Aprilia RSV Track Bike

1 May 2015 | Author: | Comments Off on Aprilia RSV Track Bike
Aprilia RSV 4

BUILDING A TRACK BIKE 101

$3000

We built this track bike from the ground up. It has never been on the track and has only been ridden about 50 miles since the build. It runs great and pulls very strong. We removed around 30-35 lbs of non-essentials so it should weigh in around 375 lbs empty.Here are some of the tasty bits: Woodcraft rearsets Woodcraft clipons CRG levers Sharkskin Kevlar race bodywork with ram air intake scoops Penske fully adjustable rear shock Re-valved Showa forks New Michilen Pilot Race DOT tires New chain and sprockets KN high flow air filter RSVR monoposto rear subframe RSVR OZ forged front wheel Billet race style gas cap New Delkevic shorty slipon exhaust (sounds like a race bike should. raw and rude) EVO open airbox

Wood Craft rearsets

Wood Craft clipons

Penske rear shock

CRG levers

SP titanium Eprom chip

SP Ti shotgun pipes

KN hi flow air filter Recent fork and shock rebuild

As both my son and I are planning on riding this bike on the track and expecting to see the speedometer in the triple digits a lot of the time, we decided to do a complete teardown, inspect and replace as necessary to the entire bike and all its components. In the aircraft industry we can this an IRAN, Inspect and Replace As Necessary. We felt this would be prudent as the bike looked like it had been ridden hard and put to bed wet.

This way we could be assured that if there were any hidden problems they would show up in the shop and not out on the track at 150 MPH.

We have two Aprilia RSVR Mille’s. two Aprilia Caponords (for touring) a Ducati 999 and 749 and this future track bike so we are no strangers to Superbikes. I am a professional aircraft mechanic and have a hanger to work in so space is not an issue.

The first task in hand was to completely disassemble the bike. We really didn’t find to much more wrong with it other then what we saw prior to tearing it down. Everything was really dirty and the frame and swingarm had to be pressure solvent washed and hand scrubbed to clean it up.

The swing arm had some dents from low-sliding on both sides, but nothing to be structurally concerned about.

I was really interested in seeing what the valve train looked like after this many hard miles. With the engine on the bench and the valve covers pulled I was shocked at what I saw. All the cam lobes and bucket followers looked like they were barely broken in. They were not even highly polished on the lobe tops as you would expect to see.

I have always felt that these Rotax engines were built to a really high standard and now I am convinced. I have since torn into two other engines with around 20,000 miles and they all looked the same. In fact looking at the cylinder bore and piston on an engine that I bought as a spare, I thought the seller just had the cylinder honed for the new rings.

After contacting him, he told me that he had not and that what I was looking at was the original cylinder with 20,000 miles. All the original hone cross-hatch patterns were still there. VERY IMPRESSIVE!

We also torn down the clutch to inspect for wear. All the plates look like new and does not have enough wear to warrant replacement. Again pretty impressive!

We will see after we get it on the track as to how well it holds up. It’s an easy replacement with the engine in the frame

These pictures will chronologically show the build up process as the bike goes back together. Every nut and bolt is Loctite’d and torqued to the book specification. We don’t want parts falling off on the track!

Most of the parts we have bought so far have been used and we found them through the AF1 Forum. It is the best for Aprilia information and support. Check it out at apriliaforum.com

Some of the parts we had to replace were:


Front wheel with a good straight used OZ wheel

New CRG parts for the clutch lever

New rearset peg and toe piece for rear brake

Used monoposto rear subframe to eliminate the biposto one

Billet race gas cap to eliminate the key lock

Rear wheel with a good straight Brembo wheel

17t front drive sprocket to up the gearing

Aprilia RSV 4
Aprilia RSV 4
Aprilia RSV 4
Aprilia RSV 4
Aprilia RSV 4

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