Aprilia RSV Tuono 2002-2005 Exhaust Silencer Muffler
Price range: £184.99 through £294.99
🎧 Included: adjustable sound — you set it, not us
- Twin Port — 4 configurations (baffle and bung, in or out)
- Single Port, Carbon Tip & Tri Oval – Single — 2 configurations (baffle in or out)
- Supplied in Standard — the quietest setting — as fitted
📦 Built & dispatched in 2–3 working days
↩️ 30-day returns
Aprilia RSV Tuono (2002-2005)
The RSV Tuono, produced between 2002 and 2005, was a naked version of the RSV1000 Mille. Designed for riders who wanted superbike power in a more relaxed, upright format, it featured a 998cc V-twin engine delivering 128 horsepower. With over 25,000 units sold, the RSV Tuono gained popularity as a versatile streetfighter.
- Everything in the Box
- Specifications
- Fitting Guide
- Road Use
- Care & Maintenance
- Delivery & Returns
- Questions
Everything in the Box
Tools you will need for fitting: hex key set · socket set · torque wrench · penetrating lubricant · silicone sealant · clean cloth
Technical Specifications
| System type | Slip-On — direct replacement for OEM silencer |
| Material | 304 Grade Stainless Steel (also available in Titanium & Carbon) |
| Weight | 2–2.8 kg across the range — lighter than OEM |
| Silencer length | 480 mm (Single / Twin Port) · 460 mm (Carbon Cap) |
| Body length | 412 mm |
| Height | 137 mm (Single / Twin Port) · 135 mm (Carbon Cap) |
| Width | 115 mm |
| Outlet diameter | 102 mm |
| Inlet clamp size | 63-68 mm (Mikalor) |
| Link pipe | LP2042 |
| Sound configs | Twin Port: 4 (Standard / Medium / Loud / Loudest) Single Port, Carbon Tip & Tri Oval – Single: 2 (baffle in / out) |
| Warranty | Purchaser's lifetime, against corrosion and manufacturing defects (Stainless & Titanium) |
| Quality standard | ISO 9001:2015 Certified |
| Manufactured | Hixon, Staffordshire, England |
Dimensions above are for the EVO range.
Fitting Guide
System type: Slip-On · Difficulty: Moderate · Estimated time: 30–45 minutes
Printed fitting guide
Choose your finish above and the matching guide will appear here.
Preparation
- Let it cool — ensure the motorcycle is completely cool before starting.
- Gather tools — hex key set, socket set, torque wrench, penetrating lubricant, silicone sealant, clean cloth.
- Lubricate fixings — spray all exhaust nuts, bolts and clamp joints, then leave 10 minutes.
- Lambda sensor — if your bike has one near the work area, disconnect it electrically first.
Remove the OEM Silencer
- Remove any bodywork or panels to access the silencer mounting and clamp.
- Remove the OEM mounting bolt or strap and loosen the exhaust clamp at the link pipe joint.
- Carefully slide the OEM silencer off the link pipe — support it, OEM units are heavy.
- Clean the exposed link pipe end; remove old gasket material or corrosion.
Install Your Blueflame System
- Dry fit first — slide the silencer on without sealant to check alignment and positioning.
- Seal & protect — apply a thin bead of silicone sealant inside the slip joint for a gas-tight seal.
- Slide the silencer onto the link pipe to the correct depth; position the clamp over the joint.
- Install the hanging strap and align with the mounting point — take care not to mark the silencer surface.
- Finger tight only at this stage to allow final adjustment.
Final Alignment & Tightening
- Ensure the silencer is straight, level and correctly positioned.
- Verify it is clear of swingarm, suspension, rear wheel, chain and foot controls throughout the full range of movement.
- Tighten to the torque specifications below — do not over-tighten.
- Reconnect the lambda sensor if disconnected. Refit any bodywork removed.
- Wipe down with a clean cloth to remove fingerprints, oils and sealant residue.
First Start & Bedding In
- Start the motorcycle in a well-ventilated area and allow it to idle for 10 minutes.
- Inspect all joints for any sign of exhaust gas leakage while idling.
- Take a short test ride of 5–10 minutes to allow the exhaust to heat-cycle and settle.
- Once fully cooled — re-check all clamps, bolts and the hanging strap. Re-torque if necessary.
Torque figures are typical for the EVO range. Check your motorcycle's handbook for the values specific to your model.
Safety notice: exhaust components become extremely hot during operation. Always allow full cooling before handling. After the initial test ride, re-check all clamps, brackets and fixings once the system has cooled completely.
Need help? Free onsite fitting is available at our Staffordshire workshop — call 01889 221854 to arrange. A written fitting guide is also included in the box.
Road Use — What You Need to Know
🚦 Homologation & Road Use
Blueflame silencers are engineered with everyday riding in mind but are not officially homologated or type-approved for road use.
When fitted with the supplied baffle and bung in Standard configuration, the exhaust is significantly quieter and produces a more refined exhaust note than with the baffle removed. This is the configuration we recommend for normal everyday riding.
For greater sound and performance where regulations permit, the baffle and bung can be removed for track-day or off-road use. Both are secured by circlips, making it quick and easy to switch between configurations using circlip pliers.
Please note: fitting the baffle and bung does not constitute homologation or type approval. It is the owner's responsibility to ensure that the motorcycle and exhaust comply with the regulations applicable to their location and intended use.
Not sure which setup is right for you? Call us on 01889 221854 — we're always happy to offer straightforward advice.
Care & Maintenance
🧼 General Cleaning
Allow the exhaust to cool completely before cleaning. Remove loose dirt with a soft dry cloth first. Use a mild, non-abrasive cleaner or warm water with mild soap on a damp microfibre cloth. Avoid pressure washers and steam cleaners.
🔬 Stubborn Marks
Isopropyl alcohol may be used sparingly on a soft cloth. Always test on a small hidden area first — alcohol can dull some clear coats. Never use abrasive compounds, wire wool or harsh solvents.
🌿 Carbon Fibre Care
Carbon silencer sleeves have a UV-resistant clear coat. Regularly apply automotive wax or a carbon-specific protectant to maintain the finish. Avoid prolonged direct sunlight when parked, as UV can gradually dull the weave appearance.
🔨 Regular Inspection
Periodically re-check all clamps, bolts and the hanging strap for tightness — especially after the first few rides and after track use. Early detection of loose fittings prevents larger issues developing.
🔇 Silencer Repacking
Over time, packing material degrades with heat cycling. Repacking is recommended when exhaust volume increases noticeably. Contact Blueflame for repacking kits on 01889 221854.
📦 Storage
Clean and dry the exhaust before extended storage. Store in a cool, dry location away from direct sunlight. Avoid contact with cables, plastics or luggage that may melt from residual heat.
Carbon heat damage warning: if you notice an amber or yellow hue developing in the resin between the carbon fibres, this is an early sign of heat damage. Discontinue use immediately and contact Blueflame — the sleeve may need inspection, repacking or replacement.
Delivery & Returns
Free UK Delivery
All UK orders delivered free, no minimum order. Shipped via TNT or FedEx. Estimated 1–2 business days after dispatch.
Built to Order
Your exhaust is made after you order it. Typical dispatch: 2–3 working days. You will receive an email confirmation when it ships.
International Shipping
Europe £25 · USA / Australia / Canada £60. Import duties and taxes may apply depending on your country — check before ordering.
30-Day Returns
Returns accepted within 30 days. If you are unsure about fitment before ordering, call us first — we would much rather sort it upfront.
Lifetime Warranty
Purchaser lifetime warranty against corrosion and manufacturing defects on all stainless steel and titanium exhaust systems.
Need Help?
Call 01889 221854 or WhatsApp us. Mon–Thu 8:30–4:30, Fri 8:30–1:00. We are a small team and always happy to chat.
Common Questions
The questions we are asked most often about fitting and living with a Blueflame exhaust.
Does the kit include the link pipe and clamp?
Yes. Every Blueflame silencer ships as a complete fitting kit — link pipe, Mikalor clamp, assembled hanging strap, plus brackets, bolts and springs where required.
Will my motorcycle need a remap after fitting?
No. Our exhausts are engineered so the bike’s factory settings do not have to be adjusted.
Will my original exhaust need cutting?
In some cases the original exhaust has to be cut to remove it from the bike. Where cutting is necessary, detailed instructions are supplied.
What power gains can I expect?
Every motorcycle is different, so we will not quote a figure we cannot stand behind. Our testing shows gains of between 2% and 7%, affected by the age, mileage and condition of your bike.
Will the silencer ever need re-packing?
No. Our design, manufacturing process and material specification mean Blueflame silencers never require re-packing.
What materials are used?
Titanium, 304 stainless steel and high-temperature carbon fibre, produced in-house.
Do both ports on the Twin Port silencer work as exhaust outlets?
Yes. Both the upper and lower ports are fully functional exhaust gas outlets. The lower (base) port is fitted with a precision-machined aluminium bung as standard.
Why is the lower port blocked off with a bung?
The bung gives a more controlled exhaust note and makes the multiple sound configurations possible.
What sound options does the Twin Port give me?
Four settings. Baffle and bung both fitted is the quietest, and how it arrives. Baffle out with the bung fitted is louder and more open. Baffle fitted with the bung out is deeper and bassier without being loud. Both removed is the loudest, with a rich bass tone.
How do I remove the baffle and bung?
Both are secured with circlips and can be changed in minutes with a pair of circlip pliers. No cutting, drilling or specialist tools.
Can I buy a replacement dB killer?
Yes, for all EVO exhausts. If you cannot identify the exact one you need from our accessories store, email a photograph of your silencer outlet to sales@blueflameperformance.com and our sales team will identify it for you.
Do you repair exhausts?
Usually, depending on the type and extent of the damage. Email photographs to sales@blueflameperformance.com and we will assess it and tell you honestly whether it is worth repairing.
Not answered here? Call 01889 221854 or WhatsApp us — Mon–Thu 8:30–4:30, Fri 8:30–1:00.
🎧 Hear What the Baffles Do
Reference recordings, so you can hear the difference between each configuration before you buy.
What these clips are — and what they are not
These are recordings of our silencers on two reference bikes: a 1000cc machine and a 125cc machine. They are not recordings of this specific model, and we are not going to pretend otherwise.
Exhaust note depends on engine size, cylinder count, state of tune and header length, so your bike will not sound identical to either clip. What these do show is how much the baffle and bung change the note — and that difference carries across models, which is the part most people are actually trying to work out.
Want something closer to your own bike? Call 01889 221854 or WhatsApp us. We will play you what we have, and tell you straight if we do not have a good match for your model.
What Buyers Say About Blueflame
Left by buyers on eBay across our full range of models. These rate Blueflame as a seller, not this specific exhaust.
in the last 6 months
Reviews for this exhaust
No reviews for this exhaust yet — be the first to leave one.
Blueflame Performance Ltd is an independent manufacturer and is not affiliated with, endorsed by or sponsored by any motorcycle manufacturer. Manufacturer and model names are used solely to indicate fitment.
Related products
-
Aprilia RSV 1000 R 2004-2010 Exhaust Silencer Muffler
Price range: £369.99 through £589.99 -
Aprilia RSV 1000 R Factory 2004-2010 Exhaust Silencer Muffler
Price range: £369.99 through £589.99 -
Aprilia RSV1000 Mille 1998-2003 Exhaust Silencer Muffler
Price range: £184.99 through £294.99 -
Benelli Tornado Tre 900 2002-2014 Exhaust Silencer Muffler
Price range: £184.99 through £294.99
