APRILIA RSV Mille 1000 1999 Installationsanleitung

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

RSV 1000 Technical Training Course

RSV Mille

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

RSV 1000 INTRODUCTION

Open your third eye !

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-powered super-sports motorcycles.

The RSV Mille marks a turning point, opens a new

chapter and becomes the new point of reference

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 its high-level technology, superior

quality of construction and its unique and

unmistakable design.

The RSV Mille brings a substantial change on the

scene of bigh-powered super-sport motorcycles. lts

manoeuvrability and easy riding - typical of two

cylinder bikes - are wedded with the versatility and

high performance of four cylinder bikes.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

THE ENGINE

The engine fitted on the RSV Mille is a completely

new type, conceived and developed by Aprilia's

engineers. It is a 60°V-formation longitudinal 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-formation two-cylinder engine 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-Vibration Double

Countershaft).This system uses an anti-vibration by

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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

The dry sump

A further innovation brought by Aprilia in producing this new engine is the use of dry-sump

lubrication, 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. In high-powered two-

cylinder engines this phenomenon is accentuated by

the high “engine braking" effect; this can cause the

so-called bouncing, 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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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-cycle is 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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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 multi-

adjustable shock-absorber with built-in "piggy-

back" 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.

Aprilia Consumer Service Spa

Technical Service and Training

Release 4 july 99

This material is didactic and

may be changed following the technical

development of the product

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.

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