1998-2003 Aprilia RST/RSV Mille Motorcycle Workshop Repair & Service Manual (360 Pages Searchable Bookmarked iPad-ready)

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Type: Motorcycle

Vendor:

Sku: 153541

Tags: 1998 1999 2000 2001 2002 2003 Aprilia Mille Misc Motorcycle Motorcycles RST RSV

Product variants

Description

This workshop repair and service manual provides comprehensive information for the Aprilia RST and RSV Mille motorcycles produced between 1998 and 2003. These Italian-engineered sportbikes are celebrated for their potent V-twin engines, delivering exhilarating performance and agile handling, distinguishing them through Italian design and craftsmanship. This manual is an essential resource for owners and technicians seeking to understand and maintain these high-performance machines, covering a wide range of technical aspects from routine maintenance to in-depth repairs. The scope of this 360-page English-language manual encompasses detailed procedures for all major systems, including the engine, fuel, ignition, cooling, transmission, suspension, brakes, and electrical systems. It offers guidance on routine maintenance tasks, comprehensive troubleshooting for common issues such as electrical gremlins and regulator/rectifier failures, and in-depth repair instructions for engine and suspension overhauls. With its searchable, bookmarked, and printable digital format, this manual serves as an authoritative guide to ensure the optimal performance and longevity of your Aprilia RST or RSV Mille.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RST / RSV Mille

Product Type:

Workshop Repair & Service Manual

Applicable Years:

1998, 1999, 2000, 2001, 2002, 2003

👋 Introduction

Market Position

Segment:

High-performance sportbike/naked sportbike.

Target Audience:

Enthusiast riders and independent repair shops.

Competitive Analysis

Competitors:

Ducati 916/996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR900RR.

Key Features

Unique Selling Points Vehicle:

V-twin engine, Italian design and craftsmanship, agile handling.

Unique Selling Points Manual:

Digital format, extensive coverage, ease of access and searchability.

📋 Manual Details

Coverage Areas

General Coverage:

Comprehensive repair and service information for Aprilia RST and RSV Mille motorcycles.

Page Count

Total Pages:

Manual Type

Type:

Workshop Repair and Service Manual

Language

Language:

English

Format

Format:

Digital (PDF)

Features:

Searchable, Bookmarked, Printable, iPad-ready

📖 Manual Coverage

Systems Covered

Engine:

Engine assembly, disassembly, inspection, troubleshooting, and repair.

Fuel System:

Fuel injection system (EFI), fuel pump, injectors, sensors, and troubleshooting.

Ignition System:

Ignition coils, spark plugs, ECU, and troubleshooting.

Cooling System:

Radiator, cooling fan, water pump, thermostat, coolant specifications, and maintenance.

Exhaust System:

Exhaust pipes, mufflers, catalytic converter (if applicable), and inspection.

Transmission Drivetrain:

Clutch operation, gearbox disassembly, assembly, inspection, and final drive maintenance.

Suspension Front:

Front forks (telescopic), seals, oil, springs, adjustments, and rebuild procedures.

Suspension Rear:

Rear shock absorber, linkage, swingarm, bearings, and adjustments.

Brakes Front:

Brake calipers, master cylinder, brake lines, discs, pads, bleeding procedures, and troubleshooting.

Brakes Rear:

Rear brake caliper, master cylinder, brake lines, disc, pads, bleeding procedures, and troubleshooting.

Wheels Tires:

Wheel bearings, tire inspection, replacement, and recommended pressures.

Electrical System:

Battery, charging system (alternator/stator, regulator/rectifier), starter motor, lighting, wiring diagrams, and component testing.

Instrumentation Controls:

Dashboard, gauges, switches, throttle, clutch lever, and brake lever adjustments.

Bodywork Frame:

Fairings, seat, fuel tank, frame inspection, and minor bodywork repairs.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug checks, brake fluid checks, coolant checks.

Troubleshooting:

Diagnostic procedures for common electrical, engine, and mechanical issues.

Engine Rebuild:

Complete engine disassembly, inspection of internal components (pistons, rings, valves, crankshaft), and reassembly.

Suspension Fork Rebuild:

Detailed steps for disassembling, cleaning, replacing seals and oil, and reassembling front forks.

Brake System Service:

Brake pad replacement, caliper servicing, master cylinder replacement, and brake fluid flushing/bleeding.

Electrical Diagnostics:

Wiring harness testing, component voltage checks, and fault diagnosis using wiring diagrams.

Torque Specifications:

Critical torque values for all major fasteners and components.

Technical Depth

Depth:

Comprehensive, covering routine maintenance to major component overhaul and repair.

📊 Manual Specifications

File Format

Format:

Searchability:

Yes (text-based PDF)

Printability:

Device Compatibility:

iPad-ready

Organization:

Bookmarked for easy navigation

⚙️ Engine Specifications

Primary Engine

Type:

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

Displacement:

996 cc (60.8 cu in)

Bore X Stroke:

98 mm x 66 mm (3.86 x 2.60 in)

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower Approx:

123 hp (91.7 kW) @ 9500 rpm

Torque Approx:

70 ft-lb (95 Nm) @ 7500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential multi-point injection

Fuel Type:

Unleaded gasoline, minimum 95 RON

Lubrication

Oil Type:

API SG/SH or JASO MA certified 10W-40 or 15W-50 synthetic motorcycle oil

Oil Capacity:

Approximately 3.4 liters (3.6 US qt) with filter change

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Clutch:

Hydraulically operated, wet multi-plate clutch

Features

Gear Ratios:

Specific ratios detailed within the manual for each gear.

Final Drive:

O-ring sealed chain

📐 Dimensions

Exterior

Length Approx:

2050 mm (80.7 in) - varies by model variant

Width Approx:

720 mm (28.3 in) - varies by model variant

Height Approx:

1150 mm (45.3 in) - varies by model variant

Weights

Dry Weight Approx:

195 kg (430 lbs) - varies by model variant

Fuel Tank Capacity:

21 liters (5.5 US gal)

🛡️ Safety Features

Active Features

Brakes:

Dual front disc brakes, single rear disc brake.

Suspension:

Adjustable front forks and rear shock absorber for improved stability and control.

Passive Features

Lighting:

Dual headlights for improved night visibility.

Frame:

Aluminum twin-spar frame providing rigidity and stability.

💡 Technology Features

Infotainment

Features:

N/A (focus on performance and mechanicals, no digital infotainment system typical of modern bikes).

Driver Assistance

Features:

N/A (no electronic rider aids like ABS or traction control common on this era of performance bike).

Connectivity

Features:

N/A (no electronic connectivity features).

🔧 Maintenance

Service Intervals

Oil Change:

Every 6,000 km (3,750 miles) or annually.

Air Filter Check:

Every 6,000 km (3,750 miles), replace as needed.

Spark Plug Check:

Every 12,000 km (7,500 miles), replace as needed.

Coolant Flush:

Every 24,000 km (15,000 miles) or every two years.

Brake Fluid Flush:

Every 24,000 km (15,000 miles) or every two years.

Fluid Specifications

Coolant:

Ethylene glycol-based antifreeze, 50% mixture with distilled water.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Fork Oil:

Specific viscosity and quantity detailed in the manual (e.g., Showa SS-02 or equivalent).

Known Issues

Electrical Gremlins:

Common issues with wiring harness integrity and stator failures, as detailed in troubleshooting sections.

Cam Chain Tensioner:

Potential wear on automatic cam chain tensioners, requiring periodic inspection or replacement with manual units.

Regulator Rectifier:

Tendency for early regulator/rectifier units to overheat and fail, impacting charging system.

📚 Vehicle History

Brand Heritage

Manufacturer:

Aprilia is an Italian manufacturer known for its performance-oriented motorcycles.

Model Evolution

Launch Year:

RSV Mille launched in 1997, RST Futura derived from it in 1999.

Key Updates During Period:

Improvements to ECU mapping, suspension components, and minor styling updates across the model years.

Production

Manufacturing Location:

Italy

🏆 Awards & Recognition

Recognitions

General:

The RSV Mille was critically acclaimed for its performance, handling, and V-twin character upon release.