APRILIA RSV 1000 TUONO R Owner`s manual

1306 5
TUONO 1000
www.serviceaprilia.com
12/2005-00
8104982
UK
workshopmanual
INTRODUCTION
TUONO 1000
INTRODUCTION
0
0 - 1
INTRODUCTION TUONO 1000
SUMMARY 0.1.
FOREWORD ................................................................................................................................................... 3
0.1.1.
FOREWORD.......................................................................................................................................... 3
0.1.2.
REFERENCE MANUALS....................................................................................................................... 4
0.1.3.
ABBREVIATIONS / SYMBOLS .............................................................................................................. 5
0-2
TUONO 1000
0.1.
FOREWORD
0.1.1.
-
-
INTRODUCTION
FOREWORD
This manual provides the information required for normal servicing.
This publication is intended for use by aprilia Dealers and their qualified mechanics; certain information has been
omitted intentionally, as this manual does not purport to provide a comprehensive treatise on mechanics. Since
complete mechanical explanations have not been included in this manual, the reader must be familiar with basic
notions of mechanics, as well as with basic repair procedures. Repairing or inspecting a motorcycle when one does
not possess such basic knowledge or training could result in improper servicing and make the motorcycle unsafe to
ride. For the same reason, certain basic precautions have been omitted in the descriptions of repair and inspection
procedures; you are therefore invited to take special care to avoid damage to motorcycle components or injury to
persons. aprilia s.p.a. undertakes to constantly improve the design of its products and the relevant literature to
ensure maximum customer satisfaction. The main technical modifications and changes in repair procedures are
communicated to all aprilia dealers and agencies world-wide. Such modifications will be included in subsequent
editions of the manual. Should you require assistance or clarifications regarding inspection and repair procedures,
please contact the aprilia SERVICE DEPT., which will be pleased to help, as well as providing you with updates
and technical modifications regarding the vehicle.
aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the
essential features of a product as specified in the relevant manual. All rights of storage using electronic means, reproduction and total or partial adaptation, whatever the means adopted, are reserved in all countries. The mention of third parties‘ products is only made for information purposes, and constitutes no engagement. aprilia s.p.a. is not liable in any way for the performance or use of these products. First edition: December 2005
Produced and printed by: VALLEY FORGE DECA
Ravenna, Modena, Turin
DECA s.r.l.
via Vincenzo Giardini, 11
48022 Lugo (RA) - Italy
Tel. +39 - 0545 216611
Fax +39 - 0545 216610
E-mail: deca@vftis.spx.com
www.vftis.com
On behalf of:
aprilia s.p.a.
via G. Galilei, 1 - 30033 Noale (VE) - Italy
Tel. +39 œ (0)41 58 29 111
Fax +39 œ (0)41 58 29 190
www.aprilia.com
www.serviceaprilia.com
0 - 3
INTRODUCTION 0.1.2.
REFERENCE MANUALS
PARTS CATALOGUES
aprilia part# (description)
3985
SPECIAL TOOLS MANUALS
aprilia part# (description)
001A00
OWNER'S MANUALS
aprilia part# (description)
8104927
8104928
8104929
8104930
CHASSIS WORKSHOP MANUAL
aprilia part# (description)
8104978
8104981
8104979
8104980
8104982
8104983
ENGINE TECHNICAL MANUAL
aprilia part# (description)
8140743
8140744
8140745
8140746
8140747
8140748
0-4
TUONO 1000
TUONO 1000
0.1.3.
#
<
>
≤
≥
~
∞
°C
°F
±
A.C.
A
Ah
API
AT
AV/DC
bar
D.C.
cc
CO
CPU
DIN
DOHC
ECU
rpm
HC
ISC
ISO
kg
kgm
km
km/h
kΩ
kPa
KS
kW
ℓ
LAP
LED
LEFT
SIDE
m/s
max
mbar
mi
MIN
MPH
MS
MΩ
N.A.
N.O.M.M.
N.O.R.M.
Nm
Ω
PICK-UP
BDC
TDC
PPC
INTRODUCTION
ABBREVIATIONS / SYMBOLS
= number
= less than
= greater than
= less than or equal to
= greater than or equal to
= approximately
= infinity
= degrees Celsius (centigrade)
= degrees Fahrenheit
= plus or minus
= alternating current
= Ampere
= Ampere per hour
= American Petroleum Institute
= high voltage
= Anti-Vibration Double Countershaft
= pressure measurement unit (1 bar = 100 kPa)
= direct current
= cubic centimetres
= carbon monoxide
= Central Processing Unit
= German industrial standards (Deutsche Industrie Norm)
= Double Overhead Camshaft
= Electronic Control Unit
= revolutions per minute
= unburnt hydrocarbons
= Idle Speed Control
= International Standardisation Organisation
= kilograms
= kilograms per metre (1 kgm = 10 Nm)
= kilometres
= kilometres per hour
= kilo Ohm
= kiloPascal (1 kPa = 0.01 bar)
= clutch side (from the German "Kupplungsseite")
= kilowatt
= litres
= racetrack lap
= Light Emitting Diode
= left side
= metres per second
= maximum
= millibar (1 mbar = 0.1 kPa)
= miles
= minimum
= miles per hour
= flywheel side (from the German "Magnetoseite")
= MegaOhm
= Not Available
= Motor Octane Number
= Research Octane Number
= Newton metre (1 Nm = 0.1 kgm)
= ohm
= pick-up
= Bottom Dead Centre
= Top Dead Centre
= Pneumatic Power Clutch
0 - 5
INTRODUCTION RIGHT
SIDE
SAE
TEST
T.B.E.I.
T.C.E.I.
T.E.
T.P.
TSI
UPSIDEDOWN
V
W
Ø
0-6
= right side
= Society of Automotive Engineers
= diagnostic check
= crown-head Allen screw
= cheese-head Allen screw
= hexagonal head
= flat head screw
= Twin Spark Ignition
= inverted fork
= volt
= watt
= diameter
TUONO 1000
TUONO 1000
GENERAL INFORMATION
GENERAL INFORMATION
1
1 - 1
GENERAL INFORMATION TUONO 1000
SUMMARY 1.1.
STRUCTURE OF THE MANUAL..................................................................................................................... 3
1.1.1.
CONVENTIONS USED IN THE MANUAL ............................................................................................. 3
1.1.2.
SAFETY WARNINGS............................................................................................................................. 4
1.2.
GENERAL RULES........................................................................................................................................... 5
1.2.1.
BASIC SAFETY RULES......................................................................................................................... 5
1.3.
DANGEROUS ELEMENTS ............................................................................................................................. 8
1.3.1.
WARNINGS ........................................................................................................................................... 8
1.4.
RUNNING-IN ................................................................................................................................................. 11
1.4.1.
RUNNING-IN........................................................................................................................................ 11
1.5.
VEHICLE IDENTIFICATION .......................................................................................................................... 12
1.5.1.
POSITION OF THE SERIAL NUMBERS ............................................................................................. 12
1-2
GENERAL INFORMATION
TUONO 1000
1.1.
1.1.1.
•
STRUCTURE OF THE MANUAL
CONVENTIONS USED IN THE MANUAL
This manual is divided in sections and subsections, each covering a set of the most significant components. For
quick reference, see the summary of sections.
Unless expressly specified otherwise, assemblies are reassembled by reversing the assembly procedure.
The terms "right" and "left" are referred to the rider seated on the vehicle in the normal riding position.
Motorcycle operation and basic maintenance are covered in the "OWNER'S MANUAL".
•
•
•
In this manual any variants are identified with these symbols:
optional
catalytic version
-
all versions
MP
national certification
SF
European certification (EURO 1 limits) VERSION:
Italy
United
Kingdom
Austria
Portugal Finland Greece
Holland
Malaysia Chile
Switzerland
Denmark
Japan
Croatia
Australia United
States of
America
Brazil South Africa
New
Zealand
Canada Belgium
Germany
France Singapore
Slovenia
Israel
Spain
South
Korea 1 - 3
GENERAL INFORMATION 1.1.2.
TUONO 1000
SAFETY WARNINGS
The symbols and warnings used throughout this manual have the following meanings:
Safety warning. When you find this symbol on the vehicle or in the manual, be careful of the potential
risk of personal injury. Disregarding the instructions identified by this symbol may compromise the
safety of the user, the motorcycle and third parties.
DANGER
Indicates a potential hazard which may result in serious injury or even death. WARNING Indicates a potential hazard which may result in minor personal injury or damage to the vehicle.
NOTE The word "NOTE" in this manual precedes important information or instructions.
1-4
TUONO 1000
1.2.
1.2.1.
GENERAL INFORMATION
GENERAL RULES
BASIC SAFETY RULES
CARBON MONOXIDE
When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated
area. Avoid starting the engine indoors. Use an exhaust emission extraction system when working indoors. DANGER
Exhaust gases contain carbon monoxide, a poisonous gas which, if inhaled, may cause loss of
consciousness or even death.
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and maintenance operations should be carried out in a well-ventilated area, with the engine
off.
Do not smoke when refuelling or in the proximity of sources of fuel vapours. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
HOT COMPONENT PARTS
The engine and the components of the exhaust system become very hot and remain hot for some time after the engine
has been stopped. Wear insulating gloves before handling these components or allow for the engine and the exhaust system to cool down
before proceeding. USED GEARBOX AND FORK FLUIDS
DANGER
Wear latex gloves when servicing.
Prolonged or repeated contact with gear fluid may cause severe skin damage. Wash your hands thoroughly after use.
For disposal, contact the nearest waste oil reclamation firm or the supplier. Wear latex gloves when servicing.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT.
KEEP AWAY FROM CHILDREN.
BRAKE FLUID
WARNING
Brake fluid can damage plastic, rubber or painted parts. When servicing the brake system, protect all such parts with a clean cloth.
Always wear safety glasses when servicing the brake system. Brake fluid is highly irritant. Avoid contact with the eyes. In case of contact with the eyes, rinse thoroughly with cool, clean water and immediately seek medical attention. KEEP AWAY FROM CHILDREN.
COOLANT
Coolant contains ethylene glycol which can be flammable under certain conditions. When ignited, ethylene glycol
produces invisible flames that can cause burns.
1 - 5
GENERAL INFORMATION TUONO 1000
DANGER
Avoid spilling coolant on hot engine parts and the exhaust system, as it may ignite and produce invisible flames. Wear latex gloves when servicing.
Though toxic, its sweet taste might attract animals. Never leave coolant in an open container or in a
position easily accessible to animals. KEEP AWAY FROM CHILDREN.
Never remove the radiator cap while the engine is still hot. Coolant is under pressure and can cause
burns.
HYDROGEN GAS AND BATTERY ELECTROLYTE
DANGER
The battery electrolyte is a toxic, caustic substance containing sulphuric acid and thus able to cause
severe burns in case of contact with the skin. Wear close-fitting gloves and protective clothing when handling this fluid. In case of contact with the skin, rinse thoroughly with fresh water. Always use eye protection as even a very small amount of the battery fluid can cause blindness. If battery fluid comes in contact with the eyes, flush thoroughly with water for fifteen minutes and contact an eye specialist immediately.
If battery fluid is swallowed accidentally, drink plenty of water or milk. Seek medical attention immediately and keep drinking milk of magnesia or vegetable oil in the meantime. The battery gives off explosive gases. Keep the battery well away from any sources of ignition, such
as flames, sparks, or any heat sources; do not smoke near the battery. Make sure the area is well ventilated when servicing or refilling the battery. KEEP AWAY FROM CHILDREN.
Battery fluid is corrosive. Do not spill it, especially on plastic parts. Make sure that the electrolyte acid is suitable for the type of battery used.
GENERAL PRECAUTIONS AND INFORMATION
Follow these instructions closely when repairing, disassembling or reassembling the motorcycle or its components.
DANGER
Using bare flames is strictly forbidden when working on the motorcycle. Before servicing or
inspecting the motorcycle: stop the engine and remove the key from the ignition switch; allow for the
engine and exhaust system to cool down; where possible, lift the motorcycle using adequate
equipment placed on firm and level ground. Be careful of any parts of the engine or exhaust system
which may still be hot to the touch to avoid scalds or burns.
Never put mechanical parts or other vehicle components in your mouth when you have both hands
busy. None of the motorcycle components are edible. Some components are harmful to the human
body or toxic.
Unless expressly indicated otherwise, reassemble the units by repeating the disassembly operations
in reverse order. Where a procedure is cross-referred to relevant sections in the manual, proceed
sensibly to avoid disturbing any parts unless strictly necessary. Do not use polishing pastes on matt
paints.
Never use fuel instead of solvent to clean the motorcycle.
Do not clean rubber or plastic parts or the seat with alcohol, petrol or solvents. Use only water and
mild detergent.
Always disconnect the battery negative (-) lead before soldering any electrical components.
When two or more persons service the same motorcycle together, special care must be taken to avoid
personal injury.
BEFORE REMOVING THE COMPONENTS
•
Clean off all dirt, mud, and dust and clear any foreign objects from the vehicle before disassembling any
components.
•
Use the model-specific special tools where specified.
1-6
TUONO 1000
GENERAL INFORMATION
DISASSEMBLING THE COMPONENTS
- Never use pliers or similar tools to loosen and/or tighten nuts and bolts. Always use a suitable spanner.
- Mark the positions of all connections (hoses, wiring, etc.) before disconnecting them. Identify each connection
using a distinctive symbol or convention.
- Mark each part clearly to avoid confusion when refitting.
- Thoroughly clean and wash any components you have removed using a detergent with low flash point.
- Mated parts should always be refitted together. These parts will have seated themselves against one another in
service as a result of normal wear and tear and should never be mixed up with other similar parts on refitting.
- Certain components are matched-pair parts and should always be replaced as a set.
- Keep away from heat sources.
REASSEMBLING THE COMPONENTS
DANGER
Never reuse a circlip or snap ring. These parts must always be replaced with new ones once they have
been removed.
When fitting a new circlip or snap ring, open the ends just enough to allow fitting to the shaft. Make a rule to check that a newly fitted circlip or snap ring is fully housed in its groove. Never use compressed air to clean bearings.
NOTE All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these
requirements.
-
-
-
-
-
-
-
-
-
Use ORIGINAL aprilia SPARE PARTS only.
Use the specified lubricants and consumables.
Where possible, lubricate a part before assembly.
When tightening nuts and bolts, start with the largest or innermost nut/bolt and observe a cross pattern. Tighten
evenly, in subsequent steps until achieving the specified torque.
Replace any self-locking nuts, gaskets, seals, circlips or snap rings, O-rings, split pins, bolts and screws which
have a damaged thread.
Lubricate the bearings abundantly before assembly.
Make it a rule to check that all components you have fitted are correctly in place.
After repairing the motorcycle and after each service inspection, perform the preliminary checks, and then test ride
the motorcycle in a private estate area or in a safe area away from traffic.
Clean all mating surfaces, oil seal edges and gaskets before assembly. Apply a thin layer of lithium grease along
the edges of oil seals. Fit oil seals and bearings with the marking or serial number facing outward (in view).
ELECTRICAL CONNECTORS
Disconnect electrical connectors as follows: failure to follow these instructions can seriously damage the connectors and the wiring.
Press the special safety hooks, where fitted. •
•
•
WARNING
Never separate two connectors by pulling on the wiring.
Grasp both connectors and pull them in opposite directions until they become separated.
Remove dirt, rust, moisture, etc., from inside the connectors with compressed air.
Ensure that the wires are securely crimped to the terminals inside each connector.
NOTE A connector will fit properly only in the matching connector and when inserted in the correct fitting position.
•
Reconnect the two connectors. Ensure that they are correctly coupled (if fitted with hooks, they should click
audibly into place).
TIGHTENING TORQUES
DANGER
Always remember that the tightening torque settings of all wheel, brake, wheel shaft and other
suspension parts play a fundamental role to ensure vehicle safety. Ensure that these values are
always within the specified limits.
Check the tightening torque settings of fastening parts at regular intervals. Always use a torque
spanner when reassembling.
Failure to observe these instructions can result in parts loosening or coming away, thus jamming a
wheel or creating other problems which would affect the handling of the motorcycle, potentially
resulting in serious injury or death.
1 - 7
GENERAL INFORMATION 1.3.
1.3.1.
TUONO 1000
DANGEROUS ELEMENTS
WARNINGS
FUEL
DANGER
The fuel used in internal combustion engines is highly flammable and can become explosive under
particular conditions.
Refuelling and maintenance operations should be carried out in a well-ventilated area, with the engine
off. Do not smoke when refuelling or in the proximity of sources of fuel vapours. Avoid contact with bare
flames, sources of sparks or any other source which may ignite the fuel or lead to explosion.
Avoid spilling fuel out of the filler, as it may ignite when in contact with hot engine parts. In the event of accidental fuel spillage, ensure that the affected area is fully dry before starting the
engine. Fuel expands from heat and when left under direct sunlight.
Never fill the fuel tank up to the rim. Tighten the filler cap securely after each refuelling. Avoid contact with skin. Do not inhale vapours. Do not swallow fuel. Do not transfer fuel between
different containers using a hose.
DO NOT DISPOSE OF FUEL IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN.
Use only premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON).
LUBRICANTS
DANGER
Correct lubrication is essential to the safety of the motorcycle. Failure to maintain the lubricant level or the use of incorrect, old or dirty lubricant can cause the engine or transmission to seize, resulting in accident, serious injury or death.
Prolonged or repeated contact with gear fluid may cause severe skin damage. Wash your hands thoroughly after use.
Do not dispose of oil in the environment. For disposal, contact the nearest waste oil reclamation firm or the supplier.
WARNING
Avoid spillage when filling the vehicle with oil. Immediately clean up any spilt oil, as it can damage painted parts.
Oil on the tyres can make them very slippery and dangerous to use. In case of leaks, do not use the motorcycle. Identify the cause of the leak and repair it.
ENGINE OIL DANGER
Prolonged or repeated contact with engine oil may cause severe skin damage. Wash your hands thoroughly after handling. Do not dispose of oil in the environment. For disposal, contact the nearest waste oil reclamation firm or the supplier. Wear latex gloves when servicing.
FRONT FORK FLUID
DANGER
Front suspension response can be modified to a certain extent by changing damping settings and/or
selecting a particular grade of oil. Standard oil viscosity: SAE 20 W. Different oil grades can be
selected to obtain a particular suspension response (choose SAE 5W for a softer suspension, 20W for
a stiffer suspension).
The two grades can also be mixed in varying solutions to obtain the desired response.
1-8
TUONO 1000
GENERAL INFORMATION
BRAKE FLUID
NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic
circuit. The information provided below applies to both brake systems.
DANGER
Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle‘s
most important safety component and using the vehicle with the brakes in less than perfect operating
condition comprises a high probability of traffic accident, which can result in serious injury or death.
The brakes are significantly less effective on a wet road surface.
DANGER
If the road surface is wet, maintain a double braking distance, as both the brakes and the grip of the tyres are significantly less effective in such conditions. Water on brakes, whether due to a recent wash or picked up from a wet road surface, puddles or drains, can result in significantly reduced brake efficiency. Failure to observe these instructions can result in serious accidents, with the risk of serious personal injury or death. The brakes are essential to your safety. Do not drive the vehicle if the brakes on not in perfect operating condition. Always check the brakes before riding the motorcycle. Brake fluid is an irritant. Avoid contact with the eyes or skin.
In the event of accidental contact, wash affected body parts thoroughly. In the event of accidental contact with the eyes, contact an eye specialist or seek medical attention.
DO NOT DISPOSE OF BRAKE FLUID IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN. Avoid spillage. Brake fluid can damage plastic or painted parts.
DANGER
Do not use brake fluids other than the specified type. Never mix different types of fluids to top up the
level, as this will damage the brake system.
Do not use brake fluid from containers which have been kept open or in storage for long periods of time. Any sudden changes in slack or hardness in the brake levers are warning signs of problems with the hydraulic circuits. Ensure that the brake discs and brake linings have not come in contact with oil or grease. This is particularly important after servicing or inspections. Ensure that the brake lines are not twisted or worn. Avoid accidental entry of water or dust into the circuit. Wear latex gloves when servicing the hydraulic circuit.
DISC BRAKES
DANGER
The brakes are the vehicle‘s most important safety component.
To ensure your personal safety, they must be in perfect working order and should be checked before every ride. A dirty disc soils the pads. Dirty pads must be replaced. Dirty or oily discs must be cleaned with a high-quality degreasing product. If the vehicle is often used on wet road surfaces or on dusty or rough tracks, or if used in competition, reduce the
service intervals by half.
Check brake pads for wear.
When the brake pads are worn, the fluid level lowers to compensate for the wear. The front brake fluid reservoir is on the right-hand side of the handlebar, next to the front brake lever. The rear brake fluid reservoir is located under the right fairing.
Do not use the vehicle if the brake system leaks fluid.
COOLANT
DANGER
Coolant is toxic when swallowed; contact with the eyes or skin can cause irritation.
In the event of contact with the skin or eyes, rinse thoroughly and repeatedly with water and seek medical attention. If swallowed, induce vomiting, thoroughly rinse mouth and throat with water and seek medical attention immediately.
DO NOT DISPOSE OF IN THE ENVIRONMENT. KEEP AWAY FROM CHILDREN.
DANGER
Avoid spilling coolant on hot engine parts, as it may ignite and produce invisible flames. Wear latex gloves
when
servicing.
Do not use the vehicle when the coolant is below the minimum level. The coolant mixture is a 50% solution of water and antifreeze. This solution is ideal for most operating temperatures and
provides good corrosion protection.
1 - 9
GENERAL INFORMATION TUONO 1000
This solution is also suitable during the warm season, as it is less likely to evaporate and will reduce the need for
frequent top-ups. In addition, less water evaporation means fewer mineral salt deposits in the radiator, which helps preserve the efficiency of the cooling system. When the temperature drops below 0"C check the cooling system frequently and add more antifreeze (up to 60%
maximum) to the solution, if needed. Use distilled water in the coolant mixture. Tap water will damage the engine. Refer to the chart given below and add the indicated quantity of antifreeze to the water to obtain a solution with the
desired freezing point: Freezing point °C (°F)
-20° (-4 °F)
-30° (-22 °F)
-40° (-40 °F)
Coolant % of volume
35
45
55
NOTE Coolants have different specifications. The protection degree is written on the label.
WARNING
Use nitrite-free and anticorrosion coolant only to ensure protection at least at -35°C (-31 °F).
DRIVE CHAIN
Check drive chain operation, wear, slack and lubrication at regular intervals.
The vehicle is equipped with an endless chain with master link.
WARNING If too slack, the chain can come off the front or rear sprocket thus resulting in serious accidents and
damage to the vehicle, with consequent serious personal injury or death. Do not use the vehicle if the chain slack has not been correctly adjusted. To check the chain, hold it where it turns on the rear sprocket and pull it as if to separate it from the
sprocket itself.
If you can move it more than 3 mm (0.125 in) from the front sprocket, it is worn; replace the chain, and the front and rear sprocket.
DANGER
Improper maintenance can cause premature wear of the chain and result in damage to both the front
and rear sprocket.
Perform chain maintenance operations more frequently if the vehicle is used on dusty roads or in
muddy areas.
TYRES
WARNING An over-inflated tyre results in a hard, uncomfortable and less secure ride. Over inflation also affects grip, especially on curves and wet surfaces.
An under-inflated tyre (insufficient pressure) can slip on the wheel rim, resulting in loss of control. Under inflation also affects grip and handling, as well as braking efficiency. Tyre changing and repair, and wheel servicing and balancing are delicate operations. They should be
carried out using adequate tools and are best left to experienced mechanics. When new, tyres can have a thin slippery protective coating. Drive carefully for the first few kilometres
(miles). Never use rubber treatment products on the tyres.
In particular, do not allow the tyre to come in contact with liquid fuel, which rapidly deteriorates the tyre rubber. In case of contact with oil or fuel, do not clean but change the tyres. DANGER
Some of the factory-assembled tyres of this vehicle are provided with wear indicators. There are various types of wear indicators. For more information on how to check the wear, contact your Dealer. Check wear visually and have the tyres replaced when they are worn. If a tyre deflates during a ride, do not attempt to continue the trip. Avoid sudden braking or steering manoeuvres, and do not decelerate abruptly. Slowly decelerate and move to the edge of the road braking with the engine until you come to a
standstill. Failure to observe these instructions can result in accidents, with the risk of serious personal injury or
death.
Never use tube tyres on tubeless tyre rims, or vice versa.
1 - 10 GENERAL INFORMATION
TUONO 1000
1.4.
1.4.1.
RUNNING-IN
RUNNING-IN
Correct engine running-is essential to ensuring proper performance and durability. Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes. Varying speed frequently is also recommended. This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when
less stressed. While it is important to put a certain amount of stress on engine components during the running-in period, it is equally important to spare the engine at this stage in the vehicle‘s life. WARNING Top acceleration performance is obtained only after covering the first 1500 km (932 mi).
Follow these recommendations:
•
Do not open the throttle completely when the engine is running at low speed, both during and after the running-in
period.
•
Until you have covered the first 100 km (62 mi), use the brakes gently and avoid harsh, prolonged braking. This will
help the brake pads bed in properly against the brake disc.
•
During the first 1000 km (621 mi), never exceed 6000 rpm (see table).
WARNING
After covering the first 1000 km (621 mi), perform the checks listed in the "After running-in" column
(see REGULAR SERVICE INTERVALS CHART) to avoid personal injury to yourself or third persons, or
vehicle damage.
•
•
Between the first 1000 km (621 mi) and 1500 km (932 mi) drive more briskly, change speed and use the maximum
acceleration only for a few seconds, in order to ensure better coupling of the components; never exceed 7500 rpm
(see table).
After the first 1500 km (932 mi) you may run the engine harder, however, without exceeding the maximum rpm
allowed (11000 rpm).
Recommended maximum rpm
Mileage km (mi)
0-1000 (621)
1000-1500 (621-932)
Over 1500 (932)
rpm
6000
7500
11000
1 - 11
GENERAL INFORMATION 1.5.
VEHICLE IDENTIFICATION
1.5.1.
POSITION OF THE SERIAL NUMBERS
These numbers are necessary for vehicle registration.
NOTE Altering the vehicle's identification numbers is
punishable by law with heavy fines and penalties. Altering
the frame number voids the warranty.
FRAME NUMBER
The frame number (1) is stamped on the right-hand side of
the headstock.
ENGINE NUMBER
The engine number (2) is stamped on the rear, near the
sprocket.
1 - 12 TUONO 1000
TUONO 1000
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE
2
2 - 1
PERIODIC MAINTENANCE
TUONO 1000
SUMMARY 2.1.
GENERAL TECHNICAL INFORMATION ........................................................................................................ 3
2.1.1.
TECHNICAL DATA ................................................................................................................................ 3
2.1.2.
SCHEDULED MAINTENANCE CHART................................................................................................. 6
2.1.3.
LUBRICANT TABLE............................................................................................................................... 8
2.1.4.
TIGHTENING TORQUES ...................................................................................................................... 9
2.1.5.
SPECIAL TOOLS ................................................................................................................................. 14
2.1.6.
LOCATION OF KEY COMPONENTS .................................................................................................. 21
2.1.7.
LOCATION OF INSTRUMENTS / CONTROLS ................................................................................... 23
2.1.8.
INSTRUMENT PANEL OPERATION ................................................................................................... 25
2.1.9.
SYSTEMS DIAGRAM .......................................................................................................................... 30
2-2
PERIODIC MAINTENANCE
TUONO 1000
2.1.
GENERAL TECHNICAL INFORMATION
2.1.1.
TECHNICAL DATA
DIMENSIONS
Max length
Max width
Max height (at headlight fairing)
Seat height
Wheelbase
Minimum ground clearance
Weight in running order
ENGINE
Model
Type
2025 mm (79.75 in)
830 mm (36.78 in)
1100 mm (43.31 in)
820 mm (32.28 in)
1410 mm (55.51 in)
130 mm (5.12 in)
209 kg (460.8 lb)
Lubrication system
Air filter
Cooling
V990 NG
Longitudinal 60° V twin-cylinder, four-stroke, four valves per cylinder, 2
overhead camshafts
2
997.6 cu cm (60.87 cu in)
97 mm/67.5 mm (3.81 in/2.65 in)
11.8 ± 0.5: 1
Electric starter
1250 ± 100 rpm
Wet multi-plate clutch with hydraulic control on left handlebar and PPC
system
Dry sump with separate oil reservoir and oil cooler
Dry cartridge filter
Liquid cooling
GEARBOX
Type
mechanical, 6-speed, with control pedal on left side of engine
Number of cylinders
Total displacement
Bore/stroke
Compression ratio
Starting
Engine idle rpm
Clutch
CAPACITIES
Fuel (including reserve)
Fuel reserve
Engine oil
Fork fluid
Coolant
Seat
Max carrying load
18 l (4.76 gal)
4 ± 1 l (1.06 ± 0.26 l)
gearbox 3700 cu cm (225.8 cu in) œ gearbox and oil filter 3900 cu cm
(238.9 cu in)
505 ± 2.5 cu cm (30.81 ± 0.15 cu in) (each leg)
2.2 l (0.58 gal) (50% water + 50% ethylene-glycol-based antifreeze)
twin seat
192 kg (423.2 lb) (rider + passenger + luggage)
TRANSMISSION RATIOS
Ratio
Primary drive ratio
1st
31/60 = 1: 1.935
2nd
3rd
4th
5th
6th
Gear ratios
15/34 = 1: 2.267
19/31 = 1: 1.632
20/26 = 1: 1.300
22/24 = 1: 1.091
25/24 = 1: 0.960
26/23 = 1: 0.885
DRIVE CHAIN
Type
Model
endless chain (without master link) with sealed links
525
FUEL SYSTEM
Type
Throttle
Multipoint electronic injection
Ø 57 mm (2.24 in)
FUEL SYSTEM
Fuel
premium grade unleaded petrol, min. O.N. 95 (RON) and 85 (MON)
Final drive ratio
16/40= 1: 2.500
Total gear ratio
1:10.968
1:7.895
1:6.290
1:5.279
1:4.645
1:4.280
2 - 3
PERIODIC MAINTENANCE
FRAME
Type
Steering head angle
Trail
SUSPENSION
Front
Travel
Rear
TUONO 1000
twin-spar frame with light-alloy cast elements and formed extruded elements
25°
100 mm (3.93 in) (with 120/70 front tyre)
Wheel travel
adjustable hydraulic upside-down telescopic fork, 43-mm Ø (1.69 in) legs
127 mm (5.00 in)
light-alloy swingarm with arms having different profiles and adjustable hydropneumatic
monoshock
135 mm (5.31 in)
BRAKES
Front
Rear
twin floating disc œ Ø 320 mm (Ø 12.60 in), four-piston callipers œ Ø 34 mm (Ø 1.34 in)
single disc œ Ø 220 mm (Ø 8.66 in), two-piston calliper œ Ø 32 mm (Ø 1.26 in)
WHEEL RIMS
Type
Front
Rear
light alloy, removable wheel shaft
3.50 x 17"
6.00 x 17"
TYRES
Wheel
Make
Model
Type
Size
** Front
PIRELLI
DIABLO
CORSA
** Rear
PIRELLI
DIABLO
CORSA
** Front
METZELER
SPORTTEC
M1
** Rear
METZELER
SPORTTEC
M1
** Front
MICHELIN
PILOT
SPORT
E
** Rear
MICHELIN
PILOT
SPORT
E
** Front
DUNLOP
** Rear
DUNLOP
* Front
PIRELLI
D 208
RR
D 208
RR
œ
* Rear
PIRELLI
Rear
METZELER
SPORTMA
X
SPORTMA
X
DRAGON
SUPERCO
RSA
DRAGON
SUPERCO
RSA
SPORTTEC
120/70œ
ZR 17"
190/50œ
ZR 17"
120/70œ
ZR 17"
190/50œ
ZR 17"
120/70œ
ZR 17"
TL
190/50œ
ZR 17"
TL
120/70œ
ZR 17"
190/50œ
ZR 17"
120/70œ
ZR 17"
Front
METZELER
œ
Rear
METZELER
Front
MICHELIN
Rear
MICHELIN
Rear
MICHELIN
RENNSPO
RT
RENNSPO
RT
PILOT
POWER
RACING
PILOT
POWER
RACING
PILOT
POWER
RACING
* = Original equipment
2-4
** = Alternative
Recommen
ded
Pressure kPa (bar)
#
Front
Rear
#
$
250 (2.5)
(36.25 PSI)
-
#
$
#
$
#
$
#
-
250 (2.5)
(36.25 PSI)
#
-
-
280 (2.8)
(40.61 PSI)
#
-
-
#
œ
250 (2.5)
(36.25 PSI)
-
#
$
250 (2.5)
(36.25 PSI)
250 (2.5)
(36.25 PSI)
-
280 (2.8)
(40.61 PSI)
280 (2.8)
(40.61 PSI)
-
280 (2.8)
(40.61 PSI)
-
œ
180/55œ
ZR 17"
#
$
-
280 (2.8)
(40.61 PSI)
M1
180/55œ
ZR 17"
120/70œ
ZR 17"
180/55œ
ZR 17"
120/70œ
ZR 17"
#
$
-
-
$
-
$
250 (2.5)
(36.25 PSI)
-
280 (2.8)
(40.61 PSI)
-
œ
$
250 (2.5)
(36.25 PSI)
180/55œ
ZR 17"
œ
$
-
280 (2.8)
(40.61 PSI)
190/50œ
ZR 17"
œ
$
-
280 (2.8)
(40.61 PSI)
œ
-
# = Road use
$= Racing
280 (2.8)
(40.61 PSI)
-
PERIODIC MAINTENANCE
TUONO 1000
SPARK PLUGS
Standard
Electrode gap
Resistance
NGK R DCPR9E
0.6 - 0.7 mm (0.023 - 0.028 in)
5 kΩ
ELECTRIC SYSTEM
Battery
Main fuses
Auxiliary fuses
Generator (permanent magnet)
12 V œ 10 Ah
30 A
5 A, 15 A, 20 A
12 V œ 500 W
BULBS
Low beam (halogen)
High beam (halogen)
Front parking light
Turn indicators
Number plate light
Rear parking/stop lights
Rev counter light
Left multi-function display light
12 V œ 55 W H11 x 2
12 V œ 55 W H11 x 2
12 V œ 5 W x 2
12 V œ 10 W (USA version 12V œ 10W)
12 V œ 5 W
LED
LED
LED
WARNING LIGHTS
Gearbox in neutral
Turn indicators
Fuel reserve
High beam light
Stand light
WARNING light
Red line
Immobilizer
LED
LED
LED
LED
LED
LED
LED
LED
2 - 5
PERIODIC MAINTENANCE
2.1.2.
TUONO 1000
SCHEDULED MAINTENANCE CHART
MAINTENANCE OPERATIONS TO BE PERFORMED BY aprilia Authorised Dealers (MAY ALSO BE PERFORMED BY
OWNER).
Key
1 = Check and clean, set or adjust, lubricate, change or replace as required; 2 = Clean; 3 = Change or replace; 4 = Set or adjust. (*) = Check every two weeks or at the specified intervals. NOTE Perform maintenance operations at half the specified intervals if the vehicle is used in rainy and dusty areas, on
uneven ground, or for racing.
Components
End of running-in
period [1000 Km
(625 mi)]
Spark plug
Air filter
Every 5000 Km
(3125 mi) (only for
intensive racetrack
use)
3
Every 10000 Km
(6250 mi) or 12
months
1
3
3
1
3
3
Engine oil filter
3
3
Engine oil filter (on oil tank)
2
2
2
Operating/setting of lights
Light system
1
1
1
Safety switches
1
Clutch fluid
1
1
1
Brake fluid
1
1
1
Coolant
1
1
Engine oil
3
3
Tyres
1
1
Tyre pressure *
Error light (on instrument
panel)
Drive chain tension and
lubrication
4
4
Brake pad wear
2-6
Every 20000 Km
(12500 mi) or 24
months
1
1
3
upon starting: 1
Every 1000 Km (625 mi): 1
1
Every 1000 Km
(625 mi): 1
Before each ride and every 2000 Km
(1250 mi): 1
PERIODIC MAINTENANCE
TUONO 1000
MAINTENANCE OPERATIONS TO BE PERFORMED BY aprilia Authorised Dealers. Key
1 = Check and clean, set or adjust, lubricate, change or replace as required (as specified in the Workshop Manual); 2 = Clean; 3 = Change or replace; 4 = Set or adjust. (*) = Only for versions with Magnesium wheels: check to ensure that wheel rim paintwork is in perfect condition. NOTE Perform maintenance operations at half the specified intervals if the vehicle is used in rainy and dusty areas, on
uneven ground, or for racing.
Components
End of running-in
period [1000 Km
(625 mi)]
Rear shock absorber
Gearbox
Bowden
cables
and
controls
Rear
suspension
connecting rod bearings
Steering bearings and
steering play:
Wheel bearings
Brake discs
Overall
operation
of
vehicle
Valve
clearance
adjustment
Braking systems
Cooling system
Clutch fluid
Brake fluid
Coolant
Front fork fluid
1
Every 5000 Km (3125
mi) (only for
intensive racetrack
use)
1
Every 10000 Km
(6250 mi): 1
1
Every 20000 Km
(12500 mi) or 24
months
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
4
1
1
every 12 months: 3
every 12 months: 3
Front fork oil seals
Brake pads
Wheels/tyres (*)
Tightness of fasteners
Cylinders synchronisation
Suspension and track
alignment
Final drive (chain and
chain sprockets)
Fuel lines
Clutch wear
Pistons
Every 10000 Km
(6250 mi) or 12
months
1
1
1
1
1
1
every 24 months: 3
every 24 months: 3
every 24 months: 3
After the first 10000 Km (6250 mi) and every
20000 Km (12500 mi) afterwards: 3
After the first 30000 Km (18650 mi) and
every 20000 Km (12500 mi) afterwards: 1
If worn: 3
1
1
1
1
1
1
every 4 years: 3
1
1
2 - 7
PERIODIC MAINTENANCE
2.1.3.
TUONO 1000
LUBRICANT TABLE
LUBRICANT
PRODUCT
Engine oil
RECOMMENDED:
EXTRA RAID 4, SAE 15W œ 50 or
TEC 4T
SAE 15W œ 50.
As an alternative to recommended oils, top brand oils meeting or exceeding
CCMC G-4, A.P.I. SG specifications can be used.
RECOMMENDED: F.A. 5W or
F.A. 20W or
FORK 5W or
FORK 20W.
When you wish to obtain an intermediate response between those offered
Front fork fluid
by
F.A. 5W and
F.A. 20W or
FORK 5W or
20W oils, you may mix the different products as follows:
FORK
SAE 10W =
F.A. 5W 67% of volume +
FORK 5W 67% of volume +
F.A. 20W 33% of volume or
FORK 20W 33% of volume.
SAE 15W =
F.A. 5W 33% of volume +
FORK 5W 33% of volume +
F.A. 20W 67% of volume or
FORK 20W 67% of volume.
Bearings and other
lubrication points
RECOMMENDED:
Bimol Grease 481,
AUTOGREASE MP or
Grease 30.
As an alternative to recommended grease, use top brand rolling bearing
grease that will resist a temperature range of -30 °C ... +140 °C (-22
°F….+284 °F) , with dropping point 150 °C ...230 °C (+302 °F….+446 °F),
high corrosion protection, good resistance to water and oxidisation.
Battery terminals
Neutral grease or Vaseline.
Chains
RECOMMENDED aerosol chain lubricant:
CHAIN LUBE.
Brake fluid
RECOMMENDED:
compatible) or
compatible).
CHAIN SPRAY or
Autofluid FR. DOT 4 (braking system is also DOT 5
BRAKE 5.1 DOT 4 (braking system is also DOT 5
NOTE Use only new brake fluid. Never mix different brands or types of
brake fluid unless you have determined that bases are compatible.
Clutch fluid
Autofluid FR. DOT 4 (clutch system is also DOT 5 compatible) or
BRAKE 5.1 DOT 4 (braking system is also DOT 5 compatible).
NOTE Use only new clutch fluid.
RECOMMENDED:
Engine coolant
2-8
ECOBLU œ 40°C or
COOL.
NOTE Use nitrite-free and anticorrosion coolant only to ensure protection at
at least 35°C (-31 °F).
PERIODIC MAINTENANCE
TUONO 1000
2.1.4.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
Front engine mount
Upper and lower rear engine
LH side
Upper and lower rear engine
RH side - adjust. bushing
Upper and lower rear engine
RH side - counter nut
Upper and lower rear engine
RH side
QUANTITY
2+2
mount,
mount,
mount,
mount,
Engine oil inlet flange
Engine oil outlet flange
Rear brake lever bracket
Rear brake master cylinder bracket
Sprocket fastener
Clutch slave cylinder fastener
Sprocket cover fastener
Fuel delivery line to throttle body
72/78Kw reduction bushing
Swingarm pivot ring nut
Swingarm pivot adjustment bushing
Swingarm pivot nut
Calliper carrier retaining pin
Chain tightener screw and nut
Rear brake line guide
Chain guard upper fixing screw
Chain guard and chain guide mount
lower fixing screw
Chain slider
Chain guide to chain guide mount
upper fixing nut
Rear stand bushing
Chain guide fixing nut
Stand bracket to frame
Side stand fixing pin
Stand switch fixing screw
Lock nut
Fork leg to top fork yoke
Fork leg to bottom fork yoke
Headstock ring nut
Headstock counter nut
Top yoke fixing plug
Front fork clamps (Showa)
Front fork clamps (Öhlins)
NUT/BOLT
ENGINE TO FRAME
M10
TORQUE
(Nm)
M10
50
2
M20x1.5
12
2
M20x1.5
50
2
M10
50
1
1
1
1
1
1+1
3
1
M5
SWINGARM
M30x1.5
M30x1.5
M20x1.5
M12
M8
M5
M5
10
10
10
25
25
50
10
10
22
(shear bolt)
Loctite 243
60
12
90
50
Man.
4
4
Loctite 243
M5
5
2
M5
3
1
M5(nut)
5
1
1
1
1
1+1
2+2
1
1
M6
M6(nut)
SIDE STAND
M10
M10x1.25
M6
M10x1.25
FRONT FORK
M8
M8
M35x1
M35x1
Loctite 243
3
1
2
1
Note
50
2
PARTS MOUNTED ON ENGINE
2
M6
2
M6
1
M6
1
M8
2
M8
1
M10
3
M6
3
M6
1
M12x1.5
TOL.
10
10
50
10
10
30
25
25
40
Man.
1
M29x1
100
2+2
2+2
M8
M6
22
12
Loctite 243
Manual + 90°
Use a torque
wrench
2 - 9
PERIODIC MAINTENANCE
DESCRIPTION
TUONO 1000
QUANTITY
NUT/BOLT
TORQUE
(Nm)
STEERING DAMPER
M6
10
M6
10
FOOTRESTS
Rider footrests
4
M8
2.5
Passenger footrests
4
M8
2.5
REAR SHOCK ABSORBER
Shock absorber to frame
1
M10
50
REAR SUSPENSION CONNECTING RODS
Single connecting rod to frame
1
M10
50
Single to double connecting rod
1
M10
50
Double connecting rod to swingarm
1
M10
50
Double connecting rod to shock
1
M10
50
absorber
ELECTRIC SYSTEM
Battery bracket
2
M5
2
Horn
1
M8
15
Odometer sensor to rear brake
1
M6
12
calliper carrier
Voltage regulator mount
2
M6
10
Voltage regulator to mount
2
M6
10
Coil mount to frame
2
M6
10
Coil to coil mount
1
M6
10
ECU
3
M6
10
Starter relay mount to seat frame
1
M6
10
Relay carrier bracket to seat frame
2
M6
3
Atmospheric pressure sensor to
1
M5
1
seat frame cover
Wire to starter motor
1
M6
5
Wires to starter relay
2
M6
4
Engine ground wire
2
M6
5
Main wiring harness plate to air
1
SWP 3.9
1
intake
LIGHTS / INSTRUMENT PANEL
Rear turn indicators
2
M4
1
Front turn indicators
2
M6
4
Tail light to tail guard
4
M5
2
Headlight to conveyor
2
M5
2
M5
2
Headlight to fairing front piece
4
Instrument panel
3
SWP5x14
3
AIR BOX
Air box cover
7
SWP5x20
3
Air box to throttle body
6
M6
5
Intake funnels
4
SWP 3.9
1
MAP sensor mount
1
SWP5x20
2
Filter frame
2
SWP5x20
2
Conveyor to frame
4
M6
10
Steering damper to frame
Steering damper to bottom fork yoke
2 - 10 TOL.
1
1
NOTE
Loctite 243
-
±20%
-
±20%
±20%
±20%
±20%
-
PERIODIC MAINTENANCE
TUONO 1000
Description
Qty
Wheel shaft nut
1
Rear chain sprocket to sprocket holder
Rear wheel shaft nut
5
1
Coolant radiator upper bracket to
frame
Electric fans to coolant radiator
Coolant radiator to upper bracket
Filler neck to coolant radiator
Coolant radiator side brackets to
engine mount spacers
Coolant radiator to side brackets
Oil cooler bracket to engine
Oil coolers to bracket
Expansion tank to frame
Expansion tank cap
Tube clamps no. 8104097
RH and LH front brake callipers
Front brake fluid reservoir to bracket
Front brake and clutch fluid reservoir
bracket
Clutch fluid reservoir to bracket
Front brake line guide to bottom fork
yoke
Brake disc
Rear brake calliper
Rear brake lever pin
Rear brake fluid reservoir
Rear brake rod counter nut
Brake disc
Front exhaust pipe to engine
Rear exhaust pipe to engine (upper
screws)
Rear exhaust pipe to engine (lower
screws)
Lambda sensor
Rear manifold guard
Silencers to mount
Guards to silencer
Type of fastener
FRONT WHEEL
M25x1.5
REAR WHEEL
M10
M25x1.5
COOLING SYSTEM
Torque
(Nm)
Tol.
80
50
120
2
M6
10
2+2
2
M6
M6
6
10
±20%
-
1
M6
-
±20%
2+2
M6
10
±20%
2
M6
4
M6
4
M6
2
M6
1
M28x3
FRONT BRAKING SYSTEM
2+2
M10x1.25
1
M6
See RH spoiler
front fixing
6
10
10
10
6
4
50
7
-
1
M6
10
1
M5
3
1
M5
4
6+6
M8
REAR BRAKING SYSTEM
2
M8
1
M8
1
M5
1
M6
5
M8
EXHAUST SYSTEM
4
M6
Note
30
25
15
3
Man.
30
Loctite 243
±20%
±20%
±20%
±20%
±20%
Loctite 243
Loctite 243
12
2
M6
/
2
M6
12
1
2
2
2
M18x1.5
M4
M8
M4
38
2,5
25
2,5
Tighten manually
2 - 11
PERIODIC MAINTENANCE
Description
TUONO 1000
Qty
Type of fastener
Torque
(Nm)
Tol.
Note
Loctite 243
FUEL PUMP
Fuel return fitting (for workshop
manual only)
Pump mount to flange (for workshop
manual only)
Lead terminals to flange (for workshop
manual only)
Fuel return cover (for workshop
manual only)
Fuel delivery line to flange
Fuel level sensor to pump mount (for
workshop manual only)
Fuel pump wiring harness to flange
(for workshop manual only)
Filler neck to tank
Fuel pump flange to tank
Oil tank nuts
Oil filter connection
Oil drain cap
Oil sight glass
Lower cover to seat frame
Seat frame lower cover to frame
Rear stand bushing securing lower
cover to seat frame
1
M6
6
±20%
3
M5
4
±20%
2
M5
5
±20%
1
M6
10
1
M12x1.5
22
2
SWP 2.9x12
1
2
M6
10
FUEL TANK
M5
M5
ENGINE OIL TANK
3
M6
1
M20x1.5
1
M8
2
M10x1
SEAT FRAME LOWER COVER
3
M6
2
M5
4
8
2
M6
Loctite 243
5
6
±20%
±20%
10
30
15
20
-
5
4
±20%
±20%
12
±20%
3
±20%
1
±20%
NUMBER PLATE HOLDER
Number plate holder to seat frame
lower cover
Cat's eye to number plate holder
Front mudguard
Rear mudguard
Tail guard to seat frame
Tail guard cover to seat frame
Side panels to tail guard
Side panels to tank
Complete cowling to oil cooler bracket
and engine spacers
Side covers, rear end
Side covers, front end (with spoiler
spacers)
Right side cover to voltage regulator
mount
RH-LH radiator fairing to fan peg
2 - 12 4
M6
2
M4
MUDGUARDS
4
M5
4
M5
TAIL GUARD
2
M5
2
M6
RIGHT / LEFT SIDE PANELS
2
M5
2
M5
COWLING
3
M6
5
5
5
7
2
5
7
RIGHT / LEFT SIDE COVERS
2
M6
7
2
M6
10
1
M6
5
RIGHT / LEFT RADIATOR FAIRING
2
SWP 3.9
1
PERIODIC MAINTENANCE
TUONO 1000
Description
Qty
Spoiler rear end to spacer
Spoiler front end to coolant radiator
Cover to oil tank
Front piece to light units and conveyor
Headlight fairing to fairing front piece
Spoiler to
brackets
coolant
radiator
Cover to bottom fork yoke
Cover to bottom fork yoke
steering damper
lower
Type of fastener
RIGHT / LEFT SPOILER
M6
M6
OIL TANK COVER
2
M5
FRONT PIECE
6
M5
HEADLIGHT FAIRING
5
M4
RADIATOR SPOILER
2
2
2
M5
FRONT FORK LOWER COVER
2
M6
with
Cover to cover base
Upper U-bolt to handlebar mounts
Handlebar mounts to fork top yoke (for
workshop manual only)
Anti-vibration weights
Anti-vibration weight end caps
LH dimmer switch
RH dimmer switch
Front brake master cylinder
Clutch master cylinder
1
M6
SEAT COVER
7
SWP 3.9
HANDLEBAR AND CONTROLS
4
M8
2
2
2
1
1
2
2
Ignition switch to yoke
Rear lock to tail guard
2
1
Lower chain slider
Seat frame
2
4
M10
M6
M18x1
M5x1
M4
M6
M6
LOCKS
M8
M22x1.5
FRAME
M6
M10
Torque
(Nm)
Tol.
Note
7
7
5
3
1
3
3
10
1
25
30
Loctite 243
10
35
1,5
1,5
8
8
25
10
Nylon nut
10
50
2 - 13
PERIODIC MAINTENANCE
2.1.5.
TUONO 1000
SPECIAL TOOLS
Suitable tools are required for correct disassembly and reassembly and a good tune-up. The use of special tools avoids the potential risk of damage as a result of inappropriate tools and/or improvised
methods. Following is a list of special tools designed specifically for this vehicle If necessary, request generic special tools. WARNING
Before using the special tools consult the provided documentation.
SUPPORT STANDS
Pos.
aprilia part# (tool name and purpose)
8140176 (complete support stands kit)
A
8146486 (front support stand)
1
xxxxxxx N.A. [central support stand]
2
8705021 (rear support stand)
3
xxxxxxx N.A. = supplied only with kit aprilia part# 8140176 (complete support stand kit)
2 - 14 TUONO 1000
Pos.
PERIODIC MAINTENANCE
aprilia part# (tool name and purpose)
A
8140203 (complete tool kit for frame components)
1
8140189 [tool for fitting oil seal for Ø 43 mm (Ø 1.70 in). Completes kit aprilia part# 8140151 (complete
fork tool kit)]
2
8140190 (tool for tightening steering head)
3
8140191 (tool for tightening swingarm pivot and engine bracket)
FORK TOOLS
Pos.
aprilia part# (tool name and purpose)
A
8140151 (complete fork tool kit)
1
3
8140145 (tool for fitting Ø 41 mm seal)
8140146 {Weight to apply to tool: aprilia part# 8140145 [tool for fitting Ø 41 mm (Ø 1.61 in) seal] and
aprilia part# 8140189 [tool for fitting oil seal for Ø 43 mm (Ø 1.70 in) hole. Completes kit aprilia part#
8140151 (complete fork tool kit)]}
8140147 (tool for holding spacer)
4
8140148 (spacer/damper rod separator plate)
5
8140149 (guard for disassembly operations)
6
8140150 (perforated rod for bleeding air from damper rod)
2
2 - 15
PERIODIC MAINTENANCE
ENGINE TOOLS
2 - 16 TUONO 1000
PERIODIC MAINTENANCE
TUONO 1000
Pos.
aprilia part# (tool name and purpose)
A
8140175 (complete engine tool kit)
1
0277680 (drift for fitting gearbox secondary shaft oil seal)
2
0277660 (drift for fitting upper counter shaft oil seal)
3
0277670 (drift for fitting coolant pump shaft housing oil seal)
4
0877257 (drift for fitting water pump shaft housing sliding ring)
5
0277510 (drift for valve guide disassembly)
6
0277210 (drift for valve guide assembly)
7
0277695 (drift for fitting valve guide oil seal)
8
8140155 (drift for fitting gearbox shaft oil seal-clutch shaft oil seal)
9
0277725 (drift for fitting crankshaft brass bushings)
10
0277720 (drift for extracting crankshaft brass bushings)
11
0277537 (drift for fitting lower counter shaft brass bushings)
12
0277727 (drift for inserting clutch cover-crankshaft brass bushings)
13
0277729 (drift for inserting lower counter shaft clutch cover brass bushings)
14
8140177 (spark plug spanner)
15
0277252 (tool for removing ignition cover)
16
0277730 (hexagonal bolt for extracting flywheel)
17
0240880 (threaded bolt for locking crankshaft at TDC)
18
0277308 (guide bushing for gearbox secondary shaft)
19
8140178 (drift for fitting and removing gudgeon pin)
20
8140181 (fuel-oil-compression pressure gauge)
21
8140182 (bushing for rotor bolt)
22
0277881 (tool for locking clutch)
23
8140156 + 8140157 + 0276377 (extractor for clutch cover brass bushings)
24
0276479 (tool for valve spring spacer)
25
8140179 (arc for valve disassembly and reassembly)
26
8157143 (RSVmille tool box compartment decal)
27
8140183 (hook for lifting engine)
28
8140184 (bushing for primary gear disassembly)
29
8140185 (hooked levers for extracting clutch plates)
30
8140188 (engine bracket)
31
8140186 (tool for compressing piston rings)
32
8140197 (drilled bolt for fuel pressure check)
33
8140205 (tool for camshaft template)
34
8140426 (panel hooks)
2 - 17
PERIODIC MAINTENANCE
MISCELLANEOUS TOOLS
2 - 18 TUONO 1000
PERIODIC MAINTENANCE
TUONO 1000
Pos.
aprilia part# (tool name and purpose)
1
8140196 [Plurigas (Italian )]
1
8140578 [Plurigas (English)]
2
8140192 (chain assembly kit)
3
8140180 (bearing extractor)
4
8140202 (exhaust gas test probes)
5
8140267 (vacuum gauge sleeve)
6
8140256 (vacuum gauge)
7
8140424 (spanner for OHLINS forks)
8
8140199 (tool holder panel)
9
8140426 (panel hooks)
10
8140432 (impact puller)
11
8140187 (engine stand)
12
8124838 (M.F. battery charger)
13
0897651 [LOCTITE® 243 blue (10 cu cm) (0.61 cu in)]
14
0899788 [LOCTITE® 648 green (5 g) (0.011 lb)]
15
0899784 (LOCTITE® 574 orange)
16
0297434 (LOCTITE® 767 Anti-Seize 15378)
17
0297433 [MOLYKOTE® G-N (50 g) (0.11 lb)]
18
0897330 (bp lz multipurpose grease)
19
0297386 [SILASTIC 732 RTV (100 g) (0.22 lb)]
20
8116067 (LOCTITE® 8150)
21
8202222 (generic adhesive sheet for panel)
22
8140074 (drift for extracting lower countershaft brass bushings)
23
8140204 (rear support stand brackets)
24
0277295 (clic clamps pliers)
2 - 19
PERIODIC MAINTENANCE
TOOLS FOR OTHER aprilia VEHICLES
Pos. aprilia part# (tool name and purpose)
1
0877650 (drift grip)
2
0277265 (extractor for counter shaft, primary shaft and secondary shaft bearing)
œ
8116050 (engine oil)
œ
8116053 (
Bimol Grease 481 grease)
8116038 (LUBERING ST grease)
œ
œ
xxxxxxx N.A. (AP-LUBE temporary lubricant)
œ
xxxxxxx N.A. (DID CHAIN LUBE grease)
œ
8116031 (—double solvent“ frame washing liquid )
œ
8116945 (—ACRILICON 28“ cyanoacrylic glue)
œ
xxxxxxx N.A. (MOTUL MOTOWASH degreaser)
œ
8116043 (ANTI-SEIZE MOTAGEPASTE AS 1800 anti-seize paste)
œ
xxxxxxx N.A. (alcohol)
œ
0898011 (LOCTITE® 275 fluorescent green)
œ
xxxxxxx N.A. (LOCTITE® 572)
xxxxxxx N.A. = not available
2 - 20 TUONO 1000
TUONO 1000
2.1.6.
PERIODIC MAINTENANCE
LOCATION OF KEY COMPONENTS
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Cowling
Side fairings
Adjustable steering damper
Left headlight
Clutch fluid reservoir
Left rear-view mirror
Engine oil tank cap
Left side panel
Rider seat
Battery
Main fuse carrier (30A)
Passenger seat lock œ glove / tool kit compartment
Passenger left footrest (Snaps closed/open)
Drive chain
Rear swingarm
Rider left footrest
Side stand
Gear change lever
Engine oil filter
Engine oil tank
Engine oil level
2 - 21
PERIODIC MAINTENANCE
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Rear shock absorber
Passenger right footrest (snaps closed/open)
Tail light
Glove / tool kit compartment
Passenger seat / seat cover
Control unit
Auxiliary fuse carrier (15A)
Right side panel
Fuel tank
Coolant expansion tank cap
Fuel tank filler cap
Air filter
Right rear-view mirror
Front brake fluid reservoir
Right headlight
Right side fairings
Horn
Expansion tank
Rear brake fluid reservoir
Rear brake master cylinder
Rear brake lever
Rider right footrest
2 - 22 TUONO 1000
PERIODIC MAINTENANCE
TUONO 1000
2.1.7.
LOCATION OF INSTRUMENTS / CONTROLS
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Clutch lever
Ignition / steering lock switch ((
Instruments and indicators
Front brake lever
Throttle twistgrip
High beam flasher button ( )
Light dimmer switch (
- )
Turn indicator switches ( )
Horn button ( )
TRIP1 / TRIP2 / MODE switch
Engine kill switch (
Starter button ( )
-
- ))
)
2 - 23
PERIODIC MAINTENANCE
TUONO 1000
Key:
1. Rev counter
2. Green neutral light (N)
3. Amber "stand down" light ( )
4. Red general warning light ( )
5. Multifunction digital display (coolant temperature œ clock - battery voltage œ lap time - engine oil pressure diagnostics
( )
6. Blue high beam light ( )
7. Amber low fuel light ( )
8. Green turn indicator light ( )
9. Red line light (red)
2 - 24 TUONO 1000
2.1.8.
PERIODIC MAINTENANCE
INSTRUMENT PANEL OPERATION
CONTROLS
Three-position selector (1) : TRIP1 / TRIP2 / ODO
SET button (2) : press briefly to scroll menu functions, hold
down to confirm selection.
When the ignition key is turned to " ", the following
instrument panel lights come on for two seconds:
•
All warning lights
•
Backlighting
•
The Tuono 1000 logo appears on the display.
The rev counter pointer (3) moves to the maximum rpm value set and then returns to its initial position. During the initial check-up, all instruments will briefly show
the current values of the corresponding parameters. With the ignition key in position — —, standard display readouts
are as follows:
A. CLOCK
B. CURRENT SPEED
C. ODOMETER
D. ENGINE TEMPERATURE
TRIP 1 AND 2
TRIP 1 and 2 modes display trip meter readouts 1 and 2. Trip meter reading is displayed at the side of the
measurement unit indication.
To select TRIP 1 or TRIP 2 mode, set selector (1) to the TRIP mode you want displayed. The following indications are displayed in the lower portion
(C) of the display:
•
TRIP METER 1/2
•
RIDING TIME 1/2
•
TOP SPEED 1/2
•
AVERAGE SPEED 1/2
Press the SET button (2) briefly to cycle through the different
indications. Hold down the SET button to reset all readings of
the selected TRIP meter.
2 - 25
PERIODIC MAINTENANCE
ODO
The MODE configuration includes all user interface functions. To select the MODE configuration, set the selector (1) to
MODE. With the vehicle stopped, at each short press of the SET
button (2), the display cycles through the following readings: •
CURRENT SPEED
•
BATTERY VOLTAGE
Holding down the SET button (2) gives access to the
configuration menu:
•
MENU
When activated, "distance to empty" indication will be
displayed in place of odometer reading.
MENU
The MENU screen configuration menu can be accessed
when the vehicle is stopped and the selector is set to MODE. To open this menu, select MENU and hold down the SET
button (2) to confirm. The configuration menu holds the following options: •
•
•
•
•
EXIT
SETTINGS
LAP TIMER
DIAGNOSIS
LANGUAGE
SETTINGS
When you select SETTINGS and hold down the SET button
(2) to confirm, a screen with the following options will appear:
•
EXIT
•
TIME SETTINGS
•
GEAR SHIFT INDICATOR
•
BACKLIGHTING
•
CHANGE THE CODE
•
CODE RECOVERY
•
°C / °F
TIME SETTINGS
This option is used to set clock time. At each press of the
SET button (2), hour setting will increase by one unit
from 1 to 12 and then will start over again from 1.
The transition from AM to PM and vice versa coincides with
the transition from 11:59 to 12:00.
Holding down the SET button (2) stores current setting and
gives access to the minutes setting mode. At each press of
the SET button (3), minutes increase by one unit up to 59 and
then go back to 0. Holding down the SET button (2)
terminates the procedure and the instrument panel returns to
the SETTINGS menu.
GEAR SHIFT INDICATOR
This mode is used to set gear change threshold. When this
mode is selected, the
2 - 26 TUONO 1000
TUONO 1000
PERIODIC MAINTENANCE
wording —GEAR SHIFT INDICATOR“ in the current display
language is displayed and
the rev counter pointer points to the current threshold setting.
At each short press of the SET button (2), threshold setting
increases by 100 RPM. Upon reaching the upper limit, at the
next press of the button the setting will decrease by 100 RPM
and vice versa.
Holding down the SET button (2) terminates the procedure
and the instrument panel returns to the SETTINGS menu.
Upon first power-up, the instrument panel defaults to the
preset RUNNING-IN RPM; the next time the instrument panel
is powered on, it will use the last set value.
•
RUNNING-IN RPM 6000
•
IDLE RPM 5000
•
MAX RPM 12000
When the set threshold is exceeded, the warning light (4) on
the instrument panel begins to flash and will keep flashing
until speed drops back below the threshold.
BACKLIGHTING
Backlighting brightness can be set at one of three preset
levels. When this option is selected, the wording
BACKLIGHTING appears on the display; at each short press
of the SET button (2), the display cycles through the following
symbols:
LOW
MEAN
HIGH
After choosing the desired brightness, hold down the SET
button (2) and the instrument panel returns to the SETTINGS
menu.
CHANGE THE CODE AND CODE RECOVERY
This function can be used to change code, provided that the
old code is known.
Upon accessing this function, the following message is displayed: —INSERT THE OLD CODE“ After the old code has been recognised, a new code can be
entered when the following prompt is displayed: —INSERT THE NEW CODE“ When finished, the display returns to the DIAGNOSIS menu. If you used the code to access the menu, this operation is not
allowed. When finished, the instrument panel returns to the SETTINGS menu. CODE RECOVERY
This function is used to change the existing code when it is
unknown; in this case, you will need at least a second ignition key in addition to the one you will
have inserted into the ignition. The system will prompt you to insert a second key with this message: —INSERT THE 2ND KEY“ The instrument panel stays on after the first key is removed;
the second key must be inserted within 20 seconds of
removing the first, otherwise the procedure is aborted. When the second key has been recognised, the system
prompts for a new code with this message: —INSERT THE NEW CODE“ When finished, the display returns to the DIAGNOSIS menu. If you used the code to access the menu, this operation is not
allowed. When finished, the instrument panel returns to the SETTINGS menu. 2 - 27
PERIODIC MAINTENANCE
ºC / ºF
This function is used to select the desired measurement unit
for ambient temperature. When this function is selected, at
each short press of the SET button (2), the display cycles
through the two measurement units:
°C / °F
After choosing the desired unit, hold down the SET button (2)
to store the setting and the instrument panel returns to the
SETTINGS menu.
LAP TIMER
When you select LAP TIMER and hold down the SET button
(2) to confirm, a screen with the following options will appear:
•
•
•
•
EXIT
LAP TIME ON
VIEW TIMES
DELETE TIMES
LAP TIME ON
This function turns on Lap Timer display in place of the clock in the upper portion of the display. When set to on, Lap Timer display is retained after a Key off, Key on sequence.
VIEW TIMES
This function displays recorded lap times.
Short-press the SET button (2) to scroll lap time screens, hold
down the button to return to the LAP TIMER menu. Recorded
lap times will be lost if the battery is disconnected.
DELETE TIMES
This function is used to delete recorded lap times. You will be asked to confirm whether you intend to proceed
before data is deleted. When finished, the display returns to
the LAP TIMER menu. Lap timer operation
To use the lap timer, select LAP TIME ON and hold down the
SET button (2) to confirm; the upper portion of the display (A)
goes into
time acquisition mode. Briefly press the SET button (2) to
start the lap timer.
Press the SET button (2) again within 10 seconds of timer
starting to cancel count and restart the timer. Pressing the
SET button (2) again after the timer has been running for over
10 seconds stops and stores current count and starts a new
count. Holding down the SET button (2) stops the lap timing
session.
When 40 lap times have been recorded, the word —FULL“ is
displayed and acquisition is terminated. To view recorded lap
times, stop the motorcycle, see (STOP) and use the VIEW
TIMES function available in the LAP TIMER menu.
2 - 28 TUONO 1000
TUONO 1000
PERIODIC MAINTENANCE
DIAGNOSIS
This function interfaces with and diagnoses the motorcycle's
on-board systems. It is password-protected and the
appropriate password is made available to Aprilia service
centres only.
LANGUAGE
This function is used to select display language.
Available options are listed below:
•
ITALIANO
•
ENGLISH
•
FRANCAIS
•
DEUTSCH
•
ESPAGNOL
When finished, the display returns to the LANGUAGE menu.
SERVICE WARNING
At the preset service intervals, a spanner symbol is displayed
to serve as a service reminder. First reminder: 1,000 Km (621.4 mi): Afterwards: every
10,000 Km (6213.7 mi) ALARM DISPLAY
If a severe failure such to lead to serious damage or affect
safety is detected, a symbol signifying its cause is shown in
the lower portion of the display (D).
Alarms are grouped into two priority classes:
High priority: Engine overtemperature, Engine oil pressure, ECU errors, Instrument panel errors; Low priority: Turn indicators and ECU disconnected. When two or more alarms from the same priority class occur
at the same time, the appropriate symbols are shown in a sequence. When high and low priority alarms occur at the same time,
only high-priority alarms are displayed. Warning light and SERVICE symbol may come on briefly at
any given time; this does not indicate a malfunction. 2 - 29
PERIODIC MAINTENANCE
2.1.9.
BRAKES
2 - 30 SYSTEMS DIAGRAM
TUONO 1000
TUONO 1000
PERIODIC MAINTENANCE
EXHAUST GAS RECOVERY
2 - 31
FUEL SYSTEM
TUONO 1000
FUEL SYSTEM
3
3-1
FUEL SYSTEM TUONO 1000
SUMMARY 3.1.
POWER SUPPLY ............................................................................................................................................ 3
3.1.1.
DIAGRAM .............................................................................................................................................. 3
3.1.2.
INJECTION SYSTEM DIAGRAM ........................................................................................................... 4
3.1.3.
CYLINDER SYNCHRONISATION AND CO LEVEL ADJUSTMENT ..................................................... 6
3.1.4.
AXONE................................................................................................................................................... 8
3.2.
FUEL PUMP .................................................................................................................................................. 16
3.2.1.
REMOVING THE PUMP UNIT............................................................................................................. 16
3.2.2.
REMOVING THE FUEL LEVEL SENSOR ........................................................................................... 17
3.2.3.
REMOVING THE DELIVERY FUEL FILTER ....................................................................................... 18
3.2.4.
REMOVING THE FUEL PUMP ............................................................................................................ 19
3.3.
THROTTLE BODY UNIT ............................................................................................................................... 21
3.3.1.
REMOVING THE THROTTLE BODY UNIT ......................................................................................... 21
3.3.2.
DISASSEMBLING THE THROTTLE UNIT........................................................................................... 24
3.3.3.
INSPECTING THE THROTTLE UNIT .................................................................................................. 27
3.3.4.
REFITTING THE THROTTLE UNIT ..................................................................................................... 28 3.3.5.
REPLACING THE THROTTLE VALVE CONTROL LEVER................................................................. 30
3.3.6.
CHECKING AXIAL PLAY ON THE THROTTLE VALVE CONTROL SHAFT ....................................... 31
3-2
TUONO 1000
3.1.
FUEL SYSTEM
POWER SUPPLY
3.1.1.
DIAGRAM
Key
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Fuel tank
Filler cap
Fuel pump unit
Breather tube for fuel vapours (caused by tank overpressure)
Excess fuel draining tube
Fuel level sensor
Delivered fuel filter
Fuel pump
Fuel delivery line
Fuel return line
3-3
FUEL SYSTEM 3.1.2.
3-4
INJECTION SYSTEM DIAGRAM
TUONO 1000
TUONO 1000
FUEL SYSTEM
Key:
1. Position of ECU
2. Ignition switch
3. Battery
4. Crankshaft position sensor
5. Camshaft position sensor
6. Engine temperature sensor
7. Air temperature sensor
8. Throttle position sensor
9. Intake pressure sensor
10. Safety system: side stand, neutral sensor
11. Test switch
12. Bank angle sensor
13. Atmospheric pressure sensor
14. Oil pressure sensor
15. Electric fan
16. Automatic choke
17. Intake flap
18. Lambda sensor
19. Diagnosis connector
20. Starter relay
21. Fuel pump
22. Injector 1
23. Injector 2
24. Coil
3-5
FUEL SYSTEM 3.1.3.
•
•
•
•
•
CYLINDER SYNCHRONISATION AND CO LEVEL ADJUSTMENT
With the engine off, connect Axone 2000 to the
diagnosis socket and to the vehicle battery.
Switch the tester on.
Connect the gas analyser tubes to the relevant fittings.
Start the setting with both throttle body bypass screws
closed.
Carry out the following procedure when the engine
temperature is above 75°C (167°F).
VARIANT 1 (version with standard exhaust pipes)
•
Using AXONE, check the —front cylinder pressure“ and
—rear cylinder pressure“ parameters; ensure that they
read:
front cylinder pressure = rear cylinder pressure œ (50 ±
10) mbar
•
•
•
Should the FRONT CYLINDER PRESSURE value be
incorrect, turn the FRONT CYLINDER bypass screw.
Read the residual CO value while alternatively opening
the
analyser
valves.
Turn the bypass screws if the value does not stay
between 0.7 and 1.2 % and if the difference between
the two readings is greater than 0.5 %.
Once the CO test is completed, ensure that the
FRONT
CYLINDER
PRESSURE
and
REAR
CYLINDER PRESSURE parameter values are
approximately within the specified range.
VARIANT 2 (version with open exhaust pipes)
DANGER
It is strictly prohibited to make racing
adjustments and ride the vehicle with said
setting on roads and motorways
CAUTION The following settings only apply to ECUs with
racing mapping for open pipes.
•
Using AXONE, check the —front cylinder pressure“ and
—rear cylinder pressure“ parameters; ensure that they
read:
front cylinder pressure = rear cylinder pressure œ (50 ±
10) mbar
3-6
TUONO 1000
TUONO 1000
•
•
•
FUEL SYSTEM
Should the FRONT CYLINDER PRESSURE value be
incorrect, turn the FRONT CYLINDER bypass screw.
Read the residual CO value while alternatively opening
the
analyser
valves.
Turn the bypass screws if the value is not between 2
and 4 % and if the difference between the two readings
is greater than 0.5 %.
Once the CO test is completed, ensure that the
FRONT
CYLINDER
PRESSURE
and
REAR
CYLINDER PRESSURE parameter values are
approximately within the specified range.
WARNING
Should the bike be fitted with an Akrapovic
complete exhaust system, please note that the
CO reading obtained with the approved exhaust
system is lower once the Akrapovic system is
installed.
3-7
FUEL SYSTEM 3.1.4.
TUONO 1000
AXONE
SYMBOL
SCREEN
ISO
ENGINE PARAMETER READING
DEVICE STATUS (in general they are —On œ Off“ values)
ENABLE DEVICES
DETECTED FAULTS
ENGINE PARAMETER ADJUSTMENT
FREEZE FRAME
SCREEN
DESCRIPTION
APPROXIMATE
VALUES
UNIT
OF
MEASURE
NOTE
ISO
Aprilia hardware
3-8
485466000
-
Aprilia software
Revision number
Engine
Manufactured on
Mapping
47
V2 œ 60° 990
dd/mm/yy
664584
-
Programming date
dd/mm/yy
-
Last programmer
85456
-
Mapping code with reversed figures. If
all figures are nought, it means the
ECU is empty (not mapped): it is
necessary to upload the suitable
mapping (see note concerning mapping
parameter)
Meaningless field
Twin-cylinder engine, 60° V, 990 cc
ECU date of manufacture
Mapping code stored in ECU.
Date last mapping was loaded:
day/month/year
ID code for the PC or Axone tester that
loaded the latest mapping. In this 5.0.2
version, the code shown is not correct:
to see it correctly, go to the ISO page
that
appears
when
selecting
REPROGRAM
FUEL SYSTEM
TUONO 1000
SCREEN
APPROXIMATE
VALUES
DESCRIPTION
UNIT
OF
MEASURE
NOTE
ENGINE
PARAMETER
READING
Water temperature
-
°C
Air temperature
-
°C
Engine rpm
-
rpm
Target idle speed
1200
rpm
Engine load
-
-
Intake pressure
650
hPa
2.7
°
-
°
Total
opening
Spark advance
throttle
Throttle position sensor
0
°
Throttle offset
-
V
Stepper motor
-
-
Battery voltage
Vehicle speed
-
V
km/h
Front cylinder pressure
680
hPa
Rear cylinder pressure
630
hPa
Lambda correction
1
-
Lambda sensor
100-900
mV
Injection time
-
ms
Atmospheric pressure
1000
hPa
The fans are activated at about 100°C.
If the signal is lost, the ECU sets linear
output for the value at 88°C (190 °F),
starting from the air temperature at
start-up (1° every 3 seconds) and
activation of the cooling fans
If the signal is lost, the ECU sets the
value at 18°C (64.4 °F)
The ECU attempts to bring the engine
to this target speed (depending on
coolant temperature).
Parameter linked to injection time
(which in turn depends on the air flow
intake determined by the throttle
opening and intake pressure). The ECU
uses this parameter to take different
mapping steps, also.
Average value measured by the sensor
connected to the two intake channels
Parameter that considers throttle
opening and stepper motor position
Parameter that reads the throttle
opening degrees. If the signal is lost,
the ECU sets the value at 9.8° and
uses the intake pressure values
After the "Initialisation" or "Throttle Pos.
Self-Learn" parameter is activated, this
value (closed throttle position) is stored
in the ECU: based on this reference
value the control unit will know the
position of the throttle at that moment
Stepper (idle) motor steps (if the signal
is missing, the ECU sets value 21)
Pressure detected in the intake channel
by the pressure sensor. If the signal is
lost, the ECU uses the throttle position
sensor values to operate the engine.
The value for the front cylinder
pressure must be 50 hPa higher than
the rear cylinder pressure
Pressure detected in the intake channel
by the pressure sensor. If the signal is
lost, the ECU uses the throttle position
sensor values to operate the engine.
The value for the front cylinder
pressure must be 50 hPa higher than
the rear cylinder pressure
The value must vary around 1 when the
ECU uses the oxygen sensor signal to
keep combustion close to the
stoichiometric value
Lambda sensor signal voltage; the
value remains fixed if the circuit is
broken
Sensor located under the seat. In case
the signal is lost, the ECU sets value at
980 hPa
3-9
FUEL SYSTEM SCREEN
DESCRIPTION
TUONO 1000
APPROXIMATE
VALUES
UNIT
OF
MEASURE
NOTE
DEVICE
STATUS
3 - 10 Bank angle sensor
normal/tip over
-
Control unit
Valid combin/Invalid combin
Oil pressure
normal/low
-
Idle speed
on/off
-
Full load
on/off
-
Engine stop
push-button
on/off
-
Ignition request
on/off
-
Lambda sensor active
on/off
-
Cut off
on/off
-
Throttle learning
completed
on/off
-
Engine warming up
on/off
-
Power latch over
on/off
-
Limited operation
on/off
-
Gearbox in neutral
Selector
Side stand
yes/no
on/off
up/down
-
Clutch pulled
yes/no
-
The ECU manages it like a status
(therefore it is not stored in the
memory): but if the circuit is broken
(sensor disconnected) the instrument
panel signals a fault, while Axone reads
"Normal" (because when correctly
connected the circuit is open) and the
engine starts
If the instrument panel is disconnected
or the CAN connection is faulty, the
ECU does not receive the code it was
expecting from the instrument panel
and therefore sets itself on "Invalid
combin". With Axone it is in any case
possible to connect to the ECU
In case of low pressure, it limits engine
rpm (if the wire is disconnected, it
indicates "Normal": this is noticed only
because, when the key is turned to
"ON", both the warning light and the oil
light on the instrument panel stay off)
Engine operating conditions at idle
speed (can be seen also with engine
off)
Engine operating conditions at full load
(engine should be running)
Engine kill push-button status and
immobilizer enable: if "OFF", one or
both devices are faulty
Correct operation can be tested with
the gear engaged and by pressing the
starter button: under these conditions,
the ECU detects the start enable (the
Axone display will read "on") but will not
start the engine, as a safety precaution.
The Axone tester could read "off" if the
right dimmer switch circuit is broken.
"ON" if the ECU is using the lambda
sensor signal to maintain stoichiometric
combustion
Is activated under certain conditions of
engine speed/ throttle position/ ….etc.
If the throttle position self-learning is
unsuccessful,
for
any
reason
whatsoever, it switches to "OFF"
When the engine is warming up, it is on
When turning the key from "ON" to
"OFF", before the ECU is disabled,
during the power latch it stores a series
of parameters (e.g. stepper motor
position)
In case a serious fault is detected,
engine rpm is limited to a certain value
Parameter currently not used
Stand position
If the clutch lever is pulled, it reads
"YES"
FUEL SYSTEM
TUONO 1000
SCREEN
DESCRIPTION
Initialisation fault
Lambda control
Engine variant
Injectors per cylinder
Knock sensor
Boost adjustment
Lambda sensor
Water injection
Idling mot. fitted
Purge valve
Electronic reverse
Electric starting
Initialised ECU
APPROXIMATE
VALUES
UNIT
OF
MEASURE
NOTE
Possible factors that may have caused
unsuccessful Throttle position learning
no/engine
speed>0/
vehicle or Initialisation, in this order: Engine
speed>0/ stepper error/ throttle speed>0/Vehicle
speed>0/stepper
position / battery voltage/ water motor
error/Incorrect
throttle
temperature / stepper motor off
position/Incorrect
battery
voltage
/Water temperature /Stepper motor
disconnected
initializ./Wait.after
start/Ric.st.lambda/Att.after
Current lambda sensor conditions
ric/Dis.for rid./Dis. for err/Att.after
int/Lambda act/Saturat.
1 if standard mapping is active, 2 if
Racing mapping is active -necessary
1/2
when using non-approved exhaust
pipes
ECU status that cannot be changed:
1cyl
should read "1cyl"
ECU status that cannot be changed:
No
should read "no"
ECU status that cannot be changed:
No
should read "no"
ECU status that can be changed with
password authority only; should usually
Yes
read "YES", i.e. lambda sensor
available
ECU status that cannot be changed:
No
should read "no"
ECU status that can be changed with
password authority only; should usually
Yes
read "YES", i.e. stepper motor available
Parameter not active (mechanical
yes/no
purge valve)
ECU status that cannot be changed:
No
should read "no"
ECU status that cannot be changed:
Yes
should read "yes"
If status is "yes", it indicates that the
parameter "Initialised ECU" was
yes/no
activated. If the ECU needs replacing,
this parameter should be activated or
the engine rpm will be limited
ENABLE
DEVICES
Delete errors
-
-
Fuel pump
-
-
Lambda sensor heating
-
-
Fan
-
-
Press ENTER to switch error status
from memorised (MEM) to deleted
(STO). The next time Axone is
connected to the ECU, the deleted
errors (STO) will no longer be displayed
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
3 - 11
FUEL SYSTEM SCREEN
DESCRIPTION
TUONO 1000
APPROXIMATE
VALUES
UNIT
OF
MEASURE
NOTE
ENABLE
DEVICES
Front injector
-
-
?P0106?
-
-
Atm.press.signal low
-
-
Atm.press.signal high
-
-
Air temperature sensor
-
-
Air temp.signal low
-
-
Air temp.signal high
-
-
Water temper.sensor
-
-
Water temp.signal low
-
-
Water temp.signal high
-
-
TPS low
-
-
TPS high
-
-
Lambda sensor
-
-
Rear injector
Front coil
Rear coil
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
The device is activated: if not correctly
activated, the tester will NOT show
failed activation immediately; it is
necessary to check the detected faults
page
DETECTED
FAULTS
3 - 12 It is displayed in case of low or zero
voltage (e.g. broken circuit).
It is displayed when excessive voltage
is detected in the sensor circuit
It is displayed when low voltage is
detected in the sensor circuit
It is displayed in case of excessive
voltage (e.g. broken circuit, but freeze
frame reads -40° maximum ohm
resistance)
It is displayed when low voltage is
detected in the sensor circuit
It is displayed in case of excessive
voltage (e.g. broken circuit, but freeze
frame reads -40° maximum ohm
resistance)
It is displayed when low voltage is
detected in the sensor circuit
It is displayed in case of excessive
voltage (e.g. broken circuit).
It is displayed if the sensor signal circuit
is broken or faulty while the sensor is
operating; it switches to STO without
reconnecting, so it does not stay in the
memory; also note that on page 3DEVICE STATUS the parameter
"Lambda correction" stays Disabled
FUEL SYSTEM
TUONO 1000
SCREEN
APPROXIMATE
VALUES
DESCRIPTION
UNIT
OF
MEASURE
Lambda sensor heat.
-
-
Lambda
ability
-
-
Fuel pump o/c
Fuel pump short-c
-
-
Front cyl.inj.open
-
-
Front cyl.inj.short-c
-
-
Rear cyl.inj.open
-
-
Rear cyl.inj.short-c
?P0336?
Engine rpm signal missing
-
-
sensor
adaptive
Engine rpm signal
-
-
Camshaft signal missing
-
-
Front coil
Rear coil
-
-
Fan
-
-
Stepper control
Oil pressure gauge
Battery voltage low
Battery voltage high
-
-
CAN line
-
-
Control unit
-
-
ECU not initialised
-
-
RAM error
Control unit
?P0608?
Starter relay open
Starter relay short-c
?P0704?
-
-
TPS
-
-
TPS align.interrupted
-
-
NOTE
It is displayed if the feeding circuit is
broken or short-circuited; it switches
from ACT to STO without reconnecting
if the engine is off, otherwise it stays
ACT, but not memorised (also note
fixed mV signal)
Lambda sensor operation outside
standard operating conditions, in both
the short and the long term.
Open circuit or earthed
Short circuit
It is a signal that can also be displayed
by chance and with no actual part fault
Short circuit
It is a signal that can also be displayed
by chance and with no actual part fault
Short circuit
It is displayed after a few minutes if the
engine is running (the ECU compares it
to the camshaft signal) or after several
starting attempts (the engine does not
start if an error is present). It switches
to MEM when the engine is switched
off, so it can be deleted even if the fault
persists
It is displayed almost immediately (the
engine starts even if the signal is
missing). It switches to MEM when the
engine is switched off, so it can be
deleted even if the fault persists
Error is detected based on relay state
(open or short circuit). As a result, a
disconnected fan connector will not be
detected
Detects stepper motor control missing
It is displayed if the CAN line is faulty or
the signal is missing: e.g. when the
instrument panel is disconnected
It is necessary to execute the control:
CPU initialised on the "Adjustable
parameters" page
Rear right position
Short circuit
The engine runs because it uses intake
pressure values.
It is displayed if "Throttle pos.selflearn." or "initialisation" were not
successful due to a failure in the throttle
position sensor signal
3 - 13
FUEL SYSTEM SCREEN
TUONO 1000
DESCRIPTION
APPROXIMATE
VALUES
Int.press.signal low
Int.press.signal high
Cut off time excess.
-
UNIT
OF
MEASURE
-
This is a first in our injection systems:
error detection is based on a critical
threshold (115°C) (239 °F) rather than
an electric fault (short or open circuit)
In the design used so far, the ECU
would only indicate an oil pressure
switch fault if a malfunction was
detected before engine starting. A
malfunction occurring after start-up
would be displayed on the instrument
panel but not stored in the ECU.
In the current design, the error is
detected and stored in the ECU
Water temperature too high
(limit exceeded)
Low oil pressure
?P1611?
?P1683?
NOTE
-
-
ADJUSTABLE
PARAMETERS
Initialisation
-
-
-
-
CO adjustment 1
-
-
CO adjustment 2
-
-
Engine variant
-
-
Lambda sensor
-
-
Idling mot. fitted
-
-
Initialised ECU
-
-
Throttle
learning
3 - 14 position
self-
To reset adaptive parameters when
changing the ECU, throttle body or
injectors (it may happen that in the first
seconds after start-up it stays at 5000
rpm). The engine starting attempts
count that appears in the error frozen
parameters is reset
The ECU self-learning procedure for
the throttle sensor position and the
stepper motor (in case the TPS or the
stepper motor are changed)
Adjustment is possible only with
PASSWORD authority, whenever it is
not possible to balance the CO rate
using the bypass screws
Adjustment is possible only with
PASSWORD authority, whenever it is
not possible to balance the CO rate
using the bypass screws
Set 1 to activate standard mapping, 2
to activate Racing mapping (with open
pipes only! e.g. Akrapovic)
Adjustment is possible only with
PASSWORD authority: to disable the
lambda sensor, regardless of the type
of mapping
Adjustment is possible only with
PASSWORD authority: to disable the
stepper motor
Enabling necessary when installing a
new ECU (enables a set of
parameters): see the same parameter
in the DEVICE PAGE
FUEL SYSTEM
TUONO 1000
SCREEN
DESCRIPTION
APPROXIMATE
VALUES
UNIT
OF
MEASURE
NOTE
%
Same as the engine parameters page,
but expressed in %
FROZEN
PARAMETERS
Engine load
Water temperature
Air temperature
Battery voltage
-
°C
°C
V
Intake pressure
64
kPa
Vehicle speed
Engine rpm
Throttle position
Dwell point cyl 1
Engine in VL mode
Cut off active
No
-
km/h
rpm
%
°
-
Frequency
2
-
Time
since start-up
3
min
Riding cycles
8
-
Operating
time
72
min
Caution: measured in kPa so, for
example, 62 kPa correspond to 620
hPa (unit of measure used in the
engine parameters reading)
Spark advance
Number of times an error is detected by
the ECU (including the checks
performed by the ECU when it switches
on, for certain types of errors)
Time elapsed since starting referred to
the last time the error in question was
detected, for example, detected in the
3rd minute
Number of times the engine was
started when the error in question was
last detected. The count resets if the
"Initialisation" parameter is enabled
Total number of minutes of engine
operation when the error in question
was last detected. It cannot be reset
(data stored in the ECU)
From the adjustable parameters page it is possible to:
•
align the throttle position sensor
•
initialise the ECU, i.e. align the throttle, reset the stepper motor and reset the lambda control adaptive parameters.
•
initialise the ECU, necessary when installing a new ECU
Throttle position sensor alignment
TPS alignment should be carried out when the throttle body and/or the ECU are changed.
•
Select: “throttle pos. self-learning“.
•
Ensure that the throttle is fully home
•
Press ENTER —
—.
•
Turn the key to —OFF“ and leave it for at least 30 seconds.
ECU initialisation
ECU initialisation is carried out in case important parts of the engine (valves, cylinder, camshaft), exhaust system, ECU, fuel
feeding system, or the lambda sensor are changed. The three correction factors for the lambda control concerning injection time are electronically reset. •
Select:“initialisation“.
•
Ensure that the throttle is fully home
•
Press ENTER —
—.
•
Turn the key to —OFF“ and leave it for at least 30 seconds.
Initialisation allows activation of the new ECU
•
Select: “initializ.complete“.
•
Follow the instructions given to activate the ECU
•
Turn the key to —OFF“ and leave it for at least 30 seconds.
3 - 15 FUEL SYSTEM 3.2.
FUEL PUMP
3.2.1.
•
REMOVING THE PUMP UNIT
Completely remove the fuel tank.
NOTE Place the tank on a clean surface with the pump unit
facing upward.
•
Loosen and remove the eight screws (1).
NOTE When reassembling, tighten all the screws (1) finger
tight, observing a cross-pattern.
WARNING
When removing the pump unit take care not to
damage the tubing and the fuel level sensor.
•
Remove the complete pump unit.
3 - 16 TUONO 1000
TUONO 1000
3.2.2.
FUEL SYSTEM
REMOVING THE FUEL LEVEL SENSOR
•
•
Remove the complete fuel unit.
Disconnect the connector.
•
•
Loosen and remove the two screws.
Remove the fuel level sensor.
3 - 17
FUEL SYSTEM 3.2.3.
•
TUONO 1000
REMOVING THE DELIVERY FUEL FILTER
Remove the complete fuel pump unit.
NOTE
Use
the
special
tool
- aprilia part# 0277295 (pliers for fitting ties).
OPT:
WARNING When reassembling, replace the tie with a new
one of the same size. Do not refit the old tie; it is no longer useable. Do not replace the tie with a screw tie or other
type of tie.
•
•
•
•
Unfasten the tie (1).
Slide the tube out of the filter.
Unfasten the tie (2).
Slide the filter out of the tube.
WARNING Do not use filters that have already been used.
•
Replace the filter with a new one of the same kind.
3 - 18 FUEL SYSTEM
TUONO 1000
3.2.4.
•
REMOVING THE FUEL PUMP
Remove the complete fuel pump unit.
NOTE
Use
the
special
tool
- aprilia part# 0277295 (pliers for fitting ties).
OPT:
WARNING When reassembling, replace the tie with a new
one of the same size. Do not refit the old tie; it is no longer useable. Do not replace the tie with a screw tie or other
type of tie.
•
•
Unfasten the tie (1).
Slide the fuel tube out of the pump
•
Disconnect the electrical connector.
•
Disconnect the electrical connector.
3 - 19
FUEL SYSTEM •
Loosen and remove the three screws.
•
Bend the side of the fuel filter and hold it in position.
NOTE Use compressed air to clean any sediments in the
filter mesh; direct the jet of air so that the impurities do not
penetrate inward.
3 - 20 TUONO 1000
TUONO 1000
3.3.
FUEL SYSTEM
THROTTLE BODY UNIT
3.3.1.
REMOVING THE THROTTLE BODY UNIT
WARNING
The screws for the basic adjustment of the
throttle valve (1) are painted and cannot be set.
The adjustment screws can be set only when
replacing the wire securing bracket (2)
completely.
The two M4x12 screws (3) for securing the
throttle valve potentiometer are painted and can
be removed only when replacing the sensor.
•
•
•
-
Partially remove the fuel tank.
Remove the air box.
Disconnect the electrical connectors:
right injector;
-
left injector;
3 - 21
FUEL SYSTEM -
throttle valve potentiometer.
NOTE Use the special tool OPT:
aprilia part# 0277295 (pliers for fitting ties).
•
•
•
Unfasten the tie (4).
Unfasten the tie (5).
Slide the tubes out of the throttle unit.
•
Disconnect the two accelerator control wires.
WARNING
When reassembling, ensure that the two
accelerator control wire adjusters are correctly
secured to their links and adjust play, if
necessary
3 - 22
TUONO 1000
TUONO 1000
•
Slide the airbox flap tube out of the throttle unit.
•
Loosen the two ties
FUEL SYSTEM
WARNING Be very careful when removing the throttle unit, as it is connected to the fuel tank by means of
the fuel line. •
•
Firmly grasp the throttle unit ; wriggle and slide it out of
the intake flanges.
Place the complete throttle unit and the connected fuel
tank on a clean surface.
When reassembling ensure that:
- the delivery fuel line is neither twisted nor in a position in
which it can be crushed by other components; if
damaged or worn it must be replaced;
- the delivery fuel line is positioned so that it reaches the
right-hand side of the throttle unit, passing under it,
between the two intake flanges;
- the throttle unit is perfectly positioned on the intake
flanges;
- The ties must be correctly fastened.
3 - 23
FUEL SYSTEM 3.3.2.
DISASSEMBLING THE THROTTLE UNIT
•
Loosen and remove the M8x1 nut (1) and remove the
spring washer.
•
Slightly turn the throttle valve control lever (2), loosen
and remove the three T.E. M5x12 screws (3).
•
Slide the complete accelerator wire securing bracket
(4) along with the two bushings (5) and the torsion
spring (6) out of the throttle unit.
•
Loosen and remove the two M6x16 screws (7) and
remove the fuel pressure regulator (8) complete with
the O-ring.
Loosen and remove the three M6x25 screws (9) and
remove the left injector bracket (10) together with the
gasket (11), injector (12) and seal (13) from the throttle
unit.
•
3 - 24 TUONO 1000
TUONO 1000
•
FUEL SYSTEM
Loosen and remove the two M6x25 screws (14);
remove the right injector bracket (15) together with the
gasket (16), injector (17) and seal (18).
NOTE The injector seal (18) can be left in the throttle unit
hole.
3 - 25
FUEL SYSTEM •
Loosen and remove the M8x1 nut (19); remove the
spring washer (20), the belt roller (21), the two
bushings (22) and the torsion spring (23).
•
Slide the fulcrum pin (24) together with the safety
washer (25) out of the hole of the accelerator wire
securing bracket and remove the two shaft gaskets
(26) together with the torsion spring (27) and the cold
starting lever (28).
3 - 26 TUONO 1000
TUONO 1000
3.3.3.
FUEL SYSTEM
INSPECTING THE THROTTLE UNIT
INJECTOR OPERATION TEST
NOTE The injectors can be tested electrically.
•
-
Check the following components:
electrical wiring and connections;
injector or ECU injection signal.
Throttle body
•
•
•
Clean all throttle body (1) openings and ducts using
compressed air.
Check the intake pressure sensor tubes (2) for
clogging.
Check the throttle valve unit and the wire securing
mechanism (3) for any mechanical damage.
NOTE Synchronise the cylinders when replacing the
synchronisation screws (4) or the O-rings (5).
•
•
•
Loosen the two cylinder synchronisation screws (4)
only if there is an air leak.
When replacing the ball joint linkage (6), unfasten the
linkage from the throttle valve control lever (7) and
from the accelerator belt roller (8).
After having fitted a new ball joint linkage (6) ensure
that it moves freely.
3 - 27
FUEL SYSTEM 3.3.4.
TUONO 1000
REFITTING THE THROTTLE UNIT
WARNING After having disassembled the throttle unit, replace all gaskets, O-rings, torsion springs, bushings and seals. These components are supplied with the repair kit. •
•
•
•
•
Fit the new O-rings (1) and seals (2) on both injectors.
Fit the injectors (3) in the left injector bracket (4) and
right injector bracket (5).
Fit the left injector bracket gasket (6), the right injector
bracket gasket (7) and the two seals (8) on the throttle
unit.
Fit the complete left injector bracket (4) and the right
injector bracket (5) on the throttle body and secure
them with the new M6x25 screws (9) (10).
If the synchronisation screws (11) and their O-rings
(12) have been replaced, moderately tighten the
screws (11) until they are flush with the surface and
then loosen by one turn.
Synchronisation screw pre-adjustment (11) : 1 turn.
WARNING
Precise screw adjustment (11)
performed with a vacuum gauge.
•
must
be
Secure the fuel pressure regulator (13) with the two
M6x16 screws (14).
NOTE Spread a thin layer of grease over the surface of the
fulcrum pin (18).
•
•
Fit the cold starting lever (15), the torsion spring (16)
and the shaft gasket (17) in the fulcrum pin (18).
Fit the complete fulcrum pin (18) on the accelerator
wire securing bracket.
NOTE Ensure that the torsion spring is hooked to the cold
starting lever (15) and to the wire securing bracket.
•
•
•
•
Spray the spring (16) with chain grease.
Fit the shaft gasket (17) on the fulcrum pin (18).
Fit the two bushings (19) and the torsion spring (20).
Fit the belt roller (21) on the accelerator wire securing
bracket.
3 - 28 TUONO 1000
FUEL SYSTEM
WARNING Ensure that the ends of the torsion spring (20) are hooked to the accelerator wire securing
staff and belt roller (21). NOTE Spray the spring (20) with temporary lubricant.
•
Fit the spring washer (22).
®
NOTE Apply LOCTITE 243 to the nut threading (23).
•
Tighten the M8x1 nut (23). ®
NOTE Apply LOCTITE 243 to the screw threading (25). •
•
Secure the accelerator wire securing bracket (24) with
the three T.E M5x12 screws (25).
Fit the throttle valve control lever (26).
3 - 29
FUEL SYSTEM 3.3.5.
REPLACING THE THROTTLE VALVE CONTROL LEVER
REMOVAL
•
Partially remove the fuel tank.
•
Remove the air box.
•
Loosen and remove the M8x1 nut (1) and remove the
spring washer.
•
Slide out the control lever (2) and set aside the two
bushings (3) and the torsion spring (4).
•
Remove the control lever (2) from the ball joint linkage
(5).
ASSEMBLY
•
Fit the two bushings (3) and the torsion spring (4) on
the throttle body.
•
Fit the throttle valve control lever (2) on the throttle
valve axis.
NOTE Spray the spring (4) with temporary lubricant.
WARNING Ensure that the ends of the torsion spring (4) are fastened to the throttle body and to the
throttle valve control (2).
•
Fit the spring washer. NOTE Apply LOCTITE 243 ® to the nut threading (1) .
•
Tighten the M8x1 nut (1).
NOTE When reassembly is completed, ensure that the
levers turn freely.
The torsion spring must return the throttle valve control lever
(2) to its original position. Check for axial play on the throttle valve control shaft 3 - 30 TUONO 1000
TUONO 1000
3.3.6.
•
•
FUEL SYSTEM
CHECKING AXIAL PLAY ON THE THROTTLE VALVE CONTROL SHAFT
Partially remove the fuel tank.
Remove the air box.
NOTE Use a thickness gauge (1) with a 0.05 mm (0.00197
in) scale.
With the throttle valves closed:
•
Using the thickness gauge (1), measure the minimum
value of play between the lever (2) and the contact
surface (3) in various points of the throttle body.
Axial play: 0.1 mm (0.0039 in).
WARNING
If the minimum value measured is less than 0.1
mm (0.0039 in), replace the entire throttle body.
With the throttle valves open:
•
Repeat the procedure above.
Axial play: 0.15 mm (0.0059 in).
WARNING
If the minimum value measured is less than
0.15 mm (0.0059 in), replace the entire throttle
body.
3 - 31
ENGINE
TUONO 1000
ENGINE
4
4-1
ENGINE TUONO 1000
SUMMARY 4.1.
ENGINE............................................................................................................................................ 3
4.1.1.
REMOVING THE ENGINE ...................................................................................................... 3
4.1.2.
INSTALLING THE ENGINE................................................................................................... 26
4.1.3.
TIGHTENING TORQUES...................................................................................................... 51
4-2
TUONO 1000
4.1.
4.1.1.
•
ENGINE
ENGINE
REMOVING THE ENGINE
•
To remove the engine, you will have to remove seat,
fuel tank and battery first.
Remove the airbox cover.
•
Remove the screws fixing the airbox to the frame.
•
Remove the six screws fixing then throttle body to the
airbox.
4-3
ENGINE •
Disconnect the bypass tubes to the throttle body and
the stepper motor connection.
•
Disconnect the oil recovery tank tube.
4-4
TUONO 1000
TUONO 1000
•
Disconnect the manifold pressure sensor and tubes
coming from the throttle body.
•
Remove the airbox.
ENGINE
4-5
ENGINE •
Disconnect the coil wiring.
•
Disconnect the accelerator control wires.
•
Disconnect the throttle potentiometer.
•
Disconnect the vacuum tubes on the throttle body.
4-6
TUONO 1000
TUONO 1000
•
Disconnect the injector connectors.
•
Loosen the ties on the intake manifolds.
ENGINE
4-7
ENGINE •
Disconnect the throttle body.
•
Plug all openings to avoid entry of impurities.
•
Unfasten the ties of the lubrication circuit tubes coming
from the oil tank.
4-8
TUONO 1000
TUONO 1000
•
ENGINE
Disconnect the oil tubes on the crankcase.
4-9
ENGINE •
Loosen the three fixing screws on the oil tank.
•
Remove the oil tank along with the tube coming from
the oil cooler.
•
Slide the breather tubes out of their housing.
•
Remove the oil tube on the crankcase.
4 - 10 TUONO 1000
TUONO 1000
•
Loosen and remove the rear brake fluid reservoir fixing
screw and move the reservoir downward keeping it
vertical.
•
Remove the clamp.
•
Remove the coolant breather tube.
•
Loosen and remove the two expansion tank fixing
screws and remove the expansion tank.
ENGINE
4 - 11
ENGINE •
Disconnect the connectors.
•
Loosen and remove the two fixing screws and remove
the voltage regulator.
•
Loosen and remove the two fixing screws and remove
the voltage regulator mounting plate.
4 - 12 TUONO 1000
TUONO 1000
•
Unscrew the stud bolt that secures the oil tube clamp
to the crankcase.
•
Disconnect the oil tube from the right-hand side.
•
Loosen and remove the four oil cooler subframe fixing
screws.
ENGINE
NOTE For the screw on the upper left-hand side, tighten the
internal nut with a spanner.
4 - 13
ENGINE •
Remove the subframe complete with oil coolers.
•
Remove the rear brake master cylinder fixing screws.
•
Unfasten the clip fixing the master cylinder to the brake
lever.
•
Disconnect the engine oil pressure sensor.
4 - 14 TUONO 1000
TUONO 1000
•
Disconnect the vehicle speed sensor, the stop light
switch and the lambda sensor connectors.
•
Remove the oil cooler lower brackets and move it
keeping it vertical.
•
Unscrew the starter motor connection.
•
Unhook the silencer fixing springs.
ENGINE
4 - 15
ENGINE •
Loosen the silencer clamp fixing screws.
•
Remove the silencers.
•
Unhook the fixing spring located between the front
cylinder manifold and the exhaust.
•
Loosen the four nuts fixing the manifold to the front
cylinder.
4 - 16 TUONO 1000
TUONO 1000
•
Remove the manifold.
•
Remove the seal.
•
Unhook the fixing spring located between the rear
manifold and the exhaust.
•
Slide the lambda sensor wiring out of the frame.
ENGINE
4 - 17
ENGINE •
Remove the exhaust complete with lambda sensor.
•
Loosen the four nuts fixing the manifold to the rear
cylinder.
•
Remove the exhaust manifold; remove the seal.
•
Disconnect the engine temperature sensor, the timing
sensor, the rpm sensor, the side stand safety switch
and the generator connectors.
4 - 18 TUONO 1000
TUONO 1000
ENGINE
4 - 19
ENGINE •
Disconnect the spark plug caps.
•
Remove the gear lever.
4 - 20 TUONO 1000
TUONO 1000
•
Remove the clutch actuator complete with flange.
•
Remove the sprocket cover and the crankcase guide
plate.
•
Unscrew the sprocket fixing bolt and set aside the seal
washer.
ENGINE
4 - 21
ENGINE •
Remove the sprocket.
•
Unfasten the ties and disconnect the coolant tubes on
the oil cooler.
•
Unscrew the earth connections on the crankcase.
•
Unscrew the neutral sensor connection.
4 - 22 TUONO 1000
TUONO 1000
•
Remove the rear brake lever.
•
Remove the lever bracket and the rear brake master
cylinder.
Remove the brake master cylinder bracket.
•
•
Disconnect the vacuum tube on the clutch pneumatic
actuator.
•
Hold up the engine with an adequate support.
ENGINE
4 - 23
ENGINE •
Remove the rear screws fixing the engine to the frame.
•
Loosen the four screws of the engine front mounts.
•
Remove the screws and the spacers located between
the frame and the engine.
4 - 24 TUONO 1000
TUONO 1000
•
Pull back the adjustment bushings between the engine
and the frame.
•
Completely lower the engine.
ENGINE
4 - 25
ENGINE 4.1.2.
INSTALLING THE ENGINE
•
Place the engine on a suitable lower support.
•
Lift the engine.
•
Position the engine so as to align the rear mounts on
the frame.
•
Fit the front left spacer.
4 - 26 TUONO 1000
TUONO 1000
•
Tighten the two screws in the front left engine mount.
•
Fit the left rear spacer and tighten the screws to the
specified torque.
•
Tighten the left rear screw.
ENGINE
4 - 27
ENGINE •
Fit the front right spacer
•
•
Tighten the two screws in the front right mount.
Tighten the four screws on the left-hand side.
•
Tighten the upper right bushing to the specified torque.
•
Tighten the upper right ring nut to the specified torque.
4 - 28 TUONO 1000
TUONO 1000
•
Tighten the lower right bushing to the specified torque.
•
Tighten the lower right ring nut to the specified torque.
•
Tighten the upper right screw.
•
•
Tighten the lower right screw.
Tighten the four screws on the right-hand side.
ENGINE
4 - 29
ENGINE •
Remove the engine lower support.
•
Reconnect the vacuum tube to the clutch pneumatic
actuator and fasten it with a tie.
•
Fit the lever and the rear brake master cylinder bracket
and tighten the screws to the specified torque.
4 - 30 TUONO 1000
TUONO 1000
•
Fit the rear brake lever and tighten the screws to the
specified torque.
•
Fit the rear brake master cylinder and connect it to the
brake lever.
•
Tighten the neutral sensor connection.
•
Reconnect the earth connection to the crankcase and
tighten the screws to the specified torque.
ENGINE
4 - 31
ENGINE •
Use ties to fasten the coolant tubes to the oil cooler
•
Place the sprocket in the correct position.
4 - 32 TUONO 1000
TUONO 1000
•
Tighten the fixing bolt to the specified torque to secure
the sprocket in place.
•
Fit the sprocket cover and the guide plate and tighten
the screws to the specified torque.
•
Fit the clutch actuator complete with flange.
ENGINE
4 - 33
ENGINE •
Fit the gear lever.
•
Insert the spark plug caps in their housing.
•
Connect the engine temperature sensor, the timing
sensor, the rpm sensor, the side stand safety switch
and the generator connectors.
4 - 34 TUONO 1000
TUONO 1000
ENGINE
4 - 35
ENGINE •
Fit the rear cylinder exhaust manifold with the washer.
•
Tighten the nuts and stud bolts to the specified torque.
•
Fit the exhaust complete with lambda sensor.
•
Hook the fixing spring located between the rear
manifold and the exhaust.
Place the lambda sensor wiring on the frame.
•
4 - 36 TUONO 1000
TUONO 1000
•
Place the exhaust gasket on the front cylinder.
•
Fit the manifold on the cylinder stud bolts and on the
exhaust.
•
Tighten the four nuts fixing the manifold to the cylinder
to the specified torque.
ENGINE
4 - 37
ENGINE •
Hook the fixing spring between the front cylinder
manifold and the exhaust.
•
Fit the silencers.
•
Tighten the silencer clamp fixing screws.
•
Hook the silencer fixing springs.
4 - 38 TUONO 1000
TUONO 1000
•
Tighten the starter motor connection.
•
Move the oil cooler toward the engine and secure the
lower supports.
•
Refit the lambda sensor, stop light switch and speed
sensor connectors.
•
Connect the engine oil pressure sensor.
ENGINE
4 - 39
ENGINE •
Fasten the clip fixing the master cylinder to the brake
lever.
•
Tighten the rear brake master cylinder fixing screws.
•
Fit the subframe complete with oil coolers.
•
Tighten the four screws to the specified torque.
4 - 40 TUONO 1000
TUONO 1000
ENGINE
NOTE For the screw on the upper left-hand side, tighten the
internal nut with a spanner.
•
Connect the oil tube from the right-hand side.
•
Tighten the stud bolt that secures the oil tube clamp to
the crankcase.
•
Fit the voltage regulator mounting plate and tighten the
two fixing screws.
4 - 41
ENGINE •
Fit the voltage regulator and tighten the two fixing
screws.
•
Restore all connections.
•
Fit the expansion tank and tighten the two fixing
screws.
4 - 42 TUONO 1000
TUONO 1000
•
Fit the coolant breather tube.
•
Fit the clamp.
•
Fit the rear brake fluid reservoir and tighten the fixing
screw.
•
Fit the oil tube on the crankcase.
ENGINE
4 - 43
ENGINE •
•
Fit the oil tank.
Tighten the three oil tank fixing screws.
•
Fit a new clamp to the tube coming from the oil cooler
and fit the tube into place in the housing.
•
Insert the breather tubes in their housing.
•
Fit the oil tubes to the engine crankcase and secure in
place with new clamps.
4 - 44 TUONO 1000
TUONO 1000
•
Remove the plugs from the ducts.
•
Fit the throttle body.
ENGINE
4 - 45
ENGINE •
Fasten the ties on the intake manifolds.
•
Connect the injector connectors.
•
Insert the vacuum tubes in the throttle body.
4 - 46 TUONO 1000
TUONO 1000
•
Connect the throttle position sensor.
•
Fit the throttle control wires and adjust play.
ENGINE
4 - 47
ENGINE •
Connect the coil wiring.
•
Fit the airbox.
•
Reconnect the manifold pressure sensor and tubes
coming from the throttle body.
4 - 48 TUONO 1000
TUONO 1000
•
Disconnect the oil recovery tank tube.
•
Disconnect the by-pass tubes to the throttle body and
the stepper motor connection.
•
Tighten the six screws fixing the throttle body to the
airbox.
ENGINE
4 - 49
ENGINE •
Fit the airbox cover.
•
Fit the battery, the fuel tank and the seat.
4 - 50 TUONO 1000
ENGINE
TUONO 1000
4.1.3.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
QUANTITY
Front engine mount
Upper and lower rear engine mount,
LH side
Upper and lower rear engine mount,
RH side of adjustment bushing
Upper and lower rear engine mount,
RH side of counter nut
Upper and lower rear engine mount,
RH side
2+2
Engine oil inlet flange
Engine oil outlet flange
Rear brake lever bracket
Rear brake master cylinder bracket
Sprocket
Clutch slave cylinder
Sprocket cover
Fuel delivery line to throttle body
72/78Kw reduction bushing
Swingarm pivot ring nut
Swingarm pivot adjustment bushing
Swingarm pivot nut
Calliper carrier retaining pin
Chain tightener screw and nut
Rear brake line guide
Chain guard upper fixing screw
Chain guard and chain eye mount
lower fixing screw
Chain slider
Chain eye to chain eye mount upper
fixing nut
Rear stand bushing
Chain eye fixing nut
NUT/BOLT
ENGINE TO FRAME
M10
TORQUE
(Nm)
M10
50
2
M20x1.5
12
2
M20x1.5
50
2
M10
50
1
1
1
1
1
1+1
3
1
M5
SWINGARM
M30x1.5
M30x1.5
M20x1.5
M12
M8
M5
M5
Note
50
2
PARTS MOUNTED ON ENGINE
2
M6
2
M6
1
M6
1
M8
2
M8
1
M10
3
M6
3
M6
1
M12x1.5
TOL.
10
10
10
25
25
50
10
10
22
Loctite 243
3
(shear bolt)
Loctite 243
60
12
90
50
Man.
4
4
Loctite 243
1
M5
5
2
M5
3
1
M5(nut)
5
2
1
M6
10
M6(nut)
10
Side stand
Stand bracket to frame
1
M10
50
Side stand fixing pin
1
M10x1.25
10
M6
10
Stand switch fixing screw
1
Counter nut
1
M10x1.25
30
FOOTRESTS
Rider footrests
4
M8
2.5
Passenger footrests
4
M8
2,5
REAR SHOCK ABSORBER
Shock absorber to frame
1
M10
50
REAR SUSPENSION CONNECTING RODS
Single connecting rod to frame
1
M10
50
Single to double connecting rod
1
M10
50
Double connecting rod to swingarm
1
M10
50
Double connecting rod to shock
1
M10
50
absorber
ELECTRIC SYSTEM
Battery bracket
2
M5
2
Horn
1
M8
15
Odometer sensor to rear brake
1
M6
12
calliper carrier
Voltage regulator mount
2
M6
10
Loctite 243
-
4 - 51
ENGINE
TUONO 1000
DESCRIPTION
QUANTITY
Voltage regulator to mount
Coil mount to frame
Coil to coil mount
ECU
Starter relay mount to seat frame
Relay carrier bracket to seat frame
Atmospheric pressure sensor to
seat frame cover
Wire to starter motor
Wires to starter relay
Engine ground wire
Main wiring harness plate to air
intake
2
2
1
3
1
2
Air box cover
Air box to throttle body
Intake funnels
MAP sensor mount
Filter frame
Conveyor to frame
Rear chain sprocket to sprocket
carrier
Rear wheel shaft nut
Coolant radiator upper bracket to
frame
Electric fans to coolant radiator
Coolant radiator to upper bracket
Filler neck to coolant radiator
Coolant radiator side brackets to
engine mount spacers
Coolant radiator to side brackets
Oil cooler bracket to engine
Oil coolers to bracket
Expansion tank to frame
Expansion tank cap
Tube clamps no. 8104097
Rear brake calliper
Rear brake lever pin
Rear brake fluid reservoir
Rear brake rod counter nut
Brake disc
Front exhaust pipe to engine
Rear exhaust pipe to engine (upper
screws)
Rear exhaust pipe to engine (lower
screws)
Lambda sensor
Rear manifold guard
Silencers to mount
Guards to silencer
Fuel return fitting (for workshop
manual only)
Pump mount to flange (for workshop
manual only)
Lead terminals to flange (for
workshop manual only)
Fuel return cover (for workshop
manual only)
4 - 52 NUT/BOLT
ELECTRIC SYSTEM
M6
M6
M6
M6
M6
M6
TORQUE
(Nm)
M5
1
1
2
2
M6
M6
M6
5
4
5
1
SWP 3.9
1
7
6
4
1
2
4
AIR BOX
SWP5x20
M6
SWP 3.9
SWP5x20
SWP5x20
M6
REAR WHEEL
3
5
1
2
2
10
1
M10
M25x1.5
COOLING SYSTEM
±20%
±20%
±20%
±20%
-
50
120
2
M6
10
2+2
2
M6
M6
6
10
±20%
-
1
M6
-
±20%
2+2
M6
10
±20%
2
M6
4
M6
4
M6
2
M6
1
M28x3
REAR BRAKING SYSTEM
2
M8
1
M8
1
M5
1
M6
5
M8
EXHAUST SYSTEM
4
M6
25
15
3
Man.
30
±20%
±20%
±20%
±20%
±20%
Loctite 243
Loctite 243
12
M6
/
2
M6
12
M18x1.5
M4
M8
M4
FUEL PUMP
See RH spoiler
front fixing
6
10
10
10
6
4
2
1
2
2
2
Note
10
10
10
10
10
3
1
5
TOL.
Tighten manually
38
2,5
25
2,5
1
M6
6
±20%
3
M5
4
±20%
2
M5
5
±20%
1
M6
10
Loctite 243
Loctite 243
ENGINE
TUONO 1000
Description
Qty
Fuel return line to flange
Fuel level sensor to pump mount (for
workshop manual only)
Fuel pump wiring harness to flange
(for workshop manual only)
1
Filler neck to tank
Fuel pump flange to tank
Lower cover to seat frame
Seat frame lower cover to frame
Rear stand bushing securing lower
cover to seat frame
1
2
M6
10
FUEL TANK
M5
M5
ENGINE OIL TANK
3
M6
1
M20x1.5
1
M8
2
M10x1
SEAT FRAME LOWER COVER
3
M6
2
M5
2
M6
Side panels to tail guard
Side panels to tank
Complete belly pan to oil cooler
bracket and engine spacers
Side covers, rear end
Side covers, front end (with spoiler
spacers)
Right side cover to voltage regulator
mount
RH-LH radiator fairing to fan peg
Spoiler rear end to spacer
Spoiler front end to coolant radiator
Cover to oil tank
Front piece to light units and conveyor
Headlight fairing to fairing front piece
radiator
lower
3
M6
5
6
±20%
±20%
10
30
15
20
-
5
4
±20%
±20%
12
±20%
5
7
2
5
7
7
2
M6
10
1
M6
5
2
Cover to cover base
7
Ignition switch to yoke
Rear lock to tail guard
2
1
Lower chain slider
Seat frame
2
4
M5
SEAT COVER
SWP 3.9
LOCKS
M8
M22x1.5
FRAME
M6
M10
Note
5
RIGHT / LEFT SIDE COVERS
2
M6
RIGHT / LEFT RADIATOR FAIRING
2
SWp 3.9
RIGHT / LEFT SPOILER
2
M6
2
M6
OIL TANK COVER
2
M5
FRONT PIECE
6
M5
HEADLIGHT FAIRING
5
M4
RADIATOR SPOILER
Tol.
22
SWP 2.9x12
4
Tail guard to seat frame
Tail guard cover to seat frame
Torque
(Nm)
2
MUDGUARDS
M5
TAIL GUARD
2
M5
2
M6
RIGHT / LEFT SIDE PANELS
2
M5
2
M5
BELLY PAN
Rear mudguard
coolant
FUEL PUMP
M12x1.5
4
8
Oil tank nuts
Oil filter connection
Oil drain plug
Oil sight glass
Spoiler to
brackets
Type of fastener
1
7
7
5
3
1
3
1
25
10
Nylon nut
10
50
4 - 53
CYCLE PARTS
TUONO 1000
CYCLE PARTS
5
5-1
CYCLE PARTS TUONO 1000
SUMMARY 5.1.
DISASSEMBLING THE UPPERWORKS......................................................................................... 4
5.1.1.
DISASSEMBLING THE UPPERWORKS ................................................................................ 4
5.1.2.
REASSEMBLING THE UPPERWORKS ................................................................................. 7
5.1.3.
TIGHTENING TORQUES...................................................................................................... 10
5.2.
FRONT FORK ................................................................................................................................ 11
5.2.1.
FRONT FORK DIAGRAM...................................................................................................... 11
5.2.2.
REMOVING THE FORK LEGS ............................................................................................. 12
5.2.3.
FITTING THE FORK LEGS ................................................................................................... 16
5.2.4.
REPLACING FORK FLUID.................................................................................................... 19
5.2.5.
FILLING THE FRONT FORK FLUID ..................................................................................... 22
5.2.6.
REPLACING THE OIL SEAL/DUST SEAL............................................................................ 25
5.2.7.
REFITTING THE OIL SEAL/DUST SEAL ............................................................................. 32
5.2.8.
CHECKING THE COMPONENTS......................................................................................... 39
5.2.9.
TIGHTENING TORQUES...................................................................................................... 43
5.3.
STEERING BEARINGS ................................................................................................................. 44
5.3.1.
DIAGRAM .............................................................................................................................. 44
5.3.2.
CHECKING PLAY.................................................................................................................. 45
5.3.3.
ADJUSTING BEARING PLAY ............................................................................................... 46
5.3.4.
TIGHTENING TORQUES...................................................................................................... 51
5.4.
REAR SUSPENSION..................................................................................................................... 53
5.4.1.
DIAGRAM .............................................................................................................................. 53
5.4.2.
DISASSEMBLING THE REAR SUSPENSION ..................................................................... 54
5.4.3.
CHECKING THE COMPONENTS......................................................................................... 56
5.4.4.
REASSEMBLING THE REAR SUSPENSION ...................................................................... 58
5.4.5.
REMOVING THE REAR SUSPENSION CONNECTING RODS .......................................... 60
5.4.6.
TIGHTENING TORQUES...................................................................................................... 61
5.5.
SWINGARM ................................................................................................................................... 62
5.5.1.
REMOVING THE SWINGARM.............................................................................................. 62
5.5.2.
CHECKING THE COMPONENTS......................................................................................... 65
5.5.3.
REMOVING THE SWINGARM BEARINGS .......................................................................... 66
5.5.4.
REFITTING THE SWINGARM .............................................................................................. 67
5.5.5.
TIGHTENING TORQUES...................................................................................................... 70
5.6.
FRONT WHEEL ............................................................................................................................. 71
DIAGRAM .............................................................................................................................. 71
5.6.1.
5.6.2.
REMOVING THE FRONT WHEEL........................................................................................ 72
5.6.3.
CHECKING THE FRONT WHEEL COMPONENTS ............................................................. 75
5.6.4.
REMOVING THE FRONT WHEEL BEARINGS .................................................................... 77
5.6.5.
REFITTING THE FRONT WHEEL BEARINGS..................................................................... 78
5.6.6.
FITTING THE WHEEL........................................................................................................... 80
5.7.
REAR WHEEL................................................................................................................................ 82
5.7.1.
DIAGRAM .............................................................................................................................. 82
5.7.2.
REMOVING THE REAR WHEEL .......................................................................................... 83
5.7.3.
REMOVING THE FINAL DRIVE UNIT .................................................................................. 85
5.7.4.
CHECKING THE REAR WHEEL COMPONENTS................................................................ 87
5.7.5.
REMOVING THE REAR WHEEL BEARINGS ...................................................................... 90
5.7.6.
REFITTING THE REAR WHEEL BEARINGS ....................................................................... 91
5.7.7.
REMOVING THE FINAL DRIVE UNIT BEARINGS .............................................................. 93
5.7.8.
REFITTING THE FINAL DRIVE UNIT BEARINGS ............................................................... 94
5.7.9.
REMOVING THE VIBRATION DAMPER SEALS ................................................................. 95
5.7.10.
REMOVING THE REAR SPROCKET ................................................................................... 96
5.7.11.
REFITTING THE REAR WHEEL........................................................................................... 97
5.7.12.
TIGHTENING TORQUES...................................................................................................... 99
5.8.
FRONT BRAKE ............................................................................................................................ 100
5.8.1.
CHANGING THE PADS ...................................................................................................... 100
5.8.2.
CHECK ................................................................................................................................ 102
5.8.3.
REMOVING THE DISCS ..................................................................................................... 103
5.8.4.
BLEEDING THE BRAKE SYSTEM ..................................................................................... 104
5.9.
REAR BRAKE PADS ................................................................................................................... 107
5.9.1.
REPLACING THE REAR BRAKE PADS............................................................................. 107
5.9.2.
CHECKING THE REAR BRAKE DISC................................................................................ 108
5.9.3.
REMOVING THE REAR BRAKE DISC ............................................................................... 109
5-2
TUONO 1000
CYCLE PARTS
5.10. CLUTCH........................................................................................................................................110
5.10.1.
BLEEDING THE CLUTCH SYSTEM....................................................................................110
5.11. CHAIN ...........................................................................................................................................111
5.11.1.
DRIVE CHAIN ......................................................................................................................111
5.11.2.
INSPECTING THE DRIVE CHAIN SLIDER.........................................................................113
5.11.3.
REMOVING THE CHAIN SLIDER .......................................................................................114
5.11.4.
LOWER CHAIN SLIDER ......................................................................................................116
5-3
CYCLE PARTS 5.1.
DISASSEMBLING THE UPPERWORKS
5.1.1.
•
•
DISASSEMBLING THE UPPERWORKS
Loosen and remove the two fixing screws (1) and set
aside the washers.
Remove the fairing (2).
•
•
Unscrew and remove the fixing pin (3).
Loosen and remove the fixing screw (4) and set aside
the washer.
•
•
Release the quick-release fitting (5) and free the tube.
Remove the fairing (6).
5-4
TUONO 1000
TUONO 1000
•
•
Loosen and remove the fixing screw (7).
Remove the fairing (8).
•
Loosen and remove the two fixing screws (9) and set
aside the washers.
Remove the fairing (10).
•
•
Loosen and remove the left fixing screw and set aside
the washer (11) .
•
Loosen and remove the front fixing screw and set
aside the washer (12) .
CYCLE PARTS
5-5
CYCLE PARTS •
•
•
•
•
Loosen and remove the right fixing screw and set aside
the washer (13) .
Remove the fairing (14).
Loosen and remove the two fixing screws and set
aside the washers (15) .
Remove the fairing (16).
•
•
Loosen and remove the two fixing screws (17) and set
aside the washers.
Unscrew and remove the fixing pin (18).
Remove the fairing (19).
•
•
Loosen and remove the fixing screw (20).
Remove the fairing (21).
5-6
TUONO 1000
TUONO 1000
5.1.2.
CYCLE PARTS
REASSEMBLING THE UPPERWORKS
•
•
Fit the fairing (21).
Tighten the fixing screw (20).
•
•
•
Fit the fairing (19).
Insert and tighten the fixing pin (18).
Tighten the two fixing screws (17).
•
•
Fit the fairing (16).
Tighten the two fixing screws (15).
•
•
Fit the fairing (14).
Tighten the right fixing screw (13).
5-7
CYCLE PARTS •
Tighten the front fixing screw (12).
•
Tighten the left fixing screw (11).
•
•
Fit the fairing (10).
Tighten the two fixing screws (9).
•
•
Fit the fairing (8).
Tighten the fixing screw (7).
5-8
TUONO 1000
TUONO 1000
•
•
Fit the fairing (6).
Fit the tube in the quick-fitting coupling (5).
•
•
Tighten the fixing screw (4).
Tighten the fixing pin (3).
•
•
Fit the fairing (2).
Tighten the two fixing screws (1).
CYCLE PARTS
5-9
CYCLE PARTS 5.1.3.
TUONO 1000
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
Description
Qty
Type of fastener
Torque
(Nm)
Side panels to tail guard
Side panels to tank
RIGHT / LEFT SIDE PANELS
2
M5
2
M5
BELLY PAN
2
5
Complete belly pan to oil cooler
bracket and engine spacers
3
7
Side covers, rear end
Side covers, front end (with spoiler
spacers)
Right side cover to voltage regulator
mount
RH-LH radiator fairing to fan peg
Spoiler rear end to spacer
Spoiler front end to coolant radiator
Cover to oil tank
Front piece to light units and conveyor
Spoiler to
brackets
5 - 10 coolant
radiator
lower
M6
RIGHT / LEFT SIDE COVERS
2
M6
7
2
M6
10
1
M6
5
RIGHT / LEFT RADIATOR FAIRING
2
SWp 3.9
RIGHT / LEFT SPOILER
2
M6
2
M6
OIL TANK COVER
2
M5
FRONT PIECE
6
M5
RADIATOR SPOILER
2
M5
1
7
7
5
3
3
Tol.
Note
TUONO 1000
5.2.
CYCLE PARTS
FRONT FORK
5.2.1.
FRONT FORK DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Right radial fork leg
Left radial fork leg
Sleeve
Damper rod bushing
Spring
Complete preload tube.
Spacer
Washer
Complete damper rod.
Washer
Ring
Complete sleeve plug.
O-ring
O-ring
O-ring
Stop ring
M8x40 flanged screw
Right leg + wheel carrier
Left leg + wheel carrier
Dust seal
Circlip
Oil seal
Ring
Bushing
Sliding bushing
Special washer
M10x1.5 screw
5 - 11
CYCLE PARTS 5.2.2.
REMOVING THE FORK LEGS
•
Support the front end of the vehicle.
•
Loosen the front mudguard screws and remove it.
•
Loosen the front callipers fixing screws and slide them
out of the disc.
5 - 12 TUONO 1000
TUONO 1000
•
Remove the wheel shaft nut.
•
Set aside the washer.
CYCLE PARTS
5 - 13
CYCLE PARTS •
Loosen the wheel shaft pinch bolts.
•
Lightly tap the wheel shaft with a rubber mallet until the
holes on the opposite side are uncovered.
•
Remove the wheel shaft using a screwdriver inside the
shaft holes.
•
During this operation, support and remove the wheel.
5 - 14 TUONO 1000
TUONO 1000
•
•
CYCLE PARTS
Support the fork and loosen the top and bottom yoke
screws.
Fit the fork leg.
5 - 15
CYCLE PARTS 5.2.3.
FITTING THE FORK LEGS
•
•
Fit the fork leg.
Adjust sleeve sliding and tighten the screws on the fork
yokes to the specified torque.
•
Fit the front wheel and insert the wheel shaft in its
housing.
•
Tighten the clamp screws (nut side) to secure the
wheel shaft.
5 - 16 TUONO 1000
TUONO 1000
•
•
•
CYCLE PARTS
Fit the washer and tighten the wheel shaft nut to the
specified torque.
Work the fork to ensure that the fork legs are aligned.
Working on both sides, tighten the clamp screws
securing the wheel shaft to the specified torque.
5 - 17
CYCLE PARTS •
Fit the callipers on the disc.
•
Fit the brake callipers and tighten the screws to the
specified torque.
WARNING
After installing the brake callipers, pull the front
brake lever a few times
5 - 18 TUONO 1000
TUONO 1000
5.2.4.
CYCLE PARTS
REPLACING FORK FLUID
•
Clamp the sleeve in a vice with the specified tool.
•
Set the spring preload to its minimum.
•
Unscrew the sleeve upper plug.
•
Clamp the fork foot with care to avoid damaging it.
5 - 19
CYCLE PARTS •
Fit the specified tool on the spring joint.
•
Push the tool downward to compress the spring and
then fit the tool spacer under the cartridge lock nut.
•
Loosen the plug by placing the key in the provided
opening and loosening the nut.
•
Remove the complete plug.
5 - 20 TUONO 1000
TUONO 1000
•
•
Remove the spacer and the washer.
Press downward against spring force and slide out the
spacer.
•
Slide out the spring joint.
•
Empty the oil into a container and remove the spring.
CYCLE PARTS
5 - 21
CYCLE PARTS 5.2.5.
FILLING THE FRONT FORK FLUID
•
Fill the fork so the air bubbles trapped inside are
released.
•
Fit the spring joint.
•
Fit the specific tool on the spring joint so the cartridge
rod is secured in position.
•
Fit the spacer and the washer.
5 - 22 TUONO 1000
TUONO 1000
•
Tighten the upper plug on the cartridge rod.
•
Clamp the sleeve in a vice with the specified tool.
CYCLE PARTS
5 - 23
CYCLE PARTS •
Tighten the upper plug to the specified torque.
5 - 24 TUONO 1000
TUONO 1000
5.2.6.
CYCLE PARTS
REPLACING THE OIL SEAL/DUST SEAL
•
Clamp the sleeve in a vice with the specified tool.
•
Set the spring preload to its minimum.
•
Unscrew the sleeve upper plug.
•
Clamp the fork foot with care to avoid damaging it.
5 - 25
CYCLE PARTS •
Fit the specified tool on the spring joint.
•
Push the tool downward to compress the spring and
then fit the tool spacer under the cartridge lock nut.
•
Loosen the plug by placing the key in the provided
opening and loosening the nut.
•
Remove the complete plug.
5 - 26 TUONO 1000
TUONO 1000
•
•
Remove the spacer and the washer.
Press downward against spring force and slide out the
spacer.
•
Slide out the spring joint.
•
Empty the oil into a container and remove the spring.
CYCLE PARTS
5 - 27
CYCLE PARTS •
Remove the spacer and the washer.
•
Loosen the cartridge fixing screw on the fork foot.
•
Set aside the centring bushing.
5 - 28 TUONO 1000
TUONO 1000
•
•
CYCLE PARTS
Slide out the sleeve dust seal using a screwdriver for
leverage.
When doing this, take care not to damage the edge of
the sleeve.
•
Remove the circlip.
•
Remove the sleeve from the slider using the sleeve as
a stop.
•
Remove the bushing , the movable bushing, the ring
and the oil seal from the slider.
5 - 29
CYCLE PARTS •
Remove the ring and the dust seal.
5 - 30 TUONO 1000
TUONO 1000
CYCLE PARTS
5 - 31
CYCLE PARTS 5.2.7.
•
•
•
•
REFITTING THE OIL SEAL/DUST SEAL
Clamp the leg in a vice with care to avoid damaging its
surfaces.
Protect the ends of the leg with adhesive tape.
Lubricate the sliding edges with fork fluid or seal
grease.
Fit the dust seal, the stop ring and the sealer ring on
the slider.
5 - 32 TUONO 1000
TUONO 1000
•
Ensure that the stamped side of the sealer ring is
facing the dust seal.
•
Proceed to fit the ring, the movable bushing and, after
having removed the tape, the fixed bushing.
CYCLE PARTS
5 - 33
CYCLE PARTS •
Fit the sleeve on the leg and, using the specific tool, fit
the oil seal in position.
•
Insert the stop ring in its housing.
•
Fit the dust seal with the specific tool.
•
Fit the centring bushing on the cartridge and place the
complete assembly in the fork.
5 - 34 TUONO 1000
TUONO 1000
•
Tighten the cartridge fixing screw on the fork foot to the
specified torque.
•
Fit the lower spacer and the washer.
•
Fit the fork spring.
CYCLE PARTS
5 - 35
CYCLE PARTS •
Fill the fork so the air bubbles trapped inside are
released.
•
Fit the spring joint.
•
Fit the specific tool on the spring joint so the cartridge
rod is secured in position.
•
Fit the spacer and the washer.
5 - 36 TUONO 1000
TUONO 1000
•
Tighten the upper plug on the cartridge rod.
•
Clamp the sleeve in a vice with the specified tool.
CYCLE PARTS
5 - 37
CYCLE PARTS •
Tighten the upper plug to the specified torque.
5 - 38 TUONO 1000
TUONO 1000
5.2.8.
CYCLE PARTS
CHECKING THE COMPONENTS
WHEEL STANCHION
Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the stanchion if badly scored. Check for stanchion buckling using a dial gauge. Replace the stanchion if buckled beyond the service limit. Buckling limit: 0.2 mm (0.008 in).
DANGER
NEVER attempt to straighten a buckled
stanchion as this would weaken the overall
structure leading to a dangerous riding
condition.
SLEEVE
Inspect for damage and/or cracking. Replace if damaged.
SPRING
Check spring condition and ensure that the length is within
the specified limits. If the length does not correspond, replace the spring. Minimum length of the free spring: 284 mm (11.18 in)
Check conditions of the following components:
œ sliding bushing;
œ guide bushing;
5 - 39
CYCLE PARTS œ damper rod. Change any component which is badly worn or damaged.
WARNING
Remove any impurities from the bushing; be
careful not to damage the surface.
When reassembling, replace the following components with
new ones:
œ gasket;
œ dust seal;
œ the two O-rings on the regulator.
Oil quantity: (505 ± 2.5) cu cm (30.81 ± 015) in. Oil level: 122 ± 2 mm (4.80 ±0.08 in); (from edge of sleeve)
NOTE To correctly measure the oil level the sleeve must be
perfectly vertical. The oil level must be the same in both
legs.
The standard adjustment of the fork meets most conditions
of high and low speed riding, whether the vehicle is
travelling with a full load or not.
It is however possible to customise the adjustment,
depending on how the vehicle is used.
WARNING
When proceeding with the adjustment, always
start from the stiffest setting (adjusters 1 and
2 turned completely clockwise). As a reference
for adjusting compression and rebound
damping, use the marks on the adjusters (1-2).
Gradually turn the adjusters (1-2) by 1/8 of a
turn each time.
5 - 40 TUONO 1000
CYCLE PARTS
TUONO 1000
DANGER
Racing adjustments must be made exclusively during organised races or sporting events held on tracks far from road circulation and
with the authorisation of the proper
authorities. It is strictly prohibited to make racing
adjustments and ride the vehicle with said
setting on roads and motorways
Front suspension
Rebound damping adjustment, screw (1)
Compression damping adjustment, screw (2)
Spring preload, nut (3)
Leg projection (A) (***) from upper yoke (excluding plug)
Standard adjustment
from completely closed (*) open (**)
1.5 turns
from completely closed (*) open (**) 1 turn
from completely closed (*) open (**)
5 projection notches
1 projection notch
(*) clockwise
(**) anticlockwise
(***) For this type of adjustment please contact exclusively an aprilia Authorised Dealer.
NOTE Öhlins forks available on request (OPT).
Öhlins front fork (OPT)
The standard adjustment of the fork meets most conditions
of high and low speed riding, whether the vehicle is
travelling with a full load or not.
It is however possible to customise the adjustment,
depending on how the vehicle is used.
WARNING
To count the number of adjusters (1-2) clicks
always start from the stiffest setting (adjuster
turned completely clockwise).
As a reference for adjusting hydraulic braking
compression and rebound damping, use the
adjusters (1-2).
Gradually turn the adjusters (1-2) 1 mark at a
time.
5 - 41
CYCLE PARTS Front suspension
Rebound damping adjustment, screw (1)
Compression damping adjustment, screw (2)
Spring preload, nut (3)
Leg projection (A) (***) from upper yoke (excluding plug)
TUONO 1000
Standard adjustment
from completely closed (*) open (**) 12 turns
from completely open (*) close (**) 8 turns
4 projection notches
(*) clockwise
(**) anticlockwise
(***) For this type of adjustment please contact exclusively an aprilia Authorised Dealer.
5 - 42 CYCLE PARTS
TUONO 1000
5.2.9.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
Fork leg to top fork yoke
Fork leg to bottom fork yoke
Headstock ring nut
Headstock counter nut
Top yoke fixing plug
Front fork clamps (Showa)
Front fork clamps (Öhlins)
Steering damper to frame
Steering damper to bottom fork yoke
Rear turn indicators
Front turn indicators
Tail light to tail guard
Headlight to conveyor
Headlight to fairing front piece
Instrument panel
Air box cover
Air box to throttle body
Intake funnels
MAP sensor mount
Filter frame
Conveyor to frame
Carbon filter to seat frame lower
cover
Wheel shaft nut
QUANTITY
1+1
2+2
1
1
1
NUT/BOLT
FRONT FORK
M8
M8
M35x1
M35x1
25
25
40
Man.
M29x1
100
2+2
2+2
M8
M6
STEERING DAMPER
1
M6
1
M6
LIGHTS / INSTRUMENT PANEL
2
M4
2
M6
4
M5
2
M5
4
M5
3
SWP5x14
AIR BOX
7
SWP5x20
6
M6
4
SWP 3.9
1
SWP5x20
2
SWP5x20
4
M6
1
M6
FRONT WHEEL
1
M25x1.5
FRONT BRAKING SYSTEM
2+2
M10x1.25
1
M6
RH and LH front brake callipers
Front brake fluid reservoir to bracket
Front brake and clutch fluid
reservoir bracket
Clutch fluid reservoir to bracket
Front brake line guide to bottom fork
yoke
Brake disc
6+6
Front mudguard
4
TORQUE
(Nm)
TOL.
NOTE
Manual + 90°
Use a torque
wrench
22
12
10
10
Loctite 243
1
4
2
2
2
3
±20%
-
3
5
1
2
2
10
±20%
±20%
±20%
±20%
-
4
80
50
7
-
1
M6
10
1
M5
3
1
M5
4
M8
MUDGUARDS
M5
30
Loctite 243
5
5 - 43
CYCLE PARTS 5.3.
STEERING BEARINGS
5.3.1.
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Top yoke
Bottom yoke
Counter nut
Ring nut
Steering safety plate
Top yoke fixing bushing
Dust seal
Dust seal
Headstock plug washer
Axial ball bearing
Steering damper
Front damper mount
M6x25 flanged screw
M8x35 TCEI screw
Handlebar lower U-bolt
Bushing
Bushing
TE pf M6x80 screw
Curved spring washer
M8x45 TCEI screw
Washer
Wire guide
5 - 44 TUONO 1000
TUONO 1000
5.3.2.
CYCLE PARTS
CHECKING PLAY
Steering bearings and steering play:
•
Place the vehicle on the central support stand.
•
Shake the fork in the direction of travel.
•
If play is noticed, proceed with adjustment
5 - 45
CYCLE PARTS 5.3.3.
ADJUSTING BEARING PLAY
•
•
•
Loosen and remove the four U-bolt fixing screws.
Remove the stand.
Remove the handlebar taking special care not to spill
oil from the clutch reservoir or from the front brake fluid
reservoir.
•
Loosen and remove the headstock upper nut and set
aside the washer.
•
Loosen the fork leg fixing screws on the upper yoke.
•
Slide out the fork upper yoke moving it toward the
instrument panel.
5 - 46 TUONO 1000
TUONO 1000
•
Straighten the safety washer on the headstock.
•
Loosen the upper ring nut and remove the safety
washer.
CYCLE PARTS
5 - 47
CYCLE PARTS •
Adjust the steering bearing preload by tightening the
lower ring nut to the specified torque.
•
Fit the safety washer.
•
Fit the upper ring nut and tighten so the grooves
correspond to the safety washer tabs.
5 - 48 TUONO 1000
TUONO 1000
•
Rivet the tabs on the upper ring nut.
•
Fit the upper fork yoke.
•
Tighten the upper bolt on the headstock to the
specified torque.
•
Tighten the fork leg fixing screws on the upper yoke to
the specified torque.
CYCLE PARTS
5 - 49
CYCLE PARTS •
•
•
Fit the handlebar.
Fit the U-bolt.
Tighten the four U-bolt fixing screws to the specified
torque.
5 - 50 TUONO 1000
CYCLE PARTS
TUONO 1000
5.3.4.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
QUANTITY
Front engine mount
Upper and lower rear engine mount,
LH side
Upper and lower rear engine mount,
RH side of adjustment bushing
Upper and lower rear engine mount,
RH side of counter nut
Upper and lower rear engine mount,
RH side
2+2
Fork leg to upper fork yoke
Fork leg to lower fork yoke
Headstock ring nut
Headstock counter nut
1+1
2+2
1
1
Upper yoke fixing plug
Front fork clamps (Showa)
Front fork clamps (Öhlins)
Steering damper to frame
Steering damper to lower fork yoke
Rear turn indicators
Front turn indicators
Tail light to tail guard
Headlight to conveyor
Headlight to fairing front piece
Instrument panel
Air box cover
Air box to throttle body
Intake funnels
MAP sensor mount
Filter frame
Conveyor to frame
Carbon filter to seat frame lower
cover
Wheel shaft nut
RH and LH front brake callipers
Front brake fluid reservoir to bracket
Front brake and clutch fluid reservoir
bracket
Clutch fluid reservoir to bracket
Front brake line guide to lower fork
yoke
Brake disc
NUT/BOLT
TORQUE
(Nm)
ENGINE TO FRAME
M10
M10
50
2
M20x1.5
12
2
M20x1.5
50
2
M10
50
FRONT FORK
M8
M8
M35x1
M35x1
25
25
40
Man.
M29x1
100
2+2
2+2
M8
M6
STEERING DAMPER
1
M6
1
M6
HEADLIGHTS / INSTRUMENT PANEL
2
M4
2
M6
4
M5
2
M5
4
M5
3
SWP5x14
AIR BOX
7
SWP5x20
6
M6
4
SWP 3.9
1
SWP5x20
2
SWP5x20
4
M6
1
M6
FRONT WHEEL
1
M25x1.5
FRONT BRAKING SYSTEM
2+2
M10x1.25
1
M6
NOTE
50
2
1
TOL.
Manual + 90°
Use a torque
wrench
22
12
10
10
Loctite 243
1
4
2
2
2
3
±20%
-
3
5
1
2
2
10
±20%
±20%
±20%
±20%
California version
only
4
80
50
7
-
1
M6
10
1
M5
3
1
M5
4
6+6
M8
30
Loctite 243
5 - 51
CYCLE PARTS Description
Cover to lower fork yoke
Cover to lower fork yoke with steering
damper
Upper U-bolt to handlebar mounts
Handlebar mounts to fork upper yoke
(for workshop manual only)
Anti-vibration weights
Anti-vibration weight end caps
LH dimmer switch
RH dimmer switch
Front brake master cylinder
Clutch master cylinder
Front mudguard
5 - 52 TUONO 1000
QUANTITY
NUT/BOLT
FRONT FORK LOWER COVER
2
M6
1
M6
HANDLEBAR AND CONTROLS
4
M8
2
2
2
1
1
2
2
4
M10
M6
M18x1
M5x1
M4
M6
M6
MUDGUARDS
M5
TORQUE
(Nm)
TOL.
NOTE
3
10
25
30
10
35
1,5
1,5
8
8
5
Loctite 243
TUONO 1000
5.4.
CYCLE PARTS
REAR SUSPENSION
5.4.1.
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Shock absorber
Double connecting rod
Roller case
D18x24x3 oil seal
Pin L=36
Screw
T-bushing
M10 flanged self-locking nut
Complete single connecting rod
M10x59 TCEI screw
M10x61 flanged screw
5 - 53
CYCLE PARTS 5.4.2.
DISASSEMBLING THE REAR SUSPENSION
•
•
Secure the motorcycle using slings and an A-frame.
Working from the right-hand side of the vehicle, loosen
the upper screw (1) but do not remove it and remove
the nut.
•
Working from the left-hand side of the vehicle, loosen
the lower screw (2) but do not remove it and remove
the nut.
•
•
Operate the A-frame to raise the motorcycle just
enough to remove load from the swingarm, but do not
lift the motorcycle off the ground.
Remove the upper screw (1).
•
Remove the lower screw (2).
5 - 54 TUONO 1000
TUONO 1000
•
CYCLE PARTS
Remove the rear shock absorber (3) from between
swingarm and rear subframe.
5 - 55
CYCLE PARTS 5.4.3.
TUONO 1000
CHECKING THE COMPONENTS
WARNING Check that the components are not deformed, broken, cracked and/or dented. Replace any damaged components
BEARINGS Manually turn the rollers; they must turn smoothly, freely and
without noise. No axial play should be noticed. Faulty bearings should be replaced. WARNING Apply grease to the rollers
SEALS
Check that all seals are intact; replace them if they are
damaged or worn.
SHOCK ABSORBER
Check that the shock absorber shows no signs of oil leaks
and that its stroke is smooth and progressive. Replace if
necessary.
REAR SUSPENSION
Spring length (preloaded) (B)
Rebound adjustment, screw
(1)
Standard adjustment
147 mm (5.79 in)
from completely closed (*)
open (**) 25 clicks
CHECK ADJUSTMENTS
(*) clockwise
(**) anticlockwise
NOTE Öhlins shock absorbers available on request (OPT).
5 - 56 TUONO 1000
CYCLE PARTS
Öhlins shock absorber (OPT) WARNING
Adjust shock absorber spring preload and
rebound damping to suit motorcycle usage
conditions.
When you increase spring preload, you
should also increase rebound damping to
avoid sudden jerks when riding.
DANGER
Racing
adjustments
must
be
made
exclusively during organised races or
sporting events held on tracks far from road
circulation and with the authorisation of the
proper authorities.
It is strictly prohibited to make racing
adjustments and ride the vehicle with said
setting on roads and motorways
WARNING
(OPT) Do not loosen the screw (8) or disturb
the membrane located underneath or the
resulting nitrogen loss will impair shock
absorber operation making the motorcycle
unsafe to ride.
Öhlins shock absorber
Rear suspension
Shock absorber centre distance (A)
Spring length (preloaded) (B)
Rebound adjustment, ring nut (1)
Compression adjustment, knob (2)
Standard adjustment
312 ±1.5 mm (12.28 ± 0.59 in)
145 mm (5.71 in)
from completely closed (*) open (**) 20 clicks
from completely closed (*) open (**) 12 clicks
CHECK ADJUSTMENTS
(*) clockwise
(**) anticlockwise
5 - 57
CYCLE PARTS 5.4.4.
REASSEMBLING THE REAR SUSPENSION
•
Fit the rear shock absorber (3) between swingarm and
rear subframe.
•
Fit the lower screw (2).
•
Operate the A-frame until aligning the frame hole with
the rear suspension upper mounting point.
Fit the upper screw (1).
•
•
Working from the right-hand side of the vehicle, fit the
nut (2) to the lower screw and tighten.
5 - 58 TUONO 1000
TUONO 1000
•
•
CYCLE PARTS
Working from the left-hand side of the vehicle, fit the
nut (1) to the upper screw and tighten.
Release the motorcycle from the A-frame and remove
the slings.
5 - 59
CYCLE PARTS 5.4.5.
•
•
•
•
•
•
•
REMOVING THE REAR SUSPENSION CONNECTING RODS
Working from the right-hand side of the vehicle, loosen
and remove the nut (1).
Remove the screw from the opposite side (2).
Loosen and remove the nut (3).
Remove the screw from the opposite side (4).
Loosen and remove the nut (5).
Remove the screw from the opposite side (6).
Remove the complete suspension connecting rod unit
(7).
NOTE When reassembling, grease the connecting rod pivot
points; ensure that all the parts are correctly positioned and
check repeatedly that all joints move freely.
5 - 60 TUONO 1000
CYCLE PARTS
TUONO 1000
5.4.6.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
QUANTITY
NUT/BOLT
TORQUE
(Nm)
REAR SHOCK ABSORBER
1
M10
50
REAR SUSPENSION CONNECTING RODS
Single connecting rod to frame
1
M10
50
Single to double connecting rod
1
M10
50
Double connecting rod to swingarm
1
M10
50
Double connecting rod to shock
1
M10
50
absorber
TOL.
NOTE
Shock absorber to frame
-
5 - 61
CYCLE PARTS 5.5.
SWINGARM
5.5.1.
•
•
REMOVING THE SWINGARM
Place the vehicle on the central support stand (OPT).
Remove the rear wheel.
NOTE Though not necessary for removing the rear wheel,
the rear support stand (OPT) is essential for keeping the
swingarm without the wheel in place.
Shim the resting surface of the rear support stand (OPT) so
it is in work position (fastened to the two swingarm pegs).
•
•
Remove the exhaust system.
Loosen and remove the three guard fixing screws and
set aside the washers.
•
Carefully rest the support plate on the ground on its
side complete with the brake calliper and the speed
sensor, connected to the tube and to the wire,
respectively.
WARNING
Do not pull the rear brake lever when the
calliper has been removed as this could cause
the piston to come out of its housing and
determine brake fluid leakage.
5 - 62 TUONO 1000
TUONO 1000
•
•
•
CYCLE PARTS
Working on the left-hand side, loosen and remove the
double-connecting rod/swingarm nut.
Remove the screw from the opposite side.
•
Working on the left-hand side, loosen and remove the
shock absorber lower nut.
Remove the screw from the opposite side.
•
Loosen and remove the nut and set aside the washer.
NOTE Use the special tool (OPT):
-
aprilia part# 8140191 (tool for tightening swingarm pivot
and supporting engine).
•
Use the box spanner to loosen and remove the ring nut
(1) on the right-hand side of the vehicle.
5 - 63
CYCLE PARTS •
Turn the swingarm pivot anticlockwise (2); this will turn
and drag the adjustment bushing (3) loosening it
completely.
WARNING
Removal must be carried out with utmost care.
Support the front end of the swingarm to avoid
accidental falling.
Place a wooden support under the front end of
the swingarm to prevent it from lowering and
keep it in position.
•
•
•
Place the support under the front end of the swingarm.
Support the front end of the swingarm.
Slide the swingarm pivot (2) out from the right-hand
side.
WARNING
When removing the swingarm ensure that the
drive chain does not tangle up.
•
•
•
Support the front of the swingarm and be prepared to
guide its movement.
Using the rear support stand, slide the swingarm out
from the rear until it is out of the way of the vehicle.
Slide the adjustment bushing (3) out of the swingarm
pivot (2)
5 - 64 TUONO 1000
CYCLE PARTS
TUONO 1000
5.5.2.
CHECKING THE COMPONENTS
WARNING Check that all components
especially those listed below.
are
intact,
SWINGARM BEARINGS Perform the check with the bearings fitted on the swingarm.
ROTATION CHECK
•
Manually turn the inner ring of each bearing. Rotation
must be continuous, smooth and silent.
If one or both bearings do not meet the specifications:
•
replace both swingarm bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
RADIAL AND AXIAL PLAY CHECK
•
Check radial and axial play.
Axial play: minimum axial play is accepted.
Radial play: none.
If one or both bearings do not meet the specifications:
•
replace both swingarm bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
SWINGARM SEALS
•
Check that all seals are intact; replace them if they are
damaged or worn.
DANGER
Always replace both seals. Always replace seals with seals of the same
type.
SWINGARM PIVOT •
Using a dial gauge, check the eccentricity of the
swingarm pivot (1). If eccentricity exceeds the specified
limits, replace the swingarm pivot (1).
Maximum eccentricity: 0.3 mm (0.012 in).
5 - 65
CYCLE PARTS 5.5.3.
•
•
•
•
•
•
REMOVING THE SWINGARM BEARINGS
Remove the swingarm.
Clean the two sides of the bearing housings with a
cloth.
Remove the bushing (1).
Remove the seal (2).
Remove the seal (3).
Remove the circlip (4).
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
TUONO 1000
OPT:
Remove the two bearings (5) and the roller bearing (6)
with the extractor.
WARNING
After removing the bearings, check to see if
they should be replaced.
•
•
•
•
Remove the inner spacer (7) and set aside the two Orings (8).
Remove the inner spacer (9).
Remove the gaskets (10).
Remove the two roller bearings with an extractor (11).
WARNING
After removing the bearings, check to see if
they should be replaced.
•
Clean the bearing housing thoroughly.
NOTE Wash all components with clean detergent.
WARNING
When reassembling, to insert the bearings, use
a drift with the same diameter as the outer ring
of the bearing.
Do not hammer the rollers and/or the inner ring.
5 - 66 TUONO 1000
5.5.4.
•
•
CYCLE PARTS
REFITTING THE SWINGARM
Smear some grease all along the swingarm pivot.
Fit the adjustment bushing (3) in its housing and
tighten it manually.
NOTE Ensure that the adjustment bushing (3) does not
protrude from the inner edge of the frame.
•
•
•
Fit the drive chain on the front part (left) of the
swingarm and secure it with adhesive tape.
Place a wooden support under the front end of the
swingarm to prevent it from lowering and keep it in
position.
Support the rear end of the swingarm using the rear
support stand (OPT).
NOTE Shim the resting surface of the rear support stand
(OPT) so it is in work position (fastened to the two swingarm
pegs).).
•
Support the front end of the swingarm; position it so
that the holes are aligned and simultaneously insert the
pivot completely (2).
NOTE Ensure that the hexagonal area of the pivot head (2)
is correctly inserted in the hexagonal housing inside the
adjustment bushing (3).
•
•
•
Fit and manually tighten the counter nut a few turns
(1).
Fit the washer and the swingarm pivot nut on the pivot
and tighten manually.
Working on the right-hand side of the vehicle, turn the
swingarm pivot (2) clockwise so it turns the adjustment
bushing (3) which will push the swingarm fully home.
5 - 67
CYCLE PARTS NOTE Use the special tool (OPT):
-
aprilia part# 8140191 (tool for tightening swingarm pivot
and supporting engine).
•
Tighten the locking ring nut with a box spanner (1).
•
Tighten the nut.
•
•
Remove the adhesive tape and free the chain.
Fit the chain on the transmission sprocket.
NOTE Apply LOCTITE® Anti-Seize to the inner teeth of the
transmission sprocket.
•
Fit the sprocket complete with chain on the shaft.
NOTE Apply LOCTITE® 243 to the screw threading.
•
•
Insert the washer on the screw.
Tighten the screw.
5 - 68
TUONO 1000
TUONO 1000
•
•
•
•
•
•
•
•
•
CYCLE PARTS
Working on the right-hand side, insert the shock
absorber lower screw.
Tighten the nut on the opposite side.
Working on the right-hand side, insert the doubleconnecting rod/swingarm screw.
Tighten the nut on the opposite side.
Fit the support plate complete with brake calliper and
speed sensor.
Tighten the three guard fixing screws complete with
washers.
Fit the sprocket cover and tighten the three screws.
Fit the rear wheel and the exhaust system.
Adjust the drive chain tension.
5 - 69
CYCLE PARTS 5.5.5.
TUONO 1000
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
QUANTITY
Front engine mount
Upper and lower rear engine mount,
LH side
Upper and lower rear engine mount,
RH side of adjustment bushing
Upper and lower rear engine mount,
RH side of counter nut
Upper and lower rear engine mount,
RH side
2+2
Swingarm pivot ring nut
Swingarm pivot adjustment bushing
Swingarm pivot nut
Calliper carrier retaining pin
Chain tightener screw and nut
Rear brake line guide
Chain guard upper fixing screw
Chain guard and chain eye mount
lower fixing screw
Chain slider
Chain eye to chain eye mount upper
fixing nut
Rear stand bushing
Chain eye fixing nut
1
1
1
1
1+1
3
1
NUT/BOLT
ENGINE TO FRAME
M10
TORQUE
(Nm)
M10
50
2
M20x1.5
12
2
M20x1.5
50
2
M10
50
60
12
90
50
Man.
4
4
1
M5
5
2
M5
3
1
M5(nut)
5
2
M6
10
1
M6(nut)
10
REAR SHOCK ABSORBER
Shock absorber to frame
1
M10
50
REAR SUSPENSION CONNECTING RODS
Single connecting rod to frame
1
M10
50
Single to double connecting rod
1
M10
50
Double connecting rod to swingarm
1
M10
50
Double connecting rod to shock
1
M10
50
absorber
REAR WHEEL
Rear chain sprocket to sprocket
5
M10
50
carrier
Rear wheel shaft nut
1
M25x1.5
120
REAR BRAKING SYSTEM
Rear brake calliper
2
M8
25
Rear brake lever pin
1
M8
15
Rear brake fluid reservoir
1
M5
3
Rear brake rod counter nut
1
M6
Man.
Brake disc
5
M8
30
MUDGUARDS
Rear mudguard
4
M5
5
FRAME
Lower chain slider
2
M6
10
EXHAUST SYSTEM
Front exhaust pipe to engine
4
M6
12
Rear exhaust pipe to engine (upper
2
M6
/
screws)
Rear exhaust pipe to engine (lower
2
M6
12
screws)
Lambda sensor
1
M18x1.5
38
Rear manifold guard
2
M4
2,5
Silencers to mount
2
M8
25
Guards to silencer
2
M4
2,5
5 - 70 Note
50
2
SWINGARM
M30x1.5
M30x1.5
M20x1.5
M12
M8
M5
M5
TOL.
Loctite 243
-
±20%
±20%
±20%
±20%
±20%
Loctite 243
Loctite 243
Tighten manually
TUONO 1000
5.6.
CYCLE PARTS
FRONT WHEEL
5.6.1.
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Naked blue front wheel
Tubeless tyre valve
Internal spacer
6005-2rs1 bearing
30x47x7 seal
Circlip
External spacer
Front brake disc
25.2x36x1 washer
Wheel shaft nut
M8x20 flanged screw
Front wheel shaft
120/70 ZR17“ front tyre
5 - 71
CYCLE PARTS 5.6.2.
REMOVING THE FRONT WHEEL
•
Support the front end of the vehicle.
•
Loosen the front mudguard screws and remove it.
•
Loosen the front calliper fixing screws and slide them
out of the disc.
5 - 72 TUONO 1000
TUONO 1000
•
Remove the wheel shaft nut.
•
Set aside the washer.
CYCLE PARTS
5 - 73
CYCLE PARTS •
Loosen the wheel shaft pinch bolts.
•
Lightly tap the wheel shaft with a rubber mallet until the
holes on the opposite side are uncovered.
•
Remove the wheel shaft using a screwdriver inside the
shaft holes.
•
During this operation, support and remove the wheel.
5 - 74 TUONO 1000
CYCLE PARTS
TUONO 1000
5.6.3.
CHECKING THE FRONT WHEEL COMPONENTS
WARNING Check that all components
especially those listed below.
are
intact,
FRONT WHEEL BEARINGS Check with the bearings fitted on the wheel.
ROTATION CHECK
•
Manually turn the inner ring of each bearing. Rotation
must be continuous, smooth and silent.
If one or both bearings do not meet the specifications:
•
replace both wheel bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
RADIAL AND AXIAL PLAY CHECK •
Check radial and axial play.
Axial play: minimum axial play is accepted.
Radial play: none.
If one or both bearings do not meet the specifications:
•
replace both wheel bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type. FRONT WHEEL SEALS
•
Check that all seals are intact; replace them if they are
damaged or worn.
DANGER
Always replace both seals. Always replace seals with seals of the same type.
FRONT WHEEL SHAFT •
Using a dial gauge, check the eccentricity of the wheel
shaft (1). If eccentricity exceeds the specified limits,
replace the wheel shaft (1).
Maximum eccentricity: 0.25 mm (0.0098 in).
5 - 75
CYCLE PARTS FRONT WHEEL RIM
•
Using a dial gauge, check that the radial (A) and axial
(B) eccentricity of the rim (2) does not exceed the
specified limit.
Excess eccentricity is usually caused by worn or
damaged bearings.
If after the bearings have been replaced the value is
not within the specified limit, replace the rim (2).
Maximum radial and axial eccentricity: 2 mm (0.0079 in).
5 - 76 TUONO 1000
CYCLE PARTS
TUONO 1000
5.6.4.
•
•
REMOVING THE FRONT WHEEL BEARINGS
Remove the front wheel.
Clean the two sides of the hub with a cloth.
Work on the right-hand side of the wheel:
•
Remove the right spacer (1).
•
Remove the seal (2).
•
Remove the circlip (3).
NOTE The circlip (3) is fitted only on the right-hand side of
the wheel.
The edges of the spacer (4) feature slots (A) to allow the
passage of the extractor teeth.
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
•
OPT:
Remove the right bearing with the extractor (5).
Set aside the inner spacer (4).
Work on the left-hand side of the wheel:
•
Remove the seal (2).
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
•
OPT:
Remove the left bearing with the extractor (6).
Clean the inner part of the hub thoroughly.
NOTE Wash all components with clean detergent.
5 - 77
CYCLE PARTS 5.6.5.
TUONO 1000
REFITTING THE FRONT WHEEL BEARINGS
If fitted:
•
Remove the front wheel bearings.
Work on the right-hand side of the wheel:
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
OPT:
Insert the right bearing (5) completely, using the drift.
NOTE The bearing must be inserted until it is fully home
against the abutment (Y).
•
Fit the circlip (3).
NOTE The circlip (3) is fitted only on the right side of the
wheel.
Work on the left-hand side of the wheel:
•
Fit the spacer (4).
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
OPT:
Insert the left bearing (6), using the drift.
NOTE Complete insertion of the left bearing (6) will couple
the following components:
-
right bearing (5);
spacer (4);
left bearing (6).
WARNING
Once it is home against the right bearing (5) do
not push further to avoid forcing the circlip (3).
NOTE Once the left bearing has been fitted (6), check that
the following components are coaxial:
•
right bearing (5);
spacer (4);
left bearing (6).
Fit a new seal (2).
Work on the right-hand side of the wheel:
•
Fit a new seal (2).
•
Fit the spacer (1) with the larger diameter facing the
vehicle exterior.
5 - 78
TUONO 1000
CYCLE PARTS
5 - 79
CYCLE PARTS 5.6.6.
FITTING THE WHEEL
•
Fit the front wheel and insert the wheel shaft in its
housing.
•
Tighten the clamp screws (nut side) to secure the
wheel shaft.
•
Fit the washer and tighten the wheel shaft nut to the
specified torque.
Work the fork to ensure that the fork legs are aligned.
•
5 - 80 TUONO 1000
TUONO 1000
•
Working on both sides, tighten the clamp screws
securing the wheel shaft to the specified torque.
•
Fit the callipers on the disc.
•
Fit the brake callipers and tighten the screws to the
specified torque.
CYCLE PARTS
WARNING
After fitting the brake callipers, pull the front
brake lever repeatedly
5 - 81
CYCLE PARTS 5.7.
REAR WHEEL
5.7.1.
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
Complete chain, with master link
Rear sprocket z=40
Naked blue rear wheel
Rear wheel vibration damper holder
190/50œZR 17" TL rear tyre
Vibration damper seal
Tubeless tyre valve
Rear wheel spacer
Retainer
M10 self-locking nut
Complete rear chain sprocket holder
Rear wheel shaft
M25x1.5 wheel shaft nut
25.2x36x1 washer
30x52x7 seal
Internal spacer
Circlip
10x20 pin
6205-2rs1 bearing
M10x30 TCEI screw
38x52x7 seal
Retaining ring for 55Ø hole
30x55x13 bearing
Vibration damper spacer
Master link
5 - 82 TUONO 1000
TUONO 1000
5.7.2.
CYCLE PARTS
REMOVING THE REAR WHEEL
•
Place the vehicle on the rear support stand.
•
Loosen and remove the wheel shaft nut.
•
Set aside the abutment washer and the left chain
tightener slider.
5 - 83
CYCLE PARTS •
Lightly tap on the wheel shaft so the head comes out of
its housing.
•
Bring the wheel forward and free the drive chain from
the rear sprocket.
•
Slide the wheel shaft out together with the right chain
tightener slider.
•
Remove the complete wheel freeing the disc from the
brake calliper.
5 - 84 TUONO 1000
TUONO 1000
5.7.3.
•
CYCLE PARTS
REMOVING THE FINAL DRIVE UNIT
Remove the rear wheel.
WARNING
Proceed with care. If the final drive unit (1) is
fitted on the vibration damper holder (2) do not
turn the rear wheel upside down or horizontally
(A) on the rear sprocket side; the final drive
unit could fall out and damage the sprocket (3).
NOTE Do not loosen the five nuts (4). The final drive unit
comes out of the vibration damper holder as a single unit.
•
Use both hands (B) to remove the final drive unit,
parallel to the wheel shaft, working from the external
diameter of the sprocket (3).
REASSEMBLY
NOTE Fit the final drive unit parallel to the wheel shaft and
place the vibration damper seals (5) in their housing on the
vibration damper holder (2).
•
Use both hands (C) to fit the final drive unit in the
vibration damper holder, from the external diameter of
the sprocket (3).
NOTE Do the following only if the left spacer (6) and/or the
right spacer (7) have come out of their housing.
•
Fit the left spacer (6) and/or the right spacer (7) in
their housings with the larger diameter facing the
vehicle exterior.
5 - 85
CYCLE PARTS 5 - 86 TUONO 1000
CYCLE PARTS
TUONO 1000
5.7.4.
CHECKING THE REAR WHEEL COMPONENTS
WARNING Check that all components
especially those listed below.
are
intact,
REAR WHEEL BEARINGS Check with the bearings fitted on the wheel.
ROTATION CHECK
•
Manually turn the inner ring of each bearing. Rotation
must be continuous, smooth and silent.
If one or both bearings do not meet the specifications:
•
replace both wheel bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
RADIAL AND AXIAL PLAY CHECK •
Check radial and axial play.
Axial play: minimum axial play is accepted.
Radial play: none.
If one or both bearings do not meet the specifications:
•
replace both wheel bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
REAR WHEEL SEALS •
Check that all seals are intact; replace them if they are
damaged or worn.
DANGER
Always replace both seals. Always replace seals with seals of the same
type.
REAR WHEEL SHAFT •
Using a dial gauge, check the eccentricity of the wheel
shaft (1). If eccentricity exceeds the specified limit,
replace the wheel shaft (1).
Maximum eccentricity: 0.25 mm (0.0098 in).
REAR WHEEL RIM
•
Using a dial gauge, check that the radial (A) and axial
(B) eccentricity of the rim (2) does not exceed the
specified limit.
Excess eccentricity is usually caused by worn or damaged
bearings. If after the bearings have been replaced the value is not
within the specified limit, replace the rim (2). Maximum radial and axial eccentricity: 2 mm (0.0079 in).
5 - 87
CYCLE PARTS FINAL DRIVE UNIT BEARINGS
Check with the bearings fitted on the final drive unit.
ROTATION CHECK
•
Remove the left spacer (3).
•
Remove the right spacer (4).
•
Manually turn the inner ring of each bearing. Rotation
must be continuous, smooth and silent.
If one or both bearings do not meet the specifications:
•
Replace both final drive unit bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
RADIAL AND AXIAL PLAY CHECK •
Check radial and axial play.
Axial play: minimum axial play is accepted.
Radial play: none.
If one or both bearings do not meet the specifications:
•
Replace both final drive unit bearings.
DANGER
Always replace both bearings. Always replace bearings with bearings of the
same type.
VIBRATION DAMPER
•
Check that the vibration damper seals (5) are not
damaged and/or excessively worn.
To perform the check:
•
Fit the complete final drive unit on the wheel (6).
•
Manually turn the sprocket (7) in both directions and
check play between the vibration damper seals (5) and
the vibration damper holder (8).
If excessive play is noticed:
•
Replace all vibration damper seals (5).
DANGER
Always replace all vibration damper seals with
seals of the same type.
5 - 88 TUONO 1000
TUONO 1000
CYCLE PARTS
REAR SPROCKET
•
Check the condition of the sprocket teeth (7).
In case of excessive wear:
•
replace the rear sprocket.
WARNING To avoid premature wear of new components,
the rear sprocket, the front sprocket and the drive chain must be replaced as a group.
5 - 89
CYCLE PARTS 5.7.5.
•
•
TUONO 1000
REMOVING THE REAR WHEEL BEARINGS
Remove the rear wheel.
Clean the two sides of the hub with a cloth.
Work on the right-hand side of the wheel:
•
Remove the right spacer (1).
•
Remove the seal (2).
•
Remove the circlip (3).
NOTE The circlip (3) is fitted only on the right side of the
wheel.
The edges of the spacer (4) feature slots (A) to allow the
passage of the extractor teeth.
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
•
OPT:
Remove the right bearing with the extractor (5).
Set aside the inner spacer (4).
Work on the left-hand side of the wheel:
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
•
Remove the left bearing with the extractor (6).
Clean the inner part of the hub thoroughly.
NOTE Wash all components with clean detergent.
5 - 90 OPT:
CYCLE PARTS
TUONO 1000
5.7.6.
REFITTING THE REAR WHEEL BEARINGS
If fitted:
•
Remove the rear wheel bearings.
Work on the right-hand side of the wheel:
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
OPT:
Insert the right bearing (5) completely, using the drift.
NOTE The right bearing must be inserted until it is fully
home against the abutment (Y).
•
Fit the circlip (3).
NOTE The circlip (3) is fitted only on the right side of the
wheel.
Work on the left-hand side of the wheel:
•
Fit the spacer (4).
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
OPT:
Insert the left bearing (6), using the drift.
NOTE Complete insertion of the left bearing (6) will couple
the following components:
-
right bearing (5);
spacer (4);
left bearing (6).
WARNING
Once it is against the right bearing (5) do not
push further to avoid forcing the circlip (3).
NOTE Once the left bearing has been fitted (6), check that
the following components are coaxial:
-
right bearing (5);
spacer (4);
left bearing (6).
Work on the right-hand side:
•
Fit a new seal (2).
•
Fit the spacer (1) with the larger diameter facing the
vehicle exterior.
5 - 91
CYCLE PARTS 5 - 92 TUONO 1000
CYCLE PARTS
TUONO 1000
5.7.7.
•
•
•
•
•
REMOVING THE FINAL DRIVE UNIT BEARINGS
Remove the final drive unit.
Clean the two sides of the hub with a cloth.
Remove the left spacer (1).
Remove the seal (2).
Remove the circlip (3).
NOTE The circlip (3) is fitted only on the left side of the final
drive unit.
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
•
•
•
•
OPT:
Remove the left bearing with the extractor (4).
Set aside the inner spacer (5).
Remove the right bearing with the extractor (6).
Set aside the right spacer (7).
Clean the inner part of the hub thoroughly.
NOTE Wash all components with clean detergent.
5 - 93
CYCLE PARTS 5.7.8.
TUONO 1000
REFITTING THE FINAL DRIVE UNIT BEARINGS
If fitted:
•
Remove the final drive unit bearings.
Work on the left-hand side:
NOTE
Use
the
special
tool
- aprilia part# 8140180 (bearing extractor)
•
OPT:
Insert the right bearing (6) completely, using the drift.
NOTE The right bearing must be inserted until it is fully
home against the abutment (Y).
•
•
Fit the inner spacer (5).
Insert the left bearing (4), using the drift.
NOTE Complete insertion of the left bearing (4) will couple
the following components:
-
•
right bearing (6);
inner spacer (5);
left bearing (4).
Fit the circlip (3).
NOTE The circlip (3) is fitted only on the left side of the final
drive unit.
•
•
Fit a new seal (2).
Fit the left spacer (1) with the larger diameter facing
the vehicle exterior.
Work on the right-hand side:
•
Fit the right spacer (7) with the larger diameter facing
the vehicle exterior.
5 - 94
TUONO 1000
5.7.9.
•
CYCLE PARTS
REMOVING THE VIBRATION DAMPER SEALS
Remove the final drive unit.
NOTE The vibration damper seals are fitted on the vibration
damper holder.
•
Remove all vibration damper seals.
5 - 95
CYCLE PARTS 5.7.10.
•
REMOVING THE REAR SPROCKET
Using a setscrew wrench (1), lock threaded pin rotation
(2), loosen and remove the self-locking nut (3) and the
threaded pin (2).
WARNING
Replace the self-locking nuts (3) every three
times the rear sprocket is removed.
Replace the self-locking nuts (3) with nuts of
the same type.
•
•
Remove the rear sprocket holder (4).
Clean the rear sprocket (5) and the holder (4) with
clean detergent.
Reassembly:
•
Fit the five threaded pins (2) on the rear sprocket (5).
•
Assemble the rear sprocket holder and the rear
sprocket complete with threaded pins.
•
Manually tighten the self-locking nuts (3).
WARNING
Do not fit the final drive unit (6) on the wheel to
tighten the self-locking nuts.
WARNING
To protect the rear sprocket, fit (wooden or
aluminium) protections on the vice grips.
Clamp only the rear sprocket in the vice; do not
clamp any other components of the final drive
group.
•
Clamp the rear sprocket in the vice.
NOTE To avoid possible deformation and/or imperfect
mating, tighten according to the instructions below:
•
•
Using a setscrew wrench (1) lock the rotation of the
threaded pin (2) and apply half the specified torque;
tighten the elements opposite each other in the
following order: (A) (B) (C) (D) (E).
Repeat the above procedure applying the specified
tightening torque.
NOTE In this way the stress applied by the fixing elements
will be evenly distributed over the joint surface.
5 - 96 TUONO 1000
TUONO 1000
5.7.11.
CYCLE PARTS
REFITTING THE REAR WHEEL
•
Fit the wheel shaft, together with the right chain guide
slider, on the swingarm.
•
Fit the rear wheel and insert the wheel shaft in its
housing.
•
Bring the wheel forward and fit the drive chain on the
rear sprocket.
•
Fit the left chain tightener slider and the abutment
washer on the shaft.
5 - 97
CYCLE PARTS •
•
Manually tighten the nut.
Check the chain tension.
•
Tighten the fixing nut to the specified torque.
5 - 98 TUONO 1000
CYCLE PARTS
TUONO 1000
5.7.12.
TIGHTENING TORQUES
WARNING
All fasteners listed in the table must be tightened to the specified torque using a torque wrench and
LOCTITE ® where specified.
DESCRIPTION
QUANTITY
Swingarm pivot ring nut
Swingarm pivot adjustment bushing
Swingarm pivot nut
Calliper carrier retaining pin
Chain tightener screw and nut
Rear brake line guide
Chain guard upper fixing screw
Chain guard and chain eye mount
lower fixing screw
Chain slider
Chain eye to chain eye mount upper
fixing nut
Rear stand bushing
Chain eye fixing nut
1
1
1
1
1+1
3
1
Rear chain sprocket to sprocket
carrier
Rear wheel shaft nut
Rear brake calliper
Rear brake lever pin
Rear brake fluid reservoir
Rear brake rod counter nut
Brake disc
Rear mudguard
Lower chain slider
Seat frame
NUT/BOLT
SWINGARM
M30x1.5
M30x1.5
M20x1.5
M12
M8
M5
M5
TORQUE
(Nm)
60
12
90
50
Man.
4
4
1
M5
5
2
M5
3
1
M5(nut)
5
2
1
M6
M6(nut)
REAR WHEEL
10
10
5
M10
1
M25x1.5
REAR BRAKING SYSTEM
2
M8
1
M8
1
M5
1
M6
5
M8
MUDGUARDS
4
M5
FRAME
2
M6
4
M10
TOL.
Note
Loctite 243
50
120
25
15
3
Man.
30
±20%
±20%
±20%
±20%
±20%
Loctite 243
Loctite 243
5
10
50
5 - 99
CYCLE PARTS 5.8.
TUONO 1000
FRONT BRAKE
5.8.1.
CHANGING THE PADS
TIGHTENING TORQUES
Brake calliper screws (1)
50 Nm (5 kgm)
WARNING
This vehicle is equipped with a double-disc
front brake system (right and left side).
Always replace all the pads of both front brake
callipers.
Replacing the pads of only one front calliper
would compromise the stability and safety of
the vehicle, potentially resulting in danger for
people, things and the vehicle itself.
NOTE The following procedure refers to a single calliper but
applies to both.
•
•
•
•
Loosen and remove the two brake calliper fixing
screws (1).
Remove the front brake calliper from the disc.
Press on the safety spring (2) and simultaneously slide
the pin out (3).
Remove the safety spring (2).
5 - 100 TUONO 1000
•
CYCLE PARTS
Remove the two pads (4).
WARNING
Do not pull the brake lever when the pads are
not in place or the calliper pistons might come
out of their housing, thus causing brake fluid
leakage.
•
Fit two new pads and position them correctly.
WARNING
Always replace all four pads and ensure they
are correctly in place inside the calliper.
•
•
•
Fit the safety spring (2).
Press on the safety spring (2) and simultaneously
insert the pin from the inside (3).
Release the safety spring (2) and hook it correctly on
the pin (3).
DANGER
When it is released, the safety spring (2) must
secure the pin (3) by entering the housings.
If positioned correctly the pin (3) will not slip
out; check this condition.
•
•
•
•
•
Fit the front brake calliper on the disc.
Manually tighten the two screws completely (1).
Pull the front brake lever to allow the brake calliper to
bed correctly.
Keeping the brake lever pulled, tighten the two screws
(1).
Check the front brake fluid level.
5 - 101
CYCLE PARTS 5.8.2.
CHECK
Brake discs:
NOTE Perform the following operations with the brake discs
fitted on the wheel, the information provided below refers to
one disc but applies to both.
•
Check disc wear by measuring the minimum thickness
in various points with a micrometer.
If the minimum thickness is lower than the minimum
value, even if only in one point, replace the disc.
Minimum disc thickness value: 4 mm (0.16 in)
•
Using a dial gauge, check that the disc maximum
oscillation does not exceed tolerance; if so, replace it.
Disc oscillation tolerance: 0.3 mm (0.012 in).
5 - 102 TUONO 1000
TUONO 1000
5.8.3.
•
CYCLE PARTS
REMOVING THE DISCS
Remove the front wheel.
NOTE The information provided below refers to one disc but
applies to both.
To loosen the screws (1) we recommend the use of a
pneumatic screw gun which will resist the strength of the
LOCTITE® 243.
•
Loosen and remove the six brake disc screws (1).
WARNING
When refitting, apply LOCTITE® 243 to the
thread of the brake disc screw (1).
NOTE When refitting, fit all the screws (1) manually and
tighten them observing a cross pattern in the following order:
A-B-C-D-E-F.
•
Remove the brake disc (2).
5 - 103
CYCLE PARTS 5.8.4.
BLEEDING THE BRAKE SYSTEM
FRONT BRAKE
NOTE Make sure to have a flexible tube and a container of
adequate size ready at hand before beginning the bleeding
procedure.
•
Connect the tube to the brake master cylinder bleed
valve.
•
Pull the lever and slightly open the bleed valve on the
master cylinder to release the air.
Close the bleed valve before reaching the end of stroke
with the lever and repeat the procedure until all the air
is released.
•
•
Working from both sides, connect the tube to the brake
calliper bleed valve.
5 - 104 TUONO 1000
TUONO 1000
•
•
•
CYCLE PARTS
Pull the brake lever and slightly open the bleed valve
on the calliper you wish to bleed to release the air.
Close the bleed valve before reaching the end of stroke
with the lever and repeat the procedure until all the air
is released.
As a precaution repeat the bleed procedure on the
brake master cylinder.
REAR BRAKE
NOTE Make sure to have a flexible tube and a container of
adequate size ready at hand before beginning the bleeding
procedure.
•
•
•
Remove the fairing, see (DISASSEMBLING THE
UPPERWORKS).
Connect the tube to the brake master cylinder bleed
valve.
•
Pull the lever and slightly open the bleed valve on the
master cylinder to release the air.
Close the bleed valve before reaching the end of stroke
with the lever and repeat the procedure until all the air
is released.
•
Connect the tube to the brake calliper bleed valve.
5 - 105
CYCLE PARTS •
•
•
Pull the brake lever and slightly open the bleed valve
on the calliper you wish to bleed to release the air.
Close the bleed valve before reaching the end of stroke
with the lever and repeat the procedure until all the air
is released.
As a precaution repeat the bleed procedure on the
brake master cylinder.
5 - 106 TUONO 1000
TUONO 1000
5.9.
5.9.1.
•
•
CYCLE PARTS
REAR BRAKE PADS
REPLACING THE REAR BRAKE PADS
Place the vehicle on the stand.
Remove the rear brake calliper.
WARNING
Do not pull the rear brake lever when the
calliper has been removed as this could cause
the piston to come out of its housing and
determine brake fluid leakage.
•
Remove the stop ring (1).
WARNING
Before removing the pin (2), check the position
of the safety spring (3); refit in the same
position.
•
•
Remove the pin (2) and collect the safety spring (3).
Remove the two pads (4) and collect the noise
dampening plates.
WARNING
Do not pull the brake lever when the pads are
not in place or the calliper pistons might come
out of their housing, thus causing brake fluid
leakage.
•
Replace the anti-vibration plates if worn.
WARNING
When refitting the anti-vibration plates, make
sure the arrows point in the direction of travel.
•
Fit the two new pads together with the anti-vibration
plates, fit them so the holes match those on the
calliper.
WARNING
Always change both pads and ensure they are
correctly in place inside the calliper.
•
•
•
•
Fit the safety spring (3).
Keeping the centre of the safety spring (3) pressed,
insert the pin (2) so it passes over it.
Fit the stop ring (1).
Check the brake fluid level
5 - 107
CYCLE PARTS 5.9.2.
CHECKING THE REAR BRAKE DISC
NOTE Perform this operation with the brake disc fitted on the
wheel.
•
•
Check disc wear by measuring the minimum thickness
in various points with a micrometer.
If the minimum thickness is lower than the minimum
value, even if only in one point, replace the disc.
Minimum disc thickness value: 4 mm (0.16 in)
•
Using a dial gauge, check that the disc maximum
oscillation does not exceed tolerance; if so, replace it.
Disc oscillation tolerance: 0.3 mm (0.012 in)
5 - 108 TUONO 1000
TUONO 1000
5.9.3.
•
CYCLE PARTS
REMOVING THE REAR BRAKE DISC
Remove the rear wheel.
NOTE To loosen the screws (1) we recommend the use of a
pneumatic screw gun which will resist the strength of the
LOCTITE® 243.
•
Loosen and remove the five brake disc screws (1).
WARNING
When refitting, apply LOCTITE® 243 to the
thread of the brake disc screw.
NOTE When refitting, fit all the screws manually and tighten
them observing a cross pattern in the following order: A-B-CD-E.
•
Remove the brake disc (2).
5 - 109
CYCLE PARTS 5.10. CLUTCH
5.10.1.
BLEEDING THE CLUTCH SYSTEM
NOTE Make sure to have a flexible tube and a container of
adequate size ready at hand before beginning the bleeding
procedure.
•
Connect the tube to the clutch control cylinder bleed
valve.
•
Pull the lever and slightly open the bleed valve on the
slave cylinder to release the air.
Close the bleed valve before reaching the end of stroke
with the lever and repeat the procedure until all the air
is released.
•
5 - 110 TUONO 1000
TUONO 1000
CYCLE PARTS
5.11. CHAIN
5.11.1.
DRIVE CHAIN
The vehicle is equipped with an endless chain that does not
contain a master link.
NOTE Halve maintenance intervals if you are riding in rainy
or dusty conditions, on rough road surfaces or when the
vehicle is used in competitions.
CHECKING PLAY
To check play:
•
Stop the engine.
•
Place the vehicle on the stand.
•
Set the gear in neutral.
•
Ensure that vertical oscillation, in an intermediate point
of the lower length of chain between the front and rear
sprockets, is about 25 mm (0.98 in).
•
Move the vehicle forward to check vertical oscillation of
the chain in other positions; play must remain constant
in all phases of wheel rotation.
ADJUSTMENT
NOTE To adjust the chain use the rear support stand OPT.
If the check determines that chain tension adjustment is
necessary:
•
Place the vehicle on the rear support stand.
•
Loosen the nut completely (1).
NOTE When centring the wheel, there are fixed references
(2-3) located in the chain tightening slider housings on the
swingarm arms, in front of the wheel shaft.
5 - 111
CYCLE PARTS •
•
•
•
•
Loosen the two lock nuts (4).
Adjust chain play by means of the adjusters (5)
ensuring that the references match on both sides of the
vehicle (2-3).
Tighten the two lock nuts (4).
Tighten the nut (1).
Check chain slack.
CHECKING CHAIN, FRONT AND REAR SPROCKET FOR
WEAR
Every 10000 km (6250 mi) check also the following parts
and ensure that the chain, front and rear sprockets show no
signs of:
-
-
-
-
-
-
damaged rollers;
loose pins;
dry, rusty, flattened or seized links;
excessive wear;
missing seals;
excessively worn or damaged front and rear sprocket
teeth.
WARNING
If the chain rollers are damaged, the pins are
loose and/or the seals are damaged or missing,
replace the entire chain assembly (front and
rear sprockets and chain).
Lubricate the chain frequently, especially dry or
rusty parts.
Flattened or seized links must be lubricated and
restored to working condition.
CLEANING AND LUBRICATION
WARNING The drive chain is fitted with seals between the
links to prevent grease from coming out. Take special care when adjusting, lubricating,
washing and replacing the chain.
Never wash the chain with jets of water, jets of steam, jets of
high pressure water and with high-flammability solvents.
•
Wash the chain with naphtha or kerosene. If it tends to
rust rapidly, perform maintenance more frequently.
Lubricate the chain every 1000 km (625 mi) and each time it
is necessary.
•
After having washed the chain, let it dry and lubricate it
with spray grease for sealed chains.
5 - 112
TUONO 1000
TUONO 1000
5.11.2.
•
•
•
CYCLE PARTS
INSPECTING THE DRIVE CHAIN SLIDER
Place the vehicle on the stand.
Ensure that the slider (1) is not worn or damaged;
replace it with a new one if necessary.
Check for chain guide wear (2).
5 - 113
CYCLE PARTS 5.11.3.
REMOVING THE CHAIN SLIDER
•
•
•
•
Place the vehicle on the rear support stand (OPT).
Loosen and remove the three screws.
Remove the sprocket cover.
Slacken chain tension.
•
Loosen and remove the sprocket fixing screw and set
aside the washers.
NOTE When reassembling apply LOCTITE® Anti-Seize to
the inner teeth of the drive sprocket and LOCTITE® 243 to
the screw threading.
•
Loosen and remove the two screws from the rider left
footpeg guard.
•
Loosen and remove the chain slider upper fixing screw
and set aside the washer.
5 - 114 TUONO 1000
TUONO 1000
•
Loosen and remove the chain slider lower fixing screw
and set aside the washer.
•
Slide the lower part of the chain slider out from the
front.
•
Remove the chain slider by sliding it out from the rear.
CYCLE PARTS
5 - 115
CYCLE PARTS 5.11.4.
LOWER CHAIN SLIDER
NOTE When checking for wear the slider must be removed.
•
•
Loosen and remove the two screws.
Remove the lower chain slider.
CHECKING WEAR
Check the wear of the chain slider.
Minimum thickness: 2 mm (0.079 in).
5 - 116 TUONO 1000
COOLING SYSTEM
TUONO 1000
COOLING SYSTEM
6
6-1
COOLING SYSTEM TUONO 1000
SUMMARY 6.1.
COOLING SYSTEM ......................................................................................................................... 3
6.1.1.
DIAGRAM ................................................................................................................................ 3
6.1.2.
FILLING THE COOLING SYSTEM ......................................................................................... 4
6-2
TUONO 1000
6.1.
6.1.1.
COOLING SYSTEM
COOLING SYSTEM
DIAGRAM
Key:
1.
2.
3.
4.
5.
6.
Cooler
Solenoid valves
Expansion tank
Oil filler
Three-way thermostatic valve
Three-way manifold
6-3
COOLING SYSTEM 6.1.2.
•
•
•
FILLING THE COOLING SYSTEM
The cooling system is filled with approximately 2.2
litres (4 pt) of fluid.
Place the vehicle on the rear stand OPT.
Loosen the radiator breather screw.
•
•
Unscrew the oil filler plug.
Pour approximately 2 litres (3.6 pt) of coolant in the
filler.
•
When the coolant starts to come out of the breather
screw on the radiator, tighten the plug to the specified
torque.
To complete the system filling procedure, continue to
pour the fluid until it reaches the upper rim of the oil
filler.
•
•
Unscrew the expansion tank plug and pour the
remaining 0.2 litres (0.36 pt) of fluid until the level is
between the MIN and MAX marks.
6-4
TUONO 1000
TUONO 1000
•
•
•
•
•
•
•
COOLING SYSTEM
Tighten the filler and the expansion tank plugs.
If fluid does not come out of the radiator breather
screw, before filling the system completely
(approximately 2 litres) (approximately 3.63 in) reach
the level in the expansion tank
Start the engine for approximately 30 seconds with the
filler plug open.
Turn off the engine and pour some coolant in the filler.
To complete the system filling procedure, continue to
pour the fluid until it reaches the upper rim of the filler.
Start the engine and bring it to operating temperature
(the electric fans must run at least 2 times), turn it off
and wait for it to cool down (approximately 12 hours).
Check that the coolant level is between the MIN and
MAX marks.
6-5
CYCLE PARTS
TUONO 1000
CYCLE PARTS
7
7-1
CYCLE PARTS TUONO 1000
SUMMARY 7.1.
ELECTRIC SYSTEM.................................................................................................................................... 3
7.1.1.
LOCATION OF THE COMPONENTS.............................................................................................. 3
7.1.2.
ELECTRIC PARTS INSPECTION TABLE ...................................................................................... 5
7.1.3.
CAN LINE ........................................................................................................................................... 14
7.1.4.
IMMOBILIZER ................................................................................................................................... 16
7.1.5.
LAMBDA SENSOR ........................................................................................................................... 18
7.1.6.
RECOVERY FUNCTION ................................................................................................................. 19
7.1.7.
ENGINE RPM LIMITATION CONDITION ..................................................................................... 20
7.1.8.
NEW MAPPING ................................................................................................................................ 21 7.1.9.
WIRING DIAGRAM ........................................................................................................................... 22
7-2
TUONO 1000
7.1.
7.1.1.
CYCLE PARTS
ELECTRIC SYSTEM
LOCATION OF THE COMPONENTS
7-3
CYCLE PARTS Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
RPM sensor
Lambda sensor
Camshaft sensor
Coolant temperature sensor
Intake air temperature sensor
Bank angle sensor
Vehicle speed sensor
Injector
Ignition coils
Throttle position sensor (TPS)
Immobilizer antenna
Starter motor
Stepper motor
Generator
Recharge voltage
Fuel pump
Fuel reserve sensor
Control unit
Headlight
Tail light
Auxiliary fuses
Main fuses
Intake pressure sensor
7-4
TUONO 1000
TUONO 1000
7.1.2.
CYCLE PARTS
ELECTRIC PARTS INSPECTION TABLE
7-5
CYCLE PARTS TUONO 1000
1
RPM SENSOR
induction sensor
It consists of a 36-tooth phonic wheel
The sensor outputs a voltage pulse every 10° of rotation to
allow the control unit to calculate engine rpm and crankshaft
position
Coil resistance 0.7 œ 1.1 KΩ (measured across pins 1a and
1b)
Alternated current at output 1 œ 2 V (measured across pins
1a and 1b)
2
LAMBDA SENSOR
oxygen sensor with heater
sensor tension between 0 and 0.9 V (measured across pins
3 and 4)
heater resistance between 12.8 and 14.2 Ω (measured
across pins 1 and 2 at 20°C œ 68°F)
Power voltage 12 V.
3
CAMSHAFT SENSOR
Hall sensor Fitted in the front cylinder head. The sensor allows the control unit to recognise the precise
sequence of each cylinder by resetting the inner counter
during the ignition asynchronous stage. 12V power across pins 3c and 3a. Square wave output with a pulse every two rpm (measured
across pins 3b and 3a)
4
COOLANT TEMPERATURE SENSOR
NTC sensor (variable resistance, the value decreases as
the temperature increases)
Temperature
°C (°F)
-30 (-22 °F)
-20 (-4 °F)
0 (32 °F)
20 (68 °F)
40 (104 °F)
60 (140 °F)
80 (176 °F)
100 (212 °F)
130 (266 °F)
7-6
Resistance average value
Ω
28000
14500
5500
2500
1200
600
320
180
90
TUONO 1000
CYCLE PARTS
5
INTAKE AIR TEMPERATURE SENSOR
NTC sensor (variable resistance, the value decreases as
the temperature increases) resistance 2.5 KΩ (temperature 20°C œ 68°F) Power supply: 5 V
6
BANK ANGLE SENSOR
resistance of 62 KΩ with sensor in its position of assembly
resistance 0 Ω when sensor is turned by 90° with respect to
position of assembly.
7
VEHICLE SPEED SENSOR
Hall sensor with square wave output at 5 pulses/rev
power voltage: 11-12V (measured across pins 1 and 3)
low signal when sensor is facing screw head (measured
across pins 2 and 3)
8
INJECTOR
resistance between 13.8 and 15.2 Ω
Power supply: 12 V
The push-button signal output by the ECU activates an
electromagnet attracting an armature and causing fuel
injection by opening the injector calibrated nozzles
Assuming that fuel properties as well as the injector 3.5 bar
pressure do not change over time, the amount of injected
fuel depends on the injectors opening time
7-7
CYCLE PARTS 9
IGNITION COILS
rear cylinder primary winding resistance between 0.40 and
1.15 Ω (measured across pins 9c and 9b) front cylinder primary winding resistance between 0.40 and
1.15 Ω (measured across pins 9a and 9b) resistance of secondary winding: between 0.40 and 1.15
Ω (measured across pins 9d and 9e)
10
THROTTLE POSITION SENSOR (TPS)
mechanically coupled to the throttle so that its output
voltage depends on throttle position.
4.5 to 5.5V power measured across pins 10a and 10c Resistance across VC (10a) and E2 (10c) = 2.87 œ 5.33 KΩ Resistance across VTA (10b) and E2 (10c) throttle open =
2.87 œ 8.41 KΩ Resistance across VTA (10b) and E2 (10c) throttle closed =
0.34 œ 5.69 KΩ. 11
IMMOBILIZER ANTENNA
winding resistance: 14 Ω
7-8
TUONO 1000
TUONO 1000
CYCLE PARTS
12
STARTER MOTOR
input at start-up: 120 A
13
STEPPER MOTOR
phase resistance: 50 Ω
The stepper motor is powered by the ECU
Its rotation is divided in —steps“.
By changing the opening steps it is possible to suitably
power the engine to help start-up procedure and correct fuel
feeding with cold engine
When the engine has reached operating temperature, the
stepper motor will be partially closed
14
GENERATOR
three-phase generator
winding resistance: 0.4 Ω
output voltage: 75 VAC (measured with the generator
disconnected from the electric system and the engine at
4000 rpm)
15
RECHARGE VOLTAGE
13.8 V measured at battery terminals (with the engine at
4000 rpm)
7-9
CYCLE PARTS 16
FUEL PUMP
input: 3.9 A
17
FUEL RESERVE SENSOR
There is no fuel level indicator; it is simply a reserve warning
light that comes on when level goes below 3.7 litres: 30
seconds after fuel is no longer reaching the sensor, it starts
conducting (and the light comes on).
7 - 10 TUONO 1000
CYCLE PARTS
TUONO 1000
18
ECU
ECU Pinout
Connector A
Pin Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Type
of
signal
Power output
Rear cylinder coil control
n.a.
Atmospheric pressure sensor power Power supply
supply (5V)
Atmospheric pressure sensor power Power supply
supply (earth)
Rpm sensor signal
Frequency
input
n.a.
Air temperature sensor signal
Analogue input
n.a.
n.a.
Minimum oil pressure sensor signal Digital input
Water temperature sensor signal
Analogue input
Manifold pressure sensor signal
Analogue input
n.a.
Purge valve control
Power output
Front cylinder 2 injector control
Power output
n.a.
n.a.
Atmospheric pressure sensor signal Analogue input
Rpm sensor signal (earth)
Power supply
Timing sensor (earth)
Power supply
Air temperature sensor signal
Power supply
n.a.
n.a.
Throttle Position Sensor signal
Analogue input
Throttle Position Sensor power Power supply
supply (earth)
n.a.
Water temperature sensor signal Power supply
(earth)
Manifolds pressure sensor power Power supply
supply (earth)
n.a.
n.a.
n.a.
n.a.
Rear cylinder 1 injector control
Power output
Timing sensor
Analogue input
Stepper stage D
Power output
Stepper stage A
Power output
Stepper stage C
Power output
Stepper stage B
Power output
Throttle position sensor power Power supply
supply (5V)
Manifolds pressure sensor power Power supply
supply (5V)
Front cylinder coil control
Power output
7 - 11
CYCLE PARTS
TUONO 1000
Connector B
Pin Description
Type of signal
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Power supply
Power supply
Power output
21
22
23
24
ECU power supply (earth)
ECU power supply (earth)
Fan
n.a.
Lambda sensor heater control
Vehicle speed sensor signal
n.a.
n.a.
Bank angle sensor signal
n.a.
ECU power supply (15)
Lambda sensor signal (earth)
ECU power supply (earth)
n.a.
Intake flap control
n.a.
Injection relay control
n.a.
n.a.
Vehicle speed sensor power
supply (earth)
Ignition request
n.a.
Side stand switch
Diagnostics line (K)
25
26
27
Clutch switch
Stop switch
CAN line (L)
28
CAN line (H)
29
30
31
32
33
34
35
36
37
38
39
40
41
Fuel pump control
n.a.
Starter relay control
ECU power supply (earth)
n.a.
n.a.
n.a.
12 V Power supply
Lambda sensor signal
n.a.
n.a.
Neutral switch
ECU power supply (earth)
19
HEADLIGHT
Low beam (halogen)
High beam (halogen)
Front parking light
7 - 12 Power output
Frequency input
Digital input
Power supply
Power supply
Power supply
Power output
Digital output
Power supply
Digital input
Digital input
Communication
line
Digital input
Digital input
Communication
line
Communication
line
Power output
Digital output
Power input
Power supply
Analogue input
Digital input
Power supply
12 V œ 55 W H11 x 2
12 V œ 55 W H11 x 2
12 V œ 5 W
CYCLE PARTS
TUONO 1000
20
TAIL LIGHT
Number plate light
12 V œ 5 W
21
AUXILIARY FUSES
A - From key to: light relay, stop, horn, parking lights (5 A).
B - From key to: turn indicators, instrument panel (5 A).
C - From battery to: key-operated positive to E.C.U. (5 A).
D - From battery to: speed sensor, fuel pump, relay, starter,
oxygen sensor (15 A).
E - From battery to: fan relay, coils, injectors, air flaps,
camshaft position sensor (15 A).
F - From ignition switch to: high beam, low beam (20 A).
NOTE There are three spare fuses (G).
22
MAIN FUSES
H- B
attery charge and vehicle electric loads (red and
red/white wires) + immobilizer (30 A).
I - injection loads (red and red/black wires) (30 A).
NOTE There is one spare fuse.
23
INTAKE PRESSURE SENSOR
Membrane sensor, in which the deformation of a membrane
is transformed in an electric signal. It is located under the air box.
The sensor is connected with the throttle body via two lines. Power supply 5V measured across pins 24a and 24b and
24a and 24c. Output voltage: at 350 mbar = 1.07V, at 950mbar = 3.76V
7 - 13
CYCLE PARTS 7.1.3.
CAN LINE
CAN line technology (Controller Area Network) is used to
connect the different electronic devices of the vehicle, so
they operate like a network of computers (Internet).
The use of a CAN line made it possible to significantly
simplify the layout of the electric system and reduce the bulk
of the wiring harness.
In addition, the CAN line avoids the duplication of sensors
because both processing units installed on the vehicle
(instrument panel and ECU) use the inputs from the same
sensors.
BENEFITS OFFERED BY CAN TECHNOLOGY
•
•
•
•
Less wires: the CAN line uses a pair of wires to
transmit information between the different nodes.
Faults Confination: nodes are capable of isolating
faults and avoid system breakdown.
Noise immunity: this is achieved through differential
signalling. Information is transmitted over the pair of
wires and the receiving device reads the difference
between the signals on the two wires. Any interference
due to external sources will affect both signal equally
and the difference between their voltages remains
constant.
Transfer Rate: messages are transferred at a bit rate of
about 250 kbps (the nodes receive data every 20 ms,
i.e. 50 times per second).
CAN PROTOCOL (CONTROLLER AREA NETWORK)
The CAN line uses the CSMA/CD communications protocol
(Carrier Sense Multiple Access /w Collision Detection)
"Carrier Sense" means that a node will determine whether
the BUS link shared by all connected devices is busy before
using the link to transmit a message. When the BUS link is
idle, multiple nodes are allowed access at the same time
(Multiple Access). When two nodes start transmission at the
same time, a collision occurs. The nodes sense a collision
(Collision Detection) and begin a process of arbitration to
determine which message has higher priority (messages are
unaffected by arbitration and the higher priority message is
given priority so there is no delay).
The CAN protocol is based on messages rather than
addresses. Messages are divided into several portions
(frames), and each frame carries different information:
message priority, data, error detection, acknowledgement of
receipt, etc. All nodes in the network receive all messages
sent over the BUS (with acknowledge or error frames) and
each node determines whether a given message is to be
processed or discarded. In addition, any node can request
information from other nodes (RTR = Remote Transmit
Request).
7 - 14
TUONO 1000
CYCLE PARTS
TUONO 1000
STARTING
The ECU will only enable starting when it recognises V990
engine model based on a CAN acknowledge message from
the instrument panel (model information is located in the
instrument panel).
Only the fuel reserve sensor is connected directly to the
instrument panel. All other sensors/switches are connected
to the ECU and the instrument panel reads relevant
information in the ECU through the CAN line.
OPERATION
LIGHTS:
Warning light
Neutral
Side stand
EFI
Oil pressure
OF
INSTRUMENT
LED
Green,
SMD
Amber,
SMD
Red,
SMD
PANEL
WARNING
Operated by
ECU through CAN line
CAN-BUS LINE SIGNALS:
Transmitted signal
Frequency [Hz]
Engine rpm
Vehicle speed
Diagnostics
Neutral (warning light)
50
Side stand (warning light)
Oil pressure (warning
light)
Water temperature
Sent signal
Frequency [Hz]
Odometer
(stored
in
injection ECU for future
50
implementations)
Model identifier
When data transmission fails (CAN line damaged and/or
disconnected), the Red Line, Warning and Side Stand lights
come on steady, the Neutral light stays off, RPM and speed
read zero, battery voltage indication reads —9.0V“ and
coolant temperature readout shows a flashing —Err“
message.
7 - 15
CYCLE PARTS 7.1.4.
IMMOBILIZER
IMMOBILIZER
The motorcycle is equipped with an immobilizer system that
inhibits engine start-up unless it receives the correct
identification code. This code is stored in a transponder
incorporated in the ignition keys supplied with the
motorcycle. Transponder data is read by an antenna
mounted on the ignition switch and connected directly to the
ECU.
The immobilizer operates independently of the CAN line.
A warning light on the instrument panel indicates the current
mode of operation of the immobilizer:
- immobilizer off - light off
- immobilizer on - light blinks every 3 seconds
approximately to act as a theft deterrent
key not recognised - light blinks every second
A power-save feature turns off the light when it has been
blinking for 240 hours
STORING KEY CODES AT FIRST POWER-UP
At first power-up, the immobilizer control unit is blank and
the LED comes on steady. To store the key codes of the two
keys supplied as standard:
- Insert the first key and turn the ignition switch to ON: the
LED goes out for 0.5 seconds and comes back on
again. When the LED comes on, turn the key to OFF.
- Insert the second key within the next 20 seconds and
turn the key to ON: the LED goes out and then blinks 4
times.
When you turn the key to OFF, the key codes are stored and
the immobilizer is switched on (the LED will blink every 3
seconds as a theft deterrent)
The key codes are now stored in the memory and the
immobilizer is switched on upon key-off (the LED will blink
every 3 seconds as a theft deterrent)
If power supply fails after storing the first key, the system is
reset (and will not retain the first key code). All vehicle and
instrument panel functions are enabled when the first key
code is stored, but the memory will not retain the code
unless the second key is recognised within the next 20
seconds.
7 - 16
TUONO 1000
TUONO 1000
CYCLE PARTS
STORING KEY CODES - NEW KEYS
The immobilizer system can store up to 4 key codes. The
procedure requires a Master Key, and can only be
performed by Authorised Dealers.
Storing a new key code deletes all existing codes; this
means the Owner must bring in all keys (new and old) he
wants enabled. The procedure is as follows:
1) Insert an enabled key and turn the key to ON and back to
OFF
2) Insert the Master Key within 20 seconds to enable the
procedure; this is indicated by the immobilizer light coming
on steady
3) Insert and turn to ON all keys to be enabled. To confirm
each key code has been stored successfully, the immobilizer
LED goes out for 0.5 sec.
4) After storing each key code, the system will wait for the
next key for 20 seconds (immobilizer LED steady on) and
then automatically terminates the procedure (the LED blinks
as many times as are the enabled keys and then goes out).
7 - 17
CYCLE PARTS 7.1.5.
LAMBDA SENSOR
It measures oxygen content in the exhaust gas and provides
indirect information on combustion.
The oxygen sensor signal allows the ECU to continuously
correct the mixture strength in case it is not ideal or
stoichiometric (lambda setting).
To obtain an optimum mixture and a stoichiometric ratio it is
necessary for the quantity of air taken in by the engine to be
equal to the theoretical amount needed to burn all the
injected fuel.
In this case, the lambda factor is 1, i.e. the ratio between air
taken in by the engine and theoretical air necessary to burn
all the injected fuel.
λ = 1 ideal mixture
λ > 1 lean/weak mixture
λ < 1 rich mixture
Oxygen sensor with heater Power supply: 12V. Sensor tension between 0 and 1 V (measured across pins 3
and 4). Heater resistance between 12.5 and 14.2 ohm (measured
across pins 1 and 2 at 20°C œ 68°F)
7 - 18 TUONO 1000
TUONO 1000
7.1.6.
CYCLE PARTS
RECOVERY FUNCTION
In case the signal of the following sensors is interrupted, the control unit either sets a series of values to let the engine
work anyway or uses a different parameter. In any case, the instrument panel highlights that there is a fault.
Air temperature
Water temperature
Barometric pressure
TPS
Intake pressure
Stepper motor
18°C (64.4 °F)
88°C (190.4 °F)
In case the signal is lost the ECU sets the value of 88°C (190.4 °F), with
linear increase by 0.33°C/sec (32.6°F/sec) starting from air temperature
upon start-up.
On the instrument panel 135 (°C) flashes and the WARNING light turns on.
980 hPa
9.8°
Uses the value from the intake pressure sensor.
Values according to engine rpm and TPS are set (front and rear cylinder
intake pressure values are fixed and are not used for engine operation)
21
7 - 19
CYCLE PARTS 7.1.7.
TUONO 1000
ENGINE RPM LIMITATION CONDITION
The control unit limits engine rpm in case one of the following events occurs:
-
-
-
-
-
-
TPS signal missing.
stepper motor signal missing.
low oil pressure.
On the Axone DEVICES STATUS page, the parameter INITIALISED ECU is "NO".
water temperature above 120 °C (248 °F).
if the ECU detects a failure of a set of signals that might compromise safe use of the vehicle. For example: TPS and
intake pressure signals missing at the same time.
7 - 20
CYCLE PARTS
TUONO 1000
7.1.8.
NEW MAPPING
On vehicles manufactured before February 2004 and up to frame no. ZD4RR00004S003947, the ECU needs to be reprogrammed with the revised mapping that ensures improved idle stability and engine performance at 2000 - 3000 rpm. ECUs with the 664582 mapping must be reprogrammed with the 664584 (VD5G684$.BIX) mapping using Axone 5.0.2.
The CO must be balanced after reprogramming the ECU, see 3.1.3 (CYLINDER SYNCHRONISATION AND CO LEVEL
ADJUSTMENT). Vehicles produced after frame no. ZD4RR00004S003947 are equipped with a new ECU and mapping; new mapping
designation is: 664583 (VD5L683$.BI). CO level adjustment and cylinder synchronisation to match the new mapping are
performed at the factory.
Vehicles produced after frame no. ZD4RR00004S003947 feature a modified wiring harness because the pick-up sensor now uses a two-pin connector (instead of the three-pin connector used in the past). The new ECUs can be retrofitted to motorcycles manufactured before frame no. ZD4RR00004S003947. SPARE ECU'S
NOTE Spare ECUs must be programmed before use; look up correct mapping in the following table:
NEW ECU
MAPPING
CODE
NOTE
664584 (VD5G684$.BIX)
664980
blank
x
664581
x
664582
x
664981
blank
664583 (VD5L683$.BIX)
x
NOTE Axone automatically detects the mapping stored in the ECU and will only allow reprogramming if the correct
mapping is selected.
When the —Enter“ key is pressed in the Adjustable Parameters screen to start ECU reprogramming, the system prompts
for the current date (dd/mm/yy); enter the current date:
When the reprogramming procedure is completed, the Axone ISO screen offers the following information for your review:
•
mapping code;
•
uploading date;
•
serial number of Axone unit used for upload procedure;
7 - 21
CYCLE PARTS 7.1.9.
7 - 22 WIRING DIAGRAM
TUONO 1000
CYCLE PARTS
TUONO 1000
Key:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
Multiple connectors
Bank angle sensors
High beam relay
Low beam relay
Horn
Clutch switch
Instrument panel diagnostics
LH dimmer switch
Instrument panel
RH dimmer switch
Ignition switch
Front stop light switch
Rear stop light switch
Rear RH turn indicator
Tail light (LED)
Rear LH turn indicator
Auxiliary fuses
Speed sensor
Flywheel
Voltage regulator
Starter motor
Starter relay
Main fuses
Battery
Injection relay
Oil pressure sensor
Purge valve (California only)
Neutral light switch
Fans
Fan relay
Lambda sensor
œ
Side stand switch
œ
Fuel level sensor
Fuel pump
Air thermistor
Coolant thermistor
Automatic choke
Intake pressure sensor
Ambient pressure sensor
Throttle sensor
Double coil
Front cyl. spark plug
Rear cyl. spark plug
Front cyl. injector
Rear cyl. injector
Camshaft sensor
Pick up
ECU
Front LH turn indicator
LH headlight
RH headlight
LH headlight parking light
LH headlight low beam bulb
LH headlight high beam bulb
RH headlight high beam bulb
RH headlight low beam bulb
RH headlight parking light
Front RH turn indicator
ECU diagnostics
Number plate light
œ
Immobilizer antenna
Twisted wire for pick up
AUXILIARY FUSES:
A 5A
NUMBER PLATE, STOP, HORN, PARKING
LIGHTS
B 5A
INST. PANEL DIAGNOSTICS, INSTRUMENT
PANEL
C 5A
KEY-OPERATED POSITIVE, TO ECU
D 15A SPEED SENSOR, FUEL PUMP, STARTER
RELAY, LAMBDA SENSOR
E 15A FAN RELAY, COILS, INJECTORS, INTAKE
FLAP, CAMS, PURGE VALVE
F 20A LOW/HIGH BEAM LIGHTS
WIRE COLOUR CODING
Ar
Orange
Az
Light blue
B
Blue
Bi
White
G
Yellow
Gr
Grey
M
Brown
N
Black
R
Red
Ro
Pink
V
Green
Vi
Violet
7 - 23
aprilia s.p.a.
via G.Galilei, 1
30033 Noale (VE) Italy
tel. +39 041.5829111
fax +39 041.5829190
www.aprilia.com
www.serviceaprilia.com