The 2002 Aprilia RSV Mille is a distinguished Italian sportbike, powered by a robust Rotax 998cc V-twin engine. Known for its potent performance and sophisticated chassis, this model competed directly with leading superbikes of its era, offering a unique blend of power, handling, and exotic Italian design. Its engineering quality is evident in features like the advanced suspension, powerful braking system, and aerodynamic fairings, all contributing to its reputation as a high-performance machine built for discerning riders.
This comprehensive Service and Repair Manual provides in-depth guidance for the 2002 Aprilia RSV Mille. It covers all essential systems, including the engine, fuel, ignition, cooling, exhaust, transmission, clutch, drivetrain, chassis, suspension, brakes, wheels, tires, electrical components, lighting, instruments, and bodywork. The manual details routine maintenance, scheduled servicing, disassembly and reassembly procedures, diagnostic techniques, troubleshooting, and repair instructions, making it an indispensable resource for owners and technicians seeking to maintain or restore the RSV Mille.
๐ท๏ธ Basic Information
Market Position:
The 2002 Aprilia RSV Mille positioned itself as a high-performance Italian sportbike, directly competing with established Japanese superbikes and other European exotic motorcycles. It was lauded for its potent V-twin engine and sophisticated chassis dynamics.
Competitive Analysis:
Competed against models such as the Ducati 996/998 series, Yamaha YZF-R1, Honda CBR929RR/CBR954RR, and Suzuki GSX-R1000. The RSV Mille offered a distinct V-twin character and often a more exotic feel.
Key Features:
Powerful Rotax V-twin engine, lightweight aluminum frame, advanced suspension components (รhlins optional on some variants), aerodynamic fairing, high-performance braking system, sophisticated electronics for its era.
Coverage Areas:
Comprehensive service and repair for the 2002 Aprilia RSV Mille
Page Count:
Hundreds of pages
Manual Type:
Service and Repair Manual
Language:
English (assumed, typical for service manuals of this nature)
Systems Covered:
Engine, Fuel System, Ignition System, Cooling System, Exhaust System, Transmission, Clutch, Drivetrain, Chassis, Suspension (Front and Rear), Brakes (Front and Rear), Wheels and Tires, Electrical System, Lighting, Instruments, Bodywork, Fairings, Maintenance Procedures, Troubleshooting
Procedures Included:
Routine maintenance, scheduled servicing, detailed disassembly and reassembly of all major components, diagnostic procedures, troubleshooting guides, repair instructions, specifications for adjustments and tolerances, electrical circuit diagrams, torque specifications, special tool requirements
Technical Depth:
Expert-level detail suitable for professional technicians and experienced DIY mechanics, covering everything from basic fluid changes to complete engine rebuilds and electrical system diagnostics.
๐ Manual Specifications
File Format:
Portable Document Format (PDF)
Print Quality:
High-resolution scans of original factory manual, optimized for clear viewing and printing. Includes legible diagrams and schematics.
Binding Type:
Digital (PDF). For print versions, binding would typically be comb or spiral for lay-flat usability.
Paper Type:
N/A (Digital Format). If printed, would be high-quality paper to withstand workshop environments.
โ๏ธ Engine Specifications
Engine Type:
Four-stroke, liquid-cooled, 60-degree V-twin
Bore X Stroke:
97 mm x 67.5 mm
Compression Ratio:
11.3:1
Horsepower:
Approx. 128 hp @ 9,700 rpm
Torque:
Approx. 72 lb-ft @ 7,000 rpm
Fuel System:
Electronic Fuel Injection (EFI) with dual throttle bodies, 54mm diameter
Fuel Type:
Unleaded Premium Gasoline (95 RON / 91 AKI)
Ignition System:
Electronic ignition with independent spark advance for each cylinder
Cooling System:
Liquid-cooled, with thermostatically controlled fan
Lubrication System:
Wet sump, forced lubrication with oil cooler
Transmission Type:
6-speed constant mesh
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Final Drive:
Chain driven
Transmission Fluid Type:
SAE 75W/90 API GL-4 or GL-5 (refer to manual for specific viscosity recommendation)
Transmission Oil Capacity:
Approx. 0.75 Liters
Width:
Approx. 720 mm (at handlebars)
Height:
Approx. 1,150 mm (at windshield)
Wheelbase:
Approx. 1,410 mm
Dry Weight:
Approx. 195 kg
Wet Weight:
Approx. 215 kg (fully fueled)
Fuel Tank Capacity:
21 Liters (including 3-liter reserve)
Front Suspension Type:
43mm upside-down telescopic fork (e.g., Showa or รhlins)
Front Suspension Travel:
Approx. 120 mm
Rear Suspension Type:
Monoshock with progressive linkage (e.g., รhlins)
Rear Suspension Travel:
Approx. 130 mm
Front Wheel Size:
3.50 x 17
Rear Wheel Size:
5.50 x 17
Front Tire Size:
120/70ZR17
Rear Tire Size:
180/55ZR17
Wheel Bolt Pattern:
N/A (typical for cast aluminum wheels)
Safety Ratings:
Motorcycle safety is primarily based on rider skill and component performance. No formal crash test ratings as with automobiles.
Active Features:
Powerful dual front disc brakes with radial-mount calipers, single rear disc brake, advanced chassis geometry for stability, well-tuned suspension.
Passive Features:
Robust frame construction, integrated fairings for rider protection, standard rider controls.
Front Brake Type:
Dual 320 mm discs, radial-mount Brembo calipers (4-piston)
Rear Brake Type:
Single 220 mm disc, Brembo caliper (2-piston)
Infotainment System:
N/A (No infotainment system on this model)
Driver Assistance Features:
N/A (No electronic rider aids like traction control or ABS on the standard 2002 model)
Performance Electronics:
Engine control unit (ECU) managing fuel injection and ignition timing. Digital dashboard with basic readouts.
Oil Change Interval:
Refer to manual (typically every 5,000 - 7,500 km or annually, whichever comes first)
Valve Clearance Check Interval:
Refer to manual (typically every 10,000 - 15,000 km)
Spark Plug Replacement Interval:
Refer to manual (typically every 15,000 - 20,000 km)
Engine Oil Type:
Fully synthetic motorcycle oil, SAE 10W-40 or 15W-50, API SG/SH/SJ or higher, JASO MA certified (refer to manual for exact specification)
Coolant Type:
Ethylene glycol-based antifreeze mixture with distilled water (50/50 ratio)
Brake Fluid Type:
DOT 4 or DOT 5.1 (refer to manual for exact specification)
Engine Oil Capacity:
Approx. 3.5 Liters (with filter change)
Cooling System Capacity:
Approx. 2.3 Liters
Known Issues:
Potential issues include stator failure, voltage regulator issues, occasional fuel pump problems, and some electrical connector degradation over time. Early models had camshaft recall. Proper maintenance is key to longevity.
Oil Filter Part Number:
Commonly compatible with HiFloFiltro HF153, K&N KN-153 (verify with manual or cross-reference)
Air Filter Part Number:
Commonly compatible with K&N RU-2810 (verify with manual or cross-reference)
Brand Heritage:
Aprilia, an Italian manufacturer, has a rich history in motorcycle racing, particularly in Grand Prix championships. This racing pedigree heavily influenced the design and performance of their road-going sportbikes.
Model Evolution:
The RSV Mille was introduced in 1997 as Aprilia's flagship superbike. The 2002 model represents a significant iteration, often featuring styling updates and mechanical refinements over earlier versions. It paved the way for later models like the RSV1000R and the groundbreaking RSV4.
Production Period:
1997 - 2003 (for the original RSV Mille design, with the 2002 model being a key year in its development)
Production Location:
Italy
๐ Awards & Recognition
Recognitions:
While specific awards for the 2002 model are difficult to pinpoint without access to contemporary reviews, the RSV Mille series was consistently praised by motorcycle journalists for its potent V-twin engine, handling, and distinctive Italian character.
