Positioning:
The Aprilia RSV Mille (including the 2005 model) was positioned as a premium, high-performance sportbike, a direct competitor to Italian and Japanese superbikes of its era, known for its sophisticated chassis and powerful V-twin engine.
Competitors:
Competed with models like the Ducati 999, Yamaha R1, Suzuki GSX-R1000, and Honda CBR1000RR.
Highlights:
Known for its potent Rotax V-twin engine, advanced Öhlins suspension (on some variants), Brembo brakes, and Italian styling. The 2005 model often represents a mature iteration of the RSV Mille platform.
Primary Coverage:
Comprehensive service and repair
Specific Systems:
Engine, Fuel System, Exhaust System, Cooling System, Lubrication System, Chassis, Electrical System, Brakes, Suspension, Wheels and Tires, Bodywork, Troubleshooting
Estimated Page Count:
Hundreds of pages (specific number not provided)
Type:
Workshop Manual / Service Manual / Repair Manual
Language:
Likely English (standard for official manuals, not explicitly stated)
Format:
Printed (implied by 'hundreds of pages' and typical workshop manual format, PDF is also common for this era)
Engine:
Detailed disassembly, assembly, diagnostics, and component testing of the V-twin engine (e.g., cylinder head, pistons, crankshaft, valve train).
Fuel System:
Information on fuel injection system, injectors, fuel pump, pressure regulator, throttle bodies, and related sensors.
Exhaust System:
Details on exhaust manifold, catalytic converter (if applicable), mufflers, and emission control components.
Cooling System:
Procedures for radiator, cooling fan, water pump, thermostat, hoses, and coolant specifications.
Lubrication System:
Information on oil pump, oil filter, oil passages, oil change intervals, and lubricant specifications.
Chassis:
Covers frame, subframe, steering head, swingarm, bearings, and related hardware.
Electrical System:
Wiring diagrams, troubleshooting electrical faults, components like starter, alternator, battery, ignition system, lighting, and sensors.
Brakes:
Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, rotors, and bleeding procedures.
Suspension:
Front forks (e.g., upside-down forks), rear shock absorber, adjustment procedures, and specifications.
Wheels And Tires:
Wheel removal/installation, tire changing, balancing, and recommended tire pressures.
Bodywork:
Fairing removal and installation, seat, fuel tank, and other body panels.
Maintenance:
Regular service checks, oil changes, filter replacements, chain adjustment, spark plug replacement, brake fluid changes, coolant flushes.
Repair:
Complete disassembly and reassembly procedures for all major and minor components, including engine rebuilds, transmission overhauls, and suspension servicing.
Troubleshooting:
Diagnostic procedures for common problems, fault codes (if applicable to the ECU), and systematic approaches to identify and fix issues.
Diagnostics:
Guidance on using diagnostic tools and interpreting sensor data for performance issues.
Technical Data:
Torque specifications for all fasteners, clearances, timing information, and measurement procedures.
Depth:
Comprehensive, covering from basic maintenance to complete engine rebuilds and advanced diagnostics. Suitable for professional mechanics and experienced DIY enthusiasts.
Level Of Detail:
High, with detailed diagrams, exploded views, and step-by-step instructions.
Type:
Four-stroke, V-twin, 60-degree cylinder angle
Displacement:
998 cc (or 997.6 cc)
Bore X Stroke:
97 mm x 67.5 mm (typical for this generation)
Compression Ratio:
11.4:1 (typical)
Valve Train:
DOHC, 4 valves per cylinder, chain-driven camshafts
Cooling System:
Liquid-cooled
Lubrication:
Wet sump (typically)
Horsepower:
Approx. 125-130 hp (at crankshaft, depending on market and specific tuning)
Torque:
Approx. 70-73 lb-ft (at crankshaft, depending on market and specific tuning)
Induction:
Fuel Injection (EFI) - likely Marelli or similar ECU
Fuel Type:
Unleaded Gasoline (95 RON recommended)
Fuel Tank Capacity:
Approx. 18 Liters (4.75 US gallons)
Oil Change:
Every 4,000-6,000 km or annually (refer to manual for precise interval and conditions).
Spark Plugs:
Check every 8,000-12,000 km, replace as needed or at major service intervals.
Chain Maintenance:
Lubricate and adjust chain every 800-1,000 km or after riding in wet conditions.
Valve Clearance Check:
Typically every 12,000-24,000 km, critical for V-twin performance.
Engine Oil:
API SG or higher, JASO MA certified, SAE 10W-40 or 15W-50 (check manual for exact viscosity based on temperature range). Capacity approx. 3.0 - 3.5 Liters with filter change.
Coolant:
Ethylene glycol based antifreeze, 50/50 mix with distilled water. Capacity approx. 2.0 Liters.
Brake Fluid:
DOT 4 or DOT 5.1 (check manual for compatibility), flush and replace every 2 years.
Clutch Fluid:
DOT 4 (typically same as brake fluid), flush and replace periodically.
Common Problems:
Potential issues can include regulator/rectifier failures, stator winding issues, clutch slave cylinder leaks, and occasional electrical gremlins. Proper maintenance and addressing minor issues promptly are key.
Maintenance Notes:
The V-twin engine requires precise timing and valve clearance adjustments. Regular checks of the electrical system, especially the charging circuit, are crucial.
Heritage:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in smaller displacement classes and MotoGP. Known for performance-oriented, technically advanced motorcycles.
Evolution:
The RSV Mille was Aprilia's flagship sportbike, introduced in 1998. The 2005 model is part of the later generation, which saw refinements in chassis, engine management, and styling. It paved the way for the RSV1000R and later RSV4 models.
Production Years:
RSV Mille: 1998-2003; RSV Mille R: 1999-2003; RSV 1000 R: 2004-2008 (2005 model falls under this new nomenclature but retains much of the Mille DNA).
Manufacturing Location:
Italy
