Positioning:
The Aprilia RSV Mille of this era was a flagship sportbike, known for its Italian engineering, powerful V-twin engine, and premium components. It competed in the superbike segment against major Japanese and European manufacturers.
Competitors:
Dominated by bikes like the Ducati 996/998, Yamaha YZF-R1, Honda CBR929RR/954RR, Suzuki GSX-R1000, and Kawasaki ZX-9R.
Performance Highlights:
V-twin torque, sophisticated chassis, excellent handling, distinctive styling.
Dealer Level Content:
This manual provides the same in-depth technical information, diagrams, and procedures that official Aprilia dealerships use, empowering owners and independent workshops with factory-level knowledge.
Engine:
V-Twin, 4-stroke, liquid-cooled, DOHC, 4 valves per cylinder
Fuel System:
Electronic Fuel Injection (EFI), fuel pump, injectors, throttle body assembly
Ignition System:
Electronic ignition, coil-on-plug
Cooling System:
Radiator, fan, coolant circulation, thermostat
Exhaust System:
Exhaust headers, catalytic converter (if applicable), mufflers
Transmission:
6-speed constant mesh gearbox, clutch operation (hydraulic actuation)
Drivetrain:
Chain drive system, rear sprocket, front sprocket, chain maintenance
Frame Chassis:
Aluminum twin-spar frame, subframe, swingarm
Suspension Front:
Telescopic forks (e.g., Öhlins or Marzocchi for some variants), adjustability (preload, rebound, compression), fork seal replacement, oil changes
Suspension Rear:
Monoshock rear suspension, adjustable linkage, shock absorber maintenance, rebuild procedures
Brakes Front:
Dual hydraulic disc brakes, caliper identification (e.g., Brembo), pad replacement, fluid bleeding, disc inspection
Brakes Rear:
Single hydraulic disc brake, caliper, pad replacement, fluid bleeding, disc inspection
Wheels Tires:
Wheel bearing maintenance, tire mounting/balancing, recommended tire sizes
Electrical System:
Battery, charging system (alternator/stator), starter motor, lighting (headlights, taillights, indicators), wiring diagrams, fuses, relays
Instrumentation Controls:
Dashboard layout, gauge functions, switchgear operation
Bodywork:
Fairings, fuel tank, seat, tail section, removal and installation procedures
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid flush, coolant flush
Engine Overhaul:
Top-end rebuild, bottom-end rebuild, piston ring replacement, valve clearance adjustment, gasket replacement
Fuel System Diagnosis:
EFI troubleshooting, injector cleaning/testing, fuel pressure testing
Electrical Troubleshooting:
Wiring fault finding using diagrams, component testing, multimeter usage
Suspension Tuning:
Fork and shock adjustment guidance, suspension rebuilds
Brake System Service:
Caliprer rebuilds, master cylinder service, bleeding procedures
Clutch Service:
Hydraulic clutch system maintenance, bleeding
Bodywork Repair:
Fairing repair and replacement, mounting point checks
Depth:
Comprehensive - from basic rider maintenance to full workshop-level engine and chassis overhauls
Diagnostics Focus:
Detailed diagnostic procedures for all major systems
Torque Specifications:
All critical fasteners and components
Special Tools:
Identification and usage of specific tools required for certain procedures
Engine Type:
Rotax 60-degree V-twin, 4-stroke
Bore X Stroke:
97 mm x 68 mm
Valve Train:
DOHC, 4 valves per cylinder, chain driven
Cooling System:
Liquid-cooled
Horsepower Claimed:
Approx. 126-133 hp @ 9,500 rpm (depending on market and specific tune)
Torque Claimed:
Approx. 100 Nm (74 lb-ft) @ 7,500 rpm
Induction:
Electronic Fuel Injection (EFI), dual injectors per cylinder
Throttle Body:
Dual Ø 53 mm throttle bodies
Fuel Pump:
Internal in-tank electric pump
Ignition Type:
Electronic ignition, Coil-on-plug (COP)
Oil System:
Wet sump with oil cooler
Oil Type Specification:
Refer to manual for exact specification, typically a high-quality synthetic motorcycle oil meeting API SG or higher and JASO MA standard, e.g., Motul 5100 15W-50 or similar.
Oil Capacity Approx:
Approx. 3.5 Liters with filter change
Oil Change:
Typically every 6,000 - 10,000 km or annually, whichever comes first. Refer to manual for exact intervals.
Spark Plugs:
Recommended replacement around 12,000 - 24,000 km, depending on plug type. Manual will specify.
Valve Clearance Check:
Crucial for V-twins. Typically around 12,000 - 24,000 km. Requires shim adjustment. Detailed procedure in manual.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment (every ~1,000 km or as needed based on wear).
Brake Fluid Flush:
Every 2 years or as per manual recommendation to maintain performance and prevent corrosion.
Coolant Flush:
Typically every 2-3 years or as specified by coolant manufacturer/Aprilia.
Engine Oil:
Synthetic motorcycle oil, e.g., 15W-50, API SG/SH/SJ, JASO MA.
Coolant:
Ethylene glycol-based antifreeze, diluted 50/50 with distilled water. Specify a coolant suitable for alluminum engines.
Brake Fluid:
DOT 4 (for both front and rear brakes, and clutch).
Electrical Connections:
Corrosion or loose connections in connectors, particularly for charging system and ECU, can cause intermittent issues.
Stator Failure:
Early models or those subjected to high heat may experience stator failure, impacting charging system performance.
Regulator Rectifier:
Can be prone to overheating and failure, leading to charging issues. Upgraded units are available.
Fuel Pump Reliability:
While generally robust, the fuel pump can be a point of failure, especially with age and fuel quality.
Clutch Slave Cylinder:
Can sometimes develop leaks or wear, affecting clutch operation.
Valve Stem Seals:
Can degrade over time, leading to oil consumption or blue smoke on startup, particularly on higher mileage examples.
