Aprilia By Akrapovic Exhaust Systems

Aprilia by Akrapovic exhaust systems incorporate the highest 

levels of engineering and design, advanced technology and 

materials, precision craftsmanship and a vast amount of lab and 

track experience. 

MATERIALS 

Raw materials including titanium, steel, and carbon fibre, are 

all chosen with the greatest care. The sound-proofing material 

used in Aprilia by Akrapovic silencers is even patented by NASA! 

Selection takes into account not only the type of material but 

its composition too. For example, Aprilia by Akrapovic exhausts 

use only 97% pure titanium, with 1.5% aluminium and 0.5% of 

bonding elements. This is because 100% pure titanium, as used 

by other manufacturers, is too fragile and simply does not last at 

the sort of temperatures that exhaust systems have to withstand. 

MACHINING 

Other ingredients of Aprilia by Akrapovic exhausts include 

almost fanatical attention to detail and the amazing combination 

of master craftsmanship and advanced technology that goes 

into the manufacturing process. The titanium sheet, for 

example, is first rolled by computer controlled roller mills to 

reduce variations in thickness to less than one hundredth of a 

millimetre. This ensures that the titanium pipework is absolutely 

perfect and enables diameter to be varied exactly as required. 

All pipework parts are then hand welded by master welders to 

ensure perfect gas flow through pipes and silencers, and to 

maintain correct running temperatures. Compared to mechanical 

welding, hand welding can deliver up to 3 HP more power! 

In the quest for perfect gas flow, some pipework parts are 

even finished by hydroforming. This advanced pipe bending 

and modelling technique uses pressures of over 4,000 bar to 

achieve absolute certainty of maximum gas flow efficiency. Every 

stage of the manufacturing process is also individually checked 

to ensure that the finished product achieves excellence and 

delivers performance identical to that available to professional 

race riders. 

TESTING 

Aprilia and Akrapovic attribute a great deal of importance 

to lab and track testing as a means of ensuring that their 

exhaust systems deliver unbeatable efficiency. Expert engineers 

specialising in mechanics, engine design and fluid dynamics 

fit prototype exhausts to selected motorcycles and run them 

on mechanical test rigs simulating normal stress, vibration 

and thermal shock, until they are sure that the systems are 

structurally and functionally perfect. This stage of testing 

guarantees that exhausts achieve not just maximum but longlasting 

performance too. Dynamic tests are then performed 

by Aprilia’s own test riders (with added assistance from Rotax 

engineers), at the Nardò racetrack, which leading car and 

motorcycle manufacturers regularly use for prototype testing. 

The Nardò circuit is famous for its unique characteristics: its 

circular shape and surface camber allow riders to compensate 

for centrifugal force at speeds from 90 to 240 km/h. The track 

thus becomes an ‘infinite straight road’ on which testers can 

push machines to their physical limits, demanding maximum 

torque and power even for extended periods of time. This sort of 

extreme testing guarantees that whoever chooses an Aprilia by 

Akrapovic exhaust system gets the absolute best money can buy. 

AWS - UK Branch Unit 15 Gregory Way South Reddish Stockport SK5 7ST Tel. 0161 475 1800 Fax 0161 475 1828 

Aprilia recommends 

RACING MOTORCYCLE EXHAUST SYSTEMS 

RSV 1000 R FACTORY 

RSV 1000 R 

TUONO 1000 R 

FACTORY 

TUONO 1000 R 

www.aprilia.com 

RSV MILLE ’99-’03 

SYSTEMS 

EXHAUST 

Aprilia by Akrapovic 

MOTORCYCLE 

Exhaust Systems RACING 

A 


Exhaust Systems 

Aprilia and Akrapovic form a truly winning team. Aprilia Racing and Akrapovic, one of the world’s top 

exhaust specialists, first joined forces on the circuits of the world SBK championship, and have never 

looked back. Now you too can push forward the frontiers of your technology, performance and passion, 

with Aprilia by Akrapovic exhaust systems. 

After the engine and chassis, the exhaust system is perhaps the most important single component on a 

racing motorcycle. Research into exhaust technology concentrates on two main areas: reduced weight 

and increased power. That is why racing exhausts always use the latest specialist materials. The benefits 

of improved exhaust technology are not limited to better engine braking and acceleration alone. Lighter 

exhausts significantly improve a motorcycle’s manoeuvrability, especially in rapid direction changes. 

Finally, in the middle and upper rev bands, racing exhausts increase the amount of power available and 

smooth out delivery, for far more performance. The structural differences between a stock exhaust and a 

racing system lie mainly in how the silencer internals and pipework are engineered. 

A STANDARD SILENCERS 

B 

The standard silencers use the ‘reflection chamber’ principle to 

reduce noise to levels that still permit adequate performance. Noise 

is muffled by the silencer internals, which force exhaust gases, and 

with them the sound waves, through a labyrinth. Standard exhausts 

generally give a satisfactory balance between noise emissions and 

road-going performance. 

B 

RACING SILENCERS (including “street legal” versions) 

B) The racing silencers (including “street legal” versions) employ 

the principle of ‘noise absorption’ to improve performance within the 

permitted limits for sound emission. The silencer internals form a 

direct, bend-free path, in which exhaust gases and sound waves are 

not deviated but absorbed by special sound-proofing material derived 

from the aerospace industry. In ‘street legal’ versions, racing exhausts 

incorporate an extra muffling device referred to as a ‘dB killer’.

RSV 1000 R + R FACTORY ’04 > ’05 

Full Racing EVO 6 


RSV 1000 R + R FACTORY ’04-’05 

8797232 

Street-legal 


(complete) 

(complete) 

WhlPwr 

3000 4000 5000 6000 7000 8000 9000 10000 11000 

EngSpd RPM (Sorted) 

standard exhaust 

full racing titanium evo 06 

EngTrq 

motorcycle model + part number 

The latest thing in exhaust technology! 

Developed by the Aprilia Racing Team and Akrapovic engineers during the 2004 Italian Superstock Championship, 

this brand new exhaust system is designed exclusively for the RSV 1000 and delivers a totally unrivalled level of 

performance as well as stunning looks. Conceived and made for the most discerning riders, this exhaust system is 

manufactured mainly from titanium, with steel centre pipes and headers to ensure extended working life, strength and 

resistance to the heat that Aprilia’s mighty 60° V twin can put out under conditions of extreme use. The pipework is 

made up from conical section pipes for optimised gas flow, hand-welded by master craftsmen. Separate sections are 

held together by top quality springs with silicon protection. 

The EVO 6 exhaust system is only available through official Aprilia dealers. 

MATERIALS SPARES 

All-titanium silencers Yes 

Titanium side pipes Yes 

Set of stainless steel centre pipes and headers Yes 

Carbon fibre brackets and hangers Yes 

Exhaust repair kit 

Exhaust maintenance kit 

WARNING 

This exhaust system is designed exclusively for competition use on dedicated 

racetracks. The silencers are destined for motorcycles used for competitive racing 

on closed circuits, off the public road network. They may not be used for any other 

purpose. These silencers must not be fitted to motorcycles destined for use on public 

roads. Installation of this exhaust system on a motorcycle makes it illegal to use that 

motorcycle on public roads, and any such use renders the user liable to prosecution. 

N.B.: Motorcycles with this kit installed cannot be fitted with a side stand. 

The manufacturer reserves the right to modify Aprilia by Akrapovic products and their technical specifications without prior notice. 

The graph shows an impressive increase in 

torque at all engine speeds, particularly in the 

band between 5500 and 7000 rpm, peaking at 

6000 rpm. Power becomes quite formidable and 

is delivered in a consistent, linear manner right 

from low revs. The bike is amazingly smooth as a 

result, with blistering acceleration out of bends 

from revs as low as 5500 to over 10000 rpm. 

And all this is achieved without affecting the 

bike’s acclaimed agility and handling. 

PERFORMANCE 

Weight of kit 7,043 kg 

Weight saving compared to original: -42,48% 

Power increase (kW) + 8.2 kW approx. 

Power increase (HP) + 11 HP approx. 

MAPPING AND CONFIGURATION (BY AN APRILIA DEALER): 

Optimal exhaust tuning requires dedicated mapping of the engine’s electronic control 

unit, which can only be done using the diagnostic instrument supplied to the Aprilia 

Service Network. 

RSV 1000 R + R FACTORY ’04 >’05 RSV MILLE ’01>’03 TUONO 1000 

The original Aprilia “Street-Legal” exhaust system. 

Fully homologated* and supplied with a genuine certificate of conformity, this exhaust system allows you to ride in 

perfectly legality on public roads and to achieve amazing performance on the racetrack, simply by removing the dB 

killer, held in place by just one screw**. The silencers share the design and therefore the performance of unrestricted 

2003 racing cans. The complete exhaust system adapts perfectly to all the Aprilia models shown, thanks to specially 

developed dedicated mapping***. The RSV TITANIUM super-EPROM chip comprises an erasable programmable 

read-only memory (EPROM) and a special protective cover to prevent tampering with the 32,000 bytes of memory that 

control injection and ignition. 

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All-titanium silencers Yes 

Steel headers, centre, 

side and rear pipes Yes 



WARNING 

*A homologation laser mark is applied at the end of the silencer, bearing homologation 

number E1 0489. These exhaust systems are approved for use in all countries where 

EU homologation standards apply, and in all countries accepting EU homologation 

directives, as stated on the accompanying certificate of homologation. Each exhaust 

kit comes with its own certificate of homologation certifying conformity to standards 

and listing motorcycle specifications. 

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RSV 1000 R + R FACTORY ’04-’05 

8796999 

RSV MILLE ’01>’03 

8797006 

TUONO 1000 (all versions) 

8796942 

The undeniable benefits of road-going homologation 

are enhanced by a significant increase in 

performance in the racing configuration (with 

the dB killer removed). The graph shows the increases 

achieved in torque and power, especially 

around 6400 rpm. You can also see that power 

rises again at 10200 rpm. Power output is impressive 

even at low revs, and makes light work of 

sports riding on winding roads. Accelerating out 

of bends and modulating power through twisting 

curves becomes so much easier. 

PERFORMANCE (with the dB killer removed) 

Weight of kit 7.60 kg 

Weight saving compared to original (RSV mille ’01-’03) -25,6% 

Weight saving compared to original (Tuono mille ’02-’05) -25,6% 

Weight saving compared to original (RSV 1000 ’04-’05) -37,9% 

Power increase (kW) + 4.5 kW approx. 

Power increase (HP) + 6.5 HP approx. 

**Removal of this screw invalidates the homologation. The dB killer can nevertheless 

be replaced using the same screw to bring noise emissions back within legal limits. 

***Except for the RSV 1000 M.Y. 2004-2005. Optimal exhaust tuning requires 

dedicated mapping of the engine’s electronic control unit, which can only be done 

using the diagnostic instrument supplied to the Aprilia Service Network. 

RSV 1000 R + R FACTORY ’04 > ’05 

Slip-on 2x2 Street-legal 


Improved agility and responsiveness on road and track. 

These slip-ons are the latest addition to the Aprilia by Akrapovic “Street-Legal” 

range, and are specially designed to achieve the best possible balance between price, 

reliability, performance and style for your RSV 1000. Their exceptionally light weight 

improves agility and riding satisfaction too. Quick and easy to fit, fully homologated* 

and supplied with a genuine certificate of conformity, these slip-ons allow you to 

ride in perfectly legality on public roads and to achieve amazing performance on the 

racetrack, simply by removing the dB killer, held in place by just one screw**. 

MAPPING: Dedicated mapping can be activated using the diagnostic instrument 

supplied to the Aprilia Service Network. 


Titanium silencers Yes 

Stainless steel side pipes Yes 



WARNING 

*A homologation laser mark is applied at the end of the silencer, bearing homologation 

number E1 0492. These exhaust systems are approved for use in all countries where 

EU homologation standards apply, and in all countries accepting EU homologation 

directives, as stated on the accompanying certificate of homologation. Each exhaust 

kit comes with its own certificate of homologation certifying conformity to standards 

and listing motorcycle specifications. 

�� 

�� 

�� 

�� 

�� 

�� 


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RSV 1000 R + R FACTORY ’04-’05 

8797221 

The ease of installation of this kit is only matched 

by the effective boost that it gives to performance, 

especially at low to medium revs. Maximum 

increase is achieved around 6200 rpm, and 

maximum power output beyond 9000 rpm is 

improved too. 

These easy to install slip-ons give your bike 

improved agility and speed, especially in terms of 

acceleration. 

PERFORMANCE (with the dB killer removed) 

Weight of kit 4.687 kg 

Weight saving compared to original -33% 

Power increase (kW) + 4 kW approx. 

Power increase (HP) + 5.5 HP approx. 

**Removal of this screw invalidates the homologation. The dB killer can nevertheless 

be replaced using the same screw to bring noise emissions back within legal limits. 

RSV MILLE ’99 > ’03 TUONO 1000 

Titanium Mono 


WhlPwr 

3000 4000 5000 6000 7000 8000 9000 

EngSpd RPM (Sorted) 

standard exhaust 

titanium mono 

10000 11000 

EngTrq 



8797218 


8797219 

TUONO 1000 (all versions) 

8797220 

Exclusive mapping specially developed by the Aprilia Racing Team. 

Conceived for competition and developed on the track, the new Racing Mono exhaust system boosts the torque and 

power of your RSV 1000 ’99-’03 or Tuono and optimises its racetrack handling. The secret lies in the dedicated 

EPROM that comes with the kit, which is only available from official Aprilia dealers. This chip is specially 

configured for compatibility with all the models covered by the Titanium Mono exhaust, ensures a perfect match 

between exhaust and bike, and harmonises overall performance. Weeks of rigorous testing, first on the bench 

and then on the track, went into developing the best possible mapping. Perfect balance between performance 

and reliability is the result. The Titanium Mono exhaust delivers an incredible weight saving and amazingly clean 

power well beyond maximum power revs. Clever design and prestige materials also mean easier control and more 

responsive handling for simply superior agility. 


Titanium silencers Yes 

Stainless steel side pipes Yes 

Exhaust maintenance kit Yes 


WARNING 

This exhaust system is designed exclusively for competition use on dedicated 

racetracks. 

The silencer is destined for motorcycles used for competitive racing on closed circuits, 

off the public road network. It may not be used for any other purpose. 

This silencer must not be fitted to motorcycles destined for use on public roads. 

Installation of this exhaust system on a motorcycle makes it illegal to use that 

motorcycle on public roads, and any such use renders the user liable to prosecution. 


The effect of the improved power delivery shown 

in the graph is amply demonstrated on the 

race track. Power is increased right through the 

medium to high rev band, with a significant boost 

at 6000 rpm, becoming even more impressive at 

7600 rpm. 

Decisively ‘muscular’ power output combined 

with a significant reduction in weight gives your 

bike amazing agility and inspires you with the 

true pleasure of sports riding. 

PERFORMANCE 

Weight of kit Kg. 2,300 

Weight saving compared to original (RSV mille ’99-’01) -47% 

Weight saving compared to original (RSV mille ’01-’03 -48% 

Weight saving compared to original (TUONO ’02-’05) -48% 

Power increase (kW) + 4 kW approx. 

Power increase (HP) + 5.5 HP approx.

Aprilia By Akrapovic Exhaust Systems

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