🏷️ Basic Information

Make:

Aprilia

Model:

RSV Mille

Model Variant:

RSV Mille (initial generation)

Chassis Code:

RP (may vary slightly by specific sub-model/year)

Engine Code:

Rotax 60° V-Twin (specific code depends on variant, e.g., RGV1000 for early models with reference to engine origin)

👋 Introduction

Category:

Sportbike / Superbike

Target Audience:

Performance motorcycle enthusiasts, track day riders, and owners seeking to perform their own maintenance and repairs.

Competitors:

Ducati 916/996, Yamaha YZF-R1, Suzuki GSX-R1000, Honda CBR900RR/954RR, Kawasaki ZX-9R.

Design Philosophy:

Aprilia's focus on Italian design, potent V-twin engine performance, and high-quality chassis components.

📋 Manual Details

Applicable Years:

Primarily 2002, but applicable to a wider range of the first generation RSV Mille, typically from 1997-2003/2004.

Total Pages:

386

Type:

Service and Repair Manual

Language:

Likely English (standard for major service manuals, confirmation may be needed)

Format:

Digital (PDF is common, though printed versions exist)

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, disassembly, assembly, torque specifications, valve clearance, timing, cooling system, lubrication system.

Fuel System:

Carburetor tuning and rebuilding (Keihin CVK or similar depending on specific variant), fuel pump, fuel tank, lines.

Ignition System:

Ignition timing, coil testing, spark plug specifications, CDI unit.

Electrical System:

Wiring diagrams, battery, charging system (alternator, regulator/rectifier), lighting, starter system, instrumentation.

Transmission Drivetrain:

Clutch operation and replacement, gearbox disassembly and assembly, gear ratios, chain and sprocket maintenance.

Suspension:

Front fork service and overhaul (including oil type and level), rear shock absorber adjustment and replacement, linkages.

Brakes:

Brake caliper overhaul, master cylinder service, brake fluid types and bleeding procedures, rotor specifications, pad replacement.

Steering:

Steering head bearing adjustment and replacement, handlebar mounting.

Cooling System:

Radiator, fan, thermostat, coolant types and capacities, bleeding procedures.

Exhaust System:

Exhaust pipe mounting, mufflers, gasket replacement.

Bodywork Frame:

Fairing removal and installation, seat, fuel tank mounting, frame inspection.

Scheduled Maintenance:

Oil changes, filter replacement, chain adjustment, spark plug replacement, valve clearance checks, brake fluid flushes.

Troubleshooting:

Diagnostic flowcharts for common issues, electrical system faults, engine performance problems.

Component Rebuild:

Detailed step-by-step instructions for overhauling major components like engines, carburetors, and brake calipers.

Adjustment Calibration:

Carburetor synchronization, chain slack, suspension settings, steering head torque.

Specifications Tables:

Comprehensive tables of all critical torque values, fluid capacities, wear limits, and electrical resistance.

Depth:

Comprehensive, covering from basic servicing to complete engine and chassis rebuilds.

Diagnostic Capability:

Detailed diagnostic procedures, including checking electrical signals, fuel delivery, and mechanical tolerances.

📊 Manual Specifications

Digital Format:

Likely PDF, offering searchability and print-on-demand capability.

Print Quality:

If printed, typically black and white with clear diagrams and text. Digital format preserves original quality.

Binding:

N/A for digital format. If printed, typically spiral-bound for lay-flat use or perfect bound.

Paper Quality:

N/A for digital format. If printed, typically on durable paper suitable for workshop environments.

⚙️ Engine Specifications

Engine Type:

Four-stroke, liquid-cooled, 60° V-twin, DOHC, 4 valves per cylinder.

Displacement:

998 cc (for most common variant; some early models might be slightly different or refer to specific Italian market configurations).

Bore X Stroke:

97 mm x 67.5 mm (typical for 998cc variant)

Compression Ratio:

10.8:1 (typical)

Horsepower:

Approx. 130-135 HP @ 9,250 RPM (at crank, depending on specific tuning and market).

Torque:

Approx. 102 Nm (75 lb-ft) @ 7,500 RPM (at crank, depending on specific tuning and market).

Carburetors:

Twin Keihin 54mm CV (Constant Velocity) carburetors (typical for 2002 model).

Fuel Type:

Unleaded gasoline, minimum 95 RON (Octane rating).

🔧 Transmission

Transmission Type:

6-speed constant mesh sequential

Optional Gearbox:

N/A (standard for the model)

Clutch Type:

Hydraulically operated, wet multi-plate clutch.

Final Drive:

Chain drive, 530 O-ring type.

📐 Dimensions

Length:

Approx. 2,050 mm (80.7 in)

Width:

Approx. 720 mm (28.3 in) at handlebars

Height:

Approx. 1,125 mm (44.3 in) at seat

Wheelbase:

Approx. 1,410 mm (55.5 in)

Dry Weight:

Approx. 195 kg (430 lbs)

Wet Weight:

Approx. 214 kg (472 lbs) (fully fueled)

Fuel Capacity:

21 liters (5.5 US gal)

🛡️ Safety Features

Safety Classification:

N/A (motorcycles are not rated by agencies like NHTSA or Euro NCAP in the same way cars are).

Braking System:

Dual 320mm discs with 4-piston radial calipers (front), Single 220mm disc with 2-piston caliper (rear).

Suspension Features:

Adjustable front forks (preload, compression, rebound), adjustable rear monoshock (preload, rebound).

Lighting:

Dual halogen headlights, LED taillight.

Frame Type:

Aluminum twin-spar frame for rigidity and light weight.

💡 Technology Features

Instrument Cluster:

Analog tachometer and digital speedometer, trip computer, coolant temperature gauge, clock.

Electronic Aids:

Basic for its era. No advanced electronic rider aids like traction control or ABS as standard on this model year. Some later variants might have had ABS as an option.

Connectivity Features:

N/A. Primarily mechanical and electrical systems.

🔧 Maintenance

Oil Change Interval:

Every 6,000 km (3,700 miles) or annually, whichever comes first. Refer to manual for exact mileage.

Valve Clearance Check:

Every 12,000 km (7,500 miles) or every two years. Check manual for exact interval.

Chain Maintenance:

Lubricate every 500-800 km (300-500 miles) and adjust slack as needed, checking tension more frequently.

Engine Oil:

SAE 10W-40 API SG or higher motorcycle specific synthetic or semi-synthetic oil. Capacity approx. 3.4 liters with filter change.

Coolant:

Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio). Capacity approx. 2.5 liters.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Clutch Fluid:

DOT 4 hydraulic clutch fluid (if applicable, same as brake).

Fork Oil:

Typically SAE 10W fork oil. Check manual for specific type and level. Capacity approx. 500-520 ml per fork leg.

Stator Failure:

Stator and regulator/rectifier failures are relatively common and can lead to charging system issues. Upgrade may be advisable.

Cam Chain Tensioner:

Automatic cam chain tensioners can wear out, causing a rattling noise. Manual or upgraded units are available.

Fuel Delivery:

Carburetor calibration and synchronization can be critical for smooth running. Diaphragms can degrade over time.

Fairing Fitment:

Some owners report minor vibration or fitment issues with fairing panels, especially after non-OEM replacements.

📚 Vehicle History

Manufacturer Origin:

Aprilia is an Italian manufacturer with a strong heritage in racing, particularly in Grand Prix motorcycles.

First Generation:

The RSV Mille marked Aprilia's significant entry into the large-displacement sportbike market, aiming to compete with established European and Japanese superbikes.

Key Engineering:

Features the Rotax 998cc V-twin engine, known for its strong torque and character. Chassis and suspension were developed with performance and handling in mind.

Subsequent Models:

Evolved into the RSV1000R and the more track-focused RSV-R (later RSV4), receiving updates to engine management, suspension, and styling over its production life.

Production Period:

First generation produced approximately from 1997 to 2003/2004.

🏆 Awards & Recognition

Performance Reviews:

Generally well-received for its potent V-twin engine and handling, often praised for its character and performance against more expensive rivals, though sometimes criticized for weight and ergonomics compared to Japanese competitors.

Motorcycle Journal Mentions:

Frequently featured and reviewed in major motorcycle publications of the era (e.g., Cycle World, Motorcyclist, MCN).

Certification Standards:

Manufactured to meet relevant European and international motorcycle safety and emissions standards for its model year.