APRILIA Tuono V4 1100 Factory 2021 Manual
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APRILIA Tuono V4 1100 Factory 2021 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 2021

  • Page 1 SERVICE STATION MANUAL 2Q000504 Tuono V4 1100 Factory...

  • Page 2: The Value Of Service

    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

    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...
  • Page 6 INDEX OF TOPICS PRE DE DELIVERY...

  • Page 7: Electrical System

    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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...

  • Page 8: Charge Level

    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. - NEVER attempt to open the battery.
  • 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: Static Test

    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 - Brake and clutch lever travel - Clutch - Check for correct operation - Engine - Check for correct general operation and absence of abnormal noise...
  • Page 12 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 13: Safety Rules

    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: Maintenance Rules

    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: Reassembling The Components

    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 Tuono V4 1100 Factory Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration. NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR- TICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.

  • Page 18: Dimensions And Mass

    LECTRONIC CONTROL SYSTEMS Specification Desc./Quantity a-PRC system (Aprilia Performance Ride Control) which includes: ALC (con- trolled launch), AEM (engine map management system), AEB (engine brake map management system), ASC (suspen- sion electronic control) (if available), ABS (anti-lock braking CHAR - 18...

  • Page 19: Drive Chain

    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 Tuono V4 1100 Factory Characteristics Specification Desc./Quantity Fuel reserve Immobilizer Neutral Frame and suspensions RAME Specification Desc./Quantity Type Aluminium, dual beam chassis with pressed and cast sheet el- ements. Steering rake angle 27° USPENSIONS Specification Desc./Quantity Front fork - Tuono V4 1100 Factory (Ohlins - ASC) With upside-down stanchions, electronic adjustment and hy- draulic operation, 1.69 in (43 mm) diam.

  • Page 21: Wheels And Tyres

    Tuono V4 1100 Factory Characteristics Brakes RAKES Specification Desc./Quantity Front Dual 330 mm (12.99 inches) diam. floating disc, forged radial- mounted single block callipers and four pistons 30 mm diam. (1.18 inches) and 2 pads - radial pump and brake pipe in metal braid.
  • Page 22 Tuono V4 1100 Factory Characteristics ETRIC SCREW TIGHTENING TORQUES Tightening torque: 3 Nm (2.21 lbf 5.5 Nm (4.05 9.5 Nm (7.00 25 Nm (18.43 50 Nm (36.87 80 Nm (59.00 lbf ft) lbf ft) lb ft) lb ft) lb ft) ETRIC SCREW TIGHTENING TORQUES ON FASTENERS WITH PLASTIC COMPRESSION WITHOUT INSERTED COL- LAR OR BUSH Tightening torque:...

  • Page 23: Special Tools

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 24 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 - 24...
  • Page 25 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 Piston assembly ring 020857Y Crankshaft support U-bolt...
  • Page 26 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 020863Y Punch assembly cage with rollers des- modromic drum...
  • Page 27 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 - 27...
  • Page 28 Tuono V4 1100 Factory Special tools Stores code Description 020364Y 25-mm guide 020359S 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 - 28...
  • Page 29 Tuono V4 1100 Factory Special tools Stores code Description 020877Y Calliper for clamps 020926Y Tool for fitting clutch bushing AP8140146 Weight AP8140189 Tool for fitting oil seal for 43 mm (1.69 in) diameter hole AP8140149 Guard for assembly operations AP8140190 Steering tightening tool 01761-04 Ohlins fork cap ring nut...
  • Page 30 Tuono V4 1100 Factory Special tools Stores code Description 020888S 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 S-TOOLS - 30...

  • Page 31: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...
  • Page 32 Tuono V4 1100 Factory Maintenance Scheduled maintenance table SCHEDULED MAINTENANCE TABLE RESERVED FOR THE US-LATAM MARKET Legenda: I: CONTROLLARE E PULIRE, REGOLARE, LUBRIFICARE O SOSTITUIRE SE NECESSARIO C: PULIRE, R: SOSTITUIRE, A: REGOLARE, L: LUBRIFICARE (1) Controllare ad ogni avviamento (2) Controllare e pulire, regolare o sostituire se necessario prima di ogni viaggio (3) Controllare e pulire, regolare o sostituire se necessario ogni 621 mi (1.000 Km).

  • Page 33: Scheduled Maintenance Table

    Tuono V4 1100 Factory Maintenance 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- ible coupling" NOTE AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.

  • Page 34: Recommended Products

    Tuono V4 1100 Factory Maintenance km x 1,000 or (months) maximum 1 (1) 10 (10) 20 (20) 30 (30) 40 (40) Tyres - pressure / wear (2) Nut/bolt tightness (5) Flexible coupling pin nuts tightening Clutch cover, flywheel and sump screw tightness Fault indicator light on instrument cluster (1) Fuel lines (4) Clutch wear (6)

  • Page 35: Spark Plug

    Tuono V4 1100 Factory Maintenance Spark plug To remove the spark plugs, the fuel tank and the complete filter box must first be removed. Then proceed as described: FRONT SPARK PLUGS Cylinder 2 / 4 • After releasing the front coil connectors from the supports on the filter housing base, disconnect them.
  • Page 36 Tuono V4 1100 Factory Maintenance • Release the connector from the sup- port on the filter housing and discon- nect it. • After having removed the fixing screw of the coil, disconnect it from the spark plug and remove it. While refitting, make sure you pass the coil wiring harness behind the wiring harnesses on the filter housing.

  • Page 37: Engine Oil

    Tuono V4 1100 Factory Maintenance • Remove the air pressure sensor fixing screw to facilitate the coil removal. • After having removed the fixing screw of the coil, disconnect it from the spark plug and remove it. While refitting, place the wiring harness under the air pressure sensor pipes.
  • Page 38 Tuono V4 1100 Factory Maintenance • Shut off the engine and wait a few sec- onds • Keep the vehicle upright with both wheels on the earth • Ensure that you are on a flat surface • Unscrew the engine oil level dipstick •...
  • Page 39 Tuono V4 1100 Factory Maintenance • Unscrew and remove the filler cap. • Drain the oil into the container; allow several minutes for oil to drain out com- pletely. • Check and, if necessary, replace the drainage plug sealing washers. •...

  • Page 40: Engine Oil Filter

    Tuono V4 1100 Factory Maintenance Verifica parastrappi • Operating from the left side of the mo- torcycle, using a torque wrench, check and if necessary tighten the nuts fixing the crown to the support to the prescri- bed torque Engine oil filter Replace the engine oil filter each time you change the engine oil.
  • Page 41 Tuono V4 1100 Factory Maintenance • After having disconnected the "VEHI- CLE" connector from the control unit, release the wiring harness from the two cable glands on the filter housing. • From the support on the filter housing disconnect the cylinder 3 coil connec- tor.
  • Page 42 Tuono V4 1100 Factory Maintenance • 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. • Remove the nine fixing screws of the filter housing cover.

  • Page 43: Air Filter Housing

    Tuono V4 1100 Factory Maintenance • 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 • - Disconnect the "ENGINE" connector from the control unit.
  • Page 44 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 45: Base Removal

    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 the power supply connector from the main wiring harness to the engine wir- ing harness.
  • Page 46 Tuono V4 1100 Factory Maintenance • Remove the air filter. • Disconnect the main wiring harness and the canister system valve from the cable gland on the filter housing base. • Operating on the left side of the vehi- cle, remove the screw that fastens the front bank oil pressure sensor to the base of the filter housing, removing al- so the gear sensor connector support...
  • Page 47 Tuono V4 1100 Factory Maintenance • Unscrew the eight screws to remove the lower intake ducts. • Partially lifting the filter housing base, after having removed the pipe clamps, disconnect the vapour recovery pipe of the blow by valve on the left and the vapour recovery pipe of the sas valve on the right.
  • Page 48 Tuono V4 1100 Factory Maintenance • Disconnect the lower injector wiring harness from the bracket located on the filter housing base. • Remove the filter housing base. Air filter housing installation To install the filter housing, carry out the removal procedure in reverse order, paying particular at- tention to the following operations: CLAMP PRE-FITTING...

  • Page 49: Checking The Valve Clearance

    Tuono V4 1100 Factory Maintenance 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. Checking the valve clearance TESTA ANTERIORE •...
  • Page 50 Tuono V4 1100 Factory Maintenance TESTA POSTERIORE • Rimuovere entrambi i corpi farfallati e le candele. • Rimuovere il coperchio testa posteri- ore e le candele. • Rimuovere il coperchio insonorizzante lato frizione. • Rimuovere il coperchio frizione. • Agendo sul dado di fissaggio dell'ing- ranaggio primaria ruotare l'albero mo- tore nel senso di rotazione del motore (senso di marcia) fino a quando le val-...
  • Page 51 Tuono V4 1100 Factory Maintenance • Portare il pistone del cilindro 1 (pistone posteriore sinistro) al PMS d'incrocio. • Rimuovere la prima vite dell'ingranag- gio di comando albero a camme. • Ruotare l'albero motore di 150° nel senso di rotazione del motore (senso di marcia).
  • Page 52 Tuono V4 1100 Factory Maintenance • Rimuovere la spina dall'ingranaggio di comando albero a camme. • Svitare e rimuovere le tre viti (1), il cav- allotto (2) e il tubetto dell'olio (3). • Installare l'apposito attrezzo per il sup- porto dell'ingranaggio albero a camme. •...
  • Page 53 Tuono V4 1100 Factory Maintenance • Svitare e rimuovere le sette viti proce- dendo per stadi e in diagonale. • Recuperare le rondelle in rame dalle viti vicino ai fori candela. • Rimuovere i cavallotti completi di anelli o-ring e spine di centraggio. •...
  • Page 54 Tuono V4 1100 Factory Maintenance • Riposizionare gli alberi a camme pre- stando attenzione affinché siano cor- rettamente fasati. Se i due alberi a camme sono correttamente fasati il dente dell'ingranaggio dell'albero a camme di scarico (indicato con un bulino) è inserito nella go- la dell'ingranaggio dell'albero a camme di aspira- zione (indicata con due bulini).
  • Page 55 Tuono V4 1100 Factory Maintenance • Posizionare il cavallotto, il tubetto dell'olio e le tre viti di fissaggio. • Serrare le dieci viti di bloccaggio degli alberi a camme procedendo per stadi e in diagonale. • Allineare l'albero a camme di aspira- zione con l'apposito foro sul cavallotto ed inserire la spina.
  • Page 56 Tuono V4 1100 Factory Maintenance • Se ciò non fosse ripetere le operazioni di fasatura. 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 57: Specific Tooling

    Tuono V4 1100 Factory Maintenance • Inserire la spina di allineamento dell'al- bero a camme d'aspirazione con il foro sul cavallotto. Specific tooling 020851Y Camshaft timing pin • Allentare la seconda vite dell'ingranag- gio di comando albero a camme. • Rimuovere la spina dall'ingranaggio di comando albero a camme.
  • Page 58 Tuono V4 1100 Factory Maintenance • Installare l'apposito attrezzo per il sup- porto dell'ingranaggio albero a camme. • Fissarlo alla testa tramite le due viti. 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 59 Tuono V4 1100 Factory Maintenance • Utilizzando una calamita rimuovere i bicchierini. • Utilizzando una calamita, rimuovere le pastiglie calibrate e sostituirle con quelle adeguate per ripristinare il cor- retto valore del gioco valvole. Consultare il paragrafo "Spessore pastiglie calibrate" per individuare uno spessore ade- guato.
  • Page 60 Tuono V4 1100 Factory Maintenance • Posizionare i cavallotti completi di anelli o-ring e spine di centraggio, in- serire le sette viti indicate avvitandole a mano. Utilizzare delle nuove rondelle in rame sulle quattro viti vicine ai fori candela. • Allentare la vite del fermo dell'ingra- naggio di distribuzione sull'attrezzo.
  • Page 61 Tuono V4 1100 Factory Maintenance • Allineare l'albero a camme di aspira- zione con l'apposito foro sul cavallotto ed inserire la spina. • Serrare a coppia la prima vite di fis- saggio dell'ingranaggio di distribu- zione. Specific tooling 020851Y Camshaft timing pin •...
  • Page 62 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) 1.95 mm (0.0768 in) 1.97 mm (0.0775 in)
  • Page 63 Tuono V4 1100 Factory Maintenance 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) 2.47 mm (0.0972 in) 2.50 mm (0.0984 in) 2.52 mm (0.0992 in)

  • Page 64: Cooling System

    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 through the specific opening on the in- ternal right fairing, ensure that the liq- uid level in the expansion tank is...
  • Page 65 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 66 LEVER IS TOO LONG, OR IN CASE OF FLUID LOSS, IT MAY BE NECESSARY TO BLEED THE AIR TRAPPED IN THE SYSTEM. HAVE THIS PROCEDURE PERFORMED BY AN Authorised Aprilia Dealer. Rear braking system • Unscrew and remove the upper nut (5) from the rear brake pump.

  • Page 67: Front Brake Lever

    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 68: Headlight Adjustment

    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 69 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 70: Index Of Topics

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 71 Tuono V4 1100 Factory Electrical system Components arrangement Key: 1. Side stand sensor 2. Fuel pump 3. Instrument cluster ELE SYS - 71...
  • Page 72 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 16.Front speed sensor 17.Rear speed sensor...

  • Page 73: Electrical System Installation

    Tuono V4 1100 Factory Electrical system THE IDENTIFICATION OF THE RELAY CANNOT BE CARRIED OUT JUST ON THE BASIS OF THE INDICATIONS BELOW: IN ANY EVENT IT SHOULD OCCUR WITH THE IDENTIFICATION OF THE COLOUR OF THE RELAY CABLES. ELAY LAYOUT Location of the Component name Position on the vehicle...
  • Page 74 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 75 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. • Check that all the connectors inside the instrument support arch have been connected cor- rectly.

  • Page 76: General Wiring Diagram

    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 - 76...
  • Page 77 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) 17.Presa USB (ove previsto) 18.Centralina ABS...
  • Page 78 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) 57.Bobina cilindro 3 (FRONT) 58.Bobina cilindro 2 (REAR)

  • Page 79: Checks And Inspections

    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.- Checks and inspections GENERAL NOTIONS FOR TROUBLESHOOTING ELECTRICAL FAULTS...
  • Page 80 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. Checking electrical CONTINUITY Purpose of check: the purpose of this check is ensure that there are no interruptions or excess re- sistance (due to corroded terminals, for example) in the circuit under inspection.
  • Page 81 Tuono V4 1100 Factory Electrical system REGARDLESS OF THE LANGUAGE SET IN THE DASHBOARD FUNCTIONS, THE KEY PRO- GRAMMING PROCEDURE CAN ONLY BE VIEWED IN ENGLISH. • To carry out the one or more key pro- gramming procedures, up to a maxi- mum of four, you must connect the motorcycle to the diagnostic tool.
  • Page 82 Tuono V4 1100 Factory Electrical system • The second key is stored and you will be asked to enter the third key (if you have one). The same operation will be repeated to store the fourth key. • To complete AND end the memorisa- tion procedure, set key to "OFF".
  • Page 83 Tuono V4 1100 Factory Electrical system To check: • To avoid an accidental short-circuit, place the power switch to "OFF". • Remove the rider saddle. • Open the covers of the secondary fuse boxes (1). • Take out one fuse at a time and check whether the filament (2) is broken.
  • Page 84 Tuono V4 1100 Factory Electrical system AUXILIARY FUSES DISTRIBUTION Specification Desc./Quantity A) 7.5A fuse Rear position, horn, licence plate light B) 5A fuse Instrument panel power supply, turn indicators, OBD power supply C) 5A fuse Positive key-on power for ECU, positive key-on power for ABS, positive key-on power for the instrument panel, positive key-on power for the right hand handlebar control set, main start relay coil, positive key-on power for inertial sensor platform...

  • Page 85: Control Unit

    Tuono V4 1100 Factory Electrical system • Per effettuare il controllo e la sostitu- zione del fusibile principale è neces- sario rimuovere le tre viti (3) che fissano il maniglione passeggero (4). • Disconnect the main relay holder from the supports and remove the protec- tion cover to gain access to the main fuse (O).
  • Page 86 Tuono V4 1100 Factory Electrical system • Rimuovere le due viti (2) che fissano il supporto cruscotto sinistro al telaio. • Estrarre la centralina (3) dal supporto e scollegare il connettore (4) per rimuoverla. CENTRALINA ASC - Diagnosi Funzione Effettua la gestione del sistema ASC, i controlli di sicurezza del sistema e la funzione di autodiagnosi Livello appartenenza schema elettrico: Centralina ASC Posizione:...
  • Page 87 Tuono V4 1100 Factory Electrical system Code Description / Symptoms 531300 Rear compression sensor - open circuit 531900 Rear compression sensor - short circuit 541300 Rear rebound sensor - open circuit 541900 Rear rebound sensor - short circuit D08700 Communication interrupted with instrument cluster ECU (DSB1) D08701 Communication interrupted with instrument cluster ECU (DSB2) D08702...
  • Page 88 Tuono V4 1100 Factory Electrical system • Scollegare la centralina 11MP (2) dal supporto (3) fissato al coperchio cassa filtro. In alternativa è possibile rimuo- vere il supporto completo di centralina svitando le tre viti di fissaggio (4). NOTE WHEN REASSEMBLING THE CONNECTORS, THE SLIDES MUST SLIDE FREELY UP TO THE LIMIT STOP, THUS FACILITATING THE CONNECTOR'S INSERTION.
  • Page 89 Tuono V4 1100 Factory Electrical system PARAMETERS: • Engine rpm / - • Air temperature / - • Engine temperature / - • Engine temp. at start-up / - (the temperature of the engine at start-up) • Track A position sensor / - (track A handle position sensor) •...
  • Page 90 Tuono V4 1100 Factory Electrical system • Exhaust val. obj. pos / - (exhaust valve objective position) • Front wheel speed / - • Rear wheel circumf. / - (rear wheel circumference) • Final transm. ratio / - (final transmission ratio) •...
  • Page 91 Tuono V4 1100 Factory Electrical system • Cruise control / - (indicates the cruise control status) • Front brake qual. switch / - (front brake lever qualified switch) • Rear brake qual. switch / - (rear brake lever qualified switch) •...
  • Page 92 Tuono V4 1100 Factory Electrical system NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN. P0604 RAM Error Electrical diagnosis: • Circuit not functioning Error cause: • Replace the injection control unit. The instrument cluster indicates the presence of this error with the MI warning light on fixed. NOTE THIS ERROR GENERATES THE RECOVERY STATUS AND ENGINE SHUT-DOWN.
  • Page 93 Tuono V4 1100 Factory Electrical system • Short-circuit to positive: check the correct electrical characteristics of the relay by discon- necting it from the wiring harness, if not ok replace the relay, if ok restore the wiring harness (blue/pink cable) •...
  • Page 94 The instrument panel 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) functional error Electrical diagnosis: • Incorrect a-PRC scheduling / Incorrect CheckSum of the software on Flash / Control unit...
  • Page 95 Tuono V4 1100 Factory Electrical system • Exhaust valve self-learn / - (exhaust valve self-learning) • Equiv. km reset. / - (equivalent km partial counter reset) • Key err count reset / - (ignition switch assembly errors counter reset) • Saved data download / - (saved data download CAUTION AFTER CANCELLING ALL THE DATA STORED DURING THE VEHICLE PRODUCTION PHASE...
  • Page 96 Tuono V4 1100 Factory Electrical system • Valore d'esempio a chiave ON: 12,0 V • Valore d'esempio a motore acceso: 14,2 V In caso di recovery questo è un valore impostato da centralina 'Tensione batteria ante Recovery • Valore d'esempio a chiave ON: 12,0 V •...
  • Page 97 Tuono V4 1100 Factory Electrical system • The error is enabled if, after 5 seconds from the key to ON, the battery voltage is judged low by the ECU. • Low voltage detected to PIN 52 of the Marelli ECU. The presence of this error is signalled by the fixed lighting of the general warning light.
  • Page 98 Tuono V4 1100 Factory Electrical system Exhaust valve Position: • 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 99 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 100 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 101 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 102 Tuono V4 1100 Factory Electrical system AFTER EACH MAINTENANCE OR CHECK OPERATION AT THE EXHAUST VALVE, PERFORM THE "EXHAUST VALVE CABLES CLEARANCE ADJUSTMENT" PROCEDURE. 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 103 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 104 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; • Connect the PADS and carry out the "valve zero"...
  • Page 105 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 106 è situato all'interno del supporto cruscotto ed è ac- cessibile dal lato sinistro del veicolo. Per accedere al connettore è necessario rimuo- vere la carrozzeria anteriore. Aprilia V4-MP Tecnology Sincronizzazione To use the system V4-MP the synchronisation that differs depending on the operating system must be performed:...

  • Page 107: Android Operating System

    Tuono V4 1100 Factory Electrical system • Turn the ignition switch of the motor- cycle ON with the PMP ECU correctly connected. • Open the App settings clicking on the icon • In the page settings click on the "Blue- Tooth"...
  • Page 108 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 109 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 110: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 111: Vehicle Preparation

    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 112 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 113 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 114 Tuono V4 1100 Factory Engine from vehicle • Remove the clamp that fastens the de- mand sensor wiring harness to the breather pipe of the expansion tank. • Remove the metal clamp and discon- nect the oil pipe from the sump. •...
  • Page 115 Tuono V4 1100 Factory Engine from vehicle • Move the metal clamps and disconnect the cooling system's pipe from the pump and the cross member that goes to the thermostatic valve. • Remove the metal clamp and discon- nect the oil pipe from the coupling. •...
  • Page 116 Tuono V4 1100 Factory Engine from vehicle • Operating from both sides, remove the two screws used to fasten the radiator to the support. • 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 117 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 118 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 119 Tuono V4 1100 Factory Engine from vehicle • Unscrew the three sprocket cover fas- tening screws and remove it. • Disconnect the rear bank lambda probe connector and release it from its support. • Release the springs and remove the central exhaust manifold by extracting it from the bottom.
  • Page 120 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 121 Tuono V4 1100 Factory Engine from vehicle • Remove the screw that fastens the en- gine support to the chassis and the three screws that fasten the support to the engine. • Remove the support. • Unscrew the fixing nuts of the rear manifolds and extract then from the rear.
  • Page 122 Tuono V4 1100 Factory Engine from vehicle • Release at the back the ABS modula- tor support from the rubber ring. • 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 123 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 124 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 125 Tuono V4 1100 Factory Engine from vehicle CAUTION THE RIGHT REAR INSERTS (-5mm (-0.19 in)) AND THE LOWER LEFT REAR INSERT (-5mm (-0.19 in)), ARE EQUAL. • Check that the adjuster bushings on the right side of the chassis are com- pletely unscrewed.
  • Page 126 Tuono V4 1100 Factory Engine from vehicle • Place the ground lead that goes to the battery and lock it together with the wir- ing harnesses on the right side using a new clamp. • Insert the four front fixing screws together with the washers and the relative supports for mounting the side fairings, making sure to insert the special spacers only for the right side, and the lower pin, inserting it from the left side, together with the washer to align the engine.
  • Page 127 Tuono V4 1100 Factory Engine from vehicle • Remove the engine support and insert the rear bank manifolds equipped with new gaskets. • Insert the locking nuts and screw them partially to facilitate the subsequent op- erations for the assembly of the ex- haust system.
  • Page 128 Tuono V4 1100 Factory Engine from vehicle • Place the stand with the support and secure it with two screws with washers. • 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 129 Tuono V4 1100 Factory Engine from vehicle • Insert the chain guide slider together with the chain guide and fasten it with the three screws. • Refit 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 130 Tuono V4 1100 Factory Engine from vehicle • Insert the gearbox lever on the primary shaft and tighten the stop screw to the specified torque. • Connect the clutch cable and, using the adjuster nuts, adjust the tension and check the play on the handlebar lever.
  • Page 131 Tuono V4 1100 Factory Engine from vehicle • Place the starter motor power cable, insert the washer and the nut and tight- en them to the specified torque. • Refit the rubber protection cover. • Refit the clamp that fastens the cooling system's pipe to the starter motor's wir- ing harness and the ground lead.
  • Page 132 Tuono V4 1100 Factory Engine from vehicle • Connect the ground leads and tighten the fixing screw to the specified torque. • 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 133 Tuono V4 1100 Factory Engine from vehicle • Operating from both sides, insert and tighten the two screws used to fasten the radiator to the support. • Refit the wiring harnesses on the radi- ator support and secure them with a new clamp.
  • Page 134 Tuono V4 1100 Factory Engine from vehicle • Connect the cooling system pipe to the pump, the cross member that goes to the thermostatic valve and secure both of them using the metal clamps. • Insert the two fixing screws of the radi- ators support bracket and tighten them to the specified torque.
  • Page 135 Tuono V4 1100 Factory Engine from vehicle • Engage the connector of the demand sensor on the exhaust valve motor support. • 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 136 Tuono V4 1100 Factory Engine from vehicle • Insert the wiring harnesses in the cable gland connected on the rear side of the canister, connect the left electric fan connector and secure it with a new clamp. • Connect the connector of the left side electric fan on the canister support.
  • Page 137 Tuono V4 1100 Factory Engine from vehicle • Insert the coolant discharge screw fit- ted with a new seal gasket and tighten it to the specified torque. • First fit a clamp on the metal plate and insert it under the ABS modulator sup- port as shown.
  • Page 138 Tuono V4 1100 Factory Engine from vehicle • Tighten the clamp that fastens the pipes of the ABS system. • 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 139: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 140 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° cyl 4: 605°...
  • Page 141 Tuono V4 1100 Factory Engine Gearbox AMBIO Pos. Descrizione Tipo Quantità Coppia Note Vite TCEI fissaggio stella M6x20 10 Nm (7.38 lbf ft) Vite pre-impregnata e in assenza 3M SCOTCH GRIP 2353 Viti pre-impregnate TSPEI fissaggio M6x16 10 Nm (7.38 lbf ft) Vite pre-impregnata piastrine fermi cuscinetti e in assenza 3M...
  • Page 142 Tuono V4 1100 Factory Engine Diagram Legenda: 1. Albero primario 2. Ingranaggio quinta marcia su primaria 3. Gabbia a rulli per ingranaggio quinta marcia su primaria 4. Rosetta di spallamento 5. Anello 6. Ingranaggio terza-quarta marcia su primaria 7. Anello 8.
  • Page 143 Tuono V4 1100 Factory Engine 20.Molla a tazza 21.Bussola a "T" 22.Ingranaggio seconda marcia su secondario 23.Gabbia a rulli per ingranaggio seconda marcia su secondario 24.Rosetta 25.Anello seeger 26.Ingranaggio sesta marcia su secondario 27.Anello seeger 28.Rosetta di spallamento 29.Gabbia a rulli per ingranaggio terza marcia su secondario 30.Ingranaggio terza marcia su secondario 31.Ingranaggio quarta marcia su secondario 32.Gabbia a rulli per ingranaggio quarta marcia su secondario...

  • Page 144: Removing The Gearbox

    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. See also Removing the gear selector Disassembling the...

  • Page 145: Gearbox Shafts

    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- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
  • Page 146 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 cover ENG - 146...
  • Page 147 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) ENG - 147...
  • Page 148 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 149: Checking The Secondary Shaft

    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) Checking the desmodromic drum...

  • Page 150: Assembling The Gearbox

    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. Assembling the gearbox •...
  • Page 151 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 • Insert the gearbox secondary shaft control rod (6) checking the presence of the springs...
  • Page 152 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 153: Gear Selector

    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 154 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 020862Y Punch assembly cage with rollers gearbox control rod •...

  • Page 155: Removing The Starter Motor

    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. Check the selector shaft and its teeth for damage and wear.
  • Page 156 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 DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL.
  • Page 157 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. Remove the needle cage (3) and the roller cage (4) from their housings on the freewheel (2) and check the rollers/needles for wear.
  • Page 158 Tuono V4 1100 Factory Engine Removing the flywheel cover • Unscrew and remove the three fasten- ing screws (1) from the soundproofing cover (2). • Remove the soundproofing cover (2). • Operando sulla base della cassa filtro, allentare la molletta di fermo e sfilare il tubo blow-by.
  • Page 159 Tuono V4 1100 Factory Engine Removing the flywheel cover components • Svitare e rimuovere le tre viti del rac- cordo impianto blow-by. • Rimuovere il raccordo impianto blow- • Rimuovere l'o-ring. DURANTE LA FASE DI RIMONTAGGIO UTILIZ- ZARE UN NUOVO ANELLO O-RING •...

  • Page 160: Magneto Flywheel Removal

    Tuono V4 1100 Factory Engine • Remove the oil seal. CAUTION DURING REFITTING REPLACE THE OIL SEAL WITH A NEW ONE OF THE SAME TYPE. SET THE NEW OIL SEAL WITH THE MARKING ON THE EDGE FACING OUTWARD. Magneto flywheel removal •...

  • Page 161: Removing The Stator

    Tuono V4 1100 Factory Engine • Prestare attenzione a recuperare la chiavetta durante l'estrazione del volano ed evitare quindi che possa cadere all'interno del motore. See also Removing the flywheel cover Removing the stator Per procedere con la rimozione dello statore, op- erare come descritto: •...
  • Page 162 Tuono V4 1100 Factory Engine • Rimuovere lo statore completo di pick- • Disconnect the wiring harness from the cover to complete the removal. Rimozione ingranaggio ruota libera Per effettuare la rimozione dell'ingranaggio di co- mando contralbero, completo di ruota libera è nec- essario rimuovere preventivamente la frizione completa.

  • Page 163: Checking The Starter Clutch

    Tuono V4 1100 Factory Engine • Rimuovere la rondella ed estrarre l'ing- ranaggio di comando contralbero/in- granaggio ruota libera prestando at- tenzione a non far cadere all'interno del motore la chiavetta. • Separare l'ingranaggio della ruota libera dall'ingranaggio di comando contralbero per acce- dere alla gabbia a rulli e alla ruota libera presente all'interno.
  • Page 164 Tuono V4 1100 Factory Engine • Bloccare la rotazione del volano utiliz- zando l'apposito attrezzo. L'ATTREZZO SPECIFICO DEVE ESSERE ADATTATO PER L'UTILIZZO SU QUESTO MO- TORE PERTANTO E' NECESSARIO ALLAR- GARE IL FORO CENTRALE QUANTO BASTA PER PERMETTERE L'INSERIMENTO COM- PLETO DEL VOLANO.
  • Page 165 Tuono V4 1100 Factory Engine • Posizionare il rasamento. • Posizionare l'anello seeger. • Sostituire con uno nuovo dello stesso tipo l'anello OR. • Posizionare il raccordo impianto blow- • Inserire e serrare a coppia le tre viti del raccordo impianto blow-by. ENG - 165...

  • Page 166: Flywheel Cover Installation

    Tuono V4 1100 Factory Engine Flywheel cover installation • Assicurarsi che i due grani di centrag- gio siano presenti sul carter. • Stendere sul bordo esterno del coper- chio uno strato di pasta sigillante. • Inserire il coperchio completo di sta- tore.
  • Page 167 Tuono V4 1100 Factory Engine Clutch side OPERCHIO FRIZIONE Pos. Descrizione Tipo Quantità Coppia Note Vite TE flangiata M6x20 10 Nm (7.38 lbf ft) Vite TE flangiata M6x35 12 Nm (8.85 lbf ft) Portare a coppia, svitare e riportare a coppia.

  • Page 168: Removing The Clutch Cover

    Tuono V4 1100 Factory Engine LUTCH Pos. Description Type Quantity Torque Notes Flanged nut fixing clutch M20x1 150 Nm (110.63 lb ft) Loct. 243 Clutch springs SHC fixing screw M6x25 10 Nm (7.38 lb ft) Removing the clutch cover • Drain the engine oil.

  • Page 169: Disassembling The Clutch

    Tuono V4 1100 Factory Engine • Unscrew and remove the five special screws (3) and the eleven fastening screws (4) around the perimeter, and retrieve the relative washers. • Rimuovere il carter frizione. • Rimuovere la guarnizione, le due spine di centraggio e l'ingranaggio di rinvio avviamento Disassembling the clutch •...
  • Page 170 Tuono V4 1100 Factory Engine • Remove the discs. • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch retainer tool • Rimuovere le due rosette e la molla a tazza.
  • Page 171 Tuono V4 1100 Factory Engine • Remove the clutch hub cam tower. • Rimuovere la rondella. • Rimuovere la campana frizione. • Remove the clutch gear that controls the oil/water pumps ENG - 171...

  • Page 172: Checking The Clutch Plates

    Tuono V4 1100 Factory Engine • Remove the needle cage. • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in) Minimum wear limit of the complete clutch...

  • Page 173: Checking The Clutch Housing

    Tuono V4 1100 Factory Engine Checking the clutch housing Check the clutch bell for damage and wear that may result in clutch irregular operation. If necessary, replace the bell. Check the riveted joint between the clutch housing and the primary drive sprocket for correct sealing and evenness.

  • Page 174: Assembling The Clutch

    Tuono V4 1100 Factory Engine Checking the clutch hub Check the clutch hub for damage and wear that may result in clutch irregular operation. If neces- sary, replace the hub. Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. •...
  • Page 175 Tuono V4 1100 Factory Engine • Insert the spacer. • Fit the needle cage. • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion ENG - 175...
  • Page 176 Tuono V4 1100 Factory Engine • Inserire la rondella. • Install the clutch hub cam tower. • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • Inserire la molla a tazza e le due ro- sette.
  • Page 177 Tuono V4 1100 Factory Engine • Block clutch housing rotation using the specific 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 178 Tuono V4 1100 Factory Engine • Insert the disc covered with friction ma- terial into the housing. • Insert the nitrided metal disc into the clutch housing. • Continue inserting, alternating a metal disc with one with friction material, end- ing with a friction material disc with a black tooth.
  • Page 179 Tuono V4 1100 Factory Engine • Place the control rod together with the thrust bearing and the shim washer. • Place the thrust plate. • Fit the clutch springs (3). • Insert the spring holder cap (2) onto the screws (1). ENG - 179...

  • Page 180: Installing The Clutch Cover

    Tuono V4 1100 Factory Engine • Tighten the six screws operating in stages and diagonally. Installing the clutch cover REMOVING THE CLUTCH CONTROL PIN BUSHING • Before carrying out the removal of the bushing, it is necessary to thread the inside to allow the extractor to tighten sufficiently.
  • Page 181 Tuono V4 1100 Factory Engine Specific tooling 020926Y Tool for fitting clutch bushing • Then insert the tool to push the bushing into the seat until it stops. • Position the starting transmission gear on the crankcase. • Position the gasket and the two dowel pins in the clutch cover.
  • Page 182 Tuono V4 1100 Factory Engine • Posizionare il coperchio insonoriz- zante (7) e dopo aver inserito le cinque viti (8) di fissaggio, serrarle a coppia. • Ripristinare l'olio motore verificando il corretto quantitativo. Heads ALVES COVER Pos. Description Type Quantity Torque Notes Head cover fixing screws...
  • Page 183 Tuono V4 1100 Factory Engine EADS Pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.38 lb ft) 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...
  • Page 184 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 screws Chain guide sliders fixing screws M6x18...

  • Page 185: Installation

    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. Recommended products Three bond Sealing paste •...
  • Page 186 Tuono V4 1100 Factory Engine • Extract the bucket tappets • Extract the adjusting shims • 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...

  • Page 187: Valve Check

    Tuono V4 1100 Factory Engine • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING. • Remove the valves. Valve check CAUTION REPLACE THE VALVES ONE AT A TIME.
  • Page 188 Tuono V4 1100 Factory Engine 0.25 mm (0.0098 in) If the valve stem, when measured with a micro- meter, is worn to its limit and the clearance ex- ceeds the specified limit, replace the valve. Recheck the clearance after replacing the valve. Characteristic Intake valve stem diameter 4.985 - 4.965 mm (0.1963 - 0.1954 in)

  • Page 189: Valve Installation

    Tuono V4 1100 Factory Engine Valve installation Le valvole di aspirazione sono dotate di doppia molla, mentre quelle di scarico hanno una sola molla. Le molle di aspirazione sono contrassegnate dal colore blu (1), mentre quelle di scarico (2) sono contrassegnate dal colore giallo.
  • Page 190 Tuono V4 1100 Factory Engine • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve springs compressor 020853Y Compresses intake valve springs 020854Y Compresses exhaust valve springs •...
  • Page 191 Tuono V4 1100 Factory Engine Crankcase RANKCASE pos. Description Type Quantity Torque Notes Stud bolts 20 Nm (14.75 lb ft) Loct. 270 TE Flanged screw M8x70 25 Nm (18.44 lb ft) Lubricate the head and under the head. TE Flanged screw M6x50 10 Nm (7.38 lb ft) Lubricate the head...
  • Page 192 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 lb ft) engine GNITION UNIT Pos. Description Type Quantity Torque Notes Hex headed nut cl.10 type 2 iso 8674 M10x1 50 Nm (36.88 lb ft) Loct.

  • Page 193: Specific Tooling

    Tuono V4 1100 Factory Engine LBERO MOTORE Pos. Descrizione Tipo Quantità Coppia Note Connecting rod screws 15 + 20 Nm (11.06 + Lubricate the head 14.75 lb ft) + 130° and under head with con PANKL Lubri- cant 01 (PLB01) Primary fixing ring nut 200 Nm (147.51 lb ft) Loct.
  • Page 194 Tuono V4 1100 Factory Engine • Svitare il dado di fissaggio dell'ingra- naggio primaria e il dado di fissaggio dell'ingranaggio di comando contral- bero. • Rimuovere l'attrezzo di fermo ed es- trarre l'ingranaggio della primaria. Specific tooling 020850Y Primary gear lock •...
  • Page 195 Tuono V4 1100 Factory Engine • Remove the countershaft from the al- ternator side. • Recuperare il distanziale. Balancing countershaft fitting Per effettuare l'installazione del contralbero di equilibratura eseguire le operazioni di seguito de- scritte: • Inserire il contralbero di equilibratura nel carter dal lato volano.
  • Page 196 Tuono V4 1100 Factory Engine • Inserire l'ingranaggio della primaria prestando attenzione a far coincidere le bulinature presenti su entrambi gli ingranaggi, come indicato. • Ruotare il contralbero sino a che la fre- satura presente sull'albero stesso co- incida con la lavorazione dell'ingranag- gio di comando contralbero per permettere l'inserimento della chiavet- CAUTION...

  • Page 197: Installing The Primary Drive Gear

    Tuono V4 1100 Factory Engine Main transmission gear removal Per effettuare la rimozione dell'ingranaggio della primaria è necessario rimuovere preventivamente il coperchio frizione, il coperchio alternatore e la frizione completa. Successivamente operare come descritto: • Posizionare l'attrezzo specifico di fer- mo dell'ingranaggio primaria Specific tooling 020850Y Primary gear lock...
  • Page 198 Tuono V4 1100 Factory Engine delle bulinature presenti nei due ingra- naggi. • Posizionare l'attrezzo di fermo e dopo aver inserito il dado, serrarlo a coppia. Specific tooling 020850Y Primary gear lock Preparation To open the crankcase, first remove the following components: •...
  • Page 199 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 200 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 201: Crankshaft Removal

    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 202: Bearing Removal

    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 203: Crankshaft Check

    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) Maximum radial clearance between the main bearings and the crankshaft pins...

  • Page 204: Piston-Cylinder Coupling

    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) Maximum radial play of crankpin 0.08 mm (0.0031 in)
  • Page 205 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: CRANKSHAFT - CONNECTING ROD BALANCING CLASSES Crankshaft balancing classes Combinations of weight classes for...
  • Page 206 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 207 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 SHAFT CATEGORY The category of the three crankshaft main journals is stamped on the flat face of the counterweight,...
  • Page 208 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 Bushing (green) Bushing (green) Bushing (yellow)
  • Page 209 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 GREEN...

  • Page 210: Specific Tooling

    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 211 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 212 Tuono V4 1100 Factory Engine • Posizionare sul basamento l'apposito attrezzo speciale. • Inserire parzialmente l'assieme pi- stone - fusto di biella nel relativo cilin- dro con la freccia (sul pistone) ruotata di 45° rispetto allo scarico. • Quando la testa di biella è scesa, fino a superare il proprio getto di lubrifica- zione, ruotare l'assieme pistone - fusto di biella con la freccia sul cielo del pi-...
  • Page 213 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 214 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 215 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 lb ft) Oil sump fixing screws 12 Nm (8.85 lb ft) Tighten to torque,...
  • Page 216 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 + Lubricate the head...

  • Page 217: Oil Pump

    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 218: Oil Pump Removal

    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 • Remove the cooling oil pump cover.
  • Page 219 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 220 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 221 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 222 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 223 Tuono V4 1100 Factory Engine SAS valve ECONDARY AIR SYSTEM Pos. Description Type Quantity Torque Notes Cylindrical head, hex. socket secon- M6x16 10 Nm (7.38 lb ft) dary air solenoid screws Diagram Valve controlled by control unit which delivers as- pirated air from the filter box to the exhaust mani- folds.
  • Page 224 Tuono V4 1100 Factory Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 224...

  • Page 225: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 226: Checking The Injector

    Tuono V4 1100 Factory Power supply Injection Checking the injector • Controllare il cablaggio elettrico e i collegamenti. • Mediante lo strumento di diagnosi nella sezione AUTODIAGNOSI / ATTIVAZIONI / ATTI- VAZIONE INIETTORE, è possibile effettuare l'attivazione degli iniettori e verificare quindi il corretto funzionamento.

  • Page 227: Checking The Throttle Body

    Tuono V4 1100 Factory Power supply Checking the throttle body The throttle bodies are maintenance free and are not serviceable. Replace the entire assembly in the event of malfunction. As all the internal components of the throttle body assembly (potentiometers and electrical motor) are contactless, no electrical diagnosis is possible.
  • Page 228 INDEX OF TOPICS SUSP USPENSIONS...
  • Page 229 Tuono V4 1100 Factory Suspensions Front Front fork Adjustment The standard front fork setting is adjusted to suit most high and low speed riding conditions, whether the vehicle is partially or fully loaded. However, the setting can be modified for specific needs according to vehicle use. RACING TRACK SETTINGS MUST BE DONE ONLY FOR OFFICIAL COMPETITIONS OR SPORTS EVENTS WHICH ARE, IN ALL CASES, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES.
  • Page 230 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 (forcella Ohlins - ASC) • Refer to the USE AND MAINTENANCE BOOKLET, paragraph "ADVANCED FUNCTIONS"...

  • Page 231: Removing The Fork Legs

    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. Removing the fork legs Per effettuare la rimozione degli steli, è necessario...

  • Page 232: Draining Oil

    Tuono V4 1100 Factory Suspensions • While supporting the stanchion, loosen the screw on the upper yoke. • Extract the stanchion and remove it • When replacing the stanchions, take care when regulating the degree to which they protrude, following the instructions provided in the "Settings" paragraph in the "Suspensions" section. Draining oil TUONO V4 1100 NOTE...
  • Page 233 Tuono V4 1100 Factory Suspensions • Operating on the upper screw, unload the spring. • Loosen the cover without unscrewing it completely. • Place the fork vertically locking it in a vice by the specific tool. • Completely unscrew the plug. Specific tooling AP8140149 Guard for assembly operations •...
  • Page 234 Tuono V4 1100 Factory Suspensions • Unscrew the cap and remove it. • Remove the spring pre-load pipe. • Remove the lock nut and the washer. • Remove the spring paying attention to drain the oil correctly. SUSP - 234...
  • Page 235 Tuono V4 1100 Factory Suspensions • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
  • Page 236 Tuono V4 1100 Factory Suspensions • Remove the complete cap. • Unscrew the nut and remove it, exert- ing slight pressure on the pre-loading spring. • Remove the pre-loading spring retain- ing ring. • Remove the pre-loading spring. SUSP - 236...

  • Page 237: Disassembling The Fork

    Tuono V4 1100 Factory Suspensions • Empty the fork oil into a special con- tainer, taking care not to let the pre- loading tube come out. Disassembling the fork TUONO V4 1100 NOTE THE FOLLOWING OPERATIONS REFER TO THE SACHS FORKS. •...
  • Page 238 Tuono V4 1100 Factory Suspensions • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem. •...
  • Page 239 Tuono V4 1100 Factory Suspensions • Remove the pre-loading tube. • Remove the wheel holder shaft (1) and the sleeve (2). • 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).
  • Page 240 Tuono V4 1100 Factory Suspensions • Remove the shaft seal (5) by levering it alternately at various points. CAUTION PROTECT THE EDGE OF THE SLEEVE IN ORDER TO AVOID RUINING IT WHILE REMOVING THE SHAFT SEAL (5). Replace the following components with new ones: - shaft seal (5) - anti-dust seal (3) CAUTION...
  • Page 241 Air filter: 40, 43, 48 Aprilia V4-MP Tecnology: 106 Battery: 95 Bushings: Chain: 19 Clutch: 67, 144, 163, 167–169, 172–174, 180 Connecting rods: 200, 204, 211 Countershaft: 193, 195, 198, 203 Crankcase: 191, 199, 203, 213 Crankshaft: 201, 203, 210...
  • Page 242 Maintenance: 14, 32 Oil filter: 40 Oil sump: 198 One-way valve: 224 Pistons: 200, 204, 211 Primary shaft: 148 Rear cylinder head valves: 56 Rear head: 186, 198, 201 Recommended products: 34 Scheduled maintenance: 32 Secondary air system: Secondary shaft: 149 Spark plug: 35 Start-up: 156 Starter motor: 155...

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