APRILIA TUONO 1000 - 2006 Manual
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APRILIA TUONO 1000 - 2006 Manual

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TUONO 1000
8104930

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Summary of Contents for APRILIA TUONO 1000 - 2006

  • Page 1 TUONO 1000 8104930...

  • Page 2: Foreword

    © 2006 aprilia s.p.a. - Noale (VE) FOREWORD INTRODUCTION NOTE This manual is an important and This manual is divided into sections, chapters integral part of your vehicle. Keep it with and paragraphs, by subject. The procedures your vehicle at all times, even if your described are laid out by single operation, and each operation is indicated by a ♦.

  • Page 3: Safety Warnings

    SAFETY WARNINGS GENERAL SAFETY RULES WARNING Gasoline is extremely flammable and The symbols and warnings used throughout CARBON MONOXIDE this manual have the following meanings: becomes explosive under certain When an operation must be performed with conditions. the engine running, position the motorcycle Safety Warning: When you find this outdoors in a well-ventilated area.

  • Page 4: Brake Fluid

    BRAKE FLUID KEEP CLUTCH FLUID AWAY FROM BATTERY HYDROGEN GAS AND CHILDREN. ELECTROLYTE WARNING COOLANT WARNING Brake fluid is extremely poisonous. Never Under certain conditions, the ethylene glycol The battery gives off toxic and explosive swallow brake fluid. Should brake fluid contained in the engine coolant is flammable: gases;...

  • Page 5: Warning - Precautions - General Advice

    NOISE EMISSION WARRANTY acts or causing thereof: National Highway Traffic Safety aprilia s.p.a. warrants that, at the time of Administration (NHTSA) in addition to a) The removal or rendering inoperative by sale, this exhaust system meets all applicable notifying aprilia.

  • Page 6: Problems That May Affect Vehicle Emissions

    CAUTION (V.I.N.) (FRAME NUMBER) VEHICLE IDENTIFICATION This product should be checked for NUMBER Every vehicle produced by aprilia receives repair or replacement if the vehicle a vehicle identification number (V.I.N.) Description of the vehicle identification noise has increased significantly stamped: number (V.I.N.), stamped on the steering...

  • Page 7: Digit Meaning

    MANUFACTURED BY APRILIA GVWR: 401 KG (883 LB) GAWR: F. 152 KG (335 LB) WITH 120/65 ZR 17 (56W) OR 120/70 ZR 17 (58 W) TIRE 17 x 3.50 - DOT-D RIM, AT 250 KPA (36 PSI) COLD GAWR: R. 249 KG (548 LB) WITH 180/55 ZR 17 (73 W) OR 190/50 ZR 17 (73 W) OR 190/55 ZR 17 (75 W) TIRE 17 x 6.00 - DOT-D RIM, AT 280 KPA (41 PSI) COLD...

  • Page 8: Position Of The Adhesive Warning Labels

    POSITION OF THE ADHESIVE WARNING LABELS use and maintenance TUONO 1000...

  • Page 9: Adhesive Warning Labels Chart

    CARBON CANISTER ATMOSPHERE Never install accessories or replacement parts not approved by Aprilia as original equipment. This can degrade the handling and safety of your motorcycle, and can cause an upset with subsequent accident and serious injury or even death.
  • Page 10 If NHTSA receives similar complaints, it may open an investigation, and if it finds that a Do not use any tire other than those reccomended and approved by Aprilia. Maintain safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

  • Page 11: California Evaporative Emission System

    CALIFORNIA EVAPORATIVE EMISSION SYSTEM FOR STATE OF CALIFORNIA ONLY. The system consists of: 1) Coal filter 2) Choke hold 3) Valve 4) Canister support plate 5) M6x20* flanged TE screw 6) 4x8 tube 7) 5.5x10 fuel line 8) D11.3 tie wrap 9) D10.1* tie wrap 10)D8* tie wrap 11)D9.1* tie wrap...

  • Page 12: Warranty Statement

    3 0 , 0 0 0 k i l o m e t e r s ( 1 8 , 6 4 1 m i l e s ) , aprilia will repair your motorcycle at no cost should contact aprilia USA, Inc., 10933 whichever occurs first.

  • Page 13: Aprilia S.p.a. - Limited

    C a l i f o r n i a motorcycle dealer located within the Administrative Code, may be performed aprilia s.p.a., Via G. Galilei, 1, 30033 United States of America in compliance by other than an authorized aprilia Noale (VE) Italy (hereinafter “aprilia”)
  • Page 14 II. LIMITATIONS. This Emission Control III. LIMITED LIABILITY B. NO EXPRESS EMISSION CONTROL System warranty shall not cover any of A. The liability of aprilia under this SYSTEM WARRANTY IS GIVEN BY the following: Emission Control System Warranty is aprilia EXCEPT AS SPECIFICALLY SET FORTH HEREIN.
  • Page 15 However, aprilia is not liable for these parts. The o w n e r i s r e s p o n s i b l e f o r t h e...

  • Page 16: General Instructions

    – COUNTRY CODE = country of approval (I, Holland South Africa UK, A, …). Switzerland New Zealand and must be provided to the Local aprilia Dealer as reference information for the Denmark Canada purchase of spare parts or specific Japan accessorie s of th e mo del you ha ve purchased.

  • Page 17: Table Of Contents

    CHECKING THE SWITCHES....... 92 CALIFORNIA EVAPORATIVE EMISSION BRAKES..............50 INSPECTING THE FRONT SYSTEM..............11 DISC BRAKES............51 AND REAR SUSPENSIONS......... 93 APRILIA S.P.A. - EMISSION CONTROL SYSTEM FRONT BRAKE ............52 FRONT SUSPENSION.......... 93 WARRANTY STATEMENT ........12 REAR BRAKE............53 STEERING DAMPER ..........95 MANUFACTURER’S EMISSIONS SYSTEM CLUTCH..............55...
  • Page 18 CHECKING THE STEERING ........98 INDICATOR BULBS..........131 CHECKING THE SWINGARM PIVOT....98 REPLACING THE LICENSE PLATE LIGHT ASSEMBLING THE PINS FOR THE REAR BULB..............132 SUPPORT STAND ..........99 TRANSPORT ........133 PLACING THE VEHICLE ON THE REAR DRAINING THE FUEL TANK......133 SUPPORT STAND ..........99 CLEANING ...........

  • Page 20: Basic Safety Rules

    BASIC SAFETY RULES The instructions given below cover normal operation of your vehicle and must be carefully observed. By following these rules you will enhance your own safety and the safety of those around you. You will also maximize the life and utility of your vehicle.
  • Page 21 Observe all rules of the road. Particularly Avoid obstacles that could damage the Always ride with both hands on the pay attention to all warning, regulatory and vehicle or make you lose control. handlebars and feet on the footrests. informational signs. Do not tailgate, do not attempt to increase Never shift gear without using the clutch, if Avoid showing off (i.e., popping wheelies).
  • Page 22 Use only the vehicle’s specific fuels and safety by providing for positive closing of lubricants indicated in the “LUBRICANT Your aprilia dealer is ready and able to the throttle. CHART”; check the oil, fuel and coolant help you with any safety problems that you levels regularly.
  • Page 23 This vehicle was not designed to be angle or color of your license plate. Do not original parts, and use only original aprilia equipped with a sidecar or to be used to cover it, even with a clear plastic covering.
  • Page 24 Never race other vehicles with your Always ride at the appropriate speed and Gradually open and close the throttle, to vehicle. avoid unnecessary harsh acceleration. avoid spinning or skidding the rear wheel. This is not only safer, but also reduces fuel Brake with both the front and rear brakes.

  • Page 25: Clothing

    Always observe posted and statutory Inevitably, the driver will look right at you, CLOTHING speed limits, but do not assume that you and yet swear that they did not see you Before riding your vehicle, make sure that can ride as fast as the speed limit under all before they turned directly into your path.

  • Page 26: Accessories

    Remember that loads tend to loosen with doubt with regard to any accessory you riding, so frequently check the security of would like to install or any load you would your load. like to carry, consult your Local aprilia Dealer. use and maintenance TUONO 1000...
  • Page 27 Do not hang anything from your vehicle This makes it more likely that the front Never carry loosely packaged items, make handlebars, fenders, or forks, because this wh e el w il l c o m e u p o f f t h e g r o un d , sure that everything that you carry on your will upset the handling of your vehicle, and especially on acceleration.

  • Page 28: Arrangement Of The Main Elements

    ARRANGEMENT OF THE MAIN ELEMENTS 1) Fairing lug 7) Engine oil reservoir plug 13) Passenger left footrest 19) Engine oil filter 2) Side fairings 8) Left side body panel (snapping, closed/open) 20) Engine oil tank 3) Adjustable steering damper 9) Rider seat 14) Drive chain 21) Engine oil level 4) Left headlight...
  • Page 29 1) Rear shock absorber 7) Auxiliary fuse carrier (15A) 14) Front brake fluid reservoir 21) Rear brake control lever 2) Passenger right footrest 8) Right side body panel 15) Right headlight 22) Rider right footrest (snapping, closed/open) 9) Fuel tank 16) Right side fairings 3) Tail light 10) Coolant expansion tank cap...

  • Page 30: Arrangement Of The Instruments/Controls

    ARRANGEMENT OF THE INSTRUMENTS/CONTROLS 1) Clutch lever 7) Dimmer switch ( 2) Ignition switch/steering lock ( 8) Turn indicator switch ( 3) Instruments and indicators 9) Horn button ( 4) Front brake lever 10) TRIP 1 / TRIP 2 / MODE switch 5) Throttle grip 11) Engine kill switch ( 6) High-beam flasher - passing button (...

  • Page 31: Instruments And Indicators

    INSTRUMENTS AND INDICATORS 1) Revolution counter 6) Blue high-beam warning light ( 2) Green neutral light ( 7) Amber low fuel warning light ( 3) Amber "stand down" light ( 8) Green turn indicator warning light ( 4) Red general warning light ( 9) Red line light 5) Multifunction digital display (coolant temperature - clock - battery voltage - lap timer - engine oil pressure...

  • Page 32: Instrument And Indicator Table

    When the ignition key is turned to " " with the engine stopped, all warning lights come on for an LED checkup and go off after two seconds. If one or more warning lights do not come on at this stage, contact an aprilia dealer. Description Function Indicates the number of revolutions of the engine per minute.
  • Page 33 Now turn the key to “ ” and check the coolant level, see page 60 (COOLANT). ( M U L T I F U N C - aprilia dealer Contact an TION COMPUT- If the maximum allowed temperature is exceeded...

  • Page 34: Multifunction Computer

    ˚F MULTIFUNCTION COMPUTER When you turn the ignition key to " ", the During the initial checkup, all instruments following instrument panel lights will turn will briefly show the current values of the Controls on for 2 seconds: corresponding parameters. 1) Switch with three positions: TRIP1 / –...
  • Page 35 TRIP TRIP METER ˚F BATTERY VOLTAGE TIME TRIP TIME CURRENT SPEED ˚F MAXIMUM SPEED ˚F TRIP ˚F AVERAGE SPEED ˚F TRIP 1 AND 2 Briefly press SET (2) to toggle between Mode these parameters. Press it for several In TRIP 1 and 2 the data concerning trip 1 The MODE configuration features the seconds to reset all data from the selected and 2 is shown.
  • Page 36 SETTINGS TIME SETTINGS MENU When confirming the SETTINGS selection This mode allows you to set the clock. In (by pressing SET (2) for several seconds) this function, hours increase by one unit the following options are displayed: every time SET (2) is pressed; when the EXIT value is 12, it goes back to 1 if SET (2) is –...
  • Page 37 When the battery is connected for the first time, the instrument panel sets to running- in rpm value; the next time the battery is connected it sets to the last set value. RUNNING-IN RPM: 6000 MINIMUM RPM: 5000 MAXIMUM RPM: 12000 When the set threshold is exceeded, the alarm light (4) on the instrument panel flashes until the value goes below the...
  • Page 38 CHANGE THE CODE "INSERT THE NEW CODE" This function is used when the old code is Once the operation is completed, the available and is to be changed. display goes back to the DIAGNOSIS menu. If you entered with the code, this Within this function, the following message operation will not be allowed.
  • Page 39 To enable it, you require a automatically set for time recording. Briefly special password available only to the press SET (2) to start recording with the aprilia Authorized Service Centers . lap timer. Language Press SET (2) again within the first 10...

  • Page 40: Service Interval

    A l a r m s a r e d i v i d e d i n t w o g r o u p s as aprilia Authorized Dealers and depending on their priority:...

  • Page 41: Controls

    CONTROLS CONTROLS ON THE LEFT HAND GRIP 1) HORN BUTTON ( The horn sounds when the button is pressed. 2) TURN INDICATOR SWITCH ( To activate the left turn indicator, move the switch to the left. To activate the right turn indicator, move the switch to the right.

  • Page 42: Controls On The Right Hand Grip

    Contact your Local aprilia event of a stuck throttle or other engine Dealer for repairs. Failure to observe runaway.

  • Page 43: Ignition Switch

    Position Function Key removal The steering It is possible is locked. to remove the It is neither key. possible to start the (LOCK) immobilizer engine, nor to system is Steering lock switch on the activated after lights. the key is removed.

  • Page 44: Unlocking/Locking The Passenger Seat/Seat Cover

    UNLOCKING/LOCKING THE T h e t a i l s e c t i o n o f t h e v e h i c l e To lock the passenger seat/seat cover PASSENGER SEAT/SEAT COVER accommodates a convenient glove / tool kit (2): c o m p a r t m e n t , s i m p l y r e m o v e t h e Position the vehicle on the stand, see...

  • Page 45: Glove/Tool Kit Compartment

    GLOVE/TOOL KIT COMPARTMENT LUGGAGE RACK FASTENINGS Small parcels can be carried only on the r e a c h t h e g l o v e / t o o l k i t passenger seat, using elastic bands. The compartment, proceed as follows: elastic bands are hooked to the two Remove the passenger seat/seat cover,...

  • Page 46: Special Tools

    SPECIAL TOOLS To perform some specific operations, it is advisable to use the following special tools (to be requested to an aprilia dealer): Tool Operations Pins (1) for the rear support stand, see Positioning of the vehicle on the rear stand.

  • Page 47: Main Components

    MAIN COMPONENTS WARNING G a s o l i n e p o i s o n o u s a n d FUEL carcinogenic and contains chemical WARNING substances that cause birth defects and o t h e r r e p r o d u c t i v e p r o b l e m s . I f Gasoline is extremely flammable and in some conditions can become explosive.

  • Page 48: Lubricants

    Lift the little cover (1). When refueling operations are completed: WARNING Insert the key (2) in the cap lock (3). WARNING Turn the key (2) clockwise, pull it and Make sure that the fuel filler cap (4) is open the fuel filler cap (4). properly closed.
  • Page 49 In case of oil leakage do not ride your CAUTION your Local aprilia Dealer. Failure to vehicle. Before using the vehicle, have it observe this warning can lead to engine repaired by your Local aprilia Dealer.

  • Page 50: Brakes

    The front brake system is equipped with indicate any discrepancy, contact your two discs, one on the right and one on the Local aprilia Dealer before riding. Wet conditions seriously degrade the left side of the front wheel. performance of your brakes. When the...

  • Page 51: Disc Brakes

    Have the brake disks checked by an Official aprilia dealer after the first 625 mi (1,000 km) and every 6,250 mi (10,000 km) thereafter. Before each ride, check the brake fluid...

  • Page 52: Front Brake

    WARNING Avoid any prolonged exposure of the brake fluid to air. The brake fluid is hygroscopic and when in contact with air it absorbs its humidity. Leave the brake fluid reservoir open O N L Y f o r t h e t i m e n e c e s s a r y f o r topping up.

  • Page 53: Rear Brake

    CHECKING THE SYSTEM CAUTION is reduced in any way, have your vehicle serviced by your Local aprilia Dealer. It NOTE Carry out these checks only on a When the disc pads wear out, the level...
  • Page 54 WARNING Do not add any additives or other substances to the brake fluid. Top up the reservoir with brake fluid, until the fluid reaches the “MAX” mark. Replace the gasket (4) in its seat correctly. CAUTION Do not tilt the reservoir (1) even if the cap (2) is tightened.

  • Page 55: Clutch

    CHILDREN. brakes is reduced in any way, have your and using the bike with a clutch that is vehicle serviced by your Local aprilia DISPOSE OF USED CLUTCH FLUID anything less than perfect is very likely Dealer.
  • Page 56 Loosen and remove the cap (2). WARNING Remove the gasket (3). Have your Local aprilia Dealer check the clutch conditions every 4,650 mi (7,500 CHECKING THE SYSTEM km). NOTE...
  • Page 57 Local aprilia Dealer. It may be necessary to have your dealer NOTE In order to fill the reservoir to the...

  • Page 58: Adjusting The Clutch Lever

    (4) is set at the desired distance. sure that the eccentric is firmly clamped in the shift lever (10). NOTE If it is necessary to further adjust the shift lever, contact your Official aprilia dealer. use and maintenance TUONO 1000...

  • Page 59: Adjusting The Rear Brake Pedal

    If you wish to adjust the clearance of the ADJUSTING THE REAR BRAKE CAUTION rear brake lever (4): PEDAL If this caution is not observed, the brake Loosen the lock nut (5) on the master The rear brake pedal (1) is adjusted to fit will remain slightly applied, with cylinder push rod (6) and run it as far most riders during manufacture.

  • Page 60: Coolant

    Have the coolant changed by your Official violently. aprilia Dealer. aprilia dealer every 2 years. If it comes in contact with the skin or The coolant is made up of 50% water and with your clothing, it may cause severe WARNING 50% antifreeze.
  • Page 61 CAUTION Have any damage or discrepancy repaired soap. Should you get coolant in your eyes, by your Local aprilia Dealer. Do not If dirt has accumulated on or around the flush with plenty of cool water and attempt to repair the cooling system filler cap, wipe the cap and the area around immediately seek medical attention.

  • Page 62: Tires

    DATA), or that have been specifically to slow you to a stop. Non-compliance km), see page 137 (TECHNICAL DATA). approved by aprilia for this vehicle. with these instructions may cause Pressure measurement must always be accidents which can result in injuries or...

  • Page 63: Automatic Lights On

    AUTOMATIC LIGHTS ON WARNING WARNING Your vehicle is equipped with lights that come New tires are often covered with a Periodically inspect the entire exhaust on automatically as soon as the ignition switch slippery mold release compound. Scrub system, including the exhaust pipe and (2) is turned to “...

  • Page 64: Instructions For Use

    INSTRUCTIONS FOR USE GETTING ON AND OFF THE CAUTION VEHICLE T h e s t a n d h a s b e e n d e s i g n e d t o The instructions below must be followed support the weight of the vehicle and a with the maximum care in order to avoid injury to persons and damage to property...
  • Page 65 GETTING ON THE VEHICLE Push down on the side stand lever with your left heel until the side stand is fully Grasp the handlebar correctly and get down. on the vehicle without loading your NOTE weight onto the side stand. If you cannot touch both feet on NOTE the ground, set your right foot firmly on the...

  • Page 66: Pre-Ride Checks

    6,250 mi (10,000 km) thereafter, the "SERVICE" warning (2) appears on the right display. In this case have a Local aprilia Dealer perform all service operations as indicated in the scheduled maintenance chart, see page 81 (REGULAR SERVICE INTERVALS CHART).

  • Page 67: Pre-Ride Checks Chart

    PRE-RIDE CHECKS CHART Component Check Page Check the operation, the idle stroke of the control levers, the fluid level and make sure there are 50, 51, 52, no leaks. 53, 97 Front and rear disc brakes Check the wear of the pads. If necessary, top up the fluid tank.

  • Page 68: Starting

    WARNING Be careful not to drop the vehicle when you first sit on it. Sit astride the vehicle, see page 64 ( G E T T I N G O N A N D O F F T H E VEHICLE).
  • Page 69 Hold the vehicle in place by applying at least one brake. Pull in the clutch lever (7) completely and put the shift lever (8) in neutral so that the green warning light “ ” (9) is on. The vehicle is equipped with a cold start feature controlled by the ECU which operates automatically when starting the engine from cold.

  • Page 70: Riding

    Contact your Local aprilia Dealer for repairs. Failure to observe this warning can lead to a serious accident and result in injury or even death.
  • Page 71 CAUTION WARNING WARNING If you carry a passenger, instruct him/her When the vehicle is new to you, practice Do not release the clutch too abruptly, or the vehicle will rear in the air (do a not to move around unduly, and to keep looking in the rearview mirrors.
  • Page 72 Dealer. Failure to observe this Pull the clutch lever (3) and lower the a n d c a u s e s r o u g h a n d j u d d e r i n g warning can lead to engine seizure, gear shift lever (4) to shift down.
  • Page 73 ; i m m e d i a t e ly contact your Official aprilia dealer lose control of your vehicle.

  • Page 74: Running-In

    RUNNING-IN WARNING WARNING The internal parts of the engine and Pay very close attention to any obstacles After the vehicle has been operated for transmission must be properly run-in to or variations of the road surface. Uneven 600 mi (1,000 km) perform the “checking ensure their long life and dependable roads, rails, manhole covers, painted operations”...

  • Page 75: Stopping

    STOPPING When the vehicle has come to rest: PARKING It is very important to choose a suitable Position the shift lever (3) in neutral WARNING parking area, respecting the road signs (green warning light “ ” (4) on). If possible, avoid stopping abruptly, and the indications given below.
  • Page 76 To leave the parking lights on: see CAUTION page 131 (PARKING-LIGHT BULB). Do not leave the ignition on if you have WARNING stopped (for emergency) the engine by moving the engine stop switch to the Make sure the vehicle is stable when “...

  • Page 77: Placing The Vehicle On The Stand

    SUGGESTIONS TO PREVENT THEFT CAUTION Do not use any "brake lock" devices. Failure to observe this warning can seriously damage the braking system and lead to an accident and result in serious injuries or death. NEVER leave the key in the ignition switch, ...
  • Page 78 IMMOBILIZER (if fitted) The vehicle is fitted with an immobilizer antitheft system that is automatically activated each time the ignition key is removed from the switch. Store the spare key in a safe place. Immobilizer system keys cannot be duplicated. If both keys are lost, you will h a v e t o h a v e a n u m b e r o f v e h i c l e components replaced (rather than just the key-operated locks).

  • Page 79: Maintenance

    Do not hesitate to contact your Local PRECAUTIONS - GENERAL ADVICE]. hot enough to cause serious burns. aprilia Dealer who has all the latest Avoid the temptation to hold any part of factory information and tools to properly the vehicle in your mouth. The coatings, service your vehicle.
  • Page 80 (1) appears on the right display. a n d m u s t b e m a i n t a i n e d a t t h e In this case have a Local aprilia Dealer prescribed values.

  • Page 81: Regular Service Intervals Chart

    24 months T H E S E O P E R A T I O N S M A Y Spark plug CARRIED OUT BY YOUR Local aprilia Dealer, OR BY THE OWNER OF THE Air filter VEHICLE. Engine oil filter...
  • Page 82 (10,000 km) or 12 (20,000 km) or 24 SHOULD ONLY BE PERFORMED BY (1,000 km)] racing use months months YOUR Local aprilia Dealer. Rear shock absorber every 6,250 mi Gearbox (10,000 km): = check and clean, adjust, lubricate or Transmission cables and controls change, if necessary;...

  • Page 83: Maintenance Record

    MAINTENANCE RECORD Owner Name Owner Address Owner Telephone Number Vehicle Identification Number (V.I.N.) (frame number) see page 86 (IDENTIFICATION DATA) Engine Number see page 86 (IDENTIFICATION DATA) aprilia Local Dealer Name aprilia Local Dealer Address aprilia Local Dealer Telephone Number...
  • Page 84 Odometer Date Maintenance Performed Dealer Stamp reading Follow use and maintenance TUONO 1000...
  • Page 85 Odometer Date Maintenance Performed Dealer Stamp reading use and maintenance TUONO 1000...

  • Page 86: Identification Data

    Local Engine no. _______________________ aprilia Dealer. JOINTS WITH CLICK CLAMPS AND Do not attempt to reinstall the removed WITH SCREW-TYPE CLAMPS click clamp, since it is unusable. Do not...

  • Page 87: Air Cleaner

    AIR CLEANER C a r e f u l l y r e a d p a g e 7 9 (MAINTENANCE). WARNING Do not use gasoline or flammable solvents to wash the air cleaner, in order to avoid fire or explosion. CAUTION Reduce the service intervals by half when the vehicle is used in rainy or...
  • Page 88 CLEANING CHANGING CAUTION CAUTION Take great care not to deform the Never reuse an air cleaner. perforated metal outside screen. It is very fragile and can be easily damaged. Replace the air cleaner (6) with a new Never use a screwdriver or other sharp one of the same type.

  • Page 89: Checking The Engine Oil Level And Topping Up

    CAUTION If the vehicle is used for racing, change the engine oil every 3,125 mi (5,000 km). Change oil more frequently if the vehicle is used in dusty conditions. CHECKING NOTE Place the vehicle on firm and flat ground. CAUTION The engine oil level must be checked when the engine is warm.
  • Page 90 Unscrew and remove the filler cap (3). DANGER DANGER CAUTION BURNS BURNS If you use a container or funnel for topping up, make sure that it is perfectly clean. Any foreign matter getting into the oil tank may lead to severe damage. WARNING Do not add any additives or other substances to the engine oil.

  • Page 91: Checking The Side Stand

    in neutral. Make sure that the stand presents no CHECKING THE SIDE STAND slack in either position (extended or To check the proper functioning of the Carefully read page 79 (MAINTENANCE) stowed). safety switch (3): page 92 (CHECKING Extend the stand, making sure that the SWITCHES).

  • Page 92: Checking The Switches

    If the engine does not stop when the correctly. The vehicle is equipped with four switches: side stand is extended, do not ride your vehicle. Contact your Local aprilia – stoplight switch on the rear brake pedal Dealer. (1); – stoplight switch on the front brake lever (2);...

  • Page 93: Inspecting The Front And Rear Suspensions

    SETTING THE FRONT FORK there must be no trace of oil on the fork The front fork oil change operation should tubes. be entrusted to your Local aprilia CAUTION Check the torque of all the fasteners on the Dealer. front fork and inspect the entire front fork to Do not force the adjusters (1-2) beyond Carefully read page 79 (MAINTENANCE).
  • Page 94 (*) = clockwise turns). (**) = counterclockwise (***) = Have this adjustment carried out exclusively by an Local aprilia Dealer For racing we recommend to fit the Öhlins multi-adjustable front fork unit . For purchase contact an Local aprilia Dealer.

  • Page 95: Steering Damper

    STEERING DAMPER REAR SUSPENSION A D J U S T I N G T H E R E A R S H O C K ABSORBER The standard model is equipped with a The rear suspension consists of a spring- N O T E steering damper.
  • Page 96 Ö h l i n s m u l t i - a d j u s t a b l e r e a r If necessary, contact your Local aprilia suspension unit . For purchase Dealer.

  • Page 97: Checking The Brake Pad Wear

    Local aprilia dusty or wet roads. one on the right and one on the left side of the Dealer.

  • Page 98: Checking The Steering

    The operations necessary for this check are seriously compromised. This could require specific skills and therefore should cause a crash and result in serious be carried out by your Local aprilia Dealer. injury or death. WARNING Have the pads and the discs replaced by your Local aprilia Dealer.

  • Page 99: Assembling The Pins For The Rear Support Stand

    Slacken the knob (5). ASSEMBLING THE PINS FOR THE PLACING THE VEHICLE ON THE Shift the fork-shaped support (4) so REAR SUPPORT STAND REAR SUPPORT STAND that its width matches the distance Place the vehicle on the stand, see Assemble the pins for the rear support between the two pins (1) fitted to the page 77 (PLACING THE VEHICLE ON stand...

  • Page 100: Placing The Vehicle On The Front Support Stand

    Should you accidentally do this, take WARNING WARNING your vehicle to your Local aprilia Have the rim replaced by your Local Dealer who will know how to repair this Make sure that the vehicle is stable.
  • Page 101 NOTE Perform the following operation only if the right spacer ring (6) has come out of its seat on the wheel: CAUTION The right spacer ring (6) has shoulders of two different diameters, pay extra care to fit the ring (6) correctly. Fit the right spacer ring (6) in its seat on the wheel (right side) with the larger diameter facing the outside of the...

  • Page 102: Rear Wheel

    REAR WHEEL serviced by your Local aprilia Dealer. It Wheel nut (2) tightening torque setting: may be necessary to have your dealer WARNING 57.86 ftlb (80 Nm).
  • Page 103 Should you accidentally do this, take your WARNING to keep the wheel in its position after vehicle to your Local aprilia Dealer who Keep your fingers well away from the chain will know how to repair this damage. loosening it.
  • Page 104 CAUTION While reassembling the rear wheel, be careful not to damage the brake line, the disc and the pads. NOTE Perform the follow operation only if the left spacer ring (10) and/or the right spacer ring (11) have come out of their seats on the wheel: Fit the left (10) and right (11) spacer rings in their seats on the wheel with the larger...

  • Page 105: Drive Chain

    Local ( 1 7 ) i n p r o p e r p o s i t i o n u n t i l i t i s aprilia Dealer. It may be necessary to DRIVE CHAIN...
  • Page 106 CHECKING THE PLAY CAUTION To check the play: L a c k o f m a i n t e n a n c e c a n c a u s e Stop the engine. p r e m a t u r e w e a r o f t h e c h a i n a n d Place the vehicle on the stand, see page 77 damage to the sprockets.
  • Page 107 Finally, check the wear of the swingarm ( 1 0 , 0 0 0 k m ) i n s p e c t t h e c h a i n a n d aprilia Dealer. protection shoe (7).

  • Page 108: Removing The Rider Seat

    Always make sure that the fuel filler cap is REMOVING THE RIDER SEAT LIFTING THE FUEL TANK correctly closed. Place the vehicle on the stand, page 77 Carefully read page 47 (FUEL) and page 79 Remove the rider seat, see page 108 (PLACING THE VEHICLE ON THE (MAINTENANCE).

  • Page 109: Removing The Side Fairings

    REMOVING THE SIDE FAIRINGS C a r e f u l l y r e a d p a g e 7 9 (MAINTENANCE). WARNING Wait until the engine and the exhaust silencer have completely cooled down. Position the vehicle on the stand, see page 77 (PLACING THE VEHICLE ON THE STAND).
  • Page 110 Release the quick-coupling to release Loosen and remove the retaining screw Loosen and remove the two retaining the hose (5). (7). screws (9) and the washers. Remove the fairing (6). Remove the fairing (8). Remove the fairing (10). use and maintenance TUONO 1000...
  • Page 111 Loosen and remove the left retaining Loosen and remove the left retaining Loosen and remove the right retaining screw (11) and the washer. screw (12) and the washer. screw (13) and the washer. Remove the fairing (14). use and maintenance TUONO 1000...
  • Page 112 Loosen and remove the two retaining Loosen and remove the two retaining Loosen and remove the retaining screw screws (15) and the washers. screws (17) and the washers. (20). Remove the fairing (16). Loosen and remove the retaining pin Remove the fairing (21). (18).

  • Page 113: Removing The Side Fairings

    NOTE Make sure that the rear fittings are positioned correctly when refitting. Repeat these operations to remove the other side fairing. NOTE The passenger seat lock or passenger seat cover will remain attached to the left side fairing. To separate them, disconnect the Bowden cable from the lock on the inside of the side fairing.

  • Page 114: Removing The Front Brake Calipers

    The front brake system is equipped with accidentally do this, take your vehicle to two separate calipers, one on the left and your Local aprilia Dealer who will know one on the right side of the vehicle. how to repair this damage.

  • Page 115: Removing The Side Stand

    Local fingers. Failure to observe this warning aprilia Dealer. It may be necessary to can cause serious injury. have your dealer bleed the system, or Insert the brake caliper (2) over the...
  • Page 116 Never lean the vehicle against walls or p ag e 1 13 ( R E M O V I N G T HE S I D E Local aprilia Dealer, to the connector (5). lay it on the ground. This could lead to FAIRINGS).
  • Page 117 NOTE Connect the wiring (6) (aprilia part # Torque wrench setting for screws (11) Store away the complete stand, 8127544) [in place of the electric and (13): 40 Nm (4 kgm). the screw (11) and the washer (12) connector (10)].

  • Page 118: Adjusting The Throttle Control

    Have your Local aprilia Dealer check Your vehicle is equipped with a double the throttle cables after the first 600 mi cable throttle. One cable opens the throttle...

  • Page 119: Spark Plugs

    The frequency with which this operation SPARK PLUGS WARNING must be carried out will vary with the use of C a r e f u l l y r e a d p a g e 7 9 E x h a u s t g a s e s c o n t a i n c a r b o n the vehicle.
  • Page 120 NOTE The vehicle is equipped with one 7) side electrode. Inspect the spark plug, and make sure that spark plug for each cylinder. there are neither carbon deposits, nor The following operations refers to the corrosion marks on the electrodes (5) and (7) spark plug installed in one cylinder only, and on the ceramic nose (6);...

  • Page 121: Changing Fuses

    Set the ignition switch to “ ” to avoid Replace the fuel tank, see page 108 the electrical system. If this occurs, take any accidental short circuit. (LIFTING THE FUEL TANK). the vehicle to your Local aprilia Dealer. use and maintenance TUONO 1000...
  • Page 122 Remove the rider seat, see page 108 ARRANGEMENT OF 5A AUXILIARY ARRANGEMENT OF 20A AUXILIARY (REMOVING THE RIDER SEAT) FUSES FUSES Open the cover of the auxiliary fuse box A) From ignition key to: F) From ignition switch to: (1). light relay, brake light, horn, parking high-beam lights, low-beam lights.

  • Page 123: Battery

    Take it to your Local Use of a more powerful charger cannot and keep open flames or sparks away aprilia Dealer for repair and service. only damage the battery irreparably, but from the battery. Keep gasoline and...

  • Page 124: Battery Storage

    Remove the rider seat, see page 108 are inexpensive and available from your (REMOVING THE RIDER SEAT). Local aprilia Dealer, and will make sure Remove the red rubber boot (1). that your battery always remains in tip Make sure that the cable terminals (2) top condition.

  • Page 125: Removing The Battery

    RECHARGING THE BATTERY Carefully read page 123 (BATTERY). WARNING This battery is completely sealed. Do not attempt to remove the caps. There is never any need to add water to this battery. Attempting to remove the caps will destroy the battery and could lead to injury through the spillage of caustic electrolyte.

  • Page 126: Installing The Battery

    Charge at voltage, amperage and time stated below. Recharge Voltage Tension Time type (hours) Normal 8 – 10 Fast Switch on the battery charger. WARNING Wait for 5 or 10 minutes after you have finished charging the battery before Connect the positive (+) cable by reinstalling it, the battery continues to INSTALLING THE BATTERY tightening the terminal screw (4).

  • Page 127: Adjusting The Headlight Beam Vertically

    Adjust the screw (1). Turn the screw clockwise to adjust the right beam higher (upwards). Turn the screw counterclockwise to a d j u s t t h e r i g h t b e a m l o w e r (downwards).

  • Page 128: Adjusting The Headlight Beam Horizontally

    WARNING M a k e s u r e t h a t t h e h o r i z o n t a l adjustment of the headlight beam is correct. Different jurisdictions have different requirements for horizontal headlight aiming.

  • Page 129: Bulbs

    . T h i s c o u l d position and wait a few minutes so that Local aprilia Dealer. This operation is temporarily blind oncoming cars, and the bulb cools down.

  • Page 130: Changing The Headlight Bulbs

    CHANGING To replace: CAUTION THE HEADLIGHT BULBS Place the vehicle on the stand, see page Never pull on the wiring to disconnect a Carefully read page 129 (BULBS). 58 (PLACING THE VEHICLE ON THE bulb connector. STAND). NOTE Before changing a bulb, check Disconnect the connector (4).

  • Page 131: Replacing The Front And Rear Direction

    Grasp the parking-light bulb holder (6) REPLACING THE FRONT AND CAUTION and pull to extract. REAR DIRECTION INDICATOR Never pull on the wiring to disconnect a Remove the bulb and fit a new bulb of BULBS bulb connector. equal rating. Read page 104 (BULBS) carefully.

  • Page 132: Replacing The License Plate Light Bulb

    REPLACING THE LICENSE PLATE LIGHT BULB Read page 129 (BULBS) carefully. Place the vehicle on the stand, see page 77 (PLACING THE VEHICLE ON THE STAND). Remove the passenger seat / glove/tool kit compartment cover, see page 45 (GLOVE/TOOL KIT COMPARTMENT). CAUTION CAUTION When refitting, make sure that the lens...

  • Page 133: Transport

    TRANSPORT SHIFT GEAR SHIFT GEAR IN NEUTRAL IN NEUTRAL POSITION POSITION DRAINING THE FUEL TANK CAUTION WARNING Never drain the fuel tank, either partially Never attempt to tow your vehicle with CAUTION or completely. This may cause damage another vehicle. Never drain the fuel tank, either partially to the inner components of the fuel or completely.

  • Page 134: Cleaning

    CLEANING Polish with silicone wax only after having carefully washed your vehicle. Do not use polishing pastes on matt paints. Do not wash the vehicle in direct sunlight, especially during the summer, when the paintwork is still warm: if the shampoo dries before being rinsed away, it can damage the paint.

  • Page 135: Long Periods Of Inactivity

    To remove dirt and mud from the painted After washing the vehicle, always: LONG PERIODS OF INACTIVITY surfaces, use a low pressure water hose. KEEP POLLUTING SUBSTANCES AND CAUTION Carefully wet the dirty parts and remove C O M P O N E N T S A W A Y F R O M mud and dirt with a soft car sponge.
  • Page 136 , CHECKS CHART). reach room temperature. Failure to available from your aprilia dealer or obs erve this warning can lead to automobile supply stores. Follow the WARNING serious burns.

  • Page 137: Technical Data

    TECHNICAL DATA DIMENSIONS Max. Length ............79.72 in (2025 mm) Max. Width ............32.68 in (830 mm) Max. height (front fairing included)....43.30 in (1100 mm) Seat height ............31.88 in (810 mm) Wheelbase ............55.51 in (1410 mm) Min. ground clearance........5.90 in (150 mm) Weight ready for starting ........
  • Page 138 Ratio Primary Secondary Final ratio Total ratio 31/60 = 1 : 1.935 15/34 = 1 : 2.267 16/40 = 1: 2.500 1:10.986 19/31 = 1 : 1.632 1: 7.895 GEAR RATIOS 20/26 = 1 : 1.300 1: 6.290 22/24 = 1 : 1.091 1: 5.279 25/24 = 1 : 0.960 1: 4.645...
  • Page 139 TIRES Original equipment: PIRELLI DIABLO CORSA; METZELER SPORTEC M1; MICHELIN Type: PILOT SPORT E; DUNLOP SPORTMAX D208RR Front ..............120/70-ZR 17" Inflating pressure..........2.5 atm (250 KPa) Rear ..............190/50 ZR 17” Inflating pressure..........2.8 atm (280 KPa) alternative: PIRELLI SUPERCORSA PRO; METZELER RENNSPORT; Type: MICHELIN PILOT POWER RACING;...
  • Page 140 WARNING LIGHTS Neutral ............... LED Turn indicators ........... LED Fuel reserve ............LED High beam............LED Stand down ............LED Warning light ............LED Red line setting ..........LED Immobilizer............LED use and maintenance TUONO 1000...

  • Page 141: Lubricant Chart

    LUBRICANT CHART (Recommended) Engine oil: EXTRA RAID 4, SAE 15W - 50 TEC 4T SAE 15W - 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) Fork oil: F.A.

  • Page 142: Wiring Diagram Tuono 1000

    WIRING DIAGRAM TUONO 1000 AUXILIARY FUSES -SPEED SENSOR -NUMBER PLATE LIGHT -STOP LIGHT -FUEL PUMP -HORN -STARTER RELAY -REAR PARKING LIGHTS -LAMBDA PAS. -FAN RELAY -COILS -INSTR. PANEL DIAG. -INJECTORS -INSTRUMENT PANEL TRIP 1 -INTAKE FLAP TRIP 2 -KEY POSITIVE MODE -CAMS SCROLL...

  • Page 143: Wiring Diagram Key - Tuono 1000

    WIRING DIAGRAM KEY - TUONO 1000 1) Starter 36) Rear right turn indicator WIRE COLOR CODING 2) Starter relay 37) Tail light (LED) Ar Orange 3) Main fuses 38) - Az Light blue 4) Purge valve (California only) 39) Speed sensor B Blue 5) Fans 40) Voltage regulator...

  • Page 144: Official Dealers And Service Centers

    When you demand aprilia Original Parts, you are purchasing products that have been developed and tested as early as the vehicle design stage. aprilia Original Parts systematically undergo strict quality control procedures to ensure total reliability and long service life.

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