Aprilia RSV4 Factory

The Aprilia RSV4 Factory is a racing machine that, in line with the Aprilia tradition, follows a completely innovative approach in its design and construction. Its narrow V engine, the use of state-of-the-art electronics, plus its lightness and extreme compactness are only a few of the features that make it unique in the world. Aprilia RSV4 Factory is designed and built with the same philosophy adopted by the Aprilia race division. This is why the RSV4 Factory is the most "complete" Superbike racing replica, ready for those who want to venture onto the track with a class leading motorcycle.

The engine of the RSV4 Factory is the most innovative and powerful Aprilia has ever built. A super-compact 999.6 cc 65? V-four cylinder engine designed for maximum power (177.5 horsepower), where powerplant engineering comes together with the finest materials and the most advanced electronic control solutions. Aprilia's engine, in fact, uses a ride-by-wire multi-map technology, a solution that opens up new frontiers for engine management, with practically infinite possibilities for further development. Besides the triple map ride-by-wire system, a sophisticated electronic injection system with two injectors and adjustable height ducts are fitted.

Aprilia RSV4 Factory's chassis is designed for the racetrack, with adjustment features that are typical of racing motorcycles. The adjustable geometry chassis allows parameters such as the position and angle of the headstock, the height of the swingarm pivot and even the engine position to be changed. The construction technology is also motorsports-derived: the RSV4 Factory chassis and swingarm are made of aluminum with variable section castings and pressings.

The components are the state-of-the-art in motorcycling technology: Ohlins Racing fork, rear monoshock and steering damper, Brembo monoblock callipers, forged aluminium rims.

DESIGN: the quest for ultimate compactness

Creating the most compact, innovative and gorgeous supersport bike on the market: a tough and intriguing challenge for Aprilia's style department! This is how RSV4 Factory was created, a motorcycle that sets new performance and riding standards while opening new horizons in ultra-sports motorcycle design. Just a few simple and distinctive styling elements highlight rather than conceal the specific technical features of the Aprilia RSV4 Factory. Its frame and engine stand out as fundamental elements of the motorbike's design. In line with Aprilia traditions, the design of RSV4 Factory does not focus merely on looks but it serves technology and performance. Every detail has been conceived not just to be unique and beautiful, but also and above all to be efficient.

The needs of the optimised dynamic intake system feeding the V4 defined the strong-charactered front, with extra-large air intakes that not only develop considerable pressure in the airbox (approx. 35 mb @ 280 km/h), but also completely separate the headlamps from the bottom of the fairing. This results in an absolutely unique style, never seen before on a sports motorcycle. The look of the RSV4 Factory is absolutely original, technological and definitely aggressive. The triple headlamp cites the original Aprilia RSV Mille that set new standards for sports twins in 1998.

Smaller, lower and narrower than any 4-cylinder bike before, the RSV4 Factory's extreme compactness is its strength, together with an almost obsessive pursuit of perfect ergonomics (crucial for perfect riding control), which has always distinguished Aprilia's road and World Championship dominating motorcycles.

In-depth aerodynamic studies minimized surfaces without compromising the bike's class-leading aerodynamics. The spectacular, ultra-compact tail fairing is one of the most distinctive features of this motorcycle. The LED taillight merges stunningly into the tail, offering excellent luminosity. Even the rear of the RSV4 Factory is absolutely unmistakable.

ENGINE: an exclusive 65? V4

The pursuit of maximum engine performance in a supersport motorcycle must be accompanied by a perfectly positioned engine in the frame. Mass centralisation, swingarm length and optimum weight distribution are ingredients for achieving the most competitive bike, together with the pursuit of maximum power and perfect power delivery.

Aprilia engineers have known for years that a narrow V-layout is the ideal technical solution for obtaining a class-beating chassis architecture that emphasises the performance of the engine. A 65-degree V-4 cylinder engine, the only solution that could ensure unparalleled performance, enabling the outstanding chassis architecture that has defined all Aprilia racing motorcycles for the past twenty years.

Besides the exclusive configuration that makes the 65? V4 unique around the world, the technical advantages of the Aprilia four-cylinder engine can be summarized as follows:

. Perfectly integrated into the frame, with optimal mass centralization and minimized inertia for benchmark agility.
. Absolute slimness, its overall width is comparable to that of a twin cylinder motorcycle, with huge benefits in terms of ergonomics and aerodynamics.
.The compactness of the engine makes a very oversquare cylinder layout possible, using large bores and subsequently larger valves, helping the engine breathe more freely and achieve higher engine speeds (14,000 usable rpm).

The engine was entirely developed by Aprilia's Research and Development Division, aiming at offering record performance and ridability in compliance with the strictest reliability and quality standards.Aprilia's V4 design exploited the most powerful computer calculation programs currently available on the market, resulting in a highly optimised engine layout. By slightly opening the angle of the V (with respect to a 60? V engine), the designers could make use of the larger space to optimize the inlet ducts and maximise engine efficiency.

The unique timing system makes extremely compact heads possible (measuring only 250mm high at the rear), especially in the area beneath the frame spars, which are thus much narrower than would otherwise be possible. The lateral timing chain drives the intake camshaft only and follows an optimized path for improved timing precision and chain durability.

A gear pair at the centre of the cylinder bank transmits drive to the exhaust camshaft. This solution made it possible to obtain an extremely compact head in the exhaust area. The V4 is even more compact than the V60 Magnesium twin mounted on the RSV 1000 R. A counterbalancer dampens vibrations even more than in a 90-degree Vee engine. The crankcase has integrated cylinder liners for maximum rigidity and consistent performance.

Electronics of the Future

Aprilia's RSV4 Factory engine features full ride-by-wire technology. There is no direct connection between throttle grip and the throttle valves, which are completely controlled by a latest generation Marelli control unit. Each bank has a dedicated servo motor actuating the two relevant throttle bodies only. Hence the two banks, and subsequently the quantity of fuel injected, can be managed independently. While this solution has been tried and tested by Aprilia, it has never been applied before on such a powerful engine, thus opening up practically infinite possibilities for power delivery control. This technology immediately benefits the rider who, thanks to the triple mapping that can be controlled directly from the handlebar, can change the engine delivery mode and thus the motorcycle's temperament at any time.

The fuel supply uses two injectors per cylinder: one injector is placed downstream of the throttle valve and a "shower" injector is placed in the airbox and starts working at high loads and revs. This is complemented by electronically controlled variable length intake ducts. At low revs and loads, the long duct favors torque and smooth power delivery. When top performance is required, the upper part of the intake duct raises, thus shortening the duct and leaving the engine free to express its full power potential. A butterfly valve in the exhaust further optimizes power delivery.

The transmission was also designed according to the most advanced criteria. To underscore the racing soul of the V4 engine, a cassette gearbox is used, with a multi-plate wet clutch disc equipped with a mechanical slipper system to optimize engine braking torque and ensure stability under hard braking.

Lastly, in order to minimize weight, Aprilia's new engine makes large use of ultralight materials; all valve covers and external housings are made from magnesium.

THE V4 ENGINE in Short

Engine capacity: 999.6 cc
Architecture: 65? V4
Power: 180 HP @12,500 rpm
Valve arrangement: 4 valves per cylinder (Titanium and Nymonic) operated directly by a camshaft driven by a mixed chain/gear system (lateral timing chain, central gear train)
Fuel system: Magneti Marelli electronic injection with 2 injectors per cylinder and integrated independent Ride by Wire system for each bank. Three mappings selectable from handlebar. Electronically controlled variable length intake ducts
Maximum rpm: 14,100 rpm
Compression ratio: 13:1
Transmission: 6-speed direct-control cassette gearbox
Clutch: multiplate wet clutch with mechanical slipper system
Exhaust system: 4 into 2 into 1 headers with oxygen sensor and single silencer with integrated catalytic converter and exhaust valve.

CHASSIS: Aprilia's entire racing know-how

Mass centralization was a must when the RSV4 Factory frame was being developed. Everything was designed in order to achieve the best possible result, starting from the tank position (crucial for riding) with most of the fuel under the saddle in order to optimize motorcycle balance and eliminate any riding differences between full and empty tank. The Aprilia RSV4 Factory is a true track-ready motorcycle, and a front/rear weight distribution of 52/48 confirms this.

In line with Aprilia race division traditions, the RSV4 structure uses castings and aluminum pressings that are welded to create a far more rigid frame than that of the RSV 1000 twin, which was already a benchmark. In particular, torsional and flex rigidities were optimized in order to offer perfect feeling and control as well as the ability to handle high power outputs such as those of the Superbike version.

Notwithstanding the higher performance, the RSV4 Factory frame weighs almost the same as the RSV, at only 10.1 kg, a lightness matched only by racing frames. The special construction technology also allows both the frame and the swingarm to show the natural and shining color of the aluminum, which makes the appearance of the RSV4 Factory very similar to that of a racing prototype.

Designed using the knowledge acquired during GP racing, the swingarm of the RSV4 Factory, like its frame, is made by combining castings (the internal part and the swingarm pin/wheel connection areas) with aluminum bent sheet elements (the external part) to form a very rigid but super light box section capable of minimizing the moving masses, heightening the responsiveness of the motorcycle to suspension adjustments. The asymmetric design, with an arch section on the right side and a reinforcing arch on the left, made it possible to implement an exhaust system with optimised internal volumes without penalizing the rigidity of the swingarm. Here too, FEM modelling was used in the design process to optimise cross sections and thicknesses. The swingarm of the RSV4 Factory weighs only 5,100 grams, close to the absolute standard threshold for this technical element.

In order to boost chassis performance and make it match the rider's style and wishes, or features of the track, Aprilia RSV4 Factory ensures a combination of adjustments that are pretty much infinite. The multi-adjustable suspensions are combined with adjustments of the headstock position and rake (through interchangeable bushings), the rear end height, the swingarm pivot height and - introducing a new capability exclusive to this bike - the engine position in the frame.

The Ohlins Racing upside-down fork has 43mm stanchions and is titanium nitride coated to minimise friction. The wheel travel is 120mm. Like in race motorcycles, the fork allows precision adjustment for compression and rebound damping and spring preload. An Ohlins Racing rear shock absorber is equipped with a "Piggyback" nitrogen canister and can be adjusted for spring preload, compression and rebound damping and length, thus allowing the height of the rear end of the bike to be changed to adjust the setup to the different riding styles and tracks. The wheel travel is 130 mm. The motorcycle is also equipped with an Ohlins Racing adjustable steering damper.

Brembo monoblock radial calipers are the state-of-the-art in racing braking systems thanks to their power, high modulability and fatigue resistance.The dual 320mm diameter stainless steel floating discs are completely new and were developed by Aprilia specifically for this motorcycle. A rotor with reduced height and asymmetric perforation were used, allowing the braking power to be improved and the front wheel to be lightened by approximately 500 grams. The floating retainer is fastened to the flange with 6 pins only in order to minimize inertia and weight.

The brake pump is the radial type to improve lever feel and response accuracy. The rear braking system is Brembo "Serie Oro" with 220-mm diameter stainless steel disc and two-piston caliper, with racing-type pump and integrated tank.

Aprilia RSV4 Factory is the most highly adjustable production motorcycle in the world, just like a real race bike.

The search for greater lightness led to implementation of new forged aluminum rims. The original design further decreases the weight (approximately 1 kg less than the RSV 1000 twin) which, together with the new brake discs, minimizes unsprung mass and rotating mass inertia, benefiting motorcycle responsiveness.

Components

The following components are worth pointing out:
- Instrument panel: the mixed type (digital-analogue), it receives all the information from the CAN line and becomes an integral and crucial part of the self-diagnosis system as it is fitted with memory. It is a real onboard computer, fitted with a dot matrix display inserted in a minimal, extremely modern and compact design that provides all the information relating to the use of the motorcycle, including: shift light, engaged gear indication, indication of the engine map being used and chronometer with time storing memory. Its functionality was improved to reach a level that is even better than that of the best products available on the market, all use modes are controlled from the left hand switchgear unit so the hands can always remain on the handlebar.

- the front headlamp uses three elements that call to mind of the first RSV 1000 twin, proving to be perfectly integrated, even from the structural point of view, with the top fairing and creating a very distinctive front. The parabolic mirror was designed with modern calculation systems that led to an excellent result: maximum visibility at night with reduced weight and size.

- The electrical system was designed in order to achieve maximum functionality, rationality and minimum weight: the result is an extremely clean and compact layout that makes maintenance operations easier and is preset for use on the racetrack as the parts dedicated to the headlamps can be easily removed. Even the turn indicators - with the front indicators incorporated in the rear view mirrors and the rear indicators in the license plate holder - can be removed quickly for use on the track, the real hunting ground of Aprilia RSV4 Factory.

ACCESSORIES

A complete range of accessories is available for Aprilia RSV4 fans:

- Akrapovic racing exhaust system
- Ohlins TTX36 rear shock absorber
- adjustable footpegs
- racing half-handlebars
- fairing protection pads
- high top fairing
- fairing caps for rear mirrors
- rear stand pins
- license plate retainer cover
- motorcycle cover
- dedicated stand
- carbon heelrests
- tank cover with backpack
- tail fairing bag
- carbon exhaust system protection
- carbon fairing pullers.

Then there is a series of options - many of which designed and manufactured specifically for racetrack use. Complementing these options are a dedicated suit and helmet.

APRILIA RSV4 FACTORY: Technical Specifications

Engine type
Aprilia longitudinal 65 V-4 cylinder, 4-stroke, liquid cooling system, double overhead camshafts (DOHC), four valves per cylinder

Fuel
Unleaded gasoline
Bore and stroke 78 x 52.3 mm

Total engine capacity
999.6 cc

Compression ratio
13:1

Maximum power at crankshaft
180 horsepower @ 12,500 rpm

Maximum torque at crankshaft
84.8 ft/lb @ 10,000 rpm

Induction and fuel system
Variable length intake ducts controlled via ECU.
4 Weber-Marelli 48-mm throttle bodies with 8 injectors and latest generation Ride-by-Wire engine management. Choice of three different engine maps selectable by the rider with bike in motion:
- Track
- Sport
- Road

Ignition
Magneti Marelli digital electronic ignition system integrated in engine control system, with one spark plug per cylinder and "stick-coil"-type coils

Starter
Electric

Exhaust system
4 into 2 into 1 layout, single oxygen sensor, lateral single silencer with engine control unit-controlled butterfly valve and integrated trivalent catalytic converter (Euro 3)

Alternator
Flywheel mounted 420W alternator with rare earth magnets

Lubrication
Wet sump lubrication system with oil radiator and two oil pumps (lubrication and cooling)

Gearbox
6-speed cassette-type gearbox
1st: 39/15 (2.6)
2nd: 33/16 (2,063)
3rd: 34/20 (1.7)
4th: 32/22 (1.455)
5th: 34/26 (1.308)
6th: 33/27 (1.222)

Clutch
Multi-disc oil-bath, with mechanical slipper system

Primary drive
Straight cut gears and integrated flexible coupling, drive ratio: 73/44 (1,659)

Secondary drive Chain:
Drive ratio: 40/16 (2.5)

Chassis
Twin-spar adjustable aluminum frame, with castings and pressings.
Envisaged adjustments:
* headstock position and rake
* engine height
* swingarm pivot height
Ohlins adjustable steering damper

Front suspension
Ohlins Racing upside-down fork, 43-mm stanchions (with TiN surface treatment). Low profile forged aluminium radial caliper mountings. Completely adjustable spring preload and hydraulic compression and rebound damping. Wheel travel: 120 mm

Rear suspension
Twin sided aluminium swingarm; mixed low thickness and sheet casting technology.Ohlins Racing monoshock with piggyback with completely adjustable: spring preload, wheelbase and hydraulic compression and rebound damping. APS progressive linkages. Wheel travel: 130 mm

Brakes
Front: Dual 320-mm diameter floating stainless steel disc with lightweight stainless steel rotor and aluminum flange with 6 pins. Brembo monoblock radial calipers with 4 34mm opposing pistons. Sintered pads. Radial pump master cylinder and metal braided brake hose

Rear: 220mm diameter disc; Brembo floating caliper with two 32mm isolated pistons. Sintered pads. Pump with integrated tank and metal braided hose

Rims
Aprilia forged aluminium alloy rims, completely machined, 5 split spokes.
Front: 3.5 x17 inch
Rear: 6.0 x17 inch

Tyres
Radial tubeless.
Front: 120/70ZR 17
Rear: 190/55ZR 17 (alternative: 190/50ZR 17)

Dimensions (default settings)
Max. length: 2040 mm
Max. width: 735 mm (at the handlebar)
Max. height: 1120 mm
Min. height from the ground: 130 mm
Saddle height: 845 mm
Centre to centre distance: 1420 mm
Trail: 105 mm
Steering angle: 24.5

Kerb weight
179 kg (394.6 lb)*

Tank
17 litres (4-litre reserve included)
*Dry weight, without battery and fluids.