APRILIA TUONO 1000 Workshop Manual
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APRILIA TUONO 1000 Workshop Manual

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TUONO 1000
1306 5
12/2005-00
workshopmanual

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Summary of Contents for APRILIA TUONO 1000

  • Page 1 TUONO 1000 1306 5 12/2005-00 workshopmanual...
  • Page 2 INTRODUCTION TUONO 1000 INTRODUCTION 0 - 1...
  • Page 3 INTRODUCTION TUONO 1000 SUMMARY 0.1. FOREWORD ..............................3 0.1.1. FOREWORD............................3 0.1.2. REFERENCE MANUALS........................4 0.1.3. ABBREVIATIONS / SYMBOLS ......................5 0 - 2...

  • Page 4: Foreword

    SERVICE DEPT., which will be pleased to help, as well as providing you with updates and technical modifications regarding the vehicle. aprilia s.p.a. reserves the right to make changes to its products at any time, barring any such changes as may alter the essential features of a product as specified in the relevant manual.

  • Page 5: Reference Manuals

    INTRODUCTION TUONO 1000 0.1.2. REFERENCE MANUALS PARTS CATALOGUES aprilia part# (description) 3985 SPECIAL TOOLS MANUALS aprilia part# (description) 001A00 OWNER'S MANUALS aprilia part# (description) 8104927 8104928 8104929 8104930 CHASSIS WORKSHOP MANUAL aprilia part# (description) 8104978 8104981 8104979 8104980 8104982 8104983...

  • Page 6: Abbreviations / Symbols

    INTRODUCTION TUONO 1000 0.1.3. ABBREVIATIONS / SYMBOLS = number < = less than > = greater than ≤ = less than or equal to ≥ = greater than or equal to = approximately ∞ = infinity °C = degrees Celsius (centigrade) °F...
  • Page 7 INTRODUCTION TUONO 1000 RIGHT SIDE = right side = Society of Automotive Engineers TEST = diagnostic check T.B.E.I. = crown-head Allen screw T.C.E.I. = cheese-head Allen screw T.E. = hexagonal head T.P. = flat head screw = Twin Spark Ignition...

  • Page 8: General Information Tuono

    GENERAL INFORMATION TUONO 1000 GENERAL INFORMATION 1 - 1...

  • Page 9: Table Of Contents

    GENERAL INFORMATION TUONO 1000 SUMMARY 1.1. STRUCTURE OF THE MANUAL........................3 1.1.1. CONVENTIONS USED IN THE MANUAL ..................... 3 1.1.2. SAFETY WARNINGS..........................4 1.2. GENERAL RULES............................5 1.2.1. BASIC SAFETY RULES......................... 5 1.3. DANGEROUS ELEMENTS ..........................8 1.3.1. WARNINGS ............................8 1.4.

  • Page 10: Structure Of The Manual

    GENERAL INFORMATION TUONO 1000 1.1. STRUCTURE OF THE MANUAL 1.1.1. CONVENTIONS USED IN THE MANUAL • This manual is divided in sections and subsections, each covering a set of the most significant components. For quick reference, see the summary of sections.

  • Page 11: Safety Warnings

    GENERAL INFORMATION TUONO 1000 1.1.2. SAFETY WARNINGS The symbols and warnings used throughout this manual have the following meanings: Safety warning. When you find this symbol on the vehicle or in the manual, be careful of the potential risk of personal injury. Disregarding the instructions identified by this symbol may compromise the safety of the user, the motorcycle and third parties.

  • Page 12: General Rules

    GENERAL INFORMATION TUONO 1000 1.2. GENERAL RULES 1.2.1. BASIC SAFETY RULES CARBON MONOXIDE When an operation must be performed with the engine running, position the motorcycle outdoors in a well-ventilated area. Avoid starting the engine indoors. Use an exhaust emission extraction system when working indoors.
  • Page 13 GENERAL INFORMATION TUONO 1000 DANGER Avoid spilling coolant on hot engine parts and the exhaust system, as it may ignite and produce invisible flames. Wear latex gloves when servicing. Though toxic, its sweet taste might attract animals. Never leave coolant in an open container or in a position easily accessible to animals.
  • Page 14 Never use compressed air to clean bearings. NOTE All bearings must run freely with no hardness or noise. Replace any bearings that do not meet these requirements. Use ORIGINAL aprilia SPARE PARTS only. Use the specified lubricants and consumables. Where possible, lubricate a part before assembly.

  • Page 15: Dangerous Elements

    GENERAL INFORMATION TUONO 1000 1.3. DANGEROUS ELEMENTS 1.3.1. WARNINGS FUEL DANGER The fuel used in internal combustion engines is highly flammable and can become explosive under particular conditions. Refuelling and maintenance operations should be carried out in a well-ventilated area, with the engine off.
  • Page 16 GENERAL INFORMATION TUONO 1000 BRAKE FLUID NOTE This vehicle is fitted with front and rear disc brakes. Each brake system is operated by an independent hydraulic circuit. The information provided below applies to both brake systems. DANGER Do not drive the vehicle if the brakes are worn or not operating correctly. The brakes are the vehicle’s most important safety component and using the vehicle with the brakes in less than perfect operating condition comprises a high probability of traffic accident, which can result in serious injury or death.
  • Page 17 GENERAL INFORMATION TUONO 1000 This solution is also suitable during the warm season, as it is less likely to evaporate and will reduce the need for frequent top-ups. In addition, less water evaporation means fewer mineral salt deposits in the radiator, which helps preserve the efficiency of the cooling system.

  • Page 18: Running-In

    GENERAL INFORMATION TUONO 1000 1.4. RUNNING-IN 1.4.1. RUNNING-IN Correct engine running-is essential to ensuring proper performance and durability. Twisty, hilly roads are ideal for an effective running-in of engine, suspension and brakes. Varying speed frequently is also recommended. This will vary the amount of stress placed on vehicle components continuously, allowing engine parts to cool down when less stressed.

  • Page 19: Vehicle Identification

    GENERAL INFORMATION TUONO 1000 1.5. VEHICLE IDENTIFICATION 1.5.1. POSITION OF THE SERIAL NUMBERS These numbers are necessary for vehicle registration. NOTE Altering the vehicle's identification numbers is punishable by law with heavy fines and penalties. Altering the frame number voids the warranty.
  • Page 20 PERIODIC MAINTENANCE TUONO 1000 PERIODIC MAINTENANCE 2 - 1...
  • Page 21 PERIODIC MAINTENANCE TUONO 1000 SUMMARY 2.1. GENERAL TECHNICAL INFORMATION ......................3 2.1.1. TECHNICAL DATA ..........................3 2.1.2. SCHEDULED MAINTENANCE CHART....................6 2.1.3. LUBRICANT TABLE..........................8 2.1.4. TIGHTENING TORQUES ........................9 2.1.5. SPECIAL TOOLS ..........................14 2.1.6. LOCATION OF KEY COMPONENTS ....................21 2.1.7.

  • Page 22: General Technical Information

    PERIODIC MAINTENANCE TUONO 1000 2.1. GENERAL TECHNICAL INFORMATION 2.1.1. TECHNICAL DATA DIMENSIONS Max length 2025 mm (79.75 in) Max width 830 mm (36.78 in) Max height (at headlight fairing) 1100 mm (43.31 in) Seat height 820 mm (32.28 in) Wheelbase 1410 mm (55.51 in)
  • Page 23 PERIODIC MAINTENANCE TUONO 1000 FRAME Type twin-spar frame with light-alloy cast elements and formed extruded elements Steering head angle 25° Trail 100 mm (3.93 in) (with 120/70 front tyre) SUSPENSION Front adjustable hydraulic upside-down telescopic fork, 43-mm Ø (1.69 in) legs Travel 127 mm (5.00 in)
  • Page 24 PERIODIC MAINTENANCE TUONO 1000 SPARK PLUGS Standard NGK R DCPR9E Electrode gap 0.6 - 0.7 mm (0.023 - 0.028 in) Resistance 5 kΩ ELECTRIC SYSTEM Battery 12 V – 10 Ah Main fuses 30 A Auxiliary fuses 5 A, 15 A, 20 A Generator (permanent magnet) 12 V –...

  • Page 25: Scheduled Maintenance Chart

    PERIODIC MAINTENANCE TUONO 1000 2.1.2. SCHEDULED MAINTENANCE CHART MAINTENANCE OPERATIONS TO BE PERFORMED BY aprilia Authorised Dealers (MAY ALSO BE PERFORMED BY OWNER). 1 = Check and clean, set or adjust, lubricate, change or replace as required; 2 = Clean;...
  • Page 26 PERIODIC MAINTENANCE TUONO 1000 MAINTENANCE OPERATIONS TO BE PERFORMED BY aprilia Authorised Dealers. 1 = Check and clean, set or adjust, lubricate, change or replace as required (as specified in the Workshop Manual); 2 = Clean; 3 = Change or replace;...

  • Page 27: Lubricant Table

    PERIODIC MAINTENANCE TUONO 1000 2.1.3. LUBRICANT TABLE LUBRICANT PRODUCT RECOMMENDED: EXTRA RAID 4, SAE 15W – 50 or TEC 4T SAE 15W – 50. Engine oil As an alternative to recommended oils, top brand oils meeting or exceeding CCMC G-4, A.P.I. SG specifications can be used.

  • Page 28: Tightening Torques

    PERIODIC MAINTENANCE TUONO 1000 2.1.4. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. Note (Nm) ENGINE TO FRAME...
  • Page 29 PERIODIC MAINTENANCE TUONO 1000 TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. NOTE (Nm) STEERING DAMPER Steering damper to frame Loctite 243 Steering damper to bottom fork yoke FOOTRESTS Rider footrests Passenger footrests REAR SHOCK ABSORBER Shock absorber to frame REAR SUSPENSION CONNECTING RODS...
  • Page 30 PERIODIC MAINTENANCE TUONO 1000 Torque Description Type of fastener Tol. Note (Nm) FRONT WHEEL Wheel shaft nut M25x1.5 REAR WHEEL Rear chain sprocket to sprocket holder Rear wheel shaft nut M25x1.5 COOLING SYSTEM Coolant radiator upper bracket to frame Electric fans to coolant radiator ±20%...
  • Page 31 PERIODIC MAINTENANCE TUONO 1000 Torque Description Type of fastener Tol. Note (Nm) FUEL PUMP Fuel return fitting (for workshop ±20% Loctite 243 manual only) Pump mount to flange (for workshop ±20% manual only) Lead terminals to flange (for workshop ±20%...
  • Page 32 PERIODIC MAINTENANCE TUONO 1000 Torque Description Type of fastener Tol. Note (Nm) RIGHT / LEFT SPOILER Spoiler rear end to spacer Spoiler front end to coolant radiator OIL TANK COVER Cover to oil tank FRONT PIECE Front piece to light units and conveyor...

  • Page 33: Special Tools

    (tool name and purpose) 8140176 (complete support stands kit) 8146486 (front support stand) xxxxxxx N.A. [central support stand] 8705021 (rear support stand) xxxxxxx N.A. = supplied only with kit aprilia part# 8140176 (complete support stand kit) 2 - 14...
  • Page 34 8140145 (tool for fitting Ø 41 mm seal) 8140146 {Weight to apply to tool: aprilia part# 8140145 [tool for fitting Ø 41 mm (Ø 1.61 in) seal] and aprilia part# 8140189 [tool for fitting oil seal for Ø 43 mm (Ø 1.70 in) hole. Completes kit aprilia part#...
  • Page 35 PERIODIC MAINTENANCE TUONO 1000 ENGINE TOOLS 2 - 16...
  • Page 36 PERIODIC MAINTENANCE TUONO 1000 Pos. aprilia part# (tool name and purpose) 8140175 (complete engine tool kit) 0277680 (drift for fitting gearbox secondary shaft oil seal) 0277660 (drift for fitting upper counter shaft oil seal) 0277670 (drift for fitting coolant pump shaft housing oil seal)
  • Page 37 PERIODIC MAINTENANCE TUONO 1000 MISCELLANEOUS TOOLS 2 - 18...
  • Page 38 PERIODIC MAINTENANCE TUONO 1000 Pos. aprilia part# (tool name and purpose) 8140196 [Plurigas (Italian )] 8140578 [Plurigas (English)] 8140192 (chain assembly kit) 8140180 (bearing extractor) 8140202 (exhaust gas test probes) 8140267 (vacuum gauge sleeve) 8140256 (vacuum gauge) 8140424 (spanner for OHLINS forks)
  • Page 39 PERIODIC MAINTENANCE TUONO 1000 TOOLS FOR OTHER aprilia VEHICLES Pos. aprilia part# (tool name and purpose) 0877650 (drift grip) 0277265 (extractor for counter shaft, primary shaft and secondary shaft bearing) – 8116050 (engine oil) – 8116053 ( Bimol Grease 481 grease) –...

  • Page 40: Location Of Key Components

    PERIODIC MAINTENANCE TUONO 1000 2.1.6. LOCATION OF KEY COMPONENTS Key: Cowling Side fairings Adjustable steering damper Left headlight Clutch fluid reservoir Left rear-view mirror Engine oil tank cap Left side panel Rider seat 10. Battery 11. Main fuse carrier (30A) 12.
  • Page 41 PERIODIC MAINTENANCE TUONO 1000 Key: Rear shock absorber Passenger right footrest (snaps closed/open) Tail light Glove / tool kit compartment Passenger seat / seat cover Control unit Auxiliary fuse carrier (15A) Right side panel Fuel tank 10. Coolant expansion tank cap 11.

  • Page 42: Location Of Instruments / Controls

    PERIODIC MAINTENANCE TUONO 1000 2.1.7. LOCATION OF INSTRUMENTS / CONTROLS Key: Clutch lever Ignition / steering lock switch (( - )) Instruments and indicators Front brake lever Throttle twistgrip High beam flasher button ( Light dimmer switch ( Turn indicator switches ( Horn button ( 10.
  • Page 43 PERIODIC MAINTENANCE TUONO 1000 Key: Rev counter Green neutral light (N) Amber "stand down" light ( ) Red general warning light ( Multifunction digital display (coolant temperature – clock - battery voltage – lap time - engine oil pressure diagnostics...

  • Page 44: Instrument Panel Operation

    All warning lights • Backlighting • The Tuono 1000 logo appears on the display. The rev counter pointer (3) moves to the maximum rpm value set and then returns to its initial position. During the initial check-up, all instruments will briefly show the current values of the corresponding parameters.
  • Page 45 PERIODIC MAINTENANCE TUONO 1000 The MODE configuration includes all user interface functions. To select the MODE configuration, set the selector (1) to MODE. With the vehicle stopped, at each short press of the SET button (2), the display cycles through the following readings: •...
  • Page 46 PERIODIC MAINTENANCE TUONO 1000 wording “GEAR SHIFT INDICATOR” in the current display language is displayed and the rev counter pointer points to the current threshold setting. At each short press of the SET button (2), threshold setting increases by 100 RPM. Upon reaching the upper limit, at the next press of the button the setting will decrease by 100 RPM and vice versa.
  • Page 47 PERIODIC MAINTENANCE TUONO 1000 º º This function is used to select the desired measurement unit for ambient temperature. When this function is selected, at each short press of the SET button (2), the display cycles through the two measurement units: °C / °F...
  • Page 48 TUONO 1000 DIAGNOSIS This function interfaces with and diagnoses the motorcycle's on-board systems. password-protected appropriate password is made available to Aprilia service centres only. LANGUAGE This function is used to select display language. Available options are listed below: • ITALIANO •...

  • Page 49: Systems Diagram

    PERIODIC MAINTENANCE TUONO 1000 2.1.9. SYSTEMS DIAGRAM BRAKES 2 - 30...
  • Page 50 PERIODIC MAINTENANCE TUONO 1000 EXHAUST GAS RECOVERY 2 - 31...
  • Page 51 FUEL SYSTEM TUONO 1000 FUEL SYSTEM 3 - 1...
  • Page 52 FUEL SYSTEM TUONO 1000 SUMMARY 3.1. POWER SUPPLY ............................3 3.1.1. DIAGRAM .............................. 3 3.1.2. INJECTION SYSTEM DIAGRAM ......................4 3.1.3. CYLINDER SYNCHRONISATION AND CO LEVEL ADJUSTMENT ............. 6 3.1.4. AXONE..............................8 3.2. FUEL PUMP ..............................16 3.2.1. REMOVING THE PUMP UNIT......................16 3.2.2.

  • Page 53: Power Supply

    FUEL SYSTEM TUONO 1000 3.1. POWER SUPPLY 3.1.1. DIAGRAM Fuel tank Filler cap Fuel pump unit Breather tube for fuel vapours (caused by tank overpressure) Excess fuel draining tube Fuel level sensor Delivered fuel filter Fuel pump Fuel delivery line 10.

  • Page 54: Injection System Diagram

    FUEL SYSTEM TUONO 1000 3.1.2. INJECTION SYSTEM DIAGRAM 3 - 4...
  • Page 55 FUEL SYSTEM TUONO 1000 Key: Position of ECU Ignition switch Battery Crankshaft position sensor Camshaft position sensor Engine temperature sensor Air temperature sensor Throttle position sensor Intake pressure sensor 10. Safety system: side stand, neutral sensor 11. Test switch 12. Bank angle sensor 13.

  • Page 56: Cylinder Synchronisation And Co Level Adjustment

    FUEL SYSTEM TUONO 1000 3.1.3. CYLINDER SYNCHRONISATION AND CO LEVEL ADJUSTMENT • With the engine off, connect Axone 2000 to the diagnosis socket and to the vehicle battery. • Switch the tester on. • Connect the gas analyser tubes to the relevant fittings.
  • Page 57 FUEL SYSTEM TUONO 1000 • Should the FRONT CYLINDER PRESSURE value be incorrect, turn the FRONT CYLINDER bypass screw. • Read the residual CO value while alternatively opening analyser valves. Turn the bypass screws if the value is not between 2 and 4 % and if the difference between the two readings is greater than 0.5 %.

  • Page 58: Axone

    FUEL SYSTEM TUONO 1000 3.1.4. AXONE SYMBOL SCREEN ENGINE PARAMETER READING DEVICE STATUS (in general they are “On – Off” values) ENABLE DEVICES DETECTED FAULTS ENGINE PARAMETER ADJUSTMENT FREEZE FRAME UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE Mapping code with reversed figures. If...
  • Page 59 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE ENGINE PARAMETER READING The fans are activated at about 100°C. If the signal is lost, the ECU sets linear output for the value at 88°C (190 °F), Water temperature °C...
  • Page 60 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE DEVICE STATUS The ECU manages it like a status (therefore it is not stored in the memory): but if the circuit is broken (sensor disconnected) the instrument Bank angle sensor...
  • Page 61 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE Possible factors that may have caused unsuccessful Throttle position learning no/engine speed>0/ vehicle or Initialisation, in this order: Engine speed>0/ stepper error/ throttle speed>0/Vehicle speed>0/stepper Initialisation fault position / battery voltage/ water...
  • Page 62 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE ENABLE DEVICES The device is activated: if not correctly activated, the tester will NOT show Front injector failed activation immediately; necessary to check the detected faults page The device is activated: if not correctly...
  • Page 63 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE It is displayed if the feeding circuit is broken or short-circuited; it switches from ACT to STO without reconnecting Lambda sensor heat. if the engine is off, otherwise it stays...
  • Page 64 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE Int.press.signal low Int.press.signal high Cut off time excess. This is a first in our injection systems: Water temperature too high error detection is based on a critical (limit exceeded) threshold (115°C) (239 °F) rather than...
  • Page 65 FUEL SYSTEM TUONO 1000 UNIT APPROXIMATE SCREEN DESCRIPTION NOTE VALUES MEASURE FROZEN PARAMETERS Same as the engine parameters page, Engine load but expressed in % Water temperature °C Air temperature °C Battery voltage Caution: measured in kPa so, for example,...

  • Page 66: Fuel Pump

    FUEL SYSTEM TUONO 1000 3.2. FUEL PUMP 3.2.1. REMOVING THE PUMP UNIT • Completely remove the fuel tank. NOTE Place the tank on a clean surface with the pump unit facing upward. • Loosen and remove the eight screws (1).

  • Page 67: Removing The Fuel Level Sensor

    FUEL SYSTEM TUONO 1000 3.2.2. REMOVING THE FUEL LEVEL SENSOR • Remove the complete fuel unit. • Disconnect the connector. • Loosen and remove the two screws. • Remove the fuel level sensor. 3 - 17...

  • Page 68: Removing The Delivery Fuel Filter

    Remove the complete fuel pump unit. NOTE special tool OPT: - aprilia part# 0277295 (pliers for fitting ties). WARNING When reassembling, replace the tie with a new one of the same size. Do not refit the old tie; it is no longer useable.

  • Page 69: Removing The Fuel Pump

    Remove the complete fuel pump unit. NOTE special tool OPT: - aprilia part# 0277295 (pliers for fitting ties). WARNING When reassembling, replace the tie with a new one of the same size. Do not refit the old tie; it is no longer useable.
  • Page 70 FUEL SYSTEM TUONO 1000 • Loosen and remove the three screws. • Bend the side of the fuel filter and hold it in position. NOTE Use compressed air to clean any sediments in the filter mesh; direct the jet of air so that the impurities do not penetrate inward.

  • Page 71: Throttle Body Unit

    FUEL SYSTEM TUONO 1000 3.3. THROTTLE BODY UNIT 3.3.1. REMOVING THE THROTTLE BODY UNIT WARNING The screws for the basic adjustment of the throttle valve (1) are painted and cannot be set. The adjustment screws can be set only when...
  • Page 72 FUEL SYSTEM TUONO 1000 throttle valve potentiometer. NOTE Use the special tool OPT: aprilia part# 0277295 (pliers for fitting ties). • Unfasten the tie (4). • Unfasten the tie (5). • Slide the tubes out of the throttle unit. •...
  • Page 73 FUEL SYSTEM TUONO 1000 • Slide the airbox flap tube out of the throttle unit. • Loosen the two ties WARNING Be very careful when removing the throttle unit, as it is connected to the fuel tank by means of the fuel line.

  • Page 74: Disassembling The Throttle Unit

    FUEL SYSTEM TUONO 1000 3.3.2. DISASSEMBLING THE THROTTLE UNIT • Loosen and remove the M8x1 nut (1) and remove the spring washer. • Slightly turn the throttle valve control lever (2), loosen and remove the three T.E. M5x12 screws (3).
  • Page 75 FUEL SYSTEM TUONO 1000 • Loosen and remove the two M6x25 screws (14); remove the right injector bracket (15) together with the gasket (16), injector (17) and seal (18). NOTE The injector seal (18) can be left in the throttle unit hole.
  • Page 76 FUEL SYSTEM TUONO 1000 • Loosen and remove the M8x1 nut (19); remove the spring washer (20), the belt roller (21), the two bushings (22) and the torsion spring (23). • Slide the fulcrum pin (24) together with the safety...

  • Page 77: Inspecting The Throttle Unit

    FUEL SYSTEM TUONO 1000 3.3.3. INSPECTING THE THROTTLE UNIT INJECTOR OPERATION TEST NOTE The injectors can be tested electrically. • Check the following components: electrical wiring and connections; injector or ECU injection signal. Throttle body • Clean all throttle body (1) openings and ducts using compressed air.

  • Page 78: Refitting The Throttle Unit

    FUEL SYSTEM TUONO 1000 3.3.4. REFITTING THE THROTTLE UNIT WARNING After having disassembled the throttle unit, replace all gaskets, O-rings, torsion springs, bushings and seals. These components are supplied with the repair kit. • Fit the new O-rings (1) and seals (2) on both injectors.
  • Page 79 FUEL SYSTEM TUONO 1000 WARNING Ensure that the ends of the torsion spring (20) are hooked to the accelerator wire securing staff and belt roller (21). NOTE Spray the spring (20) with temporary lubricant. • Fit the spring washer (22).

  • Page 80: Replacing The Throttle Valve Control Lever

    FUEL SYSTEM TUONO 1000 3.3.5. REPLACING THE THROTTLE VALVE CONTROL LEVER REMOVAL • Partially remove the fuel tank. • Remove the air box. • Loosen and remove the M8x1 nut (1) and remove the spring washer. • Slide out the control lever (2) and set aside the two bushings (3) and the torsion spring (4).

  • Page 81: Checking Axial Play On The Throttle Valve Control Shaft

    FUEL SYSTEM TUONO 1000 3.3.6. CHECKING AXIAL PLAY ON THE THROTTLE VALVE CONTROL SHAFT • Partially remove the fuel tank. • Remove the air box. NOTE Use a thickness gauge (1) with a 0.05 mm (0.00197 in) scale. With the throttle valves closed: •...
  • Page 82 ENGINE TUONO 1000 ENGINE 4 - 1...
  • Page 83 ENGINE TUONO 1000 SUMMARY 4.1. ENGINE............................3 4.1.1. REMOVING THE ENGINE ...................... 3 4.1.2. INSTALLING THE ENGINE....................26 4.1.3. TIGHTENING TORQUES...................... 51 4 - 2...

  • Page 84: Engine

    ENGINE TUONO 1000 4.1. ENGINE 4.1.1. REMOVING THE ENGINE • To remove the engine, you will have to remove seat, fuel tank and battery first. • Remove the airbox cover. • Remove the screws fixing the airbox to the frame.
  • Page 85 ENGINE TUONO 1000 • Disconnect the bypass tubes to the throttle body and the stepper motor connection. • Disconnect the oil recovery tank tube. 4 - 4...
  • Page 86 ENGINE TUONO 1000 • Disconnect the manifold pressure sensor and tubes coming from the throttle body. • Remove the airbox. 4 - 5...
  • Page 87 ENGINE TUONO 1000 • Disconnect the coil wiring. • Disconnect the accelerator control wires. • Disconnect the throttle potentiometer. • Disconnect the vacuum tubes on the throttle body. 4 - 6...
  • Page 88 ENGINE TUONO 1000 • Disconnect the injector connectors. • Loosen the ties on the intake manifolds. 4 - 7...
  • Page 89 ENGINE TUONO 1000 • Disconnect the throttle body. • Plug all openings to avoid entry of impurities. • Unfasten the ties of the lubrication circuit tubes coming from the oil tank. 4 - 8...
  • Page 90 ENGINE TUONO 1000 • Disconnect the oil tubes on the crankcase. 4 - 9...
  • Page 91 ENGINE TUONO 1000 • Loosen the three fixing screws on the oil tank. • Remove the oil tank along with the tube coming from the oil cooler. • Slide the breather tubes out of their housing. • Remove the oil tube on the crankcase.
  • Page 92 ENGINE TUONO 1000 • Loosen and remove the rear brake fluid reservoir fixing screw and move the reservoir downward keeping it vertical. • Remove the clamp. • Remove the coolant breather tube. • Loosen and remove the two expansion tank fixing screws and remove the expansion tank.
  • Page 93 ENGINE TUONO 1000 • Disconnect the connectors. • Loosen and remove the two fixing screws and remove the voltage regulator. • Loosen and remove the two fixing screws and remove the voltage regulator mounting plate. 4 - 12...
  • Page 94 ENGINE TUONO 1000 • Unscrew the stud bolt that secures the oil tube clamp to the crankcase. • Disconnect the oil tube from the right-hand side. • Loosen and remove the four oil cooler subframe fixing screws. NOTE For the screw on the upper left-hand side, tighten the internal nut with a spanner.
  • Page 95 ENGINE TUONO 1000 • Remove the subframe complete with oil coolers. • Remove the rear brake master cylinder fixing screws. • Unfasten the clip fixing the master cylinder to the brake lever. • Disconnect the engine oil pressure sensor. 4 - 14...
  • Page 96 ENGINE TUONO 1000 • Disconnect the vehicle speed sensor, the stop light switch and the lambda sensor connectors. • Remove the oil cooler lower brackets and move it keeping it vertical. • Unscrew the starter motor connection. • Unhook the silencer fixing springs.
  • Page 97 ENGINE TUONO 1000 • Loosen the silencer clamp fixing screws. • Remove the silencers. • Unhook the fixing spring located between the front cylinder manifold and the exhaust. • Loosen the four nuts fixing the manifold to the front cylinder.
  • Page 98 ENGINE TUONO 1000 • Remove the manifold. • Remove the seal. • Unhook the fixing spring located between the rear manifold and the exhaust. • Slide the lambda sensor wiring out of the frame. 4 - 17...
  • Page 99 ENGINE TUONO 1000 • Remove the exhaust complete with lambda sensor. • Loosen the four nuts fixing the manifold to the rear cylinder. • Remove the exhaust manifold; remove the seal. • Disconnect the engine temperature sensor, the timing sensor, the rpm sensor, the side stand safety switch and the generator connectors.
  • Page 100 ENGINE TUONO 1000 4 - 19...
  • Page 101 ENGINE TUONO 1000 • Disconnect the spark plug caps. • Remove the gear lever. 4 - 20...
  • Page 102 ENGINE TUONO 1000 • Remove the clutch actuator complete with flange. • Remove the sprocket cover and the crankcase guide plate. • Unscrew the sprocket fixing bolt and set aside the seal washer. 4 - 21...
  • Page 103 ENGINE TUONO 1000 • Remove the sprocket. • Unfasten the ties and disconnect the coolant tubes on the oil cooler. • Unscrew the earth connections on the crankcase. • Unscrew the neutral sensor connection. 4 - 22...
  • Page 104 ENGINE TUONO 1000 • Remove the rear brake lever. • Remove the lever bracket and the rear brake master cylinder. • Remove the brake master cylinder bracket. • Disconnect the vacuum tube on the clutch pneumatic actuator. • Hold up the engine with an adequate support.
  • Page 105 ENGINE TUONO 1000 • Remove the rear screws fixing the engine to the frame. • Loosen the four screws of the engine front mounts. • Remove the screws and the spacers located between the frame and the engine. 4 - 24...
  • Page 106 ENGINE TUONO 1000 • Pull back the adjustment bushings between the engine and the frame. • Completely lower the engine. 4 - 25...

  • Page 107: Installing The Engine

    ENGINE TUONO 1000 4.1.2. INSTALLING THE ENGINE • Place the engine on a suitable lower support. • Lift the engine. • Position the engine so as to align the rear mounts on the frame. • Fit the front left spacer.
  • Page 108 ENGINE TUONO 1000 • Tighten the two screws in the front left engine mount. • Fit the left rear spacer and tighten the screws to the specified torque. • Tighten the left rear screw. 4 - 27...
  • Page 109 ENGINE TUONO 1000 • Fit the front right spacer • Tighten the two screws in the front right mount. • Tighten the four screws on the left-hand side. • Tighten the upper right bushing to the specified torque. • Tighten the upper right ring nut to the specified torque.
  • Page 110 ENGINE TUONO 1000 • Tighten the lower right bushing to the specified torque. • Tighten the lower right ring nut to the specified torque. • Tighten the upper right screw. • Tighten the lower right screw. • Tighten the four screws on the right-hand side.
  • Page 111 ENGINE TUONO 1000 • Remove the engine lower support. • Reconnect the vacuum tube to the clutch pneumatic actuator and fasten it with a tie. • Fit the lever and the rear brake master cylinder bracket and tighten the screws to the specified torque.
  • Page 112 ENGINE TUONO 1000 • Fit the rear brake lever and tighten the screws to the specified torque. • Fit the rear brake master cylinder and connect it to the brake lever. • Tighten the neutral sensor connection. • Reconnect the earth connection to the crankcase and tighten the screws to the specified torque.
  • Page 113 ENGINE TUONO 1000 • Use ties to fasten the coolant tubes to the oil cooler • Place the sprocket in the correct position. 4 - 32...
  • Page 114 ENGINE TUONO 1000 • Tighten the fixing bolt to the specified torque to secure the sprocket in place. • Fit the sprocket cover and the guide plate and tighten the screws to the specified torque. • Fit the clutch actuator complete with flange.
  • Page 115 ENGINE TUONO 1000 • Fit the gear lever. • Insert the spark plug caps in their housing. • Connect the engine temperature sensor, the timing sensor, the rpm sensor, the side stand safety switch and the generator connectors. 4 - 34...
  • Page 116 ENGINE TUONO 1000 4 - 35...
  • Page 117 ENGINE TUONO 1000 • Fit the rear cylinder exhaust manifold with the washer. • Tighten the nuts and stud bolts to the specified torque. • Fit the exhaust complete with lambda sensor. • Hook the fixing spring located between the rear manifold and the exhaust.
  • Page 118 ENGINE TUONO 1000 • Place the exhaust gasket on the front cylinder. • Fit the manifold on the cylinder stud bolts and on the exhaust. • Tighten the four nuts fixing the manifold to the cylinder to the specified torque.
  • Page 119 ENGINE TUONO 1000 • Hook the fixing spring between the front cylinder manifold and the exhaust. • Fit the silencers. • Tighten the silencer clamp fixing screws. • Hook the silencer fixing springs. 4 - 38...
  • Page 120 ENGINE TUONO 1000 • Tighten the starter motor connection. • Move the oil cooler toward the engine and secure the lower supports. • Refit the lambda sensor, stop light switch and speed sensor connectors. • Connect the engine oil pressure sensor.
  • Page 121 ENGINE TUONO 1000 • Fasten the clip fixing the master cylinder to the brake lever. • Tighten the rear brake master cylinder fixing screws. • Fit the subframe complete with oil coolers. • Tighten the four screws to the specified torque.
  • Page 122 ENGINE TUONO 1000 NOTE For the screw on the upper left-hand side, tighten the internal nut with a spanner. • Connect the oil tube from the right-hand side. • Tighten the stud bolt that secures the oil tube clamp to the crankcase.
  • Page 123 ENGINE TUONO 1000 • Fit the voltage regulator and tighten the two fixing screws. • Restore all connections. • Fit the expansion tank and tighten the two fixing screws. 4 - 42...
  • Page 124 ENGINE TUONO 1000 • Fit the coolant breather tube. • Fit the clamp. • Fit the rear brake fluid reservoir and tighten the fixing screw. • Fit the oil tube on the crankcase. 4 - 43...
  • Page 125 ENGINE TUONO 1000 • Fit the oil tank. • Tighten the three oil tank fixing screws. • Fit a new clamp to the tube coming from the oil cooler and fit the tube into place in the housing. • Insert the breather tubes in their housing.
  • Page 126 ENGINE TUONO 1000 • Remove the plugs from the ducts. • Fit the throttle body. 4 - 45...
  • Page 127 ENGINE TUONO 1000 • Fasten the ties on the intake manifolds. • Connect the injector connectors. • Insert the vacuum tubes in the throttle body. 4 - 46...
  • Page 128 ENGINE TUONO 1000 • Connect the throttle position sensor. • Fit the throttle control wires and adjust play. 4 - 47...
  • Page 129 ENGINE TUONO 1000 • Connect the coil wiring. • Fit the airbox. • Reconnect the manifold pressure sensor and tubes coming from the throttle body. 4 - 48...
  • Page 130 ENGINE TUONO 1000 • Disconnect the oil recovery tank tube. • Disconnect the by-pass tubes to the throttle body and the stepper motor connection. • Tighten the six screws fixing the throttle body to the airbox. 4 - 49...
  • Page 131 ENGINE TUONO 1000 • Fit the airbox cover. • Fit the battery, the fuel tank and the seat. 4 - 50...

  • Page 132: Tightening Torques

    ENGINE TUONO 1000 4.1.3. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. Note (Nm) ENGINE TO FRAME Front engine mount...
  • Page 133 ENGINE TUONO 1000 TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. Note (Nm) ELECTRIC SYSTEM Voltage regulator to mount Coil mount to frame Coil to coil mount Starter relay mount to seat frame Relay carrier bracket to seat frame Atmospheric pressure sensor to...
  • Page 134 ENGINE TUONO 1000 Torque Description Type of fastener Tol. Note (Nm) FUEL PUMP Fuel return line to flange M12x1.5 Fuel level sensor to pump mount (for SWP 2.9x12 workshop manual only) Fuel pump wiring harness to flange (for workshop manual only)
  • Page 135 CYCLE PARTS TUONO 1000 CYCLE PARTS 5 - 1...
  • Page 136 CYCLE PARTS TUONO 1000 SUMMARY 5.1. DISASSEMBLING THE UPPERWORKS..................4 5.1.1. DISASSEMBLING THE UPPERWORKS ................4 5.1.2. REASSEMBLING THE UPPERWORKS ................. 7 5.1.3. TIGHTENING TORQUES...................... 10 5.2. FRONT FORK ..........................11 5.2.1. FRONT FORK DIAGRAM...................... 11 5.2.2. REMOVING THE FORK LEGS ..................... 12 5.2.3.
  • Page 137 CYCLE PARTS TUONO 1000 5.10. CLUTCH............................110 5.10.1. BLEEDING THE CLUTCH SYSTEM..................110 5.11. CHAIN ............................111 5.11.1. DRIVE CHAIN ........................111 5.11.2. INSPECTING THE DRIVE CHAIN SLIDER.................113 5.11.3. REMOVING THE CHAIN SLIDER ..................114 5.11.4. LOWER CHAIN SLIDER ......................116 5 - 3...
  • Page 138 CYCLE PARTS TUONO 1000 5.1. DISASSEMBLING THE UPPERWORKS 5.1.1. DISASSEMBLING THE UPPERWORKS • Loosen and remove the two fixing screws (1) and set aside the washers. • Remove the fairing (2). • Unscrew and remove the fixing pin (3). •...
  • Page 139 CYCLE PARTS TUONO 1000 • Loosen and remove the fixing screw (7). • Remove the fairing (8). • Loosen and remove the two fixing screws (9) and set aside the washers. • Remove the fairing (10). • Loosen and remove the left fixing screw and set aside the washer (11) .
  • Page 140 CYCLE PARTS TUONO 1000 • Loosen and remove the right fixing screw and set aside the washer (13) . • Remove the fairing (14). • Loosen and remove the two fixing screws and set aside the washers (15) . •...

  • Page 141: Reassembling The Upperworks

    CYCLE PARTS TUONO 1000 5.1.2. REASSEMBLING THE UPPERWORKS • Fit the fairing (21). • Tighten the fixing screw (20). • Fit the fairing (19). • Insert and tighten the fixing pin (18). • Tighten the two fixing screws (17). •...
  • Page 142 CYCLE PARTS TUONO 1000 • Tighten the front fixing screw (12). • Tighten the left fixing screw (11). • Fit the fairing (10). • Tighten the two fixing screws (9). • Fit the fairing (8). • Tighten the fixing screw (7).
  • Page 143 CYCLE PARTS TUONO 1000 • Fit the fairing (6). • Fit the tube in the quick-fitting coupling (5). • Tighten the fixing screw (4). • Tighten the fixing pin (3). • Fit the fairing (2). • Tighten the two fixing screws (1).

  • Page 144: Tightening Torques

    CYCLE PARTS TUONO 1000 5.1.3. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. Torque Description Type of fastener Tol. Note (Nm) RIGHT / LEFT SIDE PANELS...

  • Page 145: Front Fork

    CYCLE PARTS TUONO 1000 5.2. FRONT FORK 5.2.1. FRONT FORK DIAGRAM Key: Right radial fork leg Left radial fork leg Sleeve Damper rod bushing Spring Complete preload tube. Spacer Washer Complete damper rod. 10. Washer 11. Ring 12. Complete sleeve plug.

  • Page 146: Removing The Fork Legs

    CYCLE PARTS TUONO 1000 5.2.2. REMOVING THE FORK LEGS • Support the front end of the vehicle. • Loosen the front mudguard screws and remove it. • Loosen the front callipers fixing screws and slide them out of the disc.
  • Page 147 CYCLE PARTS TUONO 1000 • Remove the wheel shaft nut. • Set aside the washer. 5 - 13...
  • Page 148 CYCLE PARTS TUONO 1000 • Loosen the wheel shaft pinch bolts. • Lightly tap the wheel shaft with a rubber mallet until the holes on the opposite side are uncovered. • Remove the wheel shaft using a screwdriver inside the shaft holes.
  • Page 149 CYCLE PARTS TUONO 1000 • Support the fork and loosen the top and bottom yoke screws. • Fit the fork leg. 5 - 15...

  • Page 150: Fitting The Fork Legs

    CYCLE PARTS TUONO 1000 5.2.3. FITTING THE FORK LEGS • Fit the fork leg. • Adjust sleeve sliding and tighten the screws on the fork yokes to the specified torque. • Fit the front wheel and insert the wheel shaft in its housing.
  • Page 151 CYCLE PARTS TUONO 1000 • Fit the washer and tighten the wheel shaft nut to the specified torque. • Work the fork to ensure that the fork legs are aligned. • Working on both sides, tighten the clamp screws securing the wheel shaft to the specified torque.
  • Page 152 CYCLE PARTS TUONO 1000 • Fit the callipers on the disc. • Fit the brake callipers and tighten the screws to the specified torque. WARNING After installing the brake callipers, pull the front brake lever a few times 5 - 18...

  • Page 153: Replacing Fork Fluid

    CYCLE PARTS TUONO 1000 5.2.4. REPLACING FORK FLUID • Clamp the sleeve in a vice with the specified tool. • Set the spring preload to its minimum. • Unscrew the sleeve upper plug. • Clamp the fork foot with care to avoid damaging it.
  • Page 154 CYCLE PARTS TUONO 1000 • Fit the specified tool on the spring joint. • Push the tool downward to compress the spring and then fit the tool spacer under the cartridge lock nut. • Loosen the plug by placing the key in the provided opening and loosening the nut.
  • Page 155 CYCLE PARTS TUONO 1000 • Remove the spacer and the washer. • Press downward against spring force and slide out the spacer. • Slide out the spring joint. • Empty the oil into a container and remove the spring. 5 - 21...

  • Page 156: Filling The Front Fork Fluid

    CYCLE PARTS TUONO 1000 5.2.5. FILLING THE FRONT FORK FLUID • Fill the fork so the air bubbles trapped inside are released. • Fit the spring joint. • Fit the specific tool on the spring joint so the cartridge rod is secured in position.
  • Page 157 CYCLE PARTS TUONO 1000 • Tighten the upper plug on the cartridge rod. • Clamp the sleeve in a vice with the specified tool. 5 - 23...
  • Page 158 CYCLE PARTS TUONO 1000 • Tighten the upper plug to the specified torque. 5 - 24...

  • Page 159: Replacing The Oil Seal/Dust Seal

    CYCLE PARTS TUONO 1000 5.2.6. REPLACING THE OIL SEAL/DUST SEAL • Clamp the sleeve in a vice with the specified tool. • Set the spring preload to its minimum. • Unscrew the sleeve upper plug. • Clamp the fork foot with care to avoid damaging it.
  • Page 160 CYCLE PARTS TUONO 1000 • Fit the specified tool on the spring joint. • Push the tool downward to compress the spring and then fit the tool spacer under the cartridge lock nut. • Loosen the plug by placing the key in the provided opening and loosening the nut.
  • Page 161 CYCLE PARTS TUONO 1000 • Remove the spacer and the washer. • Press downward against spring force and slide out the spacer. • Slide out the spring joint. • Empty the oil into a container and remove the spring. 5 - 27...
  • Page 162 CYCLE PARTS TUONO 1000 • Remove the spacer and the washer. • Loosen the cartridge fixing screw on the fork foot. • Set aside the centring bushing. 5 - 28...
  • Page 163 CYCLE PARTS TUONO 1000 • Slide out the sleeve dust seal using a screwdriver for leverage. • When doing this, take care not to damage the edge of the sleeve. • Remove the circlip. • Remove the sleeve from the slider using the sleeve as a stop.
  • Page 164 CYCLE PARTS TUONO 1000 • Remove the ring and the dust seal. 5 - 30...
  • Page 165 CYCLE PARTS TUONO 1000 5 - 31...

  • Page 166: Refitting The Oil Seal/Dust Seal

    CYCLE PARTS TUONO 1000 5.2.7. REFITTING THE OIL SEAL/DUST SEAL • Clamp the leg in a vice with care to avoid damaging its surfaces. • Protect the ends of the leg with adhesive tape. • Lubricate the sliding edges with fork fluid or seal grease.
  • Page 167 CYCLE PARTS TUONO 1000 • Ensure that the stamped side of the sealer ring is facing the dust seal. • Proceed to fit the ring, the movable bushing and, after having removed the tape, the fixed bushing. 5 - 33...
  • Page 168 CYCLE PARTS TUONO 1000 • Fit the sleeve on the leg and, using the specific tool, fit the oil seal in position. • Insert the stop ring in its housing. • Fit the dust seal with the specific tool. •...
  • Page 169 CYCLE PARTS TUONO 1000 • Tighten the cartridge fixing screw on the fork foot to the specified torque. • Fit the lower spacer and the washer. • Fit the fork spring. 5 - 35...
  • Page 170 CYCLE PARTS TUONO 1000 • Fill the fork so the air bubbles trapped inside are released. • Fit the spring joint. • Fit the specific tool on the spring joint so the cartridge rod is secured in position. • Fit the spacer and the washer.
  • Page 171 CYCLE PARTS TUONO 1000 • Tighten the upper plug on the cartridge rod. • Clamp the sleeve in a vice with the specified tool. 5 - 37...
  • Page 172 CYCLE PARTS TUONO 1000 • Tighten the upper plug to the specified torque. 5 - 38...

  • Page 173: Checking The Components

    CYCLE PARTS TUONO 1000 5.2.8. CHECKING THE COMPONENTS WHEEL STANCHION Inspect the sliding surface for scoring and/or scratching. Eliminate minor scoring with wet sand paper (grain size 1). Replace the stanchion if badly scored. Check for stanchion buckling using a dial gauge.
  • Page 174 CYCLE PARTS TUONO 1000 – damper rod. Change any component which is badly worn or damaged. WARNING Remove any impurities from the bushing; be careful not to damage the surface. When reassembling, replace the following components with new ones: – gasket;...
  • Page 175 1 projection notch (*) clockwise (**) anticlockwise (***) For this type of adjustment please contact exclusively an aprilia Authorised Dealer. NOTE Öhlins forks available on request (OPT). Öhlins front fork (OPT) The standard adjustment of the fork meets most conditions of high and low speed riding, whether the vehicle is travelling with a full load or not.
  • Page 176 (*) close (**) 8 turns Leg projection (A) (***) from upper yoke (excluding plug) 4 projection notches (*) clockwise (**) anticlockwise (***) For this type of adjustment please contact exclusively an aprilia Authorised Dealer. 5 - 42...

  • Page 177: Tightening Torques

    CYCLE PARTS TUONO 1000 5.2.9. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. NOTE (Nm) FRONT FORK Fork leg to top fork yoke...

  • Page 178: Steering Bearings

    CYCLE PARTS TUONO 1000 5.3. STEERING BEARINGS 5.3.1. DIAGRAM Key: Top yoke Bottom yoke Counter nut Ring nut Steering safety plate Top yoke fixing bushing Dust seal Dust seal Headstock plug washer 10. Axial ball bearing 11. Steering damper 12. Front damper mount 13.

  • Page 179: Checking Play

    CYCLE PARTS TUONO 1000 5.3.2. CHECKING PLAY Steering bearings and steering play: • Place the vehicle on the central support stand. • Shake the fork in the direction of travel. • If play is noticed, proceed with adjustment 5 - 45...

  • Page 180: Adjusting Bearing Play

    CYCLE PARTS TUONO 1000 5.3.3. ADJUSTING BEARING PLAY • Loosen and remove the four U-bolt fixing screws. • Remove the stand. • Remove the handlebar taking special care not to spill oil from the clutch reservoir or from the front brake fluid reservoir.
  • Page 181 CYCLE PARTS TUONO 1000 • Straighten the safety washer on the headstock. • Loosen the upper ring nut and remove the safety washer. 5 - 47...
  • Page 182 CYCLE PARTS TUONO 1000 • Adjust the steering bearing preload by tightening the lower ring nut to the specified torque. • Fit the safety washer. • Fit the upper ring nut and tighten so the grooves correspond to the safety washer tabs.
  • Page 183 CYCLE PARTS TUONO 1000 • Rivet the tabs on the upper ring nut. • Fit the upper fork yoke. • Tighten the upper bolt on the headstock to the specified torque. • Tighten the fork leg fixing screws on the upper yoke to the specified torque.
  • Page 184 CYCLE PARTS TUONO 1000 • Fit the handlebar. • Fit the U-bolt. • Tighten the four U-bolt fixing screws to the specified torque. 5 - 50...

  • Page 185: Tightening Torques

    CYCLE PARTS TUONO 1000 5.3.4. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. NOTE (Nm) ENGINE TO FRAME...
  • Page 186 CYCLE PARTS TUONO 1000 TORQUE Description QUANTITY NUT/BOLT TOL. NOTE (Nm) FRONT FORK LOWER COVER Cover to lower fork yoke Cover to lower fork yoke with steering damper HANDLEBAR AND CONTROLS Upper U-bolt to handlebar mounts Handlebar mounts to fork upper yoke...

  • Page 187: Rear Suspension

    CYCLE PARTS TUONO 1000 5.4. REAR SUSPENSION 5.4.1. DIAGRAM Key: Shock absorber Double connecting rod Roller case D18x24x3 oil seal Pin L=36 Screw T-bushing M10 flanged self-locking nut Complete single connecting rod 10. M10x59 TCEI screw 11. M10x61 flanged screw...

  • Page 188: Disassembling The Rear Suspension

    CYCLE PARTS TUONO 1000 5.4.2. DISASSEMBLING THE REAR SUSPENSION • Secure the motorcycle using slings and an A-frame. • Working from the right-hand side of the vehicle, loosen the upper screw (1) but do not remove it and remove the nut.
  • Page 189 CYCLE PARTS TUONO 1000 • Remove the rear shock absorber (3) from between swingarm and rear subframe. 5 - 55...

  • Page 190: Checking The Components

    CYCLE PARTS TUONO 1000 5.4.3. CHECKING THE COMPONENTS WARNING Check that the components are not deformed, broken, cracked and/or dented. Replace any damaged components BEARINGS Manually turn the rollers; they must turn smoothly, freely and without noise. No axial play should be noticed.
  • Page 191 CYCLE PARTS TUONO 1000 Öhlins shock absorber (OPT) WARNING Adjust shock absorber spring preload and rebound damping to suit motorcycle usage conditions. When you increase spring preload, you should also increase rebound damping to avoid sudden jerks when riding. DANGER...

  • Page 192: Reassembling The Rear Suspension

    CYCLE PARTS TUONO 1000 5.4.4. REASSEMBLING THE REAR SUSPENSION • Fit the rear shock absorber (3) between swingarm and rear subframe. • Fit the lower screw (2). • Operate the A-frame until aligning the frame hole with the rear suspension upper mounting point.
  • Page 193 CYCLE PARTS TUONO 1000 • Working from the left-hand side of the vehicle, fit the nut (1) to the upper screw and tighten. • Release the motorcycle from the A-frame and remove the slings. 5 - 59...

  • Page 194: Removing The Rear Suspension Connecting Rods

    CYCLE PARTS TUONO 1000 5.4.5. REMOVING THE REAR SUSPENSION CONNECTING RODS • Working from the right-hand side of the vehicle, loosen and remove the nut (1). • Remove the screw from the opposite side (2). • Loosen and remove the nut (3).

  • Page 195: Tightening Torques

    CYCLE PARTS TUONO 1000 5.4.6. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. NOTE (Nm) REAR SHOCK ABSORBER...

  • Page 196: Swingarm

    CYCLE PARTS TUONO 1000 5.5. SWINGARM 5.5.1. REMOVING THE SWINGARM • Place the vehicle on the central support stand (OPT). • Remove the rear wheel. NOTE Though not necessary for removing the rear wheel, the rear support stand (OPT) is essential for keeping the swingarm without the wheel in place.
  • Page 197 • Loosen and remove the nut and set aside the washer. NOTE Use the special tool (OPT): aprilia part# 8140191 (tool for tightening swingarm pivot and supporting engine). • Use the box spanner to loosen and remove the ring nut (1) on the right-hand side of the vehicle.
  • Page 198 CYCLE PARTS TUONO 1000 • Turn the swingarm pivot anticlockwise (2); this will turn and drag the adjustment bushing (3) loosening it completely. WARNING Removal must be carried out with utmost care. Support the front end of the swingarm to avoid accidental falling.

  • Page 199: Checking The Components

    CYCLE PARTS TUONO 1000 5.5.2. CHECKING THE COMPONENTS WARNING Check that components intact, especially those listed below. SWINGARM BEARINGS Perform the check with the bearings fitted on the swingarm. ROTATION CHECK • Manually turn the inner ring of each bearing. Rotation must be continuous, smooth and silent.

  • Page 200: Removing The Swingarm Bearings

    • Remove the circlip (4). NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Remove the two bearings (5) and the roller bearing (6) with the extractor. WARNING After removing the bearings, check to see if they should be replaced.

  • Page 201: Refitting The Swingarm

    CYCLE PARTS TUONO 1000 5.5.4. REFITTING THE SWINGARM • Smear some grease all along the swingarm pivot. • Fit the adjustment bushing (3) in its housing and tighten it manually. NOTE Ensure that the adjustment bushing (3) does not protrude from the inner edge of the frame.
  • Page 202 CYCLE PARTS TUONO 1000 NOTE Use the special tool (OPT): aprilia part# 8140191 (tool for tightening swingarm pivot and supporting engine). • Tighten the locking ring nut with a box spanner (1). • Tighten the nut. • Remove the adhesive tape and free the chain.
  • Page 203 CYCLE PARTS TUONO 1000 • Working on the right-hand side, insert the shock absorber lower screw. • Tighten the nut on the opposite side. • Working on the right-hand side, insert the double- connecting rod/swingarm screw. • Tighten the nut on the opposite side.

  • Page 204: Tightening Torques

    CYCLE PARTS TUONO 1000 5.5.5. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. Note (Nm) ENGINE TO FRAME...

  • Page 205: Front Wheel

    CYCLE PARTS TUONO 1000 5.6. FRONT WHEEL 5.6.1. DIAGRAM Key: Naked blue front wheel Tubeless tyre valve Internal spacer 6005-2rs1 bearing 30x47x7 seal Circlip External spacer Front brake disc 25.2x36x1 washer 10. Wheel shaft nut 11. M8x20 flanged screw 12. Front wheel shaft 13.

  • Page 206: Removing The Front Wheel

    CYCLE PARTS TUONO 1000 5.6.2. REMOVING THE FRONT WHEEL • Support the front end of the vehicle. • Loosen the front mudguard screws and remove it. • Loosen the front calliper fixing screws and slide them out of the disc.
  • Page 207 CYCLE PARTS TUONO 1000 • Remove the wheel shaft nut. • Set aside the washer. 5 - 73...
  • Page 208 CYCLE PARTS TUONO 1000 • Loosen the wheel shaft pinch bolts. • Lightly tap the wheel shaft with a rubber mallet until the holes on the opposite side are uncovered. • Remove the wheel shaft using a screwdriver inside the shaft holes.

  • Page 209: Checking The Front Wheel Components

    CYCLE PARTS TUONO 1000 5.6.3. CHECKING THE FRONT WHEEL COMPONENTS WARNING Check that components intact, especially those listed below. FRONT WHEEL BEARINGS Check with the bearings fitted on the wheel. ROTATION CHECK • Manually turn the inner ring of each bearing. Rotation must be continuous, smooth and silent.
  • Page 210 CYCLE PARTS TUONO 1000 FRONT WHEEL RIM • Using a dial gauge, check that the radial (A) and axial (B) eccentricity of the rim (2) does not exceed the specified limit. Excess eccentricity is usually caused by worn or damaged bearings.

  • Page 211: Removing The Front Wheel Bearings

    The edges of the spacer (4) feature slots (A) to allow the passage of the extractor teeth. NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Remove the right bearing with the extractor (5). • Set aside the inner spacer (4). Work on the left-hand side of the wheel: •...

  • Page 212: Refitting The Front Wheel Bearings

    Work on the right-hand side of the wheel: NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Insert the right bearing (5) completely, using the drift. NOTE The bearing must be inserted until it is fully home against the abutment (Y).
  • Page 213 CYCLE PARTS TUONO 1000 5 - 79...

  • Page 214: Fitting The Wheel

    CYCLE PARTS TUONO 1000 5.6.6. FITTING THE WHEEL • Fit the front wheel and insert the wheel shaft in its housing. • Tighten the clamp screws (nut side) to secure the wheel shaft. • Fit the washer and tighten the wheel shaft nut to the specified torque.
  • Page 215 CYCLE PARTS TUONO 1000 • Working on both sides, tighten the clamp screws securing the wheel shaft to the specified torque. • Fit the callipers on the disc. • Fit the brake callipers and tighten the screws to the specified torque.

  • Page 216: Rear Wheel

    CYCLE PARTS TUONO 1000 5.7. REAR WHEEL 5.7.1. DIAGRAM Key: Complete chain, with master link Rear sprocket z=40 Naked blue rear wheel Rear wheel vibration damper holder 190/50–ZR 17" TL rear tyre Vibration damper seal Tubeless tyre valve Rear wheel spacer Retainer 10.

  • Page 217: Removing The Rear Wheel

    CYCLE PARTS TUONO 1000 5.7.2. REMOVING THE REAR WHEEL • Place the vehicle on the rear support stand. • Loosen and remove the wheel shaft nut. • Set aside the abutment washer and the left chain tightener slider. 5 - 83...
  • Page 218 CYCLE PARTS TUONO 1000 • Lightly tap on the wheel shaft so the head comes out of its housing. • Bring the wheel forward and free the drive chain from the rear sprocket. • Slide the wheel shaft out together with the right chain tightener slider.

  • Page 219: Removing The Final Drive Unit

    CYCLE PARTS TUONO 1000 5.7.3. REMOVING THE FINAL DRIVE UNIT • Remove the rear wheel. WARNING Proceed with care. If the final drive unit (1) is fitted on the vibration damper holder (2) do not turn the rear wheel upside down or horizontally (A) on the rear sprocket side;...
  • Page 220 CYCLE PARTS TUONO 1000 5 - 86...

  • Page 221: Checking The Rear Wheel Components

    CYCLE PARTS TUONO 1000 5.7.4. CHECKING THE REAR WHEEL COMPONENTS WARNING Check that components intact, especially those listed below. REAR WHEEL BEARINGS Check with the bearings fitted on the wheel. ROTATION CHECK • Manually turn the inner ring of each bearing. Rotation must be continuous, smooth and silent.
  • Page 222 CYCLE PARTS TUONO 1000 FINAL DRIVE UNIT BEARINGS Check with the bearings fitted on the final drive unit. ROTATION CHECK • Remove the left spacer (3). • Remove the right spacer (4). • Manually turn the inner ring of each bearing. Rotation must be continuous, smooth and silent.
  • Page 223 CYCLE PARTS TUONO 1000 REAR SPROCKET • Check the condition of the sprocket teeth (7). In case of excessive wear: • replace the rear sprocket. WARNING To avoid premature wear of new components, the rear sprocket, the front sprocket and the drive chain must be replaced as a group.

  • Page 224: Removing The Rear Wheel Bearings

    The edges of the spacer (4) feature slots (A) to allow the passage of the extractor teeth. NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Remove the right bearing with the extractor (5). • Set aside the inner spacer (4). Work on the left-hand side of the wheel:...

  • Page 225: Refitting The Rear Wheel Bearings

    Work on the right-hand side of the wheel: NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Insert the right bearing (5) completely, using the drift. NOTE The right bearing must be inserted until it is fully home against the abutment (Y).
  • Page 226 CYCLE PARTS TUONO 1000 5 - 92...

  • Page 227: Removing The Final Drive Unit Bearings

    NOTE The circlip (3) is fitted only on the left side of the final drive unit. NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Remove the left bearing with the extractor (4). • Set aside the inner spacer (5). •...

  • Page 228: Refitting The Final Drive Unit Bearings

    Work on the left-hand side: NOTE special tool OPT: - aprilia part# 8140180 (bearing extractor) • Insert the right bearing (6) completely, using the drift. NOTE The right bearing must be inserted until it is fully home against the abutment (Y).

  • Page 229: Removing The Vibration Damper Seals

    CYCLE PARTS TUONO 1000 5.7.9. REMOVING THE VIBRATION DAMPER SEALS • Remove the final drive unit. NOTE The vibration damper seals are fitted on the vibration damper holder. • Remove all vibration damper seals. 5 - 95...

  • Page 230: Removing The Rear Sprocket

    CYCLE PARTS TUONO 1000 5.7.10. REMOVING THE REAR SPROCKET • Using a setscrew wrench (1), lock threaded pin rotation (2), loosen and remove the self-locking nut (3) and the threaded pin (2). WARNING Replace the self-locking nuts (3) every three times the rear sprocket is removed.

  • Page 231: Refitting The Rear Wheel

    CYCLE PARTS TUONO 1000 5.7.11. REFITTING THE REAR WHEEL • Fit the wheel shaft, together with the right chain guide slider, on the swingarm. • Fit the rear wheel and insert the wheel shaft in its housing. • Bring the wheel forward and fit the drive chain on the rear sprocket.
  • Page 232 CYCLE PARTS TUONO 1000 • Manually tighten the nut. • Check the chain tension. • Tighten the fixing nut to the specified torque. 5 - 98...
  • Page 233 CYCLE PARTS TUONO 1000 5.7.12. TIGHTENING TORQUES WARNING All fasteners listed in the table must be tightened to the specified torque using a torque wrench and ® LOCTITE where specified. TORQUE DESCRIPTION QUANTITY NUT/BOLT TOL. Note (Nm) SWINGARM Swingarm pivot ring nut M30x1.5...

  • Page 234: Tightening Torques

    CYCLE PARTS TUONO 1000 5.8. FRONT BRAKE 5.8.1. CHANGING THE PADS TIGHTENING TORQUES Brake calliper screws (1) 50 Nm (5 kgm) WARNING This vehicle is equipped with a double-disc front brake system (right and left side). Always replace all the pads of both front brake callipers.
  • Page 235 CYCLE PARTS TUONO 1000 • Remove the two pads (4). WARNING Do not pull the brake lever when the pads are not in place or the calliper pistons might come out of their housing, thus causing brake fluid leakage. •...

  • Page 236: Check

    CYCLE PARTS TUONO 1000 5.8.2. CHECK Brake discs: NOTE Perform the following operations with the brake discs fitted on the wheel, the information provided below refers to one disc but applies to both. • Check disc wear by measuring the minimum thickness in various points with a micrometer.

  • Page 237: Removing The Discs

    CYCLE PARTS TUONO 1000 5.8.3. REMOVING THE DISCS • Remove the front wheel. NOTE The information provided below refers to one disc but applies to both. To loosen the screws (1) we recommend the use of a pneumatic screw gun which will resist the strength of the ®...

  • Page 238: Bleeding The Brake System

    CYCLE PARTS TUONO 1000 5.8.4. BLEEDING THE BRAKE SYSTEM FRONT BRAKE NOTE Make sure to have a flexible tube and a container of adequate size ready at hand before beginning the bleeding procedure. • Connect the tube to the brake master cylinder bleed valve.
  • Page 239 CYCLE PARTS TUONO 1000 • Pull the brake lever and slightly open the bleed valve on the calliper you wish to bleed to release the air. • Close the bleed valve before reaching the end of stroke with the lever and repeat the procedure until all the air is released.
  • Page 240 CYCLE PARTS TUONO 1000 • Pull the brake lever and slightly open the bleed valve on the calliper you wish to bleed to release the air. • Close the bleed valve before reaching the end of stroke with the lever and repeat the procedure until all the air is released.

  • Page 241: Rear Brake Pads

    CYCLE PARTS TUONO 1000 5.9. REAR BRAKE PADS 5.9.1. REPLACING THE REAR BRAKE PADS • Place the vehicle on the stand. • Remove the rear brake calliper. WARNING Do not pull the rear brake lever when the calliper has been removed as this could cause the piston to come out of its housing and determine brake fluid leakage.

  • Page 242: Checking The Rear Brake Disc

    CYCLE PARTS TUONO 1000 5.9.2. CHECKING THE REAR BRAKE DISC NOTE Perform this operation with the brake disc fitted on the wheel. • Check disc wear by measuring the minimum thickness in various points with a micrometer. • If the minimum thickness is lower than the minimum value, even if only in one point, replace the disc.

  • Page 243: Removing The Rear Brake Disc

    CYCLE PARTS TUONO 1000 5.9.3. REMOVING THE REAR BRAKE DISC • Remove the rear wheel. NOTE To loosen the screws (1) we recommend the use of a pneumatic screw gun which will resist the strength of the LOCTITE® 243. •...

  • Page 244: 5.10. Clutch

    CYCLE PARTS TUONO 1000 5.10. CLUTCH 5.10.1. BLEEDING THE CLUTCH SYSTEM NOTE Make sure to have a flexible tube and a container of adequate size ready at hand before beginning the bleeding procedure. • Connect the tube to the clutch control cylinder bleed valve.

  • Page 245: 5.11. Chain

    CYCLE PARTS TUONO 1000 5.11. CHAIN 5.11.1. DRIVE CHAIN The vehicle is equipped with an endless chain that does not contain a master link. NOTE Halve maintenance intervals if you are riding in rainy or dusty conditions, on rough road surfaces or when the vehicle is used in competitions.
  • Page 246 CYCLE PARTS TUONO 1000 • Loosen the two lock nuts (4). • Adjust chain play by means of the adjusters (5) ensuring that the references match on both sides of the vehicle (2-3). • Tighten the two lock nuts (4).

  • Page 247: Inspecting The Drive Chain Slider

    CYCLE PARTS TUONO 1000 5.11.2. INSPECTING THE DRIVE CHAIN SLIDER • Place the vehicle on the stand. • Ensure that the slider (1) is not worn or damaged; replace it with a new one if necessary. • Check for chain guide wear (2).

  • Page 248: Removing The Chain Slider

    CYCLE PARTS TUONO 1000 5.11.3. REMOVING THE CHAIN SLIDER • Place the vehicle on the rear support stand (OPT). • Loosen and remove the three screws. • Remove the sprocket cover. • Slacken chain tension. • Loosen and remove the sprocket fixing screw and set aside the washers.
  • Page 249 CYCLE PARTS TUONO 1000 • Loosen and remove the chain slider lower fixing screw and set aside the washer. • Slide the lower part of the chain slider out from the front. • Remove the chain slider by sliding it out from the rear.

  • Page 250: Lower Chain Slider

    CYCLE PARTS TUONO 1000 5.11.4. LOWER CHAIN SLIDER NOTE When checking for wear the slider must be removed. • Loosen and remove the two screws. • Remove the lower chain slider. CHECKING WEAR Check the wear of the chain slider.
  • Page 251 COOLING SYSTEM TUONO 1000 COOLING SYSTEM 6 - 1...
  • Page 252 COOLING SYSTEM TUONO 1000 SUMMARY 6.1. COOLING SYSTEM ......................... 3 6.1.1. DIAGRAM ..........................3 6.1.2. FILLING THE COOLING SYSTEM ..................4 6 - 2...
  • Page 253 COOLING SYSTEM TUONO 1000 6.1. COOLING SYSTEM 6.1.1. DIAGRAM Key: Cooler Solenoid valves Expansion tank Oil filler Three-way thermostatic valve Three-way manifold 6 - 3...
  • Page 254 COOLING SYSTEM TUONO 1000 6.1.2. FILLING THE COOLING SYSTEM • The cooling system is filled with approximately 2.2 litres (4 pt) of fluid. • Place the vehicle on the rear stand OPT. • Loosen the radiator breather screw. • Unscrew the oil filler plug.
  • Page 255 COOLING SYSTEM TUONO 1000 • Tighten the filler and the expansion tank plugs. • If fluid does not come out of the radiator breather screw, before filling system completely (approximately 2 litres) (approximately 3.63 in) reach the level in the expansion tank •...
  • Page 256 CYCLE PARTS TUONO 1000 CYCLE PARTS 7 - 1...
  • Page 257 CYCLE PARTS TUONO 1000 SUMMARY 7.1. ELECTRIC SYSTEM ............................ 3 7.1.1. LOCATION OF THE COMPONENTS ....................3 7.1.2. ELECTRIC PARTS INSPECTION TABLE ..................5 7.1.3. CAN LINE ............................14 7.1.4. IMMOBILIZER ........................... 16 7.1.5. LAMBDA SENSOR ........................... 18 7.1.6. RECOVERY FUNCTION .........................

  • Page 258: Electric System

    CYCLE PARTS TUONO 1000 7.1. ELECTRIC SYSTEM 7.1.1. LOCATION OF THE COMPONENTS 7 - 3...
  • Page 259 CYCLE PARTS TUONO 1000 Key: RPM sensor Lambda sensor Camshaft sensor Coolant temperature sensor Intake air temperature sensor Bank angle sensor Vehicle speed sensor Injector Ignition coils Throttle position sensor (TPS) Immobilizer antenna Starter motor Stepper motor Generator Recharge voltage...

  • Page 260: Electric Parts Inspection Table

    CYCLE PARTS TUONO 1000 7.1.2. ELECTRIC PARTS INSPECTION TABLE 7 - 5...
  • Page 261 CYCLE PARTS TUONO 1000 RPM SENSOR induction sensor It consists of a 36-tooth phonic wheel The sensor outputs a voltage pulse every 10° of rotation to allow the control unit to calculate engine rpm and crankshaft position Coil resistance 0.7 – 1.1 KΩ (measured across pins 1a and Alternated current at output 1 –...
  • Page 262 CYCLE PARTS TUONO 1000 INTAKE AIR TEMPERATURE SENSOR NTC sensor (variable resistance, the value decreases as the temperature increases) resistance 2.5 KΩ (temperature 20°C – 68°F) Power supply: 5 V BANK ANGLE SENSOR resistance of 62 KΩ with sensor in its position of assembly resistance 0 Ω...
  • Page 263 CYCLE PARTS TUONO 1000 IGNITION COILS rear cylinder primary winding resistance between 0.40 and 1.15 Ω (measured across pins 9c and 9b) front cylinder primary winding resistance between 0.40 and 1.15 Ω (measured across pins 9a and 9b) resistance of secondary winding: between 0.40 and 1.15 Ω...
  • Page 264 CYCLE PARTS TUONO 1000 STARTER MOTOR input at start-up: 120 A STEPPER MOTOR phase resistance: 50 Ω The stepper motor is powered by the ECU Its rotation is divided in “steps”. By changing the opening steps it is possible to suitably...
  • Page 265 CYCLE PARTS TUONO 1000 FUEL PUMP input: 3.9 A FUEL RESERVE SENSOR There is no fuel level indicator; it is simply a reserve warning light that comes on when level goes below 3.7 litres: 30 seconds after fuel is no longer reaching the sensor, it starts conducting (and the light comes on).
  • Page 266 CYCLE PARTS TUONO 1000 ECU Pinout Connector A Pin Description Type signal Rear cylinder coil control Power output n.a. Atmospheric pressure sensor power Power supply supply (5V) Atmospheric pressure sensor power Power supply supply (earth) Rpm sensor signal Frequency input n.a.
  • Page 267 CYCLE PARTS TUONO 1000 Connector B Pin Description Type of signal ECU power supply (earth) Power supply ECU power supply (earth) Power supply Power output n.a. Lambda sensor heater control Power output Vehicle speed sensor signal Frequency input n.a. n.a.
  • Page 268 CYCLE PARTS TUONO 1000 TAIL LIGHT Number plate light 12 V – 5 W AUXILIARY FUSES A - From key to: light relay, stop, horn, parking lights (5 A). B - From key to: turn indicators, instrument panel (5 A).

  • Page 269: Can Line

    CYCLE PARTS TUONO 1000 7.1.3. CAN LINE CAN line technology (Controller Area Network) is used to connect the different electronic devices of the vehicle, so they operate like a network of computers (Internet). The use of a CAN line made it possible to significantly simplify the layout of the electric system and reduce the bulk of the wiring harness.
  • Page 270 CYCLE PARTS TUONO 1000 STARTING The ECU will only enable starting when it recognises V990 engine model based on a CAN acknowledge message from the instrument panel (model information is located in the instrument panel). Only the fuel reserve sensor is connected directly to the instrument panel.

  • Page 271: Immobilizer

    CYCLE PARTS TUONO 1000 7.1.4. IMMOBILIZER IMMOBILIZER The motorcycle is equipped with an immobilizer system that inhibits engine start-up unless it receives the correct identification code. This code is stored in a transponder incorporated in the ignition keys supplied with the motorcycle.
  • Page 272 CYCLE PARTS TUONO 1000 STORING KEY CODES - NEW KEYS The immobilizer system can store up to 4 key codes. The procedure requires a Master Key, and can only be performed by Authorised Dealers. Storing a new key code deletes all existing codes; this means the Owner must bring in all keys (new and old) he wants enabled.

  • Page 273: Lambda Sensor

    CYCLE PARTS TUONO 1000 7.1.5. LAMBDA SENSOR It measures oxygen content in the exhaust gas and provides indirect information on combustion. The oxygen sensor signal allows the ECU to continuously correct the mixture strength in case it is not ideal or stoichiometric (lambda setting).

  • Page 274: Recovery Function

    CYCLE PARTS TUONO 1000 7.1.6. RECOVERY FUNCTION In case the signal of the following sensors is interrupted, the control unit either sets a series of values to let the engine work anyway or uses a different parameter. In any case, the instrument panel highlights that there is a fault.

  • Page 275: Engine Rpm Limitation Condition

    CYCLE PARTS TUONO 1000 7.1.7. ENGINE RPM LIMITATION CONDITION The control unit limits engine rpm in case one of the following events occurs: TPS signal missing. stepper motor signal missing. low oil pressure. On the Axone DEVICES STATUS page, the parameter INITIALISED ECU is "NO".

  • Page 276: New Mapping

    CYCLE PARTS TUONO 1000 7.1.8. NEW MAPPING On vehicles manufactured before February 2004 and up to frame no. ZD4RR00004S003947, the ECU needs to be reprogrammed with the revised mapping that ensures improved idle stability and engine performance at 2000 - 3000 rpm.

  • Page 277: Wiring Diagram

    CYCLE PARTS TUONO 1000 7.1.9. WIRING DIAGRAM 7 - 22...
  • Page 278 CYCLE PARTS TUONO 1000 Key: AUXILIARY FUSES: A 5A NUMBER PLATE, STOP, HORN, PARKING Multiple connectors LIGHTS Bank angle sensors B 5A INST. PANEL DIAGNOSTICS, INSTRUMENT High beam relay PANEL Low beam relay C 5A KEY-OPERATED POSITIVE, TO ECU Horn...
  • Page 279 G.Galilei, 1 30033 Noale (VE) Italy tel. +39 041.5829111 fax +39 041.5829190 www.aprilia.com www.serviceaprilia.com...

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