Aprilia RSV 1000 R/Factory models 2003 to 2005 (3rd Gen.) original motorcycle manufacturer's PDF repair manual download

Aprilia RSV 1000 R/Factory (3rd Gen.) Service Manual (2003-05)

Complete PDF version of the Service Manual for the Aprilia RSV 1000 R. A MUST for every RSV 1000 owner.

Download: Immediately after payment!

OEM Original factory workshop manual.

Models covered by this manual: 2003 to 2005

Number of pages: 308 pages

Table of contents:

Aprilia RSV 1000 R/Factory 2003 to 2005 (3rd Gen.)

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We do not offer printed manuals, for the following reasons:

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Aprilia RSV Mille

The Aprilia RSV 1000 – called until 2004 with the extended name of RSV Mille, then modified to make it more “international” with the numbers alone – is a motorcycle of the superbike or superbike , marketed (and updated in the various versions) by the of Noale from 1998 to 2008 .

Conceived in 1993 , it went into production only five years later. The intent of the managers and engineers of the Italian company was to build a motorcycle capable of entering a particular market segment, namely that of large-displacement sports bikes, which until then had been dominated almost exclusively by Japanese models, with the exception of made for those produced by Ducati and since 1997 also by MV Agusta.

However, to make this model exclusive, like those produced by the competition, Aprilia chose to use the RSV Mille, to participate in the Superbike World Championship, in which it took part from 1999 to 2002 , but with modest results compared to to the expectations of the eve, also due to the low competitiveness of the Dunlop tires that fitted it; the best result was in fact the 3rd place in the standings of Troy Corser in the 2000 championship.

However, it was only later decided that the RSV Mille should be an extreme sports bike, in fact initially it was a motorcycle, which was more of an ideal compromise, between sport and touring vehicle at the same time. The target was to snatch the market from the Honda VFR, for this purpose, 2001 the Aprilia RST 1000 Futura a sport-touring that used the same engine as the RSV; in addition, another model derived from the RSV, the SL 1000 Falco , had as its direct target another Honda model, the VTR 1000 Firestorm, they were two non-extreme sports bikes equipped with half-fairings.

This motorcycle went into production only five years after its conception, with a failure in sales, especially for what concerns the initial model, that is the 1998 one, probably, this was due to a design.

Despite this, however, with the advent of the RSV, Aprilia managed to offer a complete range of motorcycles: the latter, in fact, covered the only segment in which the Italian factory did not operate. Among other things, it confirmed its sporting vocation and gave a certain continuity to the top models of the various displacements, namely the Aprilia RS, proposed with 50 and 125 cm³ single cylinder and 250 cm³ twin cylinder engines. The latter were all derived from the racing cars that raced (and won) in the world championship , classes and 250.

Basically the RSV took up the same concepts, so as to keep the name (RS) unchanged, and emphasized the company’s philosophy of using sophisticated engines (V, as it was fitted with a V-twin), even for large displacements (1000 or 1000, that is the cubature of the two cylinders).

Even the decision to focus on a two-cylinder engine was not accidental; with the exception of Ducati, all major brands chose to use four-cylinder engines. Aprilia has always used engines from one to two cylinders, using the philosophy of slightly fractionated engines, which therefore also continued with the RSV.

The RSV Mille of 1998 (born in ’93), could count on an advanced technical setting and on the use of absolutely avant-garde light alloys.

Its main qualities were in the engine and the chassis , two very sophisticated devices.

V-twin four-stroke, an angle chosen to optimize fluid dynamics and to make the engine particularly compact. The engine was of the super square (typical solution of racing engines), this guarantees remarkable performances, high rotation speeds and power. The bike was characterized by a particularly manageable delivery, depending on the rider the delivery could be soft or abrupt and rough, but always manageable even by less experienced riders. Given the architecture of the engine, it was necessary to install a double anti-vibration countershaft (AVDC, Aprilia patent) to dampen the vibrations.

The most interesting / particular part of this engine is the distribution and ignition system. The engine used four valves per cylinder, controlled by a double overhead camshaft per bank which in turn was driven by a mixed system of gears and chain. The ignition, on the other hand, was electronic, and used the twin spark, i.e. with two spark plugs per cylinder. Asso Werke pistons were used on the first prototypes, produced from provisional molds initially designed for a Cagiva / Husqvarna single-cylinder which was then no longer produced; Rotax approved such molds, and the final ones, no longer needed, were modified and used to produce the pistons of the in-line 6-cylinder TVR automotive engine.

The power supply was also electronically managed, and made use of one injector per cylinder ( multipoint ). Obviously, being a petrol engine, the injection was indirect (direct injection was not yet used at the time).

The actual displacement was 997.62 cm³, and developed a maximum power to the shaft of 128 horsepower at 9250 rpm, the torque shaft was 10.5 kgm at 7000 rpm.

This liquid-cooled engine was harnessed by a double sloping beam frame, made of aluminum alloy , which was at the same time light and strong and guaranteed the bike remarkable agility and the best torsional rigidity in the category.

Other solutions of interest were the hydraulic control for the clutch, the slipper device (Pneumatic Power Clutch, another Aprilia patent – the RSV was the first production bike to mount an slipper device) and the use of a double pump trochoidal for oil circulation.

3rd generation (2003 to 2005)

The third generation begins in 2003. The power goes to 102Kw (138.7CV) in compliance with the EURO2 regulations, the bike is completely revised, semi-radial brake and clutch controls, a new fairing, the “FACTORY” version, is embellished with forged aluminum rims, mono-shock absorber and Öhlins and carbon. Aesthetically it has been reduced in all its measures to make it more compact, the entire fairing has been redesigned, also following the new aesthetic dictates of the direction indicators incorporated in the front mirrors and rear in the tail, the headlights go from one to two and the tank is resized. The frame is also new, more reactive and with a lower center of gravity, the swingarm becomes double banana to better accommodate the dual exhaust.

The engine is revised, taking the name of Magnesium (from the material in which the clutch crankcase and tappet covers are made, the magnesium). The “Twin Spark” solution is abandoned in the engine, the diameter of the exhaust valves is increased, new camshafts with different monolithic lifts and new stiffer connecting rods are used without increasing their mass, the rev limiter goes up and goes from 10200 rpm at 10600 rpm, the front air intake is also new which allows the engine to breathe which becomes dynamic and with variable geometry.

Source: Wikipedia