APRILIA TUONO V4 R 2010 Service Station Manual

page of 475

/ 475
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

SERVICE STATION MANUAL

B043120

TUONO V4 R

Table of Contents

Summary of Contents for APRILIA TUONO V4 R 2010

Page 1 SERVICE STATION MANUAL B043120 TUONO V4 R...
Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this booklet remain unchanged, Aprilia reserves the right, at any time and without being required to update this publication beforehand, to make any changes to components, parts or accessories, which it considers necessary to improve the product or which are required for manufacturing or construction reasons.
Page 3 This manual provides the main information to carry out regular maintenance operations on your vehicle. This manual is intended to aprilia Dealers and their qualified mechanics; several concepts have been deliberately omitted as they are considered unnecessary. As it is not possible to include complete mechanical notions in this manual, users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing scooters.
Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE DELIVERY...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...
Page 7 TUONO V4 R 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 let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8 TUONO V4 R Characteristics KEEP OUT OF THE REACH OF CHILDREN. DO NOT REMOVE THE RADIATOR CAP WHEN THE ENGINE IS STILL HOT. THE COOLANT IS PRESSURISED AND MAY CAUSE SCALDING. Used engine oil and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE. THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
Page 9 REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Aprilia SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10 It is recommended, during the first 1000 km (621 mi), not to exceed 7500 rpm and 9500 rpm up 2000 km (1243 mi). AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "PERIODICAL MAINTENANCE" TABLE IN THE SCHEDULED MAIN-...
Page 11 TUONO V4 R Characteristics TENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE. Vehicle identification Chassis number The chassis number is stamped on the right hand side of the headstock. This number consists of numbers and letters, as in the example shown below.
Page 12 TUONO V4 R Characteristics Specification Desc./Quantity Full loaded weight (rider only) 279 kg (615 lb) Engine ENGINE Specification Desc./Quantity Model Type 65° longitudinal V-4, 4-stroke, 4 valves per cylinder, double overhead camshafts. Engine capacity 999 cm³ (60.96 cu.in) Bore / stroke 78 mm / 52.26 mm (3.07 in / 2.06 in) Compression ratio 13 : 1...
Page 13 TUONO V4 R Characteristics Drive chain RIVE CHAIN Specification Desc./Quantity Type With sealed master link Model Regina 110 links Electrical system LECTRICAL SYSTEM Specification Desc./Quantity Spark plugs NGK CR9EKB Electrode gap 0.7 - 0.8 mm (0.027 - 0.031 in) Battery YUASA YT12A-BS, 12 V 9.5 Ah Coils Stick coil...
Page 14 TUONO V4 R Characteristics Specification Desc./Quantity Rear shock absorber Sachs piggyback shock absorber with progressive APS system and adjustable spring preload and hydraulic compression and rebound damping. Rear wheel travel 130 mm (5.12 in) SIZES A Specification Desc./Quantity Size "A" 654.5 mm (25.76 in) (measurements refer to the bare chassis) Size "B"...
Page 15 TUONO V4 R Characteristics Supply UEL SYSTEM Specification Desc./Quantity Fuel Premium unleaded petrol, minimum octane rating 95 (NORM) and 85 (NOMM) UEL SYSTEM Specification Desc./Quantity Throttle body diameter 48 mm (1.89 in) Type Electronic injection (multipoint), 2 throttle bodies motorised (ride by wire), 2 dynamic air intakes.
Page 16 TUONO V4 R Characteristics RONT FORK ACHS pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft) to the stem base) Upper cover 20 Nm (14.75 lbf ft) Upper cover locking nut 20 Nm (14.75 lbf ft)
Page 17 TUONO V4 R Characteristics TEERING pos. Description Type Quantity Torque Notes Screws fastening the raiser to the 50 Nm (36.87 lbf ft) steering upper yoke Screws fastening upper U-bolt to 25 Nm (18.43 lbf ft) handlebar Screws fastening upper yoke to stan- 25 Nm (18.43 lbf ft) chions Screws fastening lower yoke to stan-...
Page 18 TUONO V4 R Characteristics RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket CHAR - 18...
Page 19 TUONO V4 R Characteristics pos. Description Type Quantity Torque Notes Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft) to the lower yoke Front brake pump U bolt clamp 10 Nm (7.37 lbf ft) Front brake lever pin fixing screw 10 Nm (7.37 lbf ft)
Page 20 TUONO V4 R Characteristics EADLAMP pos. Description Type Quantity Torque Notes Screws fastening the headlamp to 3 Nm (1.47 lbf ft) the upper fairing fastener Screws fastening headlamp to front 4 Nm (2.95 lbf ft) fairing CHAR - 20...
Page 21 TUONO V4 R Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 22 TUONO V4 R Characteristics INDSHIELD pos. Description Type Quantity Torque Notes Top fairing fixing screw 3 Nm (2.21 lbf ft) Front turn indicator fixing screw 2.5 Nm (1.84 lbf ft) LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) CHAR - 22...
Page 23 TUONO V4 R Characteristics OOLING pos. Description Type Quantity Torque Notes Screws fastening water radiator 10 Nm (7.37 lbf ft) mounting bracket to chassis Screws fastening water radiator to 7 Nm (5.16 lbf ft) mounting bracket Screw fastening pipe grommet for 6 Nm (4.42 lbf ft) By-pass water hose Screws fastening electric fan to wa-...
Page 24 TUONO V4 R Characteristics Central part IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) CHAR - 24...
Page 25: Table Of Contents
TUONO V4 R Characteristics ADDLE pos. Description Type Quantity Torque Notes Rider saddle fixing screw 6 Nm (4.42 lbf ft) UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to...
Page 26 TUONO V4 R Characteristics OOTRESTS pos. Description Type Quantity Torques Notes Screws fastening rider footpegs to 25 Nm (18.43 lbf ft) Fix with Loctite 243 chassis Screws fastening passenger foot- 18 Nm (13.27 lbf ft) Fix with Loctite 243 pegs to saddle mounting Rider heelrest fixing screws 8 Nm (5.90 lbf ft) Passenger heelrest fixing screws...
Page 27: Torque Notes
TUONO V4 R Characteristics RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2 Manual Front mounts 2 + 2...
Page 28: Torque Notes
TUONO V4 R Characteristics LOCKS pos. Description Type Quantity Torque Notes Nut fastening saddle lock to tail fair- M22x1.5 5 Nm (3.69 lbf ft) Lock lever self-tapping screw 2 Nm (1.47 lbf ft) CHAR - 28...
Page 29 TUONO V4 R Characteristics RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft) Screw fastening the voltage regula- 6 Nm (4.42 lbf ft) tor to the inner fairing Shear head screw (to the left of the Manual...
Page 30 TUONO V4 R Characteristics ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Threaded spacer 8 Nm (5.9 lbf ft) TSPEI screw M6x35 10 Nm (7.38 lbf ft) Loct. Self-locking nut 25 Nm (18.44 lbf ft) Gearbox linkage joint to gearbox lev- 8 Nm (5.90 lbf ft) Loct.
Page 31 TUONO V4 R Characteristics ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft) CHAR - 31...
Page 32 TUONO V4 R Characteristics AIRING pos. Description Type Quantity Torque Notes Screws fastening the lower fairing to 3 Nm (2.21 lbf ft) the lower bracket Screws fixing the side fairings to the 1.5 Nm (1.10 lbf ft) side spacers Back side XHAUST pos.
Page 33 TUONO V4 R Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount CHAR - 33...
Page 34: Nm (2.95 Lbf Ft)
TUONO V4 R Characteristics EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) EAR BRAKE CALLIPER pos.
Page 35: Nm (5.16 Lbf Ft)
TUONO V4 R Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 36 TUONO V4 R 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) rod to chassis CHAR - 36...
Page 37: Nm (1.84 Lbf Ft)
TUONO V4 R Characteristics AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER...
Page 38 TUONO V4 R Characteristics pos. Description Type Quantity Torque Notes Screws fixing side fairings to tank 2 Nm (1.47 lbf ft) Screws fastening side fairings to tail 1 Nm (0.73 lbf ft) fairing Screws fastening the grab handle SWP 3.9 1.5 Nm (1.10 lbf ft) shell Rear screws fastening grab handle...
Page 39 TUONO V4 R Characteristics ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft) ing screws Battery bracket fixing screws 2 Nm (1.47 lbf ft)
Page 40 TUONO V4 R Characteristics Engine LUTCH COVER pos. Description Type Quantity Torque Notes Engine speed sensor fixing screw 8 Nm (5.9 lbf ft) TE flanged screw M6x20 12 Nm (8.85 lbf ft) Flanged TE screws M6x35 12 Nm (8.85 lbf ft) Flanged TE screws M6x22 12 Nm (8.85 lbf ft)
Page 41 TUONO V4 R Characteristics ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) CHAR - 41...
Page 42 TUONO V4 R Characteristics YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase HEADS pos. Description Type Quantity Torque Notes Exhaust stud bolts 10 Nm (7.37 lbf ft) Camshaft cam tower fixing screws M6x45 12 Nm (8.85 lbf ft) Reed valve cover fixing screws...
Page 43 TUONO V4 R Characteristics IMING SYSTEM pos. Description Type Quantity Torque Notes Screws fastening the timing system 30 Nm (22.13 lbf ft) Loct. 243 gear on the intake shaft Skid fastener screws 20 Nm (14.75 lbf ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.37 lbf ft) Loct.
Page 44 TUONO V4 R Characteristics RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 45 TUONO V4 R Characteristics RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 46 TUONO V4 R Characteristics pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw 10 Nm (7.37 lbf ft) Loct.
Page 47 TUONO V4 R Characteristics LUTCH pos. Description Type Quantity Torque Notes Clutch nut 150 Nm (110.63 lbf ft) Loct. 243 Clutch spring fastener screw 10 - 12 Nm (7.38 - 8.85 lbf ft) IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1...
Page 48 TUONO V4 R Characteristics LTERNATOR COVER pos. Description Type Quantity Torque Notes Screws fastening cover onto centre M6x25 12 Nm (8.85 lbf ft) pins Cover fastener screws, alternator M6x40 12 Nm (8.85 lbf ft) side Blow-by union fastener screws M5x16 7 Nm (5.16 lbf ft) Stator fixing screw UNI 5931 CL8.8 M6x25...
Page 49 TUONO V4 R Characteristics UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft) Oil sump fixing screws...
Page 50 TUONO V4 R Characteristics ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Water pump locking screw M6x35 10 Nm (7.37 lbf ft) Tank to pump fixing nut Flanged M6 12 Nm (8.85 lbf ft) Recommended products chart...
Page 51 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
Page 52 TUONO V4 R Special tools PECIAL TOOLS Stores code Description 020845Y Engine support 020846Y Retaining tray + plastic caps 020913Y Flywheel extractor 020914Y Flywheel retainer 020849Y Clutch retainer 020850Y Primary gear lock S-TOOLS - 52...
Page 53 TUONO V4 R Special tools Stores code Description 020851Y Camshaft timing pin 020852Y Crankshaft timing pin 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor 020855Y Lever for engaging the chain tensioner 020856Y Piston installation ring 020857Y Crankshaft bearing U bolt S-TOOLS - 53...
Page 54 TUONO V4 R Special tools Stores code Description 020858Y Device for holding the pistons in the cyl- inders AP8140199 Tool panel 020859Y Panel graphics 8140426 Hooks for panel 020860Y Engine support extension 020861Y Countershaft bushing punch 020862Y Gearbox control rod roller cage fitting punch S-TOOLS - 54...
Page 55 TUONO V4 R Special tools Stores code Description 020863Y Desmodromic drum roller cage fitting punch 020864Y Engine mounting plate 020865Y Support for camshaft gear on head 020883Y Tool for fitting/removing the timing chain tensioner 020709Y Engine support AP8140187 Engine support stand 020376Y Adapter handle S-TOOLS - 55...
Page 56 TUONO V4 R Special tools Stores code Description 020363Y 20-mm Oil seal guide 020364Y 25-mm Guide 020359Y 42 x 47 mm punch 020431Y Valve oil seal extractor AP8140180 Extractor for bushings AP8140179 Valve spring compressor S-TOOLS - 56...
Page 57 TUONO V4 R Special tools Stores code Description 0277308 Guide bushing for secondary gearbox shaft 020877Y Pliers for clamps AP8140146 Weight AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140149 Protection for fitting operations AP8140190 Tool for steering tightening 020888Y Pliers for pre-fill pipe S-TOOLS - 57...
Page 58 TUONO V4 R Special tools Stores code Description 020889Y Pumping member ring nut locking span- 020890Y Pumping member stanchion support rod AP8140181 Fuel pressure checking tool 020680Y TXB Navigator S-TOOLS - 58...
Page 59 INDEX OF TOPICS MAIN AINTENANCE...
Page 60 Correct maintenance is fundamental for ensuring the longevity of your vehicle and maintaining optimum functionality and performance. To this end, Aprilia offers a set of checks and maintenance services (at the owner's expense), that are summarised in the table shown on the following page. Any minor faults must be reported without delay to an Authorised Aprilia Dealer or Sub-Dealer without waiting until the next scheduled service to solve it.
Page 61 TUONO V4 R Maintenance km x 1000 Brake systems (6) Light circuit Stand switch Safety switches Stop switches Brake fluid (4) Coolant (4) Fork oil (7) Engine oil (6) Light aiming Fork oil seals (6) Anti-vibration buffers Tyres - pressure/wear (2) Wheels (6) Tightening torques (6) Tightening of clutch cover, flywheel and oil sump...
Page 62 TUONO V4 R Maintenance • Remove the fuel tank. • Unscrew and remove the rear coil fastener screw. • Slide off the rear coil. • Unscrew and slide off the rear spark plug. Engine oil Check NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. •...
Page 63 TUONO V4 R 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 64 TUONO V4 R Maintenance • Spread a thin layer of oil on the sealing ring of the new engine oil filter. • Insert and screw the new engine oil filter in the seat, filling the filter to 1/3 of its capacity with engine oil before fitting.
Page 65 TUONO V4 R Maintenance • Remove the air filter. Checking the valve clearance FRONT HEAD • Remove both throttle bodies and the coils. • Remove the front head cover and the spark plugs. • Remove the cap on the clutch cover in order to turn the crankshaft, taking care not to lose the O-ring.
Page 66 TUONO V4 R Maintenance REAR HEAD • Remove both throttle bodies and the spark plugs. • Remove the rear head cover. See also Removing the throttle body Spark plug Head cover removal • Use a feeler gauge to check the clear- ance between the cam on the shaft and the relative tappet for both rear head shafts.
Page 67 TUONO V4 R Maintenance Front cylinder head valves • Check the front valve head clearance and restore the correct clearance values if necessary, proceeding as described below. • Remove both head covers, the alter- nator side cover and remove the cap on the clutch cover in order to rotate the crankshaft.
Page 68 TUONO V4 R Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 69 TUONO V4 R Maintenance ing setting was not altered while the engine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1). •...
Page 70 TUONO V4 R Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the ex- haust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots). •...
Page 71 TUONO V4 R Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally. •...
Page 72 TUONO V4 R Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 73 TUONO V4 R Maintenance 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; insert the reference pin while checking with the crankshaft reference pin, that the flywheel side hole and the hole on the crankshaft are perfectly aligned. •...
Page 74 TUONO V4 R Maintenance • Fit the pin for aligning the intake cam- shaft with the hole on U-bolt. • If it was not possible before adjusting the valve clearance, check the engine timing. Specific tooling 020851Y Camshaft timing pin •...
Page 75 TUONO V4 R Maintenance setting was not altered while the en- gine was turned with only one cam- shaft drive gear fastener screw in place. • Remove the camshaft timing pin. • Unscrew and remove the two U bolt screws (1). •...
Page 76 TUONO V4 R Maintenance • Remove the intake and exhaust cam- shafts. If the two camshafts are timed correctly, the intake camshaft gear tooth (indicated with one dot) is meshed with the trough of the exhaust camshaft gear (indicated with two dots). •...
Page 77 TUONO V4 R Maintenance • Fit the U bolts with the nine O rings and locator pins. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the seven screws (2) operating in stages and diagonally. •...
Page 78 TUONO V4 R Maintenance • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw. This screw must be replaced at each reassembly. • Apply and loosely tighten the gear fix- ing screw on the camshaft. •...
Page 79 TUONO V4 R Maintenance 020852Y Crankshaft timing pin • Turn the crankshaft back to the previous position in which the camshaft and U bolt holes were aligned; Refit the reference pin while checking, using the crankshaft reference pin, that the clutch side hole and the hole in the crankshaft are perfectly aligned. •...
Page 80 TUONO V4 R Maintenance 2.2 mm (0.0866 in) 2.25 mm (0.0886 in) 2.3 mm (0.0905 in) 2.35 mm (0.0925 in) 2.4 mm (0.0945 in) 2.45 mm (0.0964 in) 2.50 mm (0.0984 in) 2.55 mm (0.1004 in) 2.6 mm (0.1024 in) 2.65 mm (0.1043 in) 2.7 mm (0.1063 in) 2.75 mm (0.1083 in)
Page 81 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 82 THERE IS ABNORMAL ENGINE PERFORMANCE • 2 - CONNECT TO THE DIAGNOSIS INSTRUMENT THROUGH CONTROL UNIT BY SE- LECTING "SELF-ACQUISITION, APRILIA, TUONO V4" • 3 - ARE CURRENT- "ATT"- or STORED- "MEM"- ERRORS SHOWN IN THE "ERRORS DISPLAY" SCREEN PAGE? YES, go to 4;...
Page 83 TUONO V4 R Troubleshooting PANEL ERRORS" SECTION. IF THERE ARE ERRORS PRESENT, SOLVE THE FAULT AND SELECT "CLEAR ERRORS"; IF THERE ARE NO ERRORS PRESENT, go to 12 • 12 - IN THE "ENGINE PARAMETER READING" SCREEN PAGE, DOES THE "AIR TEM- PERATURE"...
Page 84 TUONO V4 R Troubleshooting The engine does not start THE ENGINE DOES NOT START, THE INSTRUMENT PANEL TURNS ON. CAUTION NAVIGATOR SHOULD BE WORKING PROPERLY AND UPGRADED AT LEAST TO THE 7.0.0 VERSION OR THE PGDS UPDATED AT LEAST TO THE 3.0.0 VERSION CAUTION BEFORE ANY TROUBLESHOOTING, MAKE SURE THAT: 1) BATTERY VOLTAGE IS ABOVE 12V;...
Page 85 TUONO V4 R Troubleshooting • 8. WITH THE SWITCH SET TO "RUN", WHAT DOES THE "RUN-STOP SWITCH" STATUS ON THE DIAGNOSIS INSTRUMENT, DEVICE STATUS SCREEN PAGE, ICON 0/1 MEAN? If "RUN" is shown, go to 9; if "STOP" is shown, go to 15 •...
Page 86 TUONO V4 R Troubleshooting TROL UNIT INDICATES ERRORS RELATED TO THE FRONT AND REAR THROTTLE BODY) YES, go to 3; NO, go to 6 • 3. CHECK CONTINUITY WITH GROUND CONNECTION AT PIN 5 and 16 If there is continuity, go to 4; if there is not continuity, restore ground connection on the engine front part or restore cable harness •...
Page 87 TUONO V4 R Troubleshooting • 2. CHECK THE CONTROL UNIT CONNECTOR AS WELL AS THE DIAGNOSIS BLACK CONNECTOR YES, go to 3; NO, restore faulty connector - END • 3. CHECK CORRECT OPERATION OF THE DIAGNOSIS INSTRUMENT CONNECTION CABLE AND THE CORRECT INSTALLATION OF THE PLIERS ON THE BATTERY - END •...
Page 88 TUONO V4 R Troubleshooting PROTECTION RELAY 16 CHECK • 1. WITH KEY SET TO OFF, DISCONNECT THE RELAY CONNECTOR AND CHECK CONTINUITY OF BLUE CABLE WITH GROUND If there is continuity, go to 2; if there is not continuity, restore cable harness - END •...
Page 89 TUONO V4 R Troubleshooting • 4. REPLACE THE CONTROL UNIT - END • 5. CHECK CONTINUITY OF PINK CABLE BETWEEN SWITCH CONNECTOR AND PIN 58 OF THE CONTROL UNIT, CHECKING ALSO THE ENGINE - VEHICLE CABLE HAR- NESS CONNECTOR YES, go to 4; NO, restore the cable harness - END •...
Page 90 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 91 TUONO V4 R Electrical system RONT ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Fall sensor mounting fixing screw 8 Nm (5.9 lbf ft) Horn fixing screw 15 Nm (11.06 lbf ft) Screw fastening the voltage regula- 6 Nm (4.42 lbf ft) tor to the inner fairing Shear head screw (to the left of the Manual...
Page 92 TUONO V4 R Electrical system ENTRAL ELECTRICAL SYSTEM pos. Description Type Quantity Torque Notes Upper Silentblock nut, demand sen- 5 Nm (3.69 lbf ft) sor mounting bracket Demand sensor fixing screw to SWP 4.9 1.2 Nm (0.88 lbf ft) mounting plate Components arrangement Key: ELE SYS - 92...
Page 93 TUONO V4 R Electrical system 1. Side stand sensor 2. Fuel pump 3. Instrument panel 4. Left hand switch 5. Right hand switch 6. Water Temperature Sensor 7. Cooling fans 8. Injectors 9. Air temperature sensor 10.Air pressure sensor 11.Exhaust valve 12.Oxygen sensor 13.Speed sensor 14.Headlamp...
Page 94 TUONO V4 R Electrical system Component position Component name Location on the vehicle in the electrical circuit diagram Recovery logic relay (urgent service) In the niche of the headstock, on the right Electrical system installation INTRODUCTION Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets.
Page 95 TUONO V4 R Electrical system • 1 Regulator • 1 Demand sensor • 1 Battery • 1 QuickShift (if fitted) Small parts and mountings • 5 Large black 290x4 clamps • 14 Small black 160x2.5 clamps • 7 Rubber clamps •...
Page 96 TUONO V4 R Electrical system • 1 Engine cable harness • 1 Engine speed sensor • 1 Control unit 7SM • 1 Air temperature sensor • 1 H2O temperature sensor • 2 Coil with short cable (Cylinder 1 and Cylinder 4) •...
Page 97 TUONO V4 R Electrical system Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear part 4. ENGINE Special checks for the correct connection and laying of cables It is extremely important that any security-locks for the following connectors are properly connected and correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
Page 98 TUONO V4 R Electrical system • Engine revolution sensor connector - Output "30" • 7SM control unit connector - Outputs "25" and "26" • Coil connectors - Outputs "29", "8", "7" and "28" • Gear sensor connector - Output "15" •...
Page 99 TUONO V4 R Electrical system TABLE B1 - REGULATOR PRE-FITTING • Pre-fit two clamps for fastening of the cable harness. TABLE C - HEADLAMP PRE-FITTING • The headlamp cable harness and the relay must be fitted on the headlamp as indicated.
Page 100 TUONO V4 R Electrical system TABLE C2 - HEADLAMP PRE-FITTING • Clamps position inserting them in the connectors tongue, after connecting to the headlamp TABLE C3 - HEADLAMP PRE-FITTING • Check that the connectors are correctly inserted after placing and tightening the clamps TABLE C4 - HEADLAMP PRE-FITTING •...
Page 101 TUONO V4 R Electrical system TABLE D 1. Speed sensor cable harness routing inside the cable grommet and between throttle cables and frame • Ensure that the cable grommet is not interfering with the steering damper during its movement 2. Right switch cable harness routing 3.
Page 102 TUONO V4 R Electrical system TABLE E2 - INSTRUMENT HOLDER SUPPORT • Tighten the clamps previously fitted • Keep the area in the dotted line free from cables 1. Left light switch connectors 2. Lights relay connector 3. Front headlight connector 4.
Page 103 TUONO V4 R Electrical system TABLE E4 - INSTRUMENT HOLDER SUPPORT 1. Key switch TABLE E5 - INSTRUMENT HOLDER SUPPORT 1. Lights relay 2. Front headlight connector • Insert the front headlamp connector in its housing paying attention that it is correctly placed.
Page 104 TUONO V4 R Electrical system TABLE G 1. Clutch cable harness routing 2. Antenna cable harness routing 3. Key switch cable harness routing 4. Main cable harness routing 5. Regulator-flywheel cable harness routing 6. Control Shift cable harness routing 7. Cable harness routing to left handlebar control •...
Page 105 TUONO V4 R Electrical system TABLE B - RADIATOR AREA 1. Vehicle cable harness 2. Cable grommet TABLE B1 - RADIATOR AREA 1. Ground cable harness routing that must pass behind water pipe and behind the starter motor. 2. Starter motor cable harness routing that must pass behind water pipe.
Page 106 TUONO V4 R Electrical system TABLE B2 - RADIATOR AREA 1. Vehicle connector 2. Engine connector 3. Starter motor cable harness CAUTION CHECK THAT THE CONNECTORS ARE CORRECTLY IN- SERTED AND THAT THE PURPLE SLIDE IS AT THE END OF THE STROKE. CAUTION CHECK THAT THE CABLE ON THE STARTER MOTOR IS PLACED AS INDICATED.
Page 107 TUONO V4 R Electrical system TABLE C2 - DEMAND SENSOR 1. Demand sensor ELE SYS - 107...
Page 108 TUONO V4 R Electrical system TABLE D • Rest the left fairing on the lower sup- port and close the fairing in the upper part 1. Regulator connector TABLE E - FANS 1. Left fan connector 2. Right fan connector TABLE E1 - FANS 1.
Page 109 TUONO V4 R Electrical system TABLE G - EXHAUST VALVE ACTUATOR 1. Exhaust valve actuator cable harness routing 2 Exhaust valve actuator 3 Exhaust valve actuator connector 4. Clamp TABLE G1 - EXHAUST VALVE ACTUATOR 1 Exhaust valve actuator 2 Heat-protecting cover 3.
Page 110 TUONO V4 R Electrical system TABLE G3 - EXHAUST VALVE ACTUATOR Fitting procedure of the valve / actuator Bowden cables: • Insert the cables with the set screws closed in the following sequence: • Valve side closing cable (univocal fit- ting) •...
Page 111 TUONO V4 R Electrical system TABLE I - PINION AREA 1. Quick shift laying of cables (IF APPLICABLE) 2. Oxygen sensor cable harness routing 3. Gear sensor cable harness routing 4. Stand switch cable harness routing 5. Cable grommet • Pass the cable harnesses behind the cable grommet that closes the two fuel breather pipes...
Page 112 TUONO V4 R Electrical system TABLE N - QUICK SHIFT (IF APPLICABLE) 1. Gear sensor cable harness routing 2. Quick Shift cable harness routing 3. Stand switch cable harness routing 4. Oxygen sensor cable harness routing TABLE O 1. Quick Shift connector (IF FITTED) 2.
Page 113 TUONO V4 R Electrical system TABLE P - ECU 1. ECU connectors TABLE Q - GROUND LEADS 1. ENGINE GND eyelet from the vehicle cable har- ness 2. Engine - battery ground cable ENGINE GND eyelet 3. ENGINE GND eyelet from the engine cable har- ness 4.
Page 114 TUONO V4 R Electrical system Check that the drainage hole (7) for the water of both turn indicators is positioned downward. 1. License plate frame cable harness 2. Right rear turn indicator cable harness routing 3. 2.8 mm (0.11 in) Faston - cable colours: red and blue 4.
Page 115 TUONO V4 R Electrical system TABLE C1 - SWINGARM AREA 1. Speed sensor cable harness 2. Rear brake switch cable harness 3. Cable grommet TABLE D - REAR SADDLE MOUNTING AREA 1. Battery mounting bracket 2. Vehicle cable harness 3. Fit the (individual) fan fuse on battery mounting bracket tongue TABLE D1 - REAR SADDLE MOUNTING AREA 1.
Page 116 TUONO V4 R Electrical system TABLE D4 - REAR SADDLE MOUNTING AREA 1. Relay with relay socket rubber mounting 2. Protection relay with relay socket rubber mount- 3. Battery mounting bracket 4. Battery TABLE D4 - REAR SADDLE MOUNTING AREA 1.
Page 117 TUONO V4 R Electrical system TABLE D5 - REAR SADDLE MOUNTING AREA 1. Battery positive cable harness routing between the saddle mounting joists TABLE D6 - REAR SADDLE MOUNTING AREA 1. License plate frame cable harness connector 2. Rear headlight connector 3.
Page 118 TUONO V4 R Electrical system TABLE E - RIGHT SIDE SADDLE MOUNTING • External part: 1. Insert the screw clamp on the cable harness in the hole on the right side of the saddle mounting 2. Fuel pump connector 3. Clamps •...
Page 119 TUONO V4 R Electrical system TABLE E1 - LEFT SIDE SADDLE MOUNTING 1. Battery - engine ground cable 2. Cable grommet Engine CAUTION USE "TABLE B - ENGINE WIRING HARNESS", IN THE SECTION "ELECTRICAL SYSTEM/IN- STALLING THE ENGINE ELECTRICAL SYSTEM" AS REFERENCE FOR THE CONNECTOR OUT- PUTS TABLE A - ENGINE CABLE HARNESS 1.
Page 120 TUONO V4 R Electrical system TABLE C - FILTER BOX COVER AND LOWER FILTER BOX PREPARATION 1. Mounting for the vehicle connector 2. Supports for coils connector TABLE D - CONTROL UNIT MOUNTING PREP- ARATION 1. Control unit 2. Fit the 3 silent blocks onto the seats on the mounting;...
Page 121 TUONO V4 R Electrical system TABLE E - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING 1. Rear motorised throttle body 2. Front motorised throttle body • Before fitting the motorised throttle bodies on the cylinders, the respective engine cable harness connectors must be connected: on branch "2"...
Page 122 TUONO V4 R Electrical system TABLE E3 - MOTORISED THROTTLE BODY CONNECTION PREPARATION AND SECON- DARY AIR SOLENOID FITTING 1. Secondary air solenoid connector 2. Rubber manifolds 3. Clip-on clamps TABLE F - FITTING THE MOTORISED THROT- TLE BODIES • First fasten the "Motorised Throttle Body2 (front)"...
Page 123 TUONO V4 R Electrical system TABLE G - WATER TEMPERATURE SENSOR AND INJECTORS CONNECTION 1. Engine speed sensor connector 2. Output with derivations 3. Cable harness routing (branch "4") under the water pipe fitting 4. Engine speed sensor cable routing TABLE G1 - WATER TEMPERATURE SENSOR AND INJECTORS CONNECTION •...
Page 124 TUONO V4 R Electrical system 1. Injector 4 cable harness connector (output "6") GREY connector 2. Injector 2 cable harness connector (output "5") BROWN connector 3. Coil 2 cable harness routing (output "7") 4. Coil 2 5. Coil 4 TABLE G3 - WATER TEMPERATURE SENSOR AND INJECTORS CONNECTION •...
Page 125 TUONO V4 R Electrical system TABLE H1 - COIL AND MAP SENSOR CON- NECTION 1. Coil 4 cable harness connector (output "8") 2. Coil 4 connector TABLE H2 - COIL AND MAP SENSOR CON- NECTION 1. Coil 2 connector 2. Coil 2 cable harness connector (output "7") 3.
Page 126 TUONO V4 R Electrical system clamped, using the indicated clamp to the Blow-by pipe in the indicated posi- tion. TABLE I - GEAR SENSOR CONNECTION AND CABLE HARNESS ROUTING BY OXYGEN SENSOR • Once the "Gear Sensor" (output "15") connector has been connected to its counterpart, it must be moved behind the corrugated pipes to the position in- dicated.
Page 127 TUONO V4 R Electrical system TABLE L - AIR TEMPERATURE SENSOR CON- NECTION 1. Air temperature sensor 2. Air temperature sensor cable harness connec- tor (output "24") TABLE M - CONTROL UNIT FITTING AND CON- NECTION 1. Self-tapping screw 2. Washer TABLE M1 - CONTROL UNIT FITTING AND CONNECTION 1.
Page 128 TUONO V4 R Electrical system 3. Cable harness routing (output "25") under the mounting 4. Cable harness routing (output "25") under the mounting TABLE M3 - CONTROL UNIT FITTING AND CONNECTION • It is advisable to create a jig in order to check the correct insertion of both con- nectors TABLE N - VEHICLE CONNECTOR FASTEN-...
Page 129 TUONO V4 R Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. FRONT RIGHT TURN INDICATOR 3. TAIL LIGHT BULB (LED) 4. HIGH BEAM BULB ELE SYS - 129...
Page 130 TUONO V4 R Electrical system 5. LOW BEAM BULB 6. FRONT LEFT TURN INDICATOR 7. LIGHT LOGIC RELAY 8. LEFT LIGHT SWITCH 9. INSTRUMENT PANEL DIAGNOSIS 10.INSTRUMENT PANEL 11.EXHAUST VALVE MOTOR 12.FRONT STOP SWITCH 13.REAR STOP SWITCH 14.CLUTCH SWITCH 15.IGNITION KEY 16.PROTECTION RELAY 17.IMMOBILIZER AERIAL 18.Rear right turn indicator...
Page 131 TUONO V4 R Electrical system 43.ELECTRONIC TRANSMISSION (OPTIONAL EQUIPMENT) 44.SIDE STAND SWITCH 45.GEAR SENSOR 46.FRONT CYLINDER PRESSURE SENSOR 47.REAR CYLINDER PRESSURE SENSOR 48.FRONT CYLINDER THROTTLE 49.REAR CYLINDER THROTTLE 50.AIR TEMPERATURE SENSOR 51.Water Temperature Sensor 52.FALL SENSOR (OPTIONAL EQUIPMENT) 53.7SM CONTROL UNIT 54.HAND GRIP POSITION SENSOR 55.ENGINE SPEED SENSOR 56.COIL...
Page 132 TUONO V4 R Electrical system CONNECTOR CHECK PROCEDURE The procedure includes the following checks: 1. Observation and check of the connector position on the component or on the coupling connector, making sure that the locking catch is released. 2. Observation of the terminals on the connector: no rust marks or dirt should be present and it is important to check terminal correct positioning on the connector (i.e., all terminals aligned at the...
Page 133 TUONO V4 R Electrical system CAUTION! IF THERE IS A GROUND CONNECTION COMING FROM THE CONTROL UNIT, MAKE SURE THAT DURING THE TEST THE CONTROL UNIT IS GROUND CONNECTED TO THE CIR- CUIT. VOLTAGE check Check goal: this control is to check if a cable is energised, i.e. if it receives power supply from the battery or the control unit.
Page 134 TUONO V4 R Electrical system • The read code is not stored in the instrument panel memory Troubleshooting • Carry out key data storage procedure DSB 02 Immobilizer fault • read key code not read (key not present or transponder not working) Error cause •...
Page 135 TUONO V4 R Electrical system 1. Request all the keys of the vehicle in the customer possession. Once the instrument panel is electrically connected to the vehicle and a key is set to ON, the key is stored and the instrument panel waits for 20 seconds for a possible second key. If there is a second key, remove the first key and wait for the storage of the second key.
Page 136 TUONO V4 R Electrical system • Update • CHANGE KEYS • KM / MILES INSTRUMENT PANEL ERRORS In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connec- ted to it. Instrument panel errors In this mode, a chart is displayed showing potential errors in the immobilizer and the sensors connected to it.
Page 137 TUONO V4 R Electrical system This option deletes all instrument panel errors; a further confirmation is requested. Use Navigator to reset ECU errors. VEHICLE SERVICING RESET This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check.
Page 138 TUONO V4 R Electrical system This function is used to reset vehicle servicing. Using this function, the odometer can be reset only once within the first 200 km (124 mi) of the vehicle, provided this has not been done by the Quality Check. In order to activate this function follow the instructions in the DIAGNOSIS section.
Page 139 TUONO V4 R Electrical system Starter switch P0169 • signal not valid. Error cause • Fault in the switch (lock) of the engine start-up. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting •...
Page 140 TUONO V4 R Electrical system CAUTION THERE IS ONE SPARE FUSE (I). Control unit Removal • Remove the fuel tank. • Disconnect both control unit connec- tors • Unscrew and remove the three screws. • Remove the control unit. NOTE WHEN REFITTING THE CONNECTORS, THE SLIDES MUST MOVE FREELY TO THE END OF STROKE, WHICH HELPS WITH THE INSERTION OF THE CONNECTOR: YOU MUST HEAR THE RELEASE OF THE RETAINING TANG AT THE END OF STROKE.
Page 141 TUONO V4 R Electrical system CONTROL UNIT - Diagnosis Function it controls the Ride by wire system, the injection/ ignition, the system safety checks and the self-di- agnosis function Level in electrical circuit diagram: Each level in which the main component involves the control unit Location: •...
Page 142 TUONO V4 R Electrical system Adjustable fuel supply Adjustable fuel correction CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGIN- NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: STATUSES Engine status •...
Page 143 TUONO V4 R Electrical system • The stop light logic relay (No 22 in the wiring diagram, position in the front niche of the frame, right side, CHECK, however, the identification of the relay with the colour of the cables) is energised Error clearing Ambient parameter reading...
Page 144 TUONO V4 R Electrical system • circuit not operational Error cause • Replace injection ECU Stop lights relay error P0610 • short circuit to positive/ short circuit to negative / open circuit Error cause • If shorted to positive: excessive voltage has been detected at PIN 31. If shorted to negative: no voltage has been detected.
Page 145 TUONO V4 R Electrical system • This indication appears only if the Level 2 safety has reset the engine (C gravity). The in- strument panel does not indicate the presence of this error even in the ATT status Troubleshooting • Continue fault search for the other errors detected.
Page 146 TUONO V4 R Electrical system out of scale (check with diagnosis instrument) or current errors have been probably detected by the control unit: solve these malfunctions and repeat the procedure Battery Function Supply electricity to the vehicle from the battery YT 12A - BS that must be activated and charged.
Page 147 TUONO V4 R Electrical system • If too high: too high a voltage has been detected at PIN 42. If too low: too low a voltage has been detected at PIN 42. The instrument panel does not indicate the presence of this error even in the ATT status.
Page 148 TUONO V4 R Electrical system Sensor or its circuit malfunction are not detected by the control unit. In case of incorrect or missing speed indication on the instrument panel, carry out troubleshooting indicated below. Troubleshooting Check the speed sensor connector, the engine-vehicle cable harness and the VEHICLE connector of the Marelli control unit, specially at PIN 79: if not OK, restore;...
Page 149 TUONO V4 R Electrical system NING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER. DIAGNOSIS INSTRUMENT: STATUSES Synchronised panel • No_under analysis_standby_Yes DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS CAUTION IF THE ELECTRIC CIRCUIT IS INTERRUPTED OR SHORT-CIRCUITED, NO ERROR IS DIS- PLAYED.
Page 150 TUONO V4 R Electrical system • Unscrew and remove the nut and the stud bolt. • Retrieve the washers. • Move the hand grip position sensor, disconnect the two connectors. • Remove the hand grip position sensor. NOTE WHEN REFITTING, REMEMBER NOT TO INVERT THE CONNECTORS.
Page 151 TUONO V4 R Electrical system • on the vehicle: front left part, next to the cooling liquid radiator • connector: on the sensor Electrical specifications • Not detected by a multimeter as they are contactless: read the voltage of the 4 tracks by the diagnosis instrument Pin out: BLUE connector...
Page 152 TUONO V4 R Electrical system • Example value with key ON: 3555 mV • Example value with engine on: - Voltage value times 2 of the upper potentiometer track D Throttle grip position sensor • Example value with key ON: 1107 mV •...
Page 153 TUONO V4 R Electrical system lated, restore the wiring. If it is ground insulated, and with the key set to ON, check that there is power supply for the potentiometer PIN A and that PIN C is connected to ground. If both are correct, replace the throttle grip sensor;...
Page 154 TUONO V4 R Electrical system • if the circuit is open, shorted to negative: carry out the open circuit, shorted to negative: check the throttle grip sensor connector and the Marelli control unit connector. If not OK, restore. If OK, check circuit continuity between the two cable terminals. If not OK, restore; if OK, check the cable ground insulation (from the throttle grip sensor connector or the control unit connector): if the cable is not ground insulated, restore the wiring.
Page 155 TUONO V4 R Electrical system • Check the parameters of the blue lower connector Throttle Grip Position Sensor - tracks A and B: if one of the two values clearly deviates from 600-1400 mV, it means that this po- tentiometer is defective. Check the throttle grip sensor connector and the control unit connector: if not OK, restore.
Page 156 TUONO V4 R Electrical system Intake pressure sensor Function The pressure sensors (one per bank), are funda- mental for calculation of generated torque, for cal- culation of ambient pressure and for correct ignition timing during start-up. Operation / operating principle Diaphragm sensor which translates the diaphragm position into electrical voltage when in contact with the intake air.
Page 157 TUONO V4 R Electrical system • Example value with engine on: 721 mbar • NOTE: pressure estimated by the control unit according to the throttle position Rear Cylinder estimated Intake Pressure (1 and 3) • Example value with key ON: 1004 mbar •...
Page 158 TUONO V4 R Electrical system • If shorted to positive: see that the parameter of the front cylinders air Pressure Sensor on the diagnosis instrument reads approx. 1200 mbar; disconnect the sensor connector: if the value does not vary, it means that the cable is shorted between the control unit connector and the sensor connector: restore the cable harness;...
Page 159 TUONO V4 R Electrical system connector PIN 49 and sensor connector PIN 3 is a few tenths of an Ohm; If it is above that value, restore cable harness. Replace the sensor if it is correct. Error for unexpected air intake in the rear cylinder manifold P0210 •...
Page 160 TUONO V4 R Electrical system • A substantial difference between the estimated pressure and the measured pressure has been detected (for example, the pipe between sensor and throttle body is fully detached/ clogged or squashed). Troubleshooting • Check the pneumatic system between the pressure sensor and the socket to read pressure on the throttle body;...
Page 161 TUONO V4 R Electrical system Engine temperature sensor Function It tells the engine temperature to the control unit to improve its performance and to calculate the en- gine friction for a better estimation of the generated torque. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
Page 162 TUONO V4 R Electrical system • Example value with engine on: 25° C • The temperature value is stored during engine start-up. With key ON, value -40°C is read. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
Page 163 TUONO V4 R Electrical system • Check the sensor connector and the ENGINE connector of the Marelli control unit. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Navigator if the temperature indicated is the same as the engine tem- perature.
Page 164 TUONO V4 R Electrical system Value drawn from the signal read without taking into account any recovery: the value in the exam- ple refers to an open circuit 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 165 TUONO V4 R Electrical system Lambda sensor Function In charge of telling the control unit whether the mixture is lean or rich Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 166 TUONO V4 R Electrical system • Example value with engine on: 0.90 - 1.10mV In closed loop, the value must be close to 1.00 (values not within the 0.90 - 1.10 interval indicate a fault): for example, value 0.75 corresponds to +25% with respect to the reference injection time;...
Page 167 TUONO V4 R Electrical system covery value is displayed instead. The instrument panel does not indicate the presence of this error even in the ATT status. Troubleshooting • shorted to positive: with key set to ON, disconnect the sensor connector and measure PIN 1 voltage on the cable harness side (grey cable): if there is voltage (5 or 12 V), restore the cable harness;...
Page 168 TUONO V4 R Electrical system if not OK, restore the cable harness. If it is OK, check the continuity of the green cable (between the sensor connector PIN 3 and the ENGINE PIN 32) and restore the cable har- ness. WARNING The control unit does not detects the following malfunctions of the oxygen sensor circuit according to the signal: interrupted circuit, shorted to ground or sensor malfunction (for example non variable volt-...
Page 169 TUONO V4 R Electrical system INJECTOR Function To supply the correct amount of petrol at the right timing. Injector coil is excited for the petrol passage to open Level in electrical circuit diagram: Coils and injectors Location: • on the vehicle: on the throttle body •...
Page 170 TUONO V4 R Electrical system activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation Injector cylinder 2 • The injection relay (No. 33 in the wiring diagram, placed under saddle, next to the battery positive, CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the injector cable connected to control unit for 4 ms per second.
Page 171 TUONO V4 R Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the orange/red cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector. •...
Page 172 TUONO V4 R Electrical system • If shorted to negative: disconnect the injector connector, set the key to ON and check if there is a ground connection on the white/purple cable: if there connection, restore the cable har- ness. If there is no connection, replace the injector. •...
Page 173 TUONO V4 R Electrical system Injection load relay Location: • on the vehicle: on the tank. • connector: on right rear frame (4-ways black). Electrical characteristics: PIN 1-2: 0.5 - 1 ohm; PIN 3-4: you do not need to measure the component electrical resistance since it works correctly with suitable supply from the instrument panel only.
Page 174 TUONO V4 R Electrical system • If shorted to positive: check whether the relay electrical specifications are correct by dis- connecting it from the cable harness. If are not OK, replace the relay; if OK, restore the cable harness (Brown/Black cable). •...
Page 175 TUONO V4 R Electrical system Example value with key ON: Current ignition ad- vance Example value with engine on: Indicates the cyl- inder advance where combustion will take place. 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 176 TUONO V4 R Electrical system • If shorted to positive: excessive voltage has been detected at PIN 28 of the ENGINE con- nector. If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 28 of the ENGINE connector. Troubleshooting •...
Page 177 TUONO V4 R Electrical system • If shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable har- ness; if voltage = 0, replace the coil. •...
Page 178 TUONO V4 R 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 (+) 4.
Page 179 TUONO V4 R 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 180 TUONO V4 R 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 Voltage stored in the control unit corresponding to the Limp home position Front throttle lower position...
Page 181 TUONO V4 R Electrical system • carried out/not carried out Indicates whether the self-acquisition process through the diagnosis instrument has/has not been car- ried out: if it has been carried out once, will always be carried out unless EEPROM control unit zero setting is carried out DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS CAUTION...
Page 182 TUONO V4 R Electrical system (from throttle sensor connector or control unit connector). If it is ground insulated, check that there is power (+5 V) at the throttle body connector PIN 2, and that PIN 6 is connected to ground. If both are correct, replace the throttle body potentiometer 1 sensor, front throttle position P0125 •...
Page 183 TUONO V4 R Electrical system • short circuit to positive / short circuit to negative / open circuit, overvoltage, excessive internal temperature. Error cause • If shorted to positive: excessive voltage has been detected at PIN 29 - 41. If shorted to negative: no voltage has been detected.
Page 184 TUONO V4 R Electrical system throttle body connector and control unit connector and check if there is cables continuity; if there is no continuity, restore the cable harness. If there is continuity, with the throttle body connector connected, check that the resistance, from the throttle control unit connector, between PIN 3 and 15 is within 1 and 2.5 Ohm;...
Page 185 TUONO V4 R Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 186 TUONO V4 R Electrical system • Potentiometer 1 and potentiometer 2 do not show a logical value: the sum of the two voltages should be constant. The cause may be a malfunction in one of the two sensors or an ab- normal resistance in one of the two circuits Troubleshooting •...
Page 187 TUONO V4 R Electrical system • A correct throttle rotation cannot be detected given low ambient and engine temperatures: some ice may have formed in the duct (at each key ON). The instrument panel does not indicate the presence of this error even in the ATT status Troubleshooting •...
Page 188 TUONO V4 R Electrical system • Check if the throttle body and the intake duct are clean. If OK, replace the throttle body Front throttle minimum mechanical position self-acquisition P0182 • failed test Error cause • Position of the throttle stop not within the expected field (at each key ON) Troubleshooting •...
Page 189 TUONO V4 R Electrical system ENGINE IS STARTED, THE ACTIVATION IS NOT COMPLETED AND THE STOP LIGHTS DO NOT TURN ON. EVERY 150 KEY-ONs, HOWEVER, THE THROTTLE VALVES ARE FORCED TO ACTI- VATION. IF START-UP IS ATTEMPTED DURING THIS ACTIVATION (WHICH REQUIRES 3 SEC- ONDS), THE ENGINE WILL NOT START.
Page 190 TUONO V4 R Electrical system Error cause • An oil sensor fault is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. There is an error when the general warning light turns on.
Page 191 TUONO V4 R Electrical system • connector: between head cover and fil- ter box on left side (3-ways white con- nector). Electrical characteristics: PIN 64: gear indication: closed circuit (continuity); gear engaged: open circuit (infinite resistance). Gear engaged circuit resistance: 1st gear: 0.8 kohm, 2nd gear 0.5 kohm, 3rd gear 15.0 kohm, 4th gear 6.9 kohm, 5th gear 2.8 kohm, 6th gear 1.5 kohm.
Page 192 TUONO V4 R Electrical system • If shorted to negative: disconnect the sensor connector and with key set to ON, check Grey/ Black cable voltage: if equal to zero, restore the cable harness; if equal to approx. 5 V, replace the sensor (there is short circuit to ground of the Pink/Black cable in the section from the sensor connector to the sensor or inside the sensor).
Page 193 TUONO V4 R Electrical system the sensor and check, with key set to ON, continuity to ground of PIN 2: if there is no con- tinuity, restore the cable harness; if there is, replace the sensor. • Indication on Navigator always pulled: disconnect the terminals from the sensor and check if there is continuity between the two PINS, with clutch released: if there is continuity, replace sensor;...
Page 194 TUONO V4 R Electrical system • Indication on Navigator always down: check the connector: if not OK, restore; if it is OK, disconnect the two terminals from the sensor and check continuity to ground of PIN 1: if there is no continuity, restore the cable harness; if there is, replace the sensor •...
Page 195 TUONO V4 R Electrical system Fall sensor: Normal / Tip over • Indication on Navigator always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: If there is not continuity, replace the sensor;...
Page 196 TUONO V4 R Electrical system • on/off DIAGNOSIS INSTRUMENT: ACTIVATIONS • The fan relay (No. 36 in the wiring dia- gram, placed in the headstock niche, left side; CHECK, however, the identi- fication of the relay with the colour of the cables) is energised for 10 sec- onds.
Page 197 TUONO V4 R Electrical system SAS valve actuator Function Quickly warms up the catalytic converter and keeps the combustion rich in some critical condi- tions Operation / Operating principle The valve coil is excited to open the air passage of the filter box to the exhaust manifold Level in electrical circuit diagram: Secondary air valve and lambda probe Location:...
Page 198 TUONO V4 R Electrical system • If shorted to positive: disconnect the component, set the key to ON, start the vehicle and check if the error symptom is still "shorted to positive": it means that short circuit is between black/white cable and a cable in voltage, therefore restore cable harness; if the error symp- tom is short circuit to ground, it means that short circuit is inside the valve and therefore, you must replace the component.
Page 199 TUONO V4 R Electrical system RUN / STOP switch • Run/Stop NOTES • Indication on Navigator always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the two cables switch - Blue/Green and Yellow/ Red: If there is not continuity, replace the sensor;...
Page 200 TUONO V4 R Electrical system The system consists of a throttle valve with a re- turn spring placed on the exhaust pipe. The valve is closed via two cables actuated by an electric motor, which, in turn, is connected electrically to the instrument panel.
Page 201 TUONO V4 R Electrical system Exhaust butterfly valve • Indefinite/in research/activation with key ON/ in operation/stopped for detected malfunction/ research of zero position. NOTE: If there is no problem, it appears: in operation DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Exhaust butterfly valve stop research P0191 •...
Page 202 TUONO V4 R Electrical system • open circuit, thermal overload protection, shorted to negative, shorted to positive or short circuit between both cables. Error cause • If the circuit is open: too low current has been detected at PIN 36 - 37 of the instrument panel connector.
Page 203 TUONO V4 R Electrical system connector and if there is voltage, restore cable harness; if there is not voltage, replace in- strument panel, if there is not voltage, replace motor. • If shorted to negative, the circuit is open: check the valve connector and instrument panel connector: if not OK, restore;...
Page 204 TUONO V4 R Electrical system CAUTION BEFORE PERFORMING THIS OPERATION, CHECK THAT THE BATTERY VOLTAGE EXCEEDS 12.5 V EXHAUST THROTTLE VALVE CALIBRATION • Slacken the exhaust throttle valve ca- ble tension. • From the Adjustable parameters screen, use the diagnostic instrument to select: Acquire exhaust valve zero position •...
Page 205 TUONO V4 R Electrical system wise the failure of the following regula- tion carried out with the instrument). • Tightening the lower cable will proba- bly have caused the travel limit to shift: repeat the procedure until the correct position is obtained. •...
Page 206 PIN1 - Signal • PIN2 - Ground DIAGNOSIS INSTRUMENT: STATUSES Quick shift (electronic transmission) control status: Activated released. Aprilia Quick Shift: Present/Not present DIAGNOSIS INSTRUMENT: ELECTRICAL ERRORS Quick Shift sensor (electronic transmission) P0462. • Shorted to negative (upon key-ON)/Signal not valid.
Page 207 TUONO V4 R Electrical system Engine pinout key: Cylinder 4 coil control output PIN 1 Cylinder 3 coil control output PIN 2 Front throttle motor output (+) PIN 3 Analogue ground connection 2 PIN 4 Power ground connection 1 PIN 5 Analogue ground connection 1 PIN 6/17 Cylinder 1 injector control output PIN 8 Lambda sensor input (+) PIN 10...
Page 208 TUONO V4 R Electrical system Front throttle motor output (-) PIN 15 Power ground connection 2 PIN 16 Engine speed sensor input (-) PIN 20 Input for front throttle potentiometer 2 signal PIN 21 Lambda sensor input (-) PIN 22 Track C hand grip input PIN 23 Rear cylinder intake pressure sensor input PIN 24 Reference voltage output + 5 V: tracks A-C, rear throttle and pressure sensor PIN 25/51...
Page 209 TUONO V4 R Electrical system Vehicle pinout key: Clutch sensor input PIN 56 Analogue ground connection 2 PIN 57 "Start engine" switch input PIN 58 Electric fan relay control output PIN 61 Reference voltage output + 5V: tracks B-D and front throttle PIN 63 Neutral input PIN 64 Fall sensor input (IF APPLICABLE) PIN 65 CAN L line (high speed) PIN 66...
Page 210 TUONO V4 R Electrical system Vehicle speed input PIN 79 CAN H line (high speed) PIN 80 Engine - vehicle connector pinout key: Key PIN 1A Vehicle speed PIN 2A STOP lights relay control output PIN 3A - PIN 4A - PIN 5A - PIN 6A Analogue ground connection 2 PIN 7A...
Page 211 TUONO V4 R Electrical system Dashboard Grey-bodied instrument panel pinout key: 1 +Key 2 Right turn indicator control 3 Exhaust valve potentiometer power supply ELE SYS - 211...
Page 212 TUONO V4 R Electrical system 4 High beam lights input 6 Select 3 (Set) 7 Select 2 (Down) 8 Select 1 (Up) 9 Low fuel sensor 10 Exhaust valve potentiometer signal input 11+ Battery 12 Left turn indicator control 13 * 14 * 15 * 16 Indicator reset...
Page 213 TUONO V4 R Electrical system 25 * 26 CAN H 27 CAN L 28 ABS warning light input (if present) 29 * 30 Sensors ground connection 31 +Battery 32 Rear left turn indicator activation 33 Rear right turn indicator activation 34 Aerial 1 35 Low beam light relay activation 36 Exhaust valve A control output...
Page 214 TUONO V4 R Electrical system In order to transmit, every nod must first check that the BUS (the connection among all devices) is free before attempting to send a message with BUS (Carrier Sense). If during this period there is no activity on BUS, every nod has the same chance to send a message (Multiple Access).
Page 215 TUONO V4 R Electrical system • No communication on CAN line (PIN 66 and/or PIN 80): problem on the whole network (for example, battery cut-off or short circuited or shorted to ground). Troubleshooting • check the Marelli control unit VEHICLE connector and the engine-vehicle cable harness connector: if not OK, restore;...
Page 216 If there is no signal, no signal is received from the inertia sensor platform (Sensor Box control unit). Troubleshooting • With the diagnosis instrument carry out the specific adjustment that sets "NO PRESENT" to the Aprilia Traction Control Performance (in turns) status. Rear wheel radius acquisition P0510 • CAN error during acquisition/Invalid value. Error cause •...
Page 217 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 218 TUONO V4 R Engine from vehicle ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Threaded spacer 8 Nm (5.9 lbf ft) TSPEI screw M6x35 10 Nm (7.38 lbf ft) Loct. Self-locking nut 25 Nm (18.44 lbf ft) Gearbox linkage joint to gearbox lev- 8 Nm (5.90 lbf ft)
Page 219 TUONO V4 R Engine from vehicle ENGINE pos. Description Type Quantity Torques Notes Pinion protector casing fixing screws 8 Nm (5.9 lbf ft) Gearbox lever pin fixing screw 10 Nm (7.37 lbf ft) Gearbox lever fixing screws 10 Nm (7.37 lbf ft) Vehicle preparation Proceed as follows to remove from the chassis: •...
Page 220 TUONO V4 R Engine from vehicle See also Fairing mounting panels Lower cowl Radiator cover Fuel tank Exhaust Twistgrip position sensor Air box Removing Side stand Removing the engine from the vehicle • Detach the clutch cable. • Remove the timing sensor. ENG VE - 220...
Page 221 TUONO V4 R Engine from vehicle • Remove the engine oil pressure sen- sor. • Remove the rubber cap. • Unscrew and remove the nut, retrieve the washer and disconnect the starter motor. • Unscrew and remove the screw, re- move the cable grommet and detach the three ground cables.
Page 222 TUONO V4 R Engine from vehicle • Working on the right hand side of the vehicle, detach the exhaust valve con- trol unit connector. • Disconnect the vehicle cable harness/ engine cable harness connector • Unscrew and remove the three screws and remove the pinion cover.
Page 223 TUONO V4 R Engine from vehicle • Loosen the drive chain adjuster screws. • Loosen the rear wheel fixing nut. • Remove the pinion, releasing it from the drive chain. • Remove the side stand. • Remove the two fuel breather pipes •...
Page 224 TUONO V4 R Engine from vehicle • Remove the hand grip position sensor from the chassis. • Disconnect the voltage regulator con- nector. See also Twistgrip position sensor • Disconnect the alternator connector. • Working from the left hand side of the vehicle, unscrew and remove the screw and retrieve the washer.
Page 225 TUONO V4 R Engine from vehicle • Unscrew and remove the three plate fixing screws and remove the plate. • Unscrew and remove the subframe fix- ing screw and retrieve the washer, re- move the radiator subframe. • Disconnect the quick-shift connector (WHERE APPLICABLE).
Page 226 TUONO V4 R Engine from vehicle • Loosen the screw and slide off the gear shift lever and cable harness from the engine. • Working on the left side of the vehicle, undo and remove the two screws. • Working on the right side of the vehicle, undo and remove the two screws.
Page 227 TUONO V4 R Engine from vehicle • Unscrew and remove the screw and retrieve the nut. • Unscrew the upper adjuster screw bushing until it turns no more. • Working on the right side of the vehicle, unscrew and remove the nut and re- trieve the washer.
Page 228 TUONO V4 R Engine from vehicle • Remove the clamps on the saddle mounting. CAUTION PERFORM THE OPERATIONS BELOW AIDED BY A SECOND OPERATOR. • Lower the engine • Lift the front part of the vehicle. • Remove the front stand. •...
Page 229 TUONO V4 R Engine from vehicle • Working from the vehicle left side, in- stall the left upper engine attachment, tightening the three screws. • With the help of a second operator, secure the vehicle chassis with a hoist and onto a front and rear stand and lift the engine to place it in position.
Page 230 TUONO V4 R Engine from vehicle Engine retainer CAUTION AFTER ENGINE ALIGNMENT AND CENTRING ON THE CHASSIS, ASSURE THE CORRECT POSITION BEFORE TIGHTENING TO THE PRESCRIBED TORQUE ALL THE SCREWS IN THE ABOVE MENTIONED ORDER. Working on the left side: •...
Page 231 TUONO V4 R Engine from vehicle • Refit the clamps on the saddle mount- ing. • Place the radiator frame, the washer and tighten the screw, fastening the frame to the engine. • Place the gear lever and tighten the screw.
Page 232 TUONO V4 R Engine from vehicle • Connect the quick-shift connector (WHERE APPLICABLE). • Connect the alternator connector. • Connect the voltage regulator connec- tor. • Position and fix the hand grip position sensor to the chassis. WARNING BEFORE POSITIONING THE DEMAND SENSOR APPLY SOME LOCTITE 243 ON THE SILENT BLOCKS.
Page 233 TUONO V4 R Engine from vehicle • Connect the neutral sensor. • Place the two fuel breather pipes. • Install the side stand. • Place the pinion and insert the trans- mission chain in the seat. • Tighten the rear wheel fixing nut. •...
Page 234 TUONO V4 R Engine from vehicle • Place the two washers and tighten the pinion fixing screw. • Place the pinion cover and tighten the three screws. • Connect the vehicle cable harness / engine cable harness connector. • Working on the right side of the vehicle, connect the exhaust valve control unit connector.
Page 235 TUONO V4 R Engine from vehicle • Place the ground on the frame. • Fit the washer and tighten the nut. • Place the cable grommet and the three cable leads as shown. • Tighten the cable grommet fixing screw. •...
Page 236 TUONO V4 R Engine from vehicle • Connect the timing sensor. • Connect the clutch cable. • Check and adjust the clutch lever clearance with the adjuster screw. • The clutch lever clearance should be between 1-3 mm (0.039 - 0.12 in). ENG VE - 236...
Page 237 INDEX OF TOPICS NGINE...
Page 238 TUONO V4 R 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 239 TUONO V4 R Engine Gearbox Diagram pos. Description Type Quantity Torque Notes Connector drum fastener screw M6x20 10 Nm (7.37 lbf ft) Loct. 243 Bearing retainer plate fixing screw M6x16 10 Nm (7.37 lbf ft) Loct. 243 Flange fixing screws M8x25 25 Nm (18.44 lbf ft) Index lever fixing screw...
Page 240 TUONO V4 R Engine • Remove the Seeger ring. • Remove the water/oil pump control gear. See also Removing the gear selector Disassembling the clutch • Remove the water/oil pump control gear driving pin • Loosen the screw. • Unscrew and remove the six screws. ENG - 240...
Page 241 TUONO V4 R Engine • Screw a M10x120 screw in the secondary shaft hole, from the alternator side, to make it easier to extract the gearbox unit. • Use a rubber mallet to tap on the sec- ondary shaft from the alternator side to detach the gearbox cover from the crankcase.
Page 242 TUONO V4 R Engine • Remove both gearbox shafts from the cover. • Collect the shim washer that is located on the secondary shaft between the shaft and the cover. • Unscrew and remove the screw. • Remove the selector drum. DESMODROMIC GEARBOX CONTROL ROD DRUM ROLLER CAGE, ALTERNATOR SIDE •...
Page 243 TUONO V4 R Engine Checking the primary shaft Characteristic Maximum wear limit for the selection gear grooves 5.3 mm (0.21 in) Minimum wear limit of the pinion side primary shaft seat 24.97 mm (0.98 in) Minimum wear limit of the clutch side primary and secondary shaft seat 19.97 mm (0.79 in) Checking the secondary shaft...
Page 244 TUONO V4 R Engine Checking the forks The purpose of the springs at the end of the gearbox control rods is to reduce vibration and make it easier to engage the gears. Characteristic Maximum selection fork axial clearance 0.5 mm (0.020 in) Minimum wear limit of the selection fork guide pins 6.8 mm (0.27 in) Maximum eccentricity of the two fork guide shafts...
Page 245 TUONO V4 R Engine • Grease the bushings. • Introduce the forks in their respective seats. • Insert the desmodromic gearbox con- trol rod on the cover. • Position the selector drum. • Turn the screw without tightening it. • Position the fork bushings into the grooves on the desmodromic control rod.
Page 246 TUONO V4 R Engine • Position the special tool from the alter- nator side in order to not ruin the edges of the oil seal. • Insert the gearbox unit in the crank- case. Specific tooling 0277308 Guide bushing for secondary gearbox shaft •...
Page 247 TUONO V4 R Engine • Tighten the selector drum screw. • Insert the driving pin on the oil pump shaft. • Install the water/oil pump control gear. • Insert the Seeger ring. • Install the gear sensor, making the pin coincide with the slot on the desmo- dromic control rod.
Page 248 TUONO V4 R 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 Gearbox control rod roller cage fitting punch •...
Page 249 TUONO V4 R 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 250 TUONO V4 R Engine 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. Check the dual starter gear toothing (1) and the freewheel gear (2) to see if the material is dam- aged or deformed.
Page 251 TUONO V4 R 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 252 TUONO V4 R Engine Removing the flywheel cover • Release the clamp and detach the Blow-by pipe. • Unscrew and remove the five screws (1). • Unscrew and remove the two screws (2). • Mark the screws (1 - 2) that have dif- ferent lengths.
Page 253 TUONO V4 R Engine • Remove the flywheel cover. • Block flywheel rotation using the spe- cific tool. • Unscrew and remove the screw. Specific tooling 020848Y Flywheel retainer • Remove the tool for blocking flywheel rotation. • Insert a TCEI M10x20 screw into the crankshaft hole, which will act as a mounting base for flywheel extraction.
Page 254 TUONO V4 R Engine • Remove the flywheel cover. • Remove the circlip, thrust washer and inner sealing ring or replace if they are spoiled or in case of oil leaks. See also Removing the flywheel cover Installing the flywheel •...
Page 255 TUONO V4 R Engine • Turn the five screws (1) and the two screws (2). • Tighten the screws working in stages and diagonally. • Insert the Blow-by system pipe and fasten it with a new clamp. Clutch side LUTCH COVER pos.
Page 256 TUONO V4 R Engine pos. Description Type Quantity Torque Notes Engine timing inspection cap 25 Nm (18.44 lbf ft) Removing the clutch cover • Drain the engine oil. • Unscrew and remove the sixteen peri- metric fixing screws and retrieve the washers •...
Page 257 TUONO V4 R Engine clutch cover • Block clutch bell rotation using the spe- cific tools. • Unscrew and remove the clutch bell fixing nut. Specific tooling 020849Y Clutch retainer • Remove the slipper unit. • Remove the clutch hub. •...
Page 258 TUONO V4 R Engine • Collect the shim washer. • Collect the clutch housing. • Remove the clutch gear that controls the oil/water pumps • Remove the needle cage. ENG - 258...
Page 259 TUONO V4 R Engine • Remove the spacer. • Remove the thrust bearing. Checking the clutch plates Characteristic Maximum clutch plate deformation (in compar- ison to a flat surface) 0.15 mm (0.0059 in) Minimum wear limit of the clutch plate sliding teeth 13.5 mm (0.53 in) Minimum wear limit of the complete clutch...
Page 260 TUONO V4 R 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 261 TUONO V4 R Engine Checking the springs NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL CLUTCH SPRINGS. • Check the springs for damage and, if necessary, replace the them all togeth- • Measure the clutch spring length when unloaded; if necessary, replace the springs all together.
Page 262 TUONO V4 R Engine • Fit the needle cage. • Install the clutch gear, making it mesh with the oil/water pump control gear TURN THE CLUTCH GEAR COLLAR TOWARD THE CLUTCH BELL. • Insert the clutch bell, making it engage with the engine pinion •...
Page 263 TUONO V4 R Engine • Install the clutch hub cam tower. • Position the clutch hub. HOUSE THE THREE CLUTCH HUB CAMS IN THE SPECIFIC CLUTCH HUB CAM TOWER INCLINES. • Fit the three slipper unit clips, offsetting them by 120°. •...
Page 264 TUONO V4 R Engine • Insert the disc with friction material and the black tooth into the bell. CAUTION FOLLOWING THE TECHNICAL UPDATES, THE FIRST DUCT PIPE HAS BEEN MODIFIED. IT IS SATINIZED AND OF DIFFERENT COLOUR FROM THE OTHERS. THIS DISC IS USED IN ALL TYPES OF CLUTCH, IT IS IM- PORTANT TO FIT IT ALWAYS AS THE FIRST DUCT PIPE FROM INSIDE THE ENGINE.
Page 265 TUONO V4 R Engine • Insert the disc covered with the friction material into the bell. • Continue inserting, alternating a metal disc with one with friction material, fin- ishing with a friction material disc with a black tooth. • Place the control rod together with the thrust bearing and the shim washer.
Page 266 TUONO V4 R Engine • Place the thrust plate. CAUTION PAY ATTENTION WHEN REFITTING, RESPECT THE SEQUENCE OF SCREW, CAP, LINING AND SPRING. • Fit the clutch springs. • Fit the screw washers. • Tighten the six screws operating in stages and diagonally.
Page 267 TUONO V4 R Engine Installing the clutch cover • Position the starting transmission gear on the crankcase. • Position the gasket and the two dowel pins in the clutch cover. • Insert the clutch cover, making sure to have correctly engaged the clutch con- trol lever and the rack shaft.
Page 268 TUONO V4 R Engine ALVE COVER pos. Description Type Quantity Torque Notes Head cover fixing screws 10 Nm (7.37 lbf ft) Coil fixing screws 8 Nm (5.9 lbf ft) Loct. 243 Spark plugs 12 Nm (8.85 lbf ft) HEADS pos. Description Type Quantity...
Page 269 TUONO V4 R Engine IMING SYSTEM pos. Description Type Quantity Torque Notes Screws fastening the timing system 30 Nm (22.13 lbf ft) Loct. 243 gear on the intake shaft Skid fastener screws 20 Nm (14.75 lbf ft) Loct. 243 Skid fastener screws M6x18 10 Nm (7.37 lbf ft) Loct.
Page 270 TUONO V4 R Engine INSTALLATION • Install a new gasket in the head cover. • Smear the gasket with suitable seal- ant, in the area indicated in the figure. Recommended products Three bond Sealing paste • Smear the head surface with suitable sealant, in the area indicated in the fig- ure.
Page 271 TUONO V4 R Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150° in the direc- tion of engine rotation (direction of trav- el).
Page 272 TUONO V4 R Engine • Unscrew and remove the camshaft gear screw. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer Repeat the following operations: • move cylinder piston 1 (left rear piston) to TDC; •...
Page 273 TUONO V4 R Engine • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 274 TUONO V4 R Engine • Check that the camshaft gear works properly: if it is damaged or does not move smoothly, replace the timing chain and the camshaft gear. CAMSHAFT LOBES • Check that they do not show blue colouring, cracks or scratches; otherwise, replace the camshaft, gear and chain.
Page 275 TUONO V4 R Engine • Install the intake and exhaust camshafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots). CLEAN THOROUGHLY THE SEATS OF THE GEAR RETAINER SCREWS, ON THE INTAKE CAM- SHAFT.
Page 276 TUONO V4 R Engine • Align the intake camshaft with the spe- cific hole on the U bolt. • Insert the specified pin. Specific tooling 020851Y Camshaft timing pin • Apply Loctite 243 thread lock on the thread of the timing gear fastener screw.
Page 277 TUONO V4 R Engine screw. This screw must be replaced at each reassembly. • Tighten the second camshaft gear fix- ing screw to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock 020851Y Camshaft timing pin 020852Y Crankshaft timing pin •...
Page 278 TUONO V4 R Engine • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150° in the engine rotation direction (direction of travel), in order to align the hole on the intake camshaft with the specific hole on the U bolt;...
Page 279 TUONO V4 R Engine cylinder bank valve springs are decom- pressed. • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Remove the crankshaft locking tool. Specific tooling 020850Y Primary gear lock 020848Y Flywheel retainer •...
Page 280 TUONO V4 R Engine • Unscrew and remove the mobile chain slider screw. • Remove the mobile chain slider. • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fix- ing screws (a - b) from the flywheel side.
Page 281 TUONO V4 R Engine • Remove the front head, slipping it off the stud bolts. • Collect the gasket and the two dowel pins. • Remove the chain tensioner complete with O-ring using the specific tool. • If the O-ring is not on the chain ten- sioner, make sure it was not left in the crankcase seat.
Page 282 TUONO V4 R Engine Front head fitting • Install a new O ring on the chain ten- sioner REPLACE THE O RING UPON EACH REMOVAL. • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in).
Page 283 TUONO V4 R Engine • Install the head. • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order.
Page 284 TUONO V4 R Engine • Install both chain sliders and fasten them with the specific screws. • Turn the crankshaft from the hole on the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC overlap; • Turn the crankshaft 150°...
Page 285 TUONO V4 R Engine NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the front head, bearing in mind that: the exhaust camshaft gear tooth (indicated with a dot) is meshed with the trough of the intake camshaft gear (indicated with two dots).
Page 286 TUONO V4 R Engine • Cut the clamp that binds the chain to the gear. • Position the gear on the camshaft so that the timing hole and the gear fixing screw hole are centred with the gear slot. • Insert the specific timing pin.
Page 287 TUONO V4 R Engine • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock •...
Page 288 TUONO V4 R Engine 020852Y Crankshaft timing pin Rear head Removing camshafts • Remove the rear head cover and the clutch cover. • Move cylinder piston 1 (left rear piston) to the TDC; • Turn the crankshaft 450° (one complete turn + 90°) in the direction of motor rotation (direction of travel).
Page 289 TUONO V4 R Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. •...
Page 290 TUONO V4 R Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin • Block crankshaft rotation using one of the specific tools. • Unscrew and remove the second in- take camshaft gear screw. • Leave the gear on the camshaft. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock...
Page 291 TUONO V4 R Engine If the two camshafts are timed correctly, the intake camshaft gear tooth (indicated with one dot) is meshed with the trough of the exhaust camshaft gear (indicated with two dots). Inspecting camshafts CAMSHAFT TOOTHED WHEEL CHECK •...
Page 292 TUONO V4 R Engine Installing camshafts NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the rear head, remembering that: the intake camshaft gear tooth (indicated with a dot) is inserted in the groove of the exhaust camshaft gear (indicated with two dots).
Page 293 TUONO V4 R Engine • Fit the U bolt and the oil pipe. • Tighten the two U bolt screws (1) and the screw (2) that was not fitted previ- ously. • Align the intake camshaft with the spe- cific hole on the U bolt. •...
Page 294 TUONO V4 R Engine • Remove the two crankshaft and cam- shaft reference pins. • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. •...
Page 295 TUONO V4 R Engine • Turn the crankshaft until the gear screw covered by the head when the hole on the camshaft gear is aligned with the hole on the U bolt, is visible. • Block crankshaft rotation using one of the specific tools.
Page 296 TUONO V4 R Engine • Slide the gear off the intake camshaft. • Block the gear to the timing chain with a clamp. • Unscrew and remove the ten screws (1-2), proceeding in stages and in a crossed pattern. • Retrieve the washers from the screws (2) near the spark plug holes.
Page 297 TUONO V4 R Engine • Remove the camshaft control gear connected with a clamp to the timing chain. • Unscrew and remove the two head fas- tener screws (a - b) from the clutch side. • Loosen the six nuts on the stud bolts, proceeding in the following order 6 - 5 - 4 - 3 - 2 - 1.
Page 298 TUONO V4 R 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. Specific tooling 020883Y Tool for fitting/removing the timing chain tensioner...
Page 299 TUONO V4 R Engine • Compress the chain tensioner com- pletely, making sure that the total length is 40.05 ± 0.5 mm (1.58 ± 0.02 in). • Insert the chain tensioner into the crankcase, being careful to position it correctly. •...
Page 300 TUONO V4 R Engine • Pretighten the six nuts on the stud bolts proceeding in the following order: 1 - 2 - 3 - 4 - 5 - 6. • Then tighten them fully following the same order. • Tighten the two screws according to the sequence (a - b) •...
Page 301 TUONO V4 R Engine NOTE THIS ENGINE HAS CAMSHAFTS OF THE EXHAUST VALVES WITH CLEARANCE RECOVERY. • Install the intake and exhaust camshafts on the rear head, remembering that: the intake camshaft gear tooth (indicated with a dot) is inserted in the groove of the exhaust camshaft gear (indicated with two dots).
Page 302 TUONO V4 R Engine • Fit the U bolts with the nine O rings and locator pins. • Install the oil pipe. • Fit the new washers under the screws (2) near the spark plug holes only. • Tighten the ten screws (1 - 2) working in stages and diagonally.
Page 303 TUONO V4 R Engine 020855Y Lever for engaging the chain tensioner • Block crankshaft rotation using one of the specific tools. • Tighten the gear fixing screw on the camshaft to exactly the torque speci- fied. • Remove the crankshaft locking tool. Specific tooling 020848Y Flywheel retainer 020850Y Primary gear lock...
Page 304 TUONO V4 R Engine 020851Y Camshaft timing pin 020852Y Crankshaft timing pin Valves Valve removal • Remove the head. • Place the head on supporting surface. • Number the valves and their bucket tappets in order to position them correctly upon refitting. •...
Page 305 TUONO V4 R Engine • Remove the cotters using a magnet. • Release the valve springs. • Remove the upper cap and the springs. CAUTION THE INTAKE VALVES HAVE A DOUBLE SPRING WHERE- AS THE EXHAUST VALVES HAVE A SINGLE SPRING. •...
Page 306 TUONO V4 R Engine VALVE STEM DEVIATION Lift up the valve approx. 10 mm (0.39 in) from its seat. Measure the valve stem deviation in two perpen- dicular directions and position the dial gauge as shown in the figure. If the measured deviation exceeds the specified limit, determine if the valve or the guide must be replaced.
Page 307 TUONO V4 R Engine Position the dial gauge at a right angle to the valve head face and measure the eccentricity. If the eccentricity exceeds the specified limit, re- place the valve. Characteristic Valve head eccentricity 0.03 mm (0.0012 in) Coating may get slightly damaged in the indicated area.
Page 308 TUONO V4 R Engine • Fit the caps. • Compress the valve springs with the specific wrench and with the spring compressing tool. • Insert the cotters into the seat Specific tooling AP8140179 Valve spring compressor 020853Y Intake valve spring compressor 020854Y Exhaust valve spring compressor •...
Page 309 TUONO V4 R Engine Crankcase RANKCASES pos. Description Type Quantity Torque Notes Head stud bolts 20 Nm (14.75 lbf ft) Loct. 648 or 270 Special screw for piston cooling oil jet 6 Nm (4.42 lbf ft) Loct. 2045 Crankcase stud bolts 20 Nm (14.75 lbf ft) Loct.
Page 310 TUONO V4 R Engine IGNITION UNIT pos. Description Type Quantity Torque Notes Hex headed nut, cl.10 type 2 ISO M10x1 50 Nm (36.88 lbf ft) Loct. 243 8674 ENG - 310...
Page 311 TUONO V4 R Engine RANKSHAFT pos. Description Type Quantity Torque Notes Connecting rod screws 15 Nm (11.06 lbf ft) + Lubricate the thread 40° + 60° and under the head with Molykote Fastener ring nut for alternator side 100 Nm (73.76 lbf ft) Loct.
Page 312 TUONO V4 R Engine • Unscrew and remove the nut and col- lect the washer • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. ENG - 312...
Page 313 TUONO V4 R Engine • Remove the key on countershaft • Remove the spacer. • Remove the countershaft on the oppo- site side. BALANCING COUNTERSHAFT FITTED ON BUSHINGS • Block crankshaft rotation using the specific tool. Specific tooling 020850Y Primary gear lock ENG - 313...
Page 314 TUONO V4 R Engine • Remove the starting intermediate gear. • Unscrew and remove the nut. See also Removing the clutch cover Removing the flywheel cover • Remove the countershaft from the al- ternator side. • Remove the countershaft gear. •...
Page 315 TUONO V4 R Engine Balancing countershaft fitting • Install the spacer. THE SPACER CHAMFERED SIDE MUST BE FACING THE CRANKCASE. • Install the countershaft gear aligning the references on the countershaft gear and the primary shaft gear. NOTE THE BURIN ON THE PRIMARY SHAFT GEAR TOOTH MUST BE INSERTED INTO THE SLOT IDENTIFIED WITH TWO BURINS ON THE COUNTERSHAFT GEAR.
Page 316 TUONO V4 R Engine • Turn the nut on the countershaft. • Block crankshaft rotation using the specific tool. • Tighten the nut on the countershaft. Specific tooling 020849Y Clutch retainer Main transmission gear removal • Remove the clutch. • Turn the crankshaft and align the ref- erences on the countershaft gear and the primary shaft gear.
Page 317 TUONO V4 R Engine • Unscrew and remove the primary shaft fixing nut. • Remove the crankshaft blocking tool. Specific tooling 020850Y Primary gear lock • Remove the primary shaft gear. Installing the primary drive gear • Install the primary shaft gear correctly in its seat on the crankshaft from the clutch side.
Page 318 TUONO V4 R Engine • Insert the tone wheel on the crank- shaft. The crankshaft and the tone wheel have a bevel that identifies the fitting direction • Tighten the tone wheel fixing screw. • Remove the special tool. Specific tooling 020850Y Primary gear lock Preparation To open the crankcase, first remove the following components:...
Page 319 TUONO V4 R Engine Removing the oil sump Removing the starter motor Balancing countershaft removal Crankcase opening • Position the engine with the heads fac- ing upward, unscrew and remove the screw (24). • Turn the engine with the heads facing downward and loosen the screws in the following order: 23 - 22 - 21 - 20 - 19 - 18 - 17 - 16 - 15 - 14 - 13 - 12 - 11 - 10 - 9 - 8 - 7.
Page 320 TUONO V4 R 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 321 TUONO V4 R Engine • Remove the piston connected to the connecting rod from the cylinder side. • Extract the snap ring, slide off the pin • Mark the piston crown on the exhaust side so as to remember the refitting po- sition.
Page 322 TUONO V4 R 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. • Heat up the crankcase to 150°C (302°...
Page 323 TUONO V4 R Engine CLUTCH-SIDE • Unscrew and remove the bearing re- tainer screw. • Remove the lock. • Heat up the crankcase to 150°C (302° • Position the general tool to pull out bearings. • Remove the bearing. Bushing removal COUNTERSHAFT BUSHINGS •...
Page 324 TUONO V4 R Engine • Use the special tool to remove the semi-bushings. CAUTION CHECK THAT THE ORs ON THE TOOL ARE NOT DAM- AGED. Specific tooling 020861Y Countershaft bushing punch See also Balancing countershaft removal Crankcase opening Crankshaft check Characteristic Maximum crankshaft axial clearance after closing the crankcase...
Page 325 TUONO V4 R Engine Connecting rod check Characteristic Maximum wear limit of the rod small end 17.05 mm (0.671 in) Maximum rod small end radial clearance 0.055 mm (0.0022 in) Maximum axial clearance between the con- necting rod and the crank pin 0.55 mm (0.022 in) Maximum connection rod pin clearance 0.08 mm (0.0031 in)
Page 326 TUONO V4 R Engine WITH CLASS SELECTION Characteristic Minimum piston diameter Class A: 77.961-77.971 mm (3.0693-3.0697 in). Class B: 77.971-77.981 mm (3.0697-3.0701 in) Maximum clearance between the cylinder and piston With piston class A: 0.027-0.045 mm (0.0010-0.0017 in). With piston class B: 0.025-0.043 mm (0.0009-0.0016 in) Maximum wear limit of the pin hole on the pis- 0.055 mm (0.0022 in)
Page 327 TUONO V4 R Engine • if the piston 1 connecting rod is re- placed, the one relative to piston 2 must also be replaced and vice versa; • if the piston 3 connecting rod is re- placed, the one relative to piston 4 must also be replaced and vice versa;...
Page 328 TUONO V4 R Engine A number that indicates the position of the main journal is stamped on the crankcase: 1. flywheel side; 2. central; 3. clutch side RANKCASE CATEGORY Specification Desc./Quantity Class A Bushing seat diameter 52.023 - 52.018 mm (2.0481 - 2.0479 Class B Bushing seat diameter 52.018 - 52.013 mm (2.0479 - 2.0477 Class C...
Page 329 TUONO V4 R Engine 2. flywheel side main journal; 3. centre main journal; 4. clutch side main journal. Choose the bushings used for assembly from the following table RANKSHAFT BUSHINGS WITH REMOVABLE REELS Crankshaft main journal Class A crankcase Class B crankcase Class C crankcase Class A main journal Bushing (blue)
Page 330 TUONO V4 R Engine There are no selection classes for the countershaft bushings, there is only one type. CRANKSHAFT BUSHINGS - CONNECTING RODS Three types of semi-bushing are available: • Blue • • Yellow There are no dimension classes for the crank pins or the connecting rods. As a result, only the two semi-bushing combinations are possible: 1.
Page 331 TUONO V4 R Engine • Position the new bearing with its groove on the outside diameter facing outward with respect to the crankcase. In this way it will be possible to install the bearing retainer in the groove. • Using the suitable tools, fit the bearing in the crankcase until tool stops •...
Page 332 TUONO V4 R Engine • Position the new bearings with their groove on the outside diameter facing outward with respect to the crankcase. In this way it will be possible to install the bearing retainer in the groove. • Using the suitable tools, fit the bearing in the crankcase until tool stops.
Page 333 TUONO V4 R Engine Specific tooling 020861Y Countershaft bushing punch • Shim the crankcase sufficiently in the gearbox area in order to keep it parallel to the work table. • Heat the crankcase to a temperature of 150 °C (302 - °F). •...
Page 334 TUONO V4 R Engine • Place the ring on which the bushing is installed onto the special tool's punch. • Place the adaptor (3) on the ring for centring the bushing. • Place the punch in the crankcase, aligning the slot on the ring of the spe- cial tool with the reference marked on the crankcase exterior.
Page 335 TUONO V4 R Engine Position the sprocket (1) with the smooth side fac- ing outward of the crankshaft. Move the sprocket (1) up against the crankshaft shoulder. Position the sprocket (2) with the smooth side fac- ing the inside of the crankshaft. Move the sprocket (2) up against the crankshaft shoulder.
Page 336 TUONO V4 R Engine • 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. Specific tooling 020858Y Device for holding the pistons in the cylinders •...
Page 337 TUONO V4 R Engine • Tighten the tone wheel fixing screw. • Remove the special tool. Specific tooling 020850Y Primary gear lock Installing connecting rods - pistons The piston rings are different and are assembled with the "R" or "KDN5" markings (for the upper one) and "RN"...
Page 338 TUONO V4 R Engine NOTE THREE TYPES OF PISTON MARKINGS CAN BE FOUND ON THE ENGINE: • PISTON WITHOUT MARKING. • PISTON WITH "A" OR "B" MARKING. • PISTON WITH "AW" OR "BW ACCORDING TO THE TYPE OF PISTON MARKING, SE- LECT THE CORRESPONDING BAND.
Page 339 TUONO V4 R Engine ling on the connecting rod head must face outward of its crank pin. Specific tooling 020856Y Piston installation ring • Remember to couple the connecting rod shank and cap correctly, combin- ing the respective numerical referen- ces.
Page 340 TUONO V4 R 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 341 TUONO V4 R Engine • Turn the engine with the heads facing upward. • Tighten the screw (24). ENG - 341...
Page 342 TUONO V4 R Engine Thermal group YLINDERS PISTON pos. Description Type Quantity Torque Notes Screws fastening water union onto M6x40 10 Nm (7.37 lbf ft) crankcase Lubrication ENG - 342...
Page 343 TUONO V4 R Engine UBRICATION pos. Description Type Quantity Torque Notes Oil filter union fixing screw 30 Nm (22.13 lbf ft) Oil drainage plug 30 Nm (22.12 lbf ft) Oil sump fixing screws M6x30 12 Nm (8.85 lbf ft) Oil sump fixing screws M6x22 12 Nm (8.85 lbf ft) Oil sump fixing screws...
Page 344 TUONO V4 R Engine • Unscrew and remove the four cooling oil pump cover screws • Remove the cooling oil pump cover. • Collect the two dowel pins. • Remove the external rotor from the cover. • Remove the internal oil cooling rotor. •...
Page 345 TUONO V4 R Engine • Remove the lubrication oil pump cover and the intermediate pump casing from the shaft. • Collect the two dowel pins. • Remove the external lubrication rotor. • Remove the internal oil lubrication ro- • Collect the drive spindle. Installing •...
Page 346 TUONO V4 R Engine • Position the external rotor on the lubri- cation pump's internal rotor. • Position the dowel pins. • Position the pump cover and the inter- mediate pump casing on the lubrica- tion pump's external rotor. To check that the intermediate casing is oriented correctly, check the gasket seat.
Page 347 TUONO V4 R Engine • Position the hitch pin on the oil pump control shaft. • Position the oil cooling pump's internal rotor. • Position the dowel pins and the exter- nal rotor on the cooling oil pump cover. • Fit the pump cover on the internal rotor.
Page 348 TUONO V4 R Engine Removing the oil sump • Drain the engine oil. • Unscrew and remove the twelve oil sump screws. • Remove the oil sump. • Remove the metal gasket. • Remove the rose pipe together with the gasket.
Page 349 TUONO V4 R Engine The Blow-by system uses the rotation of the countershaft (1) to separate the engine oil into oil vapour and liquid. The oil vapours exit from the fitting (2) on the alternator cover and enter the air filter box whereas the liquid returns to the oil sump.
Page 350 TUONO V4 R Engine Inspecting the one-way valve • Unscrew and remove the three screws. • Remove the cover together with the two secondary air system valves. ENG - 350...
Page 351 INDEX OF TOPICS P SUPP OWER SUPPLY...
Page 352 TUONO V4 R Power supply Fuel pump Removing • Remove and empty the fuel tank. • Loosen the pipe grommet screw. • Detach the fuel pipe. • Unscrew and remove the screws. • Remove the fuel pump. Injection P SUPP - 352...
Page 353 TUONO V4 R Power supply Diagram key: 1. Control unit position 2. Hand grip position sensor 3. Fall sensor (if fitted) 4. Outlet valve P SUPP - 353...
Page 354 TUONO V4 R Power supply 5. Clutch position sensor 6. Fuel pump (inside the tank) 7. Air temperature sensor 8. Air pressure sensor (MAP) 9. Injectors 10.Coils (spark plug cover) 11.Engine throttle valves 12.Throttle valve position sensor 13.Electric fan 14.Starter motor 15.Gear position sensor 16.Secondary air injection valve 17.Coolant temperature sensor...
Page 355 TUONO V4 R Power supply control unit. The two throttle cables (opening and closing) actuate on a scroll mounted on a shaft and which is sent back to its home position by a return spring. On the shaft covers there are 2 double track potentiometers (4 control tracks) by means of which the torque demand is read (and checked).
Page 356 TUONO V4 R Power supply • Level 2 - comparison between requested torque and estimated torque generated by the engine • Level 3 - a microprocessor controls the correct operation of the regular microprocessor The consequent maintenance operations may be of different gravity according to the level and the defective component: A the malfunction does not affect riding in safety, the warning light turns on, the word Service is dis- played, the signal recovery value considered not reliable is used and the engine works regularly.
Page 357 TUONO V4 R Power supply Removing the throttle body • Completely remove the air filter box. • Disconnect the injector fuel pipe. • Release the snap fit clamp on the col- lars from the engine. NOTE DO NOT RELEASE THE CLAMPS COMPLETELY. LEAVE IN AN INTERMEDIATE POSITION TO FACILITATE REFIT- TING.
Page 358 TUONO V4 R 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 359 TUONO V4 R Power supply Cylinders synchronisation The control unit receives information on the intake pressure in the four ducts from the two pressure sensors: as the control unit knows the timing phase of the cylinders, it can calculate the individ- ual pressure of the four cylinders.
Page 360 TUONO V4 R Power supply The procedure then continues with screws 1 and If it is necessary to intervene on Master screws (1-4), proceed as follows: • Remove the filter casing cover. • Remove the remaining cones by undo- ing the eight screws (1). •...
Page 361 INDEX OF TOPICS SUSP USPENSIONS...
Page 362 TUONO V4 R Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Front wheel spindle nut M25x1.5 80 Nm (59 lbf ft) Front brake disc fixing screws 6 + 6 30 Nm (22.13 lbf ft) Loct. 243 Removing the front wheel •...
Page 363 TUONO V4 R Suspensions • Remove the wheel axle fixing nut. • Retrieve the sealing washer. • Loosen the screws on the wheel axle clamps. • Tap the wheel axle slightly with a rub- ber mallet so that the hole on the op- posite side is exposed.
Page 364 TUONO V4 R Suspensions CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless. If one or both bearings do not fall within the control parameters: •...
Page 365 TUONO V4 R Suspensions • Using a dial gauge, check that the ra- dial (A) and the axial (B) eccentricities of the rim do not exceed the limit value. An excessive eccentricity is usually caused by worn or damaged bearings. Replace the rim if, after replacing the bearings, the value is not within the specified limit.
Page 366 TUONO V4 R Suspensions LUTCH LEVER pos. Description Type Quantity Torque Notes Clutch lever collar fixing screws 10 Nm (7.37 lbf ft) Front fork Diagram SUSP - 366...
Page 367 TUONO V4 R Suspensions RONT FORK ACHS pos. Description Type Quantity Torque Notes TEFL screw (fasten onto Fork Hubs) M6x40 10 Nm (7.37 lbf ft) Screw (Pumping member pin fixing 30 Nm (22.13 lbf ft) to the stem base) Upper cover 20 Nm (14.75 lbf ft) Upper cover locking nut 20 Nm (14.75 lbf ft)
Page 368 TUONO V4 R Suspensions (*) = clockwise (**) = anticlockwise NOTE TO CHECK FOR FRONT FORK FAILURE, MEASURE THE DIFFERENCE BETWEEN THE BEGIN- NING OF THE WHEEL HUB AND THE END OF THE FORK SLEEVE Removing the fork legs • Remove the front wheel.
Page 369 TUONO V4 R Suspensions • Using the appropriate tool fasten the fork in the vice. Specific tooling AP8140149 Protection for fitting operations • 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.
Page 370 TUONO V4 R Suspensions • Using the specific tool, fixed to the pre- loading pipe, compress the spring. • Insert a spanner in the lock nut of the cover. Specific tooling 020888Y Pliers for pre-fill pipe • Unscrew the cap and remove it. •...
Page 371 TUONO V4 R Suspensions • Remove the spring paying attention to drain the oil correctly. • Drain the oil into a container of suitable capacity to collect fluids. DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT. DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE.
Page 372 TUONO V4 R Suspensions • Remove the retainer ring. • Take out the sleeve from the stem using the stem as a hammer puller. • Remove the fixed bushing (1), the movable bushing (2), the ring (3) and the oil seal (4) from the stem. •...
Page 373 TUONO V4 R Suspensions • Remove the pumping member pin. Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
Page 374 TUONO V4 R Suspensions • lower bushing; • piston. If there are signs of excessive wear or damage, replace the affected component. CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE. Replace the following components with new ones: •...
Page 375 TUONO V4 R Suspensions • O-Ring on the cap. Oil level: 110 +/- 2 mm (4.33 - 0.08 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL.
Page 376 TUONO V4 R Suspensions • Lock the stem in a vice without dam- aging the surface. • Protect the bearing tube end with ad- hesive tape. • Lubricate the sliding edges with fork oil or sealing grease. • Fit the dust gaiter, the retainer ring and the dust scraper on the stem.
Page 377 TUONO V4 R Suspensions • Insert the retainer ring in its position. • Fit the dust gaiter with the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices AP8140146 Weight • Insert the pumping member pin in the stem.
Page 378 TUONO V4 R Suspensions • Place the fork vertically. • Insert the washer. • Refill the fork with oil according to the prescribed quantity. • Fit the spring. CAUTION BE CAREFUL WHEN INSERTING THE SPRING SINCE THE COMPRESSED SPIRAL PART MUST BE PLACED DOWN- WARDS.
Page 379 TUONO V4 R Suspensions Specific tooling 020890Y Pumping member stanchion support AP8140147 Spacer tool • Tighten the nut as much as possible. • Insert the cover and tighten until it stops. • Remove the specific tools. • Screw the cover in the sleeve to the prescribed torque.
Page 380 TUONO V4 R Suspensions Oil level: 110 +/- 2 mm (4.33 - 0.08 in) (from the sleeve edge, without a spring and with preload pipe). THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Page 381 TUONO V4 R Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Screws fastening the raiser to the 50 Nm (36.87 lbf ft) steering upper yoke Screws fastening upper U-bolt to 25 Nm (18.43 lbf ft) handlebar Screws fastening upper yoke to stan- 25 Nm (18.43 lbf ft) chions Screws fastening lower yoke to stan-...
Page 382 TUONO V4 R 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 • Undo the counter-lock ring, then undo the lower ring in order to repeat the ad- justment procedure of the steering clearance in the correct way.
Page 383 TUONO V4 R Suspensions • Adjust the preloading of the steering bearings by tightening the lower ring nut to the prescribed torque. • Turn the steering 3-4 times completely from right to left and then check correct tightening torque of such ring nut. •...
Page 384 TUONO V4 R Suspensions Rear EAR WHEEL pos. Description Type Quantity Torque Notes Rear wheel spindle nut M25x1.5 120 Nm (88.5 lbf ft) Screws fastening sprocket on 50 Nm (36.88 lbf ft) sprocket mount Removing the rear wheel • Place the vehicle on its rear service stand.
Page 385 TUONO V4 R Suspensions • Tap the wheel axle slightly to extract the head from its seat. • Make the wheel move forward and re- lease the gearing chain from the sprocket. • Remove the wheel spindle together with the right hand chain tensioner skid.
Page 386 TUONO V4 R Suspensions • Using an Allen spanner on the related seat (1), lock the rotation of the threa- ded pin (2), unscrew and remove the self-locking nut (3) and the threaded pin (2). THE SELF-LOCKING NUTS (3) MUST BE REPLACED EV- ERY THREE SPROCKET REMOVALS.
Page 387 TUONO V4 R Suspensions Checking the rear wheel CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. REAR WHEEL BEARINGS Carry out the check with the bearings fitted on the wheel. ROTATION CHECK • Manually rotate the inside ring of each bearing. Rotation must be constant, smooth and noiseless.
Page 388 TUONO V4 R Suspensions REAR WHEEL RIM • Using a dial gauge, check that the ra- dial (A) and the axial eccentricity (B) of the rim (2) do not exceed the limit val- An excessive eccentricity is usually caused by worn or damaged bearings.
Page 389 TUONO V4 R Suspensions FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn. To check: • Fit the entire final drive unit (6) to the wheel. • Manually rotate the sprocket (7) to right and left, and check the clearance be- tween the flexible couplings (5) and their holder (8).
Page 390 TUONO V4 R Suspensions • Collect the inside spacer (12). Working from the wheel left side: • Take out the left bearing (16) with the specific extractor. Specific tooling AP8140180 Extractor for bushings • Clean the inside of the hub thoroughly. CAUTION WASH ALL THE PARTS WITH CLEAN DETERGENT.
Page 391 TUONO V4 R Suspensions • Remove the left bearing (18) with the specific extractor. • Collect the inside spacer (19). • Remove the right bearing (20) with the specific extractor. • Retrieve the right hand spacer (21). • Clean the inside of the hub thoroughly. CAUTION WASH ALL THE PARTS WITH CLEAN DETERGENT.
Page 392 TUONO V4 R Suspensions Shock absorbers 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) rod to chassis SUSP - 392...
Page 393 TUONO V4 R Suspensions Adjusting SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE AUTHORISATION OF THE RELEVANT AUTHORITIES. REAR SHOCK ABSORBER - STANDARD ADJUSTMENT FOR USE ON ROAD Specification Desc./Quantity Length of (preloaded) spring (A)
Page 394 TUONO V4 R Suspensions NOTE TO CHECK FOR REAR FAILURE, MEASURE THE DIFFER- ENCE BETWEEN THE FOLLOWING TWO FIXED POINTS: • CENTRE OF THE FRONT SCREW FASTEN- ING THE LICENSE PLATE HOLDER TO UN- DERTAIL SECTION AND • UPPER CORNER OF THE SCREW FASTEN- ING THE REAR STAND PIN ON THE SWING- Removing •...
Page 395 TUONO V4 R Suspensions Linkages Removing • Working from the left side of the vehicle, loosen and remove the nut (1). • Slide off the screw (2) from the opposite side. • Loosen and remove the nut (3). • Slide off the screw (4) from the opposite side. •...
Page 396 TUONO V4 R Suspensions UPON REFITTING, GREASE THE FULCRUM POINTS ON THE CONNECTING ROD ASSEMBLY. PAY SPECIAL ATTENTION TO THE CORRECT POSITIONING OF THE PARTS AND CHECK SEV- ERAL TIMES THAT JOINTS MOVE SMOOTHLY. SUSP - 396...
Page 397 INDEX OF TOPICS CHAS HASSIS...
Page 398 TUONO V4 R Chassis RONT CHASSIS pos. Description Type Quantity Torque Notes Upper rear mount 50 Nm (36.88 lbf ft) Threaded intake duct fastener pins 2 + 2 4 Nm (2.95 lbf ft) Loct. 243 Intake duct fixing nuts 2 + 2 Manual Front mounts 2 + 2...
Page 399 TUONO V4 R Chassis EAR CHASSIS pos. Description Type Quantity Torque Notes Saddle mounting fixing screws 50 Nm (36.88 lbf ft) Screws fastening oil radiator mount- 8 Nm (5.9 lbf ft) ing bracket to engine Passenger saddle and saddle cover 8 Nm (5.9 lbf ft) catch plate fixing screws Swinging arm...
Page 400 TUONO V4 R Chassis EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm adjuster screw bushing M30x1.5 12 Nm (8.85 lbf ft) Swingarm ring nut M30x1.5 60 Nm (44.25 lbf ft) Swingarm pin nut M20x1.5 65 Nm (47.94 lbf ft) AGIP GREASE Chain casing fixing screws 4 Nm (2.95 lbf ft)
Page 401 TUONO V4 R Chassis • Working from the right side, loosen and remove the locking ring nut. • Turn the swingarm pin (2) anticlock- wise, which turns and loosens the ad- justment bushing (3) completely. REMOVAL SHOULD BE CARRIED OUT WITH UTMOST CAUTION.
Page 402 TUONO V4 R Chassis • Remove the adjustment bushing from the swingarm pin (2). UPON REMOVING THE REAR SWINGARM PAY ATTEN- TION NOT TO JAM THE GEARING CHAIN. • If necessary, use a specific tool to re- move a pin from the drive chain. •...
Page 403 TUONO V4 R Chassis DO NOT HIT THE BALLS AND/OR THE INTERNAL RING. CHECK THAT ALL PARTS ARE IN GOOD CONDITION, ESPECIALLY THOSE LISTED AS FOL- LOWS. SWINGARM BEARINGS Carry out the check with the bearings fitted on the swingarm. ROTATION CHECK •...
Page 404 TUONO V4 R Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the adjustment bushing (3) to its seat and tighten it manually. CAUTION THE ADJUSTMENT BUSHING (3) MUST NOT PROTRUDE BEYOND THE CHASSIS INTERNAL EDGE. •...
Page 405 TUONO V4 R Chassis • Working from the right hand side of the vehicle, turn the swingarm pin (2) clockwise. This turns the adjustment bushing (3), driving the swingarm in until fully seated. • Tighten the locking ring nut (1). •...
Page 406 TUONO V4 R Chassis • Fit the washer on the screw • Tighten the screw. • Install the rear shock absorber and the linkages. • Fit the rear brake calliper plate. • Fasten the two pipe grommets on the swingarm •...
Page 407 TUONO V4 R Chassis • Move the vehicle forward so as to check vertical oscillation in other posi- tions too. clearance should remain constant at all wheel rotation phases. ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN.
Page 408 TUONO V4 R Chassis FLATTENED OR JAMMED CHAIN LINKS SHOULD BE LUBRICATED AND GOOD OPERATING CONDITIONS RESTORED. THE GEARING CHAIN HAS SEALING RINGS AMONG THE LINKS THAT KEEP THE GREASE INSIDE. ADJUST, LUBRICATE, WASH AND REPLACE THE CHAIN WITH UTMOST CAUTION. CLEANING AND LUBRICATION Do not wash the chain with water jets, steam jets, high-pressure water jets and highly flammable sol- vents.
Page 409 TUONO V4 R Chassis • Unscrew and remove the upper screw fixing the chain slider and retrieve the washer. • Unscrew and remove the lower screw fixing the chain pad and retrieve the washers. • Remove the chain skid (1). Stand CHAS - 409...
Page 410 TUONO V4 R Chassis IDE STAND pos. Description Type Quantity Torque Notes Screws fastening the stand to the 45 Nm (33.19 lbf ft) Loct. 243 chassis Linear switch retainer 4 Nm (2.95 lbf ft) Rear stand bushing fastening screws 7 Nm (5.16 lbf ft) Side stand •...
Page 411 TUONO V4 R Chassis • Remove the side stand. Exhaust XHAUST pos. Description Type Quantity Torque Notes Exhaust manifold flange fixing nuts 13 Nm (9.59 lbf ft) Silencer clamp fixing screw 10 Nm (7.37 lbf ft) Screw fastening silencer to right 25 Nm (18.44 lbf ft) hand footpeg mounting Screw fastening silencer to central...
Page 412 TUONO V4 R Chassis Removing the tail pipe • Loosen the sealing clamp between the exhaust and the central manifold. • Unscrew and remove the front screw fastening the exhaust to the chassis. • Unscrew and remove the upper attach- ment screw fixing the exhaust pipe to the chassis;...
Page 413 TUONO V4 R Chassis Removing the catalytic converter • Remove the exhaust end. • Remove the front exhaust manifold. • Remove the pinion crankcase • Disconnect the lambda sensor con- nector. • Release the oxygen sensor cable har- ness from the clamps. •...
Page 414 TUONO V4 R Chassis • Remove the front underfairings. • Remove the hand grip position sensor control unit. • Unscrew and remove both radiator up- per fixing screws. See also Fairing mounting panels Twistgrip position sensor • Release the springs between the front exhaust manifolds and the catalytic converter •...
Page 415 TUONO V4 R Chassis • Remove the front exhaust manifold. REAR EXHAUST MANIFOLDS • Remove the catalytic converter. • Remove the left rider footpeg. • Unscrew and remove the four nuts fas- tening the rear exhaust manifolds and retrieve the washers. •...
Page 416 TUONO V4 R Chassis Lower cowl • Disconnect the two exhaust butterfly valve control cables • Unscrew and remove the two valve ac- tuator motor screws • Remove the valve actuator motor to- gether with the heat shield. Engine oil cooler CHAS - 416...
Page 417 TUONO V4 R Chassis IL RADIATOR pos. Description Type Quantity Torque Notes Screws fastening oil radiator to 7 Nm (5.16 lbf ft) mounting bracket Removing • Drain the engine oil. • Remove both fairings and the radiator cowl. • Release the clamp and disconnect the right hand radiator pipe.
Page 418 TUONO V4 R Chassis • Unscrew and remove the lower radia- tor retainer. • Remove the radiator, draining com- pletely of oil. CHAS - 418...
Page 419 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 420 TUONO V4 R Braking system Rear brake calliper EAR BRAKE CALLIPER pos. Description Type Quantity Torque Notes Rear brake disc fixing screws 30 Nm (22.13 lbf ft) Loct. 243 Screw fastening odometer sensor 12 Nm (8.85 lbf ft) onto rear brake calliper mounting Rear brake calliper mounting plate 50 Nm (36.88 lbf ft) Loct.
Page 421 TUONO V4 R Braking system Front brake calliper RONT BRAKE CALLIPER pos. Description Type Quantity Torque Notes Front brake calliper fixing screws M10x1.25 2 + 2 50 Nm (36.88 lbf ft) Rear brake disc Removal • Remove the rear wheel. CAUTION TO UNSCREW THE SCREWS (1), USE AN AIR SCREWER GUN TO GIVE A CLEAN BLOW, WHICH WILL DETACH THE...
Page 422 TUONO V4 R Braking system • Unscrew and remove the five brake disc screws (1). • Remove the brake disc (2). UPON REFITTING, APPLY LOCTITE 243 ON THE THREAD OF THE BRAKE DISC SCREWS (1). CAUTION UPON REFITTING, SCREW ALL THE SCREWS (1) MAN- UALLY AND TIGHTEN THEM OPERATING DIAGONALLY FOLLOWING THIS SEQUENCE: A-B-C-D-E.
Page 423 TUONO V4 R Braking system Removal • Remove the front wheel. The following operations refers to a single disc but apply to both. To unscrew the screws (1), use an air screwer gun to give a clean blow, which will detach the screws stuck with LOCTITE 243.
Page 424 TUONO V4 R Braking system Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT SIDE). ALWAYS REPLACE ALL THE PADS FROM BOTH FRONT BRAKE CALLIPERS. REPLACING THE PADS OF ONLY ONE FRONT CALLIPER MAY JEOPARDISE THE VEHICLE STABILITY AND SAFETY, POSING SERIOUS DANGER FOR PEOPLE, OBJECTS AND THE VE- HICLE ITSELF.
Page 425 TUONO V4 R Braking system • Fit the two new pads in the correct po- sition. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CAL- LIPER. • Fit the front brake calliper on the disc. •...
Page 426 TUONO V4 R Braking system • Remove the pin (2) and retrieve the safety spring (3). • Extract the two pads (4) and retrieve the noise damping plates. • If worn, replace the vibration damping plates. AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKAGE.
Page 427 TUONO V4 R Braking system Bleeding the braking system Front If there is air in the hydraulic system, it acts as a bearing, absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking. The presence of air is signalled by the "sponginess"...
Page 428 TUONO V4 R Braking system Rear 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. The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency. CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON-...
Page 429 TUONO V4 R Braking system Front brake pump RONT BRAKE PUMP pos. Description Type Quantity Torque Notes Screw fastening front brake fluid res- 7 Nm (5.16 lbf ft) ervoir to bracket Screw fastening brake fluid reservoir 7 Nm (5.16 lbf ft) mounting bracket to handlebar Screw fastening brake pipe grommet 8 Nm (5.9 lbf ft)
Page 430 TUONO V4 R Braking system Rear brake pump EAR BRAKE PUMP pos. Description Type Quantity Torque Notes Rear brake rod lock nut 12 Nm (8.85 lbf ft) Rear brake pump fixing screws 8 Nm (5.9 lbf ft) Rear brake lever fixing screw 25 Nm (18.44 lbf ft) BRAK SYS - 430...
Page 431 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 432 TUONO V4 R 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 - 432...
Page 433 TUONO V4 R 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 434 TUONO V4 R Cooling system ATER PUMP pos. Description Type Quantity Torque Notes Screws fastening the pump to the M6x25 10 Nm (7.37 lbf ft) crankcase Water pump locking screw M6x35 10 Nm (7.37 lbf ft) Tank to pump fixing nut Flanged M6 12 Nm (8.85 lbf ft) Electric fan...
Page 435 TUONO V4 R 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 are not the same as the hole (2), com- pared to the holes (1), has a different thickness and is therefore fixed from...
Page 436 TUONO V4 R 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. FILLING •...
Page 437 TUONO V4 R Cooling system • Unscrew and remove the two screws fastening the pipe to the engine. • Retrieve the gasket and replace with a new component when refitting. See also Coolant replacement • Drain two litres of oil from the engine block.
Page 438 TUONO V4 R Cooling system • Unscrew and remove the two external pump cover fixing screws. • Unscrew and remove the inner screw. • Remove the pump cover. TO PREVENT IRREPARABLE DAMAGE TO THE PUMP, UNSCREW AND REMOVE THE INNER SCREW BEFORE REMOVING THE COVER.
Page 439 TUONO V4 R Cooling system • Replace, by one, both screws that do not fasten the pump to the crankcase with TCEI M6x35 screws. Start from the one placed on the front side of the vehicle. • Remove the water pump following the previous instructions, without disconnecting the han- dles.
Page 440 TUONO V4 R Cooling system VENT THE CABLE HARNESS FROM COMING INTO CONTACT WITH THE RADIATOR AT HIGH TEMPERATURE AND DAMAGING ITSELF. RADIATOR REMOVAL • Drain off the cooling system. • Remove the front underfairings and the hand grip position sensor •...
Page 441 TUONO V4 R Cooling system • Cut the clamp fastening the cable har- ness to the radiator return pipe on the left hand side. • Release the clamp fastening the return pipe to the radiator pipe UPON REFITTING, REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE.
Page 442 INDEX OF TOPICS BODYW ODYWORK...
Page 443 TUONO V4 R Bodywork EADLAMP pos. Description Type Quantity Torque Notes Screws fastening the headlamp to 3 Nm (1.47 lbf ft) the upper fairing fastener Screws fastening headlamp to front 4 Nm (2.95 lbf ft) fairing BODYW - 443...
Page 444 TUONO V4 R Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Screws fastening the rubber rings to SWP 4.9 3 Nm (2.21 lbf ft) the instrument panel Instrument panel mounting shell fix- SWP 4.9 2 Nm (1.47 lbf ft) ing screws Screws fastening instrument panel 8 Nm (5.9 lbf ft)
Page 445 TUONO V4 R Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Front mudguard fixing screws 4 Nm (2.95 lbf ft) Lug fixing screw 4 Nm (2.95 lbf ft) Screws fastening the lower fairing to 4 Nm (2.95 lbf ft) the lug BODYW - 445...
Page 446 TUONO V4 R Bodywork AILLIGHT pos. Description Type Quantity Torque Notes Taillight fixing screws 3 Nm (2.21 lbf ft) Taillight mounting bracket fixing 4 Nm (2.95 lbf ft) screws Rear turn indicator fixing screws 2.5 Nm (1.84 lbf ft) Taillight cover fixing screws SWP 2.9 0.5 Nm (0.37 lbf ft) LICENSE PLATE HOLDER...
Page 447 TUONO V4 R Bodywork pos. Description Type Quantity Torque Notes Screws fixing side fairings to tank 2 Nm (1.47 lbf ft) Screws fastening side fairings to tail 1 Nm (0.73 lbf ft) fairing Screws fastening the grab handle SWP 3.9 1.5 Nm (1.10 lbf ft) shell Rear screws fastening grab handle...
Page 448 TUONO V4 R Bodywork ELMET COMPARTMENT pos. Description Type Quantity Torque Notes Screws and nuts for fastening li- 4 Nm (2.95 lbf ft) cense plate holder to saddle mount- ing plate Lower saddle mounting fastener fix- 3 Nm (2.21 lbf ft) ing screws Battery bracket fixing screws 2 Nm (1.47 lbf ft)
Page 449 TUONO V4 R Bodywork UEL TANK pos. Description Type Quantity Torque Notes Special screw fastening rider saddle 4 Nm (2.95 lbf ft) to the tank Screws fixing the filler to the tank 4 Nm (2.95 lbf ft) Screws fixing the fuel pump flange to 3 Nm (2.21 lbf ft) the tank Front screws fastening the tank to...
Page 450 TUONO V4 R Bodywork AIRING pos. Description Type Quantity Torque Notes Screws fastening the lower fairing to 3 Nm (2.21 lbf ft) the lower bracket Screws fixing the side fairings to the 1.5 Nm (1.10 lbf ft) side spacers Seat •...
Page 451 TUONO V4 R Bodywork • Remove the passenger seat by raising first the end. • Complete removal by raising and slid- ing the passenger seat. CAUTION WHEN REFITTING, PAY ATTENTION TO CORRECTLY IN- SERT THE GUIDE. • Undo the two screws and remove the saddle.
Page 452 TUONO V4 R Bodywork Instrument panel • Remove the instrument panel mount- ing cover. • Move the instrument panel, removing the rubber rings from the seats on the support. • Rotate the instrument panel connector retainer lever. • Remove the connector. •...
Page 453 TUONO V4 R Bodywork Headlight fairing • Remove the side fairings. • Remove the front rivet. • Remove the windscreen by undoing the screw. • Remove the four rear screws and the two side rivets. BODYW - 453...
Page 454 TUONO V4 R Bodywork • Disconnect the three connectors. • Remove the windshield. Side body panels • Remove the saddle and the passenger saddle. • The operations described below are valid for both side fairings. • Undo and remove the three screws and remove the fairings.
Page 455 TUONO V4 R Bodywork • Unscrew and remove the screw. • Slide the side fairing by pulling it and paying attention to the slots. Fairing mounting panels • Undo and remove the two central screws. • Remove the underfairing. BODYW - 455...
Page 456 TUONO V4 R Bodywork Air box FILTER BOX COVER REMOVAL • Remove the control unit. • Disconnect the air temperature sensor connector. • Move the two rear coil connectors See also Control unit • Unscrew and remove the eight air filter box cover screws.
Page 457 TUONO V4 R Bodywork FILTER BOX BASE • Open the air filter box cover. • Unscrew and remove the air intake duct fixing screws. • Working from both sides, unscrew and remove the air pressure sensor fixing screw. • Disconnect both front coil connectors (cylinders 2 and 4).
Page 458 TUONO V4 R Bodywork • Release the cable harness from the cable grommet on the filter box. • Remove the air filter box base. Rear mudguard • Unscrew and remove the two screws. • Remove the rear mudguard. Lower cowl •...
Page 459 TUONO V4 R Bodywork • Undo and remove the rear screw. • Remove the lug and the radiator pro- tection. Fuel tank • Unscrew and remove the front screw fixing the tank. • Remove the rider saddle. • Unscrew and remove the two rear screws.
Page 460 TUONO V4 R Bodywork • Disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the tank. Front mudguard • Working from both sides, unscrew and remove the two screws. • Remove the front mudguard. Instrument cluster support REMOVAL •...
Page 461 TUONO V4 R Bodywork • Unscrew and remove the five semi- arch brace fixing screws. See also Instrument panel • Separate and remove the two semi- arch braces FITTING • Fit the right semi-arch brace, fixing it to the headstock with two screws. •...
Page 462 TUONO V4 R Bodywork • Fasten the main cable harness to the semi-arch brace with a clamp. • Gather the cables on the right semi- arch brace and fasten them provision- ally with a clamp. • Fit the left semi-arch brace, applying the five coupling screws.
Page 463 TUONO V4 R Bodywork • Join the remaining connectors and ar- range the cable carefully in the space available within the arch brace. Note that there are two pairs of connectors which may be connected incorrectly. The male connector on the cable with the red strip must be connected to the female connector on the longer cable.
Page 464 TUONO V4 R Bodywork Seat • The following operations are valid for both sides. • Unscrew and remove the screw (4). • Remove the rivet (5) placed in the low- er part of the fairing. • Unscrew and remove the screw (6). •...
Page 465 TUONO V4 R Bodywork • Previously take the battery off. • Unscrew and remove the two license plate support screws. • Remove the cover placed under the tail fairing. • Undo and remove the undertail section screw. • Disconnect the arrows connectors. •...
Page 466 TUONO V4 R Bodywork • Unscrew and remove the two rear tail- light screws. • Remove the taillight. • Remove the several electrical compo- nents. • Undo and remove the screw. • Remove the undertail section. Side air deflectors The following procedure is for a single lateral duct but is applicable to both.
Page 467 TUONO V4 R Bodywork DURING REASSEMBLY, THE DUCT MUST BE SEATED CORRECTLY ON THE FRAME TO EN- SURE THAT IT IS FLUSH WITH THE ADJACENT PARTS. See also Headlight fairing BODYW - 467...
Page 468 INDEX OF TOPICS PRE DE DELIVERY...
Page 469 TUONO V4 R 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 470 TUONO V4 R Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
Page 471 TUONO V4 R Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
Page 472 TUONO V4 R Pre-delivery Specific operations for the vehicle • Remove the screw (2). • Remove the plastic cover (1). • Fit the rear pedal in its seat. • Fit the two TCEI M8X45 screws and tighten with a torque wrench to a torque of 18 Nm (13.27 lbf ft) NOTE REPEAT THE STEPS TO FIT THE PASSENGER FOOTPEG ON THE OPPOSITE SIDE.
Page 473 Air filter: 64 Air temperature sensor: 163 Alternator: Battery: 146 Brake: 420–422, 424, 425, 429, 430 Brake calliper: 420, 421 Brake disc: 421, 422 Brake pads: 424, 425 Brake pump: 429, 430 Bulbs: Bushings: CAN line: 213 Catalytic converter: 413 Chain: 13, 406, 408 Clutch: 73, 192, 240, 255–257, 259–261, 267, 288, 295, 311, 314, 316 Coil: 174...
Page 474 Fuel pump: 139, 172, 352 Fuses: 139 Handlebar: 365 Head cover: 65–67, 73, 269, 270, 277, 288, 295 Headlight: 453, 467 Helmet compartment: Identification: 11 Instrument panel: 134, 452, 461 Intake pressure sensor: 156 License plate holder: Linkages: 395 Magneto flywheel: 252, 318 Maintenance: 8, 60 Maintenance Table: Mirrors: 451...
Page 475 Stand: 193, 220, 223, 409, 410 Start-up: 138, 250 Starter motor: 249, 319 Steering damper: 380 Stepper motor: 358 Tank: 64, 220, 459 Throttle body: 65, 66, 177, 357, 358 Transmission: 12, 316, 318 Tyres: 14 Warning lights: Water pump: 318, 343, 436 Windshield: Wiring diagram: 129...

This manual is also suitable for:

Tuono v4 r 2011 Tuono v4 r 2012 Tuono v4 r 2013

APRILIA TUONO V4 R 2010 Service Station Manual

Quick Links

Related Manuals for APRILIA TUONO V4 R 2010

Summary of Contents for APRILIA TUONO V4 R 2010

Page 25: Table Of Contents

Page 27: Torque Notes

Page 28: Torque Notes

Page 34: Nm (2.95 Lbf Ft)

Page 35: Nm (5.16 Lbf Ft)

Page 37: Nm (1.84 Lbf Ft)

This manual is also suitable for:

Table of Contents