2002-2003 Aprilia RSV Mille Workshop Service Repair Manual

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Type: Motorcycle

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Sku: 132596

Tags: 2002 2003 Aprilia Motorcycle Motorcycles RSV Mille RSV Models

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Description

The Aprilia RSV Mille, produced for the 2002-2003 model years, is a high-performance sportbike motorcycle renowned for its powerful V-twin engine, advanced chassis dynamics, and exceptional handling capabilities. Originating from Italy, the brand is recognized for its racing heritage and innovative sportbike designs, and the RSV Mille exemplifies this with its potent 998 cc V-twin engine delivering approximately 130-137 horsepower, coupled with a responsive 6-speed transmission and a robust chassis featuring advanced suspension and braking systems. This sportbike was engineered to compete with leading performance machines of its era, offering riders an exhilarating experience characterized by precise control and strong performance. This comprehensive Workshop Service Repair Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the Aprilia RSV Mille (RP chassis). It covers all essential systems, including the engine, fuel supply, cooling, electrical, and chassis components, offering step-by-step procedures for routine maintenance, major repairs, and diagnostic fault finding. The manual is designed to empower owners, mechanics, and technicians with the knowledge necessary to keep the RSV Mille in optimal condition, ensuring its performance, reliability, and longevity. Its detailed information, including technical specifications and potential issue diagnosis, makes it an indispensable resource for anyone working on this Italian sportbike.

🏷️ Basic Information

Identification

Make:

Aprilia

Model:

RSV Mille

Model Years Covered:

2002-2003

Vehicle Type:

Sportbike Motorcycle

Codes

Chassis Code General:

👋 Introduction

Market Position

Vehicle Class:

High-performance Sportbike

Target Audience:

Performance-oriented riders, DIY mechanics, track day enthusiasts

Competitive Analysis

Key Competitors Era:

Ducati 996/998, Yamaha R1, Suzuki GSX-R1000, Honda CBR900RR

Key Features

Manual Advantage:

Enables self-sufficient maintenance and repair, saving costs and enhancing understanding of the machine.

Vehicle Selling Points:

Powerful V-twin engine, advanced chassis dynamics, excellent handling and braking.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

Compatibility:

Windows / Mac

Page Count

Estimated Page Count:

High (Detailed Workshop Manual)

📖 Manual Coverage

Systems Covered

General Information:

Service And Setting Up:

Engine:

Fuel Supply System:

Cooling System:

Electrical System:

Chassis:

Repair Information:

Troubleshooting:

Analytical Index:

Procedures Included

Routine Maintenance:

Yes (Implied by Service and Setting Up)

Engine Overhaul:

Yes (Implied by Engine section)

Fuel System Cleaning And Adjustment:

Yes (Implied by Fuel Supply system)

Cooling System Flushing And Refilling:

Yes (Implied by Cooling system)

Electrical Diagnosis And Repair:

Yes (Implied by Electrical system)

Suspension Adjustment And Repair:

Yes (Implied by Chassis)

Brake System Service:

Yes (Implied by Chassis)

Diagnostic Troubleshooting:

Component Removal And Installation:

Yes (Implied by Repair Information)

Technical Depth

Depth Of Coverage:

Comprehensive Workshop Level

Diagnostic Capabilities:

Detailed troubleshooting guides and common fault diagnosis

Repair Instructions:

Step-by-step procedures for major component repairs and adjustments

Special Tools Required:

Likely includes information on Aprilia-specific tools

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable Text Content

Print Quality

Digital Quality:

High resolution, suitable for digital viewing and printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V-Twin, Four-stroke, Liquid-cooled

Displacement:

998 cc (61.0 cu in)

Bore X Stroke:

97.0 mm x 68.0 mm

Valve Train:

DOHC, 4 valves per cylinder

Performance

Horsepower Peak:

Approx. 130-137 hp (97-102 kW) at 9,500 rpm (varies by market/tune)

Torque Peak:

Approx. 70-75 lb-ft (95-102 Nm) at 7,500 rpm (varies by market/tune)

Fuel System

Fuel Delivery:

Fuel Injection (e.g., Weber Marelli or similar)

Fuel Type Recommendation:

Unleaded gasoline, minimum 95 octane RON (Research Octane Number)

Cooling System

Coolant Type:

Ethylene glycol based antifreeze coolant with corrosion inhibitors (refer to manual for specific Aprilia/Motul recommendation)

🔧 Transmission

Standard

Transmission Type:

6-speed, Constant Mesh

Optional

Optional Transmission:

Features

Clutch Type:

Wet, multi-plate clutch

Final Drive:

Chain drive

📐 Dimensions

Exterior

Length:

Approx. 2040 mm (80.3 in)

Width:

Approx. 720 mm (28.3 in) at handlebars

Height:

Approx. 1135 mm (44.7 in) at seat

Weights

Dry Weight:

Approx. 192 kg (423 lbs)

Wet Weight:

Approx. 210 kg (463 lbs) (with all fluids)

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycle specific ratings differ from cars)

Active Features

Braking System Front:

Dual 320 mm discs, radial-mount Brembo calipers

Braking System Rear:

Single 220 mm disc, Brembo caliper

Suspension Front:

43 mm upside-down telescopic fork (e.g., Showa or WP, adjustability varies by sub-model)

Suspension Rear:

Monoshock absorber with progressive linkage, adjustable preload, rebound, and compression

Passive Features

Lighting:

Halogen headlamps, LED taillight

💡 Technology Features

Infotainment

Infotainment System:

N/A (No infotainment system in the modern sense)

Driver Assistance

Traction Control:

Optional on some models, check specific bike VIN. Manual will detail its presence and function.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km or 12 months (refer to manual for precise intervals and conditions)

Spark Plug Replacement:

Typically around 12,000-24,000 km (refer to manual for specific plug type and interval)

Valve Clearance Check:

Every 12,000-24,000 km (critical for performance and engine longevity)

Fluid Specifications

Engine Oil Type Recommendation:

Fully synthetic SAE 10W-40 or 15W-50 motorcycle specific oil (e.g., Motul 3000 Plus, 5100, or 7100 series, check manual)

Coolant Capacity:

Approx. 2.5 liters (check manual for exact capacity)

Brake Fluid Type:

DOT 4

Clutch Fluid Type:

DOT 4 (Hydraulic clutch system)

Fork Oil Type And Viscosity:

Typically a 5W or 7.5W fork oil (refer to manual for exact specification and quantity)

Known Issues

Common Wear Items:

Clutch plates, wheel bearings, steering head bearings, chain and sprockets.

Potential Electrical Gremlins:

As with many bikes of this era, electrical connections and grounds can be a source of intermittent issues. Manual's electrical section is crucial.

Fuel Pump Reliability:

Early models sometimes experienced fuel pump issues; later revisions and maintenance are important.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Italy

Aprilia Legacy:

Known for racing pedigree and innovative sportbike designs.

Model Evolution

Rsv Mille Introduction:

Introduced in 1997 as Aprilia's first large-displacement sportbike, challenging established European manufacturers.

Generation Update 2002:

The 2002-2003 models represent a significant evolution with chassis refinements, engine updates, and improved electronics.

Production

Manufacturing Location:

Noale, Italy

🏆 Awards & Recognition

Recognitions

Motorcycle Press Reviews:

Generally received positive reviews for its performance, handling, and distinctive V-twin character.