APRILIA TUONO V4 R a-PRC ABS Service Station Manual

page of 527

/ 527
Bookmarks

Quick Links

Download this manual

SERVICE STATION MANUAL

2Q000037

TUONO V4 R a-PRC ABS

Summary of Contents for APRILIA TUONO V4 R a-PRC ABS

Page 1 SERVICE STATION MANUAL 2Q000037 TUONO V4 R a-PRC ABS...
Page 2 THE VALUE OF SERVICE As a result of continuous updates and specific technical training programmes for Aprilia products, only Aprilia Official Network mechanics know this vehicle fully and have the specific tools necessary to carry out maintenance and repair operations correctly.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 TUONO V4 R a-PRC ABS Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 TUONO V4 R a-PRC ABS Characteristics KEEP OUT OF THE REACH OF CHILDREN. NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS STILL HOT. COOLANT IS UNDER PRESSURE AND MAY CAUSE BURNS. Used engine oil and transmission oil CAUTION WHEN CARRYING OUT MAINTENANCE OPERATIONS, IT IS ADVISABLE TO WEAR PROTEC- TIVE IMPERMEABLE GLOVES.
Page 9 TUONO V4 R a-PRC ABS Characteristics • Remove the dirt, mud, dust and foreign objects from the vehicle before disassembling com- ponents. Wherever required, use the special tools designed for this vehicle. DISASSEMBLING COMPONENTS • Do not loosen and/or tighten the screws and nuts using pliers or other tools, but always use the specific wrench.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "RECOMMENDED PRODUCTS" TABLE IN THE SCHEDULED MAIN-...
Page 11 TUONO V4 R a-PRC ABS Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification Frame number The frame number is stamped on the right hand side of the headstock. This number consists of numbers and letters, as in the example shown below.
Page 12 27 / 33 (secondary) Final drive gear ratio 16 / 42 RACTION CONTROL Specification Desc./Quantity a-PRC system (on vehicles with a-PRC) (Aprilia Performance Ride Control), which includes traction control, wheelie control, launch control and clutchless gear shift functions. Capacities APACITY Specification Desc./Quantity Fuel tank (reserve included) 18.5 l (4.07 UKgal;...
Page 13 TUONO V4 R a-PRC ABS Characteristics Specification Desc./Quantity Fuel tank reserve 4 l (0.88 UK gal; 1.06 US gal) Engine oil oil and filter change 4 l (0.88 UK gal) Coolant 2.6 l (0.57 UK gal) Seats Maximum weight capacity...
Page 14 TUONO V4 R a-PRC ABS Characteristics USPENSION Specification Desc./Quantity Front fork Sachs upside-down stems One by One, adjustable hydraulic operation, stems diam 43 mm (1.69 in). Front wheel travel 120 mm (4.72 in) Rear shock absorber With progressive linkage with APS system. Sachs piggy-back shock absorber adjustable with spring preloading, hydraulic brake compression and rebound damping.
Page 15 TUONO V4 R a-PRC ABS Characteristics Specification Desc./Quantity 190/50 ZR17 (73W) (*) With these dimensions use only Pirelli Diablo Super- corsa SP tyres. Inflation pressure 1 passenger: 2.5 bar (250 KPa) (36.26 PSI) 2 passengers: 2.8 bar (280 KPa) (40.61 PSI)
Page 16 TUONO V4 R a-PRC ABS Characteristics RONT FORK ACHS pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cap 20 Nm (14.75 lb ft)
Page 17 TUONO V4 R a-PRC ABS Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening the raiser to the 50 Nm (36.87 lb ft) steering upper yoke Screws fastening upper U-bolt to 25 Nm (18.43 lb ft) handlebar Upper plate stem fastening screws 25 Nm (18.44 lb ft)
Page 18 TUONO V4 R a-PRC ABS Characteristics RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lb ft)
Page 19 TUONO V4 R a-PRC ABS Characteristics pos. Description Type Quantity Torque Notes Screw fastening brake fluid reservoir 7 Nm (5.16 lb ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.90 lb ft) to the lower yoke Front brake pump U bolt clamp 10 Nm (7.37 lbf ft)
Page 20 TUONO V4 R a-PRC ABS Characteristics RONT HEADLAMP pos. Description Type Quantity Torque Notes Screws fastening the headlamp to 3 Nm (1.47 lb ft) the upper fairing fastener Screws fastening headlamp to front 4 Nm (2.95 lb ft) fairing CHAR - 20...
Page 21 TUONO V4 R a-PRC ABS Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 22 TUONO V4 R a-PRC ABS Characteristics INDSHIELD pos. Description Type Quantity Torque Notes Top fairing fixing screw 3 Nm (2.21 lbf ft) Front turn indicator fixing screw 2.5 Nm (1.84 lb ft) LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lb ft)
Page 23 TUONO V4 R a-PRC ABS Characteristics OOLING pos. Description Type Quantity Torque Notes Screws fastening water radiator 10 Nm (7.37 lbf ft) mounting bracket to chassis Screws fastening water radiator to 7 Nm (5.16 lbf ft) mounting bracket Screws for fastening the water by- 6 Nm (4.43 lb ft)
Page 24 TUONO V4 R a-PRC ABS Characteristics Central part IDE STAND pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lb ft) Loct. 243 frame Linear switch retainer 4 Nm (2.95 lb ft) Rear stand bushing retaining screw 7 Nm (5.16 lb ft)
Page 25 TUONO V4 R a-PRC ABS Characteristics ADDLE pos. Description Type Quantity Torque Notes Rider saddle fixing screw 6 Nm (4.43 lb ft) UEL TANK pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft)
Page 26 TUONO V4 R a-PRC ABS Characteristics OOTRESTS pos. Description Type Quantity Torques Notes Screws used to fasten the rider's 25 Nm (18.44 lb ft) Secure using Loc- footrest to the chassis tite 243 Screws used to fasten the passeng- 18 Nm (13.28 lb ft)
Page 27 TUONO V4 R a-PRC ABS Characteristics RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts...
Page 28 TUONO V4 R a-PRC ABS Characteristics LOCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lb ft) Lock lever self-tapping screw 2 Nm (1.48 lb ft) CHAR - 28...
Page 29 TUONO V4 R a-PRC ABS Characteristics RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.90 lb ft) Horn fixing screw 15 Nm (11.06 lb ft) Screw fastening the voltage regula- 6 Nm (4.43 lb ft)
Page 30 TUONO V4 R a-PRC ABS Characteristics NGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.90 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk flat head hex socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 31 TUONO V4 R a-PRC ABS Characteristics AIRING pos. Description Type Quantity Torque Notes Screws fastening the lower fairing to 3 Nm (2.21 lb ft) the lower bracket Screws fixing the side fairings to the 1.5 Nm (1.10 lbf ft) side spacers...
Page 32 TUONO V4 R a-PRC ABS Characteristics CONTROL UNIT Pos. Description Type Quantity Torque Notes Oil tube screws M10x1 23-26 Nm (16.96-19.18 lb ft) Control unit support screws 6.8+/-1 Nm (5.01 +/-0.74 lb ft) Back side XHAUST pos. Description Type Quantity...
Page 33 TUONO V4 R a-PRC ABS Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lb ft) Screws fastening sprocket on 50 Nm (36.88 lb ft) sprocket mount CHAR - 33...
Page 34 TUONO V4 R a-PRC ABS Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lb ft) Rear brake pump fixing screws 8 Nm (5.90 lb ft) Rear brake lever fixing screw 25 Nm (18.44 lb ft)
Page 35 TUONO V4 R a-PRC ABS Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lb ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lb ft) Fork pin nut M20x1.5 65 Nm (47.94 lb ft)
Page 36 TUONO V4 R a-PRC ABS Characteristics EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lb ft) Dual connecting rod fixing screw 50 Nm (36.88 lb ft) Screw fastening single connecting 50 Nm (36.88 lb ft)
Page 37 TUONO V4 R a-PRC ABS Characteristics AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lb ft) Taillight mounting bracket fixing 4 Nm (2.95 lb ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9...
Page 38 TUONO V4 R a-PRC ABS Characteristics pos. Description Type Quantity Torque Notes Screws used to fasten the small side 2 Nm (1.48 lb ft) fairings to the tank Screws used to fasten the small side 1 Nm (0.74 lb ft)
Page 39 TUONO V4 R a-PRC ABS Characteristics ELMET COMPARTMENT Pos. Description Type Quantity Torque Notes Screws and self-locking nuts used to 4 Nm (2.95 lb ft) fasten the number plate holder to the saddle support plate Lower saddle support closure fasten- 3 Nm (2.21 lb ft)
Page 40 TUONO V4 R a-PRC ABS Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.90 lb ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) Flanged TE screws M6x35 12 Nm (8.85 lbf ft)
Page 41 TUONO V4 R a-PRC ABS Characteristics ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.38 lb ft) Coil fastening screws 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft)
Page 42 TUONO V4 R a-PRC ABS Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft)
Page 43 TUONO V4 R a-PRC ABS Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Shoe fastening screws 20 Nm (14.75 lb ft) Loct. 243...
Page 44 TUONO V4 R a-PRC ABS Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lb ft)
Page 45 TUONO V4 R a-PRC ABS Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft)
Page 46 TUONO V4 R a-PRC ABS Characteristics pos. Description Type Quantity Torque Notes Star fastening screw M6x20 10 Nm (7.38 lb ft) Loct. 243 Bearing retaining plate fastening M6x16 10 Nm (7.38 lb ft) Loct. 243 screw Flange fastening screws M8x25 25 Nm (18.44 lb ft)
Page 47 TUONO V4 R a-PRC ABS Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch nut 150 Nm (110.63 lb ft) Loct. 243 Clutch spring fastener screw 10 - 12 Nm (7.38 - 8.85 lb ft) CHAR - 47...
Page 48 TUONO V4 R a-PRC ABS Characteristics IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lb ft) Loct. 243 LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft)
Page 49 TUONO V4 R a-PRC ABS Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft)
Page 50 TUONO V4 R a-PRC ABS Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Secondary air solenoid screws 10 Nm (7.38 lb ft) ATER PUMP pos. Description Type Quantity Torque Notes Screws used to fasten the pump to M6x25 10 Nm (7.38 lb ft)
Page 51 TUONO V4 R a-PRC ABS Characteristics pos. Description Type Quantity Torque Notes Tank to pump fixing nut Flanged M6 12 Nm (8.85 lb ft) CHAR - 51...
Page 52 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 53 TUONO V4 R a-PRC ABS Special tools PECIFIC TOOLS Stores code Description 020845Y Engine support 020846Y Containment tray + plastic plugs 020847Y Flywheel extractor (Mitsubishi) 020913Y Flywheel extractor (Kokusan) 020914Y Flywheel stop 020849Y Clutch lock S-TOOLS - 53...
Page 54 TUONO V4 R a-PRC ABS Special tools Stores code Description 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020855Y Lever for engaging the chain tensioner 020856Y...
Page 55 TUONO V4 R a-PRC ABS Special tools Stores code Description 020857Y Crankshaft support U-bolt 020858Y Maintenance of the pistons in the cylin- ders AP8140199 Tool storage panel 020859Y Graphics for panels 8140426 Hooks for panel 020860Y Motor support extension 020861Y...
Page 56 TUONO V4 R a-PRC ABS Special tools Stores code Description 020862Y Punch assembly cage with rollers gear- box control rod....020863Y Punch assembly cage with rollers des- modromic drum..020864Y Engine mounting plate 020956Y Support for camshaft gear on head...
Page 57 TUONO V4 R a-PRC ABS Special tools Stores code Description 020376Y Sleeve for adaptors 020363Y 20mm oil seal guide 020364Y 25-mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor S-TOOLS - 57...
Page 58 TUONO V4 R a-PRC ABS Special tools Stores code Description AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft 020877Y Calliper for clamps 020926Y Tool for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm (1.69 in)
Page 59 TUONO V4 R a-PRC ABS Special tools Stores code Description AP8140190 Tool for steering tightening 020888Y Pre-load pipe clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure...
Page 60 INDEX OF TOPICS MAIN AINTENANCE...
Page 61 Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum function and performance. For this purpose, Aprilia has formulated a series of checks and scheduled services (at the owner's expense), are summarised in the table given in the following page. It is generally advisable to have any minor malfunctions rectified immediately by an Authorised aprilia Dealer without waiting until the next service.
Page 62 TUONO V4 R a-PRC ABS Maintenance km x 1000 Air filter (6) Engine oil filter (6) Fork General vehicle operation (6) Valve clearance (7) Cooling system (6) Brake systems (6) Light circuit Stand switch Safety switches Stop switches Brake fluid (4)
Page 63 TUONO V4 R a-PRC ABS Maintenance • Undo and remove the screw. • Slide off the front coil. • Unscrew and remove the front spark plug. REAR SPARK PLUGS • Remove the fuel tank. • Unscrew and remove the rear coil fastener screw.
Page 64 TUONO V4 R a-PRC ABS Maintenance • Shut off the engine and wait for a few seconds. • Keep the vehicle upright with both wheels on the ground. • Ensure that the vehicle is on a level surface. • Check via the inspection glass in the crankcase, that the oil level is near the upper marking.
Page 65 TUONO V4 R a-PRC ABS Maintenance • Add 4,1 l (0.90 UK gal) of new engine oil of the specified type. • Screw on the filler cap. • Warm up the engine up by running it for a few minutes, then switch it off. After thirty seconds, check the level in the sight glass.
Page 66 TUONO V4 R a-PRC ABS Maintenance • Disconnect the upper injector fuel de- livery union. See also Fuel tank • Disconnect the variable geometry in- take system connector. • Fit a suitably sized shim behind the fil- ter box cover.
Page 67 TUONO V4 R a-PRC ABS Maintenance • Remove the air filter. Checking the valve clearance FRONT HEAD • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 68 TUONO V4 R a-PRC ABS Maintenance REAR CYLINDER HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover. See also Removing the throttle body Spark plug Head cover removal • Use a feeler gauge to check the clear-...
Page 69 TUONO V4 R a-PRC ABS Maintenance Front cylinder head valves • Check the play on the front head valves and, if it is necessary to restore the correct play values, proceed as follows. • Remove both head covers, the alter-...
Page 70 TUONO V4 R a-PRC ABS Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 71 TUONO V4 R a-PRC ABS Maintenance ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1).
Page 72 TUONO V4 R a-PRC ABS Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 73 TUONO V4 R a-PRC ABS Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally.
Page 74 TUONO V4 R a-PRC ABS Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 75 TUONO V4 R a-PRC ABS Maintenance 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; insert the reference pin while checking with the crankshaft reference pin, that the flywheel side hole and the hole on the crankshaft are perfectly aligned.
Page 76 TUONO V4 R a-PRC ABS Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 77 TUONO V4 R a-PRC ABS Maintenance setting was not altered while the en- gine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1).
Page 78 TUONO V4 R a-PRC ABS Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the intake camshaft gear tooth (indicated with one dot) is meshed with the trough of the exhaust camshaft gear (indicated with two dots).
Page 79 TUONO V4 R a-PRC ABS Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally.
Page 80 TUONO V4 R a-PRC ABS Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 81 TUONO V4 R a-PRC ABS Maintenance 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; Refit the reference pin while checking, using the crankshaft reference pin, that the clutch side hole and the hole in the crankshaft are perfectly aligned.
Page 82 TUONO V4 R a-PRC ABS Maintenance 1.97 mm (0.0775 in) 2 mm (0.0787 in) 2.02 mm (0.0795 in) 2.05 mm (0.0807 in) 2.07 mm (0.0815 in) 2.1 mm (0.0827 in) 2.12 mm (0.0835 in) 2.15 mm (0.0846 in) 2.17 mm (0.0854 in) 2.2 mm (0.0866 in)
Page 83 TUONO V4 R a-PRC ABS Maintenance 2.92 mm (0.1150 in) 2.95 mm (0.1161 in) 2.97 mm (0.1169 in) 3 mm (0.1181 in) 3.02 mm (0.1189 in) 3.05 mm (0.1201 in) 3.07 mm (0.1209 in) 3.10 mm (0.1220 in) 3.12 mm (0.1228 in) 3.15 mm (0.1240 in)
Page 84 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 85 TUONO V4 R a-PRC ABS Troubleshooting TROUBLESHOOTING PROCEDURE IN THE EVENT THAT THE EFI INDICATOR LIGHT SHOULD APPEAR ON THE INSTRUMENT PANEL OR IN THE CASE OF ABNORMAL ENGINE BEHAVIOUR CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 86 TUONO V4 R a-PRC ABS Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 87 TUONO V4 R a-PRC ABS Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION THE DIAGNOSIS INSTRUMENT MUST FUNCTION CORRECTLY AND MUST BE UPDATED. CAUTION BEFORE STARTING THE TROUBLESHOOTING PROCEDURE, MAKE SURE THAT: 1) THE BATTERY VOLTAGE IS GREATER THAN 12V;...
Page 88 TUONO V4 R a-PRC ABS Troubleshooting • 8. WHEN THE PUSH-BUTTON IS IN THE "RUN" POSITION, WHAT DOES THE "RUN- STOP SWITCH" STATE ICON ON THE DIAGNOSTIC TOOL DEVICE STATES PAGE INDICATE, ICON 0/1? If it indicates the "RUN" state, go to point 9, if it indicates "STOP", go to point 15 •...
Page 89 TUONO V4 R a-PRC ABS Troubleshooting TROL UNIT INDICATES ERRORS RELATED TO THE FRONT AND REAR THROTTLE BODY) YES, go to 3; NO, go to 6 • 3. CHECK CONTINUITY WITH GROUND CONNECTION AT PIN 5 and 16 If there is continuity, go to 4; if there is not continuity, restore ground connection on the engine front part or restore cable harness •...
Page 90 TUONO V4 R a-PRC ABS Troubleshooting • 2. CHECK THE CONTROL UNIT CONNECTOR AS WELL AS THE DIAGNOSIS BLACK CONNECTOR YES, go to 3; NO, restore faulty connector - END • 3. CHECK CORRECT OPERATION OF THE DIAGNOSIS INSTRUMENT CONNECTION CABLE AND THE CORRECT INSTALLATION OF THE PLIERS ON THE BATTERY - END •...
Page 91 TUONO V4 R a-PRC ABS Troubleshooting PROTECTION RELAY 16 CHECK • 1. WITH KEY SET TO OFF, DISCONNECT THE RELAY CONNECTOR AND CHECK CONTINUITY OF BLUE CABLE WITH GROUND If there is continuity, go to 2; if there is not continuity, restore cable harness - END •...
Page 92 TUONO V4 R a-PRC ABS Troubleshooting • 4. REPLACE THE CONTROL UNIT - END • 5. CHECK CONTINUITY OF PINK CABLE BETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT, CHECKING ALSO THE ENGINE - VEHICLE CABLE HAR- NESS CONNECTOR YES, go to 4;...
Page 93 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 94 TUONO V4 R a-PRC ABS Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.90 lb ft) Horn fixing screw 15 Nm (11.06 lb ft) Screw fastening the voltage regula- 6 Nm (4.43 lb ft)
Page 95 TUONO V4 R a-PRC ABS Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lb ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lb ft)
Page 96 TUONO V4 R a-PRC ABS Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Upper injectors 9. Air temperature sensor 10.Lower injectors 11.Air pressure sensor...
Page 97 TUONO V4 R a-PRC ABS Electrical system ELAY LAYOUT Component position Component name Location on the vehicle in the electrical circuit diagram Light logic relay Left side of the front support High beam light relay Internal side, left side of the headlamp...
Page 98 TUONO V4 R a-PRC ABS Electrical system • 2 Fans • 1 Right handlebar control • 1 Left handlebar control • 1 TC control • 1 Regulator • 1 Demand sensor • 1 Battery • 1 Tone wheel reading control unit (CLF) •...
Page 99 TUONO V4 R a-PRC ABS Electrical system • 2 Spacers (there are various types of spacers) • 1 Exhaust valve opening cable • 1 Exhaust valve closing cable • 1 Instrument panel mounting cover • 1 Heat-protecting cover • 2 Adhesive sponge •...
Page 100 TUONO V4 R a-PRC ABS Electrical system • 1 Flanged M6x16 screw • 1 Secondary air solenoid mounting • 1 Secondary air pipe • 1 Secondary air pipe • 1 Secondary air pipe • 4 Rubber manifolds • 4 Clip-on clamps...
Page 101 TUONO V4 R a-PRC ABS Electrical system • Right handlebar control connector • Left handlebar control connector • Clutch connector • Relay connectors • Ignition switch connector • Immobilizer aerial connector • Oxygen sensor connector • ECU connectors (7sm) •...
Page 102 TUONO V4 R a-PRC ABS Electrical system TABLE B - REGULATOR PRE-FITTING 1. Regulator 2. Instrument panel support 3. Regulator connector 4. Flywheel connector TABLE B1 - REGULATOR PRE-ASSEMBLY PROCEDURE • Pre-assemble two clamps for securing the wiring harness. TABLE C - HEADLAMP PRE-FITTING •...
Page 103 TUONO V4 R a-PRC ABS Electrical system TABLE C1 - HEADLAMP PRE-FITTING • Check if the connectors tongues are well attached TABLE C2 - HEADLAMP PRE-FITTING • Clamps position inserting them in the connectors tongue, after connecting to the headlamp TABLE C3 - HEADLAMP PRE-FITTING •...
Page 104 TUONO V4 R a-PRC ABS Electrical system TABLE C4 - HEADLAMP PRE-FITTING • Place the cable guides TABLE C5 - HEADLAMP PRE-FITTING • Put the clamps on the cables of the front turn indicators TABLE D - FRONT SPEED SENSOR 1.
Page 105 TUONO V4 R a-PRC ABS Electrical system TABLE D1 - FRONT SPEED SENSOR 1. Cable grommet 2. Rubber clamp 3. Clamp TABLE E 1. Speed sensor cable harness routing inside the cable grommet and between throttle cables and frame •...
Page 106 TUONO V4 R a-PRC ABS Electrical system TABLE F1 - INSTRUMENT HOLDER SUPPORT • Place the branch (1) in the correspond- ing tongues as shown in the figure • Fit the front ABS sensor (2) as shown in the figure •...
Page 107 TUONO V4 R a-PRC ABS Electrical system TABLE F3 - INSTRUMENT HOLDER SUPPORT • Group the several branches locking them by means of the slotted mounting 1. Key branch 2. Instrument panel branch 3. Immobilizer antenna branch 4. Slotted mounting TABLE F4 - INSTRUMENT HOLDER SUPPORT 1.
Page 108 TUONO V4 R a-PRC ABS Electrical system TABLE F5 - INSTRUMENT HOLDER SUPPORT 1. Lights relay 2. Front headlight connector • Insert the front headlamp connector in its housing paying attention that it is correctly placed. TABLE G - CLF CONTROL UNIT PRE-ASSEM- BLY PROCEDURE 1.
Page 109 TUONO V4 R a-PRC ABS Electrical system WIRING TABLE H 1. Instrument panel 2. Washer 3 Rubber block 4. Screw TABLE I 1. Clutch wiring harness route 2. Aerial wiring harness route 3. Ignition switch wiring harness route 4. Main wiring harness route 5.
Page 110 TUONO V4 R a-PRC ABS Electrical system TABLE A1 - VEHICLE CABLE HARNESS 1. Fall sensor connector (optional equipment) 2. Safety relay connector 3. Fans relay connector 4. T-shaped bushing 5. Support fastener screw 6. Cable grommet 7. Main cable harness TABLE B - RADIATOR AREA 1.
Page 111 TUONO V4 R a-PRC ABS Electrical system TABLE B1 - RADIATOR AREA 1. Ground cable harness routing that must pass behind water pipe and behind the starter motor. 2. Starter motor cable harness routing that must pass behind water pipe.
Page 112 TUONO V4 R a-PRC ABS Electrical system TABLE C1 - DEMAND SENSOR • Check that the connectors are inserted correctly and that the security locks are in the locked position. 1. Slave Demand cable harness routing (creating a "U-bend" in the cable harness) 2.
Page 113 TUONO V4 R a-PRC ABS Electrical system TABLE C2 - DEMAND SENSOR 1. Demand sensor TABLE D • Support the left fairing on the lower mounting, insert the connector in the CLF control unit and close the fairing in the upper part 1.
Page 114 TUONO V4 R a-PRC ABS Electrical system TABLE E1 - FANS 1. Fans TABLE F 1. Right branch 2. Left branch 3. Radiator support 4. Traction control TABLE G - EXHAUST VALVE ACTUATOR 1. Exhaust valve actuator cable harness routing...
Page 115 TUONO V4 R a-PRC ABS Electrical system TABLE G1 - EXHAUST VALVE ACTUATOR 1 Exhaust valve actuator 2 Heat-protecting cover 3. Screws 4. T-shaped bushings 5. Rubber blocks 6. Spacer TABLE G2 - EXHAUST VALVE ACTUATOR 1. Closing cable 2. Opening cable •...
Page 116 TUONO V4 R a-PRC ABS Electrical system TABLE H - PINION CASING AREA 1. Quick Shift cable harness routing 2. Gear sensor cable harness routing 3. Oxygen sensor 4. Oxygen sensor cable harness routing 5. Stand switch cable harness routing 6 Stand switch 7.
Page 117 TUONO V4 R a-PRC ABS Electrical system TABLE M - QUICK SHIFT 1. Quick Shift cable harness routing TABLE N - QUICK SHIFT 1. Gear sensor cable harness routing 2. Quick Shift cable harness routing 3. Stand switch cable harness routing 4.
Page 118 TUONO V4 R a-PRC ABS Electrical system TABLE P - ECU 1. ECU connectors TABLE Q - GROUND LEADS 1. ENGINE GND eyelet from the vehicle cable har- ness 2. Engine - battery ground cable ENGINE GND eyelet 3. ENGINE GND eyelet from the engine cable har- ness 4.
Page 119 TUONO V4 R a-PRC ABS Electrical system 1. Clamp 2. Battery - engine ground cable 3. Engine - battery ground cable harness routing • The engine - battery ground cable harness must not be visible within the area indicated with...
Page 120 TUONO V4 R a-PRC ABS Electrical system TABLE C - SWINGARM AREA 1. Rubber clamp 2. Speed sensor cable harness 3. Rear brake switch cable harness TABLE C1 - SWINGARM AREA 1. Speed sensor cable harness 2. Rear brake switch cable harness 3.
Page 121 TUONO V4 R a-PRC ABS Electrical system TABLE D - REAR SADDLE MOUNTING AREA 1. Battery mounting bracket 2. Vehicle cable harness 3. Fit the (individual) fan fuse on battery mounting bracket tongue TABLE D1 - REAR SADDLE MOUNTING AREA 1.
Page 122 TUONO V4 R a-PRC ABS Electrical system TABLE D4 - REAR SADDLE MOUNTING AREA 1. Relay with relay socket rubber mounting 2. Protection relay with relay socket rubber mount- 3. Battery mounting bracket 4. Battery TABLE D4 - REAR SADDLE MOUNTING AREA 1.
Page 123 TUONO V4 R a-PRC ABS Electrical system TABLE D6 - REAR SADDLE MOUNTING AREA 1. License plate frame cable harness connector 2. Rear headlight connector 3. ECU diagnosis connector 4. Instrument panel diagnosis connector 5. License plate frame and taillight cable harness routing 6.
Page 124 TUONO V4 R a-PRC ABS Electrical system • External part: 1. Insert the screw clamp on the cable harness in the hole on the right side of the saddle mounting 2. Fuel pump connector 3. Clamps • Internal part: 4. Rear speed sensor connector 5.
Page 125 TUONO V4 R a-PRC ABS Electrical system TABLE E2 - ABS 1. Main cable harness 2. CHASSIS • Place the cable harness as indicated and by using the appropriate screws and clips fix it to the frame on the points marked by the arrows.
Page 126 TUONO V4 R a-PRC ABS Electrical system TABLE E5 - ABS 1. Main fuses 2. ABS Fuse 3. Battery cable harness 4. Connector ... • Pay close attention to the correct fitting of the cable harness "Battery positive - ABS fuses"...
Page 127 TUONO V4 R a-PRC ABS Electrical system TABLE C - FILTER BOX COVER AND LOWER FILTER BOX PREPARATION 1. Mounting for the vehicle connector 2. Supports for coils connector ELE SYS - 127...
Page 128 TUONO V4 R a-PRC ABS Electrical system TABLE D - CONTROL UNIT MOUNTING PREP- ARATION 1. Control unit 2. Fit the 3 silent blocks onto the seats on the mounting; Then, it is possible to fit the control unit by using the specific couples...
Page 129 TUONO V4 R a-PRC ABS Electrical system TABLE E1 - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING 1. Check that the connectors are inserted correctly and that the security locks are in the locked posi- tion...
Page 130 TUONO V4 R a-PRC ABS Electrical system TABLE F - FITTING THE MOTORISED THROT- TLE BODIES • First fasten the "Motorised Throttle Body2 (front)" to the rubber manifolds with the specific clip-on clamps. Then fit the "Motorised Throttle Body 1 (rear)"...
Page 131 TUONO V4 R a-PRC ABS Electrical system 1. Engine speed sensor cable routing between the front motorised throttle body and the 3-way fitting. 2. Water temperature sensor 3. Cable harness routing (branch "4") under the 3- way fitting 4. Rubber clamp.
Page 132 TUONO V4 R a-PRC ABS Electrical system routing it as shown in the following fig- ure. 1. Coil 3 cable routing 2. Injector 1 cable harness connector (output "16") BLACK CONNECTOR 3. Injector 3 cable harness connector (output "17") GREEN connector 4.
Page 133 TUONO V4 R a-PRC ABS Electrical system TABLE H2 - COIL AND MAP SENSOR CON- NECTION 1. Coil 2 connector 2. Coil 2 cable harness connector (output "7") 3. Map Sensor 2 4. Map sensor 2 cable harness connector (output "11")
Page 134 TUONO V4 R a-PRC ABS Electrical system TABLE I1 - GEAR SENSOR CONNECTION AND CABLE HARNESS ROUTING BY OXYGEN SENSOR • The "Oxygen Sensor" (output "19") ca- ble harness must go down along the left side of the engine together with the Gear Sensor cable harness.
Page 135 TUONO V4 R a-PRC ABS Electrical system TABLE M1 - CONTROL UNIT FITTING AND CONNECTION 1. Clamp 2. Check that the control unit tooth inserts in the seat placed on the filter box. TABLE M2 - CONTROL UNIT FITTING AND CONNECTION •...
Page 136 TUONO V4 R a-PRC ABS Electrical system TABLE N - VEHICLE CONNECTOR FASTEN- • The "VEHICLE" (output "1") connector must be fastened to the mounting with the white slide pre-fitted on the con- nector itself, in the position indicated in the figure.
Page 137 TUONO V4 R a-PRC ABS Electrical system General wiring diagram key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. TAIL LIGHT BULB (LED) 4. HIGH BEAM SOLENOID ELE SYS - 137...
Page 138 TUONO V4 R a-PRC ABS Electrical system 5. LOW BEAM BULB 6. FRONT LEFT TURN INDICATOR 7. LIGHT RELAY 8. LEFT LIGHT SWITCH 9. INSTRUMENT PANEL DIAGNOSIS 10.INSTRUMENT PANEL 11.EXHAUST VALVE MOTOR 12.FRONT STOP SWITCH 13.REAR STOP SWITCH 14.CLUTCH SWITCH 15.IGNITION SWITCH...
Page 139 TUONO V4 R a-PRC ABS Electrical system 43.ELECTRONIC TRANSMISSION 44.SIDE STAND SWITCH 45.GEAR SENSOR 46.FRONT CYLINDER PRESSURE SENSOR 47.REAR CYLINDER PRESSURE SENSOR 48.FRONT CYLINDER THROTTLE 49.REAR CYLINDER THROTTLE 50.AIR TEMPERATURE SENSOR 51.WATER TEMPERATURE SENSOR 52.FALL SENSOR (OPTIONAL EQUIPMENT) 53.7SM CONTROL UNIT 54.HAND GRIP POSITION SENSOR...
Page 140 TUONO V4 R a-PRC ABS Electrical system CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector correct position on the component or on the coupling con- nector, making sure that the locking catch is re- leased.
Page 141 TUONO V4 R a-PRC ABS Electrical system Continuity may also be tested by setting the tester selector to the "Ohm" symbol and checking that the resistance in the circuit is zero or of a few tenths of an Ohm. IMPORTANT: WHERE GROUND IS PROVIDED BY THE ECU, CHECK THAT THE ECU IS EFFEC- TIVELY PROVIDING THE GROUND CONNECTION FOR THE CIRCUIT DURING THE TEST.
Page 142 TUONO V4 R a-PRC ABS Electrical system • key code read but not recognised Error cause • The read code is not stored in the instrument panel memory Troubleshooting • Carry out key data storage procedure DSB 02 Immobilizer fault •...
Page 143 TUONO V4 R a-PRC ABS Electrical system Installation of new instrument panel In case the instrument panel is replaced by a new one, follow the procedure shown below so that the immobilizer system (key storage) and the exhaust butterfly valve (controlled by the ECU through the instrument panel) operate correctly.
Page 144 TUONO V4 R a-PRC ABS Electrical system • Exit • INSTRUMENT PANEL ERRORS • Error Clearing • VEHICLE SERVICING RESET • Update • CHANGE KEYS • KM / MILES INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connec- ted to it.
Page 145 TUONO V4 R a-PRC ABS Electrical system This error is signalled by the bulb icon, and the general warning light turns on as well. The instrument panel must keep all previous errors stored in its memory. DELETE ERRORS This option deletes all instrument panel errors; a further confirmation is requested. Use the diagnosis instrument to reset ECU errors.
Page 146 TUONO V4 R a-PRC ABS Electrical system • ESPAÑOL Service warning light reset VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check.
Page 147 TUONO V4 R a-PRC ABS Electrical system • Take the measurement; The correct value is determined by the value measured for each stage in which from time to time the resistance of the tester wires is subtracted, obtained by touching the two lugs.
Page 148 TUONO V4 R a-PRC ABS Electrical system • For a correct detection of the alternator voltage, a measurement must be carried out using alternatively the 3 engine side connector pins: stage "1" (pin 1-2), stage "2" (pin 1-3), stage "3" (pin 2-3) •...
Page 149 TUONO V4 R a-PRC ABS Electrical system OLD SHORT CIRCUIT CURRENT ITSUBISHI FLYWHEEL 2000 4000 6000 8000 RMS DC current (Arms) (average of the 3 stage 22 - 27 22 - 27 22 - 27 22 - 27 currents) Voltage on battery poles with engine speed always between 3000 - 5000 RPM •...
Page 150 TUONO V4 R a-PRC ABS Electrical system Starter switch P0170 • shorted to positive / open circuit, shorted to negative. Error cause • If shorted to positive: excessive voltage has been detected at PIN 58; if the circuit is open, shorted to negative: voltage equal to zero has been detected.
Page 151 TUONO V4 R a-PRC ABS Electrical system MAIN FUSES - DISTRIBUTION Main fuses are placed in the central part of the motorcycle, under the rider saddle. Characteristic Description / Value 1) 30A fuse Recharge, live positive, instrument panel permanent positive, sensorbox...
Page 152 TUONO V4 R a-PRC ABS Electrical system CONTROL UNIT - Diagnosis Function It manages the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves...
Page 153 TUONO V4 R a-PRC ABS Electrical system Fuel additive capacity Fuel additive correction CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 154 TUONO V4 R a-PRC ABS Electrical system • The stop light logic relay (no. 25 in the electrical circuit diagram, in the front niche of the frame, right side, CHECK anyway the identification of the relay with the colour of the cables)
Page 155 TUONO V4 R a-PRC ABS Electrical system • Circuit not functioning Error cause • Replace the injection control unit 'Stop lights relay error P0610 • short circuit to positive / short circuit to negative / open circuit Error cause •...
Page 156 ATT status Troubleshooting • Perform the troubleshooting for the other detected errors. a-PRC (Aprilia Performance Ride Control) operating error P0700 • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit voltage too low for a-PRC controls Error cause •...
Page 157 TUONO V4 R a-PRC ABS Electrical system unit will acquire the throttle valve position. Connect with the diagnostic tool and check that the states of "Automatic throttle valve self-learning is "performed" and "Handle self-learning" is "Not per- formed" (the latter involved the display of the message Urgent service on the instrument panel). If the automatic throttle valve self-learning indicates "Not performed"...
Page 158 TUONO V4 R a-PRC ABS Electrical system CAUTION PAY ATTENTION TO THE POSITIVE BATTERY CABLE, WHICH MUST PASS BELOW THE UPPER PART OF THE FRAME. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 159 TUONO V4 R a-PRC ABS Electrical system On the fork, right stanchion, next to the brake cal- liper support. Connector location (if available): Inside the support (2-ways black). Pin-out: • PIN 1 - Power negative/Signal nega- tive (white) • PIN 2 - Power positive/Signal positive...
Page 160 TUONO V4 R a-PRC ABS Electrical system restore cable harness; if OK, check with sensor disconnected and key ON that power voltage is slightly below battery voltage. If OK, replace the sensor; if NOT OK, replace the ABS control unit.
Page 161 TUONO V4 R a-PRC ABS Electrical system Swingarm, right side, on the brake calliper support plate. Connector location (if available): Under the right side fairing. Pin-out: • PIN 1 - Power negative/Signal nega- tive (yellow) • PIN 2 - Power positive/Signal positive...
Page 162 TUONO V4 R a-PRC ABS Electrical system restore cable harness; if OK, check with sensor disconnected and key ON that power voltage is slightly below battery voltage. If OK, replace the sensor; if NOT OK, replace the ABS control unit...
Page 163 TUONO V4 R a-PRC ABS Electrical system Engine rpm sensor Function indicates the position and speed of the crankshaft at the Marelli control unit Operation / Operating principle Inductive sensor: sinusoidal-type generated volt- age; two teeth are missing on the flywheel for the...
Page 164 TUONO V4 R a-PRC ABS Electrical system DIAGNOSTIC TOOL: LOGIC ERRORS P0336 Engine speed sensor • Signal not plausible Causes of error • Possible false contact in the electric circuit detected at PIN 20 and - 35 of the ENGINE...
Page 165 TUONO V4 R a-PRC ABS Electrical system • Move the hand grip position sensor, disconnect the two connectors. • Remove the hand grip position sensor. NOTE WHEN REFITTING, REMEMBER NOT TO INVERT THE CONNECTORS. THE LIGHT BLUE CONNECTOR HAS THE BLUE CABLE AND THE WHITE CONNECTOR HAS THE WHITE CABLE.
Page 166 TUONO V4 R a-PRC ABS Electrical system • B: Track A ground • C: Track A signal • D: Track B supply • E: Track B ground • F: Track B signal WHITE connector • A: Track C supply •...
Page 167 TUONO V4 R a-PRC ABS Electrical system • Example value with engine on: - With a released throttle grip, the value read should be 0%, whereas 100 % should be read with throttle grip fully twisted. DIAGNOSIS INSTRUMENT: STATUSES Throttle grip •...
Page 168 TUONO V4 R a-PRC ABS Electrical system • If shorted to positive: excessive voltage has been detected at PIN 13 of the VEHICLE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected...
Page 169 TUONO V4 R a-PRC ABS Electrical system if not, check the continuity of the cable that is not functioning properly: if there is continuity, replace the control unit; if not, restore the wiring White upper connector throttle grip position sensor - track D P0153 •...
Page 170 TUONO V4 R a-PRC ABS Electrical system • incongruent signal Error cause • Two illogical voltage signals have been detected at PIN 23 and 11 of the ENGINE connector (tracks A-B) Troubleshooting • Check the parameters of the white upper connector Throttle Grip Position Sensor - tracks C and D: if one of the two values clearly deviates from 600-1400 mV, it means that this potentiometer is defective.
Page 171 TUONO V4 R a-PRC ABS Electrical system Intake pressure sensor Function The pressure sensors (one per bank), are funda- mental for calculation of generated torque, for cal- culation of ambient pressure and for correct ignition timing during start-up. Operation / operating principle...
Page 172 TUONO V4 R a-PRC ABS Electrical system • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure (1 and 3) • Example value with key ON: 1004 mbar • Example value with engine on: 735 mbar •...
Page 173 TUONO V4 R a-PRC ABS Electrical system • If shorted to positive: see that the parameter of the front cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 174 TUONO V4 R a-PRC ABS Electrical system connector PIN 49 and sensor connector PIN 3 is a few tenths of an Ohm; If it is above that value, restore cable harness. Replace the sensor if it is correct. Error for unexpected air intake in the rear cylinder manifold P0210 •...
Page 175 TUONO V4 R a-PRC ABS Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). Troubleshooting • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body;...
Page 176 TUONO V4 R a-PRC ABS Electrical system Engine temperature sensor Function It tells the engine temperature to the control unit to improve its performance and to calculate the en- gine friction for a better estimation of the generated torque. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
Page 177 TUONO V4 R a-PRC ABS Electrical system • Example value with engine on: 25° C • The value of the engine start-up temperature is saved. At key ON, the value -40°C is read. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 178 TUONO V4 R a-PRC ABS Electrical system • Check the sensor connector and the ENGINE connector of the Marelli control unit. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then use the diagnostics tool to check if the temperature indicated is the same as the engine temperature.
Page 179 TUONO V4 R a-PRC ABS Electrical system Value determined from the signal read without tak- ing into consideration the recovery mode: the il- lustrative value refers to an open circuit CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING...
Page 180 TUONO V4 R a-PRC ABS Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 181 TUONO V4 R a-PRC ABS Electrical system • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time;...
Page 182 TUONO V4 R a-PRC ABS Electrical system covery value is displayed instead. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 183 TUONO V4 R a-PRC ABS Electrical system if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable har- ness.
Page 184 TUONO V4 R a-PRC ABS Electrical system INJECTOR Function To supply the correct amount of petrol at the right timing. Injector coil is excited for the petrol passage to open Level in electrical circuit diagram: Coils and injectors Location: •...
Page 185 TUONO V4 R a-PRC ABS Electrical system activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation Injector cylinder 2 • The injection relay (No. 33 in the wiring diagram, placed under saddle, next to the battery positive, CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit for 4 ms per second.
Page 186 TUONO V4 R a-PRC ABS Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the orange/red cable: if there connection, restore the cable har- ness.
Page 187 TUONO V4 R a-PRC ABS Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness.
Page 188 TUONO V4 R a-PRC ABS Electrical system Injection load relay Location: • on the vehicle: on the tank. • connector: on right rear frame (4-ways black). Electrical characteristics: PIN 1-2: 0.5 - 1 ohm; PIN 3-4: you do not need to...
Page 189 TUONO V4 R a-PRC ABS Electrical system • Short-circuit to positive: check the relay electrical specifications are correct by disconnecting it from the cable harness. If not OK, replace the relay; if OK, restore the cable harness (Brown/Black cable). •...
Page 190 TUONO V4 R a-PRC ABS Electrical system DIAGNOSTIC TOOL:PARAMETERS Example value with key ON:Actual start-up ad- vance Example value with engine on: Indicates the ad- vance of the cylinder in which the combustion will take place. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING,...
Page 191 TUONO V4 R a-PRC ABS Electrical system Electrical continuity is required in the wiring for the relay to activate correctly: no errors are generated in case of no activation. DIAGNOSIS INSTRUMENT: LOGIC ERRORS Coil 1 P0351 • shorted to positive / shorted to negative, open circuit.
Page 192 TUONO V4 R a-PRC ABS Electrical system • shorted to positive / shorted to negative, open circuit. Error cause • If shorted to positive: excessive voltage has been detected at PIN 2 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 2 of the ENGINE connector.
Page 193 TUONO V4 R a-PRC ABS Electrical system All the unit internal components (potentiometer and electric motor) are contactless; therefore, no elec- trical diagnosis is possible for the throttle body, but for the circuits connected to it only. Level in electrical circuit diagram:...
Page 194 TUONO V4 R a-PRC ABS Electrical system • Example value with engine on: 1.5° With key set to ON, the throttle is kept in position by the springs (around 5 -7°). After the engine starts up at idle, the throttle is kept close to the mechanical minimum (above or equal to 0.5°). When the gear is not engaged, at approx.
Page 195 TUONO V4 R a-PRC ABS Electrical system Front cylinders throttle Limp Home position • Example value with key ON: 878 mV Voltage stored in the control unit corresponding to the Limp home position Rear cylinders throttle Limp Home position •...
Page 196 TUONO V4 R a-PRC ABS Electrical system • Performed/Not performed Indicates if the self-learning with the diagnostic tool was performed/not performed: if it was performed one time, it will always remain performed unless a control unit EEPROM reset is carried out...
Page 197 TUONO V4 R a-PRC ABS Electrical system there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 198 TUONO V4 R a-PRC ABS Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 199 TUONO V4 R a-PRC ABS Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 200 TUONO V4 R a-PRC ABS Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 201 TUONO V4 R a-PRC ABS Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab-...
Page 202 TUONO V4 R a-PRC ABS Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 203 TUONO V4 R a-PRC ABS Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 204 TUONO V4 R a-PRC ABS Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 205 TUONO V4 R a-PRC ABS Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 206 TUONO V4 R a-PRC ABS Electrical system • connector: between the head cover and the left side of the filter casing (3 pin white connector). Electrical specifications: PIN 64: neutral indication: closed circuit (continu- ity); gear engaged: open circuit (infinite resist- ance).
Page 207 TUONO V4 R a-PRC ABS Electrical system to approx. 5V, replace the sensor (there is a short circuit to ground of the pink/black cable in the section between the sensor connector and the sensor or inside the sensor itself). Clutch lever sensor...
Page 208 TUONO V4 R a-PRC ABS Electrical system nals from the sensor and check, with key set to ON, continuity to ground of PIN 2: if there is no continuity, restore the cable harness; if there is, replace the sensor. •...
Page 209 TUONO V4 R a-PRC ABS Electrical system Side stand sensor: up/down • indication on the diagnostics tool always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness;...
Page 210 TUONO V4 R a-PRC ABS Electrical system NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSTIC TOOL: STATUSES Fall sensor: Normal / Tip over • Indication on diagnostics tool always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor;...
Page 211 TUONO V4 R a-PRC ABS Electrical system DIAGNOSTIC TOOL:STATUSES Fan relay • on/off DIAGNOSTIC TOOL:ACTIVATIONS • The fan relay (No. 36 in the electrical circuit diagram, placed in the head- stock niche, left side; CHECK, howev- er, the identification of the relay with the colour of the cables) is energised for 10 seconds.
Page 212 TUONO V4 R a-PRC ABS Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / Operating principle The valve coil is excited to open the air passage...
Page 213 TUONO V4 R a-PRC ABS Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness;...
Page 214 TUONO V4 R a-PRC ABS Electrical system RUN / STOP switch • Run/Stop NOTES • indication on the diagnostics tool always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - Blue/Green and Yellow/Red: If there is not continuity, replace the sensor;...
Page 215 TUONO V4 R a-PRC ABS Electrical system The system consists of a throttle valve with a re- turn spring placed on the exhaust pipe. The valve is closed via two cables actuated by an electric motor, which, in turn, is connected electrically to the instrument panel.
Page 216 TUONO V4 R a-PRC ABS Electrical system Exhaust butterfly valve • Indefinite/in research/activation with key ON/ in operation/stopped for detected malfunction/ research of zero position. NOTE: If there is no problem, it appears: in operation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Exhaust butterfly valve stop research P0191 •...
Page 217 TUONO V4 R a-PRC ABS Electrical system • open circuit, thermal overload protection, shorted to negative, shorted to positive or short circuit between both cables. Error cause • If the circuit is open: too low current has been detected at PIN 36 - 37 of the instrument panel connector.
Page 218 TUONO V4 R a-PRC ABS Electrical system connector and if there is voltage, restore cable harness; if there is not voltage, replace in- strument panel, if there is not voltage, replace motor. • If shorted to negative, the circuit is open: check the valve connector and instrument panel connector: if not OK, restore;...
Page 219 TUONO V4 R a-PRC ABS Electrical system CAUTION BEFORE CARRYING OUT THIS OPERATION, CHECK THAT THE BATTERY VOLTAGE IS HIGHER THAN 12.5 V CAUTION WORK ON THE MOTOR OF THE EXHAUST THROTTLE VALVE ONLY WITH THE KEY SET TO "OFF" OR ONLY AFTER DISCONNECTING THE NEGATIVE POLE OF THE BATTERY.
Page 220 TUONO V4 R a-PRC ABS Electrical system • After having pressed the enter button for the zero position search, shut off the vehicle and leave the keys in OFF, even in the event that the instruments indicate the opposite. •...
Page 221 TUONO V4 R a-PRC ABS Electrical system Quick shift Function: To signal to the control unit the request for power- assisted gear shifting. Operation / Operating principle: Normally open switch that is closed to ground when the gearbox lever is activated (only when shifting up).
Page 222 TUONO V4 R a-PRC ABS Electrical system 1 - Marelli ECU PIN 47): if OK, check pink cable and black cable insulation; if NOT OK, restore cable harness; if pink/black cable insulation is OK, replace the Marelli control unit; if NOT OK, restore cable harness.
Page 223 TUONO V4 R a-PRC ABS Electrical system "+" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error. "-" button: Pressed/Released/Invalid data due to open circuit error/Invalid data due to short circuit error DIAGNOSTIC TOOL: ELECTRICAL ERRORS "+"...
Page 224 TUONO V4 R a-PRC ABS Electrical system • Open contacts/Closed contacts Error cause: With open contacts, a voltage over zero is detected at the same time at PIN 18 and PIN 19 of the instrument panel. With closed contacts, zero voltage is detected at the same time at PIN 18 and PIN 19 of the instrument panel.
Page 225 TUONO V4 R a-PRC ABS Electrical system Inertial sensor platform (sensor box) Function: To transmit information about the motorcycle dy- namics to the Marelli control unit (e.g.: yaw rate). Electrical circuit diagram - Level in electrical circuit diagram: Traction control.
Page 226 TUONO V4 R a-PRC ABS Electrical system Sensor box error (inertia sensor platform) P0713 • Faulty sensor/Signal not valid Troubleshooting: With faulty sensor, the component inside the control unit is damaged and replacement of the control unit is recommended. With signal not valid, the sensor has generated a signal out of range that is still sent to the injection control unit together with the relevant error.
Page 227 TUONO V4 R a-PRC ABS Electrical system Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6/17 Cylinder 1 injector control output PIN 8 Lambda sensor input (+) PIN 10 Track D hand grip input PIN 11 Water temp.
Page 228 TUONO V4 R a-PRC ABS Electrical system Vehicle pinout key: Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Reference voltage output + 5V: tracks B-D and front throttle PIN 63...
Page 229 TUONO V4 R a-PRC ABS Electrical system Vehicle speed input PIN 79 CAN H line (high speed) PIN 80 Engine - vehicle connector pinout key: Key PIN 1A Vehicle speed PIN 2A STOP lights relay control output PIN 3A - PIN 4A...
Page 230 TUONO V4 R a-PRC ABS Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 230...
Page 231 TUONO V4 R a-PRC ABS Electrical system 4 High beam lights input 5 Normally open button "+" 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control 13 Normally closed button "+"...
Page 232 TUONO V4 R a-PRC ABS Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation...
Page 233 TUONO V4 R a-PRC ABS Electrical system Rear speed sensor input PIN 14 ABS warning light PIN 17 Battery for pump engine positive PIN 18 Can line Function It allows communication between the Marelli injection ECU and the instrument panel.
Page 234 TUONO V4 R a-PRC ABS Electrical system CAN Line Electrical specifications: • between PIN 66 and 80 of the control unit: approx. 130 Ohm • between PIN 26 and 27 of the instrument panel: approx. 120 Ohm Pin out: •...
Page 235 TUONO V4 R a-PRC ABS Electrical system • no signal. Error cause • No signal is received from the instrument panel. Troubleshooting • Check the connector of the instrument panel: if not OK, restore; if OK, check the continuity of the two lines from the instrument panel connector to the VEHICLE connector of the Marelli control unit: if not OK, restore the cable harness;...
Page 236 TUONO V4 R a-PRC ABS Electrical system the vehicle cable harness; if OK, check the continuity across instrument panel pin 27 and ABS control unit connector pin 11. If NOT OK, replace the cable harness; if OK, check for the correct power supply (12V) at pins 1 and 11 and ground at pins 38,39, 40 of the instru- ment panel connector.
Page 237 (Sensor box), the correct status we should find on the diagnostics instrument devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a vehicle equipped with inertia sensor platform (Sensor...
Page 238 TUONO V4 R a-PRC ABS Electrical system • CAN error during acquisition/Invalid value. Error cause • In case of CAN error during acquisition, system warns that the procedure can not be com- pleted due to a communication problem on the CAN line. In case of invalid value, it means that on key-ON an error of transcription occurred - from the non-volatile memory (EEPROM) to the volatile one (RAM) - of the value concerning the rear wheel radius.
Page 239 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 240 TUONO V4 R a-PRC ABS Engine from vehicle NGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.90 lb ft) Threaded stand-off 8 Nm (5.90 lb ft) Countersunk flat head hex socket M6x35 10 Nm (7.38 lb ft) Loct.
Page 241 TUONO V4 R a-PRC ABS Engine from vehicle • Remove the left hand rider footpeg. Position the vehicle as described: • Fasten an appropriately sized belt for the weight of the vehicle to the semi-handlebars and to a hoist. •...
Page 242 TUONO V4 R a-PRC ABS Engine from vehicle • Remove the timing sensor. • Remove the engine oil pressure sen- sor. • Remove the rubber cap. • Unscrew and remove the nut, retrieve the washer and disconnect the starter motor.
Page 243 TUONO V4 R a-PRC ABS Engine from vehicle • Unscrew and remove the nut and re- trieve the washer. • Detach the ground from the chassis. • Working on the right hand side of the vehicle, detach the exhaust valve con- trol unit connector.
Page 244 TUONO V4 R a-PRC ABS Engine from vehicle • Unscrew and remove the pinion fixing screw and retrieve the two washers. • Loosen the drive chain adjuster screws. • Loosen the rear wheel fixing nut. • Remove the pinion, releasing it from the drive chain.
Page 245 TUONO V4 R a-PRC ABS Engine from vehicle • Detach the neutral sensor. See also Side stand • Remove the hand grip position sensor from the chassis. • Disconnect the voltage regulator con- nector. See also Twistgrip position sensor ENG VE - 245...
Page 246 TUONO V4 R a-PRC ABS Engine from vehicle • Disconnect the alternator connector. • Working from the left hand side of the vehicle, unscrew and remove the screw and retrieve the washer. • Unscrew and remove the three plate fixing screws and remove the plate.
Page 247 TUONO V4 R a-PRC ABS Engine from vehicle • Disconnect the quick-shift connector. • Cut the ties fastening the cable har- ness to the engine. • Loosen the screw and slide off the gear shift lever and cable harness from the engine.
Page 248 TUONO V4 R a-PRC ABS Engine from vehicle • Working on the left side of the vehicle, undo and remove the two screws. • Working on the right side of the vehicle, undo and remove the two screws. • Also retrieve the shims on the inner side of the frame.
Page 249 TUONO V4 R a-PRC ABS Engine from vehicle • Unscrew the upper adjuster screw bushing until it turns no more. • Working on the right side of the vehicle, unscrew and remove the nut and re- trieve the washer. •...
Page 250 TUONO V4 R a-PRC ABS Engine from vehicle • Release the belts from the hoist, supporting the front part of the vehicle. • Remove the rear stand. • Remove the chassis from the engine. Installing the engine to the vehicle •...
Page 251 TUONO V4 R a-PRC ABS Engine from vehicle • the engine attachment upper fixing screw (6); • the lower rear fixing pin (3), so as to centre the engine position. Working on the right side, place and screw without tighten: •...
Page 252 TUONO V4 R a-PRC ABS Engine from vehicle • Place and tighten internally the two set pack bushings (7) to the prescribed torque. • Place again on the left side, the lower rear fixing pin (3). • Tighten the rear pin fastening nut (8).
Page 253 TUONO V4 R a-PRC ABS Engine from vehicle • Position the quick-shift cable harness and fasten using ties. • Connect the quick-shift connector. • Connect the alternator connector. • Connect the voltage regulator connec- tor. ENG VE - 253...
Page 254 TUONO V4 R a-PRC ABS Engine from vehicle • Position and fix the hand grip position sensor to the chassis. WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS. • Connect the neutral sensor. •...
Page 255 TUONO V4 R a-PRC ABS Engine from vehicle • Adjust the drive chain adjuster screws. • Place the two washers and tighten the pinion fixing screw. • Place the pinion cover and tighten the three screws. • Connect the vehicle cable harness / engine cable harness connector.
Page 256 TUONO V4 R a-PRC ABS Engine from vehicle • Working on the right side of the vehicle, connect the exhaust valve control unit connector. • Place the ground on the frame. • Fit the washer and tighten the nut. •...
Page 257 TUONO V4 R a-PRC ABS Engine from vehicle • Tighten the engine oil pressure sensor. • Connect the timing sensor. • Connect the clutch cable. ENG VE - 257...
Page 258 TUONO V4 R a-PRC ABS Engine from vehicle • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in). ENG VE - 258...
Page 259 INDEX OF TOPICS NGINE...
Page 260 TUONO V4 R a-PRC ABS Engine key: 1. rear left cylinder; 2. front left cylinder; 3. rear right cylinder; 4. front right cylinder. Combustion sequence: 1 - 3 - 2 - 4 Combustion angle: cyl 1: 0° cyl 2: 180°...
Page 261 TUONO V4 R a-PRC ABS Engine Gearbox Diagram pos. Description Type Quantity Torque Notes Star fastening screw M6x20 10 Nm (7.38 lb ft) Loct. 243 Bearing retaining plate fastening M6x16 10 Nm (7.38 lb ft) Loct. 243 screw Flange fastening screws M8x25 25 Nm (18.44 lb ft)
Page 262 TUONO V4 R a-PRC ABS Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw.
Page 263 TUONO V4 R a-PRC ABS Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 264 TUONO V4 R a-PRC ABS Engine • Remove both gearbox shafts from the cover. • Collect the shim washer that is located on the secondary shaft between the shaft and the cover. • Unscrew and remove the screw. • Remove the selector drum.
Page 265 TUONO V4 R a-PRC ABS Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in)
Page 266 TUONO V4 R a-PRC ABS Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.5 mm (0.020 in)
Page 267 TUONO V4 R a-PRC ABS Engine • Grease the bushings. • Introduce the forks in their respective seats. • Insert the desmodromic gearbox con- trol rod on the cover. • Position the selector drum. • Turn the screw without tightening it.
Page 268 TUONO V4 R a-PRC ABS Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for gearbox secondary shaft •...
Page 269 TUONO V4 R a-PRC ABS Engine • Tighten the selector drum screw. • Insert the driving pin on the oil pump shaft. • Install the water/oil pump control gear. • Insert the Seeger ring. • Install the gear sensor, making the pin coincide with the slot on the desmo- dromic control rod.
Page 270 TUONO V4 R a-PRC ABS Engine GEARBOX CONTROL ROD ROLLER CAGE, CLUTCH SIDE • Remove the lower crankcase. • The specific tool without an adaptor must be used to remove the gearbox control rod roller cage from the clutch side.
Page 271 TUONO V4 R a-PRC ABS Engine Checking the gear selector Check the stop lever for damage and wear and make sure the ball rotates freely. If necessary, replace the parts. Check the gear selector spring for damage and wear. If necessary, replace the part.
Page 272 TUONO V4 R a-PRC ABS Engine IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL. Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed.
Page 273 TUONO V4 R a-PRC ABS Engine • Fit the intermediate gear. • Fit the clutch cover. Generator side LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft)
Page 274 TUONO V4 R a-PRC ABS Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 275 TUONO V4 R a-PRC ABS Engine • Flywheel lock cod. 020914Y FIND BELOW THE REMOVING AND REFIT- TING PROCEDURE OF THE MITSUBISHI FLY- WHEEL, THE SAME PROCEDURE (EXCEPT FOR TOOLS) IS VALID ALSO FOR KOKUSAN FLYWHEEL. See also Removing the flywheel cover •...
Page 276 TUONO V4 R a-PRC ABS Engine Inspecting the cover components • Unscrew and remove the three Blow- by system fitting screws. • Remove the Blow-by system fitting. • Replace the O-ring with a new one of the same type •...
Page 277 TUONO V4 R a-PRC ABS Engine Flywheel cover installation • Insert the centring dowels in the cover. • Apply a layer of sealing paste along the external edge of the cover. • Insert the cover together with the sta- tor.
Page 278 TUONO V4 R a-PRC ABS Engine Clutch side LUTCH COVER pos. Description Type Quantity Torque Notes Rpm sensor fixing screw 8 Nm (5.90 lb ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) Flanged TE screws M6x35 12 Nm (8.85 lbf ft)
Page 279 TUONO V4 R a-PRC ABS Engine Removing the clutch cover • Drain the engine oil. • Unscrew and remove the sixteen peri- metric fixing screws and retrieve the washers. • Remove the clutch casing, retrieving the gasket, the two locator pins and the starter motor transmission gear.
Page 280 TUONO V4 R a-PRC ABS Engine • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch lock • Remove the slipper unit. • Remove the clutch hub.
Page 281 TUONO V4 R a-PRC ABS Engine • Retrieve the shim. • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 281...
Page 282 TUONO V4 R a-PRC ABS Engine • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in)
Page 283 TUONO V4 R a-PRC ABS Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness.
Page 284 TUONO V4 R a-PRC ABS Engine Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded;...
Page 285 TUONO V4 R a-PRC ABS Engine • Fit the needle cage. • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion •...
Page 286 TUONO V4 R a-PRC ABS Engine • Install the clutch hub cam tower. • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • The slipper springs are distinguishable by the cleats. In the 0.8mm spring (1) there is only one notch, while in the 0.9mm spring (2) there are two notch-...
Page 287 TUONO V4 R a-PRC ABS Engine • Fit the three slipper unit clips, offsetting them by 120°. • Install the slipper unit correctly. • Where required by the table, insert the fourth spring without teeth (1) • Where required by the table, insert the washer (2) •...
Page 288 TUONO V4 R a-PRC ABS Engine • Insert one of the metal discs into the bell (if present, insert the satinised one). • Insert the flat washer. • Insert the spring washer with the con- cave side facing out. •...
Page 289 TUONO V4 R a-PRC ABS Engine • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 290 TUONO V4 R a-PRC ABS Engine USE THE SAME SOLUTION FOR ALL THE STUD BOLTS. ORANGE SPRING CAUTION PAY ATTENTION WHEN REFITTING, RESPECT THE SEQUENCE OF SCREW, CAP, LINING AND SPRING. • Fit the clutch springs (4). • Insert the spring holder cap (2) and the shimming washers (3) onto the screws (1).
Page 291 TUONO V4 R a-PRC ABS Engine Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the removal of the bushing, it is necessary to thread the inside to allow the extractor to tighten sufficiently. INSTALLING THE CLUTCH CONTROL PIN BUSHING •...
Page 292 TUONO V4 R a-PRC ABS Engine • Position the starting transmission gear on the crankcase. • Position the gasket and the two dowel pins in the clutch cover. • Insert the clutch cover, making sure to have correctly engaged the clutch con- trol lever and the rack shaft.
Page 293 TUONO V4 R a-PRC ABS Engine HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve covers fixing screws 6 Nm (4.43 lb ft) Water outlet union fixing screw 12 Nm (8.85 lbf ft)
Page 294 TUONO V4 R a-PRC ABS Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Screw fastening the timing system 30 Nm (22.13 lb ft) Loct. 243 gear on the intake shaft Shoe fastening screws 20 Nm (14.75 lb ft) Loct. 243...
Page 295 TUONO V4 R a-PRC ABS Engine INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure. Recommended products Three bond Sealing paste • Smear the head surface with suitable sealant, in the area indicated in the fig- ure.
Page 296 TUONO V4 R a-PRC ABS Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 297 TUONO V4 R a-PRC ABS Engine • Unscrew and remove the camshaft gear screw. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC;...
Page 298 TUONO V4 R a-PRC ABS Engine • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 299 TUONO V4 R a-PRC ABS Engine • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES • Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
Page 300 TUONO V4 R a-PRC ABS Engine • Install the intake and exhaust camshafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 301 TUONO V4 R a-PRC ABS Engine • Align the intake camshaft with the spe- cific hole on the U bolt. • Insert the specified pin. Specific tooling 020851Y Camshaft timing pin • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 302 TUONO V4 R a-PRC ABS Engine screw. This screw must be replaced at each reassembly. • Tighten the second camshaft gear fix- ing screw to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer...
Page 303 TUONO V4 R a-PRC ABS Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150° in the engine rotation direction (direction of travel), in...
Page 304 TUONO V4 R a-PRC ABS Engine cylinder bank valve springs are decom- pressed. • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Remove the crankshaft locking tool.
Page 305 TUONO V4 R a-PRC ABS Engine • Unscrew and remove the mobile chain slider screw. • Remove the mobile chain slider. • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side.
Page 306 TUONO V4 R a-PRC ABS Engine • Remove the front head, slipping it off the stud bolts. • Collect the gasket and the two dowel pins. • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat.
Page 307 TUONO V4 R a-PRC ABS Engine Front head fitting • Install a new O ring on the chain ten- sioner REPLACE THE O RING UPON EACH REMOVAL. • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in).
Page 308 TUONO V4 R a-PRC ABS Engine functionality of the timing system may be compromised if the washer is bent or incorrectly positioned. THIS WASHER CANNOT BE INSTALLED ON THE CHAIN TENSIONER OF ONE CYLINDER BANK ALONE - ALWAYS INSTALL WASHERS ON BOTH CHAIN TENSIONERS.
Page 309 TUONO V4 R a-PRC ABS Engine • Tighten the two screws according to the sequence (a - b). • Install the camshaft control gear con- nected with a clamp to the timing chain. • Keep the gear in position with the chain tightened.
Page 310 TUONO V4 R a-PRC ABS Engine • Rotate the crankshaft via the opening on the clutch cover. • Position cylinder 1 piston (LH, rear pis- ton) so that it is at the point where it crosses TDC. • rotate the crankshaft 150° in the engine rotation direction (direction of travel).
Page 311 TUONO V4 R a-PRC ABS Engine • Check the number engraved on the U bolts, which must correspond with the one engraved on the head. • If the U bolts between the two heads are inverted, camshaft seizure may oc- IT IS NOT POSSIBLE TO REPLACE ONLY ONE U BOLT, IF NECESSARY: REPLACE THE ENTIRE HEAD.
Page 312 TUONO V4 R a-PRC ABS Engine • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 313 TUONO V4 R a-PRC ABS Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible.
Page 314 TUONO V4 R a-PRC ABS Engine • Insert the pin from the clutch side into the hole in the crankshaft. NOTE THE SPECIAL TOOL SHOWN HERE MUST ONLY BE USED FOR IDENTIFYING THE CORRECT POSITION OF THE CRANKSHAFT. DO NOT USE IT FOR TIGHTENING COMPONENTS.
Page 315 TUONO V4 R a-PRC ABS Engine Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en- gine rotation (direction of travel) to...
Page 316 TUONO V4 R a-PRC ABS Engine • Install the specific camshaft gear sup- port tool. • Fix it to the head using the two screws (1). • Move the gear from the camshaft to the tool. Specific tooling 020956Y Support for camshaft gear on head •...
Page 317 TUONO V4 R a-PRC ABS Engine • Fasten the camshaft in horizontal po- sition, as shown in the figure, and make it spin to check the eccentricity with a dial gauge; if necessary, replace the part. Characteristic Maximum camshaft axial clearance (intake/ex- haust) 0.4 mm (0.0016 in)
Page 318 TUONO V4 R a-PRC ABS Engine • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally.
Page 319 TUONO V4 R a-PRC ABS Engine • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft.
Page 320 TUONO V4 R a-PRC ABS Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; Refit the reference pin while checking, using the crankshaft reference pin, that the clutch side hole and the hole in the crankshaft are perfectly aligned.
Page 321 TUONO V4 R a-PRC ABS Engine Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; • turn the crankshaft by 450° (one com- plete turn + 90°) in the direction of en- gine rotation (direction of travel) to align the hole on the intake camshaft with the specific hole on the U bolt.
Page 322 TUONO V4 R a-PRC ABS Engine • Remove the intake and exhaust camshafts from the rear head. • Unscrew and remove the mobile chain slider screw. • Remove the mobile chain slider. • Unscrew and remove the fixed chain slider screw.
Page 323 TUONO V4 R a-PRC ABS Engine • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1. • After loosening all nuts, remove them in order indicated above.
Page 324 TUONO V4 R a-PRC ABS Engine • The contact surfaces with the cover and the crankcase are not scored or damaged so they jeopardise a perfect seal. • Check the status of the valve seats. • Check that the routing of the oil pipes is free and if required, clean them by blowing a jet of compressed air.
Page 325 TUONO V4 R a-PRC ABS Engine WASHER We recommend installing a washer between the crankcase and the chain tensioner to optimise the functionality of the timing system. This washer is available as a spare part. • Fit the washer onto the chain tensioner then install the chain tensioner in the relative seat in the crankcase.
Page 326 TUONO V4 R a-PRC ABS Engine • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order.
Page 327 TUONO V4 R a-PRC ABS Engine NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the rear head, remembering that: the intake camshaft gear tooth (indicated with a dot) is inserted in the groove of the exhaust camshaft gear (indicated with two dots).
Page 328 TUONO V4 R a-PRC ABS Engine • Fit the U bolts with the nine O rings and locator pins. • Install the oil pipe. • Fit the new washers under the screws (2) near the spark plug holes only. •...
Page 329 TUONO V4 R a-PRC ABS Engine 020855Y Lever for engaging the chain tensioner • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool.
Page 330 TUONO V4 R a-PRC ABS Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them correctly upon refitting.
Page 331 TUONO V4 R a-PRC ABS Engine • Remove the cotters using a magnet. • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING.
Page 332 TUONO V4 R a-PRC ABS Engine VALVE STEM DEVIATION Lift up the valve approx. 10 mm (0.39 in) from its seat. Measure the valve stem deviation in two perpen- dicular directions and position the dial gauge as shown in the figure.
Page 333 TUONO V4 R a-PRC ABS Engine Coating may get slightly damaged in the indicated area. Valve installation • Lubricate the valve stem and insert the valves on the valve guide. • Position the springs with the closest turns facing the head of the valve...
Page 334 TUONO V4 R a-PRC ABS Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs •...
Page 335 TUONO V4 R a-PRC ABS Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft)
Page 336 TUONO V4 R a-PRC ABS Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lb ft) Loct. 243 ENG - 336...
Page 337 TUONO V4 R a-PRC ABS Engine RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lb ft)
Page 338 TUONO V4 R a-PRC ABS Engine • Unscrew and remove the nut and col- lect the washer • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. ENG - 338...
Page 339 TUONO V4 R a-PRC ABS Engine • Remove the key on countershaft • Remove the spacer. • Remove the countershaft on the oppo- site side. BALANCING COUNTERSHAFT FITTED ON BUSHINGS • Block crankshaft rotation using the specific tool. Specific tooling...
Page 340 TUONO V4 R a-PRC ABS Engine • Remove the starting intermediate gear. • Unscrew and remove the nut. See also Removing the clutch cover Removing the flywheel cover • Remove the countershaft from the al- ternator side. • Remove the countershaft gear.
Page 341 TUONO V4 R a-PRC ABS Engine Balancing countershaft fitting • Install the spacer. THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE. • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear. NOTE...
Page 342 TUONO V4 R a-PRC ABS Engine • Turn the nut on the countershaft. • Block crankshaft rotation using the specific tool. • Tighten the nut on the countershaft. Specific tooling 020849Y Clutch lock Main transmission gear removal • Remove the clutch.
Page 343 TUONO V4 R a-PRC ABS Engine • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock • Remove the primary shaft gear. Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side.
Page 344 TUONO V4 R a-PRC ABS Engine • Insert the tone wheel on the crank- shaft. The crankshaft and the tone wheel have a bevel that identifies the fitting direction. • Tighten the tone wheel fixing screw. • Remove the special tool.
Page 345 TUONO V4 R a-PRC ABS Engine Removing the oil sump Balancing countershaft removal Crankcase opening • Position the engine with the heads fac- ing upward, unscrew and remove the screw (24). • Turn the engine with the heads facing downward and loosen the screws in the following order: 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7.
Page 346 TUONO V4 R a-PRC ABS Engine • Separate the crankcases, removing the lower part • Collect the three dowel pins. • The crankshaft, the pistons and the connecting rods remain in the upper crankcase. Removing connecting rods - pistons •...
Page 347 TUONO V4 R a-PRC ABS Engine • Remove the piston connected to the connecting rod from the cylinder side. • Extract the snap ring, slide off the pin • Mark the piston crown on the exhaust side so as to remember the refitting po- sition.
Page 348 TUONO V4 R a-PRC ABS Engine • Take out the crankshaft. Bearing removal AS A RESULT OF UPDATES, IT IS POSSIBLE TO IDENTIFY SOME ENGINES WITH COUNTER- SHAFT ON THE HALF BUSHINGS AND OTHERS WITH COUNTERSHAFT ON BEARINGS. (OPTION 01)
Page 349 TUONO V4 R a-PRC ABS Engine CLUTCH-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302° • Position the general tool to pull out bearings. • Remove the bearing.
Page 350 TUONO V4 R a-PRC ABS Engine • Use the special tool to remove the semi-bushings. CAUTION CHECK THAT THE ORs ON THE TOOL ARE NOT DAM- AGED. Specific tooling 020861Y Countershaft bushing punch See also Balancing countershaft removal Crankcase opening...
Page 351 TUONO V4 R a-PRC ABS Engine Connecting rod check Characteristic Maximum wear limit of the rod small end 17.05 mm (0.671 in) Maximum rod small end radial clearance 0.055 mm (0.0022 in) Maximum radial play between connecting rod and crankpin 0.55 mm (0.022 in)
Page 352 TUONO V4 R a-PRC ABS Engine 0.1 mm (0.0039 in) Maximum wear limit of the clearance between pin and pin hole on the piston 0.040 mm (0.0016 in) Maximum allowed clearance between the first piston ring and respective slot on the piston 0.1 mm (0.0039 in)
Page 353 TUONO V4 R a-PRC ABS Engine The permitted crankshaft-connecting rod balancing class combinations are listed in the following table: CRANKSHAFT-CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Balancing class combinations for Balancing class combinations for alternator side connecting rod pair primary drive side connecting rod pair...
Page 354 TUONO V4 R a-PRC ABS Engine It is fundamental that, in case of replacement of a connecting rod, also the other one installed on the same crankpin is always replaced: • if the piston 1 connecting rod is re- placed, the one relative to piston 2 must also be replaced and vice versa;...
Page 355 TUONO V4 R a-PRC ABS Engine A number that indicates the position of the main journal is stamped on the crankcase: 1. flywheel side; 2. central; 3. clutch side. RANKCASE CATEGORY Specification Desc./Quantity Class A Bushing seat diameter 52.023 - 52.018 mm (2.0481 - 2.0479 Class B Bushing seat diameter 52.018 - 52.013 mm (2.0479 - 2.0477...
Page 356 TUONO V4 R a-PRC ABS Engine Specification Desc./Quantity Class E Main journals - diameter: 45.998 - 45.993 mm (1.8109 - 1.8107 Once the categories below are checked: 1. crankcase; 2. flywheel side main journal; 3. centre main journal; 4. clutch side main journal.
Page 357 TUONO V4 R a-PRC ABS Engine CRANKSHAFT BUSHINGS - CONNECTING RODS There are two different connecting rod types dis- tinguished by the operation practised on the semi- bushings seat. ENG - 357...
Page 358 TUONO V4 R a-PRC ABS Engine For the type "A" connecting rod, three types of semi-bushings are available: • • Blue • Yellow For the coupling of the connecting rod with the crankshaft, coupling classes are not indicated, but in alternative the two following semi-bushings are available: 1.
Page 359 TUONO V4 R a-PRC ABS Engine Bearing fitting AS A RESULT OF UPDATES, IT IS POSSIBLE TO IDENTIFY SOME ENGINES WITH COUNTER- SHAFT ON THE HALF BUSHINGS AND OTHERS WITH COUNTERSHAFT ON BEARINGS. (OPTION 01) BALANCING COUNTERSHAFT BEARING INSTALLATION FLYWHEEL-SIDE •...
Page 360 TUONO V4 R a-PRC ABS Engine • Using the suitable tools, fit the bearing in the crankcase until tool stops • Fit the retainer in the bearing groove. • Tighten the bearing retainer screw. CLUTCH-SIDE • Heat up the crankcase to 150°C (302°F).
Page 361 TUONO V4 R a-PRC ABS Engine • Using the suitable tools, fit the bearing in the crankcase until tool stops. • Fit the retainer in the bearing groove. • Tighten the bearing retainer screw. • Install the balancing countershaft. Bushing fitting...
Page 362 TUONO V4 R a-PRC ABS Engine • On the outside of the crankcase, mark the passage of the countershaft lubri- cation oil. • Sprinkle the sliding surfaces of the half bushings with grease on the special tool. • Install the new half bushings, aligning the hole with the slot on the ring of the special tool.
Page 363 TUONO V4 R a-PRC ABS Engine • Remove the special tool. • Use a thin screwdriver to check that the countershaft lubrication oil passage is aligned with the hole on the installed bushing. Crankshaft fitting NOTE ACCORDING TO THE TYPE OF CRANKSHAFT, ITS INSTALLATION WILL FOLLOW TWO DIF- FERENT PROCEDURES ("OPTION 1"...
Page 364 TUONO V4 R a-PRC ABS Engine Position the sprocket (2) with the smooth side fac- ing the inside of the crankshaft. Move the sprocket (2) up against the crankshaft shoulder. OPTION 2 Crankshaft with non removable gear. When refitting the primary gear, remember to first place the lining as shown in the figure.
Page 365 TUONO V4 R a-PRC ABS Engine • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side. • Make the references on the gears of the primary shaft and the countershaft coincide. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR.
Page 366 TUONO V4 R a-PRC ABS Engine ISTONS AND PISTON RINGS COUPLING Model Engine No. Crankcase selections Piston type Piston ring EUROPE MY2011 from 8923 to 8973 without marking Chrome steel band EUROPE MY2011 from 8977 to 9007 without marking Chrome steel...
Page 367 TUONO V4 R a-PRC ABS Engine The piston rings are different and must be fitted with the markings "R" or "KDN 5" (for the upper one) and "RN" (for the lower one) facing upward. The upper ring can be of a different type according to the type of piston used.
Page 368 TUONO V4 R a-PRC ABS Engine Pre-assemble the pistons on the workbench with the connecting rod shank and the relative semi- bushing. The pre-assembly procedure is identical for all four pistons and must be done as follows: • with the piston crown parallel to the...
Page 369 TUONO V4 R a-PRC ABS Engine • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces. • Use new connecting rod screws, lubri- cating the thread and under the head.. • Proceed with tightening according to...
Page 370 TUONO V4 R a-PRC ABS Engine • Apply a layer of sealing paste along the external edge of the crankcase. • Join the two crankcases. Recommended products Three bond Sealing paste • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - •...
Page 371 TUONO V4 R a-PRC ABS Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 371...
Page 372 TUONO V4 R a-PRC ABS Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase Lubrication ENG - 372...
Page 373 TUONO V4 R a-PRC ABS Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lb ft) Oil drainage plug 30 Nm (22.13 lb ft) Oil sump fixing screws M6x30 12 Nm (8.85 lb ft)
Page 374 TUONO V4 R a-PRC ABS Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor.
Page 375 TUONO V4 R a-PRC ABS Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- •...
Page 376 TUONO V4 R a-PRC ABS Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor.
Page 377 TUONO V4 R a-PRC ABS Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover.
Page 378 TUONO V4 R a-PRC ABS Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket.
Page 379 TUONO V4 R a-PRC ABS Engine The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 380 TUONO V4 R a-PRC ABS Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 380...
Page 381 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 382 TUONO V4 R a-PRC ABS Power supply Fuel pump Removing • Remove and empty the fuel tank. • Loosen the pipe grommet screw. • Detach the fuel pipe. • Unscrew and remove the screws. • Remove the fuel pump. Injection...
Page 383 TUONO V4 R a-PRC ABS Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor (if fitted) 4. Outlet valve P SUPP - 383...
Page 384 TUONO V4 R a-PRC ABS Power supply 5. Clutch position sensor 6. Fuel pump (inside the tank) 7. Air temperature sensor 8. Air pressure sensor (MAP) 9. Injectors 10.Coils (spark plug cover) 11.Engine throttle valves 12.Throttle valve position sensor 13.Electric fan 14.Starter motor...
Page 385 TUONO V4 R a-PRC ABS Power supply control unit. The two throttle cables (opening and closing) actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring. On the shaft covers there are 2 double track potentiometers (4 control tracks) by means of which the torque demand is read (and checked).
Page 386 TUONO V4 R a-PRC ABS Power supply • Level 2 - comparison between requested torque and estimated torque generated by the engine • Level 3 - a microprocessor controls the correct operation of the regular microprocessor The consequent maintenance operations may be of different gravity according to the level and the...
Page 387 TUONO V4 R a-PRC ABS Power supply Removing the throttle body • Completely remove the air filter box. • Disconnect the injector fuel pipe. • Release the snap fit clamp on the col- lars from the engine. NOTE DO NOT RELEASE THE CLAMPS COMPLETELY. LEAVE IN AN INTERMEDIATE POSITION TO FACILITATE REFIT- TING.
Page 388 TUONO V4 R a-PRC ABS Power supply Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction. As all the internal components of the throttle body assembly (potentiometers and electrical motor) are contactless, no electrical diagnosis is possible.
Page 389 TUONO V4 R a-PRC ABS Power supply Cylinders synchronisation The control unit knows the intake pressures in the four ducts due to the two pressure sensors: know- ing the cylinder operating phases, it is able to distinguish the individual pressures of the four cyl- inders.
Page 390 TUONO V4 R a-PRC ABS Power supply The procedure then continues with screws 1 and If it is necessary to intervene on Master screws (1-4), proceed as follows: • Remove the filter casing cover. • Remove the remaining cones by undo- ing the eight screws (1).
Page 391 INDEX OF TOPICS SUSP USPENSIONS...
Page 392 TUONO V4 R a-PRC ABS Suspensions Front RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel pin nut M25x1.5 80 Nm (59.00 lb ft) Front brake disk fastening screws 6 + 6 30 Nm (22.13 lb ft) Loct. 243 Removing the front wheel •...
Page 393 TUONO V4 R a-PRC ABS Suspensions • Remove the wheel hub fastening nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps. • Tap the wheel axle slightly with a rub- ber mallet so that the hole on the op- posite side is exposed.
Page 394 TUONO V4 R a-PRC ABS Suspensions CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. CHECKING ROTATION • Manually rotate the inner race of each bearing. The race must turn smoothly without im- pediment or noise.
Page 395 TUONO V4 R a-PRC ABS Suspensions • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings.
Page 396 TUONO V4 R a-PRC ABS Suspensions LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lb ft) Front fork Diagram SUSP - 396...
Page 397 TUONO V4 R a-PRC ABS Suspensions RONT FORK ACHS pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lb ft) Screw (Piston fixing to the stem 30 Nm (22.13 lb ft) base) Upper cap 20 Nm (14.75 lb ft)
Page 398 TUONO V4 R a-PRC ABS Suspensions Specification Desc./Quantity Spring preloading, nut (3) Screw (*) 4-6 turns (**) from fully open Stems (A) (***) protrusion from top plate (excluding cover) 2-3 notches/ 8-12 mm (2-3 notches/0.32-0.47 in) (*) = clockwise (**) = anticlockwise...
Page 399 TUONO V4 R a-PRC ABS Suspensions • Using the appropriate tool fasten the fork in the vice. Specific tooling AP8140149 Guard for assembly operations • Operating on the upper screw, unload the spring. • Loosen the cover without unscrewing it completely.
Page 400 TUONO V4 R a-PRC ABS Suspensions • Using the specific tool, fixed to the pre- load pipe, compress the spring. • Insert a spanner in the lock nut of the cover. Specific tooling 020888Y Pre-load pipe clamp • Unscrew the cap and remove it.
Page 401 TUONO V4 R a-PRC ABS Suspensions • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 402 TUONO V4 R a-PRC ABS Suspensions • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem.
Page 403 TUONO V4 R a-PRC ABS Suspensions • Remove the pumping member pin. Checking the components Stem Check that the sliding surface is not scratched or scored. Any scoring can be removed by sanding with damp sandpaper (grain 1). If the scratches are deep, replace the stem.
Page 404 TUONO V4 R a-PRC ABS Suspensions • lower bushing; • plunger. If there is evidence of excessive wear or damage, replace the component concerned. CAUTION REMOVE ANY IMPURITIES FROM THE BUSHINGS, BEING CAREFUL NOT TO SCRATCH THEIR SURFACES. Replace the following components with new ones: •...
Page 405 TUONO V4 R a-PRC ABS Suspensions • O-Ring on the cap. Oil level: 110 +/- 2 mm (4.33 - 0.08 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
Page 406 TUONO V4 R a-PRC ABS Suspensions • Lock the stem in a vice without dam- aging the surface. • Protect the bearing tube end with ad- hesive tape. • Lubricate the sliding edges with fork oil or sealing grease. •...
Page 407 TUONO V4 R a-PRC ABS Suspensions • Insert the retainer ring in its position. • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140146 Weight •...
Page 408 TUONO V4 R a-PRC ABS Suspensions • Position the forks vertically. • Insert the base washer. • Fill the forks with oil, according to the indicated quantities. • Insert the spring. CAUTION PROCEED WITH CAUTION WHEN INSERTING THE SPRING AND ENSURE THAT THE PART WHERE THE SPI- RAL IS MORE COMPRESSED IS FACING DOWNWARDS.
Page 409 TUONO V4 R a-PRC ABS Suspensions insert a wrench on the nut, while com- pressing the spring. Specific tooling 020890Y Support rod of pumping unit stan- chion AP8140147 Spacer retaining device • Tighten the nut as much as possible. •...
Page 410 TUONO V4 R a-PRC ABS Suspensions Specific tooling AP8140149 Guard for assembly operations Oil level: 110 +/- 2 mm (4.33 - 0.08 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
Page 411 TUONO V4 R a-PRC ABS Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fastening the raiser to the 50 Nm (36.87 lb ft) steering upper yoke Screws fastening upper U-bolt to 25 Nm (18.43 lb ft) handlebar Upper plate stem fastening screws 25 Nm (18.44 lb ft)
Page 412 TUONO V4 R a-PRC ABS Suspensions • Remove the handlebar by unscrewing and removing the four screws. • Undo and remove the fastening cover of the upper yoke on the headstock. • Loosen the screws fixing the fork stan- chions to the upper yoke.
Page 413 TUONO V4 R a-PRC ABS Suspensions • Undo the counter-lock ring, remove the safety washer then unscrew the lower lock ring in order to adjust the steering free play correctly. • Adjust the pre-loading of the steering bearings by tightening the lower ring nut to the prescribed torque.
Page 414 TUONO V4 R a-PRC ABS Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lb ft) Screws fastening sprocket on 50 Nm (36.88 lb ft) sprocket mount Removing the rear wheel •...
Page 415 TUONO V4 R a-PRC ABS Suspensions • Tap lightly on the wheel pin to extract the head of the housing. • Rotate the wheel forwards and disen- gage the drive chain from the sprocket. • Remove the wheel pin together with the right chain guide pad.
Page 416 TUONO V4 R a-PRC ABS Suspensions • Using an Allen spanner on the related seat (1), lock the rotation of the threa- ded pin (2), unscrew and remove the self-locking nut (3) and the threaded pin (2). THE SELF-LOCKING NUTS (3) MUST BE REPLACED EV- ERY THREE CROWN GEAR REMOVALS.
Page 417 TUONO V4 R a-PRC ABS Suspensions Checking the rear wheel CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. REAR WHEEL BEARINGS Check the bearings installed on the wheel. CHECKING ROTATION • Manually rotate the inner race of each bearing. The race must turn smoothly without im- pediment or noise.
Page 418 TUONO V4 R a-PRC ABS Suspensions REAR WHEEL RIM • Using a dial gauge, check that the ra- dial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit val- An excessive eccentricity is usually caused by worn or damaged bearings.
Page 419 TUONO V4 R a-PRC ABS Suspensions FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn. To check: • Fit the entire final drive unit (6) to the wheel. • Manually rotate the sprocket (7) to right...
Page 420 TUONO V4 R a-PRC ABS Suspensions • Retrieve the inner spacer (12). On the left hand side of the wheel: • Use the extractor tool to remove the left hand bearing (16). Specific tooling AP8140180 Bearing extractor • Clean the interior of the hub thoroughly.
Page 421 TUONO V4 R a-PRC ABS Suspensions • Remove the left bearing (18) with the specific extractor. • Collect the inside spacer (19). • Remove the right bearing (20) with the specific extractor. • Retrieve the right hand spacer (21). •...
Page 422 TUONO V4 R a-PRC ABS Suspensions Shock absorbers EAR SHOCK ABSORBER pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lb ft) Dual connecting rod fixing screw 50 Nm (36.88 lb ft) Screw fastening single connecting 50 Nm (36.88 lb ft)
Page 423 TUONO V4 R a-PRC ABS Suspensions Adjusting SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD...
Page 424 TUONO V4 R a-PRC ABS Suspensions NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: • CENTRE OF THE FRONT SCREW FASTEN- ING THE LICENSE PLATE HOLDER TO UN- DERTAIL SECTION AND •...
Page 425 TUONO V4 R a-PRC ABS Suspensions Linkages Removing • Working from the left side of the vehicle, loosen and remove the nut (1). • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3).
Page 426 TUONO V4 R a-PRC ABS Suspensions UPON REFITTING, GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY. PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV- ERAL TIMES THAT JOINTS MOVE SMOOTHLY. SUSP - 426...
Page 427 INDEX OF TOPICS CHAS HASSIS...
Page 428 TUONO V4 R a-PRC ABS Chassis RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lb ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lb ft) Loct. 243 Intake duct fixing nuts...
Page 429 TUONO V4 R a-PRC ABS Chassis EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lb ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft)
Page 430 TUONO V4 R a-PRC ABS Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lb ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lb ft) Fork pin nut M20x1.5 65 Nm (47.94 lb ft)
Page 431 TUONO V4 R a-PRC ABS Chassis • Working from the right side, loosen and remove the locking ring nut. • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.
Page 432 TUONO V4 R a-PRC ABS Chassis • Remove the adjustment bushing from the swingarm pin (2). UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. • If necessary, use a specific tool to re- move a pin from the drive chain.
Page 433 TUONO V4 R a-PRC ABS Chassis DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR. SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm.
Page 434 TUONO V4 R a-PRC ABS Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the adjustment bushing (3) to its seat and tighten it manually. CAUTION THE ADJUSTMENT BUSHING (3) MUST NOT PROTRUDE BEYOND THE CHASSIS INTERNAL EDGE.
Page 435 TUONO V4 R a-PRC ABS Chassis • Working from the right hand side of the vehicle, turn the swingarm pin (2) clockwise. This turns the adjustment bushing (3), driving the swingarm in until fully seated. • Tighten the locking ring nut (1).
Page 436 TUONO V4 R a-PRC ABS Chassis • Fit the washer on the screw • Tighten the screw. • Install the rear shock absorber and the linkages. • Fit the rear brake calliper plate. • Fasten the two pipe grommets on the swingarm •...
Page 437 TUONO V4 R a-PRC ABS Chassis 3. Chain with chain stretch of 3%, which must therefore be replaced in accordance with ap- plicable legislation. Perform the procedure described as follows to check chain wear: • Tauten the chain. • Place the jaws of the tool on the rollers...
Page 438 TUONO V4 R a-PRC ABS Chassis If you need to adjust chain tension after the check: • Place the vehicle on its rear service stand (OPT). • Loosen the nut (1) completely. • Loosen both lock nuts (4). • Actuate on the adjuster screws (5) and...
Page 439 TUONO V4 R a-PRC ABS Chassis • Wash the chain with naphtha or kerosene. If it tends to rust quickly, carry out the mainte- nance operations more frequently. Lubricate the chain at the intervals shown in the routine maintenance table and whenever necessary.
Page 440 TUONO V4 R a-PRC ABS Chassis • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand IDE STAND pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lb ft)
Page 441 TUONO V4 R a-PRC ABS Chassis Side stand • Remove the clamp. • Disconnect the stand connector. • Unscrew and remove the two screws. • Remove the side stand. CHAS - 441...
Page 442 TUONO V4 R a-PRC ABS Chassis Exhaust XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lb ft) nuts Silencer clamp fixing screw - central 10 Nm (7.38 lb ft) manifold Screw used to secure the silencer to 25 Nm (18.44 lb ft)
Page 443 TUONO V4 R a-PRC ABS Chassis • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis; retrieve the collar, the washer and the nut.
Page 444 TUONO V4 R a-PRC ABS Chassis • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the screw from the cable grommet for the two exhaust butterfly valve control cables. CAUTION ON REASSEMBLY, POSITION AND TIGHTEN THE SCREW BUT NOT THE CABLE GROMMET.
Page 445 TUONO V4 R a-PRC ABS Chassis • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front exhaust manifolds and the catalytic converter • Move the radiator forward.
Page 446 TUONO V4 R a-PRC ABS Chassis REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers. • Remove both rear exhaust manifolds.
Page 447 TUONO V4 R a-PRC ABS Chassis • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler IL RADIATOR pos.
Page 448 TUONO V4 R a-PRC ABS Chassis Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe. • Release the clamp and disconnect the left hand radiator pipe.
Page 449 TUONO V4 R a-PRC ABS Chassis CHAS - 449...
Page 450 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 451 TUONO V4 R a-PRC ABS Braking system Key: 1. ABS control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main fuse 6. Injection ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.ABS control unit fuse ABS control unit pinout •...
Page 452 TUONO V4 R a-PRC ABS Braking system • PIN 12 (White/Brown) - Front speed sensor positive • PIN 13 (Yellow/Brown) - Rear speed sensor positive • PIN 14 (Yellow) - Rear speed sensor input • PIN 17 (Blue/Red) - ABS warning light •...
Page 453 TUONO V4 R a-PRC ABS Braking system ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8.
Page 454 TUONO V4 R a-PRC ABS Braking system Intakes and supplies 1. Supply to the rear brake calliper. 2. Intake from the rear brake pump. 3. Intake from the front brake pump. 4. Supply to the front brake calliper. ABS OPERATION General specifications: The front circuit is similar to the rear circuit.
Page 455 TUONO V4 R a-PRC ABS Braking system E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure reduction phase exceeds the pre-set time limit.
Page 456 TUONO V4 R a-PRC ABS Braking system - if the speed difference lasts long, the system may detect an error and deactivates the ABS system. As a consequence, the system works as any regular braking system. Riding with an active ABS system •...
Page 457 TUONO V4 R a-PRC ABS Braking system REPLACING THE ABS CONTROL UNIT • Before replacing the ABS control unit, mark the hoses so that they can be refit correctly on the new control unit. • Remove the ABS support (1), the heat shield plate (2) and finally the ABS con- trol unit.
Page 458 TUONO V4 R a-PRC ABS Braking system • Take care of hose position on the sup- port. 1. Goes to the pump. 2. Goes to the caliper. • After replacing hoses or the control unit the entire ABS system must be bled.
Page 459 TUONO V4 R a-PRC ABS Braking system ABS PIPES ROUTING TABLE A - ABS PIPES ROUTING 1. Small clamps TABLE B - ABS PIPES ROUTING 1. Rear speed sensor cable. 2. Cable guide. 3. Cable grommet. 4. Cable grommet. TABLE C - ABS PIPES ROUTING The hydraulic pipes must necessarily pass as shown in the figure.
Page 460 TUONO V4 R a-PRC ABS Braking system Guide to diagnosis FOREWORD Each time the key is set to ON, if at least one cur- rent or stored error is detected*, the ABS warning light turns on permanently. The ABS system is automatically deactivated...
Page 461 TUONO V4 R a-PRC ABS Braking system 7. CONTACT TECHNICAL SERVICE 8. CHECK: • A. Cable continuity between PIN17 of the ABS control unit connector and PIN28 of the instrument panel. • B. Check connectors - refer to the operations described in the chapter If the previous checks are OK, the causes might be: •...
Page 462 TUONO V4 R a-PRC ABS Braking system P.A.D.S. characteristic Value/example Unit of Notes measure ment Speed of the rear wheel km/h Battery voltage Front brake circuit pressure Quality test of the sensors When turning the wheel or acting on the brake, a variation of parameters must be detected.
Page 463 TUONO V4 R a-PRC ABS Braking system P.A.D.S. characteristic. Value/example Units of Notes measure ment Front wheel speed sensor electrical C1033 Short circuit or open circuit to negative or short diagnosis circuit to positive Front wheel speed sensor functional C1034...
Page 464 TUONO V4 R a-PRC ABS Braking system • Select Self-diagnosis. • Go to the page Error codes. • Select an error and show the Ambient parameter error(where provided). • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded).
Page 465 TUONO V4 R a-PRC ABS Braking system • If there is no PDF printer, there are several free programs, ask the infor- mation systems to install it. • Name the file with a name that contains the main information of the vehicle and the analysed component e.g.
Page 466 TUONO V4 R a-PRC ABS Braking system - Check the type and sizes of the fitted tyres. - Check the type and sizes of the fitted tone wheels. C1031 Rear wheel speed sensor electrical diagnosis - open circuit, shorted to negative or shorted to positive.
Page 467 TUONO V4 R a-PRC ABS Braking system The circuit is open: - Perform the check of the connectors on the components and the ABS control unit. - Check the good condition and the wiring continuity: • between ABS control unit PIN 3 and sensor PIN 1 (White cable) •...
Page 468 TUONO V4 R a-PRC ABS Braking system CAN LINE ERRORS U2921 Controller error U2922 Line failure (busoff) Error cause Communication problem on the CAN line: probable contact. Troubleshooting Check the good condition and the wiring continuity: • between ABS control unit PIN 2, instrument panel PIN 26 and injection control unit PIN 80 (Orange cable) •...
Page 469 TUONO V4 R a-PRC ABS Braking system Troubleshooting - Connect to the injection control unit diagnosis - Check according to the indication in the figure whether there is or not continuity between the contact of the switches and in the various opening/closing states: •...
Page 470 TUONO V4 R a-PRC ABS Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
Page 471 TUONO V4 R a-PRC ABS Braking system Component maintenance The vehicle is fitted with a two-channel ABS sys- tem, i.e. it works on both the front and the rear wheel. Check periodically and each time the wheels are refitted, the tone wheel (2) or the sensor (1) re- placed, that the wheel distance is constant at each 360°.
Page 472 TUONO V4 R a-PRC ABS Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake disc fixing screws 30 Nm (22.13 lb ft) Loct. 243 Odometer sensor fastening screw 10 Nm (7.38 lb ft) Rear brake calliper support plate 50 Nm (36.88 lb ft)
Page 473 TUONO V4 R a-PRC ABS Braking system Front brake calliper RONT BRAKE CALLIPER Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lb ft) Rear brake disc Removal • Remove the rear wheel.
Page 474 TUONO V4 R a-PRC ABS Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). DURING REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION DURING REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 475 TUONO V4 R a-PRC ABS Braking system Removal • Remove the front wheel The following operations refers to a single disc but apply to both. • Unscrew and remove the six brake disc screws (1). • Remove the brake disc (2).
Page 476 TUONO V4 R a-PRC ABS Braking system exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE).
Page 477 TUONO V4 R a-PRC ABS Braking system • Fit the two new pads in the correct po- sition. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CAL- LIPER. • Fit the front brake calliper on the disc.
Page 478 TUONO V4 R a-PRC ABS Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE...
Page 479 TUONO V4 R a-PRC ABS Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper.
Page 480 TUONO V4 R a-PRC ABS Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 481 TUONO V4 R a-PRC ABS Braking system • Operate the brake lever and then open the bleed valve on the calliper 1/4 of a turn to let the air out. • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air.
Page 482 TUONO V4 R a-PRC ABS Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lb ft) Rear brake pump fixing screws 8 Nm (5.90 lb ft) Rear brake lever fixing screw 25 Nm (18.44 lb ft)
Page 483 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 484 TUONO V4 R a-PRC ABS Cooling system Circuit diagram SYSTEM TYPE Self bleeding cooling circuit with aspirating centrifugal pump (1), three-way thermostat valve (2), cooling radiator (3) with electric fans (4) and expansion tank (5). key: COOL SYS - 484...
Page 485 TUONO V4 R a-PRC ABS Cooling system 1. Centrifugal pump 2. Thermostatic valve 3. Radiator 4. Electric fans 5. Expansion tank 6. With the thermostat open 7. With the thermostat closed 8. From front head 9. From rear head 10.To upper crankcase OOLING pos.
Page 486 TUONO V4 R a-PRC ABS Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws used to fasten the pump to M6x25 10 Nm (7.38 lb ft) the crankcase Water pump locking screw M6x35 10 Nm (7.38 lb ft)
Page 487 TUONO V4 R a-PRC ABS Cooling system • Internally blocking the nuts, unscrew the fixing screw from the internal part. • Make sure that the nuts and washers are retrieved. See also Fairing mounting panels Twistgrip position sensor • The retainer points of the electric fan...
Page 488 TUONO V4 R a-PRC ABS Cooling system • Unscrew and remove the system drain screw and retrieve the sealing washer. • Wait for the entire circuit to drain (en- gine+pipes+radiator) • Refit the system drain screw complete with a new washer.
Page 489 TUONO V4 R a-PRC ABS Cooling system • Unscrew and remove the two screws fastening the pipe to the engine. • Retrieve the gasket and replace with a new component when refitting. See also Coolant replacement • Drain two litres of oil from the engine block.
Page 490 TUONO V4 R a-PRC ABS Cooling system • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw. • Remove the pump cover. TO PREVENT IRREPARABLE DAMAGE TO THE PUMP, UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER.
Page 491 TUONO V4 R a-PRC ABS Cooling system • Replace, by one, both screws that do not fasten the pump to the crankcase with TCEI M6x35 screws. Start from the one placed on the front side of the vehicle. • Remove the water pump following the previous instructions, without disconnecting the han- dles.
Page 492 TUONO V4 R a-PRC ABS Cooling system VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF. RADIATOR REMOVAL • Drain off the cooling system. • Remove the front underfairings and the hand grip position sensor •...
Page 493 TUONO V4 R a-PRC ABS Cooling system • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return pipe to the radiator pipe UPON REFITTING, REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE.
Page 494 INDEX OF TOPICS BODYW ODYWORK...
Page 495 TUONO V4 R a-PRC ABS Bodywork RONT HEADLAMP pos. Description Type Quantity Torque Notes Screws fastening the headlamp to 3 Nm (1.47 lb ft) the upper fairing fastener Screws fastening headlamp to front 4 Nm (2.95 lb ft) fairing BODYW - 495...
Page 496 TUONO V4 R a-PRC ABS Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws used to fasten the rubber SWP 4.9 3 Nm (2.21 lb ft) blocks to the instrument panel Instrument panel support shell fas- SWP 4.9 2 Nm (1.48 lb ft)
Page 497 TUONO V4 R a-PRC ABS Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 4 Nm (2.95 lbf ft) Engine fairing fastening screw 4 Nm (2.95 lb ft) Screws fastening the lower fairing to 4 Nm (2.95 lb ft)
Page 498 TUONO V4 R a-PRC ABS Bodywork AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lb ft) Taillight mounting bracket fixing 4 Nm (2.95 lb ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9...
Page 499 TUONO V4 R a-PRC ABS Bodywork pos. Description Type Quantity Torque Notes Screws used to fasten the small side 2 Nm (1.48 lb ft) fairings to the tank Screws used to fasten the small side 1 Nm (0.74 lb ft)
Page 500 TUONO V4 R a-PRC ABS Bodywork ELMET COMPARTMENT Pos. Description Type Quantity Torque Notes Screws and self-locking nuts used to 4 Nm (2.95 lb ft) fasten the number plate holder to the saddle support plate Lower saddle support closure fasten- 3 Nm (2.21 lb ft)
Page 501 TUONO V4 R a-PRC ABS Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw for fastening the rid- 4 Nm (2.95 lb ft) er's saddle to the fuel tank Filler to tank retaining screws 4 Nm (2.95 lb ft) Screws fixing the fuel pump flange to 3 Nm (2.21 lb ft)
Page 502 TUONO V4 R a-PRC ABS Bodywork AIRING pos. Description Type Quantity Torque Notes Screws fastening the lower fairing to 3 Nm (2.21 lb ft) the lower bracket Screws fixing the side fairings to the 1.5 Nm (1.10 lbf ft) side spacers Seat •...
Page 503 TUONO V4 R a-PRC ABS Bodywork • Remove the passenger seat by raising first the end. • Complete removal by raising and slid- ing the passenger seat. CAUTION WHEN REFITTING, PAY ATTENTION TO CORRECTLY IN- SERT THE GUIDE. • Undo the two screws and remove the saddle.
Page 504 TUONO V4 R a-PRC ABS Bodywork Instrument panel • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the support. • Rotate the instrument panel connector retainer lever. •...
Page 505 TUONO V4 R a-PRC ABS Bodywork Headlight fairing • Remove the side fairings. • Remove the front rivet. • Remove the windscreen by undoing the screw. • Remove the four rear screws and the two side rivets. BODYW - 505...
Page 506 TUONO V4 R a-PRC ABS Bodywork • Disconnect the three connectors. • Remove the windshield. Side body panels • Remove the saddle and the passenger saddle. • The operations described below are valid for both side fairings. • Undo and remove the three screws and remove the fairings.
Page 507 TUONO V4 R a-PRC ABS Bodywork • Unscrew and remove the screw. • Slide the side fairing by pulling it and paying attention to the slots. Fairing mounting panels • Undo and remove the two central screws. • Remove the underfairing.
Page 508 TUONO V4 R a-PRC ABS Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit. • Disconnect the air temperature sensor connector. • Move the two rear coil connectors. See also Control unit • Unscrew and remove the eight air filter box cover screws.
Page 509 TUONO V4 R a-PRC ABS Bodywork FILTER BOX BASE • Open the air filter box cover. • Unscrew and remove the air intake duct fixing screws. • Working from both sides, unscrew and remove the air pressure sensor fixing screw.
Page 510 TUONO V4 R a-PRC ABS Bodywork • Release the cable harness from the cable grommet on the filter box. • Remove the air filter box base. Rear mudguard • Unscrew and remove the two screws. • Remove the rear mudguard.
Page 511 TUONO V4 R a-PRC ABS Bodywork • Undo and remove the rear screw. • Remove the lug and the radiator pro- tection. Fuel tank • Unscrew and remove the front screw fixing the tank. • Remove the rider saddle. •...
Page 512 TUONO V4 R a-PRC ABS Bodywork • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank. Front mudguard • Working on both sides of the vehicle, undo and remove the two screws. • Remove the front mudguard.
Page 513 TUONO V4 R a-PRC ABS Bodywork • Unscrew and remove the five semi- arch brace fixing screws. See also Instrument panel • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws.
Page 514 TUONO V4 R a-PRC ABS Bodywork • Fasten the main cable harness to the semi-arch brace with a clamp. • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws.
Page 515 TUONO V4 R a-PRC ABS Bodywork • Join the remaining connectors and ar- range the cable carefully in the space available within the arch brace. Note that there are two pairs of connectors which may be connected incorrectly. The male connector on the cable with the red strip must be connected to the female connector on the longer cable.
Page 516 TUONO V4 R a-PRC ABS Bodywork Seat • The following operations are valid for both sides. • Unscrew and remove the screw (4). • Remove the rivet (5) placed in the low- er part of the fairing. • Unscrew and remove the screw (6).
Page 517 TUONO V4 R a-PRC ABS Bodywork • Previously take the battery off. • Unscrew and remove the two license plate support screws. • Remove the cover placed under the tail fairing. • Undo and remove the undertail section screw. •...
Page 518 TUONO V4 R a-PRC ABS Bodywork • Unscrew and remove the two rear tail- light screws. • Remove the taillight. • Remove the several electrical compo- nents. • Undo and remove the screw. • Remove the undertail section. Side air deflectors The following procedure is for a single lateral duct but is applicable to both.
Page 519 TUONO V4 R a-PRC ABS Bodywork DURING REASSEMBLY, THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN- SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS. See also Headlight fairing BODYW - 519...
Page 520 INDEX OF TOPICS PRE DE DELIVERY...
Page 521 TUONO V4 R a-PRC ABS Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
Page 522 TUONO V4 R a-PRC ABS Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 523 TUONO V4 R a-PRC ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 524 TUONO V4 R a-PRC ABS Pre-delivery Specific operations for the vehicle • Remove the screw (2). • Remove the plastic cover (1). • Fit the rear pedal in its seat. • Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm (13.27 lbf ft)
Page 525 a-PRC setting buttons: 222 ABS: 232, 451, 461 Air filter: 65 Air temperature sensor: 178 Alternator: Battery: 146, 157 Brake: 472–474, 476, 477, 481, 482 Brake calliper: 472, 473 Brake disc: 473, 474 Brake pads: 476, 477 Brake pump: 481, 482 Bulbs: Bushings: CAN line: 233...
Page 526 Front head: 295, 302, 306, 307, 330, 344, 346 Front headlamp: Front wheel: 392, 393, 398, 475 Fuel: 66, 150, 187, 241, 382, 511 Fuel pump: 150, 187, 382 Fuses: 150 Handlebar: 395 Head cover: 67–69, 75, 294, 295, 302, 314, 320 Headlight: 505, 519 Helmet compartment: Identification: 11...
Page 527 Side fairings: 506 Side stand: 208, 441 Side stand sensor: 208 Spark plug: 62, 67, 68 Speed sensor: 158 Stand: 208, 241, 245, 440, 441 Start-up: 149, 271 Starter motor: 271 Steering damper: 410 Stepper motor: 388 Tank: 66, 241, 511 Throttle body: 67, 68, 192, 387, 388 Track: Transmission: 12, 342, 344...

APRILIA TUONO V4 R a-PRC ABS Service Station Manual

Quick Links

Related Manuals for APRILIA TUONO V4 R a-PRC ABS

Summary of Contents for APRILIA TUONO V4 R a-PRC ABS