2004 Aprilia RSV Mille R

From Aprilia's press material:

Improve the best. The new RSV 1000 R aims to do precisely this: to become the absolute epitome of sportiness, performance and design. The world's most appreciated supersport bike has become even more beautiful, more high performing and more effective. The utmost twin-cylinder sportbike.

APRILIA RSV 1000 R

Very few road bikes can boast as many official awards from sector magazines as the Aprilia RSV 1000. During its first five years of life, it has come to be regarded as the absolute benchmark for performance, rideability and track success. A supersport bike with pedigree which, thanks to its first-rate technology and the best content/price ratio on the market, has won the hearts of 27,000 riders worldwide.

The best that could be desired, at least up to now, because Aprilia has decided to move the performance, sporting and pleasure-to-ride limits up even further with the new RSV 1000 R 2004. In short, Aprilia has decided to improve the best.

The RSV 1000 R inherits the full legacy of the previous model, but shifts all the technical and performance characteristics up and adds an R to its name to symbolize this increase.

The fastest production twin-cylinder bike on the track today is even faster. The main aim of the Aprilia RSV 1000 R project was in fact to increase on-track performance.

A new engine, frame and swing arm. The overall layout is new: it is lower (-25 mm) shorter (-35 mm) and more compact. And the revolutionary design is new, with improved aerodynamic penetration. The RSV 1000 R sets a new benchmark for road sportbikes due to its technology and its extraordinary performance.

But what counts most is the further development of the concept of "total rideability" which has always characterized this bike and which has been the primary reason for its success.

The maniacal attention to ergonomics and its easy rideability make the rider feel immediately at ease with the bike so that he can quickly and almost effortlessly reach clock-times which would otherwise be unapproachable.

A less demanding ride means first and foremost a less physically and mentally tiring, faster and safer ride, during which the rider can keep his concentration higher for longer. These are determining factors for race performance, but are also important on the road.

The RSV 1000 R is Aprilia's new benchmark for road supersport bikes. Here are the project's distinctive characteristics item by item:

New design
New V 60 Magnesium engine
Air Runner air scoop
Close gear ratio
New electronic injection system with 57 mm throttle bodies
New 16-bit electronic control unit
New exhaust with double silencer, three-way catalytic converter and Lambda sensor
New aluminium alloy perimetric frame
New double banana aluminium swing arm
New rear suspension linkage
Lighter and less loaded steering plate

Attention has been paid to every minimum detail of this exclusive refined bike with its aggressive unmistakable look. The RSV 1000 R is the perfect balance between quality, technology, components and finish.

Everything has been developed, tested and suitably adjusted to further improve the performance of a bike with incomparable rideability.

The new engine has pushed performance limits even further. 138.72 hp (102 kW) at the crank giving a maximum speed of over 170 mph (280 km/h). These are the "figures" which make the RSV 1000 R a real benchmark among production twin-cylinder supersport bikes.

Its completely redesigned set-up improves the bike's dynamic characteristics in every situation, making it incredibly even more successful on the track.

All this, of course, goes hand in hand with top-quality components, selected to make the RSV 1000 R a reference supersport bike among enthusiasts.

DESIGN

When performance becomes beauty. The design of the RSV 1000 R is truly revolutionary. It is lower and more compact with an unmistakable aggressive look.

Not design for design's sake, but design at the disposal of technology and performance. Every detail has been designed not just to be pretty, but above all to be effective.

Finding the best possible air system for the V60 Magnesium engine has meant fundamental changes to the front. The air scoop has been placed in the middle of the windscreen, the point where the dynamic pressure is greatest. A fundamental factor for the bike's performance therefore also becomes a fundamental part of the design.

The front headlamp insert is split with four lamps which work together in pairs thus getting rid of that unpleasant "Cyclops effect" typical of many modern sportbikes.

The RSV 1000 R is smaller, lower and slimmer, and this dimensional compactness is its strong point. All this without forgetting ergonomics which has always distinguished the RSV range.

The slender tail quickly converts from a one-seater to a two-seater. It is extremely compact and one of the most characteristic features of the bike. The compact rear LED light provides excellent brightness despite its extremely moderate dimensions. Even seen from behind, the RSV 1000 R is immediately recognizable.

The quest for the cleanest possible line and maximum aerodynamic penetration has led to elimination of the traditional indicator lights. The front ones are now incorporated in the rear-view mirrors, and the rear ones are built into the tail.

So no protrusions for a perfectly clean line able to cut through the air like no other. Thanks to these stratagems and long studies in a wind tunnel, the RSV 1000 R further improves the already exceptional CX of the RSV Mille 2003, which drops from 0.306 to 0.3.

V60 MAGNESIUM ENGINE

The 1000 "V 60 Magnesium" marks a turning point in the history of Aprilia twin-cylinder engines. It is based on the famous and appreciated V990, but has been so completely revised that it has changed name. The far-reaching changes make it the utmost benchmark for production twin-cylinder engines. It performs exceptionally, responds in every situation and has the proverbial Aprilia reliability.

The cylinder heads with magnesium covers have been completely redesigned. On-track experience has been turned to good use to improve their fluid dynamic efficiency and optimize combustion. In particular, the squish areas between the exhaust and intake valves have been made bigger. Thanks to this new design, best performance is obtained with a single spark plug, which at the same time increases combustion efficiency precisely due to the greater turbulence.

With the new layout, it has even been possible to distribute the cooling liquid more evenly around the combustion chamber which leads to more constant efficiency and reliability. Optimization of the ignition-injection system mapping has also led to ideal combustion even at low loads and low speeds.

As well as new cylinder heads, there are also new camshafts and new valve springs. The lubrication circuit has also been completely redesigned in this delicate area, not only to improve lubrication itself, but also to minimize viscous drag and consequent power loss. The intake ducts have been redesigned to match the throttle bodies perfectly. The exhaust duct has also been redesigned: it now has an oval section to facilitate the passage of exhaust gases towards the silencer.

To improve the air supply to the "V60 Magnesium" the intake section has been completely redesigned. An air scoop, known as the "Air Runner", has been placed in the middle of the windscreen, right where the dynamic pressure is greatest and perfectly in line with the bike. A duct passes through the headstock to bring the pressurized air to the filter casing, which holds a good 10.3 litres.

A choke inside the duct, controlled by the electronic control unit, regulates air flow, thus providing the engine with the right amount of air at the right pressure at all revs. In this way, the engine performs better and provides a spurt unknown to the Aprilia V2 up to now. In fact the rev limiter has been upped to 11,000 rpm.

The mighty voice of the V60 Magnesium is muffled by two Helmotz resonators with different volumes which lower the intake noise at the most critical revs.

The airbox also houses a new air by-pass stepper motor which acts on an electronically controlled valve and sends air downstream of the butterfly valve thus making it easier to cold-start the bike and stabilizing the engine idling speed.

The Air Runner also acts as a structural component. Thanks to two light aluminium arms it holds the windscreen and the front headlight, therefore doing away with unattractive supports.

The new panel filter ensures less air resistance, therefore improving engine efficiency. It also costs less as a spare part than the previous RSV filter, leading to lower running costs.

The air intake section has been completely revised: the engine can now count on an injection system with 57 mm throttle bodies and a single injector per cylinder. Thank to the Air Runner the pressure in the airbox increases as the bike runs faster leading to a 3% gain in power at maximum speed.

A new electronic control unit, made together with Siemens VDO, manages the whole engine. It receives all the vital parameters from 15 sensors in real time (temperature: air and liquid; pressure: atmospheric, airbox and oil; Lambda sensor; rotation sensors: driveshaft, camshaft, throttle and rear wheel; position sensors: kickstand, clutch and idle; battery voltage) and redistributes them instantly to the actuators.

A 36-minus-2-tooth wheel is coupled to the driveshaft, which is therefore able to manage the engine with greater precision (every 10f, rather than every 60f).

All the data passes through a CAN line (Controlled Area Network) to the instrument panel, which acts as an autodiagnosis terminal. In the event of a malfunction, the mechanic will be able to identify the problem immediately. The CAN line uses two wires only to transmit all this data, which enormously simplifies the electrical system and keeps the overall weight of the bike down.

The already excellent performance of the V990 is outclassed by the V60 Magnesium which pumps out a maximum power of 138.72 hp (102 kW) at 9,500 rpm with maximum torque of 107 Nm at 7,500 rpm. All this despite the fact the new engine is extremely "clean" since it is fitted with a three-way catalytic converter with lambda sensor and complies with the EC Euro2 standards.

Technological research does not only mean better performance; it also means keeping this performance up over time. The reliability of the RSV 1000 R has grown along with its performance. New high resistance specially designed rods have further increased the robustness of the engine.

But the V60 Magnesium is not only more powerful and robust, it is also lighter than the old V990 thanks to the use of special materials, such as magnesium for the cylinder-head covers and clutch cover.

Aprilia was the first to use a close ratio gearbox on a production bike. The RSV 1000 R is also fitted with this device which, more than ever before, allows the rider to get the full exceptional performance from the V60 Magnesium.

The result is even more aggressive acceleration and exhilarating gear changes off the bends, which may be experienced both on the road and on the track. The engine responds absolutely brilliantly even at the highest gears thus increasing the sportiness of the bike and riding fun. This technical evolution has not eliminated those special characteristics which have made the RSV series stand out right from the first model.

Longitudinal 60f V-twin engine with 4 valves per cylinder and double overhead camshaft, controlled by a mixed chain and gear system.
Electronic fuel injection: with 57 mm throttle bodies and "Air Runner" air scoop. One injector per cylinder.
CDI ignition with 1 plug per cylinder. Ignition is controlled by an integrated engine management system which also controls injection.
Dry sump lubrication with double trochoidal pump, separate oil tank and cooling radiator.
Mixed gear/chain drive: the two gears (one for each drive chain) inserted in the base reduce the space occupied by the cylinder heads.

The sophisticated twin-cylinder engine comes complete with exclusive patent Aprilia devices:

AVDC (Anti Vibration Double Countershaft).
Hydraulically controlled clutch with radial pump, assisted by a patented PPC (Pneumatic Power Clutch) system for separate rear wheel bounce control.

EXHAUST

The new exhaust system was designed on the basis of experience acquired in the Superbike championships.

It follows the 2 in 1 in 2 layout and is completely made of stainless steel, with 10/10 mm thick manifolds and oval section head mounting flanges made of precision cast stainless steel. The silencers are lined with 8/10 mm thick stainless steel, with surface electroplating, and assembled with clamps and rivets according to the typical racing construction technique. They are positioned in order to minimize aerodynamic resistance and improve weight distribution.

FRAME

Years of high level racing have helped Aprilia R&D design an even better frame than the previous model, which was already acknowledged as one of the best production bike frames.

The primary aim when designing the new RSV 1000 R frame was perfect mass centralization. In accordance with the Aprilia tradition, the structure uses cast aluminium-silicon and die cast Peraluman 450 parts. The frame was optimized through long finite-element studies, and its torsional rigidity is 5% better than the previous model. Despite this the new frame is a good 600 grams lighter, bringing its total weight down to only 9650 grams: a weight only matched by racing bikes.

The headstock is positioned differently in order to lower the whole bike and consequently its centre of gravity. The swing arm pivot has been moved 0.5 mm forward, whereas both the swing arm mounting and the saddle frame have been lowered to make the bike more compact and concentrate its mass around the centre of gravity as much as possible.

The engine has been moved 4 mm to the right, together with the new exhaust system manifold, for perfect bike balancing.

Times change, riding styles change and bikes must change too. For this reason, the frame and swing arm assembly has been designed specifically not only to ensure maximum performance, but also to allow riders to manage skids perfectly (when entering and leaving bends).

Each component has been made more compact and optimized to adapt it to the new bike layout. The rear suspension linkage has been redesigned, the saddle frame is fixed vertically to the bike frame in order to decrease its thickness in the under-saddle area by 3 cm. The suspension supporting crossbars are cast and not extruded, so that they are better shaped around the rear suspension and contribute further towards perfect mass centralization.

The new RSV 1000 R swing arm has been designed using the know how acquired in motorbike GPs. It is also made with extruded Peraluman and cast Al Si 7. Its double banana shape leaves space for the new double-silencer exhaust system to pass through.

Again in this case, sections and thicknesses have been optimized using finite-element analysis. The RSV 1000 R swing arm weight has been decreased by a good 400 grams, to 4860 grams, well under the 5 kg threshold taken as reference for this particular component.

SUSPENSION

The Showa 43 mm upside-down fork is a perfect compromise between sportiness and road comfort. It has been taken from the racing units and has continuously adjustable preload and hydraulically adjustable rebound (2.5 turns) and compression (2.25 turns).

The Sachs mono-tube shock-absorber is fitted with a separate piggy back nitrogen cylinder built into the body. It has adjustable rebound, compression, preload and length in order to lift and lower the rear axle according to the required settings, rider's preferences and other adjustments made. Among the optional components is a continuous tyre pressure measuring system, to keep the alignment under control according to the suspension settings.

BRAKING SYSTEM

The Brembo Tripe Bridge Gold Series front system is without a doubt the best conventional system for motorbikes on the market today.

The RSV-R is fitted with two four-piston (34 mm diameter) callipers with four separate sintered pads (one per piston). The four pads double the pad-disc adhesion, thus increasing the braking force applied for the same amount of effort on the lever. Their more compact size also leads to more uniform pad wear.

The Brembo "Tripe Bridge" calliper structure (with central strengthening bridge) is the most rigid conventional system.

The double 320 mm diameter floating steel disc has a very short braking distance, in order to minimize inertia and weight, and uses an exclusive Aprilia design six-spoke flange.

The brake pump is radial to improve response precision and the feel of the lever.

The rear braking system is a Brembo Gold Series with 220 mm diameter stainless steel disc and two-piston (32 mm diameter) calliper.

Both the front and rear systems use braided metal lines taken from the aeronautics industry, which eliminate the irritating pressure smoothing effect of conventional lines and ensure maximum braking precision.

COMPONENTS

What particularly characterizes and distinguishes the Aprilia RSV 1000 R is the care and attention paid to every single component and part. This attention leads to better performance and functional characteristics, through a decrease in weight and considerable increase in product quality and finish.

Great care was particularly taken to rationalize the construction of the RSV 1000 R. Less pieces, less screws, less weight. The RSV 1000 R fairing consists of only 14 pieces compared to the 25 pieces on the previous version. The couplings have also been studied in a wind tunnel to optimize air flow over the bike, and improve CX and cooling.

As regards components, the following are worth mentioning:

Dashboard: mixed type (digital-analogue). It receives all its data from a CAN line and is an integral part of the autodiagnosis system due to its memory. It has all the indicators of the previous model (including self lap-timing with a 40 lap memory), an extremely modern compact design and a drastically decreased weight (down from 560 to only 220 g). Its functional characteristics have been improved: all the functions are controlled by three convenient keys. The LED lighting may be set to three levels: white in the analogue area and red in the digital area.
the headlight has four lights for perfect night-riding vision. The bike's highly refined finish is also evident from the care taken over apparently accessory parts, such as the lamp holders made of blue anodized aluminium.
The indicator lights are perfectly integrated into the bike. The front ones are incorporated in the rear-view mirrors and the rear ones are built into the tail. Consequently, they do not need removing for track use. The rear number plate holder may be quickly removed for the same reason.
The specially made RSV 1000 R key has internal coding, and the ignition block has an immobilizer fitted as standard.

COLOURS

The three colour combinations highlight the RSV 1000 R's modern line and are able to satisfy all tastes. The RSV 1000 R is available in Lead Grey/Magnet Grey, Aprilia Black/Diablo Black and Fluo Red/Lead Grey

All colour combinations come with polished frame and swing arm.

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