APRILIA RSV MILLE Service Repair Manual 2002 Onward

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Tipo: Motorcycle

Proveedor:

SKU: 137846

Etiquetas: 2002 Aprilia Misc Motorcycle Motorcycles RSV MILLE

Variantes de producto

Descripción

The RSV Mille, a celebrated sportbike, embodies premium Italian engineering and performance, particularly from the 2002 model year onwards. Available in variants such as the Standard, Factory, R, and Tuono, this motorcycle is powered by the robust Rotax 990 V2 engine, known for its distinctive character and strong torque delivery. With its aluminum twin-spar frame and often featuring high-quality adjustable suspension, the RSV Mille offers agile handling and a track-capable experience, making it a favored choice for enthusiast riders seeking a blend of sophisticated design and exhilarating performance within the high-performance sportbike segment. This comprehensive service repair workshop manual provides in-depth guidance for all RSV Mille models from 2002 onwards. Covering a vast array of systems including the engine, fuel, cooling, ignition, transmission, drivetrain, suspension, brakes, electrical system, and chassis, it details everything from routine maintenance and fluid changes to complete engine and gearbox rebuilds. The manual includes essential procedures for diagnostics, repair, and adjustments, alongside critical torque specifications. Its purpose is to serve as an indispensable resource for owners, mechanics, and technicians, ensuring the optimal maintenance, repair, and longevity of the RSV Mille through clear, detailed instructions and technical information.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Model Variants:

Standard, Factory, R, Tuono

Codes

Chassis Codes:

RP, RP00, RP000, AP00, AP000, AP001

Engine Codes:

Rotax 990 V2

👋 Introduction

Market Position

Segment:

High-performance sportbike segment.

Target Audience:

Enthusiast riders seeking premium Italian engineering and track-capable performance.

Competitive Analysis

Competitors:

Ducati 996/998, Yamaha R1, Suzuki GSX-R1000, Honda CBR929RR/954RR, Kawasaki ZX-9R.

Key Features

Engine Layout:

V-twin (90-degree) configuration, known for its torque and character.

Chassis:

Aluminum twin-spar frame, contributing to a rigid and agile handling platform.

Suspension:

Often equipped with high-quality adjustable suspension components (e.g., Öhlins on Factory/R models).

Brakes:

Premium braking systems, typically featuring Brembo components.

📋 Manual Details

Coverage Areas

Years Covered:

2002 onwards

Models Covered:

All RSV Mille variants (Standard, Factory, R, Tuono)

Page Count

Estimated Pages:

Extensive (specific number not provided, but described as 'full & complete')

Manual Type

Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, assembly, tuning, and troubleshooting for the Rotax 990 V2 engine.

Fuel System:

Fuel injection system (EFI) components, fuel pump, injectors, throttle bodies, fuel pressure regulator, diagnostics.

Cooling System:

Radiator, cooling fans, water pump, thermostat, coolant flow, bleeding procedures.

Ignition System:

Spark plugs, ignition coils, ECU control, timing, troubleshooting.

Transmission:

Gearbox overhaul, clutch operation (hydraulic), gear shift mechanism, lubrication, troubleshooting.

Drivetrain:

Chain and sprockets maintenance, rear wheel hub, swingarm, bearing inspection.

Suspension:

Front forks (Öhlins and standard variants), rear shock absorber, adjustment procedures, maintenance, seal replacement.

Brakes:

Brake caliper service, master cylinders, brake lines, bleeding, pad replacement, rotor inspection.

Electrical System:

Wiring diagrams, battery, starter motor, alternator, lighting, switches, ECU, fault finding.

Chassis And Frame:

Frame integrity, headstock bearings, swingarm bearings, general chassis components.

Bodywork:

Fairing removal and installation, seat, fuel tank, cosmetic repairs.

Procedures Included

Maintenance:

Regular scheduled maintenance, oil changes, filter replacements, chain lubrication and adjustment, brake fluid changes, coolant flushes.

Diagnostics:

Troubleshooting common and uncommon issues, fault code interpretation (where applicable), systematic diagnosis.

Repair:

Step-by-step instructions for all major and minor repairs across all systems.

Rebuilds:

Complete engine and gearbox rebuild procedures.

Adjustments:

Suspension settings, throttle cable slack, idle speed, clutch lever adjustment.

Torque Specifications:

Precise torque values for all critical fasteners and components.

Technical Depth

Depth:

Comprehensive, covering everything from basic servicing to complete engine and transmission overhauls. Suitable for professional mechanics and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

Type:

Searchability:

Likely searchable text within the PDF for quick information retrieval.

Print Quality

Quality:

Easy to read, professional quality for clear understanding of diagrams and text.

Binding Type

Type:

Not applicable (digital PDF format)

Paper Type

Type:

Not applicable (digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, 90-degree V-twin

Displacement:

997.6 cc (approx.)

Bore X Stroke:

97 mm x 67.5 mm (typical)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 120-130 hp @ 9000-9500 rpm (depending on variant and market).

Torque:

Approx. 95-100 Nm @ 7000-7500 rpm (depending on variant and market).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual throttle bodies.

Fuel Type:

Unleaded gasoline, 95-98 RON (Octane rating).

Fuel Tank Capacity:

Approx. 18-20 Liters

🔧 Transmission

Standard

Type:

6-speed sequential manual

Features

Clutch:

Hydraulic wet multi-plate clutch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2050 mm

Width:

Approx. 720 mm

Height:

Approx. 1150 mm

Weights

Dry Weight:

Approx. 195-205 kg (depending on variant)

Wet Weight:

Approx. 210-220 kg (depending on variant)

🛡️ Safety Features

Ratings

Crash Test Information:

Motorcycle safety is primarily based on rider skill and design features; formal crash test ratings like cars are not applicable. Manual covers braking and chassis stability.

Active Features

Braking System:

High-performance disc brakes (typically Brembo radial calipers on front).

Suspension Adjustability:

Allows riders to fine-tune for optimal handling and stability.

Passive Features

Frame Stiffness:

Contributes to predictable handling under load.

Ergonomics:

Sportbike riding position designed for rider control.

💡 Technology Features

Infotainment

System:

Basic analog instrumentation (tachometer, speedometer), warning lights, and trip computer on some variants. No advanced infotainment systems typically found on modern bikes.

Driver Assistance

Features:

No electronic rider aids like ABS, traction control, or riding modes were standard on most 2002-era models. Later models and special editions may have variations.

Connectivity

Features:

No Bluetooth or smartphone integration. Focus is on mechanical and electronic diagnostics.

🔧 Maintenance

Service Intervals

Oil Change:

Recommended every 6,000 km or annually, whichever comes first. Refer to manual for exact intervals.

Valve Check:

Typically around 12,000-24,000 km. Manual will specify exact interval.

Chain Service:

Lubricate and adjust every 1,000 km or after riding in wet conditions.

Fluid Specifications

Engine Oil:

10W-40 or 15W-50 Synthetic Motorcycle Oil (meeting API SG or higher, JASO MA specifications). Refer to manual for precise specification.

Coolant:

Ethylene glycol-based antifreeze mixture (50/50) with distilled water. Refer to manual for specific type.

Brake Fluid:

DOT 4 or DOT 5.1 brake fluid (check manual for compatibility).

Clutch Fluid:

DOT 4 or DOT 5.1 brake fluid (same as brakes, check manual).

Known Issues

Potential Issues:

Stator/regulator/rectifier failures, cam chain tensioner issues, clutch slave cylinder leaks, occasional ECU glitches. Manual provides troubleshooting for these.

Filter Part Numbers

Oil Filter:

Commonly uses aftermarket filters like Hiflofiltro HF152 or K&N KN-152. Refer to manual for OEM part number.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer with a strong racing pedigree, known for performance motorcycles.

Model Evolution

Introduction Year:

The RSV Mille was first introduced in 1997, with significant updates and refinements through its production run, including the 2002 onward models.

Key Updates 2002 Onward:

Refined engine management, improved suspension, revised chassis geometry, and styling updates.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

Industry Reputation:

Highly regarded for its V-twin engine character, handling, and performance in its class during its production years.