APRILIA TUONO R FACTORY 2007 Service Station Manual
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APRILIA TUONO R FACTORY 2007 Service Station Manual

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SERVICE STATION MANUAL
854104
TUONO R_FACTORY

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Summary of Contents for APRILIA TUONO R FACTORY 2007

  • Page 1 SERVICE STATION MANUAL 854104 TUONO R_FACTORY...
  • Page 2 The descriptions and illustrations given in this publication are not binding; While the basic characteristics as described and illustrated in this manual 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 SERVICE STATION MANUAL TUONO R_FACTORY NOTE Provides key information to make the procedure easier to understand and carry out. CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle. WARNING Refers to specific procedures to carry out to prevent injuries to the repairer. Personal safety Failure to completely observe these instructions will result in serious risk of personal injury.

  • Page 4: Index Of Topics

    INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM CLU SYS LUTCH SYSTEM COOL SYS OOLING SYSTEM BODYW ODYWORK PRE DE...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 6: Safety Rules

    TUONO R_FACTORY Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never 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 7: Maintenance Rules

    TUONO R_FACTORY 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 8 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, 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 9 TUONO R_FACTORY Characteristics • Grip the two connectors and disconnect them by pulling them in opposite directions. • If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully with a jet of compressed air. •...

  • Page 10: Vehicle Identification

    • During the first 1000 km (620 miles), never exceed 6000 rpm. AFTER THE SPECIFIED MILEAGE, TAKE YOUR VEHICLE TO AN Official Aprilia Dealer FOR THE CHECKS INDICATED IN THE "AFTER-RUN-IN" TABLE IN THE SCHEDULED MAINTENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
  • Page 11 TUONO R_FACTORY Characteristics Specification Desc./Quantity Kerb weight R 209 kg ( 461 lb) - FACT. 205 kg (452 lb) (with forged wheels, aluminium bolt and carbon bodywork parts) Engine NGINE Specification Desc./Quantity Model V990RR NG Type 60° longitudinal V-twin, 4-stroke, 4 valves per cylinder, 2 over- head camshafts.
  • Page 12 TUONO R_FACTORY Characteristics Specification Desc./Quantity 6º gear ratio 26/23 (secondary) Final drive gear ratio 16/40 Capacities APACITY Specification Desc./Quantity Fuel (reserve included) 18 l (4.76 USgal) Fuel reserve 4 +/- 1 l (1.06 +/- 0.26 USgal) Engine oil oil change: 3700 cm³ (225.78 cu.in) - oil and oil filter change: 3900 cm³...

  • Page 13: Wheels And Tyres

    TUONO R_FACTORY Characteristics Brakes RAKES Specification Desc./Quantity Front: Ø 320 mm (12.59 in) twin floating disc brake, Ø 34 mm (1.34 in) 4-plunger callipers Rear Ø 220 mm (8.66 in) disc brake, calliper with Ø 32 mm (1.25 in) twin plungers Wheels and tyres HEEL RIMS Specification...
  • Page 14 TUONO R_FACTORY Characteristics Tightening Torques ENGINE TO CHASSIS RETAINER Name Torque in Nm Front clamp M10 Rear top and bottom left clamp M10 Rear top and bottom right clamp for adjust. bushing M20x1.5 Rear top and bottom right clamp for counter ring nut M20x1.5 Rear top and bottom right clamp M10 PARTS FIXED TO THE ENGINE Name...
  • Page 15 TUONO R_FACTORY Characteristics FOOTRESTS Name Torque in Nm Driver footrests M8 Passenger footrests M8 REAR SHOCK ABSORBER Name Torque in Nm Shock absorber to chassis retainer M10 CONNECTING RODS Name Torque in Nm Single connecting rod to chassis retainer M10 Single connecting rod/double connecting rod retainer M10 Double connecting rod/swing arm retainer M10 Double connecting rod/shock absorber retainer M10...

  • Page 16: Front Braking System

    TUONO R_FACTORY Characteristics COOLING SYSTEM Name Torque in Nm Water radiator upper support to chassis retainer M6 Electrical fan to water radiator retainer M6 Water radiator to upper support retainer M6 Filler to water radiator retainer M6 Retainer for attaching water radiator side supports to engine coupling spacers M6 Water radiator to side supports retainer M6 Oil radiator support to engine retainer M6...
  • Page 17 TUONO R_FACTORY Characteristics ENGINE OIL RESERVOIR Name Torque in Nm Oil reservoir retainer (nuts) M6 Oil filter shank M20x1.5 Oil drainage plug M8 Oil level pipe retainer M10x1 LOWER SADDLE PILLAR CLAMP Name Torque in Nm Lower clamp to saddle pillar retainer M6 Lower clamp to chassis retainer M5 Rear stand bushing retainer for lower saddle pillar clamp M6 LICENSE PLATE HOLDER...
  • Page 18 TUONO R_FACTORY Characteristics FRONT Name Torque in Nm Front retainer fixing headlight assembly and deflector M5 WINDSHIELD Name Torque in Nm Front fairing retainer M4 RADIATOR SPOILER Name Torque in Nm Retainer for water radiator bottom supports M5 FORK BOTTOM CLAMP Name Torque in Nm Steering lower plate retainer M6...

  • Page 19: Oil Pump

    TUONO R_FACTORY Characteristics Name Torque in Nm Torx ball bearings of propeller shaft /crankcase [clutch side 11 - Loctite 243 (KS)] M6x12 Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)] M6x45 Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)] M6x65 Crankcase [flywheel side (MS)] / crankcase [clutch side (KS)] M6x80...
  • Page 20 TUONO R_FACTORY Characteristics IGNITION SYSTEM AND STARTER MOTOR Name Torque in Nm Camshaft position sensor / front cylinder head M6x15 Starter motor M6x30 Crankshaft position sensor / flywheel cover M6 11 - Loctite 243 Flywheel cover / generator M6x35 Magneto flywheel / freewheel housing / flywheel ring M8x18 30 - Loctite 648 Magneto flywheel / crankshaft M16x30 130 - Loctite 648...
  • Page 21 TUONO R_FACTORY Characteristics • Measurement group "A", dimension as new: bore diam. 97.000 ÷ 97.012 mm (3.81889 - 3.81936 in); wear limits: Max. diam. 97.027 mm (3.81936 in). • Measurement group "B", dimension as new: bore Diam. 97.012 - 97.025 mm (3.81936 - 3.81987 in); wear limits: Max.
  • Page 22 TUONO R_FACTORY Characteristics Check for cracks on the piston and for compres- sion on the piston sliding surface (seizing); Re- place the piston if required. CAUTION SMALL STRIATIONS ON THE PISTON LINER ARE ADMIS- SIBLE. PISTON WEAR LIMITS With an outside micrometer, measure the piston diameter at 10 mm (0.40 in) high, crosswise to the pin axis.

  • Page 23: Piston Rings

    TUONO R_FACTORY Characteristics Piston rings Measure the axial clearance (1) (2) (3) of the pis- ton rings inside the slots. • L-shaped ring: max. wear limit (1) 0.12 mm (0.0047 in). • Tapered ring with protrusion: max. wear limit (2) 0.12 mm (0.0047 in). •...
  • Page 24 TUONO R_FACTORY Characteristics From bottom to top fit the oil scraper ring (5), the tapered ring with protrusion (6) and the L-shaped ring (7); the word "TOP" on the rings must be facing up. CAUTION TURN THE PISTON RINGS SO THAT THE THREE OPENINGS ARE OFFSET AT APPROX. 120°. Crankcase - crankshaft - connecting rod Using a non-aggressive solvent thoroughly clean both sections of the engine crankcase, the ball bear- ings and all the bearing seats.
  • Page 25 TUONO R_FACTORY Characteristics Unscrew and take out the screw (2), the seal washer (3) and the nozzle (4). Check that the conducts are clean at every lubri- cating hole on both crankcase halves and if re- quired, clean them by blowing in a jet of com- pressed air.
  • Page 26 TUONO R_FACTORY Characteristics Clean the seat diameter of the main bushings inside the engine crankcase On the engine crankcase check the measurement group of the main bushings based on the colour marks. THE CRANKSHAFT LOWER MAIN BUSHING, FLYWHEEL SIDE, HAS A LUBRICATION HOLE. CAUTION THE MAIN BUSHING TOLERANCE UNIT IS ALSO MARKED WITH A COLOUR DOT.
  • Page 27 0.020 mm (0.00079 in); CAUTION DO NOT REUSE ENGINE CRANKCASE GASKETS WHICH HAVE BEEN REMOVED. USE NEW APRILIA ORIGINAL GASKETS ONLY. WITH A COMPARATOR, DETERMINE THE CRANKSHAFT AXIAL CLEARANCE AFTER CRANK- CASE HALVES COUPLING. Max. crankshaft axial clearance 0.5 mm (0.020 in). With a comparator, determine the rod small end radial clearance (12).

  • Page 28: Connecting Rods

    TUONO R_FACTORY Characteristics Also check that the material of the following com- ponents is not worn or damaged: Crankshaft keys (13) and grooves. Bearing seat colour. Crankshaft bevel surface (14), flywheel side. Clean off any re- maining LOCTITE from the thread (15) and check that it is in proper conditions.
  • Page 29 TUONO R_FACTORY Characteristics Check countershaft for wear: • main bushings (engine crankcase) area (17); wear limits Min. diam. 31.980 mm (1.25905 in). • supporting bushing areas (clutch cov- er) (18); wear limits Min. diam. 19.990 mm (0.78701 in). IF THIS MAX. RADIAL CLEARANCE ALLOWED IS EXCEE- DED, REPLACE THE WORN OUT COMPONENT.
  • Page 30 TUONO R_FACTORY Characteristics Max. countershaft axial clearance 0.30 mm (0.0012 in). Check the sides of the driving (19) and driven (20) gear teeth for damage or shape alterations. Recommended products chart ECOMMENDED PRODUCTS Product Description Specifications AGIP TEC 4T, SAE 15W-50 Engine oil Use branded oils with performances equal to or exceeding CCMC G-4 A.P.I.

  • Page 31: Index Of Topics

    INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 32 TUONO R_FACTORY Special tools PECIAL TOOLS Stores code Description 8140176 Complete front, rear and central service stands kit AP8146486 Front service stand AP8705021 Rear service stand AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices 8140190 Tool for steering tightening 8140191 Tool to tighten swing arm bolt and engine support...
  • Page 33 TUONO R_FACTORY Special tools Stores code Description 8140145 Fitting tool for Ø 41 mm (1.61 in) sealing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189 AP8140147 Spacer tool 8140148 Spacer / pumping member separating plate 8140149 Cover removal operations 8140150 Perforated rod for pumping member air...
  • Page 34 TUONO R_FACTORY Special tools Stores code Description 0277660 Buffer for fitting oil seal on upper coun- tershaft 0277670 Buffer for fitting oil seal on coolant pump shaft seat 0877257 Buffer for fitting sliding ring on coolant pump shaft seat 0277510 Buffer for removing valve guide 0277210 Buffer for fitting valve guide...
  • Page 35 TUONO R_FACTORY Special tools Stores code Description 0277720 Buffer for crankshaft bushings extractor 0277725 Buffer for fitting crankshaft bushings 0277537 Buffer for fitting countershaft bottom bushings 0277727 Buffer for fitting clutch cover - crankshaft bushings 0277729 Buffer for fitting the clutch cover - lower countershaft bushings 8140177 Spark plug wrench...
  • Page 36 TUONO R_FACTORY Special tools Stores code Description 0277730 Hexagonal bolt for removing flywheel 0240880 Threaded bolt for locking crankshaft at 0277308 Guide bushing for secondary gearbox shaft 8140178 Buffer for fitting - removing pin 8140181 manometer for fuel - oil - compression pressure 8140182 Bushing for rotor bolt...
  • Page 37 TUONO R_FACTORY Special tools Stores code Description 8140156+8140157+0276377 Extractor for clutch cover bushings 0276479 Tool for pump pressure plate AP8140179 Valve spring compressor 8157143 Adhesive for tool panel - RSTV mille 8140183 Hook for lifting engine 8140184 Bushing for removing primary transmis- sion nut 8140185 Hook lever for removing clutch discs...
  • Page 38 TUONO R_FACTORY Special tools Stores code Description 8140188 Engine support 8140186 Piston ring clamp tool 8140197 Perforated bolt for testing fuel pressure 8140205 Camshaft template tool 8140426 Hooks for panel AP8140196+AP8140578 Plurigas (AP8140196 in Italian, AP8140578 in English) AP8140192 Chain fitting kit S-TOOLS - 38...
  • Page 39 TUONO R_FACTORY Special tools Stores code Description AP8140180 Extractor for bushings 8140202 Probes for exhaust fumes analysis 8140267 Sleeve for vacuometer 8140256 Vacuometer 8140424 Wrench for OHLINS forks AP8140199 Tool panel 8140432 Expeller S-TOOLS - 39...
  • Page 40 TUONO R_FACTORY Special tools Stores code Description AP8140187 Engine support stand 8124838 MF Battery charger 0897651 LOCTITE 243 Blue (10 cm³) (0.61 in³) 0899788 LOCTITE 648 green (5 g) (0.011 lb) 0899784 LOCTITE 574 orange 0297434 LOCTITE 767 Anti-Seize 15378 0297433 MOLYKOTE G-N (50 g) (0.11 lb) S-TOOLS - 40...
  • Page 41 TUONO R_FACTORY Special tools Stores code Description 0897330 bp lz multipurpose grease 0297386 SILASTIC 732 RTV (100 g) (0.22 lb) 8116067 LOCTITE 8150 8202222 Generic adhesive film for panel 8140074 Buffer for removing lower countershaft bushings AP8140204 Supports for rear service stand 0277295 Pliers for clic clamps S-TOOLS - 41...
  • Page 42 TUONO R_FACTORY Special tools Stores code Description 0877650 Buffer handgrip 0277265 Extractor for countershaft, main and sec- ondary shaft bearings S-TOOLS - 42...

  • Page 43: Maintenance

    INDEX OF TOPICS MAIN AINTENANCE...

  • Page 44: Maintenance Chart

    TUONO R_FACTORY Maintenance Maintenance chart AT EVERY START-UP Action Warning light indicating error on the instrument panel - check BEFORE EACH RIDE AND EVERY 2000 (1250 Action Brake pad wear - Check and clean, adjust or replace if necessary AFTER-RUN 1000 (625 Action Gearing chain - Check and lubricate or replace if necessary...

  • Page 45: Every 4 Years

    TUONO R_FACTORY Maintenance Action Fork oil - Replacement Fork oil seal - Check and clean, replace if necessary Break pads - Check and replace if necessary Complete piston - Replacement Valve clearance adjustment - Adjust Wheels - Tyres - Check Bolts, nuts and screws tightening - Check and clean, adjust, grease or replace if necessary Suspension - check Brake discs thickness - Check...

  • Page 46: Fuel Filter

    TUONO R_FACTORY Maintenance Fuel filter • Remove the entire fuel pump assembly. UPON REFITTING, REPLACE CLIC CLAMP REMOVED WITH A NEW ONE OF EQUAL SIZE. Specific tooling 0277295 Pliers for clic clamps • Release the clic clamp (1). • Remove the pipe from the filter. •...
  • Page 47 TUONO R_FACTORY Maintenance • If the value of the FRONT CYLINDER PRESSURE parameter is not right, ac- tuate on the by-pass screw on the FRONT CYLINDER. • Observe the residual CO values by opening the analyser valves alternate- ly. If value is not kept around 0.7 - 1.2 % and especially if both values are dif- ferent from each other by more than 0.5 %, operate on the by-pass screws.
  • Page 48 TUONO R_FACTORY Maintenance ferent from each other by more than 0.5 %, operate on the by-pass screws. • Once the CO checking is completed, check that the value of the FRONT CYLINDER PRESSURE and REAR CYLINDER PRESSURE parameters is approximately within the requested field.

  • Page 49: Electrical System

    INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 50 TUONO R_FACTORY Electrical system Components arrangement Key: 1. Engine revolution sensor 2. Lambda probe 3. Camshaft sensor ELE SYS - 50...

  • Page 51: Electrical System Installation

    TUONO R_FACTORY Electrical system 4. Coolant temperature sensor 5. Intake air temperature sensor 6. Fall sensor 7. Vehicle speed sensor 8. Injector 9. Ignition coils 10.Throttle potentiometer (TPS) 11.Intake pressure sensor 12.Starter motor 13.Stepper 14.Generator 15.Recharge voltage 16.Fuel pump 17.Fuel reserve sensor 18.Control unit 19.Front headlamp 20.Rear light...

  • Page 52: General Wiring Diagram

    TUONO R_FACTORY Electrical system General wiring diagram Key: 1. Multiple connectors 2. Fall sensors ELE SYS - 52...
  • Page 53 TUONO R_FACTORY Electrical system 3. High-beam light relay 4. Low-beam light relay 5. Horn 6. Clutch Switch 7. Instrument panel diagnosis 8. Left light switch 9. Instrument panel 10.Right light switch 11.Key switch 12.Front stop switch 13.Rear stop switch 14.Rear right turn indicator 15.Rear light (LED) 16.Rear left turn indicator 17.Auxiliary fuses...
  • Page 54 TUONO R_FACTORY Electrical system 41.Ambient pressure sensor 42.Throttle sensor 43.Double coil 44.Front cylinder spark plug 45.Rear cylinder spark plug 46.Front cylinder injector 47.Rear cylinder injector 48.Camshaft sensor 49.Pick-up 50.ECU 51.Front left turn indicator 52.Front left headlamp 53.Front right headlamp 54.Left headlamp tail light 55.Left headlamp low-beam bulb 56.Left headlamp high-beam bulb 57.Right headlamp high-beam bulb...

  • Page 55: Checks And Inspections

    TUONO R_FACTORY Electrical system Vi Purple Checks and inspections Dashboard Immobilizer The immobilizer system is integrated to the instrument panel electronic card. The card structure should admit instrument panels without immobilizer or with the immobilizer function disabled, to be used in countries where immobilizer systems are not allowed or not fitted.
  • Page 56 TUONO R_FACTORY Electrical system At least one key must be stored, for the next start-ups. If no other keys are inserted within 20 seconds or if there is lack of power or after the fourth key is programmed, the procedure finishes and all the functions of the vehicle and the instrument panel must be enabled (even if only one key has been programmed).
  • Page 57 Diagnosis This function interfaces with the systems present on the motorbike and diagnoses them. To enable this function, enter an access code available only from aprilia service centres. This vehicle code is: 13432 If the code is incorrect, the following message is displayed:...
  • Page 58 TUONO R_FACTORY Electrical system • Incorrect code The instrument panel shows the main menu. Otherwise, the following menu is displayed: • EXIT • ECU DIAGNOSIS • INSTRUMENT PANEL ERRORS • DELETE ERRORS • RESET SERVICE • UPDATE • CHANGE KEYS •...
  • Page 59 TUONO R_FACTORY Electrical system • Error code: DSB 01 Immobilizer failure: Key code not read (Key not present or transponder not working) • Error code: DSB 02 Immobilizer failure: Aerial not working (Open or short-circuited) • Error code: DSB 03 Immobilizer failure: Internal controller failure •...

  • Page 60: Ignition Circuit

    TUONO R_FACTORY Electrical system This function is used when the old CODE is not available and it needs to be changed. In this case, two programmed keys will have to be inserted. After having checked the first key, already inserted, a second key is requested through the message: •...
  • Page 61 TUONO R_FACTORY Electrical system Battery recharge circuit Key: 1. Instrument panel 2. Key switch 3. Flywheel 4. Voltage regulator 5. Main fuses 6. Battery Start-up system check Start-up enabling switch ELE SYS - 61...
  • Page 62 TUONO R_FACTORY Electrical system Key: 1. ECU 2. Right light switch 3. Key switch 4. Main fuses 5. Battery 6. Gear in neutral switch 7. Side stand switch Starter motor check Pick-up input 120 A ELE SYS - 62...
  • Page 63 TUONO R_FACTORY Electrical system Checking the idle speed adj.system Phase resistance 50 Ohm. Stepper is supplied by the control unit. Rotation is divided into fractions called "steps". By varying the opening "steps" it is possible to prop- erly feed the engine to facilitate the start-up pro- cedure and adjust the feeding with cold engine.
  • Page 64 TUONO R_FACTORY Electrical system 8. Right headlamp low-beam bulb 9. Front right headlamp 10.Right headlamp position light 11.Right front turn indicator 12.High-beam light relay 13.Low-beam light relay 14.Instrument panel diagnosis 15.Left light switch 16.Instrument panel 17.Key switch 18.Front stop switch 19.Rear stop switch 20.Right rear turn indicator 21.Rear light (LED)

  • Page 65: Auxiliary Fuses

    TUONO R_FACTORY Electrical system Fuses AUXILIARY FUSES • A - From key to: light relay, stop, horn, tail lights (5A). • B - From key to: turn indicators, instru- ment panel (5A). • C - From battery to: permanent power supply positive to ECU (5A).
  • Page 66 TUONO R_FACTORY Electrical system 8. n.c. 9. n.c. 10.Minimum oil pressure sensor signal - Signal type: Digital input 11.Water temperature sensor signal - Signal type: Analogue input 12.Manifold pressure sensor signal - Signal type: Analogue input 13.n.c. 14.Purge valve control - Signal type: Power output 15.Front cylinder injector 2 control - Signal type: Power output 16.n.c.
  • Page 67 TUONO R_FACTORY Electrical system CONNECTOR B 1. Control unit power supply (ground) - Signal type: Supply 2. Control unit power supply (ground) - Signal type: Supply 3. Fan - Signal type: Power output 4. n.c. 5. Lambda probe heater control - Output type: Power output 6.
  • Page 68 TUONO R_FACTORY Electrical system 26.Stop switch - Output type: Digital input 27.CAN Line (L) - Output type: Communication line 28.CAN Line (H) - Output type: Communication line 29.Fuel pump control - Output type: Power out- 30.n.c. 31.Start-up relay control - Output type: Digital output 32.Control unit power supply - Output type: Power input...

  • Page 69: Throttle Position Sensor

    TUONO R_FACTORY Electrical system Throttle position sensor Mechanically coupled to the throttle so that its out- put voltage depends on the throttle position. Power supply between 4.5 and 5.5 V to be meas- ured between pins 10a and 10c Resistance between VC (10a) and E2 (10c) = 2.87 - 5.33 kOhm Resistance between VTA (10b) and E2 (10c) throt- tle open = 2.87 - 8.41 kOhm...

  • Page 70: Engine Temperature Sensor

    TUONO R_FACTORY Electrical system Engine temperature sensor NTC type sensor (variable resistance, value de- creases as temperature rises). NGINE TEMPERATURE SENSOR Resistance mean value Ohm Specification Desc./Quantity -30 °C (-22 °F) 28000 Ohm -20 °C (-4 °F) 14500 Ohm 0 °C (32 °F) 5500 Ohm 20 °C (68 °F) 2500 Ohm...
  • Page 71 TUONO R_FACTORY Electrical system Oxygen sensor with heater Sensor voltage between 0 and 0.9 V (to be meas- ured between pins 3 and 4) Heater resistance between 12.8 and 14.2 Ohm (to be measured between pins 1 and 2 at 20°C - 68° Supply voltage 12V Injector Injection diagram...

  • Page 72: Bank Angle Sensor

    TUONO R_FACTORY Electrical system 10.Rear cylinder spark plug 11.Front cylinder injector 12.Rear cylinder injector Injector Resistance between 13.8 and 15.2 Ohm. Power supply 12V The pulse signal sent by the control unit activates an electromagnet which attracts an armature that causes the nozzles set on the injector to open.
  • Page 73 TUONO R_FACTORY Electrical system Electric fan circuit Key: 1. ECU 2. Auxiliary fuse (F) 3. Fans 4. Low-beam light relay 5. Horn Connectors Engine rev. sensor Inductive type sensor. It uses a 36-tooth tone wheel. The sensor produces one voltage pulse every 10º rotation to enable the control unit to calculate the engine revs and the crankshaft position.
  • Page 74 TUONO R_FACTORY Electrical system Can line Can system advantages A CAN (controller Area network) line is a connection among the vehicle several electronic devices, organised as a computer network (Internet). The CAN network has greatly simplified the electrical system layout and consequently, its complexity. With this communication line, needless duplication of several sensors present on the motorbike has been obviated.
  • Page 75 TUONO R_FACTORY Electrical system No sensor (besides the "fuel reserve sensor") is connected to the instrument panel which reads directly from the control unit through the CAN line. All sensors/switches are connected to the engine control unit. Instrument panel warning light activation Warning lights are activated by the control unit through the CAN line •...

  • Page 76: Index Of Topics

    INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...

  • Page 77: Vehicle Preparation

    TUONO R_FACTORY Engine from vehicle Vehicle preparation To remove the engine from the chassis proceed as follows: • Remove the saddle. • Remove the fuel tank connected to the throttle body. • Disconnect the cables at both poles (positive / negative) and then remove the battery •...
  • Page 78 TUONO R_FACTORY Engine from vehicle • Unscrew the three fixing screws from the oil reservoir. ENG VE - 78...
  • Page 79 TUONO R_FACTORY Engine from vehicle • Remove the oil reservoir by sliding off the pipe coming from the radiator. • Detach the breather pipes from the compartment. • Detach the oil pipe on the engine crankcase. • Unscrew and remove the fixing screws from the rear brake fluid reservoir and slide down the reservoir, keeping it up- right.
  • Page 80 TUONO R_FACTORY Engine from vehicle • Detach the seal clamp. • Slide off the coolant breather pipe. • Unscrew and remove the expansion tank fixing screws and then remove the tank. • Undo and remove the two fixing screws and remove the voltage regulator. •...
  • Page 81 TUONO R_FACTORY Engine from vehicle • Unscrew the stud bolt fixing the oil pipe clamp to the engine crankcase. • Detach the oil pipe from the right side. • Unscrew and remove the four screws fixing the frame of the oil radiators (for the left side upper screw, lock the in- ternal nut with a spanner).
  • Page 82 TUONO R_FACTORY Engine from vehicle • Remove the entire frame with the oil radiators. • Undo the rear brake pump fixing screws. • Release the clip fixing the pump to the brake lever. • Dismount the radiator lower supports and move the radiator, keeping it up- right.
  • Page 83 TUONO R_FACTORY Engine from vehicle • Dismount the clutch actuator together with the flange. • Remove the pinion crankcase and the guiding plate on the engine crankcase. • Unscrew the bolt fixing the pinion and collect the sealing washers. • Remove the pinion.
  • Page 84 TUONO R_FACTORY Engine from vehicle • Detach the suction pipe on the clutch pneumatic actuator. • Support the engine with a specific stand. • Remove the rear screws fixing the en- gine to the chassis. • Undo the four screws of the engine front attachments.
  • Page 85 TUONO R_FACTORY Engine from vehicle • Move back the adjustment bushings between the engine and the chassis. • Lower the engine completely. Installing the engine to the vehicle • Place the engine on a suitable lower stand. • Lift the engine. •...
  • Page 86 TUONO R_FACTORY Engine from vehicle • Position the rear left spacer and screw the screws to the prescribed torque. • Screw the rear left screw. • Position the front right spacer. ENG VE - 86...
  • Page 87 TUONO R_FACTORY Engine from vehicle • Screw the two screws on the front right attachment. • Screw the four screws on the left side. • Screw the front right bushing to the prescribed torque. • Screw the upper right ring nut to the prescribed torque.
  • Page 88 TUONO R_FACTORY Engine from vehicle • Screw the lower right ring nut to the prescribed torque. • Screw the upper right screw. • Screw the lower right screw. • Tighten the four screws on the right side. • Remove the engine lower stand. •...
  • Page 89 TUONO R_FACTORY Engine from vehicle • Mount the lever support and the rear brake pump and screw the screws to the prescribed torque. • Mount the rear brake lever and screw the screws to the prescribed torque. • Mount the rear brake pump and con- nect it to the brake lever.
  • Page 90 TUONO R_FACTORY Engine from vehicle • Fit the coolant pipes on the radiator and lock them with clamps. • Position the pinion respecting the fit- ting direction. • Fasten the pinion by tightening the fix- ing bolt to the prescribed torque. •...
  • Page 91 TUONO R_FACTORY Engine from vehicle • Fit the clutch actuator together with the flange. • Fit the gearbox lever. • Insert the spark plug tubes. • Connect the connectors correspond- ing to the temperature sensor, timing sensor, engine revolution sensor, side stand safety switch and generator.
  • Page 92 TUONO R_FACTORY Engine from vehicle • Take the radiator towards the engine and reattach the lower supports. ENG VE - 92...
  • Page 93 TUONO R_FACTORY Engine from vehicle • Reattach the connections correspond- ing to the lambda probe, stop light switch and speed sensor. • Connect the engine oil pressure sen- sor. • Attach the fixing clip to the brake lever pump. • Screw again the rear brake pump fixing screws.
  • Page 94 TUONO R_FACTORY Engine from vehicle • Connect the oil pipe from the right side. • Screw the stud bolt fixing the oil pipe clamp to the engine crankcase. • Position the voltage regulator support- ing plate and screw the two fixing screws.
  • Page 95 TUONO R_FACTORY Engine from vehicle • Position the voltage regulator and screw the two fixing screws. • Reattach the general connections. • Position the expansion tank and screw the two fixing screws. • Position the coolant breather pipe. • Position the seal clamp. •...
  • Page 96 TUONO R_FACTORY Engine from vehicle • Fit the oil pipe on the engine crank- case. • Position the oil reservoir. • Screw the three fixing screws of the oil reservoir. • Fix the pipe coming from the radiator with a new clamp and insert it into the housing.
  • Page 97 TUONO R_FACTORY Engine from vehicle • Fit the oil pipes on the engine crank- case and secure them with new clamps. • Remove the protection present on the pipes. • Fit the throttle body. • Screw the clamps on the inlet manifolds. •...
  • Page 98 TUONO R_FACTORY Engine from vehicle • Connect the by-pass pipes coming from the throttle body and the Stepper motor connection. • Tighten the six fixing screws of the throttle body to the airbox. • Fit the airbox cover. • Then position the battery, the fuel tank and the saddle. ENG VE - 98...

  • Page 99: Index Of Topics

    INDEX OF TOPICS NGINE...
  • Page 100 TUONO R_FACTORY Engine Gearbox Diagram Gearbox shafts Disassembling the gearbox • Slide off the shafts on which the gear selector fork slide. ENG - 100...
  • Page 101 TUONO R_FACTORY Engine • Remove the forks of the secondary shaft selector. • Detach the main shaft fork from the guide of the desmodromic. • Remove the selector cylinder. ENG - 101...
  • Page 102 TUONO R_FACTORY Engine • Pull up the selector gear for the third and fourth gears and take out the main shaft fork. • Set the crankcase halves in horizontal position. • Hit the secondary shaft with a plastic hammer so that the two shafts come out their places together with the trans- mission gears.
  • Page 103 TUONO R_FACTORY Engine • Slide off the shim washer and the neu- tral gear of the sixth gear. • Slide off the ball bearing cage and the shim washer. ENG - 103...
  • Page 104 TUONO R_FACTORY Engine • Release the seeger ring. • Remove the fixed gear of the third and fourth gears. • Release the seeger ring. • Slide off the shim washer and the neu- tral gear of the fifth gear. ENG - 104...
  • Page 105 TUONO R_FACTORY Engine Removing the secondary shaft • Remove the shim washer. • Slide off the neutral gear of the first gear, the ball bearing cage and the shim washer. • Slide off the fixed gear of the fourth gear. ENG - 105...
  • Page 106 TUONO R_FACTORY Engine • Release the seeger ring. • Slide off the neutral gears of the third and fourth gears and the related ball bearing cages. ENG - 106...
  • Page 107 TUONO R_FACTORY Engine • Slide off the shim washer. • Release the seeger ring. • Slide off the fixed gear of the sixth gear. • Release the seeger ring. ENG - 107...
  • Page 108 TUONO R_FACTORY Engine • Slide off the shim washer and the neu- tral gear of the second gear. Checking the primary shaft Check the following components for wear: • Needle bearings (1); • Tooth (2) sides of all gears; • Coupling teeth (3) and coupling holes of transmission gears;...
  • Page 109 TUONO R_FACTORY Engine • Triangular-toothed profile (7) of the chain pinion; • The grooves for seeger rings (8) on the secondary and main shafts must be sharp-edged. CAUTION SMALL GREY SPOTS AND NOT VERY DEEP RECESSES ARE ADMISSIBLE UP TO 0.5% OF THE SIDE SURFACE MAXIMUM.

  • Page 110: Checking The Secondary Shaft

    TUONO R_FACTORY Engine Checking the secondary shaft Check the following components for wear: • Needle bearings (1); • Tooth (2) sides of all gears; • Coupling teeth (3) and coupling holes of transmission gears; • Profile for the grooved shafts (4) of the secondary and main shafts;...
  • Page 111 TUONO R_FACTORY Engine • Wear limit (12) Min. diam 24.978 mm (0.98338 in); Allowed eccentricity (13) Max. diam. 0.02 mm (0.0008 in). • Check the inside diameter of the neutral gears of the 3rd, 4th and 6th gears. Wear limit (14) Max. diam. 29.022 mm (1.14181 in). •...
  • Page 112 TUONO R_FACTORY Engine • Fit the seeger ring. • Insert the fixed wheel of the third and fourth gear. • Fit the seeger ring. • Insert the shim washer and the ball bearing cage. ENG - 112...
  • Page 113 TUONO R_FACTORY Engine • Fit the neutral gear of the sixth gear and the shim washer. • Fit the seeger ring. ENG - 113...
  • Page 114 TUONO R_FACTORY Engine Fitting the secondary shaft • Fit the neutral gear of the second gear and the shim washer on the shaft. • Fit the seeger ring. • Fit the fixed gear of the sixth gear. ENG - 114...
  • Page 115 TUONO R_FACTORY Engine • Fit the seeger ring. • Insert the shim washer. • Insert the ball bearing cages of the neutral gears of the third and fourth gears. • Fit the neutral gears of the third and fourth gears. ENG - 115...
  • Page 116 TUONO R_FACTORY Engine • Fit the seeger ring. • Fit the fixed gear of the fourth gear. • Insert the shim washer, the ball bearing cage and the neutral gear of the first gear on the shaft. ENG - 116...

  • Page 117: Assembling The Gearbox

    TUONO R_FACTORY Engine • Insert the shim washer. Assembling the gearbox • Fit the gear shafts on the crankcase. • With a plastic hammer, alternately hit both shafts in order to position them in their seats. ENG - 117...
  • Page 118 TUONO R_FACTORY Engine • Push up the selector gear of the third and fourth gears and fit the fork on the main shaft. • Position the selector forks on the sec- ondary shaft. • Fit the desmodromic into its position. •...
  • Page 119 TUONO R_FACTORY Engine • Position the shafts on which the selec- tor forks slide. Gear selector Removing the gear selector • Before starting the removal operations, engage the sixth gear. • Take out the entire selector shaft. ENG - 119...
  • Page 120 TUONO R_FACTORY Engine • Unscrew the index cap fixing screw. • Lower the gear positioning lever and take out the index cap. • Unscrew the fixing screw of the posi- tioning lever and remove the assem- bly. ENG - 120...
  • Page 121 TUONO R_FACTORY Engine Checking the gear selector Check the axial clearance of the selector forks on the inside of the corresponding grooves of the se- lector gears. Max. wear limit 0.15 mm (0.0059 in). Selector gears - Groove width (1). CAUTION IF WEAR LIMITS ARE EXCEEDED, CHECK THE SELEC- TOR FORKS AND GEARS TO SEE WHICH COMPONENTS...
  • Page 122 TUONO R_FACTORY Engine Reassembling the gear selector • Insert gear position lever spring on the crankcase. • Fit the position lever and tighten the fixing screws to the prescribed torque. • Lower the lever and insert the index cap. • Tighten the index cap fixing screw to the prescribed torque.
  • Page 123 TUONO R_FACTORY Engine • Fit the selector shaft assembly into its position. Starter motor Removing the starter motor • Unscrew the starter motor fixing screws and pull it out of its housing. Removing the idle gear • Remove the magneto flywheel. •...

  • Page 124: Generator Side

    TUONO R_FACTORY Engine • Remove the double start-up gear. • To check the start-up system gears, refer to the FREE WHEEL CHECK section. See also Magneto flywheel removal Fitting the idle gear • Position the start-up double gear. • Fit the intermediate gear. See also Magneto flywheel removal Generator side...
  • Page 125 TUONO R_FACTORY Engine Removing the flywheel cover • Remove the revolution sensor. • Unscrew and take out the screws of the flywheel cover. • Remove the flywheel cover and collect the seal gasket. See also Removing the flywheel cover components Removing the flywheel cover components •...

  • Page 126: Magneto Flywheel Removal

    TUONO R_FACTORY Engine Magneto flywheel removal • Remove the flywheel cover. • Turn the engine anticlockwise with the specific tool in order to take the front cylinder to the top dead centre in the combustion phase. • Remove the front head cover and check that the "IN"...

  • Page 127: Checking The Starter Clutch

    TUONO R_FACTORY Engine • Remove the tongue on the crankshaft. See also Removing the flywheel cover Removing the head cover Checking the starter clutch IF THE DUAL STARTER GEAR TOOTHING IS DEFORMED AFTER STARTING, THE STARTER MOTOR TOOTHING MUST BE CHECKED AS WELL. Check toothing of the start-up double gear (1), in- termediate gear (2) and freewheel gear (3) to see if the material is damaged or distorted.

  • Page 128: Installing The Flywheel

    TUONO R_FACTORY Engine Measure the gear bearings diameter. Start-up double gear: wear limit (4) max. diam. 10.10 mm (0.398 in). Intermediate gear: wear limit (5) max. diam. 10.08 mm (0.397 in). Freewheel gear: wear limit (6) max. diam. 35.07 mm (1.381 in). THE BUSHING INSIDE THE FREEWHEEL GEAR (3) MUST BE INSERTED AND FIXED SO THAT IT CANNOT MOVE FREELY.
  • Page 129 TUONO R_FACTORY Engine • Fit the freewheel on the crankshaft. • Fit the flywheel with flange. • Screw the flywheel fixing screw. • Refit the cover. Flywheel cover installation • Fit the sealing gasket on the crankcase flywheel side. ENG - 129...

  • Page 130: Removing The Clutch Cover

    TUONO R_FACTORY Engine • Fit the flywheel cover using the specific tool. • Tighten the side fixing screws to the prescribed torque. Specific tooling 0277252 Tool for removing ignition cover • Remove the specific tool. • Screw the locking screw with O-ring. •...

  • Page 131: Disassembling The Clutch

    TUONO R_FACTORY Engine Disassembling the clutch • Disconnect the diaphragm from its seat on the crankcase. • Lock the pin with an Allen wrench and unscrew the retaining nut. • Remove the washer, the disc, the dia- phragm and the aluminium disc. •...
  • Page 132 TUONO R_FACTORY Engine • Unscrew the six fixing screws from the clutch plate. • Remove the clutch plate. • Slide off the entire disengaging shaft. • Remove the clutch discs with the spe- cific tools. Specific tooling 8140185 Hook lever for removing clutch discs •...
  • Page 133 TUONO R_FACTORY Engine • This position is marked by aligning the "IN" and "EX" reference marks. • Screw the tool to lock the crankshaft but do not overtighten it. Specific tooling 0240880 Threaded bolt for locking crankshaft at TDC • Check that the crankshaft is firmly locked by turning it in both directions alternately.
  • Page 134 TUONO R_FACTORY Engine • Unscrew and remove the central lock- ing nut. • Remove the clutch locking tool, the spring washer and the clutch hub. • Remove the clutch bell with the thrust ring. ENG - 134...

  • Page 135: Checking The Clutch Plates

    TUONO R_FACTORY Engine • Take the oil pump control gear out of its fitting on the clutch bell. Ppc system • Check the diaphragm (1) for cracks and replace it, if required. Checking the clutch plates • Check the friction discs (1) and the steel discs (2) for signs of cracking as well as distortions (3) by placing them on a flat surface.
  • Page 136 TUONO R_FACTORY Engine Min. wear limit (4) 46.3 mm (1.823 in). Partial replacement (worn discs only) is not allowed. CAUTION IF ONE OR MORE (STEEL OR FRICTION) CLUTCH DISC IS WORN, THE ENTIRE CLUTCH DISC ASSEMBLY (COMPRISING TEN STEEL DISCS AND NINE FRICTION DISCS) MUST BE RE- PLACED.

  • Page 137: Assembling The Clutch

    TUONO R_FACTORY Engine Wear limits (5) Diam. 30.060 mm (1.18346 in). Check the sides of the teeth of the clutch (12) and the control gear (6) for damage or shape altera- tions. CAUTION IF THE CLUTCH GEAR OR CONTROL GEAR IS WORN OUT, THE PRIMARY TRANSMISSION UNIT SHOULD BE REPLACED.
  • Page 138 TUONO R_FACTORY Engine • Fit the thrust ring. • Fit the clutch hub, the spring washer and manually screw the fixing nut • Insert the clutch locking tool on the bell and on the clutch hub. Specific tooling 0277881 Clutch locking tool ENG - 138...
  • Page 139 TUONO R_FACTORY Engine • Screw the fixing nut according to the procedure described. • Remove clutch locking tool. • Unscrew the crankshaft locking tool. Specific tooling 0277881 Clutch locking tool 0240880 Threaded bolt for locking crankshaft at TDC • Lubricate and insert the clutch discs on the bell.
  • Page 140 TUONO R_FACTORY Engine Installing the clutch cover • Position the clutch cover. • Fix the side fixing screws. Head and timing Removing the head cover • Remove the engine from the vehicle. • Dismount the ignition spark plugs • Dismount the phase sensor. •...
  • Page 141 TUONO R_FACTORY Engine • Remove the head cylinder unit. • Unscrew and remove the four shoulder screws joining the head to the cylinder. • Separate the cylinder from the head. • Collect the gasket. See also Removing the cylinder Cylinder head Removing the overhead camshaft •...

  • Page 142: Removing The Valves

    TUONO R_FACTORY Engine NOTE THE BALANCING COUNTERSHAFT IS LOCATED ONLY AT THE REAR HEAD. • Unscrew the two fixing screws of the countershaft supporting plate. • Remove the balancing countershaft. See also Removing the cylinder head Removing the valves • When removing the valve, mark the components according to the position and the cylinder they belong to, in order...
  • Page 143 TUONO R_FACTORY Engine • Remove the bucket tappets and the adjustment shims using a magnet. • Compress the valve springs with the specific tightening bow and with the spring compressing tool. Specific tooling AP8140179 Valve spring compressor • Remove the cotters using a magnet. •...
  • Page 144 TUONO R_FACTORY Engine • Remove the valves. • Remove the oil seal from the valve stem. • Take out the valve spring cap. See also Removing the overhead camshaft ENG - 144...
  • Page 145 TUONO R_FACTORY Engine Checking the overhead camshaft Check the camshaft for damaged, distorted or worn material; replace the camshaft if required. Measure the camshaft clearance: • Set the camshafts in the head. • Apply a plastic gauge (1) on the cam- shaft bearing seats.
  • Page 146 TUONO R_FACTORY Engine Checking the balancing counter shaft CAUTION THE BUSHING SEAT (1) IS SLIGHTLY CONIC, THEREFORE THE MEASUREMENT MUST BE DONE AT THE SEAT CENTRE. Bushing seat (1): wear limit min. diam 34.98 mm (1.377 in); Ball bearing pin (2): wear limit min. diam. 14.97 mm (0.589 in).

  • Page 147: Valve Check

    TUONO R_FACTORY Engine NOTE FROM ENGINE NUMBER 8116303 (NOVEMBER 2003) THE UPPER COUNTERSHAFT AND THE RELATED SUPPORT HAVE BEEN MODIFIED. THE NEW COMPENSATING SHAFT IS NOT INTER- CHANGEABLE WITH PREVIOUS MODELS UNLESS BOTH COMPONENTS- COUNTERSHAFT AND SUPPORT- ARE REPLACED UPPER COUNTERSHAFT: IDENTIFICATION CODE 441 B WITH CYLINDRIC ROLLERS.

  • Page 148: Valve Springs

    TUONO R_FACTORY Engine VALVE SPRINGS Carry out a measurement and a visual inspection of the valve springs for damage, distortion or loss of tension. Measure the spring length at release position. Valve springs: minimum wear limit (6) 43.4 mm (1.709 in). Valve springs: minimum wear limit (7) 40.9 mm (1.610 in).
  • Page 149 TUONO R_FACTORY Engine If the width of the valve seat is not within the wear limits or if the surface is not continuous, the valve seat can be ground. Inspect the surface of the valve seat to check whether: • The seat width is not regular: Replace the valve and grind the valve seat.
  • Page 150 TUONO R_FACTORY Engine • If the faying surface on the valve is too high: Grind valve seats to 35° with a valve grinding device. • If the faying surface on the valve is too low: Grind valve seats to 55° (intake) or to 80°...

  • Page 151: Checking The Valve Guides

    TUONO R_FACTORY Engine Checking the valve guides With a dial comparator measure the valve guide wear (1). Wear limit (2) maximum diameter: 6.05 mm (0.24 in) Replace the valve guide if worn. VALVE GUIDE REMOVAL Slide off the valve stem gasket (3) and take out the valve spring washer (4).

  • Page 152: Checking The Cylinder Head

    TUONO R_FACTORY Engine • With the appropriate buffer insert the new valve guide in the cylinder head going from the oil compartment towards the combustion chamber, until the fitting punch is in flat position. Specific tooling 0277695 Buffer for fitting valve guide oil seal •...

  • Page 153: Installing The Valves

    TUONO R_FACTORY Engine Inspect for potential damage and check that the seal surfaces are even. Maximum distortion allowed:0.03 mm (0.00118 Check that the valve bowl and the guide on the head are in proper conditions. • Bowl hole on the head (1): wear limits: max.
  • Page 154 TUONO R_FACTORY Engine • Lubricate the valve stem and insert the valves on the valve guide. • Fit the valve springs with colour mark- ing facing up. • Fit the caps. • Compress the valve springs with the spring compressing tool and the spe- cific tightening bow.
  • Page 155 TUONO R_FACTORY Engine • Release the wrench, checking that the cotters are positioned correctly in the valve grooves. • Position the adjustment shims and then the bucket tappets. Installing the balancing counter shaft • Place the rear head camshafts, if they have been previously removed.
  • Page 156 TUONO R_FACTORY Engine • Place the countershaft supporting plate. • Tighten the two fixing screws on the plate to the prescribed torque. See also Installing the overhead camshaft Installing the overhead camshaft • Place the camshafts after lubricating their seats with engine oil. •...

  • Page 157: Chain Removal

    TUONO R_FACTORY Engine Installing the cylinder Timing Removing the chain tensioner • Unscrew the locking screws plus the sealing gaskets, and take out the com- plete chain tensioner. Chain removal FRONT CYLINDER • Remove the front cylinder. • Remove the movable chain tensioner pad.
  • Page 158 TUONO R_FACTORY Engine • Take out the intermediate gear. • Collect the washer. • Remove the timing chain. REAR CYLINDER • Remove the rear cylinder. • Remove the alternator. • Remove the movable chain tensioner pad. • Mark the timing chain with a colour dot so as to refit it in the same direction of rotation. •...
  • Page 159 TUONO R_FACTORY Engine See also Magneto flywheel removal Removing the cylinder Removing the chain sliders Removing the chain sliders Removing the chain sliders FIXED CHAIN PADS • Remove the head covers. • Remove the chain tensioners. FRONT CYLINDER • Remove the upper chain guide brack- •...
  • Page 160 TUONO R_FACTORY Engine REAR CYLINDER • Loosen the lock-nut of the countershaft gear with a punch inserted in the coun- tershaft. • During this operation pay attention not to load the timing chain. • Remove the upper chain guide pad. •...

  • Page 161: Checking The Chain

    TUONO R_FACTORY Engine MOBILE CHAIN PADS FRONT CYLINDER • Remove the front cylinder. • Remove the alternator. • Undo the fixing screws on the needle bearing flange. • Remove the flange together with the roller cage. • Slide off the bushing and the movable pad.
  • Page 162 TUONO R_FACTORY Engine Check if there is damage or distortions on the sides of the teeth of the timing system gears (1), on the control gears (2) and on the control inter- mediate gears (3). Check the holes in the intermediate gears (3) for wear.
  • Page 163 TUONO R_FACTORY Engine Max. wear limit (7) 15.98 mm (0.6291 in). Check if there are rolling marks on the chain guide pad (8), the chain tensioner pad (9), the chain guide (10) and the chain guide bracket (11). Rolling marks max. depth 1.2 mm (0.047 in). Check the toothing of the two timing chains (12) for potential distortions.

  • Page 164: Installing The Chain

    TUONO R_FACTORY Engine • Place the flange and the ball bearing cage. • Tighten the fixing screws to the pre- scribed torque. Installing the chain • Insert the timing chain according to the references marked at the removal phase. • Fit the intermediate gear on the engine crankcase.

  • Page 165: Cam Timing

    TUONO R_FACTORY Engine • Turn the crankshaft so that its position matches the front cylinder top dead centre. • Screw the tool to lock the crankshaft but do not overtighten. • Check that the crankshaft is firmly locked by turning it in both directions alternately. •...
  • Page 166 TUONO R_FACTORY Engine • Place the gear of the timing system control of the rear cylinder so that the reference on the intermediate gear is aligned with the reference on the crankcase. • Align the camshafts with the specific tool which is inserted on the eccentrics. •...
  • Page 167 TUONO R_FACTORY Engine FRONT CYLINDER • Remove the crankshaft locking tool. • Turn the crankshaft 300° anticlockwise so that the front cylinder piston reaches the top dead centre in the combustion phase. • Align the reference on the intermediate gear with that on the flange. •...

  • Page 168: Removing The Cylinder

    TUONO R_FACTORY Engine • Insert the toothed wheel on the cam- shaft aligning the 'IN' and 'EX' refer- ence marks. COMBUSTION SEQUENCE Cylinder-piston assembly Removing the cylinder • Unscrew the nuts and remove the cyl- inder coupling brackets. ENG - 168...

  • Page 169: Disassembling The Piston

    TUONO R_FACTORY Engine • Remove the chain sliders. • Unscrew the two screws on the timing system plate. • Remove the nuts on the cylinder stud bolts. • Remove the cylinder and the complete head together paying attention not to damage the piston.

  • Page 170: Fitting The Piston

    TUONO R_FACTORY Engine • Remove the pin. • Mark the piston crown on the exhaust side so as to remember the refitting position. • Remove the piston. See also Removing the cylinder Fitting the piston • Fit the piston. NOTE CHECK THE PISTON DIRECTION ACCORDING TO THE REFERENCES MARKED ON THE PISTON CROWN.

  • Page 171: Installing The Cylinder

    TUONO R_FACTORY Engine • Insert the pin clip. Installing the cylinder • Place the cylinder base gasket. • Fit the piston. • Remove the cloth used to prevent for- eign bodies getting into the crankcase. • Turn the rings so that the connection ends are 120 degrees from each other.
  • Page 172 TUONO R_FACTORY Engine • Fit the nuts on the cylinder stud bolts by tightening them to the prescribed torque. • Tighten the two screws to the timing system plate to the specified torque. • Proceed to time the overhead cam- shafts.
  • Page 173 TUONO R_FACTORY Engine • Unscrew the countershaft nut. • Remove the spring washer and the counterweight. • Unscrew the nut on the crankshaft us- ing the specific tool. • Remove the spring washer and the pri- mary transmission gear from the crankshaft.
  • Page 174 TUONO R_FACTORY Engine • Remove the tongue on the crankshaft. • Remove the upper washer and the control gear of the coolant pump. • Remove the intermediate gear of the coolant pump. • Remove the countershaft lower wash- • Remove the tongue from the counter- shaft.
  • Page 175 TUONO R_FACTORY Engine • - Remove the washer on the crank- shaft. • Remove the seeger ring and the thrust washer of the transmission secondary shaft. • Unscrew and remove the twenty screws coupling the crankcase. • Detach the two crankcase halves by tapping with a hammer.
  • Page 176 TUONO R_FACTORY Engine Removing the crankshaft • Take out the crankshaft. Removing the countershaft • Take out the countershaft. Disassembling the connecting rod • Before removing the connecting rods and the caps mark them so as to refit them in the same position and direction of rotation.
  • Page 177 TUONO R_FACTORY Engine • Unscrew the connecting rod screws. • Remove the caps. Inspecting the crankcase halves Using a non-aggressive solvent thoroughly clean both sections of the engine crankcase, the ball bear- ings and all the bearing seats. Clean the seal surfaces and check that they are not damaged. CAUTION TO AVOID DAMAGING BOTH CRANKCASE HALVES PLACE THEM ON A FLAT SURFACE.
  • Page 178 TUONO R_FACTORY Engine Unscrew and take out the screw (2), the seal washer (3) and the nozzle (4). Check that the conducts are clean at every lubri- cating hole on both crankcase halves and if re- quired, clean them by blowing in a jet of com- pressed air.
  • Page 179 TUONO R_FACTORY Engine Clean the seat diameter of the main bushings inside the engine crankcase On the engine crankcase check the measurement group of the main bushings based on the colour marks. THE CRANKSHAFT LOWER MAIN BUSHING, FLYWHEEL SIDE, HAS A LUBRICATION HOLE. THE MAIN BUSHING TOLERANCE UNIT IS ALSO MARKED WITH A COLOUR DOT.
  • Page 180 (7); max. wear limit 0.020 mm (0.00079 in). CAUTION DO NOT REUSE ENGINE CRANKCASE GASKETS WHICH HAVE BEEN REMOVED. USE NEW APRILIA ORIGINAL GASKETS ONLY. WITH A COMPARATOR, DETERMINE THE CRANKSHAFT AXIAL CLEARANCE AFTER CRANK- CASE HALVES COUPLING.
  • Page 181 TUONO R_FACTORY Engine IF THIS MAX. RADIAL CLEARANCE ALLOWED IS EXCEEDED, REPLACE THE WORN OUT COM- PONENT. Also check that the material of the following com- ponents is not worn or damaged: Crankshaft keys (9) and grooves. Bearing seat colour. Crankshaft bevel surface (10), flywheel side.

  • Page 182: Checking The Connecting Rod

    TUONO R_FACTORY Engine Min. radial clearance allowed 0.060 mm (0.00236 in) Radial clearance is derived from the following values: the maximum inside diameter value of the (clutch cover) supporting bushings minus the diameter value of the related supporting bushing (2) areas on the countershaft. Measure the supporting bushings (clutch cover) inside diameter.
  • Page 183 TUONO R_FACTORY Engine BLUE bushing: Thickness 1.476 - 1.481 mm (0.05811 - 0.05830 in) YELLOW bushing: Thickness 1.481 - 1.486 mm (0.05830 - 0.05850 in) Assembling the connecting rod • Fit the caps on the connecting rods re- specting the reference marks done at the removal stage.

  • Page 184: Installing The Crankshaft

    TUONO R_FACTORY Engine Installing the crankshaft • Lubricate the crankshaft pins and in- sert them into their positions. Refitting the crankcase halves • Fit the crankshaft, the complete transmission and the countershaft in the crankcase half. • Fit the sealing gaskets on the crank- case half coupling surface.
  • Page 185 TUONO R_FACTORY Engine • Insert the washer on the crankshaft. Lubrication Oil pump Removing • Remove the seeger ring. • Remove the oil pump gear. • Take out the pin on the pump shaft. ENG - 185...
  • Page 186 TUONO R_FACTORY Engine • Unscrew and remove the four fixing screws and remove the oil pump as- sembly. • While carrying out this operation, make sure the pin of the scavenge oil pump inner rotor does not fall into the crank- case.
  • Page 187 TUONO R_FACTORY Engine Inspection • Take out the scavenge oil pump outer rotor from the oil pump shaft. • Remove the pin. • Slide off the oil pump cover. • Remove the pressure pump inner ro- tor. ENG - 187...
  • Page 188 TUONO R_FACTORY Engine • Remove the pin. • Take out the pump shaft. • Remove the pressure pump outer ro- tor. CHECK Check the oil pump rotors and the sliding surfaces of the outer rotors on both the bodies and the thrust surfaces for grooves.
  • Page 189 TUONO R_FACTORY Engine CAUTION REPLACE THE FAULTY PART IF CLEARANCE EXCEEDS EITHER WEAR LIMIT. Check the adjustment piston (1) smoothness on the oil pump (4) cover. Check the adjustment piston (1) and the oil pump (4) cover for wear: • adjustment piston (1);...
  • Page 190 TUONO R_FACTORY Engine • Oil and fit the scavenge oil pump outer rotor in its base on the crankcase. • Fit the pump shaft together with the scavenge oil pump inner rotor. • Fit the pump body on the crankcase. •...
  • Page 191 TUONO R_FACTORY Engine • Fit the pin on the shaft. • Fit the pressure pump inner rotor. • Fit the oil pump cover. • Fix the cover by tightening the four fix- ing screws to the prescribed torque. • Fit the pin on the pump shaft through the grooves on the cover.
  • Page 192 TUONO R_FACTORY Engine • Fit the oil pump gear. • Lock the gear with the seeger ring. ENG - 192...

  • Page 193: Index Of Topics

    INDEX OF TOPICS P SUPP OWER SUPPLY...

  • Page 194: Circuit Diagram

    TUONO R_FACTORY Power supply Circuit diagram Key: 1. Fuel tank 2. Refuelling cap 3. Fuel pump unit 4. Fuel fumes breather pipe (fumes caused by overpressure in the tank) 5. Fuel drainage pipe "too full" 6. Fuel level sensor 7. Fuel delivery filter 8.

  • Page 195: Fuel Pump

    TUONO R_FACTORY Power supply Fuel pump Removing • Remove the entire fuel pump assem- bly. • Disconnect the clic clamp with the spe- cial tool. • Remove the fuel pipe from the pump. Specific tooling 0277295 Pliers for clic clamps •...
  • Page 196 TUONO R_FACTORY Power supply • Fold the fuel filter sideways and keep it into position. CAUTION IF THE FILTERING MESH SHOWS SIGNS OF DEPOSITS, CLEAN IT WITH A PRESSURE AIR JET, DIRECTING IT IN SO THAT IMPURITIES DO NOT COME INTO THE FILTER. Injection P SUPP - 196...
  • Page 197 TUONO R_FACTORY Power supply Diagram Key: 1. Control unit position 2. Ignition switch 3. Battery 4. Crankshaft position sensor P SUPP - 197...

  • Page 198: Checking The Injector

    TUONO R_FACTORY Power supply 5. Camshaft position sensor 6. Engine temperature sensor 7. Air temperature sensor 8. Throttle valves position sensor 9. Intake pressure sensor 10.Safety system: side stand, neutral sensor 11.Test switch 12.Fall sensor 13.Atmospheric pressure sensor 14.Oil pressure sensor 15.Electric fan 16.Automatic air 17.Intake flap...
  • Page 199 TUONO R_FACTORY Power supply • Partially remove the fuel tank. • Remove the air filter housing. • Disconnect the electric connectors: - Right injector. - Left injector. - Throttle valve potentiometer. • Get the suitable special tool. • Release the clic clamp (4). •...
  • Page 200 TUONO R_FACTORY Power supply • Disconnect the two throttle grip cables. UPON REFITTING, MAKE SURE THE TWO THROTTLE GRIP CABLE REGULATORS ARE CORRECTLY FIXED TO THEIR HOOKS. CHECK CLEARANCE AND ADJUST IT IF REQUIRED. • Remove the flap pipe for the airbox from the throttle unit.

  • Page 201: Checking The Throttle Body

    TUONO R_FACTORY Power supply • Hold the throttle unit firmly, and with short alternating movements, lift and slide it off the intake flange. • Fit the complete throttle unit together with the fuel tank on a clean surface. PAY SPECIAL ATTENTION WHEN REMOVING THE THROTTLE UNIT SINCE IT REMAINS CONNECTED TO THE FUEL TANK THROUGH THE FUEL PIPE.
  • Page 202 TUONO R_FACTORY Power supply • Undo and remove the two M6x16 screws (7) and remove the fuel pres- sure regulator (8) together with its O- rings. • Undo and remove the three M6x25 screws (9) and remove the left injector support (10) together with the corre- sponding gasket (11), the injector (12) and the sealing ring (13).
  • Page 203 TUONO R_FACTORY Power supply • Unscrew and remove the nut M8x1 (19) and remove the spring washer (20), the pulley (21), the two bushings (22) and the torsion spring (23). • Slide off the fulcrum pin (24) together with the safety washer (25) from the hole of the bracket fixing the throttle grip cables and remove the two gas- kets and the ring for shafts (26) with the...

  • Page 204: Installing The Throttle Body

    TUONO R_FACTORY Power supply • Clean all the throttle unit openings and pipes (29) with compressed air. • Check the intake pressure sensor pipes (30), making sure they are not clogged. • Check the throttle valve unit and the cable fixing mechanism (31), making sure there are no mechanical dam- ages.

  • Page 205: Mapping Type

    TUONO R_FACTORY Power supply Recovery function If the signal of the following sensors is interrupted, the control unit determines some values to keep the engine running or it uses a different parameter. The instrument panel will still warn about any malfunc- tioning.
  • Page 206 This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO DISPLAY Specification Desc./Quantity Aprilia software 000000000 (not relevant field) Service number Engine V2 - 60° 990 (2-cylinder V engine, cylinder inclination, engine capacity)
  • Page 207 TUONO R_FACTORY Power supply Engine parameter reading screen page ENGINE PARAMETER READING This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.) ENGINE PARAMETER READING DISPLAY Specification Desc./Quantity...

  • Page 208: Device Status

    TUONO R_FACTORY Power supply Specification Desc./Quantity Lambda probe Lambda probe signal voltage, fixed value if the circuit is inter- rupted Injection time - ms Atmospheric pressure Sensor placed under the saddle. If the signal is lost, the control unit sets the value to 980 hPa (14.2 PSI). Example value: 1000 hPa (14.5 PSI) Device status screen page DEVICE STATUS...

  • Page 209: Device Activation

    TUONO R_FACTORY Power supply Specification Desc./Quantity Gear in neutral Possible statuses: Yes/No Selector Parameter currently used. Possible statuses: On / Off Side stand Stand position. Possible statuses: Up/Down Clutch engaged If the clutch is engaged, YES is displayed. Possible statuses: Up/Down Initialisation problem Possible causes why the procedure carried out through the ac-...

  • Page 210: Errors Display

    TUONO R_FACTORY Power supply Specification Desc./Quantity Intake reduction There is no movable flap on this vehicle, therefore this activa- tion is unnecessary. Lambda probe heating The device is activated: if it is not correctly activated, NO is displayed immediately, which shows that it has not been acti- vated, but it is also necessary to check the errors display screen page The device is activated: if it is not correctly activated, NO is...
  • Page 211 TUONO R_FACTORY Power supply Specification Desc./Quantity ticeable on the 3-DEVICES STATUS screen page that the Lambda correction parameter remains Deactivated Lambda probe heating Appears if the supply circuit is interrupted or short circuited, turns from ACT to STO without reconnection if the bike is off. Otherwise, remains as ACT, but is not saved to the memory (also notice the mV fixed signal) Lambda probe adaptability...

  • Page 212: Adjustable Parameters

    TUONO R_FACTORY Power supply Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters. ADJUSTABLE PARAMETERS Specification Desc./Quantity Initialisation To zero set the adjustable parameters when the control unit or the throttle body or the injectors are replaced (it may occur that during the first seconds after the start-up, it remains at 5000 rpm).
  • Page 213 Iso screen page ISO DISPLAY Specification Desc./Quantity Aprilia hardware This the mapping code with the numbers inverted. If they are all zeros, this means that the control unit is blank (no mapping): the suitable mapping should be remotely uploaded (the note related to the mapping parameter can be seen).
  • Page 214 TUONO R_FACTORY Power supply Specification Desc./Quantity select the mapping for non-standard exhaust pipes (Street Le- gal, Slip on, etc.) VC5L982$.BIX File belonging to mapping 266534. Similarly to RSV 1000 '04, with the "Engine option 1" setting, select the mapping for stand- ard exhaust pipes, whereas with the "Engine option 2"...

  • Page 215: Index Of Topics

    INDEX OF TOPICS SUSP USPENSIONS...

  • Page 216: Removing The Front Wheel

    TUONO R_FACTORY Suspensions Front Removing the front wheel • Hold the vehicle front part. • Unscrew the screws fixing the front mudguard and remove it. • Unscrew the screws fixing the front pli- ers and slide them off the disc. •...

  • Page 217: Checking The Front Wheel

    TUONO R_FACTORY Suspensions • 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. • Remove the wheel axle by inserting a screwdriver in the holes on the pin.
  • Page 218 TUONO R_FACTORY Suspensions • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: • Replace both wheel bearings. ALWAYS REPLACE BOTH BEARINGS. ALWAYS REPLACE THE BEARINGS WITH OTHERS OF THE SAME TYPE.
  • Page 219 TUONO R_FACTORY Suspensions • Remove the right spacer (1). • Remove the sealing gasket (2). • Remove the circlip (3). CAUTION THE CIRCLIP (3) IS FITTED ONLY ON THE WHEEL RIGHT SIDE. The spacer end (4) is fitted with slots (A) for the extractor teeth to pass through. •...

  • Page 220: Front Fork

    TUONO R_FACTORY Suspensions Front fork Diagram Key: 1. Radial fork right stem 2. Radial fork left stem SUSP - 220...
  • Page 221 TUONO R_FACTORY Suspensions 3. Sleeve 4. Pumping member attachment bushing 5. Spring 6. Complete preloading pipe 7. Spacer (component not present in version with radial calliper) 8. Washer (component not present in version with radial calliper) 9. Complete pumping element 10.
  • Page 222 5 protrusion notches (anticlockwise) from fully closed (clockwise) Stems (A) protrusion from top plate (excluding cover) (for this type of adjustment, take your vehicle only to an official aprilia dealer) 1 protrusion notch OHLINS FORK Standard front fork setting is adjusted to suit most high and low speed riding conditions, whether the vehicle is partially or fully loaded.

  • Page 223: Removing The Fork Legs

    TUONO R_FACTORY Suspensions Removing the fork legs • Remove the front wheel. • Support the stanchion and loosen the screws on the upper and then the lower plate. • Remove the stanchion. Draining oil • Lock the clamp sleeve using the speci- fied tool.
  • Page 224 TUONO R_FACTORY Suspensions • Lock the fork end on a vice paying at- tention not to damage it. • Fit the specified tool on the spring cou- pling. • Push down the tool to compress the spring and then fit the tool spacer be- low the cartridge lock nut.
  • Page 225 TUONO R_FACTORY Suspensions • Remove the whole cap. • Remove the spacer and the washer (Component not present in version with radial calliper) • Push down and compress the spring, slide off the spacer. • Remove the spring coupling. SUSP - 225...

  • Page 226: Disassembling The Fork

    TUONO R_FACTORY Suspensions • Drain off oil into a collecting container and remove the spring. Disassembling the fork • After emptying the oil, fasten the calliper mount- ing bracket of the fork stanchion in a vice. • Position the washer and the lower spacer (com- ponent not present in version with radial caliper).
  • Page 227 TUONO R_FACTORY Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim. • Remove the retainer ring. • Take out the sleeve from the stem us- ing the stem as a hammer puller.

  • Page 228: Checking The Components

    TUONO R_FACTORY Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. SUSP - 228...
  • Page 229 TUONO R_FACTORY Suspensions 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. If over the value, replace the stem. CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
  • Page 230 TUONO R_FACTORY Suspensions Oil level: 114 mm (4,49 in) from the upper lining edge in a completely compressed position without spring or washer underneath (fork with connections for standard GRIP/CALIPER/ CLAMP). Oil level: 122 mm (4,80 in) from the upper lining edge in a completely compressed position without spring (fork connections for radial cal- ipers).
  • Page 231 TUONO R_FACTORY Suspensions • The sealing ring must be placed with the stamped part facing the dust gaiter. • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. SUSP - 231...
  • Page 232 TUONO R_FACTORY Suspensions • Fit the sleeve on the stem and with the specified tool fit the oil seal into posi- tion. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices 8140145 Fitting tool for Ø 41 mm (1.61 in) seal- ing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189...
  • Page 233 TUONO R_FACTORY Suspensions • Fit the oil seal with the specific tool. Specific tooling AP8140189 Oil seal fitting tool for Ø 43 mm (1.69 in) orifices 8140145 Fitting tool for Ø 41 mm (1.61 in) seal- ing ring 8140146 Weight to be applied to the tool: 8140145 and 8140189 •...

  • Page 234: Filling Oil

    TUONO R_FACTORY Suspensions • Fit the fork spring. • Perform the fork oil filling. Filling oil • Keep the sleeve in vertical position. • Fill up the fork so that air bubbles trap- ped inside are freed. • Fit the spring coupling. •...
  • Page 235 TUONO R_FACTORY Suspensions • Position the spacer and the washer. • (Component not present in version with radial caliper) • Screw the upper cover on the cartridge stem. SUSP - 235...

  • Page 236: Steering Bearing

    TUONO R_FACTORY Suspensions • Place the sleeve in the vice using the specified tool. • Screw the upper cover, tightening it to the prescribed torque. Specific tooling AP8140149 Protection for fitting operations Steering bearing Adjusting play Steering bearings and steering clearance: •...
  • Page 237 TUONO R_FACTORY Suspensions • Loosen the screws fixing the fork stan- chions to the upper yoke. • Slide off the fork upper plate by moving it towards the instrument panel. • Rivet the safety washer on the head- stock. • Unscrew the upper ring nut and then remove the safety washer.
  • Page 238 TUONO R_FACTORY Suspensions • Adjust the preloading of the steering bearings by tightening the lower ring nut to the prescribed torque. • Fit the safety washer. SUSP - 238...
  • Page 239 TUONO R_FACTORY Suspensions • Fit and tighten the upper ring nut so that the grooves match the tongues of the safety washer. • Rivet the tongues on the upper ring nut. • Fit the upper fork plate. SUSP - 239...

  • Page 240: Removing The Rear Wheel

    TUONO R_FACTORY Suspensions • Screw the top bolt on the headstock by tightening it to the prescribed torque. • Tighten the screws fixing the fork stems to the upper plate to the prescri- bed torque. • Fit the handlebar. • Fit the fixing U-bolt.
  • Page 241 TUONO R_FACTORY 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 242 TUONO R_FACTORY Suspensions • Remove all the flexible couplings. • 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 243: Checking The Rear Wheel

    TUONO R_FACTORY Suspensions TO AVOID POTENTIAL DISTORTIONS AND/OR INCORRECT COUPLING, TIGHTEN AS FOL- LOWS: • Using an Allen key on the specific seat (1), lock the rotation of the threaded pin (2), and applying half the specified torque, tighten the diametrically opposed elements in this se- quence: (A) (B) (C) (D) (E).

  • Page 244: Rear Wheel Rim

    TUONO R_FACTORY Suspensions REAR wheel axle • Use a dial gauge to check the wheel axle eccentricity (1). Replace the wheel axle if the eccentricity exceeds the limit value (1). Characteristic Maximum eccentricity: 0.25 mm (0.0098 in) REAR WHEEL RIM •...

  • Page 245: Flexible Coupling

    TUONO R_FACTORY Suspensions • Check the radial and axial clearance. Axial clearance: a minimum axial clearance is allowed. Radial clearance: none. If one or both bearings do not fall within the control parameters: • Replace both bearings of the final drive unit. FLEXIBLE COUPLING Check that the flexible couplings (5) are not dam- aged or excessively worn.
  • Page 246 TUONO R_FACTORY Suspensions The spacer end (12) is fitted with slots (A) for the extractor teeth to pass through. • Take out the right bearing (13) with the specific extractor. Specific tooling AP8140180 Extractor for bushings • Collect the inside spacer (12). Working from the wheel left side: •...

  • Page 247: Specific Tooling

    TUONO R_FACTORY Suspensions FINAL DRIVE UNIT - BEARING REMOVAL • Remove the final drive unit. • Clean the two sides of the hub with a cloth. • Remove the left spacer (15). • Remove the sealing gasket (16). • Remove the circlip (17). CAUTION THE CIRCLIP (17) IS FITTED ONLY ON THE FINAL DRIVE UNIT, LEFT SIDE.

  • Page 248: Shock Absorber

    TUONO R_FACTORY Suspensions Adjusting BEARINGS Make the bearings turn manually; they must rotate smoothly, continuously and silently. There must be no axial clearance. Replace the bearings if they present these prob- lems. Apply grease on the rollers. GASKETS Check that the gaskets are in good conditions; re- place them if they show signs of damage or ex- cessive wear.
  • Page 249 TUONO R_FACTORY Suspensions OHLINS shock absorber SET SPRING PRELOADING AND SHOCK ABSORBER RE- BOUND DAMPING ACCORDING TO THE VEHICLE USE CONDITIONS. IF THE SPRING PRELOADING IS INCREASED, IT IS NEC- ESSARY TO INCREASE THE REBOUND DAMPING AC- CORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. SPORT SETTINGS MAY BE USED ONLY FOR OFFICIAL COMPETITIONS TO BE CARRIED OUT ON TRACKS, AWAY FROM NORMAL ROAD TRAFFIC AND WITH THE...
  • Page 250 TUONO R_FACTORY Suspensions • Working on the left side, unscrew the lower screw (2) but do not remove it; collect the nut. • With the hoist, hold the vehicle without lifting it from the ground, thus lightening the weight on the swing arm. •...
  • Page 251 TUONO R_FACTORY Suspensions • Working on the left side, screw the nut on the upper screw (1). • Free the vehicle from the belt and the hoist. Linkages Removing • Working from the right side of the ve- hicle, loosen and remove the nut (1). •...
  • Page 252 TUONO R_FACTORY Suspensions SUSP - 252...

  • Page 253: Index Of Topics

    INDEX OF TOPICS CHAS HASSIS...

  • Page 254: Swinging Arm

    TUONO R_FACTORY Chassis Swinging arm Removing • Place the vehicle on the specific cen- tral service stand (OPT). • Remove the rear wheel. CAUTION ALTHOUGH NOT NECESSARY FOR REMOVING THE REAR WHEEL, THE REAR SERVICE STAND (OPT) IS IN- DISPENSABLE FIXING THE REAR SWING ARM WITHOUT THE WHEEL FIRMLY IN POSITION.
  • Page 255 TUONO R_FACTORY Chassis • Working on the left side, unscrew and remove the lower shock absorber nut. • From the opposite side slide off the screw. • Unscrew and remove the nut and re- trieve the washer. • Using the suitable special tool and the specific box-spanner, unscrew and re- move the locking ring nut (1) on the vehicle right-hand side.
  • Page 256 TUONO R_FACTORY Chassis • Place a mounting under the front part of the swingarm. • Support the swingarm from the front. • Remove the swingarm pin (2) from the right hand side. • Support the front part of the swingarm and be ready to accompany it.

  • Page 257: Swingarm Bearings

    TUONO R_FACTORY Chassis CHECK AND, IF REQUIRED, REPLACE THE BEARINGS AFTER EVERY BEARING REMOVAL. Specific tooling AP8140180 Extractor for bushings • Remove the internal spacer (7) and collect the two O-rings (8). • Remove the internal spacer (9). • Remove the gaskets (10). •...
  • Page 258 TUONO R_FACTORY Chassis • Check that the gaskets are in good conditions; replace them if they show signs of damage or excessive wear. ALWAYS REPLACE BOTH GASKETS. ALWAYS REPLACE THE GASKETS WITH OTHERS OF THE SAME TYPE. SWINGARM PIN • Use a dial gauge to check the swing- arm pin eccentricity.
  • Page 259 TUONO R_FACTORY Chassis • Support the swing arm from the front; place the fork so that it is aligned with the holes and, at the same time, insert the pin (2) completely. • Make sure that the hexagonal area on the pin head (2) is correctly fitted on the internal hexagonal seat of the adjust- ment bushing (3).
  • Page 260 TUONO R_FACTORY Chassis • Remove the adhesive tape freeing the chain. • Refit the chain on the transmission pinion. CAUTION APPLY LOCTITE ANTI-SEIZE ON THE INTERNAL TOOTHING OF THE TRANSMISSION PINION. • Fit the pinion and the chain on the shaft.

  • Page 261: Drive Chain

    TUONO R_FACTORY Chassis • Fit the supporting plate together with the brake calliper and the speed sen- sor. • Tighten the three screws fixing the pro- tection profile and the washers. • Fit the pinion crankcase and tighten the three screws. •...
  • Page 262 TUONO R_FACTORY Chassis remain constant at all wheel rotation phases. ADJUSTMENT CAUTION GET A SPECIFIC REAR SERVICE STAND (OPT) TO AD- JUST THE CHAIN. If you need to adjust chain tension after the check: • Place the vehicle on its rear service stand (OPT).

  • Page 263: Cleaning And Lubrication

    TUONO R_FACTORY Chassis 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 264 TUONO R_FACTORY Chassis • Unscrew and remove the two screws from the left rider footpeg protection. • 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.
  • Page 265 TUONO R_FACTORY Chassis • Remove the chain pad by pulling it backwards. The pad should be removed to check it for wear. • Unscrew and remove the two screws. • Remove the lower chain pad. WEAR CHECK Check the chain pad for wear. Minimum thickness: 2 mm (0.079 in) Removing the tail pipe •...

  • Page 266: Removing The Exhaust Manifold

    TUONO R_FACTORY Chassis • Undo the screws fixing the silencer clamp. • Remove the silencers. Removing the exhaust manifold • Unhook the retaining spring between the front cylinder manifold and ex- haust. • Undo the four nuts fixing the manifold to the front cylinder.
  • Page 267 TUONO R_FACTORY Chassis • Remove the manifold. • Collect the sealing gasket. • Unhook the retaining spring placed be- tween the rear manifold and exhaust. • Slide off the wiring of the lambda probe from the chassis. CHAS - 267...
  • Page 268 TUONO R_FACTORY Chassis • Remove the exhaust together with the lambda probe. • Undo the four nuts fixing the manifold to the rear cylinder. • Remove the exhaust manifold and col- lect the sealing gasket. CHAS - 268...

  • Page 269: Index Of Topics

    INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 270: Rear Brake Disc

    TUONO R_FACTORY Braking system Checking • The following operations must be car- ried out with the brake discs fitted on the wheel; they refer to a single disc, but apply to both. • Check the disc for wear measuring the minimum thickness at different points with a micrometer.

  • Page 271: Disc Inspection

    TUONO R_FACTORY Braking system • Unscrew and remove the five brake disc screws (1). • Remove the disc brake (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-F.

  • Page 272: Front Brake Pads

    TUONO R_FACTORY Braking system • 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-F. Front brake pads Removal THIS VEHICLE IS FITTED WITH A DOUBLE DISC FRONT BRAKING SYSTEM (RIGHT AND LEFT...

  • Page 273: Rear Brake Pads

    TUONO R_FACTORY Braking system Installing • Fit the two new pads in the correct position. ALWAYS REPLACE THE FOUR PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER. • Place the safety spring (2). • Press the safety spring (2) and, at the same time, fit the pin (3), operating on the inside.
  • Page 274 TUONO R_FACTORY Braking system • Remove the snap ring (1). BEFORE REMOVING THE PIN (2), CHECK THAT THE SAFETY SPRING (3) IS CORRECTLY POSITIONED; WHEN REFITTED, IT MUST POSITIONED IN THE SAME WAY. • Remove the pin (2) and retrieve the safety spring (3). •...
  • Page 275 TUONO R_FACTORY Braking system • Place the safety spring (3). • Hold the centre of the safety spring (3) depressed and insert the pin (2) so it passes above the spring. • Fit the retainer ring (1). • Check the brake fluid. Bleeding the braking system Front Before purging, get a flexible hose of adequate...
  • Page 276 TUONO R_FACTORY Braking system Rear Before purging, get a flexible hose of adequate size and a container of adequate capacity. • Remove the fairing. • Connect the hose on the brake pump bleed. • Operate the brake lever and then slightly open the bleed on the pump so that the air is released.

  • Page 277: Clutch System

    INDEX OF TOPICS CLU SYS LUTCH SYSTEM...

  • Page 278: Bleeding The System

    TUONO R_FACTORY Clutch system Bleeding the system Before purging, get a flexible hose of adequate size and a container of adequate capacity. • Connect the hose on the bleed of the clutch control wheel cylinder • Operate the brake lever and then slightly open the bleed on the wheel cylinder so that the air is released.

  • Page 279: Cooling System

    INDEX OF TOPICS COOL SYS OOLING SYSTEM...

  • Page 280: Water Pump

    TUONO R_FACTORY Cooling system Circuit diagram Key: 1. Radiator 2. Electrical fans 3. Expansion tank 4. Filler 5. Three-way thermostatic valve 6. Three-way manifold Water pump • Check the drain holes for potential oil or coolant leaks. REMOVE THE COOLANT PUMP ONLY IN CASE OF OIL OR COOLANT LEAKS.

  • Page 281: Pump Check

    TUONO R_FACTORY Cooling system • Slide the coolant pump gear (1) upwards and off and remove the pin (3) together with the washer (4). DO NOT DAMAGE THE THREAD OF THE COOLANT PUMP SHAFT. • Take out the shaft (5) from the coolant pump towards the coolant pump gear (1).

  • Page 282: Installing The Pump

    TUONO R_FACTORY Cooling system • Check that the material in the inter- mediate gear toothing (10) for the cool- ant pump is not damaged or broken. Measure the seat hole (11). Hole wear limit (11) Max. diam. 10.22 mm (0.4024 in). INSTALLING THE PUMP GET THE SUITABLE SPECIFIC TOOLS (OPT.) •...
  • Page 283 INDEX OF TOPICS BODYW ODYWORK...

  • Page 284: Side Fairings

    TUONO R_FACTORY Bodywork Side fairings • Loosen and remove the two fixing screws (1) and collect the washers. • Remove the fairing (2). • Unscrew and remove the fixing pin (3). • Unscrew and remove the fixing pin (4) and collect the washer. •...
  • Page 285 TUONO R_FACTORY Bodywork • Loosen and remove the two fixing screws (9) and collect the washers. • Remove the fairing (10). • Unscrew and remove the left fixing screw and collect the washer (11). • Unscrew and remove the front fixing screw and collect the washer (12).
  • Page 286 TUONO R_FACTORY Bodywork • Loosen and remove the two fixing screws (15) and collect the washers. • Remove the fairing (16). • Unscrew and remove the two fixing screws (17) and collect the washers. • Unscrew and remove the fixing pin (18).
  • Page 287 TUONO R_FACTORY Bodywork • Undo the screws fixing the airbox to the chassis • Remove the six screws fixing the throt- tle body to the airbox. BODYW - 287...
  • Page 288 TUONO R_FACTORY Bodywork • Detach the by-pass pipes directed to the throttle body and the Stepper motor connection. • Remove the oil vapour recovery pipe. • Detach the manifold pressure sensor connection and the related pipes com- ing from the throttle body. BODYW - 288...

  • Page 289: Lower Cowl

    TUONO R_FACTORY Bodywork • Remove the airbox. Lower cowl • Undo and remove the left fixing screw and collect the washer. • Undo and remove the front fixing screw and collect the washer. BODYW - 289...
  • Page 290 TUONO R_FACTORY Bodywork • Undo and remove the right fixing screw and collect the washer. • Remove the fairing. BODYW - 290...
  • Page 291 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 292 TUONO R_FACTORY Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...
  • Page 293 TUONO R_FACTORY 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 294: Static Test

    TUONO R_FACTORY 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 295 Air temperature sensor: 70 Battery: 61, 68 Brake: 270–273 Brake disc: 270, 271 Brake pads: 272, 273 CAN line: 74 Chain: 12, 157, 159, 161, 164, 261, 263 Chain tensioner: 157 Clutch: 127, 130, 131, 135–137, 140, 278 Coil: 72 Connecting rods: Connectors: 73 coolant:...
  • Page 296 Identification: 10 Instrument panel: 75 Intake pressure sensor: 69 License plate holder: Linkages: 251 Magneto flywheel: 124, 126, 159 Maintenance: 7, 44 Primary shaft: 102, 108, 111 Radiator: Rear wheel: 240, 243 Recommended products: 30 Saddle: Secondary shaft: 105, 110, 114 Shock absorber: Shock absorbers: 247 Side fairings: 284...

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