APRILIA Tuono V4 1100 Factory Service Station Manual

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SERVICE STATION MANUAL

2Q000504

Tuono V4 1100 Factory

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Summary of Contents for APRILIA Tuono V4 1100 Factory

Page 1 SERVICE STATION MANUAL 2Q000504 Tuono V4 1100 Factory...
Page 2 Only by requesting original aprilia spare parts can you be of purchasing products that were developed and tested during the design and development of the vehicle itself. All Aprilia original spare parts undergo quality control procedures to guarantee reliability and durability.
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 PRE DE DELIVERY CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE 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...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 Tuono V4 1100 Factory 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 8 Tuono V4 1100 Factory Pre-delivery TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. THE LACK OF AN ADEQUATE BATTERY CHARGE BEFORE THE FIRST USE WILL CAUSE A PREMATURE FAILURE OF THE BATTERY. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE, AND PERFORM THE REVERSE OPERATION DURING REMOVAL.
Page 9 Tuono V4 1100 Factory Pre-delivery Quick charge - Electric current: 8 A - Time: 0,5 hours WARNING THE CHARGE VOLTAGE MUST NEVER EXCEED 15V. WARNINGS - Do not knock, throw or subject the battery to violent shocks. - Do not carry the battery together with flammable, explosive or sharp objects.
Page 10 Tuono V4 1100 Factory Pre-delivery • Check that air bubbles come out of the cells; let the liquid flow into the cells for at least 20 minutes. • If no air bubbles escape and the liquid does not flow, tap lightly on the bottom of the container until the liquid begins to flow into the cells.
Page 11 Tuono V4 1100 Factory Pre-delivery - Abnormal noise Static test Static control after the test drive: - Restarting when warmed up - Idling - Uniform turning of the steering - Possible leaks - Radiator electric fans operation Functional inspection - Hydraulic braking system...
Page 12 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 13 Tuono V4 1100 Factory 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 14 Tuono V4 1100 Factory 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 15 CAUTION THE BEARING MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE THEY MUST BE REPLACED. • Use only aprilia ORIGINAL SPARE PARTS. • Always use the recommended lubricants and consumable material. • Lubricate the parts (when possible) before reassembling them.
Page 16 It is advisable to not exceed 7000 rpm for the first 1000 km (621 mi) and then not to exceed 8500 rpm up until 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 17 KEY: ZD4: WMI (World Manufacturer Identifier) code; KZ: model; A00: Europe; UA0: USA (Tuono V4 1100) B00: Europe; UB0: USA (Tuono V4 1100 Factory) 0: digit free; Y: year of manufacture; S: production plant (S= Scorzè); XXXXXX: serial number (6 digits);...
Page 18 Max. length 2,070 mm (81.50 in) Max. width 810 mm (31.88 in) Max. height (at the top fairing) (Tuono V4 1100 Factory) 1,085 mm (42.71 in) Max. height (at the top fairing) (Tuono V4 1100) 1170 mm (46.06 in) Wheelbase 1,450 mm (57.09 in)
Page 19 Tuono V4 1100 Factory Characteristics Specification Desc./Quantity system), ATC (traction control), AWC (wheelie control), AQS (Assisted upshift and downshift without using the clutch), PIT (pit lane speed control). Capacities APACITY Specification Desc./Quantity Fuel tank capacity (including reserve) 17.9 l (3.93 UK gal; 4.72 US gal) Fuel tank reserve capacity 4 l (0.88 UK gal;...
Page 20 120 mm (4.72 in) Front travel - Tuono V4 1100 (Sachs) 117 mm (4.61 in) Rear shock absorber - Tuono V4 1100 Factory (Ohlins - ASC) With progressive linkage with APS system. Shock absorber with piggy-back that can be electronically adjusted for hydraulic brake compression and extension and mechanically adjusted for spring pre-loading.
Page 21 Tuono V4 1100 Factory Characteristics Specification Desc./Quantity (1.18 inches) and 2 pads - radial pump and brake pipe in metal braid. Rear disc brake -220 mm diam. (8.66 inches), 2-piston callipers - 32 mm diam. (1.25 inches) - pump with built-in tank and metal braid pipe.
Page 22 Tuono V4 1100 Factory Characteristics ETRIC SCREW TIGHTENING TORQUES ON FASTENERS WITH PLASTIC COMPRESSION WITHOUT INSERTED COL- LAR OR BUSH Tightening torque: 1.5 Nm (1.10 lb ft) 2 Nm (1.47 lb ft) 3 Nm (2.21 lbf ft) CAUTION THE SCREWS WITH THREAD-LOCK SEALANT (PRE-IMPREGNATED) MUST BE REPLACED WITH NEW SCREWS AFTER THEY HAVE BEEN LOOSENED.
Page 23 Pos. Description Type Quantity Torque Notes Front brake calliper fastening screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) ASC (TUONO V4 1100 FACTORY) RONT FORK HLINS Pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 2 + 2 10 Nm (7.37 lbf ft)
Page 24 Tuono V4 1100 Factory Characteristics (TUONO V4 1100) RONT FORK ACHS Pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 10 Nm (7.37 lbf ft) screws ABS sensor fixing screw 8 Nm (5.90 lbf ft) Upper cap 20 Nm (14.75 lbf ft) Upper cap locking nut 20 Nm (14.75 lbf ft)
Page 25 Tuono V4 1100 Factory Characteristics TEERING Pos. Description Type Quantity Torque Notes Screws fastening raiser to upper 50 Nm (36.88 lbf ft) Loctite 243 steering yoke Upper handlebar U-bolt fastening 25 Nm (18.44 lbf ft) screws Upper plate stem fastening screws 25 Nm (18.44 lbf ft)
Page 26 Tuono V4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Anti-vibration counterweight fasten- M18x15 35 Nm (25.81 lb ft) ing bushings Traction control command fastening 2.5 Nm (1.84 lbf ft) screw Mirror retaining pin 40 Nm (29.50 lb ft)
Page 27 Tuono V4 1100 Factory Characteristics LUTCH LEVER Pos. Description Type Quantity Torque Notes Clutch lever collar fastening screws 10 Nm (7.38 lbf ft) RONT ELECTRICAL SYSTEM Pos. Description Type Quantity Torque Notes Voltage regulator fastening screws 6 Nm (4.42 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft)
Page 28 Tuono V4 1100 Factory Characteristics AIRING FRONT Pos. Description Type Quantity Torque Notes Top fairing fixing screws 0.5 Nm (0.37 lb ft) UCTS Pos. Description Type Quantity Torque Notes Duct fixing screws 4 Nm (2.95 lbf ft) CHAR - 28...
Page 29 Tuono V4 1100 Factory Characteristics RONT MUDGUARD NGINE FAIRING Pos. Description Type Quantity Torque Notes Front mudguard fixing screws 7 Nm (5.16 lbf ft) Central part CHAR - 29...
Page 30 Tuono V4 1100 Factory Characteristics OOLING Pos. Description Type Quantity Torque Notes Flanged hex. head screws for fasten- M6x20 10 Nm (7.38 lbf ft) ing the water radiator support brack- et to the frame Flanged hex. head screws for fasten- M6x20 7 Nm (5.16 lbf ft)
Page 31 Tuono V4 1100 Factory Characteristics HASSIS Pos. Description Type Quantity Torque Notes Front couplings 2 + 2 50 Nm (36.88 lbf ft) Lower rear coupling 50 Nm (36.88 lbf ft) RH lower rear regulator bushing M18x1.5 12 Nm (8.85 lbf ft) RH upper rear regulator bushing M18x1.5...
Page 32 Tuono V4 1100 Factory Characteristics EARBOX LEVER Pos. Description Type Quantity Torque Notes Pinion cover guard fastening screws 6 Nm (4.43 lbf ft) Threaded stand-off 8 Nm (5.90 lbf ft) Countersunk flat head hex socket M6x35 10 Nm (7.38 lbf ft) Loct.
Page 33 Tuono V4 1100 Factory Characteristics OOTRESTS Pos. Description Type Quantity Torque Notes Screws used to fasten the rider's 2 + 2 25 Nm (18.44 lbf ft) footrest to the chassis Screws used to fasten the passeng- 18 Nm (13.28 lbf ft)
Page 34 Tuono V4 1100 Factory Characteristics EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 Nm (4.42 lbf ft) Rear brake pump fastening screws 8 Nm (5.90 lbf ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lbf ft)
Page 35 Tuono V4 1100 Factory Characteristics IDE FAIRINGS Pos. Description Type Quantity Torque Notes Screws used to fasten the side fair- 1.5 Nm (1.11 lbf ft) ings to the spacers UEL TANK Pos. Description Type Quantity Torque Notes Fastener screw of left hand side cov- 3 Nm (2.21 lbf ft)
Page 36: Table Of Contents
Tuono V4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Screw fastening front part to frame 8 Nm (5.90 lbf ft) Screws fastening rear part to saddle 7 Nm (5.16 lbf ft) carrier subframe Tank breather connectors 3 Nm (2.21 lbf ft) Fastener screws of tilt sensor mount 7 Nm (5.16 lbf ft)
Page 37: Torque Notes
Tuono V4 1100 Factory Characteristics OCKS Pos. Description Type Quantity Torque Notes Cylindrical head hex. socket screws M5x14 4 Nm (2.95 lbf ft) for fastening filler to tank Shear head screw (to the left of the M8x28 manual tighten until the...
Page 38: Nm (5.90 Lbf Ft)
Tuono V4 1100 Factory Characteristics XHAUST Pos. Description Type Quantity Torque Notes Exhaust manifold flange fastening 13 Nm (9.59 lbf ft) nuts Silencer - central manifold clamp fas- 20 Nm (14.75 lbf ft) tening screw Screw used to secure the silencer to 25 Nm (18.44 lbf ft)
Page 39: Nm (2.21 Lbf Ft)
Tuono V4 1100 Factory Characteristics CONTROL UNIT Pos. Description Type Quantity Torque Notes Oil tube screws M10x1 23-26 Nm (16.96-19.18 lbf ft) Control unit support screws 6.8+/-1 Nm (5.01 +/-0.74 lbf ft) Back side CHAR - 39...
Page 40 Tuono V4 1100 Factory Characteristics EAR SWINGARMS Pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain guard fastening screws 2 Nm (1.47 lbf ft)
Page 41 Tuono V4 1100 Factory Characteristics EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lbf ft) Nuts used to fasten the crown to the 50 Nm (36.88 lbf ft) sprocket Rear brake disc fastening screws 30 Nm (22.13 lbf ft)
Page 42: Nm (1.84 Lbf Ft)
Tuono V4 1100 Factory Characteristics EAR SHOCK ABSORBER Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual connecting rod fixing screw 50 Nm (36.88 lbf ft) Screw fastening single connecting 50 Nm (36.88 lbf ft)
Page 43 Tuono V4 1100 Factory Characteristics EAR BODYWORK Pos. Description Type Quantity Torque Notes Passenger saddle support fixing 18 Nm (13.27 lbf ft) screws Engine CHAR - 43...
Page 44: Nm (4.43 Lbf Ft)
Tuono V4 1100 Factory Characteristics LUTCH COVER Pos. Description Type Quantity Torque Notes Flanged hex cap screw M6x20 10 Nm (7.38 lbf ft) Flanged hex cap screw M6x35 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque.
Page 45 Tuono V4 1100 Factory Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.38 lb ft) crankcase EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft)
Page 46 Tuono V4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Cam shaft cam tower fixing screws M6x45 11 Nm (8.11 lb ft) Reed valve covers fixing screws 6 Nm (4.43 lb ft) Water outlet coupling fixing screw 10 Nm (7.38 lb ft) Pre-impregnated or else Loct.
Page 47 Tuono V4 1100 Factory Characteristics RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lbf ft) + 130° and under head with PANKL Lubricant 01 (PLB01) Primary fixing ring nut 200 Nm (147.51 lbf ft)
Page 48: M10
Tuono V4 1100 Factory Characteristics RANKCASE Pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lbf ft) Loct. 270 Flanged hex cap screw M8x70 25 Nm (18.44 lbf ft) Lubricate the head and under the head. Flanged hex cap screw M6x50 10 Nm (7.38 lbf ft)
Page 49 Tuono V4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Screw fastening ground cable to the 6 Nm (4.43 lbf ft) engine EARBOX Pos. Description Type Quantity Torque Notes "Philips" cylindrical head hex. socket M6x20 10 Nm (7.38 lbf ft)
Page 50 Tuono V4 1100 Factory Characteristics LUTCH Pos. Description Type Quantity Torque Notes Flanged nut fixing clutch M20x1 150 Nm (110.63 lbf ft) Loct. 243 Clutch springs SHC fixing screw M6x25 10 Nm (7.38 lbf ft) GNITION UNIT Pos. Description Type...
Page 51: Nm (36.88 Lbf Ft)
Tuono V4 1100 Factory Characteristics Pos. Description Type Quantity Torque Notes Starter motor SHC fastener screw M6x40 10 Nm (7.38 lbf ft) Screw fastening cables to the starter 6 Nm (4.43 lbf ft) motor ENERATOR COVER Pos. Description Type Quantity...
Page 52 Tuono V4 1100 Factory Characteristics UBRICATION Pos. Description Type Quantity Torque Notes Oil filter coupling fastening screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.13 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft)
Page 53 Tuono V4 1100 Factory Characteristics ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket secon- M6x16 10 Nm (7.38 lbf ft) dary air solenoid screws CHAR - 53...
Page 54 Tuono V4 1100 Factory Characteristics ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lbf ft) for fastening the pump to the crank- case CHAR - 54...
Page 55 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 56 Tuono V4 1100 Factory Special tools PECIAL TOOLS Stores code Description 020845Y Engine support 020846Y Containment tray + plastic plugs 020847Y Flywheel extractor 020914Y Flywheel stop 020849Y Clutch retainer tool 020850Y Primary gear lock S-TOOLS - 56...
Page 57 Tuono V4 1100 Factory Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs 020981Y Lever for disarming the hydraulic tension- er of the timing chain 020980Y...
Page 58 Tuono V4 1100 Factory Special tools Stores code Description 020858Y Maintenance of the pistons in the cylin- ders AP8140199 Tool storage panel 8140426 Hooks for panel 020860Y Motor support extension 020862Y Punch assembly cage with rollers gear- box control rod...
Page 59 Tuono V4 1100 Factory Special tools Stores code Description 020956Y Support for camshaft gear on head 020883Y Fitting/removing timing chain tensioner tool 020709Y Engine support AP8140187 U-bolt for motor support 020376Y Adaptor handle 020363Y 20mm oil seal guide S-TOOLS - 59...
Page 60 Tuono V4 1100 Factory Special tools Stores code Description 020364Y 25-mm guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Bearing extractor AP8140179 Valve springs compressor 0277308 Guide bushing for gearbox secondary shaft S-TOOLS - 60...
Page 61 Tuono V4 1100 Factory Special tools Stores code Description 020877Y Calliper for clamps 020926Y Tool for fitting clutch bushing AP8140146 Weight AP8140189 Tool for mounting the oil seal for holes with diam. 43 mm (1.69 in) AP8140149 Guard for assembly operations...
Page 62 Tuono V4 1100 Factory Special tools Stores code Description 020888Y Pre-load tube clamp 020889Y Wrench for locking pumping unit ring nut 020890Y Support rod of pumping unit stanchion AP8140181 Tool for checking fuel pressure 020922Y Diagnostic tool 021017Y OBD cable for E5 vehicles...
Page 63 INDEX OF TOPICS MAIN AINTENANCE...
Page 64 Tuono V4 1100 Factory Maintenance Scheduled maintenance table SCHEDULED MAINTENANCE TABLE RESERVED FOR THE US-LATAM MARKET Key: I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE, IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check at each engine start (2) Check and clean, adjust or replace, if necessary, before every journey (3) Check and clean, adjust or replace if necessary every 621 mi (1,000 km).
Page 65 Tuono V4 1100 Factory Maintenance NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT. ENSURE THAT THE VEHICLE CALIBRATION IS UP TO DATE AFTER UPDATING THE DIAGNOS- TIC TOOL.
Page 66 Tuono V4 1100 Factory Maintenance Km x 1.000 or (months) maximum 1 (1) 10 (10) 20 (20) 30 (30) 40 (40) Fault indicator light on instrument cluster (1) Fuel lines (4) Clutch wear (6) Labour time (minutes) To carry out the correct verification "Flexible coupling pin nuts tightening" indicated in the scheduled maintenance table, refer to the corresponding procedure in chapter "Maintenance / Verification Flex-...
Page 67 Tuono V4 1100 Factory Maintenance Km x 1,000 (mi x 1,000) 1 (0.6) EVERY EVERY (6.2) (12.4) (18.6) (24.9) MONTH MONTH Engine oil filter (5) Raked General vehicle operation (5) Valve clearance (6) Cooling system (5) Brake systems (5) Light circuit...
Page 68 Tuono V4 1100 Factory Maintenance TABLE OF RECOMMENDED PRODUCTS Product Description Specifications Engine oil 10W -50 Synthetic-based lubricant for high per- SAE 10W 50; API SL; JASO MA2 formance four-stroke engines. Lithium-based grease Lithium-calcium soap based grease colour - black, contains EP (Extreme...
Page 69 Tuono V4 1100 Factory Maintenance REAR SPARK PLUGS Cylinder 1 To proceed with the removal of the cylinder 1 spark plug, proceed as described: • After removing the fixing screw of main wiring harness support, release it from the filter housing by lifting it as indica- ted.
Page 70 Tuono V4 1100 Factory Maintenance Cylinder 3 To proceed with the removal of the cylinder 3 spark plug, proceed as described: • Release the connector from the sup- port on the filter housing and discon- nect it. • Remove the air pressure sensor fixing screw to facilitate the coil removal.
Page 71 Tuono V4 1100 Factory Maintenance Check THE OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM. CAUTION DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT A STANDSTILL TO WARM UP THE ENGINE AND OBTAIN THE OPERATING TEMPERATURE OF ENGINE OIL.
Page 72 Tuono V4 1100 Factory Maintenance • Place a container with suitable capaci- ty under the drainage plug. • Unscrew and remove the drainage plug. • Unscrew and remove the filler cap. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely.
Page 73 Tuono V4 1100 Factory Maintenance • Warm up the engine up by running it for a few minutes, then switch it off. After thirty seconds, check the level with a oil level dipstick. Top up if necessary. CAUTION THE OIL LEVEL MUST NEVER DROP BELOW THE MINI- MUM MARKING OR EXCEED THE MAXIMUM MARKING;...
Page 74 Tuono V4 1100 Factory Maintenance Air filter To remove the air filter, the fuel tank must be re- moved to be able to reach the filter housing area. Then proceed as described: • - Disconnect the "ENGINE" connector from the control unit.
Page 75 Tuono V4 1100 Factory Maintenance • Remove the control unit complete with support. • After having removed the fixing screw of the engine wiring harness support, release it from the filter housing by lift- ing it as indicated. • Remove the quick shift connector from its seat.
Page 76 Tuono V4 1100 Factory Maintenance • Remove the air filter retainer by lifting • Remove the air filter. Air filter housing Air filter housing removal Remove the fuel tank to be able to reach the filter housing area and proceed as follows: COVER REMOVAL •...
Page 77 Tuono V4 1100 Factory Maintenance • Remove the three screws fixing the ECU support to the filter housing. • Remove the control unit complete with support. • After having removed the fixing screw of the engine wiring harness support, release it from the filter housing by lift- ing it as indicated.
Page 78 Tuono V4 1100 Factory Maintenance • Disconnect the intake air temperature sensor connector and the main wiring harness from the cable gland on the fil- ter housing cover. • Disconnect from the supports on the filter housing the coil connectors and...
Page 79 Tuono V4 1100 Factory Maintenance BASE REMOVAL • After having removed the filter housing cover, proceed with removing the air filter retainer by lifting it. • Remove the air filter. • Disconnect the main wiring harness and the canister system valve from the cable gland on the filter housing base.
Page 80 Tuono V4 1100 Factory Maintenance • Operating on the right side of the vehi- cle, remove the screw that fastens the rear bank oil pressure sensor to the base of the filter housing. • Unscrew the eight screws to remove the lower intake ducts.
Page 81 Tuono V4 1100 Factory Maintenance • Release from the supports the connec- tors of the front bank coils located on the filter housing base. • Disconnect the lower injector wiring harness from the bracket located on the filter housing base.
Page 82 Tuono V4 1100 Factory Maintenance nectors and of the lower injector wiring harnesses. • Subsequently, after having placed the filter housing base, close the clamp completely. FITTING THE LOWER INTAKE DUCTS • The lower intake ducts have two differ- ent lengths. The shorter ducts (A) are placed on the front bank and the longer ones (B) on the rear bank.
Page 83 Tuono V4 1100 Factory Maintenance REAR CYLINDER HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover and the spark plugs. • Remove the sound-proofing cover from the clutch side. • Remove the clutch cover.
Page 84 Tuono V4 1100 Factory Maintenance • Position cylinder 1 piston (LH, rear pis- ton) so that it is at the point where it crosses TDC. • Unscrew and remove the first screw of the camshaft drive sprocket. • rotate the crankshaft 150° in the engine rotation direction (direction of travel).
Page 85 Tuono V4 1100 Factory Maintenance • Remove the pin from the camshaft drive sprocket. • Unscrew and remove the three screws (1) and remove the bearing cap (2) and the oil pipe (3). • Install the specific camshaft gear sup- port tool.
Page 86 Tuono V4 1100 Factory Maintenance • Unscrew the seven screws in progres- sive steps in a criss-cross pattern and remove. • Retrieve the copper washers from the screws near the spark plug holes. • Remove the bearing caps complete with O-rings and alignment pins.
Page 87 Tuono V4 1100 Factory Maintenance • Refit the camshafts, ensuring that they are aligned correctly. 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 88 Tuono V4 1100 Factory Maintenance • Fit the bearing cap, the oil pipe and the three fastener screws. • Tighten the ten fastener screws of the camshafts, tightening in progressive steps in a criss-cross pattern. • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin.
Page 89 Tuono V4 1100 Factory Maintenance side hole and the hole on the crank- shaft are perfectly aligned. • If this is not the case, repeat the timing operations. Specific tooling 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Check if the clearance between the cam on the shaft and the tappet is correct.
Page 90 Tuono V4 1100 Factory Maintenance • Fit the pin for aligning the intake cam- shaft with the hole in the bearing cap. Specific tooling 020851Y Camshaft timing pin • Loosen the second screw of the cam- shaft drive sprocket. •...
Page 91 Tuono V4 1100 Factory Maintenance • Install the specific camshaft gear sup- port tool. • Fasten to the head with the two screws Specific tooling 020956Y Support for camshaft gear on head • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer.
Page 92 Tuono V4 1100 Factory Maintenance • Retrieve the buckets using a magnet. • Remove the calibrated pads with a magnet and replace with new calibra- ted pads of the size necessary to attain the correct valve clearance value. See the paragraph "Calibrated pad thickness"...
Page 93 Tuono V4 1100 Factory Maintenance • Fit the bearing caps complete with O- rings and alignment, and fit and hand- tighten the seven screws indicated. Use new copper washers on the four screws near the spark plug holes. • Loosen the camshaft sprocket lock screw on the tool.
Page 94 Tuono V4 1100 Factory Maintenance • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin. • Tighten the first fastener screw of the camshaft sprocket to the specified tor- que. Specific tooling 020851Y Camshaft timing pin •...
Page 95 Tuono V4 1100 Factory Maintenance Calibrated pad thickness Pad thickness for adjusting valve clearance correctly: 1.75 mm (0.0689 in) 1.77 mm (0.0697 in) 1.80 mm (0.0709 in) 1.82 mm (0.0716 in) 1.85 mm (0.0728 in) 1.87 mm (0.0736 in) 1.90 mm (0.0748 in) 1.92 mm (0.0756 in)
Page 96 Tuono V4 1100 Factory Maintenance 2.22 mm (0.0874 in) 2.25 mm (0.0886 in) 2.27 mm (0.0894 in) 2.3 mm (0.0905 in) 2.32 mm (0.0913 in) 2.35 mm (0.0925 in) 2.37 mm (0.0933 in) 2.4 mm (0.0945 in) 2.42 mm (0.0953 in) 2.45 mm (0.0964 in)
Page 97 Tuono V4 1100 Factory Maintenance Cooling system Level check • Shut off the engine and wait until it cools off. • Keep the vehicle upright with both wheels on a flat surface. • Looking from the left side of the vehicle...
Page 98 Tuono V4 1100 Factory Maintenance Level check Checking brake fluid • Rest the vehicle on its stand. • For the front brake, turn the handlebar all the way to the right. • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level as the plug.
Page 99 Tuono V4 1100 Factory Maintenance DOT 4 brake fluid Synthetic brake fluid. SAE J 1703; FMVSS 116; ISO 4925; CUNA NC 956 DOT4 Front braking system • Use a short cross-head screwdriver to undo the screws (1) of the front braking system fluid reservoir (2).
Page 100 Tuono V4 1100 Factory Maintenance Adjusting the levers FRONT BRAKE LEVER It is possible to adjust the distance between the end of the lever (1) and the grip (2), turning the adjuster (3). • Push the control lever (1) forwards and turn the adjuster (3) until the lever (1) is at the desired distance.
Page 101 Tuono V4 1100 Factory Maintenance • Ensure that the play is between 1 and 3 mm (0.039 and 0.12 in). In the event that the adjustment of the adjuster on the lever is not sufficient, act on the register loca- ted on the right side of the vehicle: •...
Page 102 Tuono V4 1100 Factory Maintenance To carry out vertical adjustment of the light beam: (LOW BEAM HEADLIGHTS) • Operating from the rear side of the fair- ing, under the internal bodywork, act on the adjuster ("1" left side / "2" right side).
Page 103 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 104 Tuono V4 1100 Factory Electrical system Components arrangement Key: 1. Side stand sensor 2. Fuel pump 3. Instrument cluster ELE SYS - 104...
Page 105 Tuono V4 1100 Factory Electrical system 4. Left hand switch 5. Right hand switch 6. Water temperature sensor 7. Cooling fans 8. Upper injectors 9. Lower injectors 10.air temperature sensor 11.Intake ducts 12.Air pressure sensor 13.Exhaust valve control motor 14.Front bank lambda probe 15.Rear bank lambda probe...
Page 106 1 x Main vehicle wiring harness • 1 x Licence plate holder wiring harness • 1 x Engine-Battery Earth Cable Only for TUONO V4 1100 Factory (OHLINS ASC) • 1 x Main vehicle wiring harness • 1 x Ohlins fork wiring harness Small parts and mountings •...
Page 107 Tuono V4 1100 Factory Electrical system • 2 x Spring clips • 2 x spring clips (regulator connector) • 2 x chassis gaskets • 1 x Cable glands Motorcycle division The wiring harnesses on the vehicle are subdivi- ded into three main sections, as indicated in the figure.
Page 108 Tuono V4 1100 Factory Electrical system • Check that the R&W connector is connected and routed correctly. • Check the RH and LH rear indicator connections. • Check the gear connector connection. • Check the quick shift connector connection. •...
Page 109 Tuono V4 1100 Factory Electrical system TABLE A1 - LH INSTRUMENT PANEL SUP- PORT PRE-FITTING • Place the cable gland as indicated. TABLE A2 - ROUTING THE CABLES IN THE RIGHT SIDE OF THE INSTRUMENT PANEL SUPPORT AREA • Using a rubber cable gland, fasten the...
Page 110 Tuono V4 1100 Factory Electrical system TABLE A3 - ROUTING THE CABLES IN THE LEFT SIDE OF THE INSTRUMENT PANEL SUP- PORT AREA 1. A-PRC switch wiring harness. 2. Clutch switch wiring harness. 3. LH light switch wiring harness. 4. Immobilizer signal wiring harness.
Page 111 Tuono V4 1100 Factory Electrical system TABLE A5 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • Place the branch of the main harness as indicated and fasten it using a clamp, in the position corresponding to...
Page 112 Tuono V4 1100 Factory Electrical system TABLE A7 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • Connect the GREY connector with the BLUE reference taping with its GREY counterpart that has the same BLUE reference TABLE A8 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA •...
Page 113 Tuono V4 1100 Factory Electrical system TABLE A9 - ROUTING THE CABLES IN THE IN- STRUMENT PANEL SUPPORT AREA • The cables inside the instrument panel support must be placed in such a way so as to leave sufficient space for the instrument panel connector to return, without interferences.
Page 114 Tuono V4 1100 Factory Electrical system TABLE A11 - ROUTING THE CABLES IN THE INSTRUMENT PANEL SUPPORT AREA • Connect the instrument panel connec- tor and check that a click is heard, con- firming the correct connection. • After the CLICK is heard, gently pull the instrument panel in the direction of the arrow, so as to tension the cables.
Page 115 Tuono V4 1100 Factory Electrical system TABLE B - FRONT ABS SPEED SENSOR PRE- FITTING (SACHS) • After having pre-fitted the cable gland (1) on the fork foot and having secured the sensor, arrange its wiring harness (2) as indicated and secure it with two clamps (3).
Page 116 Tuono V4 1100 Factory Electrical system TABLE B2 - FRONT ABS SPEED SENSOR • Pass the front ABS speed sensor wir- ing as shown and secure it with two clamps to the main wiring harness. TABLE B3 - FRONT ABS SPEED SENSOR •...
Page 117 Tuono V4 1100 Factory Electrical system TABLE C - MAIN WIRING HARNESS BRANCH • Using a large clamp, fasten the main wiring harness branch to the right side under-fairing, at the indicated point. TABLE D - ELECTRONIC FORKS (IF PRESENT) •...
Page 118 Tuono V4 1100 Factory Electrical system TABLE D1 - ELECTRONIC FORKS (IF PRESENT) • The wiring harness must pass inside the instrument panel support. TABLE D2 - ELECTRONIC FORKS (IF PRESENT) • The wiring harnesses that will be con- nected to the stanchion cap must pass over the front of the steering plate, as indicated.
Page 119 Tuono V4 1100 Factory Electrical system WIRING TABLE I - ELECTRONIC STEERING DAMPER (IF PRESENT) • Route the steering damper cable to- ward the damper. TABLE E1 - ELECTRONIC STEERING DAMPER (IF PRESENT) • Secure the wiring harness with a clamp, at the indicated point.
Page 120 Tuono V4 1100 Factory Electrical system TABLE F - CLUTCH SWITCH PRE-FITTING • Place the switch wiring harness as shown and insert it into its cover. TABLE F1 - CLUTCH SWITCH PRE-FITTING • After having placed the switch on the...
Page 121 Tuono V4 1100 Factory Electrical system Central part TABLE A - VEHICLE CABLE HARNESS • Place the main wiring harness as indi- cated. TABLE A1 - VEHICLE CABLE HARNESS • Check that the wiring harness with the VEHICLE connector is facing up and secure the conduit to the chassis.
Page 122 Tuono V4 1100 Factory Electrical system TABLE A2 - VEHICLE CABLE HARNESS Place the relays as indicated: • Injection relay (with red reference tape) on the right support. • Fan relay (without taping) on the sup- port, in central position.
Page 123 Tuono V4 1100 Factory Electrical system TABLE B - GEAR SENSOR • Place the gear sensor wiring harness as indicated before proceeding with the installation of the engine on the ve- hicle. TABLE C - VEHICLE ECU BRANCH • Place the two cable glands as indica- ted on the filter housing cover in order to secure the ECU branch.
Page 124 Tuono V4 1100 Factory Electrical system TABLE C1 - VEHICLE ECU BRANCH • Insert the ECU branch in the cable glands and arrange it as indicated. TABLE D - MAIN WIRING HARNESS CONNEC- TION WITH THE ECU • Connect the VEHICLE connector to the ECU, and make sure that a "...
Page 125 Tuono V4 1100 Factory Electrical system TABLE D1 - MAIN WIRING HARNESS CON- NECTION WITH THE ECU • After having connected the VEHICLE ECU connector, by pushing lightly with a finger, check if the grey lever of both connectors moves to the inside. If this happens, the connector is not secured;...
Page 126 Tuono V4 1100 Factory Electrical system TABLE F - ENGINE OIL PRESSURE SENSOR CONNECTION • Check that the terminal is connected and that the cover is inserted on the bulb correctly. TABLE F1 - ENGINE OIL PRESSURE SENSOR CONNECTION •...
Page 127 Tuono V4 1100 Factory Electrical system TABLE G1 - GROUND LEADS 1. Main wiring harness ground lead. 2. Engine-battery earth cable 3. Engine wiring harness ground lead • The ground wiring harnesses must converge at the fixing point on the en- gine.
Page 128 Tuono V4 1100 Factory Electrical system TABLE H - WIRING HARNESS ON THE LOWER CHASSIS SHOULDERS • Operating on the internal right side, se- cure the starter motor wiring harness to the cooling system pipe using a clamp. • Place the main wiring harness inside the cable gland on the internal side of the chassis.
Page 129 Tuono V4 1100 Factory Electrical system TABLE H2 - WIRING HARNESS ON THE LOW- ER CHASSIS SHOULDERS • Use a large clamp, to secure all the wiring harnesses at the indicated point, on the left side of the vehicle. TABLE I - STARTER MOTOR WIRING HAR- NESS •...
Page 130 Tuono V4 1100 Factory Electrical system TABLE K - VOLTAGE REGULATOR • Insert the pick up connector in the spe- cific tab on the internal fairing and after having connected the voltage regulator connectors, secure the voltage regula- tor and pick-up wiring harnesses using two clamps.
Page 131 Tuono V4 1100 Factory Electrical system TABLE K2 - VOLTAGE REGULATOR • Secure the wiring harnesses with a clamp, as indicated. TABLE L - EXHAUST VALVE MOTOR AREA WIRING HARNESSES • The fan (1) and ride by wire (2) wiring...
Page 132 Tuono V4 1100 Factory Electrical system TABLE L1 - EXHAUST VALVE MOTOR AREA WIRING HARNESSES • Connect the electric fan connector (3) and the ride by wire handle (4) to the counterpart and then fasten them to the exhaust valve motor support.
Page 133 Tuono V4 1100 Factory Electrical system TABLE M - RIDE BY WIRE HANDLE CABLE ROUTING • The ride by wire handle cable must pass over the main wiring harness branch that goes to the instrument pan- el and under the radiator pipe that con- nects the thermostatic valve with the radiator.
Page 134 Tuono V4 1100 Factory Electrical system TABLE N - SIDE STAND • After having placed the side stand sen- sor wiring harness as indicated, secure it with a clamp together with the lambda probe wiring and the quick shift to the crankcase cover fixing threaded pin.
Page 135 Tuono V4 1100 Factory Electrical system TABLE O1 - QUICK SHIFT • After having installed the quick shift, place the wiring harness under the sprocket protective metal casing. TABLE O2 - QUICK SHIFT • The quick shift wiring harness must be placed as indicated.
Page 136 Tuono V4 1100 Factory Electrical system TABLE O3 - QUICK SHIFT • Pass the wiring harness between the chassis and the engine, and then pass it behind the engine wiring harness at- tached to the filter housing. • Connect the connector to its counter- part and place it in the appropriate seat on the filter housing.
Page 137 Tuono V4 1100 Factory Electrical system TABLE P1 - REAR LAMBDA • Pass the wiring harness as indicated. TABLE P2 - REAR LAMBDA • After having correctly connected the rear lambda probe connector with its counterpart, secure it using the special support to the sprocket metal protec- tion cover.
Page 138 Tuono V4 1100 Factory Electrical system TABLE Q - FRONT LAMBDA • After having correctly connected the rear lambda probe connector with its counterpart, secure it using the special support to the side fairing metal sup- port. • Insert the wiring harness in the tow in- dicated cable glands.
Page 139 Tuono V4 1100 Factory Electrical system TABLE R1 - CONNECTIONS ON THE TANK • Wrap the excess cable of the fuel level sensor on the support on which the black connector of the fuel pump is lo- cated, as in the picture.
Page 140 Tuono V4 1100 Factory Electrical system TABLE X1 - LICENCE PLACE HOLDER PRE- FITTING • The right arrow is identified with the RED taping and must be inserted on the licence plate holder as indicated in the picture. The arrow with the red tape...
Page 141 Tuono V4 1100 Factory Electrical system TABLE A - IGNITION RELAY PRE-ASSEMBLY The positive battery cable must be connected to the hole identified by the letter B (Battery) using M5x8 screw 1. Starter relay 2. Battery positive cable pole (identified by the let- ter "B")
Page 142 Tuono V4 1100 Factory Electrical system TABLE C1 - PROCEDURE FOR CORRECT ABS CONTROL UNIT CONNECTOR INSERTION Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard...
Page 143 Tuono V4 1100 Factory Electrical system FIGURE D - MAIN WIRING HARNESS • The main wiring harness must pass in- side the motorcycle, on the right side. • Next to the grey taping place the suit- able cable clamp that must be inserted in the hole on the saddle column frame.
Page 144 Tuono V4 1100 Factory Electrical system FIGURE D3 - MAIN WIRING HARNESS • The central branch of the main wiring harness must be arranged as indicated and secured with the two cable glands. TABLE E - ROUTING ON THE SADDLE COLUMN FOR THE STARTER RELAY •...
Page 145 Tuono V4 1100 Factory Electrical system TABLE E2 - ROUTING ON THE SADDLE COL- UMN FOR THE STARTER RELAY • Use a rubber cable gland at the indica- ted point to secure the wiring harness- TABLE F - REAR SPEED SENSOR •...
Page 146 Tuono V4 1100 Factory Electrical system TABLE F3 - REAR SPEED SENSOR • Place the ABS rear speed sensor wir- ing harness as shown and secure it using the cable gland fastened to the rear brake calliper support. TABLE F4 - REAR SPEED SENSOR •...
Page 147 Tuono V4 1100 Factory Electrical system TABLE G1 - REAR BRAKE SWITCH • Pass the rear brake switch wiring har- ness through the cable gland inside the chassis on the right side. TABLE H - OBD2 CONNECTOR • The OBD2 wiring harness connector...
Page 148 Tuono V4 1100 Factory Electrical system TABLE K - ELECTRONIC SHOCK ABSORBER (IF PRESENT) • Fasten the two wiring harnesses of the rear damper with a cable gland fixed under the saddle. TABLE K1 - ELECTRONIC SHOCK ABSORBER (IF PRESENT) •...
Page 149 Tuono V4 1100 Factory Electrical system General wiring diagram Legenda: 1. Connettori multipli 2. Claxon 3. Devioluci sinistro 4. Devioluci sinistro 2 (manettino) ELE SYS - 149...
Page 150 Tuono V4 1100 Factory Electrical system 5. Motorino valvola di scarico 6. Cruscotto 7. Predisposizione cronometro 8. Devioluci destro 9. Interruttore stop posteriore 10.Interruttore frizione 11.Commutatore a chiave 12.Antenna immobilizer 13.Freccia posteriore destra (LED) 14.Luce targa (LED) 15.Freccia posteriore sinistra (LED) 16.Fanale posteriore (LED)
Page 151 Tuono V4 1100 Factory Electrical system 43.Sensore marcia 44.Sonda lambda cilindro 2 (FRONT) 45.Sonda lambda cilindro 1 (REAR) 46.- 47.- 48.- 49.- 50.- 51.- 52.Iniettore cilindro 4 inferiore (FRONT) 53.Iniettore cilindro 3 inferiore (REAR) 54.Iniettore cilindro 2 inferiore (FRONT) 55.Iniettore cilindro 1 inferiore (REAR) 56.Bobina cilindro 4 (FRONT)
Page 152 Tuono V4 1100 Factory Electrical system 81.Centralina sospensioni OHLINS (ove previsto) 82.Ammortizzatore sterzo (ove previsto) 83.Stelo sinistro forcella OHLINS (compression)(ove previsto) 84.Stelo destro forcella OHLINS (rebound)(ove previsto) 85.Ammortizzatore posteriore OHLINS (rebound)(ove previsto) 86.Ammortizzatore posteriore OHLINS (compression)(ove previsto) 87.CAN 2 88.Cablaggio frecce USA 89.-...
Page 153 Tuono V4 1100 Factory Electrical system FORMING EACH OF THE CHECKS INDICATED FOR TROU- BLESHOOTING. 3. Pull cables gently from the back of the connector to check that the terminals are fitted correctly on the connector and that the wires are fastened correctly to the terminals.
Page 154 Tuono V4 1100 Factory Electrical system System components Function detects the transponder code in the key and sends it to the instrument panel Level in electrical circuit diagram: Immobilizer Position: • on the vehicle: in the ignition switch as- sembly •...
Page 155 Tuono V4 1100 Factory Electrical system • An electric interruption or a ground short circuit or voltage to the circuit have been detected Troubleshooting • Check the sensor connector on the cable harness and the instrument panel connector. If not OK, restore; if OK, check electrical characteristics and aerial circuit continuity from the instrument panel connector on PIN 2 and 3: if not OK, restore cable harness;...
Page 156 Tuono V4 1100 Factory Electrical system • Enter the USER CODE to continue. • If the code entered is correct, the first key is stored. • At this point, on the digital display of the motorcycle, after the automatic restart...
Page 157 Tuono V4 1100 Factory Electrical system Diagnosis • In case of malfunction of certain or- gans, the digital display of the instru- ment panel may display errors. To check and diagnose the specific com- ponent, check the dedicated section. Maintenance icon reset The system displays the function as follows: •...
Page 158 Tuono V4 1100 Factory Electrical system Measurement of resistance (with engine off) • For a correct detection of the alternator resistance, an ambient temperature measurement must be carried out and afterwards a heat stabilisation (after turning fan on) by using a tester, using alternatively the 3 connector pins: stage "1"...
Page 159 Tuono V4 1100 Factory Electrical system • Effective resistance stage 1 = 0.62-0.47 = 0.15 Ohm • If there is a significant difference between one stage and another (other than 0.15 Ohm), this means that the alternator is defective and must be replaced.
Page 160 Tuono V4 1100 Factory Electrical system Short-circuit current • For a correct detection of the short-cir- cuit current, a connector must be pre- pared that generates a downstream short circuit between the three alterna- tor cables; • Start the engine and with a clamp am- meter measure each single cable.
Page 161 Tuono V4 1100 Factory Electrical system Start-up system check Function Communicates to the control unit the will to start- up the engine. Operation / Operating principle Press the start-up button to close the specific cir- cuit taking the PIN 58 of the control unit to a voltage equal to zero (ground closing).
Page 162 Tuono V4 1100 Factory Electrical system • Fault in the switch (lock) of the engine start-up. A continuous voltage close to 0 was detected for a certain time (e.g. locked button). • The instrument panel does not indicate the presence of this error even in the ATT status.
Page 163 Tuono V4 1100 Factory Electrical system • Take out one fuse at a time and check whether the filament (2) is broken. • Before replacing the fuse, find and solve, if possible, the reason that caused the problem. • If the fuse is damaged, replace it with one of the same current rating.
Page 164 Tuono V4 1100 Factory Electrical system The auxiliary fuses are placed on the rear part of the motorcycle, under the rider saddle. TUONO V4 1100 FACTORY • To check and replace the main fuse, remove the screw (3) that fastens the cover (4).
Page 165 Tuono V4 1100 Factory Electrical system (if applicable) REMOVAL • After removing the front bodywork, re- move the five screws (1) that join the two instrument cluster supports. • Remove the two screws (2) that secure the instrument cluster support to the frame.
Page 166 Tuono V4 1100 Factory Electrical system ELECTRONIC SUSPENSION ERROR Code Description / Symptoms 504900 Internal electronic fault 504600 Calibration Checksum error 501600 Under voltage 501700 Supply voltage over the threshold D08800 Can Bus-Off 551300 Steering damper sensor - open circuit...
Page 167 Tuono V4 1100 Factory Electrical system REMOVAL • After removing the fuel tank, discon- nect the connectors (1) from the 11MP control unit (2). • Disconnect the 11MP control unit (2) from the mount (3) fastened to the filter box cover. Alternatively, the mount...
Page 168 Tuono V4 1100 Factory Electrical system • ISO code / - • Marelli SW code / - • Serial number (NIP) • Author of the latest progr. / - (author of the latest programming) • Internal code (IDEEKE) / - •...
Page 169 Tuono V4 1100 Factory Electrical system • Rear cyl. throt corr. / - (rear cylinders throttle valve correction) • Front cyl. throt corr. / - (front cylinders throttle valve correction) • Fuel capacity / - • Rear lambda 1 adap. corr. / - (rear bank lambda 1 adaptive correction) •...
Page 170 Tuono V4 1100 Factory Electrical system • Enab. start-up / - (enable start-up) • Rear lambda 1 probe / - (rear bank lambda 1 probe) • Front lambda 2 probe / - (front bank lambda 2 probe) • Handle self-learning/ - (handle self-learning) •...
Page 171 Tuono V4 1100 Factory Electrical system • Secondary air valve / - (secondary air solenoid valve activation) • Stop light DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0601 EEPROM error Electrical diagnostic: • Circuit not functioning Error cause: • Replace the injection control unit.
Page 172 Tuono V4 1100 Factory Electrical system Electrical diagnostic: • short circuit to positive / short circuit to negative / open circuit Error cause: • Short-circuit to positive: excessive voltage has been detected on PIN 31. • If short circuit to negative: no voltage has been detected.
Page 173 The instrument cluster does not indicate the presence of this error even in the ATT status Troubleshooting • Perform the troubleshooting for the other detected errors. P1608 a-PRC (Aprilia Performance Ride Control) operating error Electrical diagnostic: • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit...
Page 174 Tuono V4 1100 Factory Electrical system • Call the Help Desk. DIAGNOSTIC TOOL: SETTINGS • Vehicle config. (km) / - (vehicle configuration (km) • Vehicle config. (miles) / - (vehicle configuration (miles) • Handle self-learning/ - (handle self-learning) • Thrott self-learn. / - (throttle self-learning) •...
Page 175 Tuono V4 1100 Factory Electrical system • on the vehicle: under the saddle • connector: on the battery Electrical specifications:12V 48Wh 280A Pin out: 1. Positive pole (red): approx. 12.6 V 2. negative pole (black): ground DIAGNOSTIC TOOL:PARAMETERS Battery voltage •...
Page 176 Tuono V4 1100 Factory Electrical system a few tenths of an Ohm: if not OK, repair the wiring harness; if OK, check that the electric generator is operating correctly: if not OK, repair. If OK, check that the voltage regulator is...
Page 177 Tuono V4 1100 Factory Electrical system Under the right dynamic air intake. Pin-out: • PIN1 - Power feed negative/Signal negative (white) • PIN2 - Power feed positive/Signal pos- itive (white/brown) DIAGNOSTIC TOOL Parameters: Speed (km/h) - Front wheel speed. DIAGNOSTIC TOOL: ELECTRICAL ERRORS...
Page 178 Tuono V4 1100 Factory Electrical system Error cause • Incorrect wheel or tone wheel dimensions. Troubleshooting - Check the type and dimensions of the installed tyres. - Check the type and dimensions of the installed tone wheels. C1034 Front wheel speed sensor Functional diagnosis: Signal not plausible.
Page 179 Tuono V4 1100 Factory Electrical system Position of connector (if applicable): Under the right side fairing. Pin-out: • PIN1 - Power feed negative/Signal negative (yellow) • PIN2 - Power feed positive/Signal pos- itive (yellow/brown) DIAGNOSTIC TOOL Parameters: Speed (km/h) - Rear wheel speed...
Page 180 Tuono V4 1100 Factory Electrical system - Disconnect the sensor connector. - Check the battery supply insulation of the two PINS. - If there is no insulation, restore the wiring harness or replace the sensor. P2158 Rear wheel speed sensor/signal •...
Page 181 Tuono V4 1100 Factory Electrical system • connector: under fuel tank on RH side (3 pin black connector) Electrical specifications: 0.79 kohm at ambient temperature Pin out: 1. positive signal 2. negative signal 3. shielding with earth connection DIAGNOSTIC TOOL:PARAMETERS...
Page 182 Tuono V4 1100 Factory Electrical system THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. Twistgrip position sensor Function The handle command is used to convert the driver's power demand to an electrical signal to be sent to the electronic control unit.
Page 183 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: check the value indicated by the parameter handle position sensor track A: disconnect the connector and read the value indicated by the diagnostic tool: if the voltage does not vary, there is a short circuit on the wiring harness of the relative cable, if the voltage goes to zero, replace the handle sensor.
Page 184 Tuono V4 1100 Factory Electrical system Functional diagnosis: • Signal not congruent Error cause: • Detected two voltages signals at PIN 39 and 13 of the ENGINE connector (tracks A-B) This error is indicated by flashing the general warning light and by lighting up in a fixed manner the MI warning light.
Page 185 Tuono V4 1100 Factory Electrical system Pin out: 1. Power supply 5V 2. Ground connection 3. Output signal DIAGNOSIS INSTRUMENT: PARAMETERS Front Cylinder Intake Pressure (2 and 4) • Example value with key ON: 1003 mbar • Example value with engine on: 720 mbar •...
Page 186 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: see that the parameter of the rear cylinders air Pressure Sensor on the diagnostic tool reads approx. 1,200 mbar; disconnect the sensor connector: if the value does not change, this means there is a short circuit in the cable between the control unit connector and the sensor connector, restore the wiring harness;...
Page 187 Tuono V4 1100 Factory Electrical system position) for continuity between PIN 3 on the sensor connector and ground: if not OK, restore the wiring harness; if OK, replace the sensor. DIAGNOSTIC TOOL: LOGIC ERRORS Rear bank air pressure sensor P0106 •...
Page 188 Tuono V4 1100 Factory Electrical system • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body; check that the intake manifold is in good conditions and the pressure reading hole is clean.
Page 189 Tuono V4 1100 Factory Electrical system Rear bank manifold pressure too low error P1604 • signal not plausible. Error cause • Small difference detected between the estimated pressure and the measured pressure: the measured pressure is below the estimated one (for example, smeared throttle body).
Page 190 Tuono V4 1100 Factory Electrical system Electrical specifications: • Resistance at 25°: 2.05 kΩ ± 100/Ω • Resistance at 60°: 575 Ω ± 15 /Ω • Resistance at 90°: 230 Ω ± 5 /Ω Pin out: 1. Greek/Black: Ground 2. Black 3.
Page 191 Tuono V4 1100 Factory Electrical system • If open circuit, short circuit to positive: check the sensor connector and the Marelli control unit connector. If they are OK, check sensor continuity: replace the sensor if not OK; if OK, check continuity between the ENGINE connector PIN 12 and the sensor PIN 3: If continuity is absent, restore the wiring harness;...
Page 192 Tuono V4 1100 Factory Electrical system Air temperature sensor Function indicates to the control unit the temperature of the intake air, used to calculate the oxygen, to opti- mise the required fuel quantity for the correct com- bustion Operation / Operating principle...
Page 193 Tuono V4 1100 Factory Electrical system • open circuit, short circuit to positive / short circuit to negative Error cause • If open circuit, short circuit to positive: an excessive voltage was detected at PIN 37 of the ENGINE connector. If short circuit to negative: zero voltage detected. The instrument panel indicates this error by lighting up in a fixed manner the MI warning light.
Page 194 Tuono V4 1100 Factory Electrical system Position: • on manifold: left side of the vehicle • connector: left side of the vehicle, fixed to the support bracket of the fairing lug (4-way connector black) Electrical specifications • Heater circuit: 7-9Ω at ambient temp.
Page 195 Tuono V4 1100 Factory Electrical system This diagnosis is activated when the correction constantly arrives -25%. 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 196 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: an excessive voltage was detected at PIN 44 of the ENGINE con- nector. • If open circuit, short circuit to negative: a voltage equal to zero was detected at PIN 44 of the ENGINE connector.
Page 197 Tuono V4 1100 Factory Electrical system • If no switching from high: is shown when the ratio control is in closed loop and when the secondary air valve is not operating. The error is validated if the engine is in CUTOFF status and the probe signal is close to 1V, or if the engine is in another operating condition that requires the injection but the switching from the"HIGH RATIO"...
Page 198 Tuono V4 1100 Factory Electrical system • on manifold: on the rear part of the ve- hicle in correspondence with the shock absorber • connector: on the right of the pinion cover (4-ways black connector) Electrical specifications • Heater circuit: 7-9Ω at ambient temp.
Page 199 Tuono V4 1100 Factory Electrical system This diagnosis is activated when the correction constantly arrives -25%. 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 200 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: an excessive voltage was detected at PIN 32 of the ENGINE con- nector. • If open circuit, short circuit to negative: a voltage equal to zero was detected at PIN 32 of the ENGINE connector.
Page 201 Tuono V4 1100 Factory Electrical system • Check the continuity of the circuit from the probe connector (PIN 1 and PIN 2) towards the probe: replace the lambda probe if there is no continuity; if there is continuity, check the sensor connector and the Marelli control unit connector: if NOT OK, restore;...
Page 202 Tuono V4 1100 Factory Electrical system Injector Lower injectors key: • 1. Lower Injector 1 • 2. Lower Injector 3 • 3. Lower Injector 2 • 4. Lower Injector 4 LOWER INJECTOR Function Provide the correct amount of fuel at the correct time.
Page 203 Tuono V4 1100 Factory Electrical system Cylinder injection time 1 • Example value with engine on: 1.9 ms Cylinder injection time 2 • Example value with engine on: 1.9 ms Cylinder injection time 3 • Example value with engine on: 1.9 ms Cylinder injection time 4 •...
Page 204 Tuono V4 1100 Factory Electrical system for 5 seconds and the injector cable connected to control unit is closed to ground for 4 ms per second. Disconnect the 4-way connector of the fuel pump to be able to hear the relay and injector activation.
Page 205 Tuono V4 1100 Factory Electrical system • If short circuit to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/green cable: if the connection is present, restore the cable harness. If there is no connection, replace the injector •...
Page 206 Tuono V4 1100 Factory Electrical system • If short circuit to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/blue cable: if the connection is present, restore the cable harness. If there is no connection, replace the injector •...
Page 207 Tuono V4 1100 Factory Electrical system 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. DIAGNOSTIC TOOL: ACTIVATION Fuel pump...
Page 208 Tuono V4 1100 Factory Electrical system Coil Function Spark generation Operation / Operating principle With inductive discharge Level in electrical circuit diagram: coils and injectors Position: • on the vehicle: on the big end covers. • connector: For each coil 3 way black connector.
Page 209 Tuono V4 1100 Factory Electrical system DIAGNOSTIC TOOL: ACTIVATIONS Coil 1: The injection relay (no. 33 in the electrical circuit diagram, placed under the 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 Brown/Yellow cable of the coil is closed to ground for 2 ms per each second.
Page 210 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 28 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil.
Page 211 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: disconnect the coil connector, turn the key to ON, activate the coil with the diagnostic tool and check the voltage at PIN 2 of the connector: if there is voltage, restore the wiring harness, if the voltage is 0, replace the coil.
Page 212 Tuono V4 1100 Factory Electrical system • on the vehicle: inside the filter box • connector: on the throttle body, in lower position, near the throttle motors Pin out: 1. potentiometer signal 1 2. supply voltage + 5V 3. throttle valve control command (+) 4.
Page 213 Tuono V4 1100 Factory Electrical system • Example value with key ON: 873 mV • Example value with engine on: 561 mV Rear throttle Potentiometer 1 (voltage) • Example value with key ON: 883 mV • Example value with engine on: 536 mV Front throttle Potentiometer 2 (voltage) •...
Page 214 Tuono V4 1100 Factory 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 • Example value with key ON: 888 mV...
Page 215 Tuono V4 1100 Factory 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 216 Tuono V4 1100 Factory Electrical system insulated, check that the power supply (+5 V) is present at PIN 2 of the throttle body con- nector and that ground is present at PIN 6, if present correctly replace the throttle body Front bank throttle valve position potentiometer sensor P0220 •...
Page 217 Tuono V4 1100 Factory Electrical system • short circuit to positive / short circuit to negative / open circuit, overcurrent, excessive internal temperature Error cause • Short-circuit to positive: excessive voltage detected on PIN 29 or 41 of the 7SM control unit.
Page 218 Tuono V4 1100 Factory Electrical system connector of the throttle body and the control unit connector and check cable 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 219 Tuono V4 1100 Factory Electrical system • Check the throttle body connector and the control unit connector. Check that the resistance of the cable between the throttle body connector (PIN 1) and the control unit (PIN 48) is a few tenths of ohm. Check that the resistance of the cable between the throttle body con- nector (PIN 4) and the control unit (PIN 50) is a few tenths of ohm.
Page 220 Tuono V4 1100 Factory Electrical system 4) and the throttle control unit (PIN 21) is a few tenths of an Ohm. If one of the two is different, restore the wiring harness if ok replace the complete throttle body Rear throttle valve Limp Home self-acquisition P1400 •...
Page 221 Tuono V4 1100 Factory Electrical system • Low power supply voltage Error cause • The throttle valve power supply voltage is too low to correctly perform the self-learning test (at each key ON). The instrument panel does not indicate the presence of this error even in...
Page 222 Tuono V4 1100 Factory Electrical system • Check the cleanliness of the throttle body and the intake duct. If ok replace the throttle body Front throttle valve recovery conditions detection (Tair,Twater) P1409 • Ice possibly present Error cause • in conditions of low ambient temperature and engine temperature, a correct throttle valve rotation was not detected: possible presence of ice in the duct (at each key ON).
Page 223 Tuono V4 1100 Factory Electrical system • Using the diagnostic tool, erase the error, then perform the throttle self-learning procedure. If the error is displayed again, it may mean a mechanical problem at the throttle boy. • Check the cleanliness of the throttle body and the intake duct. Check if there are any me- chanical ruptures.
Page 224 Tuono V4 1100 Factory Electrical system Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure (0.5 +/-0.2 bar) in the engine. Operation / Operating principle Switch normally closed (control unit signal to ground). The switch opens at pressure values above 0.5 ±...
Page 225 Tuono V4 1100 Factory Electrical system • Check if oil pressure is low with the specific gauge. Neutral sensor Function Indicates to the control unit the position of the gearbox, from 1st gear to 6th gear, and if the gearbox is in neutral or drive.
Page 226 Tuono V4 1100 Factory Electrical system • Yes/No gear engaged: 0 - 1 - 2- 3 - 4 - 5 - 6 DIAGNOSTIC TOOL: ELECTRICAL ERRORS P0914 Gear sensor Electrical diagnosis: • short circuit to positive or open circuit / short circuit to negative / signal not plausible.
Page 227 Tuono V4 1100 Factory Electrical system Position: • on the vehicle: on the handlebar. • connector: on the sensor. Electrical specifications: • Clutch engaged: closed circuit (con- tinuity) • Clutch released: open circuit (infinite resistance). Pin out: 1. voltage 5V 2.
Page 228 Tuono V4 1100 Factory Electrical system • If there is one contact: the plausibility diagnosis cannot occur only at key ON but during operation. The control unit logic requires that the released/engaged and engaged/released witching time does not exceed a certain threshold. If the operating time is too long, the error is shown.
Page 229 Tuono V4 1100 Factory Electrical system • connector: between the big end cover and the left side filter housing (2 way white connector) Pin out: 1. Ground 2. 12 V voltage Electrical specifications: • Side Stand Up: closed circuit (continu- ity) •...
Page 230 Tuono V4 1100 Factory Electrical system Electric fan circuit Function Activates coolant radiator fan Operation / Operating principle When the ECU detects a temperature of approxi- mately 101°C, it closes the connection between the fan control relay excitation circuit and ground...
Page 231 Tuono V4 1100 Factory Electrical system P0480 Cooling fan command Electrical diagnosis: • short circuit to positive/ short circuit to negative / open circuit Error cause: • Short-circuit to positive: excessive voltage has been detected at PIN 61 of the VEHICLE connector.
Page 232 Tuono V4 1100 Factory Electrical system Electrical specifications: Resistance at ambient temperature: 21 +3/- 1 Ω Pin out: 1. Power supply V batt 2. Ground DIAGNOSTIC TOOL:PARAMETERS Secondary air valve duty cycle • Example value with key ON: 0 % •...
Page 233 Tuono V4 1100 Factory Electrical system RUN/STOP switch Function Indicates the control unit if the rider wishes to en- able engine start-up or to keep the engine running. Operation / Operating principle If you want to stop the engine or to prevent it from...
Page 234 Tuono V4 1100 Factory Electrical system the Yellow/Red cable: if there is continuity with the ground, restore the wiring harness; if ok, turn the key to OFF and perform the VEHICLE connector and engine-vehicle wiring harness connector check: if not ok, restore; if ok, check the continuity of the Yellow/Pink cable be- tween the switch connector and the VEHICLE connector PIN C7 and PIN 78: if not ok, restore the wiring harness;...
Page 235 Tuono V4 1100 Factory Electrical system • on the vehicle: The motor is located in the front lower part of the engine. The valve in the exhaust pipe. • connector: on the motor. Electrical specifications: • Electric motor resistance (PIN 4-5): 2-4 •...
Page 236 Tuono V4 1100 Factory Electrical system • If the potentiometer signal is above the maximum threshold: a voltage of the maximum limit stop (open valve) was detected outside the established range. • If the potentiometer signal is under the minimum threshold: a voltage of the minimum limit stop (closed valve) was detected outside the established range.
Page 237 Tuono V4 1100 Factory Electrical system • If open circuit: a too low current consumption was detected at PIN1/PIN10 of the instrument panel connector. • If thermal protection: anomaly at the instrument panel. • If short circuit to negative: voltage equal to zero has been detected.
Page 238 Tuono V4 1100 Factory Electrical system Troubleshooting: • Short-circuit to positive: disconnect the valve connector and check with the key ON if there is ground continuity at PIN 5 of the connector: if there is voltage, disconnect the instrument panel connector as well, and if there is voltage, restore the wiring harness and if there is no voltage, replace the instrument panel;...
Page 239 Tuono V4 1100 Factory Electrical system AFTER ANY MAINTENANCE OR INSPECTION OF THE EXHAUST VALVE, ALWAYS CARRY OUT THE PROCEDURE "ADJUSTING EXHAUST VALVE ACTUATOR CABLE FREE PLAY". The system consists of a throttle valve with return spring on the exhaust. The valve is closed by means of the two cables moved by an electric motor in its turn electrically connected to the instrument panel.
Page 240 Tuono V4 1100 Factory Electrical system ADJUSTING THE PLAY OF THE EXHAUST THROTTLE VALVE CABLES • Check that the battery voltage is NOT below 12V; • Check that the cylinders are in their seat and are NOT obstructed. If the cylinders are obstructed, put them in their seats straight;...
Page 241 Tuono V4 1100 Factory Electrical system • Bring the two adjuster screws of the cables to zero, fully tightening them. CAUTION BRING BOTH NUTS OF THE TWO ADJUSTMENT SCREWS UP AGAINST THE SUPPORT PLATE, WELDED TO THE SI- LENCER; •...
Page 242 Tuono V4 1100 Factory Electrical system • Use the closing cable adjuster screw up to the value corresponding to the value "X" (see values in the table); CAUTION TURN THE ADJUSTER SCREW FULLY ANTI-CLOCKWISE (DIRECTION FOR TENSIONING THE ADJUSTER SCREW), KEEPING THE COUNTER-NUT STILL.
Page 243 Tuono V4 1100 Factory Electrical system XHAUST VALVE CLEARANCE Condition of use Closing cable - Value "X" Opening cable - Value "Y" New cables 4 +0.2mm (0.16 +0.0078 in) 1 -0.2mm (0.04 -0.0078 in) At 1,000 km (621.37 mi) and at every service 3 -0.2 mm (0.12 -0.0079 in)
Page 244 Tuono V4 1100 Factory Electrical system Engaged released. DIAGNOSTIC TOOL: ELECTRICAL ERRORS P1900 Quick Shift sensor Electrical diagnosis: • Short circuit to negative (at key ON) / Short circuit to positive (at key ON) Error cause: • If short circuit to negative: voltage equal to zero is detected at PIN 11 at key ON.
Page 245 Tuono V4 1100 Factory Electrical system • blocked signal in UP / blocked signal in DOWN / signal not plausible Error cause: • If the signal is blocked in UP: internal spring of the switch blocked in UP • If the signal is blocked in DOWN: internal spring of the switch blocked in DOWN •...
Page 246 Tuono V4 1100 Factory Electrical system • PIN 1: + 12 V power supply (green- brown) • PIN 2: ground (black-black) • PIN 3: ground (brown-black) • PIN 4: + 12 V power supply (blue-blue) • PIN 5: + 12 V power supply (yellow- white) •...
Page 247 Tuono V4 1100 Factory Electrical system panel: if voltage is below 1 V, it means that on the blue cable there is a short circuit to ground; if voltage is above 1 V (approximately battery voltage), replace the "-" button sensor.
Page 248 Tuono V4 1100 Factory Electrical system • CASE 2): if this status is displayed only with control activated, it means that at that moment a voltage below 1V, instead of battery, is being detected at PIN 20 of the instrument panel;...
Page 249 Tuono V4 1100 Factory Electrical system • Pin 4: supply (brown) DIAGNOSTIC TOOL: ELECTRICAL ERRORS DIAGNOSTIC TOOL: LOGIC ERRORS P1901 Ax acceleration sensor plausibility Functional diagnosis: • 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.
Page 250 Tuono V4 1100 Factory Electrical system 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 251 Tuono V4 1100 Factory Electrical system Engine pin-out key: • PIN 1 - Cylinder 4 coil control output • PIN 2 - Cylinder 3 coil control output • PIN 3 - Output for front throttle valve engine command (+) •...
Page 252 Tuono V4 1100 Factory Electrical system • PIN 5 - Power ground 1 • PIN 6 - Sensor ground 1 • PIN 7 - • PIN 8 - Cylinder 1 lower injector command output • PIN 9 - Lambda sensor 2 input (+) •...
Page 253 Tuono V4 1100 Factory Electrical system • PIN 42 - Key input • PIN 43 - Secondary air valve command output • PIN 44 - Lambda 2 heater command output • PIN 45 - Cylinder 4 lower injector command output •...
Page 254 Tuono V4 1100 Factory Electrical system • PIN 54 - • PIN 55 - • PIN 56 - Clutch sensor input • PIN 57 - Sensor ground 2 • PIN 58 - Engine start button input • PIN 59 - •...
Page 255 Tuono V4 1100 Factory Electrical system Engine-vehicle connector pinout key: • PIN A1 - Battery • PIN A2 - • PIN A3 - Safety • PIN A4 - • PIN A5 - • PIN A6 - Clutch released • PIN A7 - Analogic ground •...
Page 256 Tuono V4 1100 Factory Electrical system • PIN C6 - Injection relay • PIN C7 - Engine stop • PIN C8 - Power ground 2 ASC CONTROL UNIT Connector pin-out key: • PIN 1 - Battery positive • PIN 2 - •...
Page 257 Tuono V4 1100 Factory Electrical system • PIN 17 - • PIN 18 - • PIN 19 - Steering dumping 1B • PIN 20 - Steering dumping 2A • PIN 21 - Rear rebound 2B • PIN 22 - Front compression 2A •...
Page 258 Tuono V4 1100 Factory Electrical system • PIN 1 - Valve command at the exhaust (A terminal) • PIN 2 - Antenna 1 • PIN 3 - Antenna 2 • PIN 4 - • PIN 5 - • PIN 6 - Timer set-up •...
Page 259 Tuono V4 1100 Factory Electrical system ABS Modulator ABS control unit pinout key: • PIN 1 - Valve ground and ECU • PIN 2 - H CAN line (high speed) • PIN 3 - Front speed sensor input • PIN 4 - Key positive (ECU) •...
Page 260 Tuono V4 1100 Factory Electrical system Can line Function Allows the communication between the Marelli injection control unit, the instrument panel, the ABS modulator and the LH lights switch. Operation / Operating principle CAN SYSTEM ADVANTAGES A CAN line (Area network controller) is a connection between various electronic devices of a vehicle, set up as a computer network (internet).
Page 261 Tuono V4 1100 Factory Electrical system Electrical specifications: • between PIN 66 and 80 of the control unit: approx. 120 Ohm • between PIN 32 and 33 of the instrument panel: approx. 120 Ohm Pin out: • Line L: White/Black cable between PIN 66 and the Marelli control unit. PIN 32 of the instru- ment panel, PIN 3 of the LH lights switch and PIN 11 of the ABS modulator.
Page 262 Tuono V4 1100 Factory Electrical system • The injection ECU cannot send CAN signals; it receives signals from the instrument panel: the control unit may need replacing. This error is indicated by lighting up in a fixed manner the general warning light.
Page 263 Tuono V4 1100 Factory Electrical system • no signal. Error cause: • No signal is received from the LH light switch. This error is indicated by lighting up in a fixed manner the general warning light. Troubleshooting: • Check the connector of LH light switch: if not ok, restore; if ok, check the continuity of the two lines from the LH light switch connector to the VEHICLE connector of the Marelli control unit: if not ok, restore the wiring harness;...
Page 264 (Sensor box), the correct status we should find on the diagnostic tool devices status page will be: Aprilia Traction Control Performance (in a bend) PRESENT. While on a vehicle equipped with inertia sensor platform (Sensor box) and diagnostic tool...
Page 265 Tuono V4 1100 Factory Electrical system Error cause: • If there is no signal, no signal is received from the ABS control unit. This error is indicated by lighting up in a fixed manner the MI warning light. Troubleshooting: •...
Page 266 Tuono V4 1100 Factory Electrical system is continuity between PIN 2 an PIN 3 of the switch with the brake lever released; if NOT OK, replace the switch, if OK, check that there is continuity between PIN 1 and PIN 2 with the brake lever engaged;...
Page 267 Tuono V4 1100 Factory Electrical system • In the page settings click on the "Blue- Tooth" menu • Inside the "BlueTooth" page if Blue- Tooth is not active, to activate it press the button shown • BlueTooth active = Green button •...
Page 268 Tuono V4 1100 Factory Electrical system • Turn the ignition switch of the motor- cycle ON with the PMP ECU correctly connected. • Open the App's "settings" by clicking on the icon. NOTE THE ICON CAN VARY FROM ONE TO ANOTHER ANDROID VERSION •...
Page 269 Tuono V4 1100 Factory Electrical system Once the connection is established you can start the application by selecting the corresponding icon By turning off the instrument panel (key OFF) the application automatically closes CAUTION TO MAINTAIN A SUCCESSFUL CONNECTION IT IS ESSENTIAL THAT THE KEY SWITCH IS IN THE "ON"...
Page 270 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 271 Tuono V4 1100 Factory Engine from vehicle Vehicle preparation To remove the engine from the chassis, previously perform the following operations: • Remove the fuel tank and the battery. • Remove the fairings, the side fairings, the internal fairings, the fairing lug and the oil radiator guard.
Page 272 Tuono V4 1100 Factory Engine from vehicle • Remove the spacer and the canister fixing screw. • Release the wiring harnesses from the cable gland connected on the rear part of the canister, disconnect the connec- tor of the right side electric fan and remove the safety clamp applied on the connector.
Page 273 Tuono V4 1100 Factory Engine from vehicle • Remove the spacer and the fixing screw of the exhaust valve motor. • Release the connector of the right side electric fan from the exhaust valve mo- tor support and disconnect it.
Page 274 Tuono V4 1100 Factory Engine from vehicle • Remove the cable tie fastening the ca- ble of the demand sensor to the drain pipe of the expansion tank. • Remove the metal clamp and discon- nect the oil pipe from the sump.
Page 275 Tuono V4 1100 Factory Engine from vehicle • Move the metal clips along the pipe and disconnect the cooling system pipe from the pump and the connector pipe leading to the thermostat valve. • Remove the metal clamp and discon- nect the oil pipe from the coupling.
Page 276 Tuono V4 1100 Factory Engine from vehicle • On both sides of the vehicle, remove the two screws fastening the radiator to the mount. • Release the water radiator from the support on the left side and remove both radiators, by extracting them at the same time from the right side.
Page 277 Tuono V4 1100 Factory Engine from vehicle • Disconnect the engine oil pressure bulb connector. • Remove the ground leads fixing screw and release the wiring harnesses. • Move the wiring harness to the outside and fasten them using a circlip.
Page 278 Tuono V4 1100 Factory Engine from vehicle • Remove the clamp that fastens the cooling system's pipe to the starter mo- tor's wiring harness and the ground lead. • After having moved the protective cap and removed the fixing nut of the start- er motor power cable, release the wir- ing harness.
Page 279 Tuono V4 1100 Factory Engine from vehicle • Unscrew the three fastener screws of the front sprocket cover and remove the cover. • Disconnect the rear bank lambda probe connector and release it from its support. • Detach the springs and remove the centre exhaust manifold, easing it out from underneath.
Page 280 Tuono V4 1100 Factory Engine from vehicle • Unscrew the three screws of the chain guide and remove it together with the chain guide slider. • Remove the clamp that fastens the rear bank lambda probe wiring harness to the quick shift wiring harness and to the side stand switch wiring harness.
Page 281 Tuono V4 1100 Factory Engine from vehicle • Remove the screw fastening the en- gine mount to the frame and the three screws fastening the mount to the en- gine. • Remove the mount. • Unscrew the nuts fastening the rear headers and remove the headers, eas- ing out towards the rear.
Page 282 Tuono V4 1100 Factory Engine from vehicle • Partially free the ABS modulator mount from the rubber bush. • Remove the clamp that fastens the pipes of the ABS system to the metal plate. • Lifting the ABS modulator with the sup- port, extract the metal plate at the rear.
Page 283 Tuono V4 1100 Factory Engine from vehicle • Remove the internal cable gland on the right side of the vehicle to facilitate the engine removal. • Install the engine support and place a centre stand under it. Specific tooling 020864Y Engine support plate •...
Page 284 Tuono V4 1100 Factory Engine from vehicle • Disconnect the VEHICLE connector from the control unit and release the wiring harness from the cable glands. • Release the connector from the sup- port on the filter housing and discon- nect it.
Page 285 Tuono V4 1100 Factory Engine from vehicle • Check that the adjuster bushings on the right side of the chassis are com- pletely unscrewed. • Lift the engine and align it with the fix- ing holes on the chassis. •...
Page 286 Tuono V4 1100 Factory Engine from vehicle • Extract the pin until it allows screwing at the specified torque the two adjuster screws on the right side of the chassis. • Refit the pin and after having inserted the upper rear screw together with the washers, tighten al screws to the speci- fied torque.
Page 287 Tuono V4 1100 Factory Engine from vehicle • Fit the central manifold by connecting the rear manifolds, making sure to pass the rear bank lambda probe wir- ing harness inside the metal cable gland. • Connect the springs that hold the rear manifolds joined with the central mani- fold.
Page 288 Tuono V4 1100 Factory Engine from vehicle • Place the drive chain on the sprocket. • Insert the sprocket on the secondary shaft and after having placed the "T" bush and the spring washer on the fix- ing screw, tighten the screw to the specified torque.
Page 289 Tuono V4 1100 Factory Engine from vehicle • Connect the rear bank lambda probe connector, engaging in it the specific support and this in turn to the chain guide. • Restore the fuel tank breather pipe and fasten it using the rubber cable tie, to-...
Page 290 Tuono V4 1100 Factory Engine from vehicle • Connect the clutch cable and, using the adjuster nuts, adjust the tension and check the play on the handlebar lever. • Restore the front right internal cable gland on the chassis. •...
Page 291 Tuono V4 1100 Factory Engine from vehicle • Refit the clamp that fastens the cooling system's pipe to the starter motor's wir- ing harness and the ground lead. • Insert the front left internal cable gland on the chassis and refit the wiring har- nesses.
Page 292 Tuono V4 1100 Factory Engine from vehicle • Insert the front bank manifolds with new gaskets and connect them to the central manifold. • Insert the locking nuts and screw them partially to facilitate the subsequent op- erations for the assembly of the ex- haust system.
Page 293 Tuono V4 1100 Factory Engine from vehicle • Refit the wiring harnesses on the radi- ator support and secure them with a new clamp. • Connect the coolant radiator pipe on the right side and secure it using the specific metal clamp.
Page 294 Tuono V4 1100 Factory Engine from vehicle • Insert the two fixing screws of the radi- ators support bracket and tighten them to the specified torque. • Secure the demand sensor wiring har- ness to the expansion tank breather pipe using a new clamp.
Page 295 Tuono V4 1100 Factory Engine from vehicle • Engage the connector of the right side electric fan on the exhaust valve motor support. • Insert the two exhaust valve motor sup- port fixing screws and tighten them to the specified torque.
Page 296 Tuono V4 1100 Factory Engine from vehicle • Insert the two canister support fixing screws and tighten them to the speci- fied torque. • Connect the oil pipe on the sump and secure it using a new metal clamp. •...
Page 297 Tuono V4 1100 Factory Engine from vehicle • First fit a clamp on the metal plate and insert it under the ABS modulator sup- port as shown. • Insert the ABS modulator support at the back, into the rubber ring.
Page 298 Tuono V4 1100 Factory Engine from vehicle • Connect the chassis architecture/en- gine power supply connector and en- gage it in the support on the filter housing. • Insert the main wiring harness in the cable glands and connect the VEHI- CLE connector to the control unit.
Page 299 INDEX OF TOPICS NGINE...
Page 300 Tuono V4 1100 Factory 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° cyl 3: 425°...
Page 301 Tuono V4 1100 Factory Engine Gearbox EARBOX Pos. Description Type Quantity Torque Notes "Philips" cylindrical head hex. socket M6x20 10 Nm (7.38 lbf ft) Pre-coated screw - screw if not pre-coated, apply 3M SCOTCH GRIP 2353 to thread Pre-coated countersunk flat head M6x16 10 Nm (7.38 lbf ft)
Page 302 Tuono V4 1100 Factory Engine Diagram Key: 1. Primary shaft 2. Fifth speed gear on primary shaft 3. Roller bearing cage for fifth speed gear on primary shaft 4. Shoulder washer 5. Ring 6. Third-fourth speed gear on primary shaft 7.
Page 303 Tuono V4 1100 Factory Engine 20.Spring washer 21.T-shaped bushing 22.Second speed gear on secondary shaft 23.Roller bearing cage for second speed gear on secondary shaft 24.Washer 25.Seeger ring 26.Sixth speed gear on secondary shaft 27.Seeger ring 28.Shoulder washer 29.Roller bearing cage for third speed gear on secondary shaft 30.Third speed gear on secondary shaft...
Page 304 Tuono V4 1100 Factory Engine Gearbox Removing the gearbox • Remove the gearbox selector. • Remove the clutch housing. • Remove the gear sensor from the flywheel side. • Remove the Seeger ring. • Remove the water/oil pump control gear.
Page 305 Tuono V4 1100 Factory Engine • Unscrew and remove the six screws. • 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-...
Page 306 Tuono V4 1100 Factory Engine • Remove the fork (2) of the gearbox pri- mary shaft • Slide off the gearbox secondary shaft control rod (3) • Remove the forks (4) of the gearbox secondary shaft • Remove both gearbox shafts from the...
Page 307 Tuono V4 1100 Factory Engine • Remove the shim washer (5) that is lo- cated on the secondary shaft between the shaft and the cover • Loosen and remove the screw (6) • Remove the desmodromic shaft (7) • Remove the selector drum (8)
Page 308 Tuono V4 1100 Factory Engine DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE, ALTERNATOR SIDE • Remove the lower crankcase. • A suitable extractor must be used to remove the desmodromic gearbox control rod drum roller cage from the alternator side.
Page 309 Tuono V4 1100 Factory Engine Checking the secondary shaft Characteristic Maximum wear limit for selector gear splines 5.3 mm (0.21 in) Minimum wear limit of the pinion side secon- dary shaft seat 29.97 mm (1.18 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in)
Page 310 Tuono V4 1100 Factory Engine • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary. • Check the gearbox fork's movement, and replace the gearbox forks if it is irregular.
Page 311 Tuono V4 1100 Factory Engine • Move the gearbox shafts together and fit them into the support • Grease the sliding bushes of the forks • Insert the forks (5) in the specific seats of the gearbox secondary shaft •...
Page 312 Tuono V4 1100 Factory Engine • Insert the fork (7) in the specific seat of the gearbox primary shaft • Insert the gearbox primary shaft con- trol rod (8) • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal.
Page 313 Tuono V4 1100 Factory Engine • Remove the special tool from the alter- nator side. • Tighten the six screws that fasten the gearbox unit to the crankcase. Specific tooling 0277308 Guide bushing for gearbox secondary shaft • Insert the driving pin on the oil pump shaft.
Page 314 Tuono V4 1100 Factory 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. Specific tooling...
Page 315 Tuono V4 1100 Factory 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 316 Tuono V4 1100 Factory Engine • Remove the starter motor (3) from its housing. Removing the idle gear • Remove the clutch cover. • Remove the intermediate gear. Start-up system check IF THE DOUBLE STARTING GEAR TOOTHING IS DEFORMED, IT IS NECESSARY TO ALSO CHECK THE TOOTHING OF THE STARTING MOTOR.
Page 317 Tuono V4 1100 Factory Engine If deformations or broken material are found on the sliding surface, replace the freewheel gear (2). Check the freewheel sliding surface (2) for wear. Make sure that the woodruff key slot is in perfect condition.
Page 318 Tuono V4 1100 Factory Engine Generator side ENERATOR COVER Pos. Description Type Quantity Torque Notes Cover fastening screws M6x25 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque. Cover fastening screws M6x40 12 Nm (8.85 lbf ft)
Page 319 Tuono V4 1100 Factory Engine • Working from the underside of the filter box, release the retainer clip and dis- connect the blow-by pipe. If the blow-by pipe is disconnected from the fitting on the cover, and the relative metal clamp is removed, use a new clamp when re- assembling.
Page 320 Tuono V4 1100 Factory Engine • Remove the O-ring. USE A NEW O-RING WHEN REASSEMBLING • Remove the seeger ring. • Remove the shim. • Remove the oil seal. CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE.
Page 321 Tuono V4 1100 Factory Engine Magneto flywheel removal • Remove the flywheel cover. • Block flywheel rotation using the spe- cific tool. THE SPECIFIC TOOL MUST BE MODIFIED FOR USE ON THIS ENGINE, WIDENING THE CEN- TRE HOLE BY THE AMOUNT NECESSARY TO ALLOW THE TOOL TO FIT COMPLETELY ON- TO THE FLYWHEEL.
Page 322 Tuono V4 1100 Factory Engine Removing the stator To proceed with the removal of the stator, proceed as described: • Remove the three fastener screws of the stator • Remove the two fastener screws of the pickup. • Remove the stator cable retainer plate.
Page 323 Tuono V4 1100 Factory Engine Rimozione ingranaggio ruota libera In order to remove the countershaft drive gear, complete with freewheel, the complete clutch must be removed beforehand. Then proceed as described: • Fit the special primary gear lock tool Specific tooling 020850Y Primary gear lock •...
Page 324 Tuono V4 1100 Factory Engine Flywheel components check - Check that the magnets are in good conditions. - Check that the magnet support cage is not deformed or broken. Checking the starter clutch Remove the free wheel from its housing and check the rollers for signs of wear.
Page 325 Tuono V4 1100 Factory Engine Flywheel cover components installation Fit a new oil seal if the original oil seal was re- moved during disassembly. Use a suitable punch tool to install. • Lubricate the inner part of the oil seal and fit onto the cover, oriented correct- ly as shown.
Page 326 Tuono V4 1100 Factory Engine • Replace the O-ring with a new one of the same type. • Fit the connector of the blow-by sys- tem. • Fit the three screws of the blow-by sys- tem connector and tighten to the speci- fied torque.
Page 327 Tuono V4 1100 Factory Engine • Position the soundproofing cover and lock it in place using the three appro- priate screws • Working from the underside of the filter box, connect the blow-by pipe and se- cure the pipe with a new retainer clip.
Page 328 Tuono V4 1100 Factory Engine Pos. Description Type Quantity Torque Notes Flanged hex cap screw M6x35 12 Nm (8.85 lbf ft) Tighten to torque, unscrew and re- tighten to torque. Flanged hex cap screw M6x22 12 Nm (8.85 lbf ft)
Page 329 Tuono V4 1100 Factory Engine • Unscrew and remove the engine oil dipstick. • Unscrew and remove the five special screws (3) and the eleven fastening screws (4) around the perimeter, and retrieve the relative washers. • Remove the clutch crankcase.
Page 330 Tuono V4 1100 Factory Engine • Remove the thrust plate and the com- plete control rod. • Remove the discs. • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch hous- ing fixing nut.
Page 331 Tuono V4 1100 Factory Engine • Remove the clutch hub. • Remove the clutch hub cam tower. • Remove the washer. • Remove the clutch bell. ENG - 331...
Page 332 Tuono V4 1100 Factory Engine • Remove the clutch gear that controls the oil/water pumps. • Remove the needle cage. • Remove the spacer. • Remove the thrust bearing. ENG - 332...
Page 333 Tuono V4 1100 Factory Engine 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) Minimum wear limit of the complete clutch pack thickness (friction discs + steel discs) 47.6 mm (1.87 in)
Page 334 Tuono V4 1100 Factory Engine Characteristic Maximum deformation permitted on the thrust plate compression surface 0.15 mm (0.0059 in) Maximum depth of the thrust plate 27.3 mm (1.07 in) Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation.
Page 335 Tuono V4 1100 Factory Engine Assembling the clutch • Insert the thrust bearing with the collar facing the gearbox. • Insert the spacer. • Insert the roller cage. • Install the clutch gear, making it mesh with the oil/water pump control gear.
Page 336 Tuono V4 1100 Factory Engine • Insert the clutch bell, making it engage with the engine pinion. • Insert the washer. • Install the clutch hub cam tower. • Position the clutch hub. INSTALL THE THREE CLUTCH HUB CAMS IN THE RE- SPECTIVE CLUTCH BASKET INCLINES.
Page 337 Tuono V4 1100 Factory Engine • Fit the cup spring washer and the two washers. • Block clutch housing rotation using the appropriate tool. • Tighten the clutch housing fixing nut. Specific tooling 020849Y Clutch retainer tool • Insert the disc with friction material and the black tooth into the bell.
Page 338 Tuono V4 1100 Factory Engine • Insert the flat washer. • Insert the spring washer with the con- cave side facing out. • Insert the disc covered with friction ma- terial into the housing. • Insert the nitrided metal disc into the clutch housing.
Page 339 Tuono V4 1100 Factory Engine • Continue inserting, alternating a metal disc with one with friction material, end- ing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 340 Tuono V4 1100 Factory Engine • Fit the clutch springs (3). • Insert the spring holder cap (2) onto the screws (1). • Tighten the six screws working in stages and diagonally. Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING •...
Page 341 Tuono V4 1100 Factory Engine INSTALLING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the installation of the bushing, it is necessary to warm up the cover. • Position the guide (1) to insert the bushing (2) as indicated in the figure.
Page 342 Tuono V4 1100 Factory Engine • Fit and tighten the engine oil dipstick. • Fit the soundproofing cover (7), fit the five fastener screws (8) and then tight- en the screws to the specified torque. • Fill with engine oil to the correct level.
Page 343 Tuono V4 1100 Factory Engine Pos. Description Type Quantity Torque Notes TE flanged coil fixing screw M6x12 8 Nm (5.90 lb ft) Loct. 243 Spark plugs 12 Nm (8.85 lb ft) EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft)
Page 344 Tuono V4 1100 Factory 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 Chain tensioner sliders fastening 20 Nm (14.75 lb ft) Loct. 243...
Page 345 Tuono V4 1100 Factory Engine • Remove the head cover together with the sealing gasket INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure.
Page 346 Tuono V4 1100 Factory Engine Removing camshafts To remove the camshafts of the front head, follow the procedure described below: • Remove both cylinder head covers, the soundproofing covers, the alternator side cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC.
Page 347 Tuono V4 1100 Factory Engine • Loosen the second screw of the cam- shaft drive sprocket. • Remove the pin from the camshaft drive sprocket. • Unscrew and remove the three screws (1) and remove the bearing cap (2) and the oil pipe (3).
Page 348 Tuono V4 1100 Factory Engine • Move the gear from the camshaft to the tool and make sure that it is locked by fastening the tool's spacer. • Unscrew the seven screws in progres- sive steps in a criss-cross pattern and remove.
Page 349 Tuono V4 1100 Factory Engine • Fasten the camshaft horizontally, 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/ outlet) 0.3-0.1 mm (0.012-0.004 in) Check the timing chain for damage or stiffness while moving.
Page 350 Tuono V4 1100 Factory Engine • Fit the bearing caps complete with O- rings and alignment, and fit and hand- tighten the seven screws indicated. Use new copper washers on the four screws near the spark plug holes. • Loosen the camshaft sprocket lock screw on the tool.
Page 351 Tuono V4 1100 Factory Engine • Align the intake camshaft with the spe- cific hole on the bearing cap and fit the pin. • Tighten the first fastener screw of the camshaft sprocket to the specified tor- que. Specific tooling 020851Y Camshaft timing pin •...
Page 352 Tuono V4 1100 Factory Engine Front head removal In order to remove the front head, the procedures described in the paragraph "Removing the cam- shafts " (front head) must be performed beforehand. Then proceed as described: • Unscrew and remove the chain sliders' screws.
Page 353 Tuono V4 1100 Factory Engine • 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. REPLACE THE O RING UPON EACH REMOVAL.
Page 354 Tuono V4 1100 Factory Engine • 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 355 Tuono V4 1100 Factory Engine • Place a new gasket between the crank- case and the head. • Position the two centring pins. • Fit the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6.
Page 356 Tuono V4 1100 Factory Engine • Install the intake and exhaust cam- shafts 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 cam- shaft gear (indicated with two dots).
Page 357 Tuono V4 1100 Factory Engine • Install the chain shoe and the chain guide shoe, fastening with the relative screws. • Install the chain complete with timing sprocket, fitting the chain and sprocket onto the camshaft. • Turn the crankshaft in the direction of...
Page 358 Tuono V4 1100 Factory Engine • Load the chain tensioner with special tool. Specific tooling 020981Y Lever for disarming the hydraulic ten- sioner of the timing chain • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 359 Tuono V4 1100 Factory Engine Specific tooling 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; 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 360 Tuono V4 1100 Factory Engine • Continue rotating the crankshaft in the direction of rotation of the engine to complete one full turn + 90° (450° in total) relative to the starting position in the previous step. • Insert the pin from the flywheel side in- to the hole in the crankshaft.
Page 361 Tuono V4 1100 Factory Engine • Remove the second screw of the cam- shaft drive sprocket. CAUTION WORK WITH PARTICULAR CAUTION TO PREVENT THE CAMSHAFT GEAR FROM DETACHING FROM THE CAM- SHAFT. • Install the specific camshaft gear sup- port tool.
Page 362 Tuono V4 1100 Factory Engine • 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 363 Tuono V4 1100 Factory Engine Installing camshafts NOTE THE INTAKE AND EXHAUST CAMSHAFTS ARE BOTH DEDICATED FOR THE FRONT AND REAR CYLINDER BANKS. NOTE THE INTAKE AND EXHAUST CAMSHAFTS OF THE REAR CYLINDER BANK ARE IDENTIFIED BY A SINGLE LINE IN THE POSITIONS INDICATED.
Page 364 Tuono V4 1100 Factory Engine • Remove the tool for holding the cam- shaft drive sprocket gear on the head. • Apply Loctite 243 thread lock adhesive to the first screw of the camshaft sprocket and hand-tighten the screw only.
Page 365 Tuono V4 1100 Factory Engine • Continue rotating the crankshaft (in di- rection of rotation of engine) to bring it back to the previous position in which the holes in the camshaft and the bear- ing cap were aligned; insert the refer-...
Page 366 Tuono V4 1100 Factory 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 367 Tuono V4 1100 Factory 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 368 Tuono V4 1100 Factory Engine • Place a new gasket between the crank- case and the head. • Position the two centring pins. • Fit the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6.
Page 369 Tuono V4 1100 Factory Engine • Install the intake and exhaust cam- shafts 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 cam- shaft gear (indicated with two dots).
Page 370 Tuono V4 1100 Factory Engine • Install the chain shoe and the chain guide shoe, fastening with the relative screws. • Install the chain complete with timing sprocket, fitting the chain and sprocket onto the camshaft. • Turn the crankshaft in the direction of...
Page 371 Tuono V4 1100 Factory Engine • Load the chain tensioner with special tool. Specific tooling 020981Y Lever for disarming the hydraulic ten- sioner of the timing chain • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 372 Tuono V4 1100 Factory Engine Specific tooling 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 373 Tuono V4 1100 Factory Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs See also Front head removal Rear head removal •...
Page 374 Tuono V4 1100 Factory Engine • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME. DO NOT MIX THE COMPONENTS. EACH VALVE MUST BE INSERTED INTO ITS SEAT, WHICH IS MARKED PRIOR TO REMOVAL. VALVE STEM DEVIATION Lift up the valve approx.
Page 375 Tuono V4 1100 Factory Engine Support the valve with two "V" blocks as shown and check the run-out with a dial gauge. If the run-out exceeds the specified limit, replace the valve. Characteristic Valve stem run-out 0.05 mm (0.0020 in) Position the dial gauge at a right angle to the valve head face and measure the eccentricity.
Page 376 Tuono V4 1100 Factory Engine • 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. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING.
Page 377 Tuono V4 1100 Factory Engine • Release the wrench, checking that the cotters are positioned correctly in the valve grooves. • Position the adjusting shims • Position the bucket tappets. ENG - 377...
Page 378 Tuono V4 1100 Factory Engine Crankcase RANKCASE Pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lbf ft) Loct. 270 Flanged hex cap screw M8x70 25 Nm (18.44 lbf ft) Lubricate the head and under the head. Flanged hex cap screw M6x50 10 Nm (7.38 lbf ft)
Page 379 Tuono V4 1100 Factory Engine Pos. Description Type Quantity Torque Notes tion for another 60° +/- 2 Screw fastening ground cable to the 6 Nm (4.43 lbf ft) engine GNITION UNIT Pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lbf ft)
Page 380 Tuono V4 1100 Factory Engine RANKSHAFT Pos. Description Type Quantity Torque Notes Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lbf ft) + 130° and under head with PANKL Lubricant 01 (PLB01) Primary fixing ring nut 200 Nm (147.51 lbf ft)
Page 381 Tuono V4 1100 Factory Engine • Unscrew the fastener nut of the pri- mary gear and the fastener nut of the countershaft drive gear. • Remove the lock tool and remove the primary gear. Specific tooling 020850Y Primary gear lock •...
Page 382 Tuono V4 1100 Factory Engine • Remove the countershaft from the al- ternator side. • Collect the spacer. Balancing countershaft fitting To install the balancer countershaft, follow the pro- cedure described below: • Fit the balancer countershaft into the casing from the flywheel side.
Page 383 Tuono V4 1100 Factory Engine • Fit the primary gear, aligning the mark- ings on both gears correctly as shown. • Rotate the countershaft to align the slot on the shaft itself with the slot in the countershaft drive gear and permit in- stallation of the key.
Page 384 Tuono V4 1100 Factory Engine Main transmission gear removal In order to remove the primary gear, the clutch cover, alternator cover and complete clutch must be removed beforehand. Then proceed as described: • Fit the special primary gear lock tool...
Page 385 Tuono V4 1100 Factory Engine • Fit the retainer tool, fit the nut and then tighten the nut to the specified torque. Specific tooling 020850Y Primary gear lock Preparation To open the crankcase, first remove the following components: • alternator;...
Page 386 Tuono V4 1100 Factory Engine 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 387 Tuono V4 1100 Factory 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 • Remove both heads.
Page 388 Tuono V4 1100 Factory Engine • Slide off the pin See also Front head removal Rear head removal Crankshaft removal • Separate the crankcases, removing the lower part • If the heads were removed, position the specific special tool to keep the pis- tons from coming out.
Page 389 Tuono V4 1100 Factory Engine • Take out the crankshaft. Bearing removal BALANCING COUNTERSHAFT BEARING RE- MOVAL • Remove the lower crankcase. • Remove the countershaft. FLYWHEEL-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock.
Page 390 Tuono V4 1100 Factory Engine • Heat up the crankcase to 150°C (302° • Position the general tool to pull out bearings. • Remove the bearing. See also Crankcase opening Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase 0.5 mm (0.0197 in)
Page 391 Tuono V4 1100 Factory Engine Connecting rod check Characteristic Maximum wear limit of the connecting rod small end 17.03 mm (0.6705 in) Maximum connecting rod small end radial clearance 0.045 mm (0.0018 in) Maximum radial play between connecting rod and crankpin 0.55 mm (0.022 in)
Page 392 Tuono V4 1100 Factory Engine crankshafts and connecting rods have been intro- duced which are matched with each other in rela- tion to their balancing class. The class is easily identifiable as it is marked on the component itself. The permitted crankshaft-connecting rod balancing class combinations are listed in the following table:...
Page 393 Tuono V4 1100 Factory Engine The connecting rod class is stamped on its left side, viewed from the front, from the side with the bevelling on the big end hole. Bushing selection CRANKSHAFT BUSHINGS CRANKCASE CATEGORY Three crankcase classes are available (A - B- C) which differentiate in the diameter of the hole in the bearings.
Page 394 Tuono V4 1100 Factory Engine 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 Class C Bushing seat diameter 52.013 - 52.008 mm (2.0477 - 2.0475...
Page 395 Tuono V4 1100 Factory Engine RANKSHAFT BUSHINGS Crankshaft main journal Class A crankcase Class B crankcase Class C crankcase Class C main journal Bushing (yellow) Bushing (yellow) Bushing (blue) Class D main journal Bushing (green) Bushing (yellow) Bushing (yellow) Class E main journal...
Page 396 Tuono V4 1100 Factory Engine • Blue • Yellow • Green For the coupling of the connecting rod with the crankshaft, according to the engraving on the counter- weights, observe the following table: USHINGS THICKNESS Bushing colours Thickness BLUE 1.547 - 1.552 mm YELLOW 1.552 - 1.557 mm...
Page 397 Tuono V4 1100 Factory Engine Bearing fitting BALANCING COUNTERSHAFT BEARING INSTALLATION FLYWHEEL-SIDE • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020364Y 25 mm adapter 020359Y 42 x 47 mm punch 020376Y Adaptor handle •...
Page 398 Tuono V4 1100 Factory Engine • Heat up the crankcase to 150°C (302°F). • Prepare the following tools: Specific tooling 020363Y 20 mm diam. punch for crankshaft oil seal 020359Y 42 x 47 mm punch 020376Y Adaptor handle • Position the new bearings with their groove on the outside diameter facing outward with respect to the crankcase.
Page 399 Tuono V4 1100 Factory Engine Crankshaft fitting • Lubricate the crankshaft pins and in- sert them into their positions. • Install the connecting rod shank piston assembly in the relative cylinders. • Join the crankcases. • If the special tool was used, remove it to keep the pistons from coming out.
Page 400 Tuono V4 1100 Factory Engine Installing connecting rods - pistons The piston rings are different and must be fitted with the "KDN5" markings (for the upper one)(A) and "K-TOP and KDN5" markings (for the lower one )(B) facing upward. The five ring gaps (two piston rings, two oil scraper rings, one oil scraper spring) are fitted displaced 90º...
Page 401 Tuono V4 1100 Factory Engine • Position the special tool on the crank- case. • Partially insert the connecting rod shank - piston assembly in the corre- sponding cylinder with the arrow (on the piston) twisted 45°towards the ex- haust.
Page 402 Tuono V4 1100 Factory Engine Crankcase closing • Insert the crankshaft together with con- necting rods and pistons in the upper crankcase. • Position the three centring dowels in the crankcase. • Insert a new oil seal O ring in the spe- cific seat.
Page 403 Tuono V4 1100 Factory Engine • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - • Then tighten them fully following the same order. • Pre-tighten the screws in the following order: 7 - 8 - 9 - 10 - 11 - 12 - 13 - 14 - 15 - 16 - 17 - 18 - 19 - 20 - 21 - 22 - 23.
Page 404 Tuono V4 1100 Factory Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). Lubrication UBRICATION pos. Description Type Quantity Torque Notes Oil filter coupling fastening 28.5 Nm (21.02 lb ft) Oil drainage plug 30 Nm (22.13 lbf ft) Oil sump fixing screws 12 Nm (8.85 lb ft)
Page 405 Tuono V4 1100 Factory Engine RANKCASE pos. Description Type Quantity Torque Notes Piston cooling oil jet fastening 5 Nm (3.69 lb ft) Loctite 2045 - Pre- screws impregnated screw Captive crankcase fixing pins 20 Nm (14.75 lb ft) Loctite 270 Flanged base fastening nuts 15 + 20 Nm (11.06 +...
Page 406 Tuono V4 1100 Factory Engine COOLING JETS The motor is fitted with lubrication jets whose function is to increase the efficacy of the oil cooling circuit at two specific points: 1. To lubricate the piston rods/pistons at the base of each cylinder 2.
Page 407 Tuono V4 1100 Factory Engine OIL PUMP REMOVAL • Place the oil pumps on a work table. • Remove the gasket. See also Removing the gearbox Water pump • Unscrew and remove the four cooling oil pump cover screws •...
Page 408 Tuono V4 1100 Factory Engine • Unscrew and remove the four lubrica- tion oil pump cover screws. • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor.
Page 409 Tuono V4 1100 Factory Engine Installing • Position the lubrication pump internal rotor on the oil pump control shaft The lubrication pump components are larger than the cooling pump components. The lubrication pump must be fit onto the shaft from the side with the Seeger ring seat for fasten- ing the gear.
Page 410 Tuono V4 1100 Factory Engine • Tighten the four lubrication oil pump cover screws. • 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 411 Tuono V4 1100 Factory Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump • Remove the upper gasket ENG - 411...
Page 412 Tuono V4 1100 Factory Engine • Remove the rose pipe together with the gasket CAUTION THE ROSE PIPE MUST BE CAREFULLY CLEANED IN THE EVENT THAT THE ENGINE IS COMPLETELY OVER- HAULED OR IN CASE OF PROBLEM WHICH MAY HAVE GENERATED SUSPENDED DEBRIS IN THE OIL.
Page 413 Tuono V4 1100 Factory Engine Blow-by 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 414 Tuono V4 1100 Factory Engine Diagram Valve controlled by control unit which delivers as- pirated air from the filter box to the exhaust mani- folds. The advantages of this function are twofold: • the catalytic converter reaches the op- erating temperature more quickly;...
Page 415 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 416 Tuono V4 1100 Factory Power supply Circuit diagram FUEL SYSTEM LAYOUT Key: 1. Lower injectors on the rear throttle body 2. Lower injectors on the front throttle body 3. Connection 4. Front throttle body 5. Rear throttle body 6. Fuel tank 7.
Page 417 Tuono V4 1100 Factory Power supply Key: 1. Connection 2. Purge valve 3. ECU 4. "T" connection 5. Lower injectors on the rear throttle body 6. Lower injectors on the front throttle body 7. Fuel tank 8. Canister 9. Front throttle body 10.Rear throttle body...
Page 418 Tuono V4 1100 Factory Power supply Removing In order to remove the fuel pump, the tank must be removed from the vehicle beforehand. Then pro- ceed as described: • To facilitate removal of the fuel pump, remove the mount by unscrewing the fastener screw.
Page 419 Tuono V4 1100 Factory Power supply • Ease out the pump, taking particular care not to damage the pump. Injection P SUPP - 419...
Page 420 Tuono V4 1100 Factory Power supply Diagram Key: 1. Electronic suspension control unit (where applicable) 2. Demand sensor 3. Exhaust valve motor 4. ECU P SUPP - 420...
Page 421 Tuono V4 1100 Factory Power supply 5. Inertia platform 6. ABS control unit 7. Diagnostic connector (OBD II) 8. Clutch position sensor 9. Fuel pump (inside the tank) 10.air temperature sensor 11.Air pressure sensors (MAP) 12.Lower injectors 13.Coils (spark plug cover) 14.Engine throttle valve / Throttle valve position sensor...
Page 422 Tuono V4 1100 Factory Power supply Removing the injector LOWER INJECTORS DO NOT REMOVE THE LOWER INJECTORS Only the fuel pipe of the lower injectors may be removed; in order to remove the pipe, the com- plete filter box must be removed beforehand. Then proceed as described: •...
Page 423 Tuono V4 1100 Factory Power supply • Disconnect the connector. • Remove the complete throttle body. See also Air box Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction.
Page 424 Tuono V4 1100 Factory Power supply Stepper motor The control unit regulates the idle speed by controlling the throttle body motors directly. As a result, idle speed adjustment and maintenance of the components involved in idle speed regulation (stepper mo- tors, thermoactuators, etc.) are not necessary.
Page 425 INDEX OF TOPICS SUSP USPENSIONS...
Page 426 Tuono V4 1100 Factory Suspensions Front Front fork ASC (TUONO V4 1100 FACTORY) RONT FORK HLINS Pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 2 + 2 10 Nm (7.37 lbf ft) screws ABS sensor fixing screw 8 Nm (5.90 lbf ft)
Page 427 Tuono V4 1100 Factory Suspensions (TUONO V4 1100) RONT FORK ACHS Pos. Description Type Quantity Torque Notes Calliper mounting bracket fixing 10 Nm (7.37 lbf ft) screws ABS sensor fixing screw 8 Nm (5.90 lbf ft) Upper cap 20 Nm (14.75 lbf ft) Upper cap locking nut 20 Nm (14.75 lbf ft)
Page 428 3 notches/ 12 mm (3 notches/0.47 in) (*) - Clockwise (**) - Anticlockwise (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. Tuono V4 1100 Factory (Ohlins fork - ASC ) • Refer to the USE AND MAINTENANCE BOOKLET, paragraph "ADVANCED FUNCTIONS"...
Page 429 Spring pre-load (2): 5 turns from the adjustment ring nut completely unscrewed • ASC mode: A1-M1 • Stems (A) (***) protrusion from top plate: 2 notches (***) - this type of adjustment may only be made by an Authorised Aprilia Dealer. SUSP - 429...
Page 430 Tuono V4 1100 Factory Suspensions Removing the fork legs To remove the stanchions, place the motorcycle on suitable support stands, disconnect the front brake callipers and remove the mudguard, the front wheel, the side fairings and the front body- work.
Page 431 Tuono V4 1100 Factory Suspensions • During reassembly, pay attention to the adjustment of the stanchion protrusion, referring to the "Adjustment" paragraph in the "Suspensions" chapter. Draining oil TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS.
Page 432 Tuono V4 1100 Factory Suspensions • Place the fork vertically locking it in a vice by the specific tool. • Completely unscrew the plug. Specific tooling AP8140149 Guard for assembly operations • Using the specific tool, fixed to the pre- loading pipe, compress the spring.
Page 433 Tuono V4 1100 Factory Suspensions • Remove the lock nut and the washer. • 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 IN THE ENVIRONMENT.
Page 434 Tuono V4 1100 Factory Suspensions • Unscrew the upper cap from the sleeve using a specific Öhlins tool. Specific tooling 01761-04 Ohlins fork cap ring nut • Loosen the cap using a wrench in order to release the upper nut on the spring retaining ring.
Page 435 Tuono V4 1100 Factory Suspensions • Remove the pre-loading spring retain- ing ring. • Remove the pre-loading spring. • Empty the fork oil into a special con- tainer, taking care not to let the pre- loading tube come out. Disassembling the fork...
Page 436 Tuono V4 1100 Factory Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim. • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller.
Page 437 Tuono V4 1100 Factory Suspensions • Using a hook spanner lock the pump- ing member pin. • Remove the stem bottom screw. Specific tooling 020889Y Wrench for locking pumping unit ring • Remove the pumping member pin. TUONO V4 1100 FACTORY NOTE THE FOLLOWING OPERATIONS REFER TO THE OHLINS FORKS.
Page 438 Tuono V4 1100 Factory Suspensions • Clamp the sleeve in a vice and, by lev- ering it alternately at various points, remove the anti-dust seal (3) from the sleeve (2). • Remove the retaining ring (4). • Remove the shaft seal (5) by levering it alternately at various points.
Page 439 Tuono V4 1100 Factory Suspensions If the scratches are deep, replace the stanchion . Using a dial gauge, check than any bending of the stanchion is below the limit value. If it is over the limit, replace the stanchion .
Page 440 Tuono V4 1100 Factory Suspensions stanchion 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 stanchion . Using a dial gauge, check than any bending of the stanchion is below the limit value.
Page 441 Tuono V4 1100 Factory Suspensions • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
Page 442 Tuono V4 1100 Factory Suspensions • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Tool for mounting the oil seal for holes with diam. 43 mm (1.69 in) AP8140146 Weight • Insert the pumping member pin in the stem.
Page 443 Tuono V4 1100 Factory Suspensions • Install the following components on the wheel holder stanchion (1) in the order given: dust gaiter (3), retainer ring (4) and oil seal (5). • Fix the sleeve in a vice, taking care not to damage the sleeve.
Page 444 Tuono V4 1100 Factory Suspensions • Position the two halves of the special tool on the shaft behind anti-dust seal (3), together with the respective buffer. • Grip the special tool and push the anti- dust seal (3) into its housing on the sleeve (2).
Page 445 Tuono V4 1100 Factory Suspensions Oil level: 90- 2mm (3.54- 0.08 in) (from sleeve rim, without spring and total cap). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS.
Page 446 Tuono V4 1100 Factory Suspensions • Tighten the nut as much as possible. • Fully tighten the compression/rebound adjusters. • Insert the cover and tighten until it stops. • Remove the dedicated tools. • Screw the cover in the sleeve to the prescribed torque.
Page 447 Tuono V4 1100 Factory Suspensions THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS. Characteristic Fork oil 470 +/- 4 DC (28.68 +/- 0.24 cu.in) (same quantity for both stems) •...
Page 448 Tuono V4 1100 Factory Suspensions • Tighten the nut as much as possible. • Insert the cover and tighten until it stops. • Using the special Ohlins tool, tighten the cap to the prescribed torque. Steering damper TEERING Pos. Description...
Page 449 The Tuono V4 1100 version is fitted with a non-adjustable steering damper. No adjustments can be carried out. Tuono V4 1100 Factory (Ohlins shock absorber - ASC) The steering damper can be electronically adjusted, refer to paragraph "ADVANCED FUNCTIONS" in the "VEHICLE"...
Page 450 Unscrew the fixing screw at the bottom yoke. • Remove the steering damper. TUONO V4 1100 FACTORY (ASC Ohlins steering damper) • After removing the cable glands and the clamp that secure the steering damper wiring harness to it, remove the two fixing screws located on the frame and on the lower steering plate.
Page 451 Tuono V4 1100 Factory Suspensions • Disconnect the connector from the steering damper and remove it. Steering bearing TEERING Pos. Description Type Quantity Torque Notes Screws fastening raiser to upper 50 Nm (36.88 lbf ft) Loctite 243 steering yoke Upper handlebar U-bolt fastening 25 Nm (18.44 lbf ft)
Page 452 Tuono V4 1100 Factory Suspensions Pos. Description Type Quantity Torque Notes bending the tabs in the notches, it can be turned further by 35° or unscrewed by max. 10° Upper yoke fixing cap 100 Nm (73.76 lb ft) Screw fastening spacer to the chas- M8x25 20 Nm (14.75 lbf ft)
Page 453 Tuono V4 1100 Factory Suspensions • 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. • Remove the upper yoke • If necessary, remove the wiring har- ness fixed in the part below in order to remove the steering plate.
Page 454 Tuono V4 1100 Factory 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 455 Tuono V4 1100 Factory Suspensions EAR SHOCK ABSORBER Pos. Description Type Quantity Torque Notes Upper shock absorber fixing screw 50 Nm (36.88 lbf ft) Dual connecting rod fixing screw 50 Nm (36.88 lbf ft) Screw fastening single connecting 50 Nm (36.88 lbf ft)
Page 456 CAUTION FOR THE CORRECT SETTING PARAMETERS, READ THE PARAGRAPH "SETTING THE REAR SHOCK ABSORBER" CAREFULLY. TAKE YOUR VEHICLE TO AN Authorised Aprilia Dealer, IF NECESSARY. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED. 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.
Page 457 Tuono V4 1100 Factory Suspensions Tuono V4 1100 Factory (Ohlins shock absorber - ASC) • Using an adequate key, operate on the adjusting ring nut (2) to adjust the spring pre-loading (B). • The damping, compression, rear ex- tension, braking and turning accelera- tion assistance are electronically ad- justed.
Page 458 Tuono V4 1100 Factory Suspensions Removing Remove the side covers and tail fairings. Secure the front of the vehicle with straps and then support the rear of the vehicle with a workshop crane lift. Then proceed as described: The following operations are applicable for the "RSV4 1100 FACTORY"...
Page 459 Tuono V4 1100 Factory Suspensions • Disconnect the connector for the elec- tronic compression control. • Remove the screw fastening the shock absorber to the dual link. The following operations are valid for all ver- sions: • Remove the upper fixing screw of the shock absorber to the frame.
Page 460 Tuono V4 1100 Factory Suspensions • Remove the shock absorber from the right side. Linkages Removing In order to remove the linkages, the lower fairings and the exhaust silencer must be removed before- hand. After securing the front of the vehicle with...
Page 461 Tuono V4 1100 Factory Suspensions • Remove the "T" bush installed on the right hand side of the frame. Follow the procedure described below to remove the components of the single linkage. • Remove the pins. • Remove the oil seals.
Page 462 Tuono V4 1100 Factory Suspensions DUAL LINKAGE • Working on the left hand side of the vehicle, unscrew the two nuts (3) fas- tening the dual linkage to the frame and to the shock absorber, pulling the re- spective screws out from the right hand side to remove them.
Page 463 INDEX OF TOPICS CHAS HASSIS...
Page 464 Tuono V4 1100 Factory Chassis HASSIS Pos. Description Type Quantity Torque Notes Front couplings 2 + 2 50 Nm (36.88 lbf ft) Lower rear coupling 50 Nm (36.88 lbf ft) RH lower rear regulator bushing M18x1.5 12 Nm (8.85 lbf ft) RH upper rear regulator bushing M18x1.5...
Page 465 Tuono V4 1100 Factory Chassis Front wheel RONT WHEEL Pos. Description Type Quantity Torque Notes Front wheel axle nut M25x1.5 80 Nm (59.00 lb ft) Front brake disc fastening screws 6 + 6 30 Nm (22.13 lb ft) Secure using Loc-...
Page 466 Tuono V4 1100 Factory Chassis • Unscrew the screws fixing the front cal- lipers and slide them off the disc. • Remove the wheel hub fastening nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps.
Page 467 Tuono V4 1100 Factory Chassis • Remove the wheel, taking care not to lose the spacer located on the right hand side. Checking FRONT WHEEL BEARINGS Check the bearings installed on the wheel. CHECK THE CONDITION OF ALL COMPONENTS AND OF THE COMPONENTS INDICATED AS FOLLOWS IN PARTICULAR.
Page 468 Tuono V4 1100 Factory Chassis WHEEL AXLE • Use a dial gauge to check the wheel axle eccentricity. Replace the wheel axle if the eccentricity exceeds the limit value. Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value.
Page 469 Tuono V4 1100 Factory Chassis EAR WHEEL Pos. Description Type Quantity Torque Notes Rear wheel axle nut M25x1.5 120 Nm (88.51 lbf ft) Nuts used to fasten the crown to the 50 Nm (36.88 lbf ft) sprocket Rear brake disc fastening screws 30 Nm (22.13 lbf ft)
Page 470 Tuono V4 1100 Factory Chassis • Supporting the wheel and working from the right hand side of the vehicle, re- move the wheel axle (5) complete with both chain tensioners (6), retrieving the spacers (7) installed on both sides be- tween the wheel and the swingarm.
Page 471 Tuono V4 1100 Factory Chassis • Act on the threaded pin (1) with a hex- agonal wrench, blocking rotation Un- screw the DAX nut (2) and remove it • Repeat the operation to remove all the nuts and related pins.
Page 472 Tuono V4 1100 Factory Chassis • Place the pins (1) with the corresponding DAX nuts (2) paying attention so the pins are directed towards the inside the machining on the flange CAUTION WITH EVERY REMOVAL, REPLACE THE PINS AND NUTS WITH THE NEW COMPONENTS •...
Page 473 Tuono V4 1100 Factory Chassis • Check the radial and axial play. Axial play: minimal axial play is permitted. Radial: none. If one or both bearings do not fall within the control parameters: • Replace both wheel bearings. REAR WHEEL GASKETS •...
Page 474 Tuono V4 1100 Factory Chassis FINAL DRIVE UNIT BEARINGS Carry out the check with the bearings fitted on the final drive unit. ROTATION CHECK • Remove the left spacer (3). • Remove the right spacer (4). • Manually rotate the inside ring of each bearing.
Page 475 Tuono V4 1100 Factory Chassis If there is excessive wear: • Replace the sprocket. TO PREVENT NEW COMPONENTS FROM WEARING PREMATURELY, THE REAR SPROCKET, FRONT SPROCKET AND DRIVE CHAIN MUST ALWAYS BE REPLACED TOGETHER AS A SET. REAR WHEEL BEARINGS •...
Page 476 Tuono V4 1100 Factory Chassis FINAL DRIVE UNIT - BEARING REMOVAL • Remove the final drive unit. • Clean the two sides of the hub with a cloth. • Remove the left spacer (15). • Remove the sealing gasket (16).
Page 477 Tuono V4 1100 Factory Chassis Swinging arm EAR SWINGARMS Pos. Description Type Quantity Torque Notes Swingarm regulator bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ferrule M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft)
Page 478 Tuono V4 1100 Factory Chassis Pos. Description Type Quantity Torque Notes Chain guard fastening screws 2 Nm (1.47 lbf ft) Chain guard fastener screw 2 Nm (1.47 lbf ft) Rear stand bushing retaining screw 7 Nm (5.16 lbf ft) Chain tensioner shoe adjustment...
Page 479 Tuono V4 1100 Factory Chassis • Unscrew and remove the fastener screw of the front sprocket complete with the "T" bush and the cup spring washer. • Detach the front sprocket from the sec- ondary shaft, freeing if from the final drive chain.
Page 480 Tuono V4 1100 Factory Chassis • Unscrew the swingarm pin. As the pin rotates it also turns the adjustment bush, loosening it completely. • Support the front end of the swingarm and drive the swingarm pin, complete with adjuster bush, out from the right hand side.
Page 481 Tuono V4 1100 Factory Chassis • Use the specific special tool to extract the two bearings (5) and the roller bear- ing (6). CHECK AND, IF REQUIRED, REPLACE THE BEARINGS AFTER EVERY BEARING REMOVAL. Specific tooling AP8140180 Bearing extractor •...
Page 482 Tuono V4 1100 Factory Chassis • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. ALWAYS REPLACE BOTH SEALS TOGETHER. ALWAYS REPLACE THE SEALS WITH COMPONENTS OF THE SAME TYPE.
Page 483 Tuono V4 1100 Factory Chassis • Tighten the locking ring nut. • Put some grease on the swingarm pin nut as indicated. • Fit the washer on the pin, fit the nut and then tighten the nut to the specified tor- que.
Page 484 Tuono V4 1100 Factory Chassis • Refit the rear brake calliper complete with mount onto the swingarm. • Refit the cable guides onto the swing- arm. Pinion Removing In order to remove the front sprocket, first slacken the tension of the final drive chain.
Page 485 Tuono V4 1100 Factory Chassis • Remove the front sprocket (7) from the transmission shaft and free it from the drive chain. Inspection To check the state of wear of the front sprocket, simply check that the teeth of the sprocket are not worn or damaged.
Page 486 Tuono V4 1100 Factory Chassis • Fit the front sprocket cover (6), fit the three screws (7), ensuring that the bush (8) is fitted correctly in place, and tighten the screws to the specified tor- que. • Restore the drive chain to the correct tension, following the specific procedure described in the "Adjustment"...
Page 487 Tuono V4 1100 Factory Chassis • Remove the outer plate (4). • Remove the outer O-ring rings (5). • Remove the inner plate (6). • Collect the inner O-ring rings (7) and completely remove the transmission chain. CHAS - 487...
Page 488 Tuono V4 1100 Factory Chassis inspection To check the wear of the drive chain, use the chain checking instrument, P/N: Ognibene - 529510001. The different chain pitches which may be checked with the instrument are indicated on the instrument itself. There are three reference markings for each chain pitch indicated on the instrument.
Page 489 Tuono V4 1100 Factory Chassis • Place the outer O-rings (3) on the pins. • Compress the outer plate (4) using the appropriate generic tool. CAUTION BE CAREFUL NOT TO COMPRESS TOO THE OUTER PLATE TOO MUCH AS THIS COULD SEIZE THE CHAIN.
Page 490 Tuono V4 1100 Factory Chassis Adjusting The vehicle has an endless chain, without master link. NOTE HALVE THE SERVICE INTERVALS INDICATED IF THE VEHICLE IS USED IN PARTICULARLY RAINY OR DUSTY CONDITIONS, ON POOR ROADS OR FOR HIGH PERFORMANCE RIDING.
Page 491 Tuono V4 1100 Factory Chassis If you need to adjust the chain tension after the check: • Place the vehicle on its rear service stand. • Loosen the nut (1) completely. • Loosen the two lock nuts (4). • Use the adjuster screw (5) to adjust the...
Page 492 Tuono V4 1100 Factory 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 493 Tuono V4 1100 Factory Chassis • Remove the lateral screw. • Remove the upper screw. • Remove the chain slider shoe. CHAS - 493...
Page 494 Tuono V4 1100 Factory Chassis Pedaline OOTRESTS Pos. Description Type Quantity Torque Notes Screws used to fasten the rider's 2 + 2 25 Nm (18.44 lbf ft) Loctite 243 footrest to the chassis Screws for fastening the passenger's 2 + 2 18 Nm (13.28 lbf ft)
Page 495 Tuono V4 1100 Factory Chassis • Remove the three fixing screws (2) of the pinion cover (3) • Remove the fixing screw (4) of the ca- ble grommet (5) • Cut the two clamps (6) that connect the wiring of the quick-shift to the wiring of the side stand and of the lambda probe •...
Page 496 Tuono V4 1100 Factory Chassis • Remove the two fixing screws (8) of the footrest complete with leverage • If necessary, you can loosen and re- move the quick-shift fixing screw to change the O-rings. NOTE NOTE THE WIRING HARNESS DOES NOT NEED TO BE...
Page 497 Tuono V4 1100 Factory Chassis • Remove the two fastener screws of the right hand rider footpeg mount, com- plete with brake pedal. • Complete removal of the plate, remov- ing the rear brake switch. PASSENGER FOOTRESTS THE OPERATIONS DESCRIBED BELOW RE- FER TO A SINGLE PASSENGER FOOTREST, BUT ARE VALID FOR BOTH.
Page 498 Tuono V4 1100 Factory Chassis • To remove the footrest support, re- move the two screws (7). • Remove the footrest support (8). Stand IDE STAND Pos. Description Type Quantity Torque Notes Screws for fastening the stand to the 45 Nm (33.19 lbf ft) Loct.
Page 499 Tuono V4 1100 Factory Chassis Pos. Description Type Quantity Torque Notes Stand fastening pin ... Nm (... lbf ft) Fastener nut of side stand ... Nm (... lbf ft) Side stand In order to remove the side stand, the side fairings, fuel tank and front sprocket cover must be re- moved beforehand.
Page 500 Tuono V4 1100 Factory Chassis • Working outwards from the interior of the vehicle, remove the two screws fastening the mounting plate of the side stand. • Remove the side stand complete with mounting plate. Exhaust XHAUST Pos. Description Type...
Page 501 Tuono V4 1100 Factory Chassis Removing the tail pipe REMOVAL • Rest the vehicle on the rear centre stand. • Remove the three fixing screws of the heat guard. • Remove the heat guard making sure to recover the washers.
Page 502 Tuono V4 1100 Factory Chassis • Remove the screw and relative nut fas- tening the exhaust to the frame, re- trieving the collar and the spacer. • Disconnect the actuator cables of the exhaust valve. • Remove the exhaust terminal com- pletely.
Page 503 Tuono V4 1100 Factory Chassis • Tighten the screw and relative nut fas- tening the exhaust to the passenger footpeg mount, fitting the collar and spacer correctly. • Connect the actuator cables of the ex- haust valve and carry out the exhaust...
Page 504 Tuono V4 1100 Factory Chassis • Position the protection plate and fix it to the exhaust terminal using the three screws. Removing the catalytic converter In order to remove the catalytic converter, the side fairings, front exhaust headers, front sprocket cov- er and silencer must be removed beforehand.
Page 505 Tuono V4 1100 Factory Chassis • Disconnect the connector of the front cylinder bank lambda probe and de- tach it from the relative mount. • Unscrew the four fastener screws of the front cylinder bank headers and re- move the headers.
Page 506 Tuono V4 1100 Factory Chassis • Unscrew the nuts fastening the rear headers and remove the headers, eas- ing out towards the rear. Butterfly valve in exhaust • To check that the exhaust valve is working and calibrated correctly, see the paragraph "EX- HAUST VALVE"...
Page 507 Tuono V4 1100 Factory 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 508 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 509 Tuono V4 1100 Factory Braking system CONTROL UNIT Pos. Description Type Quantity Torque Notes Oil tube screws M10x1 23-26 Nm (16.96-19.18 lbf ft) Control unit support screws 6.8+/-1 Nm (5.01 +/-0.74 lbf ft) BRAK SYS - 509...
Page 510 Tuono V4 1100 Factory Braking system Operating diagram ABS functional diagram key BRAK SYS - 510...
Page 511 Tuono V4 1100 Factory Braking system 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. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open)
Page 512 Tuono V4 1100 Factory Braking system B - Pressure reduction: coincides with the recognition of the dangerous situation (wheel slippage exceeds the threshold): the system closes the inlet valve (10-11) and opens the outlet valve (12-13) temporarily. At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the pressure on the callipers partially.
Page 513 Tuono V4 1100 Factory Braking system When sensors (3) detect a significant speed difference between the rear and the front wheels (for example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation.
Page 514 Tuono V4 1100 Factory 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 515 Tuono V4 1100 Factory 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 516 Tuono V4 1100 Factory 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 517 Tuono V4 1100 Factory 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 518 Tuono V4 1100 Factory Braking system 7. CONTACT TECHNICAL SERVICE 8. PERFORM THESE CHECKS: • A. CAN line integrity from the ABS modulator (PIN 2, PIN 11) to the instrument panel (PIN 26, PIN 27). • B. Check connectors - refer to the operations described in the chapter If the above checks are OK, the causes can be: •...
Page 519 Tuono V4 1100 Factory Braking system PARAMETERS screen page This screen shows the parameters measured by the several sensors (engine revs, engine temper- ature, etc.) or values set by the control unit (injec- tion time, ignition advance, etc.) PARAMETERS AND STATUSES P.A.D.S.
Page 520 Tuono V4 1100 Factory Braking system ERRORS screen page This display shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it allows to check error clearing (STO). ERRORS Description Code Symptom Front wheel speed sensor: electrical diagnosis...
Page 521 Tuono V4 1100 Factory Braking system PADS report mode In the following are described the procedure to be performed through the diagnostic tool in order to generate an errors report: • When started the program, select the brand. • Select the vehicle and the component.
Page 522 Tuono V4 1100 Factory Braking system • Repeat the operation by selecting each error and showing the corresponding Ambient parameter error (where provi- ded). • Go to the page Report and then on Print and select the virtual PDF printer.
Page 523 Tuono V4 1100 Factory Braking system SETTINGS screen page This screen is used to adjust some control unit pa- rameters. ADJUSTMENTS P.A.D.S. characteristic. Value/example Units of Notes measure ment Encoding reset Resets the vehicle code and obtains it automati- cally from the CAN line at the next key ON...
Page 524 Tuono V4 1100 Factory Braking system • between PIN 14 of the ABS control unit and PIN 1 of the sensor (yellow cable) • between PIN 13 of the ABS control unit and PIN 2 of the sensor (yellow/brown cable) Short-circuit to negative: - Disconnect the sensor connector.
Page 525 Tuono V4 1100 Factory Braking system - If there is no insulation, restore the wiring harness or replace the sensor. Short-circuit to positive: - Disconnect the sensor connector. - Check the battery supply insulation of the two PINS. - If there is no insulation, restore the wiring harness or replace the sensor.
Page 526 Tuono V4 1100 Factory Braking system U2921 Controller error U2922 Line failure (busoff) Error cause: Communication problem on CAN line: possible contact. Troubleshooting: Check the integrity and continuity of the wiring harness: • between ABS control unit PIN 2, instrument panel PIN 33 and injection control unit PIN 80 (Orange cable) •...
Page 527 Tuono V4 1100 Factory Braking system Switch malfunction. 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 528 Tuono V4 1100 Factory Braking system • Remove the screw fastening the ABS modulator mount to the frame. • Partially free the ABS modulator mount from the rubber bush. • Remove the ABS modulator, complete with mount, from the vehicle.
Page 529 Tuono V4 1100 Factory Braking system • Remove the ABS modulator. INSTALLING THE ABS MODULATOR To install the ABS modulator, follow the procedure for removal in reverse order. Before fitting the ABS modulator complete with mount and metal plate, pre-fit a cable tie onto the plate.
Page 530 Tuono V4 1100 Factory Braking system • If the initial position of the connector and the driving lever is not that shown in fig. 1, the connector will not be prop- erly coupled and the distance meas- ured will be greater (12 mm approx.
Page 531 Tuono V4 1100 Factory Braking system It is important to check that all the tone wheels (2) are always clean. Otherwise,: delicately remove any dirt residues using a cloth or wire brush. Avoid using solvents, abrasives and air or water jets directly on the tone wheel (2).
Page 532 Tuono V4 1100 Factory Braking system Removal To remove the rear brake calliper, it is necessary to previously drain the braking system. • Remove the protective cap from the bleed nipple. • Using a container of suitable capacity to collect the oil, connect a tube to the bleed nipple and unscrew the nipple to drain the system.
Page 533 Tuono V4 1100 Factory Braking system • Remove the brake calliper. Installing To install the rear brake calliper, proceed as de- scribed: • Fit the rear brake calliper on the disc. • Fit the two fastener screws of the brake calliper and tighten to the specified tor- que.
Page 534 Tuono V4 1100 Factory 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 lbf ft) Removal NOTE THE FOLLOWING OPERATIONS REFER TO A SINGLE BRAKE CALLIPER BUT ARE VALID FOR BOTH.
Page 535 Tuono V4 1100 Factory Braking system • Using a container of suitable capacity to collect the oil and protecting the brake calliper adequately, connect a tube to the bleed nipple and unscrew the nipple to drain the system. • Remove the fastener screw of the pipe and plug the pipe.
Page 536 Tuono V4 1100 Factory Braking system To install the front brake calliper, proceed as de- scribed: • Fit the front brake calliper on the disc. • Fit the two fastener screws of the brake calliper and tighten to the specified tor- que.
Page 537 Tuono V4 1100 Factory Braking system Removal • Remove the rear wheel. • 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).
Page 538 Tuono V4 1100 Factory Braking system Disc oscillation tolerance: 0.1 mm (0.0039 in) Front brake disc 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).
Page 539 Tuono V4 1100 Factory Braking system Disc thickness minimum value: 4 mm (0.16 in) • Using a dial gauge, check that the max- imum oscillation of the disc does not exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in)
Page 540 Tuono V4 1100 Factory Braking system Installing • An arrow is stamped on the brake calliper and on the clip, which must always point in the direction of rotation of the front wheel. • Fit the clip in the brake calliper.
Page 541 Tuono V4 1100 Factory Braking system • Remove the stop ring (2). BEFORE DISCONNECTING THE PIN (3), CHECK THE PO- SITION OF THE SAFETY SPRING (4); IT MUST BE POSI- TIONED IN THE SAME WAY ON REASSEMBLY. • Remove the pin (3) and recover the safety spring (4).
Page 542 Tuono V4 1100 Factory Braking system ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Fit the safety retainer clip (4) as shown. • While pressing the centre of the safety retainer clip (4), fit the pin (3) so that it passes over the clip.
Page 543 Tuono V4 1100 Factory Braking system • Refit the rear brake calliper and fasten by tightening the two screws (1) to the specified torque. Bleeding the braking system Front TRADITIONAL BLEEDING SYSTEM 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 544 Tuono V4 1100 Factory Braking system tainer, this will release the tension on the brake lever and it which will make it arrive at the end stop. • Close the bleed valve before arriving at the end of the stroke with the lever.
Page 545 Tuono V4 1100 Factory Braking system CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING THE BRAKE CALLIPER TO RESTORE THE BRAKING SYSTEM TO ITS REGULAR USE CONDITIONS, SO THAT THE HYDRAULIC CIRCUIT IS AIR PURGED.
Page 546 Tuono V4 1100 Factory Braking system If the brake lever still feels "spongy" after completing all checks, it is necessary to bleed the brakes using this type of procedure. • With the diagnostic tool properly connected, select the function "REAR BLEEDING" in the section "SETTINGS".
Page 547 Tuono V4 1100 Factory Braking system Rear brake pump EAR BRAKE PUMP Pos. Description Type Quantity Torque Notes Rear brake rod lock nut 6 Nm (4.42 lbf ft) Rear brake pump fastening screws 8 Nm (5.90 lbf ft) Loctite 243 Rear brake lever fixing pin 25 Nm (18.44 lbf ft)
Page 548 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 549 Tuono V4 1100 Factory 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 - 549...
Page 550 Tuono V4 1100 Factory 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 551 Tuono V4 1100 Factory Cooling system ATER PUMP Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket screws M6x25 10 Nm (7.38 lbf ft) for fastening the pump to the crank- case Electric fan • Remove the front underfairings and the hand grip position sensor •...
Page 552 Tuono V4 1100 Factory 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 553 Tuono V4 1100 Factory 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 554 Tuono V4 1100 Factory Cooling system Water pump AFTER A TECHNICAL UPGRADE, IT IS POSSI- BLE THAT THE TANK IS FASTENED A BIT ON THE RIGHT OF THE WATER PUMP. FIND BELOW THE EXPLANATION OF THE RE- MOVAL PROCEDURE OF THE PUMP WITH TANK.
Page 555 Tuono V4 1100 Factory Cooling system • Undo and remove the two fastening in- ternal nuts of the water tank. • Remove the supplementary tank. • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw.
Page 556 Tuono V4 1100 Factory Cooling system IF IT IS NECESSARY TO FIT THE WATER TANK, OBSERVE THE FOLLOWING PROCEDURES. • 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.
Page 557 Tuono V4 1100 Factory Cooling system • Remove the cable tie indicated and free the wiring harnesses from the ra- diator mount. • Remove the screw fastening the radi- ator to the mount on the right hand side of the vehicle.
Page 558 Tuono V4 1100 Factory Cooling system To remove the radiator, first drain the cooling sys- tem. Then proceed as described: • Disconnect the canister from the frame and remove the clamp fastening the wiring harnesses of the alternator, the oil pressure bulb, the front cylinder bank lambda probe and the left hand electric fan.
Page 559 Tuono V4 1100 Factory Cooling system • Move the metal clips along the pipe and disconnect the cooling system pipe from the pump and the connector pipe leading to the thermostat valve. • Move the metal clip along the pipe and disconnect the cooling system pipe from the radiator.
Page 560 Tuono V4 1100 Factory Cooling system • On both sides of the vehicle, remove the two screws fastening the radiator to the mount. • Separate the water radiator from the mount on the left hand side and re- move the radiator while simultaneously removing the expansion tank on the right hand side.
Page 561 INDEX OF TOPICS BODYW ODYWORK...
Page 562 Tuono V4 1100 Factory Bodywork Seat TUONO V4 1100 FACTORY REMOVAL TAIL FAIRING / PASSENGER SEAT • Turn the key clockwise. • Lift and remove the tail fairing / pas- senger seat. TAIL FAIRING INSTALLATION • Place the tail fairing by aligning the two hooks (A) and (B) with their seats (A) and (B) on the vehicle.
Page 563 Tuono V4 1100 Factory Bodywork PASSENGER SADDLE INSTALLATION • Place the saddle by aligning the hook (C) with its seat (C) on the vehicle. • Press the saddle downward with one hand and with the other push it back- ward until it is completely coupled.
Page 564 Tuono V4 1100 Factory Bodywork • Lift the front part and at the same time detach the external pins from the sad- dle support/passenger handle. • Pull the passenger saddle to the front to release the rear hooks from the sad- dle support/passenger handle.
Page 565 Tuono V4 1100 Factory Bodywork RIDER SADDLE REMOVAL • Using the supplied hex key, unscrew and remove the two saddle fixing screws in order to remove it from the vehicle. RIDER SADDLE INSTALLATION • Perform the above described steps in reverse order.
Page 566 Tuono V4 1100 Factory Bodywork Instrument panel To remove the instrument panel, first the fairing complete with light assembly must be removed. Then proceed as described: • Unscrew the two fastener screws of the instrument panel brow and remove the brow.
Page 567 Tuono V4 1100 Factory Bodywork Headlight assy. To remove the headlight unit, first remove the top fairing, the side fairings, the internal covers and the front lock. Then proceed as described: • Remove the inner screws fastening the headlight unit to the instrument panel support.
Page 568 Tuono V4 1100 Factory Bodywork Headlight fairing • To remove the top fairing, remove the four fixing screws (1) paying attention to collect the washers. • Slide off the top fairing (2) and remove Front wheelhouse REMOVING LOWER STEERING YOKE TRIM ELEMENT •...
Page 569 Tuono V4 1100 Factory Bodywork • Remove the lower trim piece of the steering yoke. Taillight assy. • Carry out the tail fairing removal pro- cedure. • Unscrew and remove the two lateral screws. • Undo and remove the upper screw.
Page 570 Tuono V4 1100 Factory Bodywork License plate light To remove the license plate light, proceed as fol- lows: • Unscrew the screw (1) and remove the closure (2) of the license plate holder. • Disconnect the license plate light con- nector (3).
Page 571 Tuono V4 1100 Factory Bodywork • Unscrew and remove the lower screw. • Pull the front edge of the side fairing outwards and then move the fairing to- wards the rear of the vehicle to detach and remove it. Side fairings The procedure described below is for one side of the vehicle but is valid for both sides.
Page 572 Tuono V4 1100 Factory Bodywork • Remove the lower screw (3). • Move the side fairing forward to release the three inner hooking points. To remove the side fairings, follow the procedure described below: • Remove the four screws that fasten the outer part to the inner part.
Page 573 Tuono V4 1100 Factory Bodywork • Remove the two fixing screws of the inner lock of the outer part. • Release the inner lock of the outer part, at the five indicated points. Upon refitting, before tightening the screws, make sure that the inner lock is correctly coupled.
Page 574 Tuono V4 1100 Factory Bodywork • Remove the inner screw (3) fastening the under-fairing to the coolant radiator mount. • Disconnect the connectors (4) of the voltage regulator. • Remove the left hand under-fairing (5). RIGHT HAND UNDER-FAIRING • Remove the screw (1) and the relative nut that fastens the side under-fairing to the duct.
Page 575 Tuono V4 1100 Factory Bodywork • Remove the cable tie (2) fastening the main wiring harness to the under-fair- ing. • Remove the inner screw (3) fastening the under-fairing to the coolant radiator mount. • Remove the right hand under-fairing (4).
Page 576 Tuono V4 1100 Factory Bodywork • Remove the two central clips. • Remove the side fixing screws. • Lift the front headlight unit as much as needed to remove the central under- fairing. • To refit the under-fairings, carry out the procedure described previously for removal in re- verse order.
Page 577 Tuono V4 1100 Factory Bodywork • Unscrew the nuts (1) and remove the screws (2). • Disconnect the connector (3). • Remove the license plate holder (4). Rear mudguard To remove the rear mudguard, follow the proce- dure described below: •...
Page 578 Tuono V4 1100 Factory Bodywork Lower cowl To remove the lower fairings, follow the procedure described below: • Remove the front fixing screws. • On both sides of the vehicle, remove the side fixing screws. • Remove the lower fairings.
Page 579 Tuono V4 1100 Factory Bodywork • Separate the fairing lug from the two lower fairings. • Remove the fixing screw of the lower fairings. • Separate the two lower fairings. Fuel tank In order to remove the fuel tank, the rider saddle and side covers must be removed beforehand.
Page 580 Tuono V4 1100 Factory Bodywork • Remove the two rear screws (2) fas- tening the tank to the saddle carrier subframe • Uncouple from its support the connec- tor (3) of the fuel pump and disconnect • Disconnect the connector (4) of the in- ertia platform.
Page 581 Tuono V4 1100 Factory Bodywork • Lift the tank partially and disconnect the fuel pipe (6). • Remove the fuel tank (7). To remove the fuel filler, follow the procedure de- scribed below: • Remove the four fastener screws (8) of the filler.
Page 582 Tuono V4 1100 Factory Bodywork • Remove the gasket (10). To remove the fuel level probe, proceed as de- scribed below: • Remove the four fixing screws (11) of the probe. • Remove the fuel level probe (12). Rear wheelhouse...
Page 583 Tuono V4 1100 Factory Bodywork • Disconnect the fuse boxes from the mounts (2). • Free the branch of the main wiring har- ness (3) from the cable retainer clips on the splash guard. • Detach the connector (4) for connect- ing the diagnostic tool from the mount on the splash guard.
Page 584 Tuono V4 1100 Factory Bodywork • Remove the screw (7) fastening the ABS modulator mount to the frame and the screw (8) fastening the metal plate to the mount. • Partially free the ABS modulator mount from the rubber bush.
Page 585 Tuono V4 1100 Factory Bodywork Front mudguard To remove the front mudguard, follow the proce- dure described below: • Working from the right hand side of the vehicle, remove the cable guide secur- ing the front ABS sensor cable to the mudguard.
Page 586 Tuono V4 1100 Factory Bodywork • Remove the front mudguard. Rear grab rail To remove the passenger handle (IF APPLICA- BLE), first remove the passenger saddle. Then proceed as described: • Unscrew and remove the three screws (1) and remove the passenger handle (2).
Page 587 Tuono V4 1100 Factory Bodywork Instrument cluster support To remove the instrument panel support, it is nec- essary to first remove the side fairings, the front fairing with the headlight unit, the instrument panel cover and the instrument panel. Then proceed as described: •...
Page 588 Tuono V4 1100 Factory Bodywork • Remove the two screws (5) that fasten the left side instrument panel support to the chassis. • Remove the left instrument panel sup- port (6). • Remove the two clamps (7). BODYW - 588...
Page 589 Tuono V4 1100 Factory Bodywork • Disconnect the two special clamps (8) from the right side instrument panel support and release the wiring har- nesses. • Remove the two screws (9) that fasten the right side instrument panel support to the chassis.
Page 590 Tuono V4 1100 Factory Bodywork • Turn the battery so that its poles are accessible. • Unscrew and remove the screw (2) of the negative terminal (-). • Move the negative lead (3) aside. • Move the positive terminal (+) protec- tive rubber cap .
Page 591 Tuono V4 1100 Factory Bodywork The negative cable (3) must be positioned to the side of the battery (6). • Position the fuse holder complete with spacer and fix it with the two screws (1). WARNING THIS MOTORCYCLE IS EQUIPPED WITH A BATTERY THAT REQUIRES NO MAINTENANCE OTHER THAN PERIODICALLY CHECKING STATE OF CHARGE.
Page 592 Tuono V4 1100 Factory Bodywork • Unscrew and remove the screw (1) and then remove the rear seat trim (2). RIGHT HAND TAIL FAIRING • On both sides of the vehicle, remove the upper fastener screws (3). • Remove the lateral fastener screw (4).
Page 593 Tuono V4 1100 Factory Bodywork LEFT HAND TAIL FAIRING • To remove the right hand tail fairing, follow the procedure described for the left hand side, but also disconnecting the passenger seat release cable. Side air deflectors To proceed with the removal of the side ducts, it is...
Page 594 Tuono V4 1100 Factory Bodywork OPERATIONS VALID FOR ALL VERSIONS • Remove the screw and the relative nut fixing the duct to the under-fairing. • Operating through the hole on the side of the duct, unscrew and remove the internal screw.
Page 595 245 ABS: 259, 509, 518 Air filter: 74, 76, 81 Air temperature sensor: 192 Aprilia V4-MP Tecnology: 266 Battery: 157, 174, 589 Brake: 531, 534, 536, 538–540, 546, 547 Brake calliper: 531, 534 Brake disc: 536, 538...
Page 596 Front wheel: 465, 538 Fuel: 206, 417, 579 Fuel pump: 206, 417 Fuses: 162 Handlebar: Head cover: 344 Headlight: 101, 567, 568 Identification: 17 Instrument panel: 566 Intake pressure sensor: 184 Keys: 155 License plate holder: 576 Linkages: 460 Magneto flywheel: 321, 385 Maintenance: 14, 64, 157, 530 Mirrors: 565 Mudguard: 577, 585...
Page 597 Side fairings: 571 Side stand: 228, 499 Side stand sensor: 228 Spark plug: 68 Speed sensor: 176 Stand: 228, 498, 499 Start-up: 161, 316 Starter motor: 315 Steering damper: 448 Stepper motor: 424 Tank: 579 Throttle body: 211, 422, 423 Track: Transmission: 18, 384, 385 Tyres: 21...

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