Positioning:
The Aprilia RSV Mille was a highly regarded sportbike known for its performance, Italian engineering, and V-twin engine. This manual targets owners and independent workshops looking for factory-level repair information.
Competitors:
Primarily competed with Italian and European sportbikes of its era, such as Ducati superbikes, and high-performance Japanese motorcycles.
Manual Value:
Provides detailed, step-by-step instructions with exploded diagrams, essential for DIY maintenance and complex repairs, mirroring dealership resources.
Usefulness:
Empowers owners to perform their own servicing, diagnostics, and repairs, saving money and increasing understanding of their motorcycle.
Primary Coverage:
2002 Aprilia RSV Mille Factory
Secondary Coverage:
General maintenance, repair, diagnostics, and service procedures
Estimated Page Count:
Refer to dealer specifications; typically 500+ pages for full service manuals
Type:
Factory Service/Repair/Workshop Manual
Engine:
Complete engine overhaul, tuning, diagnostics, and component repair
Fuel System:
Fuel injection system, fuel pump, injectors, fuel pressure regulator, fuel tank service
Cooling System:
Radiator, coolant pump, thermostat, hoses, bleeding procedures
Electrical System:
Wiring diagrams, ignition system, charging system, lighting, starter motor, battery, ECU diagnostics
Chassis Parts:
Frame, suspension (front forks, rear shock), steering, wheels, brakes, swingarm
Bodywork:
Fairings, seat, fuel tank, tail section, disassembly and reassembly
Maintenance:
Scheduled maintenance, oil changes, filter replacements, chain adjustment, brake fluid changes, coolant changes
Repair:
Engine rebuilds, transmission service, suspension overhaul, brake caliper service, electrical component replacement
Diagnostics:
Troubleshooting common problems, reading fault codes (if applicable via diagnostic tools), component testing
Setting Up:
Initial setup, valve clearance adjustment, suspension setup, basic settings
Depth:
Comprehensive: Covers everything from basic checks and routine maintenance to complete engine and chassis rebuilds, including detailed diagnostic procedures and specifications.
Engine Type:
V-Twin, 4-stroke
Bore X Stroke:
97 mm x 68 mm
Valvetrain:
DOHC, 4 valves per cylinder
Horsepower:
Approximately 124-130 hp @ 9500 rpm (factory specifications)
Torque:
Approximately 99-101 Nm @ 7500 rpm (factory specifications)
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Size:
54 mm (typical for this model)
Cooling Method:
Liquid-cooled
Length:
Approximately 2030 mm (203 cm)
Width:
Approximately 720 mm (72 cm)
Height:
Approximately 1130 mm (113 cm)
Dry Weight:
Approximately 195 kg (430 lbs)
Wet Weight:
Approximately 215 kg (474 lbs) (with fluids)
Safety Features:
While not rated by NHTSA/Euro NCAP like cars, it features robust braking systems and a strong chassis design for its class.
Brakes Front:
Dual 320 mm discs, radial calipers (e.g., Brembo)
Brakes Rear:
Single 220 mm disc, caliper
Suspension Front:
Adjustable USD forks (e.g., Ohlins or Showa for Factory models)
Frame Type:
Aluminum twin-spar frame
Instrumentation:
Digital and analog display including speedometer, tachometer, coolant temperature, fuel level, clock, trip meters, and warning lights.
ABS:
ABS was typically optional or not standard on this specific model year and variant. Manual will clarify if present.
Diagnostic Port:
The manual will detail the location and usage of any diagnostic ports for electronic troubleshooting.
Oil Change Interval:
Typically every 4,000-6,000 km or annually, refer to manual for exact interval and oil type.
Valve Check Interval:
Typically around 10,000-12,000 km. Manual provides specific interval.
Engine Oil Type:
Fully synthetic motorcycle oil, e.g., 10W-40 or 15W-50, meeting API SG/SH/SJ or JASO MA specifications. Consult manual for exact grade.
Coolant Type:
Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). Refer to manual for specific Aprilia recommendation.
Brake Fluid Type:
DOT 4 or DOT 5.1 (high-temperature, low-viscosity fluid).
Clutch Fluid Type:
DOT 4 brake fluid.
Electrical Gremlins:
Some models of this era can be susceptible to minor electrical issues; the manual's wiring diagrams are crucial for diagnosis.
Regulator Rectifier:
Common on many bikes of this era, though not exclusively Aprilia; the manual will cover charging system diagnostics.
Vibration:
V-twin engines can produce more vibration; proper maintenance and torque specs are key. Manual offers guidance on engine mounting and related components.
Brand Focus:
Aprilia has a strong heritage in motorcycle racing, particularly in smaller displacement classes, and the RSV Mille represented their foray into the liter-class sportbike segment.
First Generation:
The RSV Mille was introduced in 1998, with significant updates and variations released throughout its production run, including the 'Factory' models which often featured higher-spec components.
Manufacturing Location:
Italy
