APRILIA RSV Mille 1000 1999 Installation guide

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.