual details dashboard functions and error codes.
ABS:
Optional on some models/years, detailed troubleshooting and maintenance procedures for ABS systems if equipped.
Diagnostics:
Onboard diagnostics (OBD) interface for ECU reading and parameter monitoring may be present on later models. Manual will describe diagnostic port location and usage.
Oil Change Interval:
Typically every 5,000 - 7,500 km or annually, whichever comes first. Manual will specify.
Air Filter Interval:
Inspect every 5,000 km, replace as needed or every 10,000-15,000 km. Manual will detail.
Spark Plug Interval:
Replace typically every 10,000 - 20,000 km. Manual will specify type and gap.
Valve Clearance Interval:
Check every 10,000 - 20,000 km. Crucial maintenance procedure detailed in the manual.
Brake Fluid:
DOT 4 or DOT 5.1 recommended. Manual will specify the exact requirement for optimal performance and longevity.
Coolant:
50/50 mixture of premium ethylene glycol-based coolant and distilled water. Manual will confirm specific type and freezing point requirements.
Common Wear Items:
Clutch wear, cam chain tensioner (especially on earlier models), stator output, voltage regulator issues, potential for fuel pump diaphragm failure. Manual provides diagnostic steps.
Electrical Gremlins:
Wiring harness integrity and connector corrosion can be issues on older bikes. The manual's wiring diagrams are invaluable for troubleshooting.
Oil Filter Part Number:
Specific part numbers for oil filters (e.g., HF153, KN-153, or OEM Aprilia part numbers) will be listed in the manual.
Air Filter Part Number:
Specific part numbers for air filters will be listed in the manual.
Manufacturer:
Aprilia is an Italian manufacturer renowned for its racing pedigree and high-performance motorcycles, particularly in the sportbike and off-road categories.
Introduction Year:
The RSV Mille model line was introduced in the late 1990s, with significant updates and evolution leading into the 2002 onwards period covered by this manual.
Key Updates Post 2002:
Includes potential updates to engine management, suspension components, braking systems, and aerodynamic fairings across various RSV Mille iterations (e.g., RSV1000R, Mille Factory, Tuono variants).
Manufacturing Location:
Primarily Italy.
Motorsport Heritage:
Aprilia has a strong presence in motorcycle racing (World Superbike, MotoGP), and the RSV Mille benefits from this technological transfer. While the manual itself doesn't receive awards, its quality reflects the brand's performance focus.
Owner Satisfaction:
Generally well-regarded for performance and handling, though maintenance complexity requires knowledgeable owners or technicians. This manual directly supports achieving higher owner satisfaction through proper care.
