Classification:
High-performance Italian sportbike
Target Audience:
Enthusiast riders and professional technicians requiring in-depth service information
Competitors:
Ducati 916/996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR900RR/929RR/954RR
Engine Architecture:
V-Twin engine with character and torque
Handling Dynamics:
Renowned for sharp handling and excellent chassis feedback
Build Quality:
Often praised for premium components and build quality
Manual Value Proposition:
Provides dealership-level technical data to enable comprehensive maintenance and repair.
Engine Mechanical:
Full disassembly and reassembly, cylinder head, pistons, crankshaft, connecting rods, valves, timing systems (chain/belt, tensioners), lubrication system (oil pump, oil filter, oil passages)
Engine Fuel System:
Fuel injection system (throttle bodies, injectors, fuel pump, pressure regulator), fuel tank, fuel lines, emissions control (EVAP)
Engine Ignition System:
Spark plugs, ignition coils, ECU control, wiring diagrams
Cooling System:
Radiator, cooling fan, thermostat, water pump, coolant hoses, coolant type and capacity
Exhaust System:
Exhaust pipes, catalytic converter (if applicable), mufflers, lambda sensors (oxygen sensors)
Transmission:
Clutch (hydraulic system, plates, springs), gearbox (gear selection, shafts, bearings), final drive (chain/sprockets, maintenance)
Brakes:
Front and rear brake calipers, master cylinders, brake lines, brake fluid type and bleeding procedure, brake disc specifications, ABS system (if equipped)
Suspension:
Front fork (spring rate, damping adjustments, oil type and level, seals), rear shock absorber (preload, rebound adjustment, service), linkages
Steering:
Handlebar, steering head bearings (adjustment, replacement), steering geometry
Electrical System:
Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting (headlights, taillights, indicators), wiring diagrams for all circuits
Electronics ECU:
Engine Control Unit (ECU) diagnostics, sensor inputs (TPS, MAP, IAT, O2), actuator outputs, wiring to ECU
Bodywork Chassis:
Frame, subframe, fairings (disassembly, installation), seat, fuel tank mounting, body panel fasteners
Maintenance Tasks:
Oil and filter changes, air filter replacement, spark plug inspection/replacement, chain lubrication and adjustment, brake pad inspection/replacement, coolant flush and fill, tire pressure checks, general lubrication
Troubleshooting:
Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting guides, fault code interpretation (if applicable)
Repair Procedures:
Step-by-step instructions for engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs, electrical component diagnosis and replacement, bodywork repairs
Technical Specifications:
Torque specifications for all fasteners, engine clearance specifications, valve lash settings, fluid capacities and types, electrical system voltage and resistance checks
Depth:
Complete Rebuild & Advanced Diagnostics
Diagnostic Tools:
Includes guidance for using diagnostic tools and interpreting sensor data (if applicable to the era).
Engine Type:
V-Twin, Four-stroke
Displacement:
998 cc (for most models in this range)
Bore X Stroke:
97 x 68 mm (typical for 998cc)
Valve Train:
DOHC, 4 valves per cylinder, Desmodromic valve actuation (some later models may differ, but RSV Mille is known for this characteristic)
Cooling Method:
Liquid-cooled
Horsepower:
Approx. 130-136 hp @ 9,200 rpm (model dependent)
Torque:
Approx. 98-101 Nm @ 7,000 rpm (model dependent)
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-point injection
Fuel Type:
Unleaded Premium (95 RON or higher recommended)
Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 20W-50 (refer to manual for exact specification)
Oil Capacity:
Approx. 3.5 - 4.0 liters (with filter change, check manual for precise figure)
Oil Change Interval:
Every 5,000-7,500 km or annually (refer to manual for precise recommendation based on usage)
Air Filter Service:
Every 5,000-10,000 km or as needed based on dusty conditions
Spark Plug Replacement:
Every 10,000-15,000 km (refer to manual for specific plug type and gap)
Chain Maintenance:
Lubricate and adjust chain every 500-1000 km, inspect for wear at regular intervals.
Brake Fluid:
DOT 4 (refer to manual for specific brand/grade recommendation)
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors (50/50 mix with distilled water recommended)
Fork Oil:
Specific viscosity and type (e.g., SAE 5W or 10W) as per manual for fork service.
Common Wear Items:
Clutch wear, regulator/rectifier failures (common on many Aprilias of this era), fuel pump issues, starter solenoid wear, cam chain tensioner wear.
Electrical Gremlins:
Wiring harness issues, connector corrosion, battery terminal corrosion are potential concerns requiring careful inspection.
Manufacturer:
Aprilia is an Italian manufacturer with a strong heritage in motorcycle racing, particularly in smaller displacement categories, but transitioned to larger sportbikes with the RSV Mille.
Introduction Year:
The RSV Mille was first introduced in 1998, but this manual covers models from 2002 onwards, indicating updates and revisions.
Key Development Phases:
The 2002 model year saw significant updates, including fuel injection, revised chassis, and improved electronics over earlier generations.
Manufacturing Location:
Italy
Model Lifespan:
The RSV Mille platform evolved into the RSV1000R and later the RSV4, with this specific generation running for several years post-2002.
