Aprilia RSV 1000 Technical training course

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Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

RSV 1000 Technical Training Course

RSV Mille

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

RSV 1000 INTRODUCTION

Open your third eye !

The originality of the technical decision the systematic use of solutions borrowed from the Racing Department and, above all, the passion and commitment applied to make every detail exclusive, form the basis of Aprilia's constructive philosophy. In particular, the RSV Mille embodies and enhances the most significant characteristics of this company's heritage, with itshigh-leveltechnology, superior quality of construction and its unique and unmistakable design.

The RSV Mille brings a substantial change on the scene ofbigh-poweredsuper-sportmotorcycles. lts manoeuvrability and easy riding - typical of two cylinder bikes - are wedded with the versatility and

The RSV Mille is the best production line bike for use on the track.

A bike that guarantees a pleasant ride, on either track or road, to satisfy even the most demanding rider who wants the best as regards easy bandling, performance, exclusive quality and technology. lt is decidedly original, exclusive and performing. A motorcycle in which the love of the racing world is translated into a wealth of important details. A bike with a superior performance, occupying a price range in line with the best of Japanese competitors.

A product which represents, to all effects, a decision in style for the buyer and, for Aprilia, the first stage of further development linked with highpowered bikes.

For Aprilia, "the sense of wonder' means breaking away from set patterns, having the courage to face new challenges, in this case shaking off a paradoxically conservatile universe such as the world of high-poweredsuper-sportsmotorcycles. TheRSV Mille marks a turning point, opens a new chapter and becomes the new point of reference

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

Design Concept:

Aprilia’s aim in making RSV Mille was to create a motorcycle with extremely compact dimensions, one that could cleave the air in an optimumn fashion and protect the rider against the impact of the wind and high speeds.

The flow inside the front ait intakes has been optimazed too, as well as the position of the intakes on the fairing.

As regards the aereodynamic result obtained, the achivied CXs value of 0,3010 is the new reference point for the category.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

THE ENGINE

The engine fitted on the RSV Mille is a completely new type, conceived and developed by Aprilia's engineers. It is a60°V-formationlongitudinal two cylinder engine, with 4 distribution valves per cylinder and a double camshaft at the head, controlled by a mixed chain and gear system. lt is fed by electronic ignition with air input through a system of dynamic air intakes. lgnition is of the CDI type, where the load of air and petrol is fired by the TSI system (Twin Spark lgnition) which uses two spark plugs per cylinder. lgnition is controlled by the integrate engine management system, which also controls injection.

While it is true that the 90' V engine is itrinsically balanced (the first order forces generated during the movement of the internal organs automatically cancel one another), it is equally true that the dimensione of the engine are penalized by the size of the angle between the cilinders.

The decision to use a 60° V-formationtwo-cylinderengine responds perfectly to the need for a lightweight, compact engine, so as not to sacrifica the design of the cycle parts with tecnical solutions and weight distribution that are not optimum.

The countershafts

The problem of the vibrations which are created inside a 60 V engine gave the designers a lot of work. The possibility of offsetting the pins of the connecting rod was discarded, as it would have required excessive widening of the dimension of the motor crankcase.

The solution found was the use of the exclusive AVDC patent (Anti-VibrationDouble Countershaft).This system uses ananti-vibrationby turning countershaft which, in the opposite direction to the engine shaft, balances the first order forces. The moment generated by the countershaft is, in turn, balanced by fitting a second countershaft (Smaller than the main one) inside the head of the rear cylinder. The result of adopting this technology is an engine with excellent characteristics of power, torque, with extremeily reduced vibrations.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

The dry sump

A further innovation brought by Aprilia in producing this new engine is the use of dry-sumplubrication, which allows a more rigid and compact engine block that the"wet-sump"solution. The system makes use of a second trochoid pump for recovery and an external oil tank, as well as a radiator positioned in front of the engine.

The power clutch

The RSV Mille has a clutch with hydraulic control, assisted by the esclusive PPC patent (Pneumatic Power Clutch) to check bouncing of the rear wheel. When decelerating suddenly, the weight of the motorcycle is transferred instantly to the front, lightening the rear axle. Inhigh-poweredtwocylinder engines this phenomenon is accentuated by the high “engine braking" effect; this can cause theso-calledbouncing, or the tendency of the rear wheel to block and lift off the ground, endangering the stability of the bike and, consequently, the vehicle's performance and safety.

Aprilia has found the ideal solution to this problem exploiting the variations in pressure which occur in the intake ducts when the throttle is opened and closed, to lighten the load on the clutch springs. By connecting the intake ducts to a "lung" situated at the side of the clutch group, the vacuum created when the throttle is closed decreases the load exerted on the disks by the springs, while when the throttle is opened again the clutch resumes operation under normal weight conditions, thus transferring all the power to the rear wheel.

This system also allows reduction of the force applied on the lever on the handlebar, when the bike is running at low rev speeds.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

lnjection

The need for suitable control of the powerful engine of the RSV Mille led the Aprilia designers to adopt an electronic management system built into the engine. All the fondamental operating parameters are constantly monitored by a sophisticated electronic controls unit which, on the basis of the data received, control operation of both the injection system and the ignition system.

The injectors are fed by a pump which produces a constant pressure of 330 Kpa. The throttle bodies have a diameter of 51 mm. Fresh air is taken in through ducts which make use of dynamic pressure when the motor-cycleis moving, sending fresh air into a large volume airbox.

The entire injection/ignition system is also equipped with a continuous Selfdiagnosis circuit (both on starting and when the bike is running); this is able to indicate any malfunctions of the system directly on the dashboard, without the aid of complicated and expensive external equipment.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

The exhaust

The exhaust system of the RSV Mille originates as the reply to four very precise requests: light weight, aerodynamic line, respect for the environment and for approval standards.

The choice of the "2 in 1 " exhaust proved to be the most appropriate since, while obtaining an internal volume of over 9 litres, the bulk and weight are lower than those of a l'2 in 2" exhaust.

The exhaust of the RSV Mille made completely of stainless steel, which ensures long life and lasting good looks.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

As regards respect for the environment, the engine of the RSV Mille complies with the parameters of the future European standards (EURO 1, which comes into force in 1999); this result is achieved without the aid of any type of catalyst, as a further guarantee of performance and attention to these problems.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

CYCLE PARTS

Jewel within the jewel, the cycle parts of the RSV Mille must be considered to all effects a true masterpiece of engineering. As beautiful as a work of art, impeccably but above all efficiently finished, instinctive and easy to drive, to quarantee optimum exploitation of all the engine power.

The best engineers in the Aprilia racing department designed the frame, giving it the most in terms of planning and knowledge of structures, choice of materials, weight distribution and dynamic behaviour.

Particular care was taken with the torsional stiffness (with a record value of 650 Kgm) and bending resistance of tbc frame, fondamental elements as regards riding precision and safety.

The splendid rear fork with differentiated arms controls, by means of linka-ges,a multiadjustableshock-absorberwithbuilt-in"piggyback" tank. The rear wheel bump position is 135 mm.

At the front the 43 mm Showa "upside-down"fork allows a bump position of 120 mm.

The cycle parts of the RSV Mille are supported by a dry weight of only 189 kg, optimally distributed with 49.2% on the front axle and 50.8% on the rear axle.

This material is didactic and

may be changed following the technical development of the product

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

COMPONENTS

Every slightest detail of the RSV Mille receives the same meticulous care from Aprilia, to transfer dove, care and enthusiasm into every bike that the company produces.

Many parts contribute to make the RSV Mille a unique and unrivalied rnotorcycle: the aluminium rear frame that supports the saddle, the beautiful exposed welds, the adiustable controls on both handlebar and pedals (where micrometric adjustment by means of a cam offers a solution to satisfy even the most demanding motorcyclist), the Brembo wheels in aluminium alloy and the steering shock absorber. These are only some of the most significant details.

Another great innovation of this rnotorcycle is the analog and digital dashboard. It is to all effects a real computer on board, able to supply the rider wíth all the information ho needs at any time.

A sophisticated, exclusive digital chronometer/clock, controlled by the flashing of the main beam headlamp, is able to store up to 40 lap times. The "red zone" on the rev counter is indicated by the flashing of a warning light (which may be set by the rider at the desired rev speed), allowing him to choose the best moment to change gear and gain precious seconds when performing the operation.

The headlamp

The headlamp is a particulary distinctive feature of the RSV Mille, characterizing its appearance and making it immediately recognizable as soon as it starts flashing. lt is a triple headlamp, in which the power of the main beam allows a broad, powerful and homogeneous beam of light, to make night riding even more safe and effective. Two 55 Watt halogen lamps are housed inside parabolas developed on the computer with the technology of complex surfaces.

This material is didactic and

may be changed following the technical development of the product