1998-2004 APRILIA RSV MILLE Motorcycle Service Repair Workshop Manual + Parts Manual (455 pages Free preview Original Fsm)

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Taper: Motorcycle

Distributeur:

UGS: 145566

Mots clés: 1998 1999 2000 2001 2002 2003 2004 Aprilia Motorcycle Motorcycles RSV MILLE RSV Models

Variantes de produits

Description

The Aprilia RSV Mille, produced from 1998 to 2004, represents a high-performance sportbike renowned for its potent V-twin engine architecture, delivering robust torque and a distinctive character. As Aprilia's flagship model of its era, it was engineered to compete directly with leading European and Japanese superbikes, often praised for its sophisticated Italian design, premium componentry, and capable chassis dynamics. This motorcycle embodies Aprilia's strong racing heritage, offering an exhilarating riding experience suitable for both spirited road use and track days. This comprehensive Workshop Service Repair Manual and Parts List, presented in English, covers the Aprilia RSV Mille models from 1998 through 2004. It provides detailed guidance on engine systems, electrical components, and chassis elements, including maintenance procedures, repair instructions, and troubleshooting diagnostics. With a total of 455 pages, this resource is an essential tool for owners and technicians alike, offering the information needed to maintain, repair, and ensure the optimal performance and longevity of the RSV Mille, including specific details on known issues and parts identification.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Codes

Production Code:

RSV Mille (Internal Aprilia chassis codes may vary by year/version)

👋 Introduction

Market Position

Motorcycle Segment:

High-performance sportbike, competitor to Italian and Japanese superbikes of the era.

Competitive Analysis

Key Competitors:

Ducati 916/996, Yamaha R1, Honda CBR900RR Fireblade, Suzuki GSX-R750/1000, Kawasaki ZX-9R.

Key Features

Unique Selling Points Of Bike:

V-twin engine architecture providing strong torque, sophisticated Italian design, premium componentry (e.g., Ohlins suspension on some variants), capable chassis.

Manual Utility

Value Proposition:

Essential resource for owners and technicians to maintain, repair, and restore the Aprilia RSV Mille, enabling cost savings and preserving the motorcycle's performance and longevity.

📋 Manual Details

Coverage Areas

Years Covered:

1998, 1999, 2000, 2001, 2002, 2003, 2004

Page Count

Service Repair Manual Pages:

Parts Manual Pages:

Total Pages:

Manual Type

Manual Type:

Official Workshop Service Repair Manual & Parts List

Language

Language:

English

Format

File Format:

Compatibility:

All Versions of Windows & Mac

Printability:

Printable without restriction

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine disassembly, assembly, tuning, troubleshooting, lubrication, cooling system, fuel supply system (carburetor/injection depending on specific model variant within the year range, though Mille typically was injected)

Electrical Systems:

Wiring diagrams, ignition system, lighting, starter motor, battery, charging system, ECU (Engine Control Unit) diagnostics

Chassis Systems:

Frame, suspension (front forks, rear shock absorber), steering, wheels, brakes (front and rear calipers, master cylinders, lines), exhaust system, bodywork, fasteners

Procedures Included

Maintenance Procedures:

Regular servicing, oil changes, filter replacements, spark plug replacement, chain adjustment, brake fluid flush, coolant flush, valve clearance adjustment

Repair Procedures:

Complete engine rebuilds, transmission repairs, suspension overhaul, brake system repairs, electrical component replacement, body panel repair and replacement

Troubleshooting Procedures:

Diagnostic flowcharts, symptom-based troubleshooting, common fault finding and rectification

Special Tool Requirements:

Identifies necessary special tools but also provides 'shortcuts' and methods to use commonly available tools, minimizing specialized purchases

Technical Depth

Depth Of Coverage:

Comprehensive from basic maintenance to full mechanical and electrical system overhaul. Suitable for both novice DIY mechanics and experienced technicians.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution scans of original factory documentation, ensuring clarity of illustrations and text.

Print Quality

Print Clarity:

Designed for clear printing, allowing for easy reference in workshop environments.

Binding Type

Binding Description:

Digital (PDF) format, printable for physical binding by the user.

Paper Type

Paper Type Description:

N/A (Digital format, user choice for printing)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, liquid-cooled, 60-degree V-twin

Displacement:

997.92 cc (Specific to early Mille models, later RSV R/Factory variants may have slight variations)

Bore X Stroke:

97 mm x 67.5 mm (Typical for early 997.92cc)

Valvetrain:

DOHC, 4 valves per cylinder

Performance

Horsepower:

Approx. 125-130 hp @ 9,500 rpm (Varies slightly by model year and region)

Torque:

Approx. 97-100 Nm (71-74 lb-ft) @ 7,500 rpm (Varies slightly by model year and region)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with dual injectors per cylinder (Typically Magneti Marelli systems)

Fuel Type:

Unleaded gasoline, minimum 95 RON

Lubrication

Oil Type:

Fully synthetic motorcycle oil, API SG or higher, JASO MA certified, viscosity SAE 10W-40 or 15W-50 (Refer to manual for exact specifications)

Cooling System

Coolant Type:

Ethylene glycol based coolant with corrosion inhibitors (typically a 50/50 mix with distilled water). Specific Aprilia recommendation preferred.

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Hydraulically operated, wet multi-plate clutch

Features

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Wheelbase:

Approx. 1410-1430 mm (Varies slightly by year/model)

Seat Height:

Approx. 810-830 mm (Varies by model/suspension setting)

Weights

Dry Weight:

Approx. 170-185 kg (Varies by model year and equipment, e.g., RSV Mille vs. RSV Mille R)

Fuel Tank Capacity:

21 Liters (Approx. 5.5 US gallons)

🛡️ Safety Features

Active Features

Braking System Front:

Dual 320 mm discs, radial-mount 4-piston calipers (e.g., Brembo).

Braking System Rear:

Single 220 mm disc, 2-piston caliper (e.g., Brembo).

Passive Features

Frame Type:

Aluminum twin-spar frame.

💡 Technology Features

Infotainment

Instrument Cluster:

Analog tachometer, digital speedometer, odometer, trip meters, coolant temperature gauge, warning lights.

Driver Assistance

ABS was not standard on all models/years during this production run. Check specific model variant; some later models may have had optional ABS.

🔧 Maintenance

Service Intervals

Oil And Filter Change:

Every 6,000 km or 12 months (Refer to specific manual for exact intervals and conditions).

Valve Clearance Check:

Every 12,000 km or 24 months (Critical for V-twin engines).

Spark Plug Replacement:

Every 12,000 km or as specified.

Fluid Specifications

Brake Fluid:

DOT 4 (Refer to manual for specific brand/type recommendation).

Clutch Fluid:

DOT 4 (Typically shared with brake system).

Fork Oil:

Specific weight (e.g., 5W or 10W) and volume per fork leg. Consult manual for precise details.

Known Issues

Common Problems:

Stator failures (common in many Aprilia models of this era), fuel pump issues, occasional electrical gremlins, starter solenoid problems. These manuals are essential for diagnosing and addressing these.

Parts Manual Utility

Parts Catalog Value:

The included Parts Manual provides OEM part numbers, exploded diagrams, and quantities, invaluable for sourcing correct replacement components.

📚 Vehicle History

Brand Heritage

Aprilia Legacy:

Aprilia has a strong racing heritage, particularly in smaller displacement classes, known for innovation and performance-oriented motorcycles.

Model Evolution

Rsv Mille Lineage:

The RSV Mille was Aprilia's flagship sportbike, designed to compete directly with established European and Japanese manufacturers. It was later succeeded by the RSV1000R and RSV4 models.

Production

Manufacturing Location:

Noale, Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Reviews:

Critically acclaimed for its performance and handling upon release, often praised for its characterful V-twin engine and excellent chassis dynamics, though sometimes criticized for its electronics or build quality consistency compared to Japanese rivals.