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Dream Factories - Tours of Aprilia and Ducati - Aprilia factory tour

Back in 2005, Niall and Jon explored inside Aprilia and Ducati's factories before taking the RSV-R and 999 on a trip along the legendary Futa Pass.

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Posted: 14 March 2008
by Jon Urry

Getting the wrong Aprilia factory is a fairly easy mistake to make. Aprilia actually have two factories near Noale, one where the bikes are made, hence the huge rack of frames sitting outside in the sun, and another housing the racing department, R&D and offices.I say it's an easy mistake because Niall and I spent 20 minutes at the wrong door. But get inside and you are instantly welcomed to the Aprilia family.

Aprilia's financial standings have been a bit shaky to say the least since the scooter bubble burst, but with its recent takeover by Piaggio things are looking a lot better. But, if the facilities are anything to go by, at least Aprilia invested wisely when the money was there. The R&D, testing and general facilities are very impressive and our tour of the factory really did show what goes into making, testing and getting any new bike through the various and ever more stringent EU laws.

Check out the technical story below to see what goes on - it really is amazing how much a bike has to go through.

Moving from the road bike testing area we entered the racing and R&D department. Despite Piaggio's decision to pull out of MotoGP, Aprilia still takes its racing very seriously. The Aprilia Racing division employs 80 people who design, test, order and store every component in-house for all classes of racing.

The storeroom alone holds over £3,500,000-worth of spares, all kept in labelled compartments - it's the ultimate pick and mix shop! Next year there will be around 20 privateer 125cc Aprilias in GPs plus the factory bikes, and 12 or so 250cc privateers, again plus the factory bikes. Fancy running a team? A factory 125cc costs £50,000 and a 250 is £70,000. And you'll be needing spares on top of that, plus a decent-sized transporter and a few grid girls.

Walking around the factory the thing that was really noticeable at Aprilia was the family atmosphere. The last year has been tough; the financial problems stopped production for two weeks in mid-summer last year and the employees really didn't know if they were going to get their marching orders or not - the factory was on the brink of closing for some time.

While Aprilia tried to put a brave face on things, a few of the employees we spoke to described the time as 'a nightmare', and it seems to have brought the whole of Aprilia closer. But all's well that ends well and, for now at least, Aprilia's future looks secure. Buoyed by the factory's restored spirit of optimism, Niall and I drew straws for who got the RSV-R's keys for the 100-mile journey to Bologna, the home of Ducati.

Continue for the Ducati Factory

How you can do it
Aprilia is based in Noale, just outside Venice. The easiest way to get to the factory is to fly to Venice Treviso airport, which is on the budget airline routes. Or you could ride your Aprilia there, of course.

INSIDE APRILIA THE TECHNICAL SIDE

Testing
You know how old gits harp on about the good old days? About how bikes had character, and used to break down every other day? Well, the reason those days are no more is due to the huge amount of rigorous testing every new bike goes through years before it ever makes it into production. Aprilia has some of the most advanced testing facilities outside Japan. Here is just a flavour of what every bike is subjected to before it is even considered for production.

Noise
In a dedicated sound room every noise the bike makes is tested, recorded and evaluated. Even the sound of the bike from the riding position is recorded and adjusted for optimum on-board aural pleasure! In the early stages of development the RSV-R's frame was found to resonate at certain rpm; this was cured by adding rubber bungs to eliminate it. The whole room is sound-proofed and has a rolling-road so the bike's engine can be run and tested.

Endurance
The frame is squashed by a few millimetres, then released, then squashed again, and again, and... in fact it's done 500,000 times to make sure the welds are strong enough to last the bike's life. For scooters, Aprilia reckon this is eight to nine years, superbikes twice this. This whole test is repeated vertically, horizontally and torsionally.

Road simulation
The bike is run on a dyno to simulate road riding. A computer controls the throttle and gears, and the dyno adds resistance to simulate hills. A bit like an exercise bike in the gym. Aprilia also has 19 engine dynos.

Vibration test
The whole bike is put on a giant vibrator and shaken senseless for 400 hours to test components for strength.

Road test
The bikes are ridden on the roads around Noale. Test devices can only tell you so much; what is important, say Aprilia, is what the bike feels like to ride..

Production
In the high season, during the summer months, the Aprilia factory's 11 production lines (seven for scooters, four for big bikes) produce 2500 bikes a day. The components aren't actually made in-house, instead whole assemblies - engines, front suspension, etc - are delivered to the factory and the bikes bolted together. The workers, 60 per line, stay in one place all day and repeat the same job over and over again. It takes around two hours to make an RSV-R from start to finish, and when the bike is completed a friendly Italian chap sticks the brand new bike on a dyno at the end of the line and runs the motor to the red-line through the gears. But it's okay, he does it in a 'kindly Italian way'. Good job you spent those 1000 miles carefully running it in, eh? And if you're looking for a job at Noale you may be interested to know that 60% of the workers are women. Come on the girls.


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