Market Position:
The Aprilia RSV Mille (RP platform) was a flagship superbike from its inception, targeting the premium sportbike segment with its Italian flair, powerful V-twin engine, and advanced chassis technology. It competed directly with established Japanese and European litre-class sportbikes.
Competitors:
Key competitors included the Ducati 996/998, Yamaha YZF-R1, Honda CBR929RR/954RR Fireblade, Suzuki GSX-R1000, and Kawasaki Ninja ZX-10R.
Key Features:
Rotax 990cc V-twin engine, advanced chassis dynamics, distinctive Italian design, high-performance braking and suspension components, focus on rider feedback.
Purpose:
This workshop service repair manual is an indispensable tool for owners and technicians seeking to maintain, diagnose, and repair the 2001-2003 Aprilia RSV Mille. It provides detailed procedures and specifications required for all mechanical and electrical aspects of the motorcycle.
Engine:
Complete overhaul, diagnostics, tuning, fuel injection, ignition system, lubrication, cooling system
Transmission:
Clutch operation and replacement, gearbox disassembly and assembly, shift mechanism, lubrication
Chassis:
Frame inspection and repair, front fork (suspension, seals, oil), rear shock absorber, steering head bearings
Brakes:
Front and rear brake system hydraulics, caliper service, disc inspection, master cylinder overhaul, bleeding procedures
Electrical:
Wiring diagrams, battery, charging system (alternator, regulator), starting system, lighting, instruments, ECU diagnostics
Fuel System:
Fuel tank, fuel pump, injectors, fuel pressure regulator, EFI system troubleshooting
Exhaust:
Exhaust system inspection, component replacement
Cooling System:
Radiator, fan, thermostat, coolant circulation, fluid specifications
Maintenance:
Scheduled maintenance, oil and filter changes, chain adjustment, tire pressure, brake pad inspection
Troubleshooting:
Diagnostic flowcharts for common issues, electrical fault finding, engine performance problems
Repair:
Component disassembly, reassembly, calibration, and replacement for all major systems
Inspection:
Pre-ride checks, detailed component inspection guidelines
Specifications:
Torque values, clearances, tolerances for all fasteners and components
Depth:
Comprehensive from basic rider maintenance to full engine and electrical system rebuilds, suitable for professional mechanics and experienced enthusiasts
Engine Type:
V-twin, four-stroke, liquid-cooled
Displacement:
998 cc (60.9 cu in)
Bore X Stroke:
97 mm x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Horsepower:
Approx. 130-135 hp @ 9,500 rpm (varies by market and specific model year)
Torque:
Approx. 100-105 Nm @ 7,000 rpm (varies by market and specific model year)
Fuel Delivery:
Electronic Fuel Injection (EFI), multi-point injection
Fuel Type:
Unleaded gasoline, minimum 95 RON
Ignition System:
Digital electronic ignition with variable ignition timing
Oil Type:
API SG or higher, JASO MA certified, SAE 10W-40 or 15W-50 (refer to manual for exact specifications)
Coolant Type:
Ethylene glycol-based coolant, 50% mixture with distilled water
Length:
Approx. 2,080 mm (81.9 in)
Width:
Approx. 720 mm (28.3 in) at handlebars
Height:
Approx. 1,135 mm (44.7 in) at seat
Wheelbase:
Approx. 1,410 mm (55.5 in)
Dry Weight:
Approx. 195 kg (430 lbs)
Wet Weight:
Approx. 210 kg (463 lbs)
Fuel Tank Capacity:
21 Liters (5.5 US gal)
Front Tire Size:
120/70 ZR17
Rear Tire Size:
190/50 ZR17
Wheel Bolt Pattern:
N/A (Magnesium alloy wheels, typically 3-bolt for race-oriented designs; specific OEM pattern required from manual)
Safety Ratings:
Motorcycles of this era are not typically assigned formal crash test ratings like automobiles. Safety relies on inherent design and rider skill.
Braking System:
Dual front discs with Brembo 4-piston calipers, single rear disc with Brembo caliper. Optional ABS was not standard on this model range but could be available on specific variants or aftermarket.
Suspension:
Fully adjustable upside-down front forks (e.g., Öhlins or Showa on some variants) and adjustable rear monoshock, providing significant control and stability.
Lighting:
Dual halogen headlights, LED tail light
Frame Construction:
Aluminum alloy twin-spar frame for rigidity and lightweight
Infotainment System:
Basic analogue and digital instrument cluster displaying speed, RPM, engine temperature, fuel level, clock, and basic trip functions. No advanced infotainment systems common in modern motorcycles.
Driver Assistance Features:
Limited. Primarily advanced chassis and suspension tuning for rider control. No electronic rider aids like traction control or advanced ABS typical of later models.
Connectivity Features:
N/A
Engine Management System:
Marelli (or similar) ECU controlling fuel injection and ignition timing. Diagnostics can be performed via specific connectors as detailed in the manual.
Oil Change Interval:
Every 5,000 - 7,500 km (3,000 - 4,500 miles) or annually, whichever comes first (refer to manual for precise intervals).
Filter Change Interval:
Typically with every oil change, or as specified in manual.
Valve Clearance Check:
Every 10,000 - 15,000 km (6,000 - 9,000 miles) (crucial for V-twins).
Chain Maintenance:
Clean and lubricate every 500 km (300 miles), adjust as needed.
Brake Fluid:
DOT 4 (refer to manual for specific DOT rating and replacement interval)
Coolant:
50% Ethylene Glycol mixture with distilled water
Fork Oil:
Specific viscosity and volume for front forks (e.g., Showa SS-47 or equivalent, 5W-10W range) - consult manual for exact type and quantity.
Common Issues:
Potential issues include stator failure (charging system), regulator/rectifier issues, fuel pump wear, occasional ECU glitches, and wear on steering head bearings. Regular maintenance is key.
Maintenance Focus Areas:
Regular inspection of the electrical connectors, fuel system cleanliness, and proper suspension setup are vital for optimal performance and longevity.
Brand Heritage:
Aprilia, an Italian manufacturer, has a rich history in motorcycle racing, particularly in smaller displacement classes and Grand Prix racing. This heritage influenced the development of their road-going sportbikes, prioritizing performance and handling.
Model Evolution:
The RSV Mille, introduced in 1998, marked Aprilia's significant entry into the litre-class superbike market. The 2001-2003 models (RP generation) represented an evolution of the original design, with refinements to the engine, chassis, electronics, and styling, including updates to the fuel injection system and chassis geometry for improved performance and handling.
Production Location:
Noale, Italy
Production Years:
1998-2003 (RP generation)
Recognitions:
The RSV Mille was widely praised by motorcycle publications for its potent V-twin engine, sophisticated chassis, and aggressive styling, often earning high marks in comparisons against its contemporaries for its unique character and performance.
Magazine Reviews:
Consistently reviewed as a top-tier sportbike, celebrated for its Italian character, sound, and track-day capability.
