Market Position:
High-performance sportbike, a premium offering from Aprilia known for its V-twin engine and racing pedigree.
Target Audience:
Enthusiasts seeking to maintain, repair, or customize their high-performance Italian sportbike.
Competitive Analysis:
Competed against other European and Japanese superbikes of its era, such as Ducati 996, Yamaha YZF-R1, Honda CBR929RR/954RR, and Suzuki GSX-R1000.
Key Features:
Powerful V-twin engine, advanced chassis design, racing-derived suspension, and sophisticated electronics for its time.
Coverage Areas:
Comprehensive service and repair for the 2002 Aprilia RSV Mille motorcycle.
Diagnostic Support:
Provides guidance for diagnosing common and complex issues across all major motorcycle systems.
Page Count:
Not specified (Digital PDF)
Manual Type:
Workshop Service Repair Manual
Purpose:
Diagnostic, repair, and maintenance guide for technicians and owners.
Document Source:
Factory/Official Service Repair Workshop Manual.
Format:
Digital PDF Download
Compatibility:
Compatible with all versions of Windows & Mac, smartphones, iPads, and other portable storage devices.
Lifetime Support:
Includes a Lifetime Protection Policy for replacement if lost or damaged.
Systems Covered:
General Information, Assembly and Disassembly, Routine Maintenance, Engine Removal and Installation, Fuel System, Lubrication and Cooling System, Engine Specifications, Transmission, Drive Chain & Sprockets, Steering System, Shocks, Body Work, Intake & Exhaust, Electrical System, Advanced Troubleshooting.
Electrical System Details:
Wiring diagrams, component locations, troubleshooting for lighting, ignition, charging system, fuel injection, and other electrical components.
Suspension Details:
Front forks (e.g., Ohlins or Showa depending on sub-model/options), rear monoshock, adjustments, maintenance, and overhaul procedures.
Chassis Details:
Frame inspection, steering head bearing maintenance, swingarm and rear suspension linkage service.
Bodywork Details:
Fairing removal and installation, seat, fuel tank mounting, tail section components.
Intake Exhaust Details:
Airbox, intake runners, exhaust header pipes, muffler assembly, and associated components.
Procedures Included:
Tune-ups, lubrication, major engine rebuilds, transmission rebuilds, disassembly, repair, assembly, inspections, troubleshooting, parts identification, torque specifications, fuel pressure charts, electrical data, compression ranges, tolerances, and more.
Engine Rebuild Scope:
Detailed procedures for piston replacement, cylinder head service, crankshaft inspection, and camshaft timing.
Fuel System Service:
Throttle body synchronization, fuel injector cleaning/replacement, fuel pressure testing, fuel pump diagnosis.
Transmission Overhaul:
Gearbox disassembly and reassembly, shift drum and fork inspection, clutch assembly and adjustment.
Cooling System Service:
Radiator flush, coolant replacement, thermostat inspection, fan operation checks.
Technical Depth:
Factory/Official OEM specifications and procedures suitable for professional mechanics and experienced enthusiasts with basic mechanical knowledge. Covers detailed step-by-step repairs.
Oem Data Provided:
Includes OEM torque specifications, fuel pressure charts, electrical connector data, compression ranges, minimum and maximum tolerances, and potential part numbers/paint codes.
Diagrams Illustrations:
Features exploded diagrams before disassembly sections, along with charts and photos to aid in procedures.
Engine Type:
V-Twin, Four-stroke
Engine Displacement:
997.6 cc
Bore X Stroke:
97 x 67.5 mm
Valve Train:
DOHC, 4 valves per cylinder
Ignition System:
Electronic ignition, likely with dual spark plugs per cylinder.
Starter System:
Electric starter.
Horsepower:
Approx. 130-135 hp (at crankshaft)
Torque:
Approx. 98-100 Nm (at crankshaft)
Compression Ratio:
Approx. 11.4:1
Fuel System Type:
Fuel Injection (Multi-point)
Fuel Type:
Unleaded gasoline (Premium/Super)
Throttle Body Size:
54 mm
Oil Change Interval:
Recommended every 5,000 - 7,500 km or annually, whichever comes first (refer to manual for specific details).
Valve Clearance Check:
Typically around 10,000 - 15,000 km (refer to manual for precise interval).
Engine Oil Type:
API SG, JASO MA certified, SAE 10W-40 synthetic or semi-synthetic motorcycle oil (specific Aprilia recommended viscosity may vary).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (50/50 mix with distilled water).
Brake Fluid Type:
DOT 4 or DOT 5.1.
Clutch Fluid Type:
DOT 4 or DOT 5.1 (same as brake fluid, unless specified otherwise).
Engine Oil Capacity:
Approx. 3.2 - 3.5 Liters (depending on filter change)
Known Issues:
Potential issues can include regulator/rectifier failure, stator issues, stator wiring harness problems, fuel pump issues, and occasional electrical gremlins. Some owners report sensitivity to maintenance quality.
Performance Tuning Considerations:
Manual provides baseline specifications; tuning for performance upgrades will require supplementary resources or expertise.
Brand Heritage:
Aprilia is an Italian manufacturer with a strong racing heritage, particularly in Grand Prix motorcycle racing, translating that expertise into their road-going sportbikes.
Model Evolution:
The RSV Mille was Aprilia's flagship sportbike, introduced to compete in the litre-class superbike market. The 2002 model represents an evolution of the original design, often featuring minor refinements in engine performance, suspension, and styling.
Key Developments 2002:
May include refined ECU mapping, updated suspension settings, or minor cosmetic changes compared to earlier models.
Production Period:
The RSV Mille platform was in production from 1998 to 2003, evolving into the RSV1000R and later the RSV4.
