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1999 Aprilia RSV Mille Workshop Service Repair Manual

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The Aprilia RSV Mille, a high-performance sportbike introduced in 1998, represents Italian engineering prowess with its longitudinal V-twin engine. This 1999 model, chassis code RP, is celebrated for its potent...
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1999 Aprilia RSV Mille Workshop Service Repair Manual
The Aprilia RSV Mille, a high-performance sportbike introduced in 1998, represents Italian engineering prowess with its longitudinal V-twin engine. This 1999 model, chassis code RP, is celebrated for its potent 998 cc, 120-130 hp V-twin engine, renowned for its power and handling characteristics, placing it firmly in the superbike category. Designed with a focus on delivering an exhilarating riding experience, the RSV Mille features advanced components for its time, including an aluminum alloy twin-spar frame, inverted cartridge forks, and a sophisticated monoshock rear suspension, all contributing to its sharp handling and overall performance, making it a compelling alternative to other European rivals. This comprehensive workshop service and repair manual is designed to provide detailed guidance for the maintenance, repair, and troubleshooting of the Aprilia RSV Mille. It covers a wide array of systems, including the engine, fuel supply, cooling, electrical, and chassis components, offering in-depth procedures for everything from routine oil changes and valve adjustments to more complex engine rebuilds and electrical system diagnostics. With its extensive coverage, including wiring diagrams, torque specifications, and symptom-based troubleshooting, this manual serves as an essential resource for owners and technicians alike to ensure the optimal performance and longevity of their motorcycle.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
1999
Product Type:
Workshop Service Repair Manual
Codes
Manual Identifier:
Not specified in provided information
Chassis Code:
RP (for RSV Mille)
👋 Introduction
Market Position
Motorcycle Segment:
High-performance sportbike
Target Audience:
Enthusiast owners, independent motorcycle repair shops
Competitive Analysis
Competitors 1999:
• Ducati 916
• Honda CBR900RR Fireblade
• Suzuki GSX-R750/1100
• Yamaha YZF-R1
Key Features Vehicle
Engine Layout:
V-twin, longitudinal
Design Philosophy:
Italian sportbike with focus on power and handling
Key Features Manual
Usability:
Quickly searchable for efficient diagnostics and repairs
Support:
Email support available for questions
📋 Manual Details
Coverage Areas
Coverage Focus:
Comprehensive service, repair, maintenance, troubleshooting, and setup
Included Chapters:
• General Information
• Service and Setting up
• Periodic Maintenance and Adjustment
• Engine
• Fuel Supply System
• Cooling System
• Electrical System
• Chassis
• Repair Information
• Troubleshooting
• Updates
• Index
Page Count
Estimated Page Count:
Typically 500-800 pages for this era and complexity of motorcycle
Manual Type
Manual Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
Digital Compatibility:
Windows / Macintosh (Win/Max)
📖 Manual Coverage
Systems Covered
Engine:
V-twin engine: disassembly, assembly, component testing, specifications
Fuel System:
Carburetor systems (if applicable), fuel injection (if applicable), fuel pump, fuel filter, fuel tank maintenance
Cooling System:
Radiator, coolant hoses, water pump, thermostat, fan operation, coolant specifications
Electrical System:
Wiring diagrams, battery, charging system (alternator, regulator/rectifier), ignition system, lighting, starter motor, fuses, relays, electronic control unit (ECU) overview
Chassis:
Frame, suspension (front forks, rear shock), steering, wheels, tires, brakes (front and rear calipers, master cylinders, lines, pads, rotors), drivetrain (chain, sprockets)
Procedures Included
Maintenance:
Oil changes, filter replacement, chain adjustment and lubrication, brake fluid changes, coolant flushes, spark plug replacement, air filter cleaning/replacement, valve clearance checks and adjustments
Repair:
Engine rebuilds, gearbox servicing, suspension overhaul, brake system repairs, electrical component replacement, bodywork repairs
Troubleshooting:
Diagnostic procedures for common faults, fault codes (if applicable), symptom-based troubleshooting guides
Setup And Adjustment:
Carburetor synchronization, suspension setup, idle speed adjustment, clutch adjustment
Technical Depth
Depth:
Comprehensive workshop level, suitable for DIY mechanics and professional technicians. Includes detailed diagrams, torque specifications, and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content within the PDF
Print Quality
Printability:
Designed for printing, with clear legible text and diagrams
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Four-stroke, liquid-cooled, 90° V-twin
Displacement:
998 cc
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Compression Ratio:
10.5:1
Performance
Horsepower:
Approximately 120-130 hp (depending on market and tuning)
Torque:
Approximately 98-105 Nm
Fuel System
Fuel Delivery:
Carbureted (Mikuni BSR 40 twin carburetors) or Fuel Injection (depending on market variant; early European models often carbureted, North American often FI)
Fuel Type:
Unleaded gasoline, minimum 95 RON
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated, wet multi-plate
Features
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2040 mm
Width:
Approx. 700 mm
Height:
Approx. 1135 mm
Weights
Dry Weight:
Approx. 195 kg
Wet Weight:
Approx. 210 kg (fully fueled)
Fuel Tank Capacity:
18 liters
🛡️ Safety Features
Ratings
Safety Certification:
EC type-approval (European markets)
Active Features
Braking System Front:
Dual 320mm discs, 4-piston radial calipers
Braking System Rear:
Single 220mm disc, 2-piston caliper
Suspension Front:
Inverted cartridge forks, adjustable preload, compression, and rebound damping
Suspension Rear:
Monoshock, adjustable preload, compression, and rebound damping
Passive Features
Frame Type:
Aluminum alloy twin-spar frame
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic analog instrumentation, no infotainment)
Driver Assistance
Driver Assistance Features:
None (No ABS, traction control, or rider aids in the 1999 model)
Connectivity
Connectivity Features:
None
Ecu
ECU Function:
Manages fuel injection (if applicable), ignition timing, and other engine parameters
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-10,000 km or annually
Valve Clearance Interval:
Typically every 12,000-20,000 km
Chain Adjustment Interval:
Check every 1,000 km, adjust as needed
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-40 or 15W-50 semi-synthetic or fully synthetic motorcycle oil
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Brake Fluid Type:
DOT 4
Clutch Fluid Type:
DOT 4 (if hydraulic)
Known Issues
Common Problems:
• Stator failure (charging system)
• Fuel pump issues (on FI models)
• Cam chain tensioner noise
• Carburetor synchronization drift
• Leaking fork seals
• Electrical connector corrosion
Maintenance Focus:
Emphasis on regular maintenance to prevent common wear-related issues
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Italy
Brand Focus:
Performance motorcycles, racing heritage
Model Evolution
Introduction Year:
1998
Generation 1:
First generation RSV Mille, significant updates throughout its production run
Production
Manufacturing Location:
Aprilia factory, Noale, Italy
🏆 Awards & Recognition
Recognitions
Notable Reviews:
Critically acclaimed for its potent V-twin engine and sharp handling upon release, often praised as a viable alternative to Italian rivals.
Ratings
Performance Class:
Superbike / Hyperbike
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