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2002 Aprilia RSV Mille Service Repair Workshop Manual

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The 2002 Aprilia RSV Mille is a high-performance sportbike from Italy, renowned for its potent V-twin engine and exceptional handling characteristics. This model, part of the RSV Mille lineage that...
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Taper: Motorcycle
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UGS: 134175
2002 Aprilia RSV Mille Service Repair Workshop Manual
The 2002 Aprilia RSV Mille is a high-performance sportbike from Italy, renowned for its potent V-twin engine and exceptional handling characteristics. This model, part of the RSV Mille lineage that began in 1998, embodies Aprilia's racing heritage and engineering prowess, offering a thrilling riding experience. With its Italian craftsmanship, the RSV Mille was designed to compete at the highest level of sportbike performance, featuring a robust 998cc V-twin engine, an aluminum twin-spar frame, and advanced suspension components. This motorcycle is engineered for riders who appreciate precision engineering and exhilarating performance on both road and track. This comprehensive factory service repair workshop manual provides detailed information essential for the maintenance and repair of your 2002 Aprilia RSV Mille. Covering a wide array of systems, including engine overhaul, fuel system, cooling, electrical, chassis components, brakes, and bodywork, the manual offers step-by-step procedures for routine maintenance, troubleshooting, and component rebuilding. It includes critical torque specifications, schematics, and diagrams to guide both do-it-yourself enthusiasts and experienced mechanics. The manual's factory-level accuracy and extensive technical data empower users to effectively service and maintain their vehicle, ensuring optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Aprilia
Model:
RSV Mille
Year:
2002
Sub Model Designation:
RSV Mille
Segment:
Sportbike / Superbike
Country Of Origin:
Italy
👋 Introduction
Market Position
Target Market:
Owners and technicians seeking comprehensive repair and maintenance information for the 2002 Aprilia RSV Mille.
Competitive Analysis
Value Proposition:
Provides factory-level technical data and procedures at a fraction of the cost of dealership service, empowering DIY repairs and informed maintenance.
Key Features
Documentation Style:
Factory-level accuracy, detailed instructions, and extensive visual aids.
Cost Effectiveness:
Inexpensive way to maintain and repair the vehicle, saving on labor costs.
📋 Manual Details
Coverage Areas
Language:
English
Format:
PDF
Compatibility:
All Versions of Windows & Mac
Delivery Method:
Instant Download
Printability:
All pages printable
Searchability:
Likely searchable text within PDF
Software Requirements:
Adobe PDF Reader & WinZip
Manual Type:
Factory Service Repair Workshop Manual
Intended Audience:
Do-it-yourselfer and experienced mechanic
📖 Manual Coverage
Systems Covered
Engine Overhaul:
Complete engine disassembly, inspection, and reassembly procedures.
Fuel System:
Carburetor or Fuel Injection system diagnosis, cleaning, adjustment, and repair.
Cooling System:
Radiator, hoses, water pump, thermostat, and coolant flow diagnostics.
Electrical System:
Wiring diagrams, battery, charging system, ignition, lighting, and ECU troubleshooting.
Chassis Components:
Frame, suspension (front and rear forks, shock absorber), steering, and wheels.
Brakes:
Front and rear brake system maintenance, caliper service, fluid bleeding, and component replacement.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Bodywork And Fairings:
Fairing removal, installation, and repair procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug service.
Troubleshooting:
Diagnostic procedures for common and complex issues.
Component Rebuild:
Detailed instructions for rebuilding major components.
Torque Specifications:
Essential torque values for critical fasteners.
Schematics And Diagrams:
High-quality diagrams and exploded views for visual guidance.
Repair Information:
Specific repair procedures for various systems.
Service And Setup:
Initial setup and ongoing service adjustments.
Technical Depth
Depth Of Coverage:
Comprehensive, covering complete disassembly to detailed component repair.
Diagnostic Capabilities:
Advanced diagnostic flowcharts and troubleshooting guides.
Illustrations Quality:
Top quality diagrams and easy-to-read text sections.
Index Type:
Analytical Index for quick reference.
📊 Manual Specifications
File Format
File Type:
PDF
File Size:
Variable (dependent on content and compression, typically 50-200MB)
Print Quality
Print Resolution:
High resolution, suitable for clear printing of text and diagrams.
Binding Type
Binding Format:
Digital (No physical binding)
Paper Type
Paper Type For Print:
Standard copier paper suitable
⚙️ Engine Specifications
Primary Engine
Engine Type:
V-Twin (90-degree V-twin)
Engine Displacement:
998cc (997.6cc)
Bore X Stroke:
97 mm x 67.5 mm
Valvetrain:
DOHC, 4 valves per cylinder
Fueling:
Carburetor (Keihin CVKD40 twin carburetors on earlier models, often updated to EFI or aftermarket carbs later - *manual will detail original spec*).
Performance
Horsepower Estimate:
Approx. 130-135 hp @ 9000 rpm (crank)
Torque Estimate:
Approx. 102 Nm (75 lb-ft) @ 7200 rpm (crank)
Fuel System
Fuel Type:
Unleaded gasoline (95 RON recommended)
🔧 Transmission
Standard
Transmission Type:
6-speed sequential manual
Optional
Optional Transmission:
N/A
Features
Clutch Type:
Wet multi-plate clutch
Final Drive:
O-ring sealed chain
📐 Dimensions
Exterior
Length:
Approx. 2040 mm (80.3 in)
Width:
Approx. 720 mm (28.3 in) at handlebars
Height:
Approx. 1135 mm (44.7 in) at seat
Weights
Dry Weight:
Approx. 175 kg (386 lbs)
Wet Weight:
Approx. 198 kg (437 lbs)
🛡️ Safety Features
Ratings
Safety Rating:
N/A (Motorcycle safety ratings are typically not applicable in the same way as cars; focus is on design and engineering)
Active Features
Braking System:
Dual front disc brakes (320mm), single rear disc brake (220mm). Often equipped with radial-mount calipers.
Suspension Design:
Adjustable front forks (e.g., Showa or Paioli) and adjustable rear monoshock absorber.
Passive Features
Frame Construction:
Aluminum twin-spar frame
💡 Technology Features
Infotainment
Instrument Cluster:
Analog tachometer and digital speedometer, odometer, trip meters, coolant temperature gauge, and warning lights.
Driver Assistance
ABS:
ABS was generally not standard on the 2002 RSV Mille, but check for specific market options or aftermarket installations.
Connectivity
ECU:
Engine Control Unit (ECU) manages fuel injection (if applicable for later models/variants) and ignition timing.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 6,000-8,000 km (3,700-5,000 miles) or annually, whichever comes first.
Valve Clearance Check:
Typically around 24,000 km (15,000 miles), but the manual will specify exact intervals.
Chain Maintenance:
Regular cleaning, lubrication, and adjustment (check slack every 1,000 km).
Fluid Specifications
Engine Oil Type:
API SG/SH or JASO MA certified, SAE 10W-40 or 15W-50 (refer to manual for specific Aprilia recommendation).
Coolant Type:
Ethylene glycol-based antifreeze/coolant with corrosion inhibitors (typically a 50/50 mix with distilled water).
Brake Fluid Type:
DOT 4 or DOT 5.1 (check manual for specific DOT rating required for calipers and master cylinders).
Fork Oil Type:
Specific weight fork oil (e.g., Showa SS-02 or equivalent, refer to manual for viscosity and level).
Known Issues
Common Problems:
Stator failure (prone on many Italian bikes of this era), potential for starter solenoid issues, cam chain tensioner wear, occasional electrical gremlins. Fuel system tuning can be sensitive.
📚 Vehicle History
Brand Heritage
Aprilia History:
Aprilia is an Italian manufacturer renowned for its success in motorcycle racing, particularly in Grand Prix and Superbike championships, leveraging this expertise into its road-going sportbikes.
Model Evolution
Rsv Mille Introduction:
The RSV Mille was Aprilia's flagship sportbike, launched in 1998, designed to compete directly with Japanese and European superbikes. The 2002 model represents a refined version with various updates over its predecessors.
Production
Production Years Mille:
1998-2003 (for the first generation Mille, with subsequent R and Factory variants)
🏆 Awards & Recognition
Recognitions
Motorcycle Reviews:
The RSV Mille was generally praised by motorcycle journalists for its handling, powerful V-twin engine, and premium Italian styling and components.
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